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Chrysler Sebring 2005 Service Manual

Chrysler Sebring 2005 Service Manual

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Page 1 We lcome 2005 JR Se bring/Stratus Se dan and Se bring Conve rtible Te chnical Publications Click on the icon for the de sire d manual Service Manual Powertrain Body Chassis Transmission...
Page 2: Table Of Contents
TABLE OF CON T EN T S INTRODUCTION ............1 SYSTEM COVERAGE .
Page 3 TABLE OF CON T EN T S - Cont inue d TRANSMISSION - NGC P0122-THROTTLE POSITION SENSOR/APPS LOW ......12 P0123-THROTTLE POSITION SENSOR/APPS HIGH .
Page 4 TABLE OF CON T EN T S - Cont inue d *NO MANUAL AUTOSTICK OPERATION ........157 *PRNDL FAULT CLEARING PROCEDURE.
Page 5 NOTES...
Page 6: Introduction
GEN ERAL I N FORM AT I ON 1 .0 I N T RODU CT I ON 1.1 SYSTEM COVERAGE Th e dia gn ost ic pr ocedu r e m a n u a l cover s a ll 2005 NGC CONTROLLER J R veh icles equ ipped wit h a 40/41TE t r a n sa xle.
Page 7: Autostick Feature (If Equipped)
GEN ERAL I N FORM AT I ON Th e con t r ol m odu le con t in u ou sly ch ecks for elec- per a t u r e, a r e r ea son a bly a ccu r a t e, du r in g n or m a l t r ica l pr oblem s, m ech a n ica l pr oblem s, a n d som e oper a t ion .
Page 8: Hard Code
GEN ERAL I N FORM AT I ON 3.3.1 HARD CODE r isen by a t lea st 22°C (40° F ) fr om en gin e st a r t in g a n d r ea ch es a m in im u m t em per a t u r e of 71°C An y Dia gn ost ic Tr ou ble Code (DTC) t h a t is set (160°...
Page 9: Clutch Volumes
GEN ERAL I N FORM AT I ON To per for m t h e Qu ick Lea r n pr ocedu r e, t h e fol- Tra n s m is s io n Effe c ts : Th ese CVIs t h a t a r e ou t of lowin g con dit ion s m u st be m et .
Page 10: Using The Drbiii
GEN ERAL I N FORM AT I ON 1. Select Tr a n sm ission syst em , t h en Miscella n eou s 3.5.1 DRBIII DOES NOT POWER UP fu n ct ion s, t h en P in ion F a ct or. Th e DRBIII will (BLANK SCREEN) displa y t h e cu r r en t t ir e size.
Page 11: Disclaimers, Safety, And Warnings
GEN ERAL I N FORM AT I ON feedba ck fr om t h e sim u la t or is in dou bt , you ca n Befor e discon n ect in g a n y h ydr a u lic t u bes, h oses, ver ify t h e sim u la t or s oper a t ion by in st a llin g it on a a n d fit t in gs, be su r e t h a t t h e syst em is fu lly depr es- kn own good veh icle.
Page 12: Warnings
GEN ERAL I N FORM AT I ON Do n ot exceed t h e lim it s sh own in t h e t a ble. Th e u se of a fu se wit h a r a t in g ot h er t h a n in dica t ed •...
Page 13: Electronic Pinion Factor Warnings (If Applicable)
GEN ERAL I N FORM AT I ON E n gin e will n ot cr a n k in pa r k or n eu t r a l > Oh m m et er • Sh ift er will be a ble t o be m oved wit h ou t t h e key >...
Page 14: Definitions
GEN ERAL I N FORM AT I ON 6.2 DEFINITIONS Rever se Clu t ch S LP K Solen oid P a ck OB D II (EU RO S TAGE III OB D ) Trip - A veh icle S S V Solen oid Swit ch Va lve st a r t a n d dr ive cycle su ch t h a t a ll on ce per t r ip dia gn ost ic m on it or s h a ve r u n .
Page 15 NOTES...
Page 16: Diagnostic Information And Procedures
7 .0 DI AGN OST I C I N FORM AT I ON AN D PROCEDU RES...
Page 17: P0122-Throttle Position Sensor/Apps Low
T RAN SM I SSI ON - N GC S y m p to m : P 0122-THROTTLE P OS ITION S EN S OR/AP P S LOW Wh e n Mo n ito re d a n d S e t Co n d itio n : P 0122-THROTTLE P OS ITION S EN S OR/AP P S LOW Wh en Mon it or ed: Con t in u ou sly wit h t h e ign it ion on a n d en gin e r u n n in g.
Page 18 T RAN SM I SSI ON - N GC P 0122-THROTTLE P OS ITION S EN S OR/AP P S LOW — Co n tin u e d TES T ACTION AP P LICAB ILITY Wit h t h e DRBIII , r ecor d t h e E ATX E VE NT DATA t o h elp iden t ify t h e con dit ion s in wh ich t h e DTC wa s set .
Page 19: P0123-Throttle Position Sensor/Apps High
T RAN SM I SSI ON - N GC S y m p to m : P 0123-THROTTLE P OS ITION S EN S OR/AP P S HIGH Wh e n Mo n ito re d a n d S e t Co n d itio n : P 0123-THROTTLE P OS ITION S EN S OR/AP P S HIGH Wh en Mon it or ed: Con t in u ou sly wit h t h e ign it ion on a n d en gin e r u n n in g.
Page 20 T RAN SM I SSI ON - N GC P 0123-THROTTLE P OS ITION S EN S OR/AP P S HIGH — Co n tin u e d TES T ACTION AP P LICAB ILITY Wit h t h e DRBIII , r ecor d t h e E ATX E VE NT DATA t o h elp iden t ify t h e con dit ion s in wh ich t h e DTC wa s set .
Page 21: P0124-Throttle Position Sensor/Apps Intermittent
T RAN SM I SSI ON - N GC S y m p to m : P 0124-THROTTLE P OS ITION S EN S OR/AP P S IN TERMITTEN T Wh e n Mo n ito re d a n d S e t Co n d itio n : P 0124-THROTTLE P OS ITION S EN S OR/AP P S IN TERMITTEN T Wh en Mon it or ed: Con t in u ou sly wit h t h e ign it ion on a n d en gin e r u n n in g.
Page 22 T RAN SM I SSI ON - N GC P 0124-THROTTLE P OS ITION S EN S OR/AP P S IN TERMITTEN T — Co n tin u e d TES T ACTION AP P LICAB ILITY Wit h t h e DRBIII , r ecor d t h e E ATX E VE NT DATA t o h elp iden t ify t h e con dit ion s in wh ich t h e DTC wa s set .
Page 23: P0218-High Temperature Operation Activated
T RAN SM I SSI ON - N GC S y m p to m : P 0218-HIGH TEMP ERATU RE OP ERATION ACTIVATED Wh e n Mo n ito re d a n d S e t Co n d itio n : P 0218-HIGH TEMP ERATU RE OP ERATION ACTIVATED Wh en Mon it or ed: Wh en ever t h e en gin e is r u n n in g.
Page 24 T RAN SM I SSI ON - N GC P 0218-HIGH TEMP ERATU RE OP ERATION ACTIVATED — Co n tin u e d TES T ACTION AP P LICAB ILITY P er for m Tr a n sm ission Cooler F low Ch eck per t h e Ser vice In for m a t ion . Did t h e Tr a n sm ission Cooler F low Ch eck t est pa ss? →...
Page 25: P0562-Low Battery Voltage
T RAN SM I SSI ON - N GC S y m p to m : P 0562-LOW B ATTERY VOLTAGE Wh e n Mo n ito re d a n d S e t Co n d itio n : P 0562-LOW B ATTERY VOLTAGE Wh en Mon it or ed: Wit h t h e en gin e r u n n in g a n d t h e P CM h a s closed t h e Tr a n sm ission Con t r ol Rela y.
Page 26 T RAN SM I SSI ON - N GC P 0562-LOW B ATTERY VOLTAGE — Co n tin u e d TES T ACTION AP P LICAB ILITY N OTE: Lo w flu id le v e l c a n be th e c a u s e o f m a n y tra n s m is s io n p ro ble m s . If th e flu id le v e l is lo w lo c a te a n d re p a ir th e le a k th e n c h e c k a n d a d ju s t th e flu id le v e l p e r th e S e rv ic e In fo rm a tio n .
Page 27 T RAN SM I SSI ON - N GC P 0562-LOW B ATTERY VOLTAGE — Co n tin u e d TES T ACTION AP P LICAB ILITY Tu r n t h e ign it ion off t o t h e lock posit ion . Discon n ect t h e P CM h a r n ess con n ect or.
Page 28 T RAN SM I SSI ON - N GC P 0562-LOW B ATTERY VOLTAGE — Co n tin u e d TES T ACTION AP P LICAB ILITY Tu r n t h e ign it ion off t o t h e lock posit ion . Discon n ect t h e P CM h a r n ess con n ect or.
Page 29 T RAN SM I SSI ON - N GC P 0562-LOW B ATTERY VOLTAGE — Co n tin u e d TES T ACTION AP P LICAB ILITY Th e con dit ion s n ecessa r y t o set t h e DTC a r e n ot pr esen t a t t h is t im e. Usin g t h e sch em a t ics a s a gu ide, in spect t h e wir in g a n d con n ect or s specific t o t h is cir cu it .
Page 30: P0602-Control Module Programming Error
T RAN SM I SSI ON - N GC S y m p to m : P 0602-CON TROL MOD U LE P ROGRAMMIN G ERROR Wh e n Mo n ito re d a n d S e t Co n d itio n : P 0602-CON TROL MOD U LE P ROGRAMMIN G ERROR Wh en Mon it or ed: Con t in u ou sly Set Con dit ion : Th e DTC will a lwa ys ligh t t h e MIL, a n d is design ed t o sign a l t h e...
Page 31: P0604-Internal Tcm
T RAN SM I SSI ON - N GC S y m p to m Lis t: P 0604-IN TERN AL TCM P 0605-IN TERN AL TCM P 0613-IN TERN AL TCM Te s t N o te : All s y m p to m s lis te d a bo v e a re d ia g n o s e d u s in g th e s a m e te s ts . Th e title fo r th e te s ts w ill be P 0604-IN TERN AL TCM.
Page 32: P0706-Check Shifter Signal
T RAN SM I SSI ON - N GC S y m p to m : P 0706-CHECK S HIF TER S IGN AL Wh e n Mo n ito re d a n d S e t Co n d itio n : P 0706-CHECK S HIF TER S IGN AL Wh en Mon it or ed: Con t in u ou sly wit h t h e ign it ion on .
Page 33 T RAN SM I SSI ON - N GC P 0706-CHECK S HIF TER S IGN AL — Co n tin u e d TES T ACTION AP P LICAB ILITY N OTE: Lo w flu id le v e l c a n be th e c a u s e o f m a n y tra n s m is s io n p ro ble m s . If th e flu id le v e l is lo w lo c a te a n d re p a ir th e le a k th e n c h e c k a n d a d ju s t th e flu id le v e l p e r th e S e rv ic e In fo rm a tio n .
Page 34 T RAN SM I SSI ON - N GC P 0706-CHECK S HIF TER S IGN AL — Co n tin u e d TES T ACTION AP P LICAB ILITY Tu r n t h e ign it ion off t o t h e lock posit ion . Rem ove t h e St a r t er Rela y.
Page 35 T RAN SM I SSI ON - N GC P 0706-CHECK S HIF TER S IGN AL — Co n tin u e d TES T ACTION AP P LICAB ILITY Tu r n t h e ign it ion off t o t h e lock posit ion . Discon n ect t h e TRS h a r n ess con n ect or.
Page 36 T RAN SM I SSI ON - N GC P 0706-CHECK S HIF TER S IGN AL — Co n tin u e d TES T ACTION AP P LICAB ILITY Tu r n t h e ign it ion off t o t h e lock posit ion . Discon n ect t h e TRS h a r n ess con n ect or.
Page 37 T RAN SM I SSI ON - N GC P 0706-CHECK S HIF TER S IGN AL — Co n tin u e d TES T ACTION AP P LICAB ILITY Tu r n t h e ign it ion off t o t h e lock posit ion . Discon n ect t h e TRS h a r n ess con n ect or.
Page 38 T RAN SM I SSI ON - N GC P 0706-CHECK S HIF TER S IGN AL — Co n tin u e d TES T ACTION AP P LICAB ILITY Tu r n t h e ign it ion off t o t h e lock posit ion . Discon n ect t h e TRS h a r n ess con n ect or.
Page 39 T RAN SM I SSI ON - N GC P 0706-CHECK S HIF TER S IGN AL — Co n tin u e d TES T ACTION AP P LICAB ILITY Usin g t h e sch em a t ics a s a gu ide, in spect t h e wir in g a n d con n ect or s. Repa ir a s n ecessa r y.
Page 40: P0711-Transmission Temperature Sensor Performance
T RAN SM I SSI ON - N GC S y m p to m : P 0711-TRAN S MIS S ION TEMP ERATU RE S EN S OR P ERF ORMAN CE Wh e n Mo n ito re d a n d S e t Co n d itio n : P 0711-TRAN S MIS S ION TEMP ERATU RE S EN S OR P ERF ORMAN CE Wh en Mon it or ed: Con t in u ou sly wit h t h e ign it ion on a n d en gin e r u n n in g.
Page 41 T RAN SM I SSI ON - N GC P 0711-TRAN S MIS S ION TEMP ERATU RE S EN S OR P ERF ORMAN CE — Co n tin u e d TES T ACTION AP P LICAB ILITY Wit h t h e DRBIII , ch eck Tr a n sm ission DTC’s.
Page 42 T RAN SM I SSI ON - N GC P 0711-TRAN S MIS S ION TEMP ERATU RE S EN S OR P ERF ORMAN CE — Co n tin u e d TES T ACTION AP P LICAB ILITY Th e con dit ion s n ecessa r y t o set t h is DTC a r e n ot pr esen t a t t h is t im e.
Page 43: P0712-Transmission Temperature Sensor Low
T RAN SM I SSI ON - N GC S y m p to m : P 0712-TRAN S MIS S ION TEMP ERATU RE S EN S OR LOW Wh e n Mo n ito re d a n d S e t Co n d itio n : P 0712-TRAN S MIS S ION TEMP ERATU RE S EN S OR LOW Wh en Mon it or ed: Con t in u ou sly wit h t h e ign it ion on a n d en gin e r u n n in g.
Page 44 T RAN SM I SSI ON - N GC P 0712-TRAN S MIS S ION TEMP ERATU RE S EN S OR LOW — Co n tin u e d TES T ACTION AP P LICAB ILITY Wit h t h e DRBIII , Ch eck t h e STARTS SINCE SE T cou n t er for P 0712. N OTE: Th is c o u n te r o n ly a p p lie s to th e la s t D TC s e t.
Page 45 T RAN SM I SSI ON - N GC P 0712-TRAN S MIS S ION TEMP ERATU RE S EN S OR LOW — Co n tin u e d TES T ACTION AP P LICAB ILITY Usin g t h e sch em a t ics a s a gu ide, in spect t h e wir in g a n d con n ect or s. Repa ir a s n ecessa r y.
Page 46: P0713-Transmission Temperature Sensor High
T RAN SM I SSI ON - N GC S y m p to m : P 0713-TRAN S MIS S ION TEMP ERATU RE S EN S OR HIGH Wh e n Mo n ito re d a n d S e t Co n d itio n : P 0713-TRAN S MIS S ION TEMP ERATU RE S EN S OR HIGH Wh en Mon it or ed: Con t in u ou sly wit h t h e ign it ion on a n d en gin e r u n n in g.
Page 47 T RAN SM I SSI ON - N GC P 0713-TRAN S MIS S ION TEMP ERATU RE S EN S OR HIGH — Co n tin u e d TES T ACTION AP P LICAB ILITY Wit h t h e DRBIII , ch eck Tr a n sm ission DTC’s. Ar e t h er e a n y Speed Sen sor DTCs pr esen t ? →...
Page 48 T RAN SM I SSI ON - N GC P 0713-TRAN S MIS S ION TEMP ERATU RE S EN S OR HIGH — Co n tin u e d TES T ACTION AP P LICAB ILITY Tu r n t h e ign it ion off t o t h e lock posit ion . Discon n ect t h e P CM C4 h a r n ess con n ect or..
Page 49 T RAN SM I SSI ON - N GC P 0713-TRAN S MIS S ION TEMP ERATU RE S EN S OR HIGH — Co n tin u e d TES T ACTION AP P LICAB ILITY Th e con dit ion s n ecessa r y t o set t h is DTC a r e n ot pr esen t a t t h is t im e. Usin g t h e sch em a t ics a s a gu ide, in spect t h e wir in g a n d con n ect or s specific t o t h is cir cu it .
Page 50: P0714-Transmission Temperature Sensor Intermittent
T RAN SM I SSI ON - N GC S y m p to m : P 0714-TRAN S MIS S ION TEMP ERATU RE S EN S OR IN TERMITTEN T Wh e n Mo n ito re d a n d S e t Co n d itio n : P 0714-TRAN S MIS S ION TEMP ERATU RE S EN S OR IN TERMITTEN T Wh en Mon it or ed: Con t in u ou sly wit h t h e ign it ion on a n d en gin e r u n n in g.
Page 51 T RAN SM I SSI ON - N GC P 0714-TRAN S MIS S ION TEMP ERATU RE S EN S OR IN TERMITTEN T — Co n tin u e d TES T ACTION AP P LICAB ILITY Wit h t h e DRBIII , Ch eck t h e STARTS SINCE SE T cou n t er for P 0714. N OTE: Th is c o u n te r o n ly a p p lie s to th e la s t D TC s e t.
Page 52: P0715-Input Speed Sensor Error
T RAN SM I SSI ON - N GC S y m p to m : P 0715-IN P U T S P EED S EN S OR ERROR Wh e n Mo n ito re d a n d S e t Co n d itio n : P 0715-IN P U T S P EED S EN S OR ERROR Wh en Mon it or ed: Th e t r a n sm ission gea r r a t io is m on it or ed con t in u ou sly wh ile t h e t r a n sm ission is in gea r.
Page 53 T RAN SM I SSI ON - N GC P 0715-IN P U T S P EED S EN S OR ERROR — Co n tin u e d TES T ACTION AP P LICAB ILITY P la ce t h e sh ift er in pa r k. St a r t t h e en gin e.
Page 54 T RAN SM I SSI ON - N GC P 0715-IN P U T S P EED S EN S OR ERROR — Co n tin u e d TES T ACTION AP P LICAB ILITY Tu r n t h e ign it ion off t o t h e lock posit ion . Discon n ect t h e P CM h a r n ess con n ect or.
Page 55 T RAN SM I SSI ON - N GC P 0715-IN P U T S P EED S EN S OR ERROR — Co n tin u e d TES T ACTION AP P LICAB ILITY Tu r n t h e ign it ion off t o t h e lock posit ion . Discon n ect t h e P CM h a r n ess con n ect or.
Page 56: P0720-Output Speed Sensor Error
T RAN SM I SSI ON - N GC S y m p to m : P 0720-OU TP U T S P EED S EN S OR ERROR Wh e n Mo n ito re d a n d S e t Co n d itio n : P 0720-OU TP U T S P EED S EN S OR ERROR Wh en Mon it or ed: Th e t r a n sm ission gea r r a t io is m on it or ed con t in u ou sly wh ile t h e t r a n sm ission is in gea r.
Page 57 T RAN SM I SSI ON - N GC P 0720-OU TP U T S P EED S EN S OR ERROR — Co n tin u e d TES T ACTION AP P LICAB ILITY St a r t t h e en gin e in pa r k. Ra ise t h e dr ive wh eels off of t h e gr ou n d.
Page 58 T RAN SM I SSI ON - N GC P 0720-OU TP U T S P EED S EN S OR ERROR — Co n tin u e d TES T ACTION AP P LICAB ILITY Tu r n t h e ign it ion off t o t h e lock posit ion . Discon n ect t h e P CM h a r n ess con n ect or.
Page 59 T RAN SM I SSI ON - N GC P 0720-OU TP U T S P EED S EN S OR ERROR — Co n tin u e d TES T ACTION AP P LICAB ILITY Tu r n t h e ign it ion off t o t h e lock posit ion . Discon n ect t h e P CM h a r n ess con n ect or.
Page 60: P0725-Engine Speed Sensor Circuit
T RAN SM I SSI ON - N GC S y m p to m : P 0725-EN GIN E S P EED S EN S OR CIRCU IT Wh e n Mo n ito re d a n d S e t Co n d itio n : P 0725-EN GIN E S P EED S EN S OR CIRCU IT Wh en Mon it or ed: Wh en ever t h e en gin e is r u n n in g.
Page 61 T RAN SM I SSI ON - N GC P 0725-EN GIN E S P EED S EN S OR CIRCU IT — Co n tin u e d TES T ACTION AP P LICAB ILITY Wit h t h e DRBIII , r ea d E n gin e DTCs. Ar e t h er e a n y E n gin e DTC’s pr esen t ? →...
Page 62: P0731-Gear Ratio Error In 1St
T RAN SM I SSI ON - N GC S y m p to m : P 0731-GEAR RATIO ERROR IN 1S T Wh e n Mo n ito re d a n d S e t Co n d itio n : P 0731-GEAR RATIO ERROR IN 1S T Wh en Mon it or ed: Th e Tr a n sm ission gea r r a t io is m on it or ed con t in u ou sly wh ile t h e t r a n sm ission is in gea r.
Page 63 T RAN SM I SSI ON - N GC P 0731-GEAR RATIO ERROR IN 1S T — Co n tin u e d TES T ACTION AP P LICAB ILITY Wit h t h e DRBIII , r ea d Tr a n sm ission DTC’s. If a n y of t h ese DTC’s a r e pr esen t , per for m t h eir r espect ive t est s fir st .
Page 64: P0732-Gear Ratio Error In 2Nd
T RAN SM I SSI ON - N GC S y m p to m : P 0732-GEAR RATIO ERROR IN 2N D Wh e n Mo n ito re d a n d S e t Co n d itio n : P 0732-GEAR RATIO ERROR IN 2N D Wh en Mon it or ed: Th e Tr a n sm ission gea r r a t io is m on it or ed con t in u ou sly wh ile t h e Tr a n sm ission is in gea r.
Page 65 T RAN SM I SSI ON - N GC P 0732-GEAR RATIO ERROR IN 2N D — Co n tin u e d TES T ACTION AP P LICAB ILITY Wit h t h e DRBIII , r ea d Tr a n sm ission DTC’s. If a n y of t h ese DTC’s a r e pr esen t , per for m t h eir r espect ive t est s fir st .
Page 66 T RAN SM I SSI ON - N GC P 0732-GEAR RATIO ERROR IN 2N D — Co n tin u e d TES T ACTION AP P LICAB ILITY If t h er e a r e n o possible ca u ses r em a in in g, view r epa ir. Repa ir Repa ir in t er n a l t r a n sm ission per t h e Ser vice In for m a t ion .
Page 67: P0733-Gear Ratio Error In 3Rd
T RAN SM I SSI ON - N GC S y m p to m : P 0733-GEAR RATIO ERROR IN 3RD Wh e n Mo n ito re d a n d S e t Co n d itio n : P 0733-GEAR RATIO ERROR IN 3RD Wh en Mon it or ed: Th e Tr a n sm ission gea r r a t io is m on it or ed con t in u ou sly wh ile t h e Tr a n sm ission is in gea r.
Page 68 T RAN SM I SSI ON - N GC P 0733-GEAR RATIO ERROR IN 3RD — Co n tin u e d TES T ACTION AP P LICAB ILITY Wit h t h e DRBIII , r ea d Tr a n sm ission DTC’s. If a n y of t h ese DTC’s a r e pr esen t , per for m t h eir r espect ive t est s fir st .
Page 69 T RAN SM I SSI ON - N GC P 0733-GEAR RATIO ERROR IN 3RD — Co n tin u e d TES T ACTION AP P LICAB ILITY If t h er e a r e n o possible ca u ses r em a in in g, view r epa ir. Repa ir Repa ir in t er n a l t r a n sm ission per t h e Ser vice In for m a t ion .
Page 70: P0734-Gear Ratio Error In 4Th
T RAN SM I SSI ON - N GC S y m p to m : P 0734-GEAR RATIO ERROR IN 4TH Wh e n Mo n ito re d a n d S e t Co n d itio n : P 0734-GEAR RATIO ERROR IN 4TH Wh en Mon it or ed: Th e Tr a n sm ission gea r r a t io is m on it or ed con t in u ou sly wh ile t h e Tr a n sm ission is in gea r.
Page 71 T RAN SM I SSI ON - N GC P 0734-GEAR RATIO ERROR IN 4TH — Co n tin u e d TES T ACTION AP P LICAB ILITY Wit h t h e DRBIII , r ea d Tr a n sm ission DTC’s. If a n y of t h ese DTC’s a r e pr esen t , per for m t h eir r espect ive t est s fir st .
Page 72 T RAN SM I SSI ON - N GC P 0734-GEAR RATIO ERROR IN 4TH — Co n tin u e d TES T ACTION AP P LICAB ILITY If t h er e a r e n o possible ca u ses r em a in in g, view r epa ir. Repa ir Repa ir in t er n a l t r a n sm ission per t h e Ser vice In for m a t ion .
Page 73: P0736-Gear Ratio Error In Reverse
T RAN SM I SSI ON - N GC S y m p to m : P 0736-GEAR RATIO ERROR IN REVERS E Wh e n Mo n ito re d a n d S e t Co n d itio n : P 0736-GEAR RATIO ERROR IN REVERS E Wh en Mon it or ed: Th e Tr a n sm ission gea r r a t io is m on it or ed con t in u ou sly wh ile t h e Tr a n sm ission is in gea r.
Page 74 T RAN SM I SSI ON - N GC P 0736-GEAR RATIO ERROR IN REVERS E — Co n tin u e d TES T ACTION AP P LICAB ILITY Wit h t h e DRBIII , r ea d Tr a n sm ission DTC’s. If a n y of t h ese DTC’s a r e pr esen t , per for m t h eir r espect ive t est s fir st .
Page 75: P0740-Tcc Out Of Range
T RAN SM I SSI ON - N GC S y m p to m : P 0740-TCC OU T OF RAN GE Wh e n Mo n ito re d a n d S e t Co n d itio n : P 0740-TCC OU T OF RAN GE Wh en Mon it or ed: Th e Tor qu e Con ver t er Clu t ch (TCC) is in F E MCC or P E MCC, Tr a n s- m ission t em per a t u r e is h ot , E n gin e t em per a t u r e is gr ea t er t h a n 38°...
Page 76 T RAN SM I SSI ON - N GC P 0740-TCC OU T OF RAN GE — Co n tin u e d TES T ACTION AP P LICAB ILITY Wit h t h e DRBIII , r ea d Tr a n sm ission DTC’s Ar e t h e DTC’s P 0750 a n d/or P 0841 pr esen t a lso? →...
Page 77: P0750-Lr Solenoid Circuit
T RAN SM I SSI ON - N GC S y m p to m : P 0750-LR S OLEN OID CIRCU IT Wh e n Mo n ito re d a n d S e t Co n d itio n : P 0750-LR S OLEN OID CIRCU IT Wh en Mon it or ed: In it ia lly a t power-u p, t h en ever y 10 secon ds t h er ea ft er.
Page 78 T RAN SM I SSI ON - N GC P 0750-LR S OLEN OID CIRCU IT — Co n tin u e d TES T ACTION AP P LICAB ILITY Wit h t h e DRBIII , r ea d Tr a n sm ission DTC’s Ar e t h er e a n y Tr a n sm ission Con t r ol Rela y DTC’s pr esen t a lso? →...
Page 79 T RAN SM I SSI ON - N GC P 0750-LR S OLEN OID CIRCU IT — Co n tin u e d TES T ACTION AP P LICAB ILITY Tu r n t h e ign it ion off t o t h e lock posit ion . Discon n ect t h e P CM h a r n ess con n ect or.
Page 80 T RAN SM I SSI ON - N GC P 0750-LR S OLEN OID CIRCU IT — Co n tin u e d TES T ACTION AP P LICAB ILITY Usin g t h e sch em a t ics a s a gu ide, in spect t h e wir in g a n d con n ect or s. Repa ir a s n ecessa r y.
Page 81: P0755-2/4 Solenoid Circuit
T RAN SM I SSI ON - N GC S y m p to m : P 0755-2/4 S OLEN OID CIRCU IT Wh e n Mo n ito re d a n d S e t Co n d itio n : P 0755-2/4 S OLEN OID CIRCU IT Wh en Mon it or ed: In it ia lly a t power-u p, t h en ever y 10 secon ds t h er ea ft er.
Page 82 T RAN SM I SSI ON - N GC P 0755-2/4 S OLEN OID CIRCU IT — Co n tin u e d TES T ACTION AP P LICAB ILITY Wit h t h e DRBIII , r ea d Tr a n sm ission DTC’s Ar e t h er e a n y Tr a n sm ission Con t r ol Rela y DTC’s pr esen t a lso? →...
Page 83 T RAN SM I SSI ON - N GC P 0755-2/4 S OLEN OID CIRCU IT — Co n tin u e d TES T ACTION AP P LICAB ILITY Tu r n t h e ign it ion off t o t h e lock posit ion . Discon n ect t h e P CM h a r n ess con n ect or.
Page 84 T RAN SM I SSI ON - N GC P 0755-2/4 S OLEN OID CIRCU IT — Co n tin u e d TES T ACTION AP P LICAB ILITY Usin g t h e sch em a t ics a s a gu ide, in spect t h e wir in g a n d con n ect or s. Repa ir a s n ecessa r y.
Page 85: P0760-Od Solenoid Circuit
T RAN SM I SSI ON - N GC S y m p to m : P 0760-OD S OLEN OID CIRCU IT Wh e n Mo n ito re d a n d S e t Co n d itio n : P 0760-OD S OLEN OID CIRCU IT Wh en Mon it or ed: In it ia lly a t power-u p, t h en ever y 10 secon ds t h er ea ft er.
Page 86 T RAN SM I SSI ON - N GC P 0760-OD S OLEN OID CIRCU IT — Co n tin u e d TES T ACTION AP P LICAB ILITY Wit h t h e DRBIII , r ea d Tr a n sm ission DTC’s Ar e t h er e a n y Tr a n sm ission Con t r ol Rela y DTC’s pr esen t a lso? →...
Page 87 T RAN SM I SSI ON - N GC P 0760-OD S OLEN OID CIRCU IT — Co n tin u e d TES T ACTION AP P LICAB ILITY Tu r n t h e ign it ion off t o t h e lock posit ion . Discon n ect t h e P CM h a r n ess con n ect or.
Page 88 T RAN SM I SSI ON - N GC P 0760-OD S OLEN OID CIRCU IT — Co n tin u e d TES T ACTION AP P LICAB ILITY Usin g t h e sch em a t ics a s a gu ide, in spect t h e wir in g a n d con n ect or s. Repa ir a s n ecessa r y.
Page 89: P0765-Ud Solenoid Circuit
T RAN SM I SSI ON - N GC S y m p to m : P 0765-U D S OLEN OID CIRCU IT Wh e n Mo n ito re d a n d S e t Co n d itio n : P 0765-U D S OLEN OID CIRCU IT Wh en Mon it or ed: In it ia lly a t power-u p, t h en ever y 10 secon ds t h er ea ft er.
Page 90 T RAN SM I SSI ON - N GC P 0765-U D S OLEN OID CIRCU IT — Co n tin u e d TES T ACTION AP P LICAB ILITY Wit h t h e DRBIII , r ea d Tr a n sm ission DTC’s Ar e t h er e a n y Tr a n sm ission Con t r ol Rela y DTC’s pr esen t a lso? →...
Page 91 T RAN SM I SSI ON - N GC P 0765-U D S OLEN OID CIRCU IT — Co n tin u e d TES T ACTION AP P LICAB ILITY Tu r n t h e ign it ion off t o t h e lock posit ion . Discon n ect t h e P CM h a r n ess con n ect or.
Page 92 T RAN SM I SSI ON - N GC P 0765-U D S OLEN OID CIRCU IT — Co n tin u e d TES T ACTION AP P LICAB ILITY Usin g t h e sch em a t ics a s a gu ide, in spect t h e wir in g a n d con n ect or s. Repa ir a s n ecessa r y.
Page 93: P0841-Lr Pressure Switch Sense Circuit
T RAN SM I SSI ON - N GC S y m p to m : P 0841-LR P RES S U RE S WITCH S EN S E CIRCU IT Wh e n Mo n ito re d a n d S e t Co n d itio n : P 0841-LR P RES S U RE S WITCH S EN S E CIRCU IT Wh en Mon it or ed: Wh en ever t h e en gin e is r u n n in g.
Page 94 T RAN SM I SSI ON - N GC P 0841-LR P RES S U RE S WITCH S EN S E CIRCU IT — Co n tin u e d TES T ACTION AP P LICAB ILITY Wit h t h e DRBIII , r ea d Tr a n sm ission DTC’s Ar e t h er e a n y Tr a n sm ission Con t r ol Rela y DTC’s pr esen t a lso? →...
Page 95 T RAN SM I SSI ON - N GC P 0841-LR P RES S U RE S WITCH S EN S E CIRCU IT — Co n tin u e d TES T ACTION AP P LICAB ILITY Tu r n t h e ign it ion off t o t h e lock posit ion . Discon n ect t h e P CM h a r n ess con n ect or.
Page 96 T RAN SM I SSI ON - N GC P 0841-LR P RES S U RE S WITCH S EN S E CIRCU IT — Co n tin u e d TES T ACTION AP P LICAB ILITY Tu r n t h e ign it ion off t o t h e lock posit ion . Discon n ect t h e Tr a n sm ission Solen oid/P r essu r e Swit ch Assem bly h a r n ess con n ect or.
Page 97: P0845-2/4 Hydraulic Pressure Test Failure
T RAN SM I SSI ON - N GC S y m p to m : P 0845-2/4 HYD RAU LIC P RES S U RE TES T FAILU RE Wh e n Mo n ito re d a n d S e t Co n d itio n : P 0845-2/4 HYD RAU LIC P RES S U RE TES T FAILU RE Wh en Mon it or ed: In a n y for wa r d gea r wit h en gin e speed a bove 1000 RP M, sh or t ly a ft er a sh ift a n d ever y m in u t e t h er ea ft er.
Page 98 T RAN SM I SSI ON - N GC P 0845-2/4 HYD RAU LIC P RES S U RE TES T FAILU RE — Co n tin u e d TES T ACTION AP P LICAB ILITY N OTE: Lo w flu id le v e l c a n be th e c a u s e o f m a n y tra n s m is s io n p ro ble m s . If th e flu id le v e l is lo w lo c a te a n d re p a ir th e le a k th e n c h e c k a n d a d ju s t th e flu id le v e l p e r th e S e rv ic e In fo rm a tio n .
Page 99 T RAN SM I SSI ON - N GC P 0845-2/4 HYD RAU LIC P RES S U RE TES T FAILU RE — Co n tin u e d TES T ACTION AP P LICAB ILITY Tu r n t h e ign it ion off t o t h e lock posit ion . Rem ove t h e St a r t er Rela y.
Page 100 T RAN SM I SSI ON - N GC P 0845-2/4 HYD RAU LIC P RES S U RE TES T FAILU RE — Co n tin u e d TES T ACTION AP P LICAB ILITY Tu r n t h e ign it ion off t o t h e lock posit ion . Discon n ect t h e P CM h a r n ess con n ect or.
Page 101 T RAN SM I SSI ON - N GC P 0845-2/4 HYD RAU LIC P RES S U RE TES T FAILU RE — Co n tin u e d TES T ACTION AP P LICAB ILITY Usin g t h e sch em a t ics a s a gu ide, in spect t h e wir in g a n d con n ect or s. Repa ir a s n ecessa r y.
Page 102: P0846-2/4 Pressure Switch Sense Circuit
T RAN SM I SSI ON - N GC S y m p to m : P 0846-2/4 P RES S U RE S WITCH S EN S E CIRCU IT Wh e n Mo n ito re d a n d S e t Co n d itio n : P 0846-2/4 P RES S U RE S WITCH S EN S E CIRCU IT Wh en Mon it or ed: Wh en ever t h e en gin e is r u n n in g.
Page 103 T RAN SM I SSI ON - N GC P 0846-2/4 P RES S U RE S WITCH S EN S E CIRCU IT — Co n tin u e d TES T ACTION AP P LICAB ILITY Wit h t h e DRBIII , r ea d Tr a n sm ission DTC’s Ar e t h er e a n y Tr a n sm ission Con t r ol Rela y DTC’s pr esen t a lso? →...
Page 104 T RAN SM I SSI ON - N GC P 0846-2/4 P RES S U RE S WITCH S EN S E CIRCU IT — Co n tin u e d TES T ACTION AP P LICAB ILITY Tu r n t h e ign it ion off t o t h e lock posit ion . Discon n ect t h e P CM h a r n ess con n ect or.
Page 105 T RAN SM I SSI ON - N GC P 0846-2/4 P RES S U RE S WITCH S EN S E CIRCU IT — Co n tin u e d TES T ACTION AP P LICAB ILITY Usin g t h e sch em a t ics a s a gu ide, in spect t h e wir in g a n d con n ect or s. Repa ir a s n ecessa r y.
Page 106: P0870-Od Hydraulic Pressure Test Failure
T RAN SM I SSI ON - N GC S y m p to m : P 0870-OD HYD RAU LIC P RES S U RE TES T FAILU RE Wh e n Mo n ito re d a n d S e t Co n d itio n : P 0870-OD HYD RAU LIC P RES S U RE TES T FAILU RE Wh en Mon it or ed: In a n y for wa r d gea r wit h en gin e speed a bove 1000 RP M sh or t ly a ft er a sh ift a n d ever y m in u t e t h er ea ft er.
Page 107 T RAN SM I SSI ON - N GC P 0870-OD HYD RAU LIC P RES S U RE TES T FAILU RE — Co n tin u e d TES T ACTION AP P LICAB ILITY N OTE: Lo w flu id le v e l c a n be th e c a u s e o f m a n y tra n s m is s io n p ro ble m s . If th e flu id le v e l is lo w lo c a te a n d re p a ir th e le a k th e n c h e c k a n d a d ju s t th e flu id le v e l p e r th e S e rv ic e In fo rm a tio n .
Page 108 T RAN SM I SSI ON - N GC P 0870-OD HYD RAU LIC P RES S U RE TES T FAILU RE — Co n tin u e d TES T ACTION AP P LICAB ILITY Tu r n t h e ign it ion off t o t h e lock posit ion . Rem ove t h e St a r t er Rela y.
Page 109 T RAN SM I SSI ON - N GC P 0870-OD HYD RAU LIC P RES S U RE TES T FAILU RE — Co n tin u e d TES T ACTION AP P LICAB ILITY Tu r n t h e ign it ion off t o t h e lock posit ion . Discon n ect t h e P CM h a r n ess con n ect or.
Page 110 T RAN SM I SSI ON - N GC P 0870-OD HYD RAU LIC P RES S U RE TES T FAILU RE — Co n tin u e d TES T ACTION AP P LICAB ILITY Usin g t h e sch em a t ics a s a gu ide, in spect t h e wir in g a n d con n ect or s. Repa ir a s n ecessa r y.
Page 111: P0871-Od Pressure Switch Sense Circuit
T RAN SM I SSI ON - N GC S y m p to m : P 0871-OD P RES S U RE S WITCH S EN S E CIRCU IT Wh e n Mo n ito re d a n d S e t Co n d itio n : P 0871-OD P RES S U RE S WITCH S EN S E CIRCU IT Wh en Mon it or ed: Wh en ever t h e en gin e is r u n n in g.
Page 112 T RAN SM I SSI ON - N GC P 0871-OD P RES S U RE S WITCH S EN S E CIRCU IT — Co n tin u e d TES T ACTION AP P LICAB ILITY Wit h t h e DRBIII , r ea d Tr a n sm ission DTC’s Ar e t h er e a n y Tr a n sm ission Con t r ol Rela y DTC’s pr esen t a lso? →...
Page 113 T RAN SM I SSI ON - N GC P 0871-OD P RES S U RE S WITCH S EN S E CIRCU IT — Co n tin u e d TES T ACTION AP P LICAB ILITY Tu r n t h e ign it ion off t o t h e lock posit ion . Discon n ect t h e P CM h a r n ess con n ect or.
Page 114 T RAN SM I SSI ON - N GC P 0871-OD P RES S U RE S WITCH S EN S E CIRCU IT — Co n tin u e d TES T ACTION AP P LICAB ILITY Usin g t h e sch em a t ics a s a gu ide, in spect t h e wir in g a n d con n ect or s. Repa ir a s n ecessa r y.
Page 115: P0884-Power Up At Speed
T RAN SM I SSI ON - N GC S y m p to m : P 0884-P OWER U P AT S P EED Wh e n Mo n ito re d a n d S e t Co n d itio n : P 0884-P OWER U P AT S P EED Wh en Mon it or ed: Wh en t h e Tr a n sm ission Con t r ol Modu le in it ia lly power s u p.
Page 116: P0888-Relay Output Always Off
T RAN SM I SSI ON - N GC S y m p to m : P 0888-RELAY OU TP U T ALWAYS OF F Wh e n Mo n ito re d a n d S e t Co n d itio n : P 0888-RELAY OU TP U T ALWAYS OF F Wh en Mon it or ed: Con t in u ou sly Set Con dit ion : Th is DTC is set wh en less t h a n 3 volt s a r e pr esen t a t t h e Tr a n sm ission...
Page 117 T RAN SM I SSI ON - N GC P 0888-RELAY OU TP U T ALWAYS OF F — Co n tin u e d TES T ACTION AP P LICAB ILITY N OTE: Lo w flu id le v e l c a n be th e c a u s e o f m a n y tra n s m is s io n p ro ble m s . If th e flu id le v e l is lo w lo c a te a n d re p a ir th e le a k th e n c h e c k a n d a d ju s t th e flu id le v e l p e r th e S e rv ic e In fo rm a tio n .
Page 118 T RAN SM I SSI ON - N GC P 0888-RELAY OU TP U T ALWAYS OF F — Co n tin u e d TES T ACTION AP P LICAB ILITY Tu r n t h e ign it ion off t o t h e lock posit ion . In st a ll a su bst it u t e Rela y in pla ce of t h e Tr a n sm ission Con t r ol Rela y.
Page 119 T RAN SM I SSI ON - N GC P 0888-RELAY OU TP U T ALWAYS OF F — Co n tin u e d TES T ACTION AP P LICAB ILITY Tu r n t h e ign it ion off t o t h e lock posit ion . Discon n ect t h e P CM h a r n ess con n ect or.
Page 120 T RAN SM I SSI ON - N GC P 0888-RELAY OU TP U T ALWAYS OF F — Co n tin u e d TES T ACTION AP P LICAB ILITY Tu r n t h e ign it ion off t o t h e lock posit ion . Discon n ect t h e P CM h a r n ess con n ect or.
Page 121: P0890-Switched Battery
T RAN SM I SSI ON - N GC S y m p to m : P 0890-S WITCHED B ATTERY Wh e n Mo n ito re d a n d S e t Co n d itio n : P 0890-S WITCHED B ATTERY Wh en Mon it or ed: Wh en t h e ign it ion is t u r n ed fr om t h e off posit ion t o t h e r u n posit ion a n d/or t h e ign it ion is t u r n ed fr om t h e cr a n k posit ion t o t h e r u n posit ion .
Page 122 T RAN SM I SSI ON - N GC P 0890-S WITCHED B ATTERY — Co n tin u e d TES T ACTION AP P LICAB ILITY Wit h t h e DRBIII , Ch eck t h e STARTS SINCE SE T cou n t er for P 0890. N o te : Th is c o u n te r o n ly a p p lie s to th e la s t D TC s e t.
Page 123 T RAN SM I SSI ON - N GC P 0890-S WITCHED B ATTERY — Co n tin u e d TES T ACTION AP P LICAB ILITY Tu r n t h e ign it ion off t o t h e lock posit ion . Discon n ect t h e P CM h a r n ess con n ect or.
Page 124: P0891-Transmission Rly Always On
T RAN SM I SSI ON - N GC S y m p to m : P 0891-TRAN S MIS S ION RLY ALWAYS ON Wh e n Mo n ito re d a n d S e t Co n d itio n : P 0891-TRAN S MIS S ION RLY ALWAYS ON Wh en Mon it or ed: Wh en t h e ign it ion is t u r n ed fr om t h e off posit ion t o t h e r u n posit ion a n d/or t h e ign it ion is t u r n ed fr om t h e cr a n k posit ion t o t h e r u n posit ion .
