Jeep Cherokee 1999 Electronic Service Manual

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Page 2 LUBRICA TION AND MAINTENANCE 0 - 1 LUBRICATION AND MAINTENANCE CON T EN T S page page GENERAL INFORMA TION ....1 MAINTENANCE SCHEDULES .
Page 3 0 - 2 LUBRICA TION AND MAINTENANCE GEN ERAL I N FORM AT I ON (Cont inue d) CLASSIFICA TION OF LUBRICANTS GEAR LUBRICANTS SAE r a t in gs a lso a pply t o m u lt iple gr a de gea r On ly lu br ica n t s bea r in g design a t ion s defin ed by lu br ica n t s.
Page 4 LUBRICA TION AND MAINTENANCE 0 - 3 GEN ERAL I N FORM AT I ON (Cont inue d) FLUID CAPACITIES MANUAL TRANSMISSION FUEL TANK AX5 (4X2) ..... 3.5 L (3.7 qt s.) AX5 (4X4) .
Page 5 0 - 4 LUBRICA TION AND MAINTENANCE M AI N T EN AN CE SCH EDU LES INDEX page GENERAL INFORMATION MAINTENANCE SCHEDULES ....4 • Rot a t e t h e t ir es a t ea ch oil ch a n ge in t er va l GEN ERAL I N FORM AT I ON sh own on Sch edu le “A”...
Page 6 LUBRICA TION AND MAINTENANCE 0 - 5 GEN ERAL I N FORM AT I ON (Cont inue d) • F lu sh a n d r epla ce en gin e coola n t if it h a s been 30,000 Miles (48 000 km) or at 24 months 30,000 m iles (48 000 km ) or 24 m on t h s sin ce la st •...
Page 7 0 - 6 LUBRICA TION AND MAINTENANCE GEN ERAL I N FORM AT I ON (Cont inue d) • Lu br ica t e st eer in g lin ka ge. • Lu br ica t e st eer in g lin ka ge. •...
Page 8 LUBRICA TION AND MAINTENANCE 0 - 7 GEN ERAL I N FORM AT I ON (Cont inue d) • Lu br ica t e st eer in g lin ka ge. • Lu br ica t e st eer in g lin ka ge. •...
Page 9 0 - 8 LUBRICA TION AND MAINTENANCE GEN ERAL I N FORM AT I ON (Cont inue d) • F lu sh a n d r epla ce en gin e coola n t if it h a s been 96,000 Miles (154 000 km) 30,000 m iles (48 000 km ) sin ce la st ch a n ge.
Page 10 LUBRICA TION AND MAINTENANCE 0 - 9 J U M P START I N G, T OWI N G AN D H OI ST I N G INDEX page page SERVICE PROCEDURES JUMP STARTING PROCEDURE ....9 EMERGENCY TOW HOOKS .
Page 11 0 - 10 LUBRICA TION AND MAINTENANCE SERV I CE PROCEDU RES (Cont inue d) • Do n ot a llow pa ssen ger s t o r ide in a veh icle (6) Allow ba t t er y in disa bled veh icle t o ch a r ge t o a t lea st 12.4 volt s (75% ch a r ge) befor e a t t em pt in g t o bein g t owed.
Page 12 CAUTION: Do not attempt to lift a Jeep vehicle with (2) At t a ch J -h ooks a r ou n d r ea r a xle sh a ft t u be ou t - a floor jack positioned under: boa r d of sh ock a bsor ber.
Page 13 0 - 12 LUBRICA TION AND MAINTENANCE SERV I CE PROCEDU RES (Cont inue d) Fig. 3 Vehicle Lifting Locations Fig. 4 Correct Vehicle Lifting Locations • Th e en gin e or t r a n sm ission oil pa n . WARNING: THE HOISTING AND JACK LIFTING •...
Page 14 LUBRICA TION AND MAINTENANCE 0 - 1 LUBRICATION AND MAINTENANCE CON T EN T S page page GENERAL INFORMA TION ....1 MAINTENANCE SCHEDULE .
Page 15 0 - 2 LUBRICA TION AND MAINTENANCE M AI N T EN AN CE SCH EDU LE INDEX page page GENERAL INFORMATION SCHEDULE—A ......2 MAINTENANCE SCHEDULE—DIESEL ENGINE .
Page 16 LUBRICA TION AND MAINTENANCE 0 - 3 GEN ERAL I N FORM AT I ON (Cont inue d) • Ch eck cor r ect t or qu e, exh a u st m a n ifold m ou n t - 60 000 KM in g n u t s.
Page 17 0 - 4 LUBRICA TION AND MAINTENANCE GEN ERAL I N FORM AT I ON (Cont inue d) • Repla ce a ir filt er elem en t . 40 000 KM • Ch eck glow plu g oper a t ion . •...
Page 18: General Informa Tion
SUSPENSION 2 - 1 SUSPENSION CON T EN T S page page ALIGNMENT ......1 REAR SUSPENSION .
Page 19 2 - 2 SUSPENSION GEN ERAL I N FORM AT I ON (Cont inue d) Fig. 1 Wheel Alignment Measurements...
Page 20 SUSPENSION 2 - 3 DI AGN OSI S AN D T EST I N G SUSPENSION AND STEERING SYSTEM CONDITION POSSIBLE CAUSES CORRECTION FRONT END NOISE 1. Loose or worn wheel bearings. 1. Adjust or replace wheel bearings. 2. Loose or worn steering or 2.
Page 21 2 - 4 SUSPENSION SERV I CE PROCEDU RES PRE-ALIGNMENT Befor e st a r t in g wh eel a lign m en t , t h e followin g in spect ion a n d n ecessa r y cor r ect ion s m u st be com - plet ed.
Page 22 SUSPENSION 2 - 5 SERV I CE PROCEDU RES (Cont inue d) Fig. 3 Steering Linkage (LHD) bolt s t o t h eir or igin a l posit ion a n d t igh t en t o 49 N·m (36 ft .
Page 23 2 - 6 SUSPENSION SPECI FI CAT I ON S (Cont inue d) Fig. 5 Steering Linkage (RHD) SPECI FI CAT I ON S MAX RT/LT ADJUSTMENT PREFERRED RANGE DIFFERENCE ALIGNMENT CAMBER − 0.75° to + − 0.25° 1.0° (fixed angle) 0.5°...
Page 24 SUSPENSION 2 - 7 FRON T SU SPEN SI ON INDEX page page DESCRIPTION AND OPERATION FRONT AXLE BUSHING ....10 SUSPENSION COMPONENTS ....7 STABILIZER BAR .
Page 25: Maintenance Schedules
2 - 8 SUSPENSION DESCRI PT I ON AN D OPERAT I ON (Cont inue d) CAUTION: Suspension components with rubber/ ou t gr ea t ly a ffect in g t h e opposit e wh eel. Wh eels a r e a t t a ch ed t o a h u b/bea r in gs wh ich bolt s t o t h e kn u ck- urethane bushings (except stabilizer bar) should be les.
Page 26 SUSPENSION 2 - 9 REM OVAL AN D I N STALLAT I ON (5) Rem ove t h e st a bilizer ba r lin k a n d sh ock a bsor ber fr om t h e a xle. (6) Rem ove t h e t r a ck ba r fr om t h e body r a il SHOCK ABSORBER br a cket .
Page 27 2 - 10 SUSPENSION REM OVAL AN D I N STALLAT I ON (Cont inue d) LOWER SUSPENSION ARM (4) Tigh t en t h e n u t a t t h e a xle t o 75 N·m (55 ft . lbs.).
Page 28 SUSPENSION 2 - 11 REM OVAL AN D I N STALLAT I ON (Cont inue d) (2) P osit ion t h e st a bilizer ba r on t h e body r a il a n d in st a ll t h e bu sh in gs a n d cla m ps. E n su r e t h e ba r is cen t er ed wit h equ a l spa cin g on bot h sides.
Page 29 2 - 12 SUSPENSION REM OVAL AN D I N STALLAT I ON (Cont inue d) Fig. 8 Hub Bearing & Knuckle WHEEL MOUNTING STUDS-FRONT (5) Tigh t en t h e ba ll st u d n u t t o 81 N·m (60 ft . lbs.).
Page 30 SUSPENSION 2 - 13 REM OVAL AN D I N STALLAT I ON (Cont inue d) SPECI AL T OOLS (3) Tigh t en lu g n u t u n t il t h e st u d is pu lled in t o t h e h u b fla n ge.
Page 31 2 - 14 SUSPENSION REAR SU SPEN SI ON INDEX page page DESCRIPTION AND OPERATION STABILIZER BAR ......15 SUSPENSION COMPONENT .
Page 32 SUSPENSION 2 - 15 DI AGN OSI S AN D T EST I N G (Cont inue d) SPRI N G AN D SH OCK ABSORBER DI AGN OSI S CONDITION POSSIBLE CAUSES CORRECTION SPRING SAGS 1. Broken leaf. 1. Replace spring. 2.
Page 33 2 - 16 SUSPENSION REM OVAL AN D I N STALLAT I ON (Cont inue d) (2) Discon n ect st a bilizer ba r lin ks fr om spr in g (2) P osit ion t h e r ea r eye in t h e sh a ckle br a cket . br a cket s (F ig.
Page 34 SUSPENSION 2 - 17 REM OVAL AN D I N STALLAT I ON (Cont inue d) NOTE: The bushing must be centered in the spring SPECI FI CAT I ON S eye. The ends of the bushing must be flush or slightly recessed within the end surfaces of the TORQUE CHART spring eye.
Page 36: Table Of Contents
DIFFERENTIAL AND DRIVELINE 3 - 1 DIFFERENTIAL AND DRIVELINE CON T EN T S page page 194 RBI AXLE ......47 PROPELLER SHAFTS .
Page 37: General Information
3 - 2 DIFFERENTIAL AND DRIVELINE GEN ERAL I N FORM AT I ON (Cont inue d) Fig. 1 Front & Rear Propeller Shafts—4WD • An gles t h a t a r e equ a l or opposit e wit h in 1 pose NLGI Gr a de 2 E P lu br ica n t .
Page 38: Diagnosis And Testing
DIFFERENTIAL AND DRIVELINE 3 - 3 GEN ERAL I N FORM AT I ON (Cont inue d) • Dou ble ca r da n (CV) u n iver sa l join t (F ig. 4) DI AGN OSI S AN D T EST I N G Non e of t h e u n iver sa l join t s a r e ser vicible.
Page 39 3 - 4 DIFFERENTIAL AND DRIVELINE DI AGN OSI S AN D T EST I N G (Cont inue d) DRI V ELI N E V I BRAT I ON If pr opeller sh a ft is su spect ed of bein g u n ba la n ced, it ca n be ver ified wit h t h e followin g pr ocedu r e: (1) Ra ise t h e veh icle.
Page 40: Service Procedures Driveline Angle Measurement Preparation
DIFFERENTIAL AND DRIVELINE 3 - 5 DI AGN OSI S AN D T EST I N G (Cont inue d) (7) If t h e pr opeller sh a ft r u n ou t is n ot wit h in spec- ifica t ion s, ver ify t h a t t h e r u n ou t of t h e t r a n sm ission / t r a n sfer ca se a n d a xle a r e wit h in specifica t ion s.
Page 41 3 - 6 DIFFERENTIAL AND DRIVELINE SERV I CE PROCEDU RES (Cont inue d) Th is m e a s u re m e n t w ill g iv e y o u th e tra n s m is - (4) Su bt r a ct sm a ller figu r e fr om la r ger (C m in u s s io n o r Ou tp u t Yo k e An g le (A).
Page 42: Removal And Installation
DIFFERENTIAL AND DRIVELINE 3 - 7 SERV I CE PROCEDU RES (Cont inue d) Fig. 11 Universal Joint Angle Example REM OVAL AN D I N STALLAT I ON (3) Rem ove t h e u n iver sa l join t st r a p bolt s a t t h e pin ion sh a ft yoke.
Page 43: Rear Propeller Shaft
3 - 8 DIFFERENTIAL AND DRIVELINE REM OVAL AN D I N STALLAT I ON (Cont inue d) Re p la c e m e n t u n iv e rs a l jo in t s tra p s a n d bo lts m u s t be in s ta lle d .
Page 44 DIFFERENTIAL AND DRIVELINE 3 - 9 DI SASSEM BLY AN D ASSEM BLY (Cont inue d) CAUTION: If the cross or bearing cap are not straight during installation, the bearing cap will score the walls of the yoke bore and damage can occur.
Page 45: Double Cardan Joint
3 - 10 DIFFERENTIAL AND DRIVELINE DI SASSEM BLY AN D ASSEM BLY (Cont inue d) (3) P la ce a bea r in g ca p over t h e t r u n n ion a n d a lign t h e ca p wit h t h e yoke bor e (F ig.
Page 46 DIFFERENTIAL AND DRIVELINE 3 - 11 DI SASSEM BLY AN D ASSEM BLY (Cont inue d) (1) Apply ext r em e pr essu r e (E P ) N.L.G.I. Gr a de 1 or 2 gr ea se t o in side of yoke bor es t o a id in in st a lla - t ion .
Page 47 3 - 12 DIFFERENTIAL AND DRIVELINE DI SASSEM BLY AN D ASSEM BLY (Cont inue d) (5) In st a ll a sn a p r in g. (8) In st a ll sn a p r in gs. Fig. 30 Install Link Yoke (9) In st a ll t h e cen t er in g kit a ssem bly in side t h e Fig.
Page 48: Cleaning And Inspection Propeller Shaft
DIFFERENTIAL AND DRIVELINE 3 - 13 DI SASSEM BLY AN D ASSEM BLY (Cont inue d) (10) P la ce t wo bea r in g ca ps on opposit e t r u n n ion s of t h e r em a in in g cr oss. F it t h e open t r u n n ion s in t o t h e lin k yoke bor es a n d t h e bea r in g ca ps in t o t h e cen t er in g kit (F ig.
Page 49: Adjustments
3 - 14 DIFFERENTIAL AND DRIVELINE ADJ U ST M EN T S ADJUSTMENT A T AXLE WITH LEAF SPRINGS Adju st t h e pin ion sh a ft a n gle a t t h e spr in gs wit h t a per ed sh im s (F ig.
Page 50 DIFFERENTIAL AND DRIVELINE 3 - 15 T U BE AN D 1 8 1 FBI AX LE INDEX page page GENERAL INFORMATION HUB BEARING AND AXLE SHAFT ... 23 181 FBI AXLE ......15 PINION GEAR .
Page 51 3 - 16 DIFFERENTIAL AND DRIVELINE GEN ERAL I N FORM AT I ON (Cont inue d) • Lu br ica n t for a xles in t en ded for h ea vy-du t y or com plet e a t u r n . Th e differ en ce m u st be com pen sa t ed t r a iler t ow u se is SAE 75W–140 SYNTH E TIC gea r for t o pr even t t h e t ir es fr om scu ffin g a n d skiddin g lu br ica n t .
Page 52 DIFFERENTIAL AND DRIVELINE 3 - 17 DI AGN OSI S AN D T EST I N G (Cont inue d) Th e n oise ca n a lso occu r du r in g a specific t ype of pin ion gea r sh a ft bor e will a lso ca u se low speed dr ivin g con dit ion .
Page 53 3 - 18 DIFFERENTIAL AND DRIVELINE DI AGN OSI S AN D T EST I N G (Cont inue d) FRONT AXLES DI AGN OSI S...
Page 54 DIFFERENTIAL AND DRIVELINE 3 - 19 DI AGN OSI S AN D T EST I N G (Cont inue d) DI AGN OSI S – CON T I N U ED...
Page 55 3 - 20 DIFFERENTIAL AND DRIVELINE SERV I CE PROCEDU RES REM OVAL AN D I N STALLAT I ON LUBRICANT CHANGE DRIVE AXLE ASSEMBL Y (1) Ra ise a n d su ppor t t h e veh icle. REMOVAL (2) Rem ove t h e lu br ica n t fill h ole plu g fr om t h e differ en t ia l h ou sin g cover.
Page 56 DIFFERENTIAL AND DRIVELINE 3 - 21 REM OVAL AN D I N STALLAT I ON (Cont inue d) (7) In st a ll t h e sh ock a bsor ber s a n d t igh t en t h e (14) Rem ove t h e coil spr in gs fr om t h e a xle.
Page 57 3 - 22 DIFFERENTIAL AND DRIVELINE REM OVAL AN D I N STALLAT I ON (Cont inue d) (1) Rem ove a xle sh a ft . (2) Rem ove t h e bea r in g ca p r et a in in g sn a p r in gs (F ig.
Page 58 DIFFERENTIAL AND DRIVELINE 3 - 23 REM OVAL AN D I N STALLAT I ON (Cont inue d) (3) In st a ll t h e pin ion wa sh er a n d a n ew n u t on t h e pin ion gea r.
Page 59 3 - 24 DIFFERENTIAL AND DRIVELINE REM OVAL AN D I N STALLAT I ON (Cont inue d) Fig. 10 Hub, Knuckle and Axle Shaft (3) Rem ove t h e br a ke ca liper a n d r ot or. Refer t o Gr ou p 5, Br a kes, for pr oper pr ocedu r es.
Page 60 DIFFERENTIAL AND DRIVELINE 3 - 25 REM OVAL AN D I N STALLAT I ON (Cont inue d) (6) In st a ll t h e h u b wa sh er a n d n u t , if n ecessa r y. Tigh t en t h e h u b n u t t o 237 N·m (175 ft .
Page 61 3 - 26 DIFFERENTIAL AND DRIVELINE REM OVAL AN D I N STALLAT I ON (Cont inue d) Fig. 15 Lower Ball Stud Remove/Install LOWER BALL STUD REPLACEMENT (4) Rem ove h u b bea r in gs a n d a xle sh a ft s. (5) Not e t h e in st a lla t ion r efer en ce let t er s st a m ped (1) P osit ion t ools a s sh own t o r em ove a n d in st a ll on t h e bea r in g ca ps a n d h ou sin g m a ch in ed sea lin g...
Page 62 DIFFERENTIAL AND DRIVELINE 3 - 27 REM OVAL AN D I N STALLAT I ON (Cont inue d) h olddown cla m ps a n d t igh t en t h e t ool t u r n bu ckle fin - ger –t igh t .
Page 63 3 - 28 DIFFERENTIAL AND DRIVELINE REM OVAL AN D I N STALLAT I ON (Cont inue d) en t ia l Bea r in g P r eloa d a n d Gea r Ba ckla sh pr oce- du r es in t h is sect ion t o det er m in e t h e pr oper sh im select ion .
Page 64 DIFFERENTIAL AND DRIVELINE 3 - 29 REM OVAL AN D I N STALLAT I ON (Cont inue d) INSTALLA TION If r epla cem en t differ en t ia l side bea r in gs or differ- en t ia l ca se a r e bein g in st a lled, differ en t ia l side bea r- in g sh im r equ ir em en t s m a y ch a n ge.
Page 65 3 - 30 DIFFERENTIAL AND DRIVELINE REM OVAL AN D I N STALLAT I ON (Cont inue d) INSTALLA TION (5) Usin g Rem over C-452 a n d H older C-3281, r em ove t h e pin ion yoke fr om pin ion sh a ft (F ig. 28). CAUTION: Do not reuse the bolts that held the ring gear to the differential case.
Page 66 DIFFERENTIAL AND DRIVELINE 3 - 31 REM OVAL AN D I N STALLAT I ON (Cont inue d) (10) Rem ove t h e r ea r pin ion bea r in g fr om t h e pin - wit h P u ller /P r ess C–293-PA...
Page 67 3 - 32 DIFFERENTIAL AND DRIVELINE REM OVAL AN D I N STALLAT I ON (Cont inue d) Fig. 35 Pinion Seal Installation Fig. 33 Rear Pinion Bearing Cup Installation Fig. 34 Pinion Outer Bearing Cup Installation Fig. 36 Rear Pinion Bearing Installation CAUTION: Never loosen pinion...
Page 68 DIFFERENTIAL AND DRIVELINE 3 - 33 REM OVAL AN D I N STALLAT I ON (Cont inue d) Fig. 37 Pinion Preload Shims–Typical Fig. 38 Pinion Yoke Installation (13) Tigh t en pin ion sh a ft n u t in 6.8 N·m (5 ft . lbs.) in cr em en t s u n t il t h e m a xim u m t igh t en in g or desir ed r ot a t in g t or qu e is r ea ch ed.
Page 69 3 - 34 DIFFERENTIAL AND DRIVELINE DI SASSEM BLY AN D ASSEM BLY STANDARD DIFFERENTIAL DISASSEMBL Y (1) Rem ove t h e r in g gea r. (2) Usin g a su it a ble r oll pin pu n ch , dr ive ou t t h e r oll pin h oldin g pin ion gea r m a t e sh a ft in t h e differ- en t ia l ca se (F ig.
Page 70 DIFFERENTIAL AND DRIVELINE 3 - 35 DI SASSEM BLY AN D ASSEM BLY (Cont inue d) • Bea r in g cu ps m u st n ot be dist or t ed or cr a cked. • Ma ch in ed su r fa ces sh ou ld be sm oot h a n d wit h - ou t a n y r a ised edges.
Page 71 3 - 36 DIFFERENTIAL AND DRIVELINE ADJ U ST M EN T S (Cont inue d) Com pen sa t ion pin ion dept h va r ia n ce If a n ew gea r set is bein g in st a lled, n ot e t h e dept h a ch ieved wit h select sh im s.
Page 72 DIFFERENTIAL AND DRIVELINE 3 - 37 ADJ U ST M EN T S (Cont inue d) PINION DEPTH MEASUREMENT AND ADJUSTMENT (4) P la ce Ar bor Disc 6732 on Ar bor D-115-3 in posi- t ion in a xle h ou sin g side bea r in g cr a dles (F ig. 48). Mea su r em en t s a r e t a ken wit h pin ion bea r in g cu ps In st a ll differ en t ia l bea r in g ca ps on Ar bor Discs a n d a n d pin ion bea r in gs in st a lled in t h e a xle h ou sin g...
Page 73: Introduction
3 - 38 DIFFERENTIAL AND DRIVELINE ADJ U ST M EN T S (Cont inue d) NOTE: If an oil slinger is used behind the inner pin- ion bearing, deduct the thickness of the slinger from the dial indicator reading and use that total for shim selection.
Page 74 DIFFERENTIAL AND DRIVELINE 3 - 39 ADJ U ST M EN T S (Cont inue d) (7) Usin g a dea d-blow t ype m a llet , sea t t h e differ- en t ia l du m m y bea r in gs t o ea ch side of t h e a xle h ou s- in g (F ig.
Page 75 3 - 40 DIFFERENTIAL AND DRIVELINE ADJ U ST M EN T S (Cont inue d) Fig. 56 Hold Differential Case and Read Dial Fig. 58 Hold Differential Case and Read Dial Indicator Indicator (22) Zer o dia l in dica t or fa ce t o poin t er (F ig. 57). (27) Rot a t e dia l in dica t or ou t of t h e wa y on gu ide st u d.
Page 76 DIFFERENTIAL AND DRIVELINE 3 - 41 ADJ U ST M EN T S (Cont inue d) GEAR CONTACT PA TTERN ANAL YSIS Aft er t h e pr oper ba ckla sh is a ch ieved, per for m Gea r Con t a ct P a t t er n An a lysis pr ocedu r e. Th e r in g a n d pin ion gea r t eet h con t a ct pa t t er n s will sh ow if t h e pin ion gea r dept h is cor r ect in t h e a xle h ou sin g.
Page 77 3 - 42 DIFFERENTIAL AND DRIVELINE ADJ U ST M EN T S (Cont inue d) Fig. 61 Gear Tooth Contact Patterns...
Page 78 DIFFERENTIAL AND DRIVELINE 3 - 43 SPECI FI CAT I ON S 181 FBI AXLE Axle Type ......H ypoid Lu br ica n t .
Page 79 3 - 44 DIFFERENTIAL AND DRIVELINE SPECI AL T OOLS (Cont inue d) Dial Indicator—C-3339 Remover—D-149 Installer—W-162-D Driver—C-3716-A Cup—8109 Handle—C-4171 Remover/Installer—6289 Installer—D-146...
Page 80 DIFFERENTIAL AND DRIVELINE 3 - 45 SPECI AL T OOLS (Cont inue d) Tool Set, Pinion Depth—6774 Installer—6761 Gauge Block—6733 Installer—6752 Installer Discs—8110 Spanner—6958 Turnbuckle—6797 Installer—C-3972-A...
Page 81 3 - 46 DIFFERENTIAL AND DRIVELINE SPECI AL T OOLS (Cont inue d) Spreader—W-129-B Remover—D-147 Adapter Kit—6987 Installer—D-144 Pilot Stud—C-3288-B Installer—W-262...
Page 82 DIFFERENTIAL AND DRIVELINE 3 - 47 1 9 4 RBI AX LE INDEX page page GENERAL INFORMATION DIFFERENTIAL SIDE BEARINGS ... . 61 194 RBI AXLE ......47 FINAL ASSEMBLY .
Page 83 3 - 48 DIFFERENTIAL AND DRIVELINE GEN ERAL I N FORM AT I ON (Cont inue d) Fig. 2 Differential Operation—Straight Ahead Driving Fig. 1 Shim Locations a llows t h e a xle sh a ft s t o t u r n a t u n equ a l speeds (F ig. a xle lu br ica n t ca pa cit y is 1.66L (3.50 pt s.) t ot a l, 3).
Page 84 DIFFERENTIAL AND DRIVELINE 3 - 49 DESCRI PT I ON AN D OPERAT I ON (Cont inue d) for ces gen er a t ed by t h e side gea r s a s t or qu e is Axle gea r pr oblem con dit ion s a r e u su a lly t h e r esu lt a pplied t h r ou gh t h e r in g gea r (F ig.
Page 85 3 - 50 DIFFERENTIAL AND DRIVELINE DI AGN OSI S AN D T EST I N G (Cont inue d) Axle sh a ft bea r in gs pr odu ce n oise a n d vibr a t ion Refer t o Gr ou p 22, Wh eels a n d Tir es, for a ddit ion a l wh en wor n or da m a ged.
Page 86 DIFFERENTIAL AND DRIVELINE 3 - 51 DI AGN OSI S AN D T EST I N G (Cont inue d) DI AGN OSI S CH ART...
Page 87 3 - 52 DIFFERENTIAL AND DRIVELINE DI AGN OSI S AN D T EST I N G (Cont inue d) DI AGN OSI S CH ART – CON T I N U ED...
Page 88 DIFFERENTIAL AND DRIVELINE 3 - 53 DI AGN OSI S AN D T EST I N G (Cont inue d) TRAC–LOK TEST SERV I CE PROCEDU RES LUBRICANT CHANGE WARNING: WHEN SERVICING VEHICLES WITH A TRAC–LOK DIFFERENTIAL DO NOT USE THE (1) Ra ise a n d su ppor t t h e veh icle.
Page 89 3 - 54 DIFFERENTIAL AND DRIVELINE REM OVAL AN D I N STALLAT I ON (8) Con n ect t h e br a ke h ose t o t h e a xle ju n ct ion block. Refer t o Gr ou p 5, Br a kes, for pr oper pr oce- du r es.
Page 90 DIFFERENTIAL AND DRIVELINE 3 - 55 REM OVAL AN D I N STALLAT I ON (Cont inue d) INSTALLA TION lapsible spacer must be installed. The torque sequence will then have to be repeated. (1) Apply a ligh t coa t in g of gea r lu br ica n t on t h e lip of pin ion sea l.
Page 91 3 - 56 DIFFERENTIAL AND DRIVELINE REM OVAL AN D I N STALLAT I ON (Cont inue d) REMOVAL W/PINION REMOVED (7) Align t h e in st a lla t ion r efer en ce m a r ks on t h e pr opeller sh a ft a n d yoke a n d in st a ll t h e pr opeller (1) Ra ise a n d su ppor t t h e veh icle.
Page 92 DIFFERENTIAL AND DRIVELINE 3 - 57 REM OVAL AN D I N STALLAT I ON (Cont inue d) Fig. 16 Pinion Yoke Installation CAUTION: Never loosen pinion gear decrease pinion gear bearing rotating torque and never exceed specified preload torque. If preload torque or rotating torque is exceeded a new col- lapsible spacer must be installed.
Page 93 3 - 58 DIFFERENTIAL AND DRIVELINE REM OVAL AN D I N STALLAT I ON (Cont inue d) (11) Ch eck r ot a t in g t or qu e wit h a (in . lbs.) t or qu e scr ew a n d pin ion m a t e gea r sh a ft fr om differ en t ia l wr en ch (F ig.
Page 94 DIFFERENTIAL AND DRIVELINE 3 - 59 REM OVAL AN D I N STALLAT I ON (Cont inue d) NOTE: Use care to prevent shaft splines from dam- aging axle shaft seal lip. Also, exercise care not to damage the wheel speed sensor on vehicles equipped with ABS brakes.
Page 95 3 - 60 DIFFERENTIAL AND DRIVELINE REM OVAL AN D I N STALLAT I ON (Cont inue d) Fig. 25 Install Dial Indicator Fig. 23 Bearing Cap Identification Fig. 26 Spread Axle Housing Fig. 24 Install Axle Housing Spreader (13) Ma r k or t a g t h e differ en t ia l bea r in g cu ps t o CAUTION: Do not spread over 0.38 mm (0.015 in).
Page 96 DIFFERENTIAL AND DRIVELINE 3 - 61 REM OVAL AN D I N STALLAT I ON (Cont inue d) (3) Spr ea d t h e h ou sin g en ou gh t o in st a ll t h e ca se in t h e h ou sin g.
Page 97 3 - 62 DIFFERENTIAL AND DRIVELINE REM OVAL AN D I N STALLAT I ON (Cont inue d) (2) P la ce differ en t ia l ca se in a su it a ble vise wit h soft m et a l ja w pr ot ect or s (F ig. 32). (3) Rem ove bolt s h oldin g r in g gea r t o differ en t ia l ca se.
Page 98 DIFFERENTIAL AND DRIVELINE 3 - 63 REM OVAL AN D I N STALLAT I ON (Cont inue d) Fig. 33 Ring Gear Bolt Installation Fig. 35 Remove Pinion Gear Fig. 34 Pinion Yoke Removal (7) Use a su it a ble pr y t ool or a slide h a m m er m ou n t ed scr ew t o r em ove t h e pin ion sh a ft sea l.
Page 99 3 - 64 DIFFERENTIAL AND DRIVELINE REM OVAL AN D I N STALLAT I ON (Cont inue d) Fig. 37 Rear Bearing Cup Removal Fig. 39 Rear Bearing Removal Fig. 38 Collapsible Spacer Fig. 40 Pinion Rear Bearing Cup Installation (5) In st a ll pin ion fr on t bea r in g, a n d oil slin ger, if refer to Pinion Gear Depth to select the proper thick- equ ipped.
Page 100 DIFFERENTIAL AND DRIVELINE 3 - 65 REM OVAL AN D I N STALLAT I ON (Cont inue d) Fig. 41 Pinion Front Bearing Cup Installation Fig. 43 Shaft Rear Bearing Installation Fig. 42 Pinion Seal Installation (10) In st a ll pin ion gea r in h ou sin g. (11) In st a ll yoke wit h In st a ller Scr ew 8112, Cu p 8109, a n d h older 6958 (F ig.
Page 101 3 - 66 DIFFERENTIAL AND DRIVELINE REM OVAL AN D I N STALLAT I ON (Cont inue d) Fig. 45 Pinion Yoke Installation Fig. 47 Check Pinion Gear Rotating Torque Fig. 46 Tightening Pinion Nut–Typical (17) In st a ll differ en t ia l in h ou sin g. FINAL ASSEMBL Y (1) Scr a pe t h e r esidu a l sea la n t fr om t h e h ou sin g a n d cover m a t in g su r fa ces.
Page 102 DIFFERENTIAL AND DRIVELINE 3 - 67 DI SASSEM BLY AN D ASSEM BLY (Cont inue d) Fig. 49 Pinion Gear Mate Shaft Lock Screw (4) Rem ove t h e differ en t ia l side gea r s a n d t h r u st wa sh er s.
Page 103 3 - 68 DIFFERENTIAL AND DRIVELINE DI SASSEM BLY AN D ASSEM BLY (Cont inue d) (2) P osit ion t h e differ en t ia l ca se on Side Gea r H oldin g Tool 6965 (F ig. 52). Fig.
Page 104 DIFFERENTIAL AND DRIVELINE 3 - 69 DI SASSEM BLY AN D ASSEM BLY (Cont inue d) Fig. 56 Threaded Adapter Installation Fig. 58 Remove Pinion Gear Thrust Washer Fig. 57 Tighten Belleville Spring Compressor Tool Fig. 59 Pinion Gear Removal (14) Rem ove pin ion gea r s fr om differ en t ia l ca se.
Page 105 3 - 70 DIFFERENTIAL AND DRIVELINE DI SASSEM BLY AN D ASSEM BLY (Cont inue d) Fig. 60 Side Gear & Clutch Disc Removal Fig. 62 Clutch Discs & Lower Side Gear Installation Fig. 61 Clutch Disc Pack Fig. 63 Upper Side Gear & Clutch Disc Pack (7) H old a ssem bly in posit ion .
Page 106 DIFFERENTIAL AND DRIVELINE 3 - 71 DI SASSEM BLY AN D ASSEM BLY (Cont inue d) PRESOAK PLA TES AND DISC (14) Rem ove F or cin g Scr ew C-6960-4, St ep P la t e C-6960-3, a n d Th r ea ded Ada pt er C-6960-1. P la t es a n d discs wit h fiber coa t in g (n o gr ooves or (15) In st a ll pin ion gea r m a t e sh a ft a n d a lign h oles lin es) m u st be pr esoa ked in F r ict ion Modifier befor e...
Page 107 3 - 72 DIFFERENTIAL AND DRIVELINE ADJ U ST M EN T S (Cont inue d) Ar bor Discs 6732, a n d Dia l In dica t or C-3339 (F ig. 66). Fig. 65 Shim Locations Not e t h e et ch ed n u m ber on t h e fa ce of t h e dr ive pin ion gea r (–1, –2, 0, +1, +2, et c.).
Page 108 DIFFERENTIAL AND DRIVELINE 3 - 73 ADJ U ST M EN T S (Cont inue d) (3) In st a ll fr on t pin ion bea r in g a n d Con e 6740 pr obe over t h e edge of t h e pin ion h eigh t block. h a n d t igh t (F ig.
Page 109 3 - 74 DIFFERENTIAL AND DRIVELINE ADJ U ST M EN T S (Cont inue d) t ia l side pla y is m ea su r ed, t h e pin ion gea r is in st a lled, a n d t h e gea r ba ckla sh sh im t h ickn ess is m ea su r ed.
Page 110 DIFFERENTIAL AND DRIVELINE 3 - 75 ADJ U ST M EN T S (Cont inue d) Fig. 73 Seat Ring Gear Side Dummy Bearing Fig. 75 Hold Differential Case and Zero Dial Indicator Fig. 76 Hold Differential Case and Read Dial Indicator (26) Su bt r a ct t h e ba ckla sh sh im t h ickn ess fr om t h e t ot a l pr eloa d sh im t h ickn ess.
Page 111 3 - 76 DIFFERENTIAL AND DRIVELINE ADJ U ST M EN T S (Cont inue d) (34) P osit ion t h e in dica t or plu n ger a ga in st a r in g gea r t oot h (F ig. 77). (35) P u sh a n d h old r in g gea r u pwa r d wh ile n ot a llowin g t h e pin ion gea r t o r ot a t e.
Page 112 DIFFERENTIAL AND DRIVELINE 3 - 77 ADJ U ST M EN T S (Cont inue d) Fig. 79 Gear Tooth Contact Patterns...
Page 113 3 - 78 DIFFERENTIAL AND DRIVELINE SPECI FI CAT I ON S 194 RBI AXLE D ES CRIP TION S P ECIF ICATION Axle Type ....Sem i–F loa t in g H ypoid Lu br ica n t .
Page 114 DIFFERENTIAL AND DRIVELINE 3 - 79 SPECI AL T OOLS (Cont inue d) Cup—8109 Wrench—C-3281 Installer—C-3972-A Handle—C-4171 Spanner—6958 Driver—C-3716-A Installer Screw—8112 Installer—D-130...
Page 115 3 - 80 DIFFERENTIAL AND DRIVELINE SPECI AL T OOLS (Cont inue d) Installer—6436 Installer—D-146 Remover—C-4345 Installer—6437 Remover—D-149 Disc, Axle Arbor—6732 Installer—W-262 Gauge Block—6735...
Page 116 DIFFERENTIAL AND DRIVELINE 3 - 81 SPECI AL T OOLS (Cont inue d) Tool Set, Pinion Depth—6774 Starting Point Shim—8107 Trac-lok Tool Set—6960 Spreader—W-129-B Holder—6965 Adapter Kit—6987 Puller—7794-A Guide Pin—C-3288-B...
Page 117 3 - 82 DIFFERENTIAL AND DRIVELINE SPECI AL T OOLS (Cont inue d) Hub Puller—6790 Bearing Remover Tool Set—6310 Dial Indicator—C-3339...
Page 118 DIFFERENTIAL AND DRIVELINE 3 - 83 8 1 /4 REAR AX LE INDEX page page GENERAL INFORMATION DIFFERENTIAL SIDE BEARINGS ... . 94 8 1/4 AXLES ......83 PINION GEAR .
Page 119 3 - 84 DIFFERENTIAL AND DRIVELINE GEN ERAL I N FORM AT I ON (Cont inue d) Fig. 1 8 1/4 Axle DESCRI PT I ON AN D OPERAT I ON STANDARD DIFFERENTIAL Th e differ en t ia l gea r syst em divides t h e t or qu e bet ween t h e a xle sh a ft s.
Page 120 DIFFERENTIAL AND DRIVELINE 3 - 85 DESCRI PT I ON AN D OPERAT I ON (Cont inue d) Fig. 3 Differential Operation—Straight Ahead Driving t u r n . Th e differ en ce m u st be com pen sa t ed for t o pr even t t h e t ir es fr om scu ffin g a n d skiddin g t h r ou gh t u r n s.
Page 121 3 - 86 DIFFERENTIAL AND DRIVELINE DI AGN OSI S AN D T EST I N G (Cont inue d) Axle com pon en t br ea ka ge is m ost oft en t h e r esu lt of: pin ion gea r sh a ft bor e will a lso ca u se low speed •...
Page 122 DIFFERENTIAL AND DRIVELINE 3 - 87 DI AGN OSI S AN D T EST I N G (Cont inue d) DI AGN OSI S CH ART...
Page 123 3 - 88 DIFFERENTIAL AND DRIVELINE DI AGN OSI S AN D T EST I N G (Cont inue d) DI AGN OSI S CH ART – CON T I N U ED...
Page 124 DIFFERENTIAL AND DRIVELINE 3 - 89 DI AGN OSI S AN D T EST I N G (Cont inue d) TRAC–LOK TEST (4) Clea n t h e h ou sin g ca vit y wit h a flu sh in g oil, ligh t en gin e oil, or lin t fr ee clot h .
Page 125 3 - 90 DIFFERENTIAL AND DRIVELINE REM OVAL AN D I N STALLAT I ON (Cont inue d) (2) P osit ion a su it a ble lift in g device u n der t h e (3) Rem ove br a ke dr u m . Refer t o Gr ou p 5, Br a kes, a xle.
Page 126 DIFFERENTIAL AND DRIVELINE 3 - 91 REM OVAL AN D I N STALLAT I ON (Cont inue d) INSTALLA TION (1) Lu br ica t e bea r in g bor e a n d sea l lip wit h gea r lu br ica n t .
Page 127 3 - 92 DIFFERENTIAL AND DRIVELINE REM OVAL AN D I N STALLAT I ON (Cont inue d) NOTE: The outer perimeter of the seal is pre-coated with a special sealant. An additional application of sealant is not required. (4) Apply a ligh t coa t in g of gea r lu br ica n t on t h e lip of pin ion sea l.
Page 128 DIFFERENTIAL AND DRIVELINE 3 - 93 REM OVAL AN D I N STALLAT I ON (Cont inue d) pin ion sh a ft n u t in 6.8 N·m (5 ft . lbs.) in cr em en t s u n t il pr oper r ot a t in g t or qu e is a ch ieved. NOTE: The bearing rotating torque should be con- stant during a complete revolution of the pinion.
Page 129 3 - 94 DIFFERENTIAL AND DRIVELINE REM OVAL AN D I N STALLAT I ON (Cont inue d) DIFFERENTIAL SIDE BEARINGS REMOVAL (1) Rem ove differ en t ia l ca se fr om a xle h ou sin g. (2) Rem ove t h e bea r in gs fr om t h e differ en t ia l ca se wit h P u ller /P r ess C-293-PA a n d Ada pt er s C-293-48 a n d P lu g SP -3289 (F ig.
Page 130 DIFFERENTIAL AND DRIVELINE 3 - 95 REM OVAL AN D I N STALLAT I ON (Cont inue d) Fig. 23 Ring Gear Bolt Installation Fig. 21 Install Differential Side Bearings PINION GEAR Th e r in g a n d pin ion gea r s a r e ser viced in a m a t ch ed set .
Page 131 3 - 96 DIFFERENTIAL AND DRIVELINE REM OVAL AN D I N STALLAT I ON (Cont inue d) (6) P a r t ia lly in st a ll pin ion n u t on t o pin ion t o pr o- t ect t h e t h r ea ds.
Page 132 DIFFERENTIAL AND DRIVELINE 3 - 97 REM OVAL AN D I N STALLAT I ON (Cont inue d) Fig. 30 Pinion Rear Bearing Cup Installation Fig. 28 Collapsible Spacer (4) In st a ll t h e pin ion fr on t bea r in g cu p (F ig. 31) wit h In st a ller D–130 a n d H a n dle C–4171.
Page 133 3 - 98 DIFFERENTIAL AND DRIVELINE REM OVAL AN D I N STALLAT I ON (Cont inue d) (9) In st a ll a n ew colla psible pr eloa d spa cer on pin - ion sh a ft a n d in st a ll pin ion gea r in h ou sin g (F ig. 34). (10) In st a ll pin ion gea r in h ou sin g.
Page 134 DIFFERENTIAL AND DRIVELINE 3 - 99 REM OVAL AN D I N STALLAT I ON (Cont inue d) • New Bea r in gs — 2 t o 5 N·m (15 t o 35 in . lbs.). Fig. 37 Pinion Mate Gear Removal Fig.
Page 135 3 - 100 DIFFERENTIAL AND DRIVELINE DI SASSEM BLY AN D ASSEM BLY (Cont inue d) Fig. 38 Trac–lok Differential Components Fig. 40 Mate Shaft Lock Screw (7) Assem ble Th r ea ded Ada pt er 8140-1 in t o t op side gea r.
Page 136 DIFFERENTIAL AND DRIVELINE 3 - 101 DI SASSEM BLY AN D ASSEM BLY (Cont inue d) Fig. 41 Mate Shaft Removal Fig. 43 Threaded Adapter Installation Fig. 42 Step Plate Tool Installation Fig. 44 Tighten Belleville Spring Compressor Tool (10) Usin g a ppr opr ia t e size feeler...
Page 137 3 - 102 DIFFERENTIAL AND DRIVELINE DI SASSEM BLY AN D ASSEM BLY (Cont inue d) Fig. 45 Remove Pinion Gear Thrust Washer Fig. 47 Side Gear & Clutch Disc Removal Fig. 46 Pinion Gear Removal ASSEMBL Y NOTE: The clutch discs are replaceable as com- plete sets only.
