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Jeep 1997 Grand Cherokee Service Manual

Jeep 1997 Grand Cherokee Service Manual

Interactive electronic service manual

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1997 Jeep Grand Cherokee

(RHD & LHD)

Interactive Electronic Service Manual!

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Page 1: Jeep Grand Cherokee
Welcome to the 1997 Jeep Grand Cherokee (RHD & LHD) Interactive Electronic Service Manual! CLICK ON VEHICLE TO BEGIN tweddle litho: dom parts cdrom demo 09/96 page 4 <output:1601 ET 05/06/97>...
Page 2: Table Of Contents
GROUP TAB LOCATOR Introduction Lubrication and Maintenance Suspension Differential and Driveline Brakes Cooling System Battery Starter Charging System Ignition System Instrument Panel and Systems Audio Systems Horns Vehicle Speed Control System Turn Signal and Flashers Windshield Wipers and Washers Lamps Restraint System Electrically Heated Systems Power Door Locks...
Page 3 VEHICLE IDENTIFICATION NUMBER DECODING CHART POSITION INTERPRETATION CODE = DESCRIPTION Country of Origin 1 = United States Make J = Jeep Vehicle Type 4 = MPV Gross Vehicle Weight Rating G = 5001-6000 lbs. Vehicle Line X = Grand Cherokee 4X2 (LHD)
Page 4: Body Code Plate
INTRODUCTION GENERAL INFORMATION (Continued) VEHICLE SAFETY CERTIFICATION LABEL A vehicle safety certification label (Fig. 1) is attached to every Chrysler Corporation vehicle. The label certifies that the vehicle conforms to all appli- cable Federal Motor Vehicle Safety Standards. The label also lists: •...
Page 5: Fastener Identification
HEADLIGHTS, WINDSHIELD WINDSCREEN ENGINE COOLANT TEMPER- BATTERY CHARGING CON- REAR WINDOW DEFOGGER REAR WINDOW WASHER LIGHTS, PANEL LIGHTS REAR WINDOW WIPER WINDSHIELD WASHER REAR HOOD (TRUNK) WINDSHIELD WIPER HAZARD WARNING AND DEFROSTING VENTILATING FAN PARKING BRAKE BRAKE FAILURE TURN SIGNAL FRONT HOOD WIPER FOG LIGHTS...
Page 6 INTRODUCTION GENERAL INFORMATION (Continued) FASTENER IDENTIFICATION...
Page 7 HOW TO DETERMINE BOLT STRENGTH Hexagon head bolt Two protruding lines Two protruding lines Hexagon flange bolt w/washer hexagon bolt No mark Welded bolt Hexagon head bolt Bolt head No. No mark Hexagon flange bolt w/washer hexagon bolt Grooved Hexagon head bolt Four protruding lines...
Page 8: Metric System
COMMON METRIC EQUIVA- 1 Cubic Inch = 16 Cubic Cen- 1 Cubic Foot = 0.03 Cubic 1 Cubic Yard = 0.8 Cubic 1 Mile = 1.6 Kilometers = Newton-Meters (N·m) = Newton-Meters (N·m) = Kilometers/Hr. (Km/h) 1 Inch = 25 Millimeters = Meters/Sec.
Page 9 INTRODUCTION GENERAL INFORMATION (Continued) METRIC CONVERSION...
Page 10 Class SPECIFIED TORQUE FOR STANDARD BOLTS 48 in.-lbf 52 in.-lbf 56 in.-lbf 65 in.-lbf 69 in.-lbf 78 in.-lbf Diameter kgf-cm ft.-lbf ft.-lbf N·m Pitch Hexagon flange bolt N·m Specified torque Hexagon head bolt kgf-cm INTRODUCTION GENERAL INFORMATION (Continued) TORQUE SPECIFICATIONS...
Page 11 VEHICLE IDENTIFICATION NUMBER DECODING CHART POSITION INTERPRETATION CODE = DESCRIPTION Country of Origin 1 = United States Make J = Jeep Vehicle Type 4 = MPV Gross Vehicle Weight Rating G = 5001-6000 lbs. Vehicle Line X = Grand Cherokee 4X2 (LHD)
Page 13: Lubrication And Maintenance
ENGINE COOLANT AUTOMATIC TRANSMISSION ENGINE OIL FLUID WINDSHIELD POWER BRAKE FLUID WASHER FLUID STEERING FLUID LUBRICATION AND MAINTENANCE 0 - 1 LUBRICATION AND MAINTENANCE CONTENTS page page GENERAL INFORMATION ....1 MAINTENANCE SCHEDULES .
Page 14 WHEEL BEARINGS CHASSIS LUBRICA- TION CHASSIS WHEEL BEARINGS 0 - 2 LUBRICATION AND MAINTENANCE GENERAL INFORMATION (Continued) Fig. 3 NLGI Symbol FLUID CAPACITIES Fig. 2 API Symbol FUEL TANK ENGINE OIL All ......87.4 L (23 gal.) SAE GRADE RATING INDICATES ENGINE OIL VISCOSITY ENGINE OIL W/FILTER CHANGE An SAE viscosity grade is used to specify the vis-...
Page 15: Maintenance Schedules
LUBRICATION AND MAINTENANCE 0 - 3 MAINTENANCE SCHEDULES INDEX page page GENERAL INFORMATION SCHEDULE—B ......5 INTRODUCTION .
Page 16 0 - 4 LUBRICATION AND MAINTENANCE GENERAL INFORMATION (Continued) • Replace spark plugs. 82,500 Miles (132 000 km) or at 66 months • Inspect drive belt. • Change engine oil. • Lubricate steering linkage. • Replace engine oil filter. • Drain and refill automatic transmission fluid. •...
Page 17 LUBRICATION AND MAINTENANCE 0 - 5 GENERAL INFORMATION (Continued) **Recommended for proper vehicle performance for 27,000 Miles (43 000 km) • Change engine oil. vehicles built for sale in California. • Replace engine oil filter. IMPORTANT: Inspection and service should also •...
Page 18 0 - 6 LUBRICATION AND MAINTENANCE GENERAL INFORMATION (Continued) • Inspect brake linings. 51,000 Miles (82 000 km) • Change engine oil. 75,000 Miles (120 000 km) • Replace engine oil filter. • Change engine oil. • Flush and replace engine coolant. •...
Page 19 LUBRICATION AND MAINTENANCE 0 - 7 GENERAL INFORMATION (Continued) • Inspect brake linings. • Lubricate steering linkage (4x4 only). 99,000 Miles (158 000 km) 117,000 Miles (187 000 km) • Change engine oil. • Change engine oil. • Replace engine oil filter. •...
Page 20 BATTERY NEGATIVE CABLE BATTERY POSITIVE CABLE NEGATIVE JUMPER CABLE POSITIVE JUMPER CABLE ENGINE GROUND TEST INDICATOR BATTERY 0 - 8 LUBRICATION AND MAINTENANCE JUMP STARTING, HOISTING AND TOWING INDEX page page SERVICE PROCEDURES JUMP STARTING PROCEDURE ... . . 8 EMERGENCY TOW HOOKS .
Page 21 WHEEL LIFT SLING TYPE FLAT BED LUBRICATION AND MAINTENANCE 0 - 9 SERVICE PROCEDURES (Continued) • Do not tow a vehicle in a manner that could onds, stop cranking engine and allow starter to cool (15 min.), before cranking again. jeopardize the safety of the operator, pedestrians or other motorists.
Page 22 VEHICLE THAT IS BEING TOWED VIA ITS TOW HOOKS. THE TOW STRAPS/CHAINS COULD BREAK AND CAUSE SERIOUS INJURY. Some Jeep vehicles are equipped with front emer- gency tow hooks. The tow hooks should be used for EMERGENCY purposes only. CAUTION: DO NOT use emergency tow hooks for tow truck hook-up or highway towing.
Page 23 LUBRICATION AND MAINTENANCE 0 - 1 LUBRICATION AND MAINTENANCE CONTENTS page page GENERAL INFORMATION ....1 MAINTENANCE SCHEDULE ....2 GENERAL INFORMATION INDEX page...
Page 24: Maintenance Schedule
0 - 2 LUBRICATION AND MAINTENANCE MAINTENANCE SCHEDULE INDEX page page GENERAL INFORMATION SCHEDULE—A ......2 MAINTENANCE SCHEDULE—DIESEL ENGINE .
Page 25 LUBRICATION AND MAINTENANCE 0 - 3 GENERAL INFORMATION (Continued) • Check correct torque, turbocharger mounting 60 000 KM • Change engine oil. nuts. • Check correct torque, water manifold bolts. • Change engine oil filter. • Replace air filter element. 1 000 KM •...
Page 26 0 - 4 LUBRICATION AND MAINTENANCE GENERAL INFORMATION (Continued) • Check glow plug operation. • Replace air filter element. • Replace fuel filter/water separator element. • Check glow plug operation. • Replace drive belt. • Check engine smoke. 45 000 KM •...
Page 27 SUSPENSION 2 - 1 SUSPENSION CONTENTS page page ALIGNMENT ......1 REAR SUSPENSION ..... 11 FRONT SUSPENSION .
Page 28 TRUE VER- ANGLE AXLE RELATIVE TO VEHICLE POSITIVE CAMBER (NOT SHOWN) TOP OF TICAL CASTER CENTER- REAR TRUST ANGLE LINE CAMBER WHEEL WHEEL OUTBOARD CENTER- LINE PIVOT CEN- NEGATIVE CAM- SCRUB RADIUS TERLINE (−) POINTS RIGHT BER ANGLE POINTSLEFT AXLE AXLE NEGATIVE TOE (TOE OUT) B >...
Page 29 SUSPENSION 2 - 3 DIAGNOSIS AND TESTING SERVICE PROCEDURES PRE-ALIGNMENT INSPECTION SPECIFICATIONS Before starting wheel alignment, the following inspection is necessary and must be completed. ALIGNMENT (1) Inspect tires for size, air pressure and tread wear. FRONT WHEELS (2) Inspect front wheel bearings for wear or adjust- ment.
Page 30: Front Suspension
LINKS LOWER SHOCK ABSORBER SION ARM SUSPEN- STEERING DAMPER UPPER SION ARM SUSPEN- STABILIZER BAR PITMANARM TRACK BAR COIL SPRING AXLE TIE ROD TUBE JOUNCEBUMPER 2 - 4 SUSPENSION FRONT SUSPENSION INDEX page page DESCRIPTION AND OPERATION STABILIZER BAR ......7 FRONT SUSPENSION .
Page 31 SUSPENSION 2 - 5 DESCRIPTION AND OPERATION (Continued) replaceable ball studs attached to the axle tube DIAGNOSIS AND TESTING yokes. Shock Absorbers: The shock absorbers dampen SHOCK DIAGNOSIS jounce and rebound motion of the vehicle over vari- A knocking or rattling noise from a shock absorber ous road conditions.
Page 32 SHOCK AXLE BRACKET ABSORBER RETAINER GROMMET RETAINER GROMMET VIEW JOUNCE BUMPER ISOLATOR COIL SPRING DIRECTION ARROW W COIL SPRING VIEW IN DIRECTION OF RETAINER ARROW Z AXLE BRACKET ADJUSTMENT CAM LOWER BRACKET FORCEMENT SUSPENSION REIN- 2 - 6 SUSPENSION REMOVAL AND INSTALLATION (Continued) (10) Tighten all suspension components to proper torque.
Page 33 RIGHT AXLE HOUSING SHOWN SIDE LOWER USPENSION CAM BOLT BOLT SPECIAL SPECIAL TOOL7603 (J-21474–18) AXLE BRACKET (J-21474–18) TOOL 7603 SPECIAL TOOL 7932–1 (J-35581–1) SPECIAL (J-21474–19) TOOL 7604 AXLE BRACKET SPECIAL SPECIAL SPECIAL SPECIAL (J-35581–2) (J-21474–19) (J-35581–2) 7932–2 (J-35581–1) TOOL 7932–2 TOOL TOOL 7932–1...
Page 34 STABILIZER BAR CLAMP BUSHING LINK REINFORCEMENT PLATE FLAG NUT TRACK BAR VIEW COTTER PIN DIRECTION ARROW W STUD PLATE VIEW TRACK BAR DIRECTION FRAME ARROW Y BRACKET RAIL 2 - 8 SUSPENSION REMOVAL AND INSTALLATION (Continued) (2) Remove upper link nuts (Fig. 7) and separate (3) Remove the bolt and flag nut from the axle links from...
Page 35 WHEEL STUD TONE WHEEL (ABS) BOLT STEERING K NUCKLE REMOVER HUB AND BEARING BRAKE SHIELD ASSEMBLY WASHER COTTER PIN RETAINER SUSPENSION 2 - 9 REMOVAL AND INSTALLATION (Continued) Fig. 9 Hub Bearing & Knuckle (5) Remove the hub mounting bolts and remove hub bearing from the steering knuckle and axle shaft.
Page 36 2 - 10 SUSPENSION SPECIFICATIONS TORQUE CHART DESCRIPTION TORQUE Shock Absorber Upper Nut ....23 N·m (17 ft. lbs.) Lower Nut ....28 N·m (250 in. lbs.) Suspension Arm Upper Nuts .
Page 37: Rear Suspension
STABILIZER B AR LOWER SION ARM SUSPEN- COIL SPRING DRIVE AXLE UPPER SHOCK SION ARM ABSORBER SUSPEN- TRACK BAR SUSPENSION 2 - 11 REAR SUSPENSION INDEX page page DESCRIPTION AND OPERATION SHOCK ABSORBER ..... 12 REAR SUSPENSION .
Page 38 COIL SPRING AXLE BRACKET CLIP VIEW SHOCK ABSORBER FRAME DIRECTION COIL SPRING RETAINER NUT ARROW Z STUD RAIL 2 - 12 SUSPENSION DIAGNOSIS AND TESTING SHOCK DIAGNOSIS A knocking or rattling noise from a shock absorber may be caused by movement between mounting bushings and metal brackets or attaching compo- nents.
Page 39 LOWER SION ARM SUSPEN- UPPER SUSPENSION AXLE BRACKET GROMMET RETAINER LINK RETAINER CLAMP GROMMET STABILIZERBAR BUSHING SUSPENSION 2 - 13 REMOVAL AND INSTALLATION (Continued) LOWER SUSPENSION ARM STABILIZER BAR REMOVAL REMOVAL (1) Raise and support the vehicle. (1) Raise and support the vehicle. Remove one (2) Remove the lower suspension arm nut and bolt wheel and tire.
Page 40 AXLE B RACKET TRACK BAR FRAME BRACKET 2 - 14 SUSPENSION REMOVAL AND INSTALLATION (Continued) TRACK BAR INSTALLATION (1) Install the track bar to the axle bracket and install a new bolt. REMOVAL (1) Raise and support the vehicle. (2) It may be necessary to pry the axle assembly (2) Remove the bolt and nut from the frame rail over to install the track bar.
Page 41 SUSPENSION 2 - 1 SUSPENSION CONTENTS page page ALIGNMENT ......1 REAR SUSPENSION ..... 14 FRONT SUSPENSION .
Page 42 2 - 2 SUSPENSION GENERAL INFORMATION (Continued) Fig. 1 Wheel Alignment Measurements (2) Inspect front wheel bearings for wear. SERVICE PROCEDURES (3) Inspect front wheels for excessive radial or lat- eral runout and balance. PRE-ALIGNMENT (4) Inspect ball studs, linkage pivot points and Before starting wheel alignment, the following steering gear for looseness, roughness or binding.
Page 43 SUSPENSION 2 - 3 SERVICE PROCEDURES (Continued) SUSPENSION AND STEERING SYSTEM DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION FRONT END NOISE 1. Loose or worn wheel bearings. 1. Replace wheel bearings. 2. Loose or worn steering or 2. Tighten or replace components as suspension components necessary.
Page 44 2 - 4 SUSPENSION SERVICE PROCEDURES (Continued) Caster can be adjusted by loosening and rotating the cams on the lower suspension arm (Fig. 2). Changing caster angle will also change the front propeller shaft angle. The propeller shaft angle has priority over caster. Refer to Group 3, Differential and Driveline for additional infor- mation.
Page 45 SUSPENSION 2 - 5 SERVICE PROCEDURES (Continued) • Vehicles with 2.5L engine: 27 N·m (20 ft. lbs.) NOTE: Make sure the toe setting does not change • Vehicles with 4.0L engine: 27 N·m (20 ft. lbs.) during clamp tightening. • Vehicles with 5.2L engine: 49 N·m (36 ft. lbs.) (5) Verify the toe setting.
Page 46 2 - 6 SUSPENSION FRONT SUSPENSION INDEX page page DESCRIPTION AND OPERATION STABILIZER BAR ..... . . 10 FRONT SUSPENSION ....6 STEERING KNUCKLE .
Page 47 SUSPENSION 2 - 7 DESCRIPTION AND OPERATION (Continued) Fig. 1 Front Suspension (LHD) NOTE: The service procedures and torque specifi- A squeaking noise from the shock absorber may be cations are the same for LHD and RHD vehicles. caused by the hydraulic valving and may be intermit- tent.
Page 48 2 - 8 SUSPENSION REMOVAL AND INSTALLATION COIL SPRING SHOCK ABSORBER REMOVAL (1) Raise and support the vehicle. Position a REMOVAL hydraulic jack under the axle to support it. (1) Remove the nut, retainer and grommet from (2) Remove rear lower suspension arm bolts. the upper stud in the engine compartment (Fig.
Page 49 SUSPENSION 2 - 9 REMOVAL AND INSTALLATION (Continued) UPPER SUSPENSION ARM REMOVAL (1) Raise and support the vehicle. (2) Remove the upper suspension arm nut and bolt at the axle bracket (Fig. 4). (3) Remove the nut and bolt at the frame rail and remove the upper suspension arm.
Page 50 2 - 10 SUSPENSION REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Position new bushing, Receiver and Installer on axle (Fig. 6). (2) Install the bushing by tightening the Long Nut. Fig. 7 Stabilizer Bar (5) Remove the supports and lower the vehicle. (6) Tighten the nuts at the axle bracket end to 95 N·m (70 ft.
Page 51 SUSPENSION 2 - 11 REMOVAL AND INSTALLATION (Continued) HUB BEARING REMOVAL (1) Raise and support the vehicle. (2) Remove the wheel and tire assembly. (3) Remove the brake caliper, rotor and ABS wheel speed sensor, refer to Group 5 Brakes. (4) Remove the cotter pin, nut retainer and axle hub nut (Fig.
Page 52 2 - 12 SUSPENSION REMOVAL AND INSTALLATION (Continued) (4) Remove stud from hub with Remover C-4150A SPECIFICATIONS (Fig. 10). TORQUE CHART DESCRIPTION TORQUE Shock Absorber Upper Nut ....23 N·m (17 ft. lbs.) Lower Nut .
Page 53 SUSPENSION 2 - 13 SPECIAL TOOLS FRONT SUSPENSION Remover C-4150A Remover/Installer Suspension Bushing 7932 (J-35581) Remover Tie Rod End MB-990635 Nut, Long 7603 (J-21474–18) Bolt, Special 7604 (J-21474–19)
Page 54 2 - 14 SUSPENSION REAR SUSPENSION INDEX page page DESCRIPTION AND OPERATION SHOCK ABSORBER ..... 15 REAR SUSPENSION ....14 STABILIZER BAR .
Page 55 SUSPENSION 2 - 15 DIAGNOSIS AND TESTING SHOCK DIAGNOSIS A knocking or rattling noise from a shock absorber may be caused by movement between mounting bushings and metal brackets or attaching compo- nents. These noises can usually be stopped by tight- ening the attaching nuts.
Page 56 2 - 16 SUSPENSION REMOVAL AND INSTALLATION (Continued) LOWER SUSPENSION ARM STABILIZER BAR REMOVAL REMOVAL (1) Raise and support the vehicle. (1) Raise and support the vehicle. Remove one (2) Remove the lower suspension arm nut and bolt wheel and tire. at the axle bracket (Fig.
Page 57 SUSPENSION 2 - 17 REMOVAL AND INSTALLATION (Continued) the frame rail bracket. Loosely install the bolt and flag nut. (3) Remove the supports and lower the vehicle. (4) Tighten the track bar bolts 100 N·m (74 ft. lbs.). SPECIFICATIONS TORQUE CHART DESCRIPTION TORQUE Shock Absorber...
Page 59 DIFFERENTIAL AND DRIVELINE 3 - 1 DIFFERENTIAL AND DRIVELINE CONTENTS page page 181 FBI AXLE ......15 216 RBA AXLE .
Page 60: General Information
STRAP REAR AXLE TRANSFER CASE CROSS CAP AND NEEDLE BEAR- INGS SEAL 3 - 2 DIFFERENTIAL AND DRIVELINE GENERAL INFORMATION (Continued) Fig. 1 Front & Rear Propeller Shafts FRONT PROPELLER SHAFT There are two front propeller shafts used on ZJ vehicles.
Page 61 ENCLOSURE CAP 1. LINK YOKE 2. SOCKET SPRING 3. SCOKET BALL RETAINER 4. THRUST WASHER 5. NEEDLE BEARINGS BOOT CLAMP JOINT ASSEMBLY BOOT BOOT CLAMP PROPELLER SHAFT 6. SEAL 7. BEARING CAP 8. REAR SPIDER 9. SOCKET YOKE 10. SOCKET BALL PROPELLER SHAFT R.P.M.
Page 62: Propeller Shafts
REFERENCE MARKS 3 - 4 DIFFERENTIAL AND DRIVELINE GENERAL INFORMATION (Continued) Also make alignment reference marks (Fig. 6) on DIAGNOSIS AND TESTING the propeller shaft yoke and axle, or transmission, yoke prior to servicing. This helps to eliminate possi- VIBRATION ble vibration.
Page 63 CLAMP SCREWDRIVER ⁄ INCH DIFFERENTIAL AND DRIVELINE 3 - 5 DIAGNOSIS AND TESTING (Continued) (3) Inspect the propeller shaft for missing balance weights, broken welds, and bent areas. If the pro- peller shaft is bent, it must be replaced. (4) Inspect the universal joints to ensure that they are not worn, are properly installed, and are cor- rectly aligned with the shaft.
Page 64: Service Procedures Driveline Angle Measurement Preparation
SLIP YOKE BEARING CAP SHAFT YOKE BEARING CAP SPECIAL SPECIAL TOOL TOOL (J23498–A) (J-23498A) 7663 7663 3 - 6 DIFFERENTIAL AND DRIVELINE SERVICE PROCEDURES DRIVELINE ANGLE MEASUREMENT PREPARATION Before measuring universal joint angles, the fol- lowing must be done; • Inflate all tires to correct pressure. •...
Page 65: Removal And Installation
SPECIAL Trans. Output Operating Angle Axle Input Operating Angle Amount of U-Joint Cancellation 3.2° or (C) 4.9° Axle Input Operating Angle 1.7° TOOL Axle (J-23498A) 4.9° Prop. −3.2° −1.7° 7663 Input 1.9° 0.2° (A) Output Yoke = 3.0° Transmission Output Operating Shaft Yoke Prop.
Page 66: Propeller Shafts
SNAP RING SCREW 19 N·m (14 ft-lbs) OUTPUT SHAFT SLIDING YOKE CLAMP PROPELLER SHAFTPINION YOKE 3 - 8 DIFFERENTIAL AND DRIVELINE REMOVAL AND INSTALLATION (Continued) (7) Separate the rear universal joint from the transfer case yoke. (8) Push rear of propeller shaft upward to clear transfer case yoke.
Page 67 BEARING CAP SOCKET PRESS CROSS CROSS YOKE DIFFERENTIAL AND DRIVELINE 3 - 9 DISASSEMBLY AND ASSEMBLY (Continued) (4) Set the yoke in an arbor press or vise with a socket whose inside diameter is large enough to receive the bearing cap positioned beneath the yoke. (5) Position the yoke with the grease fitting, if equipped, pointing up.
Page 68: Double Cardan Joint
TRUNNION BEARING CAP 3 - 10 DIFFERENTIAL AND DRIVELINE DISASSEMBLY AND ASSEMBLY (Continued) (4) et the joint in an arbor press or vise with a socket whose inside diameter is large enough to receive the bearing cap positioned beneath the link yoke. (5) Place a socket with an outside diameter smaller than the upper bearing cap on the upper bearing cap and partially press one bearing cap from...
Page 69 DIFFERENTIAL AND DRIVELINE 3 - 11 DISASSEMBLY AND ASSEMBLY (Continued) (7) Flip assembly and repeat Step 4, Step 5, and (3) Place a bearing cap over the trunnion and Step 6 to remove the opposite bearing cap. This will align the cap with the yoke bore (Fig. 25). Keep the then allow removal of the cross centering kit assem- needle bearings upright in the bearing assembly.
Page 70 3 - 12 DIFFERENTIAL AND DRIVELINE DISASSEMBLY AND ASSEMBLY (Continued) (6) Flip the propeller shaft yoke and install the (9) Install the centering kit assembly inside the bearing cap onto the opposite trunnion. Install a link yoke making sure the spring is properly posi- snap ring (Fig.
Page 71: Cleaning And Inspection
DIFFERENTIAL AND DRIVELINE 3 - 13 DISASSEMBLY AND ASSEMBLY (Continued) (11) Press the remaining two bearing caps into place and install snap rings (Fig. 31). Fig. 33 Check Assembl y CLEANING AND INSPECTION Fig. 31 Press In Bearing Cap SINGLE AND DOUBLE CARDAN JOINT (12) Tap the snap rings to allow them to seat into (1) Clean all the universal joint yoke bores with the grooves (Fig.
Page 72: Specifications Torque
CONSTANT VELOCITY JOINT BOOT AXLE CV JOINT CUP LOCK NUT FLANGE MEASUREMENT BOLTS DOUBLE CARDAN JOINT FRONT DRIVE SHAFT CV BOOT END AXLE BRACKET ADJUSTMENT CAM LOWER BRACKET FORCEMENT SUSPENSION REIN- 3 - 14 DIFFERENTIAL AND DRIVELINE ADJUSTMENTS (Continued) Fig. 34 Measurement Fig.
Page 73 DIFFERENTIAL AND DRIVELINE 3 - 15 181 FBI AXLE INDEX page page GENERAL INFORMATION DIFFERENTIAL ......30 181 FBI AXLE .
Page 74 IN STRAIGHT AHEAD DRIVING EACH WHEEL ROTATES AT 100% OF CASE PINION GEARS ROTATE WITH PINION GEAR CASE SPEED SIDE GEAR PINION GEARS ROTATE ON PINION SHAFT 100% AXLE DIFFERENTIAL CASE SPEED OUTER WHEEL 110% CASE INNER WHEEL CASE SPEED SPEED 3 - 16 DIFFERENTIAL AND DRIVELINE...
Page 75 DIFFERENTIAL AND DRIVELINE 3 - 17 DIAGNOSIS AND TESTING (Continued) driving condition. These conditions are acceleration, pinion gear shaft bore will also cause low speed deceleration, coast, or constant load. knock. When road testing, accelerate the vehicle to the VIBRATION speed range where the noise is the greatest.
Page 76 3 - 18 DIFFERENTIAL AND DRIVELINE DIAGNOSIS AND TESTING (Continued) FRONT AXLES DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION WHEEL NOISE 1. Wheel loose. 1. Tighten loose nuts. 2. Faulty, brinelled wheel bearing. 2. Faulty or brinelled bearings must be replaced. AXLE SHAFT NOISE 1.
Page 77 DIFFERENTIAL AND DRIVELINE 3 - 19 DIAGNOSIS AND TESTING (Continued) CONTINUED CONDITION POSSIBLE CAUSES CORRECTION LOSS OF LUBRICANT 2. Worn axle shaft seals. Replace worn seals. 3. Cracked differential housing. 3. Repair or replace housing as necessary. 4. Worn drive pinion gear shaft 4.
Page 78 SEALING BEAD THICK- NESS 6.35MM SURFACE (1/4”) CONTOUR OF BEAD 3 - 20 DIFFERENTIAL AND DRIVELINE SERVICE PROCEDURES (2) Position a suitable lifting device under the axle. LUBRICANT CHANGE (3) Secure axle to device. (4) Remove the wheels and tires. (1) Raise and support the vehicle.
Page 79 SMALL-DIAMETER SHAFT YOKE B EARING CAP WRENCH SOCKET BEARING CAP LARGE-DIAMETER SOCKET SNAP RINGS SNAP RINGS BEARING CAP WRENCH BEARING CAP SPINDLE YOKE BEARING VISE DIFFERENTIAL AND DRIVELINE 3 - 21 REMOVAL AND INSTALLATION (Continued) (8) Install the stabilizer bar links to the axle brackets.
Page 80 AXLE SHAFT AXLE SHAFT LARGE CLAMP JAWS OF SPECIAL TOOL C-4975A MUST BE CLOSED COMPLETELY TOGETHER HERE AXLE C/V JOINT HOUSING SPECIAL TOOL C-4975A CLAMP 3 - 22 DIFFERENTIAL AND DRIVELINE REMOVAL AND INSTALLATION (Continued) INSTALLATION INSTALLATION (1) Pack the bearing caps 1/3 full of wheel bearing (1) Slide new sealing boot large clamp over axle lubricant.
Page 81 SPECIAL TOOL C-3972–A BOOT CLAMP SPECIAL TOOL C-4975A OUTER SEALING BOOT JOINT SPECIAL TOOL C-4171 SPECIAL TOOL C-452 PINION SEAL SPECIAL TOOL 7794A SPECIAL TOOL C-3281 YOKE SLIDE HAMMER DIFFERENTIAL AND DRIVELINE 3 - 23 REMOVAL AND INSTALLATION (Continued) CAUTION: Seal must not be dimpled, stretched or out of shape in any way.
Page 82 AXLE HOUSING PINION YOKE PINION YOKE INCH POUND WRENCH TORQUE TOOL 6958 PINION FLANGE FRONTAXLE 3 - 24 DIFFERENTIAL AND DRIVELINE REMOVAL AND INSTALLATION (Continued) shaft nut in 6.8 N·m (5 ft. lbs.) increments until proper rotating torque is achieved. CAUTION: If the maximum tightening torque is reached prior to reaching the required rotating torque, the collapsible spacer may have been dam-...
Page 83 SPECIAL TOOL C-452 PINION SEAL SPECIAL TOOL 7794A SPECIAL TOOL C-3281 YOKE SLIDE HAMMER RAWHIDE HAM- DIFFERENTIAL AND DRIVELINE 3 - 25 REMOVAL AND INSTALLATION (Continued) torque wrench. Record the torque reading for instal- (4) Mark the propeller shaft and pinion yoke, or lation reference.
Page 84 SPECIAL TOOL C-3972–A AXLE HOUSING OIL SLINGER REAR BEAR- SPECIAL TOOL C-4171 COLLAPS- IBLE SPACER SHOULDER PINION GEAR PINION YOKE TOOL 6958 PINION FLANGE FRONTAXLE 3 - 26 DIFFERENTIAL AND DRIVELINE REMOVAL AND INSTALLATION (Continued) Fig. 21 Pinion Yoke Installation never exceed specified preload torque.
Page 85 TONE WHEEL (ABS) PINION YOKE INCH POUND BOLT WRENCH TORQUE STEERING K NUCKLE HUB AND BEARING BRAKE SHIELD ASSEMBLY WASHER COTTER PIN RETAINER DIFFERENTIAL AND DRIVELINE 3 - 27 REMOVAL AND INSTALLATION (Continued) (9) Slowly tighten the nut in 6.8 N·m (5 ft. lbs.) (11) Install differential assembly and axle shafts, if increments until the rotating torque is achieved.
Page 86 HUB BEARING KNUCKLE KNUCKLE AXLE AXLE SHAFT AXLE AXLE YOKE STEERING KNUCKLE LOWER BALL STUD UPPER BALL STUD 3 - 28 DIFFERENTIAL AND DRIVELINE REMOVAL AND INSTALLATION (Continued) (8) Remove hub bearing and axle shaft assembly Install the nut retainer and a new cotter pin (Fig. (Fig.
Page 87 SPECIAL TOOL 6289–4 INSTALLATION SPECIAL TOOL REMOVAL 6289–12 DIFFERENTIAL AND DRIVELINE 3 - 29 REMOVAL AND INSTALLATION (Continued) Fig. 28 Upper Ball Stud Remove/Install Fig. 29 Lower Ball Stud Remove/Install...
Page 88 DIAL INDICATOR SAFETY HOLD DOWN DOWEL INSTALLATION ENCE LETTERS REFER- INSTALLATION ENCE LETTERS REFER- AXLE HOUSING SPECIAL TOOL C-3339 3 - 30 DIFFERENTIAL AND DRIVELINE REMOVAL AND INSTALLATION (Continued) KNUCKLE INSTALLATION (1) Position the steering knuckle on the ball studs. (2) Install and tighten the bottom retaining nut to 109 N·m (80 ft.
Page 89 SPECIAL TOOL W-129–B BEARING CUPS SAFETY HOLD DOWN DIFFERENTIAL CASE DOWEL AXLE HOUSING SPECIAL TOOL C-3339 AXLE HOUSING DIFFERENTIAL AND DRIVELINE 3 - 31 REMOVAL AND INSTALLATION (Continued) holddown clamps and tighten the tool turnbuckle fin- ger–tight. Fig. 33 Spread Axle Housing Fig.
Page 90 BEARING INSTALLATION ENCE LETTERS SPECIAL TOOL REFER- C293–39 INSTALLATION ENCE LETTERS REFER- SPECIAL C-3716–A TOOL SPECIAL TOOL C-4171 3 - 32 DIFFERENTIAL AND DRIVELINE REMOVAL AND INSTALLATION (Continued) cedures in this section to determine the proper shim selection. (1) Using Installer C-3716-A and Handle C-4171, install differential side bearings (Fig.
Page 91 DISCS 8110 SPECIAL TOOL 6958 PINION YOKE TURNBUCKLE 1 in. PIPE 6797 SPECIAL TOOL C-452 SPECIAL TOOL C-3281 YOKE RAWHIDE HAM- DIFFERENTIAL AND DRIVELINE 3 - 33 REMOVAL AND INSTALLATION (Continued) Fig. 41 Pinion Yoke Removal Fig. 39 Axle Seal Installation REMOVAL (1) Remove differential assembly from axle hous- ing.
Page 92 DRIVER REMOVER HANDLE HANDLE DRIVE OIL SLINGER GEAR SHAFT REAR ADAPTERS PINION BEAR- SPECIAL C-293–PA TOOL COLLAPS- IBLE SPACER SHOULDER PINION GEAR VISE 3 - 34 DIFFERENTIAL AND DRIVELINE REMOVAL AND INSTALLATION (Continued) Fig. 43 Front Bearing Cup Removal Fig. 45 Collapsible Spacer Fig.
Page 93 SPECIAL TOOL C-3972–A HANDLE INSTALLER HANDLE INSTALLER DRIVE PINION GEAR SHAFT INSTALLA- TION TOOL REAR BEARING SPECIAL TOOL C-4171 DRIVE OIL SLINGER PINION GEAR DIFFERENTIAL AND DRIVELINE 3 - 35 REMOVAL AND INSTALLATION (Continued) Driver Handle C–4171 (Fig. 47). Verify cup is cor- rectly seated.
Page 94 AXLE HOUSING PINION YOKE OIL SLINGER REAR BEAR- PINION YOKE COLLAPS- IBLE SPACER SHOULDER PINION GEAR in. lbs. TORQUE WRENCH TOOL 6958 PINION FLANGE FRONTAXLE 3 - 36 DIFFERENTIAL AND DRIVELINE REMOVAL AND INSTALLATION (Continued) Fig. 53 Tightening Pinion Nut Fig.
Page 95 RAWHIDE HAM- CASE RING GEAR RING GEAR CASE MATE SHAFT LOCKPIN TORQUE WRENCH RING GEAR BOLT DRIFT DIFFERENTIAL AND DRIVELINE 3 - 37 REMOVAL AND INSTALLATION (Continued) REMOVAL (1) Remove differential from axle housing. (2) Place differential case in a suitable vise with soft metal jaw protectors.
Page 96 THRUST PINION MATE WASHER MATE SHAFT LOCKPIN GEAR SIDE GEAR PINION PUNCH SHAFT MATE SEALING BEAD THICK- NESS 6.35MM SURFACE (1/4”) CONTOUR OF BEAD 3 - 38 DIFFERENTIAL AND DRIVELINE DISASSEMBLY AND ASSEMBLY (Continued) with mineral spirits. Apply a bead of Mopar Silicone Rubber Sealant, or equivalent, on the housing cover (Fig.
Page 97 DIFFERENTIAL PRODUCTION NUM- GEAR MATCHING NUMBER (SAME AS RING GEAR NUM- BERS BEARING SHIM BER) DRIVE PINION GEAR DRIVE GEAR DEPTH SHIM VARIANCE PINION DEPTH DIFFERENTIAL AND DRIVELINE 3 - 39 CLEANING AND INSPECTION (Continued) Wash bearings with solvent and towel dry, or dry with compressed air.
Page 98 Original Pinion Gear Depth ARBOR DISC DIAL INDICATOR Variance ARBOR PINION SCOOTER BLOCK HEIGHT BLOCK PINION BLOCK SCREW CONE PINION HEIGHT Replacement Pinion Bear Depth Variance BLOCK PINION BLOCK 3 - 40 DIFFERENTIAL AND DRIVELINE ADJUSTMENTS (Continued) PINION GEAR DEPTH VARIANCE without any shims placed behind the rear pinion (3) Install front pinion bearing cone and Cone-nut bearing cup.
Page 99 ARBOR DISC PINION HEIGHT BLOCK PINION BLOCK ARBOR DIFFERENTIAL BEARING SHIM ARBOR DIAL INDICATOR SCOOTER BLOCK DRIVE PINION GEAR DEPTH SHIM DIFFERENTIAL AND DRIVELINE 3 - 41 ADJUSTMENTS (Continued) Fig. 65 Gauge Tools In Housing—Typical Fig. 66 Pinion Gear Depth Measurement—Typical flush against the rearward surface of the pinion sure the pinion gear depth and prepare the pinion gear height block (Fig.
Page 100 DIFFERENTIAL CASE DIFFERENTIAL CASE DIFFERENTIAL CASE SPECIAL TOOL C-3288–B AXLE HOUSING AXLE HOUSING AXLE HOUSING MALLET BEARING CAP MALLET DIFFERENTIAL CASE AXLE HOUSING 3 - 42 DIFFERENTIAL AND DRIVELINE ADJUSTMENTS (Continued) SHIM SELECTION NOTE: It is difficult to salvage the differential side bearings during the removal procedure.
Page 101 FORCE DIFFERENTIAL CASE TO PINION GEAR SIDE FORCE DIFFERENTIAL CASE TO RING GEAR SIDE FORCE DIFFERENTIAL CASE TO RING GEAR SIDE FORCE DIFFERENTIAL CASE TO PINION GEAR SIDE READ DIAL INDICATOR ZERO DIAL INDICATOR FACE READ DIAL INDICATOR DIFFERENTIAL AND DRIVELINE 3 - 43 ADJUSTMENTS (Continued) Fig.
Page 102 DIAL CATOR INDI- FOR MORE BACKLASH INCREASE SHIM THIS SIDE FOR LESS BACKLASH FOR MORE BACKLASH INCREASE SHIM THIS DIE DECREASE SHIM THIS DECREASE SHIM THIS SIDE FOR MORE BACK- FOR LESS BACKLASH SIDE FOR LESS BACK- LASH LASH 3 - 44 DIFFERENTIAL AND DRIVELINE ADJUSTMENTS (Continued) (34) Rotate the differential case several times to...
Page 103 HEEL DRIVE RING GEAR TEETH SIDE COAST SIDE OF RING GEAR TEETH HEEL PINION GEAR DEPTH SHIM CORRECT. INCREASE RING GEAR BACKLASH. PINION GEAR DEPTH SHIM CORRECT. DECREASE RING GEAR BACKLASH. RING CORRECT. THICKER PINION GEAR REQUIRED. DESIRABLE PATTERN SHOULD BE CENTERED ON THE DRIVE SIDE OF TOOTH.
Page 104 3 - 46 DIFFERENTIAL AND DRIVELINE SPECIFICATIONS (Continued) 181 FBI AXLE DESCRIPTION TORQUE Fill Hole Plug ....34 N·m (25 ft. lbs.) Diff. Cover Bolt ... . 41 N·m (30 ft. lbs.) Bearing Cap Bolt .
