Chrysler Stratus RHD 1997 Interactive Electronic Service Manual
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Chrysler Stratus RHD 1997 Interactive Electronic Service Manual

Chrysler Stratus RHD 1997 Interactive Electronic Service Manual

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Table of Contents

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Welcome to the
1997 Stratus
(RHD & LHD)
Interactive Electronic Service Manual!
CLICK ON VEHICLE TO BEGIN
tweddle litho: dom parts cdrom demo 09/96
page 1 <output:0908 ET 05/27/97>

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Summary of Contents for Chrysler Stratus RHD 1997

  • Page 1 Welcome to the 1997 Stratus (RHD & LHD) Interactive Electronic Service Manual! CLICK ON VEHICLE TO BEGIN tweddle litho: dom parts cdrom demo 09/96 page 1 <output:0908 ET 05/27/97>...
  • Page 2 CLASSIFICATION OF LUBRICANTS PARTS AND LUBRICANT RECOMMENDATIONS Only lubricants that are endorsed by the following organization should be used to service a Chrysler When service is required, Chrysler Corporation Corporation vehicle. recommends that only Mopar brand parts, lubri- •...

  • Page 3: Fluid Capacities

    0 - 2 LUBRICATION AND MAINTENANCE GENERAL INFORMATION (Continued) Wheel bearing lubricant is identified by the letter “G”. Chassis lubricant is identified by the latter “L”. The letter following the usage letter indicates the quality of the lubricant. The following symbols indi- cate the highest quality.

  • Page 4: Maintenance Schedules

    • Check all lights and all other electrical items for There are two maintenance schedules that show correct operation. the proper service for Chrysler vehicles. Use the schedule that best describes the conditions under At Each Oil Change which the vehicle is operated. Where time and mile- •...

  • Page 5: Schedule—B

    0 - 4 LUBRICATION AND MAINTENANCE GENERAL INFORMATION (Continued) • Replace air cleaner element. • Flush and replace engine coolant if it has been • Replace spark plugs on 2.0L and 2.4L 30,000 miles (48 000 km) or 24 months since last engines.
  • Page 6 LUBRICATION AND MAINTENANCE 0 - 5 GENERAL INFORMATION (Continued) • Adjust drive belt tension. • Replace engine oil filter on 2.0 liter and 2.4 liter • Change automatic transaxle fluid and filter.* engines. • Adjust drive belt tension. • Change automatic transaxle fluid and filter.* 18,000 Miles (29 000 km) •...
  • Page 7 NOTE: **This maintenance is recommended by 90,000 Miles (144 000 km) Chrysler to the owner but is not required to main- • Change engine oil. tain the warranty on the PCV valve. • Replace engine oil filter on all engines.

  • Page 8: Jump Starting, Hoisting And Towing

    BATTERY NEGATIVE CABLE BATTERY POSITIVE CABLE NEGATIVE JUMPER CABLE POSITIVE JUMPER CABLE ENGINE GROUND TEST INDICATOR BATTERY LUBRICATION AND MAINTENANCE 0 - 7 JUMP STARTING, HOISTING AND TOWING INDEX page page SERVICE PROCEDURES JUMP STARTING PROCEDURE ... . . 7 HOISTING RECOMMENDATIONS .

  • Page 9: Hoisting Recommendations

    DRIVE ON LIFT WHEEL LIFT FLAT BED FRAME CONTACT LIFT (SINGLE POST) CHASSIS LIFT (DUAL POST) 0 - 8 LUBRICATION AND MAINTENANCE OUTBOARD LIFT (DUAL POST) FLOOR JACK SERVICE PROCEDURES (Continued) DISCONNECT CABLE CLAMPS AS FOLLOWS: TOWING RECOMMENDATIONS • Disconnect BLACK cable clamp from engine RECOMMENDED TOWING EQUIPMENT ground on disabled vehicle.

  • Page 10: Service Procedures

    VENTURE UNDER A LIFTED VEHICLE IF NOT SUP- PORTED PROPERLY ON SAFETY STANDS. DO NOT TOWING—FRONT WHEEL LIFT Chrysler Corporation recommends that a vehicle be ALLOW PASSENGERS TO RIDE IN A TOWED VEHI- CLE. USE A SAFETY CHAIN THAT IS INDEPENDENT towed with the front end lifted, whenever possible.

  • Page 12: Service Procedures

    See Front Wheel Drive Specifications for correct front accuracy of the alignment, except alignment specifi- and rear wheel Toe specifications. cations recommended Chrysler Corporation (5) Thrust Angle is defined as the average of the MUST ALWAYS be used. Toe settings on each rear wheel. If this measurement...
  • Page 13 TOE OUT FRONT LOOSEN NUT TO ADJUST ADJUST TOE NEGATIVE CAMBER POSITIVE TOE IN 2 - 2 SUSPENSION DESCRIPTION AND OPERATION (Continued) Fig. 1 Alignment Camber/Toe...
  • Page 14 SUSPENSION 2 - 3 DIAGNOSIS AND TESTING SUSPENSION AND STEERING DIAGNOSIS CONDITION POSSIBLE CAUSES POTENTIAL CORRECTIONS Front End Whine On Turns 1. Defective Wheel Bearing 1. Replace Wheel Bearing 2. Incorrect Wheel Alignment 2. Check And Reset Wheel Alignment 3. Worn Tires 3.

  • Page 15: Service Procedures

    2 - 4 SUSPENSION DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES POTENTIAL CORRECTIONS Lateral Pull 1. Unequal Tire Pressure 1. Inflate All Tires To Recommended Pressure 2. Radial Tire Lead 2. Perform Lead Correction Procedure 3. Incorrect Front Wheel Camber 3.

  • Page 16: Service Procedures

    FORWARD LATERAL A RM REAR LATERAL LINK FORWARD LATERAL LINK ADJUSTING REAR LATERAL LINK 391mm 302mm (MAX) (MAX) SCREW JAM NUT (MAX) 90mm STABILIZER B AR ADJUSTING JAM NUTS SCREW SUSPENSION 2 - 5 SERVICE PROCEDURES (Continued) adjusting screw located in the forward and rear lat- eral links of the vehicles rear suspension (Fig.
  • Page 17 OUTER TIE ROD STEERING KNUCKLE ADJUSTMENT SERRATIONS JAM NUT INNER STEERING GEAR BOOTS 2 - 6 SUSPENSION SERVICE PROCEDURES (Continued) adjust Camber and Toe until both are at their pre- ferred specifications. (6) While holding adjustment screws from turning, use a crow foot and torque wrench, and tighten all lateral link adjusting screw jam nuts to a torque of 65 N·m (48 ft.
  • Page 18 SUSPENSION 2 - 7 SPECIFICATIONS VEHICLE ALIGNMENT SPECIFICATIONS AT CURB HEIGHT ACCEPTABLE ALIGNMENT FRONT WHEEL ALIGNMENT PREFERRED SETTING RANGE AT CURB HEIGHT CAMBER............ -0.6° to +0.6° +0.0° TOE— RIGHT/ 0.05°out to 0.15° in 0.05° in LEFT......... TOTAL 0.1°out to 0.3°in 0.1°...

  • Page 19: Front Suspension

    SHOCK COILSPRING TOWER NO SHEET METAL SCREWS, BOLTS, OR ANY OTHER METAL FASTENERS ARE TO BE INSTALLED IN SHOCK TOWER AREA. ALSO, NO HOLES ARE TO BE DRILLED INTO SHOCK TOWER IN THIS SAME AREA. 2 - 8 SUSPENSION FRONT SUSPENSION INDEX page page...
  • Page 20 SUSPENSION 2 - 9 DESCRIPTION AND OPERATION The top of each shock absorber assembly is bolted to the cast aluminum upper control arm bracket FRONT SUSPENSION SYSTEM DESCRIPTION which is then bolted to the shock tower of the vehicle using 4 mounting bolts. This vehicle’s front suspension is a short long arm The bottom of the shock absorber assembly design used in conjunction with a gas pressurized...
  • Page 21 2 - 10 SUSPENSION DESCRIPTION AND OPERATION (Continued) Jounce and rebound movements affecting one attempt should be made to ever add any lubri- wheel are partially transmitted to the opposite wheel cation to the lower ball joint. of the vehicle to stabilize body roll. UPPER CONTROL ARM BALL JOINT Attachment of the stabilizer bar to the front sus- pension cradle is through 2 rubber-isolator bushings...
  • Page 22 SHOCK COILSPRING ABSORBER UPPER SPRING DUST BOOT SEAT SUSPENSION 2 - 11 DIAGNOSIS AND TESTING (Continued) any component of the upper control arm. Service pro- cedures to replace the serviceable components are detailed in the specific component sections of this group.
  • Page 23 BRAKE CALIPER FLEX WHEEL SPEED SEN- SOR CABLE SPEED HOSE SENSOR CABLE BRACKET ROUTING ATTACHINGBOLT STEERING KNUCKLE UPPER UPPER CASTLENUT CLEVIS UPPER CONTROL ARM SHOCK SHOCK ABSORBER STEERING BRACKET MOUNTING BRACKET KNUCKLE ASSEMBLY CONTROL CONTROL ABSORBER COTTER PIN BALL JOINT BRAKE FLEX HOSE STEERING...
  • Page 24 COVER THRU-BOLT SHOCK LOWER CONTROL ARM MOUNTING SHOCK ABSORBER ABSORBER CLEVIS BRACKET BOLTS LOWER SHOCK TOWER CONTROL SHOCK CLEVIS BALL JOINT CAP LOCATING TAB SHOCK ABSORBER CLEVIS SPLIT CLEVIS MUST BE INSTALLED FLUSH AGAINST LOCATING LOWER CONTROL ARM ORIENTATION TAB SHOCK ABSORBER TAB HERE...
  • Page 25 BRAKE CALIPER FLEX WHEEL SPEED SEN- SOR CABLE SPEED HOSE SENSOR CABLE BRACKET ROUTING ATTACHINGBOLT STEERING KNUCKLE UPPER UPPER CASTLENUT CLEVIS UPPER CONTROL ARM SHOCK SHOCK ABSORBER STEERING BRACKET MOUNTING BRACKET KNUCKLE ASSEMBLY CONTROL CONTROL ABSORBER COTTER PIN BALL JOINT BRAKE FLEX HOSE STEERING...
  • Page 26 COVER THRU-BOLT SHOCK LOWER CONTROL ARM MOUNTING SHOCK ABSORBER ABSORBER CLEVIS BRACKET BOLTS LOWER SHOCK TOWER CONTROL SHOCK ABSORBER ASSEM- SHOCK ABSORBER CLEVIS SPECIAL GP-2020-C3.5 TOOL VISE TIE ROD END SUSPENSION 2 - 15 REMOVAL AND INSTALLATION (Continued) (7) Remove the thru-bolt (Fig. 15) attaching the shock absorber clevis to the lower control arm.
  • Page 27 SHOCK CONTROL ABSORBER/UPPER MOUNTING BRACKET WASHER CROW FOOT ISOLATOR BUSHING SHOCK SOCKET SNAP-ON A136 ABSORBER SHOCK TROL LOWER SHOCK TROL ISOLATOR ABSORBER/CON- BUSHING ABSORBER/CON- MOUNTING MOUNTING BRACKET SPRING COMPRES- BRACKET SHOCK UPPER ISOLATOR BUSHING ABSORBER SHOCK SLEEVE ABSORBER/CONTROL MOUNTING BRACKET UPPER SPRING ISO- SHOCK ABSORBER...
  • Page 28 INSTALL ABSORBER ROD IN THIS UPPER SHOCK LOWER ISOLATOR BUSHING ABSORBER CONTROL DIRECTION SHOCK CONTROL ARM MOUNTING SHOCK UPPER ISOLATOR BUSHING INSTALL ABSORBER ROD IN THIS ABSORBER BOLTS UPPER CONTROL ARM MOUNTING BRACKET DIRECTION SHOCK SUSPENSION 2 - 17 REMOVAL AND INSTALLATION (Continued) (18) Remove the 2 bolts (Fig.
  • Page 29 SHOCK CLEVIS BALL JOINT CAP LOCATING TAB SHOCK ABSORBER CLEVIS SPLIT CLEVIS MUST BE INSTALLED FLUSH AGAINST LOCATING LOWER CONTROL ARM ORIENTATION TAB SHOCK ABSORBER TAB HERE CLEVIS BALL JOINT HEAT SHIELD LOWER TROL ARM CON- 2 - 18 SUSPENSION REMOVAL AND INSTALLATION (Continued) (19) Raise vehicle and remove jack stand from under lower control arm and lower vehicle to the...
  • Page 30 DISC BRAKE CALI- LOWER CALIPER STEERING PER ASSEMBLY WIRE HANGER KNUCKLE GUIDE PIN BOLTS CONTROL ASSEMBLY CASTLENUT UPPER CONTROL ARM COTTER PIN DISC BRAKE CALI- BALL JOINT STUD STEERING PER ASSEMBLY STEERING KNUCKLE KNUCKLE ROTOR HAMMER THRU-BOLT STEERING KNUCKLE BOSS SHOCK ABSORBER CLEVIS LOWER...
  • Page 31 STABI- LIZER BAR VEHICLE BODY WRENCH ALLEN ATTACHING WRENCH BOLTS STABILIZER BAR BUSHING FRONT SUSPENSION LOWER CROSSMEMBER CLAMP CONTROL FRONT ATTACHING LOWER CONTROL ARM LOWER CROSSMEMBER SUSPENSION AND NUT CONTROL BOLT STABILIZER BAR LOWER ATTACHING BOLT AND NUT FRONT SUSPENSION CONTROL CROSSMEMBER STABILIZER BAR LINK ASSEMBLY...
  • Page 32 BALL JOINT CAP LOWER CONTROL ARM SHOCK ABSORBER CLEVIS SPRING WASHER COTTER PIN NUT LOCK HUB NUT SUSPENSION 2 - 21 REMOVAL AND INSTALLATION (Continued) suspension crossmember. Do not tighten front (10) Tighten front lower control arm nut and bolt attaching bolt at this time .
  • Page 33 CALIPER STEERING KNUCKLE GUIDE PIN BOLTS ASSEMBLY FRONT H UB DISC BRAKE CALI- PER ASSEMBLY DISC BRAKE CALI- BALL JOINT LIFT THIS END OF CALIPER AWAY PER ASSEMBLY WIRE HANGER ROTOR FROM HEAT SHIELD KNUCKLE FIRST DISC BRAKE CALI- STEERING PER ASSEMBLY UPPER CONTROL ARM STEERING...
  • Page 34 STEERING HEAT SHIELD KNUCKLE END STUD LOWER CONTROL ARM TIE ROD END SPECIAL TOOL MB-991113 TIE ROD END STEERING HEAT SHIELD KNUCKLE BRAKE CALIPER FLEX LOWER WHEEL SPEED SEN- CONTROL SOR CABLE SPEED HOSE CASTLENUT SENSOR CABLE BRACKET ROUTING COTTER PIN ATTACHINGBOLT BALL JOINT STUD STEERING...
  • Page 35 HAMMER STEERING KNUCKLE OUTER STEERING KNUCKLE BOSS JOINT BEARING SHIELD LOWER STEERING KNUCKLE HUB/BEARING CONTROL UPPER UPPER CASTLENUT UPPER CONTROL ARM SHOCK SHOCK ABSORBER MOUNTING BRACKET ASSEMBLY CONTROL CONTROL ABSORBER COTTER PIN BALL JOINT STEERING SHOCK ABSORBER KNUCKLE SPECIAL BALL JOINT STUD BALL JOINT ASSEMBLY C3894–A...
  • Page 36 HEAT SHIELD CROWFOOT 11/32 SOCKET STEERING KNUCKLE TORQUE WRENCH HUB AND BEAR- BRAKING DISC STUB NUT LOCK AXLE TORQUE WRENCH WASHER “PULL” COTTER PIN THROUGH HUB NUT “WRAP” TIGHT TIE ROD END SUSPENSION 2 - 25 REMOVAL AND INSTALLATION (Continued) knuckle (Fig.
  • Page 37 WRENCH ALLEN WRENCH LOWER CONTROL STABI- LIZER BAR VEHICLE BODY ATTACHING BOLTS STABILIZER BAR BUSHING FRONT SUSPENSION CROSSMEMBER CLAMP STABILIZER BAR LINK ASSEMBLY 2 - 26 SUSPENSION REMOVAL AND INSTALLATION (Continued) (14) Install front wheel and tire assembly. Install front wheel lug nuts and tighten in correct sequence. Then tighten to a torque of 129 N·m (95 ft.lbs.).
  • Page 38 SPRING WASHER FRONT H UB COTTER PIN NUT LOCK DISC BRAKE CALI- CALIPER STEERING LIFT THIS END OF CALIPER AWAY PER ASSEMBLY WIRE HANGER ROTOR KNUCKLE GUIDE PIN BOLTS FROM ASSEMBLY KNUCKLE FIRST DISC BRAKE CALI- STEERING PER ASSEMBLY UPPER CONTROL ARM STEERING KNUCKLE DISC BRAKE CALI-...
  • Page 39 STEERING HEAT SHIELD BALL JOINT KNUCKLE END STUD HEAT SHIELD TIE ROD END LOWER TROL ARM CON- BRAKE CALIPER FLEX LOWER WHEEL SPEED SEN- LOWER CONTROL ARM CONTROL SOR CABLE SPEED HOSE CASTLENUT SENSOR SPECIAL TOOL MB-991113 CABLE BRACKET ROUTING TIE ROD END COTTER PIN ATTACHINGBOLT...
  • Page 40 HAMMER STEERING KNUCKLE BOSS LOWER STEERING KNUCKLE CONTROL UPPER UPPER CASTLENUT UPPER CONTROL ARM SHOCK SHOCK ABSORBER STEERING MOUNTING BRACKET KNUCKLE ASSEMBLY CONTROL CONTROL ABSORBER COTTER PIN OUTER JOINT BEARING SHIELD BALL JOINT STEERING SHOCK ABSORBER KNUCKLE SPECIAL BALL JOINT STUD BALL JOINT ASSEMBLY HUB/BEARING...
  • Page 41 HUB/BEARING STEERING KNUCKLE ATTACHING BOLTS HUB/BEARING ASSEMBLY HUB AND BEAR- HEAT SHIELD STUB CROWFOOT AXLE 11/32 SOCKET WASHER STEERING KNUCKLE HUB NUT TORQUE WRENCH TIE ROD END 2 - 30 SUSPENSION REMOVAL AND INSTALLATION (Continued) (20) Mount steering knuckle securely in a vise. (5) Install tie rod end into the steering knuckle.
  • Page 42 BRAKING DISC NUT LOCK TORQUE WRENCH “PULL” COTTER PIN THROUGH “WRAP” TIGHT CALIPER STEERING LIFT THIS END OF CALIPER AWAY ROTOR KNUCKLE GUIDE PIN BOLTS FROM ASSEMBLY KNUCKLE FIRST DISC BRAKE CALI- STEERING PER ASSEMBLY STEERING KNUCKLE DISC BRAKE CALI- PER ASSEMBLY OUTBOARD BRAKE SHOE...
  • Page 43 DISC BRAKE CALI- DISC BRAKE CALI- PER ASSEMBLY WIRE HANGER ASSEMBLY STEERING (STORED) KNUCKLE BRAKING DISC UPPER CONTROL ARM STEERING KNUCKLE ROTOR STEERING KNUCKLE WHEEL STUD FRONT HUB WASHERS STEERING KNUCKLE LUG NUT FRONT HUB SPECIAL WHEEL C-4150A TOOL ABS SPEED SEN- SOR CABLE 2 - 32 SUSPENSION...
  • Page 44 SHOCK ABSORBER ASSEM- SHOCK ABSORBER CLEVIS VISE SHOCK CONTROL SPECIAL GP-2020-C3.5 ABSORBER/UPPER TOOL MOUNTING BRACKET WASHER CROW FOOT ISOLATOR BUSHING SHOCK SOCKET SNAP-ON A136 ABSORBER SUSPENSION 2 - 33 DISASSEMBLY AND ASSEMBLY SHOCK ABSORBER DISASSEMBLY CAUTION: Do not clamp the shock absorber in a vise by the body of the shock absorber.
  • Page 45 SHOCK TROL ABSORBER/CON- MOUNTING BRACKET SPRING COMPRES- SHOCK UPPER ISOLATOR BUSHING ABSORBER SHOCK ABSORBER/CONTROL MOUNTING BRACKET SHOCK ABSORBER LOWER SHOCK TROL SPRING COMPRESSOR S PRING ISOLATOR BUSHING ABSORBER/CON- MOUNTING BRACKET SPRING WASHER SLEEVE SHOCK ABSORBER ASSEM- SHOCK ABSORBER ROD UPPER SPRING ISO- DUST SHIELD DUST SHIELD LATOR...
  • Page 46 SHOCK SHOCK ABSORBER ROD SPRING COMPRESSOR FLUID RESERVOIR ABSORBER SHOCK ABSORBER ASSEMBLY COIL SEATED AGAINST ISOLATOR JOUNCE BUMPER SPRING COIL SPRING SLEEVE MUST HERE SHOCK ABSORBER CLEVIS COIL SPRING ISOLATOR LOWER SPRING SEAT SHOCK ABSORBER JOUNCE BUMPER SHOCK ABSORBER SHOCK ABSORBER ROD SUSPENSION 2 - 35 DISASSEMBLY AND ASSEMBLY (Continued)
  • Page 47 UNDERCUT SLEEVE SHOCK ABSORBER ROD STEP INSTALL ABSORBER ROD IN THIS SHOCK LOWER ISOLATOR BUSHING ABSORBER DIRECTION SHOCK SHOCK UPPER ISOLATOR BUSHING INSTALL ABSORBER ROD IN THIS ABSORBER DIRECTION SHOCK 2 - 36 SUSPENSION DISASSEMBLY AND ASSEMBLY (Continued) (4) Install the sleeve, undercut side facing down, (Fig.
  • Page 48 SPECIAL SPECIAL TOOL MB-990799 SPECIAL TOOL 6876 ISOLATOR C-4212-F SPECIAL TOOL TOOL BUSH- C-4212-F MACHINED SURFACE SIDE OF LOWER CONTROL ARM LOWER CONTROL ARM FRONT ISOLATOR BUSHING SPECIAL TOOL 6602-5 SPECIAL TOOL 6758 SPECIAL TOOL C-4366-2 SPECIAL TOOL C-4212-F LOWER CONTROL ARM SPECIAL TOOL 6756 SUSPENSION 2 - 37...
  • Page 49 SPECIAL TOOL 6756 SPECIAL TOOL C-4212-F FRONT ISOLATOR BUSHING LOWER CONTROL ARM LOWER CONTROL ARM VOID IN BUSHING IN THIS REAR ISOLATOR BUSHING REAR BUSHING SPECIAL MACHINED SURFACE ON DIRECTION LOWER CONTROL ARM MACHINED SURFACE TOOL 6760 LOWER CONTROL ARM SPECIAL TOOL 6877 SPECIAL TOOL 6876 SPECIAL TOOL...
  • Page 50 SPECIAL TOOL 6877 MACHINED SURFACE SIDE OF LOWER CONTROL ARM CLEVIS BUSHING LOWER CONTROL ARM SPECIAL TOOL 6876 SPECIAL C-4212-F TOOL BALL JOINT SEAL RETAIN- BALL JOINT SEAL UPPER SEALING RING ING RING SCREW- DRIVERS LOWER CONTROL ARM BALL JOINT SUSPENSION 2 - 39 DISASSEMBLY AND ASSEMBLY (Continued)
  • Page 51 BALL UPPER SEAL BOOT JOINT BOOT INSTALLATION SEC- SEALING RING Wipe off the grease. TION GREASE BALL JOINT STUD TAPERED BOOT INSTALLATION SEC- Wipe off the grease. SECTION TION GREASE SEAL RETAINING SEAL BOTTOM EDGE OF TOOL MUST BE EVEN WITH TOP GROOVE IN SEAL BOOT AS LOWER SPECIAL TOOL 6875-1...
  • Page 52 SEAL RETAINING R ING SPECIAL TOOL 6875 SPECIAL TOOL 6875 BOOT RETAINING RING LOWER CONTROL ARM LOWER CONTROL ARM SEAL BOOT RETAIN- SEAL BOOT BALL JOINT STUD BALL JOINT STUD CONTROL ARM ING RING UPPER SEALING RING BALL JOINT BALL JOINT SEAL BOOT LOWER CONTROL ARM SCREWDRIVER SUSPENSION...
  • Page 53 STABILIZER BAR BUSH- CONTROL ARM STABILIZER BAR BUSHING ING RETAINER SEAL BOOT CRIMPS BALL JOINT CRIMPS STABILIZER BAR SPECIAL TOOL 6758 2 - 42 SUSPENSION DISASSEMBLY AND ASSEMBLY (Continued) SPECIFICATIONS FRONT SUSPENSION FASTENER TORQUE SPECIFICATIONS DESCRIPTION TORQUE Shock Absorber To Clevis Pinch Bolt ..95 N·m (70 ft. lbs.) To Shock Tower Bolts .
  • Page 54 SUSPENSION 2 - 43 SPECIAL TOOLS FRONT SUSPENSION Remover, Ball Joint MB-990799 Puller C-3894-A Remover/Installer Control Arm Bushing6602–5 (In Tool Kit 6602) Installer, Ball Joint 6758 Installer/Receiver, Control Arm Bushing6876 Press, Ball Joint Remover InstallerC-4212F Installer, Ball Joint 6758...
  • Page 55 2 - 44 SUSPENSION SPECIAL TOOLS (Continued) Remover / Installer C-4366-2 (InTool Kit C-4366) Installer, Ball Joint Seal Boot Retainer6875 Receiver, Ball Joint 6756 Remover, Tie Rod End MB-991113 orMB-990635 Installer, Bushing 6760 Remover, Lower Ball Joint C-4150A Remover/Installer Control Arm ClevisBushing 6877...

  • Page 56: Rear Suspension

    SUSPENSION 2 - 45 REAR SUSPENSION INDEX page page GENERAL INFORMATION SERVICE PROCEDURES GENERAL INFORMATION ....45 REAR WHEEL ALIGNMENT ....48 DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION COIL SPRING...
  • Page 57 2 - 46 SUSPENSION DESCRIPTION AND OPERATION (Continued)
  • Page 58 SUSPENSION 2 - 47 DESCRIPTION AND OPERATION (Continued) COIL SPRING Lateral links, trailing arms and knuckles are nor- mally replaced only when the part has been damaged Rear coil springs are rated separately for each cor- or when the vehicle has been involved in an accident. ner or side of the vehicle depending on optional If a suspension part has been damaged, be sure to equipment and type of vehicle service.
  • Page 59 SHOCK SHOCK TOWER VEHICLE TRUNK CARPET- ABSORBER COVER 2 - 48 SUSPENSION DIAGNOSIS AND TESTING (Continued) assistance or added force attempt to move the grease SERVICE PROCEDURES fitting. If the ball joint is worn the grease fitting will move REAR WHEEL ALIGNMENT easily.
  • Page 60 SHOCK LATERAL LINK ABSORBER ASSEMBLY SHOCK TOWER ATTACHING B OLT SHOCK ABSORBER MOUNT- SHOCK ABSORBER ING NUTS SHOCK CLEVIS BRACKET ABSORBER REAR KNUCKLE SUSPENSION 2 - 49 REMOVAL AND INSTALLATION (Continued) INSTALL (1) Install shock absorber back in vehicle using the reverse sequence of removal (Fig.
  • Page 61 STABILIZER BAR ATTACHING ATTACHING BOLT FORWARD LATERAL LINK PARK BRAKE CABLE REAR LATERAL LINK ATTACHING BOLT STABILIZER BAR LINK STABILIZER BAR ATTACH- REAR REAR STABILIZER CROSSMEMBER SUSPENSION ING BRACKETS ATTACHING BOLT ATTACHING BOLT CORRECTLY POSITION STABILIZER INSTALLED UP IN CAR SIDE VIEW INCORRECTLY POSITION...
  • Page 62 UPPER CONTROL BRAKE FLEX HOSE BRAKE DRUM BRAKE SUPPORT PARK BRAKE CABLE PARK BRAKE ACTUAT- PLATE BRACKET ING LEVER SPEED SENSOR CABLE ROUTING BOLT SPEED SENSOR CABLE CLIPS SHOCK ABSORBER BOLT BRAKE PLATE 1/2” HUB/BEARING PARK BRAKE CABLE ASSEMBLY PARK BRAKE CABLE RETAINER ATTACHING SUPPORT...
  • Page 63 FORWARD LATERAL LINK REAR LATERAL LINK WIRE HANGER KNUCKLE BOLT BOLT REAR SHOCK ABSORBER REAR SUPPORT PLATE ASSEMBLY BRAKE KNUCKLE TENSION NUT BALL JOINT KNUCKLE BALL WRENCH JOINT STUD SHOCK ABSORBER CLEVIS SPECIAL BRACKET KNUCKLE CT1106 TOOL 2 - 52 SUSPENSION REMOVAL AND INSTALLATION (Continued) Fig.
  • Page 64 INNER TRAILING LINK TRAILING LINK RETAINER INNER FORWARD LINK BUSHING ERAL ARM TRAILING LAT- OUTER TRAILING REAR LATERAL ARM RETAINER KNUCKLE LINK SPEED SENSOR CABLE SPEED SENSOR BOLT HEAD OUTER TRAILING LINK BUSHING SUSPENSION 2 - 53 REMOVAL AND INSTALLATION (Continued) CAUTION: The inner and outer bushing location on the trailing link to rear knuckle attachment is...
  • Page 65 MUFFLER LATERAL LINK REAR FASCIA ATTACHING B OLT ATTACHING BOLTS MUFFLER SHOCK CLEVIS BRACKET SUPPORT BRACKET ABSORBER REAR KNUCKLE REAR SUSPENSION CROSS- KNUCKLE BALL JOINT WOODEN BLOCK MEMBER EXHAUST PIPE BALL HANGER TRANSMISSION JACK BOLT BRACKET JOINT STUD SPECIAL CT1106 TOOL REAR SUSPENSION...
  • Page 66 UPPER CONTROL BRAKE FLEX HOSE BRAKE DRUM ATTACHING BRACKET BOLTS REAR SUSPENSION CROSS- SPEED SENSOR CABLE ROUTING BOLT MEMBER SPEED SENSOR CABLE CLIPS SHOCK ABSORBER ATTACHING B OLTS BOLT UPPER CONTROL ARM UPPER CONTROL ARM SHOCK ABSORBER SHOCK ABSORBER POSITIONING H OLE REAR SUSPENSION CROSS- ATTACHING BOLTS MEMBER...
  • Page 67 BALL JOINT UPPER CONTROL ARM BALL JOINT SPECIAL TOOL 6758 SPECIAL TOOL 6804 SPECIAL TOOL 6758 SPECIAL TOOL 6804 BALL JOINT SEAL BALL JOINT SCREWDRIVER CONTROL ARM CONTROL ARM 2 - 56 SUSPENSION REMOVAL AND INSTALLATION (Continued) (6) Install muffler support bracket on rear frame rail (Fig.
  • Page 68 BALL JOINT SEAL SPECIAL TOOL 6758 CONTROL ARM MUFFLER LATERAL LINK EXHAUST PIPE REAR FASCIA ATTACHING B OLT HANGER BOLT ATTACHING BOLTS BRACKET MUFFLER SHOCK CLEVIS BRACKET SUPPORT BRACKET ABSORBER REAR KNUCKLE REAR SUSPENSION CROSSMEMBER SUSPENSION 2 - 57 REMOVAL AND INSTALLATION (Continued) CAUTION: When installing the ball joint in the upper control arm, do not press the ball joint into the control arm all the way.
  • Page 69 UPPER CONTROL REAR SUSPENSION CROSS- BRAKE FLEX HOSE BRAKE DRUM BRACKET WOODEN BLOCK MEMBER SPEED SENSOR CABLE ROUTING BOLT TRANSMISSION JACK SPEED SENSOR CABLE CLIPS SHOCK ABSORBER BOLT UPPER CONTROL ARM SHOCK ABSORBER ATTACHING BOLTS REAR SUSPENSION CROSS- REAR SUSPENSION CROSS- MEMBER ATTACHING BOLTS MEMBER...
  • Page 70 UPPER CONTROL ARM SHOCK ABSORBER POSITIONING H OLE REAR DRIFT CROSSMEMBER FRAME RAIL SUSPENSION FORWARD LATERAL LINK REAR LATERAL LINK SUSPENSION 2 - 59 REMOVAL AND INSTALLATION (Continued) (2) With the aid of a helper position rear suspen- (11) Lower vehicle to the ground. sion crossmember back in vehicle and support it (12) Check and reset if required, rear wheel align- using the transmission jack.
  • Page 71 STABILIZER BAR ATTACHING REAR SUSPENSION CROSS- FORWARD LATERAL LINK FORWARD LATERAL LINK BOLT AND WASHER STABILIZER BAR KNUCKLE WASHER MEMBER BOLT LINK REAR SUSPENSION CROSS- REAR LATERAL LINK REAR LATERAL LINK ADJUSTING SCREW KNUCKLE MEMBER BOLT BOLT 2 - 60 SUSPENSION REMOVAL AND INSTALLATION (Continued) REAR LATERAL LINK...
  • Page 72 BUSHING TRAILING LINK RETAINER BUSHING KNUCKLE BUSHING NUT BUSHING RETAINER TRAILING HANGER BRACKET HANGER BRACKET LINK WRENCH TRAILING LINK ADJUSTABLE WRENCH TRAILING LINK SPACER BUSHING RETAINER SUSPENSION 2 - 61 REMOVAL AND INSTALLATION (Continued) adjusting screw toward rear knuckle not rear suspension crossmember (Fig.
  • Page 73 INNER INNER TRAILING TRAILING OUTER OUTER BUSHING RETAINER ATTACHING INNER BUSHING RETAINER BUSHING RETAINER BOLTS 4 TRAILING TRAILING TRAILING LINK LINK TRAILING LINK BRACKET BUSHING BUSHING BUSHING HANGER INNER LINK LINK LINK LOCATING DRIFT PINS HANGER BRACKET TRAILING LINK SHOCK ABSORBER ASSEM- VISE SHOCK ABSORBER CLEVIS BRACKET...
  • Page 74 SPRING COMPRESSOR GP-2020-S2.5 SHOCK ABSORBER ASSEM- COIL SPRING SHOCK COIL SPRING SHOCK ABSORBER ROD ABSORBER MOUNT CROW FOOT SHOCK ABSORBER ROD ISOLATOR BUSHING SHOCK ABSORBER SOCKET SNAP-ON A136 SHOCK SPRING COMPRES- ABSORBER WASHER MOUNT SUSPENSION 2 - 63 DISASSEMBLY AND ASSEMBLY (Continued) (3) Mark coil spring and strut assembly right or left, according to which side of vehicle strut was removed from, and which strut coil spring was...
  • Page 75 SPRING COIL SPRING SPRING COMPRESSOR SHOCK ABSORBER ROD PRESSOR WASHER COM- SPRING ISOLATOR DUST BOOT COIL SPRING SHOCK ABSORBER JOUNCE BUMPER COIL SPRING SPRING SHOCK ABSORBER ROD SPRING COMPRESSOR COMPRES- DUST SHIELD COLLAR COIL SPRING 2 - 64 SUSPENSION DISASSEMBLY AND ASSEMBLY (Continued) (8) Remove the isolator (Fig.
  • Page 76 SLEEVE REAR UPPER ISOLATOR BUSHING COIL SPRING ISOLATOR SHOCK ABSORBER SHOCK ABSORBER MOUNT LOWER ISOLATOR BUSHING REAR SHOCK ABSORBER MOUNT SUSPENSION 2 - 65 DISASSEMBLY AND ASSEMBLY (Continued) (13) Remove the coil spring isolator (Fig. 62) from the lower spring seat on the shock absorber assem- bly.
  • Page 77 SHOCK ABSORBER ROD SHOCK ABSORBER SHOCK ABSORBER JOUNCE SHOCK ABSORBER BUMPER SLEEVE STEP SPRING COMPRESSOR SHOCK ABSORBER MOUNT ALIGN MOUNT STUD WITH BOLT HOLE IN CLEVIS BRACKET AS CLEVIS BRACKET STUD SHOWN 2 - 66 SUSPENSION DISASSEMBLY AND ASSEMBLY (Continued) (9) Install the isolator on the top of the coil spring.
  • Page 78 SUSPENSION 2 - 67 SPECIFICATIONS SPECIAL TOOLS REAR SUSPENSION FASTENER TORQUE REAR SUSPENSION SPECIFICATIONS DESCRIPTION TORQUE Brakes Support Plate Mounting Bolts . . 61 N·m (45 ft. lbs.) Brake Hose Mounting Bolt ..45 N·m (45 ft. lbs.) Brake Hose Bracket Bolt .
  • Page 80 DIFFERENTIAL AND DRIVELINE 3 - 1 DIFFERENTIAL AND DRIVELINE CONTENTS page page GENERAL INFORMATION DISASSEMBLY AND ASSEMBLY FRONT DRIVESHAFT IDENTIFICATION ..1 DRIVESHAFT RECONDITIONING FRONT DRIVESHAFTS ....1 PROCEDURE .
  • Page 81 INTERCONNECTING SHAFT TUNED DAMPER WEIGHT TRIPOD OUTER C/V JOINT BEARING SHIELD (THERMO PLASTIC) JOINT RIGHT SIDE DRIVESHAFT SEALING OUTER BOOT LEFT SIDE DRIVESHAFT (THERMO PLASTIC) JOINT TRIPOD JOINT SEALING BOOT SEALING BOOT OUTER C/V JOINT (THERMO PLASTIC) (SILICONE) SEALING BOOT INNER TRIPOD JOINT (IF ABS EQUIPPED) TONE WHEEL...
  • Page 82 SPRING WASHER FRONT H UB COTTER PIN NUT LOCK HUB NUT DIFFERENTIAL AND DRIVELINE 3 - 3 DIAGNOSIS AND TESTING (Continued) and/or contamination of the joint grease, resulting in REMOVAL AND INSTALLATION inadequate lubrication of the joint. (2) Noise may also be caused by another compo- FRONT DRIVESHAFTS nent of the vehicle coming in contact with the drive- shafts.
  • Page 83 CALIPER STEERING LIFT THIS END OF CALIPER AWAY ROTOR KNUCKLE GUIDE PIN BOLTS FROM ASSEMBLY KNUCKLE FIRST DISC BRAKE CALI- STEERING PER ASSEMBLY STEERING KNUCKLE DISC BRAKE CALI- PER ASSEMBLY OUTBOARD BRAKE SHOE STEERING DISC BRAKE CALI- HEAT SHIELD KNUCKLE PER ASSEMBLY WIRE HANGER END STUD...
  • Page 84 BRAKE CALIPER FLEX WHEEL SPEED SEN- LOWER CONTROL ARM SOR CABLE SPEED HOSE SENSOR SPECIAL TOOL MB-991113 CABLE BRACKET ROUTING TIE ROD END ATTACHINGBOLT STEERING HEAT SHIELD STEERING KNUCKLE KNUCKLE LOWER HAMMER CONTROL CASTLENUT STEERING KNUCKLE BOSS COTTER PIN BALL JOINT STUD LOWER STEERING STEERING...
  • Page 85 STEERING KNUCKLE INNER PRYBAR OUTER TRIPOD JOINT JOINT BEARING SHIELD TRANSAXLE C ASE HUB/BEARING SPLINE OILSEAL SNAP RING INTERCON- NECTING S HAFT INNER TRANSAXLE TRIPOD JOINT 3 - 6 DIFFERENTIAL AND DRIVELINE REMOVAL AND INSTALLATION (Continued) (14) Pull steering knuckle assembly out and away (16) Hold inner tripod joint and interconnecting from outer C/V joint of the driveshaft assembly (Fig.
  • Page 86 STEERING KNUCKLE BEARING SHIELD OUTER C/V JOINT OUTER JOINT BEARING SHIELD THIS OUTER C/V JOINT MUST BE FREE OF MOISTURE BEFORE INSTALLING STEERINGKNUCKLE. DEBRIS HUB/BEARING AREA BRAKE CALIPER FLEX LOWER WHEEL SPEED SEN- CONTROL SOR CABLE SPEED HOSE CASTLENUT SENSOR CABLE BRACKET ROUTING...
  • Page 87 STEERING HEAT SHIELD KNUCKLE END STUD HEAT SHIELD TIE ROD END CROWFOOT 11/32 SOCKET STEERING KNUCKLE TORQUE WRENCH CALIPER STEERING LIFT THIS END OF CALIPER AWAY ROTOR KNUCKLE GUIDE PIN BOLTS FROM ASSEMBLY KNUCKLE FIRST DISC BRAKE CALI- STEERING PER ASSEMBLY STEERING KNUCKLE DISC BRAKE CALI-...
  • Page 88 HUB AND BEAR- BRAKING DISC STUB AXLE TORQUE WRENCH WASHER HUB NUT NUT LOCK “PULL” COTTER PIN THROUGH “WRAP” TIGHT TORQUE WRENCH DIFFERENTIAL AND DRIVELINE 3 - 9 REMOVAL AND INSTALLATION (Continued) (13) Clean all foreign matter from the threads of (15) Install the spring washer, hub nut lock, and the outer C/V joint stub axle.
  • Page 89 RETAINING SNAP RING INTERCONNECTING SEALING BOOT SHAFT TRIPOD SPIDER HOUSING SPIDER JOINT ASSEM- ASSEM- 3 - 10 DIFFERENTIAL AND DRIVELINE DISASSEMBLY AND ASSEMBLY pod joint sealing boot to interconnecting shaft and discard. Remove the sealing boot from the tripod DRIVESHAFT RECONDITIONING PROCEDURE housing and slide it down the interconnecting shaft.
  • Page 90 SPIDER ASSEM- INTERCONNECTING SHAFT ASSEMBLY WHEN REMOVING SPIDER BRASS DRIFT ASSEMBLY BEARINGS SPIDER SEALING BOOT INTERCONNECTING SHAFT SPIDER ASSEMBLY RAISED BEAD IN THIS AREA INTERCONNECTING SEALING BOOT GROOVE SHAFT DIFFERENTIAL AND DRIVELINE 3 - 11 DISASSEMBLY AND ASSEMBLY (Continued) (1) Slide inner tripod joint seal boot retaining clamp, onto interconnecting shaft.
  • Page 91 RETAINING BRASS SNAP RING INTERCONNECTING INTERCONNECTING DRIFT SHAFT SHAFT DO NOT HIT BEARINGS WHEN INSTALLING THE SPIDER ASSEMBLY SPIDER ASSEM- SPIDER ASSEM- SEALINGBOOT SEALING BOOT CLAMP TRIPOD INTERCON- NECTING SHAFT SPIDER HOUSING SPECIAL TOOL C-4975A JOINT ASSEM- 3 - 12 DIFFERENTIAL AND DRIVELINE DISASSEMBLY AND ASSEMBLY (Continued) (5) Align tripod housing with spider assembly and...
  • Page 92 CLAMP JAWS OF SPECIAL TOOL C-4975A CLOSED INTERCONNECTING TOGETHER HERE COMPLETELY MUST SHAFT INNER TRIPOD JOINT SEAL- TRIM STICK ING BOOT INNER JOINT HOUSING TRIPOD SEALING SEALING BOOT BOLT CLAMP DIFFERENTIAL AND DRIVELINE 3 - 13 DISASSEMBLY AND ASSEMBLY (Continued) (9) Insert a trim stick between the tripod joint and the sealing boot to vent inner tripod joint assembly (Fig.
  • Page 93 SEALINGBOOT JAWS OF SPE- CIAL C-4975A COMPLETELY TOGETHER HERE SPECIAL SPECIAL TOOL C -4975A SEALING BOOT CLOSED C-4975A MUST TOOL TOOL TRIPOD HOUSING TRIPOD JOINT CLAMP CLAMP HOUSING INNER JOINT HOUSING CLAMP TRIPOD TOP BAND OF CLAMP MUST BE RETAINED BY TABS AS SHOWN HERE TO CORRECTLY LATCH BOOT CLAMP SPECIAL...
  • Page 94 BEARING SHIELD OUTER C/V JOINT DRIFT HAMMER OUTER SPECIAL JOINT SPECIAL C-4698–2 TOOL C-4698–1 TOOL BEARING SHIELD BEARING SEAL MUST BE FLUSH SPECIAL C-4698–2 WITH OUTER C/V JOINT TOOL FRONT SPECIAL TOOL C-4698–1 BEARING SHIELD DIFFERENTIAL AND DRIVELINE 3 - 15 DISASSEMBLY AND ASSEMBLY (Continued) CAUTION: The outer C/V joint used on this vehicle BEARING SHIELD INSTALLATION ON OUTER...
  • Page 95 3 - 16 DIFFERENTIAL AND DRIVELINE SPECIFICATIONS SPECIAL TOOLS TORQUE SPECIFICATIONS DRIVESHAFT–SPECIAL TOOLS DESCRIPTION TORQUE Caliper To Knuckle Bolts ..31 N·m (23 ft. lbs.) Driveshaft Nut ... . 244 N·m (180 ft. lbs.) Front Wheel Lug Nuts .
  • Page 96 BRAKES 5 - 1 BRAKES CONTENTS page page ANTILOCK BRAKE SYSTEM–BENDIX ABX-4 . . 77 GENERAL INFORMATION ....1 BASE BRAKE SYSTEM ....2 GENERAL INFORMATION INDEX page...

  • Page 97: Table Of Contents

    5 - 2 BRAKES BASE BRAKE SYSTEM INDEX page page DESCRIPTION AND OPERATION PARK BRAKE LEVER ....50 CHASSIS TUBES AND HOSES .

  • Page 98: Description And Operation

    BRAKE PADS AND LININGS CALIPER GUIDE PIN BOLT CALIPER GUIDE PIN BOLT OUTBOARD BRAKE SHOE INBOARD BRAKE SHOE STEERING KNUCKLE CALIPER ASSEMBLY GUIDE PIN BOLTS WEAR INDICATOR BLEEDER SCREW BRAKE ROTOR DRIVING HUB PISTON SEAL DUST SEAL BUSHING BUSHING CALIPER SLEEVE SLEEVE PISTON...

  • Page 99: Front Disc Brakes

    PISTON BRAKE PISTON SURE OFF PRES- SEAL CALIPER HOUSING CYLINDER BORE DUST BOOT PISTON SEAL BRAKE PRESSURE AUTOMATIC LOWER RETURN SPRING UPPER RETURN SPRING BRAKE SUPPORT PLATE TRAILING BRAKE SHOE LEADING BRAKE SHOE BRAKE SHOE ANCHOR MOUNTING BRACKET PARK BRAKE LEVER PARK BRAKE LEVER RELEASE BUTTON WHEEL CYLINDER...
  • Page 100 BENT NAIL REAR PARK BRAKE CABLE ATTACHMENT TO TENSION EQUALIZER PARK CABLE ATTACHMENT TO TENSION BRAKE LEVER EQUALIZER OUTPUT LEFT PORTIONING VALVE RIGHT FRAME RAIL REAR FRONT PRO- RIGHT REAR PROPORTION- REAR WHEEL BRAKE TUBES HYDRAULIC FROM MASTER CYLINDER TROL UNIT (HCU) ING VALVE FRONT CON-...
  • Page 101 TO REAR BRAKE LINE CODE LABEL STAMP O-RING SEAL TO MASTER CYLINDER OR HYDRAULIC CONTROL UNIT MASTER DER FLUID RES- MASTER POWER VACUUM BOOSTER FLUID RESERVOIR MASTER ERVOIR CYLIN- CYLINDER BRAKE CYLINDER BODY MASTER CYLINDER SEC- ONDARY PORTS MASTER CYL- I NDER MASTER CYLINDER PRI- MARY PORTS 5 - 6...
  • Page 102 MASTER CYLINDER ASSEM- MASTER CYLINDER SEC- ONDARY PORT MASTER CYLINDER PRI- BRAKE FLUID RES- ERVOIR MARY PORT MASTER CYLINDER MOUNT- MASTER CYLINDER PUSH VACUUM MASTER MOUNTING STUDS (2) OUTPUT ROD VACUUM CHECK VALVE CYLINDER CHECK VALVE ING STUDS POWER BOOSTER ASSEM- MOUNTING STUDS (4) POWER BRAKE BOOSTER DASH...

  • Page 103: Rear Wheel Hub And Bearing Assembly

    MASTER CYLINDER ASSEMBLY BRAKE TUBES MASTER CYLINDER FLUID LEVEL SENSOR LEFT SHOCK TOWER 5 - 8 BRAKES DESCRIPTION AND OPERATION (Continued) Different systems and engine combinations require As the fluid drops below the minimum level, the different vacuum hose routings. fluid level sensor closes the brake warning light cir- The power brake vacuum booster assembly mounts cuit.

  • Page 104: Diagnosis And Testing

    BRAKES 5 - 9 DIAGNOSIS AND TESTING BRAKE SYSTEM BASIC DIAGNOSIS GUIDE CHART 1 CHART 2 CHART 3 CHART 4 CHART 5 SYMPTOM MISC. WARNING POWER BRAKE WHEEL COND. LIGHT BRAKES NOISE BRAKES Brake Warning Light On Excessive Pedal Travel Pedal Goes To The Floor Stop Light On Without Brakes All Brakes Drag...

  • Page 105: Brake System Diagnosis Charts

    CHECK OBSTRUCTION OF BRAKE INSPECT FOR AND COR- RECT STOP VERIFY THAT BRAKE PEDAL IS RETURNING FULLY TO APPLY RELEASE, WHEEL BY BLEEDER TURN WHEEL TURNS, HYDRAULIC PRESSURE WAS TRAPPED LOW ENGINE VACUUM SEE CONTAMINATED BINDING CALIPER PINS OR BUSHINGS REPLACE BUSH- BLOCKED OR PINCHED LINE LINING FRONT...
  • Page 106 CHECK FLUID LEVEL SWITCH AND MASTER CYLINDER FLOAT FOR REMOVE DER RESERVOIR CAP — CHECK FLUID LEVEL PROPER OPERATION MASTER FLUID LEVEL OK LIGHT CHECK BRAKE IS FULLY RELEASED CYLIN- “ON” THAT MALFUNCTION INDICATING PARKING REPAIR OR REPLACE AS CHECK FLUID LEVEL LOW ENTIRE CHECK WARNING LIGHT IGNITION...
  • Page 107 IF VACUUM SUPPLY IS BELOW 12 INCHES — REPLACE OR REPAIR VACUUM HOSE AND VACUUM FITTINGS. ALSO TUNE OR REPAIR IF PEDAL DOES NOT DROP, CONNECT VACUUM GAUGE TO SPEED CONTROL VACUUM PORT ON POWER UNIT. WITH ENGINE ENGINE OFF. DEPRESS AND RELEASE BRAKE PEDAL SEVERAL DEPRESS PEDAL AND HOLD WITH LIGHT EFFORT OF 15 TO 25 IF POWER UNIT IS OPERATING, PEDAL WILL FALL SLIGHTLY AND THEN HOLD.

  • Page 108: Brake Noise

    CHECK FOR FROZEN PISTONS, CONTAMI- NATED BRAKE SHOES/PADS, PINCHED LINES, DEFECTIVE MASTER HIGH CHART 5 WHEEL BRAKES LEAKING SEALS, PLUGGED BANJO BOLT LOW SPEED, LIGHT PEDAL REPLACE BRAKE PADS REFER TO GROUP 2 — SUS- PITCH CYLINDER EXCESSIVE PEDAL TRAVEL AUTOMATIC REPLACE MASTER CYLINDER.

  • Page 109: Drum Brake Automatic Adjuster Operation

    LUBRICATE THIS SUR- FACE BETWEEN QUAD- RANT AND STRUT OF ADJUSTER MECHANISM QUADRANT SCREWDRIVER KNURLED PIN SPRING AUTOMATIC REAR BRAKE SUPPORT AUTOMATIC ADJUSTER MECHA- STRUT ACCESS HOLE ADJUSTER PLATE SELF NISM 5 - 14 BRAKES DIAGNOSIS AND TESTING (Continued) DRUM BRAKE AUTOMATIC ADJUSTER OPERATION Fully apply the brake pedal which will cause the brake shoes to leave the anchor.
  • Page 110 CHALK SPECIAL SPECIAL MARK C-3339 SP-1910 TOOL TOOL MILLIMETERS FROM EDGE DISC SURFACE HUB SURFACE SPECIAL SP-1910 TOOL SPECIAL C-3339 TOOL CHALK MARK BRAKES 5 - 15 DIAGNOSIS AND TESTING (Continued) ROTOR RUNOUT AND THICKNESS VARIATION Install Dial Indicator, Special Tool C-3339 and On vehicle rotor runout is the combination of the Mounting Adaptor, Special Tool SP-1910 on steering individual runout of the hub face and the runout of...