Page 138 DIFFERENTIAL AND DRIVELINE 3 - 103 DI SASSEM BLY AN D ASSEM BLY (Cont inue d) (12) Tigh t en for cin g scr ew t o 122 N·m (90 ft . lbs.) m a xim u m t o com pr ess t h e Belleville spr in gs. (13) Lu br ica t e a n d in st a ll t h r u st wa sh er s beh in d pin ion gea r s a n d a lign wa sh er s wit h a sm a ll scr ew dr iver.
Page 139 3 - 104 DIFFERENTIAL AND DRIVELINE CLEAN I N G AN D I N SPECT I ON (Cont inue d) Do n ot r edu ce t h e dia m et er of t h e a xle sh a ft sea l con - Com pen sa t ion pin ion dept h...
Page 140 DIFFERENTIAL AND DRIVELINE 3 - 105 ADJ U ST M EN T S (Cont inue d) PI N I ON GEAR DEPT H VARI AN CE Fig. 53 8 1/4 Axle Pinion Adjustment Tools Fig. 54 Gauge Block du r in g t igh t en in g t o pr even t br in ellin g bea r in g cu ps (19) P osit ion Cr ossbor e Ar bor SP -6029 in t h e dif- or bea r in gs.
Page 141 3 - 106 DIFFERENTIAL AND DRIVELINE ADJ U ST M EN T S (Cont inue d) In su fficien t a dju st er t or qu e ca n r esu lt in excessive differ en t ia l ca se fr ee-pla y a n d r in g gea r n oise. •...
Page 142 DIFFERENTIAL AND DRIVELINE 3 - 107 ADJ U ST M EN T S (Cont inue d) (3) Usin g a boxed en d wr en ch on a r in g gea r bolt , Rot a t e t h e differ en t ia l ca se on e com plet e r evolu t ion in bot h dir ect ion s wh ile a loa d is bein g a pplied fr om sh op t owel.
Page 143 3 - 108 DIFFERENTIAL AND DRIVELINE ADJ U ST M EN T S (Cont inue d) Fig. 59 Gear Tooth Contact Patterns...
Page 144 DIFFERENTIAL AND DRIVELINE 3 - 109 ADJ U ST M EN T S (Cont inue d) D ES CRIP TION TORQU E Ba ckin g P la t e Bolt ... 64 N·m (48 ft . lbs.) RWAL/ABS Sen sor Bolt .
Page 145 3 - 110 DIFFERENTIAL AND DRIVELINE SPECI AL T OOLS (Cont inue d) Puller—C-452 Handle—C-4171 Installer—C-3718 Installer—C-4076-B Adjustment Rod—C-4164 Handle—C-4735-1 Puller/Press—C-293–PA Holder—6719...
Page 146 DIFFERENTIAL AND DRIVELINE 3 - 111 SPECI AL T OOLS (Cont inue d) Holder—8138 Adapters—C-293-48 Installer—C-4345 Plug—SP-3289 Remover—C-4307 Adapters—C-293-47 Installer—C-4308 Installer—C-4340...
Page 147 3 - 112 DIFFERENTIAL AND DRIVELINE SPECI AL T OOLS (Cont inue d) Trac-lok Tools—8140 Installer—D-130 Trac-lok Tools—6960 Installer—6448 Gauge Set—C-3715-B...
Page 148 BRAKES 5 - 1 BRAKES CON T EN T S page page BASE BRAKE SYSTEM ..... 1 ANTILOCK BRAKES ..... . 30 BASE BRAK E SY ST EM INDEX page...
Page 149: General Information
5 - 2 BRAKES GEN ERAL I N FORM AT I ON flush brake system components. These are the only cleaning materials recommended. If system contam- ination is suspected, check the fluid for dirt, discol- BRAKE SYSTEM oration, or separation into distinct layers. Also P ower a ssist fr on t disc a n d r ea r dr u m br a kes a r e check the reservoir cap seal for distortion.
Page 150: Master Cylinder
BRAKES 5 - 3 DESCRI PT I ON AN D OPERAT I ON (Cont inue d) Two pu sh r ods a r e u sed in t h e boost er. Th e pr i- Th e ch a m ber a r ea s for wa r d of t h e boost er dia - m a r y pu sh r od con n ect s t h e boost er t o t h e br a ke ph r a gm s a r e exposed t o va cu u m fr om t h e in t a ke peda l.
Page 151: Combination Valve
5 - 4 BRAKES DESCRI PT I ON AN D OPERAT I ON (Cont inue d) a s a n a ssem bly. Th e r eser voir a n d gr om m et s a r e t h e on ly r epla cea ble pa r t s on t h e m a st er cylin der.
Page 152: Rear Drum Brake
BRAKES 5 - 5 DESCRI PT I ON AN D OPERAT I ON (Cont inue d) Fig. 4 Brake Components REAR DRUM BRAKE Th e br a ke syst em s u se a lea din g sh oe (pr im a r y) a n d t r a ilin g sh oe (secon da r y) (F ig.
Page 153: Brake Hoses And Lines
5 - 6 BRAKES DESCRI PT I ON AN D OPERAT I ON (Cont inue d) A pa r kin g br a ke swit ch is m ou n t ed on t h e pa r kin g la cks fr ee pla y, ch eck peda l a n d power boost er for br a ke lever a n d is a ct u a t ed by m ovem en t of t h e bein g loose or for bin d con dit ion .
Page 154 BRAKES 5 - 7 DI AGN OSI S AN D T EST I N G (Cont inue d) • Bin din g ca liper Th e pr im a r y ca u se of pu lsa t ion a r e disc br a ke •...
Page 155: Stop Lamp Switch
5 - 8 BRAKES DI AGN OSI S AN D T EST I N G (Cont inue d) SWITCH CIRCUIT IDENTIFICA TION Sever ely wor n t ir es wit h ver y lit t le t r ea d left ca n pr odu ce a gr a b-like con dit ion a s t h e t ir e loses a n d •...
Page 156: Master Cylinder/Power Booster
BRAKES 5 - 9 DI AGN OSI S AN D T EST I N G (Cont inue d) a n ABS m a lfu n ct ion h a s occu r r ed. Th e ABS la m p oper a t es in depen den t ly of t h e r ed wa r n in g la m p.
Page 157: Disc Brake Rotor
5 - 10 BRAKES DI AGN OSI S AN D T EST I N G (Cont inue d) ligh t bu lb a n d fu se is fu n ct ion a l. Repa ir or r epla ce pa r t s a s n ecessa r y a n d t est differ en t ia l pr essu r e swit ch oper a t ion a ga in .
Page 158: Brake Line And Hoses
BRAKES 5 - 11 DI AGN OSI S AN D T EST I N G (Cont inue d) if r u n ou t or va r ia t ion exceed t h ese va lu es. Repla ce in g in t h e r eser voir a n d con t a m in a t in g t h e br a ke t h e dr u m if m a ch in in g ca u ses t h e dr u m t o exceed t h e flu id.
Page 159: Base Brake Bleeding
5 - 12 BRAKES SERV I CE PROCEDU RES (Cont inue d) BASE BRAKE BLEEDING Use Mopa r br a ke flu id, or a n equ iva len t qu a lit y flu id m eet in g SAE J 1703-F a n d DOT 3 st a n da r ds on ly.
Page 160: Brake Tube Flaring
BRAKES 5 - 13 SERV I CE PROCEDU RES (Cont inue d) BRAKE TUBE FLARING A pr efor m ed m et a l br a ke t u be is r ecom m en ded a n d pr efer r ed for a ll r epa ir s. H owever, dou ble-wa ll st eel t u be ca n be u sed for em er gen cy r epa ir wh en fa ct or y r epla cem en t pa r t s a r e n ot r ea dily a va ila ble.
Page 161: Removal And Installation
5 - 14 BRAKES REM OVAL AN D I N STALLAT I ON (5) Rem ove peda l a n d su ppor t br a cket a s a n a ssem bly fr om t h e veh icle. STOP LAMP SWITCH REMOVAL (1) Rem ove st eer in g colu m n cover a n d lower t r im...
Page 162: Master Cylinder
BRAKES 5 - 15 REM OVAL AN D I N STALLAT I ON (Cont inue d) (8) If m a st er cylin der r eser voir r equ ir es ser vice, r efer t o r eser voir r epla cem en t pr ocedu r e in t h is sec- t ion .
Page 163: Front Disc Brake Caliper
5 - 16 BRAKES REM OVAL AN D I N STALLAT I ON (Cont inue d) (6) Discon n ect va cu u m h ose fr om boost er ch eck (4) Slide boost er pu sh r od on t o t h e br a ke peda l. va lve.
Page 164 BRAKES 5 - 17 REM OVAL AN D I N STALLAT I ON (Cont inue d) Fig. 24 Bottoming Caliper Piston With C-Clamp Fig. 26 Caliper Mounting Bolts Fig. 27 Caliper Removal Fig. 25 Brake Hose And Bolt INSTALLA TION (1) Clea n br a ke sh oe m ou n t in g ledges wit h wir e br u sh a n d a pply ligh t coa t of Mopa r m u lt i-m ilea ge gr ea se t o su r fa ces (F ig.
Page 165: Front Disc Brake Shoes
5 - 18 BRAKES REM OVAL AN D I N STALLAT I ON (Cont inue d) FRONT DISC BRAKE SHOES REMOVAL (1) Ra ise a n d su ppor t veh icle. (2) Rem ove wh eel a n d t ir e a ssem bly. (3) Rem ove ca liper.
Page 166: Disc Brake Rotor
BRAKES 5 - 19 REM OVAL AN D I N STALLAT I ON (Cont inue d) DRUM BRAKE SHOES (7) Wipe ca liper off wit h sh op r a gs or t owels. CAUTION: Do not use compressed air, this can REMOVAL unseat dust boot and force dirt into piston bore.
Page 167: Wheel Cylinder
5 - 20 BRAKES REM OVAL AN D I N STALLAT I ON (Cont inue d) Fig. 34 Drum Brake Components—Typical (3) Con n ect br a ke lin e t o cylin der. (4) In st a ll br a ke sh oe r et u r n spr in g. (5) In st a ll br a ke dr u m .
Page 168: Rear Parking Brake Cables
BRAKES 5 - 21 REM OVAL AN D I N STALLAT I ON (Cont inue d) (6) In st a ll a xle sh a ft , r efer t o Gr ou p 3 for pr oce- du r e. (7) Con n ect pa r kin g br a ke ca ble t o lever on sec- on da r y sh oe a n d in st a ll br a ke sh oes on su ppor t pla t e.
Page 169: Disassembly And Assembly
5 - 22 BRAKES REM OVAL AN D I N STALLAT I ON (Cont inue d) (6) Com pr ess ca ble r et a in er wit h wor m dr ive h ose cla m p a n d r em ove t h e ca ble fr om t h e pa r kin g br a ke lever ba se.
Page 170: Disc Brake Caliper
BRAKES 5 - 23 DI SASSEM BLY AN D ASSEM BLY (Cont inue d) (6) Rem ove old gr om m et s fr om cylin der body (F ig. 43). boa r d sh oe side of t h e ca liper in fr on t of t h e pist on . Th is will cu sh ion a n d pr ot ect ca liper pist on du r in g r em ova l (F ig.
Page 171 5 - 24 BRAKES DI SASSEM BLY AN D ASSEM BLY (Cont inue d) ASSEMBL Y (5) Rem ove ca liper pist on du st boot wit h su it a ble pr y t ool (F ig. 47). CAUTION: Dirt, oil, and solvents can damage cali- per seals.
Page 172: Wheel Cylinder
BRAKES 5 - 25 DI SASSEM BLY AN D ASSEM BLY (Cont inue d) WHEEL CYLINDER DISASSEMBL Y (1) Rem ove pu sh r ods a n d boot s (F ig. 55). (2) P r ess pist on s, cu ps a n d spr in g a n d expa n der ou t of cylin der bor e.
Page 173: Rear Drum Brake
5 - 26 BRAKES CLEAN I N G AN D I N SPECT I ON (Cont inue d) CAUTION: If the caliper piston is replaced, install In spect t h e br a ke sh oe con t a ct pa ds on t h e su ppor t the same type of piston in the caliper.
Page 174: Rear Drum Brake
BRAKES 5 - 27 ADJ U ST M EN T S (Cont inue d) (2) P u ll swit ch plu n ger a ll t h e wa y ou t t o fu lly ext en ded posit ion . (3) Relea se br a ke peda l.
Page 175: Parking Brake Cable Tensioner
5 - 28 BRAKES ADJ U ST M EN T S (Cont inue d) (9) Tigh t en a dju st in g n u t a t equ a lizer u n t il m a r k on t en sion er r od m oves in t o a lign m en t wit h t en sion er br a cket .
Page 176: Torque Chart
BRAKES 5 - 29 SPECI FI CAT I ON S (Cont inue d) BRAKE COMPONENTS SPECI AL T OOLS Disc Brake Caliper BASE BRAKES Type ......Slidin g D is c B ra k e Ro to r Type .
Page 177: General Informa Tion
5 - 30 BRAKES AN T I LOCK BRAK ES INDEX page page GENERAL INFORMATION SERVICE PROCEDURES ANTILOCK BRAKE SYSTEM ....30 BLEEDING ABS BRAKE SYSTEM ... 33 DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION ANTILOCK BRAKE SYSTEM .
Page 178 BRAKES 5 - 31 DESCRI PT I ON AN D OPERAT I ON (Cont inue d) br iefly cycles t h e pu m p a n d solen oids t o ver ify oper- ABS fa u lt s r em a in in m em or y u n t il clea r ed, or a t ion .
Page 179 5 - 32 BRAKES DESCRI PT I ON AN D OPERAT I ON (Cont inue d) A pr essu r e decr ea se cycle is in it ia t ed wh en speed sen sor sign a ls in dica t e h igh wh eel slip a t on e or m or e wh eels.
Page 180 BRAKES 5 - 33 DESCRI PT I ON AN D OPERAT I ON (Cont inue d) NOTE: The MDS or DRB III scan tool is used to a llows n or m a l flu id flow du r in g m oder a t e br a kin g. Th e va lve on ly con t r ols flu id flow du r in g h igh decel- diagnose the ABS system.
Page 181 5 - 34 BRAKES REM OVAL AN D I N STALLAT I ON (Cont inue d) Fig. 5 CAB Harness Connector Release Fig. 7 Front Wheel Speed Sensor (2) Apply Mopa r Lock N’ Sea l or Loct it e 242 t o bolt t h a t secu r es sen sor in st eer in g kn u ckle.
Page 182 BRAKES 5 - 35 REM OVAL AN D I N STALLAT I ON (Cont inue d) INSTALLA TION (2) Discon n ect sen sor s a t r ea r h a r n ess con n ect or s. (3) P u sh sen sor gr om m et s...
Page 183 5 - 36 BRAKES REM OVAL AN D I N STALLAT I ON (Cont inue d) (10) In st a ll br a ke dr u m a n d wh eel a n d t ir e a ssem bly. (11) Lower veh icle.
Page 184 BRAKES 5 - 37 SPECI FI CAT I ON S T0RQUE CHART D ES CRIP TION TORQU E Ac c e le ra tio n S e n s o r Sen sor Bolt ......3 N·m (27.5 in .
Page 186 CLUTCH 6 - 1 CLUTCH CON T EN T S page page GENERAL INFORMA TION MISALIGNMENT ......5 CLUTCH COMPONENTS .
Page 187: Clutch Components
6 - 2 CLUTCH GEN ERAL I N FORM AT I ON (Cont inue d) SAFETY PRECAUTIONS Use Mopa r m u lt i-m ilea ge gr ea se or a silicon e gr ea se for t h e clu t ch peda l bu sh in gs a n d pivot sh a ft . Use Mopa r h igh t em per a t u r e bea r in g gr ea se or WARNING: EXERCISE CARE WHEN SERVICING...
Page 188: Diagnosis And Testing
CLUTCH 6 - 3 DESCRI PT I ON AN D OPERAT I ON (Cont inue d) lin e. In t u r n , t h e sla ve cylin der oper a t es t h e clu t ch t h e com pon en t s.
Page 189 6 - 4 CLUTCH DI AGN OSI S AN D T EST I N G (Cont inue d) Clutch Components...
Page 190: Misalignment
CLUTCH 6 - 5 DI AGN OSI S AN D T EST I N G (Cont inue d) CLUTCH COVER cr a ckin g or wa r pa ge a ft er in st a lla t ion ; it ca n a lso wea ken t h e flywh eel a n d in t er fer e wit h pr oper clu t ch Ch eck con dit ion of t h e clu t ch cover befor e in st a lla - r elea se.
Page 191 6 - 6 CLUTCH DI AGN OSI S AN D T EST I N G (Cont inue d) DI AGN OSI S CH ART CONDITION POSSIBLE CAUSES CORRECTION Disc facing worn out 1. Normal wear. 1. Replace cover and disc. 2.
Page 192 CLUTCH 6 - 7 DI AGN OSI S AN D T EST I N G (Cont inue d) CONDITION POSSIBLE CAUSES CORRECTION Clutch disc rusted to flywheel and/or 1. Clutch not used for and extended 1. Sand rusted surfaces with 180 pressure plate.
Page 193: Service Procedures
6 - 8 CLUTCH SERV I CE PROCEDU RES CLUTCH COMPONENT LUBRICA TION P r oper clu t ch com pon en t lu br ica t ion is im por t a n t t o sa t isfa ct or y oper a t ion . Usin g t h e cor r ect lu br ica n t a n d n ot over lu br ica t in g a r e equ a lly im por t a n t .
Page 194: Removal And Installa Tion
CLUTCH 6 - 9 SERV I CE PROCEDU RES (Cont inue d) • 68 N·m (50 ft . lbs.) plu s a n a ddit ion a l t u r n of REM OVAL AN D I N STALLAT I ON 60°...
Page 195: Release Bearing
6 - 10 CLUTCH REM OVAL AN D I N STALLAT I ON (Cont inue d) RELEASE BEARING REMOVAL (1) Rem ove t r a n sm ission . (2) Discon n ect r elea se bea r in g fr om r elea se lever a n d r em ove bea r in g (F ig.
Page 196 CLUTCH 6 - 11 REM OVAL AN D I N STALLAT I ON (Cont inue d) INSTALLA TION (1) Clea n bea r in g bor e wit h solven t a n d wipe dr y wit h sh op t owel. (2) Lu br ica t e n ew pilot bea r in g wit h Mopa r h igh t em per a t u r e gr ea se.
Page 197: Specifica Tions
6 - 12 CLUTCH REM OVAL AN D I N STALLAT I ON (Cont inue d) (10) Discon n ect clu t ch in t er lock sa fet y swit ch (2) P osit ion clu t ch lin ka ge com pon en t s in veh icle. wir es.
Page 198: Clutch Components
CLUTCH 6 - 1 CLUTCH CON T EN T S page page GENERAL INFORMA TION FLYWHEEL RING GEAR ....5 CLUTCH COMPONENTS ....1 PILOT BEARING .
Page 199 6 - 2 CLUTCH REM OVAL AN D I N STALLAT I ON (Cont inue d) Fig. 1 Clutch Components (VM Diesel) INSTALLA TION (1) Ligh t ly scu ff sa n d flywh eel fa ce wit h 180 gr it em er y clot h .
Page 200: Clutch Cover And Disc
CLUTCH 6 - 3 REM OVAL AN D I N STALLAT I ON (Cont inue d) Fig. 5 Pilot Bearing Removal Fig. 3 Clutch Disc Alignment—Typical PILOT BEARING REMOVAL (1) Rem ove t h e t r a n sm ission a n d t r a n sfer ca se. Refer t o Gr ou p 21, Tr a n sm ission a n d Tr a n sfer Ca se- for pr ocedu r es.
Page 201: Flywheel
6 - 4 CLUTCH REM OVAL AN D I N STALLAT I ON (Cont inue d) INSTALLA TION block or in on e of t h e flywh eel a t t a ch in g bolt h oles. F a ce r u n ou t ca n be cor r ect ed by r esu r fa cin g if n eces- CAUTION: The bearing can be installed incorrectly sa r y.
Page 202: Flywheel Ring Gear
CLUTCH 6 - 5 REM OVAL AN D I N STALLAT I ON (Cont inue d) NOTE: The method of heating and expanding the new ring gear is extremely important. Every surface of the gear must be heated at the same time to pro- duce uniform expansion.
Page 203: Specifica Tions
6 - 6 CLUTCH SPECI FI CAT I ON S SPECI AL T OOLS SPECIFICA TIONS SPECIAL TOOLS D ES CRIP TION TORQU E Clu tc h Co v e r to F ly w h e e l Bolt s ....50 N·m (37 ft . lbs.) Clu tc h Ho u s in g to Tra n s m is s io n Bolt s .
Page 204 COOLING SYSTEM 7 - 1 COOLING SYSTEM CON T EN T S page page GENERAL INFORMA TION RADIATOR CAP—PRESSURE TESTING ..20 ACCESSORY DRIVE BELT TENSION ..2 RADIATOR COOLANT FLOW CHECK .
Page 205: General Informa Tion
7 - 2 COOLING SYSTEM GEN ERAL I N FORM AT I ON ACCESSORY DRIVE BELTS CAUTION: When installing an accessory drive belt, the belt MUST be routed correctly. If not, the engine may overheat due to water pump rotating in wrong direction.
Page 206: Description And Opera Tion
COOLING SYSTEM 7 - 3 GEN ERAL I N FORM AT I ON (Cont inue d) a ccessor ies. If specified t en sion is n ot m a in t a in ed, Th e a u xilia r y a ir-t o-oil t r a n sm ission oil cooler is belt slippa ge m a y ca u se: en gin e over h ea t in g, la ck of loca t ed in fr on t of t h e r a dia t or or A/C con den ser (if power st eer in g a ssist , loss of a ir con dit ion in g ca pa c-...
Page 207 7 - 4 COOLING SYSTEM DESCRI PT I ON AN D OPERAT I ON (Cont inue d) pon en t wit h t ie-st r a ps. Th e h ea t er wa r m s t h e en gin e pr ovidin g ea sier en gin e st a r t in g a n d fa st er wa r m -u p in low t em per a t u r es.
Page 208: Coolant Selection-Additives
COOLING SYSTEM 7 - 5 DESCRI PT I ON AN D OPERAT I ON (Cont inue d) pr even t s fr eezin g down t o -67.7° C (-90° F ). A h igh er a n d low m in er a l con t en t wa t er. On ly u se a n a n t i- per cen t a ge will fr eeze a t a wa r m er t em per a t u r e.
Page 209: Cooling System Hoses
7 - 6 COOLING SYSTEM DESCRI PT I ON AN D OPERAT I ON (Cont inue d) t h e r eser ve/over flow t a n k t o be dr a wn t h r ou gh it s A qu ick t est t o det er m in e if t h e pu m p is wor kin g is con n ect in g h ose in t o r a dia t or.
Page 210 COOLING SYSTEM 7 - 7 DESCRI PT I ON AN D OPERAT I ON (Cont inue d) Fig. 8 Typical Viscous Fan Drive On ly wh en su fficien t h ea t is pr esen t , will t h e vis- cou s fa n dr ive en ga ge.
Page 211: Diagnosis And Testing
7 - 8 COOLING SYSTEM DESCRI PT I ON AN D OPERAT I ON (Cont inue d) NOISE vided t o t h e coolin g fa n r ela y t h r ou gh pin C2 of P CM con n ect or C3.
Page 212 COOLING SYSTEM 7 - 9 DI AGN OSI S AN D T EST I N G (Cont inue d) NOISE DIAGNOSIS Noises gen er a t ed by t h e a ccessor y dr ive belt a r e m ost n ot icea ble a t idle.
Page 213 7 - 10 COOLING SYSTEM DI AGN OSI S AN D T EST I N G (Cont inue d) CONDITION POSSIBLE CAUSES CORRECTION LONGITUDAL BELT CRACKING 1. Belt has mistracked from pulley 1. Replace belt groove 2. Pulley groove tip has worn away 2.
Page 214: Cooling System Diagnosis Chart
COOLING SYSTEM 7 - 11 DI AGN OSI S AN D T EST I N G (Cont inue d) PRELIMINARY CHECKS n en t s sh ou ld be in st a lled for m odel in volved per m a n u fa ct u r er ’s specifica t ion s. ENGINE COOLING SYSTEM OVERHEA TING RECENT SERVICE OR ACCIDENT REPAIR: E st a blish wh a t dr ivin g con dit ion s ca u sed t h e com -...
Page 215 7 - 12 COOLING SYSTEM DI AGN OSI S AN D T EST I N G (Cont inue d) CONDITION POSSIBLE CAUSES CORRECTION TEMPERATURE GAUGE 1. Trailer is being towed, a steep hill is 1. This may be a temporary condition READS HIGH OR THE being climbed, vehicle is operated in and repair is not necessary.
Page 216 COOLING SYSTEM 7 - 13 DI AGN OSI S AN D T EST I N G (Cont inue d) CONDITION POSSIBLE CAUSES CORRECTION 10. Radiator or A/C condenser fins are 10. Remove insects and debris. Refer to dirty or clogged. Radiator Cleaning in this Group.
Page 217 7 - 14 COOLING SYSTEM DI AGN OSI S AN D T EST I N G (Cont inue d) CONDITION POSSIBLE CAUSES CORRECTION 5. Gauge reading high after re-starting a 5. A normal condition. No correction is warmed up (hot) engine. necessary.
Page 218 COOLING SYSTEM 7 - 15 DI AGN OSI S AN D T EST I N G (Cont inue d) CONDITION POSSIBLE CAUSES CORRECTION HOSE OR HOSES 1. Vacuum created in cooling system on 1. (a) Radiator cap relief valve stuck. COLLAPSE WHILE engine cool-down is not being relieved Refer to Radiator Cap in this group.
Page 219 7 - 16 COOLING SYSTEM DI AGN OSI S AN D T EST I N G (Cont inue d) CONDITION POSSIBLE CAUSES CORRECTION INADEQUATE HEATER 1. Has a Diagnostic trouble Code (DTC) 1. Refer to Group 25, Emissions for PERFORMANCE. been set? correct procedures and replace THERMOSTAT FAILED IN...
Page 220: Cooling System-Testing For Leaks
COOLING SYSTEM 7 - 17 DI AGN OSI S AN D T EST I N G (Cont inue d) RADIA TOR COOLANT FLOW CHECK WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. Th e followin g pr ocedu r e will det er m in e if coola n t is flowin g t h r ou gh t h e coolin g syst em .
Page 221 7 - 18 COOLING SYSTEM DI AGN OSI S AN D T EST I N G (Cont inue d) • Dr ops Qu ickly: Sh ows t h a t a ser iou s lea ka ge is WARNING: DO REMOVE CYLINDER occu r r in g.
Page 222: Electric Cooling Fan
COOLING SYSTEM 7 - 19 DI AGN OSI S AN D T EST I N G (Cont inue d) RADIA TOR CAP-TO-FILLER NECK SEAL— (4) Block t h e a ir flow t h r ou gh t h e r a dia t or. Secu r e a sh eet of pla st ic in fr on t of t h e r a dia t or (or a ir con - PRESSURE RELIEF CHECK dit ion er con den ser ).
Page 223: Service Procedures
7 - 20 COOLING SYSTEM DI AGN OSI S AN D T EST I N G (Cont inue d) WARNING: IF VEHICLE HAS BEEN RUN RECENTLY, CAUTION: Radiator pressure testing tools are very WAIT AT LEAST 15 MINUTES BEFORE REMOVING sensitive to small air leaks, which will not cause RADIATOR CAP.
Page 224: Coolant-Adding Additional
COOLING SYSTEM 7 - 21 SERV I CE PROCEDU RES (Cont inue d) COOLANT—ADDING ADDITIONAL D o n o t re m o v e ra d ia to r c a p to a d d c o o la n t to s y s te m .
Page 225: Removal And Installa Tion
7 - 22 COOLING SYSTEM SERV I CE PROCEDU RES (Cont inue d) CHEMICAL CLEANING REM OVAL AN D I N STALLAT I ON If visu a l in spect ion in dica t es t h e for m a t ion of TRANSMISSION OIL COOLERS slu dge or sca ly deposit s, u se a r a dia t or clea n er (Mopa r Ra dia t or Kleen or equ iva len t ) befor e flu sh in g.
Page 226 COOLING SYSTEM 7 - 23 REM OVAL AN D I N STALLAT I ON (Cont inue d) Fig. 18 Reserve/Overflow Tank—With Right Hand Fig. 16 Auxiliary Air-To-Oil Cooler Drive Th e wa t er pu m p ca n be r em oved wit h ou t disch a r g- in g t h e a ir con dit ion in g syst em (if equ ipped).
Page 227 7 - 24 COOLING SYSTEM REM OVAL AN D I N STALLAT I ON (Cont inue d) Fig. 19 Reverse Rotating Water Pump—Typical Fig. 20 Fan Mounting Nuts (5) Rem ove a ccessor y dr ive belt . (Refer t o Acces- sor y Dr ive Belt , Rem ova l a n d In st a lla t ion in t h is gr ou p).
Page 228 COOLING SYSTEM 7 - 25 REM OVAL AN D I N STALLAT I ON (Cont inue d) REMOVAL-4.0L ENGINE (LHD/RHD) (1) Discon n ect ba t t er y n ega t ive ca ble. (2) Dr a in t h e coolin g syst em . (Refer t o Coolin g Syst em -Dr a in in g a n d F illin g in t h is gr ou p.) (3) Discon n ect elect r ic coolin g fa n con n ect or.
Page 229 7 - 26 COOLING SYSTEM REM OVAL AN D I N STALLAT I ON (Cont inue d) Fig. 24 Power Steering Pump Attachment-4.0L INSTALLA TION-4.0L ENGINE (LHD/RHD) (1) If pu m p is bein g r epla ced, in st a ll t h e h ea t er h ose fit t in g t o t h e pu m p.
Page 230 COOLING SYSTEM 7 - 27 REM OVAL AN D I N STALLAT I ON (Cont inue d) CAUTION: When installing the accessory drive belt, (4) Rem ove t h er m ost a t h ou sin g m ou n t in g bolt s, the belt MUST be routed correctly.
Page 231 7 - 28 COOLING SYSTEM REM OVAL AN D I N STALLAT I ON (Cont inue d) (4) F or a ccess t o r a dia t or dr a in cock, r em ove r a dia - t or gr ill m ou n t in g scr ews a n d r em ove gr ill.
Page 232 COOLING SYSTEM 7 - 29 REM OVAL AN D I N STALLAT I ON (Cont inue d) INSTALLA TION Th e r a dia t or is su pplied wit h t wo a lign m en t dowels (F ig. 35). Th ey a r e loca t ed on t h e bot t om t a n k a n d fit in t o r u bber gr om m et s in t h e r a dia t or lower cr oss- m em ber.
Page 233 7 - 30 COOLING SYSTEM REM OVAL AN D I N STALLAT I ON (Cont inue d) CAUTION: A number or letter is stamped into the tongue of constant tension clamps (Fig. 7). If replacement is necessary, use only an original equipment clamp with matching number or letter.
Page 234 COOLING SYSTEM 7 - 31 REM OVAL AN D I N STALLAT I ON (Cont inue d) Fig. 33 Radiator Removal/Installation—4.0L Engines (11) Ma r k t h e posit ion of t h e h ood la t ch st r iker on t h e r a dia t or cr ossm em ber a n d r em ove h ood la t ch st r iker.
Page 235: Electric Cooling Fan-2.5L
7 - 32 COOLING SYSTEM REM OVAL AN D I N STALLAT I ON (Cont inue d) ELECTRIC COOLING FAN—2.5L Th e elect r ic fa n m odu le is on ly t o be ser viced a s a n a ssem bly.
Page 236 COOLING SYSTEM 7 - 33 REM OVAL AN D I N STALLAT I ON (Cont inue d) Fig. 36 Fan Shroud Removal/Installation Fig. 37 Fan Module Orientation and Mounting Fig. 38 Auxiliary Cooling Fan—Remove/Install— Typical...
Page 237: Engine Accessory Drive Belts
7 - 34 COOLING SYSTEM REM OVAL AN D I N STALLAT I ON (Cont inue d) ENGINE ACCESSORY DRIVE BELTS (2) Tigh t en t h e m ou n t in g bolt s t o 4 N·m (31 in . lbs.) t or qu e.
Page 238 COOLING SYSTEM 7 - 35 REM OVAL AN D I N STALLAT I ON (Cont inue d) Fig. 41 Models with 2.5L Engine—With A/C Fig. 43 Models with 4.0L Engine—Without A/C— Except RHD Fig. 42 Models with 2.5L Engine—Without A/C Fig.
Page 239 7 - 36 COOLING SYSTEM REM OVAL AN D I N STALLAT I ON (Cont inue d) Fig. 45 Models With 4.0L Engine—With A/C—With Fig. 47 Power Steering Pump Bracket and Idler Pulley Fig. 46 Models With 4.0L Engine—Without A/C— Fig.
Page 240 COOLING SYSTEM 7 - 37 REM OVAL AN D I N STALLAT I ON (Cont inue d) in g a t t a ch ed t o a n a lu m in u m br a cket on t h e r igh t (1) Loosen bu t do n ot r em ove a t t h is t im e, t h e fou r fr on t side of en gin e (F ig.
Page 241: Cleaning And Inspection
7 - 38 COOLING SYSTEM CLEAN I N G AN D I N SPECT I ON COOLING SYSTEM HOSES RADIA TOR PRESSURE CAP INSPECTION In spect t h e h oses a t r egu la r in t er va ls. Repla ce INSPECTION h oses t h a t a r e cr a cked, feel br it t le wh en squ eezed or swell excessively wh en t h e syst em is pr essu r ized.
Page 242: Torque Specifications
COOLING SYSTEM 7 - 39 SPECI FI CAT I ON S (Cont inue d) TORQUE SPECIFICA TIONS SPECI AL T OOLS COOLING D ES CRIP TION TORQU E Au to . Tra n s . Au x ilia ry Oil Co o le r Mt g.
Page 244 COOLING SYSTEM 7 - 1 COOLING SYSTEM CON T EN T S page page GENERAL INFORMA TION SERVICE PROCEDURES COOLANT ......3 COOLANT LEVEL CHECK .
Page 245: Coolant Tank
7 - 2 COOLING SYSTEM GEN ERAL I N FORM AT I ON (Cont inue d) • H oses a n d h ose cla m ps a u t om a t ic belt t en sion er is u sed t o m a in t a in cor r ect belt t en sion a t a ll t im es.
Page 246: Low Coolant Level Sensor
COOLING SYSTEM 7 - 3 GEN ERAL I N FORM AT I ON (Cont inue d) su r e/ven t ca p r a t in g t o esca pe t h r ou gh t h e ca p. Cool- a n t will flow t h r ou gh t h e t a n k a t a ll t im es du r in g en gin e oper a t ion wh et h er t h e en gin e is cold or a t n or m a l oper a t in g t em per a t u r e.
Page 247 7 - 4 COOLING SYSTEM DESCRI PT I ON AN D OPERAT I ON (Cont inue d) vides qu ick en gin e wa r m u p a n d over a ll t em per a t u r e con t r ol.
Page 248 COOLING SYSTEM 7 - 5 DESCRI PT I ON AN D OPERAT I ON (Cont inue d) t h a n et h ylen e-glycol’s fr eeze poin t . Th e boilin g poin t (pr ot ect ion a ga in st su m m er boil-over ) of pr opylen e- glycol is 125 deg.
Page 249: Automatic Belt Tensioner
7 - 6 COOLING SYSTEM DESCRI PT I ON AN D OPERAT I ON (Cont inue d) • E n gin e loa ds a n d t em per a t u r es a r e h igh su ch a s VISCOUS FAN DRIVE wh en t owin g a t r a iler.
Page 250: Diagnosis And Testing
COOLING SYSTEM 7 - 7 DESCRI PT I ON AN D OPERAT I ON (Cont inue d) WARNING: BECAUSE OF HIGH SPRING PRES- (2) TRAILE R TOWING: SURE, DO NOT ATTEMPT TO DISASSEMBLE THE Con su lt Tr a iler Towin g sect ion of own er s m a n u a l. AUTOMATIC BELT TENSIONER.
Page 251 7 - 8 COOLING SYSTEM DI AGN OSI S AN D T EST I N G (Cont inue d) COOLING SYSTEM DIAGNOSIS–DIESEL ENGINE...
Page 252 COOLING SYSTEM 7 - 9 DI AGN OSI S AN D T EST I N G (Cont inue d)
Page 253 7 - 10 COOLING SYSTEM DI AGN OSI S AN D T EST I N G (Cont inue d)
Page 254 COOLING SYSTEM 7 - 11 DI AGN OSI S AN D T EST I N G (Cont inue d)
Page 255 7 - 12 COOLING SYSTEM DI AGN OSI S AN D T EST I N G (Cont inue d)
Page 256: Radiator Coolant Flow Check
COOLING SYSTEM 7 - 13 DI AGN OSI S AN D T EST I N G (Cont inue d) THERMOSTA T a lso will en su r e a ga in st excessively h igh coola n t t em - per a t u r e.
Page 257 7 - 14 COOLING SYSTEM DI AGN OSI S AN D T EST I N G (Cont inue d) t or y. Th e a ddit ive is h igh ly visible u n der u lt r a violet 11) wh en t est in g eit h er t h e coola n t t a n k or pr essu r e ligh t (bla ck ligh t ).
Page 258 COOLING SYSTEM 7 - 15 DI AGN OSI S AN D T EST I N G (Cont inue d) su r e. In spect for in t er ior lea ka ge or do t h e In t er n a l 11) wh en t est in g eit h er t h e coola n t t a n k or pr essu r e Lea ka ge Test .
Page 259 7 - 16 COOLING SYSTEM DI AGN OSI S AN D T EST I N G (Cont inue d) BELT DIAGNOSIS Wh en dia gn osin g ser pen t in e a ccessor y dr ive belt s, sm a ll cr a cks t h a t r u n a cr oss t h e r ibbed su r fa ce of t h e belt fr om r ib t o r ib (F ig.
Page 260 COOLING SYSTEM 7 - 17 DI AGN OSI S AN D T EST I N G (Cont inue d) SERPENTINE DRIVE BELT DIAGNOSIS...
Page 261: Service Procedures
7 - 18 COOLING SYSTEM SERV I CE PROCEDU RES UNDER PRESSURE. PLACE A RAG OVER THE CAP. VERY SLOWLY ROTATE THE CAP COUNTER- CLOCKWISE ALLOWING PRESSURE TO SLOWLY COOLANT LEVEL CHECK RELEASE. AFTER ALL PRESSURE HAS BEEN Th e coola n t level is ch ecked a n d a dju st ed a t t h e RELEASED, REMOVE THE COOLANT TANK CAP pr essu r ized coola n t t a n k (F ig.
Page 262: Removal And Installa Tion
COOLING SYSTEM 7 - 19 SERV I CE PROCEDU RES (Cont inue d) (7) Wit h t h e h ea t er con t r ol u n it in t h e H E AT posi- t ion , oper a t e en gin e wit h coola n t t a n k ca p t igh t en ed. (8) Aft er en gin e h a s r ea ch ed n or m a l oper a t in g t em per a t u r e, sh u t en gin e off a n d a llow it t o cool.
Page 263: Fan Blade Removal
7 - 20 COOLING SYSTEM REM OVAL AN D I N STALLAT I ON (Cont inue d) (10) Lift r a dia t or st r a igh t u p a n d ou t of en gin e (1) Discon n ect n ega t ive ba t t er y ca ble fr om ba t t er y.
Page 264: Thermostat
COOLING SYSTEM 7 - 21 REM OVAL AN D I N STALLAT I ON (Cont inue d) REVERSE to designate their usage. Installation of (9) Rem ove fou r bolt s secu r in g fa n bla de a ssem bly t o viscou s fa n dr ive (F ig.
Page 265: Water Pump
7 - 22 COOLING SYSTEM REM OVAL AN D I N STALLAT I ON (Cont inue d) (2) Rem ove t h e u pper r a dia t or h ose a t t h e t h er m o- (6) Be su r e t h a t t h e r a dia t or dr a in is t igh t ly st a t h ou sin g.
Page 266 COOLING SYSTEM 7 - 23 REM OVAL AN D I N STALLAT I ON (Cont inue d) Fig. 22 Thermal Viscous Fan Drive and Blade Assembly (5) Rem ove t h e u pper fa n sh r ou d-t o-u pper cr oss- Fig.
Page 267 7 - 24 COOLING SYSTEM REM OVAL AN D I N STALLAT I ON (Cont inue d) Fig. 25 Coolant Tube at Water Pump Fig. 23 Hose Clamp Tool ot h er for eign m a t er ia l. In spect t h e wa t er pu m p, wa t er pu m p a da pt er a n d wa t er pu m p m a t in g su r- fa ces for er osion or da m a ge fr om ca vit a t ion .
Page 268: Cleaning And Inspection
COOLING SYSTEM 7 - 25 CLEAN I N G AN D I N SPECT I ON WA TER PUMP INSPECTION Repla ce t h e wa t er pu m p a ssem bly if it h a s a n y of t h e followin g con dit ion s: •...
Page 269: Specifica Tions
7 - 26 COOLING SYSTEM CLEAN I N G AN D I N SPECT I ON (Cont inue d) wit h wa t er, r u n en gin e a n d dr a in syst em . Repea t st a t h ou sin g a n d in st a ll t h er m ost a t .
Page 270 BA TTERY 8A - 1 BATTERY CON T EN T S page page DESCRIPTION AND OPERA TION REMOVAL AND INSTALLA TION BATTERY ....... 1 BATTERY .
Page 271 8A - 2 BA TTERY DESCRI PT I ON AN D OPERAT I ON (Cont inue d) Th e dia gn ost ic pr ocedu r es u sed in ea ch of t h ese a ge pot en t ia l of ea ch cell is r edu ced. H owever, by gr ou ps in clu de t h e m ost ba sic con ven t ion a l dia gn ost ic ch a r gin g t h e ba t t er y wit h a volt a ge h igh er t h a n t h a t m et h ods, t o t h e m or e soph ist ica t ed On -Boa r d Dia g-...