Page 105 DIFFERENTIAL AND DRIVELINE 3 - 47 SPECIAL TOOLS (Continued) Installer—W-162-D Driver—C-3716-A Cup—8109 Handle—C-4171 Remover/Installer—6289 Installer—D-146 Installer—6761 Remover—D-149...
Page 106 3 - 48 DIFFERENTIAL AND DRIVELINE SPECIAL TOOLS (Continued) Installer—6752 Gauge Block—6733 Installer Discs—8110 Puller—7794-A Turnbuckle—6797 Installer—C-4975-A Tool Set, Pinion Depth—6774...
Page 107 DIFFERENTIAL AND DRIVELINE 3 - 49 SPECIAL TOOLS (Continued) Spanner—6958 Pilot Stud—C-3288-B Installer—C-3972-A Remover—C-4345 Spreader—W-129-B Installer—D-130 Adapter Kit—6987 Installer—W-262...
Page 108 3 - 50 DIFFERENTIAL AND DRIVELINE 194 RBI AXLE INDEX page page GENERAL INFORMATION DIFFERENTIAL ......63 194 RBI AXLE .
Page 109 DIFFERENTIAL DIFFERENTIAL PINION GEAR DEPTH SHIM SHIM-PINION GEAR SIDE SHIM-RING GEAR SIDE COLLAPSIBLE SPACER RING GEAR BEARING BEARING PINION GEARS ROTATE ON IN STRAIGHT AHEAD DRIVING EACH WHEEL ROTATES AT 100% OF CASE PINION GEARS ROTATE WITH PINION SHAFT 100% PINION GEAR AXLE DIFFERENTIAL...
Page 110 CLUTCH PACK CASE RING GEAR SIDE GEAR PINION GEAR DRIVE PINION CLUTCH PACK MATE SHAFT 3 - 52 DIFFERENTIAL AND DRIVELINE DESCRIPTION AND OPERATION (Continued) • Overloading (excessive engine torque) or exceed- ing vehicle weight capacity. • Incorrect clearance or backlash adjustment. Axle component breakage is most often the result •...
Page 111 DIFFERENTIAL AND DRIVELINE 3 - 53 DIAGNOSIS AND TESTING (Continued) • High engine idle speed level. Where axle bearing damage is slight, the noise • Loose engine/transmission/transfer case mounts is usually not noticeable at speeds above 30 mph. • Worn U–joints LOW SPEED KNOCK •...
Page 112 3 - 54 DIFFERENTIAL AND DRIVELINE DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION WHEEL NOISE 1. Wheel loose. 1. Tighten loose nuts. 2. Faulty, brinelled wheel bearing. 2. Faulty or brinelled bearings must be replaced. AXLE SHAFT NOISE 1. Misaligned axle shaft tube. 1.
Page 113 DIFFERENTIAL AND DRIVELINE 3 - 55 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION LOSS OF LUBRICANT 2. Worn axle shaft seals. Replace worn seals. 3. Cracked differential housing. 3. Repair or replace housing as necessary. 4. Worn drive pinion gear shaft 4.
Page 114 SPECIAL TOOL 6790 WITH BOLT IN CENTER HOLE TORQUE WRENCH AXLE HOUSING COVER SEALANT 3 - 56 DIFFERENTIAL AND DRIVELINE DIAGNOSIS AND TESTING (Continued) TRAC–LOK TEST (4) Clean the housing cavity with a flushing oil, light engine oil, or lint free cloth. Do not use water, steam, kerosene, or gasoline for cleaning.
Page 115 SPECIAL TOOL 6958 PINION YOKE 1 in. PIPE DIFFERENTIAL AND DRIVELINE 3 - 57 REMOVAL AND INSTALLATION (Continued) (2) Position a suitable lifting device under the (11) Align propeller shaft and pinion yoke refer- axle. ence marks. Install U-joint straps and bolts. Tighten (3) Secure axle to device.
Page 116 SPECIAL TOOL C-3972–A AXLE HOUSING SPECIAL TOOL C-4171 SPECIAL TOOL C-452 PINION SEAL SPECIAL TOOL 7794A SPECIAL TOOL C-3281 YOKE SLIDE HAMMER PINION YOKE 3 - 58 DIFFERENTIAL AND DRIVELINE REMOVAL AND INSTALLATION (Continued) (2) Install yoke on the pinion gear with Screw 8112, Cup 8109, and Holder 6958 (Fig.
Page 117 1 in. PIPE SPECIAL TOOL 6958 PINION YOKE SPECIAL TOOL PINION YOKE INCH 6958 POUND WRENCH TORQUE 1 in. PIPE SPECIAL TOOL C-452 SPECIAL TOOL C-3281 YOKE DIFFERENTIAL AND DRIVELINE 3 - 59 REMOVAL AND INSTALLATION (Continued) (7) Measure the amount of torque necessary to rotate the pinion gear with a (in.
Page 118 PINION SEAL SPECIAL TOOL 7794A SLIDE HAMMER OIL SLINGER REAR BEAR- RAWHIDE HAM- COLLAPS- IBLE SPACER SHOULDER PINION GEAR 3 - 60 DIFFERENTIAL AND DRIVELINE REMOVAL AND INSTALLATION (Continued) Fig. 16 Seal Removal (4) Mark the propeller shaft and pinion yoke for installation reference.
Page 119 SPECIAL TOOL C-3972–A 1 in. PIPE AXLE HOUSING SPECIAL TOOL PINION YOKE C-4171 SPECIAL TOOL PINION YOKE INCH 6958 POUND WRENCH TORQUE DIFFERENTIAL AND DRIVELINE 3 - 61 REMOVAL AND INSTALLATION (Continued) Fig. 19 Pinion Seal Installation Fig. 21 Tightening Pinion Nut (11) Check rotating torque with an inch pound torque wrench (Fig.
Page 120 SIDE GEAR AXLE SHAFT PINION GEAR MATE SHAFT LOCK SCREW C-CLIPLOCK 3 - 62 DIFFERENTIAL AND DRIVELINE REMOVAL AND INSTALLATION (Continued) (16) Install wheel and tire assemblies. (8) Remove axle shaft. Use care to prevent damage (17) Lower vehicle. to axle shaft bearing and seal, which will remain in axle shaft tube.
Page 121 SAFETY HOLD DOWN DOWEL AXLE SHAFT TUBE SPECIAL TOOL C-4171 FOOT SPECIAL TOOL 6437 SEAL AXLE SHAFT TUBE ADAPTER THREADED ROD GUIDE PLATE GUIDE INSTALLATION ENCE LETTERS AXLE HOUSING REFER- INSTALLATION ENCE LETTERS REFER- DIFFERENTIAL AND DRIVELINE 3 - 63 REMOVAL AND INSTALLATION (Continued) (4) Remove axle shafts.
Page 122 DIAL INDICATOR SPECIAL TOOL W-129–B BEARING CUPS DIFFERENTIAL CASE SPECIAL TOOL SPECIAL TOOL C-3339 C-3339 AXLE HOUSING 3 - 64 DIFFERENTIAL AND DRIVELINE REMOVAL AND INSTALLATION (Continued) CAUTION: Do not spread over 0.38 mm (0.015 in). If the housing is over–spread, it could be distorted or damaged.
Page 123 BEARING SAFETY HOLD DOWN DOWEL INSTALLATION ENCE LETTERS AXLE HOUSING REFER- INSTALLATION ENCE LETTERS REFER- SPECIAL TOOL C-293–39 DIFFERENTIAL AND DRIVELINE 3 - 65 REMOVAL AND INSTALLATION (Continued) (2) Remove the bearings from the differential case with Puller/Press C-293-PA, C-293-39 Blocks, and Plug SP-3289 (Fig.
Page 124 RAWHIDE HAM- DIFFERENTIAL BEARING C-3716–A HANDLE C-4171 TOOL CASE RING GEAR RING GEAR CASE TORQUE WRENCH RING GEAR BOLT 3 - 66 DIFFERENTIAL AND DRIVELINE REMOVAL AND INSTALLATION (Continued) LOWER CONTROL ARM SPECIAL TOOL PINION YOKE 1 in. PIPE 6958 Fig.
Page 125 SPECIAL TOOL C-452 SPECIAL TOOL C-3281 YOKE RAWHIDE HAM- REMOVER PINION SEAL SPECIAL TOOL 7794A SLIDE HAMMER HANDLE DIFFERENTIAL AND DRIVELINE 3 - 67 REMOVAL AND INSTALLATION (Continued) (5) Using Remover C–452 and Wrench C–3281, (7) Use Remover 7794-A and slide hammer to remove the pinion yoke from pinion shaft (Fig.
Page 126 OIL SLINGER DRIVER REAR BEAR- COLLAPS- IBLE SPACER SHOULDER PINION GEAR HANDLE DRIVE GEAR SHAFT HANDLE ADAPTERS PINION SPECIAL C-293–PA TOOL INSTALLER VISE 3 - 68 DIFFERENTIAL AND DRIVELINE REMOVAL AND INSTALLATION (Continued) (10) Remove the rear bearing cup from housing (Fig.
Page 127 SPECIAL TOOL C-3972–A INSTALLER SPECIAL TOOL C-4171 HANDLE DRIVE PINION GEAR SHAFT OIL SLINGER REAR DRIVE PINION GEAR REAR BEARING BEAR- PRESS INSTALLATION TOOL COLLAPS- IBLE SPACER SHOULDER PINION GEAR DIFFERENTIAL AND DRIVELINE 3 - 69 REMOVAL AND INSTALLATION (Continued) (4) Install the pinion front bearing cup with Installer D–130 and Handle C–4171 (Fig.
Page 128 1 in. PIPE AXLE HOUSING SPECIAL TOOL PINION YOKE 6958 PINION YOKE INCH POUND WRENCH TORQUE 3 - 70 DIFFERENTIAL AND DRIVELINE REMOVAL AND INSTALLATION (Continued) (16) Check bearing rotating torque with an inch pound torque wrench (Fig. 53). The torque necessary to rotate the pinion gear should be: •...
Page 129 SEALING BEAD THICK- NESS 6.35MM SURFACE (1/4”) CONTOUR OF BEAD DIFFERENTIAL AND DRIVELINE 3 - 71 THRUST PINION MATE WASHER GEAR SIDE GEAR Fig. 55 Pinion Gear Mate Shaft Lock Screw Fig. 54 Typical Housing Cover With Sealant DISASSEMBLY AND ASSEMBLY STANDARD DIFFERENTIAL DISASSEMBLY (1) Remove pinion gear mate shaft lock screw (Fig.
Page 130 VISE SHAFT LOCK SCREW PINION THRUST WASHER SPECIAL TOOL 6965 PINION GEAR MATE SHAFT LOCK SCREW 3 - 72 DIFFERENTIAL AND DRIVELINE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 57 Trac–lok Differential Components TRAC-LOK DIFFERENTIAL (3) Remove ring gear, if necessary. Ring gear removal is necessary only if the ring gear is to be The Trac–lok differential components are illustrated in replaced.
Page 131 SPECIAL TOOL C-6960–3 DRIFT SCREWDRIVER DIFFERENTIAL CASE SIDE GEAR SLOT IN ADAPTER PINION MATE SHAFT LOWER SIDE GEAR TORQUE WRENCH SOCKET DIFFERENTIAL CASE TOOL ASSEM- BLED DIFFERENTIAL AND DRIVELINE 3 - 73 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 60 Mate Shaft Removal Fig.
Page 132 SIDE GEAR AND CLUTCH DISC PACK FEELER GAUGE RETAINER PINION GEARS THRUST WASHER TOOL DIFFERENTIAL CASE CLUTCH PACK RETAINER SIDE GEAR RETAINER 3 - 74 DIFFERENTIAL AND DRIVELINE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 64 Remove Pinion Gear Thrust Washer Fig. 66 Side Gear & ClutchDisc Removal Fig.
Page 133 DIFFERENTIAL CASE LOWER SIDE GEAR AND CLUTCH DISC PACK UPPER DIFFERENTIAL CASE CLUTCH DISC PACK SIDE GEAR DIFFERENTIAL AND DRIVELINE 3 - 75 DISASSEMBLY AND ASSEMBLY (Continued) (14) Remove Forcing Screw C-6960-4, Step Plate C-6960-3, and Threaded Adapter C-6960-1. (15) Install pinion gear mate shaft and align holes in shaft and case.
Page 134 DIFFERENTIAL SHIM-PINION GEAR SIDE BEARING PRODUCTION NUM- GEAR MATCHING NUMBER (SAME AS RING GEAR NUM- BERS BER) DRIVE GEAR VARIANCE PINION DEPTH PINION GEAR DEPTH SHIM 3 - 76 DIFFERENTIAL AND DRIVELINE CLEANING AND INSPECTION (Continued) PRESOAK PLATES AND DISC Plates and discs with fiber coating (no grooves or lines) must be presoaked in Friction Modifier before assembly.
Page 135 Original Pinion Gear Depth ARBOR DISC DIAL INDICATOR Variance ARBOR PINION SCOOTER BLOCK HEIGHT BLOCK PINION BLOCK SCREW CONE PINION HEIGHT Replacement Pinion Bear Depth Variance BLOCK PINION BLOCK DIFFERENTIAL AND DRIVELINE 3 - 77 ADJUSTMENTS (Continued) PINION GEAR DEPTH VARIANCE Fig.
Page 136 ARBOR DISC PINION HEIGHT BLOCK ARBOR DIAL INDICATOR SCOOTER BLOCK PINION BLOCK ARBOR 3 - 78 DIFFERENTIAL AND DRIVELINE ADJUSTMENTS (Continued) measured. The overall shim thickness is the total of the dial indicator reading, starting point shim thick- ness, and the preload specification added together. The gear backlash measurement determines the thickness of the shim used on the ring gear side of the differential case.
Page 137 DIFFERENTIAL AND DRIVELINE 3 - 79 ADJUSTMENTS (Continued) (16) Remove differential case, dummy bearings, and starting point shims from axle housing. (17) Install pinion gear in axle housing. Install the yoke and establish the correct pinion rotating torque. (18) Install differential case and dummy bearings in axle housing (without shims) and tighten retaining cap bolts.
Page 138 DIAL CATOR INDI- FOR MORE BACKLASH INCREASE SHIM THIS SIDE FOR LESS BACKLASH FOR MORE BACKLASH INCREASE SHIM THIS DIE DECREASE SHIM THIS DECREASE SHIM THIS SIDE FOR MORE BACK- FOR LESS BACKLASH SIDE FOR LESS BACK- LASH LASH 3 - 80 DIFFERENTIAL AND DRIVELINE ADJUSTMENTS (Continued) After the proper backlash is achieved, perform the...
Page 139 HEEL DRIVE RING GEAR TEETH SIDE COAST SIDE OF RING GEAR TEETH HEEL PINION GEAR DEPTH SHIM CORRECT. INCREASE RING GEAR BACKLASH. PINION GEAR DEPTH SHIM CORRECT. DECREASE RING GEAR BACKLASH. RING CORRECT. THICKER PINION GEAR REQUIRED. DESIRABLE PATTERN SHOULD BE CENTERED ON THE DRIVE SIDE OF TOOTH.
Page 140 3 - 82 DIFFERENTIAL AND DRIVELINE SPECIFICATIONS 194 RBI AXLE DESCRIPTION SPECIFICATION Axle Type ....Semi–Floating Hypoid Lubricant ..SAE Thermally Stable 80W–90 Lubricant Trailer Tow .
Page 141 DIFFERENTIAL AND DRIVELINE 3 - 83 SPECIAL TOOLS (Continued) Cup—8109 Wrench—C-3281 Installer—C-3972-A Handle—C-4171 Spanner—6958 Driver—C-3716-A Installer Screw—8112 Installer—D-130...
Page 142 3 - 84 DIFFERENTIAL AND DRIVELINE SPECIAL TOOLS (Continued) Installer—6436 Installer—D-146 Remover—C-4345 Installer—6437 Remover—D-149 Disc, Axle Arbor—6732 Installer—W-262 Gauge Block—6735...
Page 143 DIFFERENTIAL AND DRIVELINE 3 - 85 SPECIAL TOOLS (Continued) Tool Set, Pinion Depth—6774 Starting Point Shim—8107 Trac-lok Tool Set—6960 Spreader—W-129-B Holder—6965 Adapter Kit—6987 Puller—7794-A Guide Pin—C-3288-B...
Page 144 3 - 86 DIFFERENTIAL AND DRIVELINE SPECIAL TOOLS (Continued) Bearing Remover Tool Set—6310 Hub Puller—6790 Dial Indicator—C-3339...
Page 145 DIFFERENTIAL AND DRIVELINE 3 - 87 216 RBA AXLE INDEX page page GENERAL INFORMATION DIFFERENTIAL ..... . . 100 216 RBA AXLE ......87 FINAL ASSEMBLY .
Page 146 DIFFERENTIAL SHIM-PINION GEAR SIDE BEARING PINION GEAR DEPTH SHIM PINION GEARS ROTATE ON IN STRAIGHT AHEAD DRIVING EACH WHEEL ROTATES AT 100% OF CASE PINION GEARS ROTATE WITH PINION SHAFT 100% PINION GEAR AXLE DIFFERENTIAL CASE SPEED CASE SPEED SIDE GEAR OUTER WHEEL 110%...
Page 147 CLUTCH PACK CASE RING GEAR SIDE GEAR PINION GEAR DRIVE PINION CLUTCH PACK MATE SHAFT DIFFERENTIAL AND DRIVELINE 3 - 89 DESCRIPTION AND OPERATION (Continued) • Overloading (excessive engine torque) or exceed- ing vehicle weight capacity. • Incorrect clearance or backlash adjustment. Axle component breakage is most often the result •...
Page 148 3 - 90 DIFFERENTIAL AND DRIVELINE DIAGNOSIS AND TESTING (Continued) • High engine idle speed level. Where axle bearing damage is slight, the noise • Loose engine/transmission/transfer case mounts is usually not noticeable at speeds above 30 mph. • Worn U–joints LOW SPEED KNOCK •...
Page 149 DIFFERENTIAL AND DRIVELINE 3 - 91 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION WHEEL NOISE 1. Wheel loose. 1. Tighten loose nuts. 2. Faulty, brinelled wheel bearing. 2. Faulty or brinelled bearings must be replaced. AXLE SHAFT NOISE 1. Misaligned axle shaft tube. 1.
Page 150 3 - 92 DIFFERENTIAL AND DRIVELINE DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION LOSS OF LUBRICANT 2. Worn axle shaft seals. Replace worn seals. 3. Cracked differential housing. 3. Repair or replace housing as necessary. 4. Worn drive pinion gear shaft 4.
Page 151 TORQUE WRENCH AXLE HOUSING COVER SPECIAL TOOL 6790 WITH BOLT IN CENTER HOLE SEALANT DIFFERENTIAL AND DRIVELINE 3 - 93 DIAGNOSIS AND TESTING (Continued) TRAC–LOK TEST (4) Clean the housing cavity with a flushing oil, light engine oil, or lint free cloth. Do not use water, steam, kerosene, or gasoline for cleaning.
Page 152 SPECIAL TOOL 6958 PINION YOKE 1 in. PIPE 3 - 94 DIFFERENTIAL AND DRIVELINE REMOVAL AND INSTALLATION (Continued) (2) Position a suitable lifting device under the (11) Align propeller shaft and pinion yoke refer- axle. ence marks. Install U-joint straps and bolts. Tighten (3) Secure axle to device.
Page 153 SPECIAL TOOL C-3972–A PINION YOKE SPECIAL TOOL C-4171 SPECIAL TOOL C-452 PINION SEAL SPECIAL TOOL 7794A SPECIAL TOOL C-3281 YOKE SLIDE HAMMER SPECIAL TOOL C-3718 PINION YOKE INCH POUND WRENCH TORQUE DIFFERENTIAL AND DRIVELINE 3 - 95 REMOVAL AND INSTALLATION (Continued) (2) Install yoke on the pinion gear with Installer C-3718 and Holder 6958 (Fig.
Page 154 1 in. PIPE SPECIAL TOOL 6958 PINION YOKE SPECIAL TOOL 6958 1 in. PIPE SPECIAL TOOL C-452 SPECIAL TOOL C-3281 YOKE 3 - 96 DIFFERENTIAL AND DRIVELINE REMOVAL AND INSTALLATION (Continued) (5) If the rotating torque is low, use Holder 6958 to (10) Use Remover 7794-A and slide hammer to hold the pinion yoke (Fig.
Page 155 SPECIAL TOOL C-3972–A PINION SEAL SPECIAL TOOL 7794A SLIDE HAMMER RAWHIDE HAM- OIL SLINGER REAR BEAR- SPECIAL TOOL C-4171 COLLAPS- IBLE SPACER SHOULDER PINION GEAR DIFFERENTIAL AND DRIVELINE 3 - 97 REMOVAL AND INSTALLATION (Continued) Fig. 16 Seal Removal (9) Using Holder 6958 to hold yoke and a short length of 1 in.
Page 156 PINION YOKE 1 in. PIPE SPECIAL TOOL C-3718 SPECIAL TOOL PINION YOKE INCH 6958 POUND WRENCH TORQUE 3 - 98 DIFFERENTIAL AND DRIVELINE REMOVAL AND INSTALLATION (Continued) Fig. 20 Pinion Yoke Installation Fig. 21 Tightening Pinion Nut (7) Install the yoke washer and a new nut on the pinion gear.
Page 157 SIDE GEAR AXLE SHAFT PINION GEAR MATE SHAFT LOCK SCREW C-CLIPLOCK AXLE SHAFT TUBE FOOT ADAPTER THREADED ROD GUIDE PLATE GUIDE DIFFERENTIAL AND DRIVELINE 3 - 99 REMOVAL AND INSTALLATION (Continued) (6) Rotate differential case so that pinion mate NOTE: Use care to prevent shaft splines from dam- gear shaft lock screw is accessible.
Page 158 INSTALLATION ENCE LETTERS SPECIAL TOOL C-4171 REFER- SPECIAL TOOL 6437 SEAL AXLE SHAFT TUBE INSTALLATION ENCE LETTERS REFER- GUIDE HOUSING SPREADER AXLE HOUSING W-129B C-3288–B DIAL INDICATOR C-3339 DIFFERENTIAL 3 - 100 DIFFERENTIAL AND DRIVELINE REMOVAL AND INSTALLATION (Continued) (4) Inspect the axle shaft tube bore for roughness (3) Remove the differential bearing caps.
Page 159 DIFFERENTIAL PRY BAR INSTALLATION ENCE LETTERS REFER- RAWHIDE HAMMER INSTALLATION ENCE LETTERS REFER- DIFFERENTIAL AND DRIVELINE 3 - 101 REMOVAL AND INSTALLATION (Continued) Fig. 29 Differential Removal Fig. 30 Differential Installation against the opposite side of the housing (Fig. 28) and zero the indicator.
Page 160 SPECIAL TOOL SPECIAL TOOL SPECIAL TOOL BEARING DIFFERENTIAL TOOLC-4340 C-293–PA BEARING C-293–42 C-293–3 HANDLE C-4171 DIFFEREN- TIAL RAWHIDE HAM- RING GEAR CASE CASE TORQUE WRENCH RING GEAR BOLT RING GEAR 3 - 102 DIFFERENTIAL AND DRIVELINE REMOVAL AND INSTALLATION (Continued) Fig.
Page 161 SPECIAL TOOL 6958 PINION YOKE 1 in. PIPE SPECIAL TOOL C-452 SPECIAL TOOL C-3281 YOKE REMOVER RAWHIDE HAM- HANDLE DIFFERENTIAL AND DRIVELINE 3 - 103 REMOVAL AND INSTALLATION (Continued) PINION GEAR NOTE: The ring and pinion gears are service in a matched set.
Page 162 OIL SLINGER DRIVER REAR BEAR- COLLAPS- IBLE SPACER SHOULDER PINION GEAR HANDLE DRIVE GEAR SHAFT HANDLE ADAPTERS PINION SPECIAL C-293–PA TOOL INSTALLER VISE 3 - 104 DIFFERENTIAL AND DRIVELINE REMOVAL AND INSTALLATION (Continued) Fig. 40 Rear Bearing Cup Removal Fig. 42 Inner Bearing Removal INSTALLATION (1) Apply Mopar Door Ease stick lubricant to out- side surface of bearing cup.
Page 163 SPECIAL TOOL C-3972–A INSTALLER SPECIAL TOOL C-4171 HANDLE DRIVE PINION GEAR SHAFT OIL SLINGER REAR DRIVE PINION GEAR REAR BEARING BEAR- PRESS INSTALLATION TOOL COLLAPS- IBLE SPACER SHOULDER PINION GEAR DIFFERENTIAL AND DRIVELINE 3 - 105 REMOVAL AND INSTALLATION (Continued) Fig.
Page 164 PINION YOKE 1 in. PIPE SPECIAL TOOL SPECIAL TOOL C-3718 6958 PINION YOKE INCH POUND WRENCH TORQUE 3 - 106 DIFFERENTIAL AND DRIVELINE REMOVAL AND INSTALLATION (Continued) • Original Bearings — 1 to 3 N·m (10 to 20 in. lbs.). •...
Page 165 PINION GEAR MATE SHAFT LOCK SCREW SEALING BEAD THICK- NESS 6.35MM SURFACE (1/4”) CONTOUR OF BEAD THRUST PINION MATE WASHER GEAR SIDE GEAR DIFFERENTIAL AND DRIVELINE 3 - 107 Fig. 51 Typical Housing Cover With Sealant Fig. 53 Pinion Mate Gear Removal DISASSEMBLY AND ASSEMBLY ASSEMBLY (1) Install the differential side gears and thrust...
Page 166 VISE SHAFT LOCK SCREW PINION THRUST WASHER SPECIAL TOOL 6963–A PINION GEAR MATE SHAFT LOCK SCREW 3 - 108 DIFFERENTIAL AND DRIVELINE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 54 Trac–Lok Differential Components Fig. 56 Mate Shaft Lock Screw (9) Tighten forcing screw tool 122 N·m (90 ft. lbs.) (maximum) to compress Belleville springs in clutch packs (Fig.
Page 167 LOWER SIDE GEAR DRIFT SCREWDRIVER SIDE GEAR SLOT IN ADAPTER PINION MATE SHAFT SPECIAL TOOL C-4487–1 TORQUE WRENCH SOCKET DIFFERENTIAL CASE TOOL ASSEM- BLED DIFFERENTIAL AND DRIVELINE 3 - 109 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 57 Mate Shaft Removal Fig. 59 Threaded Adapter Installation Fig.
Page 168 THRUST WASHER SPECIAL TOOL C-4487–1 PINION GEARS FEELER GAUGE TOOL DIFFERENTIAL CASE CLUTCH PACK RETAINER SIDE GEAR RETAINER 3 - 110 DIFFERENTIAL AND DRIVELINE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 61 Remove Pinion Gear Thrust Washer Fig. 63 Side Gear & Clutch Disc Removal Fig.
Page 169 DIFFERENTIAL CASE LOWER SIDE GEAR AND CLUTCH DISC PACK UPPER DIFFERENTIAL CASE CLUTCH DISC PACK SIDE GEAR DIFFERENTIAL AND DRIVELINE 3 - 111 DISASSEMBLY AND ASSEMBLY (Continued) CLEANING AND INSPECTION AXLE COMPONENTS Wash differential components with cleaning solvent and dry with compressed air. Do not steam clean the differential components.
Page 170 PRODUCTION NUM- GEAR MATCHING NUMBER (SAME AS RING GEAR NUM- PINION GEAR AXLE HOUSING BEARING CUP BERS BER) PINION COLLAPSIBLE DRIVE GEAR PINION BEARING SPACER VARIANCE DEPTH PINION DEPTH SHIM 3 - 112 DIFFERENTIAL AND DRIVELINE ADJUSTMENTS (Continued) pinion gear are etched into the face of each gear (Fig. Note where Old and New Pinion Marking columns 67).
Page 171 Original Pinion Gear Depth ARBOR DISC DIAL INDICATOR Variance ARBOR PINION SCOOTER BLOCK HEIGHT BLOCK PINION BLOCK SCREW CONE PINION HEIGHT Replacement Pinion Bear Depth Variance BLOCK PINION BLOCK DIFFERENTIAL AND DRIVELINE 3 - 113 ADJUSTMENTS (Continued) PINION GEAR DEPTH VARIANCE Fig.
Page 172 DIFFERENTIAL CASE DIFFERENTIAL SHIM-PINION GEAR SIDE AXLE HOUSING BEARING ARBOR DISC PINION HEIGHT BLOCK ARBOR DIAL INDICATOR SCOOTER BLOCK PINION BLOCK ARBOR PINION GEAR DEPTH SHIM STARTING POINT SHIM 3 - 114 DIFFERENTIAL AND DRIVELINE ADJUSTMENTS (Continued) Fig. 71 Gauge Tools In Housing—Typical Fig.
Page 173 SPECIAL TOOL C-3288–B AXLE HOUSING DIFFERENTIAL CASE DIFFERENTIAL AND DRIVELINE 3 - 115 ADJUSTMENTS (Continued) (6) Install the marked bearing caps in their correct (20) Push and hold differential case toward pinion positions. Install and snug the bolts. gear. (7) Thread guide stud C-3288-B into rear cover (21) Zero dial indicator face to pointer.
Page 174 DIAL CATOR INDI- FOR MORE BACKLASH INCREASE SHIM THIS SIDE FOR LESS BACKLASH FOR MORE BACKLASH INCREASE SHIM THIS DIE DECREASE SHIM THIS DECREASE SHIM THIS SIDE FOR MORE BACK- FOR LESS BACKLASH SIDE FOR LESS BACK- LASH LASH 3 - 116 DIFFERENTIAL AND DRIVELINE ADJUSTMENTS (Continued) (1) Apply a thin coat of hydrated ferric oxide, or...
Page 175 HEEL DRIVE RING GEAR TEETH SIDE COAST SIDE OF RING GEAR TEETH HEEL PINION GEAR DEPTH SHIM CORRECT. INCREASE RING GEAR BACKLASH. PINION GEAR DEPTH SHIM CORRECT. DECREASE RING GEAR BACKLASH. RING CORRECT. THICKER PINION GEAR REQUIRED. DESIRABLE PATTERN SHOULD BE CENTERED ON THE DRIVE SIDE OF TOOTH.
Page 176 3 - 118 DIFFERENTIAL AND DRIVELINE SPECIFICATIONS SPECIAL TOOLS 216 RBA AXLE 216 RBA AXLE DESCRIPTION SPEC. Type ....Semi-floating Hypoid Axle Ratios .
Page 177 DIFFERENTIAL AND DRIVELINE 3 - 119 SPECIAL TOOLS (Continued) Holder—C-3281 Installer—C-4308 Installer—C-3718 Installer—C-4340 Guide Pin—C-3288-B Handle—C-4171 Dial Indicator—C-3339 Remover—C-4307...
Page 178 3 - 120 DIFFERENTIAL AND DRIVELINE SPECIAL TOOLS (Continued) Spreader—W-129-B Trac-lok Tool Set—C-4487 Installer—C-3972-A Remover—6310 Installer—D-129 Installer—6436 Remover—D-103 Installer—6437...
Page 179 DIFFERENTIAL AND DRIVELINE 3 - 121 SPECIAL TOOLS (Continued) Starting Point Shim—8107 Installer—6448 Holder—6958 Adapter—6790 Holder—6963-A Pinion Depth Set—6955 Remover—7794-A Adapter Set—6956 Gauge Block—8144...
Page 181 BRAKES 5 - 1 BRAKES CONTENTS page page ANTILOCK BRAKES ..... 35 BASE BRAKE SYSTEM ....1 BASE BRAKE SYSTEM INDEX page...
Page 182: General Information
5 - 2 BRAKES GENERAL INFORMATION flush the system with new brake fluid if contamina- tion is suspected. BRAKE SYSTEM All vehicles are equipped with power assist four- CAUTION: Use Mopar brake fluid, or an equivalent wheel disc brakes. Antilock (ABS) brakes are also quality fluid meeting SAE/DOT standards J1703 and standard equipment on all models.
Page 183: Combination Valve
BRAKES 5 - 3 DESCRIPTION AND OPERATION (Continued) through a hose attached to an intake manifold fitting FRONT DISC BRAKES at one end and to the booster check valve at the The calipers are a single piston type. The calipers other.
Page 184: Parking Brakes
MASTER MOUNTING STUD (2) VACUUM CHECK VALVE CYLINDER SECONDARY FRONT CYLINDER) MASTER SPRING PHRAGM PUSH DIA- REAR PHRAGM DIA- BOOSTER MOUNTING HOUSING STUDS (4) ATMOSPHERIC INLET ASSEMBLY VALVE SEAL PRIMARY PUSH ROD (TO BRAKE AIR FILTER PEDAL) 5 - 4 BRAKES DESCRIPTION AND OPERATION (Continued) Fig.
Page 185 PISTON BRAKE OUTBOARD SHOE CALIPER PISTON SURE OFF PRES- SEAL CALIPER HOUSING CYLINDER BORE INBOARD SHOE DUST BOOT SEAL PISTON PISTON SEAL BRAKE PRESSURE PISTON BORE PARKING SOLID (NON-VENTILATED) ROTOR REAR CALIPER AND DRUM ASSEMBLY BRAKE SURFACE DRUM CALIPER REAR DISC BRAKE MOUNTING...
Page 186 5 - 6 BRAKES DIAGNOSIS AND TESTING (Continued) separated into layers, or contains a substance badly worn. The power booster or check valve could other than brake fluid. The system seals and cups also be faulty. will also have to be replaced after flushing. Use PEDAL PULSATION clean brake fluid to flush the system.
Page 187 BRAKES 5 - 7 DIAGNOSIS AND TESTING (Continued) mountain roads. Refer to the Brake Drag information A very loud squeak or squeal is frequently a sign of in this section for causes. severely worn brake lining. If the lining has worn through to the brake shoes in spots, metal-to-metal BRAKE PULL contact occurs.
Page 188: Red Brake Warning Lamp
TERMINAL PINS PLUNGER POSITIONS TEST 5 - 8 BRAKES DIAGNOSIS AND TESTING (Continued) SWITCH CIRCUIT IDENTIFICATION (2) Stop engine and shift transmission into Neu- • Terminals 1 and 2 are for brake sensor circuit. tral. • Terminals 5 and 6 are for the stop lamp circuit. (3) Pump brake pedal until all vacuum reserve in •...
Page 189: Front Disc Brake Rotor
BOOSTER CHECK VALVE TEE FITTING SHORT CONNECTING VACUUM GAUGE VALVE SEAL APPLY TEST VACUUM HERE CLAMPTOOL HOSE INTAKE MANI- CHECK VALVE CHECK VALVE FOLD HOSE ROTOR TAKE MINIMUM OF 6 MEASUREMENTS AROUND ROTOR MICROMETER BRAKES 5 - 9 DIAGNOSIS AND TESTING (Continued) used to aid in identifying whether or not the brake light bulb and fuse is functional.
Page 190: Rear Disc Brake Rotor
DIAL INDICATOR LOCATION OF REAR ROTOR THICKNESS SPECIFI- MINIMUM CATION 5 - 10 BRAKES DIAGNOSIS AND TESTING (Continued) rotor with the wheel nuts and 4 or 5 large diameter REAR ROTOR THICKNESS VARIATION flat washers on each stud. Variations in rotor thickness will cause pedal pul- Use a dial indicator to check lateral runout (Fig.
Page 191: Service Procedures
FLUID LEVEL MARKS RESERVOIR BRAKES 5 - 11 DIAGNOSIS AND TESTING (Continued) the result of worn brake shoes, improper brake shoe BRAKE FLUID CONTAMINATION adjustment, or improperly assembled brake parts. Indications of fluid contamination are swollen or A “too loose” condition can also be caused by inop- deteriorated rubber parts.
Page 192 RESERVOIR BLEEDING TUBES BLEEDING TUBES MASTER CYLINDER HOUSING DOWEL FLUID TAINER TIALLY WITH FLUID BLEED HOSE FILLED CON- PAR- 5 - 12 BRAKES SERVICE PROCEDURES (Continued) NOTE: If master cylinders has one reservoir open- cylinder fluid level frequently and add fluid as ing, position both bleed tubes into the single reser- needed.
Page 193: Brake Line
BRAKING DISC BRAKING DISC GRINDER CUTTING TOOLS DAMPER BRAKES 5 - 13 SERVICE PROCEDURES (Continued) stem must either be pressed inward, or held outward slightly. a spring clip tool or helper is needed to hold the valve stem in position. Follow the manufacturers instructions carefully when using pressure equipment.
Page 194: Removal And Installation
SWITCH PLUNGER TERMINALS RETAINER 5 - 14 BRAKES SERVICE PROCEDURES (Continued) (9) Tighten tool handle until plug gauge is seated on jaws of flaring tool. This will start the inverted flare. (10) Remove the plug gauge and complete the inverted flare. (11) Remove the flaring tools and verify that the inverted flare is correct.
Page 195: Combination Valve
BRAKE PEDAL AND BRACKET PUSH ROD PIN ASSEM- BUSHING (FOR PIN) DASH PANELBOOSTER PUSH BOOSTER LOCK NUTS PUSH ROD RETAINER CLIP 39 N·m (29 ft. lbs) FLOORPAN MASTER CYLIN- DER/BRAKE BOOSTER ASSEMBLY BOOSTER STUD CYLINDER ATTACHING VALVE BRACKET NUTS (2) VALVE BRACKET COMBINA- TION VALVE...
Page 196: Disc Brake Caliper
VACUUM HOSE BOOSTER STUDS CHECK VALVE BUSHING (FOR PIN) PUSH ROD PIN BOOSTER LOCK 39 N·m (29 ft. BRAKE PEDAL BRACKET NUTS ASSEMBLY lbs.) DASH PANEL PUSH ROD RETAINER CLIP MASTER BOOSTER ASSEMBLY FLOORPAN CYLINDER/BRAKE BOOSTER PUSHROD 5 - 16 BRAKES REMOVAL AND INSTALLATION (Continued) INSTALLATION...
Page 197 CALIPERS FITTING WASHERS CALIPER OUTBOARD BRAKESHOE BOSS CALIPER CALIPER MOUNTER BOLT (2) C-CLAMP BRAKES 5 - 17 REMOVAL AND INSTALLATION (Continued) (6) Install wheel and tire assembly. (7) Fill master cylinder and bleed brake system. DISC BRAKE SHOES REMOVAL (1) Raise vehicle and remove front wheel and tire assemblies.
Page 198 OUTBOARD BRAKESHOE LOCATING SHOE SPRING TILT OUTBOARD TO LOCATING LUG REMOVE CALIPER CALIPER CALIPER PISTON SHOE SPRINGS MOUNTING BUSHINGSCALIPER INBOARD BRAKE- LEDGES MOUNTING SHOE BOLTS 5 - 18 BRAKES REMOVAL AND INSTALLATION (Continued) Fig. 29 Caliper Removal Fig. 31 Inboard Brake Shoe Removal (6) Remove outboard shoe by pressing one end of INSTALLATION shoe inward to disengage shoe lug.
Page 199: Disc Brake Rotor
CALIPER BOLT CORRECT SHANK LENGTH: 22 mm (0.866 in.) THREADLENGTH BOTTOM LEDGE 67 mm ( 2.637 in. ( TOP LEDGE 0.6 mm) 0.0236 BRAKESHOE TAB ON LEDGE in.) LEDGE BRAKESHOE NOTCH OUTER SURFACE SEATED ROTOR WASHER RETAINER BEARING NUT COTTER PIN NUT LOCK BRAKES 5 - 19...
Page 200: Disc Brake Shoes
CALIPER SOCKET LARGE C-CLAMP CALIPER MOUNTINGBOLT OUTBOARD SHOE OUTBOARD CALIPER BOLT SHOE INBOARD CORRECT SHANK LENGTH: BOOT/BUSHING (2) SHOE 22 mm (0.866 in.) THREADLENGTH 67 mm ( 2.637 in. ( 0.6 mm) 0.0236 in.) 5 - 20 BRAKES REMOVAL AND INSTALLATION (Continued) Fig.