Page 125 T RAN SM I SSI ON - N GC P 0891-TRAN S MIS S ION RLY ALWAYS ON — Co n tin u e d TES T ACTION AP P LICAB ILITY Wit h t h e DRBIII , Ch eck t h e STARTS SINCE SE T cou n t er for P 0891. N o te : Th is c o u n te r o n ly a p p lie s to th e la s t D TC s e t.
Page 126 T RAN SM I SSI ON - N GC P 0891-TRAN S MIS S ION RLY ALWAYS ON — Co n tin u e d TES T ACTION AP P LICAB ILITY Usin g t h e sch em a t ics a s a gu ide, in spect t h e wir in g a n d con n ect or s. Repa ir a s n ecessa r y.
Page 127: P0897-Worn Out/Burnt Transaxle Fluid
T RAN SM I SSI ON - N GC S y m p to m : P 0897-WORN OU T/B U RN T TRAN S AXLE F LU ID Wh e n Mo n ito re d a n d S e t Co n d itio n : P 0897-WORN OU T/B U RN T TRAN S AXLE F LU ID Wh en Mon it or ed: Wit h ea ch t r a n sit ion fr om fu ll Tor qu e Con ver t er t o pa r t ia l Tor qu e Con ver t er en ga gem en t for A/C bu m p pr even t ion .
Page 128 T RAN SM I SSI ON - N GC P 0897-WORN OU T/B U RN T TRAN S AXLE F LU ID — Co n tin u e d TES T ACTION AP P LICAB ILITY Tu r n t h e ign it ion off t o t h e lock posit ion . F lu sh t h e Tr a n sm ission Oil Cooler a n d lin es, r epla ce t h e Tr a n sm ission Oil F ilt er, r efill wit h n ew Tr a n sm ission F lu id, st a r t t h e en gin e, a n d a dju st t h e flu id per t h e Ser vice In for m a t ion .
Page 129: P0944-Loss Of Prime
T RAN SM I SSI ON - N GC S y m p to m : P 0944-LOS S OF P RIME Wh e n Mo n ito re d a n d S e t Co n d itio n : P 0944-LOS S OF P RIME Wh en Mon it or ed: If t h e t r a n sm ission is slippin g in a n y for wa r d gea r a n d t h e pr essu r e swit ch es a r e n ot in dica t in g pr essu r e, a loss of pr im e t est is r u n .
Page 130 T RAN SM I SSI ON - N GC P 0944-LOS S OF P RIME — Co n tin u e d TES T ACTION AP P LICAB ILITY P la ce t h e gea r select or in pa r k. St a r t t h e en gin e.
Page 131 T RAN SM I SSI ON - N GC P 0944-LOS S OF P RIME — Co n tin u e d TES T ACTION AP P LICAB ILITY If t h er e a r e n o possible ca u ses r em a in in g, view r epa ir. Repa ir Repla ce t h e Tr a n sm ission Oil P u m p per t h e Ser vice In for m a t ion .
Page 132: P0952-Autostick Input Circuit Low
T RAN SM I SSI ON - N GC S y m p to m : P 0952-AU TOS TICK IN P U T CIRCU IT LOW Wh e n Mo n ito re d a n d S e t Co n d itio n : P 0952-AU TOS TICK IN P U T CIRCU IT LOW Wh en Mon it or ed: Wh en ever t h e en gin e is r u n n in g.
Page 133 T RAN SM I SSI ON - N GC P 0952-AU TOS TICK IN P U T CIRCU IT LOW — Co n tin u e d TES T ACTION AP P LICAB ILITY Tu r n t h e ign it ion off t o t h e lock posit ion . Discon n ect t h e P CM h a r n ess con n ect or.
Page 134 T RAN SM I SSI ON - N GC P 0952-AU TOS TICK IN P U T CIRCU IT LOW — Co n tin u e d TES T ACTION AP P LICAB ILITY Th e con dit ion s n ecessa r y t o set t h is DTC a r e n ot pr esen t a t t h is t im e. Usin g t h e sch em a t ics a s a gu ide, in spect t h e wir in g a n d con n ect or s specific t o t h is cir cu it .
Page 135: P0992-2-4/Od Hydraulic Pressure Test Failure
T RAN SM I SSI ON - N GC S y m p to m : P 0992-2-4/OD HYD RAU LIC P RES S U RE TES T FAILU RE Wh e n Mo n ito re d a n d S e t Co n d itio n : P 0992-2-4/OD HYD RAU LIC P RES S U RE TES T FAILU RE Wh en Mon it or ed: In a n y for wa r d gea r wit h en gin e speed a bove 1000 RP M sh or t ly a ft er a sh ift a n d ever y m in u t e t h er ea ft er.
Page 136 T RAN SM I SSI ON - N GC P 0992-2-4/OD HYD RAU LIC P RES S U RE TES T FAILU RE — Co n tin u e d TES T ACTION AP P LICAB ILITY N OTE: Th e v e h ic le m u s t be d riv e n to s e t th is D TC. Th e tra n s m is s io n m u s t be w a rm o r h o t w ith th e En g in e RP M a bo v e 1000 RP M.
Page 137: P1652-Serial Communication Link Malfunction
T RAN SM I SSI ON - N GC S y m p to m : P 1652-S ERIAL COMMU N ICATION LIN K MALF U N CTION Wh e n Mo n ito re d a n d S e t Co n d itio n : P 1652-S ERIAL COMMU N ICATION LIN K MALF U N CTION Wh en Mon it or ed: Con t in u ou sly wit h en gin e r u n n in g.
Page 138 T RAN SM I SSI ON - N GC P 1652-S ERIAL COMMU N ICATION LIN K MALF U N CTION — Co n tin u e d TES T ACTION AP P LICAB ILITY Th e con dit ion s n ecessa r y t o set t h e DTC a r e n ot pr esen t a t t h is t im e. Ma ke su r e t o ch eck for a n y Com m u n ica t ion DTCs or cu st om er con cer n s of possible bu s pr oblem s.
Page 139: P1684-Battery Was Disconnected
T RAN SM I SSI ON - N GC S y m p to m : P 1684-B ATTERY WAS D IS CON N ECTED Wh e n Mo n ito re d a n d S e t Co n d itio n : P 1684-B ATTERY WAS D IS CON N ECTED Wh en Mon it or ed: Wh en ever t h e ign it ion is in t h e Ru n /St a r t posit ion .
Page 140 T RAN SM I SSI ON - N GC P 1684-B ATTERY WAS D IS CON N ECTED — Co n tin u e d TES T ACTION AP P LICAB ILITY H a s t h e ba t t er y been discon n ect ed, lost it ’s ch a r ge, or been r epla ced r ecen t ly? →...
Page 141 T RAN SM I SSI ON - N GC P 1684-B ATTERY WAS D IS CON N ECTED — Co n tin u e d TES T ACTION AP P LICAB ILITY Tu r n t h e ign it ion off t o t h e lock posit ion . Discon n ect t h e P CM h a r n ess con n ect or.
Page 142: P1687-No Communication With The Mic
T RAN SM I SSI ON - N GC S y m p to m : P 1687-N O COMMU N ICATION WITH THE MIC Wh e n Mo n ito re d a n d S e t Co n d itio n : P 1687-N O COMMU N ICATION WITH THE MIC Wh en Mon it or ed: Con t in u ou sly wit h en gin e r u n n in g.
Page 143 T RAN SM I SSI ON - N GC P 1687-N O COMMU N ICATION WITH THE MIC — Co n tin u e d TES T ACTION AP P LICAB ILITY Wit h t h e DRBIII , ch eck a ll of t h e ot h er m odu les on t h e veh icle for eviden ce of a veh icle bu s pr oblem .
Page 144: P1694-Bus Communication With Engine Module
T RAN SM I SSI ON - N GC S y m p to m : P 1694-B U S COMMU N ICATION WITH EN GIN E MOD U LE Wh e n Mo n ito re d a n d S e t Co n d itio n : P 1694-B U S COMMU N ICATION WITH EN GIN E MOD U LE Wh en Mon it or ed: Con t in u ou sly wit h ign it ion key on .
Page 145: P1775-Solenoid Switch Valve Latched In Tcc Position
T RAN SM I SSI ON - N GC S y m p to m : P 1775-S OLEN OID S WITCH VALVE LATCHED IN TCC P OS ITION Wh e n Mo n ito re d a n d S e t Co n d itio n : P 1775-S OLEN OID S WITCH VALVE LATCHED IN TCC P OS ITION Wh en Mon it or ed: Du r in g a n a t t em pt ed sh ift in t o 1st gea r.
Page 146 T RAN SM I SSI ON - N GC P 1775-S OLEN OID S WITCH VALVE LATCHED IN TCC P OS ITION — Co n tin u e d TES T ACTION AP P LICAB ILITY Wit h t h e DRBIII , ch eck for ot h er Tr a n sm ission DTC’s Is t h e DTC P 0841 pr esen t a lso? →...
Page 147 T RAN SM I SSI ON - N GC P 1775-S OLEN OID S WITCH VALVE LATCHED IN TCC P OS ITION — Co n tin u e d TES T ACTION AP P LICAB ILITY Tu r n t h e ign it ion off t o t h e lock posit ion . Discon n ect t h e P CM h a r n ess con n ect or.
Page 148 T RAN SM I SSI ON - N GC P 1775-S OLEN OID S WITCH VALVE LATCHED IN TCC P OS ITION — Co n tin u e d TES T ACTION AP P LICAB ILITY Tu r n t h e ign it ion off t o t h e lock posit ion . Discon n ect t h e Tr a n sm ission Solen oid/P r essu r e Swit ch Assem bly h a r n ess con n ect or.
Page 149: P1776-Solenoid Switch Valve Latched In Lr Position
T RAN SM I SSI ON - N GC S y m p to m : P 1776-S OLEN OID S WITCH VALVE LATCHED IN LR P OS ITION Wh e n Mo n ito re d a n d S e t Co n d itio n : P 1776-S OLEN OID S WITCH VALVE LATCHED IN LR P OS ITION Wh en Mon it or ed: Con t in u ou sly wh en doin g pa r t ia l or fu ll E MCC (P E MCC or F E MCC).
Page 150 T RAN SM I SSI ON - N GC P 1776-S OLEN OID S WITCH VALVE LATCHED IN LR P OS ITION — Co n tin u e d TES T ACTION AP P LICAB ILITY Wit h t h e DRBIII , ch eck for ot h er t r a n sm ission DTC’s Is t h e DTC P 0841 pr esen t a lso? →...
Page 151 T RAN SM I SSI ON - N GC P 1776-S OLEN OID S WITCH VALVE LATCHED IN LR P OS ITION — Co n tin u e d TES T ACTION AP P LICAB ILITY Rem ove t h e t r a n sm ission oil pa n a n d Va lve body a n d in spect t h e Solen oid Swit ch Va lve for st ickin g in it s bor e, r epa ir or r epla ce a s n ecessa r y.
Page 152 T RAN SM I SSI ON - N GC P 1776-S OLEN OID S WITCH VALVE LATCHED IN LR P OS ITION — Co n tin u e d TES T ACTION AP P LICAB ILITY Tu r n t h e ign it ion off t o t h e lock posit ion . Discon n ect t h e P CM h a r n ess con n ect or.
Page 153: P1790-Fault Immediately After Shift
T RAN SM I SSI ON - N GC S y m p to m : P 1790-FAU LT IMMED IATELY AF TER S HIF T Wh e n Mo n ito re d a n d S e t Co n d itio n : P 1790-FAU LT IMMED IATELY AF TER S HIF T Wh en Mon it or ed: Aft er a speed r a t io er r or is st or ed.
Page 154: P1793-Trd Link Communication Error
T RAN SM I SSI ON - N GC S y m p to m : P 1793-TRD LIN K COMMU N ICATION ERROR Wh e n Mo n ito re d a n d S e t Co n d itio n : P 1793-TRD LIN K COMMU N ICATION ERROR Wh en Mon it or ed: Th e Tr a n sm ission Con t r ol Modu le (TCM) pu lses t h e 12 volt TRD sign a l fr om t h e P ower t r a in Con t r ol Modu le (P CM) t o gr ou n d, du r in g t or qu e m a n a ged sh ift s wit h...
Page 155: P1794-Speed Sensor Ground Error
T RAN SM I SSI ON - N GC S y m p to m : P 1794-S P EED S EN S OR GROU N D ERROR Wh e n Mo n ito re d a n d S e t Co n d itio n : P 1794-S P EED S EN S OR GROU N D ERROR Wh en Mon it or ed: Th e t r a n sm ission gea r r a t io is m on it or ed con t in u ou sly wh ile t h e t r a n sm ission is in gea r.
Page 156 T RAN SM I SSI ON - N GC P 1794-S P EED S EN S OR GROU N D ERROR — Co n tin u e d TES T ACTION AP P LICAB ILITY Tu r n t h e ign it ion off t o t h e lock posit ion . Rem ove t h e St a r t er Rela y.
Page 157: P1797-Manual Shift Overheat
T RAN SM I SSI ON - N GC S y m p to m : P 1797-MAN U AL S HIF T OVERHEAT Wh e n Mo n ito re d a n d S e t Co n d itio n : P 1797-MAN U AL S HIF T OVERHEAT Wh en Mon it or ed: Wh en ever t h e en gin e is r u n n in g a n d t r a n sm ission is in t h e Au t oSt ick m ode.
Page 158 T RAN SM I SSI ON - N GC P 1797-MAN U AL S HIF T OVERHEAT — Co n tin u e d TES T ACTION AP P LICAB ILITY Th is is a n in for m a t ion a l DTC on ly. Wit h t h e DRBIII , ch eck t h e E ATX E VE NT DATA t o h elp iden t ify t h e con dit ion s in wh ich t h e DTC wa s set .
Page 159: Backup Lamps Come On While Shifter Is Not In Reverse Position
T RAN SM I SSI ON - N GC S y m p to m : *B ACKU P LAMP S COME ON WHILE S HIF TER IS N OT IN REVERS E P OS ITION P OS S IB LE CAU S ES INTE RMITTE NT WIRING AND CONNE CTORS BACKUP SUP P LY CIRCUIT SH ORT TO VOLTAGE TRANSMISSION RANGE SE NSOR...
Page 160: Backup Lamps Inoperative
T RAN SM I SSI ON - N GC S y m p to m : *B ACKU P LAMP S IN OP ERATIVE P OS S IB LE CAU S ES OP E N BACKUP LAMP BULB(S) BACKUP LAMP GROUND CIRCUIT OP E N BACKUP LAMP SUP P LY CIRCUIT OP E N F USE D IGNITION SWITCH OUTP UT CIRCUIT OP E N TRANSMISSION RANGE SE NSOR...
Page 161 T RAN SM I SSI ON - N GC *B ACKU P LAMP S IN OP ERATIVE — Co n tin u e d TES T ACTION AP P LICAB ILITY Tu r n t h e ign it ion off t o t h e lock posit ion . Discon n ect t h e TRS h a r n ess con n ect or.
Page 162: No Manual Autostick Operation
T RAN SM I SSI ON - N GC S y m p to m : *N O MAN U AL AU TOS TICK OP ERATION P OS S IB LE CAU S ES AUTOSTICK DOWNSH IF T SE NSE CIRCUIT OP E N AUTOSTICK GROUND CIRCUIT OP E N AUTOSTICK UP SH IF T SE NSE CIRCUIT OP E N F USE D IGNITION SWITCH OUTP UT CIRCUIT OP E N...
Page 163 T RAN SM I SSI ON - N GC *N O MAN U AL AU TOS TICK OP ERATION — Co n tin u e d TES T ACTION AP P LICAB ILITY Tu r n t h e ign it ion off t o t h e lock posit ion . Discon n ect t h e P CM h a r n ess con n ect or.
Page 164: Prndl Fault Clearing Procedure
T RAN SM I SSI ON - N GC S y m p to m : *P RN D L FAU LT CLEARIN G P ROCED U RE P OS S IB LE CAU S ES P RNDL FAULT CLE ARING P ROCE DURE TES T ACTION AP P LICAB ILITY...
Page 165: Transmission Noisy With No Dtc's Present
T RAN SM I SSI ON - N GC S y m p to m : *TRAN S MIS S ION N OIS Y WITH N O D TC’S P RES EN T P OS S IB LE CAU S ES INTE RNAL TRANSMISSION P ROBLE M - NOISY INTE RNAL TRANSMISSION P ROBLE M - NOISY WH ILE STANDING STILL TES T...
Page 166: Transmission Shifts Early With No Dtc's
T RAN SM I SSI ON - N GC S y m p to m : *TRAN S MIS S ION S HIF TS EARLY WITH N O D TC’S P OS S IB LE CAU S ES VE H ICLE BUS P ROBLE MS CH E CK F OR INTE RMITTE NT WIRING &...
Page 167: Transmission Simulator 8333 Will Not Power Up
T RAN SM I SSI ON - N GC S y m p to m : *TRAN S MIS S ION S IMU LATOR 8333 WILL N OT P OWER U P P OS S IB LE CAU S ES TRANSMISSION SIMULATOR WILL NOT P OWE R UP TES T ACTION...
Page 168: Verification Tests
VERI FI CAT I ON TEST S Ve rific a tio n Te s ts 40/41TE (N GC) TRAN S MIS S ION VERIF ICATION TES T - VER 1 AP P LICAB ILITY 1. N OTE: Afte r c o m p le tio n o f th e Tra n s m is s io n Ve rific a tio n Te s t, th e P o w e rtra in Ve rific a tio n Te s t m u s t be p e rfo rm e d .
Page 169 NOTES...
Page 170: Component Locations
COM PON EN T LOCAT I ON S 8 .0 COM PON EN T LOCAT I ON S 8.1 AUTOSTICK (IF EQUIPPED) 8.2 CONTROL MODULE LOCA TIONS EATX N GC 8.3 PRESSURE PORT LOCA TIONS...
Page 171: Transmission Component Locations
COM PON EN T LOCAT I ON S 8.4 TRANSMISSION COMPONENT LOCA TIONS...
Page 172: Connector Pinouts
CON N ECT OR PI N OU T S 9 .0 CON N ECT OR PI N OU T S AUTOSTICK SWITCH - NA TURAL 4 WA Y CIRCUIT FUNCTION T44 20YL (JR27) AUTOSTICK DOWNSHIFT SWITCH SIGNAL T44 20YL/LB (JR41) AUTOSTICK DOWNSHIFT SWITCH SIGNAL T5 20LG (JR27) AUTOSTICK UPSHIFT SWITCH SIGNAL...
Page 173 CON N ECT OR PI N OU T S...
Page 174: Fuses (Pdc)
CON N ECT OR PI N OU T S FUSES (PDC) FUSE AMPS FUSED CIRCUIT FUNCTION A2 12PK/BK FUSED B(+) F30 16RD FUSED B(+) A53 16RD/YL (JR41 EXPORT) FUSED B(+) A3 12RD/WT FUSED B(+) SPARE A4 12BK/PK FUSED B(+) A161 14LB/WT FUSED B(+) A1 18RD FUSED B(+)
Page 175: Powertrain Control Module C1 - Black/Black 38 Way
CON N ECT OR PI N OU T S POWERTRAIN CONTROL MODULE C1 - BLACK/BLACK 38 WA Y CIRCUIT FUNCTION Z12 16BK/TN GROUND F12 18DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) F11 18RD/WT FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) G7 18WT/OR (MTX) VEHICLE SPEED SIGNAL Z12 16BK/TN GROUND...
Page 176: Powertrain Control Module C2 - Black/Orange 38 Way
CON N ECT OR PI N OU T S POWERTRAIN CONTROL MODULE C2 - BLACK/ORANGE 38 WA Y CIRCUIT FUNCTION K96 18TN/LB (2.7L) COIL CONTROL NO. 6 K95 18TN/DG (2.7L) COIL CONTROL NO. 5 K94 18TN/LG (2.7L) COIL CONTROL NO. 4 K58 18BR/DB (2.7L) INJECTOR CONTROL NO.
Page 177: Powertrain Control Module C3 - Black/Natural 38 Way
CON N ECT OR PI N OU T S POWERTRAIN CONTROL MODULE C3 - BLACK/NA TURAL 38 WA Y CIRCUIT FUNCTION K51 20DB/VT AUTOMATIC SHUT DOWN RELAY CONTROL C27 20DB/PK HIGH SPEED RAD F AN RELAY CONTROL V35 20LG/RD S/C VENT CONTROL C24 20DB/TN LOW RAD F AN RELAY CONTROL V32 20YL/RD...
Page 178: Schematic Diagrams
SCH EM AT I C DI AGRAM S 1 0 .0 SCH EM AT I C DI AGRAM S 10.1 EA TX 40/41TE...
Page 179: Ngc 40/41Te
SCH EM AT I C DI AGRAM S 10.2 NGC 40/41TE...
Page 180: Charts And Graphs
CH ART S AN D GRAPH S 1 1 .0 CH ART S AN D GRAPH S 11.1 TRANSMISSION RANGE SENSOR STA TES 11.2 PRESSURE SWITCH STA TES...
Page 181: Solenoid Application Chart
CH ART S AN D GRAPH S 11.3 SOLENOID APPLICA TION CHART 11.4 SHIFT LEVER ERROR CODES 11.5 TRANSMISSION TEMPERA TURE SENSOR...
Page 182 GROUP TAB LOCATOR Introduction Lubrication & Maintenance Suspension Differential & Driveline Brakes Clutch Cooling Audio/Video Chime/Buzzer Electronic Control Modules Engine Systems Heated Systems Horn Ignition Control Instrument Cluster Lamps Message Systems Power Systems Restraints Speed Control Vehicle Theft Security Wipers/Washers Wiring Engine Exhaust System...
Page 184 INTRODUCTION INTRODUCTION TABLE OF CONTENTS page page BODY CODE PLATE TORQUE REFERENCES DESCRIPTION ......1 DESCRIPTION .
Page 185 INTRODUCTION BODY CODE PLATE (Continued) • EDV = 2.4L Four Cylinder 16 Valves DOHC DIGITS 7 THROUGH 23 High Output Turbo Gasoline Vehicle Identification Number • EDZ = 2.4L Four Cylinder 16 Valves DOHC Gas- • Refer to Vehicle Identification Number (VIN) oline paragraph for proper breakdown of VIN code.
Page 186 INTRODUCTION FASTENER IDENTIFICATION (Continued) BOLT MARKINGS AND TORQUES - U. S. CUSTOMARY Bolt Markings Grade 5 Grade 8 Bolt Dia. N·m Ft. Lbs N·m Ft. Lbs 1/4 - 20 125* 1/4 - 28 150* 5/16 - 18 200* 270* 5/16 - 24 240* 300* 3/8 - 16...
Page 187 INTRODUCTION FASTENER IDENTIFICATION (Continued) Fig. 2 FASTENER STRENGTH...
Page 188 INTRODUCTION FASTENER USAGE INTERNATIONAL SYMBOLS DESCRIPTION DESCRIPTION The graphic symbols illustrated in the following International Control and Display Symbols Chart are FASTENER USAGE used to identify various instrument controls. The symbols correspond to the controls and displays that WARNING: USE OF AN INCORRECT FASTENER are located on the instrument panel.
Page 189 INTRODUCTION METRIC SYSTEM (Continued) METRIC CONVERSION CHART...
Page 190 INTRODUCTION METRIC SYSTEM (Continued) CONVERSION FORMULAS AND EQUIVALENT VALUES MULTIPLY TO GET MULTIPLY TO GET in-lbs = Newton Meters N·m x 8.851 = in-lbs 0.11298 (N·m) ft-lbs = Newton Meters N·m = ft-lbs 1.3558 (N·m) 0.7376 Inches Hg (60° F) x 3.377 = Kilopascals (kPa) = Inches Hg...
Page 191 INTRODUCTION TORQUE REFERENCES Individual Torque Charts appear within many or the Groups. Refer to the Standard Torque Specifica- tions Chart for torque references not listed in the DESCRIPTION individual torque charts. TORQUE SPECIFICATIONS...
Page 192 INTERPRETATION CODE = DESCRIPTION Country of Origin 1 = Manufacture By DaimlerChrysler Corporation. Make B = Dodge C = Chrysler Vehicle Type 3 = Passenger Car Passenger Safety A = Active Front and Side Airbag D = Without Airbags E = Active Driver and Passenger Airbag...
Page 193 INTRODUCTION VEHICLE IDENTIFICATION NUMBER (Continued) POSITION INTERPRETATION CODE = DESCRIPTION Engines J = 2.4L 4 Cyl. 16V Pzev R = 2.7L 6 Cyl. 24V DOHC Gasoline S = 2.4L 4 Cyl. 16V DOHC Turbo Gasoline T = 2.7L 6 Cyl. 24V DOHC FFV X = 2.4L 4 Cyl.
Page 194 4 - AMENDMENT NUMBER VECI LABEL DESCRIPTION All models have a Vehicle Emission Control Infor- mation (VECI) Label. Chrysler permanently attaches the label in the engine compartment. It cannot be Fig. 6 MANUFACTURER PLATE removed without defacing information and destroying...
Page 196 LUBRICATION & MAINTENANCE 0 - 1 LUBRICATION & MAINTENANCE TABLE OF CONTENTS page page INTERNATIONAL SYMBOLS FLUID FILL/CHECK LOCATIONS DESCRIPTION ......1 DESCRIPTION .
Page 197 Only lubricants bearing designations defined by DaimlerChrysler Corporation vehicles. the following organization should be used to service a Only lubricants bearing designations defined by Chrysler Corporation vehicle. the following organization should be used. • Society of Automotive Engineers (SAE) • Society of Automotive Engineers (SAE) •...
Page 198 LUBRICATION & MAINTENANCE 0 - 3 FLUID TYPES (Continued) SYNTHETIC ENGINE OILS There are a number of engine oils being promoted as either synthetic or semi-synthetic. If you chose to use such a product, use o n ly those oils that are cer- tified by the American Petroleum Institute (API) to display the “Certification Mark”...
Page 199 0 - 4 LUBRICATION & MAINTENANCE FLUID TYPES (Continued) ENGINE COOLANT emergency, it should be replaced with the specified coolant as soon as possible. WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL FLEXIBLE FUEL VEHICLES (2.7L ENGINES BASE COOLANT AND IS HARMFUL IF SWAL- ONLY) LOWED OR INHALED.
Page 200 LUBRICATION & MAINTENANCE 0 - 5 FLUID TYPES (Continued) Engine Oil Selection for Operating on E-85 AUTOMATIC/MANUAL TRANSAXLE FLUID If vehicle operates on E-85 fuel either full or part- time, use only Mopar Flexible Fuel 5W-30 engine oil NOTE: All transaxles have a common transmission or an equivalent that meets DaimlerChrysler Stan- and differential sump.
Page 201 0 - 6 LUBRICATION & MAINTENANCE FLUID TYPES (Continued) SULFUR IN GASOLINE Poor quality gasoline can cause problems such as hard starting, stalling and hesitations. If you experi- If you live in the northeast United States, your ence these symptoms, try another brand of gasoline vehicle may have been designed to meet California before considering service for the vehicle.
Page 202 LUBRICATION & MAINTENANCE 0 - 7 FLUID TYPES (Continued) FLUID FILL/CHECK additives responsibility DaimlerChrysler Corporation and may not be covered LOCATIONS under the new vehicle warranty. DESCRIPTION NOTE: Intentional tampering with emissions control The fluid check/fill point locations are located in systems can result in civil penalties being assessed each applicable service manual section.
Page 203 0 - 8 LUBRICATION & MAINTENANCE MAINTENANCE SCHEDULES (Continued) Second is Schedule “A”. It is for vehicles that are • Check the automatic transmission fluid level. not operated under any of the conditions listed under • Check the brake master cylinder fluid level. Schedule B .
Page 204 LUBRICATION & MAINTENANCE 0 - 9 MAINTENANCE SCHEDULES (Continued) Miles 3,000 6,000 9,000 12,000 15,000 18,000 (Kilometers) (5 000) (29 000) 000) 000) 000) 000) Change engine oil and engine oil filter, if not replaced at 3 months. Inspect the air cleaner filter and replace if necessary.* Inspect the front and rear brake pads, linings, rotors, rear drums and shoes.
Page 205 0 - 10 LUBRICATION & MAINTENANCE MAINTENANCE SCHEDULES (Continued) Miles 57,000 60,000 63,000 66,000 69,000 72,000 (Kilometers) (91 000) (96 000) (101 000) (106 000) (110 000) (115 000) Change engine oil and engine oil filter, if not replaced at 3 months. Inspect the air cleaner filter and replace if necessary.* Replace the air cleaner filter.
Page 206 LUBRICATION & MAINTENANCE 0 - 11 MAINTENANCE SCHEDULES (Continued) Miles 93,000 96,000 99,000 100,000 102,000 105,000 (Kilometers) (149 000) (154 000) (158 000) (160 000) (163 000) (168 000) Change engine oil and engine oil filter, if not replaced at 3 months. Inspect the air cleaner filter and replace if necessary.* Replace the spark plugs on the 2.4 liter...
Page 207 0 - 12 LUBRICATION & MAINTENANCE MAINTENANCE SCHEDULES (Continued) Miles 126,000 129,000 132,000 135,000 138,000 141,000 (Kilometers) (203 000) (208 000) (212 000) (217 000) (222 000) (227 000) Change engine oil and engine oil filter, if not replaced at 3 months. Inspect the air cleaner filter and replace if necessary.* Inspect and check tension for power steering...
Page 208 LUBRICATION & MAINTENANCE 0 - 13 MAINTENANCE SCHEDULES (Continued) Miles 42,000 48,000 54,000 60,000 66,000 72,000 (Kilometers) (67 000) (77 000) (86 000) (96 000) (106 000) (115 000) [Months] [42] [48] [54] [60] [66] [72] Change engine oil and engine oil filter. Inspect the air cleaner filter and replace if required.* Replace the air cleaner filter.
Page 209 0 - 14 LUBRICATION & MAINTENANCE MAINTENANCE SCHEDULES (Continued) Miles 78,000 84,000 90,000 96,000 100,000 102,000 105,000 (Kilometers) (125 000) (134 000) (144 000) (154 000) (160 000) (163 000) (168 000) [Months] [78] [84] [90] [96] [102] [105] Replace the spark plugs on 2.4 liter engine.
Page 210 LUBRICATION & MAINTENANCE 0 - 15 MAINTENANCE SCHEDULES (Continued) NOTE: If ANY of these apply to you then flush and * This maintenance is recommended by the manu- replace the engine coolant every 160,000 km facture to the owner but is not required to maintain (100,000 miles) or 60 months, whichever comes the emissions warranty.
Page 211 0 - 16 LUBRICATION & MAINTENANCE MAINTENANCE SCHEDULES (Continued) SCHEDULE A Kilometers 12 000 24 000 36 000 48 000 60 000 (Miles) (7,500) (15,000) (22,500 (30,000) (37,500) [Months] [12] [18] [24] [30] Change engine oil and engine oil filter. Inspect the air cleaner filter and replace if necessary.* Replace the air cleaner filter.
Page 212 LUBRICATION & MAINTENANCE 0 - 17 MAINTENANCE SCHEDULES (Continued) Kilometers 132 000 144 000 156 000 160 000 168 000 (Miles) (82,000) (90,000) (97,500) (100,000) (105,000) [Months] [66] [72] [78] [84] Change engine oil and engine oil filter. Inspect the air cleaner filter and replace if required.* Replace the air cleaner filter.
Page 213 0 - 18 LUBRICATION & MAINTENANCE MAINTENANCE SCHEDULES (Continued) Kilometers 5 000 10 000 14 000 19 000 24 000 29 000 (Miles) (3,000) (6,000) (9,000) (12,000) (15,000) (18,000) Change engine oil and engine oil filter. Inspect the air cleaner filter and replace if necessary.* Inspect the front and rear brake pads, linings, rotors, rear drums and shoes.
Page 214 LUBRICATION & MAINTENANCE 0 - 19 MAINTENANCE SCHEDULES (Continued) Kilometers 91 000 96 000 101 000 106 000 110 000 115 000 (Miles) (57,000) (60,000) (63,000) (66,000) (69,000) (72,000) Change engine oil and engine oil filter. Inspect the air cleaner filter and replace if necessary.* Replace the air cleaner filter.
Page 215 0 - 20 LUBRICATION & MAINTENANCE MAINTENANCE SCHEDULES (Continued) Kilometers 149 000 154 000 158 000 160 000 163 000 168 000 (Miles) (93,000) (96,000) (99,000) (100,000) (102,000) (105,000) Change engine oil and engine oil filter. Inspect the air cleaner filter and replace if necessary.* Inspect the front and rear brake pads, linings, rotors, rear drums and shoes.
Page 216 LUBRICATION & MAINTENANCE 0 - 21 HOISTING (Continued) CAUTION: When using another vehicle as a booster, do not allow vehicles to touch. Electrical systems can be damaged on either vehicle. TO JUMP START A DISABLED VEHICLE: (1) Raise hood on disabled vehicle and visually inspect engine compartment for: •...
Page 217 0 - 22 LUBRICATION & MAINTENANCE JUMP STARTING (Continued) Do not allow weight of towed vehicle to bear on lower fascia, air dams, or spoilers. RECOMMENDED TOWING EQUIPMENT To avoid damage to bumper fascia and air dams use of a flat bed towing device or wheel lift (Fig. 9) is recommended.
Page 218 LUBRICATION & MAINTENANCE 0 - 23 TOWING (Continued) FLAT BED TOWING TIE DOWNS can be placed between the wheel lift device and the bottom of the fascia to prevent damage to vehicle during the lifting operation. The beam can removed CAUTION: Do not tie vehicle down by attaching after lifting the front of the vehicle.
Page 220 SUSPENSION 2 - 1 SUSPENSION TABLE OF CONTENTS page page SUSPENSION FRONT SUSPENSION ..... 1 STANDARD PROCEDURE - LUBRICATION REAR SUSPENSION .
Page 221 2 - 2 FRONT SUSPENSION ASSEMBLY - SHOCK ASSEMBLY ... 26 INSTALLATION - STABILIZER BAR BUSHING . 30 INSTALLATION - SHOCK ASSEMBLY ..28 UPPER BALL JOINT STABILIZER BAR DESCRIPTION...
Page 222 FRONT SUSPENSION 2 - 3 FRONT SUSPENSION (Continued) The upper control arm of the vehicle is mounted not be hoisted using equipment designed to lift a using rubber isolation bushings to an aluminum cast- vehicle by the rear axle. If this type of hoisting ing which is attached to the shock tower using 4 equipment is used, damage to rear suspension mounting bolts.
Page 223 2 - 4 FRONT SUSPENSION FRONT SUSPENSION (Continued) SPECIFICATIONS FRONT SUSPENSION FASTENER TORQUE DESCRIPTION TORQUE Shock Assembly Clevis Pinch Bolt 88 N·m (65 ft. lbs.) Shock Tower Bolts 101 N·m (75 ft. lbs.) Installer, Ball Joint 6758 Clevis To Control Arm 88 N·m (65 ft.
Page 224 FRONT SUSPENSION 2 - 5 FRONT SUSPENSION (Continued) Remover / Installer C-4366-2 (In Tool Kit C-4366) Remover, Tie Rod Receiver, Ball Joint 6756 Remover, Lower Ball Joint C-4150A Installer, Bushing 6760 Remover/Installer Control Arm Clevis Bushing 6877 Installer, Ball Joint Seal Boot Retainer 6875...
Page 225 2 - 6 FRONT SUSPENSION HUB / BEARING (3) Loosen hub nut with brakes applied. Th e h u b a n d d riv e s h a ft a re s p lin e d to g e th e r th ro u g h th e DESCRIPTION k n u c k le (be a rin g ) a n d re ta in e d by th e h u b n u t.
Page 226 FRONT SUSPENSION 2 - 7 HUB / BEARING (Continued) (6) Using a crow foot and torque wrench, tighten NOTE: Care must be taken not to separate drive- upper ball joint nut to 27 N·m (20 ft. lbs.) torque. shaft inner C/V joint during the following steps. Do (7) If equipped with antilock brakes, install wheel not allow driveshaft to hang by inner C/V joint;...
Page 227 2 - 8 FRONT SUSPENSION KNUCKLE (Continued) REMOVAL (1) Raise vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - SERVICE PROCE- DURE). (2) Remove front tire and wheel assembly from hub. CAUTION: Wheel bearing damage will result if hub nut is loosened, then vehicle is rolled on the ground or the weight of the vehicle is allowed to be supported by the tires.
Page 228 FRONT SUSPENSION 2 - 9 KNUCKLE (Continued) CAUTION: When striking the steering knuckle, do not hit the heat shield covering the ball joint grease seal. Bending the heat shield against the ball joint grease seal will cause the grease seal to fail. (9) Turn steering knuckle so front of it is facing as far outboard in wheel well as possible.
Page 229 2 - 10 FRONT SUSPENSION KNUCKLE (Continued) (3) Slide driveshaft into front hub/bearing assem- (11) Install front wheel and tire assembly. Install bly as steering knuckle is installed onto lower ball front wheel lug nuts and progressively tighten in joint stud. crisscross sequence to 135 N·m (100 ft.
Page 230 FRONT SUSPENSION 2 - 11 LOWER BALL JOINT SEAL (4) Using 2 screwdrivers (Fig. 13) remove the ball joint seal retaining ring from the bottom of the ball BOOT joint seal. REMOVAL CAUTION: The replacement of the lower ball joint seal boot can only be done in the event that the seal boot is damaged while performing a service procedure on the vehicle.
Page 231 2 - 12 FRONT SUSPENSION LOWER BALL JOINT SEAL BOOT (Continued) (4) Place Retaining Ring Installer, Special Tool, CAUTION: The ball joint used in the lower control 6875-1 over ball joint seal boot (Fig. 15). Using arm of this vehicle is a lubricated for life ball joint. adjusting knob, adjust tool so bottom edge of tool is This ball joint does not required any additional even with top of retaining ring groove in seal boot...
Page 232 FRONT SUSPENSION 2 - 13 LOWER BALL JOINT SEAL BOOT (Continued) Fig. 16 Retaining Ring And Expandable Collar Fig. 18 Retaining Ring Installed In Ball Joint Seal Installed On Tool Boot 1 - SPECIAL TOOL 6875 1 - LOWER CONTROL ARM 2 - LOWER CONTROL ARM 2 - SEAL BOOT RETAINING RING 3 - SEAL BOOT RETAINING RING...
Page 233 2 - 14 FRONT SUSPENSION LOWER CONTROL ARM (3) Remove nut attaching the outer tie rod to steering knuckle (Fig. 20). Re m o v e n u t fro m tie DESCRIPTION ro d e n d by h o ld in g tie ro d s tu d w ith a s o c k e t w h ile lo o s e n in g a n d re m o v in g n u t w ith w re n c h The lower control arm is a ductile iron casting (F ig .
Page 234 FRONT SUSPENSION 2 - 15 LOWER CONTROL ARM (Continued) (7) Remove shock absorber clevis to lower control CAUTION: No tool is to be inserted between the arm bushing, nut and thru-bolt. Separate clevis from steering knuckle and the lower ball joint to separate lower control arm (Fig.
Page 235 2 - 16 FRONT SUSPENSION LOWER CONTROL ARM (Continued) (9) Remove bolts attaching closest stabilizer bar (12) Remove nut and bolt attaching the front of bushing clamp to front suspension crossmember and lower control arm to front suspension crossmember body of vehicle (Fig. 25). (Fig.
Page 236 FRONT SUSPENSION 2 - 17 LOWER CONTROL ARM (Continued) DISASSEMBLY DISASSEMBLY - REAR ISOLATOR BUSHING To perform removal and replacement of the lower DISASSEMBLY - FRONT ISOLATOR BUSHING control arm isolator bushings, the lower control arm must be removed from the vehicle. To perform removal and replacement of the lower (1) Remove lower control arm assembly from vehi- control arm isolator bushings, the lower control arm...
Page 237 2 - 18 FRONT SUSPENSION LOWER CONTROL ARM (Continued) DISASSEMBLY - CLEVIS BUSHING (2) Start front bushing into lower control arm by h a n d , m a k in g s u re it is s qu a re w ith its m o u n t- To perform removal and replacement of the lower in g h o le in th e lo w e r c o n tro l a rm .
Page 238 FRONT SUSPENSION 2 - 19 LOWER CONTROL ARM (Continued) ASSEMBLY - REAR ISOLATOR BUSHING To perform removal and replacement of the lower control arm isolator bushings, the lower control arm must be removed from the vehicle. (1) Start rear bushing into lower control arm by h a n d , m a k in g s u re it is s qu a re w ith its m o u n tin g h o le in th e lo w e r c o n tro l a rm .
Page 239 2 - 20 FRONT SUSPENSION LOWER CONTROL ARM (Continued) (2) Mount Bushing Installer, Special Tool 6877 on joint stud castle nut (Fig. 21). D o n o t tig h te n n u t screw portion of Remover/Installer Special Tool a t th is tim e .
Page 240 FRONT SUSPENSION 2 - 21 LOWER CONTROL ARM (Continued) (15) Lower vehicle. CAUTION: When supporting lower control arm with (16) Check wheel alignment specifications and set jack stand, do not position jack stand under the ball front toe to preferred specifications. (Refer to 2 - joint cap on the lower control arm.
Page 241 2 - 22 FRONT SUSPENSION SHOCK ASSEMBLY (Continued) (2) Inspect for torn or damaged shock absorber dust boots (Fig. 38). (3) Lift the dust boot and inspect the shock absorber for evidence of fluid running from the upper end of fluid reservoir. (Actual leakage will be a stream of fluid running down the side and dripping off the lower end of the shock absorber).
Page 242 FRONT SUSPENSION 2 - 23 SHOCK ASSEMBLY (Continued) Fig. 39 Wheel Speed Sensor Cable Routing Bracket Fig. 41 Shock Absorber Clevis Bracket Pinch Bolt 1 - WHEEL SPEED SENSOR CABLE 1 - SHOCK ABSORBER ASSEMBLY 2 - SPEED SENSOR CABLE ROUTING BRACKET 2 - PINCH BOLT AND NUT 3 - STEERING KNUCKLE 3 - WHEEL SPEED SENSOR CABLE...
Page 243 2 - 24 FRONT SUSPENSION SHOCK ASSEMBLY (Continued) Fig. 43 Shock Assembly Attachment To Shock Tower 1 - SHOCK TOWER 2 - MOUNTING BOLTS DISASSEMBLY - SHOCK ASSEMBLY The shock assembly must be removed from the Fig. 44 Lower Hooks And Clamp vehicle for it to be disassembled and assembled.
Page 244 FRONT SUSPENSION 2 - 25 SHOCK ASSEMBLY (Continued) WARNING: DO NOT REMOVE THE SHOCK ROD NOTE: While removing the shock absorber from the NUT BEFORE THE COIL SPRING IS COMPRESSED. coil spring, the dust shield and cup may get caught THE COIL SPRING IS HELD UNDER PRESSURE inside coil spring requiring it to be left until the coil AND MUST BE COMPRESSED, REMOVING SPRING...
Page 245 2 - 26 FRONT SUSPENSION SHOCK ASSEMBLY (Continued) Fig. 48 Shock Absorber Rod Upper Isolator Bushing 1 - SHOCK ABSORBER/CONTROL ARM MOUNTING BRACKET 2 - SHOCK ABSORBER ROD UPPER ISOLATOR BUSHING Fig. 50 Shock Assembly Components 1 - SHOCK ABSORBER ROD BUSHING 2 - UPPER CONTROL ARM 3 - RETAINER WASHER 4 - COIL SPRING...
Page 246 FRONT SUSPENSION 2 - 27 SHOCK ASSEMBLY (Continued) (4) Place the dust shield and cup inside the coil NOTE: If installation of the upper control arm on the spring (Fig. 50). Secure the lower shock rod bushing upper mounting bracket is necessary, (Refer to 2 - retainer washer over the cup.
Page 247 2 - 28 FRONT SUSPENSION SHOCK ASSEMBLY (Continued) Fig. 53 Shock Absorber Rod Collar Installation Fig. 54 Clevis Correctly Installed On Shock Absorber 1 - COLLAR 2 - UNDERCUT 1 - SHOCK ABSORBER 3 - SHOCK ABSORBER ROD STEP 2 - SHOCK CLEVIS MUST BE INSTALLED FLUSH AGAINST LOCATING TAB HERE securing the shock absorber to the coil spring (Fig.
Page 248 FRONT SUSPENSION 2 - 29 SHOCK ASSEMBLY (Continued) REMOVAL REMOVAL - STABILIZER BAR (1) Raise vehicle on jack stands or centered on a frame contact type hoist. (Refer to LUBRICATION & MAINTENANCE/HOISTING - SERVICE PROCE- DURE). (2) Remove nuts and stabilizer bar attaching link assemblies from the front lower control arms (Fig.