Page 272 BA TTERY 8A - 3 DESCRI PT I ON AN D OPERAT I ON (Cont inue d) COLD CRANKING AMPERAGE Wh en in st a llin g a ba t t er y, be cer t a in t h a t t h e h old down fa st en er s a r e t igh t en ed t o t h e pr oper specifica - Th e Cold Cr a n kin g Am per a ge (CCA) r a t in g specifies t ion s.
Page 273 8A - 4 BA TTERY DI AGN OSI S AN D T EST I N G (Cont inue d) WARNING: bu ilt -in t est in dica t or, view t h e t est in dica t or t o •...
Page 274 BA TTERY 8A - 5 DI AGN OSI S AN D T EST I N G (Cont inue d) Battery Diagnosis Condition Possible Causes Correction The battery seems weak or 1. The battery has an 1. Refer to Battery in the Specifications section of dead when attempting to start incorrect size or rating for this group.
Page 275 8A - 6 BA TTERY DI AGN OSI S AN D T EST I N G (Cont inue d) Battery Diagnosis Condition Possible Causes Correction The battery state-of-charge 1. The battery has an 1. Refer to Battery in the Specifications section of cannot be maintained.
Page 276 BA TTERY 8A - 7 DI AGN OSI S AN D T EST I N G (Cont inue d) Refer t o Lo a d Te s t in t h e Dia gn osis a n d Test in g sec- t er y, t h e ba t t er y m u st be loa d t est ed.
Page 277 8A - 8 BA TTERY DI AGN OSI S AN D T EST I N G (Cont inue d) In a fu lly-ch a r ged ba t t er y t h e elect r olyt e will h a ve a t em per a t u r e-cor r ect ed specific gr a vit y of 1.260 t o 1.290.
Page 278 BA TTERY 8A - 9 DI AGN OSI S AN D T EST I N G (Cont inue d) t h e ba t t er y m a y be loa d t est ed t o det er m in e it s (3) Usin g a volt m et er con n ect ed t o t h e ba t t er y cr a n kin g ca pa cit y.
Page 279 8A - 10 BA TTERY DI AGN OSI S AN D T EST I N G (Cont inue d) WARNING: • IF THE BATTERY SHOWS SIGNS OF FREEZ- ING, LEAKING, LOOSE POSTS, OR LOW ELECTRO- LYTE LEVEL, DO NOT TEST, ASSIST-BOOST, OR CHARGE.
Page 280 BA TTERY 8A - 11 DI AGN OSI S AN D T EST I N G (Cont inue d) CHARGE. THE BATTERY MAY ARC INTERNALLY AND EXPLODE. PERSONAL INJURY AND/OR VEHI- CLE DAMAGE MAY RESULT. • EXPLOSIVE HYDROGEN GAS FORMS IN AND AROUND THE BATTERY.
Page 281 8A - 12 BA TTERY DI AGN OSI S AN D T EST I N G (Cont inue d) Fig. 12 Test Battery Positive Cable Resistance - Typical Fig. 10 Test Battery Negative Connection Resistance - Typical Fig. 13 Test Ground Circuit Resistance - Typical t o t wen t y-five m illia m per es (0.005 t o 0.025 a m per e) wit h t h e ign it ion swit ch in t h e Off posit ion , a n d a ll Fig.
Page 282 BA TTERY 8A - 13 DI AGN OSI S AN D T EST I N G (Cont inue d) in g a ba t t er y. In m ost ca ses, t h e ba t t er y ca n be lowest m illia m per e sca le of t h e m u lt i-m et er t o ch eck ch a r ged a n d r et u r n ed t o ser vice a ft er t h e excessive t h e low-a m per a ge IOD.
Page 283 8A - 14 BA TTERY SERV I CE PROCEDU RES (Cont inue d) CAUTION: • Always disconnect and isolate the battery neg- ative cable before charging a battery. Do not exceed sixteen volts while charging a battery. Damage to the vehicle electrical system components may result.
Page 284 BA TTERY 8A - 15 SERV I CE PROCEDU RES (Cont inue d) t er y, t h e cu r r en t a ccept ed by t h e ba t t er y will be ver y low a t fir st .
Page 285 8A - 16 BA TTERY REM OVAL AN D I N STALLAT I ON (Cont inue d) Fig. 18 Removing Cell Caps - Typical tio n s in t h e Specifica t ion s sect ion of t h is gr ou p. Con - fir m t h a t t h e r epla cem en t ba t t er y is t h e cor r ect size a n d h a s t h e cor r ect r a t in gs for t h e veh icle.
Page 286 BA TTERY 8A - 17 REM OVAL AN D I N STALLAT I ON (Cont inue d) Fig. 21 Battery Cables (4) Con n ect a n d t igh t en t h e ba t t er y posit ive ca ble t er m in a l cla m p.
Page 288 STARTING SYSTEMS 8B - 1 STARTING SYSTEMS CON T EN T S page page DESCRIPTION AND OPERA TION STARTER RELAY ......9 STARTER MOTOR .
Page 289 8B - 2 STARTING SYSTEMS DESCRI PT I ON AN D OPERAT I ON (Cont inue d) Th e dia gn ost ic pr ocedu r es u sed in ea ch of t h ese con n ect t h e r ela y com m on feed t er m in a l t o t h e r ela y gr ou ps in clu de t h e m ost ba sic con ven t ion a l dia gn ost ic n or m a lly open t er m in a l.
Page 290 STARTING SYSTEMS 8B - 3 DESCRI PT I ON AN D OPERAT I ON (Cont inue d) m ot or is r a t ed a t 1.4 kilowa t t s (a bou t 1.9 h or se- Th e st a r t er r ela y ca n n ot be r epa ir ed or a dju st ed power ) ou t pu t a t 12 volt s.
Page 291 8B - 4 STARTING SYSTEMS DI AGN OSI S AN D T EST I N G (Cont inue d) Starting System Diagnosis CONDITION POSSIBLE CAUSE CORRECTION STARTER FAILS TO 1. Battery discharged or 1. Refer to Battery in the Diagnosis and Testing section of OPERATE.
Page 292 STARTING SYSTEMS 8B - 5 DI AGN OSI S AN D T EST I N G (Cont inue d) INSPECTION r equ ir ed. Refer t o t h e pr oper sect ion of Gro u p 8W - Wirin g D ia g ra m s for com plet e ser vice in for m a t ion F or com plet e cir cu it dia gr a m s, r efer t o S ta rtin g a n d cir cu it dia gr a m s for t h e st a r t in g syst em wir in g...
Page 293 8B - 6 STARTING SYSTEMS DI AGN OSI S AN D T EST I N G (Cont inue d) t o En g in e D ia g n o s is in t h e Dia gn osis a n d Test in g la you t la bel a ffixed t o t h e u n der side of t h e P DC cover sect ion of Gr ou p 9 - E n gin e for fu r t h er t est in g of for ASD r ela y iden t ifica t ion a n d loca t ion .
Page 294 STARTING SYSTEMS 8B - 7 DI AGN OSI S AN D T EST I N G (Cont inue d) t h e ign it ion swit ch in t h e St a r t posit ion . Obser ve t h e (5) Con n ect t h e posit ive lea d of t h e volt m et er t o volt m et er.
Page 295 8B - 8 STARTING SYSTEMS DI AGN OSI S AN D T EST I N G (Cont inue d) STARTER MOTOR NOISE - 2.5L ENGINE See t h e St a r t er Mot or Noise Dia gn osis ch a r t (F ig. 7).
Page 296 STARTING SYSTEMS 8B - 9 DI AGN OSI S AN D T EST I N G (Cont inue d) CAUTION: The 2.5L engine uses a permanent mag- (3) Ch eck for con t in u it y bet ween t h e solen oid t er- net starter.
Page 297 8B - 10 STARTING SYSTEMS DI AGN OSI S AN D T EST I N G (Cont inue d) (4) Con n ect a ba t t er y t o t er m in a ls 85 a n d 86. swit ch for a n open or a sh or t .
Page 298 STARTING SYSTEMS 8B - 11 REM OVAL AN D I N STALLAT I ON (Cont inue d) Fig. 12 Starter Motor Remove/Install - 2.5L Engine Fig. 14 Starter Motor Remove/Install - 4.0L Engine (7) Discon n ect t h e solen oid t er m in a l wir e h a r n ess con n ect or fr om t h e con n ect or r ecept a cle on t h e st a r t er solen oid.
Page 299 8B - 12 STARTING SYSTEMS REM OVAL AN D I N STALLAT I ON (Cont inue d) NOTE: Shim thickness available is 0.381 mm (0.015 STARTER RELA Y in.). Refer to Starter Motor Noise - 2.5L Engine in the Diagnosis and Testing section of this group for REMOVAL more information.
Page 300 STARTING SYSTEMS 8B - 13 SPECI FI CAT I ON S STARTING SYSTEM Starter Motor and Solenoid Manufacturer Mitsubishi Engine Application 2.5L, 4.0L 2.5L - 1.2 Kilowatt (1.6 Horsepower) Power Rating 4.0L - 1.4 Kilowatt (1.9 Horsepower) Voltage 12 Volts Number of Fields Number of Poles Number of Brushes...
Page 302 STARTING SYSTEMS 8B - 1 STARTING SYSTEMS CON T EN T S page page REMOVAL AND INSTALLA TION SPECIFICA TIONS STARTER RELAY ......3 STARTING SYSTEM .
Page 303 8B - 2 STARTING SYSTEMS REM OVAL AN D I N STALLAT I ON (Cont inue d) (14) Rem ove t h e st a r t er h ea t sh ield. (15) Rem ove t h e (3) st a r t er m ot or r et a in in g bolt s. (16) Rem ove t h e st a r t er m ot or fr om t h e veh icle.
Page 304 STARTING SYSTEMS 8B - 3 REM OVAL AN D I N STALLAT I ON (Cont inue d) CAUTION: Heatshield is very sharp. Wear gloves to prevent injury. (3) In st a ll t h e st a r t er h ea t sh ield. (4) In st a ll t h e st a r t er m ot or su ppor t br a cket .
Page 305 8B - 4 STARTING SYSTEMS SPECI FI CAT I ON S STARTING SYSTEM Starter and Solenoid Engine Application 2.5L Diesel Power Rating 2.2 Kilowatt Voltage 12 Volts Number of Fields Number of Poles Number of Brushes Drive Type Planetary Gear Reduction Free Running Test Voltage 11.5 Volts Free Running Test Maximum...
Page 306 CHARGING SYSTEM 8C - 1 CHARGING SYSTEM CON T EN T S page page DESCRIPTION AND OPERA TION ON-BOARD DIAGNOSTIC TEST FOR BATTERY TEMPERATURE SENSOR ..2 CHARGING SYSTEM ....3 CHARGING SYSTEM .
Page 307 8C - 2 CHARGING SYSTEM DESCRI PT I ON AN D OPERAT I ON (Cont inue d) Th e Y t ype st a t or win din g con n ect ion s deliver t h e r efer t o Ch a r gin g Syst em Oper a t ion for a ddit ion a l in du ced AC cu r r en t t o 3 posit ive a n d 3 n ega t ive in for m a t ion .
Page 308 CHARGING SYSTEM 8C - 3 DI AGN OSI S AN D T EST I N G (Cont inue d) BA TTERY TEMPERA TURE SENSOR F or DTC in for m a t ion , r efer t o Dia gn ost ic Tr ou ble Codes in Gr ou p 25, E m ission Con t r ol Syst em .
Page 309 8C - 4 CHARGING SYSTEM REM OVAL AN D I N STALLAT I ON (Cont inue d) Fig. 4 Remove/Install Generator—4.0L Engine—RHD Fig. 2 Remove/Install Generator—2.5L Engine Fig. 5 Generator Connectors—Typical Bosch (6) RH D Veh icles: In st a ll u pper n u t (gen er a t or a dju st m en t n u t ) a n d bot h belt a dju st m en t bolt s.
Page 310 CHARGING SYSTEM 8C - 5 REM OVAL AN D I N STALLAT I ON (Cont inue d) (2) Discon n ect sen sor pigt a il h a r n ess fr om en gin e wir e h a r n ess. (3) P r y sen sor st r a igh t u p fr om ba t t er y t r a y m ou n t in g h ole.
Page 312 CHARGING SYSTEM 8C - 1 CHARGING SYSTEM CON T EN T S page page GENERAL INFORMA TION REMOVAL AND INSTALLA TION INTRODUCTION ......1 GENERATOR .
Page 313 8C - 2 CHARGING SYSTEM REM OVAL AN D I N STALLAT I ON (Cont inue d) (4) Un plu g t h e field t er m in a l con n ect or (F ig. 1) a t r ea r of gen er a t or.
Page 314 IGNITION SYSTEM 8D - 1 IGNITION SYSTEM CON T EN T S page page DESCRIPTION AND OPERA TION CRANKSHAFT POSITION SENSOR ..10 AUTOMATIC SHUTDOWN (ASD) RELAY ..2 DISTRIBUTOR .
Page 315: Automatic Shutdown (Asd) Relay
8D - 2 IGNITION SYSTEM DESCRI PT I ON AN D OPERAT I ON (Cont inue d) SPARK PLUGS a dva n ce, a n d for ch a n gin g en gin e oper a t in g con di- t ion s.
Page 316 IGNITION SYSTEM 8D - 3 DESCRI PT I ON AN D OPERAT I ON (Cont inue d) Fig. 4 Sensor Operation—2.5L 4-Cyl. Engine Fig. 3 Crankshaft Position Sensor—Typical t h e sen sor in pu t t o det er m in e t h e cr a n ksh a ft posi- t ion .
Page 317: Diagnosis And Testing
8D - 4 IGNITION SYSTEM DESCRI PT I ON AN D OPERAT I ON (Cont inue d) Wh en t h e t r a ilin g edge of t h e pu lse r in g (sh u t t er ) lea ves t h e syn c sign a l gen er a t or, t h e followin g occu r s: Th e ch a n ge of t h e m a gn et ic field ca u ses t h e syn c sig- n a l volt a ge t o swit ch low t o 0 volt s.
Page 318: Distributor Cap
IGNITION SYSTEM 8D - 5 DI AGN OSI S AN D T EST I N G (Cont inue d) If t h e ign it ion coil is bein g r epla ced, t h e secon da r y spa r k plu g ca ble m u st a lso be ch ecked.
Page 319: Spark Plug Conditions
8D - 6 IGNITION SYSTEM DI AGN OSI S AN D T EST I N G (Cont inue d) If a n oscilloscope is n ot a va ila ble, spa r k plu g ca bles Ca ble Resist a n ce ch a r t , r em ove t h e ca ble fr om t h e m a y be t est ed a s follows: dist r ibu t or ca p.
Page 320 IGNITION SYSTEM 8D - 7 DI AGN OSI S AN D T EST I N G (Cont inue d) WET FOULING OR GAS FOULING A spa r k plu g coa t ed wit h excessive wet fu el or oil is wet fou led.
Page 321: Removal And Installa Tion
8D - 8 IGNITION SYSTEM DI AGN OSI S AN D T EST I N G (Cont inue d) Fig. 15 Chipped Electrode Insulator Fig. 17 Spark Plug Overheating Det er m in e if ign it ion t im in g is over a dva n ced or if REM OVAL AN D I N STALLAT I ON ot h er oper a t in g con dit ion s a r e ca u sin g en gin e over- h ea t in g.
Page 322 IGNITION SYSTEM 8D - 9 REM OVAL AN D I N STALLAT I ON (Cont inue d) PLUG INSTALLA TION a r ou n d t h e spa r k plu g. Th is will h elp pr even t for eign m a t er ia l fr om en t er in g t h e com bu st ion ch a m ber.
Page 323 8D - 10 IGNITION SYSTEM REM OVAL AN D I N STALLAT I ON (Cont inue d) Fig. 21 Ignition Coil—4.0L Engine INSTALLA TION (1) In st a ll ign it ion coil t o br a cket on cylin der block Fig.
Page 324: Camshaft Position Sensor
IGNITION SYSTEM 8D - 11 REM OVAL AN D I N STALLAT I ON (Cont inue d) m a c h in e d to c o rre c tly s p a c e u n it to fly w h e e l. u t or h ou sin g (F ig.
Page 325 8D - 12 IGNITION SYSTEM REM OVAL AN D I N STALLAT I ON (Cont inue d) Fig. 27 Align Timing Marks be sligh t ly befor e (cou n t er clockwise of) 10 o’clock posit ion (F ig. 28). (15) 4.0L 6-Cy lin d e r En g in e : Obser ve slot in oil Fig.
Page 326 IGNITION SYSTEM 8D - 13 REM OVAL AN D I N STALLAT I ON (Cont inue d) Fig. 29 Slot At 11 O’clock Position—4.0L Engine (2) Ch eck posit ion of slot on oil pu m p gea r. On t h e 2.5L en gin e, it sh ou ld be ju st sligh t ly befor e (cou n t er- clockwise of) 10 o’clock posit ion (F ig.
Page 327 8D - 14 IGNITION SYSTEM REM OVAL AN D I N STALLAT I ON (Cont inue d) Fig. 33 Distributor Engaged Position—4.0L Fig. 31 Distributor Pre-position—All Engines 6-Cylinder Engine CAUTION: If the distributor cap is incorrectly posi- tioned on distributor housing, cap or rotor may be damaged when engine is started.
Page 328 IGNITION SYSTEM 8D - 15 REM OVAL AN D I N STALLAT I ON (Cont inue d) Fig. 34 Key Cylinder Release Tang Fig. 36 Ignition Switch Lock Tab Fig. 35 Key Cylinder and Cover Removal Fig. 37 Switch In ON Position IGNITION SWITCH REMOVAL (2) Con n ect t wo elect r ica l con n ect or s t o r ea r of ign it ion swit ch .
Page 329: Spark Plugs
8D - 16 IGNITION SYSTEM REM OVAL AN D I N STALLAT I ON (Cont inue d) P r ocedu r es sect ion of t h is gr ou p for m or e in for m a - t ion .
Page 330: Torque Chart
IGNITION SYSTEM 8D - 17 SPECI FI CAT I ON S (Cont inue d) IGNITION COIL RESISTANCE PRIMARY RESISTANCE SECONDARY RESISTANCE COIL MANUFACTURER 21-27°C (70-80°F) 21-27°C (70-80°F) Diamond 0.97 - 1.18 Ohms 11,300 - 15,300 Ohms Toyodenso 0.95 - 1.20 Ohms 11,300 - 13,300 Ohms TORQUE CHART D ES CRIP TION...
Page 332 INSTRUMENT PANEL SYSTEMS 8E - 1 INSTRUMENT PANEL SYSTEMS CON T EN T S page page DESCRIPTION AND OPERA TION GLOVE BOX COMPONENTS ....22 CIGAR LIGHTER RELAY ....4 GLOVE BOX LATCH STRIKER .
Page 333: Instrument Cluster
8E - 2 INSTRUMENT PANEL SYSTEMS DESCRI PT I ON AN D OPERAT I ON (Cont inue d) r edu ce bu zzes, squ ea ks, a n d r a t t les even on t h e Th e low-lin e clu st er in clu des t h e followin g a n a log bu m piest r oa ds.
Page 334 INSTRUMENT PANEL SYSTEMS 8E - 3 DESCRI PT I ON AN D OPERAT I ON (Cont inue d) E lect r ica lly H ea t ed Syst em s for m or e in for m a t ion on Th e sea t belt r em in der la m p is con t r olled by t h e t h e t im er fu n ct ion of t h e in st r u m en t clu st er.
Page 335: Instrument Panel Power Outlet
8E - 4 INSTRUMENT PANEL SYSTEMS DESCRI PT I ON AN D OPERAT I ON (Cont inue d) OPERA TION cu r r en t ca pa cit ies, t er m in a l pa t t er n s, a n d t er m in a l fu n ct ion s.
Page 336: Diagnosis And Testing
INSTRUMENT PANEL SYSTEMS 8E - 5 DI AGN OSI S AN D T EST I N G swit ch ou t pu t (r u n /st a r t ) cir cu it t o t h e ign it ion swit ch a s r equ ir ed.
Page 337 8E - 6 INSTRUMENT PANEL SYSTEMS DI AGN OSI S AN D T EST I N G (Cont inue d) ANTI-LOCK BRAKE SYSTEM LAMP lizer Modu le (SKIM) or t h e in pu t s t o on e of t h ese elect r on ic con t r ol m odu les.
Page 338 INSTRUMENT PANEL SYSTEMS 8E - 7 DI AGN OSI S AN D T EST I N G (Cont inue d) Fig. 1 Low-Line Instrument Cluster Actuator Test...
Page 339 8E - 8 INSTRUMENT PANEL SYSTEMS DI AGN OSI S AN D T EST I N G (Cont inue d) Fig. 2 High-Line Instrument Cluster Actuator Test...
Page 340 INSTRUMENT PANEL SYSTEMS 8E - 9 DI AGN OSI S AN D T EST I N G (Cont inue d) wh ile dr ivin g, r efer B a s e B ra k e S y s te m for veh icles bet ween t h e r ed br a ke wa r n in g in dica t or dr iver cir- n ot equ ipped wit h t h e fou r wh eel a n t i-lock br a ke sys- cu it ca vit y of t h e in st r u m en t clu st er wir e h a r n ess...
Page 341 8E - 10 INSTRUMENT PANEL SYSTEMS DI AGN OSI S AN D T EST I N G (Cont inue d) Rem ove t h e in st r u m en t clu st er. Wit h t h e t r a n sfer (5) Tu r n t h e ign it ion swit ch t o t h e Off posit ion .
Page 342: Instrument Panel Cigar Lighter
INSTRUMENT PANEL SYSTEMS 8E - 11 DI AGN OSI S AN D T EST I N G (Cont inue d) m e n t Clu s te r in t h e Con t en t s of Gr ou p 8W - Wir in g (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive Dia gr a m s.
Page 343: Instrument Panel Power Outlet
8E - 12 INSTRUMENT PANEL SYSTEMS DI AGN OSI S AN D T EST I N G (Cont inue d) CIGAR LIGHTER RELA Y a t t h e fu sed B(+) cir cu it ca vit y of t h e a ccessor y r ela y wir e h a r n ess con n ect or.
Page 344: Removal And Installa Tion
INSTRUMENT PANEL SYSTEMS 8E - 13 DI AGN OSI S AN D T EST I N G (Cont inue d) (3) Rem ove t h e pla st ic pr ot ect ive ca p fr om t h e power ou t let r ecept a cle.
Page 345 8E - 14 INSTRUMENT PANEL SYSTEMS REM OVAL AN D I N STALLAT I ON (Cont inue d) INSTRUMENT PANEL CENTER BEZEL WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, REFER GROUP PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE.
Page 346: Cigar Lighter Relay
INSTRUMENT PANEL SYSTEMS 8E - 15 REM OVAL AN D I N STALLAT I ON (Cont inue d) INSTRUMENT PANEL ACCESSORY SWITCH swit ch es, t h e ciga r ligh t er a n d t h e a ccessor y power ou t let on t h e ba ck of t h e a ccessor y swit ch bezel.
Page 347: Cluster Bezel
8E - 16 INSTRUMENT PANEL SYSTEMS REM OVAL AN D I N STALLAT I ON (Cont inue d) REMOVAL (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive ca ble.
Page 348: Headlamp Switch
INSTRUMENT PANEL SYSTEMS 8E - 17 REM OVAL AN D I N STALLAT I ON (Cont inue d) (3) P r ess fir m ly on t h e clu st er bezel over ea ch of a n d sh a ft r elea se bu t t on on t h e in boa r d side of t h e t h e sn a p clip loca t ion s u n t il ea ch of t h e sn a p clips is swit ch body.
Page 349: Instrument Cluster
8E - 18 INSTRUMENT PANEL SYSTEMS REM OVAL AN D I N STALLAT I ON (Cont inue d) INSTRUMENT CLUSTER t h e clu st er con n ect or r ecept a cles wh en t h e clu st er is in st a lled in t h e in st r u m en t pa n el.
Page 350 INSTRUMENT PANEL SYSTEMS 8E - 19 REM OVAL AN D I N STALLAT I ON (Cont inue d) (3) Tu r n t h e bu lb h older cou n t er clockwise a bou t (4) Gen t ly pu ll t h e clu st er len s a wa y fr om t h e clu s- sixt y degr ees on t h e clu st er elect r on ic cir cu it boa r d.
Page 351 8E - 20 INSTRUMENT PANEL SYSTEMS REM OVAL AN D I N STALLAT I ON (Cont inue d) CAUTION: Always use the correct bulb size and (4) Wor k a r ou n d t h e per im et er of t h e clu st er h ou s- in g t o disen ga ge ea ch of t h e la t ch es t h a t secu r e t h e type for replacement.
Page 352 INSTRUMENT PANEL SYSTEMS 8E - 21 REM OVAL AN D I N STALLAT I ON (Cont inue d) REMOVAL (4) In st a ll t h e clu st er len s on t o t h e clu st er h ou s- in g.
Page 353 8E - 22 INSTRUMENT PANEL SYSTEMS REM OVAL AN D I N STALLAT I ON (Cont inue d) REMOVAL (6) In st a ll t h e clu st er bezel on t o t h e in st r u m en t pa n el.
Page 354 INSTRUMENT PANEL SYSTEMS 8E - 23 REM OVAL AN D I N STALLAT I ON (Cont inue d) REMOVAL GLOVE BOX HINGE, BIN, INNER DOOR AND LA TCH (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive ca ble.
Page 355 8E - 24 INSTRUMENT PANEL SYSTEMS REM OVAL AN D I N STALLAT I ON (Cont inue d) GLOVE BOX LA TCH STRIKER INSTRUMENT PANEL END CAP WARNING: ON VEHICLES EQUIPPED WITH AIR- WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, REFER GROUP PASSIVE...
Page 356: Instrument Panel Center Support
INSTRUMENT PANEL SYSTEMS 8E - 25 REM OVAL AN D I N STALLAT I ON (Cont inue d) INSTRUMENT PANEL CENTER SUPPORT Rem ova l a n d In st a lla t ion sect ion of t h is gr ou p for t h e pr ocedu r es.
Page 357 8E - 26 INSTRUMENT PANEL SYSTEMS REM OVAL AN D I N STALLAT I ON (Cont inue d) INSTALLA TION te r S u p p o rt B ra c k e t in t h e Rem ova l a n d In st a lla - t ion sect ion of t h is gr ou p for t h e pr ocedu r es.
Page 358 INSTRUMENT PANEL SYSTEMS 8E - 27 REM OVAL AN D I N STALLAT I ON (Cont inue d) Fig. 23 Instrument Panel Assembly Remove/Install (2) In st a ll a n d t igh t en t h e fou r scr ews a n d t wo (8) Recon n ect t h e t wo wir e h a r n ess con n ect or s n u t s t h a t secu r e t h e t op of t h e in st r u m en t pa n el t o loca t ed n ea r t h e in st r u m en t pa n el-t o-floor wir e h a r-...
Page 359 8E - 28 INSTRUMENT PANEL SYSTEMS REM OVAL AN D I N STALLAT I ON (Cont inue d) (14) In st a ll t h e kn ee blocker on t o t h e in st r u m en t Trim in t h e Rem ova l a n d In st a lla t ion sect ion of pa n el.
Page 360 INSTRUMENT PANEL SYSTEMS 8E - 1 INSTRUMENT PANEL SYSTEMS CON T EN T S page page REMOVAL AND INSTALLA TION REAR FOG LAMP SWITCH ....1 HEADLAMP LEVELING SWITCH .
Page 361 8E - 2 INSTRUMENT PANEL SYSTEMS REM OVAL AN D I N STALLAT I ON (Cont inue d) (6) Rem ove t h e a ccessor y swit ch bezel fr om t h e (8) Rever se t h e r em ova l pr ocedu r es t o in st a ll. Be in st r u m en t pa n el.
Page 362 AUDIO SYSTEMS 8F - 1 AUDIO SYSTEMS CON T EN T S page page GENERAL INFORMA TION RADIO ....... . . 4 AUDIO SYSTEM .
Page 363: Audio System
8F - 2 AUDIO SYSTEMS DESCRI PT I ON AN D OPERAT I ON (Cont inue d) ign it ion swit ch in t h e Off posit ion , will cor r ect t h e n ect a llows t h e in st r u m en t pa n el a ssem bly t o be scr a m bled displa y con dit ion .
Page 364 AUDIO SYSTEMS 8F - 3 DI AGN OSI S AN D T EST I N G (Cont inue d) Audio System Diagnosis CONDITION POSSIBLE CAUSE CORRECTION NO AUDIO. 1. Fuse faulty. 1. Check radio fuses in junction block. Replace fuses, if 2.
Page 365 8F - 4 AUDIO SYSTEMS DI AGN OSI S AN D T EST I N G (Cont inue d) Audio System Diagnosis CONDITION POSSIBLE CAUSE CORRECTION NO COMPACT DISC 1. Faulty CD. 1. Insert known good CD and test operation. OPERATION 2.
Page 366: Antenna
AUDIO SYSTEMS 8F - 5 DI AGN OSI S AN D T EST I N G (Cont inue d) (3) If t h e veh icle is equ ipped wit h t h e In fin it y r a dio 12 volt ou t pu t cir cu it ca vit y of t h e a m plifier spea ker pa cka ge, go t o St ep 6.
Page 367 8F - 6 AUDIO SYSTEMS DI AGN OSI S AN D T EST I N G (Cont inue d) NOTE: This model has a two-piece antenna coaxial TEST 3 cable. Tests 2 and 4 must be conducted in two Test 3 ch ecks t h e con dit ion of t h e veh icle body steps to isolate a coaxial cable problem;...
Page 368: Radio
AUDIO SYSTEMS 8F - 7 DI AGN OSI S AN D T EST I N G (Cont inue d) gr ou n d cir cu it s or con n ect ion s t o gr ou n d a s r equ ir ed t er bezel a wa y fr om t h e in st r u m en t pa n el t o r elea se befor e con sider in g a n y com pon en t r epla cem en t .
Page 369: Amplifier
8F - 8 AUDIO SYSTEMS REM OVAL AN D I N STALLAT I ON (Cont inue d) SPEAKER FRONT DOOR LOWER (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive ca ble.
Page 370 AUDIO SYSTEMS 8F - 9 REM OVAL AN D I N STALLAT I ON (Cont inue d) (11) P u ll t h e spea ker a wa y fr om t h e in n er door pa n el fa r en ou gh t o a ccess a n d u n plu g t h e spea ker wir e h a r n ess con n ect or.
Page 371: Antenna
8F - 10 AUDIO SYSTEMS REM OVAL AN D I N STALLAT I ON (Cont inue d) (2) Usin g a t r im st ick or a n ot h er su it a ble wide (F ig. 12). Un plu g t h e con n ect or by pu llin g it a pa r t fla t -bla ded t ool, gen t ly pr y a r ou n d t h e per im et er wh ile t wist in g t h e m et a l con n ect or h a lves.
Page 372 AUDIO SYSTEMS 8F - 11 REM OVAL AN D I N STALLAT I ON (Cont inue d) RADIO NOISE SUPPRESSION COMPONENTS WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, REFER GROUP PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE.
Page 373: Special Tools
8F - 12 AUDIO SYSTEMS REM OVAL AN D I N STALLAT I ON (Cont inue d) SPECI AL T OOLS (3) In st a ll a n d t igh t en t h e n u t t h a t secu r es t h e en gin e-t o-body gr ou n d st r a p eyelet t o t h e st u d on t h e left u pper r ea r cor n er of t h e en gin e cylin der h ea d.
Page 374 HORN SYSTEMS 8G - 1 HORN SYSTEMS CON T EN T S page page DESCRIPTION AND OPERA TION HORN RELAY ......3 HORN .
Page 375 8G - 2 HORN SYSTEMS DESCRI PT I ON AN D OPERAT I ON (Cont inue d) OPERA TION Wh en t h e elect r om a gn et ic coil is de-en er gized, spr in g pr essu r e r et u r n s t h e m ova ble con t a ct t o t h e Wit h in t h e t wo h a lves of t h e m olded pla st ic h or n n or m a lly closed posit ion .
Page 376 HORN SYSTEMS 8G - 3 DESCRI PT I ON AN D OPERAT I ON (Cont inue d) com plet ed h or n swit ch cir cu it pr ovides a gr ou n d for t h e con t r ol coil side of t h e h or n r ela y, wh ich a ct iva t es t h e r ela y.
Page 377 8G - 4 HORN SYSTEMS DI AGN OSI S AN D T EST I N G (Cont inue d) WARNING: ON VEHICLES EQUIPPED WITH AIR- n ot OK, clea n a n d t igh t en t h e h or n m ou n t in g h a r d- BAGS, REFER GROUP...
Page 378 HORN SYSTEMS 8G - 5 REM OVAL AN D I N STALLAT I ON (Cont inue d) (3) Rem ove t h e pu sh n u t t h a t secu r es t h e r igh t (4) Rem ove t h e scr ew t h a t secu r es t h e h or n a n d cowl side in n er t r im pa n el t o t h e ju n ct ion block st u d.
Page 380 SPEED CONTROL SYSTEM 8H - 1 SPEED CONTROL SYSTEM CON T EN T S page page DESCRIPTION AND OPERA TION ROAD TEST ......3 POWERTRAIN CONTROL MODULE .
Page 381 8H - 2 SPEED CONTROL SYSTEM DESCRI PT I ON AN D OPERAT I ON (Cont inue d) OPERA TION Wh ile t h e speed con t r ol is en ga ged, t h e dr iver ca n in cr ea se t h e veh icle speed by depr essin g t h e ACCE L Wit h in t h e t wo swit ch m odu les, five m o m e n ta ry swit ch .
Page 382 SPEED CONTROL SYSTEM 8H - 3 DESCRI PT I ON AN D OPERAT I ON (Cont inue d) • Lea kin g va cu u m r eser voir. in t h is gr ou p for m or e in for m a t ion . Th e P CM ca n n ot •...
Page 383 8H - 4 SPEED CONTROL SYSTEM DI AGN OSI S AN D T EST I N G (Cont inue d) en gin e for lea ks. Also ch eck a ct u a l en gin e in t a ke in g), a n d t h en t u r n t h e cr u ise con t r ol swit ch t o t h e m a n ifold va cu u m .
Page 384 SPEED CONTROL SYSTEM 8H - 5 REM OVAL AN D I N STALLAT I ON (Cont inue d) Fig. 2 Servo Cable Clip Remove/Install—Typical (4) In st a ll ser vo m ou n t in g n u t s a n d t igh t en t o 8.5 N·m (75 in .
Page 385 8H - 6 SPEED CONTROL SYSTEM REM OVAL AN D I N STALLAT I ON (Cont inue d) VACUUM RESERVOIR REMOVAL Th e va cu u m r eser voir is loca t ed beh in d r igh t fr on t bu m per en d ca p on veh icles equ ipped wit h LH D (Left H a n d Dr ive) (F ig.
Page 386 SPEED CONTROL SYSTEM 8H - 7 REM OVAL AN D I N STALLAT I ON (Cont inue d) INSTALLA TION SPECI FI CAT I ON S (1) P osit ion r eser voir t o bu m per ba r a n d in st a ll TORQUE CHART m ou n t in g scr ews.
Page 388 VEHICLE SPEED CONTROL SYSTEM 8H - 1 VEHICLE SPEED CONTROL SYSTEM CON T EN T S page GENERAL INFORMA TION INTRODUCTION ......1 •...
Page 390 TURN SIGNAL AND HAZARD WARNING SYSTEMS 8J - 1 TURN SIGNAL AND HAZARD WARNING SYSTEMS CON T EN T S page page DESCRIPTION AND OPERA TION TURN SIGNAL SWITCH AND HAZARD COMBINATION FLASHER ....3 WARNING SWITCH .
Page 391 8J - 2 TURN SIGNAL AND HAZARD WARNING SYSTEMS DESCRI PT I ON AN D OPERAT I ON (Cont inue d) OPERA TION Wit h t h e h a za r d wa r n in g swit ch in t h e On posi- t ion , t h e h a za r d wa r n in g syst em is a ct iva t ed.
Page 392 TURN SIGNAL AND HAZARD WARNING SYSTEMS 8J - 3 DESCRI PT I ON AN D OPERAT I ON (Cont inue d) TURN SIGNAL CANCELLING CAM ou t pu t s or fu n ct ion s. Th e com bin a t ion fla sh er sh ou ld n ever be su bst it u t ed for a n ISO-r ela y or r epla ced wit h a n ISO-r ela y, or else com pon en t a n d veh icle DESCRIPTION...
Page 393 8J - 4 TURN SIGNAL AND HAZARD WARNING SYSTEMS DESCRI PT I ON AN D OPERAT I ON (Cont inue d) If t h e pr oblem bein g dia gn osed is r ela t ed t o a fa il- u r e of t h e t u r n sign a ls t o a u t om a t ica lly ca n cel follow- in g com plet ion of a t u r n , in spect t h e m u lt i-fu n ct ion swit ch for a fa u lt y or da m a ged ca n cel a ct u a t or a n d...
Page 394 TURN SIGNAL AND HAZARD WARNING SYSTEMS 8J - 5 DI AGN OSI S AN D T EST I N G (Cont inue d) (7) Tu r n t h e ign it ion swit ch t o t h e Off posit ion . (2) Usin g a n oh m m et er, per for m t h e swit ch con t i- P la ce t h e h a za r d wa r n in g swit ch in t h e On posit ion .
Page 395 8J - 6 TURN SIGNAL AND HAZARD WARNING SYSTEMS REM OVAL AN D I N STALLAT I ON (Cont inue d) TURN SIGNAL SWITCH AND HAZARD (3) Rea ch t h r ou gh t h e ou t boa r d side of t h e st eer- in g colu m n open in g t o a ccess a n d disen ga ge t h e com - WARNING SWITCH bin a t ion fla sh er wir e h a r n ess con n ect or r et a in er fr om...
Page 396 TURN SIGNAL AND HAZARD WARNING SYSTEMS 8J - 7 REM OVAL AN D I N STALLAT I ON (Cont inue d) (5) Rem ove bot h t h e u pper a n d lower sh r ou ds fr om vide a ddit ion a l clea r a n ce t o ea se m u lt i-fu n ct ion t h e st eer in g colu m n .
Page 398 WIPER AND WASHER SYSTEMS 8K - 1 WIPER AND WASHER SYSTEMS CON T EN T S page page GENERAL INFORMA TION WIPER SWITCH AND WASHER SWITCH ..3 INTRODUCTION ......1 DIAGNOSIS AND TESTING REAR WIPER AND WASHER SYSTEM .
Page 399: Description And Opera Tion
8K - 2 WIPER AND WASHER SYSTEMS GEN ERAL I N FORM AT I ON (Cont inue d) t h e dr iver wh en t h e wa sh er flu id level n eeds t o be Th e bla des a r e m ou n t ed t o spr in g-loa ded wiper ch ecked.
Page 400 WIPER AND WASHER SYSTEMS 8K - 3 DESCRI PT I ON AN D OPERAT I ON (Cont inue d) wipe cycle wh en t h e win dsh ield wiper swit ch st a lk is m oved t o t h e Off posit ion , a n d pa r ks t h e bla des in t h e lowest por t ion of t h e wipe pa t t er n .
Page 401: Washer Fluid Level Sensor
8K - 4 WIPER AND WASHER SYSTEMS DESCRI PT I ON AN D OPERAT I ON (Cont inue d) WASHER PUMP Loca t ed a t t h e h igh est poin t of t h e su pply h ose r ou t in g, ben ea t h t h e lift ga t e open in g u pper h ea der Th e wa sh er pu m ps a n d m ot or s a r e m ou n t ed n ea r ga r n ish m ou ldin g, t h e h ose con n ect s t o a ch eck va lve.
Page 402 WIPER AND WASHER SYSTEMS 8K - 5 DI AGN OSI S AN D T EST I N G (Cont inue d) WARNING: ON VEHICLES EQUIPPED WITH AIR- (4) Tu r n t h e ign it ion swit ch t o t h e Off posit ion . Discon n ect a n d isola t e t h e ba t t er y n ega t ive ca ble.
Page 403: Washer System
8K - 6 WIPER AND WASHER SYSTEMS DI AGN OSI S AN D T EST I N G (Cont inue d) (8) Ch eck for con t in u it y bet ween t h e r ea r wiper (5) Ch eck for con t in u it y bet ween t h e fr on t wa sh er m ot or con t r ol cir cu it ca vit ies of t h e r ea r wiper m ot or swit ch ou t pu t cir cu it ca vit ies of t h e fr on t wa sh er...
Page 404: Wiper Switch And Washer Switch
WIPER AND WASHER SYSTEMS 8K - 7 DI AGN OSI S AN D T EST I N G (Cont inue d) (5) Ch eck for con t in u it y bet ween t h e r ea r wa sh er m ot or con t r ol cir cu it ca vit ies of t h e r ea r wa sh er pu m p wir e h a r n ess con n ect or a n d t h e r ea r wiper / wa sh er swit ch wir e h a r n ess con n ect or.
Page 405: Removal And Installa Tion
8K - 8 WIPER AND WASHER SYSTEMS REM OVAL AN D I N STALLAT I ON WIPER ARM WIPER BLADE CAUTION: The use of a screwdriver or other prying tool to remove a wiper arm may distort it. This dis- tortion could allow the arm to come off of the pivot FRONT shaft, regardless of how carefully it is installed.
Page 406: Wiper Linkage And Pivot
WIPER AND WASHER SYSTEMS 8K - 9 REM OVAL AN D I N STALLAT I ON (Cont inue d) (4) Mou n t t h e a r m s on t h e pivot sh a ft s so t h a t t h e dist a n ce fr om t h e lower edge of t h e wiper a r m t ip t o t h e u pper edge of t h e lower win dsh ield m ou ldin g is: •...