Page 201 CALIPER MOUNTING BRACKET CON- BRACKET SHOE TABS TACT SURFACES ANTI-RATTLE SPRING SHOE TABS SPLASH SHIELD ACCESS HOLE BRAKE ADJUSTING TOOL BRAKES 5 - 21 REMOVAL AND INSTALLATION (Continued) INSTALLATION REAR DISC BRAKE ROTOR (1) Clean brake shoe contact surfaces of caliper mounting bracket (Fig.
Page 202 FRONT CABLE FRONT CABLE TEN- SIONER ADJUSTING NUT FWD CABLE SUPPORT BRACKET EQUALIZER L.R. CABLE R.R. C ABLE MODULE FRONT CABLE MODULE DIAGNOSTIC CONNEC- FRONT CABLE TEN- HARNESS WIRE MODULE SIONER ADJUSTING NUT FWD CABLE PARKING BRAKE LEVER ASSEM- SUPPORT BRACKET EQUALIZER FLOOR PAN...
Page 203: Parking Brake Shoes
CABLE BRACKET CABLE EYE- LEVER SPLASH SHIELD ACCESS HOLE BRAKE ADJUSTING TOOL BRAKES 5 - 23 REMOVAL AND INSTALLATION (Continued) INSTALLATION PARKING BRAKE SHOES (1) Connect front cable to lever assembly. (2) Seat front cable in floor pan. REMOVAL (3) Install lever assembly. (1) Raise vehicle.
Page 204 AXLE ADJUSTER SCREW FLANGE SHAFT LOWER SPRING REAR SHOE NEEDLENOSE PLIERS HOLDDOWN HOLDDOWN REAR SHOE CLIP AND PIN CLIP AND PIN REAR SHOE LEVER BOOT LEVER SPLASH SHIELD SHOE CON- TACT PADS 5 - 24 BRAKES REMOVAL AND INSTALLATION (Continued) Fig.
Page 205: Splash Shield/Caliper Bracket/Lever
LEVER CALIPER MOUNTING SPLASH SHIELD BRACKET LEVER BOOT BRACKET POP RIVETS SPLASH SHIELD BRAKES 5 - 25 REMOVAL AND INSTALLATION (Continued) (2) Engage cam in lever. Then simultaneously slide are only used during manufacture to keep the cam into place on splash shield and work lever boot in place during handling.
Page 206 BRACKET LEDGE BOOT ADHESIVE/SEALER OR CON- TACT CEMENT LEVER BOOT RIVET CAM AND LEVER REAR SHOE LEVER UPPER SPRING HOLDDOWN CLIPS AND PINS LOWER SPRING FRONT SHOE ADJUSTER SCREW RIVET SPLASH SHIELD 5 - 26 BRAKES REMOVAL AND INSTALLATION (Continued) (2) Apply thin coat of contact cement or silicone eyelet.
Page 207: Disassembly And Assembly
SPLASH SHIELD PIN PUNCH ROLL PINS BRAKESHOE LEDGE (12 O’CLOCK POSITION) RESERVOIR CALIPER LEDGES BODY REAR) PRY TOOL GROMMETS GROMMETS MASTER CYLINDER BODY RESERVOIR MASTER CYLINDER RESERVOIR GROMMET BODY BRAKES 5 - 27 REMOVAL AND INSTALLATION (Continued) (4) Loosen reservoir from grommets with pry tool (Fig.
Page 208: Disc Brake Caliper
WORK NEW GROMMETS INTO PLACE USING FINGER PRES- SURE ONLY CALIPER SHOP TOWELS OR CLOTHS PISTON AIR GUN CALIPER PADDING MATERIAL 5 - 28 BRAKES DISASSEMBLY AND ASSEMBLY (Continued) INSTALLATION CAUTION: Do not use any type of tool to install the grommets.
Page 209 REMOVE SEAL WITH WOOD PEN- CIL OR SIM- ILAR TOOL COLLAPSE BOOT WITH PUNCH OR SCREWDRIVER PISTON DUST B OOT PISTON SEAL BRAKES 5 - 29 DISASSEMBLY AND ASSEMBLY (Continued) (5) Remove caliper piston dust boot with suitable SEAL GROOVE BUSHING PISTON SEAL...
Page 210: Rear Disc Brake Caliper
PISTON BOOT PIS- TION DUST BOOT BUSHINGS BOOTS DUST BOOT HANDLE C-4171 INSTALLER C -4842 PADDING MATE- RIAL (1” THICK) 5 - 30 BRAKES DISASSEMBLY AND ASSEMBLY (Continued) (5) Install dust boot on caliper piston and seat boot in piston groove (Fig. 72). Fig.
Page 211 CALIPER CALIPER PISTON SEAL PISTON PISTON DUST BOOT AIR GUN NOZZLE PRY T OOL WOOD PENCIL PADDING BRAKES 5 - 31 DISASSEMBLY AND ASSEMBLY (Continued) (2) Install new piston seal in groove machined in SUITABLE INSTALLER TOOL SIZE PISTON DUST BOOT GROOVE DUST BOOT piston bore.
Page 212: Cleaning And Inspection
5 - 32 BRAKES DISASSEMBLY AND ASSEMBLY (Continued) SPECIAL HONE PISTON BORE CALIPER (7) Press caliper to bottom of bore after seating The bore can be lightly polished with a brake hone BUSHINGS SEATED BOOTS dust boot. Be sure to use wood block to protect piston to remove very minor surface imperfections (Fig.
Page 213: Parking Brake Shoe
SPLASH SHIELD ACCESS HOLE BRAKE ADJUSTING TOOL BRAKES 5 - 33 ADJUSTMENTS (Continued) TENSIONER ROD TO EQUALIZER BRACKET (1/4 in.) 6.5 MM TENSIONER (6) Reinstall brake drums and wheel/tire assem- blies after brake shoe adjustment is complete. (7) Lower vehicle enough for access to parking brake lever.
Page 214: Torque Chart
5 - 34 BRAKES SPECIFICATIONS (Continued) Front Disc Brake Caliper SPECIAL TOOLS Brake Booster BASE BRAKES Type ..... . Dual Diaphragm TORQUE CHART DESCRIPTION TORQUE...
Page 215: Antilock Brakes
MASTER WIRES TO WHEEL SPEED HYDRAULIC BRAKE LINES POWER BRAKE BOOSTER ACCELERATION SWITCH RIGHT FRONT WHEEL COMBINATION VALVE RIGHT REAR WHEEL LEFT FRONT WHEEL LEFT REAR WHEEL CYLINDER HCU HARNESS TO WHEELS RESERVOIR SENSORS BRAKES 5 - 35 ANTILOCK BRAKES INDEX page page...
Page 216 MOTOR 5 - 36 BRAKES DESCRIPTION AND OPERATION (Continued) the CAB will not activate any ABS components as ABS faults remain in memory until cleared, or long as sensor inputs and the acceleration switch until after the vehicle is started approximately 50 indicate normal braking.
Page 217 FRONT SENSOR REAR SENSOR PICK UP FACE PICK UP FACE BRAKES 5 - 37 DESCRIPTION AND OPERATION (Continued) A pressure decrease cycle is initiated when speed sensor signals indicate high wheel slip at one or more wheels. At this point, the CAB closes the inlet then opens the outlet valve, which also opens the return circuit to the accumulators.
Page 218 5 - 38 BRAKES DESCRIPTION AND OPERATION (Continued) ACCELERATION SWITCH NOTE: The MDS or DRB III scan tool is used to diagnose the ABS system. For additional informa- The acceleration switch is located under the rear tion refer to the Antilock Brake section in Group seat.
Page 219 CONNECTOR RELEASE MOUNTING BRACKET HCU/CAB ASSEMBLY HCU/CAB ASSEMBLY MOTOR FRAME FENDER MEMBER PANEL TONE WHEEL FRONT WHEEL SENSOR WIRE GROMMET SENSOR FRONT SENSOR FRONT SENSOR FRONT HOSE AND LINE BRACKETS WIRE WIRE BRAKE STEERING KNUCKLE SENSOR WIRE SHOCK STEERING ABSORBER KNUCKLE BRAKES 5 - 39...
Page 220 5 - 40 BRAKES REMOVAL AND INSTALLATION (Continued) (8) Remove sensor and wire assembly. INSTALLATION (1) Insert sensor through splash shield hole. INSTALLATION (2) Apply Mopar Lock N’ Seal or Loctite 242 to (1) Apply Mopar Lock N’ Seal or Loctite 242 to original sensor bolt.
Page 221 BRACKET SCREW SENSOR BOLT SWITCH PART NUMBER ACCELERATION SENSOR BRACKET FLOORPAN SENSOR RISER ACCELERATION ARROW FRONT OF SWITCH FOR PROPER MOUNTING SENSOR INDICATES MOUNTING SCREWS REAR SENSOR CONNECTORS AND WIRES DRIVER SIDE SILL B-PILLAR BRAKES 5 - 41 REMOVAL AND INSTALLATION (Continued) Fig.
Page 222 5 - 42 BRAKES DISASSEMBLY AND ASSEMBLY (Continued) ASSEMBLY SPECIFICATIONS (1) Install the CAB onto the HCU. (2) Install the CAB mounting screws and tighten TORQUE CHART to 1.8 N·m (16 in. lbs.). (3) Install pump motor connector to the CAB. DESCRIPTION TORQUE Acceleration Sensor...
Page 223 CLUTCH 6 - 1 CLUTCH CONTENTS page page GENERAL INFORMATION FLYWHEEL ......4 CLUTCH COMPONENTS .
Page 224 6 - 2 CLUTCH REMOVAL AND INSTALLATION (Continued) Fig. 1 Clutch Components (VM Diesel) INSTALLATION (1) Lightly scuff sand flywheel face with 180 grit emery cloth. Then clean surface with brake or carbu- retor cleaner. (2) Lightly lubricate pilot bearing with Mopar high temperature bearing grease.
Page 225 CLUTCH 6 - 3 REMOVAL AND INSTALLATION (Continued) Fig. 5 Pilot Bearing Removal Fig. 3 Clutch Disc Alignment—Typical PILOT BEARING REMOVAL (1) Remove transmission and transfer case. (Refer to Group 21, Transmissions And Transfer Case.) (2) Remove clutch cover and disc. (3) Remove the four bolts that attach the pilot bearing retainer to the flywheel (Fig.
Page 226 6 - 4 CLUTCH REMOVAL AND INSTALLATION (Continued) edge of chamfer in retainer bore (Fig. 7). Reposition bearing if necessary. (2) Install bearing retainer and tighten bolts. (3) Lubricate pilot bearing with Mopar high tem- perature wheel bearing grease. (4) Lightly scuff sand flywheel surface with 180 grit emery cloth.
Page 227 CLUTCH 6 - 5 REMOVAL AND INSTALLATION (Continued) (4) Install and tighten new flywheel bolts as fol- (a) Wear heat resistant gloves to handle the hot lows: ring gear. (a) Lubricate bolt threads with engine oil. (b) Align the ring gear on the flywheel evenly. (b) Install and tighten bolts to initial torque of (c) Use hammer and brass drift to tap ring gear 20 N·m.
Page 229 COOLING SYSTEM 7 - 1 COOLING SYSTEM CONTENTS page page GENERAL INFORMATION WATER PUMP TESTS ....9 COOLANT ......3 SERVICE PROCEDURES COOLING SYSTEM COMPONENTS .
Page 230: General Information
BYPASS THERMOSTAT CLOSED—HIGH FLOW THERMOSTAT OPEN—LOW FLOW HEATER COOLANT HEATER CORE BYPASS OVERFLOW TANK RADIATORWATER PUMP RESERVE/ THERMOSTAT HOUSING CROSSFLOW RADIATOR 7 - 2 COOLING SYSTEM GENERAL INFORMATION (Continued) An optional factory installed maximum duty cool- ing package is available on most models. This pack- age will provide additional cooling capacity for vehicles used under extreme conditions such as trailer towing in high ambient temperatures.
Page 231: Radiator
THREADED FAN BLADE ASSEM- VISCOUS FAN DRIVE THREADED (WATER PUMP HUB) BLY P ULLEYBOLTS SHAFT CRANKSHAFT WATER PUMP BYPASS PULLEY HOSE COOLANT OVERFLOW HOSE COOLANT RESERVE/OVER- COOLANT LEVEL SENSOR FLOW TANK WATER PUMP PUL- COOLING SYSTEM 7 - 3 GENERAL INFORMATION (Continued) •...
Page 232 BLOCK LOWER ENGINE POWER C ORD POWER CORD LOCA- TION HEATER BLOCK BLOCK HEATER 7 - 4 COOLING SYSTEM DESCRIPTION AND OPERATION (Continued) ACCESSORY DRIVE BELT TENSION Correct drive belt tension is required to ensure optimum performance of the belt driven engine acces- sories.
Page 233: Coolant Selection-Additives
COOLING SYSTEM 7 - 5 DESCRIPTION AND OPERATION (Continued) The more common type of thermostat failure, usu- ethylene-glycol. Propylene glycol also has poorer heat ally found on high mileage vehicles, is a thermostat transfer characteristics than ethylene glycol. This failed in the shut position. The temperature gauge (if can increase cylinder head temperatures under cer- equipped) will give an indication of this condition.
Page 234: Cooling System Hoses
(SHOWN IN SEALING POSITION) VACUUM VENT VALVE CROSS-SECTIONAL VIEW TOP VIEW PRESSURE RATING PRESSURE VALVE FILLER NECK SEAL ROTATION DIRECTION AS FRONT VIEW VIEWED R STAMPED INTO IMPELLER ROTATION DIRECTION AS BACK VIEW VIEWED 7 - 6 COOLING SYSTEM DESCRIPTION AND OPERATION (Continued) letter R is stamped into the back of the water pump impeller (Fig.
Page 235 MOUNTING BOLT WATER PUMP O-RING HOSE CLAMP TOOL COOLANT RETURN TUBE 6094 MOUNTING NUT HEATER HOSE HOSE CLAMP TYPICAL HOSE TYPICAL TENSION HOSE CLAMP CONSTANT CLAMP NUMBER/LETTER LOCATION COOLING SYSTEM 7 - 7 DESCRIPTION AND OPERATION (Continued) Fig. 9 Coolant Return Tube—5.2/5.9LV-8 Engines Fig.
Page 236: Diagnosis And Testing
MOUNTING THERMOSTATIC SPRING VISCOUS FAN DRIVE VISCOUS FAN DRIVE PUMP HUB WATER THERMOSTATIC MOUNTING HUB SPRING CHECK ENGINE LAMP 7 - 8 COOLING SYSTEM DESCRIPTION AND OPERATION (Continued) NOISE NOTE: It is normal for fan noise to be louder (roar- ing) when: •...
Page 237 HEADLAMP SWITCH DATA (LEFT SIDE ABOVE BRAKE PEDAL) LINK CONNECTOR COLUMN COOLING SYSTEM 7 - 9 DIAGNOSIS AND TESTING (Continued) If the problem is sensed in a monitored circuit observed, it is indicating that the battery has been often enough to indicate an actual problem, a DTC is disconnected within the last 50 key-on cycles.
Page 238 1 INCH 3/16 INCH WELDING 1 1/2 INCHES IMPELLER NORMAL NOT NORMAL CRACKS BELT OK CRACKS RELACE BELT 9 INCHES 7 - 10 COOLING SYSTEM DIAGNOSIS AND TESTING (Continued) ant temperature, it will record a Diagnostic Trouble Code (DTC) in the PCM memory. The DTC number for low coolant temperature is 17.
Page 239 COOLING SYSTEM 7 - 11 DIAGNOSIS AND TESTING (Continued) SERPENTINE DRIVE BELT DIAGNOSIS–4.0L 6-CYLINDER ENGINE CONDITION POSSIBLE CAUSES POSSIBLE CAUSES RIB CHUNKING (ONE OR MORE RIBS 1. Foreign objects imbedded in 1. Remove foreign objects from pulley HAS SEPARATED FROM BELT BODY) pulley grooves.
Page 240 7 - 12 COOLING SYSTEM DIAGNOSIS AND TESTING (Continued) SERPENTINE DRIVE BELT DIAGNOSIS-5.2/5.9L 8-CYLINDER ENGINES CONDITION POSSIBLE CAUSES CORRECTION RIB CHUNKING (ONE OR MORE 1. Foreign objects imbedded in pulley 1. Remove foreign objects from RIBS HAS SEPARATED FROM grooves. pulley grooves.
Page 241: Preliminary Checks
COOLING SYSTEM 7 - 13 DIAGNOSIS AND TESTING (Continued) PRELIMINARY CHECKS (4) RECENT SERVICE OR ACCIDENT REPAIR: Determine if any recent service has been per- formed on vehicle that may effect cooling system. ENGINE COOLING SYSTEM OVERHEATING Establish what driving conditions caused the com- This may be: •...
Page 242: Cooling System
7 - 14 COOLING SYSTEM DIAGNOSIS AND TESTING (Continued) COOLING SYSTEM DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION TEMPERATURE GAUGE READS LOW 1. Has a Diagnostic Trouble Code (DTC) 1. Refer to On-Board Diagnostics in the number 17 been set indicating a stuck open service manual text.
Page 243 COOLING SYSTEM 7 - 15 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION TEMPERATURE GAUGE READS HIGH OR 9. Coolant not flowing through system. 9. Check for coolant flow at radiator filler ENGINE COOLANT WARNING LAMP neck with some coolant removed, engine ILLUMINATES.
Page 244 7 - 16 COOLING SYSTEM DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION DETONATION OR PRE-IGNITION (NOT 1. Engine overheating. 1. Check reason for overheating and repair CAUSED BY IGNITION SYSTEM). GAUGE as necessary. MAY OR MAY NOT BE READING HIGH 2.
Page 245 COOLING SYSTEM 7 - 17 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION HEAT ODOR 1. Various heat shields are used at certain 1. Locate missing shields and replace or drive line components. One or more of these repair as necessary. shields may be missing.
Page 246 ULTRAVIOLET LIGHT METHOD Inspect the cams on the outside part of the filler All Jeep models have a leak detection additive neck. If the cams are bent, seating of pressure cap added to the cooling system before they leave the fac- valve and tester seal will be affected.
Page 247 COOLING SYSTEM 7 - 19 DIAGNOSIS AND TESTING (Continued) leakage. If no leaks are visible, inspect for internal Drain sufficient coolant to allow for thermostat leakage. Large radiator leak holes should be repaired removal. Refer to Thermostat Replacement. Discon- by a reputable radiator repair shop. nect the water pump drive belt.
Page 248: Pressure Testing Radiator Cap
TYPICAL COOLING SYSTEM PRESSURE TESTER PRESSURE CAP 7 - 20 COOLING SYSTEM DIAGNOSIS AND TESTING (Continued) WARNING: USE EXTREME CAUTION WHEN THE HOSE TO DETERMINE WHEN PRESSURE HAS ENGINE IS OPERATING. DO NOT STAND IN A BEEN RELEASED. WHEN COOLANT AND STEAM DIRECT LINE WITH THE FAN.
Page 249: Service Procedures
COOLING SYSTEM 7 - 21 DIAGNOSIS AND TESTING (Continued) LOW COOLANT LEVEL-AERATION from radiator drain cock. Do this while observing coolant reserve/overflow system tank. The coolant If the coolant level in radiator drops below top of level in reserve/overflow tank should drop slightly. If radiator core tubes, air will enter cooling system.
Page 250 COOLANT TEMPERATURE SENSOR BLOCK DRAIN PLUG BLOCK DRAIN PLUG 7 - 22 COOLING SYSTEM SERVICE PROCEDURES (Continued) (2) Fill system using a 50/50 mixture of ethylene- glycol anifreeze and low mineral conent water. Fill radiator to top and install radiator cap. Add suffi- cient coolant to the reserve/overflow tank to raise level to FULL mark.
Page 251: Removal And Installation
BRACE BOLTS BRACKET BOLTS RUBBER HOSE FRONT LOWER CROSSMEM- OIL COOLER BRACE RUBBER HOSE HOSE CLAMPS HOSE CLAMPS CLIP COOLING SYSTEM 7 - 23 SERVICE PROCEDURES (Continued) cooling tube passages. For more information, refer to operating instructions supplied with flushing equip- ment.
Page 252 ROTATION DIRECTION AS VIEWED FRONT VIEW PUMP PULLEY WATER PUMP HUB BACK VIEW ROTATION DIRECTION AS BOLTS (4) VIEWED 7 - 24 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Position cooler to vehicle. (2) Install lower hose and hose clamp to cooler. Hose clamp screws must be facing towards rear of vehicle.
Page 253 THERMAL COUS (4) FAN HUB-TO-PUMP PULLEY NUTS DRIVE (4) FAN BLADE-TO-VISCOUS VIS- DRIVE BOLTS (4) FAN HUB-TO-PUMP PULLEY FAN BLADE WATER PUMP PUL- PUMP ASSEMBLY WATER PUMP STUDS HOSE CLAMP TOOL 6094 PUMP BRACKET HOSE CLAMP COOLING SYSTEM 7 - 25 REMOVAL AND INSTALLATION (Continued) Fig.
Page 254 BOLTS LONG BOLT PULLEY SHORT TYPICAL HOSE MOUNTING LOWER VENT HOLE STUDS TYPICAL TENSION HOSE CLAMP CONSTANT CLAMP NUMBER/LETTER LOCATION HEATER HOSE FITTING UPPER VENT HOLE PUMP WATER PUMP GAS- 7 - 26 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) (13) If pump is to be replaced, the heater hose fit- ting must be removed.
Page 255 THREADED FAN BLADE ASSEM- VISCOUS FAN DRIVE THREADED (WATER PUMP HUB) BLY P ULLEYBOLTS SHAFT CRANKSHAFT WATER PUMP BYPASS PULLEY HOSE HOOD CONDENSER BRACKET LATCH BOLT FAN SHROUD MOUNTING NUTS LOWER BRACKET BOLT ALIGNMENT DOWELS UPPER BRACE BOLTS CONDENSER BOLT WATER PUMP PUL- COOLING SYSTEM...
Page 256 MOUNTING BOLT WATER PUMP FAN BLADE O-RING COOLANT RETURN TUBE IDLER PULLEY MOUNTING NUT HEATER HOSE TENSIONER WATER PUMP MOUNT- ING BOLTS TURN CLOCKWISE TO REMOVE BELT 7 - 28 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 36 Water Pump Bolts—5.2/5.9L Engines— Typical (15) Loosen clamp at water pump end of bypass hose (Fig.
Page 257 *IF VEHICLE IS NOT EQUIPPED WITH POWER STEERING, THIS WILL BE AN IDLER PULLEY. AUTOMATIC TEN- SIONER IDLER PULLEY WAT.PUMP IF W/OUT A/C LONG BOLT SHORT BOLT GASKET THERMOSTAT HOUSING THERMOSTAT GEN. CRANK A/C COMP. PWR. STRG. PULLEY PUMP COOLING SYSTEM 7 - 29 REMOVAL AND INSTALLATION (Continued) CAUTION:...
Page 258 GROOVE IDLER PULLEY GENERATOR/COMPRESSOR SUPPORT IGNITION COIL BRACKET BRACKET BRACKET AUTOMATIC BELT SIONER TEN- 7 - 30 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) INSTALLATION THERMOSTAT 5.2/5.9L ENGINES (1) Install the replacement thermostat so that the pellet, which is encircled by a coil spring, faces the REMOVAL engine.
Page 259 FAN BLADE IDLER PULLEY TENSIONER INTAKE MANIFOLD THERMOSTAT GASKET HOUSING FRONT MACHINED GROOVE THERMOSTAT TURN CLOCKWISE TO REMOVE BELT COOLING SYSTEM 7 - 31 REMOVAL AND INSTALLATION (Continued) (d) Remove belt from vehicle. (e) Remove two generator mounting bolts. Do not remove any wiring at generator.
Page 260 *IF VEHICLE IS NOT EQUIPPED WITH POWER STEERING, THIS WILL BE AN IDLER PULLEY. AUTOMATIC TEN- SIONER IDLER PULLEY WAT.PUMP IF W/OUT A/C HOSE CLAMP TOOL 6094 HOSE CLAMP GEN. CRANK A/C COMP. PWR. STRG. PULLEY PUMP 7 - 32 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) CAUTION:...
Page 261 CLAMP NUMBER/ LETTER A/C CONDENSER TYPICAL LOCA- TENSION HOSE CLAMP TION CONSTANT TYPICAL HOSE SEALS DENSER AND RADIATOR) (BETWEEN RADIATOR TO BODY SEAL LOWER SEAL CON- (RIGHT) RADIATOR TO BODY SEAL UPPER SEALS (BETWEEN RADI- ATOR AND UPPER CROSSMEM- (LEFT) BER) ALIGNMENT DOWELS (2)
Page 262 THERMAL COUS THREADED FAN BLADE ASSEM- (4) FAN HUB-TO-PUMP PULLEY NUTS DRIVE (4) FAN BLADE-TO-VISCOUS VISCOUS FAN DRIVE VIS- THREADED (WATER PUMP HUB) BLY P ULLEYBOLTS DRIVE BOLTS SHAFT (4) FAB HUB-TO-PUMP PULLEY FAN BLADE WATER PUMP PUL- CRANKSHAFT WATER PUMP WATER PUMP STUDS BYPASS...
Page 263 RADIATOR ALIGNMENT RUBBER RADIATOR DOWEL GROMMET CROSSMEMBER LOWER RUBBER AIR SEAL A/C CONDENSER SUPPORT B RACKET COOLING SYSTEM 7 - 35 REMOVAL AND INSTALLATION (Continued) support bracket to lower frame crossmember (Fig. 50). (17) Remove the remaining four bolts securing the radiator upper crossmember to the body.
Page 264 HOSE CLAMP TOOL 6094 HOSE CLAMP 7 - 36 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) (3) Connect the lower radiator hose and hose (23) Be sure of at least 25 mm (1.0 inches) clamp to radiator. between tips of fan blades and fan shroud. (24) Fill cooling system.
Page 265 CLAMP NUMBER/ LETTER TYPICAL LOCA- TENSION HOSE CLAMP TION CONSTANT TYPICAL HOSE IDLER PULLEY MOUNTING BOLT GENERATOR/COMPRESSOR WATER PUMP O-RING SUPPORT IGNITION COIL BRACKET BRACKET BRACKET COOLANT RETURN TUBE AUTOMATIC MOUNTING NUT HEATER HOSE BELT SIONER TEN- COOLING SYSTEM 7 - 37 REMOVAL AND INSTALLATION (Continued) Fig.
Page 266 FAN BLADE IDLER PULLEY TENSIONER *IF VEHICLE IS NOT EQUIPPED WITH POWER STEERING, THIS WILL BE AN IDLER PULLEY. AUTOMATIC TEN- SIONER IDLER PULLEY WAT.PUMP IF W/OUT A/C TURN CLOCKWISE TO REMOVE GEN. CRANK A/C COMP. PWR. STRG. BELT PULLEY PUMP 7 - 38 COOLING SYSTEM...
Page 267 COOLANT TEMPERATURE SENSOR BLOCK DRAIN PLUG BLOCK LOWER ENGINE POWER C ORD POWER CORD LOCA- TION HEATER BLOCK BLOCK HEATER BLOCK DRAIN PLUG COOLING SYSTEM 7 - 39 REMOVAL AND INSTALLATION (Continued) (2) Drain coolant from radiator. Refer to Draining Cooling System in this group.
Page 268 PUMP BRACKET AC + PUMP ASSEMBLY IDL + ALT + WP & FAN + PS + CRANK 7 - 40 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 63 Power Steering Pump Bracket and IdlerPulley 4.0L ENGINE REMOVAL Belt tension is adjusted at the power steering pump bracket and idler pulley assembly.
Page 269: Automatic Belt Tensioner
FAN BLADE IDLER PULLEY TENSIONER *IF VEHICLE IS NOT EQUIPPED WITH POWER STEERING, THIS WILL BE AN IDLER PULLEY. AUTOMATIC TEN- SIONER IDLER PULLEY WAT.PUMP IF W/OUT A/C TURN CLOCKWISE TO REMOVE GEN. CRANK A/C COMP. PWR. STRG. BELT PULLEY PUMP COOLING SYSTEM 7 - 41...
Page 270: Cooling System Fan 4.0L Engine
INDEXING ARROW TENSIONER MOUNTING NUT TENSIONER ASSEMBLY INDEXING MARK THERMAL COUS HOOD CONDENSER BRACKET (4) FAN HUB-TO-PUMP PULLEY NUTS DRIVE (4) FAN BLADE-TO-VISCOUS LATCH BOLT VIS- FAN SHROUD MOUNTING NUTS DRIVE BOLTS LOWER BRACKET BOLT ALIGNMENT (4) FAB HUB-TO-PUMP PULLEY DOWELS FAN BLADE WATER PUMP PUL-...
Page 271: Cooling System Fan 5.2/5.9L Engines
THREADED FAN BLADE ASSEM- VISCOUS FAN DRIVE THREADED (WATER PUMP HUB) BLY P ULLEYBOLTS SHAFT CRANKSHAFT WATER PUMP BYPASS PULLEY HOSE WATER PUMP PUL- COOLING SYSTEM 7 - 43 REMOVAL AND INSTALLATION (Continued) (5) After removing fan blade/fan drive assembly do not place the thermal viscous fan drive in the hori- zontal position.
Page 272: Cleaning And Inspection
7 - 44 COOLING SYSTEM • Water leaks from shaft seal. This is evident by CLEANING AND INSPECTION traces of coolant below vent hole • Loose or rough turning bearing. Also inspect vis- RADIATOR CAP cous fan drive • Impeller rubs either the pump body or timing INSPECTION Visually inspect the pressure valve gasket on the chain case/cover...
Page 273: Special Tools
COOLING SYSTEM 7 - 45 SPECIFICATIONS (Continued) TORQUE SPECIFICATIONS SPECIAL TOOLS SPECIAL TOOLS—COOLING DESCRIPTION TORQUE Automatic Belt Tensioner to Mounting Bracket (5.2/5.9L) Bolts ..... . 67 N·m (50 ft. lbs.) Automatic Belt Tensioner to Block (5.2/5.9L) Bolts .
Page 275: The Cooling System Regulates Engine Operating Tem
COOLING SYSTEM 7 - 1 COOLING SYSTEM CONTENTS page page GENERAL INFORMATION DRAINING COOLING SYSTEM ... . 17 COOLING SYSTEM ..... . 1 REFILLING COOLING SYSTEM .
Page 276: General Information
7 - 2 COOLING SYSTEM GENERAL INFORMATION (Continued) Fig. 1 Coolant Flow—2.5L Diesel Engine—Typical CAUTION: Plastic tanks, while stronger than brass, CAUTION: When installing a serpentine accessory subject damage impact, such drive belt, the belt MUST be routed correctly. If not, wrenches.
Page 277: Water Pump
COOLING SYSTEM 7 - 3 GENERAL INFORMATION (Continued) Fig. 2 Coolant Tank and Radiator Hoses normal operating temperature. The coolant tank is equipped with a cam type pressure/vent cap. Refer to Pressure/Vent Cap for additional information. A separate coolant reserve/overflow tank is not used with this system.
Page 278: Coolant
7 - 4 COOLING SYSTEM GENERAL INFORMATION (Continued) A quick test to determine if the pump is working is The cooling system will operate at pressures to check if the heater warms properly. A defective slightly above atmospheric pressure. This results in a water pump will not be able to circulate heated cool- higher coolant boiling point allowing increased radi- ant through the long heater hose to the heater core.
Page 279: Cooling System Hoses
COOLING SYSTEM 7 - 5 DESCRIPTION AND OPERATION (Continued) Propylene-glycol Formulations—Should Not Be Used in Chrysler Vehicles Propylene-glycol formulations do not meet Chrysler coolant specifications. It’s overall effec- tive temperature range is smaller than that of ethyl- ene-glycol. The freeze point of 50/50 propylene-glycol and water is -32 deg.
Page 280: Viscous Fan Drive
7 - 6 COOLING SYSTEM DESCRIPTION AND OPERATION (Continued) Ordinary worm gear type hose clamps (when CAUTION: Some engines equipped with serpentine equipped) can be removed with a straight screw- drive belts have reverse rotating fans and viscous driver or a hex socket. To prevent damage to fan drives.
Page 281: Diagnosis And Testing
COOLING SYSTEM 7 - 7 DESCRIPTION AND OPERATION (Continued) AUTOMATIC BELT TENSIONER DIAGNOSIS AND TESTING Drive belt tension is controlled by a spring loaded PRELIMINARY CHECKS automatic belt tensioner located below and to the front of the engine oil filter (Fig. 7). This tensioner is ENGINE COOLING SYSTEM OVERHEATING connected to a pivot bracket and a pulley (Fig.
Page 282 7 - 8 COOLING SYSTEM DIAGNOSIS AND TESTING (Continued) COOLING SYSTEM DIAGNOSIS–DIESEL ENGINE...
Page 283 COOLING SYSTEM 7 - 9 DIAGNOSIS AND TESTING (Continued)
Page 284 7 - 10 COOLING SYSTEM DIAGNOSIS AND TESTING (Continued)
Page 285 COOLING SYSTEM 7 - 11 DIAGNOSIS AND TESTING (Continued)
Page 286 7 - 12 COOLING SYSTEM DIAGNOSIS AND TESTING (Continued)
Page 287: Thermostat
COOLING SYSTEM 7 - 13 DIAGNOSIS AND TESTING (Continued) THERMOSTAT VISCOUS FAN DRIVE DIAGNOSIS TESTING Diesel engines, due to their inherent efficiency are If the fan assembly free-wheels without drag (the slower to warm up than gasoline powered engines, fan blades will revolve more than five turns when and will operate at lower temperatures when the spun by hand), replace the fan drive.
Page 288: Testing Cooling System For Leaks
Recheck the system cold if the cause of coolant loss ULTRAVIOLET LIGHT METHOD is not located during warm engine examination. All Jeep models have a leak detection additive added to the cooling system before they leave the fac- tory. The additive is highly visible under ultraviolet light (black light).
Page 289: Low Coolant Level- Aeration
COOLING SYSTEM 7 - 15 DIAGNOSIS AND TESTING (Continued) INTERNAL LEAKAGE INSPECTION BELT DIAGNOSIS Remove the oil pan drain-plug and drain a small When diagnosing serpentine accessory drive belts, amount of engine oil. Coolant, being heavier will small cracks that run across the ribbed surface of the drain first, or operate engine to churn oil, then exam- belt from rib to rib (Fig.
Page 290 7 - 16 COOLING SYSTEM DIAGNOSIS AND TESTING (Continued) SERPENTINE DRIVE BELT DIAGNOSIS...
Page 291: Service Procedures
COOLING SYSTEM 7 - 17 SERVICE PROCEDURES (1) Observe the previous WARNINGS and remove the coolant tank pressure/vent cap. COOLANT LEVEL CHECK (2) The plastic radiator draincock is located on the bottom of the left radiator tank. It can be accessed The coolant level is checked and adjusted at the from the bottom of vehicle.
Page 292: Coolant Replacement
7 - 18 COOLING SYSTEM SERVICE PROCEDURES (Continued) (1) Tighten radiator draincock COOLANT REPLACEMENT removed), the cylinder block drain-plug. It is recommended that the cooling system be (2) Remove the plastic radiator fill vent valve drained and flushed at 84,000 kilometers (52,500 (unscrews counter- clockwise) from the radiator.
Page 293: Fan Blade Removal
COOLING SYSTEM 7 - 19 REMOVAL AND INSTALLATION (Continued) tom of radiator into the rubber grommets in front lower crossmember (Fig. 16). Fig. 15 Clamp Number/Letter Location REMOVAL (1) Disconnect negative battery cable at battery. Fig. 16 Radiator Alignment Dowels—Typical (2) Observe the previous WARNINGS.
Page 294: Viscous Fan Drive
7 - 20 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) (4) Do not unbolt fan blade assembly from viscous (5) Connect negative battery cable. fan drive at this time. VISCOUS FAN DRIVE The thermal viscous fan drive (Fig. 18) is a sili- cone-fluid-filled coupling.
Page 295: Thermostat
COOLING SYSTEM 7 - 21 REMOVAL AND INSTALLATION (Continued) occur when ambient (outside air temperature) is very high. • Engine loads and temperatures are high such as when towing a trailer. • Cool silicone fluid within the fan drive unit is being redistributed back to its normal disengaged (warm) position.
Page 296: Drive Belt
7 - 22 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) DRIVE BELT CAUTION: The drive belt on the 2.5L diesel engine is equipped with a spring loaded automatic belt ten- sioner. After belt installation, do not attempt to check belt tension with a belt tension gauge. AUTOMATIC BELT TENSIONER Fig.
Page 297 COOLING SYSTEM 7 - 23 REMOVAL AND INSTALLATION (Continued) Fig. 23 Hose Clamp Tool Fig. 22 Thermal Viscous Fan Drive and Blade Assembly (8) Remove the drive belt by removing the auto- matic belt tensioner. For procedures, refer to Belt Removal/Installation in the Engine Accessory Drive Belts section of this group.
Page 298: Cleaning And Inspection
7 - 24 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) • Water leaks from the shaft seal. This is evident by traces of coolant below the vent tube drain hose • Loose or rough turning bearing. • Impeller rubs either the water pump body or water pump adapter.
Page 299: Cooling System Cleaning/Reverse Flushing
COOLING SYSTEM 7 - 25 CLEANING AND INSPECTION (Continued) motion of opposite blades should not exceed 2.0 mm Allow the coolant tank and radiator to fill with (.090 inch). Test all blades in this manner. water. When radiator is filled, apply air in short blasts allowing radiator to refill between blasts.
Page 300: Specifications
7 - 26 COOLING SYSTEM ADJUSTMENTS (Continued) group. Due to use of this belt tensioner, DO NOT TORQUE SPECIFICATIONS attempt to use a belt tension gauge on the 2.5L die- sel engine. DESCRIPTION TORQUE Automatic Belt Tensioner-to-Mounting Bracket Bolt (1) ......75 N·m SPECIFICATIONS Automatic Belt Tensioner-to-Block Bolts (2) .
Page 301 POSITIVE LOW-MAINTE- NANCE POST TERY BAT- PLATE GROUPS VENT TEST ELECTROLYTE INDICA- LEVEL VENT GREEN BALL NEGATIVE POST BATTERY 8A - 1 BATTERY CONTENTS page page GENERAL INFORMATION IGNITION-OFF DRAW TEST ....10 INTRODUCTION .
Page 302: General Information
8A - 2 BATTERY GENERAL INFORMATION (Continued) the indicator will reveal the battery condition. See charging the battery with a voltage higher than that Built-In Test Indicator in this group for more infor- of the battery, the battery discharging process is mation.
Page 303: Diagnosis And Testing
BATTERY 8A - 3 DESCRIPTION AND OPERATION (Continued) deliver for thirty seconds at -18° C (0° F). Terminal DIAGNOSIS AND TESTING voltage must not fall below 7.2 volts during or after the thirty second discharge period. The CCA required BATTERY is generally higher as engine displacement increases, The battery must be completely charged and the depending also upon the starter current draw...
Page 304 8A - 4 BATTERY DIAGNOSIS AND TESTING (Continued) • The built-in test indicator has a black or dark Completely Discharged Battery in this group for color visible. more information. • The temperature corrected specific gravity is A battery is fully-charged when: less than 1.235.
Page 305 BATTERY 8A - 5 DIAGNOSIS AND TESTING (Continued) Battery Diagnosis Condition Possible Causes Correction The battery state-of-charge cannot 1. The battery has an incorrect size 1. See Specifications in this group. be maintained. or rating for this vehicle. Replace the incorrect battery with the correct battery, if required.
Page 306: Built-In Test Indicator
SIGHT PLASTIC ROD GLASS GREEN BALL BATTERY TOP 8A - 6 BATTERY DIAGNOSIS AND TESTING (Continued) ABNORMAL BATTERY DISCHARGING PERSONAL INJURY AND/OR VEHICLE DAMAGE Any of the following conditions can result in abnor- MAY RESULT. • mal battery discharging: THE BATTERY CONTAINS SULFURIC ACID, 1.
Page 307 LOW ELECTROLYTE TEST INDICATOR/STATE-OF- CHARGE HYDROMETER FLOAT BULB BARREL TEMPERATURE READING SURFACE COHESION SPECIFIC READING GRAVITY BATTERY 8A - 7 DIAGNOSIS AND TESTING (Continued) Before testing, visually inspect the battery for any damage (a cracked case or cover, loose posts, etc.) that would cause the battery to be faulty.