  • Page 111: Proportioning Valves

    CALIPER PROPORTIONING VALVE TO MASTER CYLINDER OR HCU BRAKE PROPORTIONING VALVE FITTINGS FITTING TUBE SPECIAL TOOL C-4007–A SPECIAL TOOL 6805 PROPORTIONING VALVE TO MASTER CYLINDER OR HCU FITTING 5 - 16 BRAKES DIAGNOSIS AND TESTING (Continued) If runout is not within specifications. Install a new taining the required hydraulic pressure to the rear rotor or reface rotor, being careful to remove as little wheel brake which it controls.
  • Page 112 REAR WHEEL BRAKE TUBES FROM MASTER CYLINDER FRONT CROSSMEMBER SUSPENSION BRAKE TUBE ASSEMBLY ROUT- NON-ABS EQUIPPED PROPOR- TIONING VALVES ING BRACKET BRAKES 5 - 17 DIAGNOSIS AND TESTING (Continued) PROPORTIONING VALVE TESTING NON-ABS (4) Install Pressure Test Fitting, Special Tool BRAKES 6805-1 or 6805-2 on rear brake tube which the pro- If premature rear wheel skid occurs on a hard...
  • Page 113 LEFT PORTIONING VALVE RIGHT FRAME RAIL REAR FRONT PRO- RIGHT REAR PROPORTION- HYDRAULIC TROL UNIT (HCU) ING VALVE CON- RIGHT DRIVE SHAFT 5 - 18 BRAKES DIAGNOSIS AND TESTING (Continued) Once the wheel which is skidding first is determined, (4) Install Pressure Test Fitting, Special Tool use the following procedure to diagnose the propor- 6805-1 or 6805-2 into the outlet port of the HCU.

  • Page 114: Red Brake Warning Lamp Test

    MASTER CYLINDER MASTER CYLINDER BRAKE FLUID RESERVOIR BRAKES 5 - 19 DIAGNOSIS AND TESTING (Continued) (13) Bleed the affected brake line. See Bleeding Master cylinder reservoirs are marked with the Brake System in the Service Adjustments section of words FULL AND MIN indicating proper range of the manual for proper bleeding procedure.
  • Page 115 TRAPPED AIR CALIPER CLEAN BRAKE ASSEMBLY FLEX HOSE CLEAR HOSE FLUID BRAKE CALIPER BRAKE BLEEDER SCREW BLEEDER SCREW CALIPER GUIDE PIN BOLTS (2) 5 - 20 BRAKES SERVICE PROCEDURES (Continued) CAUTION: Before removing the master cylinder cover, wipe it clean to prevent dirt and other foreign matter from dropping into the master cylinder.
  • Page 116 MASTER FLUID RESERVOIR MASTER CYLINDER CYLINDER SPECIAL TOOL SPECIAL TOOL 6802 6802 MASTER CYLINDER ASSEMBLY BRAKES 5 - 21 SERVICE PROCEDURES (Continued) BLEEDING WITHOUT A PRESSURE BLEEDER MASTER CYLINDER BLEEDING PROCEDURE (1) Clamp the master cylinder in a vise. Attach NOTE: Correct bleeding of the brakes hydraulic Bleeding Tubes, Special Tool 6802 to the master cyl-...

  • Page 117: Brake Rotor Machining

    SPECIAL TOOL 6802 BRAKE FLUID RES- ERVOIRMASTER CYLINDER WOODEN DOWEL BRAKING DISC BRAKING DISC GRINDER CUTTING TOOLS DAMPER 5 - 22 BRAKES SERVICE PROCEDURES (Continued) (2) Fill brake fluid reservoir with brake fluid con- BRAKE ROTOR REFINISHING INFORMATION forming to DOT 3 specifications such as Mopar or an If the rotor surface is deeply scored or warped, or Equivalent.
  • Page 118 MINIMUM THICKNESS MARKINGS BRAKES 5 - 23 SERVICE PROCEDURES (Continued) The following chart shows the location of measure- The collets, shafts and adapters used on the brake ments and specifications when servicing the rotor. lathe and the bearing cups in the rotor MUST be clean and free from any chips or contamination.
  • Page 119 MAXIMUM DIAMETER MARK- HUB/BEARING ASSEMBLY REAR BRAKE DRUM BE SURE ALL BURRS ARE REMOVED FROM INSIDE OF TUBING HYDRAULIC BRAKE TUBING LINE BE SURE END OF TUBING IS SQUARE BEFORE FLARING TUBE 5 - 24 BRAKES SERVICE PROCEDURES (Continued) BRAKE DRUM MACHINING Using Tubing Cutter, Special Tool C-3478-A or equivalent, cut off damaged seat or tubing (Fig.

  • Page 120: Removal And Installation

    DOUBLE INVERTED-STYLE FLARE INVERTED TUBE NUT FLARE TUBE INVERTED DOUBLE FLARE SEAT TORQUE WRENCH BRAKES 5 - 25 SERVICE PROCEDURES (Continued) DOUBLE INVERTED TUBING FLARES REMOVAL AND INSTALLATION To make a double inverted tubing flare (Fig. 41) and (Fig. 42). Open handles of Flaring Tool, Special WHEEL AND TIRE Tool C-4047 or equivalent.
  • Page 121 CALIPER STEERING LIFT THIS END OF CALIPER AWAY ROTOR KNUCKLE GUIDE PIN BOLTS FROM ASSEMBLY KNUCKLE FIRST DISC BRAKE CALI- STEERING PER ASSEMBLY STEERING KNUCKLE DISC BRAKE CALI- PER ASSEMBLY OUTBOARD BRAKE SHOE DISC BRAKE CALI- PER ASSEMBLY WIRE HANGER UPPER CONTROL ARM STEERING KNUCKLE...

  • Page 122: Front Brake Shoes

    CALIPER STEERING LIFT THIS END OF CALIPER AWAY ROTOR KNUCKLE GUIDE PIN BOLTS FROM ASSEMBLY KNUCKLE FIRST DISC BRAKE CALI- STEERING PER ASSEMBLY STEERING KNUCKLE DISC BRAKE CALI- PER ASSEMBLY OUTBOARD BRAKE SHOE BRAKES 5 - 27 REMOVAL AND INSTALLATION (Continued) (7) Remove jackstands or lower hoist.
  • Page 123 DISC DISC BRAKE CALI- PER ASSEMBLY WIRE HANGER ASSEMBLY (STORED) STEERING KNUCKLE BRAKE BRAKING DISC CALIPER UPPER CONTROL ARM STEERING KNUCKLE ROTOR BRAKE INBOARD OUTBOARD BRAKE SHOE BRAKE SHOE SHOE BRAKE CALIPER RETAINING PINS PISTON HANGER WIRE RETAINING CLIP CALIPER ASSEMBLY ABS SPEED SEN- SOR CABLE...
  • Page 124 LEFT RIGHT OUTBOARD BRAKE INBOARD BRAKE SHOE OUTBOARD WEAR INDICATOR BRAKE SHOE SHOE BRAKE SHOE PISTON CALIPER ASSEMBLY BRAKES 5 - 29 REMOVAL AND INSTALLATION (Continued) INSTALL (5) Install the new inboard brake shoe assembly (1) Completely retract caliper piston back into pis- into the caliper piston by firmly pressing into piston ton bore of caliper assembly.

  • Page 125: Rear Brake Drum

    INSTALL THIS END OF CALI- OUTBOARD BRAKE SHOE DISC BRAKE CALIPER UNDER STEERING KNUCKLE KNUCKLE FIRST STEERING ROTOR REAR SCREW- DRIVER SUSPENSION ERAL LINK LAT- ACCESS HOLE BRAKE SUPPORT PLATE REAR BRAKE SUPPORT PLATE AUTOMATIC ADJUSTER ACCESS HOLE PLUG 5 - 30 BRAKES REMOVAL AND INSTALLATION (Continued) (7) Carefully position brake caliper and brake...

  • Page 126: Rear Brake Shoes

    HUB/BEARING ASSEMBLY BRAKE SUPPORT PLATE HUB/BEARING RETAINING NUT WHEEL NUT BRAKE DRUM AUTOMATIC LOWER RETURN SPRING UPPER RETURN SPRING BRAKE SUPPORT PLATE TRAILING BRAKE SHOE LEADING BRAKE SHOE BRAKE SHOE ANCHOR PARK BRAKE LEVER WHEEL CYLINDER HOLD DOWN CLIP HOLD DOWN CLIP MECHANISM ADJUSTER SPRING...
  • Page 127 REAR SCREW- DRIVER SUSPENSION ERAL LINK LAT- ACCESS HOLE BRAKE SUPPORT PLATE REAR BRAKE SUPPORT PLATE HUB/BEARING REAR TRAILING BRAKE SHOE ASSEMBLY BRAKE DRUM REAR LATERAL AUTOMATIC ACTUATING SPRING MECHANISM ADJUSTER REAR SUPPORTPLATE SHOCK ASSEMBLY BRAKE AUTOMATIC ADJUSTER ACCESS HOLE PLUG 5 - 32 BRAKES REMOVAL AND INSTALLATION (Continued)
  • Page 128 LEADING BRAKE SHOE LEADING BRAKE SHOE ASSEMBLY LOWER RETURN SPRING TRAILING SHOE ASSEMBLY BRAKE TRAILING BRAKE SHOE PORT PLATE BRAKE SUP- BRAKE SUPPORT LEADING BRAKE SUPPORT PLATE ADJUSTER MECHANISM BRAKE SHOE LEADING BRAKE SHOE PLATE REINFORCEMENT PLATE RETAINER UPPER RETURN SPRING BRAKES 5 - 33...
  • Page 129 TRAILING BRAKE SHOE BRAKE PORT PLATE SUP- PARK BRAKE CABLE BRAKE SUPPORT PARK BRAKE ACTUAT- PLATE ING LEVER LEADING FULLY EXTEND ADJUSTER AUTOMATIC ROTATE THIS DIRECTION ADJUSTER MECHANISM IN THIS DIRECTION BRAKE ASSEMBLY SHOE SELF RETAINER 5 - 34 BRAKES REMOVAL AND INSTALLATION (Continued) (11) Remove the brake shoe retainer and pin, (Fig.
  • Page 130 RIGHT BRAKE SHOE WEB REIN- BRAKE SHOE WEB REIN- LEFT LUBRICATE THIS SUR- FACE BETWEEN QUAD- RANT AND STRUT OF ADJUSTER MECHANISM BRAKE SHOE LINING HAND QUADRANT BRAKE SHOE WEB BRAKE SHOE WEB HAND BRAKE SHOE RIM BRAKE SHOE BRAKE SHOE FORCEMENT FORCEMENT LEADING...

  • Page 131: Rear Brake Support Plate

    AUTOMATIC ADJUSTER MECHANISM LEADING BRAKE SHOE REINFORCEMENT PLATE SELF DUST CAP HUB/BEARING ASSEMBLY 5 - 36 BRAKES REMOVAL AND INSTALLATION (Continued) (4) Install the automatic self adjuster mechanism (9) Install the automatic adjuster actuation spring on the correct leading brake shoe assembly using the first on the trailing brake shoe and then hook it onto reverse procedure as indicated in step Step 14 of the adjuster...
  • Page 132 HUB/BEARING WHEEL CYLINDER ASSEMBLY BRAKE RETAINING NUT HOSE FLEX SPINDLE 1/2” PARK BRAKE CABLE PARK BRAKE CABLE RETAINER WRENCH REAR SUPPORTPLATE BRAKE BRAKES 5 - 37 REMOVAL AND INSTALLATION (Continued) (4) Remove the rear hub and bearing assembly (7) Position a 1/2 wrench over the retainer fingers retaining nut (Fig.

  • Page 133: Rear Brake Wheel Cylinder

    WHEEL CYLINDER BRAKE HOSE FLEX WHEEL ATTACHING BOLTS REAR CYLINDER CYLINDER WHEEL 5 - 38 BRAKES REMOVAL AND INSTALLATION (Continued) (9) Bleed the vehicle’s base brakes hydraulic sys- (3) Remove rear wheel cylinder attaching bolts tem. (Fig. 80). Then pull wheel cylinder assembly off (10) After brake drums are installed, pump brake brake support plate.

  • Page 134: Rear Hub And Bearing

    HUB/BEARING REAR ASSEMBLY DUST CAP BRAKE DRUM REAR LATERAL REAR SUPPORTPLATE HUB/BEARING SHOCK ASSEMBLY ASSEMBLY BRAKE HUB/BEARING ASSEMBLY RETAINING NUT SPINDLE BRAKES 5 - 39 REMOVAL AND INSTALLATION (Continued) REAR HUB AND BEARING (5) Remove hub/bearing assembly to rear spindle retaining nut (Fig.
  • Page 135 MASTER CYLINDER ASSEM- MASTER CYLINDER SEC- ONDARY PORT MASTER CYLIN- BRAKE FLUID RES- WIRING HARNESS CONNEC- MASTER CYLINDER PRI- BRAKE FLUID RES- ERVOIR BRAKE FLUID LEVEL ERVOIR MARY PORT SEN- BRAKE FLUID RES- MASTER DER FLUID RES- ERVOIR ERVOIR CYLIN- MASTER CYLINDER SEC- MOUNTING NUTS (2) ONDARY PORTS...
  • Page 136 MASTER FLUID RESERVOIR MASTER CYLINDER CYLINDER SPECIAL TOOL 6802 SPECIAL TOOL 6802 MASTER CYLINDER ASSEMBLY SPECIAL TOOL 6802 BRAKE FLUID RES- ERVOIRMASTER CYLINDER WOODEN DOWEL BRAKES 5 - 41 REMOVAL AND INSTALLATION (Continued) BLEEDING MASTER CYLINDER (3) Using a wooden dowel per (Fig. 90), depress (1) Clamp the master cylinder in a vise.

  • Page 137: Vacuum Booster 2.0 And 2.4 Ltr. Engine

    MASTER CYLINDER REMOTE GROUND CABLE LEFT GROUNDSTUD AIR CLEANER GROUND TOWER STRUT STUD MASTER MOUNTING ASSEMBLY CYLINDER ATTACHING NUTS BRACKET MASTER SPEED LEFT CYLIN- TOWER STRUT CONTROL SERVO ELECTRICAL LEFT PURGE SOLE- CONNECTOR VACUUM HARNESS TOWER STRUT NOID LEFT STRUT TOWER SPEED CONTROL SERVO 5 - 42 BRAKES...
  • Page 138 VACUUM HOSE FROM INTAKE MANIFOLD SPEED CONTROL VACUUM EGR VALVE TRANS- RESERVOIR HOSE DUCER EGR VALVE BRAKE FLUID RES- MASTER CYLINDER ASSEMBLY ERVOIR MOUNTING NUTS (2) BRAKE TUBES MASTER CYLINDER FLUID LEVEL SENSOR MASTER CYLINDER BRAKE VACUUM BOOSTER HEATER VACUUM HOSE TO EGR LEFT SHOCK HOSES...
  • Page 139 POWER BRAKE PEDAL UUM BOOSTER BRAKE VAC- TRANSAXLE SCREWDRIVER INPUT ROD RETAINING CLIP MASTER CYLINDER AND BRAKE PEDAL PIN LEFT STRUT TOWER BRAKE TUBES FRAME FRONT RAIL DASH PANEL AIR CLEANER BRAKE P EDAL POWER BOOSTER AIR CLEANER HOSE MOUNTING BRAKE NUTS POWER...

  • Page 140: Vacuum Booster 2.5 Ltr. Engine

    MASTER CYLINDER REMOTE GROUND CABLE LEFT GROUNDSTUD AIR CLEANER GROUND TOWER STRUT STUD LEFT STRUT TOWER SPEED CONTROL SERVO BRAKES 5 - 45 REMOVAL AND INSTALLATION (Continued) INSTALL VACUUM BOOSTER 2.5 LTR. ENGINE (1) Position power brake booster onto dash panel. (2) Install and torque the 4 power brake vacuum REMOVE booster mounting nuts (Fig.
  • Page 141 INTAKE MANI- ELECTRICAL THROTTLE CONNECTOR CHAM- FOLD ATTACHINGBOLT POSITION INTAKE MANIFOLD VACUUMHOSE SENSOR THROTTLE BODY MOUNT- HOSE THROTTLE THROTTLE ING BOLTS BODY BODY AIS MOTOR SPEED THROTTLE CABLE ELECTRICAL CONTROL CONNECTOR HOSE INLET CABLE CLEANER HOUSING BRACKET EGR VALVE MOUNTING NUTS INTAKE MOUNTING BOLTS...
  • Page 142 MASTER DER FLUID RES- ERVOIR CYLIN- MASTER CYLINDER SEC- ONDARY PORTS MASTER CYLINDER ASSEMBLY PRIMARY BRAKE TUBE SECONDARY BRAKE TUBE MASTER CYL- I NDER BRAKE FLUID RES- MASTER CYLINDER ASSEMBLY ERVOIR MOUNTING NUTS (2) BRAKE TUBES MASTER CYLINDER FLUID LEVEL SENSOR MASTER CYLINDER BRAKE...
  • Page 143 TRANSAXLE DIPSTICK TUBE DIPSTICK VACUUM HARNESS POWER BRAKE BOOSTER VACUUM ELECTRICAL CONNECTOR PURGE SOLENOID TRANSAXLE ATTACHING BOLT BRAKE PEDAL BRAKE P EDAL POWER BOOSTER SCREWDRIVER INPUT ROD MOUNTING BRAKE NUTS RETAINING CLIP BRAKE PEDAL PIN 5 - 48 BRAKES REMOVAL AND INSTALLATION (Continued) (11) Remove the vacuum harness connector and (14) Locate the power brake vacuum booster input electrical connector from the purge solenoid (Fig.
  • Page 144 POWER BRAKE BOOSTER VACUUM BRAKES 5 - 49 REMOVAL AND INSTALLATION (Continued) (16) Slide power brake vacuum booster straight assembly outlet ports. Tighten all tube nuts to a forward until mounting studs clear dash panel. Then torque of 17 N·m (145 in. lbs.). lift power brake vacuum booster strait up to remove (11) Install the vehicle’s wiring harness connector it from the vehicle (Fig.
  • Page 145 REAR WHEEL BRAKE TUBES FROM MASTER CYLINDER FRONT CROSSMEMBER SUSPENSION CENTER CONSOLE COVER ATTACHING SCREWS CENTER CONSOLE CENTER CONSOLE PASSENGER SEAT ALLEN WRENCH DRIVER SEAT SHIFT KNOB BRAKE TUBE ASSEMBLY ROUT- NON-ABS EQUIPPED PROPOR- TIONING VALVES ING BRACKET 5 - 50 BRAKES REMOVAL AND INSTALLATION (Continued) Use new copper seal washers on all connections...
  • Page 146 KNOB SHIFTER HANDLE SHIFTER KNOB CLIPSBOOT PARK BRAKE HAND LEVER CENTER GEARSHIFT MECHANISM CONSOLE ATTACHING SCREWS CENTER CONSOLE SHIFTER BOOT ATTACHING SCREWS SHIFTER HANDLE SHIFTER BRAKES 5 - 51 REMOVAL AND INSTALLATION (Continued) (3) If the vehicle is equipped with a manual trans- mission remove the gearshift knob and shifter boot using the following procedure.
  • Page 147 PARK BRAKE LEVER OUT- PARK BRAKE LEVER OUT- REAR PARK BRAKE CABLES PARK BRAKE CABLE TEN- PARK BRAKE LEVER CABLE RETAINER SION EQUALIZER ADJUSTING NUT SCREWDRIVER PUT CABLE PUT CABLE ELECTRICAL CONNECTOR PARK BRAKE MECHANISM SHIFTER MECHANISM PARK BRAKE LEVER PASSENGER SEAT WIRING HARNESS GROUND SWITCH...
  • Page 148 PARK BRAKE MECHANISM MOUNTING BOLTS MOUNTING BOLTS BRACKET PARK BRAKE CABLE TEN- PARK BRAKE LEVER OUT- REAR PARK BRAKE CABLES REAR PARK BRAKE CABLES PARKING PARK BRAKE CABLE TEN- PARK BRAKE MECHANISM PARK BRAKE MECHANISM CABLE RETAINING CLIP NISM OUTPUT CABLE PARK BRAKE LEVER SION EQUALIZER SION EQUALIZER...
  • Page 149 PARK BRAKE CABLE TEN- PARK BRAKE LEVER SION EQUALIZER ADJUSTING NUT BENT NAIL 12 mm PARK BRAKE LEVER OUT- PARK BRAKE LEVER MECH- CENTER CONSOLE COVER ATTACHING SCREWS PARK BRAKE LEVER CENTER CONSOLE PASSENGER SEAT DRIVER SEAT PUT CABLE ANISM 5 - 54 BRAKES REMOVAL AND INSTALLATION (Continued)
  • Page 150 CENTER CONSOLE KNOB ALLEN WRENCH SHIFT KNOB CLIPSBOOT GEARSHIFT MECHANISM ATTACHING SCREWS CENTER CONSOLE SHIFTER HANDLE SHIFTER KNOB SHIFTER BOOT SHIFTER HANDLE BRAKES 5 - 55 REMOVAL AND INSTALLATION (Continued) (2) If vehicle is equipped with an automatic trans- mission remove the shift knob from the shifter. The gear shift knob is attached to the shifter using a set screw (Fig.
  • Page 151 PARK BRAKE LEVER OUT- CENTER CONSOLE PARK BRAKE LEVER ADJUSTING NUT PUT CABLE ATTACHING SCREWS SHIFTER REAR PARK BRAKE CABLES REAR PARK BRAKE CABLES VEHICLE CARPETING ROUTING CLIP FLOOR PAN PARK BRAKE CABLE TEN- SION EQUALIZER 5 - 56 BRAKES REMOVAL AND INSTALLATION (Continued) (9) Remove the rear park brake cable requiring service, from the park brake cable tension equalizer...
  • Page 152 REAR HUB/BEARING REAR ASSEMBLY 1/2” BOX END WRENCH PARK BRAKE DRUM BRAKE CABLE REAR LATERAL CONSOLE BRACKET VEHICLE CARPETING REAR SUPPORTPLATE SHOCK ASSEMBLY BRAKE HUB/BEARING ASSEMBLY DUST CAP RETAINING NUT SPINDLE HUB/BEARING ASSEMBLY BRAKES 5 - 57 REMOVAL AND INSTALLATION (Continued) (14) Install the box end of a 1/2 in.
  • Page 153 1/2” PARK BRAKE CABLE BRAKE SUPPORT PARK BRAKE CABLE PARK BRAKE ACTUAT- PLATE PARK BRAKE CABLE RETAINER WRENCH ING LEVER REAR SUPPORTPLATE BRAKE FRAME PARK BRAKE CABLE RAIL ROUTING BRACKETS PARK BRAKE CABLE EXHAUST PIPE FRAME RAIL ROUTING BRACKETS FUEL TANK TRAILING BRAKE SHOE...
  • Page 154 PARK BRAKE CABLE FUEL TANK SEALING GROMMET FUEL LINES VEHICLE FLOOR PAN PARK BRAKE CABLE RETAINER RETAININGTABS PARK BRAKE CABLE RETAININGBRACKET BRAKES 5 - 59 REMOVAL AND INSTALLATION (Continued) (25) Remove the park brake cable and sealing (5) Install hub/bearing assembly on rear spindle. grommet (Fig.
  • Page 155 PARK BRAKE LEVER OUT- REAR PARK BRAKE CABLES PARK BRAKE CABLE TEN- PARK BRAKE CABLE TEN- PARK BRAKE LEVER OUT- REAR PARK BRAKE CABLES PARK BRAKE MECHANISM PARK BRAKE LEVER CABLE RETAINER SION EQUALIZER SION EQUALIZER SCREWDRIVER PUT CABLE PUT CABLE REAR PARK BRAKE CABLES PARKING PARK BRAKE CABLE TEN-...

  • Page 156: Disassembly And Assembly

    STRIKER BRAKE LIGHT SWITCH BRAKE PEDAL SWITCH BRACKET BRAKES 5 - 61 REMOVAL AND INSTALLATION (Continued) (17) Check the rear wheels of the vehicle with the INSTALL park brake lever fully released, they should rotate NOTE: Prior to installing stop lamp switch into freely without dragging.

  • Page 157: Brake Fluid Level Switch

    FLUID MASTER CYLINDER RESER- VOIR MASTER CYLIN- GROMMET BRAKE FLUID RES- WIRING HARNESS CONNEC- ERVOIR BRAKE FLUID LEVEL SEN- MASTER CYLIN- FLUID MASTER FLUID RESER- BRAKE RESER- VOIR BRAKE CYLIN- VOIR FLUID LEVEL SWITCH RETAINING MASTER CYLINDER TABS BRAKE LEVEL SWITCH MASTER CYL- I NDER FLUID...
  • Page 158 SLEEVE CALIPER BUSHING CALIPER CALIPER GUIDE PIN BUSHING BUSHING BRAKES 5 - 63 DISASSEMBLY AND ASSEMBLY (Continued) ing Service in Disc Brake Caliper Service in this sec- (3) Using your fingers, collapse one side of the tion of the service manual. bushing.
  • Page 159 BE SURE BOTH BUSHING FLANGES ARE FULLY SEATED AROUND CALIPER BUSH- CALIPER ING BORES. BUSHING CALIPER BUSHING CALIPER BUSHING SLEEVE 5 - 64 BRAKES DISASSEMBLY AND ASSEMBLY (Continued) (2) Insert the folded bushing into the caliper hous- (4) Lubricate the inside surfaces of the bushing using ing (Fig.
  • Page 160 CALIPER BE SURE THE BUSHING IS FULLY SEATED IN SEAL GROOVE OF SLEEVE AS SHOWN. BUSHINGSLEEVE CALIPER SCREW DRIVER BOOT BRAKES 5 - 65 DISASSEMBLY AND ASSEMBLY (Continued) (7) Holding sleeve in place, work other end of (3) If both front caliper pistons are to be removed, bushing over end of sleeve and into the seal grove on disconnect brake tube at flexible brake hose at frame sleeve (Fig.
  • Page 161 PISTON SEAL PLASTIC TRIM STICK PISTON SEAL GROOVE CALIPER CALIPER CALIPERBORE SPECIAL C-4095 TOOL 5 - 66 BRAKES DISASSEMBLY AND ASSEMBLY (Continued) (8) Using a soft tool, such as a plastic trim stick, (10) Inspect the piston bore for scoring or pitting. work piston seal out of its groove in caliper piston Bores that show light scratches or corrosion can usu- bore (Fig.
  • Page 162 CALIPER SEAL GROOVE PISTON SEAL CALIPER SPECIAL C-4171 TOOL CALIPER SPECIAL PISTON HAMMER C-4689 TOOL BOOT BRAKES 5 - 67 DISASSEMBLY AND ASSEMBLY (Continued) CALIPER ASSEMBLY (5) Install piston into caliper bore pushing it past the piston seal until it bottoms in the caliper bore CAUTION: Excessive vise pressure will cause bore (Fig.

  • Page 163: Wheel Cylinder Rear Drum Brake

    5 - 68 BRAKES DISASSEMBLY AND ASSEMBLY (Continued) (9) Install brake pads. See Installing Brake Pads (4) Install piston in each end of cylinder having in the Brake Pad Service Procedures section of this the flat face of each piston contacting the flat face of manual.
  • Page 164 MEASURE THIS DISTANCE MEASURE THIS DISTANCE TRAILING BRAKE SHOE LEADING BRAKE SHOE PUSH-ON BOOT PISTON CYLINDER BLEEDER SCREW LUBRICATE THIS SUR- FACE BETWEEN QUAD- RANT AND STRUT OF ADJUSTER MECHANISM QUADRANT EXPANDERS KNURLED PIN SPRING SPRING PISTON AUTOMATIC ADJUSTER MECHA- STRUT PUSH-ON BOOT SELF...

  • Page 165: Rear Wheel Hub And Bearing Assembly

    STRIKER BRAKE LIGHT SWITCH BRAKE PEDAL SWITCH BRACKET 5 - 70 BRAKES CLEANING AND INSPECTION (Continued) If old springs have overheated or are damaged, ADJUSTMENTS replace. Overheating indications are paint discolora- tion or distorted end coils. STOP LAMP SWITCH (1) Remove stop lamp switch from its bracket by REAR DRUM BRAKE WHEEL CYLINDER rotating it approximately 30°...

  • Page 166: Parking Brake Adjustment

    LUBRICATE THIS SUR- FACE BETWEEN QUAD- RANT AND STRUT OF ADJUSTER MECHANISM QUADRANT KNURLED PIN SPRING AUTOMATIC ADJUSTER MECHA- STRUT SELF NISM BENT NAIL ATTACHING SCREWS CENTER CONSOLE PASSENGER SEAT DRIVER SEAT REAR PARK BRAKE CABLE ATTACHMENT TO TENSION EQUALIZER PARK CABLE ATTACHMENT TO TENSION BRAKE...
  • Page 167 CENTER CONSOLE KNOB ALLEN WRENCH SHIFT KNOB CLIPSBOOT PARK BRAKE HAND LEVER GEARSHIFT MECHANISM ATTACHING SCREWS CENTER CONSOLE SHIFTER HANDLE SHIFTER KNOB SHIFTER BOOT SHIFTER HANDLE 5 - 72 BRAKES ADJUSTMENTS (Continued) (2) If vehicle is equipped with an automatic trans- mission remove the shift knob from the shifter.
  • Page 168 PARK BRAKE LEVER OUT- CENTER CONSOLE PARK BRAKE LEVER ADJUSTING NUT PUT CABLE ATTACHING SCREWS SHIFTER PARK BRAKE LEVER OUT- REAR PARK BRAKE CABLES PARK BRAKE CABLE TEN- PARK BRAKE CABLE TEN- PARK BRAKE LEVER OUT- REAR PARK BRAKE CABLES PARK BRAKE MECHANISM PARK BRAKE LEVER CABLE RETAINER...
  • Page 169 REAR PARK BRAKE CABLES PARKING PARK BRAKE CABLE TEN- PARK BRAKE MECHANISM CABLE RETAINING CLIP NISM OUTPUT CABLE SION EQUALIZER BRAKE MECHA- PARK BRAKE CABLE TEN- PARK BRAKE LEVER SION EQUALIZER ADJUSTING NUT BENT NAIL 12 mm 5 - 74 BRAKES ADJUSTMENTS (Continued) (12) Install a new park brake lever output cable to...

  • Page 170: Specifications

    BRAKES 5 - 75 SPECIFICATIONS ACTUATION: Boost At 20 inches Of Manifold Vacuum . . . 4690 All BRAKE FLUID SCREW IN PROPORTIONING VALVE: Material ......Aluminum The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703 standards.

  • Page 171: Special Tools

    5 - 76 BRAKES SPECIAL TOOLS BASE BRAKE SYSTEM Installer, Dust Boot C-4689 Adapters, Brake Pressure Test 6805 Dial Indicator C-3339 Gauge Set C-4007-A Tubes, Master Cylinder Bleeding 6802 Handle, Universal C-4171...
  • Page 172 BRAKES 5 - 77 ANTILOCK BRAKE SYSTEM–BENDIX ABX-4 INDEX page page DESCRIPTION AND OPERATION DIAGNOSTIC TESTER (DRB) ....83 ABS AMBER WARNING LAMP FUNCTION AND DIAGNOSTIC TROUBLE CODE LOCATION .
  • Page 173 5 - 78 BRAKES DESCRIPTION AND OPERATION (Continued) • FWD—Front Wheel Drive the tires ride on a film of water. This results in the • DTC—Diagnostic Trouble Code vehicles tires leaving the road surface rendering the vehicle virtually uncontrollable. In addition, extreme ABS OPERATION AND VEHICLE PERFORMANCE steering maneuvers at high speed or high speed cor- This ABS System represents the current state-of-...
  • Page 174 MASTER CYLINDER ASSEMBLY POWER VACUUM BOOSTER BRAKE FRONT SION CROSSMEM- DRIVESHAFT SUSPEN- RIGHT FRAME RAIL STEERING GEAR HCU MOUNTING HYDRAULIC CONTROL UNIT BRACKET BRAKES 5 - 79 DESCRIPTION AND OPERATION (Continued) ABS MASTER CYLINDER AND POWER BRAKE The hydraulic control unit HCU is located on the right side of the vehicle, mounted to the front sus- VACUUM BOOSTER pension (Fig.
  • Page 175 SYSTEM RELAY AND PUMP/ MOTOR RELAY BOX SYSTEM RELAY AND PUMP/MO- TOR RELAY BOX 10 WAY CON- NECTOR 6–WAY NECTOR CON- 5 - 80 BRAKES DESCRIPTION AND OPERATION (Continued) HYDRAULIC CONTROL UNIT SHUTTLE VALVES PUMP/MOTOR RELAY OPERATION There are 4 Shuttle Valves, one for each wheel. Pump/Motor power is supplied by the Pump/Motor The Shuttle Valve is a hydraulically actuated valve Relay.
  • Page 176 TO REAR BRAKE LINE STEERING WHEEL CODE KNUCKLE SENSOR SPEED LABEL STAMP TONE WHEEL ATTACHING O-RING SEAL BOLT TO MASTER CYLINDER OR HYDRAULIC CONTROL UNIT WHEEL SPEED SEN- BRAKE SUPPORT TONE WHEEL PLATE HUB/BEARING ASSEMBLY WHEEL SPEED SENSOR DRIVESHAFT CABLE BRAKES 5 - 81 DESCRIPTION AND OPERATION (Continued)
  • Page 177 WINDSHIELD HOOD PROP ROD FLUID BOTTLE AIR CONDITION- WASHER ING HOSE CONTROLLER ANTILOCK BRAKES 60–WAY TRICAL NECTOR ELEC- CON- 5 - 82 BRAKES DESCRIPTION AND OPERATION (Continued) CONTROLLER ANTILOCK BRAKES (CAB) messages will remain in the CAB memory even after the ignition has been turned off.
  • Page 178 HOOD RELEASE DIAGNOSTIC DRIVER’S KICK PANEL NECTOR SIDE CON- BRAKES 5 - 83 DESCRIPTION AND OPERATION (Continued) tion, requiring the same hydraulic fluid modulation See the ABS System Operation section in this group at the same rate. of the service manual to familiarize yourself with the operating principles of the ABS system.
  • Page 179 5 - 84 BRAKES DIAGNOSIS AND TESTING (Continued) START-UP CYCLE INTERMITTENT DIAGNOSTIC TROUBLE CODES The self diagnostic ABS start up cycle begins when As with virtually any electronic system, intermit- the ignition switch is turned to the on position. Elec- tent faults in the ABS system may be difficult to trical checks are completed on ABS components, such accurately diagnose.
  • Page 180 TO REAR BRAKE LINE CODE LABEL STAMP O-RING SEAL TO MASTER CYLINDER OR HYDRAULIC CONTROL UNIT BRAKES 5 - 85 DIAGNOSIS AND TESTING (Continued) wheel Runout in the Specification Section in this sec- If brake fluid is contaminated, drain and thor- tion of the service manual for the tonewheel runout oughly flush system.
  • Page 181 HOOD RELEASE DIAGNOSTIC DRIVER’S KICK PANEL NECTOR SIDE CON- 5 - 86 BRAKES DIAGNOSIS AND TESTING (Continued) procedure. These circuits should only be tested procedure to be used. This brake system can be using a high impedance multi-meter or the DRB either pressure bled or manually bled.
  • Page 182 MASTER CYLINDER REMOTE GROUND CABLE LEFT GROUNDSTUD AIR CLEANER GROUND TOWER STRUT STUD LEFT STRUT TOWER SPEED CONTROL SERVO BRAKES 5 - 87 SERVICE PROCEDURES (Continued) (4) Bleed the base brake system using the stan- ABS HYDRAULIC CONTROL UNIT dard pressure or manual bleeding procedure as out- lined in the Service Adjustments section of this REMOVE service manual.
  • Page 183 CLUTCH EQUIPPED BRAKE P EDAL WITH PEDAL TRANSAXLE) THROTTLE PEDAL MANUAL DRIVER’S SEAT STEERING WHEEL NUTS 32 N·M (24 SHOULDER BOLT (250 IN. LBS.) SPRING FWD FT. LBS.) N·M GASKET NUTS 2.4/2.5L ENGINE 2.0L ENGINE SEAL RING BRAKE PEDAL HOLDING TOOL 5 - 88 BRAKES...
  • Page 184 REAR MUFFLER SUPPORT SPLASH SHIELD ISOLATORS FRONT MUFFLER SUPPORT DRIVESHAFT FRONT ISOLATOR CROSSMEMBER SUSPENSION MOUNTING BRACKET STEERING GEAR RESONATOR PORT ISOLATORS ATTACHING SHIELD HEAT BOLT SUP- EXHAUST PIPE BRAKES 5 - 89 REMOVAL AND INSTALLATION (Continued) Fig. 15 Exhaust System Support/Isolator Locations •...
  • Page 185 6–WAY RELAY BRAKE TOR CONNECTOR BRAKE TUBE PUMP/MO- TUBE ROUTING CLIP BRAKE TUBES FROM MASTER 10–WAY RELAY BOX CON- ATTACHING BOLT CYLINDER NECTOR BRAKE TUBE TO LEFT WHEEL FRONT RIGHT FRONT BRAKE DRIVESHAFT ING BOLT ATTACH- TUBE ISOLATOR/ WASHER REAR BRAKE TUBES VEHICLE FRAME PROPORTIONING MOUNTING...
  • Page 186 IF VEHICLE IS EQUIPPED REMOVE THIS TUBE FROM REMOVE VEHICLE IS EQUIPPED WITH STEERINGGEAR WITH A 2.5LTR ENGINE MOUNTINGBOLT STEERING GEAR THIS 2.5L ENGINE MOUNTING BRACKET TUBE MOUNTING ISOLATORS AND ASSEMBLY WASHERS VEHICLE FLOOR PAN MOUNTINGBOLT MOUNTING BRACKET TO REAR BRAKE LINE CODE LABEL STAMP...
  • Page 187 LEFT PORTIONING VALVE RIGHT FRAME RAIL REAR FRONT PRO- RIGHT REAR PROPORTION- HYDRAULIC TROL UNIT (HCU) ING VALVE CON- PULL RELAY BOX IN THIS DIRECTION PUMP MOTOR MOUNTING SCREWS (DO NOT REMOVE) RELAY MOUNTING RELAY BOX CONNECTOR RELAY BOX SCREWS PUMP MOTOR CONNECTOR PUMP M OTOR AND SEAL...
  • Page 188 PUMP MOTOR HOUSING PUMP MOTOR TO RELAY BOX ELECTRICAL CONNECTOR ELECTRICAL CONNECTOR PUMP MOTOR SEAL WINDSHIELD WINDOW 60–WAY HOOD PROP ROD NECTOR WASHER CON- FLUID BOTTLE AIR CONDITION- WASHER ING HOSE BOTTLE FLUID CONTROLLER RETAININGBOLT ANTILOCK BRAKES 60–WAY TRICAL NECTOR ELEC- CON- BRAKES...
  • Page 189 MOUNTING BOLT CAB AIR CONDITION- ING LINE MOUNTING BRACKET MOUNTING BOLT GROMMET RETAINER AND WHEEL SPEED SEN- SEALING CABLE ROUTING BRACKET WHEEL SPEED SEN- SPEED VEHICLE WIRING HARNESS INNER FENDER GROMMET ROUTING BRACKET SOR CABLE SOR CABLE SENSOR GROMMET RETAINING BOLT BRACKET FRONT SHOCK...
  • Page 190 SPEED STEERING BOLT STEERING KNUCKLE KNUCKLE SENSOR CABLE SPEED SENSOR PIN PUNCH SPEED HUB/BEARING HEAD SENSOR HEAD WHEEL WHEEL CABLE MUST BE LOOPED TOWARD ABSORBER THESE STEERING KNUCKLE BRAKE FLEX HOSE ROUTING SHOCK ABSORBER SPEED SPEED BETWEEN SENSOR SENSOR BRACK- SHOCK CABLE ETS.
  • Page 191 REAR VEHICLE WIRING HAR- TRUNK FLOOR DRIVESHAFT WHEEL SENSOR CABLE NESS SPEED STEERING KNUCKLE SPEED SOR HEAD SEN- REAR OF PASSEN- MENT BACK SEAT LOCATING PIN COMPART- SEALING REAR UPPER CONTROL BRAKE FLEX HOSE BRAKE DRUM GROMMET FENDER SPEED INNER BRACKET SENSOR CABLE...
  • Page 192 SPEED SENSOR CABLE SPEED SENSOR BOLT HEAD BRAKES 5 - 97 REMOVAL AND INSTALLATION (Continued) (6) Remove the rear speed sensor head from the SPECIFICATIONS rear brake support plate (Fig. 41). SPEED SENSOR TONE WHEEL RUNOUT The total indicator runout allowed for both the front and rear tone wheel measured using a dial indi- cator is 0.15 mm (.006 in.).
  • Page 194 CLUTCH CABLE BRAKE PEDAL PIVOT PIN BUSHINGS PEDAL CABLE END CLUTCH PEDAL UPSTOP/SPACER PEDAL PEDALBRACKET BUSHINGS BRAKE PEDAL CLUTCH PEDAL PIVOT PIN CLUTCH 6 - 1 CLUTCH CONTENTS page page GENERAL INFORMATION REMOVAL AND INSTALLATION CLUTCH COMPONENTS ....1 CLUTCH ASSEMBLY .

  • Page 195: Description And Operation

    CLUTCH CABLE AT CLUTCH PEDAL CLUTCH AT TRANSAXLE CABLE CLUTCH CABLE CLUTCH PEDAL RETURNSPRING UPSTOP/SPACER CLUTCH PEDAL CLUTCH POSITION SWITCH PEDAL 6 - 2 CLUTCH DESCRIPTION AND OPERATION CLUTCH PEDAL POSITION SWITCH The clutch pedal position switch functions as a CLUTCH CABLE safety interlock device.
  • Page 196 CLUTCH 6 - 3 DIAGNOSIS AND TESTING WARNING: BEFORE PERFORMING THIS STEP, BE SURE THAT THE AREA IN FRONT OF THE VEHICLE CLUTCH PEDAL POSITION SWITCH IS CLEAR OF OBSTRUCTIONS AND PEOPLE. VEHI- CLE MAY MOVE WHEN PERFORMING THIS TEST. CLUTCH PEDAL POSITION With the park brake set and the vehicle IN GEAR, SWITCH–ELECTRICAL TEST...

  • Page 197: Diagnosis And Testing

    6 - 4 CLUTCH DIAGNOSIS AND TESTING (Continued) CLUTCH DIAGNOSIS observe clutch action. If chatter, grab, slip, or improper release is experienced, remove and inspect Problem diagnosis will generally require a road the clutch components. If the problem is noise or test to determine the type of fault.
  • Page 198 CLUTCH 6 - 5 DIAGNOSIS AND TESTING (Continued) SERVICE DIAGNOSIS—CLUTCH SLIPS CONDITION POSSIBLE CAUSES CORRECTION DISC FACING WORN OUT Normal wear. Replace modular clutch assembly. Driver frequently rides (slips) clutch, Replace modular clutch assembly results in rapid wear overheating. Insufficient clutch cover diaphragm Replace modular clutch assembly spring tension CLUTCH DISC FACING...
  • Page 199 6 - 6 CLUTCH DIAGNOSIS AND TESTING (Continued) SERVICE DIAGNOSIS—IMPROPER CLUTCH RELEASE CONDITION POSSIBLE CAUSES CORRECTION CLUTCH DISC BINDS ON INPUT Clutch disc hub splines damaged Clean, smooth, and lubricate disc SHAFT SPLINES during installation and shaft splines. Replace modular clutch assembly and/or input shaft if splines are severely damaged.

  • Page 200: Clash-Into-Reverse Complaints

    CLUTCH CABLE BELL- HOUSING CLUTCH 6 - 7 DIAGNOSIS AND TESTING (Continued) DRIVE PLATE MISALIGNMENT CLASH–INTO–REVERSE COMPLAINTS Common causes of misalignment are: All JA NV T350 (A-578) manual transaxles are • Heat warping equipped with a reverse brake. It prevents clash •...
  • Page 201 CLUTCH PEDAL PIVOT PIN CABLE END CLUTCH CABLE CLUTCH PEDAL UPSTOP/SPACER CLUTCH CABLE CLUTCH PEDAL RETURNSPRING UPSTOP/SPACER CLUTCH PEDAL CLUTCH POSITION SWITCH PEDAL 6 - 8 CLUTCH REMOVAL AND INSTALLATION (Continued) (4) Guide cable through slot in transaxle and dis- (3) Connect the clutch cable to the up-stop/spacer.

  • Page 202: Release Bearing And Fork

    TRANSAXLE ENGINE UPPER COVER UPPER COVER CASE DRIVE PLATE BOLT DRIVE PLATE CLUTCH BOLT CRANKSHAFT CLUTCH ASSEMBLY PLATE BOLT DRIVE PLATE BOLT BACKING DRIVE PLATE TRANSAXLE CLUTCH 6 - 9 REMOVAL AND INSTALLATION (Continued) INSTALLATION (2) Install transaxle. See Group 21, Manual Tran- (1) Slide switch wires through slot in switch saxle, for procedure.

  • Page 203: Cleaning And Inspection

    CLUTCH CABLE AT CLUTCH PEDAL CLUTCH AT TRANSAXLE CABLE 6 - 10 CLUTCH CLEANING AND INSPECTION ADJUSTMENTS CLUTCH CONTAMINATION CLUTCH CABLE Fluid contamination is a frequent cause of clutch The manual transaxle clutch release system has a malfunctions. Oil, grease, water, or other fluids on unique self-adjusting mechanism to compensate for the clutch contact surfaces will cause faulty opera- clutch disc wear (Fig.

  • Page 204: Clutch Pedal Position Switch

    CLUTCH CABLE BELL- HOUSING CLUTCH CABLE CLUTCH PEDAL RETURNSPRING UPSTOP/SPACER CLUTCH PEDAL CLUTCH POSITION SWITCH PEDAL CLUTCH 6 - 11 ADJUSTMENTS (Continued) (3) Pull back on clutch cable housing and insert CLUTCH PEDAL POSITION SWITCH into transaxle housing (Fig. 9). The clutch pedal position switch is mounted to a bracket located behind the clutch pedal.
  • Page 206 COOLING SYSTEM 7 - 1 COOLING SYSTEM CONTENTS page page GENERAL INFORMATION RADIATOR FAN CONTROL ....17 ACCESSORY DRIVE BELTS ....3 TEMPERATURE GAUGE INDICATION .

  • Page 207: General Information

    RADIATOR COOLANT RECOV- HEAT UP SYSTEM TANK THERMOSTAT HEATER COOLDOWN HOUSING PRESSURE CAP WATER PUMP ENGINE 7 - 2 COOLING SYSTEM GENERAL INFORMATION Its primary purpose is to maintain engine temper- ature in a range that will provide satisfactory engine COOLING SYSTEM performance and emission levels under all expected driving conditions.

  • Page 208: Accessory Drive Belts

    COOLANT RECOVERY O-RING SYSTEM TANK INLET PIPE HEAT UPCOOLDOWN HEATER TUBES O-RINGS GASKETS COOLANT OUTLET COOLANT RADIATOR O-RING THERMOSTAT THERMOSTAT ELBOW INLET HOUSING GASKET CRANKSHAFT POWER HEATER DAMPER STEERING WATER PUMP PUMP THERMOSTAT HOUSING ENGINE AIR CONDITIONING COMPRESSOR PRESSURE CAP GENERATOR IDLER COOLING SYSTEM...

  • Page 209: Coolant Recovery System (Crs)

    COOLANT RECOVERY SYS- RIGHT FRAME RAIL TEM (CRS) BOTTLE TO CRS BOTTLE TO CRS BOTTLE 2.4L ENGINE 2.0L ENGINE 2.5L ENGINE SCREWS (2) TO ENGINE (40 in. lbs.) VIEW V 4.6 N·m VENT THERMOSTAT FACING O-RING O-RING THERMOSTAT THERMOSTAT HOUSING/EN- GINE OUTLET CONNECTOR THERMOSTAT HOUSING/EN- GINE OUTLET CONNECTOR...
  • Page 210 VENT INSTALLED THERMOSTAT UPWARD HOUSING THERMOSTAT COOLANT INLET ELBOW WATER PUMP O-RING INLET PIPE GASKET O-RING COOLING SYSTEM 7 - 5 GENERAL INFORMATION (Continued) The 2.5L engine thermostat is located in a thermo- The water pump is driven by the timing belt. See stat housing, located below the throttle body.
  • Page 211 OVERFLOW TRANSMISSION THERMOSTAT HOUSING/ENGINE OUTLET CONNEC- FILLER NECK COOLER NIPPLES NIPPLE MAIN SPRING GASKET RETAINER COOLING MODULE UPPER MOUNT- DRAIN COCK VENT VALVE ING POST STAINLESS-STEEL RUBBER SEALS SWIVEL TOP DUAL FANS LOWER MOUNTING ISOLA- CONDITIONING TORS CONDENSER DRAIN 7 - 6 COOLING SYSTEM GENERAL INFORMATION (Continued) COOLING SYSTEM PRESSURE CAP...

  • Page 212: Cooling System Fans

    FAN MODULE TO RADIATOR AUTOMATIC TRANSMISSION OIL FASTENERS COOLER NIPPLES EXTERNAL TO AUXILIARY COOLER RETAINING STRAPS TRANSMISSION COOLER INLET OIL COOLER TUBE NUTS AIR SHIELD AIR SHIELD RETURN COOLING SYSTEM 7 - 7 GENERAL INFORMATION (Continued) COOLING SYSTEM FANS EXTERNAL TRANSMISSION OIL COOLER—2.5L All models use electric motor driven cooling system ENGINE fans.

  • Page 213: Coolant Performance

    OVERFLOW THERMOSTAT HOUSING/ENGINE OUTLET CONNEC- FILLER NECK NIPPLE MAIN SPRING GASKET RETAINER VENT VALVE STAINLESS-STEEL RUBBER SEALS SWIVEL TOP 7 - 8 COOLING SYSTEM DESCRIPTION AND OPERATION (Continued) The thermostat is operated by a wax filled con- COOLING SYSTEM PRESSURE CAP tainer (pellet) which is sealed so that when heated to The cooling system is equipped with a pressure cap a predetermined temperature.
  • Page 214 HOSE CLAMP TOOL 6094 HOSE CLAMP COOLING SYSTEM 7 - 9 DESCRIPTION AND OPERATION (Continued) CAUTION: A number or letter is stamped into the ENGINE BLOCK HEATER tongue of constant tension clamps. If replacement The heater, operated by ordinary house current is necessary, use only a original equipment clamp (110 Volt A.C.) through a power cord and connector with matching number or letter.

  • Page 215: Water Pump-2.0/2.4L Engines

    LEFT REAR SIDE VIEW CYLINDER BLOCK 2.5L ENGINE BLOCK HEATER F WD PUMP BODY BLOCK HEATER INLET PIPE O-RING GASKET RIGHT REAR SIDE VIEW LEFT REAR SIDE 2.4L ENGINE O-RING 2.0L ENGINE WATER PUMP VIEW 7 - 10 COOLING SYSTEM DESCRIPTION AND OPERATION (Continued) Fig.