Page 407: Wiper Switch And Washer Switch
8K - 10 WIPER AND WASHER SYSTEMS REM OVAL AN D I N STALLAT I ON (Cont inue d) da m a ge t h e pa in t a r ou n d t h e pivot open in gs of t h e pa n el.
Page 408 WIPER AND WASHER SYSTEMS 8K - 11 REM OVAL AN D I N STALLAT I ON (Cont inue d) (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive ca ble.
Page 409 8K - 12 WIPER AND WASHER SYSTEMS REM OVAL AN D I N STALLAT I ON (Cont inue d) (17) Rem ove t h e win dsh ield wiper a n d wa sh er wiper a n d wa sh er swit ch r ecept a cle on t h e ba ck of swit ch fr om t h e st eer in g colu m n .
Page 410 WIPER AND WASHER SYSTEMS 8K - 13 REM OVAL AN D I N STALLAT I ON (Cont inue d) ent itself to the horizontal position when the sensor connector is pointed straight downwards. (2) Usin g a t r im st ick or a n ot h er su it a ble wide fla t -bla ded t ool, gen t ly pr y t h e wa sh er flu id level sen - sor ou t of t h e r u bber gr om m et sea l.
Page 411 8K - 14 WIPER AND WASHER SYSTEMS REM OVAL AN D I N STALLAT I ON (Cont inue d) REAR CHECK VALVE (1) Un sn a p t h e r ea r wa sh er n ozzle fr om t h e r ea r (1) Rem ove t h e fou r scr ews t h a t secu r e t h e lift ga t e wiper a r m (F ig.
Page 412 LAMPS 8L - 1 LAMPS CON T EN T S page page BULB APPLICA TION ..... . 18 LAMP DIAGNOSIS ......1 HEADLAMP ALIGNMENT .
Page 413 8L - 2 LAMPS DI AGN OSI S AN D T EST I N G (Cont inue d) CONDITION POSSIBLE CAUSES CORRECTION HEADLAMPS ARE DIM 1. Loose or corroded battery cables. 1. Clean and secure battery cable clamps WITH ENGINE IDLING and posts.
Page 414 LAMPS 8L - 3 DI AGN OSI S AN D T EST I N G (Cont inue d) FOG LAMP CONDITION POSSIBLE CAUSES CORRECTION FOG LAMPS ARE DIM 1. Loose or corroded battery cables. 1. Clean and secure battery cable clamps WITH ENGINE IDLING OR and posts.
Page 415 8L - 4 LAMPS DI AGN OSI S AN D T EST I N G (Cont inue d) HEADLAMP DELA Y MODULE body gr ou n d. Th e volt m et er sh ou ld in dica t e ba t t er y volt a ge.
Page 416 LAMPS 8L - 5 H EADLAM P ALI GN M EN T INDEX page page GENERAL INFORMATION LAMP ALIGNMENT SCREEN PREPARATION ..5 HEADLAMP ALIGNMENT ....5 VEHICLE PREPARATION FOR HEADLAMP SERVICE PROCEDURES ALIGNMENT .
Page 417 8L - 6 LAMPS SERV I CE PROCEDU RES (Cont inue d) (7) Mea su r e dist a n ce fr om t h e cen t er lin e of t h e wit h in t h e h ea dla m p t h e a lign m en t scr een t a r get veh icle t o t h e cen t er of ea ch h ea dla m p bein g a lign ed.
Page 418 LAMPS 8L - 7 SERV I CE PROCEDU RES (Cont inue d) Fig. 4 Fog Lamp Alignment —Typical SPECI AL T OOLS HEADLAMP ALIGNMENT Headlamp Aiming Kit C-4466–A Fig. 5 Fog Lamp Adjustment...
Page 419 8L - 8 LAMPS LAM P BU LB SERV I CE INDEX page page REMOVAL AND INSTALLATION FRONT PARK/TURN SIGNAL LAMP BULB ..8 BACK-UP/REAR TURN SIGNAL/TAIL LAMP HEADLAMP BULB ......8 BULB .
Page 420 LAMPS 8L - 9 REM OVAL AN D I N STALLAT I ON (Cont inue d) INSTALLA TION (2) Rem ove scr ews a t t a ch in g pa r k/t u r n sign a l la m p h ou sin g t o gr ille open in g pa n el. (1) In st a ll bu lb in socket .
Page 421 8L - 10 LAMPS REM OVAL AN D I N STALLAT I ON (Cont inue d) CENTER HIGH MOUNTED STOP LAMP (CHMSL) BULB REMOVAL (1) Rem ove t h e scr ews a t t a ch in g t h e la m p h ou sin g t o t h e lift ga t e.
Page 422 LAMPS 8L - 11 REM OVAL AN D I N STALLAT I ON (Cont inue d) Fig. 10 Reading Lamp Bulb Fig. 9 Cargo Lamp Lens (2) Sepa r a t e len s fr om la m p. (3) Rem ove len s fr om h ou sin g. (3) Gr a sp bu lb a n d pu ll ou t wa r d.
Page 423 8L - 12 LAMPS LAM P SERV I CE INDEX page page REMOVAL AND INSTALLATION HEADLAMP ......12 BACK-UP/REAR TURN SIGNAL/TAIL LAMP .
Page 424 LAMPS 8L - 13 REM OVAL AN D I N STALLAT I ON (Cont inue d) Fig. 3 Fog Lamp Fig. 5 Side Marker Lamp FRONT PARK/TURN SIGNAL LAMP INSTALLA TION (1) In st a ll bu lb a n d socket in ba ck of side m a r ker REMOVAL la m p.
Page 425 8L - 14 LAMPS REM OVAL AN D I N STALLAT I ON (Cont inue d) (3) In st a ll t h e la m p h ou sin g scr ews. Tigh t en t h e ON/OF F fu n ct ion s ea ch t im e t h e h ood is open ed a n d scr ews secu r ely.
Page 426 LAMPS 8L - 15 REM OVAL AN D I N STALLAT I ON (Cont inue d) (2) Con n ect t h e wir e h a r n ess con n ect or. (3) In st a ll t h e fa st en er s a t t a ch in g t h e la m p t o t h e r oof.
Page 427 8L - 16 LAMPS LAM P SY ST EM S INDEX page page GENERAL INFORMATION REMOVAL AND INSTALLATION DAYTIME RUNNING LAMP MODULE ..16 DAYTIME RUNNING LAMP MODULE ..17 SENTINEL HEADLAMP DELAY MODULE .
Page 428 LAMPS 8L - 17 REM OVAL AN D I N STALLAT I ON (Cont inue d) DA YTIME RUNNING LAMP MODULE (1) Discon n ect t h e wir e h a r n ess con n ect or fr om t h e m odu le.
Page 429 8L - 18 LAMPS BU LB APPLI CAT I ON INDEX page page SPECIFICATIONS INTERIOR LAMPS ..... . . 18 EXTERIOR LAMPS .
Page 430 LAMPS 8L - 1 LAMPS CON T EN T S page page REMOVAL AND INSTALLA TION FRONT TURN SIGNAL ....2 BACKUP , REAR TURN SIGNAL, TAILLIGHT HEADLIGHTS .
Page 431 8L - 2 LAMPS REM OVAL AN D I N STALLAT I ON (Cont inue d) 2. Rem ove t h e 4 scr ews h oldin g t h e h ea dligh t h ou sin g (F ig. 2). 3.
Page 432 Un der pa n el Cou r t esy la m ps (2) ... . . 168 NOTE: Numbers refer to commercial bulb types that can be purchased from your local Jeep dealer.
Page 434 PASSIVE RESTRAINT SYSTEMS 8M - 1 PASSIVE RESTRAINT SYSTEMS CON T EN T S page page DESCRIPTION AND OPERA TION CLOCKSPRING ......12 AIRBAG CONTROL MODULE .
Page 435 8M - 2 PASSIVE RESTRAINT SYSTEMS DESCRI PT I ON AN D OPERAT I ON (Cont inue d) WITH ACID, WATER, OR HEAVY METALS MAY PRO- Modu le (ACM). Th e ACM a lso con t a in s a n im pa ct sen sor a n d a sa fin g sen sor, wh ich a r e m on it or ed by DUCE HARMFUL AND IRRITATING GASES (SODIUM t h e ACM t o det er m in e wh en a n im pa ct occu r s t h a t is...
Page 436: Airbag Control Module
PASSIVE RESTRAINT SYSTEMS 8M - 3 DESCRI PT I ON AN D OPERAT I ON (Cont inue d) u n it a r e a t t a ch ed a n d sea led. Th e con ven t ion a l pyr o- ch a r ge t h e ga s it pr odu ces dir ect ly in t o t h e cu sh ion t ech n ic-t ype in fla t or a ssem bly is m ou n t ed t o st u ds on wh en su pplied wit h t h e pr oper elect r ica l sign a l.
Page 437: Clockspring
8M - 4 PASSIVE RESTRAINT SYSTEMS DESCRI PT I ON AN D OPERAT I ON (Cont inue d) cific veh icle, a n d is on ly ser viced a s a u n it wit h t h e t h a t it ca n oper a t e wit h in it s design ed t r a vel lim it s.
Page 438: Service Procedures
PASSIVE RESTRAINT SYSTEMS 8M - 5 DI AGN OSI S AN D T EST I N G (Cont inue d) (3) Usin g t h e DRB, r ea d a n d r ecor d t h e a ct ive on veh icles a r e t o be r et u r n ed.
Page 439 8M - 6 PASSIVE RESTRAINT SYSTEMS SERV I CE PROCEDU RES (Cont inue d) Rem ova l a n d In st a lla t ion sect ion of t h is gr ou p for t h e a ddit ion a l ser vice pr ocedu r es for t h e clockspr in g. WARNING: •...
Page 440: Driver Side Airbag Module Trim Cover
PASSIVE RESTRAINT SYSTEMS 8M - 7 REM OVAL AN D I N STALLAT I ON (Cont inue d) (4) Discon n ect t h e clockspr in g h or n swit ch wir e (4) F r om t h e u n der side of t h e st eer in g wh eel, h a r n ess con n ect or fr om t h e h or n swit ch feed wir e in st a ll a n d t igh t en t h e t wo dr iver side a ir ba g m odu le con n ect or, wh ich is loca t ed on t h e ba ck of t h e a ir ba g...
Page 441 8M - 8 PASSIVE RESTRAINT SYSTEMS REM OVAL AN D I N STALLAT I ON (Cont inue d) Fig. 5 Horn Switch Feed Wire Remove/Install Fig. 7 Driver Side Airbag Trim Cover Remove/Install • THE DRIVER SIDE AIRBAG MODULE TRIM COVER MUST NEVER BE PAINTED.
Page 442 PASSIVE RESTRAINT SYSTEMS 8M - 9 REM OVAL AN D I N STALLAT I ON (Cont inue d) REMOVAL (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive ca ble.
Page 443: Passenger Side Airbag Door
8M - 10 PASSIVE RESTRAINT SYSTEMS REM OVAL AN D I N STALLAT I ON (Cont inue d) (6) Rem ove t h e t wo scr ews t h a t secu r e t h e pa ssen - (6) In st a ll a n d t igh t en t h e t wo scr ews t h a t secu r e ger side a ir ba g m odu le u pper m ou n t in g br a cket s t o t h e pa ssen ger side a ir ba g m odu le u pper m ou n t in g...
Page 444 PASSIVE RESTRAINT SYSTEMS 8M - 11 REM OVAL AN D I N STALLAT I ON (Cont inue d) (2) Rem ove t h e pa ssen ger side a ir ba g m odu le fr om t h e t h r ee t a bs on t h e t op a n d t h e bot t om of t h e pa s- t h e in st r u m en t pa n el.
Page 445 8M - 12 PASSIVE RESTRAINT SYSTEMS REM OVAL AN D I N STALLAT I ON (Cont inue d) (6) In st a ll a n d t igh t en t h e t h r ee scr ews t h a t secu r e t h e ACM pr ot ect ive cover t o t h e floor pa n el a n d t h e ACM m ou n t in g br a cket .
Page 446 PASSIVE RESTRAINT SYSTEMS 8M - 13 REM OVAL AN D I N STALLAT I ON (Cont inue d) (6) Rem ove t h e st eer in g colu m n open in g cover fr om t h e in st r u m en t pa n el. Refer t o S te e rin g Co l- u m n Op e n in g Co v e r in t h e Rem ova l a n d In st a lla - t ion sect ion of Gr ou p 8E - In st r u m en t P a n el Syst em s for t h e pr ocedu r es.
Page 447: Clockspring Centering
8M - 14 PASSIVE RESTRAINT SYSTEMS REM OVAL AN D I N STALLAT I ON (Cont inue d) ADJ U ST M EN T S Ser vice r epla cem en t clockspr in gs a r e sh ipped pr e- cen t er ed a n d wit h a lockin g pin in st a lled.
Page 448: Special Tools
PASSIVE RESTRAINT SYSTEMS 8M - 15 ADJ U ST M EN T S (Cont inue d) (6) Th e clockspr in g is n ow cen t er ed. Lock t h e clockspr in g r ot or t o t h e clockspr in g ca se t o m a in t a in clockspr in g cen t er in g u n t il it is r ein st a lled on t h e st eer in g colu m n .
Page 450 ELECTRICALL Y HEA TED SYSTEMS 8N - 1 ELECTRICALLY HEATED SYSTEMS CON T EN T S page page HEA TED SEA T SYSTEM ....8 REAR WINDOW DEFOGGER SYSTEM .
Page 451: Description And Operation
8N - 2 ELECTRICALL Y HEA TED SYSTEMS GEN ERAL I N FORM AT I ON (Cont inue d) t h e defogger swit ch is t u r n ed on a ga in du r in g t h e win dow h ea t in g gr id is oper a t in g a s design ed, r efer sa m e ign it ion cycle, t h e defogger syst em will a u t o- t o P ower Mir r or in t h e Dia gn osis a n d Test in g sect ion...
Page 452: • Defogger Swit Ch
ELECTRICALL Y HEA TED SYSTEMS 8N - 3 DESCRI PT I ON AN D OPERAT I ON (Cont inue d) con t r ol ou t pu t sign a l a t t h e defogger r ela y. F or dia g- n osis of t h e CCD da t a bu s a n d t h e da t a bu s m essa ge in pu t s, a DRB sca n t ool a n d t h e pr oper Dia gn ost ic P r ocedu r es m a n u a l a r e r ecom m en ded.
Page 453 8N - 4 ELECTRICALL Y HEA TED SYSTEMS DI AGN OSI S AN D T EST I N G (Cont inue d) (1) Tu r n t h e ign it ion swit ch t o t h e On posit ion . Set t h e In st r u m en t Clu st er in t h is gr ou p.
Page 454 ELECTRICALL Y HEA TED SYSTEMS 8N - 5 DI AGN OSI S AN D T EST I N G (Cont inue d) m in a l 86 wit h t h e ign it ion swit ch in t h e On posit ion . If OK, see t h e dia gn osis for In st r u m en t Clu st er in t h is gr ou p.
Page 455: Service Procedures
8N - 6 ELECTRICALL Y HEA TED SYSTEMS SERV I CE PROCEDU RES bu s ba r. Apply a t h in la yer of epoxy t o t h e a r ea wh er e t h e t er m in a l or pigt a il wir e wa s fa st en ed a n d on t o t h e a dja cen t gr id lin e.
Page 456: Defogger Relay
ELECTRICALL Y HEA TED SYSTEMS 8N - 7 REM OVAL AN D I N STALLAT I ON (Cont inue d) Fig. 5 Accessory Switch Bezel Remove/Install (7) Wit h a sm a ll t h in -bla ded scr ewdr iver, gen t ly pr y t h e sn a p clips a t t h e t op a n d bot t om of t h e r ea r win dow defogger swit ch r ecept a cle on t h e ba ck of t h e a ccessor y swit ch bezel a n d pu ll t h e swit ch ou t of t h e...
Page 457 8N - 8 ELECTRICALL Y HEA TED SYSTEMS H EAT ED SEAT SY ST EM INDEX page page GENERAL INFORMATION HEATED SEAT RELAY ....11 INTRODUCTION .
Page 458 ELECTRICALL Y HEA TED SYSTEMS 8N - 9 DESCRI PT I ON AN D OPERAT I ON (Cont inue d) HEA TED SEA T ELEMENT and SENSOR Two h ea t ed sea t h ea t in g elem en t s a r e u sed in ea ch fr on t sea t , on e for t h e sea t cu sh ion a n d t h e ot h er for t h e sea t ba ck.
Page 459 8N - 10 ELECTRICALL Y HEA TED SYSTEMS DI AGN OSI S AN D T EST I N G (Cont inue d) Befor e t est in g t h e in dividu a l com pon en t s in t h e con n ect or.
Page 460 ELECTRICALL Y HEA TED SYSTEMS 8N - 11 DI AGN OSI S AN D T EST I N G (Cont inue d) (2) Ch eck for con t in u it y bet ween t h e t wo h ea t ed (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive sea t elem en t cir cu it ca vit ies of t h e sea t cu sh ion cover ca ble.
Page 461 8N - 12 ELECTRICALL Y HEA TED SYSTEMS REM OVAL AN D I N STALLAT I ON (5) P u ll t h e SH IM u pwa r d t o r elea se t h e t wo m ou n t in g fa st en er s fr om eit h er t h e m odu le or t h e m ou n t in g br a cket .
Page 462 POWER DISTRIBUTION SYSTEMS 8O - 1 POWER DISTRIBUTION SYSTEMS CON T EN T S page page DESCRIPTION AND OPERA TION REMOVAL AND INSTALLA TION JUNCTION BLOCK ..... . . 2 JUNCTION BLOCK .
Page 463 8O - 2 POWER DISTRIBUTION SYSTEMS DESCRI PT I ON AN D OPERAT I ON (Cont inue d) Th e P DC h ou sin g is secu r ed t o a st a m ped sh eet m et a l br a cket in t h e en gin e com pa r t m en t by m ou n t - in g slot s a n d t a bs t h a t a r e in t egr a l t o t h e P DC h ou s- in g.
Page 464 POWER DISTRIBUTION SYSTEMS 8O - 3 REM OVAL AN D I N STALLAT I ON (Cont inue d) in t h e Con t en t s of Gr ou p 8W - Wir in g Dia gr a m s for m or e in for m a t ion on t h e loca t ion s of t h e a ffect ed con - n ect or s.
Page 465 8O - 4 POWER DISTRIBUTION SYSTEMS REM OVAL AN D I N STALLAT I ON (Cont inue d) (4) E n ga ge t h e m ou n t in g slot s on t h e P DC h ou sin g wit h t h e st a n ch ion s of t h e P DC m ou n t in g br a cket a n d pu sh t h e u n it down wa r d u n t il t h e m ou n t in g br a cket la t ch es en ga ge t h e m ou n t in g t a bs on t h e...
Page 466 POWER DISTRIBUTION SYSTEMS 8O - 5 REM OVAL AN D I N STALLAT I ON (Cont inue d) (3) Recon n ect a ll of t h e wir e h a r n ess con n ect or s t o t h e con n ect or r ecept a cles on t h e ju n ct ion block.
Page 468 POWER LOCK SYSTEMS 8P - 1 POWER LOCK SYSTEMS CON T EN T S page page GENERAL INFORMA TION REMOTE KEYLESS ENTRY RECEIVER ..5 INTRODUCTION ......1 REMOTE KEYLESS ENTRY TRANSMITTER .
Page 469: Remote Keyless Entry System
8P - 2 POWER LOCK SYSTEMS GEN ERAL I N FORM AT I ON (Cont inue d) REMOTE KEYLESS ENTRY SYSTEM DOOR MODULE Th e Rem ot e Keyless E n t r y (RKE ) syst em is a r a dio A Dr iver Door Modu le (DDM) a n d a P a ssen ger fr equ en cy syst em t h a t a llows t h e u se of a r em ot e ba t - Door Modu le (P DM) a r e u sed on a ll m odels equ ipped...
Page 470: Remote Keyless Entry Receiver
POWER LOCK SYSTEMS 8P - 3 DESCRI PT I ON AN D OPERAT I ON (Cont inue d) Th e t r a n sm it t er oper a t es t wo P a n a son ic Keyless E n t r y Receiver dia gn osis in t h is gr ou p.
Page 471 8P - 4 POWER LOCK SYSTEMS DI AGN OSI S AN D T EST I N G (Cont inue d) 12-wa y DDM wir e h a r n ess con n ect or. If OK, r epla ce (2) Discon n ect a n d isola t e t h e ba t t er y n ega t ive t h e fa u lt y DDM.
Page 472: Remote Keyless Entry Receiver
POWER LOCK SYSTEMS 8P - 5 DI AGN OSI S AN D T EST I N G (Cont inue d) m ot or t o oper a t e. Un plu g ea ch power lock m ot or wir e h a r n ess con n ect or, on e a t a t im e, a n d r ech eck bot h t h e lock a n d u n lock fu n ct ion s by oper a t in g t h e power lock swit ch .
Page 473: Service Procedures
8P - 6 POWER LOCK SYSTEMS DI AGN OSI S AN D T EST I N G (Cont inue d) in t er ior cou r t esy la m p syst em is oper a t ion a l. Refer t o t or a n d a good gr ou n d wit h t h e dr iver door closed.
Page 474: Removal And Installa Tion
POWER LOCK SYSTEMS 8P - 7 SERV I CE PROCEDU RES (Cont inue d) h or n r ela y, wh en ever a va lid Lock m essa ge is (4) Lift t h e fr on t door t r im pa n el u pwa r ds a n d r eceived fr om a pr ogr a m m ed RKE r a dio t r a n sm it t er.
Page 475: Remote Keyless Entry Receiver
8P - 8 POWER LOCK SYSTEMS REM OVAL AN D I N STALLAT I ON (Cont inue d) MINI-DOME MOUNTED TYPE (3) Rem ove t h e lift ga t e t r im pa n el fr om t h e lift - ga t e.
Page 476 POWER LOCK SYSTEMS 8P - 9 REM OVAL AN D I N STALLAT I ON (Cont inue d) Fig. 7 RKE Receiver Remove/Install (7) Rever se t h e r em ova l pr ocedu r es t o in st a ll. Tigh t en t h e m ou n t in g scr ews t o 2.2 N·m (20 in .
Page 478 VEHICLE THEFT/SECURITY SYSTEMS 8Q - 1 VEHICLE THEFT/SECURITY SYSTEMS CON T EN T S page page GENERAL INFORMA TION DIAGNOSIS AND TESTING INTRODUCTION ......1 SENTRY KEY IMMOBILIZER SYSTEM .
Page 479 8Q - 2 VEHICLE THEFT/SECURITY SYSTEMS DESCRI PT I ON AN D OPERAT I ON (Cont inue d) t ech n icia n t o a ccess t h e syst em for ser vice. Th e P r ocedu r es m a n u a l a r e r equ ir ed. Th e SKIM ca n n ot SKIM a lso st or es in it s m em or y t h e Veh icle Iden t ifi- be r epa ir ed a n d, if fa u lt y or da m a ged, t h e u n it m u st ca t ion Nu m ber (VIN), wh ich it lea r n s t h r ou gh a CCD...
Page 480 VEHICLE THEFT/SECURITY SYSTEMS 8Q - 3 DESCRI PT I ON AN D OPERAT I ON (Cont inue d) DI AGN OSI S AN D T EST I N G Key” code. Th e SKIM t r a n sceiver com pa r es t h e t r a n - spon der codes wit h t h e codes st or ed in it s m em or y t o det er m in e wh et h er a va lid key is in t h e ign it ion lock SENTRY KEY IMMOBILIZER SYSTEM...
Page 481 8Q - 4 VEHICLE THEFT/SECURITY SYSTEMS DI AGN OSI S AN D T EST I N G (Cont inue d) (4) Tu r n t h e ign it ion swit ch t o t h e On posit ion . SKIS in dica t or la m p will st op fla sh in g a n d st a y on Ch eck for ba t t er y volt a ge a t t h e fu sed ign it ion swit ch solid for a bou t t h r ee secon ds t o in dica t e t h a t t h e...
Page 482 VEHICLE THEFT/SECURITY SYSTEMS 8Q - 5 REM OVAL AN D I N STALLAT I ON (Cont inue d) (10) Disen ga ge t h e st eer in g colu m n wir e h a r n ess r et a in er fr om t h e t a b on t h e t op of t h e Sen t r y Key Im m obilizer Modu le (SKIM) m ou n t in g br a cket (F ig.
Page 484 VEHICLE THEFT/SECURITY SYSTEMS 8Q - 1 VEHICLE THEFT/SECURITY SYSTEMS CON T EN T S page page GENERAL INFORMA TION DIAGNOSIS AND TESTING INTRODUCTION ......1 SENTRY KEY IMMOBILIZER SYSTEM .
Page 485 8Q - 2 VEHICLE THEFT/SECURITY SYSTEMS DESCRI PT I ON AN D OPERAT I ON (Cont inue d) SKIM a lso st or es in it s m em or y t h e Veh icle Iden t ifi- in su la t ed wit h in a n ylon m ou n t in ser t ed in t h e h ea d ca t ion Nu m ber (VIN), wh ich it lea r n s t h r ou gh a CCD of t h e key, a n d in visible ben ea t h a m olded r u bber ca p da t a bu s m essa ge fr om t h e P CM du r in g in it ia liza -...
Page 486 VEHICLE THEFT/SECURITY SYSTEMS 8Q - 3 DESCRI PT I ON AN D OPERAT I ON (Cont inue d) SENTRY KEY IMMOBILIZER SYSTEM NOTE: The following tests may not prove conclu- sive in the diagnosis of this system. The most reli- INDICA TOR LAMP able, efficient, and accurate means to diagnose the Th e Sen t r y Key Im m obilizer Syst em (SKIS) in dica -...
Page 487 8Q - 4 VEHICLE THEFT/SECURITY SYSTEMS REM OVAL AN D I N STALLAT I ON SENTRY KEY IMMOBILIZER MODULE WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO GROUP 8M - PASSIVE RESTRAINT SYS- TEMS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COM- PONENT DIAGNOSIS OR SERVICE.
Page 488 VEHICLE THEFT/SECURITY SYSTEMS 8Q - 5 REM OVAL AN D I N STALLAT I ON (Cont inue d) Fig. 3 Sentry Key Immobilizer Module Remove/Install...
Page 490 POWER SEA T SYSTEMS 8R - 1 POWER SEAT SYSTEMS CON T EN T S page page GENERAL INFORMA TION POWER SEAT ADJUSTER AND MOTORS ..2 INTRODUCTION ......1 POWER SEAT SWITCH .
Page 491 8R - 2 POWER SEA T SYSTEMS DESCRI PT I ON AN D OPERAT I ON (Cont inue d) swit ch is r elea sed, or u n t il t h e t r a vel lim it of t h e m in a l h a s ba t t er y volt a ge, r epa ir t h e open cir cu it power sea t a dju st er is r ea ch ed.
Page 492 POWER SEA T SYSTEMS 8R - 3 DI AGN OSI S AN D T EST I N G (Cont inue d) REM OVAL AN D I N STALLAT I ON POWER SEA T SWITCH (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive ca ble.
Page 493 8R - 4 POWER SEA T SYSTEMS REM OVAL AN D I N STALLAT I ON (Cont inue d) (7) Rem ove t h e power sea t swit ch fr om t h e sea t cu sh ion side sh ield. (8) Rever se t h e r em ova l pr ocedu r es t o in st a ll.
Page 494 POWER WINDOW SYSTEMS 8S - 1 POWER WINDOW SYSTEMS CON T EN T S page page GENERAL INFORMA TION DOOR MODULE ......3 INTRODUCTION .
Page 495: Power Window System
8S - 2 POWER WINDOW SYSTEMS DESCRI PT I ON AN D OPERAT I ON (Cont inue d) bet ween t h e t er m in a ls of t h e power win dow m ot or. In a ddit ion , ea ch power win dow m ot or is equ ipped Th e pa ssen ger side fr on t door a n d, on fou r-door m od- wit h a n in t egr a l self-r eset t in g cir cu it br ea ker t o pr o- els, bot h r ea r door power win dow swit ch es r eceive...
Page 496 POWER WINDOW SYSTEMS 8S - 3 DI AGN OSI S AN D T EST I N G (Cont inue d) t h e gla ss ca n be m oved sligh t ly fr om side t o side, t h e pa ssen ger side fr on t door power win dow swit ch fr on t t o r ea r, a n d u p a n d down .
Page 497: Power Window Switch
8S - 4 POWER WINDOW SYSTEMS DI AGN OSI S AN D T EST I N G (Cont inue d) POWER WINDOW MOTOR F or cir cu it descr ipt ion s a n d dia gr a m s, r efer t o 8W-60 - P ower Win dows in Gr ou p 8W - Wir in g Dia - gr a m s.
Page 498: Door Module
POWER WINDOW SYSTEMS 8S - 5 REM OVAL AN D I N STALLAT I ON (Cont inue d) a wa y fr om t h e door a r ou n d t h e per im et er t o r elea se t h e t r im pa n el r et a in er s.
Page 499: Power Window Motor
8S - 6 POWER WINDOW SYSTEMS REM OVAL AN D I N STALLAT I ON (Cont inue d) (10) Rever se t h e r em ova l pr ocedu r es t o in st a ll. Be Gr ou p 23 - Body for t h e fr on t door win dow r egu la t or cer t a in t h a t bot h of t h e swit ch sn a p r et a in er s in t h e ser vice pr ocedu r es.
Page 500 POWER MIRROR SYSTEMS 8T - 1 POWER MIRROR SYSTEMS CON T EN T S page page GENERAL INFORMA TION DIAGNOSIS AND TESTING INTRODUCTION ......1 POWER MIRROR SYSTEM .
Page 501 8T - 2 POWER MIRROR SYSTEMS DESCRI PT I ON AN D OPERAT I ON (Cont inue d) select or swit ch is m oved r igh t (r igh t m ir r or con t r ol), (4) Tu r n t h e ign it ion swit ch t o t h e Off posit ion . left (left m ir r or con t r ol), or cen t er t o t u r n t h e power Discon n ect a n d isola t e t h e ba t t er y n ega t ive ca ble.
Page 502 POWER MIRROR SYSTEMS 8T - 3 DI AGN OSI S AN D T EST I N G (Cont inue d) Ch eck for con t in u it y bet ween t h e gr ou n d cir cu it ca v- it y of t h e st a n d-a lon e swit ch wir e h a r n ess con n ect or or t h e 8-wa y DDM wir e h a r n ess con n ect or a n d a good gr ou n d.
Page 503 8T - 4 POWER MIRROR SYSTEMS REM OVAL AN D I N STALLAT I ON POWER MIRROR SWITCH Th is pr ocedu r e cover s r em ova l of t h e st a n d-a lon e t ype power m ir r or swit ch .
Page 504 POWER MIRROR SYSTEMS 8T - 5 REM OVAL AN D I N STALLAT I ON (Cont inue d) POWER MIRROR (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive ca ble.
Page 505 8T - 6 POWER MIRROR SYSTEMS REM OVAL AN D I N STALLAT I ON (Cont inue d) (11) Usin g a t r im st ick or a n ot h er su it a ble wide fla t -bla ded t ool, gen t ly pr y t h e door fla g t r im a wa y fr om t h e in n er door t o r elea se t h e t r im pa n el r et a in er.
Page 506 CHIME/BUZZER WARNING SYSTEMS 8U - 1 CHIME/BUZZER WARNING SYSTEMS CON T EN T S page page GENERAL INFORMA TION DIAGNOSIS AND TESTING CHIME WARNING SYSTEM ....1 DRIVER DOOR JAMB SWITCH .
Page 507 8U - 2 CHIME/BUZZER WARNING SYSTEMS DESCRI PT I ON AN D OPERAT I ON (Cont inue d) pr oper Dia gn ost ic P r ocedu r es m a n u a l a r e r ecom - Th e h ea dla m p swit ch ca n n ot be r epa ir ed a n d, if m en ded.
Page 508 CHIME/BUZZER WARNING SYSTEMS 8U - 3 DI AGN OSI S AN D T EST I N G (Cont inue d) HEADLAMP SWITCH (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive ca ble.
Page 509 8U - 4 CHIME/BUZZER WARNING SYSTEMS DI AGN OSI S AN D T EST I N G (Cont inue d) in st r u m en t pa n el. Refer t o Gr ou p 8E - In st r u m en t clu st er wir e h a r n ess con n ect or (con n ect or B) a n d t h e P a n el Syst em s for t h e pr ocedu r es.
Page 510 OVERHEAD CONSOLE SYSTEMS 8V - 1 OVERHEAD CONSOLE SYSTEMS CON T EN T S page page GENERAL INFORMA TION COMPASS DEMAGNETIZING ....6 INTRODUCTION ......1 COMPASS VARIATION ADJUSTMENT .
Page 511 8V - 2 OVERHEAD CONSOLE SYSTEMS DESCRI PT I ON AN D OPERAT I ON (Cont inue d) Som e of t h e fu n ct ion s a n d fea t u r es t h a t t h e t r ip cession fla g ca n exceed t h e com pen sa t in g a bilit y of com pu t er su ppor t s a n d/or con t r ols, in clu de t h e fol- t h e com pa ss u n it if pla ced on t h e r oof pa n el.
Page 512: Garage Door Opener Storage Bin
OVERHEAD CONSOLE SYSTEMS 8V - 3 DESCRI PT I ON AN D OPERAT I ON (Cont inue d) Wh en a door is open , depr essin g t h e la m p len s m essa ge in pu t s bein g r eceived fr om t h e in st r u m en t swit ch es will n ot t u r n t h e la m ps off.
Page 513: Service Procedures
8V - 4 OVERHEAD CONSOLE SYSTEMS DI AGN OSI S AN D T EST I N G (Cont inue d) SENSOR TEST d. In t h e displa y segm en t t est , if a n y segm en t sh ou ld fa il t o ligh t t h e u n it is fa u lt y a n d m u st be (1) Tu r n t h e ign it ion swit ch t o t h e Off posit ion .
Page 514 OVERHEAD CONSOLE SYSTEMS 8V - 5 SERV I CE PROCEDU RES (Cont inue d) Fig. 1 Variance Settings (2) Tu r n t h e ign it ion swit ch t o t h e On posit ion . If Th is a llows t h e com pa ss u n it t o com pen sa t e for sm a ll t h e com pa ss/t em per a t u r e da t a is n ot cu r r en t ly bein g ch a n ges in t h e r esidu a l m a gn et ism t h a t t h e veh icle...
Page 515: Removal And Installa Tion
8V - 6 OVERHEAD CONSOLE SYSTEMS SERV I CE PROCEDU RES (Cont inue d) NOTE: If the “CAL” message remains in the dis- play, either there is excessive magnetism near the compass, or the unit is faulty. Repeat the demagne- tizing and calibration procedures at least one more time.
Page 516 OVERHEAD CONSOLE SYSTEMS 8V - 7 REM OVAL AN D I N STALLAT I ON (Cont inue d) Fig. 3 Overhead Console Remove/Install Fig. 4 Trip Computer, Compass, and Thermometer Display Module Remove/Install (5) Lower t h e over h ea d con sole fa r en ou gh t o a ccess t h e t wo wir e h a r n ess con n ect or s.
Page 517: Ambient Temperature Sensor
8V - 8 OVERHEAD CONSOLE SYSTEMS REM OVAL AN D I N STALLAT I ON (Cont inue d) READING AND COURTESY LAMP BULB (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive ca ble.
Page 518: Special Tools
OVERHEAD CONSOLE SYSTEMS 8V - 9 REM OVAL AN D I N STALLAT I ON (Cont inue d) SPECI AL T OOLS (3) Un plu g t h e a m bien t t em per a t u r e sen sor wir e h a r n ess con n ect or.
Page 520 WIRING DIAGRAMS 8W - 1 WIRING DIAGRAMS CON T EN T S page page AIR CONDITIONING-HEA TER ..8W-42-1 POWER DISTRIBUTION ....8W-10-1 AIRBAG SYSTEM .
Page 522 8W - 01 GENERAL INFORMA TION 8W - 01 - 1 8 W-0 1 GEN ERAL I N FORM AT I ON INDEX page page DESCRIPTION AND OPERATION TROUBLESHOOTING TESTS ....9 CIRCUIT FUNCTIONS .
Page 523 8W - 01 - 2 8W - 01 GENERAL INFORMA TION DESCRI PT I ON AN D OPERAT I ON (Cont inue d) The System shown here is an EXAMPLE ONLY. It does not represent the actual circuit shown in the WIRING DIAGRAM SECTION.
Page 524 8W - 01 GENERAL INFORMA TION 8W - 01 - 3 DESCRI PT I ON AN D OPERAT I ON (Cont inue d) The System shown here is an EXAMPLE ONLY. It does not represent the actual circuit shown in the WIRING DIAGRAM SECTION.
Page 525 8W - 01 - 4 8W - 01 GENERAL INFORMA TION DESCRI PT I ON AN D OPERAT I ON (Cont inue d) CIRCUIT INFORMA TION CIRCUIT FUNCTIONS E a ch wir e sh own in t h e dia gr a m s con t a in s a code All cir cu it s in t h e dia gr a m s u se a n a lph a /n u m er ic wh ich iden t ifies t h e m a in cir cu it , pa r t of t h e m a in code t o iden t ify t h e wir e a n d it s fu n ct ion .
Page 526 8W - 01 GENERAL INFORMA TION 8W - 01 - 5 DESCRI PT I ON AN D OPERAT I ON (Cont inue d) SECTION IDENTIFICA TION SYMBOLS Th e wir in g dia gr a m s a r e gr ou ped in t o in dividu a l In t er n a t ion a l sym bols a r e u sed t h r ou gh ou t t h e wir- sect ion s.
Page 527 8W - 01 - 6 8W - 01 GENERAL INFORMA TION DESCRI PT I ON AN D OPERAT I ON (Cont inue d) Wiring Diagram Symbols...
Page 528 8W - 01 GENERAL INFORMA TION 8W - 01 - 7 DESCRI PT I ON AN D OPERAT I ON (Cont inue d) TERMINOLOGY Th is a list of t er m s wit h t h er e defin it ion s u sed in t h e wir in g dia gr a m s.
Page 529 8W - 01 - 8 8W - 01 GENERAL INFORMA TION DESCRI PT I ON AN D OPERAT I ON (Cont inue d) WARNING: BE SURE THAT THE IGNITION SWITCH (3) Wh en u sin g a volt m et er, be su r e t o con n ect t h e ALWAYS IS IN THE OFF POSITION, UNLESS THE gr ou n d lea d fir st .
Page 530 8W - 01 GENERAL INFORMA TION 8W - 01 - 9 DI AGN OSI S AN D T EST I N G (Cont inue d) • P r obin g Tools - Th ese t ools a r e u sed for pr obin g t er m in a ls in con n ect or s (F ig.
Page 531 8W - 01 - 10 8W - 01 GENERAL INFORMA TION DI AGN OSI S AN D T EST I N G (Cont inue d) TESTING FOR A SHORT TO GROUND TROUBLESHOOTING WIRING PROBLEMS (1) Rem ove t h e fu se a n d discon n ect a ll it em s Wh en t r ou blesh oot in g wir in g pr oblem s t h er e a r e in volved wit h t h e fu se.
Page 532 8W - 01 GENERAL INFORMA TION 8W - 01 - 11 SERV I CE PROCEDU RES (Cont inue d) Fig. 11 Using Special Tool 6742 (2) Discon n ect t h e con n ect or fr om it s m a t in g h a lf/ com pon en t .
Page 533 8W - 01 - 12 8W - 01 GENERAL INFORMA TION SERV I CE PROCEDU RES (Cont inue d) (4) P osit ion t h e con n ect or lockin g fin ger a wa y fr om t h e t er m in a l u sin g t h e pr oper pick fr om specia l t ool kit 6680.
Page 534 8W - 01 GENERAL INFORMA TION 8W - 01 - 13 SERV I CE PROCEDU RES (Cont inue d) (3) Cu t off t h e exist in g wir e con n ect or dir ect ly (3) Rem ove con n ect or lockin g wedge, if r equ ir ed beh in d t h e in su la t or.
Page 535 8W - 01 - 14 8W - 01 GENERAL INFORMA TION SERV I CE PROCEDU RES (Cont inue d) (2) Loca t e t h e diode in t h e h a r n ess, a n d r em ove t h e pr ot ect ive cover in g.
Page 536 8W - 01 GENERAL INFORMA TION 8W - 01 - 15 SPECI AL T OOLS WIRING/TERMINAL Probing Tool Package 6807 Terminal Removing Tool 6932 Terminal Removing Tool 6934 Terminal Pick 6680...
Page 538 8W - 02 COMPONENT INDEX 8W - 02 - 1 8 W-0 2 COM PON EN T I N DEX Co m p o n e n t P a g e Co m p o n e n t P a g e 1-2 An d 3-4 Solen oid .
Page 539 8W - 02 - 2 8W - 02 COMPONENT INDEX Co m p o n e n t P a g e Co m p o n e n t P a g e Lift ga t e Lock Mot or ....8W-61 Repea t er La m ps .
Page 540 8W - 10 POWER DISTRIBUTION 8W - 10 - 1 8 W-1 0 POWER DI ST RI BU T I ON Co m p o n e n t P a g e Co m p o n e n t P a g e A/C Com pr essor Clu t ch .
Page 541 8W - 10 - 2 8W-10 POWER DISTRIBUTION POWER DISTRIBUTION CENTER ENGINE STARTER MOTOR FUEL RELAY PUMP RELAY RADIATOR AUTOMATIC RELAY SHUT DOWN RELAY LAMP RELAY NO. 1 CONTROLLER ANTI-LOCK BRAKE LAMP RELAY RELAY LAMP COMPRESSOR RELAY CLUTCH NO. 2 RELAY F27 10A F24 15A...
Page 542 8W-10 POWER DISTRIBUTION 8W - 10 - 3 FUSES FUSE NO. AMPS FUSED CIRCUIT FEED CIRCUIT A1 12RD A0 6RD A2 12PK/BK A0 6RD A7 10RD/BK A0 6RD F141 12LG/RD A0 6RD A111 12RD/LG A0 6RD A3 14RD/WT A0 6RD A3 14RD/WT A17 16RD/BK A0 6RD...
Page 543 8W - 10 - 4 8W-10 POWER DISTRIBUTION CAVITY CIRCUIT FUNCTION A17 16RD/BK FUSED B(+) C3 16DB/BK A/C COMPRESSOR CLUTCH RELAY OUTPUT COMPRESSOR C13 18DB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL CLUTCH RELAY F20 18WT FUSED IGNITION SWITCH OUTPUT (ST-RUN) CAVITY CIRCUIT FUNCTION A16 16RD/LG...