Page 308 8A - 8 BATTERY DIAGNOSIS AND TESTING (Continued) EXAMPLE: A battery is tested at -12.2° C (10° F) AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT and has a specific gravity of 1.240. Determine the OF THE REACH OF CHILDREN. • IF THE BATTERY IS EQUIPPED WITH REMOV- actual specific gravity as follows: (1) Determine the number of degrees above or ABLE CELL CAPS, BE CERTAIN THAT EACH OF...
Page 309: Load Test
INDUCTION AMMETER POSITIVE CLAMP CLAMP NEGATIVE CLAMP BATTERY 8A - 9 DIAGNOSIS AND TESTING (Continued) LOAD TEST A battery load test will verify the battery cranking capacity. The test is based on the Cold Cranking Amperage (CCA) rating of the battery. Refer to the battery label, or see the Battery Classifications and Ratings chart in Specifications at the back of this group for the CCA rating of the factory-installed bat-...
Page 310 8A - 10 BATTERY DIAGNOSIS AND TESTING (Continued) from the Power Distribution Center (PDC). This will reduce battery discharging. Excessive IOD can be caused by: • Electrical items left on • Faulty or improperly adjusted switches • Faulty or shorted electronic modules and compo- nents •...
Page 311: Voltage Drop Test
FUEL GENERATOR SHUT-OFF FUEL INJECTOR PUMP FUEL SHUT-OFF SOLENOID CONNECTOR SOLENOID BATTERY 8A - 11 DIAGNOSIS AND TESTING (Continued) reading now becomes very low or non-existent, refer AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT to Group 8C - Charging System to diagnose the OF THE REACH OF CHILDREN.
Page 312: Service Procedures
VOLTMETER VOLTMETER BATTERY BATTERY STARTER ENGINE GROUND MOTOR BATTERY VOLTMETER VOLTMETER BATTERY 8A - 12 BATTERY DIAGNOSIS AND TESTING (Continued) cable clamp (Fig. 11). Rotate and hold the ignition switch in the Start position. Observe the voltmeter. If voltage is detected, correct the poor contact between the cable clamp and the terminal post.
Page 313 BATTERY 8A - 13 SERVICE PROCEDURES (Continued) WARNING: test, return the battery to use. If the battery will not • IF THE BATTERY SHOWS SIGNS OF FREEZ- endure a load test, it is faulty and must be replaced. Clean and inspect the battery holddowns, tray, ter- ING, LEAKING, LOOSE POSTS, OR LOW ELECTRO- LYTE LEVEL, DO NOT TEST, ASSIST-BOOST, OR minals, posts, and top before completing service.
Page 314: Removal And Installation
BATTERY TERMINAL BRUSH TEST INDICA- BATTERY TERMINAL BATTERY PULLER CABLE 8A - 14 BATTERY SERVICE PROCEDURES (Continued) may be good and the charging should be completed in REMOVAL AND INSTALLATION the normal manner. BATTERY Charge Rate (1) Turn the ignition switch to the Off position. Make sure all electrical accessories are turned off.
Page 315 FENDER INNER SHIELD TEMPERATURE BOLT SENSOR SCREW HOLDDOWN WHEELHOUSE SCREW THERMO- EXTENSION GUARD BATTERY TRAY PUTTY KNIFE BATTERY 8A - 15 REMOVAL AND INSTALLATION (Continued) WARNING: WEAR A SUITABLE PAIR OF RUBBER GLOVES (NOT THE HOUSEHOLD TYPE) WHEN REMOVING BATTERY HAND.
Page 316 POWER DISTRIBUTION CEN- TEST BATTERY BATTERY INDICA- TEST CATOR INDI- WARM BAKING CLEANING TERMINAL BRUSH BRUSH WATER SODA BATTERY CABLE SOLU- TION NEGATIVE CABLE 8A - 16 BATTERY REMOVAL AND INSTALLATION (Continued) Fig. 22 Battery Cables Fig. 20 Clean Battery - Typical Fig.
Page 317: Specifications Battery
BATTERY 8A - 17 SPECIFICATIONS BATTERY Battery Classifications and Ratings BCI Group Cold Crank- Size Classi- Reserve Ampere- Load Test Engine ing Amper- fication Capacity Hours Amperage (*DIN) Gasoline 34 (*H6) 120 Minutes Diesel (*H7) 135 Minutes *DIN is a European specification and is used to identify the size of batteries installed in vehicles that are built outside of North America.
Page 319: Starting Systems
STARTING SYSTEMS 8B - 1 STARTING SYSTEMS CONTENTS page page GENERAL INFORMATION CONTROL CIRCUIT TEST ....7 INTRODUCTION ......1 FEED CIRCUIT TEST .
Page 320 8B - 2 STARTING SYSTEMS DESCRIPTION AND OPERATION When the solenoid plunger hold-in coil is de-ener- gized, the solenoid plunger return spring returns the STARTING SYSTEM plunger to its relaxed position. This causes the con- tact disc to open the starter feed circuit, and the shift The starting system components form two separate lever to disengage the overrunning clutch and pinion circuits.
Page 321 STARTING SYSTEMS 8B - 3 DESCRIPTION AND OPERATION (Continued) • Battery - Visually inspect the battery for indi- The starter relay is a electromechanical device that switches battery current to the pull-in coil of the cations of physical damage and loose or corroded starter solenoid when the ignition switch is turned to cable connections.
Page 322 8B - 4 STARTING SYSTEMS DIAGNOSIS AND TESTING (Continued) Starting System Diagnosis CONDITION POSSIBLE CAUSE CORRECTION STARTER FAILS TO ENGAGE. 1. Battery discharged or faulty. 1. Refer to Group 8A - Battery. 2. Starting circuit wiring faulty. Charge or replace battery, if 3.
Page 323 POSITIVE CLAMP INDUCTION AMMETER NEGATIVE CLAMP CLAMP FUEL GENERATOR SHUT-OFF FUEL INJECTOR PUMP FUEL SHUT-OFF SOLENOID CONNECTOR SOLENOID STARTING SYSTEMS 8B - 5 DIAGNOSIS AND TESTING (Continued) COLD CRANKING TEST For circuit descriptions and diagrams, refer to 8W-21 - Starting System in Group 8W - Wiring Dia- grams.
Page 324 FUEL GENERATOR SHUT-OFF FUEL INJECTOR PUMP FUEL SHUT-OFF SOLENOID CONNECTOR SOLENOID VOLTMETER VOLTMETER BATTERY BATTERY 8B - 6 STARTING SYSTEMS DIAGNOSIS AND TESTING (Continued) • Battery is fully-charged. Refer to Group 8A - Battery for more information. • Fully engage the parking brake. •...
Page 325 STARTER ENGINE GROUND MOTOR STARTER BATTERY MOTOR VOLTMETER VOLTMETER VOLTMETER BATTERY BATTERY SOLENOID SOLENOID SOLENOID TERMINAL FIELD COIL TERMI- SOLENOID TER- OHMMETER OHMMETER MINAL STARTING SYSTEMS 8B - 7 DIAGNOSIS AND TESTING (Continued) CONTROL CIRCUIT TEST For circuit descriptions and diagrams, refer to 8W-21 - Starting System in Group 8W - Wiring Dia- grams.
Page 326 NUMBER TERMINAL LEGEND COMMON FEED IDENTIFICATION COIL GROUND COIL BATTERY NORMALLY OPEN NORMALLY CLOSED 8B - 8 STARTING SYSTEMS DIAGNOSIS AND TESTING (Continued) RELAY TEST pedal must be fully depressed for this test. Check for The starter relay is located in the Power Distribu- battery voltage at the cavity for relay terminal 86 tion Center (PDC) in the engine compartment.
Page 327 BOLT NUT (2) STARTER HEAT SHIELD MOUNTING BRACKET STRAP THIN PORTION MOUNTING BOLT (3) THICK PORTION STARTING SYSTEMS 8B - 9 DIAGNOSIS AND TESTING (Continued) (3) Check for continuity between the two cavities in the switch-half of the wire harness connector with the clutch pedal released.
Page 328 REAR BOLT SOLENOID FEED WIRE STARTER STARTER MOTOR SOLENOID BATTERY BRACKET FRONT BOLT FEED WIRE STARTER BRACE STUD BRACKET LOCKWASHER LOWER BOLT UPPER NUT REMOVE NUTS (2) 8B - 10 STARTING SYSTEMS REMOVAL AND INSTALLATION (Continued) • Front starter support bracket bolt - 47 N·m (35 (6) Reverse the removal procedures to install.
Page 329 POWER DISTRIBUTION CEN- NEGATIVE CABLE POSITIVE CABLE STARTING SYSTEMS 8B - 11 REMOVAL AND INSTALLATION (Continued) STARTER RELAY (1) Disconnect and isolate the battery negative cable. (2) Remove the cover from the Power Distribution Center (PDC) (Fig. 16). (3) Refer to the label on the PDC for starter relay identification and location.
Page 331 STARTING SYSTEMS 8B - 1 STARTING SYSTEMS CONTENTS page page REMOVAL AND INSTALLATION SPECIFICATIONS STARTER RELAY ......1 STARTING SYSTEM .
Page 332 8B - 2 STARTING SYSTEMS SPECIFICATIONS STARTING SYSTEM Starter and Solenoid Engine Application 2.5L Diesel Power Rating 2.2 Kilowatt Voltage 12 Volts Number of Fields Number of Poles Number of Brushes Drive Type Planetary Gear Reduction Free Running Test Voltage 11.5 Volts Free Running Test Maximum Amperage Draw 160 Amperes...
Page 333 CHARGING SYSTEM 8C - 1 CHARGING SYSTEM CONTENTS page page GENERAL INFORMATION CHARGING SYSTEM ..... 2 OVERVIEW ......1 CURRENT OUTPUT TEST .
Page 334: Description And Operation
8C - 2 CHARGING SYSTEM DESCRIPTION AND OPERATION (Continued) PCM. Each monitored circuit is assigned a Diagnos- ing circuit located within the Powertrain Control tic Trouble Code (DTC). The PCM will store a DTC in Module (PCM). The EVR is not serviced separately. If electronic memory for any failure it detects.
Page 335: Charging System Resistance Tests
FIELD TERMINALS B+ (OUTPUT TERMINAL) GROUND TERMINAL CHARGING SYSTEM 8C - 3 DIAGNOSIS AND TESTING (Continued) (5) Inspect generator drive belt condition and ten- (2) Check condition of battery cables at battery. sion. Tighten or replace belt as required. Refer to Clean if necessary.
Page 336 8C - 4 CHARGING SYSTEM DIAGNOSIS AND TESTING (Continued) and the Electronic Voltage Regulator (EVR) circuitry. (5) With engine speed held at 2500 rpm, slowly The second part of this test (Test 2) will determine adjust the rheostat control (load) on the tester to only generator amperage and will not include anal- obtain the highest amperage reading.
Page 337: On-Board Diagnostic Test For Charging System
SENSOR HARNESS BATTERYTRAY BATTERY TEMPERATURE SENSOR ENGINE WIR- ING HARNESS CHARGING SYSTEM 8C - 5 DIAGNOSIS AND TESTING (Continued) and a voltmeter reading of 15 volts is obtained. Immediately record ammeter reading. Do not apply load to system longer than 15 seconds as damage to test equipment may result.
Page 338 GENERATOR UPPER GENERATOR MOUNTING BOLTS MOUNTING BRACKET GROUND FIELD TERMINALS TERMINAL (B+) TERMI- (B+) WIRE HARNESS INSULATOR TERMINAL HOLDDOWN 8C - 6 CHARGING SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 3 Remove/Install Generator—5.2L/5.9LEngine Fig. 5 Remove/Install Generator Connectors— Typical CAUTION: Never force a belt over a pulley rim using a screwdriver.
Page 339 SENSOR HARNESS BATTERYTRAY BATTERY TEMPERATURE SENSOR ENGINE WIR- ING HARNESS CHARGING SYSTEM 8C - 7 REMOVAL AND INSTALLATION (Continued) BATTERY TEMPERATURE SENSOR REMOVAL (1) Remove battery. Refer to Group 8A, Battery for The battery temperature sensor is located under procedures. vehicle battery (Fig.
Page 341 CHARGING SYSTEM 8C - 1 CHARGING SYSTEM CONTENTS page page GENERAL INFORMATION REMOVAL AND INSTALLATION INTRODUCTION ......1 GENERATOR .
Page 342 8C - 2 CHARGING SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 1 Generator Terminals Fig. 3 Vacuum Pump Oil Feed Hose SPECIFICATIONS SPECIFICATIONS Battery Terminal Nut ......8.5 N·m Lower Generator Mounting Bolt .
Page 343: Ignition System
IGNITION SYSTEM 8D - 1 IGNITION SYSTEM CONTENTS page page GENERAL INFORMATION SPARK PLUG CONDITIONS ....9 INTRODUCTION ......1 TESTING FOR SPARK AT COIL .
Page 344: Description And Operation
(3) 32-WAY CONNECTORS SYNC DISTRIBUTOR GENERATOR ASSEMBLY SIGNAL PULSE RING CAMSHAFT POSITION SEN- 8D - 2 IGNITION SYSTEM DESCRIPTION AND OPERATION (Continued) • Ignition Coil sync) sensor (Fig. 2). This sensor provides fuel injec- • Secondary Ignition Cables tion synchronization and cylinder identification. •...
Page 345: Automatic Shutdown (Asd) Relay
CRANKSHAFT NOTCHES POSITION SENSOR FLYWHEEL IGNITION SYSTEM 8D - 3 DESCRIPTION AND OPERATION (Continued) SPARK PLUG CABLES Spark plug cables are sometimes referred to as sec- ondary ignition wires. These cables transfer electrical current from the ignition coil(s) and/or distributor, to individual spark plugs at each cylinder.
Page 346: Ignition Switch And Key Lock Cylinder
CRANKSHAFT FLYWHEEL NOTCHES POSITION SENSOR FLYWHEEL 8D - 4 IGNITION SYSTEM DESCRIPTION AND OPERATION (Continued) INTAKE MANIFOLD AIR TEMPERATURE SENSOR For an operational description, diagnosis and removal/installation procedures, refer to Group 14, Fuel System. IGNITION SWITCH AND KEY LOCK CYLINDER The ignition switch is located on the steering col- umn.
Page 347 CHECK SPARK CABLE FOR SPARK HERE BOOT PLUG SPARK PLUG ENGINE GROUND SPARK PLUG BOOT GOOD TWIST AND PULL PULLER IGNITION COIL COIL MOUNT- ING BOLTS IGNITION COIL COIL CONNEC- ACCESSORY DRIVE TENSIONER BELT IGNITION SYSTEM 8D - 5 DIAGNOSIS AND TESTING (Continued) IGNITION COIL TEST To perform a complete test of the ignition coil and its circuitry, refer to the DRB scan tool.
Page 348 (3) 32–WAY CONNECTORS GROUND ALLIGATOR CLIP THIS CLIP CAPACITOR .33 MF CONNECT CLIP TO COIL NEG- MOMENTARILY GROUND CLIP ATIVE THIS NEGATIVE ALLIGATOR THIS COIL CLIP 8D - 6 IGNITION SYSTEM DIAGNOSIS AND TESTING (Continued) PRIMARY RESISTANCE SECONDARY RESISTANCE COIL (MANUFACTURER) 21-27°C (70-80°F) 21-27°C (70-80°F) Diamond...
Page 349: Camshaft Position Sensor
CHARRED ERODED BROKEN TOWER CARBON PATH MINALS CRACK TER- WORN AGED ROTOR BUT- DISTRIBUTOR CARBON P ATH DAM- ROTOR CORRODED INSUFFICIENT SPRING EVIDENCE PHYSICAL CONTACT SION TEN- WITH CAP CRACKS IGNITION SYSTEM 8D - 7 DIAGNOSIS AND TESTING (Continued) Fig. 10 Cap Inspection—External—Typical Fig.
Page 350: Intake Manifold Air Temperature
SYNC DISTRIBUTOR GENERATOR ASSEMBLY SIGNAL PULSE RING CAMSHAFT POSITION SEN- 8D - 8 IGNITION SYSTEM DIAGNOSIS AND TESTING (Continued) PCM. If continuity is not present, repair the har- ness as necessary. (c) Check for continuity between the ground cir- cuit wire at the distributor connector and ground. If continuity is not present, repair the harness as necessary.
Page 351: Spark Plug Conditions
AIR GAP SPARK PLUG HEAT SHIELD BOOT NORMAL DEPOSITS BLACK COLD (CARBON) FOULING IGNITION SYSTEM 8D - 9 DIAGNOSIS AND TESTING (Continued) MINIMUM MAXIMUM 250 Ohms Per Inch 1000 Ohms Per Inch 3000 Ohms Per Foot 12,000 Ohms Per Foot SPARK PLUG CABLE RESISTANCE To test ignition coil-to-distributor cap cable, do not remove the cable from the cap.
Page 352 GROUND CENTER ELEC- TRODE ELECTRODE GROUND ELECTRODE COV- ERED WITH WHITE OR YEL- LOW DEPOSITS CENTER ELECTRODE DEPOSITS 8D - 10 IGNITION SYSTEM DIAGNOSIS AND TESTING (Continued) COLD FOULING/CARBON FOULING electrode gap bridging can be cleaned using standard Cold fouling is sometimes referred to as carbon procedures.
Page 353: Removal And Installation
GROUND ELECTRODE CENTER ELECTRODE CHIPPED INSULATOR BLISTERED GRAY COLORED INSULATOR GROUND ELECTRODE STARTING TO DISSOLVE WHITE CENTER ELECTRODE DISSOLVED IGNITION SYSTEM 8D - 11 DIAGNOSIS AND TESTING (Continued) CHIPPED ELECTRODE INSULATOR A chipped electrode insulator usually results from bending the center electrode while adjusting the spark plug electrode gap.
Page 354 FIRING ORDER: 1 5 3 6 2 4 CLOCKWISE ROTATION FRONT OF ENGINE SPARK CABLE BOOT PLUG CLOCKWISE ROTATION SPARK PLUG 1-8-4-3-6-5-7-2 SPARK PLUG BOOT FRONT TWIST AND PULL PULLER AIR GAP SPARK PLUG HEAT SHIELD BOOT 8D - 12 IGNITION SYSTEM REMOVAL AND INSTALLATION (Continued) SPARK PLUGS...
Page 355 GAUGE SPARK PLUG COIL MOUNT- ING BOLTS IGNITION COIL COIL CONNEC- ACCESSORY DRIVE TENSIONER BELT IGNITION SYSTEM 8D - 13 REMOVAL AND INSTALLATION (Continued) PLUG GAP ADJUSTMENT IGNITION COIL—5.2L/5.9L ENGINES Check the spark plug gap with a gap gauge tool. If The ignition coil is an epoxy filled type.
Page 356: Automatic Shutdown (Asd) Relay
MOUNTING BOLTS (2) CRANKSHAFT POSITION SENSOR IGNITION COIL MOUNTING BOLTS (2) ELECTRICAL CONNECTOR GROMMET POWER DISTRIBUTION CEN- 8D - 14 IGNITION SYSTEM REMOVAL AND INSTALLATION (Continued) REMOVAL The ignition coil is mounted to a bracket on the side of the engine to the front of the distributor (Fig. 28).
Page 357: Intake Manifold Air Temperature Sensor
CRANKSHAFT POSITION SENSOR PIGTAIL HARNESS TO DIS- TRIBUTOR SIDE OF ENGINE SYNC DISTRIBUTOR GENERATOR ASSEMBLY SIGNAL PULSE RING CAMSHAFT POSITION SEN- IGNITION SYSTEM 8D - 15 REMOVAL AND INSTALLATION (Continued) one bolt. A wire shield/router is attached to the sen- sor (Fig.
Page 358 ALIGNMENT MARK CRANKSHAFT VIBRATION DAMPER TIMING CHAIN COVER MARKS CAMSHAFT POSITION SENSOR DISTRIBUTOR HOUSING DISTRIBUTOR ALIGNMENT MARK CLAMP BOLT HOLDDOWN ROTOR CLAMP 8D - 16 IGNITION SYSTEM REMOVAL AND INSTALLATION (Continued) DISTRIBUTOR—5.2L/5.9L ENGINES spark plug cable (on the cap) in relation to rotor. Rotor should now be aligned to this position.
Page 359 PLASTIC MENT PIN ALIGN- IGNITION SYSTEM 8D - 17 REMOVAL AND INSTALLATION (Continued) Rotate crankshaft in a clockwise direction, as The degree scale on the SET SYNC screen of the viewed from front, until number one cylinder piston DRB is referring to fuel synchronization only. It is is at top of compression stroke (compression should not referring to ignition timing.
Page 360 SHAFT HOLDDOWN CLAMP HOLDDOWN BOLT ROLL PIN GASKET WASHER DRIVE GEAR HOUSING CAMSHAFT POSITION SEN- FORK WITH SLOT CRANKSHAFT DAMPER TIMING MARK VIBRATION 8D - 18 IGNITION SYSTEM REMOVAL AND INSTALLATION (Continued) direction of normal rotation. Do not rotate engine backward to align timing marks.
Page 361 OIL PUMP SLOT 11 O’CLOCK POSITION FRONT DISTRIBUTOR HOUSING (TOP PLASTIC RING VIEW) DISTRIBUTOR BASE PULSE RING MATING ACCESS HOLE IN POSITION O’CLOCK DISTRIBUTOR HOUSING 4.0L BASE SLOT 2.5L ALIGN. HOLE ALIGN. HOLE 6–CYLIN- ENGINE FRONT 4–CYLIN- ENGINE IGNITION SYSTEM 8D - 19 REMOVAL AND INSTALLATION (Continued) Fig.
Page 362: Powertrain Control Module (Pcm)
KEY/KEY CYLINDER POSITION) (RUN DISTRIBUTOR BASE DISTRIBUTOR CLAMP BASE SLOT HOLE (ON ENGINE) BOLT MOUNTING FRONT PANEL BRACKET LOWER IGNITION SWITCH SHROUD STEERING WHEEL TILT LEVER CLOCK SPRING UPPER S HROUD SPACER 8D - 20 IGNITION SYSTEM REMOVAL AND INSTALLATION (Continued) KEY CYLINDER REMOVAL (1) Disconnect negative cable from battery.
Page 363 PUSH PIN SLOTS ALIGNED SLOTS NOT ALIGNED PARK LOCK (RUN POSITION) DOWEL KEY-IN IGNITION SWITCH SWITCH IGNITION SWITCH & LIGHT HALO SPEED CONTROL MULTI-FUNCTION TURN SWITCH & LEVER SWITCH SIGNAL IGNITION KEY LOCK CYLIN- REAR OF IGNITION SWITCH IGNITION SYSTEM 8D - 21 REMOVAL AND INSTALLATION (Continued) IGNITION SWITCH REMOVAL...
Page 364 PARK LOCK SLIDER LINK- IGNITION KEY LOCK CYLIN- PARK LOCK (LOCK POSITION) DOWEL DRIVER STEERING WHEEL LEVER LOCK REAR OF IGNITION SWITCH IGNITION SWITCH DOWEL LOCATING HOLES STEERING COLUMN 8D - 22 IGNITION SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 51 Park Lock Linkage— AutomaticTransmission—Typical Fig.
Page 365: Specifications
FRONT FRONT OF ENGINE CLOCKWISE ROTATION 1-8-4-3-6-5-7-2 FIRING 1 5 3 6 CLOCK- WISE ROTA- ORDER: TION IGNITION SYSTEM 8D - 23 REMOVAL AND INSTALLATION (Continued) (d) Install 3 ignition switch mounting screws. ENGINE FIRING ORDER—4.0L 6-CYLINDER Tighten screws to 3 N·m .5 N·m (26 in.
Page 366 8D - 24 IGNITION SYSTEM SPECIFICATIONS (Continued) SPARK PLUGS SPARK PLUG CABLE RESISTANCE ENGINE MINIMUM MAXIMUM PLUG TYPE ELECTRODE GAP 250 Ohms Per Inch 1000 Ohms Per Inch 4.0L 6-CYL. RC12LYC 0.89 mm (.035 in.) 3000 Ohms Per Foot 12,000 Ohms Per Foot 5.2L V-8 RC12LC4 1.01 mm (.040 in.)
Page 367 INSTRUMENT PANEL SYSTEMS 8E - 1 INSTRUMENT PANEL SYSTEMS CONTENTS page page GENERAL INFORMATION INSTRUMENT CLUSTER ....10 BODY CONTROL MODULE ....4 LOW FUEL WARNING LAMP .
Page 368: General Information
8E - 2 INSTRUMENT PANEL SYSTEMS GENERAL INFORMATION INSTRUMENT PANEL Modular instrument panel construction allows all INTRODUCTION of the gauges and controls to be serviced from the This group is responsible for covering the vehicle front of the panel. In addition, most of the instru- instrument panel.
Page 369 INSTRUMENT PANEL SYSTEMS 8E - 3 GENERAL INFORMATION (Continued) • Check gauges lamp • Provide service reminders or the distance to the • Cruise-on indicator lamp next service interval • Headlamp high beam indicator lamp • The current transfer case mode of operation •...
Page 370: Body Control Module
8E - 4 INSTRUMENT PANEL SYSTEMS GENERAL INFORMATION (Continued) • Monitoring and transmitting outside ambient INDICATOR LAMP temperature data Indicator lamps are located in the instrument clus- • Monitoring and transmitting air conditioning ter, and in the Graphic Display Module (GDM) or the select switch data Vehicle Information Center (VIC).
Page 371: Description And Operation
INSTRUMENT PANEL SYSTEMS 8E - 5 DESCRIPTION AND OPERATION the internal electrical resistance of the sending unit. Refer to Group 14 - Fuel Systems for more informa- COOLANT TEMPERATURE GAUGE tion on the PCM and for the fuel gauge sending unit service procedures.
Page 372: Airbag Indicator Lamp
8E - 6 INSTRUMENT PANEL SYSTEMS DESCRIPTION AND OPERATION (Continued) received from the Powertrain Control Module (PCM) Control Module (PCM) on the Chrysler Collision on the Chrysler Collision Detection (CCD) data bus. Detection (CCD) data bus. The PCM uses an input from the engine oil pres- The PCM uses an input from the crankshaft posi- sure sensor and internal programming to decide tion sensor and internal programming to decide what...
Page 373: Anti-Lock Brake System Lamp
INSTRUMENT PANEL SYSTEMS 8E - 7 DESCRIPTION AND OPERATION (Continued) The airbag indicator lamp also has a lamp backup of the split brake hydraulic system, possibly due to feature. Following the seat belt reminder lamp dis- low brake fluid level or brake fluid leakage. The play function, if an inoperative airbag warning lamp parking brake switch closes to ground when the circuit was detected during the bulb test sequence,...
Page 374: Headlamp High Beam Indicator Lamp
8E - 8 INSTRUMENT PANEL SYSTEMS DESCRIPTION AND OPERATION (Continued) Vehicles equipped with the automatic headlamps switch is turned to the On position as a bulb test. option have an automatic funeral mode or parade After the bulb test, the instrument cluster circuitry mode.
Page 375: Seat Belt Reminder Lamp
INSTRUMENT PANEL SYSTEMS 8E - 9 DESCRIPTION AND OPERATION (Continued) tion when the exterior lamps are lighted. The lamp is to the next highest gear for the best fuel economy. hard-wired in the instrument cluster, and is com- The lamp is turned on by the instrument cluster cir- pletely controlled by the panel lamps driver circuit.
Page 376: Diagnosis And Testing
8E - 10 INSTRUMENT PANEL SYSTEMS DESCRIPTION AND OPERATION (Continued) The PCM uses an input from the water-in-fuel sen- COOLANT TEMPERATURE GAUGE sor in the fuel filter/water separator to determine If the problem being diagnosed is related to gauge that excess water has accumulated in the diesel fuel. accuracy, be certain to confirm that the problem is The PCM then sends the proper message to the with the gauge and not with cooling system perfor-...
Page 377 INSTRUMENT PANEL SYSTEMS 8E - 11 DIAGNOSIS AND TESTING (Continued) performed with the DRB scan tool as described in the Diagnosis of the oil pressure gauge, the instrument proper Body Diagnostic Procedures manual. cluster circuitry, or the CCD data bus should be per- formed with the DRB scan tool as described in the ODOMETER AND TRIP ODOMETER proper Body Diagnostic Procedures manual.
Page 378: Airbag Indicator Lamp
8E - 12 INSTRUMENT PANEL SYSTEMS DIAGNOSIS AND TESTING (Continued) VOLTMETER bus, the seatbelt reminder lamp will flash for twelve seconds or the duration of the airbag system mal- If the problem being diagnosed is related to gauge function, whichever is longer. accuracy, be certain to confirm proper charging sys- If the airbag indicator lamp fails to light when the tem operation before considering gauge replacement.
Page 379: Brake Warning Lamp
INSTRUMENT PANEL SYSTEMS 8E - 13 DIAGNOSIS AND TESTING (Continued) the ABS warning lamp driver circuit cavity of the WARNING: ON VEHICLES EQUIPPED WITH AIR- cluster wire harness connector and a good ground. BAGS, REFER GROUP PASSIVE There should be no continuity. If OK, go to Step 6. If RESTRAINT SYSTEMS BEFORE...
Page 380: Cruise-On Indicator Lamp
8E - 14 INSTRUMENT PANEL SYSTEMS DIAGNOSIS AND TESTING (Continued) (3) Disconnect and isolate the battery negative GDM ILLUMINATION cable. Unplug the white 24-way Body Control Module The diagnosis found here addresses an inoperative (BCM) wire harness connector. Check for continuity illumination lamp condition.
Page 381: Headlamp High Beam Indicator Lamp
T/C POSITION 231 TRANSFER CASE (COM- MAND-TRAC) SWITCH POSI- TION SWITCH 100 WAY T/C POSITION POSI- TION T/C POSITION GROUND #1 249 TRANSFER CASE (QUADRA-TRAC) SWITCH POSITION TRANSFER CASE 2 WD 4 ALL TIME (SELEC-TRAC) 4 PART TIME 4 PART TIME 4 LO 4 FULL TIME 4 LO...
Page 382: Low Fuel Warning Lamp
8E - 16 INSTRUMENT PANEL SYSTEMS DIAGNOSIS AND TESTING (Continued) LOW FUEL WARNING LAMP If the malfunction indicator lamp fails to light dur- ing the bulb test (about three seconds after the igni- The diagnosis found here addresses an inoperative tion switch is turned to the On position), replace the low fuel warning lamp condition.
Page 383: Seat Belt Reminder Lamp
INSTRUMENT PANEL SYSTEMS 8E - 17 DIAGNOSIS AND TESTING (Continued) harness connector. If OK, refer to Group 8L - Lamps (1) Disconnect and isolate the battery negative for diagnosis of the headlamp switch and/or the cable. Remove the instrument cluster bezel and the proper Body Diagnostic Procedures manual for diag- cluster assembly as described in this group.
Page 384 8E - 18 INSTRUMENT PANEL SYSTEMS DIAGNOSIS AND TESTING (Continued) COOLANT LEVEL LOW/COOLANT SENSOR vehicle. The VIC module uses the VIN message received on the CCD data bus from the PCM to If the problem being diagnosed is related to lamp determine if the vehicle is equipped with two-wheel accuracy, be certain to confirm that the problem is drive or four-wheel drive.
Page 385 T/C POSITION 231 TRANSFER CASE (COM- MAND-TRAC) SWITCH POSI- TION SWITCH 100 WAY T/C POSITION POSI- TION T/C POSITION GROUND #1 249 TRANSFER CASE (QUADRA-TRAC) SWITCH POSITION TRANSFER CASE 2 WD 4 ALL TIME (SELEC-TRAC) 4 PART TIME 4 PART TIME 4 LO 4 FULL TIME 4 LO...
Page 386: Wait-To-Start Lamp
8E - 20 INSTRUMENT PANEL SYSTEMS DIAGNOSIS AND TESTING (Continued) TRANSFER CASE SHIFT LEVER POSITION VIC 4WD DIS- DRIVE SYSTEM 4 FULL PLAY CHARAC- 4 PART (TRANSFER CASE) /ALL NEUTRAL 4 LO TERISTICS TIME TIME 4WD QUADRA-TRAC Nomenclature None None “LO”...
Page 387: Service Procedures
INSTRUMENT PANEL SYSTEMS 8E - 21 DIAGNOSIS AND TESTING (Continued) water accumulation in the fuel filter/water separator Module (PCM) should be performed with a DRB scan before attempting further diagnosis. Refer to Group tool as described in the proper Powertrain Diagnostic 14 - Fuel Systems for diagnosis and service of the Procedures manual.
Page 388 DEPRESS AND RELEASE THE “SET” BUTTON TO PLAYED CLOCK MODE SETTING, AND ADVANCE TO THE NEXT VIC VIC DISPLAYS CURRENT LANGUAGE SETTING. AVAILABLE LANGUAGES ARE: ENGLISH, FRENCH, GERMAN, DEPRESS “SELECT” THROUGH THE AVAILABLE SRVICE INTERVALS SERVICE INTERVAL SETTING IS DIS- END OF VIC SET-UP PROCEDURE.
Page 389 REMINDER FEATURE AFTER RECOMMENDED PROCEED AS FOLLOWS. RESET BEEN PERFORMED, SERVICE SERVICE INSTRUMENT PANEL SYSTEMS 8E - 23 SERVICE PROCEDURES (Continued) VIC Reset...
Page 390: Removal And Installation
OUTBOARD SWITCH SCREW BEZEL KNEE BLOCKER SNAP CLIP LOCA- INBOARD POD BEZEL TIONS SWITCH 8E - 24 INSTRUMENT PANEL SYSTEMS CLUSTER BEZEL SCREWS REMOVAL AND INSTALLATION SWITCH POD BEZEL WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, REFER GROUP PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING...
Page 391 REAR HOUSING COVER CLUSTER CIRCUIT AND GAUGE HOUSING MASK HOOD TRIP ODOMETER RESET LENS KNOB INSTRUMENT PANEL SYSTEMS 8E - 25 REMOVAL AND INSTALLATION (Continued) INSTRUMENT CLUSTER BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. WARNING: ON VEHICLES EQUIPPED WITH AIR- (1) Remove the cluster bezel as described in this BAGS, REFER GROUP...
Page 392 GAUGE MOUNTING SCREWS GAUGE MOUNTING SCREWS 8E - 26 INSTRUMENT PANEL SYSTEMS REMOVAL AND INSTALLATION (Continued) GAUGE (1) Remove the instrument cluster as described in this group. (2) Remove the bulb and holder from the rear of WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, REFER GROUP...
Page 393 OUTBOARD MOUNTING SCREWS SWITCH TURN CLUSTER SIGNAL INDICATOR LAMPS ILLUMINATION INDICATOR LAMPS LAMPS INBOARD SWITCH POD MOUNT- ING SCREWS INSTRUMENT PANEL SYSTEMS 8E - 27 REMOVAL AND INSTALLATION (Continued) Fig. 8 Cluster Bulb Locations (2) Remove the inboard switch pod bezel as described in this group.
Page 394: Glove Box
INSTRUMENT PANEL ARMA- TURE OUTBOARD SWITCH BODY CONTROL MODULE MOUNTING DATA SCREWS LINK NECTOR CON- 8E - 28 INSTRUMENT PANEL SYSTEMS REMOVAL AND INSTALLATION (Continued) BODY CONTROL MODULE RESTRAINT SYSTEMS BEFORE ATTEMPTING STEERING WHEEL, STEERING COLUMN, WARNING: ON VEHICLES EQUIPPED WITH AIR- INSTRUMENT PANEL COMPONENT DIAGNOSIS OR BAGS, REFER...
Page 395 MOUNTING SCREWS LATCH STRIKER GLOVE MOUNTING TABS LAMP SWITCH GLOVE BOX MODULE GLOVE BOX MOD- INSTRUMENT PANEL SYSTEMS 8E - 29 REMOVAL AND INSTALLATION (Continued) (2) Remove the three screws that secure the Graphic Display Module (GDM) or Vehicle Informa- tion Center (VIC) to the instrument panel armature (Fig.
Page 396: Instrument Panel Center Bezel
KNOB PULL BASE OUT-THROUGH MENT ELE- LIGHT RING RETAINING BOSSES-ENGAGE PLI- EXTERNAL SNAP- RING PLIERS ERS HERE PARTIALLY REMOVED 8E - 30 INSTRUMENT PANEL SYSTEMS REMOVAL AND INSTALLATION (Continued) CIGAR LIGHTER POWER OUTLET WARNING: ON VEHICLES EQUIPPED WITH AIR- WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, REFER GROUP...
Page 397 RECEIVER SCREW MOUNTING HOLES SCREW C ENTER GLOVE BOX MODULE HOUSING MOUNTING HOLES DRILL OUT RIVETS BEZEL SCREWS UPPER POWER OUTLET CIGAR LIGHTER HINGE INNER DOOR HANDLE SCREW PANEL LATCH SCREWS BEZEL SCREWS INSTRUMENT PANEL SYSTEMS 8E - 31 REMOVAL AND INSTALLATION (Continued) (3) Remove the four screws that secure the glove box hinge to the instrument panel armature.
Page 398: Instrument Panel Top Pad
LOCK CYLINDER RETAINING LATCH LATCH HANDLE RELEASE SLOTLATCH HANDLE TUMBLER SCREW COWL TOP TRIM PANEL INSTRUMENT PANEL 8E - 32 INSTRUMENT PANEL SYSTEMS REMOVAL AND INSTALLATION (Continued) GLOVE BOX LATCH AND HANDLE COWL TOP TRIM PANEL (1) Remove the glove box as described in this group.
Page 399 JUNCTION RIGHT RELAYS BLOCK COWL TRIM SIDE SCREWS MOUNTING BOLT CIRCUIT BREAKER PUSH NUT FUSES INSTRUMENT PANEL SYSTEMS 8E - 33 REMOVAL AND INSTALLATION (Continued) (2) Remove both switch pod bezels, the cluster bezel, the knee blocker, the glove box module, and the cowl top trim panel.
Page 400 BOLT OUTBOARD STUDS SWITCH BEZEL BOLT SCREW BOLT U-NUT COWL TOP TRIM PANEL BOLT LOWER PANEL REINFORCEMENT KNEE BLOCKER INSTRUMENT SCREW RECEIVER BOLT INBOARD SWITCH BEZEL 8E - 34 INSTRUMENT PANEL SYSTEMS REMOVAL AND INSTALLATION (Continued) Fig. 24 Instrument Panel Assembly Remove/Install (3) Remove the knee blocker as described in this located under the passenger side end of the instru- group.
Page 401 INSTRUMENT PANEL SYSTEMS 8E - 35 REMOVAL AND INSTALLATION (Continued) (20) Remove the two bolts that secure the ends of (25) Reverse the removal procedures to install. the instrument panel armature to the cowl side pan- Tighten the mounting hardware as follows: •...
Page 403: Knee Blocker
INSTRUMENT PANEL SYSTEMS 8E - 1 INSTRUMENT PANEL SYSTEMS CONTENTS page page GENERAL INFORMATION INSTRUMENT CLUSTER ....10 BODY CONTROL MODULE ....4 LOW FUEL WARNING LAMP .
Page 404: General Information
8E - 2 INSTRUMENT PANEL SYSTEMS GENERAL INFORMATION INSTRUMENT PANEL Modular instrument panel construction allows all INTRODUCTION of the gauges and controls to be serviced from the This group is responsible for covering the vehicle front of the panel. In addition, most of the instru- instrument panel.
Page 405: Body Control Module
INSTRUMENT PANEL SYSTEMS 8E - 3 GENERAL INFORMATION (Continued) • Check gauges lamp • The current transfer case mode of operation • Cruise-on indicator lamp (four-wheel drive models). • Headlamp high beam indicator lamp The display language choices include: • Low fuel warning lamp •...
Page 406: Instrument Panel
8E - 4 INSTRUMENT PANEL SYSTEMS GENERAL INFORMATION (Continued) • Gulf coast country over-speed warning within the instrument cluster are served by the clus- • Door lock inhibit ter circuit board and wire harness connectors. Those • Electronic odometer and trip odometer lamps located in the GDM or VIC modules are served •...