  • Page 216: Diagnosis And Testing

    COOLING SYSTEM 7 - 11 DIAGNOSIS AND TESTING COOLING SYSTEM DIAGNOSIS CONDITION POSSIBLE CAUSE CORRECTION TEMPERATURE GAUGE READS 1. Has a Diagnostic Trouble Code 1. Refer to On Board Diagnostic in (DTC) number 17 been set Group 25. Replace thermostat if indicating a stuck open engine necessary.
  • Page 217 7 - 12 COOLING SYSTEM DIAGNOSIS AND TESTING (Continued) COOLING SYSTEM DIAGNOSIS CONT. CONDITION POSSIBLE CAUSES CORRECTION TEMPERATURE GAUGE READS 7. Coolant level low in radiator but 7. (a) Check condition of radiator HIGH OR ENGINE COOLANT not in coolant overflow/reserve cap and cap seals.
  • Page 218 COOLING SYSTEM 7 - 13 DIAGNOSIS AND TESTING (Continued) COOLING SYSTEM DIAGNOSIS CONT. CONDITION POSSIBLE CAUSES CORRECTION TEMPERAUTRE GAUGE READING 1. The gauge may cycle up and 1. A normal condition. No correction IS INCONSISTENT (FLUCTUATES, down. This is due to the cycling of is necessary.
  • Page 219 7 - 14 COOLING SYSTEM DIAGNOSIS AND TESTING (Continued) COOLING SYSTEM DIAGNOSIS CONT. CONDITION POSSIBLE CAUSES CORRECTION COOLANT LOSS TO THE 1. Coolant leaks in radiator, cooling 1. Pressure test and repair as GROUND WITHOUT PRESSURE system hoses, water pump or necessary.
  • Page 220 COOLING SYSTEM 7 - 15 DIAGNOSIS AND TESTING (Continued) COOLING SYSTEM DIAGNOSIS CONT. CONDITION POSSIBLE CAUSES CORRECTION INADEQUATE AIR CONDITIONER 1. Radiator and/or air conditioning 1. Remove restriction and/or clean PERFORMANCE (COOLING condenser is restricted, obstructed as necessary. SYSTEM SUSPECTED) or dirty.
  • Page 221 7 - 16 COOLING SYSTEM DIAGNOSIS AND TESTING (Continued) COOLING SYSTEM DIAGNOSIS CONT. CONDITION POSSIBLE CAUSES CORRECTION HEAT ODOR - CONT. 2. Is temperature gauge reading 2. Refer to the previous above the normal range? Temperature Gauge Reads High in these Diagnosis Charts.

  • Page 222: Cooling System Flow Check

    COOLING SYSTEM 7 - 17 DIAGNOSIS AND TESTING (Continued) ENGINE THERMOSTAT TESTING sor which sends the message to the Engine Controller. The Engine Controller turns on the fan The thermostat is operated by a wax filled con- through the fan relay. On models equipped with auto- tainer (pellet) which is sealed so that when heated to matic transmission, a transmission fluid thermister a predetermined temperature.
  • Page 223 7 - 18 COOLING SYSTEM DIAGNOSIS AND TESTING (Continued) RADIATOR FAN OPERATION—2.4L ENGINE ELECTRIC FAN MOTOR TEST Refer to Powertrain Diagnostic Manual for proce- dure. Radiator Fan Control A/C Pressure For wiring diagrams of the fan motor systems refer A/C Off High to 8W Wiring Diagrams.

  • Page 224: Low Coolant Level Aeration

    OVERFLOW THERMOSTAT HOUSING/ENGINE OUTLET CONNEC- FILLER NECK NIPPLE MAIN SPRING GASKET RETAINER VENT VALVE STAINLESS-STEEL RUBBER SEALS SWIVEL TOP PRESSURE CAP PRESSURE TESTER COOLING SYSTEM 7 - 19 DIAGNOSIS AND TESTING (Continued) internal leak in the engine. If there is an internal PRESSURE TESTING COOLING SYSTEM leak, the engine must be disassembled for repair.

  • Page 225: Temperature Gauge Indication

    7 - 20 COOLING SYSTEM DIAGNOSIS AND TESTING (Continued) DEAERATION TEMPERATURE GAUGE INDICATION Air can only be removed from the system by gath- At idle the temperature gauge could rise slowly to ering under the pressure cap. On the next heat up it about 1/2 gauge travel.

  • Page 226: Service Procedures

    DRAIN COCK BODY COOLING SYSTEM 7 - 21 DIAGNOSIS AND TESTING (Continued) ENGINE BLOCK HEATER Check governmental regulations for disposal of used engine coolant. If unit does not operate, trouble can be in either the power cord or the heater element. Test power cord for continuity with a 110-volt voltmeter or 110- WARNING: DO NOT REMOVE THE COOLING SYS- volt test light;...

  • Page 227: Removal And Installation

    CYLINDER BLOCK PUMP BODY IMPELLER PUMP BODY O-RING 7 - 22 COOLING SYSTEM REMOVAL AND INSTALLATION INSTALLATION (1) Install new O-ring gasket in water pump body WATER PUMP—2.0/2.4L ENGINES O-ring groove (Fig. 25). CAUTION: Make sure O-ring is properly seated in REMOVAL water pump groove before tightening screws.
  • Page 228 WATER PUMP O-RING ENGINE BLOCK INLET PIPE WATER PUMP GASKET GASKET O-RING PUMP HOUSING O-RING WATER PIPE COOLING SYSTEM 7 - 23 REMOVAL AND INSTALLATION (Continued) WATER PUMP—2.5L ENGINE INSTALLATION (1) Clean all gasket and O-ring surfaces on pump and water pipe inlet tube. REMOVAL (2) Install new O-ring on water inlet pipe (Fig.
  • Page 229 WATER PUMP INLET O-RING TUBE HEATER CORE TO HEATER RADIATOR INLET VENT THERMOSTAT FACING O-RING O-RING THERMOSTAT THERMOSTAT HOUSING/EN- GINE OUTLET CONNECTOR THERMOSTAT HOUSING/EN- GINE OUTLET CONNECTOR PRESSURE CAP WATER PUMP INLET TUBE 7 - 24 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) WATER PUMP INLET TUBE—2.0/2.4L ENGINES (4) Connect lower radiator hose and heater hose to inlet tube (Fig.
  • Page 230 VENT INSTALLED THERMOSTAT UPWARD HOUSING THERMOSTAT COOLANT INLET ELBOW COOLING MODULE ISOLATOR VIEW A UPPER LOWER CROSSMEMBER CROSSMEMBER RADIATOR RADIATOR COOLING SYSTEM 7 - 25 REMOVAL AND INSTALLATION (Continued) RADIATOR REMOVAL Fig. 33 Thermostat, Housing and Inlet Elbow— 2.5LEngine INSTALLATION (1) Place the new thermostat assembly into the engine outlet connector.
  • Page 231 CONDITIONING RADIATOR MOUNTING SCREWS CONDENSER DRAIN COCK BODY 7 - 26 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) CAUTION: Avoid bending the condenser inlet tube. (7) Install upper radiator crossmember. Refer to Care should be taken not to damage radiator or Group 23, Body for procedure.

  • Page 232: Radiator Fan, Motor And Shroud

    RETAINING CLIP FAN MODULE TO RADIATOR MOTOR SHAFT FASTENERS SHROUD ASSEM- COOLING SYSTEM 7 - 27 REMOVAL AND INSTALLATION (Continued) RADIATOR FAN, MOTOR AND SHROUD FAN SHROUD All vehicles have fan shrouds to improve fan air flow efficiency. FAN SERVICE There are no repairs to be made to the fan.
  • Page 233 LEFT REAR SIDE VIEW 2.5L ENGINE BLOCK HEATER F WD BLOCK HEATER RIGHT REAR SIDE VIEW LEFT REAR SIDE 2.4L ENGINE 2.0L ENGINE VIEW 7 - 28 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) INSTALLATION (4) Fill cooling system with coolant to the proper (1) Thoroughly clean core hole and heater seat level, vent air, and inspect for leaks.
  • Page 234 CRANKSHAFT SUPPORT POWER LOCK NUT BRACKET DAMPER STEERING PUMP AIR CONDITIONING COMPRESSOR ADJUSTING BOLT GENERATOR IDLER PIVOT IDLER BOLT LOCKING BOLT LOCKING BOLT PIVOT BOLT SQUARE OPENING INCH COOLING SYSTEM 7 - 29 REMOVAL AND INSTALLATION (Continued) ACCESSORY DRIVE BELTS—2.0/2.4L ENGINES POWER STEERING PUMP BELT (1) From the top of the vehicle loosen pivot bolt C.
  • Page 235 LOCKING BOLT ADJUSTING BOLT ADJUSTMENT LOCKING BOLT (F) ADJUSTMENT SLOT SLOT LOCKING SQUARE OPENING PIVOT BOLT INCH BOLT 7 - 30 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) ACCESSORY DRIVE BELT—2.5L ENGINE (5) Tighten locking bolt F and the pivot bolt to 54 N·m (40 ft.

  • Page 236: Cleaning And Inspection

    PUMP HOUSING INLET NORMAL NOT NORMAL CRACKS BELT OK CRACKS RELACE BELT COOLING SYSTEM 7 - 31 CLEANING AND INSPECTION ACCESSORY DRIVE BELT INSPECTION Belt replacement under any or all of the following WATER PUMP—2.0/2.4L ENGINES conditions is required, excessive wear, frayed cords or Replace water pump body assembly if it has any of severe glazing.

  • Page 237: Chemical Cleaning

    OVERFLOW THERMOSTAT HOUSING/ENGINE OUTLET CONNEC- FILLER NECK NIPPLE MAIN SPRING GASKET RETAINER VENT VALVE STAINLESS-STEEL RUBBER SEALS SWIVEL TOP 7 - 32 COOLING SYSTEM CLEANING AND INSPECTION (Continued) A replacement cap must be of the type designed for REVERSE FLUSHING coolant reserve systems.

  • Page 238: Specifications

    COOLING SYSTEM 7 - 33 SPECIFICATIONS SPECIAL TOOLS COOLING SYSTEM CAPACITY COOLING ENGINE 2.0L 2.4L 2.5L (COOLANT) CAPACITY LITERS 10.0 U.S. QTS. 10.5 *CAPACITY, Includes Heater and Coolant Recovery Accessory Drive Belt Tension GaugeC-4162 System TORQUE Description Torque A/C Condenser to Radiator (All) .
  • Page 240 COOLING SYSTEM 7 - 1 COOLING SYSTEM CONTENTS page page GENERAL INFORMATION RADIATOR FAN CONTROL ....17 ACCESSORY DRIVE BELTS ....3 TEMPERATURE GAUGE INDICATION .

  • Page 241: General Information

    RADIATOR COOLANT RECOV- HEAT UP SYSTEM TANK THERMOSTAT HEATER COOLDOWN HOUSING PRESSURE CAP WATER PUMP ENGINE 7 - 2 COOLING SYSTEM GENERAL INFORMATION Its primary purpose is to maintain engine temper- ature in a range that will provide satisfactory engine COOLING SYSTEM performance and emission levels under all expected driving conditions.

  • Page 242: Accessory Drive Belts

    COOLANT RECOVERY O-RING SYSTEM TANK INLET PIPE HEAT UPCOOLDOWN HEATER TUBES O-RINGS GASKETS COOLANT OUTLET COOLANT RADIATOR O-RING THERMOSTAT THERMOSTAT ELBOW INLET HOUSING GASKET CRANKSHAFT POWER HEATER DAMPER STEERING WATER PUMP PUMP THERMOSTAT HOUSING ENGINE AIR CONDITIONING COMPRESSOR PRESSURE CAP GENERATOR IDLER COOLING SYSTEM...

  • Page 243: Coolant Recovery System (Crs)

    COOLANT RECOVERY SYS- RIGHT FRAME RAIL TEM (CRS) BOTTLE TO CRS BOTTLE TO CRS BOTTLE 2.4L ENGINE 2.0L ENGINE 2.5L ENGINE SCREWS (2) TO ENGINE (40 in. lbs.) VIEW V 4.6 N·m VENT THERMOSTAT FACING O-RING O-RING THERMOSTAT THERMOSTAT HOUSING/EN- GINE OUTLET CONNECTOR THERMOSTAT HOUSING/EN- GINE OUTLET CONNECTOR...
  • Page 244 VENT INSTALLED THERMOSTAT UPWARD HOUSING THERMOSTAT COOLANT INLET ELBOW WATER PUMP O-RING INLET PIPE GASKET O-RING COOLING SYSTEM 7 - 5 GENERAL INFORMATION (Continued) The 2.5L engine thermostat is located in a thermo- The water pump is driven by the timing belt. See stat housing, located below the throttle body.

  • Page 245: Cooling System Pressure Cap

    OVERFLOW TRANSMISSION THERMOSTAT HOUSING/ENGINE OUTLET CONNEC- FILLER NECK COOLER NIPPLES NIPPLE MAIN SPRING GASKET RETAINER COOLING MODULE UPPER MOUNT- DRAIN COCK VENT VALVE ING POST STAINLESS-STEEL RUBBER SEALS SWIVEL TOP DUAL FANS LOWER MOUNTING ISOLA- CONDITIONING TORS CONDENSER DRAIN 7 - 6 COOLING SYSTEM GENERAL INFORMATION (Continued) COOLING SYSTEM PRESSURE CAP...

  • Page 246: Engine Block Heater

    FAN MODULE TO RADIATOR AUTOMATIC TRANSMISSION OIL FASTENERS COOLER NIPPLES EXTERNAL TO AUXILIARY COOLER RETAINING STRAPS TRANSMISSION COOLER INLET OIL COOLER TUBE NUTS AIR SHIELD AIR SHIELD RETURN COOLING SYSTEM 7 - 7 GENERAL INFORMATION (Continued) COOLING SYSTEM FANS EXTERNAL TRANSMISSION OIL COOLER—2.5L All models use electric motor driven cooling system ENGINE fans.

  • Page 247: Coolant Performance

    OVERFLOW THERMOSTAT HOUSING/ENGINE OUTLET CONNEC- FILLER NECK NIPPLE MAIN SPRING GASKET RETAINER VENT VALVE STAINLESS-STEEL RUBBER SEALS SWIVEL TOP 7 - 8 COOLING SYSTEM DESCRIPTION AND OPERATION (Continued) The thermostat is operated by a wax filled con- COOLING SYSTEM PRESSURE CAP tainer (pellet) which is sealed so that when heated to The cooling system is equipped with a pressure cap a predetermined temperature.
  • Page 248 HOSE CLAMP TOOL 6094 HOSE CLAMP COOLING SYSTEM 7 - 9 DESCRIPTION AND OPERATION (Continued) CAUTION: A number or letter is stamped into the ENGINE BLOCK HEATER tongue of constant tension clamps. If replacement The heater, operated by ordinary house current is necessary, use only a original equipment clamp (110 Volt A.C.) through a power cord and connector with matching number or letter.

  • Page 249: Water Pump-2.0/2.4L Engines

    LEFT REAR SIDE VIEW CYLINDER BLOCK 2.5L ENGINE BLOCK HEATER F WD PUMP BODY BLOCK HEATER INLET PIPE O-RING GASKET RIGHT REAR SIDE VIEW LEFT REAR SIDE 2.4L ENGINE O-RING 2.0L ENGINE WATER PUMP VIEW 7 - 10 COOLING SYSTEM DESCRIPTION AND OPERATION (Continued) Fig.

  • Page 250: Diagnosis And Testing

    COOLING SYSTEM 7 - 11 DIAGNOSIS AND TESTING COOLING SYSTEM DIAGNOSIS CONDITION POSSIBLE CAUSE CORRECTION TEMPERATURE GAUGE READS 1. Has a Diagnostic Trouble Code 1. Refer to On Board Diagnostic in (DTC) number 17 been set Group 25. Replace thermostat if indicating a stuck open engine necessary.
  • Page 251 7 - 12 COOLING SYSTEM DIAGNOSIS AND TESTING (Continued) COOLING SYSTEM DIAGNOSIS CONT. CONDITION POSSIBLE CAUSES CORRECTION TEMPERATURE GAUGE READS 7. Coolant level low in radiator but 7. (a) Check condition of radiator HIGH OR ENGINE COOLANT not in coolant overflow/reserve cap and cap seals.
  • Page 252 COOLING SYSTEM 7 - 13 DIAGNOSIS AND TESTING (Continued) COOLING SYSTEM DIAGNOSIS CONT. CONDITION POSSIBLE CAUSES CORRECTION TEMPERAUTRE GAUGE READING 1. The gauge may cycle up and 1. A normal condition. No correction IS INCONSISTENT (FLUCTUATES, down. This is due to the cycling of is necessary.
  • Page 253 7 - 14 COOLING SYSTEM DIAGNOSIS AND TESTING (Continued) COOLING SYSTEM DIAGNOSIS CONT. CONDITION POSSIBLE CAUSES CORRECTION COOLANT LOSS TO THE 1. Coolant leaks in radiator, cooling 1. Pressure test and repair as GROUND WITHOUT PRESSURE system hoses, water pump or necessary.
  • Page 254 COOLING SYSTEM 7 - 15 DIAGNOSIS AND TESTING (Continued) COOLING SYSTEM DIAGNOSIS CONT. CONDITION POSSIBLE CAUSES CORRECTION INADEQUATE AIR CONDITIONER 1. Radiator and/or air conditioning 1. Remove restriction and/or clean PERFORMANCE (COOLING condenser is restricted, obstructed as necessary. SYSTEM SUSPECTED) or dirty.
  • Page 255 7 - 16 COOLING SYSTEM DIAGNOSIS AND TESTING (Continued) COOLING SYSTEM DIAGNOSIS CONT. CONDITION POSSIBLE CAUSES CORRECTION HEAT ODOR - CONT. 2. Is temperature gauge reading 2. Refer to the previous above the normal range? Temperature Gauge Reads High in these Diagnosis Charts.

  • Page 256: Cooling System Flow Check

    COOLING SYSTEM 7 - 17 DIAGNOSIS AND TESTING (Continued) ENGINE THERMOSTAT TESTING sor which sends the message to the Engine Controller. The Engine Controller turns on the fan The thermostat is operated by a wax filled con- through the fan relay. On models equipped with auto- tainer (pellet) which is sealed so that when heated to matic transmission, a transmission fluid thermister a predetermined temperature.
  • Page 257 7 - 18 COOLING SYSTEM DIAGNOSIS AND TESTING (Continued) RADIATOR FAN OPERATION—2.4L ENGINE ELECTRIC FAN MOTOR TEST Refer to Powertrain Diagnostic Manual for proce- dure. Radiator Fan Control A/C Pressure For wiring diagrams of the fan motor systems refer A/C Off High to 8W Wiring Diagrams.

  • Page 258: Low Coolant Level Aeration

    OVERFLOW THERMOSTAT HOUSING/ENGINE OUTLET CONNEC- FILLER NECK NIPPLE MAIN SPRING GASKET RETAINER VENT VALVE STAINLESS-STEEL RUBBER SEALS SWIVEL TOP PRESSURE CAP PRESSURE TESTER COOLING SYSTEM 7 - 19 DIAGNOSIS AND TESTING (Continued) internal leak in the engine. If there is an internal PRESSURE TESTING COOLING SYSTEM leak, the engine must be disassembled for repair.

  • Page 259: Temperature Gauge Indication

    7 - 20 COOLING SYSTEM DIAGNOSIS AND TESTING (Continued) DEAERATION TEMPERATURE GAUGE INDICATION Air can only be removed from the system by gath- At idle the temperature gauge could rise slowly to ering under the pressure cap. On the next heat up it about 1/2 gauge travel.

  • Page 260: Service Procedures

    DRAIN COCK BODY COOLING SYSTEM 7 - 21 DIAGNOSIS AND TESTING (Continued) ENGINE BLOCK HEATER Check governmental regulations for disposal of used engine coolant. If unit does not operate, trouble can be in either the power cord or the heater element. Test power cord for continuity with a 110-volt voltmeter or 110- WARNING: DO NOT REMOVE THE COOLING SYS- volt test light;...

  • Page 261: Removal And Installation

    CYLINDER BLOCK PUMP BODY IMPELLER PUMP BODY O-RING 7 - 22 COOLING SYSTEM REMOVAL AND INSTALLATION INSTALLATION (1) Install new O-ring gasket in water pump body WATER PUMP—2.0/2.4L ENGINES O-ring groove (Fig. 25). CAUTION: Make sure O-ring is properly seated in REMOVAL water pump groove before tightening screws.
  • Page 262 WATER PUMP O-RING ENGINE BLOCK INLET PIPE WATER PUMP GASKET GASKET O-RING PUMP HOUSING O-RING WATER PIPE COOLING SYSTEM 7 - 23 REMOVAL AND INSTALLATION (Continued) WATER PUMP—2.5L ENGINE INSTALLATION (1) Clean all gasket and O-ring surfaces on pump and water pipe inlet tube. REMOVAL (2) Install new O-ring on water inlet pipe (Fig.
  • Page 263 WATER PUMP INLET O-RING TUBE HEATER CORE TO HEATER RADIATOR INLET VENT THERMOSTAT FACING O-RING O-RING THERMOSTAT THERMOSTAT HOUSING/EN- GINE OUTLET CONNECTOR THERMOSTAT HOUSING/EN- GINE OUTLET CONNECTOR PRESSURE CAP WATER PUMP INLET TUBE 7 - 24 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) WATER PUMP INLET TUBE—2.0/2.4L ENGINES (4) Connect lower radiator hose and heater hose to inlet tube (Fig.
  • Page 264 VENT INSTALLED THERMOSTAT UPWARD HOUSING THERMOSTAT COOLANT INLET ELBOW COOLING MODULE ISOLATOR VIEW A UPPER LOWER CROSSMEMBER CROSSMEMBER RADIATOR RADIATOR COOLING SYSTEM 7 - 25 REMOVAL AND INSTALLATION (Continued) RADIATOR REMOVAL Fig. 33 Thermostat, Housing and Inlet Elbow— 2.5LEngine INSTALLATION (1) Place the new thermostat assembly into the engine outlet connector.

  • Page 265: Radiator Draincock

    CONDITIONING RADIATOR MOUNTING SCREWS CONDENSER DRAIN COCK BODY 7 - 26 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) CAUTION: Avoid bending the condenser inlet tube. (7) Install upper radiator crossmember. Refer to Care should be taken not to damage radiator or Group 23, Body for procedure.

  • Page 266: Radiator Fan, Motor And Shroud

    RETAINING CLIP FAN MODULE TO RADIATOR MOTOR SHAFT FASTENERS SHROUD ASSEM- COOLING SYSTEM 7 - 27 REMOVAL AND INSTALLATION (Continued) RADIATOR FAN, MOTOR AND SHROUD FAN SHROUD All vehicles have fan shrouds to improve fan air flow efficiency. FAN SERVICE There are no repairs to be made to the fan.
  • Page 267 LEFT REAR SIDE VIEW 2.5L ENGINE BLOCK HEATER F WD BLOCK HEATER RIGHT REAR SIDE VIEW LEFT REAR SIDE 2.4L ENGINE 2.0L ENGINE VIEW 7 - 28 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) INSTALLATION (4) Fill cooling system with coolant to the proper (1) Thoroughly clean core hole and heater seat level, vent air, and inspect for leaks.
  • Page 268 CRANKSHAFT SUPPORT POWER LOCK NUT BRACKET DAMPER STEERING PUMP AIR CONDITIONING COMPRESSOR ADJUSTING BOLT GENERATOR IDLER PIVOT IDLER BOLT LOCKING BOLT LOCKING BOLT PIVOT BOLT SQUARE OPENING INCH COOLING SYSTEM 7 - 29 REMOVAL AND INSTALLATION (Continued) ACCESSORY DRIVE BELTS—2.0/2.4L ENGINES POWER STEERING PUMP BELT (1) From the top of the vehicle loosen pivot bolt C.
  • Page 269 LOCKING BOLT ADJUSTING BOLT ADJUSTMENT LOCKING BOLT (F) ADJUSTMENT SLOT SLOT LOCKING SQUARE OPENING PIVOT BOLT INCH BOLT 7 - 30 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) ACCESSORY DRIVE BELT—2.5L ENGINE (5) Tighten locking bolt F and the pivot bolt to 54 N·m (40 ft.

  • Page 270: Water Pump-2.0/2.4L Engines

    PUMP HOUSING INLET NORMAL NOT NORMAL CRACKS BELT OK CRACKS RELACE BELT COOLING SYSTEM 7 - 31 CLEANING AND INSPECTION ACCESSORY DRIVE BELT INSPECTION Belt replacement under any or all of the following WATER PUMP—2.0/2.4L ENGINES conditions is required, excessive wear, frayed cords or Replace water pump body assembly if it has any of severe glazing.

  • Page 271: Chemical Cleaning

    OVERFLOW THERMOSTAT HOUSING/ENGINE OUTLET CONNEC- FILLER NECK NIPPLE MAIN SPRING GASKET RETAINER VENT VALVE STAINLESS-STEEL RUBBER SEALS SWIVEL TOP 7 - 32 COOLING SYSTEM CLEANING AND INSPECTION (Continued) A replacement cap must be of the type designed for REVERSE FLUSHING coolant reserve systems.

  • Page 272: Specifications

    COOLING SYSTEM 7 - 33 SPECIFICATIONS SPECIAL TOOLS COOLING SYSTEM CAPACITY COOLING ENGINE 2.0L 2.4L 2.5L (COOLANT) CAPACITY LITERS 10.0 U.S. QTS. 10.5 *CAPACITY, Includes Heater and Coolant Recovery Accessory Drive Belt Tension GaugeC-4162 System TORQUE Description Torque A/C Condenser to Radiator (All) .
  • Page 274 This vehicle has an electronic voltage regulator posts, and cable terminals must be cleaned before which controls battery charging. ONLY CHRYSLER diagnostic procedures are performed. approved battery blanket/block heater combination should be used. It is designed to provide optimum charging system performance in very cold ambient temperatures below -17.8°C (0°F).

  • Page 275: Description And Operation

    BATTERY BLANKET HEATER BATTERY 8A - 2 BATTERY DESCRIPTION AND OPERATION (Continued) will adversely affect battery charging and will result CHARGER CAPACITY in battery discharge or damage. A charger which can supply only five amperes will require a much longer period of charging than a BATTERY IGNITION OFF DRAW (IOD) charger that can supply 20 amperes or more.

  • Page 276: Battery Discharging

    BATTERY 8A - 3 DIAGNOSIS AND TESTING (Continued) (8) Immediately feel the heater cover on the inside BATTERY DISCHARGING it should be warm to the touch. If warm, heater is OK. If not OK, go to Step 9. CAUSES OF BATTERY DISCHARGING (9) Using an Ohmmeter, connect a lead across the It is normal to have up to a 30 milliamperes con- two terminals.

  • Page 277: Battery Ignition Off Draw Tests

    8A - 4 BATTERY DIAGNOSIS AND TESTING (Continued) ABNORMAL BATTERY DISCHARGING • Corroded battery posts, cables or terminals. • Loose or worn generator drive belt. • Electrical loads that exceed the output of the charging system due to equipment or accessories installed after delivery.

  • Page 278: Battery Load Test

    BATTERY 8A - 5 DIAGNOSIS AND TESTING (Continued) CAUTION: Always disconnect the milliampere (a) If meter has no reading, replace the Auto- meter before opening a door. matic Transmission Control Module. (b) If meter has a reading, there is a short cir- (1) Remove all seven fuses.
  • Page 279 INDUCTION POSITIVE CLAMP AMPMETER CLAMP NEGATIVE CLAMP 8A - 6 BATTERY DIAGNOSIS AND TESTING (Continued) (2) Use a suitable Volt/Ammeter/Load tester con- nected between remote battery terminals (Fig. 5) and (Fig. 6). Check the open circuit voltage of the battery. Voltage should be equal to or greater than 12.4 volts.

  • Page 280: Battery Open Circuit Voltage Test

    BATTERY BATTERY 8A - 7 DIAGNOSIS AND TESTING (Continued) (8) If battery passes load test, it is in good condi- Open Circuit Volts Percent Charge tion and further tests are not necessary. If it fails 11.7 volts or less load test, it should be replaced. 12.0 BATTERY OPEN CIRCUIT VOLTAGE TEST 12.2...

  • Page 281: Charging Completely Discharged Battery

    WARM WATER AND BAKING CLEANING BRUSH SODA SOLUTION BATTERY 8A - 8 BATTERY SERVICE PROCEDURES (Continued) hold downs, tray, terminals, cables, posts, and top VISUAL INSPECTION AND SERVICE before completing service. CAUTION: Do not allow baking soda solution to CHARGING COMPLETELY DISCHARGED BATTERY enter vent holes, as damage to battery can result.

  • Page 282: Battery Tray

    BATTERYTRAY BATTERY STRAP BATTERY BLANKET HEATER RETAINER STRAP BATTERY 8A - 9 REMOVAL AND INSTALLATION (Continued) WARNING: NEVER GET UNDER A LIFTED VEHI- (8) Remove bolt attaching the battery strap to the CLE IF NOT SUPPORTED PROPERLY ON SAFETY battery hold down bracket. Remove hold down bracket bolt.

  • Page 283: Specifications

    8A - 10 BATTERY SPECIFICATIONS BATTERY SPECIFICATIONS Load Test Cold Reserve Cranking (Amps) Rating @ Capacity -18°C (0°F) 260 Amp 510 Amp 110 Minutes COLD CRANK RATING The current battery can deliver for 30 seconds and maintain a terminal voltage of 7.2 volts or greater at –18°...
  • Page 284 PARK/NEUTRAL IGNITION SWITCH NEGATIVE SWITCH (AUTO. TRANS. ONLY) CABLE POSITIVE CLUTCH SWITCH (MAN. TRANSMISSION BATTERY BATTERY POSITION CABLE SOLENOID TERMINAL PEDAL RELAY THIS CIRCUIT GROUNDED AT ALL TIMES (MAN. TRANS. ONLY) FEED IGNITION POSITION ONLY) FEED GROUND CIRCUIT STARTER SOLE- STARTER RELAY STARTER...

  • Page 285: Control Circuit Test

    RELAY CAVITIES RELAY TERMINALS 8B - 2 STARTING DIAGNOSIS AND TESTING STARTER RELAY WARNING: CHECK TO ENSURE THAT THE TRANS- CONTROL CIRCUIT TEST MISSION IS IN THE PARK POSITION/NEUTRAL The starter control circuit has: WITH THE PARKING BRAKE APPLIED • Starter solenoid •...

  • Page 286: Feed Circuit Resistance Test

    STARTING 8B - 3 DIAGNOSIS AND TESTING (Continued) continuity between the cavity for relay terminal 87 IGNITION SWITCH and the starter solenoid terminal at all times. If OK, After testing starter solenoid and relay, test igni- go to Step 4. If not OK, repair the open circuit to the tion switch and wiring.

  • Page 287: Feed Circuit Test

    ATTACH TO BATTERY NEGA- BATTERY TO BATTERY POSITIVE SIDE TO ENGINE GROUND TIVE SIDE TERMINAL STARTER MOTOR REMOTE CABLE VOLTMETER VOLTMETER TERMINAL POSITIVE POSITIVE CLAMP INDUCTION AMPME- TER CLAMP NEGATIVE CLAMP 8B - 4 STARTING DIAGNOSIS AND TESTING (Continued) If reading is still above 0.2 volt after correcting FEED CIRCUIT TEST poor contacts, replace battery positive cable as neces- The following procedure will require a suitable...

  • Page 288: Starting System Test

    STARTING 8B - 5 DIAGNOSIS AND TESTING (Continued) (2) To disable the ignition and fuel systems, dis- INSPECTION connect the Automatic Shutdown Relay (ASD) in the Before removing any unit from the starting system Power Distribution Center (PDC). Refer to the PDC for repair or diagnosis, perform the following inspec- cover for the proper relay location.
  • Page 289 8B - 6 STARTING DIAGNOSIS AND TESTING (Continued) STARTING SYSTEM DIAGNOSIS CONDITION POSSIBLE CAUSE CORRECTION STARTER FAILS TO ENGAGE. 1. Battery discharged or faulty. 1. Refer to Group 8A, Battery. 2. Starting circuit wiring faulty. Charge or replace battery, if 3.

  • Page 290: Removal And Installation

    BATTERY POSITIVE WIRE GENERATOR PUSH ON SOLENOID CONNNEC- PUT WIRE OUT- VIEW A STARTING 8B - 7 REMOVAL AND INSTALLATION (4) Disconnect push on solenoid connector. (5) Remove two bolts attaching starter to trans- SAFETY SWITCHES mission housing and remove starter from vehicle. For Removal and Installation of the: INSTALLATION •...

  • Page 291: Starter Relay

    BATTERY POSI- TIVE WIRE PUSH ON SOLE- NOID CONNEC- PUSH ON SOLENOID CON- NECTOR BATTERY POSI- TIVE WIRE 8B - 8 STARTING REMOVAL AND INSTALLATION (Continued) 2.0L ENGINE WITH AUTOMATIC TRANSAXLE (5) Install bottom starter mounting bolt and – 2.4L ENGINE tighten to 54 N·m (40 ft.

  • Page 292: Specifications Starter

    STARTING 8B - 9 SPECIFICATIONS Engine Amperage Draw Test ……150-280 Amps* Engine should be up to operating temperature. STARTER Extremely heavy oil or tight engine will increase starter amperage draw. Manufacturer BOSCH MELCO NIPPONDENSO TORQUE Engine 2.0L 2.5L 2.4L Application DESCRIPTION TORQUE Power rating...
  • Page 294 CHARGING SYSTEM 8C - 1 CHARGING SYSTEM CONTENTS page page GENERAL INFORMATION CURRENT OUTPUT TEST ....6 OVERVIEW ......1 ON-BOARD DIAGNOSTIC SYSTEM TEST .

  • Page 295: Description And Operation

    8C - 2 CHARGING SYSTEM DESCRIPTION AND OPERATION (Continued) As the energized rotor begins to rotate within the DIAGNOSIS AND TESTING generator, the spinning magnetic field induces a cur- rent into the windings of the stator coil. Once the CHARGING SYSTEM generator begins producing sufficient current, it also When the ignition switch is turned to the ON posi- provides the current needed to energize the rotor.
  • Page 296 CHARGING SYSTEM 8C - 3 DIAGNOSIS AND TESTING (Continued)
  • Page 297 CHECK TION CHARGE BATTERY IF CHECK DRIVE BELT. REFER GROUP 7, COOLING SYS- CHARGING SYSTEM RESIS- IS GROUND PATH VOLTAGE CLEAN TIGHTEN CHECK ON BOARD DIAG- NOSTIC TROUBLE CODES PERFORM OUTPUT VOLT- VOLTAGE OR DTC 41 OR REFER TO VOLTAGE DROP CHARGING CHARGING ABOVE MAXIMUM OR DTC...
  • Page 298 REPEAT OUTPUT VOLTAGE TEST REPAIR PINS DISCONNECT BOTH 40 WAY CONNEC- TORS ON POWERTRAIN CONTROL MOD- ULE — INSPECT FOR DAMAGE OR REPAIR DAMAGED PIN OR PINS ON POWER- TRAIN MODULE? TO GROUND SHORT DISCONNECT FIELD TERMINAL. MEASURE RESISTANCE FROM K20 CIRCUIT ON WIRING HAR- CORROSION.

  • Page 299: Charging System Resistance Tests

    FIELD WIRE PLUG B+ TERMINAL GENERATOR VOLTMETER 8C - 6 CHARGING SYSTEM DIAGNOSIS AND TESTING (Continued) CHARGING SYSTEM RESISTANCE TESTS PREPARATION (1) Before starting test, make sure battery is in These tests will show the amount of voltage drop good condition and is fully-charged. See Group 8A, across the generator output wire from the generator Battery for more information.

  • Page 300: On-Board Diagnostic System Test

    CHARGING SYSTEM 8C - 7 DIAGNOSIS AND TESTING (Continued) The first part of this test will determine the com- onds to prevent damage to test equipment. On bined amperage output of both the generator and the certain brands of test equipment, this load will be Electronic Voltage Regulator (EVR) circuitry.
  • Page 301 CHECK REPEAT OUTPUT VOLT- REPAIR FUSE LINK AND WIRE SHORT. REFER TO GROUP REPEAT CONNEC- TIONS GOOD? VOLTAGE TEST WIRING WIRE BROKEN? REPAIR WIRE BROKEN WIRE WIRING GRAMS. OUTPUT AGE TEST DIA- CHECK DISCONNECT CHECK SHORT CIRCUIT REPEAT CHECK TIONS STARTER MOTOR, BATTERY.
  • Page 302 CHARGING SYSTEM 8C - 9 DIAGNOSIS AND TESTING (Continued) DIAGNOSTIC TROUBLE CODES A DTC does not identify which component in a cir- Diagnostic Trouble Codes (DTC) are two-digit num- cuit is bad. Thus, a DTC should be treated as a bers flashed on the malfunction indicator (Check symptom, not as the cause for the problem.

  • Page 303: Removal And Installation

    NEGATIVE BATTERY POST BATTERY INDICATOR TEST NEGATIVE CABLE FIELD WIRE PLUG ENGINE MOUNT B+ TERMINAL GENERATOR GENERATOR T-BOLT PIVOT 8C - 10 CHARGING SYSTEM DIAGNOSIS AND TESTING (Continued) RETRIEVING DIAGNOSTIC TROUBLE CODES To start this function, cycle the ignition switch ON- OFF-ON-OFF-ON within 5 seconds.

  • Page 304: Generator-3.0L Engine

    GENERATOR GENERATOR ASSEMBLY 3.0L ENGINE ASSEMBLY MOUNTING BRACKET MOUNT BRACKET GENERATOR CHARGING SYSTEM 8C - 11 REMOVAL AND INSTALLATION (Continued) (7) Install accessory drive belt, refer to Group 7, (5) Install bolt to hold top of generator to mount Cooling System for proper procedures. bracket.
  • Page 305 MOUNT PLATE DEEP SOCKET IGNITION COIL GENERATOR GENERATOR AC/HOSE PIVOT 8C - 12 CHARGING SYSTEM REMOVAL AND INSTALLATION (Continued) (13) Remove bolt holding bottom of generator to (4) Install nut to hold B+ wire terminal to back of lower pivot bracket (Fig. 10). generator.

  • Page 306: Specifications Generator

    CHARGING SYSTEM 8C - 13 SPECIFICATIONS GENERATOR Type Part Number Amperage output Nippondenso 90 A HS 4686098 86 Amp Nippondenso 120 A HS 4686099 98 Amp Part number is located on the side of the generator. TORQUE DESCRIPTION TORQUE Battery Hold Down Bolt ..14 N·m (125 in. lbs.) Generator Mounting Bolts .
  • Page 308 CHARGING SYSTEM 8C - 1 CHARGING SYSTEM CONTENTS page SPECIFICATIONS GENERATOR RATINGS ....1 SPECIFICATIONS GENERATOR RATINGS TYPE ENGINES MINIMUM TEST AMPS DENSO 2.0L 74 amps...
  • Page 310 IGNITION SYSTEM 8D - 1 IGNITION SYSTEM CONTENTS page page GENERAL INFORMATION THROTTLE POSITION SENSOR ... 14 INTRODUCTION ......2 REMOVAL AND INSTALLATION DESCRIPTION AND OPERATION AUTOMATIC SHUTDOWN RELAY...

  • Page 311: General Information

    POWER DISTRIBUTION CENTER POWERTRAIN CON- TROL MODULE 8D - 2 IGNITION SYSTEM GENERAL INFORMATION (2.0/2.4L). By switching the ground path for the coil on and off, the PCM adjusts ignition timing to meet INTRODUCTION changing engine operating conditions. On a 2.5L The PCM controls ignition timing by This group describes the ignition systems for the turning on and off a tranisistor in the distributor.
  • Page 312 IGNITION SYSTEM 8D - 3 DESCRIPTION AND OPERATION (Continued) Replace spark plugs at the intervals recommended in The spark plugs are double platinum and have a Group O - Lubrication and Maintenance. recommended service life of 100,000 miles for normal Spark plugs that have low mileage may be cleaned driving conditions per schedule A in this manual.
  • Page 313 PLATINUM SURFACE SPARK APPLY COMPOUND ANTI-SEIZE HERE ONLY TAPER GAUGE 8D - 4 IGNITION SYSTEM DESCRIPTION AND OPERATION (Continued) 2.5L SPARK PLUG GAP MEASUREMENT CAUTION: Cleaning of the platinum plug may dam- age the platinum tip. CAUTION: The Platinum pads can be damaged dur- ing the measurement of checking the gap if extreme care is not used.

  • Page 314: Automatic Shutdown Relay

    SPARK INSULATOR PLUG SPARK PLUG CABLE IGNITION COILS HIGH TENSION TOWER IGNITION COIL IGNITION COILS IGNITION SYSTEM 8D - 5 DESCRIPTION AND OPERATION (Continued) ELECTRONIC IGNITION COIL IGNITION COIL—2.5L The 2.5L engine uses an epoxy type coil. The coils WARNING: THE DIRECT IGNITION SYSTEM GEN- are not oil filled.
  • Page 315 POWER DISTRIBUTION CENTER POWERTRAIN CON- TROL MODULE 8D - 6 IGNITION SYSTEM DESCRIPTION AND OPERATION (Continued) On-Board Diagnostics. When the ignition switch is in CRANKSHAFT POSITION SENSOR On or Start, the PCM momentarily turns on the ASD The PCM determines what cylinder to fire from the relay.
  • Page 316 CRANKSHAFT MACHINED NOTCHES GENERATOR OIL FILTER POSITION SENSOR CRANKSHAFT PUSH ON CLIP ADJUSTMENT TORQUE POSITION SENSOR HOLE CONVERTOR SLOTS DRIVE PLATE PAPER SPACER CRANKSHAFT POSITION SEN- IGNITION SYSTEM 8D - 7 DESCRIPTION AND OPERATION (Continued) Fig. 8 Timing Reference Notches The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter (Fig.

  • Page 317: Camshaft Position Sensor-2.0/2.4L

    CAMSHAFT POSITION SEN- REAR OF CYLINDER HEAD TRANSAXLE HOUSING CRANKSHAFT POSITION SEN- CAMSHAFT POSITION SEN- CAMSHAFT POSITION SEN- CAM MAGNET/TARGET 8D - 8 IGNITION SYSTEM DESCRIPTION AND OPERATION (Continued) The PCM uses crankshaft position reference to determine injector sequence, ignition timing and the presence of misfire.

  • Page 318: Camshaft Position Sensor-2.5L

    TARGET MAGNET DISTRIBUTOR PULSE RING SYNC GENERATOR SIGNAL IGNITION SYSTEM 8D - 9 DESCRIPTION AND OPERATION (Continued) When the trailing edge of the shutter leaves the sync signal generator, the change of magnetic field causes the sync signal voltage to switch low to 0 volts.

  • Page 319: Intake Air Temperature

    MAP/AIR INTAKE TEMPERATURE INTAKE MANIFOLD PCV VACUUM NIPPLE SENSOR INTAKE MANIFOLD TEMPERATURE SENSOR MAP SENSOR THROTTLE BODY SEN- INTAKE PERATURE SENSOR TEM- 8D - 10 IGNITION SYSTEM DESCRIPTION AND OPERATION (Continued) INTAKE AIR TEMPERATURE SENSOR—2.0L The intake air temperature sensor measures the temperature of the air as it enters the engine.

  • Page 320: Powertrain Control Module (Pcm)

    ACCESSORY UNLOCK ON/RUN START GOOD GROUND ENGINE SPARK PLUG CABLE BOOT CHECK SPARKPLUG SPARK HERE IGNITION SYSTEM 8D - 11 DESCRIPTION AND OPERATION (Continued) THROTTLE POSITION SENSOR (TPS) Transaxle for Automatic Transmission Shifter/Igni- tion Interlock. The TPS mounts to the side of the throttle body. The TPS connects to the throttle blade shaft.

  • Page 321: Check Coil Test-2.4L

    DISTRIBUTOR 6-WAY CON- BATTERY VOLTAGE CYLINDERS 2 & 3 CYLINDERS 1 & 4 NECTOR DISTRIBUTOR 2-WAY CON- NECTOR COLOR IGNITION COIL DRIVER FUNCTION COLOR ASD RELAY OUTPUT FUNCTION GROUND CMP SENSOR SIGNAL 8D - 12 IGNITION SYSTEM FUSED IGN SWITCH OUTPUT SENSOR GROUND DIAGNOSIS AND TESTING (Continued) (2) Starting with coil insulator #1, remove it from...

  • Page 322: Check Coil Test-2.5L

    CHECK SECONDARY RESIS- TANCE ACROSS COIL TOW- IGNITION COILS CYLINDERS 1&4 BATTERY VOLTAGE CYLINDERS 2&3 IGNITION SYSTEM 8D - 13 DIAGNOSIS AND TESTING (Continued) (4) Remove ignition cables from the secondary tow- sensor signal immediately after detecting the cam- ers of the coil. Measure the secondary resistance of shaft position sensor signal.

  • Page 323: Distributor Cap Resistance Test-2.5L

    NORMAL DEPOSITS BLACK COLD (CARBON) FOULING 8D - 14 IGNITION SYSTEM DIAGNOSIS AND TESTING (Continued) light did not flash, the cause of the no-start is in test the throttle position sensor only, refer to the fol- either the crankshaft position sensor/camshaft posi- lowing: tion sensor 8 volt supply circuit, or the camshaft The Throttle Position Sensor (TPS) can be tested...
  • Page 324 GROUND ELECTRODE CENTER ELECTRODE DEPOSITS IGNITION SYSTEM 8D - 15 DIAGNOSIS AND TESTING (Continued) Some fuel refiners in several areas of the United States have introduced a manganese additive (MMT) for unleaded fuel. During combustion, fuel with MMT may coat the entire tip of the spark plug with a rust colored deposit.
  • Page 325 GROUND CENTER ELEC- ELECTRODE TRODE GROUND ELECTRODE COV- ERED WITH WHITE OR YEL- LOW DEPOSITS CENTER ELECTRODE CHIPPED INSULATOR BLISTERED GRAY COLORED INSULATOR GROUND ELECTRODE STARTING TO DISSOLVE WHITE CENTER ELECTRODE DISSOLVED 8D - 16 IGNITION SYSTEM DIAGNOSIS AND TESTING (Continued) heavy but the deposits are easily removed.

  • Page 326: Removal And Installation

    AUXILIARY JUMPER TERMINAL AIR CLEANER HOUSING POWERTRAIN CONTROL MODULE BRACKET SCREWS LEFT STRUT TOWER IGNITION SYSTEM 8D - 17 REMOVAL AND INSTALLATION INSTALLATION (1) Install PCM. Tighten mounting screws. POWERTRAIN CONTROL MODULE (2) Attach both 40-way connectors to PCM. (3) Connect negative cable to auxillary jumper ter- The PCM attaches to a bracket between the air minal.
  • Page 327 AIR INLET RESONA- SUPPORT BRACKET BOLT MAP SENSOR RESONATOR B OLT INTAKE PERATURE TEM- SEN- 8D - 18 IGNITION SYSTEM REMOVAL AND INSTALLATION (Continued) SPARK PLUGS AND CABLES—2.5L SPARK PLUG REMOVAL—#1, #3 or #5 (1) Disconnect negative cable from auxillary When replacing the spark plug and coil cables, jumper terminal.
  • Page 328 THROTTLE POSITION SEN- THROTTLE BODY THROTTLE POSITION SENSOR THROTTLEBODY IDLE CONTROL MOTOR SPEED CONTROL CABLE BOLTS TUBE EGR TUBE SUPPORT THROTTLE CABLE BRACKET BOLT RELEASE TANG IGNITION SYSTEM 8D - 19 REMOVAL AND INSTALLATION (Continued) (5) Loosen throttle body air inlet hose clamp. (9) Pry retainer tab back on throttle cable and (6) Release snaps holding air cleaner housing slide cable out of bracket (Fig.
  • Page 329 SPARK INSULATOR PLUG SPARK PLUG CABLE ELECTRICAL CONNECTOR IGNITION COILS IGNITION COIL FAS- TENERS 8D - 20 IGNITION SYSTEM REMOVAL AND INSTALLATION (Continued) (12) Remove plenum support bracket bolt located IGNITION COIL—2.0/2.4L rearward of EGR tube (Fig. 41). The electronic ignition coil pack attaches directly (13) Remove bolts holding upper intake plenum to the valve cover (Fig.

  • Page 330: Automatic Shutdown Relay

    IGNITION COIL BATTERY POSITIVE BATTERY GROUND AIR CLEANER DISTRIBUTOR HOUSING COIL TOWER CAMSHAFT POSITION SEN- REAR OF CYLINDER HEAD REAR OF CYLINDER HEAD TARGET MAGNET MOUNTING BOLT IGNITION SYSTEM 8D - 21 REMOVAL AND INSTALLATION (Continued) IGNITION COIL—2.5L CAMSHAFT POSITION SENSOR—SOHC The ignition coil is located in the distributor hous- The camshaft position sensor is mounted to the ing (Fig.

  • Page 331: Camshaft Position Sensor-Dohc

    CAMSHAFT POSITION SEN- MOUNTINGBOLT LOCATING DOWELS TARGET MAGNET LOCATING HOLES (2) 8D - 22 IGNITION SYSTEM REMOVAL AND INSTALLATION (Continued) INSTALLATION (4) Loosen screw attaching target magnet to rear The target magnet has two locating dowels that fit of camshaft (Fig. 49). into machined locating holes in end of the camshaft.

  • Page 332: Distributor-2.5L

    CRANKSHAFT DISTRIBUTOR GENERATOR OIL FILTER POSITION SENSOR HOLD DOWN BOLT CRANKSHAFT POSITION SENSOR PUSH ON CLIP ADJUSTMENT HOLE PAPER SPACER CRANKSHAFT POSITION SEN- IGNITION SYSTEM 8D - 23 REMOVAL AND INSTALLATION (Continued) CRANKSHAFT POSITION SENSOR—2.0/2.4 L (4) (Disconnect crankshaft position sensor electri- cal connector from the wiring harness connector.
  • Page 333 SPARK PLUG CABLES DISTRIBUTOR CONNEC- DISTRIBUTOR TORS SCREWS 8D - 24 IGNITION SYSTEM REMOVAL AND INSTALLATION (Continued) (8) Loosen distributor cap holddown screws and (11) Remove 2 sets of distributor holddown nuts remove cap (Fig. 54). and washers from studs. (12) Remove bolt and spark plug cable mounting bracket from top of distributor housing.

  • Page 334: Engine Coolant Temperature

    ENGINE TEMPERATURE CAMSHAFT POSITION COOLANT SENSOR SENSOR IGNITION SYSTEM 8D - 25 REMOVAL AND INSTALLATION (Continued) (9) Transfer cables from old cap to new cap. The COMBINATION ENGINE COOLANT TEMPERATURE cap is numbered and so are the cables. SENSOR—SOHC The combination engine coolant sensor is located at INSTALLATION the rear of the cylinder head next to the camshaft (1) Install distributor cap.

  • Page 335: Sensor-2.5L

    INTAKE TEMPERATURE INTAKE MANIFOLD SENSOR ENGINE COOLANT TEMPER- MAP SENSOR ATURE SENSOR THROTTLE BODY SEN- INTAKE PERATURE SENSOR TEM- INLET COOLANT FILL TUBE NECK 8D - 26 IGNITION SYSTEM REMOVAL AND INSTALLATION (Continued) INSTALLATION 2.5L (1) Install ECT sensor. Tighten sensor to 7 N·m (60 in.
  • Page 336 IGNITION SWITCH FUSE COVER PANEL RETAINING TABS LOCK CYLINDER HOUSING SCREW COVER CENTER BEZEL LOWER SCREW LOCATIONS KNEE BOLSTER SCREW COVER LOCATIONS UNDER TOP SCREWS COVER IGNITION SYSTEM 8D - 27 REMOVAL AND INSTALLATION (Continued) IGNITION SWITCH (3) Pull center bezel off (Fig. 62). The ignition switch attaches to the lock cylinder housing on the end opposite the lock cylinder (Fig.
  • Page 337 KEY CYLINDER LOWER SHROUD LOWER STEERING COLUMN SHROUD SCREW LOCA- TIONS TILT LEVER LOWER SHROUD ATTACHING SCREWS MULTI-FUNCTION SWITCH 8D - 28 IGNITION SYSTEM REMOVAL AND INSTALLATION (Continued) (6) Remove lower knee bolster screws and knee (9) Hold tilt wheel lever down and slide lower bolster.
  • Page 338 LOCK MULTI-FUNCTION RETAINING TAB CYLINDER SWITCH ATTACHING/GROUNDING SCREW SCREW- DRIVER LOCK HOUSING IGNITION SWITCH KEY IN SWITCH PRNDL SWITCH IGNITION SWITCH IGNITION SWITCH IGNITION SYSTEM 8D - 29 REMOVAL AND INSTALLATION (Continued) (12) Place key cylinder in RUN position. Depress lock cylinder retaining tab and remove key cylinder (Fig.

  • Page 339: Lock Cylinder Housing

    MOUNTINGBOLT LOCK CYLINDER RETAINING TARGET MAGNET SOCKET LOCK CYLINDER HOUSING 8D - 30 IGNITION SYSTEM REMOVAL AND INSTALLATION (Continued) (6) Connect negative cable to battery. INSTALLATION (1) Install key in lock cylinder. Turn key to run position (retaining tab on lock cylinder can be depressed).