Page 249 2 - 30 FRONT SUSPENSION STABILIZER BAR (Continued) (3) Align stabilizer bar attaching link assemblies with attaching link mounting holes in the lower con- trol arms. Install stabilizer bar attaching links into both lower control arms. Install the attaching link to lower control arm retaining nuts.
Page 250 FRONT SUSPENSION 2 - 31 UPPER CONTROL ARM DESCRIPTION The upper control arm is a high strength steel stamping. The upper control arm uses the 2 rubber bushings of the upper control arm/shock absorber mounting bracket to isolate it from the mounting bracket and the body of the vehicle.
Page 251 2 - 32 REAR SUSPENSION REAR SUSPENSION TABLE OF CONTENTS page page REAR SUSPENSION DIAGNOSIS AND TESTING - SHOCK DESCRIPTION - REAR SUSPENSION ..32 ASSEMBLY ......40 OPERATION - REAR SUSPENSION .
Page 252 REAR SUSPENSION 2 - 33 REAR SUSPENSION (Continued) CAUTION: Only frame contact or wheel lift hoisting DESCRIPTION TORQUE equipment can be used on vehicles having a fully Stud Nut 27 N·m (20 ft. lbs.) independent rear suspension. Vehicles with inde- Rear Suspension Crossmember: pendent rear suspension can not be hoisted using equipment designed to lift a vehicle by the rear...
Page 253 2 - 34 REAR SUSPENSION HUB / BEARING INSTALLATION (1) Install the hub and bearing assembly on the DESCRIPTION knuckle spindle. Install a NEW retaining nut. Tighten the retaining nut to a torque of 250 N·m The hub and bearing is a combined rear wheel hub (185 ft.
Page 254 REAR SUSPENSION 2 - 35 KNUCKLE (Continued) (3) If vehicle is equipped with antilock brakes (ABS), remove rear wheel speed sensor from brake flex hose routing bracket (Fig. 1). Fig. 2 Hub/Bearing Assembly Retaining Nut 1 - RETAINING NUT 2 - SPINDLE 3 - HUB/BEARING ASSEMBLY Fig.
Page 255 2 - 36 REAR SUSPENSION KNUCKLE (Continued) (10) Remove drum brake support plate, brake (12) Back off nut retaining upper control arm ball shoes wheel cylinder assembly/disc brake joint to knuckle until it is flush with the end of the adapter from knuckle.
Page 256 REAR SUSPENSION 2 - 37 KNUCKLE (Continued) (16) Remove the shock absorber clevis bracket to knuckle attaching nut and bolt (Fig. 8). Fig. 9 Trailing Link Bushing And Retainer Installation Fig. 8 Shock Absorber Attachment To Knuckle 1 - FORWARD LATERAL ARM 2 - REAR LATERAL ARM 1 - SHOCK ABSORBER CLEVIS BRACKET 3 - NUT...
Page 257 2 - 38 REAR SUSPENSION KNUCKLE (Continued) DIAGNOSIS AND TESTING - LATERAL LINKS (10) If equipped with ABS, install wheel speed sen- sor head (Fig. 10). Tighten speed sensor head mount- Inspect the lateral link isolator bushings and ing bolt to 7 N·m (60 in. lbs.) torque. sleeves for signs of damage or deterioration.
Page 258 REAR SUSPENSION 2 - 39 LATERAL LINK (Continued) Fig. 13 Rear Lateral Link Attachment To Knuckle Fig. 11 Stabilizer Bar To Lateral Link Attachment 1 - KNUCKLE 1 - WASHER 2 - ADJUSTING SCREW 2 - BOLT AND WASHER 3 - NUT 3 - KNUCKLE 4 - REAR LATERAL LINK 4 - STABILIZER BAR...
Page 259 2 - 40 REAR SUSPENSION LATERAL LINK (Continued) sequence until all nuts are torqued to half specifica- The components of the shock assembly listed below tion. Repeat the tightening sequence to the full spec- are serviceable: ified torque of 135 N·m (100 ft. lbs.). •...
Page 260 REAR SUSPENSION 2 - 41 SHOCK ASSEMBLY (Continued) (5) Remove the rear wheel and tire assembly from according to which side of the vehicle the shock was the vehicle. removed from, and which shock the coil spring was (6) Remove two fasteners holding the splash shield removed from.
Page 261 2 - 42 REAR SUSPENSION SHOCK ASSEMBLY (Continued) (11) Remove the jounce bumper and the collar • Check the upper and lower coil spring isolators (Fig. 17) from the rod of the shock absorber. for severe deterioration. • Inspect the dust shield for rips and deteriora- tion.
Page 262 REAR SUSPENSION 2 - 43 SHOCK ASSEMBLY (Continued) (8) Install the collar on the rod of the shock back the spring compressor upper and lower hooks, absorber assembly with the undercut side of sleeve then remove the shock assembly from the spring facing down (Fig.
Page 263 2 - 44 REAR SUSPENSION STABILIZER BAR (Continued) OPERATION Jounce and rebound movements affecting one rear wheel of the vehicle are partially transmitted to the opposite wheel of the vehicle through the stabilizer bar to stabilize body roll. DIAGNOSIS AND TESTING - STABILIZER BAR Inspect the stabilizer bar for damage or bending.
Page 264 REAR SUSPENSION 2 - 45 STABILIZER BAR (Continued) (3) Install the stabilizer bar onto the stabilizer bar (2) Remove rear wheel and tire assembly from the to forward lateral link attaching links (Fig. 21). vehicle. Install the stabilizer bar to attaching link bushings (3) At the knuckle, remove the nut, bushing on attaching links.
Page 265 2 - 46 REAR SUSPENSION TRAILING LINK (Continued) (1) Install the (black) inner bushing retainer, and CAUTION: The installation position of the bushings inner bushing (Fig. 27) on the trailing link. Install and retainers on the trailing link is important. When the trailing link, retainer and bushing on the hanger separating the trailing link from the hanger bracket, bracket (Fig.
Page 266 REAR SUSPENSION 2 - 47 TRAILING LINK (Continued) DIAGNOSIS AND TESTING - UPPER BALL (4) Install trailing link hanger bracket on vehicle and loosely install the 4 attaching bolts (Fig. 28). JOINT Then install 2 drift pins of appropriate size in posi- (1) Raise and support vehicle so that tires clear tioning holes on hanger bracket and into locating floor.
Page 267 2 - 48 REAR SUSPENSION UPPER CONTROL ARM (Continued) (1) Raise vehicle. (Refer to LUBRICATION & (5) Remove the rear exhaust pipe hanger bracket MAINTENANCE/HOISTING - STANDARD PROCE- from the rear suspension crossmember (Fig. 31). Let DURE). exhaust system drop down as far as possible. (2) Remove both rear wheel and tire assemblies from the vehicle.
Page 268 REAR SUSPENSION 2 - 49 UPPER CONTROL ARM (Continued) (7) If vehicle is equipped with antilock brakes, remove bolts and wheel speed sensor heads from both rear knuckles. (8) Remove both rear disc brake calipers from knuckles and hang out of way using wire or cord. (Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL/ BRAKE PADS/SHOES - REMOVAL).
Page 269 2 - 50 REAR SUSPENSION UPPER CONTROL ARM (Continued) (13) Lower the rear suspension crossmember far enough to access the upper control arm pivot bar to crossmember attaching bolts. (14) Remove the 2 bolts attaching the upper con- trol arm to the rear suspension crossmember (Fig. 36).
Page 270 REAR SUSPENSION 2 - 51 UPPER CONTROL ARM (Continued) Fig. 38 Installing Ball Joint In Upper Control Arm Fig. 39 Locating Rear Suspension Crossmember In Vehicle 1 - SPECIAL TOOL 6804 2 - BALL JOINT 1 - POSITIONING HOLE 3 - CONTROL ARM 2 - FRAME RAIL 4 - SPECIAL TOOL 6758 3 - REAR SUSPENSION CROSSMEMBER...
Page 271 2 - 52 WHEEL ALIGNMENT WHEEL ALIGNMENT TABLE OF CONTENTS page page WHEEL ALIGNMENT STANDARD PROCEDURE - CURB HEIGHT DESCRIPTION - WHEEL ALIGNMENT ..52 MEASUREMENT ..... . 57 DIAGNOSIS AND TESTING - SUSPENSION STANDARD PROCEDURE - WHEEL AND STEERING...
Page 272 WHEEL ALIGNMENT 2 - 53 WHEEL ALIGNMENT (Continued) CROSS CAMBER CROSS CASTER Cross camber is the difference between left and Cross caster is the difference between left and right camber. To achieve the cross camber reading, right caster. subtract the right side camber reading from the left. For example, if the left camber is +0.3°...
Page 273 2 - 54 WHEEL ALIGNMENT WHEEL ALIGNMENT (Continued) TOE-OUT ON TURNS STEERING AXIS INCLINATION (S. A. I.) Toe-out on turns is the relative positioning of the Steering axis inclination is the angle between a front wheels while steering through a turn (Fig. 4). true vertical line starting at the center of the tire at This compensates for each front wheel’s turning the road contact point and a line drawn through the...
Page 274 WHEEL ALIGNMENT 2 - 55 WHEEL ALIGNMENT (Continued) THRUST ANGLE Thrust angle is the averaged direction the rear wheels are pointing in relation to the vehicle’s center line (Fig. 6). The presence of negative or positive thrust angle causes the rear tires to track improperly to the left or right of the front tires (dog tracking).
Page 275 2 - 56 WHEEL ALIGNMENT WHEEL ALIGNMENT (Continued) CONDITION POSSIBLE CAUSES POTENTIAL CORRECTIONS 2. Incorrect Wheel Alignment 2. Check And Reset Wheel Alignment 3. Worn Tires 3. Replace Tires Front End Growl Or 1. Engine Mount Grounding 1. Reposition Engine As Required Grinding With Vehicle Going Straight At A Constant Speed...
Page 276 WHEEL ALIGNMENT 2 - 57 WHEEL ALIGNMENT (Continued) CONDITION POSSIBLE CAUSES POTENTIAL CORRECTIONS 4. Loose Or Worn Steering Shaft 4. Replace Steering Shaft Coupler Coupler Excessive Steering Effort 1. Low Tire Pressure 1. Inflate All Tires To Recommended Pressure 2. Lack Of Lubricant In Steering 2.
Page 277 2 - 58 WHEEL ALIGNMENT WHEEL ALIGNMENT (Continued) CURB HEIGHT SPECIFICATIONS VEHICLE FRONT REAR 705 mm ± 12 mm 710 mm ± 12 mm 27.75 in. ± 0.47 in. 28.0 in. ± 0.47 in. STANDARD PROCEDURE - WHEEL ALIGNMENT on a particular vehicle, look for the presence of an adjusting screw on the forward lateral links as well (1) Position the vehicle on an alignment rack.
Page 278 WHEEL ALIGNMENT 2 - 59 WHEEL ALIGNMENT (Continued) tighten all lateral link adjusting screw jam nuts to CAUTION: Do not attempt to move the adjusting 92 N·m (68 ft. lbs.) torque. This will securely hold the screws without properly loosening the jam nuts. adjusting screws from turning.
Page 279 2 - 60 WHEEL ALIGNMENT WHEEL ALIGNMENT (Continued) allow adequate space for removal of the plastic locat- (2) Loosen front inner to outer tie rod end jam ing pins that align the upper mounting bracket with nuts (Fig. 10). the shock tower. (4) Remove and discard both plastic locating pins from the shock assembly upper mounting bracket using a punch or pliers.
Page 280 WHEEL ALIGNMENT 2 - 61 WHEEL ALIGNMENT (Continued) SPECIFICATIONS NOTE: All wheel alignments are to be set with the vehicle at its proper curb height. (Refer to 2 - SUS- WHEEL ALIGNMENT PENSION/WHEEL ALIGNMENT - STANDARD PRO- CEDURE). NOTE: All specifications are given in degrees. FRONT WHEEL PREFERRED SETTING ACCEPTABLE RANGE...
Page 282 DIFFERENTIAL & DRIVELINE 3 - 1 DIFFERENTIAL & DRIVELINE TABLE OF CONTENTS page HALF SHAFT ......1 HALF SHAFT TABLE OF CONTENTS page...
Page 283 3 - 2 HALF SHAFT HALF SHAFT (Continued) Fig. 1 Unequal Length Halfshaft System 1 - STUB AXLE 8 - OUTER C/V JOINT 2 - OUTER C/V JOINT 9 - RIGHT HALFSHAFT 3 - OUTER C/V JOINT BOOT 10 - INNER TRIPOD JOINT BOOT 4 - TUNED RUBBER DAMPER WEIGHT 11 - INNER TRIPOD JOINT 5 - INTERCONNECTING SHAFT...
Page 284 HALF SHAFT 3 - 3 HALF SHAFT (Continued) REMOVAL (6) Remove the tie rod-to-steering knuckle nut (Fig. 4). Re m o v e n u t fro m tie ro d e n d by h o ld in g (1) Raise vehicle on hoist.
Page 285 3 - 4 HALF SHAFT HALF SHAFT (Continued) (8) Remove halfshaft-to-hub bearing CAUTION: No tool is to be inserted between the retaining nut (Fig. 6). steering knuckle and the lower ball joint to separate stud of lower ball joint from the steering knuckle. The steering knuckle is to be separated from the stud of the ball joint only using the procedure as described in Step 10.
Page 286 HALF SHAFT 3 - 5 HALF SHAFT (Continued) (11) Separate halfshaft from steering knuckle (Fig. CAUTION: When inserting pry bar between inner tri- 9). If d iffic u lty is e n c o u n te re d s e p a ra tin g h a lf- pod joint and transaxle case, care must be used to s h a ft fro m k n u c k le , D O N OT s trik e h a lfs h a ft ensure no damage occurs to oil seal in transaxle...
Page 287 3 - 6 HALF SHAFT HALF SHAFT (Continued) (13) Hold inner tripod joint and interconnecting shaft of driveshaft assembly. Remove inner tripod joint from transaxle, by pulling it straight out of transaxle side gear and transaxle oil seal (Fig. 12). Wh e n re m o v in g trip o d jo in t, d o n o t le t s p lin e o r s n a p rin g d ra g a c ro s s s e a lin g lip o f th e tra n s - a x le to trip o d jo in t o il s e a l.
Page 288 HALF SHAFT 3 - 7 HALF SHAFT (Continued) (7) Install the steering knuckle to ball joint stud castle nut (Fig. 15). Tighten the castle nut to 95 N·m (70 ft. lbs.). Fig. 17 Torquing Tie Rod End Nut 1 - HEAT SHIELD 2 - OUTER TIE ROD 3 - STEERING KNUCKLE Fig.
Page 289 3 - 8 HALF SHAFT HALF SHAFT (Continued) (11) Clean all foreign matter from the threads of (12) Install front wheel and tire assembly. Install the outer C/V joint stub axle. Install hub nut onto front wheel lug nuts and tighten in the correct threads of halfshaft (Fig.
Page 290 HALF SHAFT 3 - 9 HALF SHAFT (Continued) SPECIFICATIONS - HALFSHAFT TORQUE SPECIFICATIONS DESCRIPTION N·m Ft. Lbs. In. Lbs. Nut, Ball Joint-to-Knuckle — Nut, Halfshaft-to-Hub/ — Bearing Nut, Tie Rod-to-Knuckle — Nut, Wheel-to-Hub — CV BOOT - INNER SPECIAL TOOLS HALFSHAFT REMOVAL (1) Remove large boot clamp which retains inner...
Page 291 3 - 10 HALF SHAFT CV BOOT - INNER (Continued) (3) Remove snap ring which retains spider assem- (4) Slide sealing boot off interconnecting shaft. bly to interconnecting shaft (Fig. 23). Remove the (5) Thoroughly clean and inspect spider assembly, spider assembly from interconnecting shaft.
Page 292 HALF SHAFT 3 - 11 CV BOOT - INNER (Continued) (2) Install spider assembly onto interconnecting (3) Install the spider assembly to interconnecting shaft (Fig. 26). Spider assembly must be installed on shaft retaining snap ring into groove on end of inter- interconnecting shaft far enough to fully install spi- connecting shaft (Fig.
Page 293 3 - 12 HALF SHAFT CV BOOT - INNER (Continued) (6) Install inner tripod joint seal boot to intercon- (8) Position sealing boot into the tripod housing necting shaft clamp evenly on sealing boot. retaining groove. Install seal boot retaining clamp (7) Clamp sealing boot onto interconnecting shaft evenly on sealing boot.
Page 294 HALF SHAFT 3 - 13 CV BOOT - INNER (Continued) (10) With trim stick inserted between sealing boot and tripod joint housing, position the interconnecting shaft so it is at the center of its travel in the tripod joint housing. Remove the trim stick from between the sealing boot and the tripod joint housing.
Page 295 3 - 14 HALF SHAFT CV BOOT - INNER (Continued) (2) Wipe away grease to expose outer C/V joint and interconnecting shaft. (3) Remove outer C/V joint from interconnecting shaft using the following procedure: Support inter- connecting shaft in a vise e qu ip p e d w ith p ro te c - tiv e c a p s o n ja w s o f v is e to p re v e n t d a m a g e to in te rc o n n e c tin g s h a ft.
Page 296 HALF SHAFT 3 - 15 CV BOOT - OUTER (Continued) (5) Slide failed sealing boot off interconnecting shaft. (6) Thoroughly clean and inspect outer C/V joint assembly and interconnecting joint for any signs of excessive wear. If a n y p a rts s h o w s ig n s o f e x c e s - s iv e w e a r, th e d riv e s h a ft a s s e m bly w ill re qu ire re p la c e m e n t.
Page 297 3 - 16 HALF SHAFT CV BOOT - OUTER (Continued) (6) Install outer C/V joint sealing boot to intercon- (8) Position outer C/V joint sealing boot into its necting shaft clamp evenly on sealing boot. retaining groove on outer C/V joint housing. Install (7) Clamp sealing boot onto interconnecting shaft sealing boot to outer C/V joint retaining clamp evenly using crimper, Special Tool C-4975-A and the follow-...
Page 298 BRAKES 5 - 1 BRAKES TABLE OF CONTENTS page page BRAKES - BASE ......1 BRAKES - ABS .
Page 299 5 - 2 BRAKES - BASE FLUID STANDARD PROCEDURE - BRAKE ROTOR DIAGNOSIS AND TESTING - BRAKE FLUID MACHINING ......35 CONTAMINATION .
Page 300 BRAKES - BASE 5 - 3 BRAKES - BASE (Continued) STANDARD PROCEDURE - BASE BRAKE BLEEDING NOTE: For bleeding the ABS hydraulic system, (Refer to 5 - BRAKES - ABS - STANDARD PROCE- DURE). CAUTION: Before removing the master cylinder cap, wipe it clean to prevent dirt and other foreign mat- ter from dropping into the master cylinder reservoir.
Page 301 5 - 4 BRAKES - BASE BRAKES - BASE (Continued) (5) Check the brake pedal travel. If pedal travel is excessive or has not been improved, some air may DESCRIPTION N·m Lbs. Lbs. still be trapped in the system. Rebleed the brakes as Disc Brake Caliper Bleeder necessary.
Page 302 BRAKES - BASE 5 - 5 BRAKES - BASE (Continued) SPECIAL TOOLS BASE BRAKE SYSTEM Dial Indicator C-3339 Adapters, Brake Pressure Test 8187 Tubes, Master Cylinder Bleed 8358 Gauge Set Handle, Universal C-4171 Installer, Dust Boot C-4689...
Page 303 5 - 6 BRAKES - BASE BRAKE FLUID LEVEL SWITCH INSTALLATION (1) Insert brake fluid level switch into left side of REMOVAL brake fluid reservoir. Be sure switch is pushed in until retaining tabs lock it to brake fluid reservoir. (1) Remove wiring harness connector from brake (2) Connect vehicle wiring harness connector to fluid reservoir level switch on the side of the reser-...
Page 304 BRAKES - BASE 5 - 7 BRAKE LINES (Continued) hydraulic brake hoses for surface cracking, scuffing, or worn spots. If the fabric casing of the rubber hose becomes exposed due to cracks or abrasions in the rubber hose cover, the hose should be replaced imme- diately.
Page 305 5 - 8 BRAKES - BASE BRAKE PADS/SHOES - FRONT (Continued) (6) Remove caliper from caliper adapter and brake rotor. The outboard shoe will probably stay with the caliper adapter while the inboard shoe will come off with the caliper as the caliper is removed. CAUTION: Supporting weight of caliper by the flex- ible brake fluid hose can damage the hose.
Page 306 BRAKES - BASE 5 - 9 BRAKE PADS/SHOES - FRONT (Continued) Replace bo th disc brake shoes (inboard and out- (4) Install the new inboard brake shoe into the cal- board) on each caliper. It is necessary to replace the iper piston by firmly pressing its retaining clip into shoes on the opposite side of the vehicle as well as the piston bore.
Page 307 5 - 10 BRAKES - BASE BRAKE PADS/SHOES - REAR DISC (Continued) (3) Remove the 2 guide pin bolts mounting the cal- iper to the adapter (Fig. 10). Fig. 10 Caliper Guide Pin Bolts 1 - DISC BRAKE CALIPER 2 - CALIPER GUIDE PIN BOLTS (4) Remove caliper from adapter and rotor by first Fig.
Page 308 BRAKES - BASE 5 - 11 BRAKE PADS/SHOES - REAR DISC (Continued) CLEANING - DISC BRAKE SHOES caliper. Then slide brake pad down and off the cali- per (Fig. 14). WARNING: DUST AND DIRT ACCUMULATING ON BRAKE PARTS DURING NORMAL USE MAY CON- TAIN ASBESTOS FIBERS FROM PRODUCTION OR AFTERMARKET BRAKE...
Page 309 5 - 12 BRAKES - BASE BRAKE PADS/SHOES - REAR DISC (Continued) BRAKE PADS/SHOES - REAR If the brake shoe assemblies do not require replacement, be sure to reinstall the brake shoes in DRUM the original position they were remove from. REMOVAL INSTALLATION - REAR DISC BRAKE SHOES (1) Completely retract the caliper piston back into...
Page 310 BRAKES - BASE 5 - 13 BRAKE PADS/SHOES - REAR DRUM (Continued) (6) Compress cable return spring, then remove parking brake cable from parking brake lever (Fig. 17). Fig. 19 Bench Assembled Brake Shoes (Right Side Shown) 1 - LEVER 2 - UPPER RETURN SPRING Fig.
Page 311 5 - 14 BRAKES - BASE BRAKE PADS/SHOES - REAR DRUM (Continued) INSPECTION Rear brake shoe lining should show contact across the entire width of the lining and also from the heel to the toe of the lining. Replace the shoes if noted otherwise.
Page 312 BRAKES - BASE 5 - 15 BRAKE PADS/SHOES - REAR DRUM (Continued) (5) Using a brake shoe gauge, Special Tool C-3919 (10) Install the tire and wheel assembly. Tighten or equivalent, measure the inside diameter of the the wheel mounting nuts to a torque of 135 N·m (100 brake drum (Fig.
Page 313 5 - 16 BRAKES - BASE DISC BRAKE CALIPER - FRONT (Continued) (5) Remove the banjo bolt connecting the brake hose to the brake caliper (Fig. 24). There are two washers (one on each side of the brake hose fitting) that will come off with the banjo bolt.
Page 314 BRAKES - BASE 5 - 17 DISC BRAKE CALIPER - FRONT (Continued) (2) Carefully depress the brake pedal to hydrauli- cally push piston out of its bore. Once completed, apply and hold down the brake pedal to any position beyond the first inch of pedal travel using a brake pedal holding tool.
Page 315 5 - 18 BRAKES - BASE DISC BRAKE CALIPER - FRONT (Continued) To clean or flush the internal passages of the brake caliper, use fresh brake fluid or Mopar Non-Chlori- nated Brake Parts Cleaner. Never use gasoline, ker- osene, alcohol, oil, transmission fluid or any fluid containing mineral oil to clean the caliper.
Page 316 BRAKES - BASE 5 - 19 DISC BRAKE CALIPER - FRONT (Continued) (5) Position the dust boot into the counterbore of the caliper assembly piston bore. (6) Using a hammer and Installer, Special Tool C-4689 or C-4842 (depending on piston size), and Handle, Special Tool C-4171, drive the boot into the counterbore of the caliper as necessary (Fig.
Page 317 5 - 20 BRAKES - BASE DISC BRAKE CALIPER - FRONT (Continued) (Fig. 24). Tighten the banjo bolt to a torque of 35 (6) Remove caliper from adapter and rotor by first N·m (26 ft. lbs.). rotating top of caliper away from the adapter, then (8) Install the wheel and tire assembly.
Page 318 BRAKES - BASE 5 - 21 DISC BRAKE CALIPER - REAR (Continued) (1) Following the removal procedure in DISC NOTE: Do not use a screw driver or other metal tool BRAKE SHOES found in this section, remove the for seal removal. Using such tools can scratch the caliper from the brake rotor and hang the assembly bore or leave burrs on the seal groove edges.
Page 319 5 - 22 BRAKES - BASE DISC BRAKE CALIPER - REAR (Continued) CLEANING - CALIPER NOTE: To avoid damage to the bushing, do not use a sharp object to install the guide pin bushing. WARNING: DUST AND DIRT ACCUMULATING ON (2) Insert the folded bushing into the caliper BRAKE PARTS DURING NORMAL USE MAY CON- mounting boss using your fingers from the rear of...
Page 320 BRAKES - BASE 5 - 23 DISC BRAKE CALIPER - REAR (Continued) CAUTION: Force applied to the piston to seat it in the bore must be applied uniformly to avoid cock- ing and binding of the piston. (4) Install piston into caliper bore pushing it past the piston seal until it bottoms in the caliper bore (Fig.
Page 321 5 - 24 BRAKES - BASE DISC BRAKE CALIPER - REAR (Continued) (4) Carefully lower caliper and brake shoes over Drum braking surface out-of-round must not rotor reversing the removal procedure (Fig. 33). exceed 0.050 mm (0.002 inch). If the measurement is Make sure that the caliper guide pin bolts, bushings not within specification, reface or replace the drum.
Page 322 BRAKES - BASE 5 - 25 DRUM (Continued) Fig. 41 Drum Brakes Fig. 40 Drum Maximum Diameter Identification 1 - DUST CAP 1 - MAXIMUM DIAMETER IDENTIFICATION 2 - NUT 230.6 MM (9.079 IN.) 3 - DRUM 2 - BRAKE DRUM 4 - HUB AND BEARING 5 - WHEEL CYLINDER REMOVAL...
Page 323 5 - 26 BRAKES - BASE DRUM (Continued) Master cylinder reservoirs are marked, FULL and MIN, indicating the allowable brake fluid level range in the master cylinder brake fluid reservoir. CAUTION: Use only Mopar brake fluid or an equiv- alent from a tightly sealed container. Brake fluid must conform to DOT 3 specifications.
Page 324 BRAKES - BASE 5 - 27 JUNCTION BLOCK (Continued) The junction block includes two proportioning valves for the rear brakes. One valve is mounted in each end of the block (Fig. 44). The proportioning valves are not serviced separately from the junction block.
Page 325 5 - 28 BRAKES - BASE JUNCTION BLOCK (Continued) REMOVAL (7) Remove the bolts fastening the junction block mounting bracket to the lower radiator support (Fig. (1) Remove vehicle wiring harness connector from 44). brake fluid level switch in side of master cylinder (8) Remove the junction block and bracket from brake fluid reservoir (Fig.
Page 326 BRAKES - BASE 5 - 29 MASTER CYLINDER (Continued) INSTALLATION Once an adequate vacuum supply is obtained, repeat the BASIC TEST. (1) Position master cylinder assembly on studs of power brake unit, aligning push rod on power brake VACUUM LEAK TEST vacuum booster with piston of master cylinder.
Page 327 5 - 30 BRAKES - BASE POWER BRAKE BOOSTER (Continued) Fig. 49 Correctly Isolated Remote Ground Cable Fig. 51 Input Rod Retaining Pin 1 - LEFT STRUT TOWER 1 - BRAKE PEDAL 2 - GROUND STUD 2 - INPUT ROD 3 - SCREWDRIVER (6) Remove the vacuum hoses from the check valve 4 - RETAINING CLIP...
Page 328 BRAKES - BASE 5 - 31 POWER BRAKE BOOSTER (Continued) INSTALLATION - POWER BRAKE BOOSTER sure to the rear brakes above a preset level (split point). On light pedal applications equal brake pres- (1) Position power brake booster onto dash panel. sure is transmitted to both the front and rear brakes.
Page 329 5 - 32 BRAKES - BASE PROPORTIONING VALVE (Continued) (13) Bleed any air out of the system. This includes bleeding the air from the hose between the pressure test fitting and pressure gauge, which is done at the pressure gauge. (14) With the aid of a helper, apply pressure to the brake pedal until reading on proportioning valve inlet gauge (at master cylinder) is at the pressure...
Page 330 BRAKES - BASE 5 - 33 ROTOR DIAGNOSIS AND TESTING - BRAKE ROTOR Any servicing of the rotor requires extreme care to maintain the rotor within service tolerances to ensure proper brake action. Excessive runout or wobble in a rotor can increase pedal travel due to piston knock-back.
Page 331 5 - 34 BRAKES - BASE ROTOR (Continued) ROTOR RUNOUT On-vehicle rotor runout is the combination of the individual runout of the hub face and the runout of the rotor. (The hub and rotor runouts are separable). To measure rotor runout on the vehicle, first remove the tire and wheel assembly.
Page 332 BRAKES - BASE 5 - 35 ROTOR (Continued) Hub runout should not exceed 0.05 mm (0.0019 inch). If runout exceeds this specification, the hub must be replaced. Refer to SUSPENSION. If the hub runout does not exceed this specifica- tion, install the rotor back on the hub, aligning the chalk marks on the rotor with a wheel mounting stud, two studs apart from the original stud (Fig.
Page 333 5 - 36 BRAKES - BASE ROTOR (Continued) Minimum allowable thickness is the minimum NOTE: All rotors have markings for minimum allow- thickness which the brake rotor machined surface able thickness cast on an un-machined surface of may be cut to. the rotor (Fig.
Page 334 BRAKES - BASE 5 - 37 ROTOR (Continued) REMOVAL - REAR ROTOR INSTALLATION - REAR ROTOR (1) Raise vehicle. (Refer to LUBRICATION & (1) Install rotor on wheel mounting studs (Fig. 63). MAINTENANCE/HOISTING - STANDARD PROCE- (2) Install caliper and shoes on vehicle. (Refer to 5 DURE) BRAKES/HYDRAULIC/MECHANICAL/BRAKE (2) Remove rear tire and wheel.
Page 335 5 - 38 BRAKES - BASE SUPPORT PLATE (Continued) (7) Remove hub and bearing dust cap, hub and (8) Adjust brake shoes to drum diameter using bearing assembly, and brake shoes from support brake shoe gauge. (Refer to 5 - BRAKES/HYDRAU- plate.
Page 336 BRAKES - BASE 5 - 39 WHEEL CYLINDER (Continued) (6) Remove wheel cylinder mounting bolts (Fig. (10) Bleed affected wheel cylinder/circuit as neces- 66). sary. (Refer to 5 - BRAKES - STANDARD PROCE- DURE) (11) Road test vehicle stopping in both forward and reverse directions.
Page 337 5 - 40 BRAKES - BASE PARKING BRAKE (Continued) (3) Loosen adjusting nut (Fig. 68) on park brake cable output cable. This will take tension off output cable, allowing it to be easily removed from tension equalizer. Fig. 69 Output Cable To Equalizer Retaining Clip 1 - SCREWDRIVER 2 - PARK BRAKE LEVER OUTPUT CABLE 3 - CABLE RETAINER...
Page 338 BRAKES - BASE 5 - 41 PARKING BRAKE (Continued) (7) Install a n e w park brake lever output cable to tension equalizer retaining clip (Fig. 71) on tension equalizer. The cable retainer (Fig. 71) must be closed and securely latched. Fig.
Page 339 5 - 42 BRAKES - BASE CABLES - PARKING BRAKE (Continued) (4) Remove parking brake cable requiring service from the parking brake cable tension equalizer (Fig. 74). Fig. 75 Compressing Park Brake Cable Retaining Tabs 1 - BOX END WRENCH Fig.
Page 340 BRAKES - BASE 5 - 43 CABLES - PARKING BRAKE (Continued) (14) Remove parking brake cable from rear disc brake adapter or drum brake support plate. If access allows, place a 1/2 inch or 13 mm box wrench over cable housing and compress locking tabs on cable retainer (Fig.
Page 341 5 - 44 BRAKES - BASE CABLES - PARKING BRAKE (Continued) (7) Install rear wheel and tire assembly on vehicle. Tighten all wheel lug nuts in crisscross pattern to one-half specified torque. Then repeat pattern, fully tightening nuts to 135 N·m (100 ft. lbs.). (8) Lower vehicle.
Page 342 BRAKES - BASE 5 - 45 CABLES - PARKING BRAKE (Continued) CAUTION: A new retainer (Fig. 83) must be used NOTE: Actuating the parking brake lever to its fully when installing the park brake mechanism output applied position one time after tightening the cable on the cable tension equalizer.
Page 343 5 - 46 BRAKES - BASE LEVER - PARKING BRAKE REMOVAL (1) Remove the floor console. (Refer to 23 - BODY/ INTERIOR/FLOOR CONSOLE - REMOVAL) (2) Lower parking brake lever handle. (3) Loosen adjusting nut on park brake lever out- put cable (Fig.
Page 344 BRAKES - BASE 5 - 47 LEVER - PARKING BRAKE (Continued) (4) Install a NEW park brake cable tension equal- izer on the park brake lever output cable and rear park brake cables (Fig. 88). Fig. 89 Cable Retainer Installed On Tension Equalizer 1 - REAR PARK BRAKE CABLES 2 - CABLE RETAINING CLIP...
Page 345 5 - 48 BRAKES - BASE SHOES - PARKING BRAKE REMOVAL (1) Remove disc brake caliper from adapter and rotor (See Disc Brake Shoe Removal). (2) Remove rotor from hub/bearing. (3) Remove dust cap from hub/bearing. (4) Remove hub/bearing rear retaining nut and washer.
Page 346 BRAKES - BASE 5 - 49 SHOES - PARKING BRAKE (Continued) (10) Pull the rear park brake shoe away from the caliper adapter (Fig. 94). Remove the upper return spring (Fig. 94) from between the park brake shoes. Fig. 95 Front Park Brake Shoe Hold Down Clip 1 - FRONT BRAKE SHOE ASSEMBLY 2 - HOLD DOWN CLIP Fig.
Page 347 5 - 50 BRAKES - ABS BRAKES - ABS TABLE OF CONTENTS page page BRAKES - ABS INSTALLATION ......56 DESCRIPTION REAR WHEEL SPEED SENSOR DESCRIPTION - ANTILOCK BRAKES...
Page 348 BRAKES - ABS 5 - 51 BRAKES - ABS (Continued) DESCRIPTION - TRACTION CONTROL ticking, popping, or groaning noises heard by the driver. This is normal and is due to pressurized fluid This vehicle uses the Brake Traction Control Sys- being transferred between the master cylinder and tem (BTCS) type traction control.
Page 349 5 - 52 BRAKES - ABS BRAKES - ABS (Continued) PREMATURE ABS CYCLING same time the inlet valve is switched on in case of another brake application. Symptoms of premature ABS cycling include: click- The EVBP will remain functional during many ing sounds from the solenoid valves;...
Page 350 BRAKES - ABS 5 - 53 BRAKES - ABS (Continued) CAUTION CAUTION: Many components of the ABS System are not serviceable and must be replaced as an The ABS uses an electronic control module, the assembly. Do not disassemble any component ABM.
Page 351 5 - 54 BRAKES - ABS BRAKES - ABS (Continued) Before road testing a brake complaint vehicle, note It is important to note that excessive air in the whether the red BRAKE warning indicator lamp, amber brake system will cause a soft or spongy feeling ABS warning indicator lamp, or both are turned on.
Page 352 BRAKES - ABS 5 - 55 BRAKES - ABS (Continued) SPECIFICATIONS ABS FASTENER TORQUE Refer to BRAKE FASTENER TORQUE. (Refer to 5 - BRAKES - BASE - SPECIFICATIONS) TONE WHEEL RUNOUT DESCRIPTION SPECIFICATION Front Tone Wheel 0.25 mm (0.009 in.) Maximum Runout Rear Tone Wheel 0.25 mm (0.009 in.)
Page 353 5 - 56 BRAKES - ABS FRONT WHEEL SPEED SENSOR (Continued) INSTALLATION This procedure is for the removal and installation of one of the two front wheel speed sensors. CAUTION: Proper installation of wheel speed sen- sor cables is critical to continued system operation. Be sure that cables are installed in retainers.
Page 354 BRAKES - ABS 5 - 57 FRONT WHEEL SPEED SENSOR (Continued) (4) Install speed sensor head on steering knuckle (Fig. 6). When installing speed sensor head on steer- ing knuckle, apply a small amount of grease on speed sensor locating pin (Fig. 6). Use Mopar, Multi-Pur- pose Grease or an equivalent on speed sensor head locating pin.
Page 355 5 - 58 BRAKES - ABS REAR WHEEL SPEED SENSOR (Continued) (4) Push foam sleeve up off connector (Fig. 9) and disconnect speed sensor harness connector from vehi- cle wiring harness. Fig. 10 Rear Speed Senor Cable Attachment To Body 1 - SEALING GROMMET RETAINER 2 - BRAKE FLEX HOSE 3 - SPEED SENSOR CABLE...
Page 356 BRAKES - ABS 5 - 59 REAR WHEEL SPEED SENSOR (Continued) INSTALLATION attaching bolt (Fig. 10). Securely tighten retainer attaching bolt. (5) Install the tire and wheel assembly on vehicle. INSTALLATION - JR27 (6) Lower vehicle. (7) Connect speed sensor harness connector to CAUTION: Proper installation of wheel speed sen- vehicle wiring harness behind rear seat back.
Page 357 5 - 60 BRAKES - ABS TRACTION CONTROL SWITCH REMOVAL NOTE: Before proceeding, review all WARNINGS and CAUTIONS. (Refer to 19 - STEERING/COLUMN - WARNING) (Refer to 19 - STEERING/COLUMN - CAUTION) (1) Open hood and remove remote ground cable from ground stud on left front shock tower.
Page 358 BRAKES - ABS 5 - 61 HCU (HYDRAULIC CONTROL OPERATION - HYDRAULIC CIRCUITS AND VALVES UNIT) The hydraulic fluid control valves within the HCU control the flow of pressurized brake fluid to the DESCRIPTION wheel brakes during the different modes of ABS The hydraulic control unit (HCU) is mounted to braking.
Page 359 5 - 62 BRAKES - ABS HCU (HYDRAULIC CONTROL UNIT) (Continued) NORMAL BRAKING HYDRAULIC CIRCUIT, SOLENOID VALVE, AND SHUTTLE VALVE FUNCTION (ABS WITH TRACTION CONTROL) The hydraulic diagram (Fig. 16) shows a vehicle with traction control in the normal braking mode. The diagram shows no wheel spin or slip occurring relative to the speed of the vehicle.
Page 360 BRAKES - ABS 5 - 63 HCU (HYDRAULIC CONTROL UNIT) (Continued) ABS BRAKING HYDRAULIC CIRCUIT, SOLENOID VALVE, AND SHUTTLE VALVE FUNCTION (ABS WITH TRACTION CONTROL) The hydraulic diagram (Fig. 17) shows the vehicle in the ABS braking mode. The diagram shows one wheel is slipping because the driver is attempting to stop the vehicle at a faster rate than is allowed by the surface on which the tires are riding.
Page 361 5 - 64 BRAKES - ABS HCU (HYDRAULIC CONTROL UNIT) (Continued) ABS TRACTION CONTROL HYDRAULIC CIRCUIT, SOLENOID VALVE, AND SHUTTLE VALVE FUNCTION (ABS WITH TRACTION CONTROL) The hydraulic diagram (Fig. 18) shows the vehicle in the traction control (TC) mode. The diagram shows a drive wheel is spinning and brake pressure is required to reduce its speed.
Page 362 BRAKES - ABS 5 - 65 ICU (INTEGRATED CONTROL OPERATION UNIT) For information of the ICU, refer to these individ- ual components of the ICU: • ANTILOCK BRAKE MODULE (ABM) (Refer to DESCRIPTION 8 - ELECTRICAL/ELECTRONIC CONTROL MOD- The Hydraulic Control Unit (HCU) and the ULES/ANTILOCK BRAKE MODULE - OPERA- Antilock Brake Module (ABM) used with this TION)
Page 363 5 - 66 BRAKES - ABS ICU (INTEGRATED CONTROL UNIT) (Continued) (5) Clean any debris away from the fittings on top (9) Remove the rear chassis brake tubes at the of the ICU. ICU (Fig. 23). (6) Remove the two brake tubes coming from the primary and secondary master cylinder ports at the ICU (Fig.
Page 364 BRAKES - ABS 5 - 67 ICU (INTEGRATED CONTROL UNIT) (Continued) DISASSEMBLY (1) If the mounting bracket needs to be removed from the ICU, remove the single mounting bolt (Fig. 27), then slide the ICU’s mounting pins out of the grommets in the bracket.
Page 365 5 - 68 BRAKES - ABS ICU (INTEGRATED CONTROL UNIT) (Continued) (3) Separate the ABM from the HCU (Fig. 29). Fig. 30 Solenoid Valve Seal 1 - SEAL Fig. 29 ABM Assembly To HCU 2 - SOLENOID VALVE STEM 1 - ABM 2 - HCU 3 - SOLENOID VALVE STEM ASSEMBLY...
Page 366 BRAKES - ABS 5 - 69 ICU (INTEGRATED CONTROL UNIT) (Continued) (5) Install the rear chassis brake tubes at the ICU (9) Install the air cleaner housing. (Refer to 9 - (Fig. 23). Tighten the tube nuts to 17 N·m (145 in. ENGINE/AIR INTAKE SYSTEM/AIR...
Page 368 CLUTCH 6 - 1 CLUTCH TABLE OF CONTENTS page page CLUTCH INSTALLATION ......6 DESCRIPTION .
Page 369 6 - 2 CLUTCH CLUTCH (Continued) OPERATION MECHANICAL The clutch assembly is designed to transmit power from the engine to the manual transaxle. This is accomplished by the friction and clamping force gen- erated when the spring loaded pressure plate locks the clutch disc to the flywheel (Fig.
Page 370 CLUTCH 6 - 3 CLUTCH (Continued) SERVICE DIAGNOSIS - CLUTCH GRAB/CHATTER CONDITION POSSIBLE CAUSES CORRECTION CLUTCH DISC FACING Oil leak at engine rear main or Correct leak and replace modular clutch COVERED WITH OIL OR transaxle input shaft seal. assembly. GREASE Too much grease applied to splines Apply lighter coating of grease to splines.
Page 371 6 - 4 CLUTCH CLUTCH (Continued) SERVICE DIAGNOSIS - IMPROPER CLUTCH RELEASE CONDITION POSSIBLE CAUSES CORRECTION CLUTCH DISC BINDS ON Clutch disc hub splines damaged Clean, smooth, and lubricate disc and shaft INPUT SHAFT SPLINES during installation splines. Replace modular clutch assembly, or clutch disc, and/or input shaft if splines are severely damaged.
Page 372 CLUTCH 6 - 5 CLUTCH (Continued) DIAGNOSIS AND TESTING - CLUTCH CHATTER DIAGNOSIS AND TESTING - CLASH-INTO- COMPLAINTS REVERSE COMPLAINTS For all clutch chatter complaints, perform the fol- All T350 manual transaxles are equipped with a lowing: reverse brake. It prevents clash when shifting into (1) Check for loose, misaligned, or broken engine reverse, but only if the vehicle is not moving.
Page 373 6 - 6 CLUTCH CLUTCH (Continued) SPECIAL TOOLS Puller, C-3752 Fig. 5 Clutch Pedal Upstop Spacer and Return Spring 1 - UPSTOP SPACER 2 - RETURN SPRING 3 - CLUTCH PEDAL Remover/Installer, 6891 4 - CLUTCH CABLE CLUTCH PEDAL REMOVAL (1) Remove instrument panel left lower sound insulator.
Page 374 CLUTCH 6 - 7 CLUTCH PEDAL INTERLOCK defective (shorted out) and must be replaced. If the vehicle does not crank proceed to the next step. SWITCH WARNING: BEFORE PERFORMING THIS STEP, BE DIAGNOSIS AND TESTING - CLUTCH PEDAL SURE THAT THE AREA IN FRONT OF THE VEHICLE INTERLOCK SWITCH IS CLEAR OF OBSTRUCTIONS AND PEOPLE.