Page 407: Description And Operation
INSTRUMENT PANEL SYSTEMS 8E - 5 DESCRIPTION AND OPERATION the internal electrical resistance of the sending unit. Refer to Group 14 - Fuel Systems for more informa- COOLANT TEMPERATURE GAUGE tion on the PCM and for the fuel gauge sending unit service procedures.
Page 408: Airbag Indicator Lamp
8E - 6 INSTRUMENT PANEL SYSTEMS DESCRIPTION AND OPERATION (Continued) received from the Powertrain Control Module (PCM) Control Module (PCM) on the Chrysler Collision on the Chrysler Collision Detection (CCD) data bus. Detection (CCD) data bus. The PCM uses an input from the engine oil pres- The PCM uses an input from the crankshaft posi- sure sensor and internal programming to decide tion sensor and internal programming to decide what...
Page 409: Anti-Lock Brake System Lamp
INSTRUMENT PANEL SYSTEMS 8E - 7 DESCRIPTION AND OPERATION (Continued) The airbag indicator lamp also has a lamp backup of the split brake hydraulic system, possibly due to feature. Following the seat belt reminder lamp dis- low brake fluid level or brake fluid leakage. The play function, if an inoperative airbag warning lamp parking brake switch closes to ground when the circuit was detected during the bulb test sequence,...
Page 410: Cruise-On Indicator Lamp
8E - 8 INSTRUMENT PANEL SYSTEMS DESCRIPTION AND OPERATION (Continued) Vehicles equipped with the automatic headlamps switch is turned to the On position as a bulb test. option have an automatic funeral mode or parade After the bulb test, the instrument cluster circuitry mode.
Page 411: Turn Signal Indicator Lamp
INSTRUMENT PANEL SYSTEMS 8E - 9 DESCRIPTION AND OPERATION (Continued) tion when the exterior lamps are lighted. The lamp is to the next highest gear for the best fuel economy. hard-wired in the instrument cluster, and is com- The lamp is turned on by the instrument cluster cir- pletely controlled by the panel lamps driver circuit.
Page 412: Diagnosis And Testing
8E - 10 INSTRUMENT PANEL SYSTEMS DESCRIPTION AND OPERATION (Continued) The PCM uses an input from the water-in-fuel sen- COOLANT TEMPERATURE GAUGE sor in the fuel filter/water separator to determine If the problem being diagnosed is related to gauge that excess water has accumulated in the diesel fuel. accuracy, be certain to confirm that the problem is The PCM then sends the proper message to the with the gauge and not with cooling system perfor-...
Page 413 INSTRUMENT PANEL SYSTEMS 8E - 11 DIAGNOSIS AND TESTING (Continued) ODOMETER AND TRIP ODOMETER SPEEDOMETER If the problem being diagnosed is related to gauge If the problem being diagnosed is related to gauge accuracy, be certain to confirm that the problem is accuracy, be certain to confirm that the problem is with the gauge and not with an incorrect speedome- with the gauge and not with an incorrect speedome-...
Page 414: Airbag Indicator Lamp
8E - 12 INSTRUMENT PANEL SYSTEMS DIAGNOSIS AND TESTING (Continued) WARNING: ON VEHICLES EQUIPPED WITH AIR- diagnosis of the lamp, the instrument cluster cir- BAGS, REFER TO GROUP 8M - PASSIVE RESTRAINT cuitry, the CCD data bus, and the Body Control Mod- ule (BCM) should be performed with a DRB scan tool SYSTEMS BEFORE ATTEMPTING STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COM-...
Page 415: Brake Warning Lamp
INSTRUMENT PANEL SYSTEMS 8E - 13 DIAGNOSIS AND TESTING (Continued) BRAKE WARNING LAMP the check gauges lamp still fails to operate, diagnosis of the lamp, the instrument cluster circuitry, the The diagnosis found here addresses an inoperative CCD data bus, and the Body Control Module (BCM) brake warning lamp condition.
Page 416: Graphic Display Module
8E - 14 INSTRUMENT PANEL SYSTEMS DIAGNOSIS AND TESTING (Continued) 8H - Vehicle Speed Control and/or to the proper Pow- If only individual illumination lamps are inopera- ertrain Diagnostic Procedures manual for diagnosis. tive, replace the faulty bulbs. If all of the illumina- For circuit descriptions and diagrams, refer to 8W-33 tion lamps are inoperative, proceed as follows.
Page 417: Headlamp High Beam Indicator Lamp
INSTRUMENT PANEL SYSTEMS 8E - 15 DIAGNOSIS AND TESTING (Continued) case wire harness connectors. Connect the battery with a known good unit. If the indicator lamp still negative cable and check the operation of the inoper- fails to operate, diagnosis of the lamp, the instru- ative lamp.
Page 418 8E - 16 INSTRUMENT PANEL SYSTEMS DIAGNOSIS AND TESTING (Continued) WARNING: ON VEHICLES EQUIPPED WITH AIR- brighten and dim when the panel lamp dimmer BAGS, REFER TO GROUP 8M - PASSIVE RESTRAINT switch adjusted. diagnosis found here addresses an inoperative master lighting indicator SYSTEMS BEFORE ATTEMPTING STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COM- lamp condition.
Page 419: Turn Signal Indicator Lamp
INSTRUMENT PANEL SYSTEMS 8E - 17 DIAGNOSIS AND TESTING (Continued) WARNING: ON VEHICLES EQUIPPED WITH AIR- and diagrams, refer to 8W-40 - Instrument Cluster in BAGS, REFER TO GROUP 8M - PASSIVE RESTRAINT Group 8W - Wiring Diagrams. SYSTEMS BEFORE ATTEMPTING STEERING WHEEL, WARNING: ON VEHICLES EQUIPPED WITH AIR- STEERING COLUMN, OR INSTRUMENT PANEL COM- BAGS, REFER TO GROUP 8M - PASSIVE RESTRAINT...
Page 420 8E - 18 INSTRUMENT PANEL SYSTEMS DIAGNOSIS AND TESTING (Continued) (1) Unplug the coolant level sensor wire harness WARNING: ON VEHICLES EQUIPPED WITH AIR- connector on the coolant reserve bottle. Check for BAGS, REFER TO GROUP 8M - PASSIVE RESTRAINT continuity between the ground circuit cavity of the SYSTEMS BEFORE ATTEMPTING STEERING WHEEL, wire harness connector and a good ground.
Page 421 INSTRUMENT PANEL SYSTEMS 8E - 19 DIAGNOSIS AND TESTING (Continued) Fig. 2 Transfer Case Switch programming, and inputs from the combination WASHER LEVEL LOW/WASHER SENSOR BAD flasher on the fused ignition switch output (L5) cir- If the problem being diagnosed is related to lamp cuit, and a vehicle speed sensor (distance) message accuracy, be certain to confirm that the problem is received on the CCD data bus from the Powertrain...
Page 422: Wait-To-Start Lamp
8E - 20 INSTRUMENT PANEL SYSTEMS DIAGNOSIS AND TESTING (Continued) WARNING: ON VEHICLES EQUIPPED WITH AIR- still fails to operate, diagnosis of the lamp, the BAGS, REFER TO GROUP 8M - PASSIVE RESTRAINT instrument cluster circuitry, or the CCD data bus should be performed with a DRB scan tool as SYSTEMS BEFORE ATTEMPTING STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COM-...
Page 423 INSTRUMENT PANEL SYSTEMS 8E - 21 SERVICE PROCEDURES (Continued) VIC Initial Set-Up...
Page 424 8E - 22 INSTRUMENT PANEL SYSTEMS SERVICE PROCEDURES (Continued) VIC Reset...
Page 425: Removal And Installation
INSTRUMENT PANEL SYSTEMS 8E - 23 REMOVAL AND INSTALLATION SWITCH POD BEZEL WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, REFER TO GROUP 8M - PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COM- PONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSI- BLE PERSONAL INJURY.
Page 426: Gauge
8E - 24 INSTRUMENT PANEL SYSTEMS REMOVAL AND INSTALLATION (Continued) INSTRUMENT CLUSTER (2) Remove the instrument cluster as described in this group. WARNING: ON VEHICLES EQUIPPED WITH AIR- (3) Remove the trip odometer reset knob by pulling BAGS, REFER TO GROUP 8M - PASSIVE RESTRAINT it off of the switch stem (Fig.
Page 427 INSTRUMENT PANEL SYSTEMS 8E - 25 REMOVAL AND INSTALLATION (Continued) Fig. 7 Gauge Mounting Screws Fig. 8 Cluster Bulb Locations (3) Remove the gauge(s) from the front of the clus- PONENT DIAGNOSIS OR SERVICE. FAILURE TO ter circuit and gauge housing. TAKE THE PROPER PRECAUTIONS COULD RESULT (4) Reverse the removal procedures to install.
Page 428 8E - 26 INSTRUMENT PANEL SYSTEMS REMOVAL AND INSTALLATION (Continued) (3) Unplug the bulb from the holder. (1) Disconnect and isolate the battery negative cable. CAUTION: Always use the correct bulb size and type (2) Remove the inboard switch pod bezel as for replacement.
Page 429 INSTRUMENT PANEL SYSTEMS 8E - 27 REMOVAL AND INSTALLATION (Continued) the upper edge of the glove box module to the instru- ment panel armature. (9) Lower the glove box module far enough to unplug the wire harness connectors from the glove box lamp and switch, the cigar lighter and lamp, and the power outlet.
Page 430: Glove Box Lamp And Switch
8E - 28 INSTRUMENT PANEL SYSTEMS REMOVAL AND INSTALLATION (Continued) GLOVE BOX LAMP AND SWITCH WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, REFER TO GROUP 8M - PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COM- PONENT DIAGNOSIS OR SERVICE.
Page 431: Power Outlet
INSTRUMENT PANEL SYSTEMS 8E - 29 REMOVAL AND INSTALLATION (Continued) the door gently until the pivot pin on the opposite side of the door snaps into the other pivot receptacle. INSTRUMENT PANEL CENTER BEZEL WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, REFER TO GROUP 8M - PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COM-...
Page 432 8E - 30 INSTRUMENT PANEL SYSTEMS REMOVAL AND INSTALLATION (Continued) (1) Disconnect and isolate the battery negative (4) Reverse the removal procedures to install. cable. GLOVE BOX HINGE (2) Drill out the two rivets that secure the glove (1) Remove the glove box as described in this box hinge to the lower edge of the glove box module group.
Page 433 INSTRUMENT PANEL SYSTEMS 8E - 31 REMOVAL AND INSTALLATION (Continued) (3) Insert a small screwdriver into the retaining (3) Pull the panel up far enough to unplug the tumbler release slot and depress the retaining tum- wire harness connector for the solar sensor, or to bler (Fig.
Page 434 8E - 32 INSTRUMENT PANEL SYSTEMS REMOVAL AND INSTALLATION (Continued) (3) Remove the push nut that secures the right cowl side trim panel to the junction block stud (Fig. 22). Fig. 23 Junction Block Remove/Install (3) Remove the knee blocker as described in this group.
Page 435 INSTRUMENT PANEL SYSTEMS 8E - 33 REMOVAL AND INSTALLATION (Continued) Fig. 24 Instrument Panel Assembly Remove/Install (14) Unplug all of the instrument panel wire har- (21) Remove the cowl top trim panel as described ness connectors from the junction block on the right in this group.
Page 437: Audio Systems
AUDIO SYSTEMS 8F - 1 AUDIO SYSTEMS CONTENTS page page GENERAL INFORMATION AUDIO SYSTEM ......4 INTRODUCTION .
Page 438: Description And Operation
8F - 2 AUDIO SYSTEMS DESCRIPTION AND OPERATION izer (RBN sales code) with CD changer control feature, or the AM/FM/CD/cassette/3-band graphic RADIO equalizer (RAZ sales code) radio receivers. Two rock- er-type switches are mounted on the back (instru- Factory-installed receiver availability this ment panel side) of the steering wheel spokes.
Page 439: Ignition-Off Draw Fuse
AUDIO SYSTEMS 8F - 3 DESCRIPTION AND OPERATION (Continued) IGNITION-OFF DRAW FUSE ANTENNA All vehicles are equipped with an Ignition-Off Antenna availability is affected by the country for Draw (IOD) fuse that is removed when the vehicle is which the vehicle is manufactured. All models built shipped from the factory.
Page 440: Diagnosis And Testing
8F - 4 AUDIO SYSTEMS DESCRIPTION AND OPERATION (Continued) • Power connections should be made directly to rent and ground to the proper brushes of the revers- ible power antenna motor when the ignition switch the battery, and fused as closely to the battery as and radio switch are turned to the On or Off posi- possible.
Page 441 AUDIO SYSTEMS 8F - 5 DIAGNOSIS AND TESTING (Continued) Audio System Diagnosis CONDITION POSSIBLE CAUSE CORRECTION NO AUDIO. 1. Fuse faulty. 1. Check radio fuses in fuseblock 2. Radio connector faulty. module. Replace fuses, if required. 3. Wiring faulty. 2. Check for loose or corroded radio 4.
Page 442 8F - 6 AUDIO SYSTEMS DIAGNOSIS AND TESTING (Continued) RADIO (5) Connect the battery negative cable. Turn the ignition switch to the On position. Check for battery If the vehicle is equipped with remote radio voltage at the fused ignition switch output circuit switches located on the backs of the steering wheel cavity of the left (gray) radio wire harness connector.
Page 443 AUDIO SYSTEMS 8F - 7 DIAGNOSIS AND TESTING (Continued) OK, go to Step 7. If not OK, repair the short circuit (speaker resistance). If OK, go to Step 4. If not OK, as required. go to Step 5. (7) Check for continuity between the radio control (4) Install a known good radio.
Page 444 8F - 8 AUDIO SYSTEMS DIAGNOSIS AND TESTING (Continued) wire harness connectors for continuity to ground. In each case there should be no continuity. If OK, go to Step 13. If not OK, repair the short circuit as required. (13) For each inoperative speaker location, check the resistance between the amplified feed (+) circuit and the amplified return (-) circuit cavities of the amplifier wire harness connectors.
Page 445 AUDIO SYSTEMS 8F - 9 DIAGNOSIS AND TESTING (Continued) (3) If the resistance is more than one ohm, check jumper to the power antenna driver circuit cavity the braided ground strap connected to the engine and of the power antenna motor wire harness connec- the vehicle body for being loose, corroded, or dam- tor.
Page 446: Radio Frequency Interference
CLUSTER BEZEL SCREWS 8F - 10 AUDIO SYSTEMS DIAGNOSIS AND TESTING (Continued) RADIO FREQUENCY INTERFERENCE (4) The radio is now ready for normal operation. The security code must be reentered any time the radio or vehicle is disconnected from battery feed. WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, REFER...
Page 447 MOUNTING SCREWS CCD DATA BUS CONNEC- GRAY 7–WAY CONNECTOR RADIO MOUNTING SCREWS SPEED SWITCHES CONTROL DRIVER’S AIRBAG MODULE AIRBAG WIRE SCREWS HORN SWITCH WIRE AUDIO SYSTEMS 8F - 11 REMOVAL AND INSTALLATION (Continued) Fig. 3 Radio Remove/Install Fig. 5 Driver Airbag Module Remove/Install switch wire harness connectors from the back of the airbag module.
Page 448: Speaker
SPEED SWITCHES CONTROL MOUNTING SCREWS REMOTE RADIO SWITCHES CONNECTORS RETAINING SCREWS MOUNTING SCREWS COWL TOP TRIM PANEL INSTRUMENT PANEL RADIO AMPLIFIER 8F - 12 AUDIO SYSTEMS REMOVAL AND INSTALLATION (Continued) INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRE- CAUTIONS COULD RESULT IN ACCIDENTAL AIR- BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
Page 449 U-NUT FRONT DOOR U-NUT POWER LOCK COURTESY KEY CYLINDER SWITCH CONNECTOR MOTOR CONNECTOR LAMP SCREW POWER DOW MOTOR WIN- SPEAKER POWER LOCK/WINDOW SWITCH POWER MIRROR SWITCH CON- REAR DOOR U-NUT TRIM PANEL PLUG CONNECTOR PLASTIC NUT POWER CONNEC- NECTOR BEZEL MIR- AUDIO SYSTEMS 8F - 13...
Page 450 WOOFER POWER WINDOW CONNECTOR MOTOR TWEETER POWER WINDOW MOTOR POWER WINDOW SWITCH CONNECTOR PLASTIC NUT POWER LOCK MOTOR SPEAKER SCREW RETAINER 8F - 14 AUDIO SYSTEMS REMOVAL AND INSTALLATION (Continued) (4) Remove the trim cap and screw near the rear (3) From the inside of the sound bar, use a pair of of the door armrest.
Page 451 SCREW ADAPTER SOUND BAR CAP NUT TWEETER TOOL ANTENNA MAST ANTENNA ADAPTER CAP NUT AUDIO SYSTEMS 8F - 15 REMOVAL AND INSTALLATION (Continued) Fig. 16 Sound Bar Remove/Install Fig. 17 Fixed Antenna Mast Remove/Install- Typical (3) Remove the five screws that secure the sound bar to the upper liftgate opening reinforcement.
Page 452 ANTENNA LEAD CAPNUT JUNCTION RIGHT BLOCK COWL TRIM SIDE MAST SCREWS PUSH NUT ANTENNA LEAD ANTENNA LEAD ESCUTCHEON CAPNUT POWER ANTENNA BOLT (2) 8F - 16 AUDIO SYSTEMS REMOVAL AND INSTALLATION (Continued) Fig. 19 Fixed Antenna Body and Cable Remove/ Fig.
Page 453 AUDIO SYSTEMS 8F - 17 REMOVAL AND INSTALLATION (Continued) (10) Pull the antenna wire harness and coaxial cable out through the right cowl side outer panel and remove the power antenna unit from the vehicle. (11) Reverse the removal procedures to install. Tighten the hardware as follows: •...
Page 455: Horn Systems
HORN SYSTEMS 8G - 1 HORN SYSTEMS CONTENTS page page GENERAL INFORMATION HORN SWITCH ......3 INTRODUCTION .
Page 456 NUMBER TERMINAL LEGEND COMMON FEED IDENTIFICATION COIL GROUND COIL BATTERY NORMALLY OPEN NORMALLY CLOSED 8G - 2 HORN SYSTEMS DESCRIPTION AND OPERATION (Continued) BODY CONTROL MODULE the PDC label for horn relay identification and loca- tion. A Body Control Module (BCM) is used on this Remove the horn relay from the PDC as described model to control and integrate many of the electronic in this group to perform the following tests:...
Page 457 POWER DISTRIBUTION CEN- NEGATIVE CABLE HORN SYSTEMS 8G - 3 DIAGNOSIS AND TESTING (Continued) (5) The coil ground terminal (85) is connected to (5) Depress the center of the airbag module cover the electromagnet in the relay. It is grounded and check for continuity between the horn switch through the horn switch when the horn switch is feed wire and the horn switch ground wire on the...
Page 458 8G - 4 HORN SYSTEMS REMOVAL AND INSTALLATION (Continued) (8) Test the relay operation. HORN SWITCH WARNING: ON VEHICLES EQUIPPED WITH DRIVER SIDE AIRBAG, THE HORN SWITCH IS INTE- GRAL TO THE AIRBAG MODULE TRIM COVER. SERVICE OF THIS COMPONENT SHOULD BE PER- FORMED ONLY CHRYSLER-TRAINED...
Page 459: Vehicle Speed Control System
VEHICLE SPEED CONTROL SYSTEM 8H - 1 VEHICLE SPEED CONTROL SYSTEM CONTENTS page page GENERAL INFORMATION SPEED CONTROL ELECTRICAL TEST ..5 INTRODUCTION ......1 SPEED CONTROL SERVO .
Page 460: General Information
8H - 2 VEHICLE SPEED CONTROL SYSTEM DESCRIPTION AND OPERATION (Continued) SERVO CABLE be corrected before proceeding. Refer to Group 8E, Instrument Panel and Gauges for speedometer diag- The speed control servo cable is connected between nosis. the speed control vacuum servo diaphragm and the If a road test verifies a system problem and the throttle body control linkage.
Page 461 VEHICLE SPEED CONTROL SYSTEM 8H - 3 DIAGNOSIS AND TESTING (Continued) • a two-digit number flashed on the Malfunction (2) Count the number of times the MIL (check Indicator (Check Engine) Lamp engine lamp) on the instrument panel flashes on and •...
Page 462 8H - 4 VEHICLE SPEED CONTROL SYSTEM DIAGNOSIS AND TESTING (Continued) SPEED CONTROL SYSTEM DIAGNOSTIC TROUBLE CODE DESCRIPTIONS GENERIC SCAN DESCRIPTION OF DIAGNOSTIC TROUBLE DRB SCAN TOOL DISPLAY CODE TOOL CODE CODE CODE Battery Disconnect Direct battery input to PCM was disconnected within the last 50 Key-on cycles.
Page 463 SWITCH VEHICLE SPEED CONTROL SYSTEM 8H - 5 DIAGNOSIS AND TESTING (Continued) SPEED CONTROL ELECTRICAL TEST (3) Check continuity of each individual speed con- trol switch module as shown in chart (Fig. 1). If OK, Two different test methods may be used to check reinstall switch.
Page 464: Overshoot/Undershoot On Speed Control Set
PIN 3 SERVO MOUNTING NUTS (2) PIN 2 SERVO CABLE PIN 1 8H - 6 VEHICLE SPEED CONTROL SYSTEM DIAGNOSIS AND TESTING (Continued) The engine must be started and running for the following voltage tests. (1) Start engine. (2) Disconnect 4–way electrical connector at servo (Fig.
Page 465: Servo Cable
SERVO MOUNTING NUTS (2) SERVO CABLE MOUNTINGSCREW SPEED CONTROL SWITCHES VEHICLE SPEED CONTROL SYSTEM 8H - 7 REMOVAL AND INSTALLATION (Continued) (7) Remove clip attaching cable to servo. (8) Remove servo from mounting bracket. Fig. 4 Speed Control Servo Fig. 5 Speed Control Switches INSTALLATION INSTALLATION (1) Position servo to mounting bracket.
Page 466: Vacuum Reservoir
VEHICLE SPEED CONTROL CABLE BELLCRANK CABLE PUSH SPEED CONTROL CONNEC- CABLE RESERVOIR ATTACHING SCREW BATTERY TRAY VACUUM RESERVOIR VACUUM HOSE PUSH 8H - 8 VEHICLE SPEED CONTROL SYSTEM REMOVAL AND INSTALLATION (Continued) POWERTRAIN CONTROL MODULE For Removal/Installation refer to Powertrain Con- trol Module in Group 14, Fuel Injection System.
Page 467: Specifications
VEHICLE SPEED CONTROL SYSTEM 8H - 9 SPECIFICATIONS TORQUE CHART Description Torque Servo Mounting Bracket-to-Servo Nuts ....8.5 N·m (75 in. lbs.) Servo Mounting Bracket-to-Body Nuts .
Page 469 VEHICLE SPEED CONTROL SYSTEM 8H - 1 VEHICLE SPEED CONTROL SYSTEM CONTENTS page GENERAL INFORMATION INTRODUCTION ......1 •...
Page 471: Turn Signal And Hazard Warning Systems
TURN SIGNAL AND HAZARD WARNING SYSTEMS 8J - 1 TURN SIGNAL AND HAZARD WARNING SYSTEMS CONTENTS page page GENERAL INFORMATION VEHICLE INFORMATION CENTER ..2 INTRODUCTION ......1 DIAGNOSIS AND TESTING DESCRIPTION AND OPERATION INTRODUCTION...
Page 472 WINDSHIELD WASHER BUT- WINDSHIELD WIPER CON- TROL CONTROL STALK H AZARD WARNING BUTTON MULTI-FUNCTION SWITCH 8J - 2 TURN SIGNAL AND HAZARD WARNING SYSTEMS DESCRIPTION AND OPERATION (Continued) If supplemental lighting is added to the turn signal lamp circuits, such as when towing a trailer with lights, the combination flasher will automatically compensate.
Page 473 TURN SIGNAL AND HAZARD WARNING SYSTEMS 8J - 3 DIAGNOSIS AND TESTING (Continued) WARNING: ON VEHICLES EQUIPPED WITH AIR- output circuit cavity for the combination flasher in BAGS, REFER GROUP PASSIVE the junction block. If OK, go to Step 6. If not OK, repair the open circuit to the turn signal fuse as RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING...
Page 474 JUNCTION RIGHT BLOCK COWL TRIM SIDE SCREWS PUSH NUT VIEW FROM TERMINAL CASE 8J - 4 TURN SIGNAL AND HAZARD WARNING SYSTEMS Fig. 2 Multi-Function Switch Continuity REMOVAL AND INSTALLATION COMBINATION FLASHER WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, REFER GROUP PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY...
Page 475 OUTBOARD SWITCH SCREW BEZEL KNEE BLOCKER SNAP CLIP LOCA- INBOARD POD BEZEL TIONS SWITCH PANEL BRACKET LOWER SHROUD STEERING COL- UMN ASSY. STEERING WHEEL TILT LEVER MULTI-FUNCTION SWITCH CONNEC- CLOCK SPRING UPPER S HROUD TURN SIGNAL SWITCH AND SPACER LEVER TURN SIGNAL AND HAZARD WARNING SYSTEMS 8J - 5 REMOVAL AND INSTALLATION (Continued)
Page 476 8J - 6 TURN SIGNAL AND HAZARD WARNING SYSTEMS REMOVAL AND INSTALLATION (Continued) • Multi-function switch wire harness connector (14) Gently pull the switch away from the column. Loosen the wire harness connector screw. The screw screw - 2 N·m (17 in. lbs.) •...
Page 477: Wiper And Washer Systems
WIPER AND WASHER SYSTEMS 8K - 1 WIPER AND WASHER SYSTEMS CONTENTS page page GENERAL INFORMATION WIPER SWITCH AND WASHER SWITCH ..3 INTRODUCTION ......1 DIAGNOSIS AND TESTING DESCRIPTION AND OPERATION INTERMITTENT WIPE RELAY .
Page 478: Description And Operation
8K - 2 WIPER AND WASHER SYSTEMS DESCRIPTION AND OPERATION (Continued) The washers will operate only when the ignition arms, and windshield or rear glass should be cleaned switch is in the Accessory or On positions. A circuit with a sponge or cloth and windshield washer fluid, a breaker located in the junction block protects the cir- mild detergent, or a non-abrasive cleaner.
Page 479: Body Control Module
WINDSHIELD WASHER BUT- WINDSHIELD WIPER CON- TROL CONTROL STALK H AZARD WARNING BUTTON MULTI-FUNCTION SWITCH WIPER AND WASHER SYSTEMS 8K - 3 DESCRIPTION AND OPERATION (Continued) where a nut secures the wiper motor crank arm to other switch functions, refer to the proper group. the motor output shaft.
Page 480: Intermittent Wipe Relay
8K - 4 WIPER AND WASHER SYSTEMS DESCRIPTION AND OPERATION (Continued) modes. On models with the optional automatic head- Each washer pump and motor unit has a threaded lamps, the BCM can be programmed to automatically nipple, which is installed through a rubber grommet turn on the headlamps when the windshield wipers seal inserted in a hole near the bottom of the reser- are turned on.
Page 481 WIPER AND WASHER SYSTEMS 8K - 5 DESCRIPTION AND OPERATION (Continued) nozzle snaps into a hole in the liftgate outer panel, (5) Turn the ignition switch to the Off position. above the liftgate glass. Disconnect and isolate the battery negative cable. The washer nozzle is not adjustable.
Page 482: Washer System
8K - 6 WIPER AND WASHER SYSTEMS DIAGNOSIS AND TESTING (Continued) (d) Check for battery voltage at the wiper park voltage at the rear wiper motor control circuit cavity switch sense circuit cavity of the wiper motor wire of the rear wiper motor wire harness connector. harness connector with the wiper switch in the Repeat the test for the rear wiper motor control Low or High position, then move the switch to the...
Page 483: Wiper Switch And Washer Switch
WIPER AND WASHER SYSTEMS 8K - 7 DIAGNOSIS AND TESTING (Continued) zero ohms. If OK, go to Step 4. If not OK, repair the washer switch. Measure the voltage at the rear ground circuit as required. washer motor control circuit cavity of the rear (4) Connect the battery negative cable.
Page 484 MULTIFUNCTION SWITCH PINS NUMBER TERMINAL LEGEND COMMON FEED IDENTIFICATION COIL GROUND COIL BATTERY NORMALLY OPEN NORMALLY CLOSED 8K - 8 WIPER AND WASHER SYSTEMS DIAGNOSIS AND TESTING (Continued) BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. RELAY TEST The intermittent wipe relay is located in the Power Distribution Center (PDC) in the engine compart- ment.
Page 485: Removal And Installation
RUBBER ELEMENT CHANNEL CLAW RELEASE TAB TO GRASP AND PULL VERTABRA WIPER AND WASHER SYSTEMS 8K - 9 DIAGNOSIS AND TESTING (Continued) (BCM) wire harness connector at all times. If OK, go Once the claws are released from the retaining to Step 3.
Page 486 ⁄ ⁄ ⁄ ⁄ LOCKING LATCH 8K - 10 WIPER AND WASHER SYSTEMS REMOVAL AND INSTALLATION (Continued) To remove the rear wiper blade and/or element, proceed as follows: (1) Lift the rear wiper arm to raise the wiper blade and element off of the liftgate glass. (2) Remove the wiper blade from the wiper arm, or the wiper element from the wiper blade as follows: (a) To remove the wiper blade from the wiper...
Page 487: Wiper Motor
WIPER ARM RETAINING NUT RAMP REAR WIPER BLADE INSTALLATION PARK POSITION PIVOT COVER POSI- TION FENDER WASHER HOSE BOLTS (5) WIPER LINKAGE WIPER BLADE SCREWS (6) COWL GRILLE WIPER ARM WIPER AND WASHER SYSTEMS 8K - 11 REMOVAL AND INSTALLATION (Continued) Fig.
Page 488 POWER DISTRIBUTION CEN- REAR WIPER BLADE BEZEL NEGATIVE CABLE NUT G ASKET SCREW MOTOR 8K - 12 WIPER AND WASHER SYSTEMS REMOVAL AND INSTALLATION (Continued) Fig. 10 Rear Wiper Motor Remove/Install (9) Reverse the removal procedures to install. Tighten the mounting hardware as follows: •...
Page 489: Wiper Switch And Washer Switch
OUTBOARD SWITCH SCREW BEZEL KNEE BLOCKER SNAP CLIP LOCA- INBOARD POD BEZEL TIONS SWITCH PANEL BRACKET LOWER SHROUD STEERING COL- UMN ASSY. STEERING WHEEL TILT LEVER MULTI-FUNCTION SWITCH CONNEC- CLOCK SPRING UPPER S HROUD TURN SIGNAL SWITCH AND SPACER LEVER WIPER AND WASHER SYSTEMS 8K - 13 REMOVAL AND INSTALLATION (Continued)
Page 490 INBOARD SWITCH POD MOUNT- ING SCREWS 8K - 14 WIPER AND WASHER SYSTEMS REMOVAL AND INSTALLATION (Continued) (15) Unplug the wire harness connector from the (5) Remove the inboard switch pod from the multi-function switch. instrument panel. (16) Reverse the removal procedures to install. (6) Reverse the removal procedures to install.
Page 491 LAMPS 8L - 1 LAMPS CONTENTS page page BULB APPLICATION ..... 19 LAMP DIAGNOSIS ..... . . 1 HEADLAMP ALIGNMENT .
Page 492 8L - 2 LAMPS DIAGNOSIS AND TESTING (Continued) HEADLAMP DIAGNOSIS HEADLAMP DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION HEADLAMPS ARE DIM 1. Loose or corroded battery cables. 1. Clean and secure battery cable clamps WITH ENGINE IDLING and posts. OR IGNITION TURNED 2.
Page 493 LAMPS 8L - 3 DIAGNOSIS AND TESTING (Continued) FOG LAMP DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION FOG LAMPS ARE DIM 1. Loose or corroded 1. Clean and secure battery cable clamps and posts. WITH ENGINE IDLING battery cables. OR IGNITION TURNED OFF.
Page 494 8L - 4 LAMPS DIAGNOSIS AND TESTING (Continued) DAYTIME RUNNING LAMP DIAGNOSIS DAYTIME RUNNING LAMP DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION DAYTIME RUNNING LAMPS DO 1. Poor connection at DRL module. 1. Secure connector on DRL NOT WORK 2. Parking brake engaged. module.
Page 495 REPLACE ALL FAULTY OR INCORRECT BULBS. REFER BULB APPLICATION CHART. LAMP RESET IGNITION SWITCH ON-OFF- FAILURE DISPLAYED ON VIC? MESSAGE CYCLING DONE ARE THE TAIL/STOP AND CHMSL DO TAIL/STOP AND CHMSL LAMPS BULBS? REFER TO BULB APPLICATION CHART. HAVE LAMPS CORRECT TIONAL? FUNC-...
Page 496 8L - 6 LAMPS DIAGNOSIS AND TESTING (Continued) NOTE: The Lamp Outage Module contains an inter- (VIC). The circuit breaker will reset once the vehicle nal circuit breaker. When the module senses an is turned off for approximately 60 seconds. Contin- overload it will trip the circuit breaker and illumi- uous tripping of the circuit breaker may indicate a nate a failure in the Vehicle Information Center...
Page 497: Headlamp Alignment
VEHICLE CENTERLINE CENTER OF VEHICLE TO CENTER OF LEFT EDGE OF HIGH INTENSITY ZONE HEADLAMP LENS FRONT OF HEADLAMP TOP EDGE OF HIGH INTENSITY ZONE 7.62 METERS (25 FEET) FLOOR HEADLAMP LENS CENTER LAMPS 8L - 7 HEADLAMP ALIGNMENT INDEX page page GENERAL INFORMATION...
Page 498 8L - 8 LAMPS SERVICE PROCEDURES (Continued) (6) Fuel tank should be FULL. Add 2.94 kg (6.5 mm (2 in.) above to 50 mm (2 in.) below headlamp lbs.) of weight over the fuel tank for each estimated centerline. The side-to-side left edge of high intensity gallon of missing fuel.
Page 499 VEHICLE ADJUSTMENT SCREW CENTERLINE FOG LAMP CENTER OF VEHICLE TO CENTER OF FOG LAMP LENS ACCESS COVER CLIP BULB SOCKET BRACKET FRONT OF FOG LAMP 7.62 METERS (25 FEET) HIGH-INTENSITY AREA FLOOR TO CENTER OF FOG LAMP LENS 100 mm (4 in.) LAMPS 8L - 9 SERVICE PROCEDURES (Continued)
Page 500 LOCKRING CONNECTOR BULB ASSEMBLY ADJUSTMENT SCREW FOG LAMP ACCESS COVER CLIP BULB SOCKET BRACKET 8L - 10 LAMPS LAMP BULB SERVICE INDEX page page REMOVAL AND INSTALLATION OVERHEAD CONSOLE READING LAMP BULB . . 12 CARGO LAMP BULB ....12 PARKING LAMP BULB .
Page 501 BACK-UP BULB SOCKET TAIL/STOP BULB SOCKET TAIL LAMP LAMPS 8L - 11 REMOVAL AND INSTALLATION (Continued) INSTALLATION CAUTION: Do not touch the bulb glass with fin- gers or other oily surfaces. Reduced bulb life will result. (1) Position bulb element in fog lamp. (2) Connect wire connectors at bulb.
Page 502 CONSOLE LENS FLAT BLADE 8L - 12 LAMPS REMOVAL AND INSTALLATION (Continued) INSTALLATION DOME LAMP BULB (1) Insert the replacement bulb in the lamp base socket. Rotate it clockwise. REMOVAL (2) Connect the wire harness connector to the (1) Insert a flat blade screwdriver in slot at front lamp.
Page 503 ADJUSTMENT SCREW FOG LAMP ACCESS COVER CLIP BULB SOCKET BRACKET LAMPS 8L - 13 LAMP SERVICE INDEX page page REMOVAL AND INSTALLATION LICENSE PLATE LAMP ....14 CARGO LAMP .
Page 504 MOUNTING SCREWS MOUNTING SCREW PARK LAMP MOUNTING SCREW SIDE MARKER TURN SIGNAL HEADLAMP MOUNTING TAB TURN SIGNAL BULB REMOVAL MOUNTING SLOT PARK LAMP MOUNTING TABS RIGHT REAR LAMP 8L - 14 LAMPS REMOVAL AND INSTALLATION (Continued) TAIL, STOP, TURN SIGNAL, BACK-UP AND SIDE MARKER LAMP The stop, turn signal, back-up and rear side marker lamps are incorporated into the tail lamp.
Page 505 CHMSL TRIM PANEL LIFTGATE HOOD LAMP ASSEMBLY HOOD BULB HOOD WIRING LAMP LAMPS 8L - 15 REMOVAL AND INSTALLATION (Continued) CENTER HIGH MOUNTED STOP LAMP (CHMSL) REMOVAL (1) Raise liftgate. (2) Remove upper liftgate trim panel. (3) Remove CHMSL lamp mounting screws (Fig. (4) Remove CHMSL lamp.
Page 506 DOME BRACKET LAMP DOME READING LAMP LENS 8L - 16 LAMPS REMOVAL AND INSTALLATION (Continued) CARGO LAMP REMOVAL (1) Insert a flat blade screwdriver in slots provided at lower portion of lens. (2) Rotate screwdriver upward until lens snaps out of housing.
Page 507 POWER DISTRIBUTION CENTER BRACKET DAYTIME RUNNING MODULE LAMP LAMPS 8L - 17 LAMP SYSTEMS INDEX page page GENERAL INFORMATION REMOVAL AND INSTALLATION AUTO HEADLAMP SENSOR ....17 AUTO HEADLAMP SENSOR .
Page 508 8L - 18 LAMPS REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Reverse the removal procedure. LAMP OUTAGE MODULE REMOVAL (1) Disconnect battery negative cable. (2) Remove spare tire from carrier. (3) Remove access door. (4) Remove screw holding module to inner quarter panel (Fig.
Page 509 LAMPS 8L - 19 BULB APPLICATION INDEX page page GENERAL INFORMATION INTERIOR LAMPS ..... . 19 GENERAL INFORMATION ....19 SPECIFICATIONS EXTERIOR LAMPS .
Page 511 LAMPS 8L - 1 LAMPS CONTENTS page page BULB APPLICATION ..... . 9 LAMP SERVICE ......6 LAMP BULB SERVICE .
Page 512 8L - 2 LAMPS SERVICE PROCEDURES INDEX page SERVICE PROCEDURES HEADLAMP ALIGNMENT ....2 (7) Fuel tank should be FULL. Add 2.94 kg (6.5 SERVICE PROCEDURES lbs.) of weight over the fuel tank for each estimated HEADLAMP ALIGNMENT...
Page 513 LAMPS 8L - 3 SERVICE PROCEDURES (Continued) (5) Jounce front suspension three times by pushing HEADLAMP ADJUSTMENT downward on front bumper and releasing. A properly aimed low beam headlamp will project (6) Measure the distance from the center of head- the top edge of high intensity pattern on screen from lamp lens to the floor.
Page 514 8L - 4 LAMPS LAMP BULB SERVICE INDEX page page REMOVAL AND INSTALLATION REAR FOG LAMP BULB ....5 HEADLAMP BULB ......4 SIDE REPEATER LAMP BULB .
Page 515 LAMPS 8L - 5 REMOVAL AND INSTALLATION (Continued) REAR FOG LAMP BULB REMOVAL (1) Remove the tail lamp. (2) Grasp the fog lamp bulb socket and rotate counterclockwise (Fig. 4). Separate socket from lamp. (3) Rotate bulb in the socket counterclockwise and remove bulb from socket.
Page 516 8L - 6 LAMPS LAMP SERVICE INDEX page page REMOVAL AND INSTALLATION REAR FOG LAMP ......6 HEADLAMP .
Page 517 LAMPS 8L - 7 REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Position the reflector on the rear bumper (Fig. (2) Install the nut attaching the reflector to the rear bumper. Fig. 3 Rear Bumper Reflector...