  • Page 340: Sensor-2.4L

    FIRING ORDER 1–3–4–2 FRONT IGNITION COIL VEHICLE FRONT OF ENGINE 1 - 2 - 3 - 4 - 5 - 6 FIRING ORDER CONNECTOR IGNITION SYSTEM 8D - 31 SPECIFICATIONS TORQUE SPECIFICATION VECI LABEL DESCRIPTION TORQUE If anything differs between the specifications found Air Inlet tube Clamp .

  • Page 341: Spark Plug Cable Resistance-2.5L

    8D - 32 IGNITION SYSTEM SPECIFICATIONS (Continued) SPARK PLUG CABLE RESISTANCE—2.0L CABLE RESISTANCE #1,#4 3500 ohms— 4900 ohms #2,#3 2950 ohms— 4100 ohms SPARK PLUG CABLE RESISTANCE—2.4L CABLE RESISTANCE #1,#4 3500 ohms— 4900 ohms #2,#3 2950 ohms— 4100 ohms SPARK PLUG CABLE RESISTANCE—2.5L MINIMUM MAXIMUM 250 Ohms Per Inch...
  • Page 342 DIAMOND (BRASS TOWERS) IGNITION SYSTEM 8D - 33 SPECIFICATIONS (Continued) IGNITION COILS Primary Resistance Secondary Resis- Engines Coil Manufacture at 21°C-27°C (70°F- tance at 21°C-27°C (70°F-80°F) 80°F) 2.0/2.4L Toyodenso/Diamond 0.51 TO 0.61 Ohms 11,500 to 13,500 Ohms 2.5L Melco 0.6 TO 0.8 Ohms 12,500 to 18,000 Ohms Coil Polarity Coil Polarity...
  • Page 343 8D - 34 IGNITION SYSTEM SPECIFICATIONS (Continued)
  • Page 344 IGNITION SYSTEM 8D - 1 IGNITION SYSTEM CONTENTS page page GENERAL INFORMATION THROTTLE POSITION SENSOR ... 14 INTRODUCTION ......2 REMOVAL AND INSTALLATION DESCRIPTION AND OPERATION AUTOMATIC SHUTDOWN RELAY...

  • Page 345: General Information

    POWER DISTRIBUTION CENTER POWERTRAIN CON- TROL MODULE 8D - 2 IGNITION SYSTEM GENERAL INFORMATION (2.0/2.4L). By switching the ground path for the coil on and off, the PCM adjusts ignition timing to meet INTRODUCTION changing engine operating conditions. On a 2.5L The PCM controls ignition timing by This group describes the ignition systems for the turning on and off a tranisistor in the distributor.
  • Page 346 IGNITION SYSTEM 8D - 3 DESCRIPTION AND OPERATION (Continued) Replace spark plugs at the intervals recommended in The spark plugs are double platinum and have a Group O - Lubrication and Maintenance. recommended service life of 100,000 miles for normal Spark plugs that have low mileage may be cleaned driving conditions per schedule A in this manual.
  • Page 347 PLATINUM SURFACE SPARK APPLY COMPOUND ANTI-SEIZE HERE ONLY TAPER GAUGE 8D - 4 IGNITION SYSTEM DESCRIPTION AND OPERATION (Continued) 2.5L SPARK PLUG GAP MEASUREMENT CAUTION: Cleaning of the platinum plug may dam- age the platinum tip. CAUTION: The Platinum pads can be damaged dur- ing the measurement of checking the gap if extreme care is not used.

  • Page 348: Automatic Shutdown Relay

    SPARK INSULATOR PLUG SPARK PLUG CABLE IGNITION COILS HIGH TENSION TOWER IGNITION COIL IGNITION COILS IGNITION SYSTEM 8D - 5 DESCRIPTION AND OPERATION (Continued) ELECTRONIC IGNITION COIL IGNITION COIL—2.5L The 2.5L engine uses an epoxy type coil. The coils WARNING: THE DIRECT IGNITION SYSTEM GEN- are not oil filled.
  • Page 349 POWER DISTRIBUTION CENTER POWERTRAIN CON- TROL MODULE 8D - 6 IGNITION SYSTEM DESCRIPTION AND OPERATION (Continued) On-Board Diagnostics. When the ignition switch is in CRANKSHAFT POSITION SENSOR On or Start, the PCM momentarily turns on the ASD The PCM determines what cylinder to fire from the relay.
  • Page 350 CRANKSHAFT MACHINED NOTCHES GENERATOR OIL FILTER POSITION SENSOR CRANKSHAFT PUSH ON CLIP ADJUSTMENT TORQUE POSITION SENSOR HOLE CONVERTOR SLOTS DRIVE PLATE PAPER SPACER CRANKSHAFT POSITION SEN- IGNITION SYSTEM 8D - 7 DESCRIPTION AND OPERATION (Continued) Fig. 8 Timing Reference Notches The crankshaft position sensor mounts to the engine block behind the generator, just above the oil filter (Fig.

  • Page 351: Camshaft Position Sensor-2.0/2.4L

    CAMSHAFT POSITION SEN- REAR OF CYLINDER HEAD TRANSAXLE HOUSING CRANKSHAFT POSITION SEN- CAMSHAFT POSITION SEN- CAMSHAFT POSITION SEN- CAM MAGNET/TARGET 8D - 8 IGNITION SYSTEM DESCRIPTION AND OPERATION (Continued) The PCM uses crankshaft position reference to determine injector sequence, ignition timing and the presence of misfire.

  • Page 352: Camshaft Position Sensor-2.5L

    TARGET MAGNET DISTRIBUTOR PULSE RING SYNC GENERATOR SIGNAL IGNITION SYSTEM 8D - 9 DESCRIPTION AND OPERATION (Continued) When the trailing edge of the shutter leaves the sync signal generator, the change of magnetic field causes the sync signal voltage to switch low to 0 volts.

  • Page 353: Intake Air Temperature Sensor-2.4/2.5L

    MAP/AIR INTAKE TEMPERATURE INTAKE MANIFOLD PCV VACUUM NIPPLE SENSOR INTAKE MANIFOLD TEMPERATURE SENSOR MAP SENSOR THROTTLE BODY SEN- INTAKE PERATURE SENSOR TEM- 8D - 10 IGNITION SYSTEM DESCRIPTION AND OPERATION (Continued) INTAKE AIR TEMPERATURE SENSOR—2.0L The intake air temperature sensor measures the temperature of the air as it enters the engine.

  • Page 354: Diagnosis And Testing

    ACCESSORY UNLOCK ON/RUN START GOOD GROUND ENGINE SPARK PLUG CABLE BOOT CHECK SPARKPLUG SPARK HERE IGNITION SYSTEM 8D - 11 DESCRIPTION AND OPERATION (Continued) THROTTLE POSITION SENSOR (TPS) Transaxle for Automatic Transmission Shifter/Igni- tion Interlock. The TPS mounts to the side of the throttle body. The TPS connects to the throttle blade shaft.

  • Page 355: Check Coil Test-2.4L

    DISTRIBUTOR 6-WAY CON- BATTERY VOLTAGE CYLINDERS 2 & 3 CYLINDERS 1 & 4 NECTOR DISTRIBUTOR 2-WAY CON- NECTOR COLOR IGNITION COIL DRIVER FUNCTION COLOR ASD RELAY OUTPUT FUNCTION GROUND CMP SENSOR SIGNAL 8D - 12 IGNITION SYSTEM FUSED IGN SWITCH OUTPUT SENSOR GROUND DIAGNOSIS AND TESTING (Continued) (2) Starting with coil insulator #1, remove it from...

  • Page 356: Check Coil Test-2.5L

    CHECK SECONDARY RESIS- TANCE ACROSS COIL TOW- IGNITION COILS CYLINDERS 1&4 BATTERY VOLTAGE CYLINDERS 2&3 IGNITION SYSTEM 8D - 13 DIAGNOSIS AND TESTING (Continued) (4) Remove ignition cables from the secondary tow- sensor signal immediately after detecting the cam- ers of the coil. Measure the secondary resistance of shaft position sensor signal.

  • Page 357: Distributor Cap Resistance Test-2.5L

    NORMAL DEPOSITS BLACK COLD (CARBON) FOULING 8D - 14 IGNITION SYSTEM DIAGNOSIS AND TESTING (Continued) light did not flash, the cause of the no-start is in test the throttle position sensor only, refer to the fol- either the crankshaft position sensor/camshaft posi- lowing: tion sensor 8 volt supply circuit, or the camshaft The Throttle Position Sensor (TPS) can be tested...
  • Page 358 GROUND ELECTRODE CENTER ELECTRODE DEPOSITS IGNITION SYSTEM 8D - 15 DIAGNOSIS AND TESTING (Continued) Some fuel refiners in several areas of the United States have introduced a manganese additive (MMT) for unleaded fuel. During combustion, fuel with MMT may coat the entire tip of the spark plug with a rust colored deposit.
  • Page 359 GROUND CENTER ELEC- ELECTRODE TRODE GROUND ELECTRODE COV- ERED WITH WHITE OR YEL- LOW DEPOSITS CENTER ELECTRODE CHIPPED INSULATOR BLISTERED GRAY COLORED INSULATOR GROUND ELECTRODE STARTING TO DISSOLVE WHITE CENTER ELECTRODE DISSOLVED 8D - 16 IGNITION SYSTEM DIAGNOSIS AND TESTING (Continued) heavy but the deposits are easily removed.

  • Page 360: Removal And Installation

    AUXILIARY JUMPER TERMINAL AIR CLEANER HOUSING POWERTRAIN CONTROL MODULE BRACKET SCREWS LEFT STRUT TOWER IGNITION SYSTEM 8D - 17 REMOVAL AND INSTALLATION INSTALLATION (1) Install PCM. Tighten mounting screws. POWERTRAIN CONTROL MODULE (2) Attach both 40-way connectors to PCM. (3) Connect negative cable to auxillary jumper ter- The PCM attaches to a bracket between the air minal.
  • Page 361 AIR INLET RESONA- SUPPORT BRACKET BOLT MAP SENSOR RESONATOR B OLT INTAKE PERATURE TEM- SEN- 8D - 18 IGNITION SYSTEM REMOVAL AND INSTALLATION (Continued) SPARK PLUGS AND CABLES—2.5L SPARK PLUG REMOVAL—#1, #3 or #5 (1) Disconnect negative cable from auxillary When replacing the spark plug and coil cables, jumper terminal.
  • Page 362 THROTTLE POSITION SEN- THROTTLE BODY THROTTLE POSITION SENSOR THROTTLEBODY IDLE CONTROL MOTOR SPEED CONTROL CABLE BOLTS TUBE EGR TUBE SUPPORT THROTTLE CABLE BRACKET BOLT RELEASE TANG IGNITION SYSTEM 8D - 19 REMOVAL AND INSTALLATION (Continued) (5) Loosen throttle body air inlet hose clamp. (9) Pry retainer tab back on throttle cable and (6) Release snaps holding air cleaner housing slide cable out of bracket (Fig.
  • Page 363 SPARK INSULATOR PLUG SPARK PLUG CABLE ELECTRICAL CONNECTOR IGNITION COILS IGNITION COIL FAS- TENERS 8D - 20 IGNITION SYSTEM REMOVAL AND INSTALLATION (Continued) (12) Remove plenum support bracket bolt located IGNITION COIL—2.0/2.4L rearward of EGR tube (Fig. 41). The electronic ignition coil pack attaches directly (13) Remove bolts holding upper intake plenum to the valve cover (Fig.

  • Page 364: Automatic Shutdown Relay

    IGNITION COIL BATTERY POSITIVE BATTERY GROUND AIR CLEANER DISTRIBUTOR HOUSING COIL TOWER CAMSHAFT POSITION SEN- REAR OF CYLINDER HEAD REAR OF CYLINDER HEAD TARGET MAGNET MOUNTING BOLT IGNITION SYSTEM 8D - 21 REMOVAL AND INSTALLATION (Continued) IGNITION COIL—2.5L CAMSHAFT POSITION SENSOR—SOHC The ignition coil is located in the distributor hous- The camshaft position sensor is mounted to the ing (Fig.

  • Page 365: Camshaft Position Sensor-Dohc

    CAMSHAFT POSITION SEN- MOUNTINGBOLT LOCATING DOWELS TARGET MAGNET LOCATING HOLES (2) 8D - 22 IGNITION SYSTEM REMOVAL AND INSTALLATION (Continued) INSTALLATION (4) Loosen screw attaching target magnet to rear The target magnet has two locating dowels that fit of camshaft (Fig. 49). into machined locating holes in end of the camshaft.

  • Page 366: Crankshaft Position Sensor-2.0/2.4 L

    CRANKSHAFT DISTRIBUTOR GENERATOR OIL FILTER POSITION SENSOR HOLD DOWN BOLT CRANKSHAFT POSITION SENSOR PUSH ON CLIP ADJUSTMENT HOLE PAPER SPACER CRANKSHAFT POSITION SEN- IGNITION SYSTEM 8D - 23 REMOVAL AND INSTALLATION (Continued) CRANKSHAFT POSITION SENSOR—2.0/2.4 L (4) (Disconnect crankshaft position sensor electri- cal connector from the wiring harness connector.

  • Page 367: Distributor Cap-2.5L

    SPARK PLUG CABLES DISTRIBUTOR CONNEC- DISTRIBUTOR TORS SCREWS 8D - 24 IGNITION SYSTEM REMOVAL AND INSTALLATION (Continued) (8) Loosen distributor cap holddown screws and (11) Remove 2 sets of distributor holddown nuts remove cap (Fig. 54). and washers from studs. (12) Remove bolt and spark plug cable mounting bracket from top of distributor housing.

  • Page 368: Distributor Rotor-2.5L

    ENGINE TEMPERATURE CAMSHAFT POSITION COOLANT SENSOR SENSOR IGNITION SYSTEM 8D - 25 REMOVAL AND INSTALLATION (Continued) (9) Transfer cables from old cap to new cap. The COMBINATION ENGINE COOLANT TEMPERATURE cap is numbered and so are the cables. SENSOR—SOHC The combination engine coolant sensor is located at INSTALLATION the rear of the cylinder head next to the camshaft (1) Install distributor cap.

  • Page 369: Sensor-2.5L

    INTAKE TEMPERATURE INTAKE MANIFOLD SENSOR ENGINE COOLANT TEMPER- MAP SENSOR ATURE SENSOR THROTTLE BODY SEN- INTAKE PERATURE SENSOR TEM- INLET COOLANT FILL TUBE NECK 8D - 26 IGNITION SYSTEM REMOVAL AND INSTALLATION (Continued) INSTALLATION 2.5L (1) Install ECT sensor. Tighten sensor to 7 N·m (60 in.
  • Page 370 IGNITION SWITCH FUSE COVER PANEL RETAINING TABS LOCK CYLINDER HOUSING SCREW COVER CENTER BEZEL LOWER SCREW LOCATIONS KNEE BOLSTER SCREW COVER LOCATIONS UNDER TOP SCREWS COVER IGNITION SYSTEM 8D - 27 REMOVAL AND INSTALLATION (Continued) IGNITION SWITCH (3) Pull center bezel off (Fig. 62). The ignition switch attaches to the lock cylinder housing on the end opposite the lock cylinder (Fig.
  • Page 371 KEY CYLINDER LOWER SHROUD LOWER STEERING COLUMN SHROUD SCREW LOCA- TIONS TILT LEVER LOWER SHROUD ATTACHING SCREWS MULTI-FUNCTION SWITCH 8D - 28 IGNITION SYSTEM REMOVAL AND INSTALLATION (Continued) (6) Remove lower knee bolster screws and knee (9) Hold tilt wheel lever down and slide lower bolster.
  • Page 372 LOCK MULTI-FUNCTION RETAINING TAB CYLINDER SWITCH ATTACHING/GROUNDING SCREW SCREW- DRIVER LOCK HOUSING IGNITION SWITCH KEY IN SWITCH PRNDL SWITCH IGNITION SWITCH IGNITION SWITCH IGNITION SYSTEM 8D - 29 REMOVAL AND INSTALLATION (Continued) (12) Place key cylinder in RUN position. Depress lock cylinder retaining tab and remove key cylinder (Fig.

  • Page 373: Lock Cylinder Housing

    MOUNTINGBOLT LOCK CYLINDER RETAINING TARGET MAGNET SOCKET LOCK CYLINDER HOUSING 8D - 30 IGNITION SYSTEM REMOVAL AND INSTALLATION (Continued) (6) Connect negative cable to battery. INSTALLATION (1) Install key in lock cylinder. Turn key to run position (retaining tab on lock cylinder can be depressed).

  • Page 374: Sensor-2.4L

    FIRING ORDER 1–3–4–2 FRONT IGNITION COIL VEHICLE FRONT OF ENGINE 1 - 2 - 3 - 4 - 5 - 6 FIRING ORDER CONNECTOR IGNITION SYSTEM 8D - 31 SPECIFICATIONS TORQUE SPECIFICATION VECI LABEL DESCRIPTION TORQUE If anything differs between the specifications found Air Inlet tube Clamp .

  • Page 375: Spark Plug Cable Resistance-2.0L

    8D - 32 IGNITION SYSTEM SPECIFICATIONS (Continued) SPARK PLUG CABLE RESISTANCE—2.0L CABLE RESISTANCE #1,#4 3500 ohms— 4900 ohms #2,#3 2950 ohms— 4100 ohms SPARK PLUG CABLE RESISTANCE—2.4L CABLE RESISTANCE #1,#4 3500 ohms— 4900 ohms #2,#3 2950 ohms— 4100 ohms SPARK PLUG CABLE RESISTANCE—2.5L MINIMUM MAXIMUM 250 Ohms Per Inch...
  • Page 376 DIAMOND (BRASS TOWERS) IGNITION SYSTEM 8D - 33 SPECIFICATIONS (Continued) IGNITION COILS Primary Resistance Secondary Resis- Engines Coil Manufacture at 21°C-27°C (70°F- tance at 21°C-27°C (70°F-80°F) 80°F) 2.0/2.4L Toyodenso/Diamond 0.51 TO 0.61 Ohms 11,500 to 13,500 Ohms 2.5L Melco 0.6 TO 0.8 Ohms 12,500 to 18,000 Ohms Coil Polarity Coil Polarity...
  • Page 377 8D - 34 IGNITION SYSTEM SPECIFICATIONS (Continued)
  • Page 378 IGNITION SYSTEM 8D - 1 IGNITION SYSTEM CONTENTS page page DESCRIPTION AND OPERATION SPECIFICATIONS SPARK PLUGS — 2.5L With Leaded SPARK PLUGS ......1 Fuel Option .
  • Page 380 IGNITION SYSTEM 8D - 1 IGNITION SYSTEM CONTENTS page page DESCRIPTION AND OPERATION SPECIFICATIONS SPARK PLUGS — 2.5L With Leaded SPARK PLUGS ......1 Fuel Option .
  • Page 382 INSTRUMENT PANEL AND SYSTEMS 8E - 1 INSTRUMENT PANEL AND SYSTEMS CONTENTS page page GENERAL INFORMATION GLOVE BOX DOOR HANDLE ....9 ELECTRO/MECHANICAL INSTRUMENT GLOVE BOX DOOR LOCK ....9 CLUSTER .
  • Page 383 TEMPERATURE/COMPASS MINI TRIP COMPUTER 8E - 2 INSTRUMENT PANEL AND SYSTEMS GENERAL INFORMATION (Continued) The gauges are the magnetic air-core type. When the ignition switch is OFF, the gauge pointers should rest at or below the low graduation. DESCRIPTION AND OPERATION AUTOSTICK Vehicles with Autostick will have a unique Trans- mission Range Indicator display (Fig.
  • Page 384 INSTRUMENT PANEL AND SYSTEMS 8E - 3 DESCRIPTION AND OPERATION (Continued) play SC. If the temperature is less than -40°C (-40°F) INSTRUMENT CLUSTER SELF- DIAGNOSTICS or the temperature sending line is an open circuit, Initiate instrument cluster self-diagnostic the compass and ambient temperature screen will depressing the odometer/trip reset button while turn- OC.
  • Page 385 8E - 4 INSTRUMENT PANEL AND SYSTEMS DIAGNOSIS AND TESTING (Continued) CHEC 4 - AUTOMATIC TRANSMISSION CHEC 2 - WARNING LAMP DISPLAY If any V/F segment does not light, replace Odome- SERVICE ENGINE SOON ter/Transmission Range Indication. SEAT BELT CHEC 4 - TRANSMISSION RANGE INDICATOR AIRBAG V/F DISPLAY CHARGING SYSTEM...
  • Page 386 INSTRUMENT PANEL AND SYSTEMS 8E - 5 SERVICE PROCEDURES Calibrate the compass by driving the vehicle in a circle with a constant speed between 5 and 11 MPH COMPASS CALIBRATION PROCEDURE (8 and 18 Km/h), the diameter should be between 6 and 27.5 meters (30 and 90 feet).
  • Page 387 ATTACHINGSCREWS INSTRUMENT CLUS- TER HOOD 8E - 6 INSTRUMENT PANEL AND SYSTEMS SERVICE PROCEDURES (Continued) DIRECT METHOD (2) Tilt steering column down to its lowest posi- Turn the vehicle to head in either a North or South tion. direction. The vehicle must be within 45 degrees of (3) Remove instrument panel center bezel by dis- the North or South position or the SETTING the engaging the four clips (Fig.
  • Page 388 VEHICLE THEFT SECURITY TRANSMISSION INDICATOR CONNECTOR *ILLUMINATION LAMP RETAINING SCREWS CHARGING SYSTEM MIL/CHECK ENGINE OIL PRESSURE SYSTEM LED RIGHT TURN HIGH BEAM LEFT TURN SEAT BELT FOG LAMP LOW FUEL NOT USED NOT USED VTSS LED AIR BAG HI TEMP CRUISE RANGE BRAKE...
  • Page 389 MASK/LENSSCREWS MASK/LENS SCREWS CLUSTERSCREWS CLUSTER SCREWS MASK/LENS SCREWS MASK/LENS SCREWS CLUSTERSCREWS CLUSTER SCREWS MASK/LENSSCREWS MASK/LENS SCREWS CLUSTER ODOMETER/TRANSMISSION RANGE RETAINING SCREWS INDICATOR BACK VTSS LED NECTOR COVER CON- 8E - 8 INSTRUMENT PANEL AND SYSTEMS REMOVAL AND INSTALLATION (Continued) (3) Remove the cubby bin mounting screws and remove bin.
  • Page 390 INSTRUMENT PANEL AND SYSTEMS 8E - 9 REMOVAL AND INSTALLATION (Continued) GLOVE BOX DOOR HANDLE INSTRUMENT CLUSTER REMOVAL REMOVAL (1) Open glove door. To service any instrument cluster component, the (2) Remove four door handle attaching screws. instrument cluster must be removed from the instru- (3) Remove handle.
  • Page 391 END COVER KNEE BOLSTER SPEAKERS INSTRUMENT CLUSTER HVAC GLOVE BOX LOCK TOP COVER CUBBYBIN CENTER BEZEL SCREW CYLINDER PASSENGER BAG MODULE END COVER INSTRUMENT CLUS- AIR- RADIO TER HOOD 8E - 10 INSTRUMENT PANEL AND SYSTEMS REMOVAL AND INSTALLATION (Continued) REMOVAL When removing a passenger airbag module refer to Group 8M, Restraint Systems for Passenger Air Bag...
  • Page 392 INSTRUMENT PANEL AND SYSTEMS 8E - 11 REMOVAL AND INSTALLATION (Continued) (3) Remove transmission range indicator bezel INSTALLATION from floor console. Use care not to mar the bezel or For installation, reverse the above procedures. DO console. NOT CONNECT battery negative remote cable. Refer (4) Remove floor center console.
  • Page 393 SPEAKER JUNCTION/BCM 8E - 12 INSTRUMENT PANEL AND SYSTEMS REMOVAL AND INSTALLATION (Continued) INSTALLATION INSTALLATION For installation, reverse the above procedures. For installation, reverse the above procedures. Ensure the two center clips are engaged first. Place Ensure that the wire terminals and connectors are in thumb in VIN opening and pull towards pad to good condition and connectors are properly installed.
  • Page 394 INSTRUMENT PANEL AND SYSTEMS 8E - 13 MOUNTING SCREWS REMOVAL AND INSTALLATION (Continued) MASK/LENS INSTALLATION For installation, reverse the above procedures. REMOVAL SPEEDOMETER/TACHOMETER AND ODOMETER Remove mask/lens retaining screws and remove TRANSMISSION RANGE INDICATOR mask/lens (Fig. 11). INSTALLATION REMOVAL For installation, reverse the above procedures. (1) Remove mask/lens retaining...
  • Page 396 INSTRUMENT PANEL AND GAUGE 8E - 1 INSTRUMENT PANEL AND GAUGE CONTENTS page page GENERAL INFORMATION REMOVAL AND INSTALLATION ELECTRO/MECHANICAL INSTRUMENT FUEL GAUGE AND TEMPERATURE GAUGE . . . 1 CLUSTER ......1 HEADLAMP LEVELING SWITCH .
  • Page 397 8E - 2 INSTRUMENT PANEL AND GAUGE DIAGNOSIS AND TESTING (Continued) (4) Turn headlamps OFF. Connect the wire harness connector to the headlamp leveling switch. Turn ON the headlamp switch to the low beam position. Check volt- age at Pin 3, while rotating the headlamp leveling switch knob through it’s range.
  • Page 398 INSTRUMENT PANEL AND GAUGE 8E - 3 REMOVAL AND INSTALLATION (Continued) HEADLAMP LEVELING SWITCH SPEEDOMETER/TACHOMETER AND ODOMETER TRANSMISSION RANGE INDICATOR REMOVAL (1) Disconnect and isolate the battery negative REMOVAL cable. (1) Remove mask/lens retaining screws (2) Using a trim stick or other suitable wide flat remove mask/lens.

  • Page 400: Audio Systems

    AUDIO SYSTEMS 8F - 1 AUDIO SYSTEMS CONTENTS page page GENERAL INFORMATION POWER ANTENNA ..... . 13 INTRODUCTION ......1 REMOVAL AND INSTALLATION DESCRIPTION AND OPERATION DOOR MOUNTED SPEAKER .

  • Page 401: Audio Diagnostic Test Procedures

    8F - 2 AUDIO SYSTEMS • If resistance is less than two ohms, replace DIAGNOSIS AND TESTING speaker. If resistance is OK, repair wires AUDIO DIAGNOSTIC TEST PROCEDURES MECHANICAL NOISE DISTORTION • Check trim for loose parts, and speaker attach- CAUTION: The CD player will only operate between ments for buzzes approximate temperatures of -23°C and +65°C (-10°F...
  • Page 402 1 — AMP ON-OFF SIGNAL/ANT UP SIGNAL 2 — LEFT REAR SPEAKER FEED (+) 3 — RIGHT REAR SPEAKER FEED (+) 4 — LEFT FRONT SPEAKER FEED (+) 5 — RIGHT FRONT SPEAKER FEED (+) 6 — LEFT REAR SPEAKER RETURN (-) 7 —...
  • Page 403 REPAIR AS NECES- REPAIR AS NECES- SARY CHECK SPEAKER CONNECTOR SARY (A) LOOSE CONNECTIONS CONDITION OK? REPAIR AS NECES- (B) BROKEN WIRES (C) CORROSION EXCHANGE RADIO CHECK RADIO CONNECTOR FOR: (A) LOOSE CONNECTIONS SARY TEST RESISTANCE BETWEEN THE SPEAKER PLUS AND MINUS TERMINALS FOR A READING FOR: TIONS OK? (B) BROKEN WIRES...
  • Page 404 CHECK FOR NOISE WITH THE IGNITION IN ACCES- SORY POSITION, WITH ALL ELECTRICAL ACCESSORIES OFF AND DRIVER’S DOOR CLOSED FOR AT LEAST 60 REPLACE DEFECTIVE USING A TEST ANTENNA, CHECK ANTENNA COAXIAL - CONNECT FROM BODY CHECK STRAPS. OTHER ELECTRICAL COM- PONENTS START ENGINE...
  • Page 405 EXCHANGE U NIT GOOD TAPE KNOWN CHECK OBSTRUCTION TAPE OBSTRUCTION PLAYER PLAYS OK? INOPERA- FOUND? TIVE BEHIND DOORS ADVISE WORN OR DEFECTIVE REPAIR AS NEC- SPOOL(S) OWNER CASE ESSARY EATS TAPES. (DIRTY CAPSTAN AND DRIVE TAPE SYSTEM) CLEAN EXCHANGE UNIT HEAD CLEANER WITH POOR...
  • Page 406 1 — AMP ON-OFF SIGNAL/ANT UP SIGNAL 2 — LEFT REAR SPEAKER FEED (+) 3 — RIGHT REAR SPEAKER FEED (+) 4 — LEFT FRONT SPEAKER FEED (+) 5 — RIGHT FRONT SPEAKER FEED (+) 6 — LEFT REAR SPEAKER RETURN (-) 7 —...
  • Page 407 CHECK RADIO AND AMPLI- CHECK NECTOR WITH IGNITION ON USING CHECK FOR BATTERY VOLT- AGE AT PIN 8 & 10 OF THE USING CHECK AMPLIFIER SUBSTITUTE CHECK TO FUSE FOR HIGH RESIS- TANCE CHECK BETWEEN CHECK FOR BATTERY VOLT- AGE AT PIN 1 OF THE BLACK RADIO CONNECTOR (A) LOOSE CONNECTIONS KNOWN GOOD AMPLIFIER...
  • Page 408 REPAIR REPLACE NECESSARY USING AN OHMMETER, WITH BOTH RADIO AND AMPLIFIER CONNEC- TORS DISCONNECTED, CHECK WIRES FROM THE RADIO CONNEC- TOR TO THE AMPLIFIER CONNECTOR FOR SHORT TO GROUND. REFER TO 8W, WIRING DIAGRAMS. PLACE ONE LEAD OF THE OHM- METER TO EACH TERMINAL AND THE OTHER LEAD TO BODY AMPLIFIER DISCONNECT...
  • Page 409 START ENGINE WITH ENGINE RUNNING. IF THERE IS STATIC/NOISE CHECK THE FOLLOW- CHECK CHECK ANY OTHER ELECTRICAL COM- PONENTS REPAIR AS NECES- ENGINE (B) CHECK GROUND CONNECTIONS REPAIR AS NEC- (C) CHECK ANTENNA MOUNTING (A) IGNITION SYSTEM FAULTS MOTORS GROUND ESSARY SARY CAUSE NOISE...
  • Page 410 EXCHANGE U NIT GOOD TAPE KNOWN CHECK OBSTRUCTION TAPE OBSTRUCTION PLAYER PLAYS OK? INOPERA- FOUND? TIVE BEHIND DOORS ADVISE WORN OR DEFECTIVE REPAIR AS NEC- SPOOL(S) OWNER CASE ESSARY EATS TAPES. (DIRTY CAPSTAN AND DRIVE TAPE SYSTEM) CLEAN EXCHANGE UNIT HEAD CLEANER WITH POOR...
  • Page 411 NOTE: THE CD PLAYER WILL ONLY OPERATE BETWEEN APPROXIMATE TEMPERA- TURES OF −23°C AND +65°C (-10°F AND +145°F) INSERT GOOD CD LABEL SIDE EXCHANGE UNIT CD INOPERATIVE WILL BATTERY VOLT- AGE 11 VOLTS IS CD IN UNIT? OR MORE PLAY? KNOWN REPAIR AS NECES- WILL...

  • Page 412: Power Antenna

    MAST POINT TEST RADIO TEST POINT DISCONNECT TEST POINT POWER ANTENNA ASSEM- RUBBER GROM- GROUND STRAP AUDIO SYSTEMS 8F - 13 DIAGNOSIS AND TESTING (Continued) Refer to Group 8W, Wiring Diagrams for the proper (3) If the motor will not operate, replace the connector.

  • Page 413: Removal And Installation

    SPEAKER GRILLE SPEAKER 8F - 14 AUDIO SYSTEMS REMOVAL AND INSTALLATION (c) Lift rear edge of top cover using a trim stick along rear edge. DOOR MOUNTED SPEAKER (d) While lifting rear edge slide top cover rear- ward to disengage front clips and remove the top CAUTION: Do not operate the radio with speaker cover.

  • Page 414: Power Antenna Mast

    RUBBER GROMMET FIX ANTENNA CONTACT SPRING FRONT TOOTH MUST FACE TO FRONT OF GROMMET (SERRATED) ANTENNA MAST SIDE AUDIO SYSTEMS 8F - 15 REMOVAL AND INSTALLATION (Continued) the slot in the body before installing antenna. Ensure (3) Replace the cap nut and tighten to 1.5 N·m (15 the ball of the antenna body is inside grommet.

  • Page 415: Rear Speaker

    MOUNTING SCREWS 8F - 16 AUDIO SYSTEMS REMOVAL AND INSTALLATION (Continued) PASSENGER SEAT AMPLIFIER Fig. 9 Radio Assembly Fig.10 Rear Speakers REAR SPEAKER REMOTE AMPLIFIER CAUTION: Do not operate the radio with speaker REMOVAL leads detached. Damage to the output devices may (1) Remove the right front seat.
  • Page 416 + POSITIVE — NEGA- TIVE HORNS 8G - 1 HORNS CONTENTS page page DESCRIPTION AND OPERATION HORNS WILL NOT SOUND ....2 HORN RELAY ......1 SYSTEM TEST .

  • Page 417: Horn Relay

    CONTACT AREA (4) AIR BAG MODULE LOCATIONS H/LP RELAY MOUNTING BRACKET CIRCUIT BREAKERS MOUNTING BOLTS HORN RELAY 8G - 2 HORNS DIAGNOSIS AND TESTING (Continued) • When the Driver Airbag Module is pressed the (2) Using ohmmeter, test between the Junction contact ring touches the bracket mounting bolts and Block relay terminal 7 and ground for continuity.

  • Page 418: System Test

    HORNS 8G - 3 DIAGNOSIS AND TESTING (Continued) relay to ground. Refer to Group 8W, Wiring Diagrams (a) If continuity is detected, repair open circuit for circuit information. If continuity is detected, the between the relay and the horn switch. circuit is grounded between the Junction Block and (b) If NO continuity, replace airbag cover.
  • Page 419 8G - 4 HORNS REMOVAL AND INSTALLATION (Continued) HORN SYSTEM TEST CONDITION POSSIBLE CAUSE CORRECTION Horn sounds continuously. (1) Faulty horn relay. (1) Refer to horn relay test. NOTE: Immediately unplug horn (2) Horn control circuit to relay (2) Check horn relay terminal 8 in and relay in the Junction Block shorted to ground.

  • Page 420: Removal And Installation

    HORNS 8G - 5 REMOVAL AND INSTALLATION HORNS REMOVAL (1) Hoist and support front vehicle on safety stands. (2) The horns are located behind the front fascia on the right front frame rail. Remove the splash shield as necessary for access. front. (3) Disconnect the wire connector from the horn.
  • Page 422 HORN SPEED SWITCHES CONTROL VEHICLE SPEED CONTROL SYSTEM 8H - 1 VEHICLE SPEED CONTROL SYSTEM CONTENTS page page GENERAL INFORMATION OVERSHOOT/UNDERSHOOT ON SPEED INTRODUCTION ......1 CONTROL SET .

  • Page 423: General Information

    VACUUM VIEW Y RESER- VOIR 2.0L/2.4L THROTTLE BODY VIEW Z 2.5L SERVO NECTOR SPEED CON- TROL SERVO CON- 8H - 2 VEHICLE SPEED CONTROL SYSTEM GENERAL INFORMATION (Continued) Fig. 2 Speed Control System The system is designed to operate at speeds above ERATE, SET/COAST and CANCEL modes.

  • Page 424: Automatic Speed Control Overspeed

    VEHICLE SPEED CONTROL SYSTEM 8H - 3 DESCRIPTION AND OPERATION (Continued) • The VSS signal decreases at a rate of 10 mph avoid an inappropriate upshift. The upshift is also per second (indicates that the vehicle may have delayed for 0.5 seconds after reaching the 8 degrees decelerated at an extremely high rate) throttle opening in anticipation that the driver might •...

  • Page 425: Diagnosis And Testing

    HOOD RELEASE DIAGNOSTIC DRIVER’S KICK PANEL NECTOR SIDE CON- 8H - 4 VEHICLE SPEED CONTROL SYSTEM DESCRIPTION AND OPERATION (Continued) the PCM determines when a deceleration condition (2) After switch has been cycled three times, occurs. observe MALFUNCTION INDICATOR LAMP (check engine) indicator on instrument cluster.
  • Page 426 VEHICLE SPEED CONTROL SYSTEM 8H - 5 DIAGNOSIS AND TESTING (Continued) SPEED CONTROL DIAGNOSTIC TROUBLE CODES Diagnostic Trouble Code Hex Code DRB Scan Tool Display Description of Diagnostic Trouble Code 15** No Vehicle Speed No vehicle distance Sensor Signal (speed) sensor signal detected during road load conditions.
  • Page 427 8H - 6 VEHICLE SPEED CONTROL SYSTEM DIAGNOSIS AND TESTING (Continued) 40 way connector. Wiggle wires while preforming If any information is needed concerning wiring, test. If no continuity, repair circuit. refer to Group 8W, Wiring Diagrams (Fig. 4). (5) If continuity, disconnect the servo connector. CAUTION: When test probing for voltage or conti- Test continuity from pin 2 of connector and ground to nuity at electrical connectors, care must be taken...
  • Page 428 POWERTRAIN SPEED SPEED CNT MODE SELECT K29 BRAKE SWITCH SIGNAL SPEED CONTROL VACUUM PARK/NEUTRAL SWITCH V35 SPEED CNT VENT BRAKE LAMP SWITCH VACUUM RESERVOIR V36 SPEED CNT VAC SENSOR VACUUM SOURCE THROTTLE BODY (INST. CLUSTER) RESUME/ACCEL CLOCK SPRING CRUISE LIGHT CCD BUS BAR VACUUM LINE SET/COAST...

  • Page 429: Servo Vacuum Test

    CONNECTORS FROM TERMINAL END SHOWN PIN 1 PIN 2 PIN 3 PIN 4 PIN 1 PIN 2 PIN 3 PIN 4 8H - 8 VEHICLE SPEED CONTROL SYSTEM DIAGNOSIS AND TESTING (Continued) OVERSHOOT/UNDERSHOOT ON SPEED CONTROL (10) Connect 4 way electrical connector and vac- uum harness to servo.

  • Page 430: Stop Lamp Switch Test

    INDEX KEY PULL PLUNGER POWER BLACK DISTRIBUTION CENTER GRAY POWERTRAIN CON- TROL MODULE VEHICLE SPEED CONTROL SYSTEM 8H - 9 DIAGNOSIS AND TESTING (Continued) (4) Using an ohmmeter, touch a lead to each pin. ELECTRICAL TESTS AT POWERTRAIN CONTROL The meter should read no continuity. Press the SET MODULE button, the ohmmeter should read 1,978 to 2,022 (1) Unplug 2 40-way connectors from the Power-...

  • Page 431: Vacuum Supply Test

    SERVO 8H - 10 VEHICLE SPEED CONTROL SYSTEM DIAGNOSIS AND TESTING (Continued) (3) Place ignition switch in the ON position for the VACUUM SUPPLY TEST following tests. (1) Disconnect vacuum hose at the servo and (a) Connect wire connectors to both switches. install a vacuum gauge in the hose (Fig.

  • Page 432: Speed Control Servo Cable

    THROTTLE MOUNTING SCREW MOUNTING TAB CONTROL SHIELD VEHICLE SPEED CONTROL SYSTEM 8H - 11 REMOVAL AND INSTALLATION (Continued) INSTALLATION SPEED CONTROL SERVO CABLE (1) Install servo cable to servo and install clip. (2) Install speed control cable to throttle cam. REMOVAL (3) Connect vacuum hose to servo.

  • Page 433: Vacuum Reservoir

    CABLE TABS CLASP 8H - 12 VEHICLE SPEED CONTROL SYSTEM REMOVAL AND INSTALLATION (Continued) VACUUM RESERVOIR The vacuum reservoir is located on the dash panel next to the brake booster. REMOVAL (1) 2.5L ONLY Remove the intake manifold, refer to Group 11 Exhaust System and Intake Manifold. (2) Disconnect vacuum hoses from reservoir.
  • Page 434 TURN SIGNAL AND FLASHERS 8J - 1 TURN SIGNAL AND FLASHERS CONTENTS page page GENERAL INFORMATION MULTI-FUNCTION SWITCH ....4 MULTI-FUNCTION SWITCH ....1 REMOVAL AND INSTALLATION DESCRIPTION AND OPERATION COMBINATION FLASHER...
  • Page 435 EXTERIOR LIGHTING CON- TURN SIGNAL TROL CONTROL STALK PANEL DIMMER SWITCH HAZARD WARNING BUTTON CANCELING CAM WINDSHIELD WASHER CONTROL WIPER/ 8J - 2 TURN SIGNAL AND FLASHERS Fig. 1 Multi-Function Switch • Panel dimmer, rotating dimmer switch regulates DESCRIPTION AND OPERATION density of the instrument panel illumination.
  • Page 436 TURN SIGNAL AND FLASHERS 8J - 3 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION SYSTEM DOES NOT FLASH ON 1. Faulty external lamp. 1. Replace lamp. ONE SIDE, INDICATOR LAMP 2. Poor ground at lamp. 2. Check and /or replace wiring. FLASHES AT DOUBLE NORMAL 3.
  • Page 437 8J - 4 TURN SIGNAL AND FLASHERS DIAGNOSIS AND TESTING (Continued) MULTI-FUNCTION SWITCH (1) Remove multi-function switch, refer to removal and installation procedures below. (2) Using an ohmmeter, test for continuity (no resistance) between the terminals of the switch as shown in the following continuity charts (Fig.
  • Page 438 TURN SIGNAL AND FLASHERS 8J - 5 DIAGNOSIS AND TESTING (Continued) Fig. 3 Multi-Function SwitchContinuity Test...
  • Page 439 MULTI-FUNCTION SWITCH COMBINATION FLASHER 8J - 6 TURN SIGNAL AND FLASHERS REMOVAL AND INSTALLATION INSTALLATION For installation, reverse the above procedures. MOUNTING SCREWS COMBINATION FLASHER (1) Tighten multi-function switch to column retain- ing screws to 2.3 N·m (20 in. lbs.) torque. The flasher is mounted to the back side of the (2) Tighten steering column cover retaining screws multi-function switch.

  • Page 440: Windshield Wipers And Washers

    WINDSHIELD WIPERS AND WASHERS 8K - 1 WINDSHIELD WIPERS AND WASHERS CONTENTS page page GENERAL INFORMATION WASHER RESERVOIR PUMP ... . . 10 MULTI-FUNCTION SWITCH ....1 WASHER RESERVOIR .

  • Page 441: General Information

    EXTERIOR LIGHTING CON- TURN SIGNAL TROL CONTROL STALK PANEL DIMMER SWITCH HAZARD WARNING BUTTON CANCELING CAM WINDSHIELD WASHER CONTROL WIPER/ 8K - 2 WINDSHIELD WIPERS AND WASHERS GENERAL INFORMATION (Continued) Fig. 1 Multi-Function Switch The wiper motor and washer motor are designed to DESCRIPTION AND OPERATION reduce radio frequency interference and provide elec- tro-magnetic compatibility (RFI/EMC) in the vehicle...

  • Page 442: Wiper Blades

    AIR FOIL WINDSHIELD WIPERS AND WASHERS 8K - 3 DESCRIPTION AND OPERATION (Continued) WIPER BLADES DIAGNOSIS AND TESTING When the wiper blade rubber element is exposed to MULTI-FUNCTION SWITCH – WINDSHIELD WIPER the weather for a long period of time, it tends to lose wiping ability.

  • Page 443: Wiper

    H/LP RELAY CIRCUIT BREAKERS AUTOMATIC SHUTDOWN HIGH RADIATOR FAN RELAY (10) RELAY (12) WINDSHIELD WIPER MOTOR SPEED LIGHT GRAY NOT USED (8) LOW SPEED RADIA- TOR FAN RELAY (11) NOT USED (6) NOT USED (1) ENGINE STARTER MOTOR FUNCTION RELAY (9) HORN RELAY HIGH SPEED OUTPUT TRANSMISSION CONTROL...
  • Page 444 WHITE CONNECTOR WINDSHIELD WIPERS AND WASHERS 8K - 5 DIAGNOSIS AND TESTING (Continued) OK, replace motor. If not repair the ground circuit as (b) Using an ohmmeter, check for continuity necessary. from terminal 2 of wiper switch connector to termi- (5) The wiper switch in the ON position.

  • Page 445: Wiper Motor System

    8K - 6 WINDSHIELD WIPERS AND WASHERS DIAGNOSIS AND TESTING (Continued) (4) If wipers will not run at low speed, using an WIPER WILL RUN CONTINUOUSLY WITH ohmmeter, check for open circuit. Check between ter- SWITCH IN THE INTERMITTENT POSITION. minal 11 of the HI-LO wiper relay to Pin B of the WHEN COLUMN SWITCH IS TURNED OFF, wiper motor wire harness connector for continuity.
  • Page 446 WINDSHIELD WIPERS AND WASHERS 8K - 7 DIAGNOSIS AND TESTING (Continued) POSSIBLE CONDITION CORRECTION CAUSES WIPER BLADES DO NOT 1. Wiper arms 1. Remove wiper arms and run wiper motor to park PARK PROPERLY improperly parked. position. Refer to Wiper Arm Replacement. 2.

  • Page 447: Removal And Installation

    MOUNTING SCREWS 8K - 8 WINDSHIELD WIPERS AND WASHERS REMOVAL AND INSTALLATION MULTI-FUNCTION SWITCH REMOVAL (1) Disconnect battery negative cable. (2) Remove the upper steering column cover. Refer to steering column cover removal procedures below. (3) Remove multi-function switch mounting screws (Fig.
  • Page 448 VIEW Y VIEW Z WASHER PUMP RESERVOIR VIEW W WINDSHIELD WIPERS AND WASHERS 8K - 9 REMOVAL AND INSTALLATION (Continued) Fig. 11 Washer Fluid Hose Location WASHER RESERVOIR INSTALLATION For installation, reverse the above procedures. REMOVAL (1) Disconnect washer fluid hose at in-line connec- tor on top of the right shock tower.

  • Page 449: Washer Reservoir Pump

    RUBBER RESERVOIR GROM- PUMP ARM RELEASE TAB VERTEBRA RUBBER ELEMENT RELEASE TAB 8K - 10 WINDSHIELD WIPERS AND WASHERS REMOVAL AND INSTALLATION (Continued) WASHER RESERVOIR PUMP (4) Install arm head cover. WIPER BLADE REMOVAL (1) Partially remove the bumper facia as needed to REMOVAL gain access to the reservoir pump.

  • Page 450: Wiper Motor

    VERTEBRA RUBBER ELEMENT CHANNEL CLAW TO GRASP AND SLOT PULL WINDSHIELD WIPERS AND WASHERS 8K - 11 REMOVAL AND INSTALLATION (Continued) (2) Remove blade assembly from arm by pushing release tab under arm tip and slide blade away from arm tip (Fig. 14) and (Fig. 15). Gently place wiper arm tip on windshield.

  • Page 451: Cleaning And Inspection

    COWL SCREEN WIPER MOTOR ASSEM- COWL SCREEN TIP OF BLADE TO COWL SCREEN 18 TO 42MM (3/4 TO 1 5/8 INS.) 8K - 12 WINDSHIELD WIPERS AND WASHERS REMOVAL AND INSTALLATION (Continued) cleaned with a sponge or cloth and a mild detergent or nonabrasive cleaner.
  • Page 452 LAMPS 8L - 1 LAMPS CONTENTS page page BULB APPLICATION ..... 17 LAMP BULB SERVICE ....8 EXTERIOR LAMP SWITCHES .
  • Page 453 8L - 2 LAMPS GENERAL INFORMATION (Continued) DIAGNOSTIC PROCEDURES connectors, relay, high beam dimmer switch and headlamp switch. Refer to Group 8W, Wiring Dia- When a vehicle experiences problems with the grams for component locations and circuit informa- headlamp system, verify the condition of the battery tion connections, charging system, headlamp bulbs, wire HEADLAMP DIAGNOSIS...
  • Page 454 LAMPS 8L - 3 GENERAL INFORMATION (Continued) FOG LAMP DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION FOG LAMPS ARE DIM WITH 1. Loose or corroded battery cables. 1. Clean and secure battery cable ENGINE IDLING clamps and posts. OR IGNITION TURNED OFF. 2.
  • Page 455 ACCEPTABLE UP TO .75° DOWN BUBBLE LEVEL RANGE .75° ADJUSTER GAUGE WHEEL ZERO MARK 8L - 4 LAMPS HEADLAMP AND FOG LAMP ALIGNMENT INDEX page page GENERAL INFORMATION HEADLAMP ADJUSTMENT USING ALIGNMENT HEADLAMP ALIGNMENT PREPARATION ..4 SCREEN .
  • Page 456 CENTER OF HEADLAMPS 5” 8” 9” 7” FRONT OF HEADLAMPS CENTER OF VEHICLE 7.62 METERS (25 FT.) LEFT/RIGHT ADJUSTER UP/DOWN ADJUSTER HEADLAMP GAUGE BUBBLE LEVEL RADIATOR WHEEL CLOSURE PANEL LAMPS 8L - 5 ADJUSTMENTS (Continued) Fig. 3 Headlamp Alignment Screen (7) Measure distance from the centerline of the To adjust headlamp alignment, rotate alignment vehicle to the center of each headlamp being aligned.
  • Page 457 CENTER OF FOGLAMP 7.62 METERS (25 FT.) TOP OF BEAM PATTERN FRONT OF FOGLAMP FOG LAMP UP/DOWN ADJUSTER 8L - 6 LAMPS ADJUSTMENTS (Continued) To adjust fog lamp alignment, rotate alignment screw to achieve the specified low beam hot spot pat- tern (Fig.
  • Page 458 LAMPS 8L - 7 EXTERIOR LAMP SWITCHES INDEX page page REMOVAL AND INSTALLATION HEADLAMP SWITCH ..... 7 HEADLAMP DIMMER SWITCH ....7 HEADLAMP DIMMER SWITCH REMOVAL AND INSTALLATION The headlamp dimmer switch is incorporated into...
  • Page 459 8L - 8 LAMPS LAMP BULB SERVICE INDEX page page REMOVAL AND INSTALLATION FOG LAMP BULB ......9 ASH RECEIVER/CUP HOLDER LAMP BULB .
  • Page 460 LAMPS 8L - 9 REMOVAL AND INSTALLATION (Continued) FOG LAMP WIRE CONNECTOR BULB (2) Disengage wire connector from back of fog lamp. (3) Rotate bulb base counterclockwise one quarter turn. (4) Pull bulb from back of lamp (Fig. 5). HEADLAMP MODULE PARK AND TURN SIGNAL SOCKET LAMP...
  • Page 461 BULB CIRCUIT BOARD SOCKET CIRCUIT BOARD TAIL, STOP AND TURN SIG- SOCKET NAL LAMP BULB BACK-UP LAMP 8L - 10 LAMPS REMOVAL AND INSTALLATION (Continued) DOME LAMP BULB (7) Pull bulb from socket. REMOVAL (1) Remove lamp lens from lamp assembly by inserting a flat bladed pry tool in the slot provided in the bezel.
  • Page 462 TRUNK LATCH SOCKET CENTER HIGH BULB STOP LAMP MOUNTER LAMPS 8L - 11 REMOVAL AND INSTALLATION (Continued) CENTER HIGH MOUNTED STOP LAMP (CHMSL) LICENSE PLATE LAMP BULB BULB REMOVAL (1) Remove screws holding license plate lamp to REMOVAL rear bumper fascia. (1) Release trunk latch and open trunk.
  • Page 463 HEADLAMP MODULE RADIATOR CLOSURE PANEL FRONT FASCIA FOG LAMP 8L - 12 LAMPS LAMP SERVICE INDEX page page REMOVAL AND INSTALLATION GLOVE BOX LAMP ..... 13 ASH RECEIVER/CUP HOLDER LAMP .
  • Page 464 WIRE CONNECTOR WING-NUTS TRUNK TAIL LAMP LAMPS 8L - 13 REMOVAL AND INSTALLATION (Continued) (3) Push bezel and lamp assembly into cubby bin to engage tabs. FRONT READING LAMP REMOVAL (1) Pull downward on reading lamp to disengage clips holding reading lamp to roof header. (2) Disengage wire connector from reading lamp.
  • Page 465 TAIL LAMP CIRCUIT BOARD CHMSL TRUNK LID 8L - 14 LAMPS LICENSE PLATE LAMP REMOVAL AND INSTALLATION (Continued) (2) Using a plastic trim stick, Special Tool C-4755, disengage the forward or rear edge of PRNDL bezel from floor console. (3) Pull upward carefully on PRNDL bezel and dis- engage tabs from rear floor console bezel.
  • Page 466 FUSE BRACKET MULTI FUNCTION MODULE BLOCK DAYTIME RUNNING MODULE LAMP LAMPS 8L - 15 LAMP SYSTEMS INDEX page page DESCRIPTION AND OPERATION DIAGNOSIS AND TESTING DAYTIME RUNNING LAMP (CANADA) ..15 GENERAL LAMP SYSTEM DIAGNOSTIC HEADLAMP TIME DELAY SYSTEM .
  • Page 467 8L - 16 LAMPS DIAGNOSIS AND TESTING (Continued) ILLUMINATED ENTRY DIAGNOSTIC PROCEDURES Refer to Group 8W, Wiring Diagrams for compo- nent location and circuit information. Refer to Body When testing the system, all doors must be closed Systems Diagnostic Procedures Manual for more to prevent courtesy lamps from lighting.
  • Page 468 LAMPS 8L - 17 BULB APPLICATION INDEX page page SPECIFICATIONS GENERAL INFORMATION ....17 EXTERIOR LAMPS ..... 17 INTERIOR LAMPS .
  • Page 470 LAMPS 8L - 1 LAMPS CONTENTS page page BULB APPLICATION ..... . 10 LAMP DIAGNOSIS ......1 HEADLAMP AND FOG LAMP ALIGNMENT .
  • Page 471 8L - 2 LAMPS HEADLAMP AND FOG LAMP ALIGNMENT INDEX page page GENERAL INFORMATION ALIGNMENT SCREEN ....2 HEADLAMP ALIGNMENT PREPARATION ..2 ADJUSTMENTS HEADLAMP/FOG LAMP ADJUSTMENT USING GENERAL INFORMATION...
  • Page 472 LAMPS 8L - 3 ADJUSTMENTS (Continued) Fig. 1 Headlamp Alignment Screen—Typical Fig. 2 Fog Lamp Alignment-Typical...
  • Page 473 8L - 4 LAMPS LAMP BULB SERVICE INDEX page page REMOVAL AND INSTALLATION PARK LAMP BULB ......5 CENTER HIGH MOUNTED STOP LAMP REAR FOG LAMP BULB .
  • Page 474 LAMPS 8L - 5 REMOVAL AND INSTALLATION (Continued) (4) Rotate socket counterclockwise one quarter turn. (5) Pull socket from back of lamp (Fig. 4). (6) Twist and pull bulb from socket. Fig. 6 Park Lamp Bulb INSTALLATION Reverse the preceding operation. SIDE REPEATER LAMP BULB Fig.
  • Page 475 8L - 6 LAMPS REMOVAL AND INSTALLATION (Continued) (2) Separate rear fog lamp from rear bumper fas- INSTALLATION cia (Fig. 8). Reverse the preceding operation. (3) Rotate rear fog lamp socket counterclockwise CENTER HIGH MOUNTED STOP LAMP (CHMSL) one quarter turn. BULB (4) Pull socket from rear fog lamp (Fig.
  • Page 476 LAMPS 8L - 7 LAMP SERVICE INDEX page page REMOVAL AND INSTALLATION HEADLAMP MODULE ..... 7 CENTER HIGH MOUNTED STOP LAMP LICENSE PLATE LAMP .
  • Page 477 8L - 8 LAMPS REMOVAL AND INSTALLATION (Continued) INSTALLATION NOTE: Make sure headlamp leveling motor ball stud lines up with socket in headlamp module. (1) Insert and rotate headlamp leveling motor into the headlamp module. (2) With a flat blade screwdriver gently pry on headlamp reflector mechanism and fully seat head- lamp leveling motor ball stud into the socket (Fig.
  • Page 478 LAMPS 8L - 9 REMOVAL AND INSTALLATION (Continued) (2) Disengage wire connector from CHMSL har- ness. (3) Remove nuts holding CHMSL to trunk lid. (4) Separate CHMSL from trunk lid. INSTALLATION Reverse the preceding operation. LICENSE PLATE LAMP REMOVAL (1) Remove screws holding license plate lamp to rear bumper fascia.
  • Page 479 8L - 10 LAMPS BULB APPLICATION INDEX page SPECIFICATIONS EXTERIOR LAMPS ..... . . 10 SPECIFICATIONS EXTERIOR LAMPS Back-up ......P21–5W Fog .