Page 375 6 - 8 CLUTCH CLUTCH PEDAL INTERLOCK SWITCH (Continued) CLUTCH RELEASE BEARING REMOVAL (1) Disconnect battery negative cable. AND LEVER (2) Remove steering column lower panel. (3) Remove knee bolster. DESCRIPTION (4) Disconnect position switch connector. A conventional release bearing is used to engage (5) Depress wing tabs on switch and push switch and disengage the clutch pressure plate.
Page 376 CLUTCH 6 - 9 CLUTCH RELEASE BEARING AND LEVER (Continued) REMOVAL NOTE: Remove release lever pivot ball only if replacement is necessary. (1) Remove the transaxle from the vehicle. (Refer to 21 - TRANSMISSION/TRANSAXLE/T350 MAN- (7) Remove pivot ball using slide hammer C-3752 UAL - REMOVAL) and remover/installer 6891 (Fig.
Page 377 6 - 10 CLUTCH CLUTCH RELEASE CABLE DESCRIPTION 2.0L equipped models use a cable style clutch release system. The clutch cable assembly (Fig. 11) carries the movement of the clutch pedal to the clutch release bearing. The cable is designed to main- tain tension against the clutch fork, or lever, and has a built in self-adjusting mechanism, which compen- sates for clutch disc wear.
Page 378 CLUTCH 6 - 11 CLUTCH RELEASE CABLE (Continued) (2) Connect clutch release cable core to upstop spacer. (3) Connect upstop spacer to clutch pedal pin and secure with retainer clip. (4) Route clutch release cable through engine com- partment as removed, and connect clutch release cable to clutch release lever (Fig.
Page 379 6 - 12 CLUTCH MODULAR CLUTCH (Continued) Fig. 15 Modular Clutch Removal/Installation 1 - MODULAR CLUTCH ASSEMBLY 3 - TRANSAXLE 2 - CLIP 4 - CLUTCH MODULE BOLT (4)
Page 380 COOLING 7 - 1 COOLING TABLE OF CONTENTS page page COOLING ACCESSORY DRIVE ..... . . 4 SPECIFICATIONS ENGINE ....... 10 ACCESSORY DRIVE BELT TENSION .
Page 381 7 - 2 COOLING COOLING (Continued) TORQUE DESCRIPTION N·m Ft. Lbs. In. Lbs. Accessory Drive Belt Tensioner Bracket (2.0L)—Fasteners — Accessory Drive Belt Tensioner Assembly(2.4L)—Fastener — Accessory Drive Belt Tensioner Bracket (2.7L)—Fasteners — A/C Condenser to Radiator—Fasteners — Coolant Outlet Connector —Bolts —...
Page 382 COOLING 7 - 3 COOLING (Continued) SPECIAL TOOLS COOLING SYSTEM Filling Aid Funnel 8195 DRB III with PEP Module – OT-CH6010A Cooling System Tester 7700 Belt Tension Gauge Adapter – 8371 Coolant Refractometer 8286 Hose Clamp Pliers 8495 Hose Clamp Pliers 6094...
Page 383 7 - 4 ACCESSORY DRIVE ACCESSORY DRIVE TABLE OF CONTENTS page page DRIVE BELTS CLEANING ......7 DESCRIPTION .
Page 384 ACCESSORY DRIVE 7 - 5 DRIVE BELTS (Continued) DIAGNOSIS AND TESTING - ACCESSORY DRIVE BELTS Satisfactory performance of the belt driven accesso- ries depends on belt condition and proper belt tension. ACCESSORY DRIVE BELT DIAGNOSIS CONDITION POSSIBLE CAUSE CORRECTION INSUFFICIENT ACCESSORY 1.
Page 385 7 - 6 ACCESSORY DRIVE DRIVE BELTS (Continued) 2.7L ACCESSORY DRIVE BELT TENSION CHART Accessory Belt Tension Drive Belt 185 - 235 204 - 230 lbs. Conditioning Compressor/ 110 - 160 157 - 190 Used* Generator 120 - 180 122 - 170 lbs.
Page 386 ACCESSORY DRIVE 7 - 7 DRIVE BELTS (Continued) POWER STEERING PUMP BELT (1) Raise vehicle on hoist. (2) Remove right front wheel and belt splash shield. (3) Remove the air conditioning compressor/gener- ator belt. (4) Loosen belt adjusting bolt. It is not necessary to loosen the pivot bolt on the power steering pump.
Page 387 7 - 8 ACCESSORY DRIVE DRIVE BELTS (Continued) POWER STEERING PUMP BELT (1) Install power steering pump belt on pulleys (Fig. 7). (2) Insert a 1/2” drive breaker bar into the square opening on the power steering pump bracket. (3) Hold clockwise pressure on power steering pump bracket and tighten adjusting bolt/nut.
Page 388 ACCESSORY DRIVE 7 - 9 DRIVE BELTS (Continued) POWER STEERING PUMP BELT TENSIONING (3) Remove torque wrench from tensioner bracket, and torque lower tensioner bracket fastener to 28 (1) Insert a 1/2” drive breaker bar into the square N·m (250 in. lbs.). opening on the power steering pump bracket.
Page 389 7 - 10 ENGINE ENGINE TABLE OF CONTENTS page page ENGINE REMOVAL DESCRIPTION - COOLING SYSTEM ..11 REMOVAL - 2.0L/2.4L ....30 OPERATION .
Page 390 ENGINE 7 - 11 DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - WATER PUMP . . . 42 DIAGNOSIS AND TESTING - RADIATOR REMOVAL FAN CONTROL ..... . . 39 REMOVAL - 2.0L/2.4L .
Page 391 7 - 12 ENGINE ENGINE (Continued) Fig. 1 COOLING MODULE 1 - RADIATOR FAN MODULE 9 - COMBINATION A/C CONDENSER AND TRANSMISSION OIL COOLER 2 - FAN MODULE TO RADIATOR FASTENERS 10 - CONDENSER TO RADIATOR FASTENER 3 - TRANSMISSION COOLER TUBE BRACKET 11 - TRANSMISSION COOLER TUBE (OUTLET) 4 - BRACKET FASTENER 12 - TRANSMISSION COOLER TUBE FASTENER...
Page 392 ENGINE 7 - 13 ENGINE (Continued) Fig. 2 Cooling System Operation - 2.0L/2.4L 1 - HEATER 6 - WATER PUMP 2 - HEAT UP 7 - ENGINE 3 - COOL DOWN 8 - COOLANT RECOVERY CONTAINER 4 - PRESSURE CAP 9 - RADIATOR 5 - COOLANT OUTLET CONNECTOR...
Page 393 7 - 14 ENGINE ENGINE (Continued) Fig. 3 Cooling System Operation - 2.7L 1 - HEATER CORE 5 - WATER PUMP 2 - COOLANT PRESSURE CONTAINER 6 - THERMOSTAT 3 - COOLANT OUTLET CONNECTOR 7 - RADIATOR 4 - ENGINE...
Page 394 ENGINE 7 - 15 ENGINE (Continued) DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - COOLING SYSTEM DIAGNOSIS CONDITION POSSIBLE CAUSE CORRECTION TEMPERATURE GAUGE READS 1. Diagnostic Trouble Code (DTC) 1. (Refer to Appropriate Diagnostic set indicating a stuck open engine Information) Replace thermostat, if thermostat.
Page 395 7 - 16 ENGINE ENGINE (Continued) CONDITION POSSIBLE CAUSE CORRECTION 6. Poor seals at pressure cap. 6. (a) Check condition of cap and cap seals. (Refer to 7 - COOLING/ ENGINE/RADIATOR PRESSURE CAP - INSPECTION) Replace cap if necessary. (b) Check condition of filler neck. If neck is damaged, replace as necessary.
Page 396 ENGINE 7 - 17 ENGINE (Continued) CONDITION POSSIBLE CAUSE CORRECTION 14. Dragging Brakes. 14. Inspect brake system and repair as necessary. (Refer to 5 - BRAKES/HYDRAULIC/ MECHANICAL - DIAGNOSIS AND TESTING) 15. Bug screen or other aftermarket 15. Remove bug screen or accessory is being used causing accessory.
Page 397 7 - 18 ENGINE ENGINE (Continued) CONDITION POSSIBLE CAUSE CORRECTION 7. Cylinder head gasket leaking 7. (a) Check for cylinder head allowing exhaust gas to enter gasket leaks. Repair as necessary. cooling system. This will cause (Refer to 9 - ENGINE/CYLINDER thermostat to open late.
Page 398 ENGINE 7 - 19 ENGINE (Continued) CONDITION POSSIBLE CAUSE CORRECTION HOSE OR HOSES COLLAPSE 1. Vacuum created in cooling 1. (a) Radiator pressure cap relief WHEN ENGINE IS COOLING system on engine cool-down is not valve stuck. (Refer to 7 - COOLING/ being relieved through coolant ENGINE/RADIATOR PRESSURE recovery container system.
Page 399 7 - 20 ENGINE ENGINE (Continued) CONDITION POSSIBLE CAUSE CORRECTION INADEQUATE AIR CONDITIONER 1. Radiator and/or air conditioning 1. Remove restriction and/or clean PERFORMANCE (COOLING condenser is restricted, obstructed as necessary. SYSTEM SUSPECTED) or dirty. 2. Electric radiator fan not operating 2.
Page 400 ENGINE 7 - 21 ENGINE (Continued) CONDITION POSSIBLE CAUSE CORRECTION POOR DRIVEABILITY 1. For proper driveability, good 1. (Refer to the Appropriate (THERMOSTAT POSSIBLY STUCK vehicle emissions and for Diagnostic Information) Replace OPEN). GAUGE MAY BE READING preventing build-up of engine oil thermostat if necessary.
Page 401 7 - 22 ENGINE ENGINE (Continued) DIAGNOSIS AND TESTING - COOLING SYSTEM LEAK TESTING WARNING: IF VEHICLE HAS BEEN RUN RECENTLY, WAIT 15 MINUTES BEFORE REMOVING PRESSURE CAP. PLACE A SHOP TOWEL OVER THE CAP, AND WITHOUT PUSHING DOWN, ROTATE IT COUNTER- CLOCKWISE TO THE FIRST STOP.
Page 402 ENGINE 7 - 23 ENGINE (Continued) • High reading shown on the temperature gauge. proper cooling system pressure cap is used. Verify • Loss of coolant flow through the heater core. proper pressure cap part number. • Corrosion in the cooling system. 2.7L •...
Page 403 7 - 24 ENGINE ENGINE (Continued) Fig. 7 Fluid Level Check - 2.7L 1 - COOLANT PRESSURE CONTAINER 3 - ENGINE OIL FILL 2 - COOLANT PRESSURE CAP 4 - ENGINE OIL DIPSTICK COOLING SYSTEM - DRAINING COOLING SYSTEM - FILLING When servicing the cooling system, it is essential that coolant does not drip onto the accessory drive CAUTION: Do not use well water or suspect water...
Page 404 ENGINE 7 - 25 ENGINE (Continued) (4) Remove cooling system pressure cap and fill (3) Attach a 6.35 mm (0.250 in.) inside diameter cooling system with recommended coolant. clear hose that is 120.0 cm (48 in.) long to the bleed (5) Slowly continue filling until a steady stream of valve.
Page 405 7 - 26 ENGINE ENGINE (Continued) AREA. DO NOT OPEN A COOLING SYSTEM WHEN THE ENGINE IS AT OPERATING TEMPERATURE OR HOT UNDER PRESSURE, PERSONAL INJURY CAN RESULT. AVOID RADIATOR COOLING FAN WHEN ENGINE COMPARTMENT RELATED SERVICE IS PERFORMED, PERSONAL INJURY CAN RESULT. CAUTION: Use of Propylene Glycol based coolants is not recommended, as they provide less freeze protection and less boiling protection.
Page 406 ENGINE 7 - 27 COOLANT (Continued) ture. The higher the concentration of ethylene glycol, (4) Remove bolts attaching coolant outlet connec- the larger the number of balls that will float, and tor. higher the freeze protection (up to a maximum of (5) Remove coolant outlet connector.
Page 407 7 - 28 ENGINE COOLANT OUTLET CONNECTOR (Continued) COOLANT RECOVERY (5) Remove bolts attaching coolant outlet connector (Fig. 12). CONTAINER - 2.0L/2.4L (6) Remove coolant outlet connector. DESCRIPTION The coolant recovery system consists of a container and an overflow hose that is connected to the coolant outlet connector (Fig.
Page 408 ENGINE 7 - 29 COOLANT RECOVERY CONTAINER - 2.0L/2.4L (Continued) (4) Disconnect the overflow hose from coolant out- let connector. (5) Remove coolant recovery container screws. (6) Remove coolant recovery container. INSTALLATION (1) Install container in mounting position and install attaching screws. (2) Connect the overflow hose to the coolant outlet connector.
Page 409 7 - 30 ENGINE ENGINE BLOCK HEATER REMOVAL REMOVAL - 2.0L/2.4L DESCRIPTION (1) Drain cooling system (Refer to 7 - COOLING/ ENGINE - STANDARD PROCEDURE). DESCRIPTION - 2.0L/2.4L (2) Raise vehicle on hoist. The block heater is operated by ordinary house (3) Detach power cord plug from heater.
Page 410 ENGINE 7 - 31 ENGINE BLOCK HEATER (Continued) INSTALLATION voltage value at the PCM ECT sensor signal circuit. The ECT sensor provides input for various PCM operations. The PCM uses the input to control air- INSTALLATION - 2.0L/2.4L fuel mixture, timing, and radiator fan on/off times. (1) Thoroughly clean core hole and heater seat.
Page 411 7 - 32 ENGINE ENGINE COOLANT TEMPERATURE SENSOR (Continued) INSTALLATION water pump pressure, which forces the valve to open. Coolant leakage into the pellet will cause a thermo- (1) Install ECT sensor. Torque sensor to 19 N·m stat to fail open. Do not attempt to free up a thermo- (168 in.
Page 412 ENGINE 7 - 33 ENGINE COOLANT THERMOSTAT (Continued) Fig. 20 Thermostat and Housing—2.7L Engine 1 - THERMOSTAT AND GASKET 2 - THERMOSTAT HOUSING/COOLANT INLET (4) Connect hoses to coolant outlet connector. Fig. 19 Coolant Outlet Connector - 2.0L/2.4L (5) Fill cooling system (Refer to 7 - COOLING/EN- 1 - PRESSURE CAP GINE - STANDARD PROCEDURE).
Page 413 7 - 34 ENGINE ENGINE COOLANT THERMOSTAT (Continued) INSTALLATION - 2.7L (1) Clean gasket sealing surfaces. NOTE: Install thermostat with the bleed valve located at the 12 o’clock position. (2) Install thermostat and gasket into the thermo- stat housing. (3) Install thermostat and housing to cylinder block.
Page 414 ENGINE 7 - 35 HOSE CLAMPS (Continued) NOTE: Special Tool 8495 was specifically designed for use on the “Low Profile” type hose clamps used at the coolant outlet connector hoses on the 2.7L engine. The pliers are also compatible with other styles of constant tension type hose clamps.
Page 415 7 - 36 ENGINE RADIATOR (Continued) CLEANING Clean radiator fins are necessary for good heat transfer. The radiator and air conditioning fins should be cleaned when an accumulation of debris has occurred. With the engine cold, apply cold water and compressed air to the back (engine side) of the radiator to flush the radiator and/or A/C condenser of debris.
Page 416 ENGINE 7 - 37 PRESSURE CAP (Continued) CAUTION: The Cooling System Tester Tool is very sensitive to small air leaks that will not cause cool- ing system problems. A pressure cap that does not have a history of coolant loss should not be replaced just because it leaks slowly when tested with this tool.
Page 417 7 - 38 ENGINE PRESSURE CAP (Continued) CLEANING n ip p le , and pump air into the system. The pressure cap upper gasket should relieve pressure at 69-124 Use only a mild soap to clean the pressure cap. kPa (10-18 psi), and hold pressure at 55 kPa (8 psi) minimum.
Page 418 ENGINE 7 - 39 PRESSURE CAP (Continued) Fig. 32 Fan Module 1 - RADIATOR FAN MOTOR 2 - RADIATOR 3 - RADIATOR DRAINCOCK DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - RADIATOR FAN CONTROL Fan control is accomplished three ways. The fan runs when the air conditioning pressure reaches a set psi see charts below.
Page 419 7 - 40 ENGINE RADIATOR FAN(S) (Continued) RADIATOR FAN OPERATION—2.0L ENGINE RADIATOR FAN OPERATION—2.7L ENGINE Radiator Fan Control A/C Pressure Radiator Fan Control A/C Pressure A/C Off High A/C Off High Fan On: 104°C 110°C Fan On: 104°C 110°C (220°F) (230°F) (220°F) (230°F)
Page 420 ENGINE 7 - 41 RADIATOR FAN(S) (Continued) (2) Remove thermostat (Refer to 7 - COOLING/ ENGINE/ENGINE COOLANT THERMOSTAT REMOVAL). (3) Disconnect engine coolant temperature sensor connector. (4) Disconnect heater supply hose. (5) Remove housing attaching bolts (Fig. 34). (6) Remove housing and gasket (Fig. 34). Fig.
Page 421 7 - 42 ENGINE THERMOSTAT HOUSING (Continued) INSTALLATION - 2.4L (1) Clean all gasket sealing surfaces. (2) Install gasket and housing (Fig. 34). Tighten bolts to 28 N·m (20 ft. lbs.). (3) Reconnect heater supply hose. (4) Reconnect engine coolant temperature sensor connector.
Page 422 ENGINE 7 - 43 WATER PUMP (Continued) REMOVAL (3) Remove the timing chain cover, timing chain, and all chain guides (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL - 2.0L/2.4L REMOVAL). (1) Disconnect negative battery cable. (4) Remove bolts attaching water pump to block (2) Drain cooling system (Refer to 7 - COOLING/ (Fig.
Page 423 7 - 44 ENGINE WATER PUMP (Continued) below the pump primary weep hole/passage is consid- ered normal operation. (3) Coolant leaks: If the pump primary weep pas- sage is plugged, coolant may come from the second- ary weep passage and collect in the valley of the engine.
Page 424 ENGINE 7 - 45 WATER PUMP (Continued) (5) Rotate inlet tube while removing from the engine block (Fig. 43). Fig. 42 Water Pump Body 1 - IMPELLER 2 - PUMP BODY 3 - O-RING INSTALLATION - 2.7L (1) Clean all sealing surfaces. (2) Install water pump and gasket.
Page 425 7 - 46 TRANSMISSION TRANSMISSION TABLE OF CONTENTS page page TRANSMISSION COOLER HOSES REMOVAL ......46 DESCRIPTION .
Page 426 AUDIO/VIDEO 8A - 1 AUDIO/VIDEO TABLE OF CONTENTS page page AUDIO REMOVAL ......7 DESCRIPTION .
Page 427 8A - 2 AUDIO/VIDEO 2004 JR Service Manual AUDIO (Continued) Publication No. 81-270-04025A 04JR8A-2 September, 2003 DIAGNOSIS AND TESTING - AUDIO AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISO- An y d ia g n o s is o f th e Au d io s y s te m s h o u ld LATE THE BATTERY NEGATIVE (GROUND) CABLE, be g in w ith th e u s e o f th e D RB III d ia g n o s tic...
Page 428 AUDIO/VIDEO 8A - 3 2004 JR Service Manual AUDIO (Continued) Publication No. 81-270-04025A 04JR8A-3 September, 2003 CONDITION POSSIBLE CAUSES CORRECTION 3. Wiring faulty between radio 3. Check wiring for open or short, repair wiring as and speaker. necessary. 4. Wiring faulty between radio 4.
Page 429 8A - 4 AUDIO/VIDEO 2004 JR Service Manual AUDIO (Continued) Publication No. 81-270-04025A 04JR8A-4 September, 2003 CONDITION POSSIBLE CAUSES CORRECTION NO COMPACT DISC 1. Faulty CD. 1. Insert known good CD and test operation. OPERATION 2. Foreign material on CD. 2.
Page 430 AUDIO/VIDEO 8A - 5 ANTENNA BODY & CABLE (Continued) coaxial connector for the radio. Check the ohmmeter reading for continuity. (3) There should be continuity. The ohmmeter should register only a fraction of an ohm resistance. High or infinite resistance indicates a damaged or open antenna conductor.
Page 431 8A - 6 AUDIO/VIDEO ANTENNA BODY & CABLE (Continued) (4) Check the resistance again with an ohmmeter. The CD changer contains a Load/Eject button and If the resistance is still more then one ohm, replace an indicator LED for each of the six disc positions as the faulty antenna body and cable.
Page 432 AUDIO/VIDEO 8A - 7 POWER ANTENNA - EXPORT (2) Install mounting bolts to antenna. Tighten to 12 N·m (110 in. lbs.). (3) Connect antenna cable. DIAGNOSIS AND TESTING - POWER ANTENNA (4) Connect electrical connector to antenna. - EXPORT (5) Connect drain tube. Refer to the appropriate wiring information.
Page 433 8A - 8 AUDIO/VIDEO REMOTE SWITCHES (Continued) The two remote radio switch units share a common (1) Disconnect and isolate the battery negative steering wheel wire harness with the vehicle speed cable. Remove the remote radio switch(es) (Fig. 5) control switches. The steering wheel wire harness is from the steering wheel.
Page 434 AUDIO/VIDEO 8A - 9 REMOTE SWITCHES (Continued) (4) Disconnect and isolate the battery negative cable. Disconnect the 18-way instrument panel wire harness connector from the BCM. Check for continu- ity between the remote radio switch ground circuit cavities of the steering wheel wire harness connec- tors for both remote radio switches and a good ground.
Page 435 8A - 10 AUDIO/VIDEO REMOTE SWITCHES (Continued) (4) Install the speed control switch located on the same side of the steering wheel as the remote radio switch. (Refer to 8 - ELECTRICAL/SPEED CON- TROL/SWITCH - INSTALLATION). (5) Install the driver side airbag module to the steering wheel.
Page 436 AUDIO/VIDEO 8A - 11 SPEAKER WARNING: DISABLE THE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING DESCRIPTION COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISOLATE THE BATTERY STANDARD - JR41 NEGATIVE (GROUND) CABLE, THEN WAIT TWO MIN- The standard equipment speaker system includes UTES FOR THE AIRBAG SYSTEM CAPACITOR TO speaker in four locations: One 15.2 cm X 22.9 cm (6...
Page 437 8A - 12 AUDIO/VIDEO SPEAKER (Continued) REMOVAL INSTRUMENT PANEL (1) Disconnect and isolate battery negative cable. FRONT DOOR - JR41 (2) Remove A-pillar trim. (1) Disconnect and isolate the battery negative cable. (2) Remove door trim panel (Refer to 23 - BODY/ DOOR - FRONT/TRIM PANEL - REMOVAL).
Page 438 AUDIO/VIDEO 8A - 13 SPEAKER (Continued) (3) Install speaker screws. Tighten to 3 N·m (30 in. lbs.). (4) Install door trim panel. (5) Reconnect battery negative cable. FRONT DOOR SPEAKER – JR27 (1) Connect the wire harness connector to speaker. (2) Install the speaker to the door trim panel.
Page 440 CHIME/BUZZER 8B - 1 CHIME/BUZZER TABLE OF CONTENTS page page CHIME/BUZZER DIAGNOSIS AND TESTING - EXTERIOR DESCRIPTION ......1 LAMPS LEFT ON .
Page 441 8B - 2 CHIME/BUZZER CHIME/BUZZER (Continued) SINGLE WARNING CHIME After bulb check at power-up, if any of the follow- ing indicators are still activated, the cluster will request a single chime from the BCM. ABS, Air Bag, Check Engine, Charging System, Engine Tempera- ture, Low Fuel (after 10 seconds for accurate fuel information), and BRAKE (if speed is greater than 2 mph).
Page 442 CHIME/BUZZER 8B - 3 CHIME/BUZZER (Continued) CHIMES CONTINUE WHEN HEADLAMPS ARE (4) Remove BCM from Junction Block. Check for battery voltage at terminal JB-12 and ignition feed TURNED OFF AND/OR KEY IS REMOVED FROM at terminal JB-6 of BCM. Refer to the appropriate IGNITION wiring information.
Page 444 ELECTRONIC CONTROL MODULES 8E - 1 ELECTRONIC CONTROL MODULES TABLE OF CONTENTS page page ELECTRONIC CONTROL MODULES DATA BUS COMMUNICATION RECEIVE - STANDARD PROCEDURE - PCM/SKIM PCM INPUT ......10 PROGRAMMING .
Page 445 8E - 2 ELECTRONIC CONTROL MODULES ELECTRONIC CONTROL MODULES (Continued) NOTE: If three attempts are made to enter secure NOTE: If the PCM and the SKIM are replaced at the access mode using an incorrect PIN, secured same time, all vehicle keys will need to be replaced access mode will be locked out for one hour.
Page 446 ELECTRONIC CONTROL MODULES 8E - 3 ANTILOCK BRAKE MODULE The ABM constantly monitors the antilock brake system for proper operation. If the ABM detects a fault, it will send a message to the mechanical DESCRIPTION instrument cluster (MIC) instructing it to turn on the The Antilock Brake Module (ABM) is a micropro- amber ABS warning indicator lamp and disable the cessor-based device which monitors the antilock...
Page 447 8E - 4 ELECTRONIC CONTROL MODULES ANTILOCK BRAKE MODULE (Continued) INSTALLATION REMOVAL Due to packaging and limited space it is necessary The Junction Block and Body Control Module to install the Antilock Brake Module on the HCU, (BCM) are attached to each other. After removal they then install the ICU on the vehicle as an assembly.
Page 448 ELECTRONIC CONTROL MODULES 8E - 5 BODY CONTROL MODULE (Continued) (8) Install the wire harness connectors to the Junc- multiplexed heated seat switch request circuit for tion Block. each of the two heated seat switches and the heated (9) Install the silencer. seat sensor inputs from the seat cushions of each (10) Install the left lower instrument panel trim.
Page 449 8E - 6 ELECTRONIC CONTROL MODULES HEATED SEAT MODULE (Continued) for the proper MUX signal (resistance range of 0-500 ohms, refer to the heated seat switch diagnosis and testing). If OK replace the heated seat module. If not OK, test the heated seat switch and harness as described in this section.
Page 450 ELECTRONIC CONTROL MODULES 8E - 7 POWERTRAIN CONTROL MODULE (Continued) • Low Speed Fan Relay power is shut off to the fuel injectors, ignition coils, • MTV Actuator fuel pump and the heating element in each oxygen • Proportional Purge Solenoid sensor.
Page 451 8E - 8 ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE (Continued) Certain mechanical problems within the clutch assemblies (broken return springs, out of position snap rings, excessive clutch pack clearance, improper assembly, etc.) can cause inadequate or out-of-range clutch volumes. Also, defective Input/Output Speed Sensors and wiring can cause these conditions.
Page 452 ELECTRONIC CONTROL MODULES 8E - 9 POWERTRAIN CONTROL MODULE (Continued) • Fluid temperature SHIFT SCHEDULES • Software level The PCM has programming that allows it to select As driving conditions change, the PCM appropri- a variety of shift schedules. Shift schedule selection ately adjusts the shift schedule.
Page 453 8E - 10 ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE (Continued) OPERATION - SENSOR RETURN - PCM INPUT • Battery temperature • Camshaft Position Sensor (NGC) The sensor return circuit provides a low electrical • Crankshaft Position Sensor (NGC) noise ground reference for all of the systems sensors. •...
Page 454 ELECTRONIC CONTROL MODULES 8E - 11 POWERTRAIN CONTROL MODULE (Continued) REMOVAL - NGC CONTROLLER ings will be correct. To properly read and/or reset the Pinion Factor, it is necessary to use a scan tool. U S E THE S CAN TOOL TO REP ROGRAM THE (1) Plug the scan tool into the diagnostic connector N EW P CM WITH THE VEHICLES ORIGIN AL located under the instrument panel.
Page 455 8E - 12 ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE (Continued) miles) of usage, update the mileage and vehicle iden- WARNING: If the negative battery cable is not dis- tification number (VIN) in the new PCM. Use the connected the possibility of damaging the Power- scan tool to change the millage and VIN in the PCM.
Page 456 ELECTRONIC CONTROL MODULES 8E - 13 SENTRY KEY IMMOBILIZER MODULE (Continued) recovered, new ignition keys will be required. The FORMING FURTHER DIAGNOSIS OR SERVICE. THIS scan tool will alert the technician if key replacement IS THE ONLY SURE WAY TO DISABLE THE AIRBAG is necessary.
Page 457 8E - 14 ELECTRONIC CONTROL MODULES SENTRY KEY IMMOBILIZER MODULE (Continued) RITY - STANDARD PROCEDURE) Sentry Key STEERING COLUMN OPENING COVER - INSTAL- Immobilizer Module Initialization. LATION). (2) Carefully position the SKIM, the mounting (6) Install the knee bolster (Refer to 23 - BODY/ bracket and the antenna ring onto the steering col- INSTRUMENT PANEL/INSTRUMENT...
Page 458 ENGINE SYSTEMS 8F - 1 ENGINE SYSTEMS TABLE OF CONTENTS page page BATTERY SYSTEM ......1 STARTING .
Page 459 8F - 2 BATTERY SYSTEM BATTERY SYSTEM (Continued) • B a tte ry He a te r B la n k e t - The battery heater to start and the battery to charge properly, all of the blanket is used to improve battery cold start ability. components that are used in these systems must per- •...
Page 460 BATTERY SYSTEM 8F - 3 BATTERY SYSTEM (Continued) BATTERY SYSTEM DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION THE BATTERY SEEMS 1. The battery has an 1. Refer to Battery Specifications for the proper WEAK OR DEAD WHEN incorrect size or rating for size and rating.
Page 461 8F - 4 BATTERY SYSTEM BATTERY SYSTEM (Continued) BATTERY SYSTEM DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION THE BATTERY STATE OF 1. The battery has an 1. Refer to Battery Specifications for the proper CHARGE CANNOT BE incorrect size or rating for specifications.
Page 462 BATTERY SYSTEM 8F - 5 BATTERY SYSTEM (Continued) 7. A faulty or incorrect starting system component. Refer to Starting System for the proper starting sys- tem diagnosis and testing procedures. 8. A faulty or incorrect battery. Refer to Standard Procedures for the proper battery diagnosis and test- ing procedures.
Page 463 8F - 6 BATTERY SYSTEM BATTERY SYSTEM (Continued) • Gro u p S ize - The outside dimensions and ter- • Re s e rv e Ca p a c ity - The Reserve Capacity (RC) minal placement of the battery conform to standards rating specifies the time (in minutes) it takes for bat- established by the Battery Council International tery terminal voltage to fall below 10.5 volts, at a...
Page 464 BATTERY SYSTEM 8F - 7 BATTERY (Continued) OPERATION MICRO 420 BATTERY TESTER The Micro 420 automotive battery tester is The battery is designed to store electrical energy in designed to help the dealership technicians diagnose a chemical form. When an electrical load is applied to the cause of a defective battery.
Page 465 8F - 8 BATTERY SYSTEM BATTERY (Continued) tery, retest the battery using the OUT-OF-VEHICLE test before replacing. (6) While viewing the battery test result, press the CODE button and the tester will prompt you for the last 4 digits of the VIN. Use the UP/DOWN arrow buttons to scroll to the correct character;...
Page 466 BATTERY SYSTEM 8F - 9 BATTERY (Continued) CHARGING A COMPLETELY DISCHARGED WARNING: EXPLOSIVE HYDROGEN GAS FORMS IN BATTERY AND AROUND THE BATTERY. DO NOT SMOKE, USE FLAME, OR CREATE SPARKS NEAR THE BAT- The following procedure should be used to recharge TERY.
Page 467 8F - 10 BATTERY SYSTEM BATTERY (Continued) STANDARD PROCEDURE - OPEN-CIRCUIT CHARGE RATE TABLE VOLTAGE TEST Voltage Hours A battery open-circuit voltage (no load) test will 16.0 volts maximum up to 4 hours show the approximate state-of-charge of a battery. 14.0 to 15.9 volts up to 8 hours This test can be used in place of the hydrometer test...
Page 468 BATTERY SYSTEM 8F - 11 BATTERY (Continued) STANDARD PROCEDURE - IGNITION-OFF Excessive IOD can be caused by: • Electrical items left on. DRAW TEST • Faulty or improperly adjusted switches. The term Ignition-Off Draw (IOD) identifies a nor- • Faulty or shorted electronic modules and compo- mal condition where power is being drained from the nents.
Page 469 8F - 12 BATTERY SYSTEM BATTERY (Continued) place process to identify and correct all sources of excessive IOD. It is now safe to select the lowest mil- liampere scale of the multi-meter to check the low- amperage IOD. CAUTION: Do not open any doors, or turn on any electrical accessories with the lowest milliampere scale selected, or the multi-meter may be damaged.
Page 470 BATTERY SYSTEM 8F - 13 BATTERY HOLDDOWN (Continued) Fig. 7 JR Battery Tray and Holddown Hardware 1 - BATTERY HOLDOWN STRAP 3 - BATTERY HEATER BLANKET 2 - BATTERY HOLDOWN STRAP 4 - BATTERY TRAY (5) Remove the short bolt from the battery hold The battery negative cable wires have a black insu- down and remove the hold down.
Page 471 8F - 14 BATTERY SYSTEM BATTERY CABLES (Continued) secured to the opposite ends of the battery cable • If the vehicle is equipped with an automatic wires from the female battery terminal clamps pro- transmission, place the gearshift selector lever in the vide secure and reliable connection of the battery Park position.
Page 472 BATTERY SYSTEM 8F - 15 BATTERY CABLES (Continued) Fig. 11 Test Ground Circuit Resistance - Typical Fig. 9 Test Battery Positive Connection Resistance - 1 - VOLTMETER Typical 2 - BATTERY 1 - VOLTMETER 3 - ENGINE GROUND 2 - BATTERY REMOVAL nection at the starter solenoid B(+) terminal stud.
Page 473 8F - 16 BATTERY SYSTEM BATTERY TRAY (Continued) Fig. 12 JR Battery Tray and Holddown Hardware 1 - BATTERY HOLDOWN STRAP 3 - BATTERY HEATER BLANKET 2 - BATTERY HOLDOWN STRAP 4 - BATTERY TRAY the battery holddown hardware combine to secure and stabilize the battery in the engine compartment, which prevents battery movement during vehicle operation.
Page 474 BATTERY SYSTEM 8F - 17 BATTERY HEATER BLANKET (Continued) (8) Disconnect the heater blanket from the vehicles electrical system. Using an Ohmmeter, connect the leads across the two wire terminals coming from the heater blanket. A resistance value of 220 to 280 ohms should be present.
Page 475 8F - 18 CHARGING CHARGING TABLE OF CONTENTS page page CHARGING OPERATION ......20 DESCRIPTION - CHARGING SYSTEM .
Page 476 CHARGING 8F - 19 CHARGING (Continued) and is gradually reduced as the calculated battery Test (Refer to 8 - ELECTRICAL/BATTERY SYSTEM/ temperature increases. BATTERY - STANDARD PROCEDURE) The ambient temperature sensor is used to control • loose generator belt. the battery voltage based upon ambient temperature INSPECTION (approximation of battery temperature).
Page 477 8F - 20 CHARGING CHARGING (Continued) SPECIFICATIONS GENERATOR Type Engine Minimun Test Amperage DENSO 2.0L 135 Amp DENSO 2.4L 135 Amp DENSO 2.7L 135 Amp Test Specification: 1. Engine RPM : 2500 RPM ±20 RPM 2. Voltage Output : 14.0 V ± 0.5 V 3.
Page 478 CHARGING 8F - 21 GENERATOR (Continued) Fig. 1 Remove Battery Cable at Shock Tower Fig. 3 GENERATOR AND MAP SENSOR 1 - Generator 2 - MAP Sensor Fig. 2 Wiring Connections 1 - B+ TERMINAL 2 - CASE GROUND 3 - FEED 4 - TO PCM (11) Remove the generator bolts.
Page 479 8F - 22 CHARGING GENERATOR (Continued) REMOVAL - 2.7L (1) Open Hood. (2) Disconnect the negative battery cable. (3) Raise vehicle and support. (4) Remove the accessory drive belt splash shield. (5) Loosen the accessory drive belt refer to the cooling section.
Page 480 CHARGING 8F - 23 VOLTAGE REGULATOR field. The EVR circuitry monitors system line voltage at the PDC and calculated battery temperature or inlet air temperature sensor (refer to Inlet Air Tem- DESCRIPTION perature Sensor, if equipped, for more information ). The Electronic Voltage Regulator (EVR) is not a It then determines a target charging voltage.
Page 481 8F - 24 STARTING STARTING TABLE OF CONTENTS page page STARTING STARTER MOTOR DESCRIPTION ......24 REMOVAL OPERATION .
Page 482 STARTING 8F - 25 STARTING (Continued) STARTER SOLENOID Circuit Test procedure. If not OK, replace the faulty relay. WARNING: CHECK TO ENSURE THAT THE TRANS- MISSION IS IN THE PARK POSITION WITH THE PARKING BRAKE APPLIED. (1) Verify battery condition. Battery must be in good condition with a full charge before performing any starter tests.
Page 483 8F - 26 STARTING STARTING (Continued) RELAY CIRCUIT TEST IGNITION SWITCH (1) The relay common feed terminal cavity (30) is After testing starter solenoid and relay, test igni- connected to battery voltage and should be hot at all tion switch and wiring. Refer to the Ignition Section times.
Page 484 STARTING 8F - 27 STARTING (Continued) • Wirin g - Visually inspect the wire harness for • P o w e r D is tribu tio n Ce n te r (P D C) - Visually damage. Repair or replace any faulty wiring, as inspect the B+ connections at the PDC for physical required.
Page 485 8F - 28 STARTING STARTING (Continued) CONDITION POSSIBLE CAUSE CORRECTION 5. LOOSE 5. INSPECT FOR LOOSE CONNECTIONS. CONNECTION AT BATTERY, PDC, STARTER, OR ENGINE GROUND. 6. FAULTY TEETH ON 6. ROTATE FLYWHEEL 360°, AND INSPECT TEETH AND RING RING GEAR. GEAR REPLACED IF DAMAGED.
Page 486 STARTING 8F - 29 STARTING (Continued) tery cable terminal on starter solenoid. Rotate and (2) Connect a volt-ampere tester to the battery ter- hold the ignition switch in the START position. If minals. Refer to the operating instructions provided voltage reads above 0.2 volt, correct poor contact at with the tester being used.
Page 487 8F - 30 STARTING STARTER MOTOR (Continued) Fig. 2 STARTER - 4 CYLINDER Fig. 4 O2 SENSOR (7) Remove the front mount bracket from engine block. (8) Remove the battery cable from starter (Fig. 5). Fig. 3 STARTER REMOVAL - 4 CYLINDER REMOVAL - 2.7L (1) Open Hood.
Page 488 STARTING 8F - 31 STARTER MOTOR (Continued) (5) Connect the battery cable and torque nut to 8.5 N·m (75 in. lbs.). (6) Install the front mount bracket and check heat shield location. (7) Install bolt the upper bolt and torque bolt to 54 N·m (40 ft.
Page 490 HEATED SYSTEMS 8G - 1 HEATED SYSTEMS TABLE OF CONTENTS page page HEATED GLASS ......1 HEATED SEAT SYSTEM .
Page 491 8G - 2 HEATED GLASS HEATED GLASS (Continued) OPERATION The electric backlight (EBL) system is controlled by a momentary switch located in the A/C-heater control on the instrument panel (Fig. 2). When the rear window defogger switch is pressed to the On position, the body control module (BCM) energizes the rear window defogger (EBL) relay and battery current is then directed through the relay and to the...
Page 492 HEATED GLASS 8G - 3 HEATED GLASS (Continued) When the above steps have been completed and the vided a ground path by the control circuitry within rear glass heating grid is still inoperative, one or the body control module (BCM). more of the following is faulty: The EBL relay is located in the junction block (JB) •...
Page 493 8G - 4 HEATED GLASS REAR WINDOW DEFOGGER RELAY (Continued) • The coil battery terminal (12) receives fused bat- tery current through an ignition switch output circuit only when the ignition switch is in the Run or Acc position. • The normally open terminal (15) provides fused battery current to the rear window defogger grid through the EBL relay only when the EBL relay coil is energized.
Page 494 HEATED GLASS 8G - 5 REAR WINDOW DEFOGGER SWITCH (Continued) TESTING WITHOUT SCAN TOOL NOTE: For circuit descriptions and diagrams of the rear window defogger (EBL) system, refer to 8W - WIRING DIAGRAM INFORMATION. (1) Remove the A/C-heater control from the instru- ment panel.
Page 495 8G - 6 HEATED GLASS REAR WINDOW DEFOGGER GRID LINES (Continued) (3) Remove the package separator clamp and mix ing and call a physician immediately. Use with ade- the two conductive epoxy components thoroughly quate ventilation. Do not use near fire or flame. within the packaging.
Page 496 HEATED GLASS 8G - 7 REAR WINDOW DEFOGGER GRID LINES (Continued) securely fastened to the rear window defogger bus (4) Properly orient the new terminal(s) with the bar by soldering. attaching clip facing outboard in the original loca- (1) If the grid terminal(s) is broken and a portion tion(s) on the grid bus bar and hold the terminal(s) of the terminal is still attached to the heating grid, with a metal pick or other suitable pointed tool.
Page 497 8G - 8 HEATED MIRRORS HEATED MIRRORS TABLE OF CONTENTS page page HEATED MIRRORS OPERATION ......8 DESCRIPTION .
Page 498 HEATED SEAT SYSTEM 8G - 9 HEATED SEAT SYSTEM TABLE OF CONTENTS page page HEATED SEAT SYSTEM REMOVAL ......11 DESCRIPTION .
Page 499 8G - 10 HEATED SEAT SYSTEM HEATED SEAT SYSTEM (Continued) ature of the seat cushion cover at the heated seat One temperature sensor is used for each outboard sensors is below the designed temperature set points seating position of the front seat, and it is located in of the system and the system voltage is above the the center insert area of the seat cushion cover.
Page 500 HEATED SEAT SYSTEM 8G - 11 HEATED SEAT ELEMENT (Continued) SEAT BACK power will be restored when the system voltage rises above 12.2 volts for 14 seconds and stays there. The (1) Disconnect and isolate the battery negative cycle will repeat if the system voltage again drops cable.
Page 501 8G - 12 HEATED SEAT SYSTEM HEATED SEAT SWITCH (Continued) OPERATION The heated seat switches receive battery current through a fused ignition switch output (run) circuit when the ignition switch is in the On position. The two six-position rotating-type switches provide a hard-wired voltage signal to the heated seat module to power the heated seat element of the selected seat and maintain the requested temperature setting.
Page 502 HEATED SEAT SYSTEM 8G - 13 HEATED SEAT SWITCH (Continued) (1) Remove the heated seat switch as described in CHECKING PASSENGER HEATED SEAT SWITCH this group and inspect the connector for damage. SWITCH POSITION RESISTANCE VALUE (2) Unplug the 7-way connector from the switch ( ) BETWEEN PINS PF and check the harness terminals for proper ignition &...
Page 504 HORN 8H - 1 HORN TABLE OF CONTENTS page page HORN SYSTEM INSTALLATION ......3 DESCRIPTION .
Page 505 8H - 2 HORN HORN SYSTEM (Continued) CONDITION POSSIBLE CAUSE CORRECTION (3) PINCHED HORN (3) REMOVE DRIVER AIRBAG SWITCH WIRE UNDER MODULE AND CHECK FOR DRIVER AIRBAG MODULE. RUBBING, SHORTED OR LOOSE WIRE CONNECTOR AND REPAIR AS NECESSARY. (4) FAULTY HORN SWITCH (4) REPLACE DRIVER AIRBAG MODULE TRIM.
Page 506 HORN 8H - 3 HORN FUSE OK (1) Remove the horn relay from the Junction DIAGNOSIS AND TESTING - HORN Block. (2) Using a continuity tester, Depress horn switch Refer to the appropriate wiring information. The and test continuity from the X3 cavity of the horn wiring information includes wiring diagrams, proper relay to ground.
Page 507 8H - 4 HORN HORN RELAY (1) Remove horn relay from the Junction Block. (2) Using ohmmeter, test between the Junction Block relay terminal 7 and ground for continuity. DESCRIPTION (a) When the horn contact is not depressed, no The horn relay is a International Standards Orga- continuity.
Page 508 IGNITION CONTROL 8I - 1 IGNITION CONTROL TABLE OF CONTENTS page page IGNITION CONTROL INSTALLATION DESCRIPTION - IGNITION SYSTEM ..1 INSTALLATION - 4 CYLINDER ... . . 5 OPERATION - IGNITION SYSTEM .