Page 544 8W-10 POWER DISTRIBUTION 8W - 10 - 5 CAVITY CIRCUIT FUNCTION F61 20WT/OR FUSED B(+) L92 20PK FOG LAMP RELAY OUTPUT LAMP L139 20VT FOG LAMP RELAY OUTPUT RELAY NO. 1 Z1 20BK GROUND Z1 20BK GROUND L35 20BR/WT FOG LAMP RELAY CONTROL L77 20BR/YL FUSED LEFT INBOARD TAIL LAMP L77 20BR/YL...
Page 545 8W - 10 - 6 8W-10 POWER DISTRIBUTION DIESEL POWER DISTRIBUTION CENTER FUEL ENGINE HEATER STARTER RELAY MOTOR RELAY RADIATOR AUTOMATIC SHUT RELAY DOWN RELAY CONTROLLER LAMP ANTI-LOCK RELAY BRAKE RELAY COMPRESSOR USED CLUTCH RELAY F27 10A F24 10A F21 20A F26 20A F23 15A F20 20A...
Page 546 8W-10 POWER DISTRIBUTION 8W - 10 - 7 DIESEL FUSES FUSE NO. AMPS FUSED CIRCUIT FEED CIRCUIT A54 12RD/GY A0 6RD A54 12RD/GY A0 6RD A16 12RD/LG A0 6RD A1 12RD A0 6RD A61 14LG/RD A0 6RD A41 16YL A0 6RD A3 14RD/WT A0 6RD A7 10RD/BK...
Page 547 8W - 10 - 8 8W-10 POWER DISTRIBUTION DIESEL CAVITY CIRCUIT FUNCTION A17 16RD/BK FUSED B(+) C3 16DB/BK A/C COMPRESSOR CLUTCH RELAY OUTPUT COMPRESSOR C13 20DB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL CLUTCH RELAY F20 18WT FUSED IGNITION SWITCH OUTPUT (ST-RUN) CAVITY CIRCUIT FUNCTION...
Page 548 8W-10 POWER DISTRIBUTION 8W - 10 - 9 DIESEL CAVITY CIRCUIT FUNCTION A41 16YL FUSED B(+) ENGINE T141 20YL IGNITION SWITCH OUTPUT (START) STARTER MOTOR RELAY Z1 20BK GROUND T40 16BR STARTER RELAY OUTPUT CAVITY CIRCUIT FUNCTION F61 20WT/OR FUSED B(+) L139 20VT FOG LAMP RELAY OUTPUT L77 18BR/YL...
Page 549 8W - 10 - 10 8W-10 POWER DISTRIBUTION S118 FUSIBLE BATTERY LINK BK/WT (8W-20-2) ENGINE GENERATOR STARTER (8W-20-2) MOTOR (8W-21-2) (8W-21-3) (8W-21-4) (8W-21-5) (8W-21-6) POWER DISTRIBUTION CENTER FUSE FUSE FUSE FUSE FUSE (8W-10-2) (8W-10-14) (8W-10-14) (8W-10-19) (8W-10-20) (8W-10-20) F141 A111 PK/BK RD/BK LG/RD...
Page 550 8W-10 POWER DISTRIBUTION 8W - 10 - 11 POWER FROM DISTRIBUTION FUSE 11 CENTER (PDC) (8W-10-2) (8W-10-10) FUSE FUSE FUSE (ABS) (8W-10-25) (8W-10-29) (8W-10-23) FUSE FUSE (ABS) (8W-10-26) (8W-10-23) (8W-10-27) RD/DG RD/DB TN/BK RD/LG CONTROLLER CONTROLLER S135 C100 AUTOMATIC ANTI-LOCK ANTI-LOCK SHUT DOWN BRAKE...
Page 551 8W - 10 - 12 8W-10 POWER DISTRIBUTION DIESEL S118 FUSIBLE BATTERY LINK BK/GY (8W-20-3) ENGINE GENERATOR STARTER (8W-20-3) MOTOR (8W-21-6) POWER DISTRIBUTION CENTER FUSE FUSE FUSE (8W-10-6) (8W-10-18) (8W-10-18) (8W-10-22) FUSE FUSE (8W-10-18) (8W-10-15) LG/RD RD/GY RD/GY RD/LG C100 FUEL S153 S153...
Page 552 8W-10 POWER DISTRIBUTION 8W - 10 - 13 DIESEL POWER FROM DISTRIBUTION FUSE 12 CENTER (PDC) (8W-10-6) (8W-10-12) FUSE FUSE FUSE (8W-10-24) (8W-10-22) (8W-10-32) FUSE FUSE (ABS) (8W-10-28) (8W-10-24) F141 PK/DB LG/RD RD/DB BK/PK C100 RADIATOR CONTROLLER JUNCTION JUNCTION UNDERHOOD BRAKE ANTI-LOCK BLOCK...
Page 553 8W - 10 - 14 8W-10 POWER DISTRIBUTION BATT A0 (8W-10-10) POWER BRAKE DISTRIBUTION WARNING CENTER PRESSURE FUSE FUSE (8W-10-2) SWITCH (8W-40-9) GY/BK C100 S211 PK/BK GY/BK C201 C203 C100 FROM S210 (8W-10-16) GY/BK PARK BRAKE PK/BK GY/BK SWITCH (8W-40-9) IGNITION SWITCH KEY-IN...
Page 554 8W-10 POWER DISTRIBUTION 8W - 10 - 15 DIESEL BRAKE BATT A0 (8W-10-12) WARNING POWER PRESSURE DISTRIBUTION SWITCH CENTER (8W-40-9) FUSE FUSE (8W-10-6) GY/BK C100 S211 PK/BK GY/BK FROM S210 C201 C203 (8W-10-16) C100 GY/BK GY/BK PK/BK PARK BRAKE SWITCH (8W-40-10) IGNITION SWITCH...
Page 555 8W - 10 - 16 8W-10 POWER DISTRIBUTION INSTRUMENT PASSENGER PASSENGER CLUSTER POWER POWER (8W-40-11) LOCK/ LOCK/ WINDOW WINDOW SWITCH SWITCH BATT A1 (FULL (FULL (8W-10-14) OPTIONS) OPTIONS) (8W-10-15) (8W-61-2) (8W-61-3) C300 C306 C201 C203 S210 IGNITION HEADLAMP SWITCH SWITCH KEY-IN 1 START 0 OFF...
Page 556 8W-10 POWER DISTRIBUTION 8W - 10 - 17 BATT A2 (8W-10-14) (8W-10-15) PK/BK IGNITION SWITCH 1 START 2 RUN 0 OFF 3 LOCK 4 ACC (8W-10-14) (8W-10-15) BK/OR C201 BK/OR JUNCTION BLOCK (8W-12-2) FUSE FUSE FUSE FUSE (8W-12-16) (8W-12-21) (8W-12-21) (8W-12-18) (8W-12-17) (8W-12-22)
Page 557 8W - 10 - 18 8W-10 POWER DISTRIBUTION DIESEL BATT A0 (8W-10-12) POWER DISTRIBUTION CENTER FUSE FUSE FUSE (8W-10-6) RD/LG RD/GY RD/GY S153 S151 RD/GY RD/LG RD/LG RD/LG POWER DISTRIBUTION AUTOMATIC CENTER SHUT FUSE FUSE (8W-10-6) DOWN RELAY (8W-30-19) (8W-10-34) A142 A142 DG/OR...
Page 558 8W-10 POWER DISTRIBUTION 8W - 10 - 19 BATT A0 (8W-10-10) POWER DISTRIBUTION CENTER FUSE (8W-10-2) RD/BK JUNCTION BLOCK (8W-12-2) FUSE FUSE FUSE FUSE FUSE (8W-12-5) (8W-12-5) (8W-12-18) (8W-12-20) (8W-12-20) (8W-12-19) CIGAR HORN CIRCUIT LIGHTER RELAY BREAKER RELAY (8W-41-2) (8W-41-2) (8W-41-3) (8W-41-3) (8W-12-26)
Page 559 8W - 10 - 20 8W-10 POWER DISTRIBUTION BATT A0 (8W-10-10) POWER DISTRIBUTION CENTER FUSE FUSE (8W-10-2) F141 A111 LG/RD RD/LG RADIATOR C100 RELAY A111 (IN PDC) RD/LG (8W-42-8) C201 C202 RADIATOR A111 MOTOR RD/LG (8W-42-8) HVAC UNIT (8W-42-2) (8W-42-3) (8W-42-4) (8W-42-5) J998W-7...
Page 560 8W-10 POWER DISTRIBUTION 8W - 10 - 21 BATT A0 (8W-10-10) POWER DISTRIBUTION CENTER FUSE FUSE FUSE (8W-10-2) RD/WT RD/WT RD/BK RD/BK DB/GY COMPRESSOR CLUTCH RELAY (IN PDC) (8W-42-6) DB/BK 4.0L C100 OTHER C108 C100 DB/BK DB/GY COMPRESSOR CLUTCH (8W-42-6) RD/WT HEADLAMP SWITCH...
Page 561 8W - 10 - 22 8W-10 POWER DISTRIBUTION DIESEL BATT A0 (8W-10-12) POWER DISTRIBUTION CENTER FUSE FUSE FUSE FUSE (8W-10-6) LG/RD BK/PK RD/WT JUNCTION BLOCK (8W-12-2) C100 REAR ENGINE WINDOW DEFOGGER STARTER RELAY MOTOR (8W-48-2) RELAY (8W-48-3) (IN PDC) (8W-21-6) FUSE FUSE SPARE...
Page 562 8W-10 POWER DISTRIBUTION 8W - 10 - 23 BATT A0 (8W-10-10) POWER DISTRIBUTION CENTER FUSE FUSE FUSE FUSE (8W-10-2) (ABS) (ABS) BK/PK RD/DG RD/DB ENGINE CONTROLLER STARTER ANTI-LOCK MOTOR BRAKE RELAY (4.0L) (IN PDC) (8W-35-2) (8W-21-2) JUNCTION (8W-21-3) BLOCK (8W-21-4) (8W-12-2) (8W-21-5) REAR...
Page 563 8W - 10 - 24 8W-10 POWER DISTRIBUTION DIESEL BATT A0 (8W-10-12) POWER DISTRIBUTION CENTER FUSE FUSE FUSE FUSE FUSE (8W-10-6) (ABS) (ABS) A111 F141 RD/BK RD/LG LG/RD C100 RADIATOR RD/DG RD/DB RELAY C201 C202 (IN PDC) (8W-42-8) HVAC CONTROLLER UNIT ANTI-LOCK RADIATOR...
Page 564 8W-10 POWER DISTRIBUTION 8W - 10 - 25 BATT A0 (8W-10-10) POWER DISTRIBUTION CENTER FUSE (8W-10-2) S135 JUNCTION UNDERHOOD BLOCK LAMP/ (8W-12-2) MERCURY SWITCH (8W-44-6) C314 TRANSMISSION C201 CONTROL MODULE (4.0L) S347 S361 (8W-31-4) (8W-10-26) (8W-10-27) S214 CARGO RADIO C208 C207 LAMP/ (8W-47-2)
Page 565 8W - 10 - 26 8W-10 POWER DISTRIBUTION EXCEPT BUILT-UP-EXPORT BATT A0 FROM (8W-10-10) JUNCTION POWER BLOCK DISTRIBUTION (8W-10-25) CENTER FUSE (8W-10-10) TN/BK C100 C100 TN/BK TN/BK HEADLAMP S218 SWITCH (8W-50-2) TN/BK TN/BK TN/BK SKIM OTHERS DATA HEADLAMP DATA S361 LINK SWITCH LINK...
Page 566 8W-10 POWER DISTRIBUTION 8W - 10 - 27 BUILT-UP-EXPORT GAS BATT A0 FROM (8W-10-10) JUNCTION POWER BLOCK DISTRIBUTION (8W-10-25) CENTER FUSE (8W-10-2) TN/BK C100 C100 TN/BK S218 TN/BK TN/BK TN/BK SKIM OTHERS POWER HEADLAMP DATA ANTENNA SWITCH LINK RELAY (8W-50-4) CONNECTOR (8W-47-4) (8W-30-16)
Page 567 8W - 10 - 28 8W-10 POWER DISTRIBUTION DIESEL BATT A0 (8W-10-12) POWER DISTRIBUTION CENTER FUSE (8W-10-6) JUNCTION UNDERHOOD BLOCK LAMP/ (8W-12-2) MERCURY SWITCH (8W-44-7) S347 C314 OTHERS FULL OPTIONS C201 RIGHT VISOR/ VANITY LAMP COMPASS (8W-44-5) (8W-49-2) (8W-49-3) CARGO LEFT LAMP/ VISOR/...
Page 568 8W-10 POWER DISTRIBUTION 8W - 10 - 29 BATT A0 (8W-10-10) POWER DISTRIBUTION CENTER FUSE (8W-10-2) RD/LG AUTOMATIC SHUT DOWN RELAY (IN PDC) (8W-30-2) A999 A999 POWER DISTRIBUTION FUSE FUSE CENTER (8W-10-2) A142 F142 DG/OR DG/WT S137 A142 A142 DG/OR DG/OR C107 A142...
Page 569 8W - 10 - 30 8W-10 POWER DISTRIBUTION FROM S109 (8W-10-29) A142 DG/OR S113 A142 A142 A142 DG/OR DG/OR DG/OR FUEL FUEL FUEL INJECTOR INJECTOR INJECTOR NO. 2 NO. 4 NO. 6 (8W-30-6) (8W-30-6) (4.0L) (8W-30-6) A142 A142 A142 DG/OR DG/OR DG/OR FUEL...
Page 570 8W-10 POWER DISTRIBUTION 8W - 10 - 31 BATT A0 (8W-10-10) POWER DISTRIBUTION CENTER FUSE FUSE (8W-10-2) DG/BK FUEL PUMP RELAY (IN PDC) (8W-30-3) (8W-30-4) A141 BK/PK DG/WT DG/BK C107 C100 A141 DG/WT C200 C204 A141 BK/PK DG/WT DG/BK COMBINATION FUEL POWERTRAIN FLASHER...
Page 571 8W - 10 - 32 8W-10 POWER DISTRIBUTION DIESEL BATT A0 (8W-10-12) POWER DISTRIBUTION CENTER FUSE FUSE FUSE FUSE (8W-10-6) PK/DB WT/OR RD/BK RD/BK DB/GY C100 C100 LAMP COMPRESSOR RELAY CLUTCH PK/DB (IN PDC) RELAY DB/GY (IN PDC) (8W-42-7) BRAKE L139 LAMP SWITCH...
Page 572 8W-10 POWER DISTRIBUTION 8W - 10 - 33 BATT A0 (8W-10-10) POWER DISTRIBUTION CENTER FUSE FUSE FUSE (8W-10-2) BUILT-UP -EXPORT EXCEPT BUILT-UP -EXPORT PK/DB C100 WT/OR WT/OR PK/DB LAMP LAMP RELAY RELAY BRAKE (IN PDC) NO. 1 LAMP (IN PDC) (8W-50-17) SWITCH (8W-50-15)
Page 573 8W - 10 - 34 8W-10 POWER DISTRIBUTION DIESEL BATT A16 (8W-10-18) POWER DISTRIBUTION AUTOMATIC CENTER SHUT (8W-10-6) DOWN RELAY (8W-30-19) A142 DG/OR S137 (8W-10-18) A142 DG/OR BATT A0 (8W-10-12) POWER DISTRIBUTION CENTER FUSE FUSE (8W-10-6) F142 DG/OR S156 C100 F142 F142 F142...
Page 574 8W-10 POWER DISTRIBUTION 8W - 10 - 35 DIESEL BATT A0 (8W-10-12) POWER DISTRIBUTION CENTER FUSE FUSE (8W-10-6) BK/PK WT/OR LAMP RELAY (IN PDC) (8W-50-18) L139 C100 C100 C100 L139 FRONT LAMP BK/PK SWITCH (8W-50-18) S230 C100 COMBINATION DIODE FLASHER MODULE (8W-52-4) (8W-51-8)
Page 575 8W - 10 - 36 8W-10 POWER DISTRIBUTION DIESEL BATT A0 (8W-10-12) POWER DISTRIBUTION CENTER FUSE (8W-10-6) TN/BK C100 C100 TN/BK S218 TN/BK TN/BK TN/BK POWER HEADLAMP DATA ANTENNA SWITCH LINK RELAY (8W-50-4) CONNECTOR (8W-47-4) (8W-30-31) J998W-7 XJI01036...
Page 576 8W - 12 JUNCTION BLOCK 8W - 12 - 1 8 W-1 2 J U N CT I ON BLOCK Co m p o n e n t P a g e Co m p o n e n t P a g e A/C Com pr essor Clu t ch Rela y .
Page 577 8W - 12 - 2 8W-12 JUNCTION BLOCK SPARE RELAY CIGAR LIGHTER RELAY HORN RELAY REAR WINDOW DEFOGGER RELAY FRONT OF JUNCTION BLOCK J998W-7 XJI01202...
Page 578 8W-12 JUNCTION BLOCK 8W - 12 - 3 FUSES FUSE NO. AMPS FUSED CIRCUIT FEED CIRCUIT A7 10RD/BK F38 16RD/LB INTERNAL A7 10RD/BK L33 20RD L3 16RD/OR L43 20VT L4 16VT/WT L44 20VT/RD L4 16VT/WT E2 20OR E1 20TN INTERNAL L7 18BK/YL A21 12DB F87 20WT/BK...
Page 579 8W - 12 - 4 8W-12 JUNCTION BLOCK CIRCUIT BREAKERS CB NO. AMPS FUSED CIRCUIT FEED CIRCUIT INTERNAL A31 12BK/WT F37 14RD/LB A7 10RD/BK V6 16DB A31 12BK/WT CAVITY CIRCUIT FUNCTION INTERNAL FUSED B (+) CIGAR Z1 14BK GROUND LIGHTER A31 12BK/WT FUSED IGNITION SWITCH OUTPUT (RUN-ACC) RELAY...
Page 580 8W-12 JUNCTION BLOCK 8W - 12 - 5 (8W-10-19) BATT A7 (8W-10-24) JUNCTION BLOCK (8W-12-2) FUSE FUSE CIGAR LIGHTER RELAY (8W-41-2) (8W-41-3) RD/LB C201 C201 RD/LB POWER CIGAR OUTLET LIGHTER (8W-41-2) (8W-41-2) (8W-41-3) (8W-41-3) XJI01205 J998W-7...
Page 581 8W - 12 - 6 8W-12 JUNCTION BLOCK HEADLAMP BEAM SELECT SWITCH (8W-50-5) (8W-50-6) (8W-50-7) (8W-50-8) RD/OR S213 (8W-50-5) (8W-50-6) (8W-50-7) (8W-50-8) RD/OR C201 RD/OR JUNCTION BLOCK (8W-12-2) LAMP FUSE FUSE RELAY NO. 1 (IN PDC) (EXCEPT BUILT- UP-EXPORT) (8W-50-15) BR/WT RD/OR C106...
Page 582 8W-12 JUNCTION BLOCK 8W - 12 - 7 HEADLAMP BEAM SELECT SWITCH (8W-50-5) (8W-50-6) (8W-50-7) (8W-50-8) VT/WT C201 VT/WT JUNCTION BLOCK (8W-12-2) FUSE FUSE VT/RD S133 C106 EXCEPT EXCEPT EXCEPT BUILT- BUILT-UP BUILT- BUILT-UP BUILT-UP BUILT- UP-EXPORT -EXPORT UP-EXPORT -EXPORT -EXPORT UP-EXPORT OTHER...
Page 583 8W - 12 - 8 8W-12 JUNCTION BLOCK HEADLAMP SWITCH (8W-50-2) (8W-50-4) C201 JUNCTION BLOCK FUSE (8W-12-2) S315 C206 C201 PRNDL TRANSFER ILLUMINATION CASE (A/T) SWITCH (8W-44-2) ILLUMINATION (8W-44-3) (8W-44-2) (8W-44-3) S215 A/C- POLICE PACKAGE OTHERS HEATER CONTROL RADIO REAR (8W-42-4) EXTENDED (8W-47-2)
Page 584 8W-12 JUNCTION BLOCK 8W - 12 - 9 HEADLAMP SWITCH (8W-50-2) (8W-50-3) JUNCTION BLOCK FUSE (8W-12-2) S215 C203 RADIO REAR (8W-47-3) WINDOW (8W-47-10) DEFOGGER SWITCH (8W-48-3) OR/BK INSTRUMENT FRONT REAR CLUSTER (8W-40-15) LAMP LAMP SWITCH SWITCH (BUILT-UP-EXPORT) (8W-44-4) (8W-51-11) C206 A/C- PRNDL TRANSFER...
Page 585 8W - 12 - 10 8W-12 JUNCTION BLOCK EXCEPT BUILT-UP-EXPORT HEADLAMP SWITCH (8W-50-2) (8W-50-3) BK/YL S206 C201 BK/YL JUNCTION BLOCK (8W-12-2) RADIO FUSE (8W-47-2) (8W-47-3) (8W-47-9) (8W-47-10) BR/YL BR/YL S311 TRAILER BR/YL BR/YL CONNECTOR (8W-54-2) C327 TRAILER LAMP BR/YL OTHERS RELAY C106 NO.
Page 586 8W-12 JUNCTION BLOCK 8W - 12 - 11 BUILT-UP-EXPORT HEADLAMP SWITCH (8W-50-4) BK/YL S206 C201 BK/YL JUNCTION BLOCK (8W-12-2) FUSE RADIO (8W-47-2) (8W-47-3) (8W-47-9) (8W-47-10) BR/YL DIESEL S311 TRAILER BR/YL BR/YL BR/YL CONNECTOR (8W-54-2) TRAILER OTHERS C327 C323 LAMP LAMP RELAY RELAY (IN PDC)
Page 587 8W - 12 - 12 8W-12 JUNCTION BLOCK ST-RUN A21 (8W-10-16) COMPRESSOR JUNCTION CLUTCH BLOCK RELAY (8W-12-2) (IN PDC) FUSE FUSE FUSE (8W-42-6) (8W-42-7) SPARE DAYTIME RUNNING LAMP MODULE (EXCEPT BUILT-UP TRANSMISSION -EXPORT) RANGE (8W-50-19) C201 SENSOR WT/BK (4.0L) RADIATOR (8W-31-6) FULL RELAY...
Page 588 8W-12 JUNCTION BLOCK 8W - 12 - 13 ST-RUN A21 (8W-10-16) JUNCTION BLOCK DAYTIME (8W-12-2) RUNNING LAMP FUSE FUSE FUSE COMPRESSOR MODULE SPARE CLUTCH (EXCEPT RELAY BUILT-UP (IN PDC) -EXPORT) (8W-42-6) (8W-50-19) (8W-42-7) TRANSMISSION RANGE SENSOR (4.0L) (8W-31-6) C100 S159 EXCEPT DIESEL 4.0L A/T...
Page 589 8W - 12 - 14 8W-12 JUNCTION BLOCK 2.5L ST-RUN A21 (8W-10-16) JUNCTION BLOCK (8W-12-2) FUSE DB/WT S130 DB/WT DB/WT DB/WT DB/WT DB/WT ENGINE CONTROL MODULE (DIESEL) (8W-30-19) FUEL PUMP RELAY (IN PDC) (GAS) (8W-30-3) FUEL (8W-30-4) HEATER RELAY C107 (IN PDC) (DIESEL) (8W-30-21)
Page 590 8W-12 JUNCTION BLOCK 8W - 12 - 15 4.0L ST-RUN A21 (8W-10-16) JUNCTION BLOCK (8W-12-2) FUSE DB/WT S130 DB/WT DB/WT DB/WT DB/WT TRANSMISSION CONTROL MODULE (RHD) DB/WT DB/WT (8W-31-4) AUTOMATIC FUEL S136 SHUT PUMP DOWN RELAY RELAY (IN PDC) (IN PDC) (8W-30-3) DB/WT DB/WT...
Page 591 8W - 12 - 16 8W-12 JUNCTION BLOCK (8W-10-22) RUN A22 BATT A4 (8W-10-17) (8W-10-23) JUNCTION BLOCK (8W-12-2) FUSE REAR WINDOW DEFOGGER RELAY (8W-48-2) FUSE FUSE SPARE LB/WT LB/YL BK/WT BK/WT C201 PASSENGER POWER C326 MIRROR LB/YL (8W-48-2) LB/WT S202 BK/WT C312 LB/YL...
Page 592 8W-12 JUNCTION BLOCK 8W - 12 - 17 (8W-10-22) RUN A22 BATT A4 (8W-10-17) (8W-10-23) JUNCTION BLOCK (8W-12-2) FUSE REAR WINDOW DEFOGGER RELAY (8W-48-3) FUSE FUSE SPARE LB/WT BK/WT LB/YL BK/WT BK/WT C204 DRIVER C326 POWER MIRROR (8W-48-3) LB/YL REAR WINDOW INSTRUMENT DEFOGGER...
Page 593 8W - 12 - 18 8W-12 JUNCTION BLOCK (8W-10-19) (8W-10-14) BATT A7 RUN-ACC A31 ST A41 (8W-10-17) (8W-10-24) (8W-10-15) JUNCTION BLOCK (8W-12-2) FUSE FUSE FUSE FUSE 2.5L A/T 4.0L A/T RD/WT YL/DG C201 YL/RD YL/RD YL/RD RD/WT CLUTCH CLUTCH INTERLOCK INTERLOCK RADIO SWITCH...
Page 594 8W-12 JUNCTION BLOCK 8W - 12 - 19 (8W-10-19) (8W-10-14) BATT A7 RUN-ACC A31 ST A41 (8W-10-17) (8W-10-24) (8W-10-15) JUNCTION BLOCK (8W-12-2) FUSE FUSE FUSE FUSE YL/DG OTHER BUILT-UP-EXPORT RD/WT YL/RD S232 C100 C204 YL/DG YL/RD RADIO REAR (8W-47-3) (8W-47-10) LAMP YL/DG RELAY...
Page 595 8W - 12 - 20 8W-12 JUNCTION BLOCK (8W-10-19) BATT A7 (8W-10-24) JUNCTION BLOCK (8W-12-2) FUSE FUSE HORN RELAY (8W-41-2) (8W-41-3) BK/RD BK/RD C201 RD/OR BK/RD DG/RD C301 C323 S131 BK/RD RD/OR BK/RD DG/RD DG/RD CLOCKSPRING (8W-41-2) (8W-41-3) OVERHEAD HORN MODULE SWITCH (8W-49-4)
Page 596 8W-12 JUNCTION BLOCK 8W - 12 - 21 RUN A22 (8W-10-17) JUNCTION BLOCK (8W-12-2) FUSE FUSE FUSE SPARE BR/PK DB/WT DB/WT DIESEL C201 S134 DB/WT S219 BR/PK CONTROLLER ANTI-LOCK DB/WT DB/WT BRAKE REAR RELAY WIPER/ DB/WT DB/WT (IN PDC) WASHER DB/WT (8W-35-5) SWITCH...
Page 597 8W - 12 - 22 8W-12 JUNCTION BLOCK RUN A22 (8W-10-17) JUNCTION BLOCK (8W-12-2) FUSE FUSE FUSE SPARE BR/PK DB/WT DB/WT DIESEL REAR WIPER/ S134 DB/WT WASHER SWITCH (8W-53-6) CONTROLLER (8W-53-7) ANTI-LOCK DB/WT DB/WT BRAKE RELAY CONTROLLER BR/PK (IN PDC) ANTI-LOCK (8W-35-5) BRAKE...
Page 598 8W-12 JUNCTION BLOCK 8W - 12 - 23 HEADLAMP SWITCH HEADLAMP (8W-50-2) SWITCH (8W-50-3) OUTPUT (8W-50-4) BK/YL S206 (8W-12-10) (8W-12-11) C201 BK/YL JUNCTION BLOCK (8W-12-2) FUSE DIESEL DG/YL DG/YL DG/YL C321 C106 BUILT-UP-EXPORT OTHER DG/YL DG/YL DG/YL RIGHT S101 TAIL/ STOP RIGHT LAMP...
Page 599 8W - 12 - 24 8W-12 JUNCTION BLOCK (8W-10-14) RUN A22 ST-RUN A21 RUN-ACC A31 (8W-10-17) (8W-10-16) (8W-10-15) JUNCTION BLOCK (8W-12-2) FUSE FUSE CIRCUIT BREAKER LG/YL DB/YL C201 C200 C307 AIRBAG DRIVER PASSENGER CONTROL POWER POWER LOCK/ LOCK/ MODULE (8W-43-2) WINDOW WINDOW SWITCH...
Page 600 8W-12 JUNCTION BLOCK 8W - 12 - 25 (8W-10-14) RUN A22 ST-RUN A21 RUN-ACC A31 (8W-10-17) (8W-10-16) (8W-10-15) JUNCTION BLOCK (8W-12-2) FUSE FUSE CIRCUIT BREAKER LG/YL DB/YL C204 C202 C307 LG/YL DB/YL AIRBAG PASSENGER DRIVER CONTROL POWER POWER LOCK/ LOCK/ MODULE (8W-43-3) WINDOW...
Page 601 8W - 12 - 26 8W-12 JUNCTION BLOCK EXCEPT BUILT-UP-EXPORT BATT A7 RUN-ACC A31 (8W-10-19) (8W-10-14) JUNCTION BLOCK (8W-12-2) CIRCUIT CIRCUIT BREAKER BREAKER RD/LB C201 FRONT WIPER HEATED OTHER MOTOR SEATS (8W-53-2) C316 C316 WIPE/ WASH SWITCH (8W-53-2) RD/LB S356 RD/LB RD/LB RD/LB...
Page 602 8W-12 JUNCTION BLOCK 8W - 12 - 27 BUILT-UP-EXPORT (8W-10-19) (8W-10-14) BATT A7 RUN-ACC A31 (8W-10-24) (8W-10-15) JUNCTION BLOCK (8W-12-2) CIRCUIT CIRCUIT BREAKER BREAKER RD/LB HEATED C201 OTHER SEATS C316 C316 S356 WIPE/ RD/LB RD/LB RD/LB RD/LB RD/LB WASH SWITCH C329 (8W-53-2) FRONT...
Page 603 8W - 12 - 28 8W-12 JUNCTION BLOCK BATT A0 (8W-10-10) POWER DISTRIBUTION CENTER FUSE (8W-10-2) (8W-10-25) S135 JUNCTION UNDERHOOD BLOCK LAMP/ (8W-12-2) MERCURY SWITCH (8W-44-6) C314 OTHERS SKIM TRANSMISSION C201 CONTROL MODULE (4.0L) S347 S361 (8W-31-4) (8W-10-26) (8W-10-26) (8W-10-27) (8W-10-27) S214 CARGO...
Page 604 8W-12 JUNCTION BLOCK 8W - 12 - 29 DIESEL BATT A0 (8W-10-12) POWER DISTRIBUTION CENTER FUSE (8W-10-6) (8W-10-28) UNDERHOOD JUNCTION LAMP/ BLOCK MERCURY (8W-12-2) SWITCH (8W-44-7) C314 C201 S347 (8W-10-28) S214 CARGO RADIO C208 C207 LAMP/ (8W-47-2) (8W-47-3) SWITCH (8W-44-8) (8W-44-9) INSTRUMENT CLUSTER...
Page 605 8W - 12 - 30 8W-12 JUNCTION BLOCK HEADLAMP LEFT RIGHT SWITCH COURTESY COURTESY (8W-50-2) LAMP LAMP (8W-50-3) (8W-44-6) (8W-44-6) (8W-50-4) (8W-44-7) (8W-44-7) BK/WT BK/WT C208 C207 S201 C201 JUNCTION BLOCK (8W-12-2) OVERHEAD MODULE BASE/POLICE S345 FULL OPTIONS MIDLINE DOME LAMP OVERHEAD (8W-44-5)
Page 606 8W-12 JUNCTION BLOCK 8W - 12 - 31 PASSENGER PASSENGER POWER DOOR LOCK/ LOCK WINDOW MOTOR SWITCH (8W-61-4) (8W-61-4) PK/BK OR/BK OR/BK PK/BK S317 S316 PK/BK OR/BK JUNCTION BLOCK (8W-12-2) PK/BK OR/BK S307 S306 PK/BK OR/BK PK/BK OR/BK PK/BK OR/BK PK/BK OR/BK C305...
Page 607 8W - 12 - 32 8W-12 JUNCTION BLOCK PASSENGER POWER LOCK/ WINDOW SWITCH (8W-61-5) PK/BK OR/BK S323 S322 PK/BK OR/BK PK/BK OR/BK PASSENGER DOOR C305 LOCK MOTOR (8W-61-5) PK/BK OR/BK S307 S306 PK/BK OR/BK PK/BK OR/BK PK/BK OR/BK PK/BK OR/BK C309 C304 C326...
Page 608 8W-12 JUNCTION BLOCK 8W - 12 - 33 POWER DRIVER MIRROR POWER SWITCH MIRROR (LHD) (LHD) (8W-62-8) (8W-62-8) P91 20BK/WT WT/BK C305 PASSENGER POWER WT/BK MIRROR (LHD) C200 (8W-62-8) WT/BK C201 WT/BK WT/BK JUNCTION BLOCK (8W-12-2) WT/BK WT/BK WT/BK C203 WT/BK S359 (RHD)
Page 609 8W - 12 - 34 8W-12 JUNCTION BLOCK DRIVER DRIVER POWER POWER LOCK/ MIRROR WINDOW (FULL SWITCH OPTIONS) (FULL (8W-62-2) (8W-62-3) OPTIONS) (8W-62-4) OR/YL OR/YL OR/YL S328 YL/BK OR/YL C305 YL/BK OR/YL C200 YL/BK OR/YL C201 YL/BK OR/YL JUNCTION BLOCK (8W-12-2) YL/BK OR/YL...
Page 610 8W-12 JUNCTION BLOCK 8W - 12 - 35 PASSENGER POWER MIRROR (FULL OPTIONS) (8W-62-7) DB/WT OR/YL OR/YL S328 OR/YL C305 OR/YL C204 YL/BK OR/YL JUNCTION BLOCK (8W-12-2) DB/WT YL/LB OR/YL S318 OR/YL OR/YL OR/YL DRIVER DRIVER POWER POWER LOCK/ MIRROR WINDOW (FULL SWITCH...
Page 611 8W - 12 - 36 8W-12 JUNCTION BLOCK PASSENGER POWER DRIVER POWER MIRROR POWER MIRROR SWITCH MIRROR (LHD) (8W-62-9) (8W-48-3) (8W-48-2) PASSENGER POWER LOCK/ WINDOW S360 SWITCH (8W-15-13) (LHD) (8W-61-2) PASSENGER POWER MIRROR S319 (8W-48-2) (8W-15-13) FULL OPTIONS POWER POWER MIRRORS MIRRORS JUNCTION...
Page 612 8W - 15 GROUND DISTRIBUTION 8W - 15 - 1 8 W-1 5 GROU N D DI ST RI BU T I ON Co m p o n e n t P a g e Co m p o n e n t P a g e A/C Com pr essor Clu t ch .
Page 613 8W - 15 - 2 8W-15 GROUND DISTRIBUTION TRANSFER TRANSFER OXYGEN ENGINE CASE CASE SENSOR STARTER SWITCH SWITCH MOTOR (8W-40-9) (8W-40-9) DOWNSTREAM RELAY (2.5L M/T) (8W-30-8) (IN PDC) (8W-21-4) POWERTRAIN BK/WT CONTROL MODULE 242 4WD 231 4WD (M/T 231) POWER OXYGEN (8W-30-11) STEERING...
Page 614 8W-15 GROUND DISTRIBUTION 8W - 15 - 3 DIESEL CONTROLLER POWERTRAIN ANTI-LOCK CONTROL BRAKE MODULE (8W-35-5) (8W-30-20) DATA LINK CONNECTOR (8W-30-31) ENGINE CONTROL MODULE (8W-30-19) BK/TN C100 C100 BK/TN BK/TN BK/TN BK/TN BK/TN BK/TN C100 S146 BK/TN S150 BATTERY (8W-20-3) BK/TN G102 G104...
Page 615 8W - 15 - 4 8W-15 GROUND DISTRIBUTION LHD 2.5L GAS REAR WINDSHIELD WASHER WASHER LAMP LAMP PUMP PUMP RELAY RELAY NO. 2 NO. 1 (8W-53-4) (8W-53-2) (IN PDC) (IN PDC) (DRL) (DRL) (8W-50-16) (8W-50-16) UNDERHOOD LAMP/ MERCURY SWITCH (8W-44-6) VEHICLE SPEED CONTROL...
Page 616 8W-15 GROUND DISTRIBUTION 8W - 15 - 5 LHD 4.0L EXCEPT BUILT-UP-EXPORT REAR WINDSHIELD WASHER WASHER PUMP PUMP (8W-53-2) (8W-53-4) (8W-53-5) (8W-53-6) (8W-53-7) WASHER FRONT TRANSMISSION FLUID WIPER RANGE LEVEL MOTOR SENSOR SWITCH (8W-53-2) (A/T) (8W-40-6) (8W-31-6) S141 UNDERHOOD VEHICLE LAMP/ LAMP SPEED...
Page 617 8W - 15 - 6 8W-15 GROUND DISTRIBUTION RHD GAS REAR WINDSHIELD VEHICLE WASHER WASHER SPEED PUMP PUMP CONTROL (8W-53-2) SERVO (8W-53-6) (8W-33-4) UNDERHOOD CONTROLLER LAMP/ ANTI-LOCK MERCURY BRAKE SWITCH RELAY (8W-44-6) (IN PDC) (8W-35-4) S132 G106 (8W-15-7) WASHER FRONT TRANSMISSION FLUID WIPER...
Page 618 8W-15 GROUND DISTRIBUTION 8W - 15 - 7 EXCEPT BUILT-UP-EXPORT LEFT LEFT LEFT LEFT HEADLAMP FRONT FRONT (8W-50-5) LAMP PARK/ PARK/ (8W-50-6) (8W-50-15) TURN TURN SIGNAL SIGNAL LAMP LAMP NO. 1 NO. 2 (8W-50-11) (8W-50-11) S103 S158 RIGHT RIGHT RIGHT RIGHT FRONT FRONT...
Page 619 8W - 15 - 8 8W-15 GROUND DISTRIBUTION BUILT-UP-EXPORT LHD 4.0L A/T REAR WINDSHIELD VEHICLE CONTROLLER WASHER WASHER SPEED ANTI-LOCK PUMP PUMP CONTROL BRAKE SERVO RELAY (8W-53-4) (8W-53-2) (IN PDC) (8W-33-4) (8W-35-4) UNDERHOOD LAMP/ MERCURY SWITCH (8W-44-6) S132 WASHER FRONT TRANSMISSION FLUID WIPER...
Page 620 8W-15 GROUND DISTRIBUTION 8W - 15 - 9 BUILT-UP-EXPORT LHD 4.0L M/T REAR WINDSHIELD ENGINE WASHER WASHER STARTER PUMP PUMP MOTOR RELAY (8W-53-4) (8W-53-2) (IN PDC) (8W-21-5) UNDERHOOD VEHICLE LAMP/ SPEED MERCURY CONTROL SWITCH SERVO (8W-44-6) (8W-33-4) WASHER FRONT FLUID WIPER LEVEL MOTOR...
Page 621 8W - 15 - 10 8W-15 GROUND DISTRIBUTION BUILT-UP-EXPORT GAS LEFT LEFT REPEATER LAMP LEFT LAMP LAMP RELAY FRONT (8W-50-12) (8W-50-17) (IN PDC) TURN (8W-50-17) SIGNAL LEFT LAMP LEFT LEFT NO. 2 HEADLAMP BR/WT CITY FRONT (8W-50-12) (8W-50-7) LAMP TURN (8W-50-8) (8W-50-12) SIGNAL...
Page 622 8W-15 GROUND DISTRIBUTION 8W - 15 - 11 DIESEL TRANSFER WINDSHIELD FUEL CASE WASHER HEATER SWITCH PUMP RELAY (231 4WD) (IN PDC) (8W-53-3) (8W-40-10) (8W-30-21) WASHER REAR ENGINE FLUID WASHER STARTER LEVEL PUMP MOTOR SWITCH (8W-53-5) RELAY C111 (8W-53-7) (8W-40-7) (IN PDC) (8W-40-8) (8W-21-6)
Page 623 8W - 15 - 12 8W-15 GROUND DISTRIBUTION DIESEL LEFT LEFT LEFT CONTROLLER FRONT REPEATER ANTI-LOCK TURN LAMP LAMP BRAKE SIGNAL (8W-50-12) (8W-50-18) RELAY LAMP (IN PDC) NO. 1 (8W-35-5) (8W-50-12) BK/YL LEFT LAMP FRONT RELAY C114 TURN (IN PDC) SIGNAL (8W-50-18) LEFT...
Page 624 8W-15 GROUND DISTRIBUTION 8W - 15 - 13 OVERHEAD PASSENGER POWER DRIVER MODULE POWER MIRROR POWER (8W-49-2) MIRROR SWITCH MIRROR (8W-49-3) (LHD) (8W-62-9) (8W-48-2) (8W-48-2) PASSENGER COMPASS POWER (8W-49-2) LOCK/ (8W-49-3) WINDOW S360 SWITCH DOME (LHD) LAMPS (8W-61-2) PASSENGER SWITCH POWER (8W-44-5) MIRROR...
Page 625 8W - 15 - 14 8W-15 GROUND DISTRIBUTION EXCEPT BUILT-UP-EXPORT FROM FROM JUNCTION EXTENDED FRONT C201 BLOCK IDLE (8W-15-13) (8W-15-13) SWITCH LAMP (8W-30-14) SWITCH (8W-44-2) (8W-44-4) POLICE OTHERS PACKAGE REAR COMBINATION REAR WINDOW FLASHER WIPER/ DEFOGGER WASHER (8W-52-2) SWITCH SWITCH (8W-48-2) (8W-53-4) (8W-48-3)
Page 626 8W-15 GROUND DISTRIBUTION 8W - 15 - 15 BUILT-UP-EXPORT HVAC REAR POWER UNIT WINDOW ANTENNA FROM (8W-42-6) DEFOGGER RELAY FROM JUNCTION SWITCH (RHD) C201 BLOCK (8W-48-2) (8W-47-4) (8W-15-13) (8W-15-13) (8W-48-3) COMBINATION FLASHER (8W-52-3) (8W-52-4) FRONT REAR C204 C201 WIPER/ LAMP WASHER SWITCH SWITCH...
Page 627 8W - 15 - 16 8W-15 GROUND DISTRIBUTION WIPE/ BRAKE HEADLAMP IGNITION WASH LAMP DELAY SWITCH SWITCH SWITCH MODULE (8W-10-14) (8W-10-15) (8W-53-2) (8W-33-4) (8W-50-9) (8W-53-3) (8W-33-5) (8W-50-10) HEADLAMP SWITCH (8W-50-2) (8W-50-3) (8W-50-4) S207 SENTRY HVAC COMPASS UNIT (8W-49-2) IMMOBILIZER (8W-42-2) (8W-49-3) (8W-42-3) MODULE...
Page 628 8W-15 GROUND DISTRIBUTION 8W - 15 - 17 LEFT LEFT DRIVER LEFT TAIL/ BACK-UP POWER TURN STOP LAMP MIRROR SIGNAL LAMP (8W-51-7) (8W-48-2) LAMP (8W-51-3) (8W-52-5) (8W-52-6) LEFT DRIVER POWER REAR POWER MIRROR LOCK/ SWITCH LAMP WINDOW (BUILT-UP (8W-62-8) SWITCH -EXPORT) (8W-60-4) (8W-51-10)
Page 629 8W - 15 - 18 8W-15 GROUND DISTRIBUTION LEFT LEFT LEFT LEFT TAIL/ TURN BACK-UP REAR STOP SIGNAL LAMP LAMP LAMP (8W-51-7) LAMP (BUILT-UP (8W-51-3) (8W-51-4) -EXPORT) (8W-51-10) S341 TRAILER PRNDL EXCEPT ILLUMINATION BUILT-UP BUILT-UP CONNECTOR (A/T) TRANSFER -EXPORT -EXPORT (8W-54-2) (8W-44-4) CASE...
Page 630 8W-15 GROUND DISTRIBUTION 8W - 15 - 19 RIGHT RIGHT RIGHT RIGHT REAR TAIL/ TURN BACK-UP STOP SIGNAL LAMP LAMP LAMP LAMP (8W-51-7) (BUILT-UP- (8W-51-3) (8W-51-4) EXPORT) (8W-51-10) S348 RIGHT PASSENGER REAR DOOR DOOR JAMB JAMB SWITCH SWITCH (8W-39-6) (8W-39-6) C319 C318 C321...
Page 631 8W - 15 - 20 8W-15 GROUND DISTRIBUTION RIGHT RIGHT RIGHT RIGHT REAR TAIL/ TURN BACK-UP STOP SIGNAL LAMP LAMP LAMP LAMP (8W-51-7) (BUILT-UP (8W-51-3) (8W-51-4) -EXPORT) (8W-51-10) S348 DRIVER DRIVER DRIVER DOOR POWER POWER JAMB LOCK/ MIRROR SWITCH WINDOW (FULL SWITCH OPTIONS)
Page 632 8W-15 GROUND DISTRIBUTION 8W - 15 - 21 LICENSE LIFTGATE REAR LAMP SWITCH WIPER MOTOR (8W-51-3) (8W-44-8) (8W-44-9) (8W-53-4) (8W-53-5) (8W-53-6) (8W-53-7) C330 S334 CENTER HIGH MOUNTED STOP LAMP (8W-51-3) C310 C311 REAR WINDOW DEFOGGER C325 (8W-48-2) (8W-48-3) C310 C312 G304 XJI01521 J998W-7...
Page 633 8W - 15 - 22 8W-15 GROUND DISTRIBUTION LEFT RIGHT POWER POWER SEAT SEAT SWITCH SWITCH (8W-63-2) (8W-63-3) C362 C363 S350 LEFT RIGHT HEATED HEATED HEATED SEAT SEAT SEAT RELAY BACK BACK (8W-63-6) (8W-63-5) (8W-63-5) G305 LEFT RIGHT S354 HEATED HEATED SEAT SEAT...
Page 634 8W - 20 CHARGING SYSTEM 8W - 20 - 1 8 W-2 0 CH ARGI N G SY ST EM Co m p o n e n t P a g e Co m p o n e n t P a g e Au t om a t ic Sh u t Down Rela y .
Page 635 8W - 20 - 2 8W-20 CHARGING SYSTEM POWER FUSIBLE LINK DISTRIBUTION CENTER FUSE (8W-10-2) (8W-10-29) S118 RD/LG BK/WT AUTOMATIC BATTERY SHUT DOWN GENERATOR RELAY (IN PDC) (8W-30-2) A999 A999 ENGINE B(+) STARTER MOTOR (8W-21-2) (8W-21-3) (8W-21-4) FUSE (8W-21-5) 24 (PDC) (8W-10-29) DG/OR POWER...
Page 636 8W-20 CHARGING SYSTEM 8W - 20 - 3 DIESEL POWER FUSIBLE LINK DISTRIBUTION CENTER FUSE (8W-10-6) (8W-10-18) S118 RD/LG BK/GY ENGINE GENERATOR STARTER MOTOR (8W-21-6) S151 BATTERY (8W-10-18) RD/LG AUTOMATIC SHUT DOWN RELAY DG/OR (IN PDC) (8W-30-19) C120 A142 DG/OR DG/OR S137 (8W-10-18)
Page 638 8W - 21 STARTING SYSTEM 8W - 21 - 1 8 W-2 1 START I N G SY ST EM Co m p o n e n t P a g e Co m p o n e n t P a g e Ba t t er y .
Page 639 8W - 21 - 2 8W-21 STARTING SYSTEM 2.5L GAS A/T ST A41 (8W-10-17) JUNCTION POWER BLOCK FUSE DISTRIBUTION (8W-12-2) CENTER FUSE (8W-10-2) (8W-12-18) (8W-12-19) (8W-10-23) YL/RD C100 YL/RD YL/RD CLUTCH CLUTCH INTERLOCK INTERLOCK SWITCH SWITCH JUMPER JUMPER T141 T141 C100 ENGINE STARTER...
Page 640 8W-21 STARTING SYSTEM 8W - 21 - 3 4.0L A/T ST A41 (8W-10-17) JUNCTION POWER BLOCK FUSE DISTRIBUTION (8W-12-2) CENTER FUSE (8W-10-2) (8W-12-18) (8W-12-19) (8W-10-23) YL/RD C100 CLUTCH INTERLOCK SWITCH JUMPER T141 C100 ENGINE STARTER MOTOR RELAY BATTERY (IN PDC) (8W-20-2) BK/WT BK/WT...
Page 641 8W - 21 - 4 8W-21 STARTING SYSTEM 2.5L GAS M/T ST A41 (8W-10-17) JUNCTION POWER BLOCK DISTRIBUTION CENTER (8W-12-2) FUSE FUSE (8W-10-2) (8W-12-18) (8W-10-23) (8W-12-19) YL/RD C100 CLUTCH CLUTCH INTERLOCK INTERLOCK SWITCH SWITCH BATTERY (8W-20-2) C100 T141 ENGINE STARTER MOTOR RELAY (IN PDC)
Page 642 8W-21 STARTING SYSTEM 8W - 21 - 5 4.0L M/T ST A41 (8W-10-17) JUNCTION POWER BLOCK DISTRIBUTION CENTER (8W-12-2) FUSE FUSE (8W-10-2) (8W-12-18) (8W-10-23) (8W-12-19) YL/RD C100 CLUTCH CLUTCH INTERLOCK INTERLOCK SWITCH SWITCH BATTERY (8W-20-2) C100 T141 ENGINE STARTER MOTOR RELAY (IN PDC) C108...
Page 643 8W - 21 - 6 8W-21 STARTING SYSTEM DIESEL ST A41 (8W-10-17) JUNCTION POWER BLOCK DISTRIBUTION (8W-12-2) FUSE CENTER FUSE (8W-10-6) (8W-12-18) (8W-12-19) (8W-10-22) YL/RD C100 CLUTCH INTERLOCK SWITCH BATTERY (8W-20-3) T141 C100 ENGINE STARTER MOTOR RELAY (IN PDC) S141 C111 (8W-15-11) S132...
Page 644 8W - 30 FUEL/IGNITION SYSTEM 8W - 30 - 1 8 W-3 0 FU EL/I GN I T I ON SY ST EM Co m p o n e n t P a g e Co m p o n e n t P a g e A/C Com pr essor Clu t ch Rela y .
Page 645 8W - 30 - 2 8W-30 FUEL/IGNITION SYSTEM ST-RUN A21 BATT A0 (8W-10-16) (8W-10-10) JUNCTION POWER BLOCK DISTRIBUTION CENTER (8W-12-2) FUSE FUSE FUSE (8W-10-2) (8W-12-14) (8W-10-29) (8W-10-31) (8W-12-15) RD/LG DG/BK DB/WT S130 (8W-12-14) FUEL FUSED (8W-12-15) PUMP B(+) RELAY (IN PDC) DB/WT DB/WT (8W-30-3)
Page 646 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 3 LHD GAS ST-RUN A21 BATT A0 (8W-10-16) (8W-10-10) JUNCTION POWER BLOCK DISTRIBUTION CENTER (8W-12-2) FUSE FUSE (8W-10-2) (8W-12-14) (8W-10-31) (8W-12-15) DB/WT DB/BK S130 (8W-12-14) (8W-12-15) FUEL PUMP RELAY (IN PDC) A141 DG/WT C100 K226 A141...
Page 647 8W - 30 - 4 8W-30 FUEL/IGNITION SYSTEM RHD GAS ST-RUN A21 BATT A0 (8W-10-16) (8W-10-10) JUNCTION POWER BLOCK DISTRIBUTION CENTER (8W-12-2) FUSE FUSE (8W-10-2) (8W-12-14) (8W-10-31) (8W-12-15) DB/WT DB/BK S130 (8W-12-14) (8W-12-15) FUEL PUMP RELAY (IN PDC) A141 DG/WT C100 K226 A141...
Page 648 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 5 BATT A16 (8W-10-29) POWER DISTRIBUTION AUTOMATIC CENTER SHUT DOWN (8W-10-2) RELAY (8W-30-2) A999 A999 POWER DISTRIBUTION FUSE CENTER (8W-10-2) FUSE (8W-10-29) 24 (PDC) (8W-10-29) S115 A142 (8W-70-4) DG/OR S137 (8W-10-29) A142 CRANKSHAFT POSITION SUPPLY DG/OR...
Page 649 8W - 30 - 6 8W-30 FUEL/IGNITION SYSTEM BATT A16 (8W-10-29) POWER DISTRIBUTION AUTOMATIC CENTER SHUT FUSE DOWN (8W-10-2) RELAY (8W-30-2) (8W-10-29) A999 A999 A142 DG/OR S137 (8W-10-29) C107 FUSE S109 24 (PDC) (8W-10-29) (8W-10-29) A142 DG/OR S113 (8W-10-30) A142 A142 A142 A142...
Page 650 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 7 THROTTLE POSITION SENSOR 2.5L 4.0L K167 BR/YL OR/DB S112 OR/DB OR/DB 4.0L A/T OTHER C107 USED OR/DB TRANSMISSION THROTTLE CONTROL POSITION S115 MODULE SENSOR (8W-70-4) (8W-31-5) SIGNAL S114 (8W-70-2) K167 K167 K167 BR/YL BR/YL BR/YL...
Page 651 8W - 30 - 8 8W-30 FUEL/IGNITION SYSTEM BATT A16 (8W-10-29) POWER DISTRIBUTION AUTOMATIC CENTER SHUT FUSE DOWN (8W-10-2) RELAY (8W-30-2) (8W-10-29) A999 A999 F142 DG/WT C107 F142 FUSE 21 (PDC) DG/WT (8W-10-29) S110 (8W-10-29) F142 F142 DG/WT DG/WT OXYGEN OXYGEN SENSOR SENSOR...
Page 652 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 9 MANIFOLD ABSOLUTE PRESSURE SENSOR K167 BR/YL S114 (8W-70-2) K167 BR/YL S111 S115 (8W-70-2) (8W-70-4) K167 BR/YL VEHICLE VEHICLE SPEED SUPPLY SPEED SENSOR SENSOR SUPPLY SIGNAL WT/OR S108 WT/OR OTHER C107 USED WT/OR K167 DAYTIME VEHICLE...
Page 653 8W - 30 - 10 8W-30 FUEL/IGNITION SYSTEM LEFT RIGHT SPEED SPEED CONTROL CONTROL SWITCH SWITCH 1 SET 1 RESUME/ACCEL 2 ON/OFF 2 CANCEL 3 COAST (8W-33-2) (8W-33-2) K167 K167 RD/LG BR/YL RD/LG BR/YL S221 S222 CLOCKSPRING BK/LB BK/RD RD/LG C100 C100 S138...