  • Page 480: Restraint System

    DLING AN UNDEPLOYED AIRBAG MODULE, THE If the Driver/Passenger Airbag Module is defective TRIM SIDE OF THE AIRBAG SHOULD BE POINTING and not deployed, refer to Chrysler Corporation cur- AWAY FROM THE BODY TO MINIMIZE POSSIBILITY rent return list for proper handling procedures.

  • Page 481: Description And Operation

    DATA LINK CONNECTOR DRIVER AIRBAG MODULE PASSENGER AIRBAG MOD- AIRBAG CONTROL MODULE 8M - 2 RESTRAINT SYSTEM DESCRIPTION AND OPERATION (Continued) The ACM monitors the system to determine the system readiness. The ACM stores sufficient energy to deploy the airbags for approximately two minutes after the battery is disconnected.

  • Page 482: Service Procedures Cleanup Procedure

    RESTRAINT SYSTEM 8M - 3 • Passenger Airbag Module SERVICE PROCEDURES • Instrument panel plastic retainer and steel rein- CLEANUP PROCEDURE forcement assembly The components above must be replaced because of Roll or fold the Passenger Airbag Module towards visible or non visible structural damage. the instrument panel surface and close the door over The glove box, top cover, cluster hood, steering col- the folded bag.

  • Page 483: Removal And Installation

    (8) Do not connect battery negative remote cable. Refer above to Diagnosis and Testing for Airbag Sys- WARNING: REPLACE AIRBAG SYSTEM COMPO- tem Test procedures. NENTS WITH CHRYSLER MOPAR SPECIFIED REPLACEMENT PARTS. SUBSTITUTE PARTS MAY VISUALLY APPEAR INTERCHANGEABLE, INTERNAL DIFFERENCES MAY RESULT IN INFE- RIOR OCCUPANT PROTECTION.

  • Page 484: Driver Airbag Module

    LOCK HOUSING LATCHES SPEED CONTROL WIRES 2–WAY CONNECTOR 4–WAY CONNECTOR SQUIB WIRE HORN WIRE RESTRAINT SYSTEM 8M - 5 REMOVAL AND INSTALLATION (Continued) (3) Remove the Driver Airbag Module attaching (2) Center the clockspring by ensuring the yellow T-30 Torx bolts from back side of the steering wheel. indicator visually seen through the centering window.

  • Page 485: Passenger Airbag Module

    DRIVER AIRBAG LOCATION PINS CLOCKSPRING MODULE CONNEC- MODULE ATTACHING B OLTS 8M - 6 RESTRAINT SYSTEM REMOVAL AND INSTALLATION (Continued) (5) When replacing a deployed Driver Airbag Mod- (3) Remove the transmission range indicator bezel ule, the clockspring must also be replaced. Refer to from floor console.
  • Page 486 END COVER KNEE BOLSTER SPEAKERS INSTRUMENT CLUSTER HVAC GLOVE BOX LOCK TOP COVER CUBBYBIN CENTER BEZEL SCREW CYLINDER PASSENGER BAG MODULE END COVER INSTRUMENT CLUS- AIR- RADIO TER HOOD RESTRAINT SYSTEM 8M - 7 REMOVAL AND INSTALLATION (Continued) Fig. 7 Instrument Panel Components INSTALLATION (1) Disconnect and isolate the battery negative remote cable (Fig.

  • Page 487: Steering Wheel

    8M - 8 RESTRAINT SYSTEM REMOVAL AND INSTALLATION (Continued) remote cable. Refer to Diagnosis and Testing for Air- INSTALLATION bag System Test procedures. (1) Ensure that the road wheels are in the straight ahead position. (2) Ensure that the clockspring is centered by using the centering indicator.
  • Page 488 REAR WINDOW DEFOGGER SWITCH ELECTRICALLY HEATED SYSTEMS 8N - 1 ELECTRICALLY HEATED SYSTEMS CONTENTS page page DESCRIPTION AND OPERATION SYSTEM TEST ......2 HVAC CONTROL MODULE .
  • Page 489 PICK-UP VIEW FROM INSIDE VEHI- LEADS GROUND REAR WINDOW DEFOGGER VOLTAGE FEED VOLTMETER MID-POINT BUS BARS 8N - 2 ELECTRICALLY HEATED SYSTEMS DIAGNOSIS AND TESTING SYSTEM TEST Electrically heated rear window defogger operation can be checked in vehicle in the following manner: (1) Turn ignition switch to the ON position.
  • Page 490 H/LP RELAY CIRCUIT BREAKERS HORN RELAY HORN ELECTRICALLY HEATED SYSTEMS 8N - 3 DIAGNOSIS AND TESTING (Continued) (1) Remove the control switch from console and do (c) Use a known good relay. If not OK, repair cir- not disconnect control switch (Fig. 4). cuits as necessary.
  • Page 491 8N - 4 ELECTRICALLY HEATED SYSTEMS SERVICE PROCEDURES (Continued) The repair of the grid lines or the terminal is pos- (10) After conductive epoxy is properly cured sible using the Mopar Repair Package or equivalent. remove wedge from terminal and check out operation (1) Mask repair area so conductive epoxy can be of rear window defogger.

  • Page 492: Heated Seats

    ELECTRICALLY HEATED SYSTEMS 8N - 1 ELECTRICALLY HEATED SYSTEMS CONTENTS page HEATED SEATS ......1 HEATED SEATS INDEX page...

  • Page 493: Description And Operation

    8N - 2 ELECTRICALLY HEATED SYSTEMS DESCRIPTION AND OPERATION DIAGNOSIS AND TESTING HEATED SEAT SWITCH HEATED SEAT SYSTEM The heated seat switch is located in the floor con- For circuit descriptions and diagrams, refer to sole. The two six-position rotating-type switches, one 8W-63 - Power Seat With Heated Seats in Group 8W switch for each front seat, provide a voltage signal to - Wiring Diagrams.

  • Page 494: Heated Seat Element

    ELECTRICALLY HEATED SYSTEMS 8N - 3 DIAGNOSIS AND TESTING (Continued) HEATED SEAT CONTROL MODULE cushion connector. If OK, replace the faulty seat cushion cover (Fig. 2). For circuit descriptions and diagrams refer to 8W-63 - Power Seats With Heated Seats in Group 8W - Wiring Diagrams.
  • Page 495 8N - 4 ELECTRICALLY HEATED SYSTEMS REMOVAL AND INSTALLATION (Continued) (3) Pull the heated seat switch out from the floor console far enough to unplug the wiring connector. (4) Remove the switch from the floor console. (5) Reverse the removal procedures to install. HEATED SEAT CONTROL MODULE (1) Move the power seat adjuster to its upper-most and rearward-most stop positions.

  • Page 496: General Information

    POWER DOOR LOCKS 8P - 1 POWER DOOR LOCKS CONTENTS page page POWER DOOR LOCKS ....1 REMOTE KEYLESS ENTRY ....4 POWER DOOR LOCKS INDEX page...

  • Page 497: Child Protection Lock

    LHVIEW + TO LOCK DIRECTION ARROW Z 8P - 2 POWER DOOR LOCKS DESCRIPTION AND OPERATION (Continued) tion, all doors will lock. This feature operates To test an individual door latch, disconnect the differently on each door. Turn key in the driver’s door electrical connector from the latch.

  • Page 498: Door Lock System

    POWER DOOR LOCKS 8P - 3 DIAGNOSIS AND TESTING (Continued) (b) Check Pin 2 of the connector for battery volt- age. If OK, go to Switch Test. If not OK, check fuse 4 in the Junction Block, if fuse is OK, repair wire as necessary.

  • Page 499: Remote Keyless Entry

    BATTERY 8P - 4 POWER DOOR LOCKS REMOTE KEYLESS ENTRY INDEX page page GENERAL INFORMATION REMOVAL AND INSTALLATION INTRODUCTION ......4 JUNCTION BLOCK/BODY CONTROL MODULE .
  • Page 500 POWER DOOR LOCKS 8P - 5 DIAGNOSIS AND TESTING (Continued) • Body Control Module Driver door will unlock with the key fob • Door lock switches transmitter, but all other doors will not A blown fuse is the probable cause. The Body Con- unlock.
  • Page 501 8P - 6 POWER DOOR LOCKS REMOVAL AND INSTALLATION SPECIFICATIONS JUNCTION BLOCK/BODY CONTROL MODULE TRANSMITTER CONTROL RANGE Refer to Group 8E, Instrument Panel and Systems. Operation range is within 7 meters (23 ft.) of the BCM. ADJUSTMENTS PROGRAMMING RKE MODULE The scan tool (DRB) and the transmitter must be used to program the Remote Keyless Entry Module.

  • Page 502: Vehicle Theft Security System

    VEHICLE THEFT SECURITY SYSTEM 8Q - 1 VEHICLE THEFT SECURITY SYSTEM CONTENTS page page DESCRIPTION AND OPERATION HORN RELAY ......1 CENTRAL LOCK/UNLOCK SYSTEM .
  • Page 503 8Q - 2 VEHICLE THEFT SECURITY SYSTEM DIAGNOSIS AND TESTING (Continued) SYSTEM SELF-TESTS VTSS DOOR LOCK SWITCH A diagnostics test mode is available in the system REMOVAL to verify operation of all monitored switches or cir- (1) Refer to Group 23, Body for door trim and cuits.

  • Page 504: Power Seats

    BLACK POWER SEATS 8R - 1 POWER SEATS CONTENTS page page DESCRIPTION AND OPERATION SEAT MOTOR SWITCH ....2 INTRODUCTION ......1 VOLTAGE .
  • Page 505 8R - 2 POWER SEATS DIAGNOSIS AND TESTING (Continued) SEAT MOTOR SWITCH (1) Remove switch from mounting position. (2) Using an ohmmeter, perform the Switch Conti- nuity Tests below and refer to (Fig. 2) for Pin loca- tions. If there is no continuity at any of the switch positions, replace switch.

  • Page 506: Power Windows

    POWER WINDOWS 8S - 1 POWER WINDOWS CONTENTS page page GENERAL INFORMATION WINDOW SWITCH ..... . . 1 INTRODUCTION ......1 REMOVAL AND INSTALLATION DIAGNOSIS AND TESTING WINDOW MOTOR .
  • Page 507 CONTINUITY SWITCH POSITION TERMINALS BETWEEN PIN 2 to 5 PIN 1 to 4 PIN 1 to 4 PIN 5 to 6 PIN 2 to 5 PIN 1 to 6 DOWN MOTOR MOUNTING SCREWS CLAMP REGULATOR TO SEC- TOR GEAR 8S - 2 POWER WINDOWS BE PINCHED BY SMALL MOVEMENTS OF REGULA- TOR LINKAGE.
  • Page 508 POWER WINDOWS 8S - 3 REMOVAL AND INSTALLATION (Continued) WINDOW SWITCH PASSENGER SWITCH REMOVAL MASTER SWITCH (1) Remove passenger door trim panel, refer to REMOVAL Group 23 Body, for removal procedures. (1) Remove driver’s door trim panel, refer to Group (2) Disconnect switch wire connector.

  • Page 510: Power Mirrors

    POWER MIRRORS 8T - 1 POWER MIRRORS CONTENTS page page DESCRIPTION AND OPERATION MIRROR MOTOR ......1 HEATED MIRROR .
  • Page 511 SWITCH Move Button POSI- TION Mirror in R Position Mirror in L Position CONTINUITY BETWEEN TER- PIN 1 to 5 PIN 2 to 8 PIN 1 to 7 PIN 2 to 6 PIN 1 to 8 PIN 2 to 5 PIN 1 to 6 PIN 2 to 7 PIN 1 to 5...
  • Page 512 TRANSMISSION SEAT BELT WARNING LAMP INDICATOR DISPLAY DOOR BODY CONTROL MODULE KEY-IN IGNITION SWITCH ALL OTHER DOORS SEAT BELT SWITCH AJAR SWITCH DRIVE DOOR PANEL LAMP CHIME UNIT BATTERY BATTERY GROUND IGNITION RANGE BUS — BUS + CHIME WARNING/REMINDER SYSTEM 8U - 1 CHIME WARNING/REMINDER SYSTEM CONTENTS...
  • Page 513 BODY CONTROL MODULE H/LP RELAY CIRCUIT BREAKERS HORN RELAY HORN 8U - 2 CHIME WARNING/REMINDER SYSTEM DIAGNOSIS AND TESTING Module. Refer to Group 8W, Wiring Diagrams for ter- minal location. CHIME CONDITIONS (5) If voltage not OK, repair as necessary. FASTEN SEAT BELT LAMP OR TONE NO TONE WHEN IGNITION SWITCH IS CONTINUE FOR MORE THAN 10 SECONDS...
  • Page 514 CHIME WARNING/REMINDER SYSTEM 8U - 3 DIAGNOSIS AND TESTING (Continued) NO TONE WHEN IGNITION KEY IS LEFT IN lamp switch to Body Control Module wiring for short IGNITION SWITCH AND IT IS IN THE OFF to battery. (3) Inspect Body Control Module connectors and POSITION WITH DRIVER’S DOOR IS OPEN (1) Check left door jamb switch for good ground wires for proper connection.
  • Page 516 CHIME WARNING/REMINDER SYSTEM 8U - 1 CHIME WARNING/REMINDER SYSTEM CONTENTS page page GENERAL INFORMATION HIGH SPEED WARNING CHIME ... . . 1 INTRODUCTION ......1 DIAGNOSIS AND TESTING DESCRIPTION AND OPERATION CHIME CONDITIONS .
  • Page 517 8U - 2 CHIME WARNING/REMINDER SYSTEM DIAGNOSIS AND TESTING Module. Refer to Group 8W, Wiring Diagrams for ter- minal location. CHIME CONDITIONS (5) If voltage not OK, repair as necessary. FASTEN SEAT BELT LAMP OR TONE NO TONE WHEN IGNITION SWITCH IS CONTINUE FOR MORE THAN 10 SECONDS TURNED ON AND DRIVERS SEAT BELT IS AFTER SEAT BELTS ARE FASTENED AND...
  • Page 518 CHIME WARNING/REMINDER SYSTEM 8U - 3 DIAGNOSIS AND TESTING (Continued) Module. Refer to Group 8W, Wiring Diagrams for ter- and ignition feed at terminal JB-6 of Body Control minal location. Module. Refer to Group 8W, Wiring Diagrams for ter- (6) If voltage not OK, repair as necessary. minal location.

  • Page 520: Wiring Diagrams

    WIRING DIAGRAMS 8W - 1 WIRING DIAGRAMS CONTENTS page page 8W-01 GENERAL INFORMATION ..8W-01-1 8W-46 TRAVELER ....8W-46-1 8W-02 COMPONENT INDEX .
  • Page 522 8W - 01 GENERAL INFORMATION 8W - 01 - 1 8W-01 GENERAL INFORMATION INDEX page page DESCRIPTION AND OPERATION DIAGNOSIS AND TESTING CIRCUIT IDENTIFICATION ....3 CHECKING FOR TERMINAL SPREADING .
  • Page 523 8W - 01 - 2 8W - 01 GENERAL INFORMATION DESCRIPTION AND OPERATION (Continued) NOTES are used to help describe how switches or WIRE CODE IDENTIFICATION components operate to complete a particular circuit. Each wire shown in the diagrams contains a code They are also used to indicate different conditions (Fig.
  • Page 524 8W - 01 GENERAL INFORMATION 8W - 01 - 3 DESCRIPTION AND OPERATION (Continued) CIRCUIT IDENTIFICATION CONNECTORS All circuits in the diagrams use an alpha/numeric Connectors shown in the diagrams are identified code to identify the wire and its function (Fig. 3). To using the international standard arrows for male and identify which circuit code applies to a system, refer female terminals (Fig.
  • Page 525 8W - 01 - 4 8W - 01 GENERAL INFORMATION DESCRIPTION AND OPERATION (Continued) Fig. 5 Symbol Identification...
  • Page 526 8W - 01 GENERAL INFORMATION 8W - 01 - 5 DESCRIPTION AND OPERATION (Continued) ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES All ESD sensitive components are solid state and a symbol (Fig. 6) is used to indicate this. When han- dling any component with this symbol comply with the following procedures to reduce the possibility of electrostatic charge build up on the body and inad- vertent discharge into the component.
  • Page 527 8W - 01 - 6 8W - 01 GENERAL INFORMATION DIAGNOSIS AND TESTING (Continued) size tool from Special Tool Package 6807, and insert (2) Connect the other lead of the voltmeter to the it into the terminal being tested. Use the other end selected test point.
  • Page 528 8W - 01 GENERAL INFORMATION 8W - 01 - 7 DIAGNOSIS AND TESTING (Continued) Fig. 10 Testing for Continuity Fig. 11 Testing for Voltage Drop (4) Start connecting the items in the fuse circuit (6) Verify proper operation. For this step check for one at a time.
  • Page 529 8W - 01 - 8 8W - 01 GENERAL INFORMATION SERVICE PROCEDURES (Continued) into the proper cavities. For additional connector pin- out identification, refer to the wiring diagrams. (8) Insert the connector locking wedge into the repaired connector, if required. Connect connector to its mating half/compo- nent.
  • Page 530 8W - 01 GENERAL INFORMATION 8W - 01 - 9 SERVICE PROCEDURES (Continued) for soldered connections. Check that the overall length is the same as the original (Fig. 16). Fig. 17 Augat Connector Repair Fig. 16 Stagger Cutting Wires (7) Remove 1 inch of insulation from each wire. Place a piece of heat shrink tubing over one side of the wire.
  • Page 531 8W - 01 - 10 8W - 01 GENERAL INFORMATION SERVICE PROCEDURES (Continued) (11) Push the two ends of wire together until the strands of wire are close to the insulation. (12) Twist the wires together. (13) Solder the connection together using rosin core type solder only.
  • Page 532 8W - 01 GENERAL INFORMATION 8W - 01 - 11 SPECIAL TOOLS WIRING/TERMINAL Terminal Removing Tool 6932 Probing Tool Package 6807 Terminal Removing Tool 6934 Terminal Pick 6680...
  • Page 534 8W - 02 COMPONENT INDEX 8W - 02 - 1 8W-02 COMPONENT INDEX INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 535 8W - 02 - 2 8W - 02 COMPONENT INDEX Component Page Component Page Intake Air Temperature/Manifold Recline Motor ......8W-63 Absolute Pressure (IAT/MAP) Sensor .

  • Page 536: 01 General Information

    8W - 02 COMPONENT INDEX 8W - 02 - 3 8W-02 COMPONENT INDEX INDEX page GENERAL INFORMATION INTRODUCTION ......3 GENERAL INFORMATION INTRODUCTION This section provides an alphabetical listing of all...
  • Page 538 8W - 10 - 2 8W - 10 POWER DISTRIBUTION 8W-10 POWER DISTRIBUTION INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 555 8W - 10 - 18 8W - 10 POWER DISTRIBUTION 8W-10 POWER DISTRIBUTION DESCRIPTION AND OPERATION This section covers the power distribution center and all circuits involved with it. For additional infor- mation on system operation, refer to the appropriate section of the wiring diagrams.
  • Page 556 8W - 12 JUNCTION BLOCK 8W - 12 - 1 8W-12 JUNCTION BLOCK INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 574 8W - 12 JUNCTION BLOCK 8W - 12 - 19 8W-12 JUNCTION BLOCK DESCRIPTION AND OPERATION This section identifies the fuses, relays, module, and internal circuitry of the junction block. For addi- tional information on system operation, refer to the appropriate group of the wiring diagrams.
  • Page 576 8W - 15 GROUND DISTRIBUTION 8W - 15 - 1 8W-15 GROUND DISTRIBUTION INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 584 8W - 15 GROUND DISTRIBUTION 8W - 15 - 9 8W-15 GROUND DISTRIBUTION DESCRIPTION AND OPERATION This section identifies the grounds, splices that connect to those grounds, and the components that connect those grounds. For additional information on system operation, refer to the appropriate section of the wiring diagrams.
  • Page 586 8W - 20 CHARGING SYSTEM 8W - 20 - 1 8W-20 CHARGING SYSTEM INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .

  • Page 588: 20 Charging System

    8W - 20 CHARGING SYSTEM 8W - 20 - 3 8W-20 CHARGING SYSTEM INDEX page DESCRIPTION AND OPERATION CHARGING SYSTEM ..... . 3 When there is current present in the field, and the DESCRIPTION AND OPERATION rotor is turning, the stator in the generator produces...
  • Page 590 8W - 21 STARTING SYSTEM 8W - 21 - 1 8W-21 STARTING SYSTEM INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .

  • Page 592: 21 Starting System

    8W - 21 STARTING SYSTEM 8W - 21 - 3 8W-21 STARTING SYSTEM INDEX page page DESCRIPTION AND OPERATION STARTING SYSTEM STARTING SYSTEM (MANUAL TRANSAXLE) ....3 (AUTOMATIC TRANSAXLE) .
  • Page 594 8W - 30 FUEL/IGNITION SYSTEM 8W - 30 - 1 8W-30 FUEL/IGNITION SYSTEM INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 613 8W - 30 - 20 8W - 30 FUEL/IGNITION SYSTEM 8W-30 FUEL/IGNITION SYSTEM INDEX page page DESCRIPTION AND OPERATION IDLE AIR CONTROL MOTOR ....25 AUTOMATIC SHUT-DOWN RELAY ... 21 IGNITION COIL PACK (2.0L and 2.4L) .
  • Page 614 8W - 30 FUEL/IGNITION SYSTEM 8W - 30 - 21 DESCRIPTION AND OPERATION (Continued) A twisted pair of wires, circuits D1 and D2, connect FUEL PUMP MOTOR to the data link connector. These wires are connected The fuel pump motor, located in the fuel tank, is to the CCD Bus.
  • Page 615 8W - 30 - 22 8W - 30 FUEL/IGNITION SYSTEM DESCRIPTION AND OPERATION (Continued) Circuit G7, from the VSS, provides an input signal (circuits K41 and K141) through circuit K4. Circuit to the PCM. The G7 circuit connects to cavity 66 of K4 connects to cavity 43 of the PCM connector.
  • Page 616 8W - 30 FUEL/IGNITION SYSTEM 8W - 30 - 23 DESCRIPTION AND OPERATION (Continued) CAMSHAFT POSITION SENSOR (2.0L and 2.4L) HELPFUL INFORMATION Circuit K4 splices to supply ground for the signals Circuit K7 supplies 8 volts from the Powertrain from the following: Control Module (PCM) to the camshaft position sen- •...
  • Page 617 8W - 30 - 24 8W - 30 FUEL/IGNITION SYSTEM DESCRIPTION AND OPERATION (Continued) Circuit K6 is spliced and provides 5 volts to the BATTERY TEMPERATURE SENSOR A/C pressure switch and the throttle position sensor. The battery temperature sensor draws voltage Circuit K4 splices to supply ground for the signals from the Powertrain Control Module (PCM) on circuit from the following:...
  • Page 618 8W - 30 FUEL/IGNITION SYSTEM 8W - 30 - 25 DESCRIPTION AND OPERATION (Continued) HELPFUL INFORMATION HELPFUL INFORMATION • Refer to group 14 for system operation. Circuit A142 splices to supply voltage to the fuel injectors, ignition coil, ASD relay, generator, and the IDLE AIR CONTROL MOTOR upstream and downstream (2.5L only) heated oxygen sensors.
  • Page 619 8W - 30 - 26 8W - 30 FUEL/IGNITION SYSTEM DESCRIPTION AND OPERATION (Continued) VAPOR CANISTER LEAK DETECTOR ELECTRONIC EGR TRANSDUCER (EET) SOLENOID Power for the vapor canister leak detector is pro- Circuit A142 supplies voltage to the EET solenoid. vided on circuit F18.
  • Page 620 8W - 31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 1 8W-31 TRANSMISSION CONTROL SYSTEM INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 628 8W - 31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 9 8W-31 TRANSMISSION CONTROL SYSTEM INDEX page page DESCRIPTION AND OPERATION TORQUE MANAGEMENT INPUT ... . 10 AUTO STICK ......10 TRANSMISSION CONTROL MODULE (TCM) .

  • Page 629: 30 Fuel/Ignition System

    8W - 31 - 10 8W - 31 TRANSMISSION CONTROL SYSTEM DESCRIPTION AND OPERATION (Continued) SOLENOIDS AND PRESSURE SWITCHES Power for the A81 circuit is supplied by circuit A51. This circuit is protected by a 10 amp fuse The Solenoid and Pressure Switch assembly, located in cavity 7 of the Power Distribution Center located in the transmission, is used to control the (PDC).
  • Page 630 8W - 31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 11 DESCRIPTION AND OPERATION (Continued) • Circuit K4 is used to provide the throttle posi- Circuit G7, from the TCM, provides an input signal tion sensor ground to the Powertrain Control Module to the PCM.
  • Page 632 8W - 33 VEHICLE SPEED CONTROL 8W - 33 - 1 8W-33 VEHICLE SPEED CONTROL INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 635 8W - 33 - 4 8W - 33 VEHICLE SPEED CONTROL 8W-33 VEHICLE SPEED CONTROL INDEX page page DESCRIPTION AND OPERATION HELPFUL INFORMATION ....4 CRUISE (VEHICLE SPEED CONTROL) VEHICLE SPEED CONTROL .
  • Page 636 8W - 35 ANTI-LOCK BRAKES 8W - 35 - 1 8W-35 ANTI-LOCK BRAKES INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 642 8W - 35 ANTI-LOCK BRAKES 8W - 35 - 7 8W-35 ANTI-LOCK BRAKES INDEX page page DESCRIPTION AND OPERATION DATA LINK CONNECTOR ....8 ABS PUMP MOTOR RELAY .
  • Page 643 8W - 35 - 8 8W - 35 ANTI-LOCK BRAKES DESCRIPTION AND OPERATION (Continued) The solenoids use a common ground on the Z1 cir- PARK BRAKE SWITCH INPUT cuit. There are two Z1 circuits from the modulator. Circuit G9 provides a park brake switch input to Both of these grounds terminate at the right frame the Controller Anti-Lock Brakes (CAB).
  • Page 644 8W - 40 INSTRUMENT CLUSTER 8W - 40 - 1 8W-40 INSTRUMENT CLUSTER INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 652 8W - 40 INSTRUMENT CLUSTER 8W - 40 - 9 8W-40 INSTRUMENT CLUSTER INDEX page page DESCRIPTION AND OPERATION HELPFUL INFORMATION ....12 ABS WARNING LAMP .
  • Page 653 8W - 40 - 10 8W - 40 INSTRUMENT CLUSTER DESCRIPTION AND OPERATION (Continued) Powertrain Control Module (PCM) across the CCD culate the proper milage for the vehicle the BCM Bus to the BCM. The BCM calculates the position of receives information from the Powertrain Control the tachometer pointer based on the input from the Module (PCM) and the Transmission Control Module...
  • Page 654 8W - 40 INSTRUMENT CLUSTER 8W - 40 - 11 DESCRIPTION AND OPERATION (Continued) the Body Control Module (BCM) on the G74 circuit. CCD Bus. When the Airbag Control Module (ACM) Circuit G75 is used for the drivers door. When any of detects a problem in the system it sends a signal on the switches are grounded (door ajar), and the vehi- the CCD Bus to the BCM.
  • Page 655 8W - 40 - 12 8W - 40 INSTRUMENT CLUSTER DESCRIPTION AND OPERATION (Continued) The G9 circuit is used to connect the switches to provided on the Z1 circuit and terminates at the the cluster. Grounding for the brake warning lamp instrument panel left side cowl.
  • Page 656 8W - 41 HORN/CIGAR LIGHTER/POWER OUTLET 8W - 41 - 1 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .

  • Page 658: Power Outlet

    8W - 41 HORN/CIGAR LIGHTER/POWER OUTLET 8W - 41 - 3 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET INDEX page page DESCRIPTION AND OPERATION HORNS ....... . 3 CIGAR LIGHTER .
  • Page 660 8W - 42 AIR CONDITIONING-HEATER 8W - 42 - 1 8W-42 AIR CONDITIONING-HEATER INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 664 8W - 42 AIR CONDITIONING-HEATER 8W - 42 - 5 8W-42 AIR CONDITIONING-HEATER INDEX page page DESCRIPTION AND OPERATION BLOWER MOTOR OPERATION ....6 A/C EVAPORATOR TEMPERATURE SENSOR . . . 5 HELPFUL INFORMATION .
  • Page 665 8W - 42 - 6 8W - 42 AIR CONDITIONING-HEATER DESCRIPTION AND OPERATION (Continued) relays. The C3 circuit connects from the relay to the When HIGH speed fan operation is required the A/C compressor clutch. PCM grounds circuit C27. This causes the contacts in The A/C compressor clutch receives this current the relay to CLOSE connecting circuits A16 and C25.
  • Page 666 8W - 43 AIRBAG SYSTEM 8W - 43 - 1 8W-43 AIRBAG SYSTEM INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 669 8W - 43 - 4 8W - 43 AIRBAG SYSTEM 8W-43 AIRBAG SYSTEM INDEX page page DESCRIPTION AND OPERATION AIRBAG SQUIB (AIRBAG IGNITER) ... 4 AIRBAG CONTROL MODULE (ACM) ..4 AIRBAG WARNING LAMP .
  • Page 670 8W - 44 INTERIOR LIGHTING 8W - 44 - 1 8W-44 INTERIOR LIGHTING INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 674 8W - 44 INTERIOR LIGHTING 8W - 44 - 5 8W-44 INTERIOR LIGHTING INDEX page page DESCRIPTION AND OPERATION IGNITION KEY HALO LAMP ....5 ASH RECEIVER LAMP .
  • Page 675 8W - 44 - 6 8W - 44 INTERIOR LIGHTING DESCRIPTION AND OPERATION (Continued) cuit Z1. This circuit terminates at the instrument Ground for the lamp(s) can also be supplied on cir- panel left side cowl after passing through the ground cuit M2 when the Body Control Module (BCM) sup- joint in the junction block.
  • Page 676 8W - 45 BODY CONTROL MODULE 8W - 45 - 1 8W-45 BODY CONTROL MODULE INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 687 8W - 45 - 12 8W - 45 BODY CONTROL MODULE 8W-45 BODY CONTROL MODULE INDEX page page DESCRIPTION AND OPERATION ILLUMINATED ENTRY ....12 DOOR AJAR WARNING .
  • Page 688 8W - 45 BODY CONTROL MODULE 8W - 45 - 13 DESCRIPTION AND OPERATION (Continued) KEY-IN IGNITION WARNING FUNERAL MODE DISPLAY ILLUMINATION The Key-In chime is used to indicate to the opera- The Body Control Module (BCM) controls the tor that the key is in the ignition with the driver’s intensity of the instrument cluster vacuum florescent door OPEN.
  • Page 690 8W - 46 TRAVELER 8W - 46 - 1 8W-46 TRAVELER INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 692 8W - 46 TRAVELER 8W - 46 - 3 8W-46 TRAVELER DESCRIPTION AND OPERATION The traveler is also interfaced with the CCD Bus. This interface allows the traveler to receive the nec- TRAVELER essary information for display to the operator. The circuits involved are D1 for CCD (+), and D2 for CCD Power for the traveler is supplied from two (-).
  • Page 694 8W - 47 AUDIO SYSTEM 8W - 47 - 1 8W-47 AUDIO SYSTEM INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 697 8W - 47 - 4 8W - 47 AUDIO SYSTEM 8W-47 AUDIO SYSTEM INDEX page page DESCRIPTION AND OPERATION RADIO ILLUMINATION ..... 4 CCD BUS .
  • Page 698 8W - 47 AUDIO SYSTEM 8W - 47 - 5 DESCRIPTION AND OPERATION (Continued) Circuit X52 is the feed for the right rear speaker to 8W-12 for additional information on the IOD fuse. the power amplifier. Circuit X58 is the return from The IOD fuse is removed during vehicle shipping to the amplifier to the radio.
  • Page 700 8W - 48 REAR WINDOW DEFOGGER 8W - 48 - 1 8W-48 REAR WINDOW DEFOGGER INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .

  • Page 702: 48 Rear Window Defogger

    8W - 48 REAR WINDOW DEFOGGER 8W - 48 - 3 8W-48 REAR WINDOW DEFOGGER INDEX page page DESCRIPTION AND OPERATION REAR WINDOW DEFOGGER ....3 HELPFUL INFORMATION .
  • Page 704 8W - 50 FRONT LIGHTING 8W - 50 - 1 8W-50 FRONT LIGHTING INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 708 8W - 50 FRONT LIGHTING 8W - 50 - 5 8W-50 FRONT LIGHTING INDEX page page GENERAL INFORMATION HEADLAMP DELAY ..... . . 6 INTRODUCTION .
  • Page 709 8W - 50 - 6 8W - 50 FRONT LIGHTING DESCRIPTION AND OPERATION (Continued) • Check for a blown 20 amp fuse located in cavity Ground for the lamps is different for the left and 7 of the junction block. right lamps.
  • Page 710 8W - 51 REAR LIGHTING 8W - 51 - 1 8W-51 REAR LIGHTING INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 713 8W - 51 - 4 8W - 51 REAR LIGHTING 8W-51 REAR LIGHTING INDEX page page DESCRIPTION AND OPERATION STOP LAMPS ......4 BACK-UP LAMPS .
  • Page 714 8W - 52 TURN SIGNALS 8W - 52 - 1 8W-52 TURN SIGNALS INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .

  • Page 717: 52 Turn Signals

    8W - 52 - 4 8W - 52 TURN SIGNALS 8W-52 TURN SIGNALS INDEX page page DESCRIPTION AND OPERATION TURN SIGNALS ......4 HAZARD FLASHERS .
  • Page 718 8W - 52 TURN SIGNALS 8W - 52 - 5 DESCRIPTION AND OPERATION (Continued) • For the right front lamp check the grounding HELPFUL INFORMATION • Check the 20 amp fuses located in cavities 6, point at the right frame rail. •...
  • Page 720 8W - 53 WIPERS 8W - 53 - 1 8W-53 WIPERS INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 723 8W - 53 - 4 8W - 53 WIPERS 8W-53 WIPERS INDEX page page DESCRIPTION AND OPERATION MIST FUNCTION ......4 HELPFUL INFORMATION .
  • Page 724 8W - 53 WIPERS 8W - 53 - 5 DESCRIPTION AND OPERATION (Continued) tent wipe relay to switch from its normally grounded HI SPEED OPERATION position and connect circuit A5 to circuit V5. The A5 When HIGH speed operation is selected, a multi- circuit is protected by a 40 amp fuse located in cavity plexed signal is sent to the Body Control Module 14 of the PDC.
  • Page 726 8W - 60 POWER WINDOWS 8W - 60 - 1 8W-60 POWER WINDOWS INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 729 8W - 60 - 4 8W - 60 POWER WINDOWS 8W-60 POWER WINDOWS INDEX page page DESCRIPTION AND OPERATION POWER WINDOWS ..... . . 4 HELPFUL INFORMATION .
  • Page 730 8W - 60 POWER WINDOWS 8W - 60 - 5 DESCRIPTION AND OPERATION (Continued) the switch, connects the Q17 circuit to the Z1 circuit. door switch to the master switch. A bus bar, internal The Z1 circuit is terminated at the instrument panel to the switch, connects the Q18 circuit to the Z1 cir- left side cowl.
  • Page 732 8W - 61 POWER DOOR LOCKS 8W - 61 - 1 8W-61 POWER DOOR LOCKS INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 735 8W - 61 - 4 8W - 61 POWER DOOR LOCKS 8W-61 POWER DOOR LOCKS DESCRIPTION AND OPERATION the appropriate resistor, to the P96 circuit for the right front door, and circuit P97 for the left front POWER DOOR LOCKS door.
  • Page 736 8W - 62 POWER MIRRORS 8W - 62 - 1 8W-62 POWER MIRRORS INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 738 8W - 62 POWER MIRRORS 8W - 62 - 3 8W-62 POWER MIRRORS INDEX page page DESCRIPTION AND OPERATION POWER MIRRORS ......3 HELPFUL INFORMATION .
  • Page 740 8W - 63 POWER SEAT 8W - 63 - 1 8W-63 POWER SEAT INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 743 8W - 63 - 4 8W - 63 POWER SEAT 8W-63 POWER SEAT INDEX page page DESCRIPTION AND OPERATION POWER HEATED SEATS ....4 HELPFUL INFORMATION .
  • Page 744 8W - 64 POWER SUNROOF 8W - 64 - 1 8W-64 POWER SUNROOF INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
  • Page 746 8W - 64 POWER SUNROOF 8W - 64 - 3 8W-64 POWER SUNROOF INDEX page DESCRIPTION AND OPERATION POWER SUNROOF ..... . . 3 When the operator selects the CLOSE function, DESCRIPTION AND OPERATION voltage is provided on the Q42 circuit from the con-...
  • Page 748 8W - 65 SPEED PROPORTIONAL STEERING 8W - 65 - 1 8W-65 SPEED PROPORTIONAL STEERING INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .

  • Page 750: 65 Speed Proportional Steering

    8W - 65 SPEED PROPORTIONAL STEERING 8W - 65 - 3 8W-65 SPEED PROPORTIONAL STEERING INDEX page page DESCRIPTION AND OPERATION SPEED PROPORTIONAL STEERING ..3 HELPFUL INFORMATION ....3 (PDC).

  • Page 752: 8W-70 Splice Information

    8W - 70 SPLICE INFORMATION 8W - 70 - 1 8W-70 SPLICE INFORMATION INDEX page SCHEMATICS AND DIAGRAMS ............1 Component Page Component...
  • Page 760 8W - 80 CONNECTOR PIN-OUTS 8W - 80 - 1 8W-80 CONNECTOR PIN-OUTS INDEX page SCHEMATICS AND DIAGRAMS ............1 Component Page Component...
  • Page 761 8W - 80 - 2 8W - 80 CONNECTOR PIN-OUTS Component Page Component Page C310 .......8W-80-13 Fuel Injector No.
  • Page 762 8W - 80 CONNECTOR PIN-OUTS 8W - 80 - 3 Component Page Component Page Left Headlamp ..... . .8W-80-29 Right Fog Lamp ..... .8W-80-38 Left Park/Turn Signal Lamp .
  • Page 808 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 1 8W-90 CONNECTOR/GROUND LOCATIONS INDEX page page DESCRIPTION AND OPERATION INTRODUCTION ......1 CONNECTOR/GROUND LOCATIONS .
  • Page 809 8W - 90 - 2 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued) Connector Color Location Fig. Connector Color Location Fig. Name/Number Name/Number C224 Left Side of Fuel Injector #1 At Injector Steering (2.0L/2.4L) Column Fuel Injector #1 At Injector C305 Near Trunk (2.5L)
  • Page 810 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 3 DESCRIPTION AND OPERATION (Continued) Connector Color Location Fig. Connector Color Location Fig. Name/Number Name/Number Headlamp At Switch Left Door At Switch Switch Arm/Disarm Switch High Note Horn Right Front Fender Left Front Door At Speaker Speaker...
  • Page 811 8W - 90 - 4 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued) Connector Color Location Fig. Connector Color Location Fig. Name/Number Name/Number MAP Sensor Rear of Intake Right Front At Switch (2.5L) Door Arm/ Disarm Switch Master Power At Switch WIndow Switch Right Front...
  • Page 812 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 5 DESCRIPTION AND OPERATION (Continued) Connector Color Location Fig. Connector Color Location Fig. Name/Number Name/Number Speed Left Side of Trunk Lamp At Lamp Proporitional Steering Gear Turbine Speed Front of Steering Module Sensor Transmission Stop Lamp...
  • Page 813 8W - 90 - 6 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued)
  • Page 814 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 7 DESCRIPTION AND OPERATION (Continued)
  • Page 815 8W - 90 - 8 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued)
  • Page 816 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 9 DESCRIPTION AND OPERATION (Continued)
  • Page 817 8W - 90 - 10 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued)
  • Page 818 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 11 DESCRIPTION AND OPERATION (Continued)
  • Page 819 8W - 90 - 12 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued)
  • Page 820 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 13 DESCRIPTION AND OPERATION (Continued)
  • Page 821 8W - 90 - 14 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued)
  • Page 822 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 15 DESCRIPTION AND OPERATION (Continued)
  • Page 823 8W - 90 - 16 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued)
  • Page 824 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 17 DESCRIPTION AND OPERATION (Continued)
  • Page 825 8W - 90 - 18 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued)
  • Page 826 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 19 DESCRIPTION AND OPERATION (Continued)
  • Page 827 8W - 90 - 20 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued)
  • Page 828 8W - 90 CONNECTOR/GROUND LOCATIONS 8W - 90 - 21 DESCRIPTION AND OPERATION (Continued) Fig. 16 Door Connections (Front) Fig. 17 Door Connections (Rear)
  • Page 829 8W - 90 - 22 8W - 90 CONNECTOR/GROUND LOCATIONS DESCRIPTION AND OPERATION (Continued) Fig. 18 Deck Lid Connections...
  • Page 830 8W - 95 SPLICE LOCATIONS 8W - 95 - 1 8W-95 SPLICE LOCATIONS INDEX page page DESCRIPTION AND OPERATION SPLICE LOCATIONS ..... . 1 INTRODUCTION .
  • Page 831 8W - 95 - 2 8W - 95 SPLICE LOCATIONS DESCRIPTION AND OPERATION (Continued) Fig. 1 Engine Compartment Splices Fig. 2 Engine Compartment Splices...
  • Page 832 8W - 95 SPLICE LOCATIONS 8W - 95 - 3 DESCRIPTION AND OPERATION (Continued) Fig. 3 Engine Compartment Splices Fig. 4 Transmission Splices...
  • Page 833 8W - 95 - 4 8W - 95 SPLICE LOCATIONS DESCRIPTION AND OPERATION (Continued)
  • Page 834 8W - 95 SPLICE LOCATIONS 8W - 95 - 5 DESCRIPTION AND OPERATION (Continued)
  • Page 835 8W - 95 - 6 8W - 95 SPLICE LOCATIONS DESCRIPTION AND OPERATION (Continued)
  • Page 836 8W - 95 SPLICE LOCATIONS 8W - 95 - 7 DESCRIPTION AND OPERATION (Continued) Fig. 8 Deck Lid Splices Fig. 9 Door Splices...
  • Page 838 ENGINE 9 - 1 ENGINE CONTENTS page page 2.0L SOHC ENGINE ..... 12 ENGINE DIAGNOSIS ..... . 7 2.4L ENGINE .
  • Page 839 CYLINDER CUP PLUG BLOCK DRIFT SECOND REMOVE PLUG FIRST STRIKE HERE WITH HAMMER WITH PLIERS 9 - 2 ENGINE GENERAL INFORMATION (Continued) GASKET DISASSEMBLY Parts assembled with form-in-place gaskets may be disassembled without unusual effort. some instances, it may be necessary to lightly tap the part with a mallet or other suitable tool to break the seal between the mating surfaces.
  • Page 840 CROSS-HATCH PATTERN ENGINE 9 - 3 GENERAL INFORMATION (Continued) mal firing indicators fouled, hot, oily, etc. Record cyl- scuffing, scoring or scratches. Usually a few strokes inder number of spark plug for future reference. will clean up a bore and maintain the required lim- Disconnect coil wire from distributor and its.
  • Page 841 PLASTIGAGE 9 - 4 ENGINE GENERAL INFORMATION (Continued) NOTE: REMOVE ALL SHIMS BEFORE REASSEM- BLING ENGINE Fig. 3 Plastigage Placed in Lower Shell Engine crankshaft bearing clearances can be deter- Fig. 4 Clearance Measurement mined by use of Plastigage or equivalent. The follow- ing is the recommended procedure for the use of ALTERNATIVE METHOD Plastigage:...
  • Page 842 ENGINE LEVEL STICK DIP- ENGINE 9 - 5 GENERAL INFORMATION (Continued) imately 6.35 mm (1/4 in.) off center and away from (4) With all spark plugs removed, rotate engine the oil hole (Fig. 3). In addition, suspect areas can be crankshaft using a breaker bar and socket.
  • Page 843 All engines are equipped with a high quality full- cans (Fig. 7). flow, disposable type oil filter. Chrysler Corporation recommends a Mopar or equivalent oil filter be used. ENGINE OIL CHANGE...
  • Page 844 ENGINE 9 - 7 ENGINE DIAGNOSIS INDEX page page DIAGNOSIS AND TESTING GENERAL INFORMATION ....7 CYLINDER COMBUSTION PRESSURE INSPECTION (ENGINE OIL LEAKS IN LEAKAGE TEST .
  • Page 845 9 - 8 ENGINE DIAGNOSIS AND TESTING (Continued) cause of low compression unless some malfunc- Perform the test procedures on each cylinder tion is present. according to the tester manufacturer’s instructions. (11) Clean or replace spark plugs as necessary While testing, listen for pressurized air escaping and adjust gap as specified in Group 8, Electrical.
  • Page 846 ENGINE 9 - 9 DIAGNOSIS AND TESTING (Continued) (2) Add an oil soluble dye (use as recommended by If the leakage occurs at the crankshaft rear oil seal manufacturer). Start the engine and let idle for area: approximately 15 minutes. Check the oil dipstick to (1) Disconnect the battery.
  • Page 847 9 - 10 ENGINE DIAGNOSIS AND TESTING (Continued) ENGINE DIAGNOSIS—PERFORMANCE CONDITION POSSIBLE CAUSES CORRECTION ENGINE WILL NOT START 1. Weak battery. 1. Test battery specific gravity. Charge or replace as necessary. 2. Corroded or loose battery connections. 2. Clean and tighten battery connections. Apply a coat of light mineral grease to the terminals.
  • Page 848 ENGINE 9 - 11 DIAGNOSIS AND TESTING (Continued) ENGINE DIAGNOSIS—MECHANICAL CONDITION POSSIBLE CAUSES CORRECTION NOISY VALVES 1. High or low oil level in crankcase. 1. Checkfor correct oil level (refer to Group 0, Lubrication and Maintenance). 2. Thin or diluted oil. 2.
  • Page 849 ENGINE IDENTIFI- CATION LOCATION 9 - 12 2.0L SOHC ENGINE 2.0L SOHC ENGINE INDEX page page DESCRIPTION AND OPERATION OIL FILTER ......41 ENGINE COMPONENTS .
  • Page 850 OIL FILTER ADAPTER OIL PICK-UP TUBE OIL PAN GASKET OIL PUMP BODY DRAIN PLUG OIL PAN O-RING O-RING O-RING NIPPLE FILTER 2.0L SOHC ENGINE 9 - 13 DESCRIPTION AND OPERATION (Continued) ENGINE LUBRICATION SYSTEM route oil from main bearing journals to connecting Engine Lubrication Components ENGINE LUBRICATION Refer to Group 0, Lubrication and Maintenance for...
  • Page 851 9 - 14 2.0L SOHC ENGINE DESCRIPTION AND OPERATION (Continued) CAMSHAFT/HYDRAULIC LASH ADJUSTERS shafts supplies oil to the hydraulic lash adjusters, A vertical hole at the number five bulkhead routes camshaft and valve mechanisms. pressurized oil through a restrictor up into the cylin- CAMSHAFT —...
  • Page 852 Refer to Cylinder Bore and Piston Specifications Table. Fig. 4 Piston Measurements Chrysler engines use pistons designed specifically for each engine model. Clearance and sizing locations vary with respect to engine model. NOTE: Pistons and cylinder bores should be mea- sured at normal room temperature, 21°C (70°F).
  • Page 853 FEELER GAUGE FEELER GAUGE 9 - 16 2.0L SOHC ENGINE SERVICE PROCEDURES (Continued) Ring Position Ring Gap Wear Limit Upper Ring 0.23 to 0.52 0.8 mm (0.031 in.) (0.009 to 0.020 in.) Intermediate 0.049 to 0.78 1.0 mm Ring (0.0039 in.) (0.019 to 0.031 in.) Oil Control...
  • Page 854 2.0L SOHC ENGINE 9 - 17 SERVICE PROCEDURES (Continued) Fig. 9 Checking Connecting Rod Side Clearance Fig. 12 Checking Crankshaft End Play—Dial Indicator CONNECTING ROD BEARING OIL CLEARANCE age any bearing surface. Do not loosen main bearing New Part: 0.026 to 0.059 mm cap.
  • Page 855 FRAME R AIL RIGHT ENGINE SUPPORT 45 FT. LBS. (61 N·m) ASSEMBLY TRANSMISSION TRANSMISSION BRACKET 61 N·m (45 ft. lbs.) 33 N·m (24 ft. lbs.) TORQUE TRANSMISSION SUPPORT ASSEM- GROUND CABLE LEFT FRAME RAIL 9 - 18 2.0L SOHC ENGINE REMOVAL AND INSTALLATION performance and should not be replaced.
  • Page 856 SUPPORT REAR STRUT BRACKET SUPPORT TRANSMISSION BRACKET MODELS) (SOME STRUT REAR 61 N·m (45 ft. lbs.) 110 N·m (80 ft. lbs.) DAMPER LOWER ENGINE ENGINE SUPPORT MODULE MOUNT REAR TORQUE BRACKET TORQUE FRONT RADIATOR WEIGHT STARTER WIRING CLIP MODELS) ENGINE ENGINE) (SOME ENGINE...
  • Page 857 WHEELHOUSE STRUT A/C COMPRESSOR ENGINE ENGINE SUPPORT MOD- SPLASH SHIELD PUSH-IN FASTENER NUT-SNAP STRUT (SOME MODELS) FENDER FRONT ACCESSORY BELT SPLASH SHIELD PUSH-IN FAS- BRACKET FRONT TORQUE MOUNT TENER FASCIA DRIVE PLACE FRONT SUP- PORT ENGINE FLANGE UNDER BLOCK PLACE REAR SUP- PORT LOCATING HOLE IN SPECIAL...
  • Page 858 AIR INLET DUCT SPARK INSULATOR PLUG SPARK PLUG CABLE IGNITION COILS 2.0L SOHC ENGINE 9 - 21 REMOVAL AND INSTALLATION (Continued) (5) Install transmission and engine braces and splash shields. (6) Connect exhaust system to manifold. Refer to Group 11, Exhaust System and Intake Manifold for procedure and torque specifications.
  • Page 859 SPARK PLUG TUBE CYLINDER HEAD COVER SPARK PLUG TUBE SEAL LOCKING PLIERS 9 - 22 2.0L SOHC ENGINE REMOVAL AND INSTALLATION (Continued) (3) Mark rocker arm shaft assemblies for installa- tion. (4) Remove rocker arm shaft bolts. Refer to proce- dure outlined in this section.
  • Page 860 EXHAUST ROCKER ARM SHAFT INTAKE ROCKER ARM ROCKER SHAFT RETAINERS ROLLER EXHAUST ROCKER ARM EXHAUST INTAKE ROCKER ASSEMBLY PLASTIC SHAFT ROCKER HYDRAULIC LASH SPACERS ASSEMBLY ADJUSTERS INTAKE ROCKER ARM SHAFT 2.0L SOHC ENGINE 9 - 23 REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Lubricate camshaft journals.
  • Page 861 EXHAUST ROCKER ARM SHAFT NOTCHES FACING UP AND TOWARD THE TIMING BELT SIDE OF THE ENGINE AIR HOSE VALVE SPRING COMPRES- SPECIAL MD-998772A TOOL VALVE SEAL TOOL VALVE STEM ADAPTER 6779 INTAKE ROCKER ARM SHAFT 9 - 24 2.0L SOHC ENGINE REMOVAL AND INSTALLATION (Continued) lash adjuster and rocker arm are serviced as an VALVE SEALS AND SPRINGS IN VEHICLE...