Page 509 8I - 2 IGNITION CONTROL IGNITION CONTROL (Continued) SPECIFICATIONS TORQUE DESCRIPTION N·m Ft. Lbs. In. Lbs. 2.0/2.4L Target Magnet Screw 2.4L Camshaft Sensor 12.9 Screw 2.0L Camshaft Sensor Screw 2.7L Camshaft Sensor Screw 2.0/2.4L Ignition coil bolts 11.9 2.7L Ignition coil bolts 2.4L Spark Plugs *(Torque 17.6 ±2 13 ±2...
Page 510 IGNITION CONTROL 8I - 3 AUTO SHUT DOWN RELAY (Continued) solenoid equipped) wastegate solenoid (1) Remove the negative battery cable. equipped), and NVLD solenoid (if equipped). (2) Disconnect the PCV hose and reposition. For both SBEC and NGC vehicles, the ASD relay (3) Disconnect electrical connectors from the cam- also provides a sense circuit to the PCM for diagnos- shaft position sensor (Fig.
Page 511 8I - 4 IGNITION CONTROL CAMSHAFT POSITION SENSOR (Continued) REMOVAL - 2.7L The camshaft position sensor is mounted in the front of the head. (1) Disconnect electrical connector from sensor. (2) Remove camshaft position sensor screw. (3) Without pulling on the connector, pull the sen- sor out of the chain case cover (Fig.
Page 512 IGNITION CONTROL 8I - 5 IGNITION COIL (Continued) REMOVAL REMOVAL - 2.7L (1) Prior to removing the ignition coils, spray com- REMOVAL - 4 Cylinder pressed air around the coil area and spark plug (Fig. The electronic ignition coil pack attaches directly to the valve cover (Fig.
Page 513 8I - 6 IGNITION CONTROL IGNITION COIL (Continued) Fig. 8 IGNITION COIL REMOVAL Fig. 9 Ignition Coil Capacitor (3) Connect the electrical connector. 1 - Ignition Coils 2 - Ignition Capacitor IGNITION COIL CAPACITOR Knock sensors contain a piezoelectric material which constantly vibrates and sends an input voltage (signal) to the PCM while the engine operates.
Page 514 IGNITION CONTROL 8I - 7 KNOCK SENSOR (Continued) NOTE: Over or under tightening affects knock sen- sor performance, possibly causing improper spark control. REMOVAL REMOVAL - 4 CYLINDER The knock sensor threads into the side of the cyl- inder block (Fig. 10). Fig.
Page 515 8I - 8 IGNITION CONTROL SPARK PLUG (Continued) DESCRIPTION - PLATINUM PLUGS The V6 engines use platinum resistor spark plugs. They have resistance values of 6,000 to 20,000 ohms when checked with at least a 1000 volt tester. For spark plug identification and specifications, Refer to the Specifications section.
Page 516 INSTRUMENT CLUSTER 8J - 1 INSTRUMENT CLUSTER TABLE OF CONTENTS page page INSTRUMENT CLUSTER INSTRUMENT CLUSTER MASK/LENS DESCRIPTION ......1 REMOVAL .
Page 517 8J - 2 INSTRUMENT CLUSTER INSTRUMENT CLUSTER (Continued) A self-test of the cluster can also be initiated by NOTE: When replacing a cluster, the original pressing and holding the odometer reset button and optional bulbs (ABS, rear fog, front fog, traction switching the ignition from lock to unlock.
Page 518 INSTRUMENT CLUSTER 8J - 3 VACUUM FLUORESCENT (8) Remove the VF-display from the cluster. DISPLAY INSTALLATION (1) Position the VF-display onto the dial assembly REMOVAL and install the two screws. (1) Open hood and disconnect the negative battery (2) Carefully push the dial assembly into the hous- cable remote terminal from the remote battery post.
Page 520 LAMPS 8L - 1 LAMPS TABLE OF CONTENTS page page HEADLAMP UNIT - EXPORT REMOVAL ......3 STANDARD PROCEDURE - HEADLAMP UNIT INSTALLATION .
Page 521 8L - 2 LAMPS HEADLAMP UNIT - EXPORT (Continued) Fig. 1 HEADLAMP ALIGNMENT SCREEN - EXPORT 1 - CENTER OF VEHICLE 5 - 10 METERS (32.8 ft.) 2 - CENTER OF HEADLAMPS 6 - HORIZONTAL CUT-OFF LINE 3 - 15° CUT-OFF LINE 7 - 130mm 4 - FRONT OF HEADLAMP To adjust headlamp alignment, rotate alignment...
Page 522 LAMPS 8L - 3 HEADLAMP UNIT - EXPORT (Continued) REMOVAL (7) Disconnect the wiring harness from the lamps. (8) Disconnect electrical connector from headlamp leveling motor. (9) Remove the headlamp unit (Fig. 4). Fig. 3 HEADLAMP UNIT ALIGNMENT AND MOUNTING SCREWS 1 - HEADLAMP UNIT HORIZONTAL ADJUSTER Fig.
Page 524 MESSAGE SYSTEMS 8M - 1 MESSAGE SYSTEMS TABLE OF CONTENTS page page COMPASS/MINI-TRIP COMPUTER ... . . 1 UNIVERSAL TRANSMITTER ....5 COMPASS/MINI-TRIP COMPUTER TABLE OF CONTENTS page...
Page 525 8M - 2 COMPASS/MINI-TRIP COMPUTER COMPASS/MINI-TRIP COMPUTER (Continued) OPERATION tool and the proper Body Diagnostic Procedures Man- ual or by the following procedure. Actuation of the STEP button will cause the Com- (1) With the ignition switch in the OFF position, pass Mini-Trip Computer to change mode of opera- press both the US/M and STEP button.
Page 526 COMPASS/MINI-TRIP COMPUTER 8M - 3 COMPASS/MINI-TRIP COMPUTER (Continued) VARIANCE SETTING PROCEDURE Variance is the difference between magnetic North and geographic North. (1) Depress the STEP and US/M buttons simulta- neously until VAR appears in the display, then release the buttons. (2) The CMTC will display the current variance zone (1-15).
Page 527 8M - 4 COMPASS/MINI-TRIP COMPUTER COMPASS/MINI-TRIP COMPUTER (Continued) REMOVAL (1) Disconnect and isolate the battery negative remote cable. (2) Remove the Instrument Cluster Bezel from the vehicle (Refer to 23 - BODY/INSTRUMENT PANEL/ CLUSTER BEZEL - REMOVAL). (3) With the cluster bezel removed, remove the two screws attaching the Compass Mini-Trip Computer (Traveler) Module to the cluster bezel (Fig.
Page 528 UNIVERSAL TRANSMITTER 8M - 5 UNIVERSAL TRANSMITTER TABLE OF CONTENTS page page UNIVERSAL TRANSMITTER DIAGNOSIS AND TESTING - UNIVERSAL DESCRIPTION ......5 TRANSMITTER .
Page 530 POWER SYSTEMS 8N - 1 POWER SYSTEMS TABLE OF CONTENTS page page POWER LOCKS ......1 POWER TOP - CONVERTIBLE .
Page 531 8N - 2 POWER LOCKS POWER LOCKS (Continued) system is enabled the automatic door locks will work The front doors can be locked or unlocked mechan- automatically. ically with the locking knob regardless of electrical Auto unlock on exit is a feature which, when locking and unlocking actuation with the front door enabled, automatically unlocks all doors upon the knobs.
Page 532 POWER LOCKS 8N - 3 POWER LOCKS (Continued) REMOTE KEYLESS ENTRY available, check the high current fuse G in the Power Distribution Center, located in the engine compart- The transmitter has four buttons for operation. ment. They are LOCK, UNLOCK, DECK LID RELEASE, To diagnose the Remote Keyless Entry (RKE) Sys- and PANIC.
Page 533 8N - 4 POWER LOCKS DOOR LOCK MOTOR DOOR LOCK SWITCH CONTINUITY DIAGNOSIS AND TESTING - DOOR LOCK SWITCH CONTINUITY RESISTANCE MOTOR POSITION BETWEEN VALUE Make certain battery is in normal condition before LOCK 1 AND 4 2700 ± 10% circuits are tested.
Page 534 POWER LOCKS 8N - 5 DECKLID RELEASE SWITCH STANDARD PROCEDURE - RKE TRANSMITTER PROGRAMMING REMOVAL The Remote Keyless Entry (RKE) Transmitter(s) (1) Disconnect and isolate the battery negative can be programmed with the use of the DRB III cable. scan tool, or by the customer. (2) Remove left lower instrument panel cover.
Page 535 8N - 6 POWER LOCKS REMOTE KEYLESS ENTRY INSTALLATION MODULE (1) Snap the remote keyless entry module onto the BCM. (2) Connect BCM to the Junction Block. REMOVAL (3) Connect the BCM and junction block together. (1) Disconnect the remote battery negative cable (4) Install the Junction Block/BCM into vehicle.
Page 536 POWER MIRRORS 8N - 7 POWER MIRRORS TABLE OF CONTENTS page page POWER MIRRORS POWER MIRROR SWITCH DESCRIPTION ......7 DIAGNOSIS AND TESTING - POWER MIRROR OPERATION .
Page 537 8N - 8 POWER MIRRORS AUTOMATIC DAY / NIGHT MIRROR (Continued) (2) Turn the ignition switch to the On position. Check for battery voltage at the fuse in the junction block. If OK, go to Step 3. If not OK, repair the open circuit to the ignition switch as required.
Page 538 POWER MIRRORS 8N - 9 POWER MIRROR SWITCH SWITCH POSITION CONTINUITY BETWEEN MIRROR SELECT SWITCH IN RIGHT POSITION DIAGNOSIS AND TESTING - POWER MIRROR 10 AND 3 SWITCH 9 AND 7 (1) Remove power mirror switch (Refer to 8 - 7 AND 4 ELECTRICAL/POWER MIRRORS/POWER MIRROR SWITCH - REMOVAL).
Page 539 8N - 10 POWER SEAT SYSTEM POWER SEAT SYSTEM TABLE OF CONTENTS page page POWER SEAT SYSTEM REMOVAL ......13 DESCRIPTION .
Page 540 POWER SEAT SYSTEM 8N - 11 POWER SEAT SYSTEM (Continued) CIRCUIT BREAKER TEST track or recliner adjuster motor. The selected adjuster motor operates to move the seat track or Find correct circuit breaker on fuse block. Pull out recliner through its drive unit in the selected direc- slightly but be sure that circuit breaker terminals tion until the switch is released, or until the travel still contact terminals in fuse block.
Page 541 8N - 12 POWER SEAT SYSTEM DRIVER SEAT SWITCH (Continued) of the circuit breaker must not be allowed to con- (2) Using an ohmmeter, perform the switch conti- tinue, or the motor may be damaged. See the owner’s nuity tests. Refer to the appropriate Switch Continu- manual in the vehicle glove box for more information ity Test table and the seat switch connector (Fig.
Page 542 POWER SEAT SYSTEM 8N - 13 DRIVER SEAT SWITCH (Continued) Fig. 4 Power Seat Switch and Seat Side Shield (2) Install the knobs on the switch (if required). (3) Connect wiring electrical connector on switch. (4) Install the seat cushion side shield. Refer to the Body section of the service manual for the proce- dure.
Page 543 8N - 14 POWER SEAT SYSTEM POWER SEAT TRACK (Continued) The power seat adjuster and motors cannot be or lower the entire seat assembly. The third motor is repaired, and are serviced only as a complete unit. If the horizontal adjustment motor, which moves the any component in this unit is faulty or damaged, the seat track in the forward and rearward directions.
Page 544 POWER SEAT SYSTEM 8N - 15 POWER SEAT TRACK (Continued) (5) Using a voltmeter, connect the ground lead to (5) Remove the bolts retaining the power seat PIN B of the switch harness connector. Connect the track to the seat assembly and remove. positive lead to PIN A (Fig.
Page 545 8N - 16 POWER TOP - CONVERTIBLE POWER TOP - CONVERTIBLE TABLE OF CONTENTS page page POWER TOP - CONVERTIBLE SWITCH - POWER TOP DESCRIPTION ......16 DESCRIPTION .
Page 546 POWER TOP - CONVERTIBLE 8N - 17 POWER TOP - CONVERTIBLE (Continued) • To p U p - Holding the switch in this position (5) Disconnect the power top relay assembly. With raises the convertible top to the closed position. It the ignition switch in the “RUN”...
Page 547 8N - 18 POWER TOP - CONVERTIBLE RELAY - POWER TOP (Continued) (7) Verify normal power top system operation. SWITCH - POWER TOP DESCRIPTION The power top switch is located in the in the center floor console. The switch has three distinct functions: •...
Page 548 POWER TOP - CONVERTIBLE 8N - 19 SWITCH - POWER TOP (Continued) Diagnostic Procedures Information. The scan tool can CHART. If OK, use a scan tool and the proper Diag- provide confirmation that the Programmable Com- nostic Procedures Information to complete diagnosis munications Interface (PCI) data bus is functional, of the power top system.
Page 549 8N - 20 POWER TOP - CONVERTIBLE SWITCH - POWER TOP (Continued) REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Using a suitable flat bladed tool, pry up on the top side of the floor console switch plate (Fig. 5). Fig.
Page 550 POWER TOP - SUNROOF 8N - 21 POWER TOP - SUNROOF TABLE OF CONTENTS page page POWER TOP - SUNROOF STANDARD PROCEDURE - INITIALIZATION . 24 DESCRIPTION ......21 REMOVAL .
Page 551 8N - 22 POWER TOP - SUNROOF POWER TOP - SUNROOF (Continued) Check the condition of the circuit protection and wire and connector repair procedures, details of wire inspect all wiring connector pins for proper engage- harness routing and retention, connector pin-out ment and continuity.
Page 552 POWER TOP - SUNROOF 8N - 23 POWER TOP - SUNROOF (Continued) SYMPTOM POSSIBLE CAUSE CORRECTION Sunroof vents, but does not Binding cable or mechanism. Repair or replace binding cable as open. necessary. Inoperative sunroof OPEN circuit. Check the condition of the circuit, connections and wiring.
Page 553 8N - 24 POWER TOP - SUNROOF MOTOR/MODULE - SUNROOF (Continued) STANDARD PROCEDURE STANDARD PROCEDURE - RE-INITIALIZATION STANDARD PROCEDURE - POWER SUNROOF NOTE: If for some reason the sunroof is not oper- TIMING ating normally it may be necessary to re-initialize the sunroof assembly.
Page 554 POWER TOP - SUNROOF 8N - 25 MOTOR/MODULE - SUNROOF (Continued) • The glass panel has not reached its closed posi- (7) Remove headliner as necessary to gain access tion. to sunroof motor/module. (Refer to 23 - BODY/INTE- RIOR/HEADLINER - REMOVAL). NOTE: if the initialization procedure is not carried (8) Disconnect the motor/module wire harness con- out completely, it must be started over.
Page 555 8N - 26 POWER TOP - SUNROOF SWITCH - SUNROOF the 5 volt reference voltage from the module signal- ing it to perform the desired function. DESCRIPTION F o r c o m p le te c irc u it d ia g ra m s , re fe r to th e a p p ro p ria te w irin g in fo rm a tio n .
Page 556 POWER TOP - SUNROOF 8N - 27 SWITCH - SUNROOF (Continued) INSTALLATION Fig. 2 SUNROOF SWITCH PINOUT REMOVAL Fig. 4 SUNROOF SWITCH RETAINING CLIPS 1 - RETAINING CLIPS 2 - ELECTRICAL CONNECTOR RECEPTACLE (1) Position the sunroof switch in the vehicle. (2) Connect the switch electrical connector to the connector receptacle, (Fig.
Page 557 8N - 28 POWER WINDOWS POWER WINDOWS TABLE OF CONTENTS page page POWER WINDOWS REMOVAL ......29 DESCRIPTION .
Page 558 POWER WINDOWS 8N - 29 POWER WINDOWS (Continued) WINDOW DROP RELAY TEST - JR27 ONLY (c) Reverse battery leads in Step 1 and Step 2 and window should now move. If window does not The following test should be performed if all win- move, replace motor.
Page 559 8N - 30 POWER WINDOWS WINDOW SWITCH (Continued) down position will move the drivers side window SWITCH POSITION CONTINUITY completely down. The electronic switch will automat- BETWEEN ically disconnect the motor approximately 1 second RIGHT REAR UP 1 AND 4 after the window bottoms out.
Page 560 RESTRAINTS 8O - 1 RESTRAINTS TABLE OF CONTENTS page page RESTRAINTS PASSENGER AIRBAG WARNINGS ......2 DESCRIPTION .
Page 561 8O - 2 RESTRAINTS RESTRAINTS STATIC ELECTRICAL ACTIVITY WITH THE FABRIC AIRBAG FACING UP. IF NOT STORED PROPERLY, A WARNINGS PREMATURE DEPLOYMENT COULD HAPPEN AND RESULT IN PERSONAL INJURY OR DEATH. WARNING: THIS SYSTEM IS A SENSITIVE, COM- CAUTION: PLEX UNIT. DISCONNECT AND ISOLATE THE BAT- Deployed and Nondeployed Air Bags may or may TERY NEGATIVE...
Page 562 RESTRAINTS 8O - 3 RESTRAINTS (Continued) STANDARD PROCEDURE CURTAIN AIRBAG After a Curtain Airbag has been deployed due to a STANDARD PROCEDURE - HANDLING collision. the following MU S T be replaced: • Curtain Airbag Assembly AIRBAGS • Headliner • A, B, and C-Pillar Trim on deployed side. DEPLOYED AIRBAG •...
Page 563 8O - 4 RESTRAINTS RESTRAINTS (Continued) repaired and, if faulty or damaged, they must be replaced as a unit with their mounting bracket. Fig. 1 VACUUM HEATER AND A/C OUTLETS - TYPICAL CHILD RESTRAINT ANCHOR DESCRIPTION Fig. 2 CHILD RESTRAINT LOWER ANCHORS Vehicles manufactured for sale in the North Amer- ican market are equipped with a Lower Anchors and 1 - REAR SEAT BACK...
Page 564 RESTRAINTS 8O - 5 CHILD RESTRAINT ANCHOR (Continued) (1) Place LATCH bracket on studs and install wire leads sandwiched between two narrow strips of retaining nuts. Torque nuts to 40 N·m (350 in. lbs.). plastic film. (2) Install the rear seat cushion (Refer to 23 - Like the clock spring in a timepiece, the clock BODY/SEATS/SEAT CUSHION - INSTALLATION).
Page 565 8O - 6 RESTRAINTS CLOCK SPRING (Continued) REMOVAL restraint to driver or outboard passengers in the event of a side impact collision. (1) Disconnect and isolate the battery negative remote cable. OPERATION (2) Wait two minutes for the system reserve capac- The Occupant Restraint Controller (ORC) controls itor to discharge before servicing any airbag compo- the curtain airbags.
Page 566 RESTRAINTS 8O - 7 CURTAIN AIRBAG (Continued) REMOVAL (4) Install the remaining two long retaining bolts to attach the curtain airbag. Torque bolts to 11 ± 1 (1) Open hood and disconnect the negative battery N·m (97.36 ± 10 in. lbs.). cable remote terminal from the remote battery post- (5) Install the five short retaining bolts along the .Wait two minutes for the system reserve capacitor to...
Page 567 8O - 8 RESTRAINTS DRIVER AIRBAG TRIM COVER (Continued) (2) Wait two minutes for the system reserve capac- (5) Secure the horn switch ground (black) connec- itor to discharge before servicing any airbag compo- tor to the airbag mounting plate tab. nents.
Page 568 RESTRAINTS 8O - 9 FRONT SEAT BELT BUCKLE - JR27 ONLY (Continued) WARNING: DO NOT CONNECT THE BATTERY NEG- ATIVE CABLE REMOTE TERMINAL. REFER TO ELECTRICAL, RESTRAINTS, DIAGNOSIS AND TEST- ING - AIRBAG SYSTEM FIRST. FAILURE TO DO SO COULD RESULT IN OCCUPANT PERSONAL INJURY OR DEATH.
Page 569 8O - 10 RESTRAINTS OCCUPANT RESTRAINT CONTROLLER (Continued) The warning equipment is tested for a few seconds IF THE PASSENGER AIRBAG IS TAMPERED WITH, every time the vehicle is started. IT COULD PREMATURELY DEPLOY AND CAUSE PERSONAL INJURY OR DEATH. REMOVAL The most visible part of the Passenger Airbag is the passenger airbag decorative cover located just...
Page 570 RESTRAINTS 8O - 11 PASSENGER AIRBAG (Continued) door tabs down to engage on the instrument panel (5) Remove bolt attaching seat belt anchor to floor retainer. pan (Fig. 4). (2) Install the two nuts and two screws attaching airbag assembly to the instrument panel collar and torque nuts and screws to 7.5 ±...
Page 571 8O - 12 RESTRAINTS SATELLITE ACCELERATION COULD RESULT IN OCCUPANT PERSONAL INJURY OR DEATH. SENSOR SEAT BELT CINCH BAR DESCRIPTION Vehicles equipped with side impact airbags use two STANDARD PROCEDURE - SEAT BELT CINCH Satellite Acceleration Sensors (SAS). One is located on each respective side body B-pillar.
Page 572 RESTRAINTS 8O - 13 SEAT BELT CINCH BAR (Continued) (6) The cinch bar should engage the belt webbing and prevent it from being pulled through to the lap belt side of the latch plate. If the cinching mecha- nism is loose or fails to maintain proper lap belt adjustment while the latch plate is buckled, a seat belt cinch bar repair is required.
Page 573 8O - 14 RESTRAINTS SEAT BELT CINCH BAR (Continued) Fig. 9 CINCH BAR INSTALL 1 - CINCH BAR 2 - LATCH PLATE BAR 3 - LATCH PLATE Fig. 8 CINCH BAR REMOVE 4 - SEAT BELT WEBBING 1 - CINCH BAR COVER 2 - LATCH PLATE BAR 3 - SPRING (2) 4 - CINCH BAR...
Page 574 RESTRAINTS 8O - 15 SEAT BELT CINCH BAR (Continued) OPERATION (3) Align the cinch bar cover with the slots in the cinch bar, then slide the cover forward and snap it This belt system attaches to a reclinable seat back into place (Fig.
Page 575 8O - 16 RESTRAINTS SEAT BELT CONTROL TIMER MODULE - JR27 - EXPORT (Continued) • Solenoid shorted to battery. • No acceleration within the last 10 timer cycles • Internal fault. (one timer cycle - key ON plus 30 minute minimum •...
Page 576 RESTRAINTS 8O - 17 SEAT BELT CONTROL TIMER MODULE - JR27 - EXPORT (Continued) (5) If the voltage is OK, go to Step 6. If no voltage open or shorted circuit and repair as necessary or is detected, check for an open circuit between fuse replace door ajar switch.
Page 577 8O - 18 RESTRAINTS SEAT BELT HEIGHT ADJUSTER (Continued) (2) Remove bolt attaching turning loop to belt height adjuster. (3) Remove upper B-pillar trim panel. (4) Remove bolt attaching seat belt height adjuster to B-pillar. (5) Remove seat belt height adjuster from vehicle. INSTALLATION (1) Place seat belt height adjuster into position.
Page 578 RESTRAINTS 8O - 19 SEAT BELT & RETRACTOR - WARNING: DO NOT CONNECT THE BATTERY NEG- ATIVE CABLE REMOTE TERMINAL. REFER TO FRONT OUTBOARD ELECTRICAL, RESTRAINTS, DIAGNOSIS AND TEST- ING - AIRBAG SYSTEM FIRST. FAILURE TO DO SO REMOVAL COULD RESULT IN OCCUPANT PERSONAL INJURY Inspect the condition of the shoulder belt and lap OR DEATH.
Page 579 8O - 20 RESTRAINTS SEAT BELT TENSIONER WARNING: WHEN FRONT AIRBAG DEPLOYED, TENSIONER WILL HAVE DESCRIPTION DEPLOYED AND MUST BE REPLACED. THIS WILL REQUIRE THE ENTIRE FRONT SEAT BELT & RETRACTOR ASSEMBLY TO BE REPLACED. FAIL- JR41 URE TO DO SO COULD RESULT IN OCCUPANT The seat belt system incorporates Tensioner Mod- PERSONAL INJURY OR DEATH.
Page 580 SPEED CONTROL 8P - 1 SPEED CONTROL TABLE OF CONTENTS page page SPEED CONTROL INSTALLATION ......4 DESCRIPTION SWITCH DESCRIPTION...
Page 581 8P - 2 SPEED CONTROL SPEED CONTROL (Continued) DOWNSHIFT DELAY AUTOMATIC SPEED CONTROL OVERSPEED REDUCTION DESCRIPTION Downshift delay features have been added to DESCRIPTION reduce the number and frequency of downshifts when Transmission control software includes an auto- operating in hilly or mountainous country. matic speed control overspeed reduction feature.
Page 582 SPEED CONTROL 8P - 3 SPEED CONTROL (Continued) Once the speed control has been disengaged, NOTE: Turning the system off by depressing the depressing the RESUME switch when speed is OFF switch or turning off the ignition switch will greater than 20 mph allows the vehicle to resume erase the set speed stored in the PCM.
Page 583 8P - 4 SPEED CONTROL SERVO (Continued) REMOVAL INSTALLATION (1) Disconnect the negative battery cable (Fig. 2). (1) With throttle in full open position feed cable sleeve through hole in bracket, then align hole in speed control cable sleeve with hole in servo pin and install retaining clip (Fig.
Page 584 SPEED CONTROL 8P - 5 SWITCH (Continued) (3) Install airbag, refer to the Restraint Systems section. (4) Install the negative battery cable. VACUUM RESERVOIR DESCRIPTION The vacuum reservoir is located under the left front headlamp, in front of the battery. It is made of plastic and does not contain any other parts, such as a check valve.
Page 585 8P - 6 SPEED CONTROL VACUUM RESERVOIR (Continued) INSTALLATION (3) Install bolt through to reservoir to frame rail. (4) Install the front fascia, refer to the Frames and (1) Connect vacuum hose to reservoir by inserting Bumper/Front Fascia section for more information. nail head pegs on reservoir into the keyhole slots in the frame rail and slide down to lock it into place.
Page 586 VEHICLE THEFT SECURITY 8Q - 1 VEHICLE THEFT SECURITY TABLE OF CONTENTS page page VEHICLE THEFT SECURITY TRANSPONDER KEY DESCRIPTION ......1 DESCRIPTION .
Page 587 8Q - 2 VEHICLE THEFT SECURITY VEHICLE THEFT SECURITY (Continued) NOTE: The VTSS will not arm by pushing down the CAUTION: The VTSS indicator LED will trigger and door lock mechanism. This will manually override engine will continue to run if the vehicle is the system.
Page 588 VEHICLE THEFT SECURITY 8Q - 3 VEHICLE THEFT SECURITY (Continued) bilizer Module (SKIM) is placing the proper messages on the PCI bus, and that the Powertrain Control Module (PCM) is receiving the PCI bus messages. Refer to the proper Body Diagnostic Procedures man- ual, and Wiring Diagrams for complete circuit descriptions and diagrams.
Page 589 8Q - 4 VEHICLE THEFT SECURITY TRANSPONDER KEY (Continued) Common communication problems: is displayed • P ro g ra m m in g N o t Atte m p te d • Two transponder keys too close together. after an Erase All Keys function is executed. •...
Page 590 VEHICLE THEFT SECURITY 8Q - 5 TRANSPONDER KEY (Continued) These steps must be completed in their entirety for The indicator is controlled by the Body Control Mod- each additional Sentry Key to be programmed. If any ule (BCM) based upon messages it receives from the of the above steps are not completed in the given Sentry Key Immobilizer Module (SKIM) on the PCI sequence, or within the allotted time, the SKIS will...
Page 592 WIPERS/WASHERS 8R - 1 WIPERS/WASHERS TABLE OF CONTENTS page page WIPERS/WASHERS INSTALLATION ......4 DESCRIPTION .
Page 593 8R - 2 WIPERS/WASHERS WIPERS/WASHERS (Continued) system, in addition to low and high speeds, has a over loads by a fuse in the junction block. This pro- delay mode and a pulse wipe mode. tects the circuitry of the wiper system and the vehi- The intermittent wiper function is integral to the cle.
Page 594 WIPERS/WASHERS 8R - 3 WIPERS/WASHERS (Continued) DIAGNOSIS AND TESTING - WINDSHIELD is properly connected to all connectors before starting normal diagnosis and repair procedures. Refer to the WASHERS WINDSHIELD WASHER DIAGNOSIS table. Whenever a windshield washer malfunction occurs, first verify that the windshield washer wire harness WINDSHIELD WASHER DIAGNOSIS CONDITION POSSIBLE CAUSE...
Page 595 8R - 4 WIPERS/WASHERS WASHER RESERVOIR (Continued) (7) Drain washer fluid from reservoir into an (4) Remove the arm from the pivot by using a uni- appropriate container. versal claw puller or by hand rock gently side to side (8) Disconnect the washer hose from the reservoir. and slide.
Page 596 WIPERS/WASHERS 8R - 5 WIPER BLADES slightly roll over center when the blade reverses direction. A wiper blade insert that has lost flexibility or a wiper arm that has lost spring tension, will REMOVAL cause the blade to skip or chatter across the wind- (1) Lift wiper arm to raise blade off glass.
Page 597 8R - 6 WIPERS/WASHERS WIPER MOTOR (Continued) (3) Remove one retaining nut to linkage crank to (5) Install the motor retaining bolts. Torque bolts motor shaft and remove crank. to 9 ± 1 N·m (80 ± 9 in. lbs.). (4) Remove the rubber grommet on shaft. (6) Install the motor shaft grommet.
Page 598 WIPERS/WASHERS 8R - 7 WIPER MOTOR ASSEMBLY (2) Connect harness clip to the forward mounting leg. (3) Place assembly into position, install the two REMOVAL mounting bolts, and tighten the mounting bolts to 10 (1) Disconnect and isolate the battery negative to 12 N·m (89 to 106 in.
Page 600 WIRING 8W - 1 WIRING TABLE OF CONTENTS page page WIRING DIAGRAM INFORMATION..8W-01-1 BODY CONTROL MODULE ... . . 8W-45-1 COMPONENT INDEX ....8W-02-1 AUDIO SYSTEM .
Page 602 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 1 8W-01 WIRING DIAGRAM INFORMATION TABLE OF CONTENTS page page WIRING DIAGRAM INFORMATION STANDARD PROCEDURE - TESTING FOR A DESCRIPTION SHORT TO GROUND ....9 DESCRIPTION - HOW TO USE WIRING STANDARD PROCEDURE - TESTING FOR A DIAGRAMS .
Page 603 8W - 01 - 2 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) Fig. 1 WIRING DIAGRAM EXAMPLE 1...
Page 604 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 3 WIRING DIAGRAM INFORMATION (Continued) Fig. 2 WIRING DIAGRAM EXAMPLE 2...
Page 605 8W - 01 - 4 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) Fig. 3 WIRING DIAGRAM SYMBOLS...
Page 606 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 5 WIRING DIAGRAM INFORMATION (Continued) WIRE COLOR CODE CHART LHD ....Left Hand Drive Vehicles RHD ....Right Hand Drive Vehicles ATX .
Page 607 8W - 01 - 6 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) DESCRIPTION - CIRCUIT FUNCTIONS DESCRIPTION - SECTION IDENTIFICATION AND INFORMATION All circuits in the diagrams use an alpha/numeric code to identify the wire and it’s function. To identify The wiring diagrams are grouped into individual which circuit code applies to a system, refer to the sections.
Page 608 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 7 WIRING DIAGRAM INFORMATION (Continued) DESCRIPTION - CONNECTOR, GROUND AND WARNING: BE SURE THAT THE IGNITION SWITCH SPLICE INFORMATION ALWAYS IS IN THE OFF POSITION, UNLESS THE PROCEDURE REQUIRES IT TO BE ON. CAUTION: Not all connectors are serviced.
Page 609 8W - 01 - 8 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) • Ohmmeter - Used to check the resistance factory items added to the vehicle before doing any between two points of a circuit. Low or no resistance diagnosis.
Page 610 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 9 WIRING DIAGRAM INFORMATION (Continued) STANDARD PROCEDURE - TESTING OF VOLTAGE POTENTIAL (1) Connect the ground lead of a voltmeter to a known good ground (Fig. 7). (2) Connect the other lead of the voltmeter to the selected test point.
Page 611 8W - 01 - 10 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) STANDARD PROCEDURE - TESTING FOR A VOLTAGE DROP (1) Connect the positive lead of the voltmeter to the side of the circuit closest to the battery (Fig. 9). (2) Connect the other lead of the voltmeter to the other side of the switch, component or circuit.
Page 612 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 11 CONNECTOR INSTALLATION (1) Insert the removed terminal in the same cavity REMOVAL on the repair connector. (2) Repeat steps for each terminal in the connec- (1) Disconnect battery. tor, being sure that all wires are inserted into the (2) Release Connector Lock (Fig.
Page 613 8W - 01 - 12 8W-01 WIRING DIAGRAM INFORMATION CONNECTOR (Continued) Fig. 11 EXAMPLES OF CONNECTOR SECONDARY TERMINAL LOCKS 1 - Secondary Terminal Lock...
Page 614 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 13 CONNECTOR (Continued) Fig. 12 TERMINAL REMOVAL 1 - TYPICAL CONNECTOR 7 - MOLEX CONNECTOR 2 - PICK FROM SPECIAL TOOL KIT 6680 8 - SPECIAL TOOL 6742 3 - APEX CONNECTOR 9 - THOMAS AND BETTS CONNECTOR 4 - PICK FROM SPECIAL TOOL KIT 6680 10 - SPECIAL TOOL 6934...
Page 615 8W - 01 - 14 8W-01 WIRING DIAGRAM INFORMATION DIODE TERMINAL REMOVAL REMOVAL (1) Disconnect the battery. (1) Follow steps for removing terminals described (2) Locate the diode in the harness, and remove in the connector removal section. the protective covering. (2) Cut the wire 6 inches from the back of the con- (3) Remove the diode from the harness, pay atten- nector.
Page 616 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 15 WIRE (5) Solder the connection together using rosin core type solder only (Fig. 16). STANDARD PROCEDURE - WIRE SPLICING CAUTION: DO NOT USE ACID CORE SOLDER. When splicing a wire, it is important that the cor- rect gage be used as shown in the wiring diagrams.
Page 618 8W-02 COMPONENT INDEX 8W - 02 - 1 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 A/C Compressor Clutch ....8W-42 Engine Coolant Temp Sensor .
Page 619 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 Oil Pressure Switch ....8W-40 Seat Belt Solenoids .
Page 620 8W-10 POWER DISTRIBUTION 8W - 10 - 1 8W-10 POWER DISTRIBUTION 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 Compressor Clutch ....8W-10-17 Fuse 20 .
Page 648 8W-12 JUNCTION BLOCK 8W - 12 - 1 8W-12 JUNCTION 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-Heater Control ....8W-12-14, 18 Left Fog Lamp .
Page 676 8W-15 GROUND DISTRIBUTION 8W - 15 - 1 8W-15 GROUND DISTRIBUTION 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-Heater Control ..... 8W-15-8 Left Park/Turn Signal Lamp .
Page 700 8W-18 BUS COMMUNICATIONS 8W - 18 - 1 8W-18 BUS COMMUNICATIONS Co m p o n e n t P a g e Co m p o n e n t P a g e Airbag Control Module ....8W-18-3 G203 .
Page 704 8W-20 CHARGING SYSTEM 8W - 20 - 1 8W-20 CHARGING SYSTEM Co m p o n e n t P a g e Co m p o n e n t P a g e Auto Shut Down Relay ....8W-20-2 G103 .
Page 706 8W-21 STARTING SYSTEM 8W - 21 - 1 8W-21 STARTING SYSTEM Co m p o n e n t P a g e Co m p o n e n t P a g e Battery ......8W-21-2, 3 Ignition Switch .
Page 710 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 1 8W-30 FUEL/IGNITION SYSTEM 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 Compressor Clutch Relay ..8W-30-5 Fuse 24 .
Page 736 8W-31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 1 8W-31 TRANSMISSION CONTROL SYSTEM Co m p o n e n t P a g e Co m p o n e n t P a g e Automatic Day/Night Mirror ... 8W-31-5 Input Speed Sensor .
Page 746 8W-33 VEHICLE SPEED CONTROL 8W - 33 - 1 8W-33 VEHICLE SPEED CONTROL Co m p o n e n t P a g e Co m p o n e n t P a g e Body Control Module ....8W-33-2 G203 .
Page 750 8W-35 ANTI-LOCK BRAKES 8W - 35 - 1 8W-35 ANTI-LOCK BRAKES Co m p o n e n t P a g e Co m p o n e n t P a g e Anti-Lock Brake Module ... 8W-35-2, 3, 4 G113 .
Page 756 8W-39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 1 8W-39 VEHICLE THEFT SECURITY SYSTEM Co m p o n e n t P a g e Co m p o n e n t P a g e Body Control Module ..8W-39-2, 3, 4, 5, 6, 7 Horn Relay .
Page 764 8W-40 INSTRUMENT CLUSTER 8W - 40 - 1 8W-40 INSTRUMENT CLUSTER Co m p o n e n t P a g e Co m p o n e n t P a g e Airbag Control Module ....8W-40-4 G103 .
Page 772 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET 8W - 41 - 1 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET Co m p o n e n t P a g e Co m p o n e n t P a g e Body Control Module ....8W-41-2 G301 .
Page 776 8W-42 AIR CONDITIONING-HEATER 8W - 42 - 1 8W-42 AIR CONDITIONING-HEATER 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 Compressor Clutch ....8W-42-9 Fuse 12 .
Page 786 8W-43 OCCUPANT RESTRAINT SYSTEM 8W - 43 - 1 8W-43 OCCUPANT RESTRAINT SYSTEM Co m p o n e n t P a g e Co m p o n e n t P a g e Airbag Control Module . . 8W-43-2, 3, 4, 5, 6, 7, 8, 9 G302 .
Page 798 8W-44 INTERIOR LIGHTING 8W - 44 - 1 8W-44 INTERIOR LIGHTING 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-Heater Control ....8W-44-6 Instrument Cluster .
Page 806 8W-45 BODY CONTROL MODULE 8W - 45 - 1 8W-45 BODY CONTROL MODULE 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 EVAPorator Temperature Sensor . . 8W-45-8, 10 G108 .
Page 824 8W-47 AUDIO SYSTEM 8W - 47 - 1 8W-47 AUDIO SYSTEM Co m p o n e n t P a g e Co m p o n e n t P a g e Antenna ....8W-47-2, 3, 4, 5, 11 Left Rear Speaker .
Page 836 8W-48 REAR WINDOW DEFOGGER 8W - 48 - 1 8W-48 REAR WINDOW 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 A/C-Heater Control ....8W-48-2 G303 .
Page 840 8W-50 FRONT LIGHTING 8W - 50 - 1 8W-50 FRONT LIGHTING Co m p o n e n t P a g e Co m p o n e n t P a g e Auto Headlamp Relay ....8W-50-6 Headlamp Beam Select Switch .
Page 856 8W-51 REAR LIGHTING 8W - 51 - 1 8W-51 REAR LIGHTING Co m p o n e n t P a g e Co m p o n e n t P a g e Anti-Lock Brake Module ....8W-51-3 Left Rear Fog Lamp .
Page 868 8W-52 TURN SIGNALS 8W - 52 - 1 8W-52 TURN SIGNALS Co m p o n e n t P a g e Co m p o n e n t P a g e Combination Flasher ....8W-52-2 Left Park/Turn Signal Lamp .
Page 872 8W-53 WIPERS 8W - 53 - 1 8W-53 WIPERS Co m p o n e n t P a g e Co m p o n e n t P a g e Body Control Module ... . . 8W-53-2, 3, 4 G103 .
Page 876 8W-60 POWER WINDOWS 8W - 60 - 1 8W-60 POWER WINDOWS Co m p o n e n t P a g e Co m p o n e n t P a g e Body Control Module ....8W-60-6 Junction Block .
Page 884 8W-61 POWER DOOR LOCKS 8W - 61 - 1 8W-61 POWER DOOR LOCKS Co m p o n e n t P a g e Co m p o n e n t P a g e Body Control Module ... 8W-61-3, 4, 5, 6 Left Rear Door Lock Motor/Ajar Switch .
Page 890 8W-62 POWER MIRRORS 8W - 62 - 1 8W-62 POWER MIRRORS Co m p o n e n t P a g e Co m p o n e n t P a g e Automatic Day/Night Mirror ..8W-62-5, 6 G301 .
Page 896 8W-63 POWER SEAT 8W - 63 - 1 8W-63 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 Body Control Module ....8W-63-5 Heated Seat Relay .
Page 902 8W-64 POWER SUNROOF 8W - 64 - 1 8W-64 POWER SUNROOF Co m p o n e n t P a g e Co m p o n e n t P a g e Circuit Breaker No. 2 (JB) ... . . 8W-64-2 Sunroof Control Module .
Page 904 8W-66 POWER TOP 8W - 66 - 1 8W-66 POWER TOP Co m p o n e n t P a g e Co m p o n e n t P a g e Body Control Module ....8W-66-2, 3 Junction Block .
Page 908 8W-70 SPLICE INFORMATION 8W - 70 - 1 8W-70 SPLICE INFORMATION 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 ......8W-10-14, 15 S212 .
Page 914 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 1 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 A/C Compressor Clutch (2.4L/2.7L) ..8W-80-4 C225 .
Page 915 Heated Seat Switch ....8W-80-51 Left Turn Lamp (Chrysler/Except JR41 Horizontal Motor (JR27) ....8W-80-52...
Page 916 Right Tail/Turn Signal Lamp (JR41 Dodge) . 8W-80-91 Power Amplifier C2 (JR27 Premium) ..8W-80-74 Right Turn Lamp (Chrysler/Except JR41 Power Amplifier C2 (JR41 Premium) ..8W-80-75 Dodge) ......8W-80-91 Power Antenna (Export) .
Page 917 8W - 80 - 4 8W-80 CONNECTOR PIN-OUTS A/C COMPRESSOR CLUTCH (2.4L/2.7L) - LT . GRAY 2 WAY CIRCUIT FUNCTION C3 14DB/BK A/C COMPRESSOR CLUTCH RELAY OUTPUT A/C COMPRESSOR CLUTCH (2.0L) - BLACK 2 WAY CIRCUIT FUNCTION C3 14DB/BK A/C COMPRESSOR CLUTCH RELAY OUTPUT A/C EVAPORATOR TEMPERATURE SENSOR - BLACK 2 WAY CIRCUIT FUNCTION...
Page 918 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 5 A/C-HEATER CONTROL C1 (MTC) - NATURAL 8 WAY CIRCUIT FUNCTION C57 20DB/GY SENSOR GROUND C16 20LB/YL FUSED REAR WINDOW DEFOGGER RELAY OUTPUT E17 18YL/BK DAY BRIGHTNESS SENSE E2 20OR PANEL LAMPS DRIVER C21 20DB/OR A/C SWITCH SENSE C58 20RD/TN...
Page 919 8W - 80 - 6 8W-80 CONNECTOR PIN-OUTS AIRBAG CONTROL MODULE (ORC) (BASE) - YELLOW 23 WAY CIRCUIT FUNCTION R56 20LB/DG PASSENGER SEAT BELT TENSIONER LINE 1 R54 20LB/YL PASSENGER SEAT BELT TENSIONER LINE 2 R62 20OR/YL PASSENGER SQUIB 2 LINE 1 R64 20TN/YL PASSENGER SQUIB 2 LINE 2 R42 20BK/YL...
Page 920 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 7 AIRBAG CONTROL MODULE C1 (ORC) (PREMIUM) - YELLOW 32 WAY CIRCUIT FUNCTION R53 20LG/YL DRIVER SEAT BELT TENSIONER LINE 2 R55 20LG/DG DRIVER SEAT BELT TENSIONER LINE 1 R56 20LB/DG PASSENGER SEAT BELT TENSIONER LINE 1 R54 20LB/YL PASSENGER SEAT BELT TENSIONER LINE 2 R77 20LB/BR...
Page 921 8W - 80 - 8 8W-80 CONNECTOR PIN-OUTS AIRBAG CONTROL MODULE C2 (ORC) (PREMIUM) - YELLOW 32 WAY CIRCUIT FUNCTION R45 20DG/LB DRIVER SQUIB 1 LINE 2 R43 20BK/LB DRIVER SQUIB 1 LINE 1 R61 20OR/LB DRIVER SQUIB 2 LINE 1 R63 20TN/LB DRIVER SQUIB 2 LINE 2 R44 20DG/YL...