Page 654 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 11 (8W-12-18) ST T141 ST F45 (8W-12-18) (8W-12-19) POWER DISTRIBUTION OTHER 4.0L A/T CENTER (8W-10-2) ENGINE STARTER MOTOR RELAY (8W-21-2) YL/RD YL/RD (8W-21-3) (8W-21-4) (8W-21-5) BRAKE 2.5L A/T LAMP EXCEPT BUILT- BK/WT SWITCH UP-EXPORT OTHER (8W-33-4)
Page 655 8W - 30 - 12 8W-30 FUEL/IGNITION SYSTEM GAS EXCEPT BUILT-UP-EXPORT ST-RUN A21 (8W-10-16) JUNCTION BLOCK (8W-12-2) FUSE FUSE (8W-12-14) (8W-12-12) (8W-12-15) (8W-12-13) DB/WT S130 (8W-12-14) (8W-12-15) C201 OTHER 4.0L LHD A/T C100 DB/WT C100 S136 (8W-12-15) DB/WT S159 (8W-12-12) C107 (8W-12-13) S161...
Page 656 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 13 POWERTRAIN CONTROL MODULE BRAKE MOTOR MOTOR MOTOR MOTOR LAMP NO. 3 NO. 2 NO. 1 NO. 4 SWITCH DRIVER DRIVER DRIVER DRIVER SENSE WT/PK 4.0L A/T OTHER S140 (8W-31-7) WT/PK WT/PK C100 BR/WT YL/BK GY/RD...
Page 657 8W - 30 - 14 8W-30 FUEL/IGNITION SYSTEM GAS EXCEPT BUILT-UP-EXPORT POWERTRAIN HEADLAMP PANEL CONTROL POWER SWITCH LAMPS MODULE STEERING DIMMER (8W-50-2) PRESSURE SWITCH (8W-50-3) SWITCH IDLE SIGNAL ACTUATOR SIGNAL C201 4.0L A/T 2.5L 4.0L A/T 2.5L RUN A22 (8W-10-17) JUNCTION BLOCK DB/BR...
Page 658 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 15 (8W-12-12) ST-RUN F20 (8W-12-13) POWER DISTRIBUTION CENTER RADIATOR COMPRESSOR (8W-10-2) CLUTCH RELAY RELAY (8W-42-8) (8W-42-6) GENERATOR GENERATOR (8W-20-2) FIELD GENERATOR DRIVER DRIVER DG/OR C108 C107 DB/OR DB/PK DG/OR POWERTRAIN RADIATOR GENERATOR GENERATOR CONTROL COMPRESSOR DRIVER...
Page 659 8W - 30 - 16 8W-30 FUEL/IGNITION SYSTEM BATT A0 (8W-10-10) POWER DISTRIBUTION CENTER FUSE (8W-10-2) (8W-10-26) (8W-10-27) TN/BK C100 LHD EXCEPT BUILT-UP-EXPORT OTHER HEADLAMP S218 FUSED SWITCH (8W-10-26) B(+) (8W-10-27) (8W-50-2) TN/BK DATA LINK CONNECTOR BK/TN LG/BK C100 2.5L 4.0L S139 BK/TN...
Page 660 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 17 DATA SENTRY LINK CONNECTOR IMMOBILIZER TWISTED MODULE PAIR VT/BR WT/BK (EXCEPT TWISTED POLICE/ PAIR POSTAL) VT/BR WT/BK (8W-39-8) S238 S239 TWISTED TWISTED PAIR PAIR VT/BR WT/BK VT/BR WT/BK VT/BR WT/BK C201 VT/BR WT/BK VT/BR WT/BK...
Page 661 8W - 30 - 18 8W-30 FUEL/IGNITION SYSTEM DATA SENTRY LINK CONNECTOR IMMOBILIZER TWISTED MODULE PAIR VT/BR WT/BK (EXCEPT TWISTED POLICE/ PAIR POSTAL) VT/BR WT/BK (8W-39-9) S238 S239 TWISTED TWISTED PAIR PAIR VT/BR WT/BK VT/BR WT/BK VT/BR WT/BK C204 VT/BR WT/BK VT/BR WT/BK...
Page 662 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 19 DIESEL BATT A0 ST-RUN A21 (8W-10-12) (8W-10-16) POWER JUNCTION DISTRIBUTION BLOCK CENTER (8W-12-2) FUSE FUSE (8W-10-6) (8W-10-8) (8W-12-14) RD/LG S151 (8W-10-18) RD/LG RD/LG AUTOMATIC DB/WT SHUT DOWN RELAY (IN PDC) S130 A142 (8W-12-14) DG/OR S137...
Page 663 8W - 30 - 20 8W-30 FUEL/IGNITION SYSTEM DIESEL BATT A16 BATT A16 (8W-10-18) (8W-10-18) POWER DISTRIBUTION AUTOMATIC CENTER FUSE SHUT (8W-10-6) DOWN RELAY (8W-10-18) (8W-30-19) GENERATOR GENERATOR (8W-20-3) A142 FIELD GENERATOR DRIVER RD/LG DG/OR DRIVER S137 DG/OR (8W-10-18) C120 A142 A142 DG/OR...
Page 664 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 21 DIESEL ST-RUN A21 BATT A0 BATT A16 (8W-10-16) (8W-10-12) (8W-10-18) JUNCTION POWER BLOCK DISTRIBUTION AUTOMATIC CENTER (8W-12-2) SHUT FUSE FUSE DOWN (8W-10-6) RELAY (8W-30-19) (8W-12-14) (8W-10-22) A142 DB/WT DG/OR S130 S137 (8W-12-14) (8W-10-18) LG/RD A142...
Page 665 8W - 30 - 22 8W-30 FUEL/IGNITION SYSTEM DIESEL BATT A16 BATT A0 (8W-10-18) (8W-10-12) POWER DISTRIBUTION AUTOMATIC CENTER SHUT FUSE FUSE (8W-10-6) FUSE DOWN RELAY (8W-30-19) (8W-10-18) (8W-10-18) (8W-10-34) A142 F142 DG/OR DG/OR RD/GY RD/GY S156 S153 (8W-10-34) (8W-10-18) F142 DG/OR RD/GY...
Page 666 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 23 DIESEL BATT A16 (8W-10-18) POWER DISTRIBUTION AUTOMATIC CENTER FUSE SHUT (8W-10-6) DOWN RELAY (8W-10-34) (8W-30-19) A142 A142 F142 DG/OR DG/OR DG/OR S137 S156 (8W-10-18) (8W-10-34) A142 F142 DG/OR DG/OR FUEL FUEL FUEL PUMP QUANTITY SHUT-OFF...
Page 667 8W - 30 - 24 8W-30 FUEL/IGNITION SYSTEM DIESEL (8W-12-12) ST-RUN F20 (8W-12-13) FUEL POWER PUMP DISTRIBUTION MODULE CENTER COMPRESSOR CONTROL MEASURE (8W-10-6) CLUTCH SLEEVE COIL RELAY (8W-42-7) K134 K135 LG/OR LB/BK WT/BK DB/OR ENGINE CONTROL SLEEVE SLEEVE CONTROL COMPRESSOR SLEEVE POSITION POSITION...
Page 668 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 25 DIESEL PEDAL PEDAL PEDAL POSITION IDLE POSITION POSITION SENSOR POSITION SENSOR SENSOR SENSOR SUPPLY SWITCH SIGNAL GROUND GROUND BK/LB NEEDLE NEEDLE NEEDLE MOVEMENT MOVEMENT MOVEMENT SENSOR SENSOR SENSOR B(+) B(-) S149 (8W-70-3) K151 K255 VT/WT...
Page 669 8W - 30 - 26 8W-30 FUEL/IGNITION SYSTEM DIESEL ENGINE CONTROL ENGINE MODULE COOLANT VEHICLE TEMP. SENSOR SPEED SENSOR GROUND SIGNAL SIGNAL WT/OR TN/BK BK/LB VEHICLE S149 VEHICLE SPEED SPEED (8W-70-3) SENSOR SENSOR SENSOR SUPPLY GROUND SIGNAL BK/LB K167 BR/YL WT/OR C120 C111...
Page 670 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 27 DIESEL PRESSURE CRANKSHAFT HIGH SWITCH CRANKSHAFT POSITION OUTPUT PRESSURE POSITION SENSOR SENSOR SENSOR SWITCH GROUND SIGNAL (8W-42-7) LG/BK GY/BK DB/WT C120 HEATER SELECT INPUT CONTROL (8W-42-4) (8W-42-5) LG/BK GY/BK DB/WT ENGINE SENSOR CRANKSHAFT CONTROL GROUND...
Page 671 8W - 30 - 28 8W-30 FUEL/IGNITION SYSTEM DIESEL S138 (8W-70-3) K167 K167 K167 K167 BR/YL BR/YL BR/YL BR/YL C100 C200 C204 K167 K167 BR/YL BR/YL K167 BATTERY BR/YL TEMPERATURE SENSOR FUEL COOLANT LEVEL SWITCH SENSOR K226 DB/LG WATER FUEL C200 C204 SENSOR...
Page 672 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 29 DIESEL BATT A0 (8W-10-12) POWER DISTRIBUTION CENTER FUSE (8W-10-6) (8W-10-32) ENGINE CONTROL MODULE BRAKE SPEED LAMP BRAKE CONTROL SWITCH SWITCH SENSOR SWITCH OUTPUT SENSE GROUND SENSE PK/DB WT/TN WT/PK BK/LB RD/LG S147 S149 (8W-10-32) (8W-70-3)
Page 673 8W - 30 - 30 8W-30 FUEL/IGNITION SYSTEM DIESEL (8W-12-12) ST-RUN F20 ST-RUN A21 (8W-10-16) (8W-12-13) POWER JUNCTION BLOCK DISTRIBUTION RADIATOR CENTER (8W-12-2) FUSE (8W-10-6) RELAY (8W-42-8) (8W-12-12) (8W-12-13) WT/BK FULL BASE OPTIONS S225 (8W-12-12) DB/PK C201 WT/BK S216 (8W-12-12) (8W-12-13) TELL TALE...
Page 674 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 31 DIESEL BATT A0 (8W-10-12) POWER DISTRIBUTION CENTER FUSE (8W-10-6) (8W-10-36) TN/BK C100 S218 (8W-10-36) TN/BK TN/BK DATA LINK HEADLAMP HEADLAMP CONNECTOR SWITCH SWITCH OUPUT (8W-50-4) BK/TN LG/BK C100 BK/TN S146 S139 (8W-15-3) ENGINE BK/TN BK/TN...
Page 676 8W - 31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 1 8 W-3 1 T RAN SM I SSI ON CON T ROL SY ST EM Co m p o n e n t P a g e Co m p o n e n t P a g e Br a ke La m p Swit ch .
Page 677 8W - 31 - 2 8W-31 TRANSMISSION CONTROL SYSTEM 2.5L GAS ST-RUN A21 ST T141 (8W-10-16) (8W-21-2) JUNCTION POWER BLOCK DISTRIBUTION ENGINE CENTER (8W-12-2) STARTER FUSE FUSE (8W-10-2) MOTOR RELAY (8W-21-2) (8W-12-14) (8W-12-12) (8W-12-13) BK/WT C201 DB/WT C107 C100 C100 S130 (8W-12-14) S159...
Page 678 8W-31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 3 2.5L GAS RUN A22 (8W-10-17) JUNCTION BLOCK FUSE (8W-12-2) (8W-12-21) DB/WT S219 (8W-12-21) C201 DB/WT S217 (8W-12-21) SHIFT LOCK SOLENOID S204 WT/PK WT/PK WT/PK BRAKE C100 LAMP SWITCH (8W-33-4) WT/PK S207 (8W-15-16) POWERTRAIN BRAKE...
Page 679 8W - 31 - 4 8W-31 TRANSMISSION CONTROL SYSTEM 4.0L ST-RUN A21 BATT A0 (8W-10-16) (8W-10-10) JUNCTION POWER BLOCK DISTRIBUTION CENTER (8W-12-2) FUSE FUSE (8W-10-2) (8W-12-15) (8W-10-25) DB/WT S130 (8W-12-15) DB/WT S135 (8W-10-25) S136 (8W-12-15) DB/WT TRANSMISSION FUSED FUSED CONTROL IGNITION B(+) SWITCH...
Page 680 8W-31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 5 4.0L POWERTRAIN CONTROL MODULE SENSOR (8W-30-5) SUPPLY GROUND K167 BR/YL S115 S111 (8W-70-4) (8W-70-2) K167 BR/YL S114 K167 (8W-70-2) BR/YL K167 BR/YL C107 THROTTLE POSITION SENSOR (8W-30-7) K167 OR/DB BR/YL S112 (8W-30-7) S138 (8W-70-2)
Page 681 8W - 31 - 6 8W-31 TRANSMISSION CONTROL SYSTEM 4.0L ST-RUN A21 (8W-10-16) JUNCTION BLOCK (8W-12-2) FUSE FROM ENGINE STARTER (8W-12-12) MOTOR (8W-12-13) RELAY (8W-21-3) C201 BK/WT C100 S159 (8W-12-12) (8W-12-13) TRANSMISSION RANGE SENSOR BR/LG LG/BK VT/WT S141 (8W-15-5) (8W-15-6) (8W-15-8) BUILT-UP EXCEPT BUILT...
Page 682 8W-31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 7 4.0L RUN A22 (8W-10-17) DATA JUNCTION TWISTED LINK BLOCK PAIR CONNECTOR FUSE (8W-12-2) (8W-30-16) (8W-30-17) (8W-30-18) (8W-12-21) VT/BR WT/BK DB/WT S219 (8W-12-21) S239 S238 (8W-30-17) (8W-30-17) C201 (8W-30-18) (8W-30-18) DB/WT DB/WT S217 (8W-12-21) VT/BR...
Page 684 8W - 33 VEHICLE SPEED CONTROL 8W - 33 - 1 8 W-3 3 V EH I CLE SPEED CON T ROL Co m p o n e n t P a g e Co m p o n e n t P a g e Br a ke La m p Swit ch .
Page 685 8W - 33 - 2 8W-33 VEHICLE SPEED CONTROL LEFT RIGHT SPEED SPEED CONTROL CONTROL SWITCH SWITCH 1 SET 1 RESUME/ACCEL 2 ON/OFF 2 CANCEL 3 COAST K167 K167 RD/LG BR/YL RD/LG BR/YL S221 S222 CLOCKSPRING RD/LG BK/LB BK/RD C100 K167 BR/YL S138...
Page 686 8W-33 VEHICLE SPEED CONTROL 8W - 33 - 3 DIESEL LEFT RIGHT SPEED SPEED CONTROL CONTROL SWITCH SWITCH 1 SET 1 RESUME/ACCEL 2 ON/OFF 2 CANCEL 3 COAST K167 K167 RD/LG BR/YL RD/LG BR/YL S221 S222 K167 RD/LG BR/YL CLOCKSPRING RD/LG BK/LB BK/RD...
Page 687 8W - 33 - 4 8W-33 VEHICLE SPEED CONTROL BATT A0 (8W-10-10) POWER DISTRIBUTION CENTER FUSE (8W-10-2) (8W-10-33) YL/RD YL/RD WT/PK C100 PK/DB S204 (8W-31-3) BRAKE C100 LAMP SWITCH WT/PK WT/PK DB/RD WT/TN S207 C100 (8W-15-16) S203 DB/RD C100 (8W-10-33) G108 (8W-15-16) OTHER...
Page 688 8W-33 VEHICLE SPEED CONTROL 8W - 33 - 5 DIESEL BATT A0 (8W-10-12) PEDAL POSITION POWER THROTTLE SENSOR DISTRIBUTION POSITION PEDAL (8W-30-25) CENTER SENSOR POSITION FUSE (8W-10-6) SIGNAL SENSOR SUPPLY (8W-10-32) K255 OR/DB WT/DG VT/WT PK/DB ENGINE THROTTLE PEDAL CONTROL POSITION POSITION SUPPLY...
Page 690 8W - 35 ANTI-LOCK BRAKES 8W - 35 - 1 8 W-3 5 AN T I -LOCK BRAK ES Co m p o n e n t P a g e Co m p o n e n t P a g e ABS In dica t or .
Page 691 8W - 35 - 2 8W-35 ANTI-LOCK BRAKES BATT A0 (8W-10-10) POWER DISTRIBUTION CENTER FUSE FUSE FUSE (8W-10-2) (8W-10-23) (8W-10-23) (8W-10-33) (8W-10-35) DATA LINK CONNECTOR PK/DB (8W-30-16) C100 PK/DB C100 BRAKE LAMP 4.0L 2.5L SWITCH (8W-33-4) SWITCH WT/TN S139 (8W-30-16) S203 (8W-10-33) WT/TN...
Page 692 8W-35 ANTI-LOCK BRAKES 8W - 35 - 3 DIESEL BATT A0 (8W-10-12) POWER DISTRIBUTION CENTER FUSE FUSE FUSE (8W-10-6) (8W-10-24) (8W-10-24) (8W-10-32) PK/DB C100 PK/DB BRAKE LAMP SWITCH (8W-33-5) DATA LINK SWITCH WT/TN CONNECTOR (8W-30-31) S203 (8W-10-32) RD/DG RD/DB WT/TN C100 PK/OR YL/VT...
Page 693 8W - 35 - 4 8W-35 ANTI-LOCK BRAKES RUN A22 ST-RUN A21 (8W-10-17) (8W-10-16) JUNCTION BLOCK (8W-12-2) FUSE FUSE (8W-12-21) (8W-12-12) (8W-12-22) (8W-12-13) DB/WT WT/BK FULL BASE OPTIONS S225 (8W-12-12) C201 S216 (8W-12-12) (8W-12-13) WT/BK INSTRUMENT S134 CLUSTER (8W-12-21) (8W-40-2) (8W-12-22) INDICATOR (8W-40-6)
Page 694 8W-35 ANTI-LOCK BRAKES 8W - 35 - 5 DIESEL RUN A22 ST-RUN A21 (8W-10-17) (8W-10-16) JUNCTION BLOCK (8W-12-2) FUSE FUSE (8W-12-21) (8W-12-12) (8W-12-22) (8W-12-13) WT/BK DB/WT FULL BASE OPTIONS S225 (8W-12-12) C201 S216 (8W-12-12) (8W-12-13) INSTRUMENT CLUSTER (8W-40-3) INDICATOR (8W-40-7) (8W-40-8) LAMP RELAY...
Page 695 8W - 35 - 6 8W-35 ANTI-LOCK BRAKES LEFT RIGHT FRONT FRONT WHEEL WHEEL SPEED SPEED SENSOR SENSOR LEFT RIGHT REAR REAR WHEEL WHEEL SPEED SPEED SENSOR SENSOR LG/DB YL/DB TWISTED TWISTED TWISTED TWISTED PAIR PAIR PAIR PAIR C109 C109 RD/DB LG/DB WT/DB...
Page 696 8W - 39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 1 8 W-3 9 V EH I CLE T H EFT SECU RI T Y SY ST EM Co m p o n e n t P a g e Co m p o n e n t P a g e Ca r go La m p/Swit ch .
Page 697 8W - 39 - 2 8W-39 VEHICLE THEFT SECURITY SYSTEM (8W-10-10) BATT A0 (8W-10-12) POWER DISTRIBUTION CENTER FUSE (8W-10-2) (8W-10-6) PASSENGER (8W-10-25) DOOR POWER (8W-10-28) DOOR UNLOCK LOCK/ LOCK RELAY WINDOW CONTROL CONTROL SWITCH (8W-61-2) DIESEL UNDERHOOD LB/RD DB/PK FUSED S135 LAMP/ B (+)
Page 698 8W-39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 3 (8W-10-10) BATT A0 (8W-10-12) PASSENGER POWER DOOR POWER DISTRIBUTION DOOR UNLOCK LOCK/ CENTER LOCK RELAY WINDOW FUSE CONTROL CONTROL (8W-10-2) SWITCH (8W-10-6) (8W-61-3) (8W-10-25) (8W-10-28) LB/RD C305 DIESEL S135 UNDERHOOD FUSED (8W-10-25) LB/RD...
Page 699 8W - 39 - 4 8W-39 VEHICLE THEFT SECURITY SYSTEM (8W-10-21) BATT A17 ST-RUN A21 (8W-10-16) (8W-10-32) POWER JUNCTION DISTRIBUTION BLOCK CENTER (8W-12-2) FUSE FUSE (8W-10-2) (8W-10-6) (8W-10-21) (8W-12-12) (8W-10-32) DB/GY WT/BK BASE FULL OPTIONS S225 (8W-12-12) WT/BK C100 C201 WT/BK S216 (8W-12-12)
Page 700 8W-39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 5 (8W-10-21) BATT A17 ST-RUN A21 (8W-10-16) (8W-10-32) POWER JUNCTION DISTRIBUTION BLOCK CENTER (8W-12-2) FUSE FUSE (8W-10-2) (8W-10-6) (8W-10-21) (8W-12-13) (8W-10-32) DB/GY WT/BK C100 S216 (8W-12-13) DB/GY WT/BK SENTRY FUSED FUSED B(+) IGNITION SWITCH...
Page 701 8W - 39 - 6 8W-39 VEHICLE THEFT SECURITY SYSTEM HEADLAMP OVERHEAD DOOR CARGO SWITCH MODULE JAMB COURTESY (8W-49-4) LAMP/ (8W-50-2) SWITCH LAMP (8W-50-4) SWITCH SENSE CONTROL (8W-44-8) IGNITION SWITCH DOOR (8W-10-14) JAMB (8W-10-15) S345 SWITCH (8W-12-30) SENSE C314 JUNCTION BLOCK (8W-12-2) BK/LB...
Page 702 8W-39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 7 OVERHEAD HEADLAMP DOOR MODULE SWITCH JAMB CARGO COURTESY SWITCH (8W-49-5) (8W-50-3) LAMP/ LAMP SENSE IGNITION (8W-50-4) DOOR SWITCH CONTROL SWITCH JAMB (8W-44-8) SWITCH (8W-10-14) SENSE (8W-10-15) BK/LB S345 C314 (8W-12-30) BK/LB JUNCTION S200...
Page 703 8W - 39 - 8 8W-39 VEHICLE THEFT SECURITY SYSTEM DATA LINK INSTRUMENT SENTRY CONNECTOR CLUSTER (8W-30-17) (8W-40-3) IMMOBILIZER MODULE (EXCEPT POLICE/ POSTAL) VT/BR WT/BK WT/BK VT/BR WT/BK VT/BR TWISTED TWISTED TWISTED PAIR PAIR PAIR S238 (8W-30-17) S239 (8W-30-17) TWISTED PAIR TWISTED (8W-10-19)
Page 704 8W-39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 9 DATA LINK INSTRUMENT SENTRY CONNECTOR CLUSTER (8W-30-18) (8W-40-3) IMMOBILIZER (8W-30-31) MODULE (EXCEPT POLICE/ POSTAL) WT/BK VT/BR WT/BK VT/BR VT/BR WT/BK TWISTED TWISTED TWISTED PAIR PAIR PAIR S238 (8W-30-18) S239 TWISTED (8W-30-18) TWISTED PAIR...
Page 706 8W - 40 INSTRUMENT CLUSTER 8W - 40 - 1 8 W-4 0 I N ST RU M EN T CLU ST ER Co m p o n e n t P a g e Co m p o n e n t P a g e ABS In dica t or .
Page 707 8W - 40 - 2 8W-40 INSTRUMENT CLUSTER (8W-10-10) BATT A0 ST-RUN A21 (8W-10-16) (8W-10-12) POWER JUNCTION DISTRIBUTION BLOCK CENTER (8W-12-2) FUSE FUSE (8W-10-2) (8W-10-6) (8W-10-25) (8W-12-12) (8W-10-28) (8W-12-13) DIESEL WT/BK UNDERHOOD LAMP/ S135 MERCURY (8W-10-25) SWITCH FULL (DIESEL) OPTIONS BASE (8W-44-7) JUNCTION...
Page 708 8W-40 INSTRUMENT CLUSTER 8W - 40 - 3 (8W-12-12) ST-RUN F87 (8W-12-13) INSTRUMENT CLUSTER CHECK UPSHIFT FUEL GAUGES INDICATOR WARNING WARNING (M/T) INDICATOR INDICATOR FUSED LOW FUEL CHECK GAUGES UPSHIFT IGN. WARNING WARNING INDICATOR (ST-RUN) INDICATOR INDICATOR CONTROL CONTROL CONTROL FUEL GAUGE TACHOMETER...
Page 709 8W - 40 - 4 8W-40 INSTRUMENT CLUSTER (8W-12-12) ST-RUN F87 (8W-12-13) INSTRUMENT CLUSTER CHECK ENGINE WARNING INDICATOR FUSED CHECK ENGINE ENGINE IGNITION WARNING COOLANT SWITCH INDICATOR TEMPERATURE PRESSURE OUTPUT CONTROL GAUGE GAUGE (ST-RUN) CONTROL CONTROL ENGINE COOLANT PRESSURE TEMPERATURE GAUGE GAUGE VT/BR...
Page 710 8W-40 INSTRUMENT CLUSTER 8W - 40 - 5 DIESEL (8W-12-12) ST-RUN F87 (8W-12-13) INSTRUMENT CLUSTER CHECK ENGINE WARNING INDICATOR FUSED CHECK ENGINE ENGINE IGNITION WARNING COOLANT SWITCH INDICATOR TEMPERATURE PRESSURE OUTPUT CONTROL GAUGE GAUGE (ST-RUN) CONTROL CONTROL ENGINE COOLANT PRESSURE TEMPERATURE GAUGE GAUGE...
Page 711 8W - 40 - 6 8W-40 INSTRUMENT CLUSTER LHD GAS ST-RUN F87 (8W-12-12) INSTRUMENT CLUSTER AIRBAG SEAT WARNING BELT WASHER INDICATOR INDICATOR WARNING FLUID INDICATOR INDICATOR FUSED AIRBAG SEAT IGNITION WARNING BELT WASHER SWITCH INDICATOR WARNING FLUID OUTPUT CONTROL INDICATOR INDICATOR (ST-RUN) CONTROL...
Page 712 8W-40 INSTRUMENT CLUSTER 8W - 40 - 7 LHD DIESEL ST-RUN F87 (8W-12-12) INSTRUMENT CLUSTER AIRBAG SEAT WARNING BELT WASHER INDICATOR INDICATOR WARNING FLUID INDICATOR INDICATOR FUSED AIRBAG SEAT IGNITION WARNING BELT WASHER SWITCH INDICATOR WARNING FLUID OUTPUT CONTROL INDICATOR INDICATOR (ST-RUN) CONTROL...
Page 713 8W - 40 - 8 8W-40 INSTRUMENT CLUSTER ST-RUN F87 (8W-12-13) INSTRUMENT CLUSTER AIRBAG SEAT WARNING BELT WASHER INDICATOR INDICATOR WARNING FLUID INDICATOR INDICATOR FUSED AIRBAG SEAT IGNITION WARNING BELT WASHER SWITCH INDICATOR WARNING FLUID OUTPUT CONTROL INDICATOR INDICATOR (ST-RUN) CONTROL CONTROL SEAT...
Page 714 8W-40 INSTRUMENT CLUSTER 8W - 40 - 9 (8W-12-12) ST-RUN F87 (8W-12-13) INSTRUMENT CLUSTER FULL PART BRAKE TIME TIME WARNING INDICATOR INDICATOR INDICATOR G106 G107 BK/WT BK/RD GY/WT C100 G106 G107 BK/WT BK/RD GY/WT C107 BRAKE WARNING G106 G107 PRESSURE SWITCH BK/WT BK/RD...
Page 715 8W - 40 - 10 8W-40 INSTRUMENT CLUSTER DIESEL (8W-12-12) ST-RUN F87 (8W-12-13) INSTRUMENT CLUSTER FULL PART BRAKE TIME TIME WARNING INDICATOR INDICATOR INDICATOR G106 G107 BK/WT BK/RD GY/WT C100 USED G107 BK/RD GY/WT C111 BRAKE PRESSURE G107 SWITCH BK/RD TRANSFER CASE GY/BK...
Page 716 8W-40 INSTRUMENT CLUSTER 8W - 40 - 11 (8W-10-25) BATT M1 (8W-10-28) INSTRUMENT CLUSTER FUSED B(+) CHIME CONTROL S210 (8W-10-16) IGNITION HEADLAMP SWITCH SWITCH KEY-IN (8W-10-14) 0 OFF SWITCH (8W-10-15) 1 PARK 2 HEAD (8W-50-2) (8W-50-3) (8W-50-4) BK/LB BK/LB S200 (8W-10-16) C200 C203...
Page 717 8W - 40 - 12 8W-40 INSTRUMENT CLUSTER OVERHEAD RUN A22 (8W-10-17) MODULE JUNCTION (8W-49-6) BLOCK (8W-12-2) SENTRY FUSE TWISTED PAIR IMMOBILIZER VT/BR WT/BK (8W-12-16) MODULE (EXCEPT COMPASS OTHER COMPASS OTHER POLICE/ S344 S346 REAR POSTAL) TWISTED (8W-30-17) (8W-30-17) WINDOW (8W-39-8) DEFOGGER PAIR...
Page 718 8W-40 INSTRUMENT CLUSTER 8W - 40 - 13 OVERHEAD RUN A22 (8W-10-17) MODULE JUNCTION (8W-49-6) BLOCK (8W-12-2) SENTRY FUSE TWISTED PAIR IMMOBILIZER VT/BR WT/BK (8W-12-17) MODULE (EXCEPT COMPASS OTHER COMPASS OTHER POLICE/ REAR S344 S346 POSTAL) TWISTED WINDOW (8W-30-18) (8W-30-18) (8W-39-9) DEFOGGER PAIR...
Page 719 8W - 40 - 14 8W-40 INSTRUMENT CLUSTER HEADLAMP DIMMER SWITCH BEAM HIGH TURN SELECT BEAM SIGNAL/ SWITCH OUTPUT HAZARD LEFT RIGHT (8W-50-5) TURN TURN (8W-50-6) SWITCH SIGNAL SIGNAL (8W-50-7) (8W-52-2) (8W-50-8) (8W-52-3) RD/OR (8W-52-4) LG/WT S213 (8W-50-5) (8W-50-6) FROM (8W-50-7) (8W-50-8) LAMP...
Page 720 8W-40 INSTRUMENT CLUSTER 8W - 40 - 15 (8W-10-26) BATT F34 (8W-10-27) (8W-10-36) HEADLAMP SWITCH 0 OFF 1 PARK 2 HEAD 3 DIM 4 BRIGHT LIFTGATE LIFTGATE (8W-50-2) SWITCH AJAR (8W-50-3) (8W-44-8) SWITCH (8W-50-4) SENSE C201 TN/BK JUNCTION BLOCK C310 (8W-12-2) FUSE C311...
Page 721 8W - 40 - 16 8W-40 INSTRUMENT CLUSTER (8W-12-12) ST-RUN F87 (8W-12-13) INSTRUMENT CLUSTER CRUISE ENGAGED INDICATOR FUSED CRUISE IGNITION ENGAGED SWITCH INDICATOR OUTPUT CONTROL (ST-RUN) VT/BR WT/BK TWISTED PAIR S239 S238 (8W-30-17) (8W-30-17) (8W-30-18) (8W-30-18) VT/BR WT/BK C100 4.0L A/T OTHER OTHER 4.0L A/T...
Page 722 8W-40 INSTRUMENT CLUSTER 8W - 40 - 17 DIESEL ST-RUN A21 (8W-10-16) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-12) (8W-12-13) WT/BK FULL BASE OPTIONS S225 WATER WATER (8W-12-12) FUEL FUEL SENSOR SENSE C201 (8W-30-28) WT/BK COOLANT COOLANT LEVEL S216 SWITCH SWITCH (8W-12-12) SENSE (8W-30-28) (8W-12-13)
Page 724 8W - 41 HORN/CIGAR LIGHTER/POWER OUTLET 8W - 41 - 1 8 W-4 1 H ORN /CI GAR LI GH T ER/POWER OU T LET Co m p o n e n t P a g e Co m p o n e n t P a g e Ciga r Ligh t er .
Page 725 8W - 41 - 2 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET (8W-10-14) (8W-10-19) RUN-ACC A31 BATT A7 (8W-10-15) (8W-10-24) JUNCTION BLOCK (8W-12-2) FUSE FUSE FUSE (8W-12-5) (8W-12-5) (8W-12-20) CIGAR HORN LIGHTER RELAY RELAY RD/LB BK/RD BK/RD DG/RD S131 S314 (8W-10-19) C301 (8W-15-13) (8W-10-24) (8W-12-20) DG/RD...
Page 726 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET 8W - 41 - 3 (8W-10-14) (8W-10-19) RUN-ACC A31 BATT A7 (8W-10-15) (8W-10-24) JUNCTION BLOCK (8W-12-2) FUSE FUSE FUSE (8W-12-5) (8W-12-5) (8W-12-20) CIGAR HORN LIGHTER RELAY RELAY RD/LB BK/RD BK/RD DG/RD C301 S131 (8W-10-19) S208 (8W-10-24) (8W-15-14) (8W-12-20) (8W-15-15)
Page 728 8W - 42 AIR CONDITIONING-HEA TER 8W - 42 - 1 8 W-4 2 AI R CON DI T I ON I N G-H EAT ER Co m p o n e n t P a g e Co m p o n e n t P a g e A/C Com pr essor Clu t ch .
Page 729 8W - 42 - 2 8W-42 AIR CONDITIONING-HEATER LHD HEATER ONLY (8W-10-10) RUN A22 BATT A0 (8W-10-17) (8W-10-12) JUNCTION POWER DIESEL BLOCK DISTRIBUTION CENTER (8W-12-2) FUSE (8W-10-2) FUSE FUSE (8W-10-6) (8W-12-21) (8W-10-24) (8W-10-20) A111 RD/LG DB/WT C100 HEATER CONTROL 1 HIGH 2 MEDIUM 2 3 MEDIUM 1 MODE...
Page 730 8W-42 AIR CONDITIONING-HEATER 8W - 42 - 3 RHD HEATER ONLY (8W-10-10) RUN A22 BATT A0 (8W-10-17) (8W-10-12) JUNCTION POWER DIESEL BLOCK DISTRIBUTION CENTER (8W-12-2) FUSE (8W-10-2) FUSE FUSE (8W-10-6) (8W-12-22) (8W-10-24) (8W-10-20) A111 RD/LG DB/WT C100 HEATER CONTROL 1 HIGH 2 MEDIUM 2 3 MEDIUM 1 MODE...
Page 731 8W - 42 - 4 8W-42 AIR CONDITIONING-HEATER (8W-10-10) RUN A22 BATT A0 (8W-10-17) (8W-10-12) JUNCTION POWER DIESEL BLOCK DISTRIBUTION CENTER (8W-12-2) FUSE (8W-10-2) FUSE FUSE (8W-10-6) (8W-12-21) (8W-10-24) (8W-10-20) A111 RD/LG DB/WT C100 A/C- HEATER CONTROL 1 HIGH MODE 2 MEDIUM 2 3 MEDIUM 1 4 LOW...
Page 732 8W-42 AIR CONDITIONING-HEATER 8W - 42 - 5 (8W-10-10) RUN A22 BATT A0 (8W-10-17) JUNCTION POWER DIESEL BLOCK DISTRIBUTION CENTER (8W-12-2) FUSE (8W-10-2) FUSE FUSE (8W-10-6) (8W-12-22) (8W-10-24) (8W-10-20) A111 DB/WT RD/LG S219 C100 (8W-12-22) A/C- HEATER CONTROL 1 HIGH 2 MEDIUM 2 3 MEDIUM 1 4 LOW...
Page 733 8W - 42 - 6 8W-42 AIR CONDITIONING-HEATER (8W-12-12) (8W-10-21) ST-RUN F20 BATT A17 RUN A22 (8W-10-17) (8W-12-13) (8W-10-32) POWER JUNCTION DISTRIBUTION BLOCK CENTER (8W-12-2) FUSE COMPRESSOR (8W-10-2) CLUTCH RELAY (8W-12-21) (8W-12-22) HVAC BLEND UNIT DOOR DB/WT FEEDBACK GROUND SIGNAL S219 DB/OR DB/BK...
Page 734 8W-42 AIR CONDITIONING-HEATER 8W - 42 - 7 DIESEL (8W-12-12) ST-RUN F20 BATT A17 (8W-10-32) (8W-12-13) POWER DISTRIBUTION CENTER COMPRESSOR (8W-10-6) CLUTCH RELAY DB/OR ENGINE CONTROL COMPRESSOR DB/BK CLUTCH MODULE RELAY (8W-30-24) CONTROL (8W-30-27) SWITCH SENSE C120 DB/WT DB/BK C120 COMPRESSOR DB/WT CLUTCH...
Page 735 8W - 42 - 8 8W-42 AIR CONDITIONING-HEATER (8W-12-12) ST-RUN F20 BATT F141 (8W-10-20) (8W-12-13) POWER DISTRIBUTION RADIATOR CENTER (8W-10-2) RELAY (8W-10-6) DIESEL DB/PK DB/PK ENGINE RADIATOR CONTROL RELAY MODULE CONTROL (8W-30-30) RADIATOR MOTOR POWERTRAIN RADIATOR CONTROL RELAY MODULE CONTROL (8W-30-15) G106 (8W-15-7)
Page 736 8W - 43 AIRBAG SYSTEM 8W - 43 - 1 8 W-4 3 AI RBAG SY ST EM Co m p o n e n t P a g e Co m p o n e n t P a g e Air ba g Con t r ol Modu le .
Page 737 8W - 43 - 2 8W-43 AIRBAG SYSTEM RUN A22 ST-RUN A21 (8W-10-17) (8W-10-16) JUNCTION BLOCK (8W-12-2) FUSE FUSE (8W-12-24) (8W-12-24) LG/YL DB/YL AIRBAG FUSED FUSED CONTROL IGNITION IGNITION SWITCH SWITCH MODULE OUTPUT OUTPUT (RUN) (ST-RUN) GROUND WT/BK VT/BR TWISTED BASE FULL OPTIONS PAIR...
Page 738 8W-43 AIRBAG SYSTEM 8W - 43 - 3 RUN A22 ST-RUN A21 (8W-10-17) (8W-10-16) JUNCTION BLOCK (8W-12-2) FUSE FUSE (8W-12-25) (8W-12-25) LG/YL DB/YL C204 LG/YL DB/YL AIRBAG FUSED FUSED CONTROL IGNITION IGNITION SWITCH SWITCH MODULE OUTPUT OUTPUT (RUN) (ST-RUN) GROUND WT/BK VT/BR TWISTED...
Page 739 8W - 43 - 4 8W-43 AIRBAG SYSTEM AIRBAG CONTROL MODULE DRIVER DRIVER PASSENGER PASSENGER AIRBAG AIRBAG AIRBAG AIRBAG LINE 1 LINE 2 LINE 2 LINE 1 DG/LB BK/LB BK/YL DG/YL TWISTED TWISTED PAIR PAIR C205 DG/LB BK/LB BK/YL DG/YL TWISTED TWISTED PAIR...
Page 740 8W - 44 INTERIOR LIGHTING 8W - 44 - 1 8 W-4 4 I N T ERI OR LI GH T I N G Co m p o n e n t P a g e Co m p o n e n t P a g e A/C- H ea t er Con t r ol .
Page 741 8W - 44 - 2 8W-44 INTERIOR LIGHTING LHD EXCEPT BUILT-UP-EXPORT HEADLAMP C206 PANEL SWITCH LAMPS (8W-50-2) DIMMER PRNDL SWITCH ILLUMINATION SIGNAL JUNCTION (A/T) BLOCK TRANSFER FUSE (8W-12-2) CASE SWITCH ILLUMINATION (8W-12-8) C201 C206 S315 (8W-12-8) C201 S314 (8W-15-13) S215 (8W-12-8) C201 POLICE...
Page 742 8W-44 INTERIOR LIGHTING 8W - 44 - 3 LHD BUILT-UP-EXPORT C206 HEADLAMP PANEL SWITCH LAMPS (8W-50-4) DIMMER PRNDL SWITCH ILLUMINATION SIGNAL JUNCTION (A/T) BLOCK TRANSFER FUSE (8W-12-2) CASE SWITCH ILLUMINATION (8W-12-8) C201 C206 S315 (8W-12-8) C201 S314 (8W-15-13) S215 (8W-12-8) C201 RADIO REAR...
Page 743 8W - 44 - 4 8W-44 INTERIOR LIGHTING HEADLAMP PANEL C206 SWITCH LAMPS (8W-50-3) DIMMER (8W-50-4) SWITCH SIGNAL PRNDL TRANSFER ILLUMINATION ILLUMINATION CASE (A/T) SWITCH ILLUMINATION JUNCTION OR/BK BLOCK FUSE (8W-12-2) (8W-12-9) C203 C206 S313 (8W-15-18) S215 S309 (8W-12-9) (8W-15-18) G302 (8W-15-18) A/C-...
Page 744 8W-44 INTERIOR LIGHTING 8W - 44 - 5 (8W-10-25) BATT M1 (8W-10-28) JUNCTION BLOCK (8W-12-2) OTHERS SKIM S361 (8W-10-26) (8W-10-27) S347 (8W-10-26) FULL OPTIONS OTHERS (8W-10-27) (8W-10-28) MIDLINE BASE/POLICE COMPASS (8W-49-2) (8W-49-3) DOME (8W-49-4) LAMPS (8W-49-5) SWITCH RIGHT VISOR/ DOME VANITY LAMP LAMP...
Page 745 8W - 44 - 6 8W-44 INTERIOR LIGHTING BATT A0 (8W-10-10) POWER DISTRIBUTION FROM DOME CENTER FUSE LAMPS (8W-10-2) FROM SWITCH COMPASS (8W-10-25) FULL BASE (8W-44-5) OPTIONS S135 (8W-10-25) JUNCTION BLOCK (8W-12-2) C201 C314 S214 (8W-10-25) S304 (8W-44-7) (8W-44-8) C208 C207 (8W-44-9) C201...
Page 746 8W-44 INTERIOR LIGHTING 8W - 44 - 7 DIESEL BATT A0 (8W-10-12) FROM DOME POWER LAMPS DISTRIBUTION FROM SWITCH COMPASS CENTER FUSE (8W-10-6) FULL BASE (8W-44-5) OPTIONS (8W-10-28) JUNCTION BLOCK (8W-12-2) C201 C314 S214 (8W-10-28) S304 (8W-44-6) (8W-44-8) C208 C207 (8W-44-9) C201 RIGHT...
Page 747 8W - 44 - 8 8W-44 INTERIOR LIGHTING FROM FROM JUNCTION JUNCTION BLOCK BLOCK (8W-44-6) (8W-44-6) (8W-44-7) (8W-44-7) (8W-44-9) (8W-44-9) S304 C314 C317 C320 C318 C319 CARGO LAMP/ SWITCH LEFT RIGHT REAR REAR DOOR DOOR GY/BK JAMB JAMB C314 SWITCH SWITCH C326 GY/BK...
Page 748 8W-44 INTERIOR LIGHTING 8W - 44 - 9 FROM FROM JUNCTION JUNCTION BLOCK BLOCK (8W-44-6) (8W-44-6) (8W-44-7) (8W-44-7) (8W-44-8) (8W-44-8) S304 C314 C317 C320 C318 C319 CARGO LAMP/ SWITCH LEFT RIGHT REAR REAR DOOR DOOR GY/BK JAMB JAMB C314 SWITCH SWITCH C326 GY/BK...
Page 750 8W - 47 AUDIO SYSTEM 8W - 47 - 1 8 W-4 7 AU DI O SY ST EM Co m p o n e n t P a g e Co m p o n e n t P a g e An t en n a .
Page 751 8W - 47 - 2 8W-47 AUDIO SYSTEM LHD 6 SPEAKER SYSTEM (8W-10-26) (8W-10-10) BATT F34 BATT A0 (8W-10-27) (8W-10-12) HEADLAMP POWER SWITCH DISTRIBUTION DIESEL 0 OFF CENTER 1 PARK FUSE (8W-10-2) 2 HEAD FUSE FUSE (8W-10-6) 3 DIM 4 BRIGHT (8W-10-25) (8W-50-2) (8W-10-28)
Page 752 8W-47 AUDIO SYSTEM 8W - 47 - 3 RHD 6 SPEAKER SYSTEM (8W-10-26) (8W-10-10) BATT F34 BATT A0 (8W-10-27) (8W-10-12) HEADLAMP POWER SWITCH DISTRIBUTION DIESEL 0 OFF CENTER 1 PARK FUSE (8W-10-2) 2 HEAD FUSE FUSE (8W-10-6) 3 DIM 4 BRIGHT (8W-10-25) (8W-50-3) (8W-10-28)
Page 753 8W - 47 - 4 8W-47 AUDIO SYSTEM BUILT-UP-EXPORT (8W-10-10) BATT A0 (8W-10-12) POWER DISTRIBUTION DIESEL CENTER RADIO (8W-10-2) FUSE FUSE (8W-10-6) RADIO (8W-10-36) (8W-10-27) OUTPUT DG/RD TN/BK S229 C100 DG/RD DG/RD TN/BK S218 C200 C203 (8W-10-27) (8W-10-36) DG/RD DG/RD TN/BK POWER POWER...
Page 754 8W-47 AUDIO SYSTEM 8W - 47 - 5 LHD 6 SPEAKER SYSTEM RADIO LEFT LEFT LEFT LEFT REAR REAR FRONT FRONT RADIO SPEAKER SPEAKER SPEAKER SPEAKER OUTPUT EXCEPT BUILT-UP-EXPORT BUILT-UP-EXPORT S229 BR/YL BR/LB BR/RD (8W-47-4) DG/RD C200 BR/YL BR/LB BR/RD DG/RD POWER LEFT...
Page 755 8W - 47 - 6 8W-47 AUDIO SYSTEM RHD 6 SPEAKER SYSTEM RADIO LEFT LEFT LEFT LEFT FRONT FRONT REAR REAR RADIO SPEAKER SPEAKER SPEAKER SPEAKER OUTPUT EXCEPT BUILT-UP-EXPORT BUILT-UP-EXPORT S229 BR/YL BR/LB BR/RD (8W-47-4) DG/RD C203 BR/YL BR/LB BR/RD DG/RD POWER LEFT...
Page 756 8W-47 AUDIO SYSTEM 8W - 47 - 7 LHD 6 SPEAKER SYSTEM RADIO RIGHT RIGHT RIGHT RIGHT REAR REAR FRONT FRONT SPEAKER SPEAKER SPEAKER SPEAKER DB/WT DB/OR DB/RD C200 DB/WT DB/OR DB/RD POWER RIGHT RIGHT RIGHT RIGHT AMPLIFIER REAR REAR FRONT FRONT SPEAKER...
Page 757 8W - 47 - 8 8W-47 AUDIO SYSTEM RHD 6 SPEAKER SYSTEM RADIO RIGHT RIGHT RIGHT RIGHT REAR REAR FRONT FRONT SPEAKER SPEAKER SPEAKER SPEAKER DB/WT DB/OR DB/RD C203 DB/WT DB/OR DB/RD POWER RIGHT RIGHT RIGHT RIGHT AMPLIFIER REAR REAR FRONT FRONT SPEAKER...
Page 758 8W-47 AUDIO SYSTEM 8W - 47 - 9 LHD 4 SPEAKER SYSTEM (8W-10-26) BATT F34 (8W-10-27) HEADLAMP SWITCH 0 OFF C201 1 PARK 2 HEAD 3 DIM 4 BRIGHT (8W-50-2) (8W-50-4) (8W-10-25) (8W-10-14) BATT M1 RUN-ACC A31 (8W-10-28) (8W-10-15) JUNCTION BLOCK (8W-12-2) FUSE...
Page 759 8W - 47 - 10 8W-47 AUDIO SYSTEM RHD 4 SPEAKER SYSTEM (8W-10-26) BATT F34 (8W-10-27) HEADLAMP SWITCH 0 OFF 1 PARK 2 HEAD 3 DIM 4 BRIGHT (8W-50-3) (8W-50-4) BK/YL S206 (8W-12-10) (8W-12-11) (8W-10-25) (8W-10-14) BATT M1 RUN-ACC A31 (8W-10-28) (8W-10-15) JUNCTION...
Page 760 8W-47 AUDIO SYSTEM 8W - 47 - 11 4 SPEAKER SYSTEM RADIO LEFT LEFT RIGHT RIGHT REAR REAR REAR REAR SPEAKER(+) SPEAKER(-) SPEAKER(+) SPEAKER(-) BR/YL BR/LB DB/WT DB/OR C200 C203 C200 C203 C200 C203 C200 C203 BR/YL BR/LB DB/WT DB/OR C314 DB/WT DB/OR...
Page 762 8W - 48 REAR WINDOW DEFOGGER 8W - 48 - 1 8 W-4 8 REAR WI N DOW DEFOGGER Co m p o n e n t P a g e Co m p o n e n t P a g e Dr iver P ower Mir r or .
Page 763 8W - 48 - 2 8W-48 REAR WINDOW DEFOGGER (8W-10-22) RUN A22 BATT A4 (8W-10-17) (8W-10-23) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-16) REAR FUSE WINDOW DEFOGGER RELAY (8W-12-16) C201 LB/WT BK/WT BK/WT C201 LB/YL C326 PASSENGER S202 C312 POWER INSTRUMENT REAR WINDOW C310 (8W-12-16) MIRROR...
Page 764 8W-48 REAR WINDOW DEFOGGER 8W - 48 - 3 (8W-10-22) RUN A22 BATT A4 (8W-10-17) (8W-10-23) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-17) FUSE REAR WINDOW (8W-12-17) DEFOGGER RELAY C16 20BK/WT C204 LB/WT BK/WT BK/WT LB/YL C326 C305 DRIVER C312 FULL POWER INSTRUMENT OPTIONS MIRRORS...
Page 766 8W - 49 OVERHEAD CONSOLE 8W - 49 - 1 8 W-4 9 OV ERH EAD CON SOLE Co m p o n e n t P a g e Co m p o n e n t P a g e Am bien t Air Tem per a t u r e Sen sor .
Page 767 8W - 49 - 2 8W-49 OVERHEAD CONSOLE (8W-10-10) BATT A0 ST-RUN A21 (8W-10-16) (8W-10-12) POWER JUNCTION DISTRIBUTION BLOCK FUSE CENTER (8W-12-2) FUSE (8W-10-2) (8W-10-6) (8W-12-12) (8W-10-25) (8W-10-28) DIESEL WT/BK S135 (8W-10-25) S225 (8W-12-12) UNDERHOOD FUSED JUNCTION LAMP/ (B+) BLOCK MERCURY WT/BK (8W-12-2)
Page 768 8W-49 OVERHEAD CONSOLE 8W - 49 - 3 (8W-10-10) BATT A0 ST-RUN A21 (8W-10-16) (8W-10-12) POWER JUNCTION DISTRIBUTION BLOCK FUSE CENTER (8W-12-2) FUSE (8W-10-2) (8W-10-6) (8W-12-13) (8W-10-25) (8W-10-28) DIESEL WT/BK S135 (8W-10-25) S216 (8W-12-13) JUNCTION UNDERHOOD FUSED BLOCK LAMP/ B(+) WT/BK (8W-12-2) MERCURY...
Page 769 8W - 49 - 4 8W-49 OVERHEAD CONSOLE (8W-10-19) BATT A7 (8W-10-24) JUNCTION AMBIENT AMBIENT BLOCK TEMPERATURE HORN TEMPERATURE (8W-12-2) SENSOR SENSOR RELAY SENSOR SIGNAL GROUND (8W-41-2) VT/LG BK/LB PASSENGER C100 DOOR POWER DOOR UNLOCK LOCK/ BK/RD LOCK RELAY WINDOW CONTROL CONTROL VT/LG...
Page 770 8W-49 OVERHEAD CONSOLE 8W - 49 - 5 (8W-10-19) BATT A7 (8W-10-24) JUNCTION AMBIENT AMBIENT AMBIENT BLOCK TEMPERATURE TEMPERATURE HORN TEMPERATURE (8W-12-2) SENSOR SENSOR RELAY SENSOR SIGNAL GROUND (8W-41-3) VT/LG BK/LB PASSENGER DOOR POWER DOOR UNLOCK C100 LOCK/ BK/RD LOCK RELAY WINDOW CONTROL...