  • Page 862: Cylinder Head

    EXHAUST ROCKER ARM/HY- DRAULIC LASH ADJUSTER VALVE RETAINER SPACER ASSEMBLY CAMSHAFT SEAL RETAINER SPRING SPARK VALVE RETAINING LOCKS PLUG TUBE SEAL VALVE RETAINING LOCKS VALVE VALVE SPRING SEAT VALVESPRING VALVE SPRING RETAINER SEAL ASSEMBLY INTAKE ROCKER ARM/HYDRAULIC CAMSHAFT LASH ADJUSTER ASSEMBLY VALVE SPRING SEAT ASSEMBLY SPACER...
  • Page 863 FEELER GAUGE STRAIGHT EDGE AIR INLET DUCT 9 - 26 2.0L SOHC ENGINE REMOVAL AND INSTALLATION (Continued) REMOVAL (1) Perform fuel system pressure release procedure before attempting any repairs. Refer to Group 14, Fuel System (2) Disconnect negative battery cable. Drain cool- ing system.
  • Page 864 MIDDLE BOTTOM CUT AWAY VIEW OF VALVE SUREMENT GUIDE LOCA- TIONS MEA- VALVE SPRING HEAT TESTER SPRING 13.25 - 13.75 MM (.521 - .541 IN.) VALVE GUIDE TORQUE WRENCH 2.0L SOHC ENGINE 9 - 27 REMOVAL AND INSTALLATION (Continued) (3) Before removing valves, remove any burrs from valve stem lock grooves to prevent dam- age to the valve guides.
  • Page 865 VALVE MARGIN VALVE FACE A — SEAT WIDTH (INTAKE AND EXHAUST 0.9 TO 1.3 mm (.035 TO .051 IN.) B — FACE ANGLE (INTAKE & EXHAUST: 44 C — SEAT ANGLE (INTAKE & EXHAUST: 45°-45 D — SEAT CONTACT AREA E —...
  • Page 866 GARTER VALVE SPRING SEAT VALVE SEAL TOOL VALVE STEM SPRING CYLINDER HEAD SUR- FACE WHEELHOUSE SPLASH SHIELD PUSH-IN FASTENER NUT-SNAP FENDER ACCESSORY BELT SPLASH SHIELD PUSH-IN FAS- TENER FASCIA DRIVE 2.0L SOHC ENGINE 9 - 29 REMOVAL AND INSTALLATION (Continued) (5) Install rocker shafts...
  • Page 867 SPECIAL TOOL 6827–A M12–1.75 x 150 MM BOLT, WASHER BEARING INSERT FROM TOOL 6792 SPECIAL THRUST SPECIAL TOOL 1026 ENGINE MOUNT BRACKET- ACCESS PLUG TO-ENGINE FASTENERS FASTENERS X — INDICATES RETAIN- ING CLIP LOCATION 9 - 30 2.0L SOHC ENGINE REMOVAL AND INSTALLATION (Continued) (3) Remove crankshaft...
  • Page 868 FRONT TIMING BELT CRANKSHAFT ACCESS PLUG COVER DAMPER BOLT CAMSHAFT BOLT WASHER TIMING BELT CAMSHAFT SPROCKET CRANKSHAFT TIMING MARK SPROCKET SPROCKET TENSIONER REAR TIMING BELT COVER OIL PUMP BODY BRACKET WATER PUMP ARROW REAR COVER 2.0L SOHC ENGINE 9 - 31 REMOVAL AND INSTALLATION (Continued) Fig.
  • Page 869 WHEELHOUSE SPECIAL TOOL 1026 SPLASH SHIELD PUSH-IN FASTENER NUT-SNAP FENDER SPECIAL ACCESSORY 6827–A INSERT BELT SPLASH SHIELD PUSH-IN FAS- TOOL TENER FASCIA DRIVE ENGINE MOUNT BRACKET- ACCESS PLUG TO-ENGINE FASTENERS FASTENERS INDICATES CLIP LOCATION RETAINING 9 - 32 2.0L SOHC ENGINE REMOVAL AND INSTALLATION (Continued) REMOVAL—TIMING BELT (4) Lower vehicle and place a jack under engine.
  • Page 870 TIMING BELT TEN- TENSIONER PIVOT SIONER TENSIONER FASTENERS LOCKING PIN TIMING MARK SPROCKET TDCMARK TENSIONER BENCH VISE (WITH SOFT ARROW REAR COVER JAWS) 2.0L SOHC ENGINE 9 - 33 REMOVAL AND INSTALLATION (Continued) Fig. 59 Compressing Timing Belt Tensioner Fig. 58 Remove Timing Belt CAMSHAFT AND CRANKSHAFT TIMING PROCEDURE AND BELT INSTALLATION —SOHC ENGINE...
  • Page 871 T.D.C. MARK CAMSHAFT T.D.C. REMOVE CLEAR- CRANKSHAFT T.D.C. SIONER UP TO MOVE TEN- ANCE T.D.C. REFER- ENCE MARK 1/2 NOTCH LOCATION INSTALL WRENCH HERE TORQUE M12–1.75 WASHER BEARING FROM 150 MM BOLT, PLACE A 1/8 INCH BEAD OF SEALER AT THE PARTING LINE OF THE OIL PUMP TO ENGINE TOOL 6792 SPECIAL...
  • Page 872 (2 INCHES) (1/2 INCH) 50.8 MM 12.7 MM GRIND SPECIAL SPECIAL TOOL MD C-4679–A TOOL 998306 2.0L SOHC ENGINE 9 - 35 REMOVAL AND INSTALLATION (Continued) (2) Install a new oil pan gasket to pan. (3) Remove camshaft seal using Special Tool (3) Install pan and tighten screws to 12 N·m (105 C-4679–A (Fig.
  • Page 873 SPECIAL TOOL 6827 — A SPECIAL TOOL SPECIAL TOOL 6793 INSERT 1026 PROTECTOR INSTALLER SPECIAL TOOL 6780–1 SPECIAL TOOL6771 SEAL 9 - 36 2.0L SOHC ENGINE REMOVAL AND INSTALLATION (Continued) FRONT CRANKSHAFT OIL SEAL (4) Using Tool 6771 to remove front crankshaft oil seal (Fig.
  • Page 874 M12 — 1.75 WASHER BEARING FROM SPECIAL TOOL 6792 150 MM BOLT, TOOL 6792 SPECIAL THRUST REAR CRANKSHAFT SCREW- DRIVER SEAL ENGINE BLOCK REAR CRANKSHAFT SEAL ENGINE BLOCK CRANK- REAR SHAFT SHAFT SCREW- METAL CASE DUST LIP PRY IN THIS DIRECTION CRANK- DRIVER...
  • Page 875 SPECIAL TOOL 6926–1 PILOT SPECIAL 6792–2 INSTALLER SPECIAL TOOL 6926–1 PILOT TOOL SEAL SPECIAL TOOL 6926–2 INSTALLER SEAL 9 - 38 2.0L SOHC ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 76 Rear Crankshaft Seal and SpecialTool 6926-1 Fig. 78 Rear Crankshaft Seal—Installation CRANKSHAFT REMOVAL (1) Remove oil filter and adapter from bedplate.
  • Page 876 MAIN BED PLATE ASSEMBLY CRANKSHAFT POSITION CONNECTING BEARING SOR (CPS) INDICATES DOWEL LOCA- SEN- BEARINGS CAP/ PISTON AND CONNECT- ING ROD ASSEMBLY TION O-RING BOLT SEAL NIPPLE OIL FILTER ADAPTER THRUST BEARINGS FRONT OF ENGINE UPPER (GROOVED) BEARING SEAL PASSAGE O-RING 2.0L SOHC ENGINE 9 - 39...
  • Page 877 FRONT OIL GROOVES OIL HOLES LOWER UPPER BEARINGS BEARINGS O-RING LUBRICATION GROOVES OIL HOLES 9 - 40 2.0L SOHC ENGINE REMOVAL AND INSTALLATION (Continued) NOTE: The upper and lower main Bearing shells are Not interchangeable. The lower shells have a revised tab to prevent improper installation.
  • Page 878 O-RING INDICATES DOWEL LOCA- TION ADAPTER FRONT OF ENGINE FILTER OIL FILTER LOCATE WRENCH BAND AT BASE OF FILTER OIL FILTER WRENCH LOCATING ROLL 2.0L SOHC ENGINE 9 - 41 REMOVAL AND INSTALLATION (Continued) down together until the bedplate contacts the cylin- OIL FILTER der block.
  • Page 879 6827–A INSERT SPECIAL TOOL SPECIAL TOOL 6793 SPECIAL TOOL 1026 9 - 42 2.0L SOHC ENGINE REMOVAL AND INSTALLATION (Continued) (4) Remove Crankshaft Sprocket using Special Tool (6) Remove oil pump, (Fig. 87) and front crank- 6793 and insert C4685–C2 (Fig. 86). shaft seal.
  • Page 880 APPLY MAKER PUMP PROTECTOR GASKET FLANGE BODY INSTALLER SPECIAL TOOL 6780–1 O-RING TIGHTEN NUT TO INSTALL SPECIAL TOOL 6792 WEIGHT DESIGNATION AND DIRECTIONAL ARROW WILL IMPRINTED AREA THIS SEAL 2.0L SOHC ENGINE 9 - 43 REMOVAL AND INSTALLATION (Continued) (2) Apply Mopar Gasket Maker to oil pump as shown in (Fig.
  • Page 881 SPACER EXPANDER NO. 2 PISTON RING NO. 1 PISTON RING OIL RING SIDE RAIL END SIDE RAIL 9 - 44 2.0L SOHC ENGINE REMOVAL AND INSTALLATION (Continued) (3) Pistons will have a stamping in the approxi- mate location shown in (Fig. 91). These stamps will be either a directional arrow or a weight identifica- tion for the assembly.
  • Page 882 NO. 2 RING GAP AND SPACER GAP OF LOWER SIDE RAIL EXPANDER FRONT OF ENGINE NO. 1 RING GAP GAP OF UPPER SIDE RAIL RELIEF V ALVE RETAINER CAP SPRING GASKET OIL PUMP BODY 2.0L SOHC ENGINE 9 - 45 REMOVAL AND INSTALLATION (Continued) (6) Tap the piston down in cylinder bore, using a hammer handle.
  • Page 883 FEELER OUTERROTOR INNER ROTOR GAUGE OIL PUMP COVER STRAIGHT EDGE PUMP BODY VALVE TESTER SPRING TORQUE WRENCH 9 - 46 2.0L SOHC ENGINE CLEANING AND INSPECTION (Continued) CLEANING Clean all valve guides, valves and valve spring assemblies thoroughly with suitable cleaning solution before reassembling.
  • Page 884 STEM VALVE SPRING RETAINER LOCK GROOVE INTAKE V ALVE EXHAUST VALVE FACE MARGIN OUTERROTOR INNER ROTOR OIL PUMP COVER PUMP BODY 2.0L SOHC ENGINE 9 - 47 CLEANING AND INSPECTION (Continued) Intake and Exhaust Valves Fig. 102 Checking Oil Pump Cover Flatness (3) Measure thickness and diameter of outer rotor.
  • Page 885 FEELER OUTER ROTOR OUTER ROTOR GAUGE FEELER GAUGE INNER ROTOR FEELER STRAIGHT EDGE GAUGE 9 - 48 2.0L SOHC ENGINE CLEANING AND INSPECTION (Continued) (5) Slide outer rotor into pump housing, press to (7) Place a straightedge across the face of the one side with fingers and measure clearance between pump housing, between bolt holes.
  • Page 886 FRONT MIDDLE OF BORE SIZING PISTON 2.0L SOHC ENGINE 9 - 49 CLEANING AND INSPECTION (Continued) specified clearances may be maintained. Refer to ADJUSTMENTS Honing Cylinder Bores outlined in the Stan- dard Service Procedures for specification and ENGINE SUPPORT ADJUSTMENT procedures.
  • Page 887 9 - 50 2.0L SOHC ENGINE SPECIFICATIONS ENGINE 2.0L SOHC Ring Gap Oil Control (Steel Rails) ....0.23 - 0.66 mm (0.009 - 0.026 in.) Cylinder Block Ring Side Clearance Both Cylinder Bore Diameter .
  • Page 888 2.0L SOHC ENGINE 9 - 51 SPECIFICATIONS (Continued) ENGINE 2.0L SOHC Runout (Max.) ....0.050 mm (0.002) Width (Finish) Intake Rocker Arm Shaft and Exhaust ....0.75 – 1.25 mm Rocker Arm Shaft (0.030 –...
  • Page 889 9 - 52 2.0L SOHC ENGINE SPECIFICATIONS (Continued) TORQUE CHART 2.0L SOHC Intake Manifold Bolts ....12 N·m (105 in. lbs.) Oil Filter Adapter DESCRIPTION .
  • Page 890 2.0L SOHC ENGINE 9 - 53 SPECIAL TOOLS ENGINE 2.0L SOHC Camshaft Sprocket Remover/InstallerAdapter C-4687-1 Puller 1026 Camshaft Seal Remover C-4679-A Crankshaft Damper Removal Insert6827-A Camshaft Seal Installer MD-998306 Camshaft Sprocket Remover/InstallerC-4687 Crankshaft Damper Installer 6792...
  • Page 891 9 - 54 2.0L SOHC ENGINE SPECIAL TOOLS (Continued) Crankshaft Damper Installer C-4685-C Cylinder Bore Indicator C-119 Valve Spring Compressor MD-998772-A Front Crankshaft Seal Remover 6771 Spring Compressor Adapter 6779 Front Crankshaft Seal Installer 6780 Valve Spring Compressor C-3575-A Crankshaft Sprocket Remover 6793...
  • Page 892 2.0L SOHC ENGINE 9 - 55 SPECIAL TOOLS (Continued) Crankshaft Sprocket Installer 6792 Rear Crankshaft Seal Guide and Installer6926-1 and 6926-2 Pressure Gage C-32932 Valve Spring Tester C-647...
  • Page 893 9 - 56 2.4L ENGINE 2.4L ENGINE INDEX page page DESCRIPTION AND OPERATION LEFT SIDE MOUNT ..... 64 ENGINE COMPONENTS .
  • Page 894 ENGINE IDENTIFICATION LOCATION 2.4L ENGINE 9 - 57 DESCRIPTION AND OPERATION ENGINE Engine—2.4L ENGINE IDENTIFICATION GENERAL SPECIFICATIONS The engine identification number is located on the Type ..... In-Line OHV, DOHC rear of the cylinder block (Fig.
  • Page 895 9 - 58 2.4L ENGINE DESCRIPTION AND OPERATION (Continued) CYLINDER BLOCK AND BEDPLATE ASSEM- rubber valve stem seals are integral with the spring BLY: A closed deck design is used for cooling and seats. Valve springs, spring retainers, and locks are weight reduction with water pump molded into the conventional.
  • Page 896 (Fig. 2). Refer to (Fig. 3) for specifications. Correct piston to bore clearance must be established in order to assure quiet and economical operation. Chrysler engines use pistons designed specifically for each engine model. Clearance and sizing locations vary with respect to engine model.
  • Page 897 FEELER GAUGE SPACER EXPANDER NO. 2 PISTON RING NO. 1 PISTON RING OIL RING FEELER GAUGE SIDE RAIL 9 - 60 2.4L ENGINE SERVICE PROCEDURES (Continued) FITTING PISTON RINGS (2) Check piston ring to groove side clearance (Fig. 6). Refer to specification in piston ring specifications (1) Wipe cylinder bore clean.
  • Page 898 NO. 2 RING GAP AND SPACER GAP OF LOWER SIDE RAIL EXPANDER FRONT OF ENGINE SIDE RAIL END NO. 1 RING GAP GAP OF UPPER SIDE RAIL 2.4L ENGINE 9 - 61 SERVICE PROCEDURES (Continued) (3) Install upper side rail first and then the lower imately 6.35 mm (1/4 in.) off center and away from side rail.
  • Page 899 FRONT OIL GROOVES LOWER BEARINGS UPPER BEAR- OIL HOLES INGS LUBRICATION GROOVES OIL HOLES 9 - 62 2.4L ENGINE SERVICE PROCEDURES (Continued) CRANKSHAFT SPECIFICATION TABLE Crankshaft End-Play New Part: 0.09 - 0.24 mm (0.0035 - 0.0094 in.) Wear Limit: 0.37 mm (0.015 in.) Main Bearing Clearance New Part: 0.018 - 0.058 mm (0.0007 - 0.0023 in.) Connecting Rod Bearing Clearance...
  • Page 900 FRONT OF ENGINE 2.4L ENGINE 9 - 63 SERVICE PROCEDURES (Continued) (3) Zero the dial indicator. (4) Move crankshaft all the way to the front and read the dial indicator. Refer to Crankshaft Specifi- cation Table for end-play specification. CRANKSHAFT SPECIFICATION TABLE Crankshaft End-Play New Part: 0.09 - 0.24mm (0.0035 - 0.0094 in.) Wear Limit: 0.37 mm (0.015 in.)
  • Page 901 SUPPORT REAR STRUT BRACKET BRACKET MODELS) (SOME REAR DAMPER LOWER ENGINE ENGINE SUPPORT MODULE MOUNT FRONT RADIATOR WEIGHT MODELS) (SOME ENGINE PORT MOUNT SUP- ENGINE SUPPORT SUPPORT TRANSMISSION REAR MOUNT MODULE REAR TORQUE BRACKET STRUT 61 N·m (45 ft. lbs.) 110 N·m (80 ft.
  • Page 902 TRANSMISSION TRANSMISSION STRUT A/C COMPRESSOR ENGINE BRACKET ENGINE SUPPORT MOD- STRUT (SOME MODELS) 61 N·m (45 ft. lbs.) GROUND CABLE TRANSMISSION FRONT TORQUE LEFT BRACKET ASSEMBLY FRONT TORQUE SUPPORT MOUNT FRAME RAIL FRAME R AIL RIGHT ENGINE SUPPORT 45 FT. LBS. (61 N·m) ASSEMBLY 33 N·m (24 ft.
  • Page 903 9 - 66 2.4L ENGINE REMOVAL AND INSTALLATION (Continued) (3) Drain cooling system. Refer to Draining Cool- (26) Remove engine and transmission mount bolts. ing System in Group 7. (27) Raise vehicle slowly. It may be necessary to (4) Discharge Air Conditioning System. move the engine/transmission assembly on the cradle (5) Disconnect automatic transmission cooler lines to allow for removal around body flanges.
  • Page 904 SPECIAL TOOLS POST 6848 SPECIAL TOOL 6710 CRA- SPECIAL TOOL 6135 DOLLY WITH ADAPTERS 6909 SPECIAL TOOLS FRONT VIEW REAR VIEW POST 6848 2.4L ENGINE 9 - 67 REMOVAL AND INSTALLATION (Continued) Fig. 23 Positioning Engine Cradle SupportPost Mounts...
  • Page 905 ONE PIECE RUBBER GAS- IGNITION COIL FASTENERS SPARK PLUG WELL SEALS GROUND STRAP F R 0 N T 9 - 68 2.4L ENGINE REMOVAL AND INSTALLATION (Continued) CYLINDER HEAD COVER (a) Tighten all fasteners to 4.5 N·m (40 in. lbs.) (b) Tighten all fasteners to 9.0 N·m (80 in.
  • Page 906 REMOVE OUTSIDE BEARING CAPS FIRST FRONT CAM CAP LEFT REAR CAM CAP 1.5 mm (.060 in.) DIAMETER BEAD OF MOPAR GASKET MAKER 2.4L ENGINE 9 - 69 REMOVAL AND INSTALLATION (Continued) to 12 N·m (105 in. lbs.) in sequence shown in (Fig. 30).
  • Page 907 ROLLER LASH ADJUSTER POCKET NICKEL PLATED LINK AND MARK CHAIN (CUTAWAY) COVER GUIDE STUD PIVOT SCREW NICKEL LINK AND DOT PLATED ADJUST GEAR/SPROCKET SCREW TENSIONER GEAR COVER (ADJUSTER) SCREWS 9 - 70 2.4L ENGINE REMOVAL AND INSTALLATION (Continued) Inspect the cam follower assembly for wear or damage (Fig.
  • Page 908 REAR GEAR COVER STUD (DOU- BLE ENDED) COVER BALANCESHAFT DRIVE GEAR GEAR(S) CARRIERDOWEL DRIVEN GEAR CARRIER REAR COVER BALANCESHAFT CARRIER 2.4L ENGINE 9 - 71 REMOVAL AND INSTALLATION (Continued) (2) Remove gear cover retaining stud (double BALANCE SHAFT CARRIER ended to also retain chain guide). Remove cover and REMOVAL balance shaft gears (Fig.
  • Page 909 DRIVE SPROCKET GEAR ALIGNMENT DOTS KEY WAYS UP ALIGN FLAT ON SPROCKET WITH FLAT SPROCKET FACING FRONT CRANKSHAFT SPECIAL NO. 6052 TOOL WITH INSTALL CHAIN WITH ALL LOWER LINK 8 LINK FROM UPPER MUST LINE UP WITH NOTCH PARTING MARK ON SPROCKET NICKEL PLATED LINK ONE MAIN BEARING NICKEL...
  • Page 910 PIVOT B OLT TENSIONER (0.039 (ADJUSTER) SHIM IN.) BOLT AIR HOSE VALVE SPRING COMPRES- SOR MD 998772A 2.4L ENGINE 9 - 73 REMOVAL AND INSTALLATION (Continued) adjustment slot to take up all slack. Chain must VALVE SPRINGS AND VALVE SEALS IN VEHICLE have shoe radius contact as shown in (Fig.
  • Page 911 VALVE RETAINER SPRING VALVE RETAINING LOCKS VALVE VALVE SPRING SEAT VALVESPRING SEAL ASSEMBLY STRETCHED UNSTRETCHED BOLT BOLT THREADS ARE NOT STRAIGHT ON LINE THREADS ARE STRAIGHT ON LINE 9 - 74 2.4L ENGINE REMOVAL AND INSTALLATION (Continued) Necking can be checked by holding a scale or straight edge against the threads.
  • Page 912 VALVE SEAL TOOL VALVE STEM SPECIAL TOOL 1026 GARTER VALVE SPRING SEAT SPRING SPECIAL 6827–A INSERT TOOL CYLINDER HEAD SUR- FACE 2.4L ENGINE 9 - 75 REMOVAL AND INSTALLATION (Continued) Install coil pack and plug wires onto the (3) Install valve springs and retainers. Compress engine.
  • Page 913 UPPER TIMING BOLT COVER ENGINE SUPPORT BRACKET LOWER M12–1.75 WASHER BEARING COVER FASTENERS TIMING FROM FASTENERS FASTENERS 150 MM BOLT, TOOL 6792 BELT SPECIAL THRUST REAR COVER TO CYLINDER REAR COVER TO ENGINE BLOCK FASTENERS HEAD FASTENERS BELT TENSIONER 9 - 76 2.4L ENGINE REMOVAL AND INSTALLATION (Continued) INSTALLATION...
  • Page 914 UPPER TIMING BELT COVER ENGINE SUPPORT BRACKET LOWER COVER FASTENERS TIMING FASTENERS FASTENERS BELT CAMSHAFT TIMING MARKS CRANKSHAFT AT TDC 6mm ALLEN WRENCH BELT TENSIONER TOGETHER WRENCH ALLEN 2.4L ENGINE 9 - 77 REMOVAL AND INSTALLATION (Continued) (5) Install front cover. Refer to Front Cover instal- lation procedure outlined in this section.
  • Page 915 TENSIONER BRACKET ALIGNMENT FLATS BELT TENSIONER CAMSHAFT CAMSHAFT 1/2 NOTCH LOCATION SPROCKET SPROCKET EXHAUST INTAKE 9 - 78 2.4L ENGINE REMOVAL AND INSTALLATION (Continued) TIMING BELT TENSIONER (6) Rotate crankshaft 2 revolutions and check the (1) If replacing timing belt tensioner, remove the alignment of the timing marks (Fig.
  • Page 916 MOVE SPROCKET CAMSHAFT TIMING MARKS INSTALL PLACE A 3 MM (1/8 INCH) BEAD OF SEALANT AT THE PARTING LINE OF THE 1/2 NOTCH LOCATION CRANKSHAFT AT TDC OIL PUMP BODY TO ENGINE BLOCK BELT BELT SLACK DIRECTION CAMSHAFT TAKE THIS ADAPTER C-4687–1 OIL PICK-UP TUBE...
  • Page 917 SPECIAL SPECIAL TOOL C-4679 MD 998306 TOOL REAR TIMING BELT COVER SPECIAL CRANKSHAFT SPROCKET TOOL 1026 SPECIAL TOOL SPECIAL TOOL 6793 6771 SPECIAL 6827–A INSERT TOOL 9 - 80 2.4L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 64 Crankshaft Damper—Removal Fig. 62 Camshaft Oil Seal—Removal WithC-4679–A Fig.
  • Page 918 SPECIAL TOOL PROTECTOR SEAL 6780 TIGHTEN NUT TO INSTALL M12–1.75 WASHER BEARING SPECIAL TOOL FROM 150 MM BOLT, TOOL 6792 6792 SPECIAL THRUST 2.4L ENGINE 9 - 81 REMOVAL AND INSTALLATION (Continued) (2) Place seal into opening with seal spring towards the inside of engine.
  • Page 919 REAR CRANKSHAFT SCREW- DRIVER SEAL ENGINE BLOCK SPECIAL TOOL 6926–1 PILOT REAR CRANKSHAFT SEAL ENGINE BLOCK CRANK- REAR SHAFT SHAFT SCREW- METAL CASE DUST LIP PRY IN THIS DIRECTION CRANK- DRIVER SEAL SEAL SPECIAL 6792–2 INSTALLER SPECIAL TOOL 6926–1 PILOT SPECIAL TOOL 6926–2...
  • Page 920 LUBRICATION GROOVES OIL HOLES FRONT OF ENGINE 2.4L ENGINE 9 - 83 REMOVAL AND INSTALLATION (Continued) (3) Remove Balance Shafts Assembly. Refer to pro- (4) Apply 1.5 to 2.0 mm (0.059 to 0.078 in.) bead of cedure outlined in this section. Mopar Torque Cure Gasket Maker to cylinder block (4) Remove all main bearing cap bedplate bolts as shown in (Fig.
  • Page 921 OIL PICK-UP TUBE OIL PUMP BODY GASKET WINDAGE TRAY DRAIN PLUG OIL PAN COLLAR O-RING FILTER WITH CRANKSHAFT SPROCKET SPECIAL TOOL 6793 9 - 84 2.4L ENGINE REMOVAL AND INSTALLATION (Continued) (9) Install main bearing bedplate to engine block (3) Remove collar and Oil Pan. Refer to Oil Pan bolts (11 thru 20), and torque each bolt to 28 N·m (20 Removal in this section.
  • Page 922 APPLY GASKET MAKER TO OIL PUMP BODY FLANGE TIGHTEN NUT TO INSTALL SPECIAL TOOL SPECIAL TOOL PROTECTOR SEAL 6780 6792 2.4L ENGINE 9 - 85 REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Make sure all surfaces are clean and free of oil and dirt.
  • Page 923 DIRECTIONAL ARROW WILL BE IMPRINTED IN THIS AREA NO. 2 RING GAP AND SPACER GAP OF LOWER SIDE RAIL EXPANDER FRONT OF ENGINE NO. 1 RING GAP GAP OF UPPER SIDE RAIL 9 - 86 2.4L ENGINE REMOVAL AND INSTALLATION (Continued) Fig.
  • Page 924 OIL PICK-UP TUBE OIL PUMP BODY GASKET WINDAGE TRAY DRAIN PLUG OIL PAN COLLAR O-RING FILTER WITH 2.4L ENGINE 9 - 87 REMOVAL AND INSTALLATION (Continued) (10) Using a feeler gauge, check connecting rod (a) Remove the threaded plug and gasket from side clearance (Fig.
  • Page 925 MIDDLE BOTTOM FEELER GAUGE CUT AWAY VIEW OF VALVE SUREMENT STRAIGHT EDGE GUIDE LOCA- TIONS MEA- SPRING HEAT 13.25 - 13.75 MM (.521 - .541 IN.) VALVE GUIDE 9 - 88 2.4L ENGINE CLEANING AND INSPECTION CYLINDER HEAD CLEANING Remove all gasket material from cylinder head and block.
  • Page 926 INNER ROTOR ROTOR OIL PUMP COVER OIL PUMP BODY OUTER ROTOR OIL PUMP COVER FASTENER O-RING SEAL STRAIGHT EDGE FEELER GAUGE 2.4L ENGINE 9 - 89 CLEANING AND INSPECTION (Continued) (2) Lay a straightedge across the pump cover sur- (6) Install inner rotor into pump housing. If clear- face (Fig.
  • Page 927 OUTER FEELER GAUGE FEELER GAUGE ROTOR OUTER ROTOR STRAIGHT EDGE FEELER GAUGE INNER R OTOR 9 - 90 2.4L ENGINE CLEANING AND INSPECTION (Continued) (10) If oil pressure is low and pump is within CRANKSHAFT specifications, inspect for worn engine bearings or The crankshaft journals should be checked for other reasons for oil pressure loss.
  • Page 928 FRONT MIDDLE OF BORE ROLLER LASH ADJUSTER POCKET SIZING PISTON 2.4L ENGINE 9 - 91 CLEANING AND INSPECTION (Continued) ADJUSTMENTS ENGINE SUPPORT ADJUSTMENT The right and left support assemblies are slotted to allow for right/left drive train adjustment in relation to drive shaft assembly length.
  • Page 929 9 - 92 2.4L ENGINE SPECIFICATIONS ENGINE 2.4L Piston Ring Gap Top Compression Ring ..0.25 - 0.51 mm (0.0098 - 0.020 in.) Type ....In-Line OHV, DOHC 2nd Compression Ring .
  • Page 930 2.4L ENGINE 9 - 93 SPECIFICATIONS (Continued) Camshaft Exhaust ..5.906 - 5.924 mm (0.233 - 0.233 in.) Bearing Bore Diameter Valve Margin Intake ... 1.285 - 1.615 mm No.
  • Page 931 9 - 94 2.4L ENGINE SPECIFICATIONS (Continued) TORQUE CHART 2.4L Exhaust Manifold to Cylinder Head Bolts ....23 N·m (200 in. lbs.) Exhaust Manifold Heat Shield DESCRIPTION .
  • Page 932 2.4L ENGINE 9 - 95 SPECIAL TOOLS ENGINE 2.4L Cradle 6710 Puller 1026 Post Kit Engine Cradle 6848 Crankshaft Damper Removal Insert6827-A Camshaft Sprocket Remover C-4687 Dolly 6135 Camshaft Seal Remover C-4679-A...
  • Page 933 9 - 96 2.4L ENGINE SPECIAL TOOLS (Continued) Camshaft Seal Installer MD-998306 Cylinder Bore Gage C-119 Crankshaft Damper Installer 6792 Crankshaft Sprocket Remover 6793 Valve Spring Compressor MD-998772-A Crankshaft Sprocket Remover InsertC-4685-C2 Valve Spring Compressor Adapter 6779 Crankshaft Seal Remover 6771...
  • Page 934 2.4L ENGINE 9 - 97 SPECIAL TOOLS (Continued) Post Adapter 8130 Oil Pressure Gage C-3292 Front Crankshaft Oil Seal Installer6780 Rear Crankshaft Seal Guide and Installer6926-1 and 6926-2 Balance Shaft Sprocket Installer6052 Post Kit Engine Cradle 6848...
  • Page 935 9 - 98 2.5L ENGINE 2.5L ENGINE INDEX page page DESCRIPTION AND OPERATION OIL FILTER ......123 ENGINE COMPONENTS .
  • Page 936 AND VIN NUMBER SERIAL NUMBER ENGINE FILTER 2.5L ENGINE 9 - 99 DESCRIPTION AND OPERATION ENGINE IDENTIFICATION The engine identification number is located on the rear of the cylinder block just below the cylinder head (Fig. 1). Fig. 1 Engine Identification ENGINE—2.5L...
  • Page 937 CYLINDER WALLS SPLASH LUBRI- CATED FROM DIRECTED HOLES IN * NO. 2 CAMSHAFT CAP (FRONT AND REAR) RECEIVES OIL FROM CYLINDER HEAD TO SUPPLY ROCKERS, LASH ADJUSTERS, CAMSHAFT JOURNALS CONNECTING RODS CYLINDER CAMSHAFT BOLTS HEAD JOUR- NALS PICKUP CAMSHAFT JOURNALS PUMP RELIEF VALVE MAIN...
  • Page 938 2.5L ENGINE 9 - 101 DESCRIPTION AND OPERATION (Continued) the oil pump case and the rear is retained in a die- adjusters assemblies which pivot on rocker arm cast aluminum block-mounted housing. shafts. All valves have 6 mm diameter chrome plated valve stems.
  • Page 939 PISTON O.D. MENT LOCATION MEASURE- FEELER GAUGE 9 - 102 2.5L ENGINE SERVICE PROCEDURES (Continued) Fig. 5 Measuring Piston for Clearance andWear Fig. 3 Measure Cylinder Bore Refer to (Fig. 7) for specification. Fig. 4 Measure Piston (1) Bore to specified clearance between the piston O.D.
  • Page 940 SPACER EXTENDER NO. 2 PISTON RING PISTON RING OIL RING SIDE RAIL NO. 2 RING GAP AND SPACER RING SIDE EXPANDER GAP UPPER RAIL NO. 2 RING - INSTALL FIRST SIDE SIDE RAIL LOWER NO. 1 RING GAP RAIL PISTON PIN 2.5L ENGINE 9 - 103 SERVICE PROCEDURES (Continued)
  • Page 941 9 - 104 2.5L ENGINE SERVICE PROCEDURES (Continued) (10) Position piston ring end gaps as shown in (Fig. 12). (11) Position oil ring expander gap at least 45° from the side rail gaps but not on the piston pin cen- ter or on the thrust direction.
  • Page 942 PLASTIC GAUGE CRANKSHAFT SIZE IDENTI- CONNECTING ROD JOUR- MAIN JOURNAL FICATION 2.5L ENGINE 9 - 105 SERVICE PROCEDURES (Continued) PLASTIGAGE MEASUREMENT (1) Measure the crankshaft journal diameter and (1) Remove oil from journal and bearing shell. confirm its classification from the following (Fig. 20). (2) Install crankshaft.
  • Page 943 IDENTIFICATION COLOR 9 - 106 2.5L ENGINE SERVICE PROCEDURES (Continued) CAMSHAFT END PLAY (1) Oil camshaft journals and install camshaft without rocker arm assemblies. (2) Using a suitable tool, move camshaft as far rearward as it will go. (3) Zero dial indicator (Fig. 24). (4) Move camshaft as far forward as it will go.
  • Page 944 SUPPORT REAR STRUT BRACKET SUPPORT TRANSMISSION BRACKET MODELS) (SOME SUP- PORT STRUT STRUT REAR 61 N·m (45 ft. lbs.) 110 N·m (80 ft. lbs.) DAMPER LOWER ENGINE ENGINE SUPPORT MODULE MOUNT TORQUE 61 N·m (45 ft. lbs.) REAR TORQUE BRACKET TORQUE FRONT RADIATOR...
  • Page 945 TRANSMISSION TRANSMISSION BRACKET 61 N·m (45 ft. lbs.) GROUND CABLE TRANSMISSION TORQUE LEFT ASSEMBLY SUPPORT FRAME RAIL OIL PAN MATTING SURFACE FRONT OF ENGINE SPECIAL TOOL 6973 33 N·m (24 ft. lbs.) 9 - 108 2.5L ENGINE REMOVAL AND INSTALLATION (Continued) (1) Support the transmission with a transmission (15) Disconnect exhaust pipe from manifold.
  • Page 946 SPECIAL ADJUSTABLE SPECIAL TOOL SUP- PORT BARS 6810-3A NO. 6848 POSTS TOOL SPECIAL SPECIAL SPECIAL ENGINE CRADLE NO. 6810 TOOL DOLLY NO. 6135 TOOL NO. 6810 CRADLE ENGINE ENGINE TOOL 2.5L ENGINE 9 - 109 REMOVAL AND INSTALLATION (Continued) (7) Install power steering pump and reservoir. Refer to Group 7, Cooling System Accessory Drive Section for belt tension adjustment.
  • Page 947 INTAKE CAMSHAFT INTAKE ROCKER ARM ROCKER ARMS CYLINDER (RIGHT SIDE) COVER SHAFT HEAD SEAL SPRINGCAP GASKET BREATHER HOSE VALVE STEM SEAL SPRING SEAT HEAD GASKETS WASHER SPRING VALVE CYLINDER HEAD BOLT SPRING PCV VALVE RETAINER LOCKS SEALS SPARK PLUG SEAL TUBE O-RINGEXHAUST CYLINDER...
  • Page 948 TIMING BELT END CYLINDER HEAD BOLT AND WASHER 1 0 mm ALLEN EXHAUST ROCKER INTAKE ROCKER ARMS ARMS SPECIAL TOOL MD998443 ROCKER SHAFT RETAINERS ROCKER SPRINGS SHAFT 2.5L ENGINE 9 - 111 REMOVAL AND INSTALLATION (Continued) (5) Remove exhaust manifolds and cross over Refer to Group 11, Intake and Exhaust Manifolds for pro- cedure.
  • Page 949 ROCKER EXHAUST INTAKE SPRING ORIENTATION ROCKER ROCKER TIGHTEN SEQUENCE TIGHTEN SEQUENCE SHAFT DIRECTIONAL SHAFT SHAFT FLAT HYDRAULIC ADJUSTER EXHAUST LASH INTAKE ROCKER ROCKER TIGHTEN SEQUENCE SPECIAL TIGHTEN SEQUENCE MD998443 TOOL SHAFT SHAFT ROLLER ROCKER ARM 9 - 112 2.5L ENGINE REMOVAL AND INSTALLATION (Continued) Fig.
  • Page 950 MOUNTING ADAPTER 6865 POST 6886 SPECIAL MD998774 TOOL FORCING FORCING ARM 6887 SCREW 6765 SCREW 2.5L ENGINE 9 - 113 REMOVAL AND INSTALLATION (Continued) (2) Using a suitable tool, move camshaft as far rearward as it will go. (3) Zero dial indicator (Fig. 41). (4) Move camshaft as far forward as it will go.
  • Page 951 SILVER INTAKE EXHAUST BLACK ENAMELED END SPECIAL MD998774 TOOL SPRING SPRING SEAT RETAINER STEM SEAL VALVE STEM SEAL 9 - 114 2.5L ENGINE REMOVAL AND INSTALLATION (Continued) spring retainer locks, retainer, valve spring, and (4) Install valve spring with the enamelled ends valve (Fig.
  • Page 952 BOLT 182 N·m (134 FT. WHEELHOUSE TORQUE CRANKSHAFT BOLT LBS.) SPLASH SHIELD SQUARE WASHER PUSH-IN FASTENER 1/2” NUT-SNAP FENDER ACCESSORY BELT SPLASH SHIELD CRANKSHAFT PUSH-IN FAS- SPROCKET RUBBER TENER FASCIA DRIVE ENGINE BRACKET UPPER BELT COVER FASTENERS LOWER TIMING BELT COVER FASTENERS TENERS RIGHT...
  • Page 953 ENGINE 45 N·m (33 ft. lbs.) BRACKETTENSIONER MOUNT 23 N·m (17 ft. CAMSHAFT SPROCKET BOLT PULLEY TENSIONER UPPER RIGHT TIMING lbs.) 48 N·m (35 ft. 88 N·m (65 ft. lbs.) BELT COVER lbs.) 44 N·m (33 ft. CAMSHAFT SPROCKET TENSIONER lbs.) TIMING BELT CRANKSHAFT...
  • Page 954 LOCKING PIN RIGHT TIMING MARKS SPROCKET ALIGN TIMING MARKS LEFT SOFT JAW VISE SPROCKET SPECIAL MD 998767 TOOL TIMING MARKS 2.5L ENGINE 9 - 117 REMOVAL AND INSTALLATION (Continued) (3) Install timing belt on rear camshaft sprocket first and install a binder clip on the belt and sprocket so the belt will not slip out of position.
  • Page 955 SPECIAL TOOL 6847 SPECIAL MD-998713 TOOL SPECIAL TOOL 6863 SEAL CAMSHAFT 9 - 118 2.5L ENGINE REMOVAL AND INSTALLATION (Continued) (8) Pull tensioner plunger pin. CAMSHAFT OIL SEAL (9) Rotate crankshaft 2 revolutions in a clockwise (1) Apply light coat of engine oil to the camshaft direction ONLY and check the alignment of the tim- oil seal lip.
  • Page 956 OIL PICKUP GASKET DRAIN PLUG BOLT GASKET SCREW SPECIAL MD-998717 CRANKSHAFT TOOL GUIDE .157 in (4 mm) DIAMETER OF SEAL PUMP CASE SEALANT 2.5L ENGINE 9 - 119 REMOVAL AND INSTALLATION (Continued) OIL PAN REMOVAL (1) Disconnect battery negative remote cable (Fig. 62).
  • Page 957 FASTENER LENGTH 25 MM (1 OIL PUMP ASSEM- IN.) SEAL TORQUE GASKET 30 MM (1 3/16 IN.) 60 MM (2 3/8 IN.) 31/32 IN.) 50 MM (1 THRUST BEARINGS MAIN (2 PAIRS) UPPER ING (GROOVED) BEARING BEAR- LOCK CAP MONOB- CASE SEAL 10mm (104 IN.
  • Page 958 GROOVED THRUST WITHOUT TAB BEARING THRUST BEAR- ING WITH TAB FRONT MONOBLOCK BEARING CAP MAIN PLAIN 2.5L ENGINE 9 - 121 REMOVAL AND INSTALLATION (Continued) INSTALLATION (5) Install lower main bearing shells without oil (1) Install upper main bearing shells making cer- grooves in monoblock cap.
  • Page 959 CRANKSHAFT FRONT BEARING CAP BEARING BOLT CYLINDER BLOCK TIMING BELT END 9 - 122 2.5L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 70 Crankshaft Main Bearing Cap Fig. 71 Crankshaft End Play—Typical Fig. 72 Crankshaft Specifications...
  • Page 960 HOUSING SPECIAL MD-998718 SEAL TOOL MOPAR SILICONE RUBBER ADHESIVE SEALANT GASKET BRACKET 25 MM (1 IN.) FILTER 30 MM (1 3/16 IN.) 60 MM (2 3/8 IN.) 23 N·m (17 IN. LBS.) 31/32 IN.) 50 MM (1 2.5L ENGINE 9 - 123 REMOVAL AND INSTALLATION (Continued) REAR CRANKSHAFT SEAL AND RETAINER INSTALLATION...
  • Page 961 “L” ARROW TOWARD FRONT OF FORWARD CYLINDERS 2-4-6 ENGINE FACE .118 in. (3 mm) OF SEALANT SPACER EXTENDER NO. 2 PISTON RING CYLINDER NUM- PISTON RING OIL RING SIDE RAIL 9 - 124 2.5L ENGINE REMOVAL AND INSTALLATION (Continued) 14 N·m (10 ft. lbs.) M10 bolts 41 N·m (30 ft. lbs.). See (Fig.
  • Page 962 RING NO. 2 RING - INSTALL FIRST SIDE RAIL NO. 2 RING GAP AND SPACER SIDE EXPANDER GAP UPPER RAIL SIDE LOWER NO. 1 RING GAP RAIL PISTON PIN 2.5L ENGINE 9 - 125 REMOVAL AND INSTALLATION (Continued) Fig. 84 Piston Ring End Gap Position Fig.
  • Page 963 NOTCHES BEARING HOLD ALIGNMENT MARKS CYLINDER NUM- EXHAUST ROCKER INTAKE ROCKER ARMS OIL PUMP BODY SEAL ARMS INNER R OTOR OUTER PLUG ROTOR RELIEF ROCKER SHAFT RETAINERS PUMP COVER ROCKER SPRING VALVE PRESSURE SPRINGS SHAFT RELIEF VALVE O-RINGS SCREW PLUG 9 - 126 2.5L ENGINE REMOVAL AND INSTALLATION (Continued)
  • Page 964 LOBE BEARING JOURNAL ACTUAL WEAR AUTO-LASH ADJUSTER MIDDLE OF BORE FRONT USE FOR SIZ- ING PISTON WEAR ZONE - MIKE HERE UNWORN AREA - MIKE HERE 2.5L ENGINE 9 - 127 DISASSEMBLY AND ASSEMBLY (Continued) lobes show signs of pitting on the nose, flank or base circle;...
  • Page 965 MIDDLE BOTTOM CUT AWAY VIEW OF VALVE SUREMENT GUIDE LOCA- TIONS MEA- 9 - 128 2.5L ENGINE CLEANING AND INSPECTION (Continued) Fig. 95 Checking Wear on Valve Guide—Typical VALVE DIMENSIONS INTAKE VALVE STEM DIAMETER: 6.00 mm (2.36 in.) Fig. 93 Distortion Check FACE ANGLE: 45°...
  • Page 966 HYDRAULIC (17 IN. LBS.) 23 N·m ADJUSTER GASKET LASH BRACKET SPECIAL MD998443 TOOL ROLLER ROCKER ARM FILTER OIL PUMP BODY SEAL INNER R OTOR OUTER PLUG ROTOR RELIEF (0.004 TO 0.007 INCH) 0.10 TO 0.18 mm PUMP COVER SPRING VALVE PRESSURE RELIEF VALVE...
  • Page 967 ALIGNMENT MARKS (0.0015 TO 0.0035 INCH) 0.04 TO 0.09 mm ENGINE BRACKET UPPER BELT COVER FASTENERS LOWER TIMING BELT COVER FASTENERS TENERS RIGHT FAS- TIMING TOOTH CANVAS MISSING PEELING RUBBER EXPOSED EXPOSED FIBER PEELING CRACKS UPPER LEFT COVER FASTENERS ROUNDED EDGE ABNORMAL TIMING (FLUFFY STRAND)
  • Page 968 MARK AND IS NOT FULL WIDTH OF THE FACE SEAT CONTACT LENGTH MARGIN EXHAUST INTAKE 2.5L ENGINE 9 - 131 CLEANING AND INSPECTION (Continued) (8) Measure Valve spring free length and if the spring is square (Fig. 108). Refer to (Fig. 109) for specifications.
  • Page 969 9 - 132 2.5L ENGINE ADJUSTMENTS (2) Loosen the right engine support assembly ver- tical fasteners. ENGINE SUPPORT ADJUSTMENT (3) Loosen the left engine support assembly verti- cal bolts. The right and left support assemblies are slotted to (4) Pry the engine right or left as required to allow for right/left drive train adjustment in relation achieve the proper drive shaft assembly length.
  • Page 970 2.5L ENGINE 9 - 133 SPECIFICATIONS (Continued) ENGINE SPECIFICATIONS (CONT.) Description Standard Dimension Service Limit Piston O.D........83.5 mm —...
  • Page 971 9 - 134 2.5L ENGINE SPECIFICATIONS (Continued) TORQUE CHART 2.5L DESCRIPTION TORQUE DESCRIPTION TORQUE Intake Manifold Plenum Bolt . . . 18 N·m (13 ft. lbs.) Cylinder Head Cover Bolt ..3.5 N·m (2.5 ft. lbs.) Intake Manifold Plenum Rocker Arm and Rocker Arm Support Bolt M8 .
  • Page 972 2.5L ENGINE 9 - 135 SPECIAL TOOLS ENGINE 2.5L Installer MD-998713 Remover C-4679-A Installer MD-998718 Insert C-4685-C2 Compressor C-3422-B Installer MD-998717 Holders MD-998443...
  • Page 973 9 - 136 2.5L ENGINE SPECIAL TOOLS (Continued) Puller 1026 Adapter 6526 Installer 6052 Wrench MD-998767 Dolly 6135 Compressor MD-998772-A Fixture Engine 6710 Installer MD-998774...
  • Page 974 2.5L ENGINE 9 - 137 SPECIAL TOOLS (Continued) Screw 6765 Engine Cradle Posts 6848 Bracket Cradle Post Support 6973 Adapter 6779 Adapter 6885 Support Bar Cradle 6710-3A Posts 6886 Holder 6847...
  • Page 975 9 - 138 2.5L ENGINE SPECIAL TOOLS (Continued) Adapter 6887 Camshaft Seal Installer 6863...
  • Page 976 ENGINE 9 - 1 ENGINE CONTENTS page STANDARD SERVICE PROCEDURES ..1 STANDARD SERVICE PROCEDURES GENERAL INFORMATION rial is for use between two machined surfaces. Do not use on flexible metal flanges. FORM-IN-PLACE GASKETS MOPAR TORQUE CURE GASKET MAKER There are numerous places where form-in-place...
  • Page 977 9 - 2 ENGINE GENERAL INFORMATION (Continued) is recommended during assembly to prevent smear- is placed in the center of the gasket contact area. ing the material off location. Uncured sealant may be removed with a shop towels. The Mopar Silicone Rubber Adhesive Sealant gas- Components should be torqued in place while the ket material or equivalent should be applied in a con- sealant is still wet to the touch (within 10 minutes).
  • Page 978 CLAMP ON HEAT SHIELD FLEX-JOINT DOWNSTREAM OXYGEN SENSOR HEATED LOCA- TION BAND CLAMP RESONATOR SUPPORT BAND CLAMP FRONT MUFFLER SUPPORT REAR MUFFLER SUPPORTS EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 1 EXHAUST SYSTEM AND INTAKE MANIFOLD CONTENTS page page GENERAL INFORMATION REMOVAL AND INSTALLATION CATALYTIC CONVERTERS .