Page 518 8L - 8 LAMPS LAMP SYSTEMS INDEX page REMOVAL AND INSTALLATION HEADLAMP LEVELING MOTOR ... . . 8 REMOVAL AND INSTALLATION HEADLAMP LEVELING MOTOR REMOVAL (1) Remove headlamp. (2) Remove screws attaching leveling motor to grille opening reinforcement (GOR) (Fig.
Page 519 LAMPS 8L - 9 BULB APPLICATION INDEX page SPECIFICATIONS EXTERIOR LAMPS ..... . . 9 SPECIFICATIONS EXTERIOR LAMPS LAMP BULB Front Fog Lamp .
Page 521: Passive Restraint Systems
PASSIVE RESTRAINT SYSTEMS 8M - 1 PASSIVE RESTRAINT SYSTEMS CONTENTS page page GENERAL INFORMATION CLEANUP PROCEDURE ....4 INTRODUCTION ......1 REMOVAL AND INSTALLATION DESCRIPTION AND OPERATION AIRBAG CONTROL MODULE...
Page 522: General Information
8M - 2 PASSIVE RESTRAINT SYSTEMS GENERAL INFORMATION (Continued) WARNING: DESCRIPTION AND OPERATION • THE AIRBAG SYSTEM IS A SENSITIVE, COM- AIRBAG MODULE PLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIR- BAG SYSTEM OR RELATED STEERING WHEEL, DRIVER SIDE The airbag module protective trim cover is the STEERING COLUMN, OR INSTRUMENT PANEL...
Page 523: Airbag Control Module
PASSIVE RESTRAINT SYSTEMS 8M - 3 DESCRIPTION AND OPERATION (Continued) STORAGE AIRBAG CONTROL MODULE An airbag module must be stored in its original, The Airbag Control Module (ACM) contains the special container until used for service. Also, it must impact sensor, and a microprocessor that monitors be stored in a clean, dry environment;...
Page 524: Service Procedures
16–WAY DATA LINK CONNECTOR BOTTOM OF INSTRU- MENT PANEL 8M - 4 PASSIVE RESTRAINT SYSTEMS DIAGNOSIS AND TESTING (Continued) additional service procedures on the steering wheel and steering column. DEPLOYED Any vehicle which is to be returned to use after an airbag deployment, must have both airbag modules, the clockspring, the instrument panel top pad, and the passenger side airbag rear mounting bracket...
Page 525: Removal And Installation
DRIVER’S AIRBAG MODULE AIRBAG WIRE SCREWS HORN SWITCH WIRE PASSIVE RESTRAINT SYSTEMS 8M - 5 SERVICE PROCEDURES (Continued) vehicle and work your way inside, so that you avoid DRIVER SIDE kneeling or sitting on a non-cleaned area. (1) Disconnect and isolate the battery negative Be sure to vacuum the heater and air conditioning cable.
Page 526: Driver Side Airbag Trim Cover And Horn Switch
PASSENGER’S AIRBAG MODULE FRONT MOUNTING BRACKET MOUNTING SCREWS WIRING TROUGH REAR MOUNTING BRACKET 8M - 6 PASSIVE RESTRAINT SYSTEMS REMOVAL AND INSTALLATION (Continued) (2) Remove the instrument panel top pad. Refer to DRIVER SIDE AIRBAG TRIM COVER AND HORN Group 8E - Instrument Panel Systems for the proce- SWITCH dures.
Page 527: Passenger Side Airbag Rear Mounting Bracket
LOWER WIRE RETAINERS TRIM COVER RETAINER INFLATOR HORN SWITCH GROUNDWIRE STUDS HORN SWITCH FEED AIRBAG UPPER NUT (4) RETAINER HOUSING WIRE HORN SWITCH LOCKING BLOCK AIRBAG HOUSING LOCKING BLOCKS RETAINER SLOTS RETAINER SLOTS TRIM COVER HORN SWITCH TRIM COVER PASSIVE RESTRAINT SYSTEMS 8M - 7 REMOVAL AND INSTALLATION (Continued) Fig.
Page 528 PASSENGER SIDE END OF REAR MOUNTING BRACKET INSTRUMENT PANEL REAR BRACKET BOLTS REAR BRACKET BOLTS REAR CONTROL OPENING — MOUNTING BRACKET HEATER 8M - 8 PASSIVE RESTRAINT SYSTEMS REMOVAL AND INSTALLATION (Continued) (2) Remove the screws that secure the instrument ING TO DIAGNOSE OR SERVICE ANY AIRBAG panel wire harness trough to the airbag rear mount- SYSTEM OR RELATED STEERING WHEEL, STEER-...
Page 529 SQUEEZE LATCHES PULL TWO LOCKS OUT TRANSFER CASE SHIFTER CONSOLE SHIFTER INDICATOR BRACKET BEZEL TRANSFER CASE SHIFTER PARKING INDICATOR BRAKE BEZEL FULL PARKING BRAKE CONSOLE FLOOR AIRBAG CONTROL MODULE SCREWS (4) AIRBAG CONTROL MODULE PARKING BRAKE LEVER FLOOR PAN TRANSMIS- SION TUNNEL PASSIVE RESTRAINT SYSTEMS 8M - 9...
Page 530: Clockspring Centering
STEERING WHEEL CLOCK SPRING TILT LEVER SCREWS LOWER SHROUD UPPER SHROUD 8M - 10 PASSIVE RESTRAINT SYSTEMS REMOVAL AND INSTALLATION (Continued) (1) Turn the steering wheel until the front wheels Centering in this group before installing the steering are in the straight-ahead position before starting the wheel.
Page 531 PASSIVE RESTRAINT SYSTEMS 8M - 11 ADJUSTMENTS (Continued) (2) Disconnect and isolate the battery negative cable. If the airbag has not been deployed, wait two minutes for the system capacitor to discharge before further service. (3) Remove the airbag module as described in this group.
Page 533: Electrically Heated Systems
ELECTRICALLY HEATED SYSTEMS 8N - 1 ELECTRICALLY HEATED SYSTEMS CONTENTS page page DEFOGGER SYSTEM ..... 1 HEATED SEATS ......7 DEFOGGER SYSTEM INDEX page...
Page 534: General Information
8N - 2 ELECTRICALLY HEATED SYSTEMS GENERAL INFORMATION (Continued) NOTE: This group covers both Left-Hand Drive vides a hard-wired ground signal to the Body Control (LHD) and Right-Hand Drive (RHD) versions of this Module (BCM) each time it is depressed. The BCM rear window defogger timer and logic circuitry model.
Page 535: Diagnosis And Testing
TERMINAL “A” GROUND WIRE VOLTMETER HEATED REAR WINDOW DEFOGGER GRID MID-POINT (TYPICAL) “C” TERMINAL “B” FEED WIRE ELECTRICALLY HEATED SYSTEMS 8N - 3 DESCRIPTION AND OPERATION (Continued) by controlling the current feeds to their respective The above checks will confirm system operation. outside rear view mirror heating elements.
Page 536 8N - 4 ELECTRICALLY HEATED SYSTEMS DIAGNOSIS AND TESTING (Continued) not change. If OK, go to Step 4. If not OK, repair the (5) Unplug the white 24-way wire harness connec- circuit to ground as required. tor from the Body Control Module (BCM). Check for (4) Connect the negative lead of the voltmeter to continuity between the rear window defogger switch the right side bus bar and touch each grid line at...
Page 537: Service Procedures
RELAY CAVITIES RELAY TERMINALS MASKING TAPE BREAK GRID LINE ELECTRICALLY HEATED SYSTEMS 8N - 5 DIAGNOSIS AND TESTING (Continued) AREAS WITH SOAP AND WATER. FOR CONTACT WITH THE EYES, FLUSH WITH PLENTY OF WATER. DO NOT TAKE INTERNALLY. IF TAKEN INTER- NALLY, INDUCE VOMITING AND CALL A PHYSICIAN IMMEDIATELY.
Page 538: Removal And Installation
INBOARD SWITCH POD MOUNT- ING SCREWS JUNCTION RIGHT BLOCK COWL TRIM SIDE SCREWS PUSH NUT 8N - 6 ELECTRICALLY HEATED SYSTEMS SERVICE PROCEDURES (Continued) (9) Allow the epoxy to cure 24 hours at room tem- (7) Reverse the removal procedures to install. perature, or use a heat gun with a 260°...
Page 539: Heated Seats
ELECTRICALLY HEATED SYSTEMS 8N - 7 HEATED SEATS INDEX page page GENERAL INFORMATION HEATED SEAT ELEMENT ....9 INTRODUCTION ......7 HEATED SEAT SENSOR .
Page 540 8N - 8 ELECTRICALLY HEATED SYSTEMS DESCRIPTION AND OPERATION (Continued) switches and their LED cannot be repaired. If either Before testing the individual components in the switch or LED is faulty, the inboard switch pod unit heated seat system, check the following: •...
Page 541 ELECTRICALLY HEATED SYSTEMS 8N - 9 DIAGNOSIS AND TESTING (Continued) case, there should be no continuity. If OK, go to Step (3) Check for continuity between one of the heated 6. If not OK, replace the faulty inboard switch pod. seat driver circuit cavities of the seat cover half of (6) Move both heated seat switches to the Low the heated seat cushion wire harness connector and...
Page 542 INBOARD SWITCH POD MOUNT- ING SCREWS 8N - 10 ELECTRICALLY HEATED SYSTEMS SEAT CUSHION FRAME POWER ADJUSTER RECLINER HEATED MODULE SEAT MOUNTING CONTROL SCREW REMOVAL AND INSTALLATION (Continued) (1) Disconnect and isolate the battery negative (7) Gently pry the power recliner adjuster lower cable.
Page 543 POWER LOCK SYSTEMS 8P - 1 POWER LOCK SYSTEMS CONTENTS page page GENERAL INFORMATION DOOR MODULE ......4 INTRODUCTION .
Page 544: General Information
8P - 2 POWER LOCK SYSTEMS GENERAL INFORMATION (Continued) Refer to 8W-61 - Power Door Locks in Group 8W - sends messages to the radio (if the radio is CCD data Wiring Diagrams for circuit descriptions and dia- bus capable), the PDM, and the Memory Seat Module grams.
Page 545: Body Control Module
POWER LOCK SYSTEMS 8P - 3 DESCRIPTION AND OPERATION (Continued) Some of the features and functions of the power One of the functions and features that the BCM lock and Remote Keyless Entry (RKE) systems made supports and controls on models so equipped, is the possible because of the communication of the door Remote Keyless Entry (RKE) Panic Mode.
Page 546: Remote Keyless Entry Receiver
8P - 4 POWER LOCK SYSTEMS DESCRIPTION AND OPERATION (Continued) • If the system fails to function with either the the RKE system. In addition, vehicles with the optional memory system must have their access switches or the transmitter, see the Circuit Breaker codes programmed in the RKE receiver so that the diagnosis in this group.
Page 547: Power Lock Motor
POWER LOCK SYSTEMS 8P - 5 DIAGNOSIS AND TESTING (Continued) between the ground circuit cavity of the door module repair the short or open circuits to the door module wire harness connector and a good ground. There as required. If not OK, replace the faulty lock motor. should be continuity.
Page 548: Service Procedures
U-NUT FRONT DOOR U-NUT MEMORY SWITCH POWER MOUNTING SCREWS CONNECTOR CONNECTOR MIRROR DOOR MODULE 12–WAY CON- NECTOR 8P - 6 POWER LOCK SYSTEMS DIAGNOSIS AND TESTING (Continued) be continuity. If OK, go to Step 7. If not OK, replace the faulty push button switch. (7) Unplug the liftglass release solenoid wire har- ness connector.
Page 549: Power Lock Motor
OUTSIDE LOCK LATCH ROD LOCK SOLE- LATCH NOID HAN- LATCH ACCESS HOLE INSIDE LOCK ROD INSIDE RELEASE LATCH ROD DOOR REAR DOOR U-NUT TRIM PANEL PLUG BEZEL LATCH MOUNTING BOLTS POWER LOCK SYSTEMS 8P - 7 REMOVAL AND INSTALLATION (Continued) NOTE: If a new door module is installed, the pro- (6) Remove the power lock motor and latch assem- grammable features must be enabled and/or dis-...
Page 550 LOWER TRIM PANEL LATCH SCREWS UPPER PANEL TRIM LIFTGATE LATCH ADJUST- MENT SCREW 8P - 8 POWER LOCK SYSTEMS REMOVAL AND INSTALLATION (Continued) LOCK LINKAGE CLIP LIFTGATE DISARM ACTUATOR SWITCH LIFTGATE LOCK ROD NOTE: To aid in the removal of the trim panel, start at the bottom of the panel.
Page 551 VEHICLE THEFT/SECURITY SYSTEMS 8Q - 1 VEHICLE THEFT/SECURITY SYSTEMS CONTENTS page page GENERAL INFORMATION PARK LAMP RELAY ..... . 4 ARMING .
Page 552: General Information
8Q - 2 VEHICLE THEFT/SECURITY SYSTEMS GENERAL INFORMATION (Continued) item on the DRB scan tool for the procedures. Once complete until all the doors and the liftgate are this condition has been met, the PCM will allow the closed. engine no-run feature to arm. Following successful passive or active VTSS arm- Once the VTSS engine no-run feature has been ing, the VTSS set lamp on the top of the instrument...
Page 553: Power-Up Mode
VEHICLE THEFT/SECURITY SYSTEMS 8Q - 3 GENERAL INFORMATION (Continued) VEHICLE IMMOBILIZER SYSTEM feature alerts the driver that the VTSS was activated Active disarming of the vehicle immobilizer system while the vehicle was unattended. occurs when the Unlock button of either of the two Remote Keyless Entry...
Page 554: Auto Headlamp Relay
8Q - 4 VEHICLE THEFT/SECURITY SYSTEMS DESCRIPTION AND OPERATION (Continued) DOOR AJAR SWITCH the relay coil. See the Diagnosis and Testing section of this group for more information on the operation of The door ajar switches are mounted to the pillar in the auto headlamp relay.
Page 555: Set Lamp
NUMBER TERMINAL LEGEND COMMON FEED IDENTIFICATION COIL GROUND COIL BATTERY NORMALLY OPEN NORMALLY CLOSED VEHICLE THEFT/SECURITY SYSTEMS 8Q - 5 DESCRIPTION AND OPERATION (Continued) SET LAMP WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, REFER GROUP PASSIVE The set lamp is a red light-emitting diode mounted RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY with the auto headlamp ambient light sensor on top STEERING...
Page 556: Door Lock Cylinder Switch
REAR DOOR SWITCH AJAR SCREW FRONT DOOR AJAR SWITCH SCREW OUTSIDE DOOR HAN- LINKAGE CLIP LOCK CYLINDER U-CLIP 8Q - 6 VEHICLE THEFT/SECURITY SYSTEMS REMOVAL AND INSTALLATION (Continued) NOTE: To aid in the removal of the trim panel, start at the bottom of the panel. (7) Unplug the wire harness connectors from the door module and set the trim panel aside.
Page 557: Liftgate Lock Cylinder Switch
LOCK CYLIN- LOWER TRIM PANEL UPPER PANEL TRIM LIFTGATE DOOR ARM SWITCH DIS- LOWER TRIM PANEL UPPER LOCK RETAIN- ING CLIP LOCK PANEL TRIM HANDLE LIFTGATE LATCH POWER ACTUATOR LOCK HANDLE LATCH HANDLE LOCK ROD VEHICLE THEFT/SECURITY SYSTEMS 8Q - 7 REMOVAL AND INSTALLATION (Continued) Fig.
Page 558 LOWER TRIM PANEL LOCK UPPER LINKAGE CLIP LIFTGATE DISARM ACTUATOR PANEL TRIM LIFTGATE SWITCH LIFTGATE LOCK ROD REAR JUNCTION RIGHT BLOCK COWL LATCH MOTOR WIPER SWITCH TRIM SIDE SCREWS PUSH NUT REINFORCE- MENT 8Q - 8 VEHICLE THEFT/SECURITY SYSTEMS REMOVAL AND INSTALLATION (Continued) Fig.
Page 559: Set Lamp
POSITIVE CABLE OILED WASHER NEGATIVE CABLE FELT POWER TION CENTER DISTRIBU- VEHICLE THEFT/SECURITY SYSTEMS 8Q - 9 REMOVAL AND INSTALLATION (Continued) (6) Unplug the headlamp or park lamp relay from SET LAMP the junction block. (7) Install the headlamp or park lamp relay by WARNING: ON VEHICLES EQUIPPED WITH AIR- aligning the relay terminals with the cavities in the BAGS,...
Page 561 VEHICLE THEFT/SECURITY SYSTEMS 8Q - 1 VEHICLE THEFT/SECURITY SYSTEMS CONTENTS page page GENERAL INFORMATION POWER-UP MODE ..... . 5 ARMING .
Page 562: General Information
8Q - 2 VEHICLE THEFT/SECURITY SYSTEMS GENERAL INFORMATION (Continued) still arm if the hood is open, but the engine compart- ness complexity, reduce internal controller hardware, ment will not be protected. Once the 15 second arm- and reduce component sensor current loads. At the ing function is complete, the set lamp will flash at a same time, this system provides increased reliability, slower rate to indicate that the VTSS is armed.
Page 563: Horn Relay
VEHICLE THEFT/SECURITY SYSTEMS 8Q - 3 DESCRIPTION AND OPERATION (Continued) LIFTGATE AJAR SWITCH The horn relay is a electromechanical device that switches battery current to the horns when the horn The liftgate ajar switch is integral to the liftgate switch or the Body Control Module (BCM) grounds latch assembly on the liftgate.
Page 564 8Q - 4 VEHICLE THEFT/SECURITY SYSTEMS DESCRIPTION AND OPERATION (Continued) tion switch to the OFF position and using one of the the immobilizer receiver. Refer to the Vehicle Theft following methods. Security System menu item on the DRB scan tool for (1) Press the LOCK button on the RKE transmit- the procedures.
Page 565: Power-Up Mode
VEHICLE THEFT/SECURITY SYSTEMS 8Q - 5 DESCRIPTION AND OPERATION (Continued) POWER-UP MODE WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, REFER GROUP PASSIVE When the vehicle immobilizer system senses that RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY the vehicle battery has been disconnected and recon- STEERING WHEEL, STEERING...
Page 566: Service Procedures
8Q - 6 VEHICLE THEFT/SECURITY SYSTEMS SERVICE PROCEDURES on the DRB scan tool for further diagnosis. If not OK, repair the open circuit to the PDC fuse as VEHICLE IMMOBILIZER SYSTEM required. ENABLING WARNING: ON VEHICLES EQUIPPED WITH AIR- The vehicle immobilizer system is disabled when it BAGS, REFER GROUP...
Page 567: Removal And Installation
VEHICLE THEFT/SECURITY SYSTEMS 8Q - 7 REMOVAL AND INSTALLATION (2) Remove the screw securing the hood switch to the right inner fender ledge (Fig. 2). IMMOBILIZER RECEIVER WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, REFER GROUP PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING...
Page 568: Door Lock Cylinder Switch
8Q - 8 VEHICLE THEFT/SECURITY SYSTEMS REMOVAL AND INSTALLATION (Continued) (3) Pull the switch from the mounting hole in the door opening far enough to access the wire harness connector. (4) Unplug the wire harness connector from the switch. (5) Reverse the removal procedures to install. Tighten the switch mounting screw to 1.7 N·m (15 in.
Page 569 VEHICLE THEFT/SECURITY SYSTEMS 8Q - 9 REMOVAL AND INSTALLATION (Continued) LIFTGATE AJAR SWITCH (8) Reverse the removal procedures to install. Tighten the latch mounting screws to 7 N·m (62 in (1) Disconnect and isolate the battery negative lbs.). cable. (2) Remove the screws that secure the liftgate LIFTGATE LOCK CYLINDER SWITCH lower trim panel to the liftgate (Fig.
Page 570 8Q - 10 VEHICLE THEFT/SECURITY SYSTEMS REMOVAL AND INSTALLATION (Continued) (6) Reverse the removal procedures to install. (7) Reverse the removal procedures to install. Tighten the latch mounting nuts to 11 N·m (100 in. LIFTGLASS AJAR SWITCH lbs.). (1) Disconnect and isolate the battery negative AUTO HEADLAMP AND PARK LAMP RELAYS cable.
Page 571: Set Lamp
VEHICLE THEFT/SECURITY SYSTEMS 8Q - 11 REMOVAL AND INSTALLATION (Continued) (10) Install the right cowl side trim and the fuse INSTRUMENT PANEL COMPONENT DIAGNOSIS OR access panel. SERVICE. FAILURE TO TAKE THE PROPER PRE- CAUTIONS COULD RESULT IN ACCIDENTAL AIR- HORN RELAY BAG DEPLOYMENT AND POSSIBLE PERSONAL (1) Disconnect and isolate the battery negative...
Page 573: Power Seat Systems
POWER SEAT SYSTEMS 8R - 1 POWER SEAT SYSTEMS CONTENTS page page GENERAL INFORMATION POWER LUMBAR ADJUSTER AND MOTOR . . . 5 INTRODUCTION ......1 POWER LUMBAR SWITCH .
Page 574: Description And Operation
8R - 2 POWER SEAT SYSTEMS DESCRIPTION AND OPERATION dently of each other. When the seat switch is pushed to the Up or Down position, both the front and rear MEMORY SEAT MODULE motors operate in unison, moving the entire seat up or down.
Page 575: Diagnosis And Testing
POWER SEAT SYSTEMS 8R - 3 DESCRIPTION AND OPERATION (Continued) POWER LUMBAR ADJUSTER AND MOTOR (1) Locate the correct circuit breaker in the junc- tion block. Pull out the circuit breaker slightly, but There is a reversible motor that operates the power be sure that the terminals still contact the terminals lumbar adjuster.
Page 576 8R - 4 POWER SEAT SYSTEMS DIAGNOSIS AND TESTING (Continued) Fig. 2 Power Lumbar Switch Continuity assembly. If the circuits are not OK, repair the wire harness as required. POWER RECLINER ADJUSTER AND MOTOR The tests below apply to a power seat system with- out the memory system option.
Page 577: Removal And Installation
POWER POWER SEAT/RECLINER LUMBAR SWITCH SWITCH SEAT SIDE SHIELD CUSHION POWER SEAT SYSTEMS 8R - 5 DIAGNOSIS AND TESTING (Continued) (4) Test the power seat switch as described in this (3) Remove the three screws that secure the seat group. If the switch tests OK, check the wire harness cushion side shield to the seat cushion frame.
Page 578 POWER SEAT SCREWS (4) SEAT SEAT SEAT BACK FRAME CUSHION BACK FRAME POWER ADJUSTER RECLINER HEATED MODULE RECLINER SEAT MOUNTING CONTROL DUON COVER SCREW 8R - 6 POWER SEAT SYSTEMS REMOVAL AND INSTALLATION (Continued) (5) Remove the two bolts that secure the power recliner adjuster lower bracket to the seat cushion frame (Fig.
Page 579 LUMBAR MOTOR HEAD U-NUT SLEEVE GUIDE RESTRAINT BACK PANEL LUMBAR POWER SEAT SYSTEMS 8R - 7 BRACKET SLIDE WIRE TABS RETAINERS HARNESS MEMORY MODULE SEAT REMOVAL AND INSTALLATION (Continued) (3) Replace the seat back frame assembly, which (8) Release the two retainers that secure the mem- includes the lumbar adjuster and motor (Fig.
Page 581 POWER WINDOW SYSTEMS 8S - 1 POWER WINDOW SYSTEMS CONTENTS page page GENERAL INFORMATION DOOR MODULE ......3 INTRODUCTION .
Page 582: Power Window System
8S - 2 POWER WINDOW SYSTEMS DESCRIPTION AND OPERATION (Continued) Each power window switch, except the lockout Some of the features and functions of the power switch, is illuminated by a Light-Emitting Diode window system made possible because of the commu- (LED) when the ignition switch is turned to the On nication of the door modules on the CCD data bus position.
Page 583: Diagnosis And Testing
POWER WINDOW SYSTEMS 8S - 3 DESCRIPTION AND OPERATION (Continued) through these same two connections will cause the nostic Procedures manual to diagnose the door mod- motor to rotate in the opposite direction. ules and the CCD data bus. If not OK, repair the In addition, each power window motor is equipped open circuit to the junction block as required.
Page 584 8S - 4 POWER WINDOW SYSTEMS DIAGNOSIS AND TESTING (Continued) senger side front or rear window that operates from Window Motors. If not OK, replace the faulty door the switch on that door, but does not operate from module. the master switch on the driver side front door, use a (9) Disconnect and isolate the battery negative DRB scan tool and the proper Body Diagnostic Pro- cable.
Page 585: Power Window Motor
U-NUT FRONT DOOR U-NUT POWER WINDOW SYSTEMS 8S - 5 DIAGNOSIS AND TESTING (Continued) (1) Disconnect and isolate the battery negative should be no binding or sticking of the window glass cable. or lift mechanism through the entire travel range. If (2) Remove the power window switch from the not OK, refer to Group 23 - Body to check the win- rear door trim panel as described in this group.
Page 586: Power Window Switch
MEMORY SWITCH POWER MOUNTING SCREWS CONNECTOR CONNECTOR MIRROR DOOR MODULE REAR DOOR U-NUT TRIM PANEL PLUG 12–WAY CON- NECTOR BEZEL REAR POWER SLIDE WINDOW SWITCH LOOSEN 2 NUTS REAR DOOR TRIM PANEL RECEPTACLE SWITCH 8S - 6 POWER WINDOW SYSTEMS REMOVAL AND INSTALLATION (Continued) (4) Remove the trim cap and screw near the rear of the door armrest.
Page 587 LOOSEN ONLY REGULATOR SCREWS LOOSEN ONLY CHANNEL ATTACHING SCREWS REGULATOR LOOSEN ONLY SCREWS LOOSEN 2 NUTS S LIDE CHANNEL ATTACH- ING SCREW LOOSEN ONLY POWER WINDOW SYSTEMS 8S - 7 REMOVAL AND INSTALLATION (Continued) (4) Slide the door glass rearward to remove it from the nuts.
Page 588 8S - 8 POWER WINDOW SYSTEMS REMOVAL AND INSTALLATION (Continued) possible and push down. Tighten the two loose win- (15) Use an adhesive/sealant to install the plastic dow regulator screws to 12 N·m (105 in. lbs.). watershield to the door inner panel. (13) Attach the door glass by sliding the two nuts (16) Reverse the remaining removal procedures to into the slotted holes on the regulator lift plate.
Page 589: Outside Power Mirrors
POWER MIRROR SYSTEMS 8T - 1 POWER MIRROR SYSTEMS CONTENTS page page AUTOMATIC DAY/NIGHT MIRROR ... 6 OUTSIDE POWER MIRRORS ....1 OUTSIDE POWER MIRRORS INDEX page...
Page 590: General Information
8T - 2 POWER MIRROR SYSTEMS GENERAL INFORMATION (Continued) enhanced diagnostics, and allows the addition of DOOR MODULE many new feature capabilities. A Driver Door Module (DDM) and a Passenger This group covers only the conventional diagnostic Door Module (PDM) are used on this model to control procedures for the power mirror system components.
Page 591: Power Mirror
POWER MIRROR SYSTEMS 8T - 3 DIAGNOSIS AND TESTING (Continued) (1) Check the circuit breaker in the junction block. If OK, go to Step 2. If not OK, replace the faulty cir- cuit breaker. (2) Check the fuse in the Power Distribution Cen- ter (PDC).
Page 592: Removal And Installation
FRONT DOOR TRIM PANEL BEZEL U-NUT U-NUT PLUG 8T - 4 POWER MIRROR SYSTEMS DIAGNOSIS AND TESTING (Continued) replace the faulty power mirror. If not OK, repair the (6) Remove the screw located above the front door circuits to the automatic day/night mirror as speaker grille.
Page 593: Power Mirror
POWER MIRROR SYSTEMS 8T - 5 REMOVAL AND INSTALLATION (Continued) POWER MIRROR (1) Disconnect and isolate the battery negative cable. (2) Remove the front door trim panel as described under Door Module in this group. (3) Unplug the electrochromic mirror wire harness connector, if equipped.
Page 594 8T - 6 POWER MIRROR SYSTEMS AUTOMATIC DAY/NIGHT MIRROR INDEX page page GENERAL INFORMATION DIAGNOSIS AND TESTING INTRODUCTION ......6 AUTOMATIC DAY/NIGHT MIRROR .
Page 595 FORWARD FACING SENSOR SWITCH REAR FACING SENSOR CONNECTOR POWER MIRROR SYSTEMS 8T - 7 DIAGNOSIS AND TESTING (Continued) mirror should return to its normal reflectance. If not OK, replace the faulty mirror unit. REMOVAL AND INSTALLATION AUTOMATIC DAY/NIGHT MIRROR (1) Disconnect and isolate the battery negative cable.
Page 597 CHIME/BUZZER WARNING SYSTEMS 8U - 1 CHIME/BUZZER WARNING SYSTEMS CONTENTS page page GENERAL INFORMATION DIAGNOSIS AND TESTING INTRODUCTION ......1 DRIVER DOOR AJAR SWITCH .
Page 598 8U - 2 CHIME/BUZZER WARNING SYSTEMS DESCRIPTION AND OPERATION (Continued) This group only covers the diagnosis and service of signal to the Body Control Module (BCM) park lamp the hard-wired inputs used by the BCM to determine relay output circuit when the park or head lamps are that a chime tone should be generated.
Page 599 CHIME/BUZZER WARNING SYSTEMS 8U - 3 DIAGNOSIS AND TESTING (Continued) DRIVER SEAT BELT SWITCH SERVICE. FAILURE TO TAKE THE PROPER PRE- CAUTIONS COULD RESULT IN ACCIDENTAL AIR- For circuit descriptions and diagrams, refer to BAG DEPLOYMENT AND POSSIBLE PERSONAL 8W-45 - Body Control Module in Group 8W - Wiring INJURY.
Page 600 8U - 4 CHIME/BUZZER WARNING SYSTEMS DIAGNOSIS AND TESTING (Continued) (1) Disconnect and isolate the battery negative REMOVAL AND INSTALLATION cable. Remove the outboard switch pod from the instrument panel. Refer to Group 8E - Instrument CHIME WARNING SYSTEM SWITCHES Panel Systems for the procedures.
Page 601: Overhead Console Systems
OVERHEAD CONSOLE SYSTEMS 8V - 1 OVERHEAD CONSOLE SYSTEMS CONTENTS page page GENERAL INFORMATION THERMOMETER DISPLAY MODULE ..3 INTRODUCTION ......1 SERVICE PROCEDURES DESCRIPTION AND OPERATION COMPASS CALIBRATION...
Page 602: Description And Operation
8V - 2 OVERHEAD CONSOLE SYSTEMS DESCRIPTION AND OPERATION (Continued) The push button (Step and U.S./Metric) switch module. The displayed temperature is not an instant module in the overhead console is hard-wired to the reading of conditions, but an average temperature. It trip computer.
Page 603: Diagnosis And Testing
OVERHEAD CONSOLE SYSTEMS 8V - 3 DESCRIPTION AND OPERATION (Continued) door are selected and mounted on a post in the cen- SELF-DIAGNOSTIC TEST ter of the storage bin door. The peg(s) selected and/or A self-diagnostic test is used to determine that the the post must be long enough to depress the button trip computer, compass, thermometer, and all of the of the transmitter, when the garage door opener stor-...
Page 604: Service Procedures
8V - 4 OVERHEAD CONSOLE SYSTEMS DIAGNOSIS AND TESTING (Continued) and thermometer display module display. The sensor (5) Check for continuity between the ambient tem- is mounted outside the passenger compartment near perature sensor signal circuit cavity of the black the front and center of the vehicle.
Page 605 OVERHEAD CONSOLE SYSTEMS 8V - 5 SERVICE PROCEDURES (Continued) Fig. 1 Variance Settings NOTE: Whenever the compass is calibrated manu- may be too close to a strong magnetic field. Repeat ally, the variation number must also be reset. See the calibration procedure in another location. the Compass Variation Adjustment procedure, in this group.
Page 606: Removal And Installation
AT LEAST TWO FEET AND PULL TIP OF DEGAUSSING TOOL AWAY WINDSHIELD EDGE DISCONNECT START OVERHEAD CONSOLE OVERHEAD CONSOLE BRACKET HEADLINER 8V - 6 OVERHEAD CONSOLE SYSTEMS SERVICE PROCEDURES (Continued) (6) Place a piece of paper approximately 22 by 28 REMOVAL AND INSTALLATION centimeters (8.5 by 11 inches), oriented on the vehicle lengthwise from front to rear, on the center line of...
Page 607: Push Button Module
MINI OVERHEAD CONSOLE SCREW SCREW SNAP CLIPS BRACKET OVERHEAD CONSOLE SYSTEMS 8V - 7 REMOVAL AND INSTALLATION (Continued) Fig. 5 Trip Computer, Compass, and Fig. 4 Overhead Console Remove/Install -Short-Type ThermometerDisplay Module Remove/Install - TRIP COMPUTER, COMPASS, AND Typical THERMOMETER DISPLAY MODULE (4) Remove the push button module from the con- (1) Remove the overhead console as described in sole.
Page 608 8V - 8 OVERHEAD CONSOLE SYSTEMS REMOVAL AND INSTALLATION (Continued) AMBIENT TEMPERATURE SENSOR (1) Disconnect and isolate the battery negative cable. (2) Remove the radiator grille unit. Refer to Group 23 - Body for the procedures. (3) Locate the temperature sensor, on the radiator support behind the grille (Fig.
Page 609: Wiring Diagrams
WIRING DIAGRAMS 8W - 1 WIRING DIAGRAMS CONTENTS page page 8W-01 GENERAL INFORMATION ..8W-01-1 8W-46 MESSAGE CENTER ... . 8W-46-1 8W-02 COMPONENT INDEX ... 8W-02-1 8W-47 AUDIO SYSTEM .
Page 611 8W - 01 GENERAL INFORMATION 8W - 01 - 1 8W-01 GENERAL INFORMATION INDEX page page DESCRIPTION AND OPERATION TROUBLESHOOTING TESTS ....6 CIRCUIT IDENTIFICATION ....3 TROUBLESHOOTING TOOLS .
Page 612 8W - 01 - 2 8W - 01 GENERAL INFORMATION DESCRIPTION AND OPERATION (Continued) that may appear on the vehicle. For example, an WIRE CODE IDENTIFICATION up-to and after condition. Each wire shown in the diagrams contains a code CAUTIONS are used to indicate information that (Fig.
Page 613 8W - 01 GENERAL INFORMATION 8W - 01 - 3 DESCRIPTION AND OPERATION (Continued) CIRCUIT IDENTIFICATION All circuits in the diagrams use an alpha/numeric code to identify the wire and its function (Fig. 3). To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart.
Page 614 8W - 01 - 4 8W - 01 GENERAL INFORMATION DESCRIPTION AND OPERATION (Continued) Fig. 5 Symbol Identification...
Page 615 8W - 01 GENERAL INFORMATION 8W - 01 - 5 DESCRIPTION AND OPERATION (Continued) ELECTROSTATIC DISCHARGE (ESD) SENSITIVE CAUTION: Most of the electrical components used in today’s vehicle are solid state. When checking DEVICES voltages in these circuits use a meter with a 10-me- All ESD sensitive components are solid state and a gohm or greater impedance.
Page 616 8W - 01 - 6 8W - 01 GENERAL INFORMATION DIAGNOSIS AND TESTING (Continued) TROUBLESHOOTING TESTS Before beginning any tests on a vehicles electrical system use the Wiring Diagrams and study the cir- cuit. Also refer to the Troubleshooting Wiring Prob- lems section in this section.
Page 617 8W - 01 GENERAL INFORMATION 8W - 01 - 7 DIAGNOSIS AND TESTING (Continued) (8) Center the heat shrink tubing over the joint, and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing.
Page 618 8W - 01 - 8 8W - 01 GENERAL INFORMATION SERVICE PROCEDURES (Continued) (4) Using special tool 6742 release the locking fin- gers on the terminal (Fig. 13). (5) Pull on the wire to remove it from the connec- tor. (6) Repair or replace the connector or terminal, as necessary.
Page 619 8W - 01 GENERAL INFORMATION 8W - 01 - 9 SERVICE PROCEDURES (Continued) (4) Position the connector locking finger away from Cut off the existing wire connector directly the terminal using the proper pick from special tool behind the insulator. Remove six inches of tape from kit 6680.
Page 620 8W - 01 - 10 8W - 01 GENERAL INFORMATION SERVICE PROCEDURES (Continued) Remove connector locking wedge, if required (Fig. 21). Fig. 23 Terminal Removal Using Special Tool (12) Twist the wires together. (13) Solder the connection together using rosin Fig.
Page 621 8W - 01 GENERAL INFORMATION 8W - 01 - 11 SERVICE PROCEDURES (Continued) (4) Remove the insulation from the wires in the harness. Only remove enough insulation to solder in the new diode. (5) Install the new diode in the harness, making sure current flow is correct.
Page 623 8W - 02 COMPONENT INDEX 8W - 02 - 1 8W-02 COMPONENT INDEX INDEX page GENERNAL INFORMATION ............. . . 4 Component Page Component...
Page 624 8W - 02 COMPONENT INDEX 8W - 02 - 3 Component Page Component Page Fuel Sender Unit ..... . 8W-30 Oil Pressure Gauge .
Page 625 8W - 02 COMPONENT INDEX 8W - 02 - 3 Component Page Component Page Splice Information ..... 8W-70 Turn Signal Indicator Lamps ... . . 8W-40 Steering Wheel Speed Sensor .
Page 626 8W - 02 - 4 8W - 02 COMPONENT INDEX 8W-02 COMPONENT INDEX GENERAL INFORMATION INTRODUCTION This section provides an alphabetical listing of all the components covered in group 8W. For information on system operation, refer to the appropriate section of the wiring diagrams.
Page 627 8W - 10 POWER DISTRIBUTION 8W - 10 - 1 8W-10 POWER DISTRIBUTION INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
Page 628 8W - 10 - 2 8W-10 POWER DISTRIBUTION POWER DISTRIBUTION CENTER ENGINE STARTER MOTOR RELAY FUEL INTERMITTENT PUMP WIPER RELAY RELAY ABS MAIN RELAY AUTOMATIC SHUT DOWN RELAY COMPRESSOR CLUTCH RELAY HORN F21 15A F18 15A RELAY F20 20A F17 15A TRANSMISSION F19 20A F16 15A...
Page 629 8W-10 POWER DISTRIBUTION 8W - 10 - 3 BATTERY (8W-20-2) (8W-20-3) POWER DISTRIBUTION CENTER FUSE FUSE FUSE 175A (8W-10-4) (8W-10-5) (8W-10-7) FUSE FUSE FUSE FUSE (DIESEL) (8W-10-4) (8W-10-6) (8W-10-9) (8W-10-18) A900 A900 RD/BK OR/YL OR/YL RD/DB RD/VT RD/WT RD/WT WT/OR RD/TN S137 JUNCTION...
Page 630 8W - 10 - 4 8W-10 POWER DISTRIBUTION BATT A0 (8W-10-3) POWER DISTRIBUTION CENTER FUSE FUSE (8W-10-3) 175A A900 A900 RD/BK OR/YL OR/YL POWER DISTRIBUTION FUSE CENTER (8W-10-3) JUNCTION BLOCK (8W-12-2) REAR WINDOW F250 DEFOGGER RELAY RD/GY (8W-48-2) S137 FUSE COMPRESSOR CLUTCH RD/BK...
Page 631 8W-10 POWER DISTRIBUTION 8W - 10 - 5 BATT A0 (8W-10-3) POWER DISTRIBUTION CENTER FUSE FUSE (8W-10-3) HORN RELAY (8W-39-6) (8W-41-2) DG/YL S106 RD/DB DG/YL DG/YL CONTROLLER HORN HORN FUSED ANTI-LOCK NO. 1 NO. 2 B(+) BRAKE (8W-39-6) (8W-39-6) (8W-41-2) (8W-41-2) (8W-35-2) ZG001004...
Page 632 8W - 10 - 6 8W-10 POWER DISTRIBUTION BATT A0 (8W-10-3) POWER DISTRIBUTION CENTER (8W-10-3) FUSE RD/VT C160 MANUAL S225 RD/VT DG/RD HIGH BLOWER SPEED POWER BLOWER MODULE MOTOR (8W-42-3) RELAY (8W-42-3) BR/RD BR/RD S224 BR/RD C206 PK/DB BLOWER AUTOMATIC HIGH MOTOR TEMPERATURE...