Page 771 8W - 49 - 6 8W-49 OVERHEAD CONSOLE DATA LINK CONNECTOR (8W-30-17) (8W-30-18) TWISTED VT/BR WT/BK PAIR S239 S238 (8W-30-17) (8W-30-17) (8W-30-18) (8W-30-18) VT/BR WT/BK C201 C201 TWISTED PAIR VT/BR WT/BK C301 VT/BR WT/BK OTHER COMPASS COMPASS OTHER S344 S346 (8W-30-17) (8W-30-17) (8W-30-18)
Page 772 8W - 50 FRONT LIGHTING 8W - 50 - 1 8 W-5 0 FRON T LI GH T I N G Co m p o n e n t P a g e Co m p o n e n t P a g e Con t r oller An t i-Lock Br a ke Rela y .
Page 773 8W - 50 - 2 8W-50 FRONT LIGHTING LHD EXCEPT BUILT-UP-EXPORT BATT A0 (8W-10-10) POWER DISTRIBUTION CENTER FUSE FUSE (8W-10-2) RD/WT HEADLAMP (8W-10-26) (8W-10-21) DAYTIME FUSED DELAY RUNNING B(+) MODULE LAMP MODULE (8W-50-9) GROUND (8W-50-19) TN/BK RD/WT C100 FUSE DATA 6 (JB) FROM FROM...
Page 774 8W-50 FRONT LIGHTING 8W - 50 - 3 RHD EXCEPT BUILT-UP-EXPORT BATT A0 (8W-10-10) POWER DISTRIBUTION CENTER FUSE FUSE (8W-10-2) HEADLAMP (8W-10-26) (8W-10-21) DELAY MODULE (8W-50-9) GROUND TN/BK RD/WT C100 TN/BK FUSE FROM FROM S201 S210 6 (JB) RD/WT S218 (8W-12-30) (8W-10-16) (8W-12-9)
Page 775 8W - 50 - 4 8W-50 FRONT LIGHTING BUILT-UP-EXPORT (8W-10-10) BATT A0 (8W-10-12) POWER DISTRIBUTION DIESEL DIESEL CENTER (8W-10-2) FUSE FUSE FUSE FUSE (8W-10-6) HEADLAMP DELAY (8W-10-36) (8W-10-27) (8W-10-22) (8W-10-21) MODULE (8W-50-10) GROUND TN/BK RD/WT FUSE C100 FROM 6 (JB) S201 (8W-12-8) RD/WT...
Page 776 8W-50 FRONT LIGHTING 8W - 50 - 5 LHD EXCEPT BUILT-UP-EXPORT INSTRUMENT DAYTIME FROM DIMMER HEADLAMP CLUSTER RUNNING FROM HIGH SWITCH DELAY HEADLAMP (8W-40-14) LAMP BEAM HIGH INDICATOR MODULE SWITCH BEAM MODULE DRIVER OUTPUT (8W-50-2) (8W-50-2) (8W-50-19) RD/GY HEADLAMP C100 BEAM SELECT SWITCH...
Page 777 8W - 50 - 6 8W-50 FRONT LIGHTING RHD EXCEPT BUILT-UP-EXPORT FROM HEADLAMP FROM DELAY HEADLAMP MODULE SWITCH (8W-50-3) (8W-50-3) HEADLAMP INSTRUMENT BEAM DIMMER CLUSTER SELECT SWITCH (8W-40-14) HIGH SWITCH BEAM 1 FLASH OUTPUT 2 LOW 3 HIGH VT/WT RD/OR RD/OR S213 RD/OR...
Page 778 8W-50 FRONT LIGHTING 8W - 50 - 7 LHD BUILT-UP-EXPORT FROM INSTRUMENT HEADLAMP FROM HIGH CLUSTER S226 SWITCH BEAM (8W-40-14) INDICATOR (8W-50-4) (8W-50-4) DRIVER HEADLAMP RD/GY BEAM C100 SELECT SWITCH 1 FLASH RD/GY 2 LOW C100 3 HIGH VT/WT RD/OR RD/OR S213 C201...
Page 779 8W - 50 - 8 8W-50 FRONT LIGHTING RHD BUILT-UP-EXPORT FROM HEADLAMP FROM S226 SWITCH (8W-50-4) (8W-50-4) INSTRUMENT DIMMER CLUSTER SWITCH HIGH (8W-40-14) HEADLAMP BEAM OUTPUT BEAM SELECT SWITCH 1 FLASH 2 LOW RD/OR 3 HIGH VT/WT RD/OR S213 RD/OR JUNCTION BLOCK (8W-12-2)
Page 780 8W-50 FRONT LIGHTING 8W - 50 - 9 EXCEPT BUILT-UP-EXPORT BATT A0 ST-RUN A21 (8W-10-10) (8W-10-16) POWER JUNCTION DISTRIBUTION BLOCK CENTER (8W-12-2) FUSE FUSE (8W-10-2) (8W-12-12) (8W-10-21) (8W-12-13) WT/BK RD/WT RD/WT C100 DAYTIME FUSED BASE FULL OPTIONS RUNNING B(+) LAMP MODULE S225 RD/WT...
Page 781 8W - 50 - 10 8W-50 FRONT LIGHTING BUILT-UP-EXPORT (8W-10-10) BATT A0 ST-RUN A21 (8W-10-16) (8W-10-12) POWER JUNCTION DISTRIBUTION BLOCK DIESEL CENTER (8W-12-2) FUSE (8W-10-2) (8W-10-6) (8W-12-12) FUSE FUSE (8W-12-13) (8W-10-21) (8W-10-22) WT/BK BASE FULL OPTIONS RD/WT S225 C100 (8W-12-12) WT/BK WT/BK RD/WT...
Page 782 8W-50 FRONT LIGHTING 8W - 50 - 11 EXCEPT BUILT-UP-EXPORT BATT F34 (8W-10-26) TURN HEADLAMP SIGNAL/ LEFT SWITCH HAZARD TURN 1 PARK SWITCH SIGNAL 2 HEAD (PART OF 0 OFF MULTI- (8W-50-2) FUNCTION (8W-50-3) SWITCH) LG/WT (8W-52-2) S209 (8W-52-5) BK/YL S206 LG/WT (8W-12-10)
Page 783 8W - 50 - 12 8W-50 FRONT LIGHTING BUILT-UP-EXPORT (8W-10-27) BATT F34 TURN (8W-10-36) SIGNAL/ LEFT HEADLAMP HAZARD TURN SWITCH SIGNAL SWITCH 1 PARK (8W-52-3) 2 HEAD (8W-52-4) 0 OFF (8W-50-4) LG/WT S209 BK/YL (8W-52-6) S206 (8W-12-11) LG/WT C100 BK/YL C201 LG/WT C106...
Page 784 8W-50 FRONT LIGHTING 8W - 50 - 13 EXCEPT BUILT-UP-EXPORT BATT F34 (8W-10-26) TURN SIGNAL/ HEADLAMP RIGHT HAZARD TURN SWITCH SIGNAL SWITCH 1 PARK (8W-52-2) 2 HEAD 0 OFF (8W-50-2) (8W-50-3) S212 BK/YL (8W-52-7) S206 (8W-12-10) C100 BK/YL C201 C106 BK/YL JUNCTION S100...
Page 785 8W - 50 - 14 8W-50 FRONT LIGHTING BUILT-UP-EXPORT (8W-10-27) BATT F34 TURN (8W-10-36) SIGNAL/ HEADLAMP RIGHT HAZARD TURN SWITCH SWITCH SIGNAL 1 PARK (8W-52-3) 2 HEAD (8W-52-4) 0 OFF (8W-50-4) BK/YL S212 S206 (8W-52-8) (8W-12-11) BK/YL C100 C201 C106 BK/YL JUNCTION BLOCK...
Page 786 8W-50 FRONT LIGHTING 8W - 50 - 15 EXCEPT BUILT-UP-EXPORT BATT F34 (8W-10-26) JUNCTION HEADLAMP BLOCK BK/YL SWITCH (8W-12-2) 1 PARK FUSE 2 HEAD 0 OFF C201 (8W-50-2) (8W-12-10) (8W-50-3) C106 BK/YL BK/YL S206 BR/YL BR/YL S104 (8W-12-10) (8W-12-10) BATT F61 (8W-10-33) POWER DISTRIBUTION...
Page 787 8W - 50 - 16 8W-50 FRONT LIGHTING DAYTIME BATT F34 (8W-10-26) RUNNING HIGH JUNCTION HEADLAMP LAMP BEAM BLOCK SWITCH MODULE INDICATOR (8W-12-2) 1 PARK DRIVER (8W-50-19) FUSE 2 HEAD 0 OFF BK/YL INSTRUMENT (8W-50-2) (8W-12-10) CLUSTER C201 HIGH (8W-40-14) BEAM INDICATOR L77 20BR...
Page 788 8W-50 FRONT LIGHTING 8W - 50 - 17 BUILT-UP-EXPORT GAS BATT F34 (8W-10-27) HEADLAMP JUNCTION BK/YL SWITCH BLOCK 1 PARK FUSE (8W-12-2) 2 HEAD 0 OFF C201 (8W-50-4) (8W-12-11) LEFT BK/YL BK/YL CITY BR/YL S206 LAMP C106 (8W-50-12) (8W-12-11) L77 20BR/YL BATT F61 (8W-10-33) DIODE...
Page 789 8W - 50 - 18 8W-50 FRONT LIGHTING DIESEL BATT F34 (8W-10-36) HEADLAMP JUNCTION SWITCH BK/YL BLOCK 1 PARK FUSE (8W-12-2) 2 HEAD 0 OFF C201 (8W-50-4) (8W-12-11) BR/YL LEFT BK/YL BK/YL CITY BR/YL S206 LAMP (8W-50-12) (8W-12-11) BATT F61 (8W-10-35) POWER DISTRIBUTION...
Page 790 8W-50 FRONT LIGHTING 8W - 50 - 19 (8W-10-16) BATT A0 ST-RUN A21 (8W-10-10) POWER JUNCTION DISTRIBUTION BLOCK CENTER (8W-12-2) FUSE (8W-10-2) FUSE RIGHT FUSED VEHICLE HEADLAMP RIGHT (8W-12-12) VEHICLE SPEED (8W-10-21) (8W-50-5) SPEED SENSOR (8W-50-6) BEAM SENSOR (8W-30-9) SIGNAL OUTPUT VT/RD WT/OR...
Page 791 8W - 50 - 20 8W-50 FRONT LIGHTING BUILT-UP-EXPORT HEADLAMP BEAM BEAM SELECT C201 RELAY SWITCH OUTPUT (8W-50-7) (8W-50-8) JUNCTION BLOCK (8W-12-2) VT/WT FUSE FUSE (8W-12-7) (8W-12-7) VT/RD S133 C106 (8W-12-7) HEADLAMP LEVELING SWITCH VT/RD BR/YL C100 C106 BR/YL VT/RD VT/RD BK/GY C106...
Page 792 8W - 51 REAR LIGHTING 8W - 51 - 1 8 W-5 1 REAR LI GH T I N G Co m p o n e n t P a g e Co m p o n e n t P a g e Ba ck-Up La m p Swit ch .
Page 793 8W - 51 - 2 8W-51 REAR LIGHTING (8W-10-10) BATT A0 (8W-10-26) BATT F34 (8W-10-12) (8W-10-27) POWER (8W-10-36) DIESEL DISTRIBUTION HEADLAMP CENTER SWITCH (8W-10-2) FUSE FUSE (8W-10-6) 1 PARK 2 HEAD 0 OFF (8W-10-32) (8W-10-33) (8W-50-2) (8W-50-3) (8W-50-4) BK/YL PK/DB S206 C100 (8W-12-10)
Page 794 8W-51 REAR LIGHTING 8W - 51 - 3 FROM FROM FUSE S203 (8W-51-2) 7 (JB) (8W-51-2) WT/TN BR/YL S302 (8W-10-32) S311 (8W-10-33) FROM (8W-12-10) FUSE (8W-12-11) TRAILER TOW OTHER WT/TN WT/TN 23 (JB) BR/YL BR/YL C323 (8W-51-2) C327 C326 C321 TRAILER TOW OTHERS S336...
Page 795 8W - 51 - 4 8W-51 REAR LIGHTING TURN SIGNAL/ LEFT RIGHT HAZARD TURN TURN SWITCH SIGNAL SIGNAL (8W-52-2) (8W-52-3) BR/RD DG/RD C200 C204 C200 C204 S312 TRAILER (8W-70-4) OTHERS C323 BR/RD S335 C321 (8W-54-3) C322 BR/RD RIGHT DG/RD TURN LEFT SIGNAL TURN...
Page 796 8W-51 REAR LIGHTING 8W - 51 - 5 ST-RUN A21 (8W-10-16) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-12) (8W-12-13) C201 C100 S159 (8W-12-12) (8W-12-13) 4.0L A/T OTHER C107 TRANSMISSION 2.5L A/T RANGE SENSOR S161 (8W-31-6) BACK-UP PARK/ LAMP NEUTRAL SWITCH POSITION BR/LG SWITCH (8W-31-2) S142...
Page 797 8W - 51 - 6 8W-51 REAR LIGHTING DIESEL ST-RUN A21 (8W-10-16) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-12) (8W-12-13) C201 C100 S159 (8W-12-12) (8W-12-13) C111 BACK-UP SWITCH BR/LG C111 BR/LG C100 BR/LG C200 C204 BR/LG BR/LG S303 S303 (8W-51-7) (8W-51-7) J998W-7 XJI05106...
Page 798 8W-51 REAR LIGHTING 8W - 51 - 7 FROM FROM C200 C204 (8W-51-5) (8W-51-5) (8W-51-6) (8W-51-6) S303 BR/LG BR/LG TRAILER OTHERS C321 C323 S339 (8W-54-2) BR/LG C322 BR/LG LEFT RIGHT BACK-UP BACK-UP LAMP LAMP S341 S348 (8W-15-17) (8W-15-19) (8W-15-18) EXCEPT BUILT- (8W-15-20) UP EXPORT BUILT-UP-EXPORT...
Page 799 8W - 51 - 8 8W-51 REAR LIGHTING BUILT-UP-EXPORT LHD (8W-10-14) RUN-ACC A31 (8W-10-15) FRONT HEADLAMP JUNCTION HEAD SWITCH BLOCK LAMP LAMP LAMP (8W-50-4) SWITCH (8W-12-2) RELAY SWITCH FUSE OUTPUT OUTPUT (8W-50-17) (8W-50-18) (8W-12-18) S230 S226 YL/DG (8W-10-35) (8W-50-4) (8W-50-17) C201 YL/DG C100...
Page 800 8W-51 REAR LIGHTING 8W - 51 - 9 BUILT-UP-EXPORT RHD (8W-10-14) RUN-ACC A31 (8W-10-15) FRONT HEADLAMP JUNCTION HEAD SWITCH BLOCK LAMP LAMP LAMP (8W-50-4) SWITCH (8W-12-2) RELAY SWITCH FUSE OUTPUT OUTPUT (8W-50-17) (8W-50-18) (8W-12-19) S230 S226 (8W-10-35) (8W-50-4) (8W-50-17) YL/DG C100 S232 DIODE...
Page 801 8W - 51 - 10 8W-51 REAR LIGHTING BUILT-UP-EXPORT LHD FROM FROM S215 FROM FROM REAR (8W-12-8) REAR REAR LAMP LAMP LAMP RELAY RELAY RELAY (8W-51-8) (8W-51-8) (8W-51-8) LG/BK BR/WT BR/WT C200 REAR BR/WT REAR LAMP SWITCH SWITCH ILLUMINATION LAMP S308 INDICATOR BR/WT...
Page 802 8W-51 REAR LIGHTING 8W - 51 - 11 BUILT-UP-EXPORT RHD FROM FROM REAR S215 FROM (8W-12-9) REAR LAMP RELAY LAMP (8W-51-9) RELAY (8W-51-9) S220 BR/WT LG/BK BR/WT C203 REAR REAR LAMP BR/WT SWITCH SWITCH ILLUMINATION LAMP S308 INDICATOR BR/WT BR/WT C322 C321 OR/WT...
Page 804 8W - 52 TURN SIGNALS 8W - 52 - 1 8 W-5 2 T U RN SI GN ALS Co m p o n e n t P a g e Co m p o n e n t P a g e Com bin a t ion F la sh er .
Page 805 8W - 52 - 2 8W-52 TURN SIGNALS EXCEPT BUILT-UP-EXPORT RUN A22 BATT A0 (8W-10-17) (8W-10-10) JUNCTION POWER BLOCK DISTRIBUTION CENTER (8W-12-2) FUSE FUSE (8W-10-2) (8W-12-16) (8W-10-31) (8W-12-17) BK/PK C100 C201 BK/PK COMBINATION FUSED FUSED FLASHER IGNITION B(+) SWITCH HAZARD OUTPUT FLASHER (RUN)
Page 806 8W-52 TURN SIGNALS 8W - 52 - 3 BUILT-UP-EXPORT GAS BATT A0 RUN A22 (8W-10-10) (8W-10-17) POWER JUNCTION DISTRIBUTION BLOCK CENTER (8W-12-2) FUSE FUSE (8W-10-2) (8W-12-16) (8W-10-31) (8W-12-17) BK/PK C100 C201 POWER ANTENNA RELAY (RHD) BK/PK GROUND (8W-47-4) COMBINATION FUSED FUSED FLASHER B(+)
Page 807 8W - 52 - 4 8W-52 TURN SIGNALS DIESEL BATT A0 RUN A22 (8W-10-12) (8W-10-17) POWER JUNCTION DISTRIBUTION BLOCK CENTER (8W-12-2) FUSE FUSE (8W-10-6) (8W-12-16) (8W-10-35) (8W-12-17) BK/PK C100 C201 POWER ANTENNA RELAY (RHD) BK/PK GROUND (8W-47-4) COMBINATION FUSED FUSED FLASHER B(+) IGNITION...
Page 808 8W-52 TURN SIGNALS 8W - 52 - 5 EXCEPT BUILT-UP-EXPORT FROM FROM TURN TURN SIGNAL/ SIGNAL/ HAZARD HAZARD TRAILER SWITCH SWITCH OTHER (8W-52-2) (8W-52-2) C323 S335 DG/RD DG/RD (8W-54-3) LG/WT DG/RD C200 C204 S209 DG/RD DG/RD DG/RD C322 LG/WT LG/WT C100 DG/RD INSTRUMENT...
Page 809 8W - 52 - 6 8W-52 TURN SIGNALS BUILT-UP-EXPORT FROM FROM TURN TURN SIGNAL/ SIGNAL/ HAZARD HAZARD SWITCH SWITCH (8W-52-3) (8W-52-3) (8W-52-4) (8W-52-4) TRAILER OTHER C323 LG/WT S335 (8W-54-3) DG/RD DG/RD S209 DG/RD C200 C204 LG/WT LG/WT DG/RD C100 DG/RD DG/RD C322 INSTRUMENT...
Page 810 8W-52 TURN SIGNALS 8W - 52 - 7 EXCEPT BUILT-UP-EXPORT FROM FROM TURN TURN SIGNAL/ SIGNAL/ HAZARD HAZARD SWITCH SWITCH (8W-52-2) (8W-52-2) BR/RD S212 C200 C204 C100 INSTRUMENT BR/RD RIGHT CLUSTER TURN S312 SIGNAL (8W-40-14) C106 (8W-70-4) BR/RD S100 C321 (8W-50-13) BR/RD RIGHT...
Page 811 8W - 52 - 8 8W-52 TURN SIGNALS BUILT-UP-EXPORT FROM FROM TURN TURN SIGNAL/ SIGNAL/ HAZARD HAZARD SWITCH SWITCH (8W-52-3) (8W-52-3) (8W-52-4) (8W-52-4) BR/RD S212 C200 C204 C100 INSTRUMENT RIGHT BR/RD CLUSTER TURN SIGNAL (8W-40-14) S312 C106 (8W-70-4) BR/RD S116 C321 (8W-50-14) BR/RD...
Page 812 8W - 53 WIPERS 8W - 53 - 1 8 W-5 3 WI PERS Co m p o n e n t P a g e Co m p o n e n t P a g e A/C- H ea t er Con t r ol ....8W-53-6, 7 H ea dla m p Swit ch .
Page 813 8W - 53 - 2 8W-53 WIPERS RUN-ACC A31 (8W-10-14) JUNCTION BLOCK (8W-12-2) CIRCUIT BREAKER (8W-12-26) (8W-12-27) C201 WIPE/ WASH SWITCH 0 OFF 1 DELAY 2 LOW 3 HIGH 4 WASH INTERMITTENT WIPER 5 INTERMITTENT LOGIC WIPER MOTOR RELAY DG/YL BR/VT BR/WT C100...
Page 814 8W-53 WIPERS 8W - 53 - 3 DIESEL RUN-ACC A31 (8W-10-15) JUNCTION BLOCK (8W-12-2) CIRCUIT BREAKER (8W-12-27) C201 WIPE/ WASH SWITCH 0 OFF 1 DELAY 2 LOW 3 HIGH 4 WASH INTERMITTENT WIPER LOGIC 5 INTERMITTENT WIPER MOTOR RELAY DG/YL BR/VT BR/WT C100...
Page 815 8W - 53 - 4 8W-53 WIPERS LHD GAS HEADLAMP RUN A22 (8W-10-17) PANEL JUNCTION SWITCH JUNCTION LAMPS BLOCK (8W-50-2) BLOCK DIMMER (8W-50-4) FUSE (8W-12-2) SWITCH (8W-12-2) SIGNAL FUSE (8W-12-8) (8W-12-21) E2 20OR S315 (8W-12-8) BR/PK C201 C201 S215 (8W-12-8) BR/PK REAR WIPER/...
Page 816 8W-53 WIPERS 8W - 53 - 5 LHD DIESEL RUN A22 (8W-10-17) JUNCTION BLOCK JUNCTION FUSE (8W-12-2) HEADLAMP BLOCK PANEL SWITCH (8W-12-2) LAMPS FUSE (8W-50-4) (8W-12-8) DIMMER SWITCH SIGNAL (8W-12-21) E2 20OR S315 (8W-12-8) BR/PK C201 C201 S215 (8W-15-8) BR/PK REAR WIPER/ WASHER...
Page 817 8W - 53 - 6 8W-53 WIPERS RHD GAS HEADLAMP RUN A22 (8W-10-17) PANEL JUNCTION SWITCH JUNCTION LAMPS BLOCK (8W-50-3) DIMMER BLOCK FUSE (8W-50-4) (8W-12-2) SWITCH (8W-12-2) SIGNAL FUSE (8W-12-9) (8W-12-22) S215 (8W-12-9) A/C- FUSED HEATER PANEL BR/PK LAMPS CONTROL DIMMER (8W-44-4) SWITCH...
Page 818 8W-53 WIPERS 8W - 53 - 7 RHD DIESEL JUNCTION RUN A22 (8W-10-17) BLOCK JUNCTION FUSE (8W-12-2) BLOCK HEADLAMP (8W-12-2) PANEL SWITCH (8W-12-9) FUSE LAMPS (8W-50-4) DIMMER SWITCH (8W-12-22) SIGNAL S215 (8W-12-9) A/C- FUSED BR/PK HEATER PANEL LAMPS CONTROL DIMMER (8W-44-4) SWITCH SIGNAL...
Page 820 8W - 54 TRAILER TOW 8W - 54 - 1 8 W-5 4 T RAI LER T OW Co m p o n e n t P a g e Co m p o n e n t P a g e Br a ke La m p Swit ch .
Page 821 8W - 54 - 2 8W-54 TRAILER TOW (8W-10-26) BATT F34 (8W-10-27) (8W-10-36) S206 HEADLAMP SWITCH (8W-12-10) (8W-12-11) 1 PARK 2 HEAD C201 BK/YL 0 OFF (8W-50-2) (8W-50-3) (8W-50-4) BK/YL JUNCTION BLOCK (8W-12-2) FUSE FROM S303 (8W-12-10) (8W-12-11) (8W-51-7) BR/YL BR/LG S311 C323...
Page 822 8W-54 TRAILER TOW 8W - 54 - 3 (8W-10-19) BATT A7 (8W-10-24) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-20) RD/OR C323 S338 TURN BRAKE TURN (8W-12-20) BRAKE SIGNAL/ LAMP SIGNAL/ LEFT RIGHT LAMP HAZARD SWITCH HAZARD TURN TURN SWITCH SWITCH SWITCH (8W-33-4) SIGNAL SIGNAL OUTPUT...
Page 824 8W - 60 POWER WINDOWS 8W - 60 - 1 8 W-6 0 POWER WI N DOWS Co m p o n e n t P a g e Co m p o n e n t P a g e Cir cu it Br ea ker 28 (J B) .
Page 825 8W - 60 - 2 8W-60 POWER WINDOWS (8W-10-14) RUN-ACC A31 (8W-10-15) JUNCTION BLOCK (8W-12-2) CIRCUIT BREAKER (8W-12-24) C201 C200 C307 F81 14TN DRIVER POWER LOCK/ WINDOW SWITCH 1 UP 2 DOWN 3 LOCK 4 UNLOCK BR/WT VT/WT C306 S329 C303 (8W-15-17) PASSENGER...
Page 826 8W-60 POWER WINDOWS 8W - 60 - 3 (8W-10-14) RUN-ACC A31 (8W-10-15) JUNCTION BLOCK (8W-12-2) CIRCUIT BREAKER (8W-12-25) DRIVER POWER LOCK/ WINDOW SWITCH 1 UP 2 DOWN 3 LOCK 4 UNLOCK BR/WT VT/WT S319 C303 (8W-15-20) C303 BR/WT VT/WT C307 C306 S305 PASSENGER...
Page 827 8W - 60 - 4 8W-60 POWER WINDOWS RUN-ACC F81 (8W-12-24) DRIVER POWER LOCK/ WINDOW SWITCH 1 UP 2 DOWN 3 LOCK 4 UNLOCK S329 (8W-15-17) DB/WT RD/BK GY/BK DG/WT C307 C306 S309 (8W-15-17) DB/WT RD/BK GY/BK DG/WT S305 G302 (8W-60-2) (8W-15-17) C309...
Page 828 8W-60 POWER WINDOWS 8W - 60 - 5 RUN-ACC F81 (8W-12-25) DRIVER POWER LOCK/ WINDOW SWITCH 1 UP 2 DOWN 3 LOCK 4 UNLOCK S319 (8W-15-20) DB/WT RD/BK GY/BK DG/WT C303 DB/WT RD/BK GY/BK DG/WT S305 (8W-60-3) C309 C304 LEFT RIGHT REAR REAR...
Page 830 8W - 61 POWER DOOR LOCKS 8W - 61 - 1 8 W-6 1 POWER DOOR LOCK S Co m p o n e n t P a g e Co m p o n e n t P a g e Cir cu it Br ea ker 28 (J B) .
Page 831 8W - 61 - 2 8W-61 POWER DOOR LOCKS (8W-10-19) (8W-10-14) OVERHEAD BATT A7 RUN-ACC A31 (8W-10-24) (8W-10-15) DOOR MODULE JUNCTION UNLOCK DOOR (8W-49-4) BLOCK RELAY LOCK CONTROL CONTROL (8W-12-2) FUSE CIRCUIT BREAKER (8W-12-18) (8W-12-24) LB/RD C301 DB/PK LB/RD C300 DB/PK LB/RD PASSENGER...
Page 832 8W-61 POWER DOOR LOCKS 8W - 61 - 3 (8W-10-19) (8W-10-14) BATT A7 RUN-ACC A31 (8W-10-24) (8W-10-15) JUNCTION OVERHEAD DOOR BLOCK MODULE UNLOCK DOOR (8W-12-2) (8W-49-5) FUSE CIRCUIT RELAY LOCK BREAKER CONTROL CONTROL (8W-12-19) (8W-12-25) LB/RD C301 DB/PK LB/RD C204 C202 C203 DB/PK...
Page 833 8W - 61 - 4 8W-61 POWER DOOR LOCKS PASSENGER POWER DOOR DOOR LOCK/ LOCK UNLOCK WINDOW DRIVER DRIVER SWITCH OR/BK PK/BK S317 S316 (8W-12-31) (8W-12-31) OR/BK OR/BK PK/BK PK/BK PASSENGER DOOR LOCK MOTOR JUNCTION BLOCK (8W-12-2) OR/BK PK/BK S307 (8W-12-31) S306 (8W-12-31)
Page 834 8W-61 POWER DOOR LOCKS 8W - 61 - 5 PASSENGER POWER DOOR DOOR LOCK/ UNLOCK LOCK WINDOW DRIVER DRIVER SWITCH OR/BK PK/BK S323 S322 (8W-12-32) (8W-12-32) OR/BK OR/BK PK/BK PK/BK PASSENGER DOOR LOCK MOTOR C305 OR/BK PK/BK S306 (8W-12-32) S307 (8W-12-32) PK/BK OR/BK...
Page 836 8W - 62 POWER MIRRORS 8W - 62 - 1 8 W-6 2 POWER M I RRORS Co m p o n e n t P a g e Co m p o n e n t P a g e Dr iver P ower Lock/Win dow Swit ch .
Page 837 8W - 62 - 2 8W-62 POWER MIRRORS LHD EXCEPT BUILT-UP-EXPORT FULL OPTIONS RUN-ACC A31 (8W-10-14) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-18) YL/DG C201 YL/DG C200 YL/DG C305 YL/DG DRIVER POWER LOCK/ WINDOW SWITCH 0 REST 1 LEFT 2 RIGHT 3 UP 4 DOWN 5 DRIVER MIRROR 6 PASSENGER MIRROR...
Page 838 8W-62 POWER MIRRORS 8W - 62 - 3 BUILT-UP-EXPORT LHD FULL OPTIONS (8W-10-14) RUN-ACC A31 (8W-10-15) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-18) YL/DG C201 YL/DG C200 YL/DG YL/DG C305 REAR FUSED IGNITION SWITCH LAMP OUTPUT YL/DG RELAY (RUN-ACC) (8W-51-8) DRIVER POWER LOCK/ WINDOW SWITCH...
Page 839 8W - 62 - 4 8W-62 POWER MIRRORS LHD FULL OPTIONS RUN-ACC F83 (8W-12-18) DRIVER POWER LOCK/ WINDOW SWITCH 0 REST 1 LEFT 2 RIGHT 3 UP 4 DOWN 5 DRIVER MIRROR 6 PASSENGER MIRROR OR/YL YL/BK S329 S328 (8W-15-17) (8W-12-34) C305 OR/YL...
Page 840 8W-62 POWER MIRRORS 8W - 62 - 5 RHD GAS FULL OPTIONS RUN-ACC A31 (8W-10-14) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-19) YL/DG BUILT- EXCEPT BUILT-UP-EXPORT UP-EXPORT S232 (8W-12-19) YL/DG C300 S352 (8W-12-19) DRIVER POWER LOCK/ WINDOW SWITCH 0 REST 1 LEFT 2 RIGHT 3 UP 4 DOWN...
Page 841 8W - 62 - 6 8W-62 POWER MIRRORS RHD DIESEL FULL OPTIONS RUN-ACC A31 (8W-10-15) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-19) YL/DG S232 (8W-12-19) C300 YL/DG S352 (8W-12-19) DRIVER POWER LOCK/ WINDOW SWITCH 0 REST 1 LEFT 2 RIGHT 3 UP 4 DOWN 5 DRIVER MIRROR 6 PASSENGER MIRROR...
Page 842 8W-62 POWER MIRRORS 8W - 62 - 7 RHD FULL OPTIONS RUN-ACC F83 (8W-12-19) DRIVER POWER LOCK/ WINDOW SWITCH 0 REST 1 LEFT 2 RIGHT 3 UP 4 DOWN 5 DRIVER MIRROR 6 PASSENGER MIRROR OR/YL DB/WT YL/LB S319 S318 (8W-15-20) (8W-12-35) OR/YL...
Page 843 8W - 62 - 8 8W-62 POWER MIRRORS LHD EXCEPT FULL OPTIONS RUN-ACC F83 (8W-12-18) POWER MIRROR SWITCH 1 RIGHT 2 UP 3 LEFT 4 DOWN YL/BK DB/WT OR/YL WT/BK S329 DRIVER (8W-15-17) POWER MIRROR JUNCTION BLOCK (8W-12-2) WT/BK OR/YL C307 JUNCTION BLOCK...
Page 844 8W-62 POWER MIRRORS 8W - 62 - 9 RHD EXCEPT FULL OPTIONS RUN-ACC F83 (8W-12-19) POWER MIRROR SWITCH 1 RIGHT 2 UP 3 LEFT 4 DOWN DB/WT YL/LB YL/BK S360 (8W-15-13) OR/YL WT/BK DRIVER POWER MIRROR JUNCTION BLOCK (8W-12-2) YL/BK C204 JUNCTION OR/YL...
Page 846 8W - 63 POWER SEA T 8W - 63 - 1 8 W-6 3 POWER SEAT Co m p o n e n t P a g e Co m p o n e n t P a g e Cir cu it Br ea ker 29 (J B) .
Page 847 8W - 63 - 2 8W-63 POWER SEAT (8W-10-19) BATT A7 (8W-10-24) JUNCTION BLOCK (8W-12-2) CIRCUIT BREAKER (8W-12-26) (8W-12-27) RD/LB C316 HEATED OTHER SEATS RD/LB RD/LB S356 (8W-12-26) (8W-12-27) C362 LEFT POWER SEAT SWITCH 1 FRONT DOWN 2 FRONT UP 3 REAR DOWN 4 REAR UP 5 FORWARD...
Page 848 8W-63 POWER SEAT 8W - 63 - 3 (8W-10-19) BATT A7 (8W-10-24) JUNCTION BLOCK (8W-12-2) CIRCUIT BREAKER (8W-12-26) (8W-12-27) RD/LB C316 HEATED OTHER SEATS S356 (8W-12-26) (8W-12-27) RD/LB RD/LB RD/LB C362 RD/LB C363 LEFT FUSED POWER HEADLAMP SWITCH SEAT RD/LB OUTPUT SWITCH (8W-63-2)
Page 849 8W - 63 - 4 8W-63 POWER SEAT HEATED SEATS (8W-10-14) RUN-ACC A31 (8W-10-15) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-18) (8W-12-19) YL/DG YL/DG C300 C201 HEATED FUSED SEAT IGNITION SWITCH RELAY OUTPUT (8W-63-6) (RUN-ACC) YL/DG YL/DG S352 C200 (8W-12-19) C324 S351 YL/DG (8W-12-18) C316...
Page 850 8W-63 POWER SEAT 8W - 63 - 5 HEATED SEATS SEAT HEAT INTERFACE LEFT LEFT RIGHT RIGHT HEAT HEAT HEAT HEAT MODULE ELEMENT SENSE SENSOR SENSE ELEMENT GROUND OUTPUT INPUT FEED INPUT OUTPUT P143 P144 BK/OR BK/DG BK/YL PK/BK BK/LG C329 C329 P143...
Page 851 8W - 63 - 6 8W-63 POWER SEAT HEATED SEATS (8W-10-19) ST-RUN A21 BATT A7 (8W-10-16) (8W-10-24) JUNCTION BLOCK (8W-12-2) FUSE CIRCUIT BREAKER (8W-12-18) (8W-12-19) (8W-12-26) (8W-12-27) YL/DG YL/DG RD/LB C300 C201 S352 (8W-12-19) YL/DG C200 YL/DG C324 YL/DG S351 YL/DG (8W-12-18) YL/DG...
Page 852 8W - 70 SPLICE INFORMA TION 8W - 70 - 1 8 W-7 0 SPLI CE I N FORM AT I ON Co m p o n e n t P a g e Co m p o n e n t P a g e S100 .
Page 853 8W - 70 - 2 8W-70 SPLICE INFORMATION FUEL CLOCKSPRING PUMP (8W-30-10) MODULE (8W-30-3) (8W-30-4) BATTERY K167 TEMPERATURE BR/YL SENSOR (4.0L) (8W-30-10) BK/LB BK/RD C204 C200 TRANSMISSION K167 CONTROL MODULE BR/YL (4.0L) C100 K167 (8W-31-5) BR/YL K167 K167 C100 BR/YL BR/YL S138 INTAKE...
Page 854 8W-70 SPLICE INFORMATION 8W - 70 - 3 DIESEL LEFT RIGHT SPEED SPEED CONTROL CONTROL SWITCH SWITCH (8W-33-3) (8W-33-3) S222 FUEL ENGINE K167 PUMP COOLANT MODULE TEMPERATURE BR/YL SENSOR (8W-30-23) NO. 1 CLOCKSPRING (8W-30-26) (8W-33-3) PEDAL ENGINE POSITION CONTROL SENSOR MODULE (8W-30-25) (8W-30-23)
Page 855 8W - 70 - 4 8W-70 SPLICE INFORMATION ENGINE POWERTRAIN CRANKSHAFT THROTTLE CONTROL POSITION POSITION PRESSURE MODULE SENSOR SENSOR SENSOR (8W-30-5) (8W-30-5) (8W-30-7) (8W-30-10) MANIFOLD ABSOLUTE PRESSURE SENSOR CAMSHAFT (8W-30-9) POSITION SENSOR (8W-30-5) S115 (GAS) TURN SIGNAL/ HAZARD SWITCH (8W-52-2) (8W-52-3) (8W-52-4) BR/RD...
Page 856 8W - 80 CONNECTOR PIN-OUTS 8W - 80 - 1 8 W-8 0 CON N ECT OR PI N -OU T S Co m p o n e n t P a g e Co m p o n e n t P a g e A/C Com pr essor Clu t ch .
Page 857 8W - 80 - 2 8W - 80 CONNECTOR PIN-OUTS Co m p o n e n t P a g e Co m p o n e n t P a g e Glow P lu g Rela y ....8W-80-47 P a ssen ger Door J a m b Swit ch .
Page 858 8W - 80 CONNECTOR PIN-OUTS 8W - 80 - 3 Co m p o n e n t P a g e Co m p o n e n t P a g e Sen t r y Key Im m obilizer Modu le ..8W-80-84 Tr a n sm ission Con t r ol Modu le .
Page 859 8W - 80 - 4 8W-80 CONNECTOR PIN-OUTS BLACK CIRCUIT FUNCTION C3 14DB/BK A/C COMPRESSOR CLUTCH RELAY OUTPUT Z1 16BK GROUND A/C COMPRESSOR CLUTCH (DIESEL) CIRCUIT FUNCTION BLACK Z8 12BK/VT GROUND C7 12BK/TN HIGH SPEED BLOWER MOTOR C6 14LB M2 BLOWER MOTOR DRIVER C5 14LG M1 BLOWER MOTOR DRIVER C4 14TN...
Page 860 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 5 CIRCUIT FUNCTION C21 20DB/PK A/C SWITCH SENSE C90 20LG A/C SWITCH SENSE A/C LOW PRESSURE SWITCH (GAS) CIRCUIT FUNCTION R45 18DG/LB DRIVER AIRBAG LINE 1 R43 18BK/LB DRIVER AIRBAG LINE 2 YELLOW R42 18BK/YL PASSENGER AIRBAG LINE 2 R44 18DG/YL...
Page 861 8W - 80 - 6 8W-80 CONNECTOR PIN-OUTS BLACK CIRCUIT FUNCTION F20 18WT FUSED IGNITION SWITCH OUTPUT (ST-RUN) BACK-UP LAMP L10 18BR/LG BACK-UP LAMP FEED SWITCH (GAS) BLACK CIRCUIT FUNCTION K118 18PK/YL BATTERY TEMPERATURE SENSOR SIGNAL K167 20BR/YL SENSOR GROUND BATTERY TEMPERATURE SENSOR...
Page 862 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 7 CIRCUIT CIRCUIT Z1 18BK 18BK G106 20BK/WT G106 20BK/WT G107 20BK/RD G107 20BK/RD L39 20LB 20LB L139 20VT L139 20VT C90 20LG 20LG C90 18LG C90 18LG BLACK BLACK C100 C100 (LHD) (LHD) V3 16BR/WT 16BR/WT...
Page 863 8W - 80 - 8 8W-80 CONNECTOR PIN-OUTS (CONTINUED) CIRCUIT CIRCUIT L50 20WT/TN L50 20WT/TN L50 18WT/TN L50 18WT/TN G9 20GY/BK G9 20GY/BK L10 18BR/LG L10 18BR/LG V10 18BR V10 18BR V20 18BK/WT V20 18BK/WT F34 18TN/BK F34 18TN/BK Z12 20BK/TN Z12 20BK/TN Z12 18BK/TN Z12 18BK/TN...
Page 864 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 9 CIRCUIT CIRCUIT Z1 18BK 18BK G106 20BK/WT G106 20BK/WT G107 20BK/RD G107 20BK/RD L39 20LB 20LB L139 20VT L139 20VT C90 18LG 20LG Z12 18BK/TN Z12 18BK/TN G29 20BK/LB G29 20BK/LB F20 18WT F20 18WT G99 20GY/WT G99 20GY/WT...
Page 865 8W - 80 - 10 8W-80 CONNECTOR PIN-OUTS (CONTINUED) CIRCUIT CIRCUIT F45 20YL/RD F45 20YL/RD T141 20YL T141 20YL F1 20DB/GY 20DB/GY K185 20OR/LB K185 20OR/LB G86 18TN/OR G86 20TN/OR G154 18VT/LG G154 20VT/LG L13 20BR/YL L13 20BR/YL D20 18LG/BK V30 20DB/RD 20DB/RD F32 20PK/DB...
Page 866 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 11 CIRCUIT CIRCUIT 18BR/YL 18BR/YL L33 20RD 18RD BLACK BLACK L61 20LG 20LG Z1 20BK 18BK 16BK/GY Z15 18BK/GY L34 20RD/OR 18RD/OR L77 20BR L77 20BR L39 20LB 20LB L43 20VT 18VT C106 C106 L60 20TN 20TN...
Page 867 8W - 80 - 12 8W-80 CONNECTOR PIN-OUTS CIRCUIT CIRCUIT A142 18DG/OR A142 18DG/OR K20 18DG K20 18DG BLACK BLACK K167 20BR/YL K167 20BR/YL G7 20WT/OR G7 20WT/OR Z1 20 BK T41 20BK/WT T41 20BK/WT F142 20DG/WT F142 20DG/WT G107 20BK/RD G107 20BK/RD C107 C107...
Page 868 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 13 CIRCUIT CIRCUIT A142 18DG/OR A142 18DG/OR K20 18DG K20 18DG BLACK BLACK K167 20BR/YL K167 20BR/YL G7 20WT/OR G7 20WT/OR Z1 20 BK T41 20BK/WT T41 18BK/WT F142 20DG/WT F142 20DG/WT G107 20BK/RD G107 20BK/RD C107 C107...
Page 869 8W - 80 - 14 8W-80 CONNECTOR PIN-OUTS BLACK BLACK CIRCUIT CIRCUIT T40 16BR T40 16BR 18DG/OR 16DG/OR 18DG 18DG 16DB/BK C108 16DB/BK C108 CIRCUIT CIRCUIT BLACK BLACK 18YL/VT B41 20YL/VT 18TN/WT B42 20TN/WT 18PK/OR B43 20PK/OR 18YL/DB 18YL/DB 18YL 18YL 18LG/DB 18LG/DB...
Page 870 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 15 BLACK BLACK CIRCUIT CIRCUIT L60 18TN L60 18GY Z1 18BK Z1 18BK C115 C115 (BUILT-UP-EXPORT) (BUILT-UP-EXPORT) BLACK BLACK CIRCUIT CIRCUIT K7 20OR K7 18OR G60 18GY/YL G60 18GY/YL K167 20BR/YL K167 18BR/YL C116 C116 (DIESEL)
Page 871 8W - 80 - 16 8W-80 CONNECTOR PIN-OUTS CIRCUIT CIRCUIT 18DG 16DG 18BR/RD 16BR/RD P91 20WT/BK P91 20WT/BK 18VT 16VT 18DB/RD 16DB/RD 18BR/YL 16BR/YL 18BR/LB 16BR/LB 18DB/WT 16DB/WT GRAY GRAY 18DB/OR 16DB/OR 18DG/RD 16DG/RD A141 16DG/WT A141 16DG/WT 14VT 16VT K226 20DB/LG K226...
Page 872 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 17 CIRCUIT CIRCUIT F20 18WT F20 18WT C16 20LB/YL 20LB/YL L5 20BK 20BK C36 20RD/WT C36 20RD/WT F87 20WT/BK 20WT/BK M1 20PK 20PK Z1 20BK Z1 20BK V6 16DB 16DB P36 20PK/VT P36 20PK/VT A31 12BK/WT 12BK/WT A111 12RD/LG...
Page 873 8W - 80 - 18 8W-80 CONNECTOR PIN-OUTS (CONTINUED) CIRCUIT CIRCUIT F83 18YL/DG F83 18YL/DG 18BK/YL L7 18BK/YL 20YL M2 20YL 16RD F30 16RD 18VT/BR D1 20VT/BR 18WT/BK D2 20WT/BK 16RD/WT X12 16RD/WT 20VT/BR D1 20VT/BR 20WT/BK D2 20WT/BK 20BK/LG Z2 20BK/LG 14TN C4 14TN...
Page 874 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 19 CIRCUIT CIRCUIT 12BK/TN C7 12BK/TN 12TN F81 12TN BLACK BLACK Z8 12BK/VT Z8 16BK/VT Z8 12BK/PK A111 12RD/LG A111 12RD/LG 14LB C6 14LB C5 14LG C5 14LG C202 C202 C4 14TN C4 14TN (RHD) (RHD) CIRCUIT...
Page 875 8W - 80 - 20 8W-80 CONNECTOR PIN-OUTS CIRCUIT CIRCUIT 20VT/BR 18VT/BR WHITE 20WT/BK 18WT/BK BLACK 16VT 16VT A141 16DG/WT A141 16DG/WT 18BR/LG 18BR/LG 20WT/TN 20WT/TN 20BR/RD 20BR/RD 20DG/RD 20DG/RD C204 C204 (RHD) (RHD) 18DB/YL 18DB/YL 18LG/YL 18LG/YL 16RD 16RD Z1 20BK Z1 20BK C6 20RD/WT...
Page 876 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 21 BLACK BLACK CIRCUIT CIRCUIT 20OR 20OR 20BK 20BK C206 C206 (M/T) (M/T) BLACK BLACK CIRCUIT CIRCUIT 20PK 18PK 20YL 18BK/WT C207 C207 BLACK BLACK CIRCUIT CIRCUIT 20PK 18PK 20YL 18BK/WT C208 C208 NATURAL NATURAL CIRCUIT...
Page 877 8W - 80 - 22 8W-80 CONNECTOR PIN-OUTS CIRCUIT CIRCUIT WHITE D1 20VT/BR D1 20VT/BR D2 20WT/BK D2 20WT/BK G32 20BK/LB G32 20BK/LB G31 20VT/LG G31 20VT/LG Z2 20BK/LG Z2 20BK/LG F87 20WT/BK F87 20WT/BK X3 20BK/RD X3 20BK/RD C301 C301 P55 20DB P55 20DB/PK...
Page 878 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 23 BLACK BLACK CIRCUIT CIRCUIT Q18 14GY/BK 14GY/BK 14DG/WT Q28 14DG/WT Q1 14YL 14YL P33 16OR/BK 16OR/BK P34 16PK/BK 16PK/BK C304 C304 (LHD) (LHD) BLACK BLACK CIRCUIT CIRCUIT 14GY/BK 14GY/BK 14DG/WT 14DG/WT 14YL 14YL 16OR/BK 16OR/BK...
Page 879 8W - 80 - 24 8W-80 CONNECTOR PIN-OUTS CIRCUIT CIRCUIT X85 18BR/RD 18BR/RD X54 18VT X54 18VT X87 18DG 18LG/VT X56 18DB/RD X56 18DB/RD P59 20LB/RD P59 20LB/RD P33 16OR/BK 16OR/BK WHITE WHITE P34 16PK/BK 16PK/BK P35 20OR/VT 18OR/VT P36 20PK/VT 18PK/VT P71 20YL P71 20YL...
Page 880 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 25 WHITE WHITE CIRCUIT CIRCUIT 14TN 12TN 14YL 14YL Z1 12BK 12BK Z1 16BK C307 C307 BLACK BLACK CIRCUIT CIRCUIT 14DB/WT 14DB/WT 14RD/BK 14RD/BK 14YL 14YL 16OR/BK 16OR/BK C309 C309 16PK/BK 16PK/BK (FULL OPTIONS) (FULL OPTIONS) CIRCUIT BLACK...
Page 881 8W - 80 - 26 8W-80 CONNECTOR PIN-OUTS CIRCUIT CIRCUIT 18TN/BK 16TN/BK X52 18DB/WT 18DB/WT 18TN/RD 16TN/RD X58 18DB/OR 18DB/OR C314 C314 16BR/DB 18WT/BK 18BR/YL X51 18BR/YL 16BR/YL 18WT/RD 18BR/LB X57 18BR/LB M1 18PK M1 20PK 20PK 20YL 20YL 20GY/BK 20GY/BK BLACK BLACK...
Page 882 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 27 GRAY GRAY CIRCUIT CIRCUIT 18YL 20YL 18BK/LB 20BK/LB 18BK 20BK C318 C318 BLACK BLACK CIRCUIT CIRCUIT 18YL 20YL 18BK 20BK C319 C319 BLACK BLACK CIRCUIT CIRCUIT 18YL 20YL 18BK 20BK C320 C320 BLACK CIRCUIT CIRCUIT...
Page 883 8W - 80 - 28 8W-80 CONNECTOR PIN-OUTS CIRCUIT CIRCUIT BLACK BLACK L63 18DG/RD L63 20DG/RD Z1 16BK Z1 18BK Z1 18BK L38 18OR/WT L38 18BR/WT L10 18BR/LG L10 18BR/LG C322 C322 L50 18WT/TN L50 20WT/TN (TRAILER TOW) (TRAILER TOW) L77 18BR L77 18BR/YL CIRCUIT...
Page 884 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 29 BLACK BLACK CIRCUIT CIRCUIT 18WT/TN 18DG/WT Z1 18BK 18BK C325 C325 BLACK BLACK CIRCUIT CIRCUIT 16OR/BK P33 16OR/BK 16PK/BK P34 16PK/BK 20GY/BK M4 20GY/BK 12BK/WT C15 12BK/WT 18WT/TN L50 20WT/TN C326 C326 BLACK BLACK CIRCUIT...
Page 885 8W - 80 - 30 8W-80 CONNECTOR PIN-OUTS CIRCUIT CIRCUIT P133 18TN/DG P133 18TN/DG P134 18TN/RD P134 18TN/RD BLACK P137 18VT BLACK P137 18VT P138 18VT/LG P138 18VT/LG P139 18VT/WT P139 18VT/WT P140 18VT/BK P140 18VT/BK P87 18BK/OR P87 18BK/OR P141 18TN/LB P141 18TN/LB P143 18BK/DG...
Page 886 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 31 BLACK BLACK CIRCUIT CIRCUIT P141 18TN/LB P141 18TN/LB P143 18BK/DG P143 18BK/DG 18BK/OR P87 18BK/OR 18BK Z1 18BK C332 C332 BLACK CIRCUIT CIRCUIT 14RD/LB F37 14RD/LB 14BK Z1 14BK C362 C362 BLACK CIRCUIT CIRCUIT F37 14RD/LB...
Page 887 8W - 80 - 32 8W-80 CONNECTOR PIN-OUTS BLACK CIRCUIT FUNCTION Z1 18BK GROUND L50 18DG/WT BRAKE LAMP SWITCH OUTPUT CENTER HIGH MOUNTED STOP LAMP BLACK CIRCUIT FUNCTION F30 16RD CIGAR LIGHTER RELAY OUTPUT Z1 16BK GROUND CIGAR LIGHTER CIRCUIT FUNCTION NATURAL 20BK/RD...
Page 888 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 33 GREEN CIRCUIT FUNCTION F45 20YL/RD FUSED B(+) ENGINE STARTER MOTOR RELAY T141 20YL IGNITION SWITCH OUTPUT (START) IGNITION SWITCH OUTPUT (START) T141 20YL CLUTCH INTERLOCK F45 20YL/RD FUSED B(+) ENGINE STARTER MOTOR RELAY SWITCH BLACK CIRCUIT...
Page 889 8W - 80 - 34 8W-80 CONNECTOR PIN-OUTS CIRCUIT FUNCTION Z1 20BK GROUND M1 20PK FUSED B(+) BLACK G31 20VT/LG AMBIENT TEMPERATURE SENSOR SIGNAL D1 20VT/BR CCD BUS (+) F87 20WT/BK FUSED IGNITION SWITCH OUTPUT (ST-RUN) M2 20YL COURTESY LAMP DRIVER COMPASS G32 20BK/LB AMBIENT TEMPERATURE SENSOR GROUND...
Page 890 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 35 BLACK CIRCUIT FUNCTION K3 20LG/BK SENSOR GROUND K24 20GY/BK CRANKSHAFT POSITION SENSOR SIGNAL CRANKSHAFT POSITION SENSOR (DIESEL) BLACK CIRCUIT FUNCTION 18GY/BK CRANKSHAFT POSITION SENSOR SIGNAL K167 20BR/YL SENSOR GROUND 20OR 5 VOLT SUPPLY CRANKSHAFT POSITION SENSOR (GAS)
Page 891 8W - 80 - 36 8W-80 CONNECTOR PIN-OUTS CIRCUIT FUNCTION 16RD DIMMER SWITCH HIGH BEAM OUTPUT BLACK 16RD/GY HIGH BEAM INDICATOR DRIVER F20 18WT FUSED IGNITION SWITCH OUTPUT (ST-RUN) 14RD/WT FUSED B(+) 20WT/OR VEHICLE SPEED SENSOR SIGNAL DAYTIME RUNNING 16BK/TN GROUND LAMP MODULE (EXCEPT BUILT-...