  • Page 979: General Information

    MUFFLER GROUND STRAP RESONATOR HEAT SHIELD HEAT SHIELD 11 - 2 EXHAUST SYSTEM AND INTAKE MANIFOLD GENERAL INFORMATION (Continued) CAUTION: Due to exterior physical similarities of reduce the efficiency of the heat shields result- some catalytic converters with pipe assemblies, ing in excessive floor pan temperatures and objectionable fumes.

  • Page 980: Description And Operation

    EXHAUST MANI- NUT 28 N·m (250 in. lbs.) SHOULDER FOLD SPRING BOLT FLANGE BELLOWS END CAPS EXHAUST PIPE SHOULDERBOLT SPRING NUT SEAL RING EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 3 GENERAL INFORMATION (Continued) This joint actually moves back and forth as the DESCRIPTION AND OPERATION engine moves, preventing breakage that could occur from the back-and-forth motion of a transverse...
  • Page 981 REAR EXHAUST MANIFOLD REAR HEAT SHIELD EXHAUST MANIFOLD 30 N·m (22 ft. lbs.)13 N·m (10 ft. lbs.) RIGHT SIDE MANIFOLD SUP- UPPER INTAKE MANIFOLD 18 N·m (13 ft. lbs.) LOWER MANIFOLD LOWER INTAKE MANIFOLD PORT NUT 59 N·m (43 ft. INTAKE 18 N·m (13 ft.

  • Page 982: Exhaust System

    EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 5 DIAGNOSIS AND TESTING EXHAUST SYSTEM CONDITION POSSIBLE CAUSES CORRECTION EXCESSIVE EXHAUST NOISE (a) Exhaust manifold cracked or (a) Replace manifold (UNDER HOOD) broken (b) Manifold to cylinder head leak (b) Tighten manifold and/or replace gasket (c) EGR Valve to manifold gasket (c) Tighten fasteners or replace...

  • Page 983: Removal And Installation

    CATALYTIC AND PIPE ASSEMBLY CONVERTER RESONATOR ASSEMBLY PIPE CLAMP CLAMP MUFFLER AND PIPE ASSEM- 11 - 6 EXHAUST SYSTEM AND INTAKE MANIFOLD REMOVAL AND INSTALLATION EXHAUST PIPE AND MUFFLER REMOVAL (1) Raise vehicle on hoist and apply penetrating oil to clamp nuts of component being removed (Fig. 1). (2) Remove clamp and supports at muffler to reso- nator assembly (Fig.
  • Page 984 OXYGEN SENSORS OXYGEN SENSORS SHOULDER BOLT 2.4L ENGINE 2.5L ENGINE 2.0L ENGINE SEAL RING GASKET GASKET SPRING BOLT EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 7 REMOVAL AND INSTALLATION (Continued) (6) Vehicle equipped with 2.5L engine disconnect upstream heated oxygen sensor. (7) Remove catalytic converter to exhaust manifold attaching fasteners (Fig.
  • Page 985 REAR MUFFLER SUPPORT TORQUE SPECI- FICATION ISOLATORS CLAMP SIZE GROUND STRAP MUFFLER/FRONT PIPE SUP- PORT ISOLATOR AUXILIARY JUMPER TERMINAL RESONATOR SUPPORT ISO- AIR CLEANER HOUSING LATORS LEFT STRUT TOWER 11 - 8 EXHAUST SYSTEM AND INTAKE MANIFOLD REMOVAL AND INSTALLATION (Continued) Fig.
  • Page 986 INTAKE AIR TEMPERATURE TO LEAK DETECTION PUMP THROTTLE POSITION SENSOR THROTTLE BODY SENSOR TO PCV VACUUM SOURCE VAPOR VACUUM SOURCE BRAKE SEN- EGR TUBE TO INTAKE MANIFOLD FASTENERS MAP SENSOR CANISTER BOOSTER KNOCK SENSOR INTAKE AIR TEMPERATURE BRAKE SENSOR TUBE FASTENERS BOOSTER CONNECTION VALVE...
  • Page 987 INTAKE THROTTLE BODY WATER INLET SUPPORT MANIFOLD GASKET MANIFOLD CAPTIVE O-RING GASKET INJECTOR RAIL MOUNTS 11 - 10 EXHAUST SYSTEM AND INTAKE MANIFOLD REMOVAL AND INSTALLATION (Continued) (1) Install new intake manifold gasket (2.4L) or O-rings (2.0L), and tighten fasteners to 11.9 N·m (105 in.
  • Page 988 HEAT CLEANER BRACKET SHIELD ATTACHING SCREWS FASTENERS HEATED OXYGEN SENSOR LOWER FAS- TENER EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 11 REMOVAL AND INSTALLATION (Continued) (3) Remove 8 exhaust manifold retaining fasteners and remove exhaust manifold (Fig. 20) and (Fig. 22). Fig.
  • Page 989 REAR EXHAUST MANIFOLD REAR HEAT SHIELD EXHAUST MANIFOLD 30 N·m (22 ft. lbs.)13 N·m (10 ft. lbs.) AUXILIARY JUMPER RIGHT SIDE MANIFOLD SUP- TERMINAL UPPER INTAKE MANIFOLD 18 N·m (13 ft. lbs.) LOWER MANIFOLD LOWER INTAKE MANIFOLD PORT AIR CLEANER HOUSING NUT 59 N·m (43 ft.
  • Page 990 THROTTLE BODY SUPPORT BRACKET BOLT THROTTLE POSITION SENSOR MAP SENSOR INTAKE PERATURE TEM- SEN- THROTTLE POSITION SEN- SPEED CONTROL CABLE BOLTS TUBE EGR TUBE THROTTLEBODY IDLE SUPPORT THROTTLE CABLE CONTROL BRACKET MOTOR BOLT RELEASE TANG EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 13 REMOVAL AND INSTALLATION (Continued) Fig.
  • Page 991 TIMING BELT SIDE EXHAUST OVER PIPE CROSS- ATTACHING BOLTS FUEL FUEL RAIL RAIL SPACERS BOLTS 11 - 14 EXHAUST SYSTEM AND INTAKE MANIFOLD REMOVAL AND INSTALLATION (Continued) (7) Install bolts at plenum support brackets. Tighten bolts to 18 N·m (13 ft. lbs.). (8) Install EGR tube to plenum.

  • Page 992: Cleaning And Inspection

    REAR OF INTAKE MANI- REAR EXHAUST MANIFOLD FOLD FLANGE HEAT SHIELD THROTTLE BODY MANIFOLD GASKET CAPTIVE O-RING GASKET INJECTOR RAIL MOUNTS EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 15 REMOVAL AND INSTALLATION (Continued) Fig. 36 Intake Manifold O-Rings—2.0LEngine EXHAUST MANIFOLD—2.0/2.4L ENGINES (1) Discard gasket and clean all gasket from sur- faces of manifolds and cylinder head.

  • Page 993: Specifications

    11 - 16 EXHAUST SYSTEM AND INTAKE MANIFOLD SPECIFICATIONS TORQUE Description Torque Band Clamp Fastener ....80 N·m (60 ft. lbs.) Body Heat Shields Fasteners .
  • Page 994 EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 1 EXHAUST SYSTEM AND INTAKE MANIFOLD CONTENTS page GENERAL INFORMATION EXHAUST SYSTEM ..... . 1 tems for vehicles operating on leaded fuel do not use GENERAL INFORMATION a catalytic converter.
  • Page 995 11 - 2 EXHAUST SYSTEM AND INTAKE MANIFOLD GENERAL INFORMATION (Continued) Fig. 2 Exhaust System—Leaded Fuel...
  • Page 996 LICENSE PLATE LAMP HAR- BUMPER REINFORCEMENT PUSH-IN FASTENERS PUSH-IN FASTENER PUSH-IN FASTENER DH/DP/PH-MODEL REAR FASCIA CP-MODEL HOOKS HOOKS NESS BUMPERS AND FRAME 13 - 1 BUMPERS AND FRAME CONTENTS page page BUMPERS ......1 SPECIFICATIONS .
  • Page 997 FRONT CROSSMEMBER SUSPENSION ENGINE RADIATOR CLOSURE PANEL PORT MODULE R ADIATOR SUPPORT SUP- CROSSMEMBER 13 - 2 BUMPERS AND FRAME FRAME INDEX page page REMOVAL AND INSTALLATION FRONT SUSPENSION CROSSMEMBER ..2 ENGINE SUPPORT MODULE .
  • Page 998 BUMPERS AND FRAME 13 - 3 REMOVAL AND INSTALLATION (Continued) (12) Remove bolts holding rear of crossmember to frame rail torque boxes. (13) Lower front suspension crossmember away from bottom of vehicle. INSTALLATION (1) Raise front suspension crossmember into posi- tion on vehicle.
  • Page 999 A = RADIATOR INSULATOR A = BOTTOM OF EXTENSION B = FENDER FRONT BOLT B = BOTTOM OF RADIATOR CLOSURE C = HOOD SLAM BUMPER C = REAR OF SUSPENSION CROSSMEMBER 13 - 4 BUMPERS AND FRAME D = STRUT FORWARD NUT D = PLP E = STRUT REARWARD NUT SPECIFICATIONS...
  • Page 1000 TO REAR MID PLP ZERO PLANE WINDSHIELD TO FRONT MID PLP TROUGH JOINT OPEN- B/S/A CORNER TO CORNER A = REAR MID PLP A = FRONT PLP A = REAR MID PLP B = CENTER OF TRACK BAR MOUNT B = ENGINE COMPARTMENT REAR PLP B = REAR RAIL TO FLOOR LOCATOR C = CENTER OF REAR CROSSMEMBER C = FRONT MID PLP...
  • Page 1001 13 - 6 BUMPERS AND FRAME SPECIFICATIONS (Continued)
  • Page 1002 FUEL SYSTEM 14 - 1 FUEL SYSTEM CONTENTS page page FUEL DELIVERY SYSTEM ....3 GENERAL INFORMATION ....1 FUEL INJECTION SYSTEM .
  • Page 1003 Problems that are the result of using methanol/ mance and lowest emissions operating on high qual- gasoline blends are not the responsibility of Chrysler ity unleaded gasoline, it will perform equally well Corporation and may not be covered by the vehicle and produce even lower emissions when operating on warranty.
  • Page 1004 FUEL SYSTEM 14 - 3 FUEL DELIVERY SYSTEM INDEX page page DESCRIPTION AND OPERATION FUEL TANK DRAINING ....10 ELECTRIC FUEL PUMP ....4 HOSES AND CLAMPS .
  • Page 1005 The fuel pump has a maximum deadheaded pres- FUEL TANK sure output of approximately 635 kPa (95 psi). The The fuel tanks of all Chrysler Motors built vehicles regulator adjusts fuel system pressure to approxi- are equipped with fuel and vapor controls that allow mately 338 kPa (49 psi).
  • Page 1006 FUEL INJEC- TORS FUEL INJECTOR TOP (FUEL ENTRY) NOZZLE INTAKE MANI- FUEL RAIL FOLD FUEL SYSTEM 14 - 5 DESCRIPTION AND OPERATION (Continued) supplied to the injector, the armature and needle FUEL PRESSURE REGULATOR move a short distance against a spring, allowing fuel The fuel system uses a nonadjustable pressure reg- to flow out the orifice.
  • Page 1007 RETAINER “EAR” CASING WINDOW WINDOW RETAINER TAB O RINGS NIPPLE FUEL RAIL TEST PORT FUEL PRES- SURE GAUGE C-4799-B 14 - 6 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) Fuel tubes connect fuel system components with (2) Connect Fuel Pressure Gauge C-4799B to test plastic quick-connect fuel fittings.
  • Page 1008 FUEL RELEASE ADAPTER 6539 BETWEEN FUEL PUMP AND FUEL FIL- TER. CONNECT GAUGE C-4799B TO ADAPTER. PRES- PRESSURE SPECIFICATIONS FUEL RESTRICTION BETWEEN FUEL PUMP INLET AND FUEL SUPPLY NIP- FUEL INLET STRAINER PLUGGED REPLACE INLET STRAINER FUEL PRESSURE STILL LOW BELOW SURIZE SYSTEM.
  • Page 1009 LEVEL SENSOR FULL STOP 50 OHMS MINIMUM SENSOR EMPTY STOP 1050 GROUND SENSOR FUEL PUMP MODULE CONNECTOR TER- FLOAT POSITION (HEIGHT) FUEL PUMP GROUND 10 OHMS FLOAT POSITION FLOAT MINAL PIN-OUTS LEVEL SENSOR SIGNAL FUEL PUMP VOLTAGE SUP- FUEL LEVEL SENSOR RESISTANCE 6539 FUEL...
  • Page 1010 CHECK POWER FEED AND GROUND BETWEEN PCM AND THE INJECTOR REFER GRAMS FOR COLOR CODES AND PIN TERMINAL NUM- TEST THE ENGINE CON- TROL SYSTEM WITH THE CIRCUIT IS OK. CHECK FOR FUEL DELIVERY AT SUS- PECT INJECTOR BY REMOV- ING THE INJECTOR FROM THE RAIL AND OBSERVING RESTRICTIONS IN THE RAIL...
  • Page 1011 FUEL RAIL HOSE C-4799-1 ATTACHED PORT TEST TEST PORT FUEL RAIL FUEL TANK DRAIN PLUG 14 - 10 FUEL SYSTEM SERVICE PROCEDURES FUEL SYSTEM PRESSURE RELEASE PROCEDURE—2.5L FUEL SYSTEM PRESSURE RELEASE PROCEDURE—2.0/2.4L CAUTION: Do not attempt to start the engine for several minutes to avoid hydrostatic lock.
  • Page 1012 SHOULDER (ON TUBE) WINDOW TAB (2) FUEL SYSTEM 14 - 11 SERVICE PROCEDURES (Continued) HOSES AND CLAMPS (1) Using a clean lint free cloth, clean the fuel tube nipple and retainer. Inspect all hose connections (clamps and quick con- (2) Prior to connecting the fitting to the fuel tube, nect fittings) for completeness and leaks.
  • Page 1013 FUEL TUBE PLASTIC INSTALLATION PUSH PUSH RETAINER REMOVAL PUSH PUSH QUICK CONNECT FITTING PUSH BATTERY POSITIVE BATTERY GROUND AIR CLEANER 14 - 12 FUEL SYSTEM SERVICE PROCEDURES (Continued) PLASTIC RETAINER RING TYPE FITTING the component. The plastic retainer ring must be This type of fitting can be identified by the use of a pressed squarely into the fitting body.
  • Page 1014 FUEL PUMP MODULE LOCK SPECIAL TOOL 6856 RING FUEL PUMP MOD- O-RING FUEL SYSTEM 14 - 13 REMOVAL AND INSTALLATION (Continued) FUEL PUMP RELAY (7) Remove fuel pump module and O-ring from tank (Fig. 15). Discard O-ring. The fuel pump relay is located in the PDC. The inside top of the PDC cover has a label showing relay and fuse location.
  • Page 1015 FUEL FILTER FUEL PUMP MODULE LOCK FUEL LINES RING FUEL FILTER REAR CROSSMEMBER FUEL FILL NECK 14 - 14 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) (2) From inside trunk, disconnect fuel pump mod- (10) Disconnect fuel supply line from the fuel ule wiring jumper from main body harness.
  • Page 1016 TABS (4) PRY BETWEEN REGULATOR AND HOUSING FUEL REGULATOR PRESSURE UPPER O-RING LOWER 0-RING TABS INLET STRAINER FUEL SYSTEM 14 - 15 REMOVAL AND INSTALLATION (Continued) FUEL PRESSURE REGULATOR (3) Fold tangs on regulator retainer over tabs on housing. The fuel pressure regulator is part of the fuel pump module (Fig.
  • Page 1017 FUEL LEVEL SENSOR CON- TERMINAL REMOVAL TOOL ELECTRICAL CONNECTOR RETAINING TABS NECTOR PRY AGAINST LEVEL SEN- OPENING IN MODULE LEVEL SENSOR FUEL LEVEL SENSOR 14 - 16 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) reservoir body lock over the locking tangs on the (3) Insert a screwdriver between the fuel pump strainer.
  • Page 1018 WRAP PUMP MODULE WIRES GROOVE CHANNEL LEVEL SENSOR REAR VIEW SENSOR LEVEL LEVEL SENSOR GROUND LEVEL SENSOR SIGNAL FUEL PUMP SUPPLY PUMP GROUND FUEL SYSTEM 14 - 17 REMOVAL AND INSTALLATION (Continued) INSTALLATION (4) Install level sensor wires in connector. Push (1) Insert level sensor wires into bottom of opening the wires up through the connector and then pull in module.
  • Page 1019 IGNITION COIL FUEL RAIL FUEL QUICK- CONNECTS LINE THROTTLE BODY SUPPORT BRACKET BOLT THROTTLE POSITION SENSOR MAP SENSOR INTAKE PERATURE TEM- SEN- FUEL SUP- FUEL INJEC- PLY LINE 14 - 18 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) (4) Disconnect electrical connectors from fuel injec- (3) Disconnect fuel supply tube from rail.
  • Page 1020 THROTTLE POSITION SEN- SPEED CONTROL CABLE BOLTS TUBE EGR TUBE THROTTLEBODY IDLE SUPPORT THROTTLE CABLE CONTROL BRACKET MOTOR BOLT RELEASE TANG FUEL FUEL RAIL RAIL SPACERS BOLTS FUEL SYSTEM 14 - 19 REMOVAL AND INSTALLATION (Continued) (14) Remove plenum support bracket bolt located rearward of EGR tube (Fig.
  • Page 1021 FUEL RAIL PLIERS FUEL INJECTOR INJECTOR CLIP INJECTOR CLIP FUEL INJECTOR FUEL RAIL 14 - 20 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) (7) Install EGR tube to plenum. Tighten EGR tube to intake manifold plenum screws to 11 N·m (95 in. lbs) torque.
  • Page 1022 FUEL FILLER HOSE FUEL TANK DRAIN PLUG HOSE CLAMP FUEL INLET TANK FUEL PUMP MODULE REAR CROSS MEM- FUEL TANK VAPOR FUEL FILTER FUEL TANK LINE FUEL SYSTEM 14 - 21 REMOVAL AND INSTALLATION (Continued) (6) Position a fuel approved container, with a WARNING: WRAP SHOP...
  • Page 1023 FILLER CAP FILLER NECK DASHPANEL PEDAL S HAFT CABLE 14 - 22 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) (10) Fill fuel tank, install filler cap, and connect (2) Reach behind the top of the pedal shaft and battery cable. push the retainer toward rear of vehicle (Fig. 42). It may be necessary to squeeze retainer ears together CAUTION: When using the ASD Fuel System Test, on dash side of pedal shaft.
  • Page 1024 SPEED THROTTLE LEVER CONTROL CABLE THROTTLE CABLE SPEED CONTROL THROTTLE CABLE CABLE THROTTLE LEVER THROTTLE CABLE CABLE TABS RELEASE TANG CLASP FUEL SYSTEM 14 - 23 REMOVAL AND INSTALLATION (Continued) THROTTLE CABLE—2.0/2.4L (3) Place cable through slot in top of pedal shaft. (4) Step on pedal and retainer will snap into place.
  • Page 1025 14 - 24 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) INSTALLATION SPECIFICATIONS (1) From the engine compartment, push the cable end fitting and grommet into the dash panel. TORQUE (2) Install cable housing (throttle body end) into the cable mounting bracket on the engine. DESCRIPTION TORQUE (3) Place cable through slot in top of pedal shaft.
  • Page 1026 FUEL SYSTEM 14 - 25 FUEL INJECTION SYSTEM INDEX page page GENERAL INFORMATION RADIATOR FAN RELAYS—PCM OUTPUT ..41 INTRODUCTION ..... . . 26 SCI RECEIVE—PCM INPUT .
  • Page 1027 14 - 26 FUEL SYSTEM SPECIFICATIONS (Continued) THROTTLE POSITION SENSOR (TPS)— VEHICLE SPEED SENSOR ....61 2.0/2.4L ......53 SPECIFICATIONS THROTTLE POSITION SENSOR (TPS)—2.5L .
  • Page 1028 FUEL SYSTEM 14 - 27 GENERAL INFORMATION (Continued) • The number of engine revolutions since cranking IGNITION SWITCH ON (ZERO RPM) MODE When the ignition switch activates the fuel injec- was initiated tion system, the following actions occur: During Start-up the PCM maintains ignition tim- •...
  • Page 1029 14 - 28 FUEL SYSTEM GENERAL INFORMATION (Continued) instrument panel). Also, the PCM stores an engine The PCM may receive a closed throttle input from misfire DTC in memory. the Throttle Position Sensor (TPS) when it senses an The PCM performs several diagnostic routines. abrupt decrease in manifold pressure.
  • Page 1030 POWER DISTRIBUTION CENTER POWERTRAIN CON- TROL MODULE FUEL SYSTEM 14 - 29 DESCRIPTION AND OPERATION (Continued) POWER DISTRIBUTION CENTER receives input signals from various switches and sen- sors that are referred to as PCM Inputs. Based on The Power Distribution Center (PDC) is located these inputs, the PCM adjusts various engine and next to the battery (Fig.
  • Page 1031 14 - 30 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) • Engine speed (crankshaft position sensor) AUTOMATIC SHUTDOWN (ASD) SENSE—PCM • Intake air temperature INPUT • Manifold absolute pressure The ASD sense circuit informs the PCM when the • Throttle position ASD relay energizes.
  • Page 1032 CAMSHAFT POSITION SEN- CAMSHAFT POSITION SEN- REAR OF CYLINDER HEAD MACHINED NOTCHES CRANKSHAFT POSITION SENSOR FUEL SYSTEM 14 - 31 DISTRIBUTOR PULSE RING SYNC GENERATOR SIGNAL DESCRIPTION AND OPERATION (Continued) 2.0/2.4L ENGINES The sensor also acts as a thrust plate to control The camshaft position sensor attaches to the rear camshaft endplay.
  • Page 1033 CRANKSHAFT DISTRIBUTOR GENERATOR OIL FILTER POSITION SENSOR HOLD DOWN BOLT CRANKSHAFT POSITION SENSOR ENGINE COOLANT TEMPER- ATURE SENDING UNIT ENGINE TEMPERATURE CAMSHAFT POSITION COOLANT SENSOR SENSOR COOLANT FILLER CAP 14 - 32 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) The crankshaft position sensor mounts to the When the engine is cold, the PCM will provide engine block behind the generator, just above the oil slightly richer air- fuel mixtures and higher idle...
  • Page 1034 ENGINE COOLANT TEMPER- ATURE SENSOR EXHAUST MANIFOLD OXYGEN CATALYTIC UPSTREAM SORS SEN- VERTOR CON- HEATED GEN SENSOR OXY- INLET COOLANT FILL TUBE NECK FUEL SYSTEM 14 - 33 DESCRIPTION AND OPERATION (Continued) The heating element in the sensor provides heat to the sensor ceramic element.
  • Page 1035 CATALYTIC CONVER- DOWNSTREAM HEATED OXYGEN SENSOR MAP/AIR INTAKE TEMPERATURE INTAKE MANIFOLD PCV VACUUM NIPPLE SENSOR INTAKE MANIFOLD TEMPERATURE SENSOR MAP SENSOR SEN- INTAKE PERATURE SENSOR THROTTLE BODY TEM- 14 - 34 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) DOWNSTREAM OXYGEN SENSOR The downstream heated oxygen sensor threads into the outlet pipe at the rear of the catalytic convertor (Fig.
  • Page 1036 STARTER MOTOR KNOCK SEN- POWER PRESSURE SWITCH STEERING FUEL SYSTEM 14 - 35 DESCRIPTION AND OPERATION (Continued) the intensity of the engine knock vibration increases, When power steering pump pressure exceeds 4137 the knock sensor output voltage also increases. kPa (600 psi), the switch is open. The PCM increases idle air flow through the IAC motor to prevent engine stalling.
  • Page 1037 TRANSMISSION RANGE SWITCH OUTPUT SPEED SENSOR PARK/NEUTRAL SWITCH (BLACK) THROTTLE THROTTLE POSITION SENSOR BODY THROTTLE POSITION SENSOR IDLE AIR CON- TROL MOTOR 14 - 36 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) SCI RECEIVE—PCM INPUT Along with inputs from other sensors, the PCM uses TPS input to determine current engine operat- SCI Receive is the serial data communication ing conditions.
  • Page 1038 TRANSAXLE SPEED SENSOR RETAINING BOLT SPEED SENSOR BATTERY POSITIVE BATTERY GROUND AIR CLEANER FUEL SYSTEM 14 - 37 DESCRIPTION AND OPERATION (Continued) MANUAL disables the A/C compressor clutch for several sec- The vehicle speed sensor is located in the transmis- onds.
  • Page 1039 ELECTRICAL CONNECTION DRIVER’S MASTER CYLINDER SIDE TOWER STRUT ELECTRICAL CONNECTION EGR VALVE EXHAUST VACUUM SUPPLY PRESSURE BACK DUTY CYCLE PURGE SOLENOID 14 - 38 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) The ASD relay and fuel pump relay are located in ELECTRIC EGR TRANSDUCER—PCM OUTPUT—...
  • Page 1040 VACUUM INLET EGR TRANSDUCER SERVICE PORT CAM SENSOR EGR VALVE EGR SOLENOID PRESSURE TRANSDUCER BACK BACK VACUUM TO EGR VALVE PRESSURE OUTLET HOSE THROTTLE POSITION SEN- IDLE CONTROL MOTOR THROTTLEBODY IDLE FRESH AIR CONTROL OPENING MOTOR FUEL SYSTEM 14 - 39 DESCRIPTION AND OPERATION (Continued) The solenoid/transducer and EGR valve mount to The throttle body has an air bypass passage that...
  • Page 1041 HOOD RELEASE DIAGNOSTIC DRIVER’S KICK PANEL NECTOR SIDE CON- IGNITION COIL NOZZLE FUEL INJECTOR SPARK SPARK PLUG CABLE INSULATOR PLUG SPARK PLUG CABLE AND BOOT TOP (FUEL ENTRY) IGNITION COILS 14 - 40 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) DATA LINK CONNECTOR The data link connector (diagnostic connector) links the DRB scan tool with the Powertrain Control Module (PCM).
  • Page 1042 IGNITION COIL DISTRIBUTOR HOUSING COIL TOWER FUEL SYSTEM 14 - 41 DESCRIPTION AND OPERATION (Continued) seconds and any diagnostic trouble codes stored in the PCM will be displayed. Refer to On-Board Diag- nostics in Group 25, Emission Control Systems Diag- nostic Trouble Code Descriptions.
  • Page 1043 THROTTLE POSITION THROTTLE SENSOR BODY IDLE CONTROL MOTOR IDLE AIR CONTROL MOTOR THROTTLE POSITION SEN- IDLE AIR CONTROL THROTTLE BODY MOTOR 14 - 42 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) the necessary position. This signal is sent over the CCD Bus to the instrument cluster. 5 VOLT SUPPLY—PCM OUTPUT The PCM supplies 5 volts to the following sensors: •...
  • Page 1044 REMOTE POWER DISTRIBUTION CEN- TIVE TERMINAL POSI- 40-WAY REMOTE NEGATIVE CONNEC- TERMINAL TORS PCV VALVE CONNECTION CONNECTION TO INTAKE MANIFOLD COVER VALVE INTAKE MANI- FOLD PCVVALVE PCV VALVE FRONT COVER VALVE FUEL SYSTEM 14 - 43 DIAGNOSIS AND TESTING VISUAL INSPECTION Before diagnosing or servicing the fuel injection system, perform a visual inspection for loose, discon- nected, or misrouted wires and hoses.
  • Page 1045 MAP/AIR INTAKE TEMPERATURE INTAKE MANIFOLD PCV VACUUM NIPPLE SENSOR INTAKE MANIFOLD TEMPERATURE SENSOR MAP SENSOR SEN- INTAKE PERATURE SENSOR THROTTLE BODY TEM- IGNITION COIL FUEL RAIL FUEL QUICK- CONNECTS LINE SPARK INSULATOR PLUG SPARK PLUG CABLE IGNITION COILS FUEL SUP- FUEL INJEC- PLY LINE 14 - 44...
  • Page 1046 SPARK PLUG CABLES ELECTRICAL CONNECTION DISTRIBUTOR DRIVER’S MASTER CYLINDER SIDE CONNEC- TOWER STRUT TORS STARTER MOTOR KNOCK SEN- ENGINE TEMPERATURE CAMSHAFT POSITION COOLANT SENSOR SENSOR DUTY CYCLE PURGE CAMSHAFT POSITION SEN- SOLENOID FUEL SYSTEM 14 - 45 DIAGNOSIS AND TESTING (Continued) 2.5L (13) Check electrical connection at the knock sen- (b) Inspect distributor connectors (Fig.
  • Page 1047 ENGINE COOLANT TEMPER- ATURE SENDING UNIT ENGINE COOLANT TEMPER- ATURE SENSOR CRANKSHAFT VACUUM INLET EGR TRANSDUCER SERVICE PORT CAM SENSOR GENERATOR EGR VALVE OIL FILTER POSITION SENSOR EGR SOLENOID PRESSURE TRANSDUCER BACK BACK VACUUM TO EGR VALVE PRESSURE OUTLET HOSE COOLANT INLET COOLANT FILL...
  • Page 1048 DISTRIBUTOR OUTPUT SPEED SENSOR SPEED SENSOR PINION HOLD DOWN BOLT RETAINING BOLT VEHICLE SPEED SENSOR MANUAL VALVE LEVER CRANKSHAFT POSITION SENSOR POWER PRESSURE SWITCH STEERING EXHAUST MANIFOLD OXYGEN CATALYTIC UPSTREAM SORS SEN- VERTOR CON- HEATED GEN SENSOR OXY- FUEL SYSTEM 14 - 47 DIAGNOSIS AND TESTING (Continued) Fig.
  • Page 1049 DOWNSTREAM HEATED OXYGEN REAR SEAT BACK SENSOR FUEL PUMP MODULE CON- TRUNK FLOOR NECTOR RUBBER GROMMET CATALYTIC VERTER CON- NUMBER TERMINAL LEGEND COMMON FEED IDENTIFICATION COIL GROUND COIL BATTERY NORMALLY OPEN NORMALLY CLOSED 14 - 48 FUEL SYSTEM DIAGNOSIS AND TESTING (Continued) Fig.
  • Page 1050 TER- MINAL 1 TER- MINAL 3 TER- MINAL 2 FUEL SYSTEM 14 - 49 DIAGNOSIS AND TESTING (Continued) minals 87 and 30. The ohmmeter should not show KNOCK SENSOR continuity between relay terminals 87A and 30. The knock sensor can be tested with a digital volt- (8) Disconnect jumper wires.
  • Page 1051 THROTTLEBODY PURGE HOSE THROTTLE BODY PURGE SPECIAL TOOL #6457 SPECIAL PURGE NIP- NIP- #6457 TOOL PURGE HOSE 14 - 50 FUEL SYSTEM DIAGNOSIS AND TESTING (Continued) The Throttle Position Sensor (TPS) can be tested (4) Use a piece of hose to attach Air Metering Ori- with a digital voltmeter.
  • Page 1052 FUEL SYSTEM 14 - 51 DIAGNOSIS AND TESTING (Continued) (12) Shut off engine. Odometer Reading IDLE RPM (13) Remove Air Metering Orifice 6457. Install purge hose. Below 1000 Miles 550 - 1300 RPM (14) Remove cap from PCV valve. Connect hose to Above 1000 Miles 600 - 1300 RPM PCV valve.
  • Page 1053 SPEED THROTTLE LEVER CONTROL CABLE THROTTLE CABLE INTAKE MANIFOLD CABLE TABS RE-USABLE CLASP GASKET 14 - 52 FUEL SYSTEM REMOVAL AND INSTALLATION (5) Remove EVAP purge hose from nipple on throt- tle body. THROTTLE BODY—2.0/2.4L ENGINES (6) Remove 2 screws holding cable mounting bracket and support bracket.
  • Page 1054 SPEED CONTROL THROTTLE CABLE CABLE THROTTLE LEVER THROTTLE CABLE THROTTLE POSITION SENSOR RELEASE TANG IDLE AIR CON- TROL MOTOR FUEL SYSTEM 14 - 53 REMOVAL AND INSTALLATION (Continued) THROTTLE BODY—2.5L ENGINE INSTALLATION (1) Attach electrical connectors to idle air control motor and throttle position sensor.
  • Page 1055 THROTTLE SHAFT TABS THROTTLE RETAINING SCREWS POSITION SENSOR 14 - 54 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) INSTALLATION REMOVAL (1) The throttle shaft end of the throttle body (1) Disconnect EVAP purge hose from throttle slides into a socket in the TPS (Fig. 77). The socket body.
  • Page 1056 THROTTLE POSITION SENSOR THROTTLE SHAFT TABS IDLE AIR CONTROL MOTOR RETAINER SCREWS IDLE AIR CONTROL MOTOR IDLE AIR CON- TROL MOTOR FUEL SYSTEM 14 - 55 REMOVAL AND INSTALLATION (Continued) (5) Install EVAP purge hose to throttle body nip- ple. Fig.
  • Page 1057 MAP/AIR PCV VACUUM NIPPLE INTAKE MANIFOLD TEMPERATURE SENSOR 14 - 56 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) (2) Carefully place idle air control motor into INSTALLATION throttle body. NOTE: To eliminate a chance of transmitting noises (3) Install mounting screws. Tighten screws to 3 into the body, make sure the hood release cable is N·m (25 in.
  • Page 1058 INTAKE TEMPERATURE INTAKE MANIFOLD SENSOR MAP SENSOR SEN- INTAKE PERATURE SENSOR THROTTLE BODY TEM- AUXILIARY JUMPER TERMINAL AIR CLEANER HOUSING POWERTRAIN CONTROL MODULE BRACKET SCREWS LEFT STRUT TOWER FUEL SYSTEM 14 - 57 REMOVAL AND INSTALLATION (Continued) MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR 2.5L (4) 3.4 N·m (30 in.
  • Page 1059 EXHAUST PIPE FLANGE CROW UPSTREAM OXYGEN SEN- WRENCH FOOT CATALYTIC UPSTREAM VERTOR CON- HEATED GEN SENSOR OXY- 14 - 58 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) (4) Lift PCM up to remove it from vehicle. UPSTREAM HEATED OXYGEN SENSOR—2.5L INSTALLATION REMOVAL (1) Install PCM.
  • Page 1060 DOWNSTREAM HEATED MOUNTING BOLTS OXYGEN SENSOR CATALYTIC AIR INLET RES- CONVERTOR ONATOR RESONATOR INLET RESONATOR CLAMP SCREW FUEL SYSTEM 14 - 59 REMOVAL AND INSTALLATION (Continued) 771-64 or equivalent. New sensors have compound on (2) Loosen screw holding resonator to throttle body the threads and do not require an additional coating.
  • Page 1061 AIR INLET RESONA- AIR INLET RES- ONATOR RESONATOR B OLT CLEANER HOUSING HOUSING CLEANER HOUSING COVER AIR CLEANER ELEMENT CLASPS HOUSING COVER 14 - 60 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) 2.5L FILTER ELEMENT REPLACEMENT REMOVAL REMOVAL (1) Unfasten clasps on rear of air cleaner housing (1) Remove bolt holding resonator to intake mani- cover.
  • Page 1062 ENGINE COOLANT TEMPER- ATURE SENDING UNIT ENGINE TEMPERATURE CAMSHAFT POSITION COOLANT SENSOR SENSOR HOUSING AIR CLEANER ELEMENT COOLANT HOUSING FILLER CAP COVER FUEL SYSTEM 14 - 61 REMOVAL AND INSTALLATION (Continued) ENGINE COOLANT TEMPERATURE SENSOR 2.5L The engine coolant temperature sensor is located 2.0L next to the fill neck (Fig.
  • Page 1063 TRANSAXLE SPEED SENSOR RETAINING BOLT SPEED SENSOR 14 - 62 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) INSTALLATION SPECIFICATIONS The speed sensor gear meshes with a gear on the output shaft. VECI LABEL (1) With O-ring in place, install sensor. If anything differs between the specifications found (2) Install mounting bolt.
  • Page 1064 FUEL SYSTEM 14 - 63 SPECIAL TOOLS FUEL Spanner Wrench 6856 Extractor C–4334 Metering Orifice Pressure Gauge Assembly C–4799–B Fuel Line Tool Fuel Pressure Test Adapter 6539 Fuel Line Adapter...
  • Page 1065 14 - 64 FUEL SYSTEM SPECIAL TOOLS (Continued) Fuel Line Adapter 1/4...
  • Page 1066 Problems that are the result of using methanol/ can cause damage and should be reported to your gasoline blends are not the responsibility of Chrysler dealer immediately. Engine damage as a result of Corporation and may not be covered by the vehicle heavy knock operation may not be covered by the warranty.
  • Page 1067 14 - 2 FUEL SYSTEM IMMOBILIZER INDEX page page GENERAL INFORMATION IMMOBILIZER TRANSMITTER ....3 ARMING ....... . 4 VEHICLE IMMOBILIZER SYSTEM .
  • Page 1068 Powertrain Control Module (PCM) and/or the (3) Allowing a cool-down period between starts, go DRB scan tool on the Chrysler Collision Detection back to Step 1 a total of twenty times. After twenty (CCD) data bus network.
  • Page 1069 14 - 4 FUEL SYSTEM GENERAL INFORMATION (Continued) driver side end of the heater-A/C housing. The ing, the system will have to be actively disarmed receiver is connected to the dash panel cross-body using one of the transmitters. wiring harness. The power-up mode logic also applies if the battery For diagnosis of the vehicle immobilizer receiver or goes dead, and battery jump-starting is attempted.
  • Page 1070 FUEL SYSTEM 14 - 5 FUEL INJECTION SYSTEM INDEX page GENERAL INFORMATION MODES OF OPERATION — LEADED FUEL PACKAGE ......5 ibration use predetermined parameters, based on GENERAL INFORMATION inputs recieved from the Throttle Position Sensor...
  • Page 1072 STEERING 19 - 1 STEERING CONTENTS page page GENERAL INFORMATION ....1 SPEED PROPORTIONAL POWER STEERING POWER STEERING GEAR ....36 GEAR .
  • Page 1073 19 - 2 STEERING DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION Objectionable Hiss Or Whistle 1. Damaged or mispositioned 1. Check for proper seal between steering column coupler to dash steering column coupler and dash panel seal. seal. 2. Noisy valve in power steering 2.
  • Page 1074 STEERING 19 - 3 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION Power steering pump growl results from the development of high pressure fluid flow. Normally this noise should not be high enough to be objectionable. Abnormal situations, such as a low oil level causing aeration or hose touching the vehicle body, can create a noise level that could bring complaints.
  • Page 1075 19 - 4 STEERING DIAGNOSIS AND TESTING (Continued) BINDING STICKING SEIZED CONDITION POSSIBLE CAUSES CORRECTION CATCHES, STICKS IN CERTAIN 1. Low power steering fluid level. 1. Fill power steering fluid reservoir POSITIONS OR IS DIFFICULT TO to specified level and perform TURN.
  • Page 1076 STEERING 19 - 5 DIAGNOSIS AND TESTING (Continued) LOW ASSIST, NO ASSIST, HARD STEERING CONDITION POSSIBLE CAUSES CORRECTION STIFF, HARD TO TURN, 1. Tires not properly inflated. 1. Inflate tires to specified pressure. SURGES, MOMENTARY INCREASE IN EFFORT WHEN TURNING. 2.
  • Page 1077 19 - 6 STEERING DIAGNOSIS AND TESTING (Continued) POOR RETURN TO CENTER CONDITION POSSIBLE CAUSES CORRECTION STEERING WHEEL DOES NOT 1. Tires not 1. Inflate tires to specified pressure. WANT TO RETURN TO CENTER inflated to specified pressure. POSITION. 2. Improper front wheel alignment. 2.
  • Page 1078 STEERING 19 - 7 DIAGNOSIS AND TESTING (Continued) LOOSE STEERING CONDITION POSSIBLE CAUSES CORRECTION EXCESSIVE STEERING WHEEL 1. Air in the fluid of the power 1. Fill power steering fluid reservoir KICKBACK OR TO MUCH steering system. to the specified level. Perform STEERING WHEEL FREE PLAY.
  • Page 1079 19 - 8 STEERING DIAGNOSIS AND TESTING (Continued) VEHICLE LEADS TO THE SIDE CONDITION POSSIBLE CAUSES CORRECTION STEERING WHEEL DOES NOT 1. Radial tire lead. 1.Rotate tires as recommended in WANT RETURN TO CENTER the Tire And Wheel Group of this POSITION.
  • Page 1080 STEERING 19 - 9 DIAGNOSIS AND TESTING (Continued) FOAMY OR MILKY POWER STEERING FLUID CONDITION POSSIBLE CAUSES CORRECTION AERATION AND OVERFLOW OF 1. Air leaks. 1. Check for an air leak into the FLUID. power steering system as described under Sucking Air Diagnosis and correct condition.

  • Page 1081: Power Steering Pump

    POWER PUMP FLUID SUPPLY POWER PUMP DISCHARGE STEERING STEERING FITTING FITTING POWER POWER POWER STEERING PUMP STEERING STEERING SHAFT SEAL HOUSING SHAFT PUMP PUMP 19 - 10 STEERING POWER STEERING PUMP INDEX page page DESCRIPTION AND OPERATION POWER STEERING FLUID SUPPLY HOSE POWER STEERING FLUID PRESSURE RESERVOIR TO POWER STEERING PUMP SWITCH...
  • Page 1082 WIRING CONNECTOR HARNESS POWER STEERING PRES- SURE SWITCH SPEED STEERING SOLENOID MOD- POWER STEERING GEAR PROPORTIONAL STEERING 19 - 11 DESCRIPTION AND OPERATION (Continued) • Power steering fluid reservoirs, related compo- POWER STEERING FLUID PRESSURE SWITCH nents and attaching hardware. On some vehicles equipped with power steering, a •...
  • Page 1083 POWER POWER STEERING PUMP STEERING PRESSURE HOSE ADAPTER PUMP TINGS FIT- SPECIAL TOOL 6815 19 - 12 STEERING DIAGNOSIS AND TESTING (Continued) flow test is performed using Pressure/Flow Tester, (5) Start engine and let idle long enough to circu- Special Tool 6815 (Fig. 3). late power steering fluid through flow/pressure test and get air out of fluid.
  • Page 1084 POWER FLOW POWER VALVE FITTING STEERING CONTROL STEERING PUMP HOUSING PUMP POWER STEERING PRESSURE HOSE ABS HYDRAULIC CON- POWER STEERING PRES- FLUID POWER STEERING FLUID SURE HOSE TROL SUPPLY HOSE UNIT SHIELD HEAT STEERING 19 - 13 SERVICE PROCEDURES (Continued) Wipe reservoir filler cap free of dirt.
  • Page 1085 SUCTION POWER ATTACHING BOLT STEERING FITTING PUMP WIRING CONNECTOR HARNESS POWER STEERING PRES- SURE SWITCH SPEED STEERING SOLENOID MOD- POWER STEERING GEAR PROPORTIONAL POWER STEERING PUMP SUCTION FITTING 19 - 14 STEERING SERVICE PROCEDURES (Continued) (3) Remove and discard O-ring seal from fitting. (3) Install power steering fluid supply hose on suc- tion port fitting, being sure hose clamp is installed on ASSEMBLE...
  • Page 1086 POWER STEERING RETURN HOSE POWER POWER STEERING PRES- POWER BOLT TO BE REMOVED ROUTING BRACKET PRESSURE HOSE STEERING POWER STEERING GEAR SURE HOSE RESERVOIR STEERING BRACKET ROUTING FLUID BOLT POWER STEERING RETURN HOSE STEERING 19 - 15 REMOVAL AND INSTALLATION (Continued) ing harness connector is fully engaged with locking (2) Lower the front suspension crossmember far tab on power steering pressure switch.
  • Page 1087 EGR VALVE CYLINDER HEAD POWER ROUTING BRACKET RETURN HOSE ROUTING STEERING POWER ROUTING RETURN HOSE ATTACHING BOLTS ROUTING BRACKETS STEERING BRACK- BRACKET POWER STEERING PRES- POWER PRESSURE HOSE SURE HOSE STEERING POWER POWER STEERING PUMP STEERING PRESSURE HOSE PUMP 19 - 16 STEERING REMOVAL AND INSTALLATION (Continued) (7) Remove the power steering pressure hose from...
  • Page 1088 POWER STEERING PRES- SURE HOSE TORQUE WRENCH POWER STEERING RETURN STEERINGGEAR HOSE STEERING 19 - 17 REMOVAL AND INSTALLATION (Continued) (Fig. 14) tighten the power steering pressure hose (15) Add power steering fluid if necessary. tube nut to a torque of 31 N·m (275 in. lbs.). (16) Lower the vehicle and turn the steering wheel slowly from lock to lock.
  • Page 1089 POWER POWER POWER POWER HOSE CLAMP STEERING STEERING STEERING RETURN HOSE SUPPLY HOSE STEERING RESERVOIR POWER STEERING PRES- RETURN HOSE FLUID FLUID FLUID FLUID SURE HOSE POWER STEERING RESERVOIR FLUID POWER STEERING RETURN HOSE POWER POWER STEERING PRES- RETURN HOSE LEFT FRAME RAIL BOLT TO BE REMOVED TRANSAXLE...
  • Page 1090 POWER RETURN HOSE ROUTING STEERING ROUTING ATTACHING BOLTS ROUTING BRACKETS BRACK- BRACKET POWER PRESSURE HOSE STEERING STEERING 19 - 19 REMOVAL AND INSTALLATION (Continued) If vehicle is equipped with a 2.5 liter If vehicle is equipped with a 2.5 liter engine, remove the 2 routing brackets (Fig.
  • Page 1091 POWER POWER POWER STEERING PUMP STEERING STEERING SUPPLY HOSE RESERVOIR FLUID FLUID 19 - 20 STEERING REMOVAL AND INSTALLATION (Continued) POWER STEERING FLUID SUPPLY HOSE CAUTION: Care must be used when installing power steering fluid supply hose on power steering RESERVOIR TO POWER STEERING PUMP 2.0L fluid reservoir.
  • Page 1092 INTAKE MANIFOLD POWER STEERING PUMP POWER STEERING FLUID POWER STEERING POWER FLUID STEERING FLUID POWER STEERING FLUID SUPPLY HOSE (TO PUMP) RESERVOIR RETURN HOSE SUPPLY HOSE STEERING 19 - 21 REMOVAL AND INSTALLATION (Continued) POWER STEERING FLUID SUPPLY HOSE RESERVOIR TO POWER STEERING PUMP 2.5L ENGINE REMOVE (1) Using a siphon pump, remove as much power...
  • Page 1093 SPLASH SHIELD POWER POWER STEERING PRES- BRAKE TUBE STEERING SURE HOSE PUMP POWER STEERING PRESSURE HOSE ABS HYDRAULIC CON- POWER FRONT BOLT STEERING FLUID POWER STEERING FLUID MOUNTING TROL BRACKET CAST MOUNTING BRACKET PUMP SUPPLY HOSE UNIT ALUMINUM SHIELD HEAT POWER STEERING PUMP...
  • Page 1094 GROMMET RETAINER AND CABLE ROUTING BRACKET WHEEL SPEED SEN- SPEED DRIVESHAFT ROUTING BRACKET SOR CABLE SENSOR HEAT SHIELD POWER STEERING PUMP BOLT CAST STEERING KNUCKLE B OLT ALUMINUM SHOCK ABSORBER BRACKET WHEEL SPEED SEN- WHEEL SEALING VEHICLE WIRING HARNESS CABLE ROUTING HOLE INNER FENDER GROMMET EXTENSION...
  • Page 1095 POWER STEERING PRES- SURE HOSE ADJUSTING HOLE P OWER STEERING PUMP BOLT FRONT MOUNTING BRACKET POWER STEERING PUMP DRIVE BELT 19 - 24 STEERING REMOVAL AND INSTALLATION (Continued) INSTALL (1) Install power steering pump and mounting bracket as an assembly back in vehicle, using reverse order of removal.
  • Page 1096 SPLASH SHIELD POWER STEERING PUMP POWER POWER STEERING PRES- STEERING PRESSURE HOSE ABS HYDRAULIC CON- FLUID SURE HOSE POWER STEERING FLUID TROL POWER SUPPLY HOSE UNIT STEERING SHIELD PUMP HEAT STEERING 19 - 25 REMOVAL AND INSTALLATION (Continued) (25) Start engine, then slowly turn steering wheel (7) Remove the power steering fluid pressure hose right and left several times until lightly contacting from pressure fitting on power steering pump (Fig.
  • Page 1097 ACCESSORY POWER ADJUSTING MOUNTING BRACKET ING PUMP SLOT STEER- DRIVE ADJUSTING SLOT BOLT BOLT POWER PUMP MOUNTINGBRACKET POWER STEERING STEERING FRONT PUMP ENGINE ACCESSORY DRIVE BOLT BRACKET 19 - 26 STEERING REMOVAL AND INSTALLATION (Continued) (9) Remove bolt at adjusting slot in accessory drive (11) Remove the power steering pump drive belt mounting bracket, (Fig.
  • Page 1098 POWER STEERING PUMP POWER MOUNTING BRACKET ADJUSTING HOLE STEERING PUMP STEERING 19 - 27 REMOVAL AND INSTALLATION (Continued) (9) Install a 1/2 in. breaker bar in the square CAUTION: Do not use automatic transmission fluid adjusting hole in the front power steering pump in power steering system.
  • Page 1099 POWER POWER STEERING BOLT STEERING COOLER FLUID COOLER POWER FLUID BUMPER STEERING FORCEMENT HOSE CLAMPS HOSES FLUID REIN- RETAINING PIN INTERMEDIATE SHAFT STEERING BRAKE P EDAL SHAFT GEAR COUPLER PINCH BOLT 19 - 28 STEERING REMOVAL AND INSTALLATION (Continued) (3) Remove the hose clamps (Fig. 37) from the (5) Lower the vehicle to a point where front tires power steering fluid hoses.
  • Page 1100 BRACKET LEFT FRAME RAIL POWER STEERING BOLT COOLER FLUID POWER ROUTING CLIP POWER STEERING STEERING HOSE CLAMPS COOLER LINES HOSES FLUID FLUID RETURN HOSE LEFT FRAME RAIL POWER TRANSAXLE PRESSURE HOSE POWER STEERING GEAR STEERING HOSE CLAMP POWER STEERING COOLER CLIP LINES POWER STEERING RETURN...
  • Page 1101 POWER STEERING PRES- SURE HOSE TORQUE WRENCH POWER STEERING RETURN STEERINGGEAR HOSE 19 - 30 STEERING REMOVAL AND INSTALLATION (Continued) (2) Install the cooler lines in the routing clip on (10) Install the front fascia and grill on the vehi- the left frame rail (Fig.
  • Page 1102 POWER POWER FLUID RESERVOIR FLUID RESERVOIR STEERING STEERING MOUNTING BOLTS ATTACHING B OLTS STEERING 19 - 31 REMOVAL AND INSTALLATION (Continued) (6) Remove bolts attaching power steering fluid (2) Install power steering fluid return and supply reservoir to engine (Fig. 45) or (Fig. 46). hose, on power steering fluid reservoir fittings.
  • Page 1103 POWER POWER POWER SPECIAL TOOL C-4333 PUMP PULLEY STEERING STEERING STEERING PUMP OR C-4068 PULLEY PUMP POWER STEERING PUMP PULLEY MUST BE STARTED SQUARELY ON SHAFT OF POWER STEERING PUMP AS SHOWN VISE POWER POWER STEERING PUMP SPECIAL SPECIAL TOOL 6936 STEERING C-4063 TOOL...
  • Page 1104 POWER SPECIAL TOOL C-4333 PUMP PULLEY STEERING OR C-4068 VISE POWER POWER POWER POWER STEERING PUMP SPECIAL TOOL 6936 STEERING STEERING STEERING PUMP PULLEY PULLEY PUMP PUMP POWER STEERING PUMP PULLEY MUST BE STARTED SQUARELY ON SHAFT OF POWER STEERING PUMP AS SHOWN STEERING 19 - 33 DISASSEMBLY AND ASSEMBLY (Continued)
  • Page 1105 SPECIAL C-4063 TOOL WRENCHES POWER STEERING PUMP POWER STEERING PUMP BRACKET 19 - 34 STEERING DISASSEMBLY AND ASSEMBLY (Continued) (4) Mount Installer, Special Tool C-4063 in internal SPECIFICATIONS threads of the power steering pump shaft and against Special Tool 6936 on power steering pump POWER STEERING PUMP FLOW SPECIFICATIONS pulley (Fig.
  • Page 1106 STEERING 19 - 35 SPECIAL TOOLS POWER STEERING PUMP P/S System Analyzer 6815 Installer C-4063B Puller C-4333...