Page 922 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 9 ANTI-LOCK BRAKE MODULE - 47 WAY CIRCUIT FUNCTION A10 12RD/DG FUSED B(+) (PUMP) L50 20WT/TN BRAKE LAMP SWITCH OUTPUT F12 18DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) D25 18YL/VT PCI BUS Z102 12BK GROUND A20 12RD/DB FUSED B(+) (VALVE)
Page 923 8W - 80 - 10 8W-80 CONNECTOR PIN-OUTS AUTO HEADLAMP RELAY (PREMIUM) - NATURAL 5 WAY CIRCUIT FUNCTION L109 20WT FUSED IGNITION SWITCH OUTPUT L124 20WT/DB AUTO HEADLAMP RELAY CONTROL A3 16RD/WT FUSED B(+) L309 20WT/OR AUTO HEADLAMP RELAY OUTPUT AUTOMATIC DAY/NIGHT MIRROR - BLACK 7 WAY CIRCUIT FUNCTION...
Page 924 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 11 AUTOSTICK SWITCH - NATURAL 4 WAY CIRCUIT FUNCTION T44 20YL (JR27) AUTOSTICK DOWNSHIFT SWITCH SIGNAL T44 20YL/LB (JR41) AUTOSTICK DOWNSHIFT SWITCH SIGNAL T5 20LG (JR27) AUTOSTICK UPSHIFT SWITCH SIGNAL T5 20LG/LB (JR41) AUTOSTICK UPSHIFT SWITCH SIGNAL Z191 20BK GROUND...
Page 925 8W - 80 - 12 8W-80 CONNECTOR PIN-OUTS BLOWER MOTOR - BLACK 2 WAY CIRCUIT FUNCTION C72 12GY (ATC) BLOWER MOTOR SUPPLY C7 12BK (MTC) BLOWER MOTOR DRIVER C71 12DB (ATC) BLOWER MOTOR GROUND C1 12DG (MTC) FUSED IGNITION SWITCH OUTPUT (RUN) BLOWER MOTOR POWER MODULE C1 (ATC) - BLACK 4 WAY CIRCUIT FUNCTION...
Page 926 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 13 BODY CONTROL MODULE C1 - 16 WAY CIRCUIT FUNCTION E19 20RD PANEL LAMPS DRIVER X3 20BK/RD HORN/RADIO CONTROL MUX G69 20BK/OR VTSS INDICATOR DRIVER G26 20LB KEY-IN IGNITION SWITCH SENSE L177 20WT/OR (PREMIUM) PARK LAMP RELAY CONTROL P58 20WT (EXPORT) RKE EXTERNAL ANTENNA...
Page 927 8W - 80 - 14 8W-80 CONNECTOR PIN-OUTS BODY CONTROL MODULE C3 - GRAY 16 WAY CIRCUIT FUNCTION D25 20OR PCI BUS (PCM) D25 18YL/VT PCI BUS (ABS) D25 20VT/YL PCI BUS (PCM) V55 20TN/RD FRONT WIPER PARK SWITCH SENSE V14 20RD/VT FRONT WIPER ON/OFF RELAY CONTROL V16 20VT/PK...
Page 928 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 15 BRAKE FLUID LEVEL SWITCH - BLACK 2 WAY CIRCUIT FUNCTION G9 20GY/BK BRAKE WARNING INDICATOR DRIVER Z231 20BK GROUND BRAKE LAMP SWITCH - GRAY 6 WAY CIRCUIT FUNCTION K29 20WT/PK BRAKE SWITCH SIGNAL Z241 20BK (2.7L MTX) GROUND Z241 20BK/LG (EXCEPT 2.7L MTX)
Page 929 8W - 80 - 16 8W-80 CONNECTOR PIN-OUTS C100 - LT . GREEN (HEADLAMP AND DASH SIDE) CIRCUIT A15 16PK A51 20RD/WT D6 20PK/LB (EATX) D20 20LG D21 20PK G6 18GY K29 20WT/PK (EATX) K29 20WT/PK (EATX) L101 18RD (EXPORT) L101 18RD (EXPORT) C101 - LT .
Page 930 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 17 C104 (EATX) - LT . GRAY (HEADLAMP AND DASH SIDE) CIRCUIT T9 20OR/BK T54 20VT/YL T41 20BK/WT T16 20RD T19 20WT T41 20BK/WT T50 20DG T59 20PK T60 20BR C104 (EATX) - LT . GRAY (AUTOMATIC TRANS- MISSION SIDE) CIRCUIT T9 18OR/BK...
Page 931 8W - 80 - 18 8W-80 CONNECTOR PIN-OUTS C105 (EATX) - BLACK (AUTOMATIC TRANSMIS- SION SIDE) CIRCUIT F20 18WT T1 20LG/BK T3 18VT T13 18DB/BK T14 18LG/WT T20 18LB T42 20VT/WT T47 18YL/BK T52 18RD/BK L1 18VT/BK C111 - BLACK (ENGINE HARNESS SIDE) CIRCUIT Z1 20BK C3 14DB/BK...
Page 932 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 19 C121 - NATURAL (HEADLAMP AND DASH SIDE) CIRCUIT K106 20WT/DG K107 20OR L95 18DG/YL (JR27 EXPORT) A45 18BR (JR27) B1 20YL/DB (ABS) B2 20YL (ABS) P86 16PK/BK (HEATED SEAT) A25 12DB (JR27) T44 20YL (AUTOSTICK) T5 20LG (AUTOSTICK) Z2 20BK/TN...
Page 933 8W - 80 - 20 8W-80 CONNECTOR PIN-OUTS C169 (2.0L MTX) - BLACK (HEADLAMP AND DASH SIDE) CIRCUIT K7 18OR K4 18BK/LB G7 18WT/OR F20 18WT L1 18VT/BK C169 (2.0L MTX) - BLACK (MTX HARNESS SIDE) CIRCUIT K7 18OR/WT K4 20BK/LB G7 18WT/OR F20 18WT L1 18VT/BK...
Page 934 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 21 C171 (2.4L PZEV) - DK. GRAY (ASSEMBLY SIDE) CIRCUIT Z14 10TN A161 10BK C171 (2.4L PZEV) - DK. GRAY (HEADLAMP AND DASH SIDE) CIRCUIT Z14 16BK/YL A161 14LB/WT C200 (ATC) - (HVAC SIDE) CIRCUIT C34 20DB/WT C35 20DG/YL...
Page 935 8W - 80 - 22 8W-80 CONNECTOR PIN-OUTS C200 (ATC) - WHITE (INSTRUMENT PANEL SIDE) CIRCUIT C34 20DB/WT C35 20DG/YL C33 20DB/RD C32 20GY/DB C57 20DB/YL C26 20PK/DB C1 12DG C7 18BK/TN C12 20LG/BK C36 18RD/WT C37 20YL Z118 12BK C56 20RD/LG C200 (MTC) - NATURAL (HVAC SIDE) CIRCUIT...
Page 936 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 23 C200 (MTC) - NATURAL (INSTRUMENT PANEL SIDE) CIRCUIT C34 20DB/WT C35 20DG/YL C33 20DB/RD C4 16TN C57 20DB/YL C26 20PK/DB C7 14BK/TN C1 14DG C12 20LG/BK C36 18RD/WT C37 20YL C5 16LG C6 14LB C32 20GY/DB C225 - BLACK (JUMPER SIDE)
Page 937 L60 20TN L7 20BK/YL Z151 18BK C301 - BLACK (RIGHT REAR LAMP SIDE) CIRCUIT L1 18VT/BK L50 18WT/TN L60 18LG (CHRYSLER EXPORT) L60 18TN (DODGE) L60 18LG (JR27) L7 18BK/YL Z151 18BK C302 - BLACK (INSTRUMENT PANEL SIDE) CIRCUIT F30 18RD...
Page 938 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 25 C302 - BLACK (UNIBODY SIDE) CIRCUIT F30 18RD (EXCEPT JR41 BASE) G9 20GY/BK G73 20LG/OR (VTSS) L36 18LG (REAR FOG LAMPS) P97 20WT/DG P175 20OR/BK P177 20DB/WT Q1 14YL/WT (JR41) Q1 14YL (JR41) C303 - LT .
Page 939 8W - 80 - 26 8W-80 CONNECTOR PIN-OUTS C303 - LT . GRAY (UNIBODY SIDE) CIRCUIT F11 20RD/WT (AUTOSTICK) F13 18DB (JR27 EXPORT) G75 20TN (JR41) G72 20DG/OR (JR27 EXPORT) P96 20WT/LG P176 20PK/BK P178 20PK/LB Q13 14DB (JR27) Q17 14DB/WT (JR41) Q14 14GY (JR27) Q18 14GY/BK (JR41) Q23 14RD/WT (JR27)
Page 940 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 27 C304 (JR41) - YELLOW (UNIBODY SIDE) CIRCUIT R53 20LG/YL (EXCEPT SIDE AIRBAG) R13 20LG/TN (SIDE AIRBAG) R55 20LG/DG (EXCEPT SIDE AIRBAG) R15 20LG/BR (SIDE AIRBAG) R54 20LB/YL (EXCEPT SIDE AIRBAG) R14 20TN/LG (SIDE AIRBAG) R56 20LB/DG (EXCEPT SIDE AIRBAG) R16 20BK/LG (SIDE AIRBAG) C305 (JR41) - BLACK (CHMSL SIDE)
Page 941 8W - 80 - 28 8W-80 CONNECTOR PIN-OUTS C306 - BLACK (UNIBODY SIDE) CIRCUIT X93 18WT/RD X94 18TN/VT X91 18WT/BK X92 18TN/BK X60 20DG/RD (EXPORT) C307 - NATURAL (DOME LAMP SIDE) CIRCUIT M2 18YL (JR27) M2 20YL (JR41) F20 20BK/WT (AUTOMATIC DAY/NIGHT MIRROR) G38 18GY (JR27) L1 18BK/VT (JR27 AUTOMATIC DAY/...
Page 942 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 29 C308 (JR41) - BLUE (UNIBODY SIDE) CIRCUIT P179 20OR/BR P181 20PK/BK Q1 14YL Q17 14DB/WT Q27 14RD/BK G77 20TN/OR Z317 20BK/VT C309 (JR27 POWER SEAT) - GRAY (POWER SEAT JUMPER SIDE) CIRCUIT F35 16RD Z1 16BK C309 (JR27 POWER SEAT) - GRAY (UNIBODY...
Page 943 8W - 80 - 30 8W-80 CONNECTOR PIN-OUTS C309 (JR41 POWER SEAT) - BLACK (POWER SEAT JUMPER SIDE) CIRCUIT F35 16RD Z1 16BK C310 - BROWN (INSTRUMENT PANEL SIDE) CIRCUIT M1 20PK P97 20WT/DG P91 22WT/BK P95 22DB Q16 14BR/WT Q14 14GY (JR27) Q18 14GY/BK (JR41) Q37 20OR/WT (JR27)
Page 944 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 31 C311 - BLUE (INSTRUMENT PANEL SIDE) CIRCUIT Q1 14YL (JR41) Q23 14RD/WT (JR27) Q27 14RD/BK (JR41) Q13 14DB (JR27) Q17 14DB/WT (JR41) F21 14TN Q26 14VT/WT Z314 14BK/TN (JR27) Z243 14BK/TN (JR41) Q24 14DG (JR27) Q28 14DG/WT (JR41) X87 20LG/VT (JR27 BASE)
Page 945 8W - 80 - 32 8W-80 CONNECTOR PIN-OUTS C312 (EXCEPT JR41 BASE) - BLACK (CONSOLE SIDE) CIRCUIT F20 20YL/BK (JR27) Q31 20OR/DB (JR27) Z316 18BK/WT (POWER OUTLET) Z249 20BK (JR27) M1 18PK M2 18YL F30 18RD (POWER OUTLET) C312 (EXCEPT JR41 BASE) - BLACK (UNIBODY SIDE) CIRCUIT F20 20WT (JR27)
Page 946 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 33 C315 - BROWN (RIGHT FRONT DOOR SIDE) CIRCUIT M1 20PK P96 20WT/LG P90 22LG/BK P90 22LG/BK (JR27) P92 22YL C16 20LB/YL (JR27 PREMIUM) C16 20LB/OR (JR41 PREMIUM) P94 22WT/YL G74 20TN/RD C316 - BLUE (INSTRUMENT PANEL SIDE) CIRCUIT P176 20OR/WT (JR27) P176 20PK/BK (JR41)
Page 947 8W - 80 - 34 8W-80 CONNECTOR PIN-OUTS C316 - BLUE (RIGHT FRONT DOOR SIDE) CIRCUIT P176 20PK/BK P178 20PK/LB Q1 14YL (JR41) Q16 14BR/WT Q26 14VT/WT Z315 14BK (JR27) Z242 20BK (JR41) X80 18LB/BK X82 18LB/VT F21 14TN (JR27) C318 (JR41) - BLUE (RIGHT REAR DOOR SIDE) CIRCUIT P180 18OR/TN...
Page 948 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 35 C320 (JR27) - BLACK (REAR SIDE) CIRCUIT L7 18BK/YL Z149 18BK C320 (JR27) - BLACK (UNIBODY SIDE) CIRCUIT L7 20BK/YL Z149 18BK C320 (JR41) - BLACK (REAR SIDE) CIRCUIT L7 18BK/YL (EXPORT) Z150 18BK L36 18LG (REAR FOG LAMPS) C320 (JR41) - BLACK (UNIBODY SIDE)
Page 949 8W - 80 - 36 8W-80 CONNECTOR PIN-OUTS C321 - BLACK (UNIBODY SIDE) CIRCUIT A141 16DG/WT G4 20DB Z211 16BK F12 20DB/WT (LEAK DETECTION) K106 20WT/DG (LEAK DETECTION) K107 20OR (LEAK DETECTION) C322 (JR27 EXPORT) - BLACK (FOG LAMP HARNESS SIDE) CIRCUIT Z149 18BK L36 18LG...
Page 950 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 37 C323 - BLACK (SWITCH SIDE) CIRCUIT P7 20LB/BK F11 20RD P8 20LB/WT F99 20RD/BK F98 20RD/WT Z260 20BK C324 - BLACK (JUMPER SIDE) CIRCUIT P86 16PK/BK Z121 16BK P7 20LB/BK F99 20RD/WT C324 - BLACK (SEAT SIDE) CIRCUIT P86 16PK/BK...
Page 951 8W - 80 - 38 8W-80 CONNECTOR PIN-OUTS C325 - BLACK (SEAT SIDE) CIRCUIT P86 16PK/BK Z122 16BK P8 20LB/WT F98 20RD/WT CAMSHAFT POSITION SENSOR - BLACK 3 WAY CIRCUIT FUNCTION K6 20VT/WT 5 VOLT SUPPLY K4 20BK/LB SENSOR GROUND 1 K44 20TN/YL CMP SIGNAL CD CHANGER - BLACK 8 WAY...
Page 952 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 39 CENTER HIGH MOUNTED STOP LAMP (JR41) - BLACK 2 WAY CIRCUIT FUNCTION Z1 18BK GROUND L50 18BK/TN BRAKE LAMP SWITCH OUTPUT CLOCKSPRING C1 - YELLOW 5 WAY CIRCUIT FUNCTION V37 20RD/LG S/C SWITCH SIGNAL Z123 20BK/OR GROUND X3 20BK/RD...
Page 953 8W - 80 - 40 8W-80 CONNECTOR PIN-OUTS COIL ON PLUG NO. 1 (2.7L) - BLACK 2 WAY CIRCUIT FUNCTION F42 18DG/LG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT K91 18TN/RD COIL CONTROL NO. 1 COIL ON PLUG NO. 2 (2.7L) - BLACK 2 WAY CIRCUIT FUNCTION F42 18DG/LG...
Page 954 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 41 COIL ON PLUG NO. 5 (2.7L) - BLACK 2 WAY CIRCUIT FUNCTION F42 18DG/LG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT K95 18TN/DG COIL CONTROL NO. 5 COIL ON PLUG NO. 6 (2.7L) - BLACK 2 WAY CIRCUIT FUNCTION F42 18DG/LG...
Page 955 8W - 80 - 42 8W-80 CONNECTOR PIN-OUTS DATA LINK CONNECTOR - BLACK 16 WAY CIRCUIT FUNCTION D25 20VT/YL PCI BUS (DLC) Z305 20BK/YL GROUND Z306 20BK/VT GROUND D21 20PK SCI TRANSMIT F11 20RD/WT FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) D6 20PK/LB SCI RECEIVE (TCM) D20 20LG SCI RECEIVE...
Page 956 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 43 DECKLID RELEASE SWITCH - BLACK 2 WAY CIRCUIT FUNCTION P1 20BK/WT DECKLID RELEASE SWITCH SENSE Z223 20BK/DB GROUND DOME LAMP (JR41) - BLACK 3 WAY CIRCUIT FUNCTION M1 20PK FUSED B(+) M2 20YL COURTESY LAMPS DRIVER M2 20YL (PREMIUM) COURTESY LAMPS DRIVER...
Page 957 8W - 80 - 44 8W-80 CONNECTOR PIN-OUTS DRIVER DOOR LOCK MOTOR/AJAR SWITCH - BLACK 4 WAY CIRCUIT FUNCTION G75 20TN DRIVER DOOR AJAR SWITCH SENSE Z314 20BK (JR27) GROUND Z243 20BK (JR41) GROUND P177 20DB/WT DRIVER UNLOCK RELAY OUTPUT P175 20OR/BK DRIVER LOCK RELAY OUTPUT DRIVER DOOR LOCK SWITCH - NATURAL 4 WAY...
Page 958 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 45 DRIVER POWER WINDOW MOTOR (JR41) - LT . GRAY 2 WAY CIRCUIT FUNCTION Q21 16WT LEFT FRONT WINDOW DRIVER (DOWN) Q11 16LB DRIVER POWER WINDOW DRIVER (UP) DRIVER SEAT BELT SOLENOID (JR27 EXPORT) - NATURAL 2 WAY CIRCUIT FUNCTION R7 18OR/BK...
Page 959 8W - 80 - 46 8W-80 CONNECTOR PIN-OUTS DRIVER SEAT BELT TENSIONER (JR41) - YELLOW/BLACK 2 WAY CIRCUIT FUNCTION R53 20LG/YL DRIVER SEAT BELT TENSIONER LINE 2 R55 20LG/DG DRIVER SEAT BELT TENSIONER LINE 1 EGR SOLENOID (2.4L PZEV/2.7L) - BLACK 6 WAY CIRCUIT FUNCTION K235 20LG/PK...
Page 960 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 47 FOG LAMP RELAY (PREMIUM) - NATURAL 5 WAY CIRCUIT FUNCTION L35 20BR/WT FOG LAMP SWITCH SENSE E17 18YL/BK DAY BRIGHTNESS SENSE L39 18LB FRONT FOG LAMP INDICATOR DRIVER A15 16PK/LB FUSED B(+) FRONT VERTICAL MOTOR (JR27) - BLACK 2 WAY CIRCUIT FUNCTION...
Page 961 8W - 80 - 48 8W-80 CONNECTOR PIN-OUTS FRONT WIPER MOTOR - BLACK 4 WAY CIRCUIT FUNCTION V55 20TN/RD FRONT WIPER PARK SWITCH SENSE Z114 20BK GROUND V3 16BR/WT FRONT WIPER LOW SPEED OUTPUT V4 16RD/YL FRONT WIPER HIGH SPEED OUTPUT FUEL INJECTOR NO.
Page 962 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 49 FUEL INJECTOR NO. 2 (2.0L/2.4L) - BLACK 2 WAY CIRCUIT FUNCTION F42 18DG/LG AUTOMATIC SHUT DOWN RELAY OUTPUT K12 18TN INJECTOR CONTROL NO. 2 FUEL INJECTOR NO. 3 (2.0L/2.4L) - BLACK 2 WAY CIRCUIT FUNCTION F42 18DG/LG...
Page 963 8W - 80 - 50 8W-80 CONNECTOR PIN-OUTS FUEL INJECTOR NO. 4 (2.0L/2.4L) - BLACK 2 WAY CIRCUIT FUNCTION F42 18DG/LG AUTOMATIC SHUT DOWN RELAY OUTPUT K14 18LB/BR INJECTOR CONTROL NO. 4 FUEL INJECTOR NO. 5 (2.7L) - BLACK 2 WAY CIRCUIT FUNCTION F42 18DG/LG...
Page 964 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 51 GENERATOR - BLACK 2 WAY CIRCUIT FUNCTION Z12 20BK/TN GROUND K20 18DG GENERATOR FIELD DRIVER HEADLAMP LEVELING SWITCH (EXPORT) - BLACK 3 WAY CIRCUIT FUNCTION L7 18BK/YL FUSED PARK LAMP RELAY OUTPUT Z3 16BK/OR (JR27) GROUND Z3 16BK (JR41)
Page 965 8W - 80 - 52 8W-80 CONNECTOR PIN-OUTS HORIZONTAL MOTOR (JR27) - BLACK 2 WAY CIRCUIT FUNCTION P17 18RD/LB LEFT SEAT HORIZONTAL REARWARD P15 18YL/LB LEFT SEAT HORIZONTAL FORWARD HORIZONTAL MOTOR (JR41) - BLACK 2 WAY CIRCUIT FUNCTION P15 16YL/LB LEFT SEAT HORIZONTAL REARWARD P17 16RD/LB LEFT SEAT HORIZONTAL FORWARD...
Page 966 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 53 IGNITION SWITCH C1 - BLACK 2 WAY CIRCUIT FUNCTION A51 20RD/WT FUSED B(+) A81 20DG/RD FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) IGNITION SWITCH C2 - BLACK 10 WAY CIRCUIT FUNCTION A2 12PK/BK FUSED B(+) A22 12BK/OR FUSED IGNITION SWITCH OUTPUT (RUN) A1 18RD...
Page 967 8W - 80 - 54 8W-80 CONNECTOR PIN-OUTS INPUT SPEED SENSOR - GRAY 2 WAY CIRCUIT FUNCTION T13 18DB/BK SPEED SENSOR GROUND T52 18RD/BK INPUT SPEED SENSOR SIGNAL INSTRUMENT CLUSTER - 26 WAY CIRCUIT FUNCTION D25 20VT/OR PCI BUS (MIC) D25 20VT/RD PCI BUS (TRAVELER) G69 20BK/OR...
Page 968 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 55 JUNCTION BLOCK BODY CONTROL MODULE JB - 12 WAY CIRCUIT FUNCTION L3 14RD/OR DIMMER SWITCH HIGH BEAM OUTPUT INTERNAL FUSED B(+) INTERNAL REAR WINDOW DEFOGGER RELAY CONTROL INTERNAL HEADLAMP DELAY RELAY OUTPUT INTERNAL HEADLAMP DELAY RELAY CONTROL INTERNAL...
Page 969 8W - 80 - 56 8W-80 CONNECTOR PIN-OUTS JUNCTION BLOCK C3 - WHITE 4 WAY CIRCUIT FUNCTION A7 16RD/BK FUSED B(+) A13 12PK/WT FUSED B(+) A3 12RD/WT FUSED B(+) A4 12BK/PK FUSED B(+) JUNCTION BLOCK C4 - BLUE 10 WAY CIRCUIT FUNCTION Z106 18BK/OR...
Page 970 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 57 JUNCTION BLOCK C6 - WHITE 6 WAY CIRCUIT FUNCTION A22 12BK/OR FUSED IGNITION SWITCH OUTPUT (RUN) L4 16VT/WT DIMMER SWITCH LOW BEAM OUTPUT L4 16VT/WT (BASE/EXPORT) DIMMER SWITCH LOW BEAM OUTPUT L3 14RD/OR DIMMER SWITCH HIGH BEAM OUTPUT A3 16RD/WT FUSED B(+)
Page 971 8W - 80 - 58 8W-80 CONNECTOR PIN-OUTS JUNCTION BLOCK C9 - WHITE 12 WAY CIRCUIT FUNCTION F35 16RD (POWER SEATS) FUSED B(+) F20 20WT FUSED IGNITION SWITCH OUTPUT (RUN) F20 20WT (JR27) FUSED IGNITION SWITCH OUTPUT (RUN) Z313 14BK GROUND L60 20TN RIGHT TURN SIGNAL...
Page 972 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 59 KNOCK SENSOR - BLACK 2 WAY CIRCUIT FUNCTION K42 20DB/LG (2.0L/2.4L) KS SIGNAL K45 20BK/VT (2.7L) KS RETURN K45 20BK/VT (2.0L/2.4L) KS RETURN K42 20DB/LG (2.7L) KS SIGNAL KNOCK SENSOR (2.7L) - BLACK 2 WAY CIRCUIT FUNCTION K45 20BK/VT...
Page 973 8W - 80 - 60 8W-80 CONNECTOR PIN-OUTS LEFT FRONT DOOR SPEAKER - BLACK 3 WAY CIRCUIT FUNCTION X85 18LG/DG (BASE) LEFT FRONT SPEAKER (-) X85 18LG/DG (PREMIUM) AMPLIFIED LEFT FRONT SPEAKER (-) X87 18LG/VT (BASE) LEFT FRONT SPEAKER (+) X87 18LG/VT (PREMIUM) AMPLIFIED LEFT FRONT SPEAKER (+) LEFT FRONT INSTRUMENT PANEL SPEAKER (JR27 BASE) - WHITE 2 WAY...
Page 974 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 61 LEFT FRONT WHEEL SPEED SENSOR - BLACK 2 WAY CIRCUIT FUNCTION B9 20RD LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUP- B8 20RD/DB LEFT FRONT WHEEL SPEED SENSOR SIGNAL LEFT HEADLAMP (EXCEPT EXPORT) - BLACK 3 WAY CIRCUIT FUNCTION L43 18VT...
Page 975 8W - 80 - 62 8W-80 CONNECTOR PIN-OUTS LEFT LICENSE LAMP (JR41 EXPORT) - NATURAL 2 WAY CIRCUIT FUNCTION L7 18BK/YL FUSED PARK LAMP RELAY OUTPUT Z150 18BK GROUND LEFT PARK/TURN SIGNAL LAMP - BLACK 3 WAY CIRCUIT FUNCTION L61 16LG LEFT TURN SIGNAL L7 20BK/BR HEADLAMP SWITCH OUTPUT...
Page 976 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 63 LEFT REAR FOG LAMP (JR27 EXPORT) - GRAY 2 WAY CIRCUIT FUNCTION Z149 18BK GROUND L36 18LG REAR FOG LAMP CONTROL LEFT REAR FOG LAMP (JR41 EXPORT) - GRAY 3 WAY CIRCUIT FUNCTION Z150 18BK GROUND...
Page 977 8W - 80 - 64 8W-80 CONNECTOR PIN-OUTS LEFT REAR SPEAKER - 3 WAY CIRCUIT FUNCTION X91 18WT/BK (BASE) LEFT REAR SPEAKER (-) X91 18WT/BK (PREMIUM) AMPLIFIED LEFT REAR SPEAKER (-) X93 18WT/RD (BASE) LEFT REAR SPEAKER (+) X93 18WT/RD (PREMIUM) AMPLIFIED LEFT REAR SPEAKER (+) LEFT REAR WHEEL SPEED SENSOR - BLACK 2 WAY CIRCUIT...
Page 978: Left Tail/Turn Signal Lamp
FUNCTION Z150 18BK GROUND L7 18BK/YL FUSED PARK LAMP RELAY OUTPUT L61 18LG LEFT TURN SIGNAL LEFT TURN LAMP (CHRYSLER/EXCEPT JR41 DODGE) - TAN 2 WAY CIRCUIT FUNCTION L61 18LG LEFT TURN SIGNAL Z149 18BK (JR27) GROUND Z150 18BK (JR41)
Page 979: License Lamp
8W - 80 - 66 8W-80 CONNECTOR PIN-OUTS LICENSE LAMP (JR41 EXCEPT EXPORT) - NATURAL 2 WAY CIRCUIT FUNCTION L7 18BK/YL FUSED PARK LAMP RELAY OUTPUT Z150 18BK GROUND MANIFOLD ABSOLUTE PRESSURE SENSOR - GRAY 3 WAY CIRCUIT FUNCTION K1 20DG/RD MAP SIGNAL K4 20BK/LB SENSOR GROUND 1...
Page 980 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 67 MASTER POWER WINDOW SWITCH - BLUE 12 WAY CIRCUIT FUNCTION F21 14TN FUSED IGNITION SWITCH OUTPUT (RUN) Q17 14DB/WT (EXCEPT JR27) MASTER WINDOW SWITCH LEFT REAR UP Q13 14DB (JR27) LEFT REAR WINDOW DRIVER UP Q290 14YL/OR (JR27) MASTER WINDOW SWITCH LEFT REAR DOWN Q27 14RD/BK (JR41)
Page 981 8W - 80 - 68 8W-80 CONNECTOR PIN-OUTS MULTI-FUNCTION SWITCH C2 - BLUE 12 WAY CIRCUIT FUNCTION L4 16VT/WT (EXCEPT PREMIUM) DIMMER SWITCH LOW BEAM OUTPUT L309 20WT/OR (PREMIUM) AUTO HEADLAMP RELAY OUTPUT L4 16VT/WT DIMMER SWITCH LOW BEAM OUTPUT L3 14RD/OR DIMMER SWITCH HIGH BEAM OUTPUT A3 16RD/WT...
Page 982 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 69 OUTPUT SPEED SENSOR - GRAY 2 WAY CIRCUIT FUNCTION T13 18DB/BK SPEED SENSOR GROUND T14 18LG/WT OUTPUT SPEED SENSOR SIGNAL OVERHEAD MAP/COURTESY LAMPS (JR41) - BLACK 3 WAY CIRCUIT FUNCTION Z312 20BK GROUND M1 20PK FUSED B(+)
Page 983 8W - 80 - 70 8W-80 CONNECTOR PIN-OUTS OXYGEN SENSOR 1/2 DOWNSTREAM (2.0L/2.4L) - 4 WAY CIRCUIT FUNCTION Z186 20BK GROUND K199 18BR/VT O2 1/2 HEATER CONTROL K904 18DB/DG O2 RETURN (DOWN) K141 20TN/WT O2 1/2 SIGNAL OXYGEN SENSOR 1/2 RIGHT BANK DOWN (2.7L) - 4 WAY CIRCUIT FUNCTION Z188 20BK...
Page 984 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 71 PARK LAMP RELAY (PREMIUM) - NATURAL 5 WAY CIRCUIT FUNCTION L177 20WT/OR PARK LAMP RELAY CONTROL F33 18PK/RD FUSED B(+) L7 16BK/YL HEADLAMP SWITCH OUTPUT L7 16BK/YL HEADLAMP SWITCH OUTPUT F33 20PK/RD FUSED B(+) PASSENGER AIRBAG - YELLOW 4 WAY CIRCUIT...
Page 985 8W - 80 - 72 8W-80 CONNECTOR PIN-OUTS PASSENGER HEATED SEAT MODULE - BLACK 6 WAY CIRCUIT FUNCTION P86 16PK/BK HEATED SEAT RELAY OUTPUT Z122 16BK GROUND F98 20RD/WT PASSENGER HEATED SEAT FEED P8 20LB/WT PASSENGER HEATED SEAT SWITCH OUTPUT PASSENGER POWER WINDOW MOTOR (JR27) - BLACK 2 WAY CIRCUIT FUNCTION...
Page 986 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 73 PASSENGER SEAT BELT SOLENOID (JR27) - BLACK 2 WAY CIRCUIT FUNCTION R8 18OR/RD PASSENGER SEAT BELT SOLENOID CONTROL Z219 18BK GROUND PASSENGER SEAT BELT TENSIONER (JR27) - YELLOW 4 WAY CIRCUIT FUNCTION R54 20LB/YL PASSENGER SEAT BELT TENSIONER LINE 2 R56 20LB/DG...
Page 987 8W - 80 - 74 8W-80 CONNECTOR PIN-OUTS POWER AMPLIFIER C1 (JR41 PREMIUM) - WHITE 22 WAY CIRCUIT FUNCTION F75 16VT FUSED B(+) Z115 16BK/RD GROUND X60 20DG/RD RADIO 12V OUTPUT X54 20VT RIGHT FRONT SPEAKER (+) X53 20DG LEFT FRONT SPEAKER (+) X52 20DB/WT RIGHT REAR SPEAKER (+) X51 20BR/YL...
Page 988 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 75 POWER AMPLIFIER C2 (JR41 PREMIUM) - WHITE 12 WAY CIRCUIT FUNCTION X87 18LG/VT AMPLIFIED LEFT FRONT SPEAKER (+) X82 18LB/VT AMPLIFIED RIGHT FRONT SPEAKER (+) X83 18YL/RD AMPLIFIED LEFT INSTRUMENT PANEL SPEAKER (+) X86 18OR/RD AMPLIFIED RIGHT INSTRUMENT PANEL SPEAKER X85 18LG/DG...
Page 989 8W - 80 - 76 8W-80 CONNECTOR PIN-OUTS POWER OUTLET (JR27/JR41 EXPORT) - BLACK 3 WAY CIRCUIT FUNCTION F30 18RD FUSED B(+) Z316 18BK/WT GROUND POWER SEAT SWITCH (JR27) - 12 WAY CIRCUIT FUNCTION F35 16RD FUSED B(+) Z1 16BK GROUND P21 18RD/LG LEFT SEAT FRONT UP...
Page 990 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 77 POWER STEERING PRESSURE SWITCH (2.0L) - BLACK 2 WAY CIRCUIT FUNCTION K10 20DB/LG POWER STEERING PRESSURE SWITCH SENSE Z244 20BK GROUND POWER TOP PUMP MOTOR (JR27) - RED 2 WAY CIRCUIT FUNCTION P3 12YL TOP UP RELAY OUTPUT P4 12RD...
Page 991 8W - 80 - 78 8W-80 CONNECTOR PIN-OUTS POWERTRAIN CONTROL MODULE C1 - BLACK/BLACK 38 WAY CIRCUIT FUNCTION Z12 16BK/TN GROUND F12 18DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) F11 18RD/WT FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) G7 18WT/OR (MTX) VEHICLE SPEED SIGNAL Z12 16BK/TN GROUND C18 20DB...
Page 992 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 79 POWERTRAIN CONTROL MODULE C2 - BLACK/ORANGE 38 WAY CIRCUIT FUNCTION K96 18TN/LB (2.7L) COIL CONTROL NO. 6 K95 18TN/DG (2.7L) COIL CONTROL NO. 5 K94 18TN/LG (2.7L) COIL CONTROL NO. 4 K58 18BR/DB (2.7L) INJECTOR CONTROL NO.
Page 993 8W - 80 - 80 8W-80 CONNECTOR PIN-OUTS POWERTRAIN CONTROL MODULE C3 - BLACK/NATURAL 38 WAY CIRCUIT FUNCTION K51 20DB/VT AUTOMATIC SHUT DOWN RELAY CONTROL C27 20DB/PK HIGH SPEED RAD F AN RELAY CONTROL V35 20LG/RD S/C VENT CONTROL C24 20DB/TN LOW RAD F AN RELAY CONTROL V32 20YL/RD S/C SUPPLY...
Page 994 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 81 POWERTRAIN CONTROL MODULE C4 - BLACK/GREEN 38 WAY CIRCUIT FUNCTION T60 20BR OD SOLENOID CONTROL T59 20PK UD SOLENOID CONTROL T19 20WT 2-4 SOLENOID CONTROL T20 20LB L/R SOLENOID CONTROL Z14 16BK/YL GROUND Z13 16BK/RD GROUND...
Page 995 8W - 80 - 82 8W-80 CONNECTOR PIN-OUTS RADIATOR F AN - BLACK 4 WAY CIRCUIT FUNCTION Z212 14BK GROUND Z213 14BK GROUND C23 12DG LOW RAD F AN RELAY OUTPUT C25 12YL HIGH RAD F AN RELAY OUTPUT RADIO C1 - WHITE 22 WAY CIRCUIT FUNCTION X12 18RD/WT...
Page 996 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 83 RADIO C2 - BLACK 10 WAY CIRCUIT FUNCTION X40 22GY/WT AUDIO OUT RIGHT Z4 22BK/OR GROUND C235 WT/LB CD GROUND SHIELD D25 22VT/YL PCI BUS X112 22RD IGNITION SWITCH OUTPUT (RUN-ACC) X41 22DG/WT AUDIO OUT LEFT Z140 22BK/TN GROUND...
Page 997 8W - 80 - 84 8W-80 CONNECTOR PIN-OUTS RECIRCULATION DOOR ACTUATOR - 2 WAY CIRCUIT FUNCTION C32 20GY/DB RECIRCULATION DOOR DRIVER C34 20DB/WT COMMON DOOR DRIVER RECLINE MOTOR (JR41) - GREEN 2 WAY CIRCUIT FUNCTION P41 16GY/WT LEFT SEAT RECLINER SWITCH UP P43 16GY/LB LEFT SEAT RECLINER SWITCH DOWN RIGHT BACK-UP LAMP - GRAY 2 WAY...
Page 998 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 85 RIGHT FOG LAMP (JR41) - BLACK 2 WAY CIRCUIT FUNCTION L39 20LB FOG LAMP RELAY OUTPUT Z144 20BK GROUND RIGHT FRONT DOOR SPEAKER - BLACK 3 WAY CIRCUIT FUNCTION X80 18LB/BK (BASE) RIGHT FRONT SPEAKER (-) X80 18LB/BK (PREMIUM) AMPLIFIED RIGHT FRONT SPEAKER (-)
Page 999 8W - 80 - 86 8W-80 CONNECTOR PIN-OUTS RIGHT FRONT INSTRUMENT PANEL SPEAKER (JR41 PREMIUM) - 3 WAY CIRCUIT FUNCTION X84 18OR/BK AMPLIFIED RIGHT INSTRUMENT PANEL SPEAKER (-) X86 18OR/RD AMPLIFIED RIGHT INSTRUMENT PANEL SPEAKER RIGHT FRONT WHEEL SPEED SENSOR - BLACK 2 WAY CIRCUIT FUNCTION B7 20WT...
Page 1000 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 87 RIGHT LICENSE LAMP (JR27) - NATURAL 2 WAY CIRCUIT FUNCTION L7 18BK/YL FUSED PARK LAMP RELAY OUTPUT Z149 18BK GROUND RIGHT LICENSE LAMP (JR41 EXPORT) - NATURAL 2 WAY CIRCUIT FUNCTION L7 18BK/YL FUSED PARK LAMP RELAY OUTPUT Z150 18BK GROUND...
Page 1001: Rear Fog Lamp Relay
8W - 80 - 88 8W-80 CONNECTOR PIN-OUTS RIGHT REAR DOOR LOCK MOTOR/AJAR SWITCH (JR41) - BLACK 4 WAY CIRCUIT FUNCTION G76 20TN/YL RIGHT REAR DOOR AJAR SWITCH SENSE Z318 18BK GROUND P182 18PK/DB RIGHT REAR UNLOCK RELAY OUTPUT P180 18OR/TN RIGHT REAR LOCK RELAY OUTPUT RIGHT REAR FOG LAMP (JR27 EXPORT) - GRAY 2 WAY CIRCUIT...
Page 1002 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 89 RIGHT REAR POWER WINDOW SWITCH (JR41) - BLUE 6 WAY CIRCUIT FUNCTION Q24 14DG RIGHT REAR WINDOW DRIVER DOWN Q18 14GY/BK MASTER WINDOW SWITCH RIGHT REAR (UP) Q28 14DG/WT MASTER WINDOW SWITCH RIGHT REAR (DOWN) Q14 14GY RIGHT REAR WINDOW DRIVER UP Q1 14YL...
Page 1003: Right Tail/Side Marker Lamp
8W - 80 - 90 8W-80 CONNECTOR PIN-OUTS RIGHT SIDE IMPACT SENSOR 1 - GRAY 2 WAY CIRCUIT FUNCTION R16 20BK/LG RIGHT SIDE IMPACT SENSOR 1 GROUND R14 20TN/LG RIGHT SIDE IMPACT SENSOR 1 SIGNAL RIGHT SPEED CONTROL SWITCH - LT . GREEN 2 WAY CIRCUIT FUNCTION V37 22RD/LG...
Page 1004: Right Tail/Turn Signal Lamp
FUNCTION Z151 18BK GROUND L7 18BK/YL FUSED PARK LAMP RELAY OUTPUT L60 18TN RIGHT TURN SIGNAL RIGHT TURN LAMP (CHRYSLER/EXCEPT JR41 DODGE) - TAN 2 WAY CIRCUIT FUNCTION L60 18LG RIGHT TURN SIGNAL Z151 18BK GROUND RIGHT VISOR/VANITY LAMPS - BLACK 2 WAY...
Page 1005 8W - 80 - 92 8W-80 CONNECTOR PIN-OUTS SENTRY KEY IMMOBILIZER MODULE - BLACK 6 WAY CIRCUIT FUNCTION D25 20VT/PK PCI BUS (SKIM) F12 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) Z110 20BK GROUND A51 20RD/WT FUSED B(+) SUN SENSOR (ATC) - BLACK 4 WAY CIRCUIT FUNCTION C57 20DB/GY...
Page 1006 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 93 THROTTLE POSITION SENSOR (2.0L/2.4L) - GRAY 3 WAY CIRCUIT FUNCTION K6 20VT/WT 5 VOLT SUPPLY K22 20OR/DB TP SIGNAL K4 20BK/LB SENSOR GROUND 1 THROTTLE POSITION SENSOR (2.7L) - BLACK 3 WAY CIRCUIT FUNCTION K6 20VT/WT...
Page 1007: Transmission Range Sensor
8W - 80 - 94 8W-80 CONNECTOR PIN-OUTS TRANSMISSION RANGE SENSOR - DK. GRAY 10 WAY CIRCUIT FUNCTION F20 18WT FUSED IGNITION SWITCH OUTPUT (RUN) T13 20DB/BK SPEED SENSOR GROUND T54 18VT/YL TRANSMISSION TEMPERATURE SENSOR SIGNAL T41 20BK/LB TRS T41 SENSE L1 18VT/BK BACK-UP LAMP FEED T1 20LG/BK...
Page 1008 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 95 VEHICLE SPEED CONTROL SERVO - BLACK 4 WAY CIRCUIT FUNCTION V36 20TN/RD S/C VACUUM CONTROL V35 20LG/RD S/C VENT CONTROL V30 20DB/RD SPEED CONTROL BRAKE SWITCH OUTPUT Z190 20BK GROUND VEHICLE SPEED SENSOR (2.0L MTX) - BLACK 3 WAY CIRCUIT FUNCTION K7 18OR/WT...
Page 1010 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 1 8W-91 CONNECTOR/GROUND/SPLICE LOCATION TABLE OF CONTENTS page CONNECTOR/GROUND/SPLICE LOCATION DESCRIPTION ......1 CONNECTOR/GROUND/SPLICE tor, ground, and splice identification.
Page 1011 8W - 91 - 2 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Connector Name/Number Color Location Fig. Back-Up Lamp Switch (MTX) Rear of Transmission Battery Negative Post Left Side Engine Compartment Battery Positive Post Left Side Engine Compartment 8, 9 Battery Positive Terminal Left Side Engine Compartment Blend Door Actuator At Blend Door, Bottom Center of HVAC...
Page 1012 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 3 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Connector Name/Number Color Location Fig. C311 Lower Left Side Instrument Panel 21, 23 C312 (Except JR41 Domestic) Center Behind Occupant Restraint Controller C315 Right Side Instrument Panel 21, 26, 50, 51 C316 Right Side Instrument Panel 21, 26, 50, 51...
Page 1013 8W - 91 - 4 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Connector Name/Number Color Location Fig. Decklid Cylinder Lock Switch At Decklid 56, 57 (VTSS) Decklid Release Solenoid/Ajar At Decklid 56, 57 Switch Decklid Release Switch Left Side Instrument Panel 21, 23 Dome Lamp At Lamp...
Page 1014 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 5 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Connector Name/Number Color Location Fig. Fuel Pump Module C1 LT/GY Center Rear of Trunk Area Generator (2.0L/2.4L) Rear of Generator Generator (2.7L) Rear of Generator 15, 16 Ground Jumper (Transmission) Lower Left Engine Compartment Headlamp Delay Relay In Junction Block...
Page 1015 8W - 91 - 6 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Connector Name/Number Color Location Fig. Left Fog Lamp On Airbag Module At Headliner Left Front Door Speaker At Speaker, Similar to Right, See Passenger Door Connectors Left Front Instrument Panel At Speaker 21, 22 Speaker...
Page 1016 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 7 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Connector Name/Number Color Location Fig. Noise Suppressor At Left Front of Engine Head Oil Pressure Switch (2.0L/ LT/GN Rear of Engine at Switch 2.4L) Oil Pressure Switch (2.7L) LT/GN Rear of Engine at Switch Output Speed Sensor Left Side of Transmission...