Page 892 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 37 BLACK CIRCUIT FUNCTION M2 18YL COURTESY LAMPS DRIVER G16 18BK/LB DRIVER DOOR AJAR SWITCH SENSE 18BK GROUND DRIVER DOOR JAMB SWITCH CIRCUIT FUNCTION P34 16PK/BK DOOR UNLOCK DRIVER P33 16OR/BK DOOR LOCK DRIVER DRIVER DOOR LOCK MOTOR CIRCUIT...
Page 893 8W - 80 - 38 8W-80 CONNECTOR PIN-OUTS CIRCUIT FUNCTION WHITE P71 20YL LEFT POWER MIRROR LEFT MOVEMENT P71 20YL/LB LEFT POWER MIRROR LEFT MOVEMENT P76 20OR/YL COMMON F83 18YL/DG FUSED IGNITION SWITCH OUTPUT (RUN-ACC) P74 20DB RIGHT POWER MIRROR LEFT MOVEMENT Z1 14BK GROUND DRIVER POWER...
Page 894 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 39 BLACK CIRCUIT FUNCTION Q11 14LB LEFT WINDOW DRIVER (UP) Q21 14WT LEFT FRONT WINDOW DRIVER DOWN DRIVER POWER WINDOW MOTOR (LHD) BLACK CIRCUIT FUNCTION Q11 14BR LEFT WINDOW DRIVER (UP) Q21 14VT LEFT FRONT WINDOW DRIVER DOWN DRIVER POWER WINDOW MOTOR...
Page 895 8W - 80 - 40 8W-80 CONNECTOR PIN-OUTS CIRCUIT FUNCTION FUEL TEMPERATURE SENSOR SIGNAL K156 20GY K2 20TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL K68 18LG/YL NEEDLE MOVEMENT SENSOR (-) SLEEVE POSITION SENSOR (-) K134 20LB/BK K57 20LG/OR CONTROL SLEEVE POSITION SENSOR BLACK K135 20WT/BK SLEEVE POSITION SENSOR(+)
Page 896 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 41 CIRCUIT FUNCTION Z12 14BK/TN GROUND A142 16DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT C13 20DB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL K159 18VT/RD ENGINE SPEED SENSOR SIGNAL C103 18DG A/C SWITCH SIGNAL K29 20WT/PK BRAKE SWITCH SENSE C22 20DB/WT A/C SWITCH SENSE...
Page 897 8W - 80 - 42 8W-80 CONNECTOR PIN-OUTS BLACK CIRCUIT FUNCTION K167 20BR/YL SENSOR GROUND ENGINE COOLANT K2 18TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL TEMPERATURE SENSOR (GAS) BLACK CIRCUIT FUNCTION K2 18TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL K4 18BK/LB SENSOR GROUND ENGINE COOLANT TEMPERATURE...
Page 898 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 43 CIRCUIT FUNCTION F20 18WT FUSED IGNITION SWITCH OUTPUT (ST-RUN) EVAP LEAK K106 18WT/DG LEAK DETECTION PUMP SOLENOID CONTROL DETECTION K105 18OR LEAK DETECTION PUMP SWITCH SENSE PUMP (EXCEPT BUILT-UP -EXPORT) WHITE CIRCUIT FUNCTION Z1 20BK GROUND...
Page 899 8W - 80 - 44 8W-80 CONNECTOR PIN-OUTS CIRCUIT FUNCTION A93 14RD/BK FUEL HEATER RELAY OUTPUT FUEL HEATER Z1 14BK GROUND (DIESEL) CIRCUIT FUNCTION A142 18DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT K11 18WT/DB FUEL INJECTOR NO. 1 DRIVER FUEL INJECTOR NO. 1 (2.5L GAS) CIRCUIT FUNCTION...
Page 900 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 45 BLACK CIRCUIT FUNCTION A142 18DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT 18WT/DB FUEL INJECTOR NO. 1 DRIVER FUEL INJECTOR NO. 1 (4.0L GAS) BLACK CIRCUIT FUNCTION A142 18DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT 18TN FUEL INJECTOR NO.
Page 901 8W - 80 - 46 8W-80 CONNECTOR PIN-OUTS BLACK CIRCUIT FUNCTION K226 20DB/LG FUEL LEVEL SENSOR SIGNAL K167 20BR/YL SENSOR RETURN 3 2 1 FUEL LEVEL SENSOR (DIESEL) BLACK CIRCUIT FUNCTION A141 16DG/WT FUEL PUMP RELAY OUTPUT K226 20DB/LG FUEL LEVEL SENSOR SIGNAL K167 20BR/YL SENSOR GROUND...
Page 902 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 47 CIRCUIT FUNCTION A54 10RD/GY FUSED B (+) F142 18DG/OR FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT K152 18WT GLOW PLUG RELAY OUTPUT K154 10GY GLOW PLUG RELAY (DIESEL) BLACK CIRCUIT FUNCTION L4 16VT/WT LOW BEAM RELAY OUTPUT L2 14LG HEADLAMP SWITCH OUTPUT...
Page 903 8W - 80 - 48 8W-80 CONNECTOR PIN-OUTS CIRCUIT FUNCTION BLACK Z15 20BK/GY GROUND L44 20VT/RD FUSED RIGHT LOW BEAM OUTPUT L13 20BR/YL HEADLAMP ADJUST SIGNAL HEADLAMP LEVELING SWITCH (BUILT-UP-EXPORT) BLACK CIRCUIT FUNCTION E1 20TN PANEL LAMPS DIMMER SWITCH SIGNAL L2 14LG HEADLAMP SWITCH OUTPUT M2 20YL...
Page 904 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 49 CIRCUIT FUNCTION F235 16RD B(+) TO HEATED SEAT MODULE F235 16RD B(+) TO HEATED SEAT MODULE F83 18YL/DG FUSED IGNITION SWITCH OUTPUT (RUN-ACC) Z1 18BK GROUND HEATED SEAT RELAY F37 14RD/LB FUSED B(+) CIRCUIT FUNCTION Z1 20BK...
Page 905 8W - 80 - 50 8W-80 CONNECTOR PIN-OUTS BLACK CIRCUIT FUNCTION K19 18GY IGNITION COIL NO. 1 DRIVER A142 18DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT A142 18DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT K19 18GY IGNITION COIL NO. 1 DRIVER IGNITION COIL CIRCUIT FUNCTION 20BK...
Page 906 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 51 CIRCUIT FUNCTION BLACK G78 20TN/BK LIFTGATE AJAR SWITCH SENSE 20GY/WT RED BRAKE WARNING INDICATOR DRIVER 20OR FUSED PANEL LAMPS DIMMER SWITCH SIGNAL 20LG/OR ABS INDICATOR DRIVER 16RD/GY HIGH BEAM INDICATOR DRIVER 20BK/LG GROUND G29 20BK/LB LOW WASHER FLUID SENSE...
Page 907 8W - 80 - 52 8W-80 CONNECTOR PIN-OUTS GRAY CIRCUIT FUNCTION K167 20BR/YL SENSOR GROUND 18BK/RD INTAKE AIR TEMPERATURE SENSOR SIGNAL INTAKE AIR TEMPERATURE SENSOR CIRCUIT FUNCTION 20VT/RD FUSED RIGHT LOW BEAM OUTPUT NATURAL 20YL/RD FUSED B(+) ENGINE STARTER MOTOR RELAY L78 18DG/YL FUSED HEADLAMP SWITCH OUTPUT 20DG/YL...
Page 908 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 53 NATURAL CIRCUIT FUNCTION 20YL COURTESY LAMPS DRIVER 20BK GROUND 20PK FUSED B(+) JUNCTION BLOCK - C3 CIRCUIT FUNCTION 12BK/WT FUSED IGNITION SWITCH OUTPUT (RUN-ACC) 12DB FUSED IGNITION SWITCH OUTPUT (ST-RUN) 14YL FUSED IGNITION SWITCH OUTPUT (ST) 12BK/OR FUSED IGNITION SWITCH OUTPUT (RUN) 18BK/YL...
Page 909 8W - 80 - 54 8W-80 CONNECTOR PIN-OUTS CIRCUIT FUNCTION 20BK/RD HORN RELAY CONTROL NATURAL 20OR/YL COMMON P91 20WT/BK LEFT/RIGHT POWER MIRROR HORIZONTAL SUPPLY 20LB/YL FUSED REAR WINDOW DEFOGGER RELAY OUTPUT 16RD FUSED B(+) 12TN FUSED IGNITION SWITCH OUTPUT (RUN-ACC) JUNCTION 20DB RIGHT POWER MIRROR LEFT MOVEMENT...
Page 910 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 55 NATURAL CIRCUIT FUNCTION 14TN FUSED IGNITION SWITCH OUTPUT (RUN-ACC) JUNCTION BLOCK - C8 CIRCUIT FUNCTION P33 16OR/BK DOOR LOCK DRIVER 20DB RIGHT POWER MIRROR LEFT MOVEMENT 20BK/WT FUSED REAR WINDOW DEFOGGER RELAY OUTPUT NATURAL 20YL/BK RIGHT POWER MIRROR UP MOVEMENT...
Page 911 8W - 80 - 56 8W-80 CONNECTOR PIN-OUTS CIRCUIT FUNCTION L77 20BR FUSED LEFT INBOARD TAIL LAMP Z1 20BK GROUND LEFT CITY LAMP (BUILT-UP-EXPORT) BLACK CIRCUIT FUNCTION 18PK FUSED B(+) 18BK/WT COURTESY LAMPS DRIVER LEFT COURTESY LAMP GRAY CIRCUIT FUNCTION 20BK GROUND 20LB...
Page 912 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 57 GRAY CIRCUIT FUNCTION Z1 18BK GROUND L77 18BR FUSED LEFT INBOARD TAIL LAMP L61 18LG LEFT TURN SIGNAL LEFT FRONT PARK/TURN SIGNAL LAMP NO.1 (EXCEPT BUILT-UP- EXPORT) GRAY CIRCUIT FUNCTION Z1 18BK GROUND L77 18BR FUSED LEFT INBOARD TAIL LAMP...
Page 913 8W - 80 - 58 8W-80 CONNECTOR PIN-OUTS GRAY CIRCUIT FUNCTION 18RD/DB LEFT FRONT WHEEL SPEED SENSOR (-) 18RD LEFT FRONT WHEEL SPEED SENSOR (+) LEFT FRONT WHEEL SPEED SENSOR CIRCUIT FUNCTION 18RD FUSED LEFT HIGH BEAM OUTPUT 20RD FUSED LEFT HIGH BEAM OUTPUT 18VT FUSED LEFT LOW BEAM OUTPUT 18BK...
Page 914 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 59 CIRCUIT FUNCTION P137 18VT LEFT SEAT LOW HEAT LED DRIVER Z1 18BK GROUND F83 18YL/DG FUSED IGNITION SWITCH OUTPUT (RUN-ACC) LEFT HEATED P139 18VT/WT LEFT SEAT HIGH HEAT LED DRIVER SEAT SWITCH LEFT SEAT HEATER SWITCH MUX P133 18TN/DG BLACK...
Page 915 8W - 80 - 60 8W-80 CONNECTOR PIN-OUTS BLACK CIRCUIT FUNCTION 20LG/DB LEFT REAR WHEEL SPEED SENSOR (-) 20LG LEFT REAR WHEEL SPEED SENSOR (+) LEFT REAR WHEEL SPEED SENSOR BLACK CIRCUIT FUNCTION 14DB POWER WINDOW LEFT REAR B(+) UP 14RD/WT LEFT REAR WINDOW DRIVER DOWN LEFT REAR...
Page 916 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 61 NATURAL CIRCUIT FUNCTION L77 20BR FUSED LEFT INBOARD TAIL LAMP L61 20LG LEFT TURN SIGNAL LEFT SIDE MARKER LAMP (EXCEPT BUILT -UP-EXPORT) CIRCUIT FUNCTION X57 18BR/LB LEFT REAR SPEAKER (-) X91 16BR/DB AMPLIFIED LEFT REAR SPEAKER (-) LEFT X51 18BR/YL...
Page 917 8W - 80 - 62 8W-80 CONNECTOR PIN-OUTS CIRCUIT FUNCTION Z1 18BK GROUND LEFT TURN L63 18DG/RD LEFT TURN SIGNAL SIGNAL LAMP CIRCUIT FUNCTION 18BK/YL FUSED B(+) 18BK GROUND LICENSE LAMP BLACK CIRCUIT FUNCTION P33 16OR/BK DOOR LOCK DRIVER P34 16PK/BK DOOR UNLOCK DRIVER LIFTGATE LOCK MOTOR...
Page 918 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 63 CIRCUIT FUNCTION 18PK/BK COOLANT LEVEL SWITCH SENSE K167 20BR/YL SENSOR GROUND LOW COOLANT SWITCH (DIESEL) BLACK CIRCUIT FUNCTION K167 20BR/YL SENSOR GROUND 18DG/RD MANIFOLD ABSOLUTE PRESSURE SENSOR SIGNAL MANIFOLD 20OR 5V SUPPLY ABSOLUTE PRESSURE SENSOR...
Page 919 8W - 80 - 64 8W-80 CONNECTOR PIN-OUTS BLACK CIRCUIT FUNCTION F142 20DG/WT FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT 20BK GROUND OXYGEN K167 18BR/YL SENSOR GROUND SENSOR 1/2 K141 18TN/WT OXYGEN SENSOR 1/2 SIGNAL DOWNSTREAM BLACK CIRCUIT FUNCTION F20 18WT FUSED IGNITION SWITCH OUTPUT (ST-RUN) T41 18BK/WT PARK NETURAL POSITION SWITCH SENSE...
Page 920 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 65 CIRCUIT FUNCTION P34 16PK/BK DOOR UNLOCK DRIVER Q22 14VT RIGHT FRONT WINDOW DRIVER (DOWN) Q26 14VT/WT MASTER SWITCH RIGHT FRONT WINDOW MOTOR (DOWN) BLUE Q16 14BR/WT MASTER WINDOW SWITCH RIGHT FRONT DOWN P33 16OR/BK DOOR LOCK DRIVER PASSENGER...
Page 921 8W - 80 - 66 8W-80 CONNECTOR PIN-OUTS CIRCUIT FUNCTION P72 20YL/BK RIGHT POWER MIRROR UP MOVEMENT RIGHT POWER MIRROR LEFT MOVEMENT P74 20DB 20OR/YL COMMON P91 20WT/BK LEFT/RIGHT POWER MIRROR HORIZONTAL SUPPLY P74 20DB RIGHT POWER MIRROR LEFT MOVEMENT P76 20OR/YL COMMON PASSENGER...
Page 922 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 67 BLACK CIRCUIT FUNCTION Q12 14BR RIGHT FRONT WINDOW DRIVER (UP) Q22 14VT RIGHT FRONT DRIVER (DOWN) PASSENGER POWER WINDOW MOTOR CIRCUIT FUNCTION BLACK K4 20BK/LB SENSOR GROUND K151 20WT LOW IDLE POSITION SENSE K22 20OR/DB THROTTLE POSITION SENSE SIGNAL K255 20WT/DG...
Page 923 8W - 80 - 68 8W-80 CONNECTOR PIN-OUTS CIRCUIT FUNCTION F75 16VT FUSED B(+) F75 16VT FUSED B(+) NATURAL X87 18LG/VT AMPLIFIED LEFT DOOR SPEAKER (+) X94 18TN/RD RIGHT REAR SPEAKER (+) X93 18WT/RD LEFT REAR SPEAKER (-) Z5 16BK/LB GROUND Z5 16BK/LB GROUND...
Page 924 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 69 CIRCUIT FUNCTION X13 18WT RADIO CHOKE OUTPUT X14 18DG POWER ANTENNA B(+) DOWN POWER ANTENNA X17 18GY POWER ANTENNA UP (-) RELAY - C2 (BUILT-UP-EXPORT) CIRCUIT FUNCTION Z1 20BK GROUND Z1 14BK GROUND F83 18YL/DG FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
Page 925 8W - 80 - 70 8W-80 CONNECTOR PIN-OUTS CIRCUIT FUNCTION A142 16DG/DR AUTOMATIC SHUT DOWN RELAY OUTPUT K167 18BR/YL SENSOR RETURN K159 18VT/RD ENGINE SPEED SENSOR SIGNAL 18PK/BK COOLANT LEVEL SWITCH SENSE K222 18TN/RD SECONDARY ENGINE COOLANT TEMP SENSOR 18OR 5 VOLT SUPPLY 18LB/BK FUEL MONITOR OUTPUT SIGNAL...
Page 926 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 71 CIRCUIT FUNCTION 18DB/WT FUSED IGNITION SWITCH OUTPUT (ST-RUN) K167 18BR/YL SENSOR GROUND 18BK/WT PARK/NEUTRAL POSITION SWITCH SENSE 18BK GROUND T41 18BK/WT TRANSMISSION RANGE SWITCH SENSE 18GY IGNITION COIL NO. 1 DRIVER 18GY/BK CRANKSHAFT POSITION SENSOR SIGNAL 18YL/BK IDLE AIR CONTROL NO.
Page 927 8W - 80 - 72 8W-80 CONNECTOR PIN-OUTS CIRCUIT FUNCTION 18DG GENERATOR FIELD DRIVER (+) 18RD/LG WIPER PARK SWITCH SENSE POWERTRAIN CONTROL MODULE - C2 (DIESEL) 18GY/YL ENGINE OIL PRESSURE SENSOR SIGNAL 18WT/OR VEHICLE SPEED SENSOR SIGNAL J998W-7 XJI08072...
Page 928 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 73 CIRCUIT FUNCTION K11 18WT/DB FUEL INJECTOR NO.1 DRIVER K13 18YL/WT FUEL INJECTOR NO.3 DRIVER K15 18PK/BK FUEL INJECTOR NO.5 DRIVER 18DG GENERATOR FIELD DRIVER (+) TORQUE CONVERTER CLUTCH SOLENOID CONTROL K54 18OR/BK K16 18LG/BK FUEL INJECTOR NO.6 DRIVER K12 18TN...
Page 929 8W - 80 - 74 8W-80 CONNECTOR PIN-OUTS CIRCUIT FUNCTION C103 18DG A/C SWITCH SIGNAL GRAY G154 18VT/LG LOW COOLANT INDICATOR DRIVER G86 18TN/OR WATER-IN-FUEL INDICATOR DRIVER A142 16DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT K118 18PK/YL BATTERY TEMPERATURE SENSOR SIGNAL G55 18OR/BK ENGINE DISABLE SIGNAL POWERTRAIN...
Page 930 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 75 CIRCUIT FUNCTION 18DB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL 18DB/PK RADIATOR FAN RELAY CONTROL 18DB/YL AUTOMATIC SHUT DOWN RELAY CONTROL 18TN/RD SPEED CONTROL VACUUM SOLENOID CONTROL 18LG/RD SPEED CONTROL VENT SOLENOID CONTROL GRAY K106 18WT/DG LEAK DETECTION PUMP SOLENOID CONTROL 18YL/RD...
Page 931 8W - 80 - 76 8W-80 CONNECTOR PIN-OUTS CIRCUIT FUNCTION 20OR FUSED PANEL LAMPS DIMMER SWITCH SIGNAL 20BK GROUND PRNDL ILLUMINATION (A/T) LT.GRAY CIRCUIT FUNCTION C25 12LB RADIATOR FAN RELAY OUTPUT 12BK GROUND RADIATOR FAN MOTOR CIRCUIT FUNCTION BLACK 16DG/RD RADIO 12V OUTPUT 16BR/YL LEFT REAR SPEAKER (+)
Page 932 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 77 CIRCUIT FUNCTION F83 18YL/DG FUSED IGNITION SWITCH OUTPUT (RUN-ACC) L36 18LG/BK REAR FOG LAMP Z1 18BK GROUND L38 18BR/WT REAR FOG LAMP SWITCH OUTPUT L38 18BR/WT REAR FOG LAMP SWITCH OUTPUT L25 18BR FUSED B(+) REAR FOG LAMP RELAY...
Page 933 8W - 80 - 78 8W-80 CONNECTOR PIN-OUTS BLACK CIRCUIT FUNCTION 20BK GROUND 18BK/WT REAR WASHER MOTOR CONTROLLER 20OR FUSED PANEL LAMPS DIMMER SWITCH SIGNAL 18BR/LG REAR WIPER MOTOR CONTROL 18BR/PK FUSED IGNITION SWITCH OUTPUT (RUN) REAR WIPER/ FUSED IGNITION SWITCH OUTPUT (RUN) 18BR/PK WASHER SWITCH GRAY...
Page 934 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 79 BLACK CIRCUIT FUNCTION X80 18LB/BR RIGHT FRONT DOOR SPEAKER (-) X56 18DB/RD RIGHT FRONT DOOR SPEAKER (-) RIGHT FRONT DOOR SPEAKER (+) X82 18LB/RD RIGHT FRONT RIGHT FRONT DOOR SPEAKER (+) X54 18VT DOOR SPEAKER BLACK CIRCUIT...
Page 935 8W - 80 - 80 8W-80 CONNECTOR PIN-OUTS GRAY CIRCUIT FUNCTION Z1 18BK GROUND L60 18TN RIGHT TURN SIGNAL RIGHT FRONT TURN SIGNAL LAMP NO.2 (BUILT-UP-EXPORT) CIRCUIT FUNCTION B6 18WT/DB RIGHT FRONT WHEEL SPEED SENSOR (-) B7 18WT RIGHT FRONT WHEEL SPEED SENSOR (+) RIGHT FRONT WHEEL SPEED SENSOR...
Page 936 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 81 CIRCUIT FUNCTION P138 18VT/LG RIGHT SEAT LOW HEAT LED DRIVER Z1 18BK GROUND F83 18YL/DG FUSED IGNITION SWITCH OUTPUT (RUN-ACC) RIGHT HEATED P140 18VT/BK RIGHT SEAT HIGH HEAT LED DRIVER SEAT SWITCH RIGHT SEAT HEATER SWITCH MUX P134 18TN/RD BLACK...
Page 937 8W - 80 - 82 8W-80 CONNECTOR PIN-OUTS CIRCUIT FUNCTION 20YL/DB REAR WHEEL SENSOR (-) 20YL REAR WHEEL SENSOR (+) RIGHT REAR WHEEL SPEED SENSOR BLACK CIRCUIT FUNCTION Q14 14GY POWER WINDOW RIGHT REAR B(+) UP Q24 14DG POWER WINDOW RIGHT REAR B(+) DOWN RIGHT REAR WINDOW MOTOR BLUE...
Page 938 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 83 CIRCUIT FUNCTION K167 20BR/YL SENSOR GROUND RIGHT SPEED V37 20RD/LG SPEED CONTROL SWITCH SIGNAL CONTROL SWITCH CIRCUIT FUNCTION Z1 18BK GROUND L78 18DG/YL FUSED HEADLAMP SWITCH OUTPUT L50 18WT/TN BRAKE LAMP SWITCH OUTPUT RIGHT TAIL/ STOP LAMP CIRCUIT...
Page 939 8W - 80 - 84 8W-80 CONNECTOR PIN-OUTS CIRCUIT FUNCTION P133 18TN/DG LEFT SEAT HEATER SWITCH MUX SENSOR FEED P141 18TN/LB BLACK P86 18PK/BK RIGHT HEAT ELEMENT OUTPUT F235 16RD B(+) TO HEATED SEAT MODULE FROM RELAY P87 18BK/OR LEFT HEAT ELEMENT OUTPUT B(+) TO HEATED SEAT MODULE FROM RELAY F235 16RD P144 18BK/YL...
Page 940 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 85 NATURAL CIRCUIT FUNCTION K167 20BR/YL SENSOR GROUND 18OR/DB THROTTLE POSITION SENSOR SIGNAL 20OR/DB THROTTLE POSITION SENSOR SIGNAL THROTTLE 20OR VOLT SUPPLY POSITION SENSOR CIRCUIT FUNCTION F20 18WT FUSED IGNITION SWITCH OUTPUT (ST-RUN) TORQUE CONVERTER K54 18OR/BK TORQUE CONVERTER CLUTCH SOLENOID CONTROL...
Page 941 8W - 80 - 86 8W-80 CONNECTOR PIN-OUTS BLACK CIRCUIT FUNCTION G107 20BK/RD 4WD SWITCH SENSE (PART-TIME) Z1 18BK GROUND GROUND Z1 20BK TRANSFER CASE SWITCH (231 4WD) BLACK CIRCUIT FUNCTION Z1 18BK GROUND G106 20BK/WT 4WD SWITCH SENSE (FULL-TIME) G107 20BK/RD 4WD SWITCH SENSE (PART-TIME) TRANSFER...
Page 942 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 87 CIRCUIT FUNCTION T31 20VT/LG INPUT SPEED SENSOR GROUND T52 20RD/BK INPUT SPEED SENSOR SIGNAL T13 20DB/BK OUTPUT SPEED SENSOR GROUND 20LG/WT OUTPUT SPEED SIGNAL 20WT/BK CCD BUS (-) BLACK CCD BUS (+) 20VT/BR 18VT TRS T3 SENSE...
Page 943 8W - 80 - 88 8W-80 CONNECTOR PIN-OUTS CIRCUIT FUNCTION BLACK L60 20TN RIGHT TURN SIGNAL L62 20BR/RD RIGHT TURN SIGNAL L55 20RD/WT COMBINATION FLASHER INPUT L6 20RD/WT FLASHER OUTPUT L12 20VT/TN HAZARD FLASHER SELECT SIGNAL L63 20DG/RD LEFT TURN SIGNAL TURN SIGNAL/ L61 20LG/WT LEFT TURN SIGNAL...
Page 944 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 89 CIRCUIT FUNCTION K6 18VT/OR 5V SUPPLY K167 18BR/YL SENSOR GROUND G7 18WT/OR VEHICLE SPEED SENSOR SIGNAL VEHICLE SPEED SENSOR (GAS) BLACK CIRCUIT FUNCTION 20BK GROUND 20BK/LB WASHER FLUID SWITCH SENSE WASHER FLUID LEVEL SWITCH BLACK CIRCUIT...
Page 946 8W - 90 CONNECTOR LOCA TIONS 8W - 90 - 1 8 W-9 0 CON N ECT OR LOCAT I ON S DESCRI PT I ON AN D OPERAT I ON ea ch sect ion for con n ect or n u m ber iden t ifica t ion . Refer t o t h e in dex for t h e pr oper figu r e n u m ber.
Page 947 8W - 90 - 2 8W - 90 CONNECTOR LOCA TIONS DESCRI PT I ON AN D OPERAT I ON (Cont inue d) Connector Color Location Fig. Connector Color Location Fig. Name/Number Name/Number C205 At Center 17, 18, C325 T/O Near Console Liftgate Grommet...
Page 948 8W - 90 CONNECTOR LOCA TIONS 8W - 90 - 3 DESCRI PT I ON AN D OPERAT I ON (Cont inue d) Connector Color Location Fig. Connector Color Location Fig. Name/Number Name/Number Controller At Controller 8, 9, Engine Control Rear of Engine Anti-Lock Brake Anti-Lock Brake...
Page 949 8W - 90 - 4 8W - 90 CONNECTOR LOCA TIONS DESCRI PT I ON AN D OPERAT I ON (Cont inue d) Connector Color Location Fig. Connector Color Location Fig. Name/Number Name/Number Fuel Pump Left Side of 36, 37 Generator At Generator 13, 14,...
Page 950 8W - 90 CONNECTOR LOCA TIONS 8W - 90 - 5 DESCRI PT I ON AN D OPERAT I ON (Cont inue d) Connector Color Location Fig. Connector Color Location Fig. Name/Number Name/Number Junction Block - At Junction Left Heated At Seat Block Seat Cushion...
Page 951 8W - 90 - 6 8W - 90 CONNECTOR LOCA TIONS DESCRI PT I ON AN D OPERAT I ON (Cont inue d) Connector Color Location Fig. Connector Color Location Fig. Name/Number Name/Number Manifold At Throttle 13, 14, Power Antenna Rear of Engine Absolute Body...
Page 952 8W - 90 CONNECTOR LOCA TIONS 8W - 90 - 7 DESCRI PT I ON AN D OPERAT I ON (Cont inue d) Connector Color Location Fig. Connector Color Location Fig. Name/Number Name/Number Rear Fog Lamp Instrument Right Headlamp At Headlamp Switch Panel Leveling Motor...
Page 953 8W - 90 - 8 8W - 90 CONNECTOR LOCA TIONS DESCRI PT I ON AN D OPERAT I ON (Cont inue d) Connector Color Location Fig. Connector Color Location Fig. Name/Number Name/Number Seat Belt Switch Near Center 21, 22 Transmission Console Control...
Page 954 8W - 90 CONNECTOR LOCA TIONS 8W - 90 - 9 DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Page 955 8W - 90 - 10 8W - 90 CONNECTOR LOCA TIONS DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Page 956 8W - 90 CONNECTOR LOCA TIONS 8W - 90 - 11 DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Page 957 8W - 90 - 12 8W - 90 CONNECTOR LOCA TIONS DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Page 958 8W - 90 CONNECTOR LOCA TIONS 8W - 90 - 13 DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Page 959 8W - 90 - 14 8W - 90 CONNECTOR LOCA TIONS DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Page 960 8W - 90 CONNECTOR LOCA TIONS 8W - 90 - 15 DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Page 961 8W - 90 - 16 8W - 90 CONNECTOR LOCA TIONS DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Page 962 8W - 90 CONNECTOR LOCA TIONS 8W - 90 - 17 DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Page 963 8W - 90 - 18 8W - 90 CONNECTOR LOCA TIONS DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Page 964 8W - 90 CONNECTOR LOCA TIONS 8W - 90 - 19 DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Page 965 8W - 90 - 20 8W - 90 CONNECTOR LOCA TIONS DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Page 966 8W - 90 CONNECTOR LOCA TIONS 8W - 90 - 21 DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Page 967 8W - 90 - 22 8W - 90 CONNECTOR LOCA TIONS DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Page 968 8W - 90 CONNECTOR LOCA TIONS 8W - 90 - 23 DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Page 969 8W - 90 - 24 8W - 90 CONNECTOR LOCA TIONS DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Page 970 8W - 90 CONNECTOR LOCA TIONS 8W - 90 - 25 DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Page 971 8W - 90 - 26 8W - 90 CONNECTOR LOCA TIONS DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Page 972 8W - 90 CONNECTOR LOCA TIONS 8W - 90 - 27 DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Page 973 8W - 90 - 28 8W - 90 CONNECTOR LOCA TIONS DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Page 974 8W - 90 CONNECTOR LOCA TIONS 8W - 90 - 29 DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Page 975 8W - 90 - 30 8W - 90 CONNECTOR LOCA TIONS DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Page 976 8W - 90 CONNECTOR LOCA TIONS 8W - 90 - 31 DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Page 977 8W - 90 - 32 8W - 90 CONNECTOR LOCA TIONS DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Page 978 8W - 90 CONNECTOR LOCA TIONS 8W - 90 - 33 DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Page 979 8W - 90 - 34 8W - 90 CONNECTOR LOCA TIONS DESCRI PT I ON AN D OPERAT I ON (Cont inue d) Fig. 26 ABS G-Sensor...
Page 980 8W - 90 CONNECTOR LOCA TIONS 8W - 90 - 35 DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Page 981 8W - 90 - 36 8W - 90 CONNECTOR LOCA TIONS DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Page 982 8W - 90 CONNECTOR LOCA TIONS 8W - 90 - 37 DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Page 983 8W - 90 - 38 8W - 90 CONNECTOR LOCA TIONS DESCRI PT I ON AN D OPERAT I ON (Cont inue d) Fig. 30 Liftgate...
Page 984 8W - 90 CONNECTOR LOCA TIONS 8W - 90 - 39 DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Page 985 8W - 90 - 40 8W - 90 CONNECTOR LOCA TIONS DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Page 986 8W - 90 CONNECTOR LOCA TIONS 8W - 90 - 41 DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Page 987 8W - 90 - 42 8W - 90 CONNECTOR LOCA TIONS DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Page 988 8W - 90 CONNECTOR LOCA TIONS 8W - 90 - 43 DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Page 989 8W - 90 - 44 8W - 90 CONNECTOR LOCA TIONS DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Page 990 8W - 90 CONNECTOR LOCA TIONS 8W - 90 - 45 DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Page 991 8W - 90 - 46 8W - 90 CONNECTOR LOCA TIONS DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Page 992 8W - 90 CONNECTOR LOCA TIONS 8W - 90 - 47 DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Page 994 8W - 95 SPLICE LOCA TIONS 8W - 95 - 1 8 W-9 5 SPLI CE LOCAT I ON S DESCRI PT I ON AN D OPERAT I ON sect ion for splice n u m ber iden t ifica t ion . Refer t o t h e in dex for pr oper splice n u m ber.
Page 995 8W - 95 - 2 8W - 95 SPLICE LOCA TIONS DESCRI PT I ON AN D OPERAT I ON (Cont inue d) Splice Number Location Fig. Splice Number Location Fig. S147 (Diesel) Left Rear of Engine 17,18 S212 (RHD) In Lower Instrument Compartment Panel Trough...
Page 996 8W - 95 SPLICE LOCA TIONS 8W - 95 - 3 DESCRI PT I ON AN D OPERAT I ON (Cont inue d) Splice Number Location Fig. Splice Number Location Fig. S305 Between Right Tail S334 Liftgate Lamp and Power Seat S335 Trailer Tow Harness S306...
Page 997 8W - 95 - 4 8W - 95 SPLICE LOCA TIONS DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Page 998 8W - 95 SPLICE LOCA TIONS 8W - 95 - 5 DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Page 999 8W - 95 - 6 8W - 95 SPLICE LOCA TIONS DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Page 1000 8W - 95 SPLICE LOCA TIONS 8W - 95 - 7 DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Page 1001 8W - 95 - 8 8W - 95 SPLICE LOCA TIONS DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Page 1002 8W - 95 SPLICE LOCA TIONS 8W - 95 - 9 DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Page 1003 8W - 95 - 10 8W - 95 SPLICE LOCA TIONS DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Page 1004 8W - 95 SPLICE LOCA TIONS 8W - 95 - 11 DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Page 1005 8W - 95 - 12 8W - 95 SPLICE LOCA TIONS DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Page 1006 8W - 95 SPLICE LOCA TIONS 8W - 95 - 13 DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Page 1007 8W - 95 - 14 8W - 95 SPLICE LOCA TIONS DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Page 1008 8W - 95 SPLICE LOCA TIONS 8W - 95 - 15 DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Page 1009 8W - 95 - 16 8W - 95 SPLICE LOCA TIONS DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Page 1010 8W - 95 SPLICE LOCA TIONS 8W - 95 - 17 DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Page 1011 8W - 95 - 18 8W - 95 SPLICE LOCA TIONS DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Page 1012 8W - 95 SPLICE LOCA TIONS 8W - 95 - 19 DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Page 1013 8W - 95 - 20 8W - 95 SPLICE LOCA TIONS DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Page 1014 8W - 95 SPLICE LOCA TIONS 8W - 95 - 21 DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Page 1015 8W - 95 - 22 8W - 95 SPLICE LOCA TIONS DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Page 1016 8W - 95 SPLICE LOCA TIONS 8W - 95 - 23 DESCRI PT I ON AN D OPERAT I ON (Cont inue d)
Page 1018 ENGINE 9 - 1 ENGINE CON T EN T S page page 2.5L ENGINE ......15 ENGINE DIAGNOSIS .
Page 1019 9 - 2 ENGINE GEN ERAL I N FORM AT I ON (Cont inue d) in ch ) dr op is pla ced in t h e cen t er of t h e ga sket con - t a per a n d ou t -of-r ou n d a s well a s r em ovin g ligh t t a ct a r ea .
Page 1020 ENGINE 9 - 3 GEN ERAL I N FORM AT I ON (Cont inue d) MEASURING WITH PLASTIGAGE CRANKSHAFT MAIN BEARING CLEARANCE E n gin e cr a n ksh a ft bea r in g clea r a n ces ca n be det er- m in ed by u se of P la st iga ge, or equ iva len t .
Page 1021 9 - 4 ENGINE GEN ERAL I N FORM AT I ON (Cont inue d) P la st iga ge in pla ce be a ssem bled. Tigh t en t h e r od ca p (1) P er for m t h e F u el P r essu r e Relea se P r ocedu r e n u t s t o r equ ir ed t or qu e.
Page 1022 ENGINE 9 - 5 GEN ERAL I N FORM AT I ON (Cont inue d) API SERVICE GRADE CERTIFIED Th e en gin e oil level in dica t or (Dipst ick) is loca t ed a t t h e r igh t r ea r of bot h 2.5L en gin es a n d 4.0L Use a n en gin e oil t h a t is AP I Ser vice Gr a de Cer t i- en gin es.
Page 1023 9 - 6 ENGINE GEN ERAL I N FORM AT I ON (Cont inue d) Fig. 7 Engine Oil Dipstick—4.0L Engine Fig. 8 Oil Filter—2.5L Engine (5) Rem ove dr a in plu g fr om cr a n kca se a n d a llow oil t o dr a in in t o pa n .
Page 1024 ENGINE 9 - 7 GEN ERAL I N FORM AT I ON (Cont inue d) USED ENGINE OIL DISPOSAL Ca r e sh ou ld be exer cised wh en disposin g u sed en gin e oil a ft er it h a s been dr a in ed fr om a veh icle en gin e.
Page 1025 9 - 8 ENGINE EN GI N E DI AGN OSI S INDEX page page DIAGNOSIS AND TESTING ENGINE OIL LEAK INSPECTION ... . 10 CYLINDER COMBUSTION PRESSURE ENGINE OIL PRESSURE ....10 LEAKAGE TEST .
Page 1026 ENGINE 9 - 9 DI AGN OSI S AN D T EST I N G (Cont inue d) • E xh a u st a n d in t a ke va lve lea ks (im pr oper sea t - CYLINDER-TO-CYLINDER LEAKAGE TEST in g).
Page 1027 9 - 10 ENGINE DI AGN OSI S AN D T EST I N G (Cont inue d) ENGINE OIL LEAK INSPECTION INSPECTION FOR REAR SEAL AREA LEAKS Sin ce it is som et im es difficu lt t o det er m in e t h e Begin wit h a t h or ou gh visu a l in spect ion of t h e sou r ce of a n oil lea k in t h e r ea r sea l a r ea of t h e en gin e, pa r t icu la r ly a t t h e a r ea of t h e su spect ed lea k.
Page 1028 ENGINE 9 - 11 DI AGN OSI S AN D T EST I N G (Cont inue d) SERVICE DIAGNOSIS—PERFORMANCE EN GI N E PERFORM AN CE DI AGN OSI S CH ART CONDITION POSSIBLE CAUSES CORRECTION ENGINE WILL NOT CRANK 1.
Page 1029 9 - 12 ENGINE DI AGN OSI S AN D T EST I N G (Cont inue d) CONDITION POSSIBLE CAUSES CORRECTION ENGINE STALLS OR ROUGH 1. Carbon build-up on throttle plate 1. Remove throttle body and IDLE de-carbon. (Refer to Group 14 for correct procedures) 2.
Page 1030: Lubrica Tion And Maintenance
ENGINE 9 - 13 DI AGN OSI S AN D T EST I N G (Cont inue d) SERVICE DIAGNOSIS—MECHANICAL EN GI N E M ECH AN I CAL DI AGN OSI S CH ART CONDITION POSSIBLE CAUSES CORRECTION NOISY VALVES/LIFTERS 1.
Page 1031 9 - 14 ENGINE DI AGN OSI S AN D T EST I N G (Cont inue d) CONDITION POSSIBLE CAUSES CORRECTION 4. Excessive main bearing clearance 4. Measure bearings for correct clearance. Repair as necessary 5. Excessive end play 5.
Page 1032 2.5L ENGINE 9 - 15 2 .5 L EN GI N E INDEX page page DESCRIPTION AND OPERATION INTAKE MANIFOLD—2.5L ENGINE ..29 ENGINE DESCRIPTION ....15 OIL PAN .
Page 1033 9 - 16 2.5L ENGINE DESCRI PT I ON AN D OPERAT I ON (Cont inue d) BUILD DA TE CODE LUBRICA TION SYSTEM Th e en gin e Bu ild Da t e Code is loca t ed on a A gea r —t ype posit ive displa cem en t...
Page 1034 2.5L ENGINE 9 - 17 DESCRI PT I ON AN D OPERAT I ON (Cont inue d) Oil Lubrication System—2.5L Engine...
Page 1035 9 - 18 2.5L ENGINE DESCRI PT I ON AN D OPERAT I ON (Cont inue d) OIL PUMP PRESSURE MU S T be re p la c e d a s c o m p le te s e ts . Tin coa t ed pist on s sh ou ld n ot be u sed a s r epla cem en t s for coa t ed Th e MINIMUM oil pu m p pr essu r e is 89.6 kP a (13 pist on s.
Page 1036 2.5L ENGINE 9 - 19 SERV I CE PROCEDU RES (Cont inue d) Fig. 4 Bore Gauge Fig. 6 Ring Side Clearance Measurement Rin g S id e Cle a ra n c e Me a s u re m e n t Top Com pr ession Rin g .
Page 1037 9 - 20 2.5L ENGINE SERV I CE PROCEDU RES (Cont inue d) Rin g Ga p Me a s u re m e n t Top Com pr ession Rin g ..0.229 t o 0.610 m m (0.0090 t o 0.0240 in ch ) Secon d Com pr ession Rin g .
Page 1038 2.5L ENGINE 9 - 21 SERV I CE PROCEDU RES (Cont inue d) Fig. 14 Locking Tab Inspection Fig. 15 Scoring Caused by Insufficient Lubrication or by Damaged Crankshaft Pin Journal Fig. 12 Ring Gap Orientation (4) Use pist on r in g com pr essor t o in st a ll t h e r od a n d pist on a ssem blies.
Page 1039 9 - 22 2.5L ENGINE SERV I CE PROCEDU RES (Cont inue d) (6) In st a ll bea r in g ca p a n d con n ect in g r od on t h e jou r n a l a n d t igh t en n u t s t o 45 N·m (33 ft . lbs.) t or qu e.
Page 1040 2.5L ENGINE 9 - 23 SERV I CE PROCEDU RES (Cont inue d) (11) F OR EXAMP LE: If t h e in it ia l clea r a n ce wa s 0.0762 m m (0.003 in ch ), 0.025 m m (0.001 in ch ) u n der size in ser t s wou ld r edu ce t h e clea r a n ce by 0.025 m m (0.001 in ch ).

Jeep Cherokee 1999 Electronic Service Manual

Differential and Driveline

Brakes

Clutch

Clutch

Cooling System

Cooling System

Ignition System

Instrument Panel Systems

Audio Systems

Wiper and Washer Systems

Passive Restraint Systems

Electrically Heated Systems

Power Lock Systems

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