  • Page 1107: Power Steering Gear

    JAM NUT INNER TIE ROD STEERING STEERING GEAR BOOT SHAFT GEAR STEERING FLUID LINES MOUNTING BUSHING GEAR POWER POWER PRESSURE SWITCH GEAR HOUSING STEERING STEERING STEERING GEAR BOOT INNER TIE ROD JAM NUT TIE ROD END TIE ROD EN 19 - 36 STEERING POWER STEERING GEAR INDEX...
  • Page 1108 POWER STEERING PRES- FLOW CONTROL VALVE FIT- POWER STEERING PUMP SURE HOSE ADAPTER TING TINGS FIT- SPECIAL TOOL 6815 STEERING 19 - 37 DIAGNOSIS AND TESTING (3) Connect the inlet hose on the Pressure Gauge, Special Tool 6815 using required adapter, Special POWER STEERING PUMP FLOW RATE AND Tool 6972 to the pressure fitting on the power steer- ing pump.
  • Page 1109 MASTER CYLINDER REMOTE GROUND CABLE LEFT GROUNDSTUD AIR CLEANER GROUND TOWER STRUT STUD STEERING HEAT SHIELD RETAINING PIN INTERMEDIATE KNUCKLE END STUD SHAFT TIE ROD END STEERING BRAKE P EDAL SHAFT GEAR COUPLER LEFT STRUT TOWER SPEED CONTROL SERVO PINCH BOLT 19 - 38 STEERING DIAGNOSIS AND TESTING (Continued)
  • Page 1110 LOWER CONTROL ARM SPECIAL TOOL MB-991113 TIE ROD END STEERING HEAT SHIELD KNUCKLE FRONT CROSSMEMBER TO BODY, FRONT TO BACK LOCATING FRONT FRAME RAIL TO CROSS- MEMBER FRONT LOWER CON- FRAME CROSSMEMBER ATTACHING BRACKET LOWER CONTROL ARM TRANSAXLE OUTER TIE ROD TROL ARM CROSSMEMBER INNER TIE ROD...
  • Page 1111 STABILIZER BAR BUSHING FRONT FRAME CROSSMEMBER LOWER ATTACHING BOLTS STABILIZER BAR CROSSMEMBER RAIL VEHICLE BODY BRACKET SUSPENSION CONTROL CLAMP FRONT CROSSMEMBER SUSPENSION FRONT CROSSMEMBER TO BODY SIDE TO SIDE LOCATING SUSPENSION MARK FRONT ENGINE CROSSMEMBER SUSPENSION THRU-BOLT SUPPORT BRACKET SHOCK ABSORBER ATTACHING B OLTS CLEVIS LOWER...
  • Page 1112 ENGINE TRANSAXLE REAR SUPPORT BRACKET MOUNTING BRACKET ATTACHING BOLTS SUPPORT BRACKET BOLT STABILIZER BAR FRONT SUSPENSION CROSS- CROSSMEMBER MEMBER STEERING GEAR FRONT POWER CROSSMEMBER PRESSURE HOSE CROSSMEMBER FRONT SUSPENSION POWER STEERING GEAR STEERING MOUNTING BOLT POWER STEERING RETURN CROSSMEMBER STABILIZER BAR LOWER CONTROL ARM MOUNTING BOLT HOSE...
  • Page 1113 FRONT STEERING GEAR FRONT CROSSMEMBER SUSPENSION REAR MOUNTING BOLT FRONT MOUNTING ISOLATOR BOLT ATTACHING CROSSMEMBER SUSPENSION BOLTS (2) SADDLE BRACKET FRONT SUPPORTED ANTILOCK BRAKES STEERINGGEAR STEERING GEAR CROSSMEMBER CONTROL UNIT SUSPENSION HYDRAULIC 19 - 42 STEERING REMOVAL AND INSTALLATION (Continued) 21) to the front suspension crossmember.
  • Page 1114 HEAT SHIELD CROWFOOT 11/32 SOCKET STEERING KNUCKLE TORQUE WRENCH BALL JOINT CAP LOWER CONTROL ARM SHOCK ABSORBER CLEVIS TIE ROD END STEERING 19 - 43 REMOVAL AND INSTALLATION (Continued) (8) Install vehicle wiring harness connector (Fig. 18) onto power steering fluid pressure switch on steering gear assembly.
  • Page 1115 SCREWDRIVER ISOLATOR STEERING MOUNTINGBRACKET BUSHING GEAR SLEEVE STEERING STEERING STEERING ING BOLT ISOLATOR BUSH- GEAR GEAR ING BRACKET ING BRACKET MOUNT- MOUNT- GEAR MOUNT- STEERING ING BOLT ISOLATOR BUSH- STEERING GEAR ISOLATOR GEAR MOUNT- BUSHING SLEEVE 19 - 44 STEERING REMOVAL AND INSTALLATION (Continued) (24) Check front alignment and adjust the front Toe setting on the vehicle.
  • Page 1116 OUTER TIE ROD INNER TIE ROD JAM NUT CLAMP INNER TIE ROD TIE ROD BOOT STEERING GEAR STEERING GEAR CLAMP SPECIAL C-4975A TOOL WHEN INSTALLING CLAMP TIGHTEN THERE IS NO GAP HERE INNER TOOL BOOT CLAMP UNTIL TIE ROD BOOT STEERING 19 - 45 DISASSEMBLY AND ASSEMBLY (Continued)
  • Page 1117 OUTER TIE ROD JAM NUT INNER TIE ROD STEERING HEAT SHIELD KNUCKLE END STUD LOWER CONTROL ARM TIE ROD END SPECIAL TOOL MB-991113 TIE ROD END HEAT SHIELD STEERING KNUCKLE 19 - 46 STEERING DISASSEMBLY AND ASSEMBLY (Continued) (3) Lubricate inner tie rod boot groove with sili- (2) Remove nut attaching outer tie rod end to cone type lubricant, then install tie rod boot to inner steering knuckle (Fig.
  • Page 1118 HEAT SHIELD CROWFOOT 11/32 SOCKET STEERING KNUCKLE TORQUE WRENCH TIE ROD END STEERING 19 - 47 DISASSEMBLY AND ASSEMBLY (Continued) (4) Install tie rod end into the steering knuckle. SPECIFICATIONS Start tie rod end to steering knuckle attaching nut onto stud of tie rod end. While holding stud of tie rod STEERING GEAR FASTENER TORQUE end stationary, tighten tie rod end to steering SPECIFICATIONS...
  • Page 1119 TIE ROD END JAM NUT INNER TIE ROD TIE ROD BOOT MOUNTING ISOLATOR STEERING HOUSING STEERING GEAR GEAR TUBES FLUID SOLENOID TROL MODULE CON- INNER TIE ROD SOLENOID CONTROL VALVE JAM NUT BOOT 19 - 48 STEERING SPEED PROPORTIONAL POWER STEERING GEAR INDEX page page...
  • Page 1120 SOLENOID CONTROL MOD- STEERING WIRING HARNESS TO FLUID LINES CONTROL SOLENOID GEAR SOLENOID VEHICLE STEERING CONNECTOR HARNESS GEAR WIRING MODULE ATTACHING CLIPS STEERING GEAR SOLENOID CONTROL MOD- POWER FLUID LINES STEERING STEERING 19 - 49 DIAGNOSIS AND TESTING REMOVE (1) Remove wiring harness connectors from sole- SPEED PROPORTIONAL STEERING SYSTEM noid control module (Fig.
  • Page 1121 SOLENOID CONTROL MOD- STEERING WIRING HARNESS TO FLUID LINES CONTROL SOLENOID GEAR SOLENOID VEHICLE STEERING CONNECTOR HARNESS GEAR WIRING 19 - 50 STEERING REMOVAL AND INSTALLATION (Continued) REMOVE (1) Remove electrical connector to the solenoid con- trol valve, at solenoid control module (Fig. 4). Fig.

  • Page 1122: Steering Column

    INTERMEDIATE SHAFT COU- PLER INTERMEDIATE INTERMEDIATE SHAFT FLEX SHAFT LOWER STEERING COLUMN MOUNTING BRACKET JOINT STEERING COLUMN UPPER MOUNTING BRACKET TILT TORSION SPRING TILT LEVER SHIPPING PIN LOCK CYLINDER HOUSING IGNITION SWITCH SWITCH HOUSING HALO LIGHT STEERING 19 - 51 STEERING COLUMN INDEX page...
  • Page 1123 19 - 52 STEERING DIAGNOSIS AND TESTING WARNING: THE AIR BAG SYSTEM IS A SENSITIVE, COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE STEERING COLUMN ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL THE AIR BAG SYSTEM COMPONENTS YOU MUST For diagnosis of conditions relating to the steering FIRST DISCONNECT AND ISOLATE THE BATTERY column, refer to the steering system diagnosis charts, NEGATIVE (GROUND) CABLE.
  • Page 1124 MASTER CYLINDER REMOTE GROUND CABLE LEFT GROUNDSTUD AIR CLEANER GROUND TOWER STRUT STUD FUSE CENTER COVER PANEL BEZEL SCREW COVER LEFT STRUT TOWER SPEED CONTROL SERVO STEERING 19 - 53 REMOVAL AND INSTALLATION (Continued) REMOVE (4) Remove fuse panel cover from left end of (1) Remove remote ground cable (Fig.
  • Page 1125 LOWER SCREW LOCATIONS CONNECTOR LOCK ELECTRICAL CONNECTOR LEAD KNEE BOLSTER SCREW COVER AIRBAG MOD- CLOCKSPRING ELEC- LOCATIONS UNDER TOP SCREWS TRICAL LEAD COVER 19 - 54 STEERING REMOVAL AND INSTALLATION (Continued) (6) Remove screws attaching the instrument panel WARNING: WHEN HANDLING AN UNDEPLOYED top cover to the instrument panel (Fig.
  • Page 1126 SPEED STEERING WHEEL HORN GROUND SWITCH WIRE STEERING CONTROL PULLER WIRE WHEEL AIRBAG STEERING ELECTRICAL RETAINING NUT AIRBAG LEAD WHEEL SPEED SWITCH WIRE STEERING MOUNTING CONTROL BRACKET WHEEL TILT LEVER WIRING HARNESS CON- CLOCKSPRING CLOCKSPRING NECTORS ATTACHINGSCREWS STEERING WIRING HARNESS CONNEC- HALO LIGHT SHROUDS COLUMN...
  • Page 1127 MULTI-FUNCTION IGNITION SWITCH SWITCH MULTI-FUNCTION SWITCH WIRING HARNESS MULTI-FUNCTION SWITCH WIRING HAR- MULTI-FUNCTION SWITCH NESS CONNECTOR CONNECTOR RETAINING PIN INTERMEDIATE HOUSING LOCK SHAFT STEERING BRAKE P EDAL SHAFT GEAR LOCKING TAB COUPLER KEY CYL- INDER SHIFTER IGNITION INTERLOCK CABLE PINCH BOLT 19 - 56 STEERING REMOVAL AND INSTALLATION (Continued)
  • Page 1128 UPPER MOUNTING BRACKET LOCKING HOLES DRILL BITS MOUNTING STEERING STEERING COLUMN MOUNTING BRACKET COLUMN TILT LEVER THESE 2 MOUNTING STUDS MUST BE IN THE CENTER OF THE MOUNTING CAPSULES AS SHOWN BEFORE TIGHT- ENING AND TORQUING THE UPPER SUPPORT BRACKET UPPER MOUNTINGNUTS MOUNT NUTS.
  • Page 1129 19 - 58 STEERING REMOVAL AND INSTALLATION (Continued) (5) If vehicle is equipped with an automatic tran- (12) Connect the horn ground wire from the clock- saxle, install the shifter/ignition interlock cable (Fig. spring on the airbag mounting bracket in steering 15) in the lock cylinder housing.
  • Page 1130 STEERING COLUMN STEERING COLUMN LOWER SPECIAL MOUNTING BRACKET 6831–A SHAFT TOOL FLEX JOINT FLEX JOINT INTERMEDIATE S HAFT SCREW- DRIVER STEERING COLUMN LOWER MOUNTING BRACKET ROLL PIN K NURLED NUT INTERMEDIATE SHAFT STEERING 19 - 59 REMOVAL AND INSTALLATION (Continued) CAUTION: When reconnecting battery on a vehicle this group of the service manual for the required that has had the air bag module removed, ensure...
  • Page 1131 SPECIAL 6831–A TOOL FLEX JOINT INTERMEDIATE S HAFT ROLL PIN KNURLED NUT 19 - 60 STEERING REMOVAL AND INSTALLATION (Continued) (2) Install steering coupler on steering shaft until SPECIFICATIONS correctly positioned to allow spring pin to be installed in coupler. STEERING COLUMN FASTENER TORQUE (3) Install Puller, Special Tool 6831-A through cen- SPECIFICATIONS...
  • Page 1132 TRANSAXLE 21 - 1 TRANSAXLE CONTENTS page page 41TE TRANSAXLE ..... . 42 NV T350 (A-578) MANUAL TRANSAXLE ..1 NV T350 (A-578) MANUAL TRANSAXLE INDEX page...

  • Page 1133: Gear Ratios

    REVERSE LAMP SWITCH SHIFT LEVER CROSSOVER LEVER VENT LABEL CODE METAL I.D. TAG 21 - 2 TRANSAXLE GENERAL INFORMATION (Continued) Fig. 3 Bar Code Label Fig. 1 External Transaxle Components between the models. Refer to the identification tag CAUTION: The transaxle output shaft is serviced as on the transaxle to determine which transaxle the a unit.

  • Page 1134: Hard Shifting

    TRANSAXLE 21 - 3 GENERAL INFORMATION (Continued) following chart. The chart also shows which transax- DIAGNOSIS AND TESTING les are available with the reverse–input shaft brake. This brake allows easier shifting into reverse and COMMON PROBLEM CAUSES helps eliminate reverse gear clash. The majority of transaxle malfunctions are a result ENGINE 2.0 SOHC...

  • Page 1135: Fluid Drain And Fill

    DRAIN PLUG LEFT DRIVESHAFT SEAL RUBBER PLUG FILL KNOB SHIFTER HANDLE SHIFTER KNOB CLIPSBOOT RIGHT DRIVE- SHAFT SEAL 21 - 4 TRANSAXLE SERVICE PROCEDURES REMOVAL AND INSTALLATION FLUID DRAIN AND FILL GEARSHIFT KNOB All NV T350 (A-578) transaxles are equipped with REMOVAL a fill plug.
  • Page 1136 SHIFTCABLE SHIFTER BOOT SCREWDRIVERS SHIFTER HANDLE CONSOLE CONSOLE SCREWS CONSOLE CONSOLE SCREWS TRANSAXLE 21 - 5 REMOVAL AND INSTALLATION (Continued) GEARSHIFT BOOT CAUTION: Pry up with equal force on both sides of shifter cable isolator bushings to avoid damaging REMOVAL cable isolator bushings.
  • Page 1137 CABLE CLIPS SHIFTER SHIFTER SHIFTER KNOB CABLES SPEED SENSOR PINION RETAINING BOLT VEHICLE SPEED SENSOR GEARSHIFT SHIFTER BOOT MECHANISM CONSOLE 21 - 6 TRANSAXLE REMOVAL AND INSTALLATION (Continued) (8) Pull up on parking brake handle. Pull up on rear of console and remove console. (9) Remove floor pan grommet from floor pan.

  • Page 1138: Axle Seals

    BACK-UP SWITCH LAMP VEHICLE SPEED LEFT FRAME RAIL SENSOR CLUTCH CABLE TRANSAXLE 21 - 7 REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) To install, reverse removal procedure. Teflon tape or equivalent must be used on switch threads. CAUTION: Do not overtighten switch. (2) Confirm back-up lamps are functioning prop- erly following installation.

  • Page 1139: Shift Shaft Seals

    PRY TOOL AXLE SEAL SHIFTCABLE EGR TUBE SCREWDRIVERS CLUTCH CABLE BELLHOUSING 21 - 8 TRANSAXLE REMOVAL AND INSTALLATION (Continued) • Shift levers (2) Insert a flat–blade pry tool at outer edge of • Back up lamp switch axle shaft seal (Fig. 18). •...
  • Page 1140 TRANSAXLE ACCELERATOR BOLT CABLE ENDS LINKAGE BOLT BRACKET ACCELERATOR CABLE BRACKET THROTTLE BODY SUP- STARTER BOLT BELLHOUSING PORT BRACKET STUD TRANSAXLE 21 - 9 REMOVAL AND INSTALLATION (Continued) Fig. 23 Accelerator Cable Bracket Fig. 21 Linkage Bracket Bolts (7) Disconnect accelerator cables ends from throt- tle body (Fig.
  • Page 1141 UPPER HOUSING BOLTS UPPER BELL TRANSAXLE MOUNT LEFT TRANSAXLE FRONT MOUNT LOWER ENGINE CROSSBAR BRACKET MOUNT ENGINE BRIDGE FIXTURE 21 - 10 TRANSAXLE REMOVAL AND INSTALLATION (Continued) (10) Remove left transaxle mount upper bolts (Fig. 26). Fig. 28 Engine Bridge Fixture Fig.
  • Page 1142 REAR TRANSAXLE MOUNT BRACKET LOWER REAR MOUNT BOLTS CROSSBAR FRONT ENGINE BRACKET TRANSAXLE REAR TRANSAXLE MOUNT HOUSING BRACKET GROUND CABLE REAR LATERAL BEND- ING STRUT TRANSAXLE 21 - 11 REMOVAL AND INSTALLATION (Continued) Fig. 31 Lower Crossbar Rear Bolts (22) Remove (3) bolts on front engine mount bracket (aluminum) (Fig.
  • Page 1143 DRIVE PLATE TO TURN CLOCKWISE LOWER ENGINE PULLEY CLUTCH BOLTS LOWER BELL HOUSING BOLTS CASE BOLTS 21 - 12 TRANSAXLE REMOVAL AND INSTALLATION (Continued) (28) Rotate engine clockwise to gain access to driveplate clutch bolts (Fig. 36). Remove driveplate clutch bolts (Fig. 37). Fig.
  • Page 1144 GEAR CASE HALF PRY TOOL BELLHOUSING CASE HALF GEAR CASE HALF PRY SLOT BELLHOUSING HALF DIFFERENTIAL CASE HALVES INPUT SHAFT REVERSE IDLE GEAR CASE REVERSE GEAR SHAFT IDLE OUTPUT SHAFT INPUT SHAFT CASE DIFFERENTIAL REVERSE IDLE SHAFT REVERSE IDLER SHAFT BOLT CASE TRANSAXLE...
  • Page 1145 REVERSE FORK BRACKET SCREWS ( 2) REVERSE FORK REVERSE CAM SHIFT BLOCKOUT ASSEMBLY BLOCKER BRACKET SELECTOR SHIFT ASSEMBLY SHAFT TRAN- SAXLE CASE SNAP RING PLIERS END COVER SELECTOR SPACER (PLASTIC) SHAFT SHIFT BLOCKER ASSEMBLY 21 - 14 TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) (8) Remove two screws retaining reverse fork bracket (Fig.
  • Page 1146 6785 BENCH FIXTURE END COVER SHIMS SNAP RING PLIERS SNAP RINGS CASE TRANSAXLE BEARING BEARING BENCH FIXTURE FIXTURE GEARTRAIN BENCH FIXTURE FIXTURE TRANSAXLE CASE TRANSAXLE C ASE PRESS R AM TRANSAXLE CASE TRANSAXLE 21 - 15 DISASSEMBLY AND ASSEMBLY (Continued) Fig.
  • Page 1147 REVERSE BRAKE SHIM REVERSE FRICTION CONE TROUGH BRAKE FEED REVERSE BRAKE BLOCKING RING REVERSE BRAKE NEEDLE BEARING REVERSE BRAKE FRICTION CONE 21 - 16 TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 57 Oil Feed Trough Fig. 59 Reverse Brake Friction Cone (18) TRANSAXLE W/REVERSE...
  • Page 1148 6785 BENCH FIXTURE 6785 BENCH FIXTURE 1–2 SHIFT FORK REVERSE BRAKERACE SHIFT BLOCKER ASSEMBLY 6785 BENCH FIXTURE GEARTRAIN 6785 BENCH FIXTURE 1–2 SHIFT FORK INPUT AND OUTPUT SHAFTS BENCH FIXTURE TRANSAXLE 21 - 17 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 65 Gear Train Removal Fig.
  • Page 1149 6785 BENCH FIXTURE REVERSE BRAKERACE REVERSE BRAKE NEEDLE BEARING SHIFT BLOCKER ASSEMBLY REVERSE BRAKE BLOCKING RING REVERSE BRAKE SHIM REVERSE FRICTION CONE REVERSE BRAKE FRICTION BRAKE CONE 21 - 18 TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) (3) Install shift blocker assembly into bench fix- (6) Install reverse brake blocking ring (Fig.
  • Page 1150 BENCH FIXTURE GEARTRAIN CASE TRANSAXLE CASE INPUT SHAFT FRICTION CONE LUGS SPECIAL TOOL C-4992-1 TRAN- SAXLE CASE SNAP RING END COVER PLIERS SNAP RINGS INPUT AND OUTPUT BEARINGS TRANSAXLE 21 - 19 DISASSEMBLY AND ASSEMBLY (Continued) (9) Install gear–case half over bench fixture (Fig. 74).
  • Page 1151 SELECTOR REVERSE SHIFT IDLE GEAR ASSEMBLY SHAFT REVERSE GEAR SHAFT IDLE INPUT SHAFT CASE REVERSE FORK BRACKET SCREWS ( 2) REVERSE FORK REVERSE CAM SHIFT CASE BLOCKOUT ASSEMBLY BLOCKER BRACKET REVERSE IDLE SHAFT REVERSE IDLER SHAFT BOLT 21 - 20 TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) (16) Turn selector shaft into slot on blocker assem-...
  • Page 1152 INPUT SHAFT OUTPUT SHAFT DIFFERENTIAL CASE SPECIAL TOOL C-4995 INCH-POUND TORQUE WRENCH SPECIAL TOOLC-4995 T-HANDLE DIAL TOR SET INDICA- TRANSAXLE 21 - 21 DISASSEMBLY AND ASSEMBLY (Continued) medium load in an upward direction while rolling differential assembly back and forth (Fig. 85). Record end play.
  • Page 1153 INPUT SHAFT 3RD SPEED GEAR STOP RING SLEEVE STOP RING 5TH SPEED GEAR 4TH SPEED GEAR STOP RING SLEEVE SYNCHRONIZER SNAP RING PRESS RAM ASSEMBLY SNAP RING INPUT SHAFT PLIERS INPUT SHAFT BEARING SPLITTER INPUT SHAFT BEARING SPLIT- CAGED NEEDLE BEARING 21 - 22 TRANSAXLE...
  • Page 1154 SEPARATIONPIN SPLIT PLIERS WASHER THRUST SPLIT THRUST WASHER RING INPUT SHAFT INPUT SHAFT INPUT SHAFT INPUT SHAFT INPUT SHAFT SNAP RING PLIERS SYNCHRO CAGED SNAP RING SYNCHRO- NIZER ASSEMBLY BEARING NEEDLE 4TH GEAR TRANSAXLE 21 - 23 DISASSEMBLY AND ASSEMBLY (Continued) (4) Remove 4-5 gears split thrust washer ring (Fig.
  • Page 1155 PRESS R AM SYNCHRONIZER ASSEMBLY INPUT SHAFT 3RD GEAR CAGED NEEDLE BEARING 3RD GEAR INPUT SHAFT SEPARATIONPIN 3RD GEAR SYNCHRONIZER PRESS R AM PLIERS ASSEMBLY BEARING INPUT SHAFT SPLITTER SPECIAL C-3717 TOOL 21 - 24 TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) (10) Install input shaft in shop press.

  • Page 1156: Output Shaft

    SPLIT WASHER THRUST INPUT SHAFT SPLIT WASHER RINGINPUT SHAFT INPUT SHAFT CAGED NEEDLE THRUST BEARING 5TH SPEED PRESS R AM SNAP RING GEAR SNAP RING PLIERS INPUT SHAFT BEARING SPLITTER SYNCHRONIZER SPECIAL TOOLC-3717 BEARING SPLIT- ASSEMBLY TRANSAXLE 21 - 25 DISASSEMBLY AND ASSEMBLY (Continued) Fig.
  • Page 1157 SPECIAL TOOL C-293-45 SPECIAL TOOL C-293-PA 1ST GEAR STOP RING SLEEVE REVERSE GEAR STOP RING SPEED GEAR DIFFERENTIAL OUTPUT ASSEMBLY SPECIAL TOOLC-4996 SHAFT SPEED SENSOR DRIVE DIFFERENTIAL BEARING CONE BEARING CONE SPECIAL C-4996 SPECIAL TOOLC-4171 POSITION) (NOTE TOOL ARBOR PRESS RAM GEAR SPECIAL ADAPTER...
  • Page 1158 DIFFERENTIAL SPEEDOMETER RING DRIVE GEAR ASSEMBLY BOLTS GEAR SPEEDOMETER RING GEAR BEARING DRIVE GEAR SPEEDOMETER DRIVE GEAR SPEEDOMETER DIFFERENTIAL DIFFERENTIAL ASSEMBLY ASSEMBLY DRIVE GEAR TRANSAXLE 21 - 27 DISASSEMBLY AND ASSEMBLY (Continued) RING GEAR Fig. 113 Speedometer Drive Gear Removed Fig.
  • Page 1159 SPEEDOMETER SPEEDOMETER PRESS RAM STEEL STOCK DRIVE GEAR DRIVE GEAR DIFFERENTIAL ASSEMBLY DIFFERENTIAL SPECIAL ASSEMBLY PRESS L-4440 TOOL DIFFERENTIAL ASSEMBLY PINION SHAFT RETAINING SPEEDOMETER SPEEDOMETER RING GEAR PINION RETAINING PIN DRIVE GEAR SHAFT DRIVE GEAR 21 - 28 TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) (2) Using Miller Tool # L-4440 and steel stock, DIFFERENTIAL GEARS press speedometer drive gear onto differential (Fig.
  • Page 1160 DIFFERENTIAL PINION GEARS SIDE GEARS ASSEMBLY DIFFERENTIAL PINION SHAFT RETAINING ASSEMBLY PINION S HAFT SPEEDOMETER PINION S HAFT DRIVE GEAR PINION RETAINING PIN PINION GEAR THRUST SHAFT DIFFERENTIAL ASSEMBLY WASHERS PINION PINION S HAFT SPEEDOMETER GEAR SIDE THRUST WASH- PINION SHAFT RETAINING THICKNESS) (SELECT SPEEDOMETER...
  • Page 1161 SPEEDOMETER SPEEDOMETER PINION SHAFT RETAINING PINION RETAINING PIN DRIVE GEAR DRIVE GEAR SHAFT DIFFERENTIAL MOVE SIDE GEAR MOVE SIDE GEAR SPECIAL TOOL C-4996 SIDE GEAR UP AND DOWN ASSEMBLY UP AND DOWN SPECIAL C-4996 (NOTE POSI- (NOTE POSITION) TOOL TION) DIFFERENTIAL DIAL INDICATOR DIAL INDICATOR SET...

  • Page 1162: Shift Rails Overhaul

    INPUT SHAFT BALL SLEEVE SPRING BALL SLEEVE INPUT SHAFT BALLSPRING SNAP RING CLUTCH TRANSAXLE 21 - 31 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 126 Synchronizer Assembly Fig. 129 Keys in Hub SHIFT RAILS OVERHAUL (1) Remove shift rails from the geartrain. (2) To service the 5-R shift rail, remove the C-clip retaining the reverse shift lever arm.
  • Page 1163 AXLE SEAL TOOL 6709 PRY TOOL AXLE SEAL TOOL C-4171 LARGER DIAMETER CAGE BEARING RETAINER OUTPUT BEARING INPUT BEARING RING OUTPUT BEARING RACE 21 - 32 TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) AXLE SHAFT SEALS Install bearing with larger diameter cage ring facing out.
  • Page 1164 OUTPUT SHAFT BEAR- TOOLC-4171 TOOLC-4628 SPECIAL TOOL 6787 OUTPUT BEAR- ING RACE ING RACE C-3752 DIFFERENTIAL BEARING BELLHOUSING HALF BEARING SPECIAL TOOL 6342 RETAINER OUTPUT BEAR- INPUT BEARING AND INPUT BEAR- SLEEVE TRANSAXLE 21 - 33 DISASSEMBLY AND ASSEMBLY (Continued) INPUT BEARING AND SLEEVE The input bearing is a one–piece bearing and sleeve unit (Fig.
  • Page 1165 SPECIAL TOOL C-4680-1 SPECIAL TOOL 4894 BELLHOUSING HALF SLEEVE AND BEARING ASSEMBLY GEAR CASE SPECIAL TOOL L-4518 SPECIAL TOOL L-4518 WRENCH GEAR CASE 21 - 34 TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) (2) Install tool #C-4680-1 over input bearing (Fig. (2) Install Miller tool #L-4518 into the differential 138).
  • Page 1166 SPECIAL TOOL 6786 INPUT BEARING SLIDE HAMMER SHIFTER RAIL C-3752 BUSHING SELECTOR SLIDE HAMMER SHAFT C-3752 CROSSOVER S HAFT SNAP RING SPECIAL SHIFT SHAFT TOOL 6786 BUSHING TRANSAXLE 21 - 35 DISASSEMBLY AND ASSEMBLY (Continued) SHIFT RAIL BUSHINGS (2) With the transaxle disassembled, remove the crossover shaft seal.
  • Page 1167 SHIFTER SLIDE HAMMER BUSHING SHAFT DEEP WELL SOCKET SHIFTER BUSHING SHAFT TROUGH FEED 21 - 36 TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) INSTALLATION REAR BEARING OIL FEED TROUGH The bearing oil feed trough is retained in the case (1) Position replacement bushing over selector by a pin that is molded into the case and clips that shaft bore.

  • Page 1168: Synchronizer

    CROSSOVER CABLE ADJUST- MENT SHIFTER MECHANISM SHIFTER HANDLE ADJUSTMENT SCREW ⁄ ” DRILL BIT SELECTOR CABLECLIPS CABLE CROSSOVER CABLE SHIFTER TRANSAXLE 21 - 37 CLEANING AND INSPECTION (Continued) SYNCHRONIZER CLEAN Do not attempt to clean the blocking rings in sol- vent.

  • Page 1169: Differential Bearing Preload Adjustment

    SPECIAL TOOL C-4995 T-HANDLE DIAL TOR SET INDICA- INCH-POUND TORQUE WRENCH SPECIAL TOOLC-4995 21 - 38 TRANSAXLE ADJUSTMENTS (Continued) ings, if one input shaft bearing is defective, replace (8) Remove case bolts. Remove clutch bellhousing both input shaft bearings. differential bearing cup. Install shim(s) selected in (5) Bearing cones must not be reused if removed.
  • Page 1170 TRANSAXLE 21 - 39 SPECIFICATIONS (Continued) DESCRIPTION TORQUE Power Hop Damper to Frame Bkt. . 54 N·m (40 ft. lbs.) Power Hop Damper to Trans. Bkt. . 54 N·m (40 ft. lbs.) Reverse Fork Bracket ..11 N·m (96 in. lbs.) Reverse Idler Shaft Bolt .
  • Page 1171 21 - 40 TRANSAXLE SPECIAL TOOLS (Continued) Bearing Installer C-4628 Adapter C-4996 Seal Remover C-4680 Installer L-4410 Seal Installer C-4992 Special Jaw Set L-4518 Torque Tool C-4995 Bearing Splitter 1130...
  • Page 1172 TRANSAXLE 21 - 41 SPECIAL TOOLS (Continued) Driver 6342 Remover 6786 Seal Installer 6709 Remover 6787 Bearing Remover 6768 Bench Fixture 6785...
  • Page 1173 21 - 42 TRANSAXLE 41TE TRANSAXLE INDEX page page GENERAL INFORMATION PINION FACTOR PROCEDURE ... . 54 41TE FOUR SPEED AUTOMATIC TRANSAXLE QUICK LEARN PROCEDURE . . . 54 TRANSAXLE ......42 REMOVAL AND INSTALLATION FLUID LEVEL AND CONDITION .
  • Page 1174 IDENTIFICATION TAG TRANSAXLE 21 - 43 GENERAL INFORMATION (Continued) FLUID LEVEL AND CONDITION NOTE: The transmission and differential sump have a common oil sump with an opening between the two. The torque converter fills in both the (P) Park and (N) Neutral positions.
  • Page 1175 SPECIAL ADDITIVES operating clearances. The solenoids operate the valves directly without any intermediate element. Chrysler Corporation does not recommend the Direct operation means that these units must have addition of any fluids to the transaxle, other than the very high output. They must close against the size- fluid listed above.
  • Page 1176 TRANSAXLE 21 - 45 DESCRIPTION AND OPERATION (Continued) fied terms, the upshift logic allows the releasing ele- trol Module (dependent on which fault is set), the ment to slip backwards slightly. This ensures that it powertrain control module will turn on a MIL (Mal- does not have excess capacity.
  • Page 1177 21 - 46 TRANSAXLE DESCRIPTION AND OPERATION (Continued) LOCK or ACCESSORY position, unless shifter is in AUTOMATIC SHIFTS WILL OCCUR UNDER the PARK position. THE FOLLOWING CONDITIONS GEARSHIFT AND PARKING LOCK CONTROLS TYPE OF SHIFT APPROXIMATE SPEED The transaxle is controlled by a lever type gear- 4-3 coast downshift 13 mph shift incorporated within the floor shift mechanism.
  • Page 1178 TRANSAXLE 21 - 47 DIAGNOSIS AND TESTING (Continued) • Mechanical malfunctions The clutch that is slipping can be determined by • Electronic malfunctions checking for a DTC code 50–54 and noting the tran- Diagnosis of these problems should always begin saxle operation in all selector positions.
  • Page 1179 TORQUE CONVERTER OFF LOW/REVERSE CLUTCH UNDERDRIVE CLUTCH OVERDRIVE CLUTCH REVERSE CLUTCH 2/4 CLUTCH 21 - 48 TRANSAXLE DIAGNOSIS AND TESTING (Continued) Test port locations are shown in (Fig. 2). (3) Allow vehicle wheels to turn and increase throttle opening to achieve an indicated vehicle speed of 20 mph.
  • Page 1180 TOOL 6056 ACCUMULATORS TRANSAXLE 21 - 49 DIAGNOSIS AND TESTING (Continued) Gear Selector Actual PRESSURE TAPS Position Gear Underdrive Overdrive Reverse Torque Low/ Clutch Clutch Clutch Converter 4CLUTCH Reverse Clutch Off Clutch PARK PARK 60-110 0 mph 115-145 REVERSE REVERSE 165-235 50-100 165-235...
  • Page 1181 TOOL 6056 AIR NOZZLE 21 - 50 TRANSAXLE DIAGNOSIS AND TESTING (Continued) FLUID LEAKAGE-TORQUE CONVERTER HOUSING AREA (1) Check for source of leakage. (2) Fluid leakage at or around the torque converter area may originate from an engine oil leak. The area should be examined closely.
  • Page 1182 TRANSAXLE 21 - 51 DIAGNOSIS AND TESTING (Continued) • DIAGNOSTIC TROUBLE CODE 70–Autostick switch signal and processes the data. The TCM sends the Shift Lever Position (SLP) information to the Switch Error • DIAGNOSTIC TROUBLE CODE 71–High Pow- BCM via the CCD bus. The BCM then outlines the appropriate shifter position indicator in the instru- ertrain Temperature–(Transmission oil temperature ment cluster.
  • Page 1183 DIPSTICK ADD WARM HOT Temperature (°F) NOMINAL FILL LINE TRANSAXLE DIPSTICK 21 - 52 TRANSAXLE SERVICE PROCEDURES (Continued) (8) Recheck fluid level after transaxle is at normal operating temperature. The level should be in the HOT region (Fig. 5). Fig. 5 Oil Level Indicator Fig.
  • Page 1184 FROM COOLER TO COOLER TRANSAXLE 21 - 53 SERVICE PROCEDURES (Continued) ALUMINUM THREAD REPAIR NOTE: When flushing transmission cooler and lines, ALWAYS reverse flush. Damaged or worn threads in the aluminum tran- saxle case and valve body can be repaired by the use (5) Connect the BLUE pressure line to the OUT- of Heli-Coils, or equivalent.
  • Page 1185 21 - 54 TRANSAXLE SERVICE PROCEDURES (Continued) (3) Using compressed air (under 40 psi.) in inter- Failure to perform this procedure will cause a No mittent spurts, blow any remaining mineral spirits Speedometer Operation condition. from the cooler, again in the reverse direction. This procedure must be performed if the Transmis- (4) Pump one (1) quart of automatic transmission sion Control Module has been replaced.
  • Page 1186 GEARSHIFT MECHANISM ADJUSTMENT SHIFTER/IGNITION INTERLOCKCABLE CABLE END TRANSAXLE 21 - 55 REMOVAL AND INSTALLATION (Continued) (10) Remove the front half of the floor console. INSTALLATION Refer to Group 23, Body. (1) For installation, reverse removal steps. Tighten (11) Using a flat blade pry tool, remove the shifter the nuts at the base of the gearshift mechanism to 17 cable core end from the shift lever pin.
  • Page 1187 FUSE CENTER COVER PANEL BEZEL SCREW COVER KEY CYLINDER LOWER SHROUD LOWER STEERING COLUMN SHROUD LOWER SCREW LOCATIONS SCREW LOCA- TIONS COVER KNEE BOLSTER SCREW SCREWS LOCATIONS UNDER TOP COVER 21 - 56 TRANSAXLE REMOVAL AND INSTALLATION (Continued) (7) Remove fuse panel cover from left end of (10) Pull instrument panel top cover up enough to instrument panel.
  • Page 1188 TILT LEVER LOWER SHROUD INTERLOCK CABLE IGNITION SWITCH INTERLOCK CABLE IGNITION LOCK CYL- INDER TRANSAXLE 21 - 57 REMOVAL AND INSTALLATION (Continued) (14) Hold tilt wheel lever down and slide lower (3) Install the interlock cable into the interlock shroud forward to remove it from column (Fig. 16). housing at the steering column (Fig.
  • Page 1189 MOUNTING SCREW INTERLOCK MECHANISM INPUT INPUT (TURBINE) SPEED (TURBINE) SENSOR SPEED SENSOR SOLENOID ASSEMBLY SOUND COVER OUTPUT SPEED SENSOR 21 - 58 TRANSAXLE REMOVAL AND INSTALLATION (Continued) INTERLOCK MECHANISM SOLENOID ASSEMBLY-REPLACE REMOVAL (1) Remove the lower column covers, knee bolster and shrouds.
  • Page 1190 SOCKET SOUND COVER ATTACHING PLATE SOUND 8-WAY WRENCH SOLENOID ATTACHING PLATE ASSEMBLY NECTOR CON- COVER SOLENOID ASSEMBLY GAS- ATTACHING KETS SCREWS MANUAL SHAFT RETAINING TRANSMISSION SCREW RANGE SENSOR TRANSMISSION RANGE MANUAL SHAFT RETAINING SEN- MANUAL SHAFT SEAL SCREW SEAL VALVE BODY TRANSAXLE 21 - 59 REMOVAL AND INSTALLATION (Continued)
  • Page 1191 INPUT VALVE BODY (TURBINE) SENSOR SPEED TRANSMISSION RANGE SEN- OUTPUT SPEED SENSOR 21 - 60 TRANSAXLE REMOVAL AND INSTALLATION (Continued) SPEED SENSOR-OUTPUT CAUTION: When disconnecting speed sensor con- nector, be sure that the weather seal does not fall off or remain in old sensor. The output speed sensor is located to the right of the manual shift lever (Fig.
  • Page 1192 (USE RTV UNDER OIL PAN BOLT HEADS) O-RING BOLTS 1/8 INCH BEAD OF RTV OIL FILTER SEALANT OIL FIL- TRANSMISSION CONTROL MODULE TRANSAXLE 21 - 61 REMOVAL AND INSTALLATION (Continued) 2.4 LITER ENGINE VALVE BODY REMOVAL REMOVAL (1) Disconnect battery negative cable at the left strut tower.

  • Page 1193: Transaxle

    SCREWDRIVER VALVE BODY VALVE ATTACHING BOLTS BODY (18) TRANSMISSION VALVE BODY SENSOR RANGE NEGA- TIVE CABLE PARK VALVE BODY SPRAG PARK SPRAG GUIDE ROLLERS BRACKET 21 - 62 TRANSAXLE REMOVAL AND INSTALLATION (Continued) Fig. 38 Valve Body Removed Fig. 35 Valve Body Attaching Bolts CAUTION: The valve body manual shaft pilot may distort and bind the manual valve if the valve body is mishandled or dropped.
  • Page 1194 SOLENOID PACK NECTOR CON- ENGINE BRIDGE FIXTURE TRANSMISSION TRANSAXLE SHIFT CABLE SHIFT SHIFT CABLE CONTROL MODULE COOLER LINES LEVER CLAMP TRANSAXLE 21 - 63 REMOVAL AND INSTALLATION (Continued) (2) Remove air cleaner duct. (7) Remove shift cable at lever and at clamp on (3) Remove transmission control module (TCM) transaxle (Fig.
  • Page 1195 SPLASH SHIELD UPPER TRAN- SAXLE MOUNT UPPER TRANSAXLE MOUNT STARTER 21 - 64 TRANSAXLE REMOVAL AND INSTALLATION (Continued) (9) Remove left upper transaxle mount top bolts (13) Remove remaining left upper mount bolts (Fig. 46). (Fig. 48). Fig. 48 Left Mount Bolts Fig.
  • Page 1196 DRIVE PLATE LOWER ENGINE PULLEY TRANSMISSION TRANSAXLE JACK K-FRAME MOUNT STEERING RACK MOUNT DRIVE PLATE TURN CLOCKWISE SWAY BOLT MOUNT TRANSAXLE 21 - 65 REMOVAL AND INSTALLATION (Continued) NOTE: The 2.4 liter engine has an oil pan collar bracket attached to the transaxle bell housing. Refer to Group 9–Engine, for the proper Removal and Installation procedure.
  • Page 1197 OIL PUMP SEAL HANDLE TOOL C-4193 TOOL C-3981-B C-4171 TOOL TRANSMISSION TRANSMISSION TRANSMISSION PARKING SPRAG ROD RETAINING SCREW RETAINING SCREW RETAINING SCREW ROOSTER COMB MANUAL SHAFT VALVE BODY SENSOR SENSOR SENSOR RANGE RANGE RANGE 21 - 66 TRANSAXLE REMOVAL AND INSTALLATION (Continued) (30) Remove upper and lower transaxle bell hous- DISASSEMBLY AND ASSEMBLY ing bolts.
  • Page 1198 2–4 ACCUMULATOR RETAIN- 2–4 ACCUMULATOR PISTON VALVE BODY SCREWS VALVE BODY SCREWS VALVE BODY SCREWS VALVE BODY SCREWS RETAINER PLATE ROOSTER COMB DETENT SPRING DETENT SPRING MANUAL SHAFT VALVE BODY ING PLATE SPRINGS OVERDRIVE OVERDRIVE SEPARATOR PLATE SEPARATOR PLATE TRANSFER PLATE TRANSFER PLATE THERMAL VALVE CLUTCH...
  • Page 1199 (#4) BALL CHECK LOCATION (#2) BALL CHECK LOCATION LOW/REVERSE TORQUE CONVERTER CON- TORQUE (#) BALL CHECK LOCATION SOLENOID SWITCH VALVE 2–4 ACCUMULATOR REGULATOR VALVE T/C LIMIT VALVE MANUAL VALVE CLUTCH VALVE CONVERTER TROL VALVE RETAINER SWITCH VALVE SPECIAL TOOL 6301 21 - 68 TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued)
  • Page 1200 (USE RTV UNDER OIL PAN BOLT HEADS) BOLTS VALVE BODY 1/8 INCH BEAD OF RTV REGULATOR VALVE TOOL 6302 OIL FILTER SEALANT SPRING SCREWDRIVER O-RING VALVE ATTACHING BOLTS BODY OIL FIL- (18) REGULATOR VALVE PARK VALVE BODY SPRAG PARK SPRAG SPRING RETAINER GUIDE ROLLERS...
  • Page 1201 TRANSMISSION VALVE BODY SEAL RING (2) VALVE BODY SENSOR RANGE RETURNSPRING ACCUMULATOR ACCUMULATOR RETURN SPRINGS RETURN SPRINGS (UNDERDRIVE) (UNDERDRIVE) SEAL RING SEAL RING SEAL RING SEAL RING PISTON PISTON SNAP RING PLUG OVERDRIVE UNDERDRIVE CLUTCH ACCUMU- CLUTCH LATOR ACCUMU- LATOR 21 - 70 TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued)
  • Page 1202 RETURN ACCUMULATOR PIS- PISTON SPRINGS (NOTE NOTCH) SUITABLE TOOL PISTON PETROLATUM ADJUSTABLE SEAL RINGS SEAL RINGS PLIERS PLUG PUMP HOUS- PUMP INPUT SHAFT PUMP PULLERS ATTACHING BOLTS C-3752 TOOL DIAL INDICATOR TRANSAXLE 21 - 71 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 80 Low/Reverse Accumulator Plug (Cover) Fig.
  • Page 1203 “PUSH IN” ON INPUT SHAFT GASKET WHILE REMOVING PUMP PUMP GAS- OIL PUMP #1 CAGED NEEDLE #4 THRUST COOLER WASHER BEARING BYPASS VALVE INPUT CLUTCHES ASSEMBLY NOTE: TANGED SIDE OUT 21 - 72 TRANSAXLE DISASSEMBLY AND ASSEMBLY (Continued) CAUTION: Be sure input speed sensor is removed before removing oil pump.
  • Page 1204 REAR #6 NEEDLE BEAR- GEAR WASHER THRUST BEARING NEEDLE FRONT CARRIER AND REAR ANNULUS (TWIST AND PULL OR PUSH TO REMOVE OR INSTALL). FRONT ASSEMBLY ASSEMBLY GEAR 24 CLUTCH RETURN COMPRESS JUST ENOUGH TO REMOVE OR INSTALL SNAP RING SPRING SNAP RING TOOL 5058 SCREW-...
  • Page 1205 CLUTCH CAUTION: IDENTIFY PACKS ORIGINAL PLACEMENT PLATE (4) RETAINER CLUTCH ASSURE CLUTCH NOTE POSITION RETURNSPRING CLUTCH RETURN SPRING LOW/REVERSE A THRU H INSTALLATION TAPERED SNAP ENDS BETWEEN 9:00 & 10:00 SEQUENCE REACTION PLATE RING TRANSAXLE CASE OIL PAN FACE CLUTCH LONG TAB VIEW FROM BELLHOUSING START...
  • Page 1206 SCREW- DRIVER ONE DISC FROM LOW/REVERSE TAPERED SNAP RING AS SHOWN) (INSTALL CLUCTH DO NOT SCRATCH REAR SCREWDRIVER CLUTCH PLATE CAUTION: TAG AND IDEN- TIFY PACKS TO ASSURE ORIGINAL PLACEMENT. COVER BOLTS LOW/REVERSE REACTION PLATE CLUTCH PLATES (5) LOW/REVERSE REACTION PLATE FLAT CLUTCH DISCS (5) REAR COVER (FLAT SIDE UP)
  • Page 1207 TRANSFER SHAFT GEAR TRANSFER S HAFT SPECIAL TOOL 6259 REAR COVER LOCK WASHER 1/8 INCH BEAD OF MOPAR SILI- CONE RUBBER ADHESIVE SEAL- ANT AS SHOWN OUTPUT GEAR TRANSFER TRANSFER SHAFTGEAR SPECIAL WRENCHES SPECIAL L-4407 TOOL SHAFT GEAR L-4407–6 TOOL 200 FT.
  • Page 1208 TRANSFER TRANSFER SHAFT GEAR WRENCHES SHIM (SELECT) BEARING CUP RETAINER SHAFT GEAR ALIGN INDEXING TAB TO TOOL WITH TOOL TOOL L-4539–2 BUTTON 5048–4 SLOT JAWS 5048 TRANSFER USE REMOVED BEARING CUP SHAFT GEAR TRANSFER BEARING TO SUPPORT RETAINER TOOL 5052 RETAINER WRENCHES ARBOR...
  • Page 1209 SPECIAL TOOL 5049–A SNAP RING PLIERS TOOL 6051 ARBOR PRESS R AM OUTPUT GEAR TRANSFER S HAFT TRANSFER SHAFT BEARING BEARING CONE TOOL P-334 TRANSFER SHAFT SNAP RING TRANSFER SHAFT BAF- OUTPUT GEAR BEARING CUP TOOL 6052 TOOL 6259 BEARING CONE TRANSFER SHAFT NEW BEARING CONE ARBOR...
  • Page 1210 OUTPUT GEAR- OUTPUT RETAINING BOLT STIRRUP BOLT GEAR RETAINING STRAP BOLTS RETAINING STRAP STIRRUP RETAINING S TRAP STIRRUP STIRRUP RETAINING STRAP STIRRUP RETAINING STRAP RETAINING STRAP TABS STIRRUP RETAINING S TRAP TURN CLOCKWISE TURN CLOCKWISE TRANSAXLE 21 - 79 DISASSEMBLY AND ASSEMBLY (Continued) output gear and prevent the stirrup retaining bolts from backing out.
  • Page 1211 CONED LOCK OUTPUT GEAR WASHER TOOL L-4407 BOLT BOLTS TOOL L-4407–6 WRENCHES TOOL 6261 WITH STUD BUTTON TOOL 6055 WRENCHES OUTPUT GEAR WRENCHES OUTPUT GEAR OUTPUTGEAR TORQUE WRENCH 200 FT. LBS. TOOL JAWS 5048–5 AND BUTTON L-4539–2 5048 REAR RIER ASSEM- TOOL 6259 SHIM WITH...
  • Page 1212 ARBOR PRESS RAM ASSEMBLY REAR CAR- RIER OUTPUT GEAR WRENCHES TOOL 5048–3 AND BUTTON 6055 HANDLE C-4171 REAR 5048 TOOL 5052 WITH ASSEMBLY CARRIER JAWS LOW/REVERSE REAR TOOL 6057 TOOL 5058–3 ARBOR PRESS RAM ASSEMBLY RETURN SPRING CARRIER CLUTCH TOOL 5059 SNAP (INSTALL SHOWN)
  • Page 1213 PARK SPRAG GUIDE BRACKET SNAP RING OPENING MUST LOW/REVERSE HAMMER PISTON DRIFT TOOL 6057 BETWEEN LEVERS (AS SHOWN) RETURN SPRING ANCHOR SHAFT SPRING PISTON SNAP PLIERS ANTIRATCHET RING SPRING PIVOT ANCHOR SHAFT PLUG SHAFT ANTIRATCHET GUIDE ANCHOR SHAFT SPRING BRACKET PAWL GUIDE PLIERS...

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Stratus lhd 1997

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