Page 1017 8W - 91 - 8 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Connector Name/Number Color Location Fig. Power Top Pump Motor At Motor Power Top Switch At switch on Center Console Power Top Up/Down Relays At Relay Powertrain Control Module C1 At Module (NGC) Powertrain Control Module C1...
Page 1018 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 9 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Connector Name/Number Color Location Fig. Right Power Mirror At Mirror 50, 51 Right Rear Door Lock In Door near Latch Motor/Ajar Switch Right Rear Fog Lamp (Export) At Lamp Right Rear Power Window At Motor Motor (JR41)
Page 1019 8W - 91 - 10 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) GROUNDS Connector Name/Number Location Fig. G100 Left Strut Tower G103 Near Left Strut Tower G104 (2.7L) Near EGR Solenoid G106 Right Headlamp Area G108 Left Headlamp Area G113 Left Headlamp Area G201 Center Body Between Occupant Restraint Controller and 21, 39...
Page 1020 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 11 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Splice Number Location Fig. S125 Near A/T inline Connectors S127 Left Front Engine Compartment S130 Near T/O for Left Headlamp S131 Near T/O for Brake Fluid Level Switch S135 Near T/O for Power Steering Pressure Switch S137 (2.7L) In Engine Valley Near Left Engine Head...
Page 1021 8W - 91 - 12 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Splice Number Location Fig. S304 Between Left Tail/Stop Lamp and Left Turn Lamp S305 Between Right Tail/Stop Lamp and Right Turn Lamp S306 Near Rear Window Defogger S307 Near C320 S310 2.4 (60mm)Toward Passenger Heated Seat Module, from Harness tie down...
Page 1022 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 13 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 1 RIGHT HEADLAMP CONNECTORS Fig. 2 RIGHT FRONT LIGHTING CONNECTORS...
Page 1023 8W - 91 - 14 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 3 RIGHT SIDE ENGINE COMPARTMENT CONNECTORS Fig. 4 LEFT FRONT ENGINE COMPARTMENT CONNECTORS...
Page 1024 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 15 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1025 8W - 91 - 16 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 6 LEFT REAR ENGINE COMPARTMENT CONNECTORS Fig. 7 LEFT FOG LAMP...
Page 1026 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 17 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 8 POWER DISTRIBUTION CENTER Fig. 9 BATTERY CABLE CONNECTORS...
Page 1027 8W - 91 - 18 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1028 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 19 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1029 8W - 91 - 20 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1030 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 21 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1031 8W - 91 - 22 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1032 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 23 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1033 8W - 91 - 24 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 16 GENERATOR AND A/C CONNECTORS...
Page 1034 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 25 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 17 INLET AIR TEMPERATURE SENSOR 2.7L Fig. 18 REAR ENGINE CONN 2.0L/2.4L...
Page 1035 8W - 91 - 26 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 19 OXYGEN SENSORS 2.0L/2.4L Fig. 20 OXYGEN SENSORS 2.7L...
Page 1036 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 27 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1037 8W - 91 - 28 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1038 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 29 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1039 8W - 91 - 30 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 24 LEFT INSTRUMENT PANEL INLINES Fig. 25 BRAKE LAMP SWITCH...
Page 1040 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 31 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1041 8W - 91 - 32 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 27 CENTER INSTRUMENT PANEL REAR Fig. 28 CENTER INSTRUMENT PANEL CONNECTORS...
Page 1042 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 33 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 29 INSTRUMENT CLUSTER Fig. 30 STEERING COLUMN...
Page 1043 8W - 91 - 34 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1044 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 35 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1045 8W - 91 - 36 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 33 GLOVE BOX CONNECTORS Fig. 34 HVAC CONNECTORS (MTC)
Page 1046 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 37 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 35 HVAC RIGHT (ATC) Fig. 36 BLOWER MOTOR POWER MODULE...
Page 1047 8W - 91 - 38 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 37 HVAC LEFT (ATC) Fig. 38 HEADER CONNECTORS...
Page 1048 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 39 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1049 8W - 91 - 40 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1050 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 41 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1051 8W - 91 - 42 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1052 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 43 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1053 8W - 91 - 44 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 44 DRIVER POWER SEAT SWITCH Fig. 45 DRIVER POWER SEAT MOTORS...
Page 1054 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 45 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1055 8W - 91 - 46 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 47 RIGHT REAR QUARTER PANEL...
Page 1056 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 47 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1057 8W - 91 - 48 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1058 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 49 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1059 8W - 91 - 50 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1060 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 51 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 1061 8W - 91 - 52 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 53 TRUNK CONNECTORS (JR-27) Fig. 54 TRUNK CONNECTORS (JR-41)
Page 1062 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 53 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 55 CENTER HIGH MOUNTED STOP LAMP Fig. 56 DECKLID CONNECTORS (JR-27)
Page 1063 8W - 91 - 54 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 57 DECKLID CONNECTORS (JR-41)
Page 1064 8W-97 POWER DISTRIBUTION 8W - 97 - 1 8W-97 POWER DISTRIBUTION TABLE OF CONTENTS page page POWER DISTRIBUTION OPERATION ......3 OPERATION .
Page 1065 8W - 97 - 2 8W-97 POWER DISTRIBUTION CENTER CONSOLE POWER OUTLET REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Open the console lid (Fig. 1). Fig. 2 CIGAR LIGHTER / POWER OUTLET BASE REMOVAL Fig. 1 POWER OUTLET 1 - RETAINING BOSSES-ENGAGE PLIERS HERE 1 - POWER OUTLET 2 - PARTIALLY REMOVED...
Page 1066 8W-97 POWER DISTRIBUTION 8W - 97 - 3 IOD FUSE (Continued) system or condition, other than the same purpose as proper fuse identification. The left instrument panel that of any other standard circuit protection device. endcap must be removed to access components other The IOD fuse can be used by the vehicle owner as than the fuses in the JB.
Page 1067 8W - 97 - 4 8W-97 POWER DISTRIBUTION JUNCTION BLOCK (Continued) REMOVAL (10) With the Junction Block/BCM removed from the vehicle, separate the BCM from the Junction Block. WARNING: (11) Remove the BCM attaching screws. ON VEHICLES EQUIPPED WITH AIRBAGS, REFER (12) Disconnect BCM from the Junction Block.
Page 1068 8W-97 POWER DISTRIBUTION 8W - 97 - 5 POWER DISTRIBUTION CENTER (Continued) any internal circuit of the PDC or the PDC housing (5) Install and tighten the fasteners that secure is faulty or damaged, the entire PDC and headlamp/ each of the engine compartment wire harness ground dash wire harness unit must be replaced.
Page 1070 ENGINE 9 - 1 ENGINE TABLE OF CONTENTS page page ENGINE 2.0L DOHC ......1 ENGINE 2.7L DOHC ..... . 150 ENGINE 2.4L DOHC .
Page 1071 9 - 2 ENGINE 2.0L DOHC ENGINE BLOCK DIAGNOSIS AND TESTING DESCRIPTION ......37 CHECKING ENGINE OIL PRESSURE .
Page 1072 ENGINE 2.0L DOHC 9 - 3 ENGINE 2.0L DOHC DESCRIPTION The 2.0 Liter (122 cu. in.) in-line four cylinder engine is a dual over-head camshaft with hydraulic lash adjusters and four valves per cylinder design (Fig. 1). The engine does not have provisions for a free wheeling valvetrain.
Page 1073 9 - 4 ENGINE 2.0L DOHC ENGINE 2.0L DOHC (Continued) The cylinders are numbered from front of the These malfunctions may be classified as either engine to the rear. The firing order is 1–3–4–2. mechanical (e.g., a strange noise), or performance The engine identification number is located on the (e.g., engine idles rough and stalls).
Page 1074 ENGINE 2.0L DOHC 9 - 5 ENGINE 2.0L DOHC (Continued) ENGINE DIAGNOSIS - PERFORMANCE CONDITION POSSIBLE CAUSE CORRECTION ENGINE WILL NOT START 1. Weak battery. 1. Test battery. Charge or replace as necessary. (Refer to 8 - ELECTRICAL/BATTERY SYSTEM - DIAGNOSIS AND TESTING) 2.
Page 1075 9 - 6 ENGINE 2.0L DOHC ENGINE 2.0L DOHC (Continued) CONDITION POSSIBLE CAUSE CORRECTION ENGINE LOSS OF POWER 1. Dirty or incorrectly gapped plugs. 1. Clean plugs and set gap. 2. Contamination in fuel system. 2. Clean system and replace fuel filter.
Page 1076 ENGINE 2.0L DOHC 9 - 7 ENGINE 2.0L DOHC (Continued) ENGINE DIAGNOSIS - MECHANICAL CONDITION POSSIBLE CAUSES CORRECTION VALVETRAIN NOISE 1. High or low oil level in 1. Check and correct engine oil crankcase. level. 2. Thin or diluted oil. 2.
Page 1077 9 - 8 ENGINE 2.0L DOHC ENGINE 2.0L DOHC (Continued) CONDITION POSSIBLE CAUSES CORRECTION MAIN BEARING NOISE 1. Insufficient oil supply. 1. Check engine oil level. 2. Low oil pressure. 2. Check engine oil level. Inspect oil pump relief valve and spring. 3.
Page 1078 ENGINE 2.0L DOHC 9 - 9 ENGINE 2.0L DOHC (Continued) CONDITION POSSIBLE CAUSES CORRECTION OIL CONSUMPTION OR SPARK 1. PCV system malfunction. 1. Check system and repair as PLUGS FOULED necessary. (Refer to 25 - EMISSIONS CONTROL/ EVAPORATIVE EMISSIONS/PCV VALVE - DIAGNOSIS AND TESTING) 2.
Page 1079 9 - 10 ENGINE 2.0L DOHC ENGINE 2.0L DOHC (Continued) Start and operate the engine until it attains nor- CAUTION: Do not subject the engine assembly to mal operating temperature, then turn the engine more than 20.6 kpa (3 PSI) of test pressure. OFF.
Page 1080 ENGINE 2.0L DOHC 9 - 11 ENGINE 2.0L DOHC (Continued) (5) If the leak is not detected, very slowly turn the (5) Identify the fluid in the cylinder(s) (i.e., cool- crankshaft and watch for leakage. If a leak is ant, fuel, oil or other). detected between the crankshaft and seal while (6) Make sure all fluid has been removed from the slowly turning the crankshaft, it is possible the...
Page 1081 9 - 12 ENGINE 2.0L DOHC ENGINE 2.0L DOHC (Continued) will not cure if left in the uncovered tube. The • Metal scraper anaerobic material is for use between two machined • Abrasive pad or paper to clean cylinder block surfaces.
Page 1082 ENGINE 2.0L DOHC 9 - 13 ENGINE 2.0L DOHC (Continued) holes (Fig. 4). (In addition, suspected areas can be checked by placing the Plastigage in the suspected area). Torque the bearing cap/bed plate bolts of the bearing being checked to the proper specifications. Fig.
Page 1083 9 - 14 ENGINE 2.0L DOHC ENGINE 2.0L DOHC (Continued) • Using a blade or suitable hose cutter, cut trans- (37) Remove intake manifold (Refer axle oil cooler lines off flush with fittings. Plug lines ENGINE/MANIFOLDS/INTAKE MANIFOLD and fittings to prevent debris from entering transaxle REMOVAL).
Page 1084 ENGINE 2.0L DOHC 9 - 15 ENGINE 2.0L DOHC (Continued) Fig. 6 Positioning Engine Cradle Support Post Mounts 1 - SPECIAL TOOLS POST 6848 3 - SPECIAL TOOL 6135 DOLLY 2 - SPECIAL TOOLS POST 6848 WITH ADAPTERS 6909 4 - SPECIAL TOOL 6710 CRADLE...
Page 1085 9 - 16 ENGINE 2.0L DOHC ENGINE 2.0L DOHC (Continued) (13) Connect coolant recovery container overflow (39) Install throttle body air inlet hose and air hose. cleaner housing assembly. (14) Connect throttle and speed control cables. (40) Fill engine crankcase with proper oil to cor- (15) Connect ground cable to left side transaxle rect level.
Page 1086 ENGINE 2.0L DOHC 9 - 17 ENGINE 2.0L DOHC (Continued) PISTONS PISTON RINGS DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Metric Standard Metric Standard Piston Diameter 87.463-87.481 3.4434-3.4441 Ring Gap-Top Compression 0.23-0.52 mm 0.009-0.020 in. Ring Clearance @ 17.5 mm (11/16 0.018-0.050 0.0007-0.0020 Wear Limit 0.8 mm 0.031 in.
Page 1087 9 - 18 ENGINE 2.0L DOHC ENGINE 2.0L DOHC (Continued) CRANKSHAFT CAMSHAFT DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Metric Standard Metric Standard Connecting Rod Journal 47.9924- 1.8894-1.8900 25.976-25.995 Journal Diameter No. 1.022-1.023 in. 48.0076 mm Diameter Main Bearing Bearing 51.9924- 2.0469-2.0475 0.025-0.065 0.0009-0.0025 Journal Clearance -...
Page 1088 ENGINE 2.0L DOHC 9 - 19 ENGINE 2.0L DOHC (Continued) VALVE SEAT DESCRIPTION SPECIFICATION Metric Standard DESCRIPTION SPECIFICATION -Exhaust 110.89-111.69 4.365-4.397 in. Metric Standard Angle 44.5°- 45° Valve Stem Seat Diameter Diameter— 34.37- 4.63mm 1.353-1.363in. -Intake 5.934-5.952 0.2337-0.2344 Intake Seat -Exhaust 5.906-5.924 0.2326-0.2333...
Page 1089 9 - 20 ENGINE 2.0L DOHC ENGINE 2.0L DOHC (Continued) VALVE SPRINGS TORQUE DESCRIPTION SPECIFICATION DESCRIPTION N·m Lbs. Lbs. Metric Standard Camshaft Sprocket-Bolt Free Length 50.8 mm 2.00 in. (Approx.) Connecting Rod 27 + ⁄ Cap-Bolts turn ⁄ Nominal Force 311 N ±...
Page 1090 ENGINE 2.0L DOHC 9 - 21 ENGINE 2.0L DOHC (Continued) SPECIAL TOOLS 2.0L DOHC ENGINE Cradle 6710 Puller 1026 Post Kit Engine Cradle 6848 Crankshaft Damper Removal Insert 6827-A Camshaft Sprocket Remover/Installer C-4687 Crankshaft Damper/Sprocket Installer 6792 Camshaft Sprocket Remover/Installer Adapter C-4687-1 Dolly 6135 Camshaft Seal Remover C-4679A...
Page 1091 9 - 22 ENGINE 2.0L DOHC ENGINE 2.0L DOHC (Continued) Camshaft Seal Installer MD-998306 Valve Spring Compressor Adapter 6779 Valve Spring Compressor C-3422-D Valve Spring Compressor 8215-A Spring Compressor Adaptor 6526 Adaptor 8436 Valve Spring Tester C-647 Valve Spring Compressor MD-998772-A Cylinder Bore Gage C-119...
Page 1092 ENGINE 2.0L DOHC 9 - 23 ENGINE 2.0L DOHC (Continued) Adaptor 8406 Connecting Rod Guides 8189 Rear Crankshaft Seal Guide and Installer 6926-1 and 6926-2 Crankshaft Sprocket Remover 6793 Crankshaft Sprocket Remover Insert C-4685-C2 Driver Handle C-4171 Crankshaft Seal Remover 6771 Front Crankshaft Oil Seal Installer 6780 Cooling System Tester 7700 Oil Pressure Gage C-3292...
Page 1093 9 - 24 ENGINE 2.0L DOHC ENGINE 2.0L DOHC (Continued) Combustion Leak Tester C-3685-A Pressure Transducer CH7059 DRB III with PEP Module OT-CH6010A Cylinder Compression Pressure Adaptor 8116...
Page 1094 ENGINE 2.0L DOHC 9 - 25 AIR CLEANER ELEMENT AIR CLEANER HOUSING REMOVAL REMOVAL (1) Disconnect negative battery cable. (1) Disconnect negative battery cable. (2) Disconnect inlet air temperature sensor electri- (2) Disconnect inlet air temperature sensor electri- cal connector. cal connector.
Page 1095 9 - 26 ENGINE 2.0L DOHC CYLINDER HEAD Possible indications of the cylinder head gasket leaking between a cylinder and an adjacent water jacket are: DESCRIPTION • Engine overheating The cross flow designed, aluminum cylinder head • Loss of coolant contains dual over-head camshafts with four valves •...
Page 1096 ENGINE 2.0L DOHC 9 - 27 CYLINDER HEAD (Continued) FUEL SYSTEM/FUEL DELIVERY - STANDARD Remove all gasket material from cylinder head and PROCEDURE) block. (Refer to 9 - ENGINE - STANDARD PROCE- (2) Disconnect negative battery cable. DURE) Be careful not to gouge or scratch the alumi- (3) Drain cooling system (Refer to 7 - COOLING/ num head sealing surface.
Page 1097 9 - 28 ENGINE 2.0L DOHC CYLINDER HEAD (Continued) Fig. 14 Cylinder Head Gasket Positioning 1 - PART NUMBER FACES UP Fig. 12 Valve Guide Height 2 - NO. 1 CYLINDER 1 - VALVE GUIDE (3) Install cylinder head on block. 2 - 13.25 - 13.75 MM (4) Tighten the cylinder head bolts in the sequence (0.521 - 0.541 IN.)
Page 1098 ENGINE 2.0L DOHC 9 - 29 CYLINDER HEAD (Continued) CAMSHAFT OIL SEAL(S) (5) Install rocker arms and camshafts (Refer to 9 - ENGINE/CYLINDER HEAD/CAMSHAFT(S) INSTALLATION). REMOVAL (6) Install cylinder head cover (Refer to 9 - (1) Remove timing belt. (Refer to 9 - ENGINE/ ENGINE/CYLINDER HEAD/CYLINDER HEAD...
Page 1099 9 - 30 ENGINE 2.0L DOHC CAMSHAFT OIL SEAL(S) (Continued) INSTALLATION (1) Shaft seal surface must be free of varnish, dirt or nicks. Polish with 400 grit paper if necessary. (2) Install camshaft seals into cylinder head using Special Tool MD-998306 until flush with head (Fig. 18).
Page 1100 ENGINE 2.0L DOHC 9 - 31 CAMSHAFT(S) (Continued) Fig. 20 Camshaft End Play - Typical Fig. 22 Camshaft Bearing Cap - Removal (4) Remove camshaft sprockets and rear timing 1 - REMOVE OUTSIDE BEARING CAPS FIRST belt cover (Refer to 9 - ENGINE/VALVE TIMING/ TIMING BELT / CHAIN COVER(S) - REMOVAL).
Page 1101 9 - 32 ENGINE 2.0L DOHC CAMSHAFT(S) (Continued) (1) Lubricate all camshaft bearing journals, rocker TIMING BELT / CHAIN COVER(S) - INSTALLA- arms and camshaft lobes. TION). (2) Install all rocker arms in original positions, if (9) Install timing belt and front timing belt cover reused.
Page 1102 ENGINE 2.0L DOHC 9 - 33 CYLINDER HEAD COVER (Continued) Fig. 27 Spark Plug Well Seals Fig. 29 Sealer Locations 1 – SEALER LOCATION (b) Tighten all bolts to 9.0 N·m (80 in. lbs.). (c) Tighten all bolts to 12 N·m (105 in. lbs.). Fig.
Page 1103 9 - 34 ENGINE 2.0L DOHC HYDRAULIC LASH ADJUSTERS DIAGNOSIS AND TESTING HYDRAULIC LASH ADJUSTER NOISE DIAGNOSIS A tappet-like noise may be produced from several items. Check the following items. (1) Engine oil level too high or too low. This may cause aerated oil to enter the adjusters and cause them to be spongy.
Page 1104 ENGINE 2.0L DOHC 9 - 35 ROCKER ARMS REMOVAL NOTE: This procedure is for in-vehicle service with camshafts installed. (1) Disconnect negative battery cable. (2) Remove cylinder head cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD COVER(S) - REMOVAL). (3) Remove spark plugs. (4) Rotate engine until the camshaft lobe, on the Fig.
Page 1105 9 - 36 ENGINE 2.0L DOHC VALVE SPRINGS AND SEALS (Continued) (2) Install valve spring and retainer, use Special Tool MD-998772-A with adapter 6779 to compress valve springs only enough to install locks (Fig. 34). Correct alignment of tool is necessary to avoid nick- ing valve stems.
Page 1106 ENGINE 2.0L DOHC 9 - 37 VALVE SPRINGS AND SEALS (Continued) gral with the block. The bed plate and block are serviced as an assembly. Fig. 36 Valve Stem Oil Seal Tool 1 - VALVE SEAL TOOL Fig. 38 Cylinder Block and Bed plate 2 - VALVE STEM 1 - CYLINDER BLOCK 2 - BED PLATE...
Page 1107 9 - 38 ENGINE 2.0L DOHC ENGINE BLOCK (Continued) the cylinder walls are badly scuffed or scored, the cylinder block should be replaced, and new pistons and rings fitted. Fig. 39 Cylinder Bore Cross-Hatch Pattern 1 - CROSS-HATCH PATTERN 2 - 40°–60° CAUTION: Ensure all abrasives are removed from engine parts after honing.
Page 1108 ENGINE 2.0L DOHC 9 - 39 CRANKSHAFT (Continued) (2) Move crankshaft all the way to the rear of its (7) Remove crankshaft vibration damper (Refer to travel. ENGINE/ENGINE BLOCK/VIBRATION (3) Zero the dial indicator. DAMPER - REMOVAL). (4) Move crankshaft all the way to the front of its (8) Remove front timing belt cover, front engine travel and read the dial indicator.
Page 1109 9 - 40 ENGINE 2.0L DOHC CRANKSHAFT (Continued) (14) Remove oil pump pick-up tube. (15) Remove oil pump (Refer to 9 - ENGINE/LU- BRICATION/OIL PUMP - REMOVAL). (16) Remove crankshaft position sensor (Fig. 42). (17) Using a permanent ink or paint marker, iden- tify cylinder number on each connecting rod cap (Fig.
Page 1110 ENGINE 2.0L DOHC 9 - 41 CRANKSHAFT (Continued) Fig. 45 Crankshaft Journal Measurements Fig. 47 Installing Main Bearing Upper Shell 1 - LUBRICATION GROOVES 2 - O-RING 3 - OIL HOLES NOTE: Always use NEW mounting screws whether installing original or new target ring. (4) Install N EW mounting screws finger tight starting with the #1 location.
Page 1111 9 - 42 ENGINE 2.0L DOHC CRANKSHAFT (Continued) CAUTION: Use extreme care when handling crank- shaft. Tone wheel damage can occur if crankshaft is mis-handled. CAUTION: Do not get oil on the bed plate mating surface. It will affect the ability of the sealer to seal the bed plate to cylinder block.
Page 1112 ENGINE 2.0L DOHC 9 - 43 CRANKSHAFT (Continued) CRANKSHAFT OIL SEAL - (19) Install each bolt finger tight then alternately torque each bolt to assemble the cap properly. FRONT (20) Tighten the connecting rod bolts using the 2 step torque-turn method. Tighten according to the REMOVAL following values: (1) Remove the accessory drive belts.
Page 1113 9 - 44 ENGINE 2.0L DOHC CRANKSHAFT OIL SEAL - FRONT (Continued) Fig. 52 Crankshaft Key 1 - CRANKSHAFT KEY Fig. 54 Front Crankshaft Oil Seal - Installation 1 - PROTECTOR 2 - SEAL 3 - SPECIAL TOOL 6780–1 4 - INSTALLER Fig.
Page 1114 ENGINE 2.0L DOHC 9 - 45 CRANKSHAFT OIL SEAL - REAR (Continued) (3) Insert a 3/16 flat bladed screwdriver between lation of seal. Ensure that the lip of the seal is facing the dust lip and the metal case of the crankshaft towards the crankcase during installation.
Page 1115 9 - 46 ENGINE 2.0L DOHC PISTON & CONNECTING ROD (Continued) are used to provide alignment and durability in the assembly. The pistons and connecting rods are ser- viced as an assembly. STANDARD PROCEDURE - PISTON TO CYLINDER BORE FITTING NOTE: Pistons and cylinder bores should be mea- sured at normal room temperature, 70°F (21°C).
Page 1116 ENGINE 2.0L DOHC 9 - 47 PISTON & CONNECTING ROD (Continued) be either a directional arrow or a weight identifica- tion for the assembly. L is for light and H is for heavy. These assemblies should all be the same weight class.
Page 1117 9 - 48 ENGINE 2.0L DOHC PISTON & CONNECTING ROD (Continued) INSTALLATION (11) Before installing the N EW bolts, the threads should be coated with clean engine oil. (1) Install piston rings on piston (Refer to 9 - (12) Install connecting rod lower bearing half into ENGINE/ENGINE BLOCK/PISTON RINGS...
Page 1118 ENGINE 2.0L DOHC 9 - 49 CONNECTING ROD BEARINGS (Continued) 1. Tighten the bolts to 27 N·m (20 ft. lbs.). 2. Tighten the connecting rod bolts an additional 1/4 TU RN . (5) Using a feeler gauge, check connecting rod side clearance (Fig.
Page 1119 9 - 50 ENGINE 2.0L DOHC PISTON RINGS (Continued) Install rings with manufacturers identification (3) Install No. 2 piston ring and then No. 1 piston mark facing up, to the top of the piston (Fig. 70). ring (Fig. 70). (4) Position piston ring end gaps as shown in (Fig. 72).
Page 1120 ENGINE 2.0L DOHC 9 - 51 STRUCTURAL COLLAR (Continued) (7) Remove front and rear engine mount through bolts. (8) Slowly lower engine down with screw jack. (9) Remove accessory drive belts (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL). (10) Remove crankshaft damper bolt.
Page 1121 9 - 52 ENGINE 2.0L DOHC VIBRATION DAMPER (Continued) ENGINE MOUNTING ADJUSTMENTS ENGINE SUPPORT ADJUSTMENT The right and left support assemblies are slotted to allow for right/left drive train adjustment in relation to drive shaft assembly length. Check and reposition right and left engine support assemblies as required.
Page 1122 ENGINE 2.0L DOHC 9 - 53 LEFT MOUNT (Continued) Fig. 77 Left Side Mount - Typical 1 - TRANSMISSION SUPPORT ASSEMBLY Fig. 78 Engine Mounting—Right Side 2 - LEFT FRAME RAIL 3 - GROUND CABLE 1 - ENGINE SUPPORT BRACKET 4 - BOLT (D) 2 - FRAME RAIL 5 - TRANSMISSION BRACKET...
Page 1123 9 - 54 ENGINE 2.0L DOHC FRONT MOUNT (Continued) (6) Loosen front mount though bolt. (7) Remove mount bracket. (8) Remove rear mount to suspension crossmember attaching bolts. (9) Remove rear mount. Fig. 79 FRONT ENGINE MOUNT 1 - HORIZONTAL THROUGH BOLT 2 - VERTICAL BOLT(S) Fig.
Page 1124 ENGINE 2.0L DOHC 9 - 55 LUBRICATION the length of the cylinder head. The restrictor, an integral part of the cylinder head gasket, provides increased oil flow to the main oil gallery. The cam- DESCRIPTION shaft journals are partially slotted to allow a prede- The lubrication system is a full-flow filtration, termined amount of pressurized oil to pass into the pressure feed type.
Page 1125 9 - 56 ENGINE 2.0L DOHC LUBRICATION (Continued) STANDARD PROCEDURE ENGINE OIL LEVEL CHECK The best time to check engine oil level is after it has sat overnight, or if the engine has been running, allow the engine to be shut off for at least 5 minutes before checking oil level.
Page 1126 ENGINE 2.0L DOHC 9 - 57 OIL (Continued) Fig. 83 Fluid Level Check - 2.0/2.4L 1 - COOLANT RECOVERY CONTAINER 3 - ENGINE OIL FILL 2 - COOLANT PRESSURE CAP 4 - ENGINE OIL DIPSTICK the seam at the base of the filter. The oil filter seam that joins the can to the base, is reinforced by the base plate.
Page 1127 9 - 58 ENGINE 2.0L DOHC OIL FILTER (Continued) INSTALLATION (1) Clean and check the filter mounting surface. The surface must be smooth, flat and free of debris or old pieces of rubber. (2) Lubricate new filter gasket. (3) Screw filter on until gasket contacts base (Fig. 85).
Page 1128 ENGINE 2.0L DOHC 9 - 59 OIL PAN (Continued) OIL PUMP (8) Install oil filter adaptor (Fig. 86) (Refer to 9 - ENGINE/LUBRICATION/OIL FILTER ADAPTER - INSTALLATION). REMOVAL (9) Install oil filter (Refer to 9 - ENGINE/LUBRI- (1) Disconnect negative cable from battery. CATION/OIL FILTER - INSTALLATION).
Page 1129 9 - 60 ENGINE 2.0L DOHC OIL PUMP (Continued) INSPECTION (9) Remove the oil pick-up tube. (10) Remove the oil pump (Fig. 91) and front (1) Clean all parts thoroughly. Mating surface of crankshaft seal. the oil pump should be smooth. Replace pump cover if scratched or grooved.
Page 1130 ENGINE 2.0L DOHC 9 - 61 OIL PUMP (Continued) Fig. 94 Checking Oil Pump Cover Flatness Fig. 92 Oil Pressure Relief Valve 1 - STRAIGHT EDGE 1 - RETAINER CAP 2 - FEELER GAUGE 2 - GASKET 3 - OIL PUMP COVER 3 - OIL PUMP BODY 4 - RELIEF VALVE 5 - SPRING...
Page 1131 9 - 62 ENGINE 2.0L DOHC OIL PUMP (Continued) Fig. 97 Measuring Outer Rotor Clearance in Fig. 99 Measuring Clearance Over Rotors Housing 1 - FEELER GAUGE 2 - STRAIGHT EDGE 1 - FEELER GAUGE 2 - OUTER ROTOR (3) Install spring and relief valve (Fig. 92). (4) Install threaded plug and gasket to the oil pump (Fig.
Page 1132 ENGINE 2.0L DOHC 9 - 63 OIL PUMP (Continued) (10) Install timing belt tensioner pulley bracket (Refer to 9 - ENGINE/VALVE TIMING/ TMNG BELT/CHAIN TENSIONER&PULLEY INSTALLATION). (11) Install the timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT AND SPROCKETS - INSTALLATION).
Page 1133 9 - 64 ENGINE 2.0L DOHC INTAKE MANIFOLD (Continued) CLEANING (4) Remove throttle body air inlet hose and air cleaner housing assembly. (1) Discard gasket(s). (5) Remove throttle and speed control cables from (2) Clean all sealing surfaces. throttle lever and bracket. (6) Remove EGR tube (if equipped).
Page 1134 ENGINE 2.0L DOHC 9 - 65 EXHAUST MANIFOLD (Continued) CLEANING (1) Discard gasket (if equipped) and clean all sur- faces of manifold and cylinder head. INSPECTION (1) Inspect manifold gasket surfaces for flatness with straight edge. Surface must be flat within 0.15 mm per 300 mm (0.006 in.
Page 1135 9 - 66 ENGINE 2.0L DOHC VALVE TIMING (10) Remove the right engine mount (Refer to 9 - ENGINE/ENGINE MOUNTING/RIGHT MOUNT - REMOVAL). STANDARD PROCEDURE (11) Remove front engine mount bracket (Fig. 108). (12) Remove the front timing belt cover (Fig. 108). VALVE TIMING VERIFICATION (1) Remove number one spark plug.
Page 1136 ENGINE 2.0L DOHC 9 - 67 TIMING BELT COVER(S) (Continued) (5) Install timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT AND SPROCKETS - INSTALLATION). (6) Install front cover. FRONT COVER (1) Install front cover and tighten bolts to 12 N·m (105 in.
Page 1137 9 - 68 ENGINE 2.0L DOHC TIMING BELT AND valve components may occur. Always align timing marks before removing timing belt. SPROCKETS (1) Disconnect negative battery cable. (2) Remove the front timing belt cover (Fig. 110) (Refer to 9 - ENGINE/VALVE TIMING/TIMING REMOVAL BELT COVER(S) - REMOVAL).
Page 1138 ENGINE 2.0L DOHC 9 - 69 TIMING BELT AND SPROCKETS (Continued) (3) Rotate crankshaft until timing marks are aligned at both the camshafts and crankshaft (Fig. 111) and (Fig. 112). Fig. 111 Camshaft Timing Marks 1 - ALIGN CAMSHAFT SPROCKET TIMING MARKS TOGETHER 2 - CENTERLINE Fig.
Page 1139 9 - 70 ENGINE 2.0L DOHC TIMING BELT AND SPROCKETS (Continued) (3) Remove crankshaft sprocket using Special Tools 6793 and insert C-4685-C2 (Fig. 115). Fig. 115 Crankshaft Sprocket - Removal Fig. 116 Crankshaft Sprocket—Installation 1 - SPECIAL TOOL 6793 1 - SPECIAL TOOL 6792 2 - SPECIAL TOOL C-4685–C2 2 - TIGHTEN NUT TO INSTALL 3 - CRANKSHAFT SPROCKET...
Page 1140 ENGINE 2.0L DOHC 9 - 71 TIMING BELT AND SPROCKETS (Continued) the setting notch, continue rotating the top plate counterclockwise until the setting notch is aligned with the spring tang (Fig. 120). Using the allen wrench to prevent the top plate from moving, torque the tensioner lock nut to 30 N·m (22 ft.
Page 1141 9 - 72 ENGINE 2.0L DOHC TIMING BELT AND SPROCKETS (Continued) Fig. 122 Timing Belt Tensioner Assembly 1 - SPRING TANG 2 - LOCK NUT 3 - TOP PLATE Fig. 121 Timing Belt Tension Verification 4 - PULLEY 5 - SETTING NOTCH 1 - SPRING TANG 2 - TOLERANCE WINDOW 6 - BRACKET...
Page 1142 ENGINE 2.4L DOHC 9 - 73 ENGINE 2.4L DOHC TABLE OF CONTENTS page page ENGINE 2.4L DOHC REMOVAL ......102 DESCRIPTION .
Page 1143 9 - 74 ENGINE 2.4L DOHC FLEX PLATE REMOVAL ......129 REMOVAL ......116 INSTALLATION .
Page 1144 ENGINE 2.4L DOHC 9 - 75 ENGINE 2.4L DOHC DIAGNOSIS AND TESTING ENGINE DIAGNOSIS - INTRODUCTION DESCRIPTION Engine diagnosis is helpful in determining the The 2.4 Liter (148 cu. in.) in-line four cylinder causes of malfunctions not detected and remedied by engine is a double over head camshaft with hydraulic routine maintenance.
Page 1145 9 - 76 ENGINE 2.4L DOHC ENGINE 2.4L DOHC (Continued) ENGINE DIAGNOSIS - PERFORMANCE CONDITION POSSIBLE CAUSE CORRECTION ENGINE WILL NOT START 1. Weak battery. 1. Test battery. Charge or replace as necessary. (Refer to 8 - ELECTRICAL/BATTERY SYSTEM - DIAGNOSIS AND TESTING) 2.
Page 1146 ENGINE 2.4L DOHC 9 - 77 ENGINE 2.4L DOHC (Continued) CONDITION POSSIBLE CAUSE CORRECTION ENGINE LOSS OF POWER 1. Dirty or incorrectly gapped plugs. 1. Clean plugs and set gap. 2. Contamination in fuel system. 2. Clean system and replace fuel filter.
Page 1147 9 - 78 ENGINE 2.4L DOHC ENGINE 2.4L DOHC (Continued) ENGINE DIAGNOSIS - MECHANICAL CONDITION POSSIBLE CAUSES CORRECTION VALVETRAIN NOISE 1. High or low oil level in 1. Check and correct engine oil crankcase. level. 2. Thin or diluted oil. 2.
Page 1148 ENGINE 2.4L DOHC 9 - 79 ENGINE 2.4L DOHC (Continued) CONDITION POSSIBLE CAUSES CORRECTION MAIN BEARING NOISE 1. Insufficient oil supply. 1. Check engine oil level. 2. Low oil pressure. 2. Check engine oil level. Inspect oil pump relief valve and spring. 3.
Page 1149 9 - 80 ENGINE 2.4L DOHC ENGINE 2.4L DOHC (Continued) CONDITION POSSIBLE CAUSES CORRECTION OIL CONSUMPTION OR SPARK 1. PCV system malfunction. 1. Check system and repair as PLUGS FOULED necessary. (Refer to 25 - EMISSIONS CONTROL/ EVAPORATIVE EMISSIONS/PCV VALVE - DIAGNOSIS AND TESTING) 2.
Page 1150 ENGINE 2.4L DOHC 9 - 81 ENGINE 2.4L DOHC (Continued) Start and operate the engine until it attains nor- CAUTION: Do not subject the engine assembly to mal operating temperature, then turn the engine more than 20.6 kpa (3 PSI) of test pressure. OFF.
Page 1151 9 - 82 ENGINE 2.4L DOHC ENGINE 2.4L DOHC (Continued) (5) If the leak is not detected, very slowly turn the (5) Identify the fluid in the cylinder(s) (i.e., cool- crankshaft and watch for leakage. If a leak is ant, fuel, oil or other). detected between the crankshaft and seal while (6) Make sure all fluid has been removed from the slowly turning the crankshaft, it is possible the...
Page 1152 ENGINE 2.4L DOHC 9 - 83 ENGINE 2.4L DOHC (Continued) will not cure if left in the uncovered tube. The • Metal scraper anaerobic material is for use between two machined • Abrasive pad or paper to clean cylinder block surfaces.
Page 1153 9 - 84 ENGINE 2.4L DOHC ENGINE 2.4L DOHC (Continued) holes (Fig. 4). (In addition, suspected areas can be checked by placing the Plastigage in the suspected area). Torque the bearing cap/bed plate bolts of the bearing being checked to the proper specifications. Fig.
Page 1154 ENGINE 2.4L DOHC 9 - 85 ENGINE 2.4L DOHC (Continued) (11) Disconnect transmission shift cable. (42) Raise vehicle enough to allow engine dolly (12) Disconnect engine electrical harness from 6135 and cradle 6710 with posts 6848 to be installed PCM and bulkhead connectors. under vehicle (Fig.
Page 1155 9 - 86 ENGINE 2.4L DOHC ENGINE 2.4L DOHC (Continued) Fig. 6 Positioning Engine Cradle Support Post Mounts 1 - SPECIAL TOOLS POST 6848 3 - SPECIAL TOOL 6135 DOLLY 2 - SPECIAL TOOLS POST 6848 WITH ADAPTERS 6909 4 - SPECIAL TOOL 6710 CRADLE...
Page 1156 ENGINE 2.4L DOHC 9 - 87 ENGINE 2.4L DOHC (Continued) SPECIFICATIONS (17) Connect positive cable to battery and PDC. (18) Raise vehicle on hoist. (19) Install torque converter bolts. 2.4L ENGINE (20) Install structural collar and torque reaction GENERAL SPECIFICATIONS bracket (Refer to 9 - ENGINE/ENGINE BLOCK/ STRUCTURAL COVER - INSTALLATION).
Page 1157 9 - 88 ENGINE 2.4L DOHC ENGINE 2.4L DOHC (Continued) PISTONS DESCRIPTION SPECIFICATION Metric Standard DESCRIPTION SPECIFICATION Metric Standard 0.0133-0.0566 Turbo 0.34-1.44 mm Piston Diameter 87.456-87.474 3.4431-3.4439 Length Clearance @ 72.75-73.25 24.6 mm (0.551 0.018-0.0516 0.0007-0.0020 Non-Turbo 2.864-2.883 in. in.) from bottom 65.41-65.85 of skirt Turbo...
Page 1158 ENGINE 2.4L DOHC 9 - 89 ENGINE 2.4L DOHC (Continued) CONNECTING ROD DESCRIPTION SPECIFICATION Metric Standard DESCRIPTION SPECIFICATION Plunger Travel 3.0 mm 0.118 in. Metric Standard Minimum (Dry) Bearing 0.025–0.071 0.0009–0.0027 Clearance CYLINDER HEAD CAMSHAFT BEARING BORE DIAMETER Wear Limit 0.075 mm 0.003 in.
Page 1159 9 - 90 ENGINE 2.4L DOHC ENGINE 2.4L DOHC (Continued) CYLINDER HEAD VALVES DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Metric Standard Metric Standard Material Cast Aluminum Face Angle - Intake and 44.5 - 45° Gasket Exhaust Thickness 0.71 mm 0.028 in. (Compressed) Head Diameter 34.67 - 34.93 1.364 - 1.375...
Page 1160 ENGINE 2.4L DOHC 9 - 91 ENGINE 2.4L DOHC (Continued) VALVE STEM TO GUIDE CLEARANCE DESCRIPTION SPECIFICATION Metric Standard DESCRIPTION SPECIFICATION Tip Clearance Between Rotors 0.20 mm 0.008 in. Metric Standard (Max.) Intake 0.048 - 0.066 0.0018 - 0.0025 OIL PRESSURE Max.
Page 1161 9 - 92 ENGINE 2.4L DOHC ENGINE 2.4L DOHC (Continued) SPECIAL TOOLS DESCRIPTION N·m Lbs. Lbs. 2.4L ENGINE Flex Plate to Crankshaft Engine Mount Bracket Right-Bolts Engine Mounting-Bolts (Refer to 9 ENGINE/ ENGINE MOUNTING) Exhaust Manifold to Cylinder Head-Bolts Exhaust Manifold Heat Shield-Bolts Intake Manifold -Bolts Puller 1026...
Page 1162 ENGINE 2.4L DOHC 9 - 93 ENGINE 2.4L DOHC (Continued) Post Kit Engine Cradle 6848 Valve Spring Compressor 8215-A Camshaft Sprocket Holder 6847 Adaptor 8436 Camshaft Seal Remover C-4679A Valve Spring Compressor MD998772A Camshaft Seal Installer MD-998306 Valve Spring Compressor Adapter 6779 Crankshaft Damper/Sprocket Installer 6792...
Page 1163 9 - 94 ENGINE 2.4L DOHC ENGINE 2.4L DOHC (Continued) Front Crankshaft Oil Seal Remover 6771 Valve Spring Tester C-647 Indicator, Cylinder Bore C-119 Oil Pressure Gauge C-3292 Adapter 8406 Connecting Rod Guides 8189 Rear Crankshaft Oil Seal Installer 6926 Crankshaft Sprocket Remover 6793 Crankshaft Sprocket Remover Insert C-4685-C2 Driver Handle C-4171...
Page 1164 ENGINE 2.4L DOHC 9 - 95 ENGINE 2.4L DOHC (Continued) Balance Shaft Sprocket Installer 6052 DRB III with PEP Module OT-CH6010A Front Crankshaft Oil Seal Installer 6780 Pressure Transducer CH7059 Cooling System Tester 7700 Cylinder Compression Pressure Adaptor 8116 Combustion Leak Tester C-3685-A...
Page 1165 9 - 96 ENGINE 2.4L DOHC AIR CLEANER ELEMENT AIR CLEANER HOUSING REMOVAL REMOVAL (1) Disconnect negative battery cable. (1) Disconnect negative battery cable. (2) Disconnect inlet air temperature sensor electri- (2) Disconnect inlet air temperature sensor electri- cal connector. cal connector.
Page 1166 ENGINE 2.4L DOHC 9 - 97 CYLINDER HEAD DESCRIPTION There will be two different cylinder heads that will be used on the 2.4L engine. One will used on federal package engine and the other on PZEV (partially zero emmision vehicle) used in California emmission packages.
Page 1167 9 - 98 ENGINE 2.4L DOHC CYLINDER HEAD (Continued) VISUAL TEST METHOD With the engine cool, remove the coolant pressure cap. Start the engine and allow it to warm up until thermostat opens. If a large combustion/compression pressure leak exists, bubbles will be visible in the coolant. COOLING SYSTEM TESTER METHOD WARNING: WITH COOLING SYSTEM TESTER IN PLACE, PRESSURE WILL BUILD UP FAST.
Page 1168 ENGINE 2.4L DOHC 9 - 99 CYLINDER HEAD (Continued) DURE). Be careful not to gouge or scratch the alumi- num head sealing surface. Clean all engine oil passages. INSPECTION Cylinder head must be flat within 0.1 mm (0.004 in.) (Fig. 12). (2) Inspect camshaft bearing journals for scoring.
Page 1169 9 - 100 ENGINE 2.4L DOHC CYLINDER HEAD (Continued) (13) Install accessory drive belts (Refer to 7 - CAUTION: Do not use a torque wrench for the COOLING/ACCESSORY DRIVE/DRIVE BELTS - Fourth step. INSTALLATION). • F o u rth : Tu rn a ll bo lts a n a d d itio n a l 1/4 (14) Connect exhaust pipe to exhaust manifold.