Page 633 8W-10 POWER DISTRIBUTION 8W - 10 - 7 BATT A0 (8W-10-3) POWER BRAKE DISTRIBUTION WARNING CENTER SWITCH FUSE (8W-10-3) (8W-40-6) ENGINE STARTER MOTOR RELAY (8W-21-3) (8W-21-4) RD/WT LG/BK GY/BK C144 C233 LG/BK RD/WT ENGINE C234 STARTER MOTOR (8W-21-3) (8W-21-4) S210 RD/WT RD/WT GY/BK...
Page 634 8W - 10 - 8 8W-10 POWER DISTRIBUTION BATT A1 BATT A1 (8W-10-7) (8W-10-7) IGNITION SWITCH 1 START 2 RUN 0 OFF 3 ACC DB/GY BK/OR JUNCTION BLOCK (8W-12-2) FUSE FUSE (8W-12-5) (8W-12-5) DB/GY POWER DISTRIBUTION FUSE CENTER (8W-10-3) (8W-10-13) (8W-10-14) JUNCTION BLOCK...
Page 635 8W-10 POWER DISTRIBUTION 8W - 10 - 9 BATT A0 BATT A1 (8W-10-3) (8W-10-7) POWER IGNITION DISTRIBUTION SWITCH CENTER 1 START FUSE (8W-10-3) 2 RUN 0 OFF 3 ACC WT/OR C233 WT/OR RD/BK FUSE FUSE (8W-12-3) (8W-12-20) REAR JUNCTION BLOCK LAMP RELAY (8W-12-2)
Page 636 8W - 10 - 10 8W-10 POWER DISTRIBUTION BATT A0 (8W-10-3) POWER DISTRIBUTION CENTER FUSE FUSE (8W-10-3) A250 RD/LG CONTROLLER FUSED ANTI-LOCK B(+) BRAKE (8W-35-2) JUNCTION BLOCK (8W-12-2) CIRCUIT FUSE FUSE FUSE BREAKER (8W-12-7) (8W-12-8) (8W-12-8) (8W-12-7) J978W-3 ZG001009...
Page 637 8W-10 POWER DISTRIBUTION 8W - 10 - 11 BATT A0 (8W-10-3) POWER DISTRIBUTION CENTER FUSE (8W-10-3) RD/LB (8W-50-2) JUNCTION BLOCK (8W-12-2) AUTOMATIC FUSE HEADLAMP RELAY (8W-50-2) (8W-12-14) RD/LB TN/BK HEADLAMP SWITCH 1 AUTO CIRCUIT 2 OFF BREAKER 3 PARK 4 LOW (8W-50-5) F34 16TN/BK HEADLAMP...
Page 638 8W - 10 - 12 8W-10 POWER DISTRIBUTION BATT A0 (8W-10-3) POWER DISTRIBUTION CENTER FUSE (8W-10-3) YL/RD JUNCTION BLOCK (8W-12-2) FUSE FUSE CIRCUIT BREAKER (8W-12-12) (8W-12-16) (8W-12-18) FUSE FUSE FUSE (8W-12-11) (8W-12-16) (8W-12-16) J978W-3 ZG001011...
Page 639 8W-10 POWER DISTRIBUTION 8W - 10 - 13 DIESEL ENGINE BATT A0 ST-RUN A21 (8W-10-3) (8W-10-8) POWER DISTRIBUTION CENTER (8W-10-3) FUSE FUSE FUSE WT/RD S101 (8W-10-15) JUNCTION BLOCK (8W-12-2) LAMP RELAY (8W-50-6) C131 S105 (8W-12-24) WT/RD HEADLAMP LEFT RIGHT POWERTRAIN FUSED SWITCH CONTROL...
Page 640 8W - 10 - 14 8W-10 POWER DISTRIBUTION GAS ENGINES BATT A0 ST-RUN A21 (8W-10-3) (8W-10-8) POWER DISTRIBUTION CENTER (8W-10-3) FUSE FUSE FUSE FUSE DG/BK S101 FUEL TRANSMISSION (8W-10-15) CONTROL PUMP RELAY RELAY (IN PDC) (IN PDC) (8W-31-2) (8W-30-16) JUNCTION BLOCK (8W-12-2) LAMP...
Page 641 8W-10 POWER DISTRIBUTION 8W - 10 - 15 FROM POWER DISTRIBUTION FUEL CENTER (8W-10-13) HEATER (8W-10-14) RELAY (DIESEL) (8W-30-27) S101 FUEL DUTY PUMP CYCLE RELAY EVAP/ C131 C236 (IN PDC) PURGE (GAS) SOLENOID (8W-30-16) (GAS) (8W-30-4) (8W-30-4) AUTOMATIC COMPRESSOR SHUT CLUTCH DOWN RELAY...
Page 642 8W - 10 - 16 8W-10 POWER DISTRIBUTION GAS ENGINES BATT A0 (8W-10-3) POWER DISTRIBUTION CENTER FUSE (8W-10-3) RD/YL S100 RD/YL RD/YL AUTOMATIC SHUT DOWN RELAY (IN PDC) C131 (8W-30-5) A142 A142 RD/YL DG/OR DG/OR POWERTRAIN FUSED AUTOMATIC CONTROL B(+) SHUT DOWN MODULE...
Page 643 8W-10 POWER DISTRIBUTION 8W - 10 - 17 GAS ENGINES FROM FUEL FUEL FUEL AUTOMATIC INJECTOR INJECTOR INJECTOR SHUT NO. 2 NO. 4 NO. 6 DOWN (8W-30-15) (8W-30-15) (8W-30-15) RELAY (8W-10-16) A142 FUEL FUEL FUEL INJECTOR INJECTOR DG/OR INJECTOR NO. 3 NO.
Page 644: Diesel Engine
8W - 10 - 18 8W-10 POWER DISTRIBUTION DIESEL ENGINE BATT F61 (8W-10-9) POWER DISTRIBUTION CENTER FUSE FUSE (8W-10-3) RD/YL RD/TN F5 16 RD/YL AUTOMATIC SHUT DOWN RELAY (IN PDC) K900 A142 PK/BK DG/OR FUEL HEATER C132 C131 RELAY (IN PDC) (8W-30-27) K900 A142...
Page 645 8W-10 POWER DISTRIBUTION 8W - 10 - 19 DIESEL ENGINE FROM C131 (8W-10-18) A142 DG/OR S129 A142 A142 A142 A142 DG/OR DG/OR DG/OR DG/OR POWERTRAIN GLOW AUTOMATIC SOLENOID CONTROL PLUG SHUTDOWN RELAY (8W-30-28) MODULE RELAY OUTPUT (8W-30-27) (8W-30-26) S128 A142 A142 A142 A142...
Page 646 8W - 10 - 20 8W-10 POWER DISTRIBUTION FUSE NO. AMPS FEED CIRCUIT FUSED CIRCUIT A11 6RD/BK B(+) SPARE A900 12OR/YL FUSED B(+) A900 12OR/YL FUSED B(+) A12 12RD/TN FUSED B(+) A10 10RD/DB FUSED B(+) F31 16VT FUSED B(+) A19 12RD/VT FUSED B(+) A1 12RD/WT FUSED B(+)
Page 647 8W-10 POWER DISTRIBUTION 8W - 10 - 21 HORN CIRCUIT FUNCTION RELAY F31 16VT FUSED B(+) X2 16DG/YL HORN RELAY OUTPUT F31 16VT FUSED B(+) FUSED B(+) F31 16VT X4 20GY/OR HORN RELAYCONTROL TRANSMISSION CIRCUIT FUNCTION CONTROL RELAY F92 18LG FUSED B(+) T20 18LB TRANSMISSION RELAY OUTPUT...
Page 648 8W - 10 - 22 8W-10 POWER DISTRIBUTION AUTOMATIC CIRCUIT FUNCTION SHUT DOWN RELAY F5 18RD/YL FUSED B(+) FUSED B(+)* F5 16RD/YL* F5 16RD/YL* FUSED B(+)* A142 18DG/OR FUSED B(+) FUSED B(+)* A142 16DG/OR* A142 16DG/OR FUSED B(+) F5 16 RD/YL FUSED B(+) K900 20PK/WT AUTOMATIC SHUT DOWN RELAY CONTROL...
Page 649 8W-10 POWER DISTRIBUTION 8W - 10 - 23 ENGINE STARTER CIRCUIT FUNCTION MOTOR RELAY A1 12RD/WT FUSED B(+) ENGINE STARTER MOTOR RELAY OUTPUT T40 12LG/BK T141 14YL/TD FUSED IGNITION SWITCH OUTPUT (ST) Z4 20BK PARK NEUTRAL POSITION SWITCH SENSE T41 20BK/WT PARK NEUTRAL POSITION SWITCH SENSE FUEL CIRCUIT...
Page 650 8W - 10 - 24 8W - 10 POWER DISTRIBUTION 8W-10 POWER DISTRIBUTION DESCRIPTION AND OPERATION This section covers the power distribution center and all circuits involved with it. For additional infor- mation on system operation, refer to the appropriate wiring diagrams.
Page 651 8W - 12 JUNCTION BLOCK 8W - 12 - 1 8W-12 JUNCTION BLOCK INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
Page 652 8W - 12 - 2 8W-12 JUNCTION BLOCK TOP OF JUNCTION BLOCK POWER ANTENNA CIGAR PARK AUTO COUTESY RELAY LAMP LIGHTER HEADLAMP ELECTRONIC LAMP (EXPORT ONLY) RELAY RELAY RELAY FLASHER RELAY 5 10 (NOT USED) ENGINE LAMP RELAY REAR WINDOW DEFOGGER RELAY ENGINE B...
Page 653 8W-12 JUNCTION BLOCK 8W - 12 - 3 RUN-ACC A31 BATT F61 (8W-10-9) (8W-10-9) JUNCTION BLOCK FUSE FUSE FUSE USED RD/GY RD/BK JUNCTION BLOCK CIGAR LIGHTER RELAY (8W-41-3) RD/DB RADIO CIGAR LIGHTER (8W-47-2) (8W-41-3) ZG001202 J978W-3...
Page 654 8W - 12 - 4 8W-12 JUNCTION BLOCK RUN-ACC A31 (8W-10-9) JUNCTION BLOCK (8W-12-2) CIRCUIT FUSE BREAKER (DIESEL) (GAS) LG/BK LG/BK BR/PK BR/PK C231 LG/RD LG/RD INTERMITTENT BODY REAR WIPER CONTROL WIPER/ SWITCH MODULE WASHER LG/BK (PART OF (8W-45-2) SWITCH MULTI-FUNCTION (8W-53-4) SWITCH)
Page 655 8W-12 JUNCTION BLOCK 8W - 12 - 5 FROM ST-RUN A21 (8W-10-8) C231 (8W-12-4) JUNCTION BLOCK (8W-12-2) FUSE FUSE USED (GAS) (DIESEL) LG/BK DB/GY DB/WT WT/PK BK/WT INSTRUMENT BK/WT AIRBAG CLUSTER FUSED CONTROL IGN. (8W-40-5) (ST-RUN) MODULE (8W-43-2) POWER DISTRIBUTION FUSE S215 CENTER...
Page 656 8W - 12 - 6 8W-12 JUNCTION BLOCK RUN A22 (8W-10-8) JUNCTION BLOCK ELECTRONIC (8W-12-2) FLASHER FUSED (8W-52-2) FUSE IGN. (8W-52-6) HEADLAMP (RUN) LEVELING SWITCH (8W-50-11) YL/DG YL/DG OVERHEAD CONSOLE OTHERS S212 YL/DG BK/VT MINI OVERHEAD OVERHEAD CONSOLE CONSOLE S323 AUTOMATIC YL/DG YL/DG...
Page 657 8W-12 JUNCTION BLOCK 8W - 12 - 7 FROM FROM BATT A250 (8W-10-10) JUNCTION JUNCTION BLOCK BLOCK JUNCTION (8W-12-6) (8W-12-6) BLOCK (8W-12-2) FUSE CIRCUIT BREAKER BK/VT YL/DG RD/LG C334 C351 STOP DRIVER PASSENGER FUSED LAMP DOOR DOOR B (+) SWITCH MODULE MODULE (8W-33-2)
Page 658 8W - 12 - 8 8W-12 JUNCTION BLOCK BATT A250 (8W-10-10) JUNCTION BLOCK (8W-12-2) FUSE FUSE PK/BK S315 BODY CONTROL MODULE PK/BK PK/BK PK/BK (8W-45-4) C372 C323 S201 PK/BK TRAILER AUTOMATIC CIRCUIT HEADLAMP BREAKER LIGHT (8W-54-2) (8W-54-5) SENSOR/ VTSS AFTERMARKET DATA OTHERS LIFTGLASS...
Page 659 8W-12 JUNCTION BLOCK 8W - 12 - 9 BATT A900 RUN A22 (8W-10-4) (8W-10-8) JUNCTION BLOCK REAR (8W-12-2) FUSE WINDOW DEFOGGER RELAY FUSE USED USED LB/YL BK/WT DB/WT WT/RD C301 REAR CONTROLLER WINDOW ANTI-LOCK DEFOGGER BRAKE SWITCH BK/WT (8W-35-2) (8W-48-2) DIESEL C322 C322...
Page 660 8W - 12 - 10 8W-12 JUNCTION BLOCK RUN A22 (8W-10-8) JUNCTION BLOCK (8W-12-2) FUSE PK/DG DG/PK MANUAL S218 HEATER PK/DG PK/DG PK/DG DG/PK DG/PK C302 SWITCH AUTOMATIC HEATER TEMPERATURE CONTROL CONTROL PK/DG (8W-44-11) (8W-42-5) MODULE (8W-42-9) S317 C206 MANUAL HEATER PK/DG PK/DG...
Page 661 8W-12 JUNCTION BLOCK 8W - 12 - 11 RADIO POWER POWER (8W-47-3) AMPLIFIER AMPLIFIER RADIO RADIO RADIO (8W-47-3) (8W-47-3) OUTPUT OUTPUT OUTPUT DG/RD DG/RD DG/RD PREMIUM BATT A7 (8W-10-12) JUNCTION BLOCK (8W-12-2) FUSE POWER ANTENNA RELAY 1 UP 2 DOWN (EXPORT) ELECTRONIC FUSED...
Page 662 8W - 12 - 12 8W-12 JUNCTION BLOCK BATT A7 (8W-10-12) JUNCTION BLOCK (8W-12-2) FUSE COURTESY LAMP RELAY (8W-44-8) C159 S321 (8W-12-13) LEFT KEY-IN COURTESY SWITCH/ LAMP HALO (8W-44-2) LAMP (8W-44-2) GLOVE CARGO LAMP LAMP (8W-44-5) (8W-44-2) UNDERHOOD RIGHT LAMP COURTESY LAMP (8W-44-2)
Page 663 8W-12 JUNCTION BLOCK 8W - 12 - 13 FROM JUNCTION BLOCK (8W-12-12) S321 RIGHT OVERHEAD VISOR/ CONSOLE VANITY (8W-49-3) LAMP (8W-44-5) LEFT DOME/ VISOR/ READING VANITY LAMP LAMP (8W-44-3) (8W-44-5) ZG001212 J978W-3...
Page 664 8W - 12 - 14 8W-12 JUNCTION BLOCK BATT A6 (8W-10-11) JUNCTION BLOCK (8W-12-2) FUSE PARK LAMP RELAY JUNCTION BLOCK (8W-12-15) RD/LB PK/OR DB/RD DB/RD BODY PARK PARK CONTROL LAMP LAMP RELAY RELAY MODULE CONTROL OUTPUT (8W-45-4) HEADLAMP SWITCH (8W-50-7) J978W-3 ZG001213...
Page 665 8W-12 JUNCTION BLOCK 8W - 12 - 15 JUNCTION FROM BLOCK JUNCTION (8W-12-2) BLOCK (8W-12-14) USED USED DB/RD DB/RD DB/RD DB/RD S103 RADIO (8W-47-2) DB/RD DB/RD C102 C150 DB/RD DB/RD S415 S410 DB/RD DB/RD RIGHT LEFT VEHICLE FRONT FRONT INFORMATION PARK PARK CENTER...
Page 666 8W - 12 - 16 8W-12 JUNCTION BLOCK BATT A7 (8W-10-12) JUNCTION BLOCK (8W-12-2) FUSE FUSE FUSE USED LG/BK WT/RD RD/WT WT/RD PREMIUM OVERHEAD CONSOLE OTHERS WT/RD WT/RD VEHICLE GRAPHIC INFORMATION DISPLAY CENTER MODULE (8W-46-4) (8W-46-2) RADIO (8W-47-2) AUTOMATIC TEMPERATURE CONTROL MODULE (8W-42-2)
Page 667 8W-12 JUNCTION BLOCK 8W - 12 - 17 TURN INSTRUMENT PARK/ AUTOMATIC SIGNAL/ CLUSTER NEUTRAL DAY/ HAZARD (8W-40-4) POSITION NIGHT WARNING SWITCH MIRROR SWITCH (8W-44-6) (8W-44-6) (8W-52-2) TN/DB TN/DB BR/LG BK/RD C131 BR/LG JUNCTION BLOCK (8W-12-2) SIDE TN/DB REPEATER BR/LG LAMPS OTHERS C150...
Page 668 8W - 12 - 18 8W-12 JUNCTION BLOCK BATT A7 (8W-10-12) JUNCTION BLOCK (8W-12-2) CIRCUIT BREAKER C335 C329 S403 DRIVER MEMORY DRIVER DRIVER FUSED FUSED LUMBAR SEAT SEAT POWER B (+) B (+) SWITCH MODULE HEATER SEAT (8W-63-3) (8W-63-2) CONTROL SWITCH MODULE (8W-63-8)
Page 669 8W-12 JUNCTION BLOCK 8W - 12 - 19 VEHICLE GRAPHIC VEHICLE GRAPHIC INFORMATION DISPLAY INFORMATION DISPLAY CENTER MODULE CENTER MODULE (8W-46-5) (8W-46-3) (8W-46-5) (8W-46-3) LB/RD LB/RD LG/OR LG/OR C212 LG/OR LG/OR PREMIUM OTHERS PREMIUM OTHERS OVERHEAD OVERHEAD CONSOLE CONSOLE JUNCTION BLOCK (8W-12-2) LG/OR...
Page 670 8W - 12 - 20 8W-12 JUNCTION BLOCK BATT F61 (8W-10-9) JUNCTION BLOCK (8W-12-2) FUSE REAR LAMP RELAY DG/YL C307 LG/RD LG/OR HEADLAMP LAMP SWITCH OUTAGE (8W-51-7) MODULE (8W-51-7) J978W-3 ZG001219...
Page 671 8W-12 JUNCTION BLOCK 8W - 12 - 21 SUNROOF DOME/ CONTROL READING MODULE LAMP (8W-64-2) (8W-44-3) GRAPHIC OVERHEAD DISPLAY CONSOLE MODULE (8W-49-3) (8W-46-2) LEFT RIGHT VISOR/ VISOR/ VANITY VANITY LAMP LAMP C371 (8W-44-5) (8W-44-5) AUTOMATIC DAY/ NIGHT MIRROR (8W-44-6) S322 DOME/ OVERHEAD READING...
Page 672 8W - 12 - 22 8W-12 JUNCTION BLOCK LEFT KEY-IN COURTESY SWITCH/ LAMP HALO (8W-44-2) LAMP (8W-44-2) RIGHT CARGO COURTESY LAMP LAMP (8W-44-5) (8W-44-2) FROM FROM OVERHEAD DOME/ CONSOLE READING FROM (8W-12-21) LAMP S322 (8W-12-21) (8W-12-21) OTHERS SUNROOF JUNCTION BLOCK (8W-12-2) COURTESY LAMP...
Page 673 8W-12 JUNCTION BLOCK 8W - 12 - 23 HORN RELAY (IN PDC) (8W-41-2) GY/OR RUN A22 (8W-10-8) JUNCTION BLOCK (8W-12-2) FUSE GY/OR GY/OR VEHICLE BODY AIRBAG FUSED SPEED CONTROL CONTROL IGN. (RUN) CONTROL/ MODULE MODULE HORN (8W-45-3) (8W-43-2) SWITCH (8W-41-2) ZG001222 J978W-3...
Page 674 8W - 12 - 24 8W-12 JUNCTION BLOCK BATT A6 BATT F62 (8W-10-11) (8W-10-13) (8W-10-14) JUNCTION BLOCK (8W-12-2) AUTOMATIC HEADLAMP LAMP RELAY RELAY BK/OR TN/BK DG/YL HEADLAMP BODY SWITCH CONTROL (8W-50-7) MODULE (8W-45-5) S105 F34 16TN/BK HEADLAMP HEADLAMP DIMMER SWITCH SWITCH (8W-50-2) (8W-50-2)
Page 675 8W-12 JUNCTION BLOCK 8W - 12 - 25 FUSES FUSE NO. SIZE FEED CIRCUIT FEED CIRCUIT A31 12RD/BK X12 18RD/GY A31 12RD/BK A31 18RD/BK V23 18BR/PK A31 12RD/BK V23 20BR/PK A21 12DB/GY G5 18DB/WT F87 20BK/WT A21 12DB/GY F87 18WT/PK F83 18YL/DG A22 12BK/OR F83 20YL/DG...
Page 676 8W - 12 - 26 8W-12 JUNCTION BLOCK CIRCUIT BREAKERS CIRCUIT BREAKER SIZE FEED CIRCUIT FUSED CIRCUIT F86 16LG/BK A31 12RD/BK F86 16LG/BK F86 16LG/RD A31 12RD/BK F86 18LG/BK F81 10TN A250 10RD F81 12TN 35 16RD A7 12YL/RD F35 16RD RELAYS REAR CAVITY...
Page 677 8W-12 JUNCTION BLOCK 8W - 12 - 27 REAR WINDOW CAVITY CIRCUIT FUNCTION DEFOGGER RELAY A900 OR/YL FUSED B(+) C14 WT/RD REAR WINDOW DEFOGGER RELAY CONTROL A900 OR/YL FUSED B(+) C15 BK/WT REAR WINDOW DEFOGGER RELAY OUTPUT POWER CAVITY CIRCUIT FUNCTION ANTENNA RELAY...
Page 678 8W - 12 - 28 8W-12 JUNCTION BLOCK COURTESY CAVITY CIRCUIT FUNCTION LAMP COURTESY LAMP RELAY OUTPUT RELAY M2 YL COURTESY LAMP RELAY CONTROL M112 BR/LG M1 PK FUSED B(+) Z1 BK GROUND CAVITY CIRCUIT FUNCTION LAMP FUSED B(+) RELAY F62 RD FOG LAMP RELAY CONTROL L95 DG/YL...
Page 679 8W - 12 JUNCTION BLOCK 8W - 12 - 29 8W-12 JUNCTION BLOCK DESCRIPTION AND OPERATION This section covers the junction block and all cir- cuits involved with it. For additional information on system operation, please refer to the appropriate sec- tion of the wiring diagrams.
Page 681 8W - 15 GROUND DISTRIBUTION 8W - 15 - 1 8W-15 GROUND DISTRIBUTION INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
Page 682 8W - 15 - 2 8W-15 GROUND DISTRIBUTION GAS ENGINES BATTERY GENERATOR DATA (8W-20-2) LINK (8W-20-3) CONNECTOR (8W-30-2) (8W-30-18) (8W-30-19) BK/OR S126 C236 G100 G101 POWERTRAIN BK/OR CONTROL MODULE (8W-30-3) C132 BK/TN BK/TN BK/OR G104 G103 J978W-3 ZG001501...
Page 683 8W-15 GROUND DISTRIBUTION 8W - 15 - 3 DIESEL ENGINE BATTERY DATA LINK CONNECTOR (8W-30-30) GROUND GROUND (8W-30-31) (8W-30-32) BK/OR C236 G100 G101 BK/OR CONTROLLER C132 (8W-30-22) POWERTRAIN CONTROL MODULE (8W-30-22) GROUND GROUND BK/OR BK/TN BK/TN BK/TN BK/TN BK/TN S130 BK/TN G104 G103...
Page 684 8W - 15 - 4 8W-15 GROUND DISTRIBUTION DIESEL ENGINE STOP UNDERHOOD LEFT LEFT FRONT FRONT LAMP LAMP TURN PARK SWITCH (8W-44-2) SIGNAL LAMP (8W-33-2) (8W-33-4) LAMP (8W-50-9) (8W-52-3) WINDSHIELD WASHER PUMP S149 MOTOR (8W-53-2) C159 LEFT LEFT HEADLAMP LAMP (8W-50-3) (8W-50-6) C102...
Page 685 8W-15 GROUND DISTRIBUTION 8W - 15 - 5 GAS ENGINES SPEED LEFT LEFT FRONT FRONT PROPORTIONAL TURN PARK STEERING SIGNAL LAMP MODULE LAMP (8W-50-9) (8W-65-2) (8W-52-3) WINDSHIELD WASHER PUMP S149 MOTOR (8W-53-2) WINDSHIELD LEFT LEFT WIPER HEADLAMP MOTOR LAMP (8W-50-3) (8W-53-3) (8W-50-6) C102...
Page 686 8W - 15 - 6 8W-15 GROUND DISTRIBUTION DIESEL ENGINE FOUR FUEL RIGHT RIGHT WHEEL FRONT FRONT HEATER DRIVE PARK TURN (8W-30-28) SWITCH LAMP SIGNAL (8W-46-3) (8W-50-10) LAMP (8W-46-5) (8W-52-3) MASS SOLENOID FLOW (8W-30-28) MODULE (8W-30-26) S134 S152 RIGHT HORN HEADLAMP NO.
Page 687 8W-15 GROUND DISTRIBUTION 8W - 15 - 7 GAS ENGINES UPSTREAM FOUR RIGHT RIGHT HEATED FRONT WHEEL FRONT OXYGEN PARK DRIVE TURN SENSOR LAMP SWITCH SIGNAL (8W-30-13) (8W-50-10) (8W-46-3) LAMP (8W-30-14) (8W-46-5) (8W-52-3) DOWNSTREAM HEATED OXYGEN SENSOR (8W-30-13) (8W-30-14) BK/TN BK/TN BK/TN S130...
Page 688 8W - 15 - 8 8W-15 GROUND DISTRIBUTION AUTOMATIC UNDERHOOD BLOWER TEMPERATURE LAMP POWER CONTROL (GAS) MODULE MODULE (8W-44-2) (8W-42-3) (8W-42-2) BLOWER MOTOR HEATER (8W-42-3) CONTROL (8W-42-5) C206 C159 S226 C206 VEHICLE FUEL SPEED HEATER CONTROL RELAY SERVO (IN PDC) (GAS) (DIESEL) (8W-33-2)
Page 689 8W-15 GROUND DISTRIBUTION 8W - 15 - 9 CENTER CENTER CENTER HIGH HIGH HIGH MOUNTED MOUNTED MOUNTED STOP STOP STOP LAMP LAMP LAMP NO. 1 NO. 2 NO. 3 (8W-51-5) (8W-51-5) (8W-51-5) Z1 20BK Z1 20BK LEFT BACK-UP LAMP (8W-51-6) FACTORY TRAILER TRAILER...
Page 690 8W - 15 - 10 8W-15 GROUND DISTRIBUTION REAR LEFT RIGHT WIPER LICENSE LICENSE MOTOR LAMP LAMP (8W-53-4) (8W-51-6) (8W-51-6) REAR WINDOW DEFOGGER (8W-48-2) S419 LIFTGATE LIFTGATE CYLINDER AJAR LOCK SWITCH SWITCH (8W-44-14) (8W-39-5) C364 LIFTGLASS LIFTGLASS AJAR RELEASE SWITCH SOLENOID (8W-44-14) (8W-61-5)
Page 691 8W-15 GROUND DISTRIBUTION 8W - 15 - 11 RIGHT RIGHT TAIL/ BACK-UP STOP LAMP LAMP (8W-51-6) (8W-51-4) RIGHT RIGHT REAR REAR FROM TURN C359 S328 LAMP SIGNAL (8W-15-9) (8W-15-10) (8W-51-7) LAMP (8W-52-5) (8W-52-7) C326 S417 C325 C320 S316 G300 S314 (8W-15-12) ZG001507 J978W-3...
Page 692 8W - 15 - 12 8W-15 GROUND DISTRIBUTION VEHICLE LAMP INFORMATION OUTAGE CENTER MODULE (8W-46-6) (8W-51-5) FROM FROM FROM S316 C328 C372 BK/LB (8W-15-11) (8W-15-9) (8W-15-9) C307 BK/LB C316 OTHERS LAMP OUTAGE MODULE S314 DRIVER LEFT DRIVER DOOR COURTESY DOOR MODULE LAMP MODULE...
Page 693 8W-15 GROUND DISTRIBUTION 8W - 15 - 13 POWER RADIO AIRBAG AMPLIFIER (8W-47-2) CONTROL MODULE (8W-47-10) (8W-43-2) BK/LB C305 PREMIUM RADIO OTHER BK/LB BK/LB BK/LB BK/PK S309 BK/LB BK/LB G303 PASSENGER PASSENGER POWER LUMBAR SEAT SWITCH SWITCH (8W-63-4) (8W-63-9) PASSENGER PASSENGER HEATED HEATED...
Page 694 8W - 15 - 14 8W-15 GROUND DISTRIBUTION RIGHT PASSENGER PASSENGER COURTESY DOOR DOOR LAMP MODULE MODULE (8W-44-2) (8W-60-3) (8W-60-3) (8W-61-3) (8W-61-3) (8W-62-3) (8W-62-3) S325 FROM RIGHT S406 REAR (8W-15-13) FULL POWER POWER OPTION GROUP WINDOW C351 SWITCH (8W-60-4) C345 C335 S333 S304...
Page 695 8W-15 GROUND DISTRIBUTION 8W - 15 - 15 MEMORY DRIVER SEAT LUMBAR MODULE SWITCH (8W-63-2) (8W-63-2) DRIVER DRIVER POWER HEATED SEAT SEAT SWITCH BACK (8W-63-8) (8W-63-11) DRIVER DRIVER SEAT HEATED HEATER SEAT CONTROL CUSHION MODULE (8W-63-11) (8W-63-14) S402 LEFT SEAT FUEL FLOOR REAR...
Page 696 8W - 15 - 16 8W-15 GROUND DISTRIBUTION SUNROOF CONTROL MODULE (8W-64-2) OVERHEAD DOME/ CONSOLE READING (8W-49-2) LAMP (8W-44-3) LEFT AUTOMATIC VISOR/ DAY/ VANITY NIGHT LAMP MIRROR (8W-44-5) (8W-44-7) C371 RIGHT VISOR/ VANITY LAMP (8W-44-5) S322 JUNCTION COURTESY ELECTRONIC BLOCK LAMP FLASHER (8W-12-2)
Page 697 8W-15 GROUND DISTRIBUTION 8W - 15 - 17 BLEND DOOR HEATER ACTUATOR CONTROL (8W-42-7) (8W-42-5) JUNCTION BLOCK CIGAR (8W-12-2) CIGAR LIGHTER LIGHTER (8W-41-3) RELAY (8W-41-3) VT/WT POWER OUTLET (8W-41-3) C206 FROM GLOVE JUNCTION BLOCK RECEIVER (8W-15-16) LAMP LAMP (8W-44-2) (8W-44-12) VT/WT VT/WT S220...
Page 698 8W - 15 - 18 8W-15 GROUND DISTRIBUTION VEHICLE INSTRUMENT BODY INFORMATION CLUSTER CONTROL CENTER (8W-40-2) MODULE (8W-46-4) (8W-45-2) GRAPHIC VEHICLE DISPLAY SPEED MODULE CONTROL/ (8W-46-2) HORN SWITCH (8W-33-3) BK/OR BK/OR BK/OR BK/OR BK/OR BK/OR OVERHEAD MINI CONSOLE OVERHEAD CONSOLE S205 HEADLAMP SWITCH...
Page 699 8W - 15 GROUND DISTRIBUTION 8W - 15 - 19 8W-15 GROUND DISTRIBUTION DESCRIPTION AND OPERATION This section identifies the grounds, splices that connect to those grounds, and the components that connect those grounds. For additional information on system operation, refer to the appropriate section of the wiring diagrams.
Page 701 8W - 20 CHARGING SYSTEM 8W - 20 - 1 8W-20 CHARGING SYSTEM INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
Page 702 8W - 20 - 2 8W-20 CHARGING SYSTEM DIESEL ENGINE POWER BATTERY DISTRIBUTION CENTER (8W-10-3) FUSE 175A (8W-10-4) ENGINE STARTER MOTOR (8W-21-3) RD/BK GENERATOR G100 G101 A142 DG/YL DG/OR S129 (8W-70-7) A142 DG/OR C131 A142 DG/OR POWERTRAIN AUTOMATIC GENERATOR SHUT CONTROL FIELD DOWN...
Page 703 8W-20 CHARGING SYSTEM 8W - 20 - 3 GAS ENGINES POWER BATTERY DISTRIBUTION CENTER (8W-10-3) FUSE 175A (8W-10-4) ENGINE STARTER MOTOR RD/BK (8W-21-4) S126 S137 (8W-15-2) GENERATOR G100 G101 (8W-15-2) DG/VT TRANSMISSION CONTROL C144 RELAY (IN PDC) (8W-31-2) BR/OR S126 C132 (8W-15-2) C132...
Page 704 8W - 20 - 4 8W-20 CHARGING SYSTEM DIESEL ENGINE BATT A0 (8W-10-3) POWER DISTRIBUTION CENTER (8W-10-3) FUSE (8W-10-16) RD/YL RD/YL AUTOMATIC SHUT DOWN RELAY (IN PDC) K900 PK/BK A142 DG/OR C132 C131 K900 A142 PK/BK DG/OR S129 AUTOMATIC (8W-70-7) CONTROLLER SHUT DOWN...
Page 705 8W-20 CHARGING SYSTEM 8W - 20 - 5 GAS ENGINES BATT A0 ST-RUN A21 (8W-10-3) (8W-10-8) POWER DISTRIBUTION CENTER (8W-10-3) FUSE FUSE FUSE (8W-10-16) (8W-10-7) (8W-10-14) RD/YL RD/WT S100 S101 ENGINE (8W-10-16) (8W-10-15) STARTER MOTOR RELAY RD/YL (IN PDC) (8W-21-4) AUTOMATIC SHUT DOWN...
Page 706 8W - 20 - 6 8W - 20 CHARGING SYSTEM 8W-20 CHARGING SYSTEM DESCRIPTION AND OPERATION HELPFUL INFORMATION • Circuit A21 passes through the junction block CHARGING SYSTEM before reaching fuse 18 in the PDC. • The ASD relay supplies battery voltage for the The charging system is an integral part of the bat- fuel injectors, ignition coil, and the heated oxygen tery and starting systems.
Page 707 8W - 21 STARTING SYSTEM 8W - 21 - 1 8W-21 STARTING SYSTEM INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
Page 708 8W - 21 - 2 8W-21 STARTING SYSTEM DIESEL ENGINE POWER DISTRIBUTION FUSE CENTER (8W-10-3) (8W-10-7) ENGINE STARTER RD/WT MOTOR (8W-21-3) C233 RD/WT RD/WT S210 (8W-10-7) ENGINE RD/WT STARTER MOTOR RELAY IGNITION (8W-21-3) SWITCH 1 START 2 RUN 0 OFF 3 ACC (8W-10-7) A41B...
Page 709 8W-21 STARTING SYSTEM 8W - 21 - 3 DIESEL ENGINE FROM IGNITION SWITCH (8W-21-2) A41B CLUTCH INTERLOCK FROM SWITCH POWER DISTRIBUTION CENTER (8W-21-2) T141 YL/RD C233 RD/WT T141 YL/RD ENGINE STARTER MOTOR RELAY (IN PDC) LG/BK C144 FROM POWER DISTRIBUTION CENTER LG/BK (8W-21-2)
Page 710 8W - 21 - 4 8W-21 STARTING SYSTEM GAS ENGINES POWER DISTRIBUTION CENTER FUSE (8W-10-3) (8W-10-7) C233 BATTERY RD/WT RD/WT S210 (8W-10-7) RD/WT IGNITION SWITCH 1 START 2 RUN 0 OFF 3 ACC (8W-10-7) C233 T141 YL/RD ENGINE STARTER MOTOR RELAY (IN PDC) BK/WT...
Page 711 8W - 21 STARTING SYSTEM 8W - 21 - 5 8W-21 STARTING SYSTEM STARTING SYSTEM (DIESEL) DESCRIPTION AND OPERATION Power for the coil side of the engine starter motor STARTING SYSTEM relay is supplied on circuit T141. This circuit is HOT Circuit A0 from the battery is double crimped at when the operator has moved the ignition key to the the positive battery post.
Page 713 8W - 30 FUEL/IGNITION SYSTEMS 8W - 30 - 1 8W-30 FUEL/IGNITION SYSTEMS INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
Page 714 8W - 30 - 2 8W-30 FUEL/IGNITION SYSTEM GAS ENGINES (8W-10-10) BATT A250 JUNCTION BLOCK (8W-12-2) FUSE (8W-12-8) S201 (8W-12-8) DATA LINK CONNECTOR BK/PK BK/OR BK/WT C236 C235 C234 C234 BK/OR C132 BK/PK BK/OR BK/WT G103 S200 BK/PK BK/PK BK/PK SPEED CONTROLLER POWERTRAIN...
Page 715 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 3 GAS ENGINES POWERTRAIN GENERATOR (8W-10-3) BATT A0 CONTROL (8W-20-3) GENERATOR GENERATOR POWER MODULE FIELD FIELD DISTRIBUTION SOURCE SOURCE CENTER FUSE (8W-10-3) (8W-10-14) DG/VT DG/VT C144 DG/VT POWER DISTRIBUTION TRANSMISSION CENTER CONTROL (8W-10-3) RELAY GENERATOR (8W-20-3)
Page 716 8W - 30 - 4 8W-30 FUEL/IGNITION SYSTEM GAS ENGINES BATT A0 ST-RUN A21 (8W-10-3) (8W-10-8) POWER DISTRIBUTION CENTER FUSE FUSE (8W-10-3) (8W-10-16) (8W-10-14) RD/YL S100 S101 (8W-10-16) (8W-10-15) RD/YL EVAPORATIVE DUTY SYSTEM CYCLE LEAK EVAP/ C131 C131 DETECTION PURGE PUMP SOLENOID RD/YL...
Page 717 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 5 GAS ENGINES ST-RUN A21 (8W-10-8) BATT A0 (8W-10-3) POWER DISTRIBUTION CENTER FUSE FUSE (8W-10-3) (8W-10-14) (8W-10-16) RD/YL S101 S100 (8W-10-15) (8W-10-16) RD/YL AUTOMATIC SHUT DOWN RELAY (IN PDC) K900 A142 A142 PK/WT DG/OR DG/OR C131...
Page 718 8W - 30 - 6 8W-30 FUEL/IGNITION SYSTEM GAS ENGINES POWERTRAIN CONTROL MODULE SUPPLY VT/WT S132 VT/WT TRANSMISSION SOLENOID ASSEMBLY (8W-31-3) BK/LB COMPRESSOR CLUTCH PRESSURE 4.0L 5.2L RELAY SWITCH (IN PDC) BK/LB BK/LB S127 (8W-70-2) BK/LB S135 (8W-70-3) DB/BK DB/RD BK/LB POWERTRAIN GOVERNOR...
Page 719 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 7 GAS ENGINES POWERTRAIN THROTTLE MANIFOLD CONTROL POSITION ABSOLUTE MODULE SENSOR PRESSURE (8W-30-8) SENSOR SUPPLY (8W-30-9) (8W-30-8) (8W-30-9) WT/BK WT/BK WT/BK S133 WT/BK WT/BK CAMSHAFT CRANKSHAFT POSITION POSITION SUPPLY SUPPLY SENSOR SENSOR CAMSHAFT CRANKSHAFT POSITION POSITION...