Page 1170 ENGINE 2.4L DOHC 9 - 101 CAMSHAFT OIL SEAL(S) (Continued) Fig. 19 Camshaft Seal - Installation 1 - SPECIAL TOOL MD-998306 Fig. 17 Camshaft Sprocket - Removal/Installation dynamic oil seal is used for oil control at the front of the camshaft. 1 - SPECIAL TOOL 6847 Fig.
Page 1171 9 - 102 ENGINE 2.4L DOHC CAMSHAFT(S) (Continued) STANDARD PROCEDURE (7) Identify the camshafts before removing from the head. The camshafts are not interchangeable. (8) Remove camshafts from cylinder head. MEASURING CAMSHAFT END PLAY (1) Oil camshaft journals and install camshaft NOTE: If removing rocker arms, identify for reinstal- WITHOU T rocker arms.
Page 1172 ENGINE 2.4L DOHC 9 - 103 CAMSHAFT(S) (Continued) (3) Measure the lobe actual wear (unworn area - wear zone = actual wear) (Fig. 24) and replace cam- shaft if out of limit. Standard value is 0.0254 mm (0.001 in.), wear lim it is 0.254 mm (0.010 in.). Fig.
Page 1173 9 - 104 ENGINE 2.4L DOHC CYLINDER HEAD COVER (Continued) (b) Tighten all fasteners to 9.0 N·m (80 in. lbs.) (c) Tighten all fasteners to 12 N·m (105 in. lbs.) Fig. 29 Cylinder Head Cover Tightening Sequence (4) Install ignition coil and plug wires. Tighten fas- Fig.
Page 1174 ENGINE 2.4L DOHC 9 - 105 HYDRAULIC LASH ADJUSTERS (Continued) INTAKE/EXHAUST VALVES & arm over adjuster. Normal adjusters should feel very firm. Spongy adjusters can be bottomed out easily. SEATS • Remove suspected lash adjusters, and replace as necessary. DESCRIPTION REMOVAL The valves are made of heat resistant steel.
Page 1175 9 - 106 ENGINE 2.4L DOHC ROCKER ARMS (Continued) VALVE SPRINGS & SEALS REMOVAL REMOVAL - CYLINDER HEAD ON (1) Disconnect negative battery cable. (2) Remove timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN SPROCKETS - REMOVAL). (3) Remove cylinder head cover (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD...
Page 1176 ENGINE 2.4L DOHC 9 - 107 VALVE SPRINGS & SEALS (Continued) INSPECTION (1) Whenever valves have been removed for inspec- tion, reconditioning or replacement, valve springs should be tested for correct tension. Discard the springs that do not meet specifications. The following specifications apply to both intake and exhaust valves springs: •...
Page 1177 9 - 108 ENGINE 2.4L DOHC VALVE SPRINGS & SEALS (Continued) STANDARD PROCEDURE (4) Check the valve spring installed height B after refacing the valve and seat (Fig. 36). Make sure mea- surements are taken from top of spring seat to the CYLINDER BORE HONING bottom surface of spring retainer.
Page 1178 ENGINE 2.4L DOHC 9 - 109 ENGINE BLOCK (Continued) A controlled hone motor speed between 200–300 RPM is necessary to obtain the proper cross- hatch angle. The number of up and down strokes per minute can be regulated to get the desired 40–60 degree angle.
Page 1179 9 - 110 ENGINE 2.4L DOHC CRANKSHAFT (Continued) REMOVAL - CRANKSHAFT NOTE: Crankshaft can not be removed when engine is in vehicle. (1) Remove engine assembly from vehicle (Refer to 9 - ENGINE - REMOVAL). (2) Separate transaxle from engine. (3) Remove drive plate/flex plate.
Page 1180 ENGINE 2.4L DOHC 9 - 111 CRANKSHAFT (Continued) (23) Remove the target ring mounting screws and discard. (24) Remove the target ring from the crankshaft. INSPECTION The crankshaft journals should be checked for excessive wear, taper and scoring (Fig. 43). Limits of taper or out of round on any crankshaft journals should be held to 0.025 mm (0.001 in.).
Page 1181 9 - 112 ENGINE 2.4L DOHC CRANKSHAFT (Continued) (5) Torque all mounting screws with T30 torx bit to 13 Nm (110 in-lbs) following the torque sequence. Fig. 47 BED PLATE SEALING Fig. 46 Target Ring Torque Sequence 1 - TARGET RING CAUTION: Use extreme care when handling crank- shaft.
Page 1182 ENGINE 2.4L DOHC 9 - 113 CRANKSHAFT (Continued) the rear crankshaft counterweight. This will hold the (32) Install crankshaft rear oil seal (Refer to 9 - crankshaft in it’s furthest forward position. ENGINE/ENGINE BLOCK/CRANKSHAFT • Step 5: Install and tighten bolts (1–10) in SEAL - REAR - INSTALLATION).
Page 1183 9 - 114 ENGINE 2.4L DOHC CRANKSHAFT OIL SEAL - FRONT (Continued) Fig. 50 Front Crankshaft Oil Seal—Removal 1 - SPECIAL TOOL 6771 2 - REAR TIMING BELT COVER INSTALLATION (1) Install new seal by using Special Tool 6780 (Fig. 51). (2) Place seal into opening with seal spring towards the inside of engine.
Page 1184 ENGINE 2.4L DOHC 9 - 115 CRANKSHAFT OIL SEAL - REAR (Continued) Fig. 54 Rear Crankshaft Seal and Special Tool Fig. 53 Rear Crankshaft Oil Seal - Removal 6926-1 1 - REAR CRANKSHAFT SEAL 1 - SPECIAL TOOL 6926–1 PILOT 2 - ENGINE BLOCK 2 - SEAL 3 - ENGINE BLOCK...
Page 1185 9 - 116 ENGINE 2.4L DOHC CRANKSHAFT OIL SEAL - REAR (Continued) Fig. 57 Flex Plate 1 - ADAPTOR PLATE 2 - BOLT 3 - BOLT (QTY. 8) 4 - FLEX PLATE PISTON & CONNECTING ROD DESCRIPTION The pistons are made of a cast aluminum alloy. The pistons have pressed-in pins attached to forged powdered metal connecting rods.
Page 1186 ENGINE 2.4L DOHC 9 - 117 PISTON & CONNECTING ROD (Continued) Fig. 58 Piston Measurement 1 - PISTON DIAMETER Fig. 60 Piston Markings 2 - 14 mm (0.551 in.) 1 - DIRECTIONAL ARROW WILL BE IMPRINTED IN THIS AREA CAUTION: DO NOT use a number stamp or a punch to mark connecting rods.
Page 1187 9 - 118 ENGINE 2.4L DOHC PISTON & CONNECTING ROD (Continued) Fig. 61 Identify Connectng Rod to Cylinder - Typical Fig. 63 Piston Ring End Gap Position 1 - GAP OF LOWER SIDE RAIL 2 - NO. 1 RING GAP 3 - GAP OF UPPER SIDE RAIL 4 - NO.
Page 1188 ENGINE 2.4L DOHC 9 - 119 PISTON & CONNECTING ROD (Continued) (5) Using a feeler gauge, check connecting rod side clearance (Fig. 66). Refer to clearance specifications (Refer to 9 - ENGINE - SPECIFICATIONS). Fig. 65 Checking Connecting Rod Side Clearance - Typical (15) Install Balance Shaft Carrier Assembly (Refer to 9 - ENGINE/VALVE TIMING/BALANCE SHAFT...
Page 1189 9 - 120 ENGINE 2.4L DOHC PISTON RINGS (Continued) INSTALLATION NOTE: The identification mark on face of upper and intermediate piston rings must point toward top of piston. Install rings with manufacturers identification mark facing up, to the top of the piston (Fig. 70). Fig.
Page 1190 ENGINE 2.4L DOHC 9 - 121 PISTON RINGS (Continued) VIBRATION DAMPER (1) Install oil ring expander (Fig. 70). (2) Install upper side rail first and then the lower side rail. Install the side rails by placing one end REMOVAL between the piston ring groove and the oil ring (1) Disconnect negative battery cable.
Page 1191 9 - 122 ENGINE 2.4L DOHC VIBRATION DAMPER (Continued) Fig. 74 Vibration Damper - Removal Fig. 75 Vibration Damper - Installation 1 - SPECIAL TOOL 6827-A INSERT 1 - M12–1.75 × 150 MM BOLT, WASHER AND THRUST BEARING FROM SPECIAL TOOL 6792 2 - SPECIAL TOOL 8454 PULLER STRUCTURAL COLLAR INSTALLATION...
Page 1192 ENGINE 2.4L DOHC 9 - 123 STRUCTURAL COLLAR (Continued) ENGINE SUPPORT ADJUSTMENT (1) Remove the load on the engine motor mounts by carefully supporting the engine and transmission assembly with a floor jack. (2) Loosen the right engine support assembly ver- tical fasteners.
Page 1193 9 - 124 ENGINE 2.4L DOHC LEFT MOUNT (Continued) Fig. 77 Left Side Mount - Typical 1 - TRANSMISSION SUPPORT ASSEMBLY 2 - LEFT FRAME RAIL Fig. 78 Engine Mounting—Rear 3 - GROUND CABLE 1 - REAR TORQUE BRACKET 4 - BOLT (D) 2 - REAR MOUNT 5 - TRANSMISSION BRACKET 3 - THROUGH BOLT...
Page 1194 ENGINE 2.4L DOHC 9 - 125 RIGHT MOUNT (Continued) Fig. 79 Engine Mounting—Right Side 1 - ENGINE SUPPORT BRACKET 2 - FRAME RAIL 3 - RIGHT ENGINE MOUNT Fig. 80 FRONT ENGINE MOUNT (2) Install the mount to engine support bracket 1 - HORIZONTAL THROUGH BOLT bolts and tighten to 61 N·m (45 ft.
Page 1195 9 - 126 ENGINE 2.4L DOHC LUBRICATION DESCRIPTION NOTE: Some 2.4L engines are not equipped with a oil pan gasket. Use the appropriate RTV sealant. The lubrication system is a full-flow filtration, pressure feed type. The oil pump (Fig. 81) is mounted in the front engine cover and driven by the crank- shaft.
Page 1196 ENGINE 2.4L DOHC 9 - 127 LUBRICATION (Continued) DIAGNOSIS AND TESTING OPERATION Engine oil drawn up through the pickup tube and CHECKING ENGINE OIL PRESSURE is pressurized by the oil pump and routed through the full-flow filter to the main oil gallery running the (1) Disconnect and remove oil pressure switch.
Page 1197 9 - 128 ENGINE 2.4L DOHC OIL (Continued) Fig. 83 Fluid Level Check - 2.0/2.4L 1 - COOLANT RECOVERY CONTAINER 3 - ENGINE OIL FILL 2 - COOLANT PRESSURE CAP 4 - ENGINE OIL DIPSTICK (2) Remove oil fill cap. (3) Raise vehicle on hoist.
Page 1198 ENGINE 2.4L DOHC 9 - 129 OIL (Continued) (2) Lubricate new oil filter gasket with clean NOTE: Care should be exercised when disposing engine oil. used engine oil after it has been drained from a (3) Screw oil filter (Fig. 85) on until the gasket vehicle engine.
Page 1199 9 - 130 ENGINE 2.4L DOHC OIL PAN (Continued) (1) Clean oil pan and block surfaces. Clean cured RTV from oil pan and bed plate with a plastic or brass scraper. (2) Clean all sealing surfaces with MOPAR Brake Parts Cleaner. (3) Inspect surfaces for damage, replace as needed.
Page 1200 ENGINE 2.4L DOHC 9 - 131 OIL PRESSURE SENSOR/ (3) Remove Timing Belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT/CHAIN SWITCH SPROCKETS - REMOVAL). (4) Remove Oil Pan (Refer to 9 - ENGINE/LUBRI- REMOVAL CATION/OIL PAN - REMOVAL). (1) Raise vehicle. (5) Remove Crankshaft Sprocket using Special Tool (2) Position oil collecting container under pressure 6793 and insert C-4685-C2 (Fig.
Page 1201 9 - 132 ENGINE 2.4L DOHC OIL PUMP (Continued) Fig. 92 Oil Pump and Pick-up Tube 1 - OIL PAN GASKET 5 - OIL PICK-UP TUBE 2 - O-RING 6 - DRAIN PLUG 3 - OIL PUMP BODY 7 - OIL PAN 4 - FILTER...
Page 1202 ENGINE 2.4L DOHC 9 - 133 OIL PUMP (Continued) INSPECTION (1) Clean all parts thoroughly. Mating surface of the oil pump should be smooth (Fig. 93). Replace pump cover if scratched or grooved. (2) Lay a straightedge across the pump cover sur- face (Fig.
Page 1203 9 - 134 ENGINE 2.4L DOHC OIL PUMP (Continued) Fig. 96 Measuring Fig. 98 Measuring Clearance Between Rotors 1 - FEELER GAUGE 2 - INNER ROTOR 3 - OUTER ROTOR Fig. 97 Measuring Outer Rotor Clearance in Housing Fig. 99 Measuring Clearance Over Rotors 1 - FEELER GAUGE 2 - OUTER ROTOR 1 - FEELER GAUGE...
Page 1204 ENGINE 2.4L DOHC 9 - 135 OIL PUMP (Continued) NOTE: Front crankshaft seal MUST be out of pump to align, or damage may result. (5) Install new front crankshaft seal using Special Tool 6780 (Fig. 101). Fig. 102 Crankshaft Sprocket—Installation 1 - SPECIAL TOOL 6792 2 - TIGHTEN NUT TO INSTALL INTAKE MANIFOLD...
Page 1205 9 - 136 ENGINE 2.4L DOHC INTAKE MANIFOLD (Continued) (3) Drain cooling system (Refer to 7 - COOLING/ (16) Remove intake manifold fasteners. Remove ENGINE - STANDARD PROCEDURE). intake manifold. (4) Remove throttle body air inlet hose and air CLEANING cleaner housing assembly.
Page 1206 ENGINE 2.4L DOHC 9 - 137 INTAKE MANIFOLD (Continued) Fig. 106 PZEV Manifold and Check Valve Fig. 104 Intake Manifold Tightening Sequence 1 - Check Valve EXHAUST MANIFOLD 2 - Exhaust Manifold 3 - Heat Sheild Mounting Location REMOVAL (6) Remove exhaust manifold heat shield (Fig. (1) Disconnect negative battery cable.
Page 1207 9 - 138 ENGINE 2.4L DOHC EXHAUST MANIFOLD (Continued) INSPECTION (1) Inspect manifold gasket surfaces for flatness with straight edge. Surface must be flat within 0.15 mm per 300 mm (0.006 in. per foot) of manifold length. (2) Inspect manifolds for cracks or distortion. Replace manifold as necessary.
Page 1208 ENGINE 2.4L DOHC 9 - 139 TIMING BELT COVER(S) (Continued) (4) Remove both camshaft sprockets. Hold cam- shaft sprockets with Special Tool 6847 while remov- ing center bolts (Fig. 112). Fig. 110 Front Timing Belt Covers Fig. 112 Camshaft Sprocket - Removal/Installation 1 - UPPER TIMING BELT COVER FASTENERS 1 - SPECIAL TOOL 6847 2 - ENGINE SUPPORT BRACKET FASTENERS...
Page 1209 9 - 140 ENGINE 2.4L DOHC TIMING BELT COVER(S) (Continued) INSTALLATION (7) Disconnect generator connections. Remove gen- erator and bracket. (8) Remove upper and lower timing belt covers FRONT COVER - UPPER (Refer to 9 - ENGINE/VALVE TIMING/TIMING (1) Install timing belt cover. Torque fasteners to 6 BELT COVER(S) - REMOVAL) (Fig.
Page 1210 ENGINE 2.4L DOHC 9 - 141 TIMING BELT AND SPROCKET(S) (Continued) Fig. 116 Camshaft Sprocket - Removal/Installation 1 - SPECIAL TOOL 6847 (3) Remove crankshaft sprocket using Special Tools 6793 and insert C-4685-C2 (Fig. 117). Fig. 114 Crankshaft and Camshaft Timing 1 - CAMSHAFT TIMING MARKS 2 - CRANKSHAFT TDC MARKS 3 - TRAILING EDGE OF SPROCKET TOOTH...
Page 1211 9 - 142 ENGINE 2.4L DOHC TIMING BELT AND SPROCKET(S) (Continued) INSTALLATION INSTALLATION - CRANKSHAFT SPROCKET CAUTION: The crankshaft sprocket is set to a pre- determined depth from the factory for correct tim- ing belt tracking. If removed, use of Special Tool 6792 is required to set the sprocket to original installation depth.
Page 1212 ENGINE 2.4L DOHC 9 - 143 TIMING BELT AND SPROCKET(S) (Continued) Fig. 121 Timing Belt Tension Adjustment 1 - ALIGN SETTING NOTCH WITH SPRING TANG 2 - TOP PLATE 3 - 6mm ALLEN WRENCH 4 - LOCK BOLT 5 - SETTING NOTCH 6 - SPRING TANG (13) Install AC/Generator belt tensioner.
Page 1213 9 - 144 ENGINE 2.4L DOHC TIMING BELT AND SPROCKET(S) (Continued) TIMING BELT TENSIONER & PULLEY REMOVAL (1) Remove the timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT AND SPROCKETS - REMOVAL). (2) Remove timing belt idler pulley (Fig. 124). Fig.
Page 1214 ENGINE 2.4L DOHC 9 - 145 TIMING BELT TENSIONER & PULLEY (Continued) (6) Install the timing belt (Refer to 9 - ENGINE/ VALVE TIMING/TIMING BELT AND SPROCKETS - INSTALLATION). Fig. 125 Camshaft Sprocket - Removal/Installation 1 - SPECIAL TOOL 6847 Fig.
Page 1215 9 - 146 ENGINE 2.4L DOHC BALANCE SHAFTS AND (3) If replacing crankshaft sprocket, remove oil pump (Refer to 9 - ENGINE/LUBRICATION/OIL CARRIER ASSEMBLY PUMP - REMOVAL). (4) Remove chain cover, guide and tensioner. Dis- DESCRIPTION card pivot screw and adjuster screw. (Fig. 129). The 2.4L engine is equipped with two nodular cast (5) Remove screw retaining balance shaft drive iron balance shafts installed in a cast aluminum car-...
Page 1216 ENGINE 2.4L DOHC 9 - 147 BALANCE SHAFTS AND CARRIER ASSEMBLY (Continued) Fig. 131 Gear Cover and Gears 1 - STUD (DOUBLE ENDED) 2 - DRIVE GEAR 3 - DRIVEN GEAR 4 - CARRIER DOWEL 5 - GEAR(S) 6 - GEAR COVER Fig.
Page 1217 9 - 148 ENGINE 2.4L DOHC BALANCE SHAFTS AND CARRIER ASSEMBLY (Continued) INSTALLATION BALANCE SHAFT INSTALLATION/TIMING Balance shaft and carrier assembly installation is the reverse of the removal procedure. D u rin g in s ta l- la tio n c ra n k s h a ft-to -ba la n c e s h a ft tim in g m u s t be e s ta blis h e d .
Page 1218 ENGINE 2.4L DOHC 9 - 149 BALANCE SHAFTS AND CARRIER ASSEMBLY (Continued) (c) Place a shim 1 mm (0.039 in.) thick x 70 mm (2.75 in.) long between tensioner and chain. Push tensioner and shim up against the chain. Ap p ly firm p re s s u re 2.5–3 Kg (5.5–6.6 lbs .) d ire c tly be h in d th e a d ju s tm e n t s lo t to ta k e u p a ll s la c k .
Page 1219 9 - 150 ENGINE 2.7L DOHC ENGINE 2.7L DOHC TABLE OF CONTENTS page page ENGINE 2.7L DOHC CYLINDER HEAD COVER - LEFT DESCRIPTION ......152 REMOVAL .
Page 1220 ENGINE 2.7L DOHC 9 - 151 CRANKSHAFT MAIN BEARINGS OPERATION ......215 STANDARD PROCEDURE - CRANKSHAFT REMOVAL .
Page 1221 9 - 152 ENGINE 2.7L DOHC ENGINE 2.7L DOHC DESCRIPTION The 2.7 Liter (167 Cubic Inches) 60 degree V-6 engine is a double overhead camshaft design with hydraulic lifters and four valves per cylinder (Fig. 1). The engine does not have provisions for a free wheel- ing valve train.
Page 1222 ENGINE 2.7L DOHC 9 - 153 ENGINE 2.7L DOHC (Continued) DIAGNOSIS AND TESTING Additional tests and diagnostic procedures may be necessary for specific engine malfunctions that can- not be isolated with the Service Diagnosis charts. DIAGNOSIS AND TESTING - ENGINE Information concerning additional tests and diagno- DIAGNOSIS - INTRODUCTION sis is provided within the following:...
Page 1223 9 - 154 ENGINE 2.7L DOHC ENGINE 2.7L DOHC (Continued) CONDITION POSSIBLE CAUSE CORRECTION ENGINE LOSS OF POWER 1. Dirty or incorrectly gapped plugs. 1. Set gap as needed or replace plug(s). 2. Contamination in fuel system. 2. Clean system and replace fuel filter.
Page 1224 ENGINE 2.7L DOHC 9 - 155 ENGINE 2.7L DOHC (Continued) DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICAL CONDITION POSSIBLE CAUSES CORRECTION VALVETRAIN NOISE 1. High or low oil level in 1. Check and correct engine oil crankcase. level. 2. Thin or diluted oil. 2.
Page 1225 9 - 156 ENGINE 2.7L DOHC ENGINE 2.7L DOHC (Continued) CONDITION POSSIBLE CAUSES CORRECTION MAIN BEARING NOISE 1. Insufficient oil supply. 1. Check engine oil level. 2. Low oil pressure. 2. Check engine oil level. Inspect oil pump relief valve and spring. 3.
Page 1226 ENGINE 2.7L DOHC 9 - 157 ENGINE 2.7L DOHC (Continued) CONDITION POSSIBLE CAUSES CORRECTION OIL CONSUMPTION OR SPARK 1. PCV system malfunction. 1. Check system and repair as PLUGS FOULED necessary. (Refer to Appropriate Diagnostic Manual) 2. Worn, scuffed or broken rings. 2.
Page 1227 9 - 158 ENGINE 2.7L DOHC ENGINE 2.7L DOHC (Continued) should maintain 483 kPa (70 psi) minimum, 1,379 • If the leakage occurs at the crankshaft rear oil kPa (200 psi) maximum, with 552 kPa (80 psi) rec- seal area, refer to the section, Inspection for Rear ommended.
Page 1228 ENGINE 2.7L DOHC 9 - 159 ENGINE 2.7L DOHC (Continued) CAUTION: Use extreme caution when crankshaft CAUTION: Squirt approximately one teaspoon of oil polishing is necessary to remove minor nicks and into the cylinders, rotate engine to lubricate the cyl- scratches.
Page 1229 9 - 160 ENGINE 2.7L DOHC ENGINE 2.7L DOHC (Continued) ing clearance or alignment of these components. The NOTE: Multi-Layer Steel (MLS) head gaskets require material cures slowly in the absence of air when a scratch free sealing surface. torqued between two metallic surfaces, and will rap- Only use the following for cleaning gasket surfaces: idly cure when heat is applied.
Page 1230 ENGINE 2.7L DOHC 9 - 161 ENGINE 2.7L DOHC (Continued) or cooler circuit. A service splice kit will be installed upon reassembly. • Disconnect transmission electrical harness con- nectors (C104 & C105) (Refer to 8 - ELECTRICAL/ CONNECTOR/GROUND LOCATIONS DESCRIPTION). •...
Page 1231 9 - 162 ENGINE 2.7L DOHC ENGINE 2.7L DOHC (Continued) • Mark flex plate to torque converter position. Remove torque converter bolts. (35) Ma n u a l Tra n s m is s io n Equ ip p e d Ve h ic le s : •...
Page 1232 ENGINE 2.7L DOHC 9 - 163 ENGINE 2.7L DOHC (Continued) (17) Install exhaust cross-under pipe (Refer to 11 - (42) Install throttle body air inlet hose and air EXHAUST SYSTEM/CROSS-OVER PIPE - INSTAL- cleaner housing assembly. LATION). (43) Fill engine crankcase with proper oil to cor- (18) Install structural collar (Refer to 9 - ENGINE/ rect level.
Page 1233 9 - 164 ENGINE 2.7L DOHC ENGINE 2.7L DOHC (Continued) PISTONS PISTON RING SIDE CLEARANCE Specification Specification Description Description Metric Standard Metric Standard Material Aluminum Alloy Compression 0.035-0.083 0.0013-0.0032 Piston Diameter 85.983 mm 3.3851 in. Ring-Top ±0.019 ±0.0017 Compression 0.040-0.080 0.0016-0.0031 Clearance at - 0.0096 to...
Page 1234 ENGINE 2.7L DOHC 9 - 165 ENGINE 2.7L DOHC (Continued) CRANKSHAFT MAIN BEARING JOURNALS VALVE TIMING-INTAKE VALVES Specification Description Specification Description Metric Standard Opens (ATDC) 2° Diameter 63.49–63.51 2.4997–2.5004 Closes (ABDC) 44° Duration 222° Bearing 0.035–0.053 0.0014–0.0021 Clearance VALVE TIMING-EXHAUST VALVES Bearing Clearance 0.087 mm...
Page 1235 9 - 166 ENGINE 2.7L DOHC ENGINE 2.7L DOHC (Continued) VALVES VALVE SPRING Specification Specification Description Description Metric Standard Metric Standard Face Angle 44.5°-45.5° Free Length— Intake & Head Diameter- 1.3256-1.3358 45.63 mm 1.7965 in. 33.67-33.93 Exhaust Intake (Approx.) Head Diameter- 27.67-27.93 1.0894-1.1000 Spring...
Page 1236 ENGINE 2.7L DOHC 9 - 167 ENGINE 2.7L DOHC (Continued) OIL PRESSURE Specification Description Metric Standard Specification Pressure @ Description 300–724 kPa 45–105 psi 3000 RPM Metric Standard *CAUTION: If oil pressure is zero at idle, DO NOT run (NOTE: At Normal Operating Temperatures) engine at 3000 RPM.
Page 1237 9 - 168 ENGINE 2.7L DOHC ENGINE 2.7L DOHC (Continued) DESCRIPTION N·m Lbs. Lbs. Starter Mounting - Bolts Structural Collar (Refer to 9 - ENGINE/ENGINE BLOCK/ STRUCTURAL COVER - INSTALLATION) Thermostat Housing/Water Inlet Connector - Bolts Throttle Body - Bolts Timing Chain Cover - M6 Bolts Timing Chain Cover - M10 Bolts Timing Chain Tensioner (Primary)
Page 1238 ENGINE 2.7L DOHC 9 - 169 ENGINE 2.7L DOHC (Continued) Crankshaft Seal Remover 6771 Crankshaft Seal & Sprocket Installer 6780-1 Puller 8454 Crankshaft Seal Protector 6780-2 Crankshaft Damper Remover Insert 8194 Puller 5048 Crankshaft Damper Installer Screw 8179 Crankshaft Damper Installer 6792-1 Puller Adaptor 8539...
Page 1239 9 - 170 ENGINE 2.7L DOHC ENGINE 2.7L DOHC (Continued) Crankshaft Rear Seal Guide 6926-1 & Installer 6926-2 Valve Spring Compressor 8215-A Adaptor 8216-A Driver Handle C-4171 Valve Spring Compressor C-3422-D Crankshaft Real Seal Retainer Alignment Fixture 8225 Valve Spring Adapter 6526 Timing Chain Tensioner Resetting Gauge 8186 Dial Indicator C-3339...
Page 1240 ENGINE 2.7L DOHC 9 - 171 ENGINE 2.7L DOHC (Continued) Connecting Rod Installation Guides 8189 Main Bearing Remover/Installer C-3059 Valve Spring Tester C-647 Pressure Gauge C-3292 Valve Spring Compressor MD-998772-A Adapter 8406 Valve Spring Adapter 6527 DRB III with PEP Module – OT-CH6010A Indicator Bore Size C-119...
Page 1241 9 - 172 ENGINE 2.7L DOHC ENGINE 2.7L DOHC (Continued) Pressure Transducer CH7059 Combustion Leak Tester C-3685-A Adaptor 8116 Cooling System Tester 7700...
Page 1242 ENGINE 2.7L DOHC 9 - 173 AIR CLEANER ELEMENT (4) Loosen hose clamp at throttle body (Fig. 9). Remove hose from throttle body. REMOVAL (1) Disconnect negative battery cable. (2) Disconnect inlet air temperature sensor electri- cal connector (Fig. 7). Fig.
Page 1243 9 - 174 ENGINE 2.7L DOHC AIR CLEANER ELEMENT (Continued) INSTALLATION (1) Clean any debris from inside air cleaner hous- ing. (2) Install air cleaner element into air cleaner housing (Fig. 11). Verify element rests properly on mounting bosses inside air cleaner housing. Fig.
Page 1244 ENGINE 2.7L DOHC 9 - 175 AIR CLEANER HOUSING (Continued) • Engine misfiring • Poor fuel economy Possible indications of the cylinder head gasket leaking between a cylinder and an adjacent water jacket are: • Engine overheating • Loss of coolant •...
Page 1245 9 - 176 ENGINE 2.7L DOHC CYLINDER HEAD (Continued) Fig. 15 CYLINDER HEAD, VALVES, & SPRINGS 1 - VALVE KEEPER 7 - VALVE-EXHAUST 2 - SPRING RETAINER 8 - VALVE-INTAKE 3 - VALVE KEEPER 9 - CYLINDER HEAD 4 - VALVE SPRING-EXHAUST 10 - VALVE STEM SEAL 5 - SPRING RETAINER 11 - VALVE SPRING-INTAKE...
Page 1246 ENGINE 2.7L DOHC 9 - 177 CYLINDER HEAD (Continued) (5) Allow the sealant to cure for at least 20 min- (12) Remove cylinder head covers (Refer to 9 - utes. ENGINE/CYLINDER HEAD/CYLINDER HEAD (6) Assemble any components removed in step # 1 COVER(S) - REMOVAL).
Page 1247 9 - 178 ENGINE 2.7L DOHC CYLINDER HEAD (Continued) (24) Remove cylinder head bolts reverse sequence of installation (Fig. 20) starting with bolts 11–9, then bolts 8–1. Fig. 18 Camshaft Bearing Caps (23) For right cylinder head removal: • Remove cylinder head ground strap. •...
Page 1248 ENGINE 2.7L DOHC 9 - 179 CYLINDER HEAD (Continued) INSTALLATION (25) Remove cylinder head(s). (26) Remove and discard cylinder head gasket. (27) Clean cylinder head and block sealing sur- NOTE: The cylinder head bolts are tightened using faces. (Refer to 9 - ENGINE/CYLINDER HEAD - a torque plus angle procedure.
Page 1249 9 - 180 ENGINE 2.7L DOHC CYLINDER HEAD (Continued) (15) Install lower and upper intake manifolds (Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANI- FOLD - INSTALLATION). (16) Connect oil pressure sensor connector. Install oil pressure sensor heat shield. (17) Install catalytic converter(s) (Refer to 11 - EXHAUST SYSTEM/CATALYTIC CONVERTER - INSTALLATION).
Page 1250 ENGINE 2.7L DOHC 9 - 181 CAMSHAFT(S) (Continued) Fig. 25 Camshaft and Valvetrain Components 1 – CAMSHAFT BEARING CAP - INTAKE 7 – CAMSHAFT (SECONDARY) CHAIN TENSIONER 2 – CAMSHAFT BEARING CAP - EXHAUST 8 – CYLINDER BLOCK 3 – CAMSHAFT - EXHAUST 9 –...
Page 1251 9 - 182 ENGINE 2.7L DOHC CAMSHAFT(S) (Continued) (5) Rotate the cams so that the plated links and dots are facing the 12:00 O’clock position (Fig. 29). (6) Install cams to cylinder head. Ensure that rocker arms are correctly seated and in proper posi- tions.
Page 1252 ENGINE 2.7L DOHC 9 - 183 CYLINDER HEAD COVER - LEFT REMOVAL (1) Disconnect negative battery cable. (2) Remove upper intake manifold (Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANIFOLD REMOVAL). (3) Disconnect electrical connectors from ignition coils and capacitor. Reposition electrical harness. (4) Remove ground strap from cylinder head cover stud.
Page 1253 9 - 184 ENGINE 2.7L DOHC CYLINDER HEAD COVER - INTAKE/EXHAUST VALVES & RIGHT SEATS REMOVAL DESCRIPTION (1) Disconnect negative battery cable. The valves are made of heat resistant steel, and (2) Remove upper intake manifold (Refer to 9 - have chrome plated stems to prevent scuffing (Fig.
Page 1254 ENGINE 2.7L DOHC 9 - 185 INTAKE/EXHAUST VALVES & SEATS (Continued) the bottom edge of valve face, then raise valve seat (4) Position valve springs and retainer on spring with a 65 degree stone. seat (Fig. 34). (5) Compress valve spring with a valve spring NOTE: Valve seats which are worn or burned can compressor.
Page 1255 9 - 186 ENGINE 2.7L DOHC INTAKE/EXHAUST VALVES & SEATS (Continued) INSPECTION VALVES (1) Clean and inspect valves thoroughly. Replace burned, warped and cracked valves. (2) Measure valve stems for wear (Fig. 35). For valve specifications, (Refer to 9 - ENGINE - SPECI- FICATIONS).
Page 1256 ENGINE 2.7L DOHC 9 - 187 VALVE SPRINGS (4) Remove upper intake manifold. (Refer to 9 - ENGINE/MANIFOLDS/INTAKE MANIFOLD REMOVAL) DESCRIPTION (5) Remove cylinder head covers. (Refer to 9 - The valve springs are made from high strength, ENGINE/CYLINDER HEAD/CYLINDER HEAD chrome-silicon steel (Fig.
Page 1257 9 - 188 ENGINE 2.7L DOHC VALVE SPRINGS (Continued) (9) Using Special Tool MD 998772A with adapter 6779, compress valve spring and remove valve locks, retainer, and valve spring. (10) Remove valve stem seal (Refer to 9 - ENGINE/CYLINDER HEAD/VALVE STEM SEALS - REMOVAL).
Page 1258 ENGINE 2.7L DOHC 9 - 189 VALVE SPRINGS (Continued) INSTALLATION - OFF VEHICLE (1) If removed, install valve(s). (Refer to 9 - ENGINE/CYLINDER HEAD/INTAKE/EXHAUST VALVES & SEATS - INSTALLATION) (2) If valves or seats have been reground, check valve tip height (A) (Fig. 40). If valve tip height for intake valve is greater than 47.59 mm (1.8737 in.) or 49.14 mm (1.9347 in.) for exhaust valve, grind valve tip until within specifications.
Page 1259 9 - 190 ENGINE 2.7L DOHC VALVE STEM SEALS (Continued) INSTALLATION (tappet) type noise can sometimes be difficult. As a result, an initial misdiagnosis may occur. (1) The valve stem seal/valve spring seat should be Refer to LASH ADJUSTER (TAPPET) NOISE pushed firmly and squarely over the valve guide CHART indicating possible lash adjuster (tappet) using the valve stem as guide.
Page 1260 ENGINE 2.7L DOHC 9 - 191 HYDRAULIC LASH ADJUSTERS (Continued) POSSIBLE CAUSES CORRECTION 6. Worn valve guide(s). 6. Ream guide(s) and replace valve(s) with oversize valves and seal(s). 7. Air injested into oil due to broken or cracked oil 7. Inspect pickup tube and replace as necessary. pump pickup tube.
Page 1261 9 - 192 ENGINE 2.7L DOHC ROCKER ARMS (Continued) (4) Install rocker arm in original position (if reused) over valve and lash adjuster. Release tension on valve spring. NOTE: Inspect rocker arm for proper engagement into lash adjuster and valve tip. (5) Repeat procedure for each rocker arm being installed.
Page 1262 ENGINE 2.7L DOHC 9 - 193 ENGINE BLOCK (Continued) Fig. 46 ENGINE BLOCK AND CRANKSHAFT 1 - MAIN CAP BOLT—VERTICAL 5 - MAIN CAP BOLT —HORIZONTAL 2 - MAIN CAP 6 - CYLINDER BLOCK 3 - MAIN BEARING—LOWER 7 - CRANKSHAFT 4 - MAIN BEARING—UPPER minute can be regulated to get the desired 40–60 degree angle.
Page 1263 9 - 194 ENGINE 2.7L DOHC ENGINE BLOCK (Continued) CONNECTING ROD BEARINGS INSPECTION ENGINE BLOCK STANDARD PROCEDURE - CONNECTING ROD (1) Clean cylinder block thoroughly and check all AND BEARING FITTING core hole plugs for evidence of leaking. (2) If new core plugs are to be installed, (Refer to 9 CONNECTING ROD BEARING - ENGINE - STANDARD PROCEDURE - ENGINE Fit all connecting rods on one bank until complete.
Page 1264 ENGINE 2.7L DOHC 9 - 195 CONNECTING ROD BEARINGS (Continued) Compare measurement to specification listed in engine specifications (Refer to 9 - ENGINE - SPECI- FICATIONS). Repeat procedure for each connecting rod. Turn crankshaft for connecting rod accessibility. Fig. 51 Connecting Rod Side Clearance Measuring CRANKSHAFT Fig.
Page 1265 9 - 196 ENGINE 2.7L DOHC CRANKSHAFT (Continued) (16) Remove connecting rod bearing caps. Use care to prevent damage to the crankshaft bearing sur- faces. CAUTION: Care should be taken not to damage the fractured rod and cap joint face surfaces or damage to the engine may occur.
Page 1266 ENGINE 2.7L DOHC 9 - 197 CRANKSHAFT (Continued) Fig. 55 CYLINDER BLOCK AND CRANKSHAFT 1 - MAIN CAP BOLT—VERTICAL 5 - MAIN CAP BOLT —HORIZONTAL 2 - MAIN CAP 6 - CYLINDER BLOCK 3 - MAIN BEARING—LOWER 7 - CRANKSHAFT 4 - MAIN BEARING—UPPER INSTALLATION NOTE: Upper and lower bearing halves are NOT...
Page 1267 9 - 198 ENGINE 2.7L DOHC CRANKSHAFT (Continued) onto the machined shelf between the No. 3 upper BLOCK/CRANKSHAFT SEAL REAR main bulk head and crankshaft thrust surface (Fig. INSTALLATION). 57). (13) Install oil pump assembly (Refer to 9 - (4) Move crankshaft rearward. Lubricate and ENGINE/LUBRICATION/OIL PUMP - INSTALLA- install the rear thrust washer by rolling the thrust TION).
Page 1268 ENGINE 2.7L DOHC 9 - 199 CRANKSHAFT MAIN BEARINGS (Continued) NOTE: Service main bearings have a number from 1–5 marked in ink on the bearing surface (Fig. 60). For verification, use the MAIN BEARING SELEC- TION CHART—2.7L for number to size identification. The upper main bearing has a oil feed hole and a center groove to allow lubrication of the main journal and must be properly positioned in the block.
Page 1269 9 - 200 ENGINE 2.7L DOHC CRANKSHAFT OIL SEAL - FRONT REMOVAL (1) Remove crankshaft vibration damper. (Refer to ENGINE/ENGINE BLOCK/VIBRATION DAMPER - REMOVAL) (2) Install Special Tool 8194, Insert into crankshaft nose. Remove seal using Special Tool 6771, Remover (Fig.
Page 1270 ENGINE 2.7L DOHC 9 - 201 CRANKSHAFT OIL SEAL - REAR (Continued) Fig. 63 Rear Crankshaft Oil Seal Removal - Typical 1 - REAR CRANKSHAFT SEAL 2 - ENGINE BLOCK 3 - ENGINE BLOCK Fig. 64 Crankshaft Rear Seal - Installation 4 - REAR CRANKSHAFT SEAL METAL CASE 1 - C-4171 HANDLE 5 - PRY IN THIS DIRECTION...
Page 1271 9 - 202 ENGINE 2.7L DOHC CRANKSHAFT REAR OIL SEAL RETAINER (Continued) (4) While applying firm pressure to the seal retainer against Special Tools 8225 (Fig. 66), tighten seal retainer screws to 12 N·m (105 in. lbs.). Fig. 66 Seal Retainer Alignment - Typical 1 - SPECIAL TOOLS 8225 2 - SEAL RETAINER (5) Install oil pan and crankshaft rear oil seal.
Page 1272 ENGINE 2.7L DOHC 9 - 203 PISTON & CONNECTING ROD (Continued) ro d s . Pistons and connecting rods are serviced as an assembly for balance. REMOVAL (1) Remove top ridge of cylinder bores with a reli- able ridge reamer before removing pistons from cyl- inder block.
Page 1273 9 - 204 ENGINE 2.7L DOHC PISTON & CONNECTING ROD (Continued) (9) Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod into position on connecting rod journal. (10) Lubricate rod bolts and bearing surface with engine oil.
Page 1274 ENGINE 2.7L DOHC 9 - 205 PISTON RINGS (Continued) Fig. 72 Piston and Connecting Rod Positioning (Front View of Engine) 2 - OIL SQUIRT HOLE 1 - MAJOR THRUST SIDE OF PISTON Fig. 74 Measuring Piston Ring Side Clearance Fig. 73 CHECK GAP ON PISTON RINGS 1 - FEELER GAUGE 1 - FEELER GUAGE •...
Page 1275 9 - 206 ENGINE 2.7L DOHC PISTON RINGS (Continued) • No. 2 Intermediate piston ring. • No. 1 Upper piston ring. (2) Install oil ring expander. Install the side rail by placing one end between the piston ring groove and the oil ring expander. Hold end firmly and press down the portion to be installed until side rail is in position.
Page 1276 ENGINE 2.7L DOHC 9 - 207 VIBRATION DAMPER REMOVAL (1) Disconnect negative battery cable. (2) Raise vehicle on hoist. (3) Remove right front wheel and belt splash shield. (4) Remove accessory drive belts (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - REMOVAL).
Page 1277 9 - 208 ENGINE 2.7L DOHC STRUCTURAL COLLAR (Continued) LEFT MOUNT INSTALLATION REMOVAL CAUTION: The collar must be tightened using this service procedure, as damage to transaxle case (1) Disconnect negative battery cable. and/or oil pan may occur. (2) Remove throttle body air inlet hose and air cleaner housing assembly.
Page 1278 ENGINE 2.7L DOHC 9 - 209 REAR MOUNT (6) Lower vehicle. Install throttle body air inlet hose and air cleaner housing assembly. REMOVAL RIGHT MOUNT (1) Remove throttle body air inlet hose and air cleaner housing assembly. (2) Remove three vertical bolts attaching rear REMOVAL mount bracket to transaxle case (Fig.
Page 1279 9 - 210 ENGINE 2.7L DOHC RIGHT MOUNT (Continued) (7) Install coolant bottle (Refer to 7 - COOLING/ ENGINE/COOLANT RECOVERY PRESS CON- TAINER - INSTALLATION). FRONT MOUNT REMOVAL (1) Raise vehicle. (2) Remove front mount to bracket horizontal through bolt (Fig. 85). (3) Loosen the rear mount through bolt.
Page 1280 ENGINE 2.7L DOHC 9 - 211 LUBRICATION (Continued) Fig. 86 Cylinder Block Oil Lubrication System 1 - TO RIGHT CYLINDER HEAD 5 - OIL FILTER 2 - TO LEFT CYLINDER HEAD 6 - TO CRANKSHAFT MAIN JOURNALS 3 - OIL PUMP 7 - MAIN OIL GALLERY 4 - OIL PICKUP TUBE FROM:...
Page 1281 9 - 212 ENGINE 2.7L DOHC LUBRICATION (Continued) Fig. 87 Cylinder Head Oil Lubrication System - Left Side 1 - CAM JOURNALS 4 - OIL FEED FROM BLOCK 2 - OIL FEED TO CAMSHAFT (SECONDARY) CHAIN TENSIONER 5 - VENT HOLE 3 - LASH ADJUSTER BORES 6 - ACCUMULATOR FROM:...
Page 1282 ENGINE 2.7L DOHC 9 - 213 LUBRICATION (Continued) Fig. 88 Cylinder Head Oil Lubrication System - Right Side 1 - OIL FEED TO CAMSHAFT (SECONDARY) CHAIN TENSIONER 5 - VENT HOLE 2 - OIL FEED TO TIMING CHAIN (PRIMARY) TENSIONER 6 - OIL FEED FROM BLOCK 3 - CAM JOURNALS 7 - LASH ADJUSTOR BORES...

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