Page 720 8W - 30 - 8 8W-30 FUEL/IGNITION SYSTEM 5.2L ENGINE POWERTRAIN CONTROL MODULE SUPPLY WT/BK S133 (8W-30-7) WT/BK WT/BK MANIFOLD THROTTLE ABSOLUTE POSITION PRESSURE SENSOR SENSOR RD/WT BK/LB BK/LB OR/DB S136 (8W-70-4) BK/LB BK/LB BK/LB ENGINE INTAKE COOLANT S135 TEMPERATURE TEMPERATURE (8W-70-3) SENSOR...
Page 721 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 9 4.0L ENGINE POWERTRAIN CONTROL MODULE SUPPLY WT/BK S133 (8W-30-7) WT/BK WT/BK MANIFOLD THROTTLE ABSOLUTE POSITION PRESSURE SENSOR SENSOR BK/LB BK/LB OR/DB S127 (8W-70-2) BK/LB BK/LB BK/LB ENGINE INTAKE COOLANT S135 TEMPERATURE TEMPERATURE (8W-70-3) SENSOR SENSOR...
Page 722 8W - 30 - 10 8W-30 FUEL/IGNITION SYSTEM GAS ENGINES POWERTRAIN CONTROL OUTPUT OUTPUT SHAFT SHAFT PARK/ SPEED MODULE SPEED SPEED NEUTRAL STOP CONTROL SENSOR SENSOR PRESSURE POSITION LAMP ON/OFF SIGNAL SIGNAL SENSOR SWITCH SENSOR SWITCH SWITCH SIGNAL SENSE GROUND SENSE SENSE YL/RD...
Page 723 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 11 5.2L ENGINE BATT F5 (8W-10-16) POWER DISTRIBUTION AUTOMATIC CENTER SHUT (8W-10-3) DOWN RELAY (8W-20-5) A142 DG/OR C131 A142 DG/OR S128 (8W-70-7) A142 DG/OR S129 (8W-70-7) A142 A142 A142 A142 DG/OR DG/OR DG/OR DG/OR FUEL FUEL...
Page 724 8W - 30 - 12 8W-30 FUEL/IGNITION SYSTEM 5.2L ENGINE BATT F5 (8W-10-16) POWER DISTRIBUTION AUTOMATIC CENTER SHUT (8W-10-3) DOWN RELAY (8W-20-5) A142 DG/OR C131 A142 DG/OR S128 (8W-70-7) A142 A142 A142 A142 DG/OR DG/OR DG/OR DG/OR FUEL FUEL FUEL FUEL INJECTOR INJECTOR...
Page 725 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 13 5.2L ENGINE BATT F5 (8W-10-16) POWER DISTRIBUTION AUTOMATIC CENTER SHUT (8W-10-3) DOWN RELAY (8W-20-5) A142 DG/OR C131 POWERTRAIN A142 POWERTRAIN CONTROL DOWNSTREAM CONTROL UPSTREAM DG/OR MODULE HEATED MODULE HEATED OXYGEN OXYGEN S128 SENSOR SENSOR (8W-70-7)
Page 726 8W - 30 - 14 8W-30 FUEL/IGNITION SYSTEM 4.0L ENGINE BATT F5 (8W-10-16) POWER DISTRIBUTION AUTOMATIC CENTER SHUT (8W-10-3) DOWN RELAY (8W-20-5) A142 DG/OR POWERTRAIN POWERTRAIN CONTROL CONTROL C131 UPSTREAM DOWNSTREAM MODULE MODULE HEATED HEATED OXYGEN OXYGEN SENSOR SENSOR A142 SIGNAL SIGNAL DG/OR...
Page 727 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 15 4.0L ENGINE BATT F5 (8W-10-16) POWER DISTRIBUTION AUTOMATIC CENTER SHUT (8W-10-3) DOWN RELAY (8W-20-5) A142 POWERTRAIN CONTROL DG/OR FUEL FUEL FUEL MODULE INJECTOR INJECTOR INJECTOR NO. 2 NO. 4 NO. 6 DRIVER DRIVER DRIVER C131...
Page 728 8W - 30 - 16 8W-30 FUEL/IGNITION SYSTEM GAS ENGINES ST-RUN A21 BATT A0 (8W-10-8) (8W-10-3) POWERTRAIN BATTERY CONTROL POWER TEMPERATURE MODULE DISTRIBUTION SENSE SIGNAL CENTER FUSE FUSE (8W-10-3) T222 (8W-10-14) (8W-10-14) RD/YL DG/BK BATTERY TEMPERATURE S101 SENSOR (8W-10-15) BK/LB FUEL PUMP RELAY...
Page 729 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 17 GAS ENGINES POWERTRAIN CONTROL MODULE VEHICLE SPEED SPEED CONTROL SENSOR 5 VOLT SENSOR SWITCH GROUND SUPPLY SIGNAL SIGNAL BK/LB VT/WT WT/OR S135 (8W-70-3) 5.2L 4.0L C234 BK/LB BK/LB S132 (8W-70-2) C131 S131 (8W-70-2) BK/LB S102...
Page 730 8W - 30 - 18 8W-30 FUEL/IGNITION SYSTEM GAS ENGINES DATA LINK CONNECTOR TWISTED PAIR WT/BK S203 TWISTED WT/BK PAIR TWISTED WT/BK WT/BK WT/BK WT/BK WT/BK WT/BK WT/BK PAIR TWISTED BODY PAIR CONTROL C302 C231 C235 RADIO MODULE (8W-47-2) (8W-45-2) WT/BK WT/BK WT/BK...
Page 731 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 19 GAS ENGINES DATA LINK CONNECTOR TWISTED VT/BR PAIR S204 TWISTED VT/BR VT/BR VT/BR VT/BR VT/BR VT/BR VT/BR VT/BR PAIR TWISTED PAIR RADIO (8W-47-2) C302 C231 BODY CONTROL MODULE (8W-45-2) TWISTED C235 PAIR VT/BR VT/BR TWISTED...
Page 732 8W - 30 - 20 8W-30 FUEL/IGNITION SYSTEM 5.2L ENGINE IDLE CONTROL MOTOR MOTOR MOTOR MOTOR MOTOR NO. 3 NO. 2 NO. 1 NO. 4 BR/WT YL/BK GY/RD VT/BK POWERTRAIN CONTROL MOTOR MOTOR MOTOR MOTOR NO. 3 NO. 2 NO. 1 NO.
Page 733 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 21 4.0L ENGINE IDLE CONTROL MOTOR MOTOR MOTOR MOTOR MOTOR NO. 3 NO. 2 NO. 1 NO. 4 BR/WT YL/BK GY/RD VT/BK POWERTRAIN CONTROL MOTOR MOTOR MOTOR MOTOR NO. 3 NO. 2 NO. 1 NO.
Page 734 8W - 30 - 22 8W-30 FUEL/IGNITION SYSTEM DIESEL ENGINE ST-RUN A21 BATT A0 (8W-10-8) (8W-10-3) POWER DISTRIBUTION CENTER FUSE FUSE (8W-10-3) (8W-12-20) (8W-10-13) WT/RD S101 (8W-10-15) PRESSURE SWITCH (8W-42-13) POWERTRAIN C131 C131 CONTROL MODULE SWITCH SIGNAL DB/RD S138 C132 (8W-10-15) C103 DB/RD...
Page 735 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 23 DIESEL ENGINE CONTROLLER THROTTLE WAIT PEDAL POSITION COIL IDLE POSITION POSITION SENSOR DRIVER START SENSOR SWITCH SUPPLY SIGNAL LAMP SIGNAL K255 K151 K185 WT/DG VT/WT OR/DB OR/LB OR/RD C182 K255 K151 WT/DG VT/WT OR/DB C307...
Page 736 8W - 30 - 24 8W-30 FUEL/IGNITION SYSTEM DIESEL ENGINE NEEDLE CRANK VEHICLE CONTROLLER MOVEMENT POSITION SPEED SENSOR SENSOR SENSOR SIGNAL SIGNAL POWERTRAIN VEHICLE WATER CONTROL SPEED MODULE SENSOR FUEL SENSOR SUPPLY SENSOR G123 BR/BK GY/BK WT/OR WT/OR OR/WT DG/WT S140 WATER NEEDLE...
Page 737 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 25 DIESEL ENGINE CONTROLLER SLEEVE CONT SLEEVE FUEL FUEL POSITION SLEEVE POSITION TIMING TEMPERATURE SENSOR POSITION SENSOR SHUT-OFF SHUT-OFF SENSOR SENSOR SENSOR FEED SIGNAL K134 K135 K238 K153 K156 LB/BK LG/OR WT/BK FUEL SLEEVE CONT SLEEVE...
Page 738 8W - 30 - 26 8W-30 FUEL/IGNITION SYSTEM DIESEL ENGINE FUEL AUTO AUTO PUMP SHUT SHUT BATT A0 MODULE (8W-10-3) DOWN DOWN RELAY RELAY SENSOR OUTPUT OUTPUT GROUND A142 A142 DG/OR DG/OR BK/LB S421 S128 S136 (8W-70-7) (8W-70-8) A142 A142 DG/OR DG/OR BK/LB...
Page 739 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 27 DIESEL ENGINE BATT A0 ST-RUN A21 (8W-10-3) (8W-10-8) (8W-12-5) POWER (8W-39-2) DISTRIBUTION CENTER FUSE FUSE FUSE (8W-10-3) (8W-10-16) (8W-10-18) (8W-12-20) S101 RD/YL RD/TN (8W-10-15) FUEL HEATER RELAY RD/YL (IN PDC) AUTOMATIC SHUT DOWN RELAY (IN PDC)
Page 740 8W - 30 - 28 8W-30 FUEL/IGNITION SYSTEM DIESEL ENGINE FROM POWERTRAIN FROM FUEL CONTROL FROM HEATER MODULE CONTROLLER S129 CONTROL FUEL (8W-30-27) (8W-30-27) SENSE RELAY (8W-30-27) A142 LB/BK GY/YL DG/OR OR/DB C131 S420 LB/BK OR/DB OR/DB C131 C304 SOLENOID DG/WT DG/WT LB/BK...
Page 741 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 29 DIESEL ENGINE POWERTRAIN ENGINE CONTROL COOLANT MODULE LEVEL PRESSURE SENSOR SWITCH SENSOR SIGNAL SENSE SIGNAL K222 TN/RD PK/BK GY/YL C131 C917 ENGINE COOLANT TEMPERATURE SENSOR PK/BK GY/YL COOLANT LEVEL PRESSURE TN/BK BK/LB SENSOR SENSOR S136...
Page 742 8W - 30 - 30 8W-30 FUEL/IGNITION SYSTEM DIESEL ENGINE BATT A250 (8W-10-10) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-8) S201 (8W-12-8) DATA FUSED LINK B (+) CONNECTOR TRANSMIT RECEIVE RECEIVE RECEIVE TRANSMIT BK/PK BK/OR C235 C234 C236 CONNECTION BK/PK BK/OR BK/WT C132 C234 BK/OR...
Page 743 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 31 DIESEL ENGINE DATA LINK CONNECTOR WT/BK S203 WT/BK WT/BK WT/BK WT/BK WT/BK WT/BK WT/BK WT/BK C302 C231 C235 BODY RADIO CONTROL (8W-47-2) MODULE (8W-45-2) WT/BK WT/BK WT/BK C132 INSTRUMENT VEHICLE CLUSTER INFORMATION (8W-40-3) CENTER (8W-46-7)
Page 744 8W - 30 - 32 8W-30 FUEL/IGNITION SYSTEM DIESEL ENGINE DATA LINK CONNECTOR VT/BR S204 VT/BR VT/BR VT/BR VT/BR VT/BR VT/BR VT/BR VT/BR C302 C231 C235 BODY RADIO CONTROL (8W-47-2) MODULE (8W-45-2) VT/BR VT/BR VT/BR C132 INSTRUMENT VEHICLE CLUSTER INFORMATION (8W-40-3) CENTER VT/BR...
Page 745 8W - 30 FUEL/IGNITION SYSTEMS 8W - 30 - 33 8W-30 FUEL/IGNITION SYSTEMS INDEX page page DESCRIPTION AND OPERATION FUEL PUMP MODULE (DIESEL) ... . 34 ACCELERATOR PEDAL POSITION SENSOR FUEL PUMP MODULE .
Page 746 8W - 30 - 34 8W - 30 FUEL/IGNITION SYSTEMS DESCRIPTION AND OPERATION (Continued) PCM GROUND (DIESEL) plies power to various components and modules in the fuel system. Ground for the Powertrain Control Module (PCM) is supplied on the Z12 circuit. This circuit connects to HELPFUL INFORMATION four cavities in the PCM and terminates at the PCM •...
Page 747 8W - 30 FUEL/IGNITION SYSTEMS 8W - 30 - 35 DESCRIPTION AND OPERATION (Continued) FUEL LEVEL SENSOR The PCM provides a ground for the heated oxygen The fuel level sensor is a variable resistor. Circuit sensor signals (circuits K41 and K141) through cir- G40 provides the fuel level input to the Powertrain cuit K4.
Page 748 8W - 30 - 36 8W - 30 FUEL/IGNITION SYSTEMS DESCRIPTION AND OPERATION (Continued) • Manifold absolute pressure sensor causing a change in current draw. The K2 circuit • Oil pressure sensor connects to cavity A16 of the PCM. • Powertrain control module The PCM provides a ground for the engine coolant •...
Page 749 8W - 30 FUEL/IGNITION SYSTEMS 8W - 30 - 37 DESCRIPTION AND OPERATION (Continued) Circuit K22 delivers the TPS signal to the PCM. Circuit K25 splices to supply 5 volts to the cam- Circuit K22 connects to cavity A23 of the PCM. shaft position sensor, crankshaft position sensor and The PCM provides a ground for the throttle posi- throttle position sensor.
Page 750 8W - 30 - 38 8W - 30 FUEL/IGNITION SYSTEMS DESCRIPTION AND OPERATION (Continued) • Transmission solenoid assembly Circuit K12 provides ground for injector number two. • Upstream heated oxygen sensor The K12 circuit connects to cavity B15 of the PCM. •...
Page 751 8W - 30 FUEL/IGNITION SYSTEMS 8W - 30 - 39 DESCRIPTION AND OPERATION (Continued) FUEL QUANTITY ACTUATOR IDLE AIR CONTROL (IAC) MOTOR Power for the fuel quantity Actuator is supplied on The Powertrain Control Module (PCM) operates circuit A142. This circuit is HOT when the contacts the idle air control motor through 4 circuits;...
Page 753 8W - 31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 1 8W-31 TRANSMISSION CONTROL SYSTEM INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
Page 754 8W - 31 - 2 8W-31 TRANSMISSION SYSTEM POWERTRAIN GENERATOR BATT A0 (8W-10-3) CONTROL (8W-20-3) GENERATOR POWER MODULE FIELD DISTRIBUTION (8W-30-3) SOURCE CENTER FUSE (8W-10-3) (8W-10-14) DG/VT DG/VT C144 DG/VT POWER DISTRIBUTION TRANSMISSION CENTER CONTROL (8W-10-3) RELAY BR/OR C131 C132 TRANSMISSION SOLENOID ASSEMBLY...
Page 755 8W-31 TRANSMISSION SYSTEM 8W - 31 - 3 POWERTRAIN CONTROL MODULE (8W-30-6) SUPPLY VT/WT S132 (8W-70-2) VT/WT TRANSMISSION SOLENOID ASSEMBLY BK/LB 4.0L 5.2L BK/LB BK/LB S127 (8W-70-2) BK/LB S135 (8W-70-3) BK/LB POWERTRAIN GOVERNOR SENSOR TRANSMISSION CONTROL PRESSURE GROUND TEMPERATURE SIGNAL SENSOR MODULE SIGNAL...
Page 756 8W - 31 - 4 8W-31 TRANSMISSION SYSTEM POWERTRAIN CONTROL OUTPUT OUTPUT MODULE SHAFT SHAFT SPEED SPEED THROTTLE VEHICLE (8W-30-8) SENSOR SENSOR POSITION SPEED (8W-30-9) SIGNAL SIGNAL SENSOR SENSOR SENSOR (8W-30-10) SIGNAL SUPPLY GROUND SUPPLY SIGNAL (8W-30-17) WT/BK S133 (8W-30-7) LG/WT DB/BK OR/DB...
Page 757 8W-31 TRANSMISSION SYSTEM 8W - 31 - 5 ST-RUN A21 RUN A22 (8W-10-8) (8W-10-8) JUNCTION BLOCK (8W-12-2) FUSE FUSE (8W-10-5) (8W-12-10) (8W-12-5) POWERTRAIN CONTROL OVERDRIVE BK/WT MODULE SWITCH S215 (8W-30-4) SENSE (8W-12-5) BK/WT PK/DG SHIFT C234 S218 INTERLOCK (8W-12-10) PK/DG OVERDRIVE PRESSURE SWITCH...
Page 758 8W - 31 - 6 8W-31 TRANSMISSION SYSTEM DIESEL ENGINE POWERTRAIN OUTPUT OUTPUT CONTROL CONTROLLER SHAFT SHAFT SPEED SPEED MODULE THROTTLE (8W-30-23) SENSOR SENSOR PEDAL IDLE POSITION (8W-70-2) SIGNAL SIGNAL POSITION POSITION SENSOR SENSOR SWITCH SUPPLY SIGNAL K255 K151 OR/DB LG/WT DB/BK WT/DG...
Page 759 8W - 31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 7 8W-31 TRANSMISSION CONTROL SYSTEM INDEX page page DESCRIPTION AND OPERATION SHIFT INTERLOCK ..... . . 7 GOVERNOR PRESSURE SENSOR .
Page 760 8W - 31 - 8 8W - 31 TRANSMISSION CONTROL SYSTEM DESCRIPTION AND OPERATION (Continued) B29 of the PCM. Circuit K6 from cavity B31 of the Circuit K4 also provides ground for the signals PCM supplies 5 volts to the sensor. The PCM pro- from the following: •...
Page 761 8W - 33 VEHICLE SPEED CONTROL 8W - 33 - 1 8W-33 VEHICLE SPEED CONTROL INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
Page 762 8W - 33 - 2 8W-33 VEHICLE SPEED CONTROL GAS ENGINES POWERTRAIN BATT A250 (8W-10-10) CONTROL JUNCTION SPEED SPEED SPEED MODULE CONTROL CONTROL CONTROL STOP BLOCK VACUUM VENT ON/OFF LAMP (8W-30-4) (8W-12-2) FUSE SOLENOID SOLENOID SWITCH SWITCH (8W-30-4) (8W-30-10) CONTROL CONTROL SENSE SENSE...
Page 763 8W-33 VEHICLE SPEED CONTROL 8W - 33 - 3 GAS ENGINES POWERTRAIN CONTROL MODULE VEHICLE SPEED SPEED CONTROL (8W-30-17) SENSOR 5 VOLT SENSOR SWITCH GROUND SUPPLY SIGNAL SIGNAL BK/LB VT/WT WT/OR S135 (8W-70-3) 5.2L 4.0L C234 BK/LB BK/LB S132 (8W-70-2) C131 S131 (8W-70-2)
Page 764 8W - 33 - 4 8W-33 VEHICLE SPEED CONTROL DIESEL ENGINE POWERTRAIN CONTROLLER CONTROL SPEED (8W-30-29) MODULE CONTROL STOP ON/OFF LAMP SWITCH SWITCH SENSE SENSE BATT A250 (8W-10-10) JUNCTION BLOCK FUSE (8W-12-2) YL/RD (8W-12-7) C132 YL/RD C234 RD/LG YL/RD STOP LAMP SWITCH WT/TN...
Page 765 8W-33 VEHICLE SPEED CONTROL 8W - 33 - 5 DIESEL ENGINE CONTROLLER (8W-30-24) VEHICLE SPEED SPEED CONTROL SENSOR SENSOR SWITCH GROUND SIGNAL SIGNAL POWERTRAIN VEHICLE CONTROL SPEED MODULE BK/LB SENSOR SENSOR (8W-30-24) GROUND SUPPLY SIGNAL WT/OR S136 (8W-70-8) BK/LB C144 K167 C131 BR/YL...
Page 766 8W - 33 - 6 8W - 33 VEHICLE SPEED CONTROL 8W-33 VEHICLE SPEED CONTROL DESCRIPTION AND OPERATION switch disconnects circuits V32 and V30, power is removed from the speed control servo. VEHICLE SPEED CONTROL HELPFUL INFORMATION The Powertrain Control Module (PCM) operates Circuit K4 also provides ground for some of the the vehicle speed control system.
Page 767 8W - 35 ALL-WHEEL ANTI-LOCK BRAKES 8W - 35 - 1 8W-35 ALL-WHEEL ANTI-LOCK BRAKES INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
Page 768 8W - 35 - 2 8W-35 ANTI-LOCK BRAKES RUN A22 BATT A0 (8W-10-8) (8W-10-3) JUNCTION POWER BLOCK DISTRIBUTION CENTER (8W-12-2) FUSE FUSE FUSE (8W-10-3) (8W-12-9) (8W-10-10) (8W-10-5) DB/WT RD/LG RD/DB CONTROLLER FUSED FUSED FUSED ANTI-LOCK IGN. B (+) B (+) (ST-RUN) BRAKE RECEIVE...
Page 769 8W-35 ANTI-LOCK BRAKES 8W - 35 - 3 BATT A250 (8W-10-10) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-7) RD/LG STOP LAMP SWITCH (8W-33-2) WT/TN SWITCH C305 WT/TN S312 (8W-70-5) WT/TN PK/OR YL/VT TN/WT C304 C304 WT/TN PK/OR YL/VT TN/WT CONTROLLER STOP SENSOR ACCEL ACCEL ANTI-LOCK...
Page 770 8W - 35 - 4 8W-35 ANTI-LOCK BRAKES LEFT RIGHT REAR FRONT WHEEL WHEEL SPEED SPEED SENSOR SENSOR LEFT RIGHT FRONT REAR WHEEL WHEEL SPEED SPEED SENSOR SENSOR LG/DB WT/DB RD/DB YL/DB TWISTED TWISTED PAIR PAIR TWISTED TWISTED PAIR PAIR C304 C304 TWISTED...
Page 771 8W - 35 ALL-WHEEL ANTI-LOCK BRAKES 8W - 35 - 5 8W-35 ALL-WHEEL ANTI-LOCK BRAKES INDEX page page DESCRIPTION AND OPERATION INTRODUCTION ......5 ABS WARNING LAMP .
Page 773 8W - 39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 1 8W-39 VEHICLE THEFT SECURITY SYSTEM INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
Page 774 8W - 39 - 2 8W-39 VEHICLE THEFT SECURITY SYSTEM BATT A0 (8W-10-3) POWER DISTRIBUTION CENTER FUSE FUSE (8W-10-3) (8W-10-7) (8W-10-13) (8W-10-14) RD/WT RD/WT DB/GY C233 ENGINE STARTER MOTOR RELAY RD/WT S101 (IN PDC) (8W-10-15) (8W-21-3) (8W-21-4) S210 RD/WT RD/WT IGNITION C236 SWITCH...
Page 775 8W-39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 3 BATT A0 (8W-10-3) POWER DISTRIBUTION CENTER FUSE FUSE (8W-10-3) (8W-10-11) (8W-10-10) A250 RD/LB JUNCTION BLOCK (8W-12-2) FUSE FUSE (8W-12-14) (8W-12-8) PARK LAMP RELAY DB/RD S201 (8W-12-8) AUTOMATIC HEADLAMP LIGHT SENSOR/ VTSS (8W-45-4) (8W-50-5)
Page 776 8W - 39 - 4 8W-39 VEHICLE THEFT SECURITY SYSTEM BODY CONTROL HOOD MODULE AJAR LIFTGATE SWITCH AJAR (8W-45-2) SENSE SWITCH (8W-45-10) (VTSS) SENSE GROUND GROUND GROUND BR/TN TN/BK BK/OR C235 C321 BR/TN TN/BK HOOD S202 S205 SWITCH (8W-15-18) (8W-15-18) S329 (8W-44-14) (8W-45-11)
Page 777 8W-39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 5 BODY LEFT LEFT RIGHT RIGHT CONTROL REAR FRONT REAR FRONT MODULE DOOR DOOR DOOR DOOR AJAR AJAR VTSS AJAR AJAR SWITCH SWITCH DISARM SWITCH SWITCH SENSE SENSE SENSE SENSE SENSE TN/OR VT/YL TN/YL...
Page 778 8W - 39 - 6 8W-39 VEHICLE THEFT SECURITY SYSTEM BATT A0 (8W-10-3) POWER DISTRIBUTION CENTER FUSE (8W-10-3) (8W-10-5) F31 16 VT HORN RELAY (IN PDC) DG/YL GY/OR S106 JUNCTION BLOCK (8W-12-2) DG/YL DG/YL HORN HORN NO. 2 NO. 1 GY/OR GY/OR CLOCKSPRING...
Page 779 8W - 39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 7 8W-39 VEHICLE THEFT SECURITY SYSTEM INDEX page page DESCRIPTION AND OPERATION VEHICLE THEFT SECURITY SYSTEM INTRODUCTION ......7 OPERATION .
Page 781 8W - 40 INSTRUMENT CLUSTER 8W - 40 - 1 8W-40 INSTRUMENT CLUSTER INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
Page 782 8W - 40 - 2 8W-40 INSTRUMENT CLUSTER BATT A250 (8W-10-10) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-8) S201 (8W-12-8) INSTRUMENT CLUSTER AIRBAG SEAT CHECK WARNING BELT ENGINE FUEL LAMP WARNING LAMP WARNING LAMP LAMP FUSED B(+) GROUND BK/OR S216 S205 (8W-15-17) (8W-15-18) BK/OR C307...
Page 783 8W-40 INSTRUMENT CLUSTER 8W - 40 - 3 INSTRUMENT ENGINE COOLANT CLUSTER FUEL VOLT PRESSURE TEMPERATURE GAUGE METER GAUGE GAUGE FUEL VOLT ENGINE COOLANT GAUGE METER PRESSURE TEMPERATURE GAUGE GAUGE CONTROL SPEEDOMETER TACHOMETER CONTROL CONTROL SPEEDOMETER TACHOMETER VT/BR WT/BK TWISTED PAIR S204 (8W-30-19)
Page 784 8W - 40 - 4 8W-40 INSTRUMENT CLUSTER BODY HEADLAMP CONTROL SWITCH MODULE (8W-50-5) (8W-45-10) LG/DB C234 S209 (8W-44-11) LG/DB INSTRUMENT C102 CLUSTER ILLUMINATION LAMPS TN/DB S409 (8W-15-5) LEFT RIGHT TURN TURN GROUND SIGNAL SIGNAL INDICATOR INDICATOR TN/DB LAMP LAMP LEFT FRONT TURN...
Page 785 8W-40 INSTRUMENT CLUSTER 8W - 40 - 5 BATT A250 ST-RUN A21 (8W-10-10) (8W-10-8) JUNCTION BLOCK (8W-12-2) FUSE FUSE (8W-12-5) (8W-12-8) DIESEL BK/WT LAMP S201 S215 DRIVER (8W-12-8) (8W-12-5) BK/WT BK/WT INSTRUMENT CLUSTER BRAKE HIGH CHECK CRUISE WARNING BEAM GAGES LAMP LAMP INDICATOR...
Page 786 8W - 40 - 6 8W-40 INSTRUMENT CLUSTER BODY CONTROL BRAKE MODULE SWITCH (8W-45-9) SENSE GY/BK S303 (8W-45-9) (8W-45-9) (8W-50-4) (8W-50-4) GY/BK C304 OTHERS GY/BK GY/BK BRAKE WARNING SWITCH GY/BK C234 GY/BK IGNITION SWITCH 1 START 2 RUN 0 OFF 3 ACC (8W-10-7) J978W-3...
Page 787 8W - 40 INSTRUMENT CLUSTER 8W - 40 - 7 8W-40 INSTRUMENT CLUSTER INDEX page page DESCRIPTION AND OPERATION OIL PRESSURE GAUGE ....7 ABS WARNING LAMP .
Page 788 8W - 40 - 8 8W - 40 INSTRUMENT CLUSTER DESCRIPTION AND OPERATION (Continued) Powertrain Control Module (PCM) transmits the the turn signal indicator lamps. Circuit L64 powers data over the CCD bus. the right turn signal indicator lamp. Circuit L65 powers the left indicator lamp.
Page 789 8W - 41 HORN/CIGAR LIGHTER 8W - 41 - 1 8W-41 HORN/CIGAR LIGHTER INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
Page 790 8W - 41 - 2 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET BATT A0 (8W-10-3) POWER DISTRIBUTION CENTER FUSE (8W-10-3) (8W-10-5) F31 16 VT HORN RELAY GY/OR DG/YL JUNCTION BLOCK (8W-12-2) S106 DG/YL DG/YL GY/OR GY/OR HORN HORN NO. 2 NO. 1 CLOCKSPRING BODY HORN (8W-45-3)
Page 791 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET 8W - 41 - 3 BATT A7 BATT F61 RUN-ACC A31 (8W-10-12) (8W-10-9) (8W-10-9) JUNCTION BLOCK FUSE FUSE FUSE (8W-12-2) (8W-12-16) (8W-12-3) (8W-12-3) CONNECTION RD/BK JUNCTION BLOCK CIGAR (8W-12-2) LIGHTER RELAY RD/DB POWER CIGAR OUTLET LIGHTER S220 (8W-15-17) S216...
Page 792 8W - 41 - 4 8W - 41 HORN/CIGAR LIGHTER 8W-41 HORN/CIGAR LIGHTER DESCRIPTION AND OPERATION SORY or RUN position, the switch connects circuit A1 from fuse 8 in the Power Distribution Center HORN (PDC) to circuit A31. Circuit A31 powers relay coil. Circuit Z1 provides ground for the relay coil.
Page 793 8W - 42 AIR CONDITIONING/HEATER 8W - 42 - 1 8W-42 AIR CONDITIONING/HEATER INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
Page 794 8W - 42 - 2 8W-42 AIR CONDITIONING-HEATER BATT A7 BATT A0 (8W-10-12) (8W-10-3) JUNCTION POWER BLOCK DISTRIBUTION (8W-12-2) CENTER FUSE FUSE (8W-10-3) (8W-12-16) (8W-10-6) WT/RD RD/VT C160 AUTOMATIC FUSED TEMPERATURE B (+) CONTROL MODULE GROUND BLOWER MOTOR (MANUAL A/C HEATER) C206 S221 S226...
Page 795 8W-42 AIR CONDITIONING-HEATER 8W - 42 - 3 BATT A0 (8W-10-3) POWER DISTRIBUTION CENTER FUSE (8W-10-3) (8W-10-6) RD/VT C160 S225 RD/VT DG/RD HIGH SPEED BLOWER MOTOR RELAY BR/RD S224 BR/RD BR/RD C206 BLOWER BLOWER FUSED BLOWER POWER MOTOR B (+) MOTOR DRIVER MODULE...
Page 796 8W - 42 - 4 8W-42 AIR CONDITIONING-HEATER FROM FROM BLOWER BLOWER FROM BLOWER MOTOR MOTOR MOTOR MODULE MODULE (8W-42-3) (8W-42-3) (8W-42-3) BR/YL S226 C206 YL/BR C160 C206 AUTOMATIC BLOWER TEMPERATURE POWER MODULE CONTROL OUTPUT MODULE SELECT PANEL INPUT LAMP S124 (8W-15-8) S214...
Page 797 8W-42 AIR CONDITIONING-HEATER 8W - 42 - 5 BLOWER RUN A22 (8W-10-8) MOTOR JUNCTION RESISTOR BLOCK BLOCK FUSE (8W-12-2) (8W-12-10) S221 BK/TN C206 BLOWER MOTOR (8W-42-2) (8W-42-3) DG/PK BK/TN HEATER HEATER CONTROL CONTROL 1 DEFROST ILLUM. 2 MIX MODE SWITCH BLOWER BLOWER SWITCH SWITCH...
Page 798 8W - 42 - 6 8W-42 AIR CONDITIONING-HEATER AUTOMATIC BLEND IN-CAR TEMPERATURE DOOR TEMPERATURE SOLAR CONTROL SENSOR SENSOR SENSOR ACTUATOR MODULE SIGNAL SIGNAL GROUND (ATC) (8W-42-7) (8W-42-8) RD/TN BK/WT LG/WT S222 IN-CAR SOLAR TEMPERATURE SENSOR SENSOR LG/WT LG/WT C206 MODE SENSOR DOOR GROUND...
Page 799 8W-42 AIR CONDITIONING-HEATER 8W - 42 - 7 MANUAL RUN A22 (8W-10-8) JUNCTION BLOCK FUSE (8W-12-2) (8W-12-10) FROM FROM FROM HEATER HEATER HEATER CONTROL CONTROL CONTROL (8W-42-5) (8W-42-5) (8W-42-5) PK/DG DB/RD VT/WT S218 C206 S220 C206 (8W-12-10) (8W-15-17) DB/RD VT/WT PK/DG C206 C206...
Page 800 8W - 42 - 8 8W-42 AIR CONDITIONING-HEATER MODE DOOR ACTUATOR TN/BK LG/WT DG/YL S222 C206 S223 C206 LG/WT LG/WT DG/YL C206 C206 LG/WT BR/WT S219 (8W-42-6) LG/WT AUTOMATIC AUTOMATIC MODE MODE SENSOR MODE TEMPERATURE TEMPERATURE DOOR DOOR GROUND DOOR SUPPLY MOTOR MOTOR...
Page 801 8W-42 AIR CONDITIONING-HEATER 8W - 42 - 9 RUN A22 (8W-10-8) JUNCTION DATA BLOCK LINK (8W-12-2) CONNECTOR (8W-30-18) FUSE (8W-30-19) (8W-30-31) (8W-30-32) (8W-12-10) TWISTED VT/BR WT/BK PAIR S204 S203 (8W-30-19) (8W-30-18) (8W-30-32) (8W-30-31) PK/DG DG/PK VT/BR WT/BK AUTOMATIC FUSED TEMPERATURE IGN.
Page 802 8W - 42 - 10 8W-42 AIR CONDITIONING-HEATER GAS ENGINES ST-RUN A21 BATT A900 (8W-10-8) (8W-10-4) POWER DISTRIBUTION FUSE CENTER FUSE (8W-10-3) (8W-10-4) (8W-10-13) F250 S101 RD/GY (8W-10-15) COMPRESSOR CLUTCH RELAY (IN PDC) DB/RD DB/YL DIESEL 4.0L 5.2L DB/YL DB/YL POWERTRAIN C131 C144...
Page 803 8W-42 AIR CONDITIONING-HEATER 8W - 42 - 11 DIESEL ENGINE BATT A0 (8W-10-3) POWER DISTRIBUTION CENTER FUSE FUSE (8W-10-3) FUSE (8W-10-18) (8W-10-4) (8W-10-4) A900 F250 RD/YL OR/YL RD/GY F5 16 RD/YL AUTOMATIC SHUT DOWN RELAY (IN PDC) A142 DG/OR COMPRESSOR CLUTCH RELAY (IN PDC)
Page 804 8W - 42 - 12 8W-42 AIR CONDITIONING-HEATER GAS ENGINES FROM COMPRESSOR CLUTCH RELAY (8W-42-10) DB/RD POWERTRAIN CONTROL COMPRESSOR CLUTCH MODULE RELAY (8W-30-6) PRESSURE CONTROL SWITCH DB/BK PRESSURE SWITCH DB/OR C144 DB/OR HIGH PRESSURE SWITCH C144 S104 (8W-15-7) G106 (8W-15-7) J978W-3 ZG004210...
Page 805 8W-42 AIR CONDITIONING-HEATER 8W - 42 - 13 DIESEL ENGINE FROM COMPRESSOR CLUTCH RELAY (8W-42-11) DB/BK C131 DB/BK HIGH PRESSURE SWITCH DB/OR C144 DB/OR PRESSURE SWITCH POWERTRAIN CONTROL MODULE SWITCH (8W-30-22) SIGNAL DB/RD C132 C103 DB/RD CONTROLLER SWITCH COMPRESSOR SIGNAL CLUTCH (8W-30-29) RELAY...
Page 806 8W - 42 - 14 8W - 42 AIR CONDITIONING/HEATER 8W-42 AIR CONDITIONING/HEATER INDEX page page GENERAL INFORMATION BLEND DOOR MOTOR—AUTOMATIC INTRODUCTION ......14 TEMPERATURE CONTROL .
Page 807 8W - 42 AIR CONDITIONING/HEATER 8W - 42 - 15 DESCRIPTION AND OPERATION (Continued) Module (BCM) receives the A/C select signal on cir- When the ignition switch is in the START or RUN cuit C90. After receiving the input, the BCM signals position, it connects circuit A1 from PDC fuse 8 to the Powertrain Control Module (PCM) on the CCD circuit A21.
Page 808 8W - 42 - 16 8W - 42 AIR CONDITIONING/HEATER DESCRIPTION AND OPERATION (Continued) pressure switch connects circuit C21 to ground cir- switch in the blend door motor. The ATC module cuit Z1. If the A/C low pressure and high pressure receives the sensor signal from the blend door motor switches are closed, the PCM senses the A/C request on circuit C36.
Page 809 8W - 43 AIRBAG SYSTEM 8W - 43 - 1 8W-43 AIRBAG SYSTEM INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
Page 810 8W - 43 - 2 8W-43 AIRBAG SYSTEM RUN A22 ST-RUN A21 (8W-10-8) (8W-10-8) JUNCTION BLOCK (8W-12-2) FUSE FUSE (8W-12-23) (8W-12-5) DB/WT AIRBAG FUSED FUSED CONTROL IGN. IGN. (RUN) (ST-RUN) MODULE DRIVER DRIVER PASSENGER PASSENGER AIRBAG AIRBAG AIRBAG AIRBAG LINE 1 LINE 2 LINE 1 LINE 2...
Page 811 8W-43 AIRBAG SYSTEM 8W - 43 - 3 BATT A250 (8W-10-10) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-8) S201 (8W-12-8) INSTRUMENT CLUSTER (8W-40-2) (8W-40-3) AIRBAG WARNING LAMP BUS (+) BUS (-) GROUND TWISTED PAIR VT/BR WT/BK BK/OR S216 S205 S204 S203 (8W-15-17) (8W-15-18) (8W-30-19) (8W-30-18)
Page 812 8W - 43 - 4 8W - 43 AIRBAG SYSTEM 8W-43 AIRBAG SYSTEM INDEX page page DESCRIPTION AND OPERATION AIRBAG WARNING LAMP ....4 AIRBAG IMPACT SENSOR .
Page 813 8W - 44 INTERIOR LIGHTING 8W - 44 - 1 8W-44 INTERIOR LIGHTING INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
Page 814 8W - 44 - 2 8W-44 INTERIOR LIGHTING BATT A7 (8W-10-12) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-12) KEY-IN GLOVE LEFT RIGHT COURTESY COURTESY SWITCH/ LAMP LAMP LAMP HALO C159 LAMP JUNCTION BLOCK (8W-12-2) COURTESY LAMP RELAY (8W-44-8) UNDERHOOD LAMP MERCURY SWITCH S220 (8W-15-17) S216...
Page 815 8W-44 INTERIOR LIGHTING 8W - 44 - 3 BATT A7 (8W-10-12) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-12) S321 (8W-12-13) DOME/ READING LAMP SUNROOF OTHERS S322 S334 (8W-15-16) (8W-12-21) JUNCTION BLOCK (8W-12-2) COURTESY LAMP RELAY (8W-44-8) ZG004402 J978W-3...
Page 816 8W - 44 - 4 8W-44 INTERIOR LIGHTING BATT A7 (8W-10-12) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-12) S321 (8W-12-13) OVERHEAD CONSOLE (8W-49-2) (8W-49-3) SUNROOF OTHERS S322 (8W-15-16) S334 (8W-12-21) JUNCTION BLOCK (8W-12-2) COURTESY LAMP RELAY (8W-44-8) J978W-3 ZG004403...
Page 817 8W-44 INTERIOR LIGHTING 8W - 44 - 5 BATT A7 (8W-10-12) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-12) S321 (8W-12-13) LEFT RIGHT CARGO VISOR/ VISOR/ LAMP VANITY VANITY LAMP LAMP UNIVERSAL GARAGE DOOR OPENER WT/LG BODY LIFTGATE CONTROL COURTESY S322 LAMP MODULE (8W-12-21) DISABLE (8W-45-10)
Page 818 8W - 44 - 6 8W-44 INTERIOR LIGHTING RUN A22 (8W-10-8) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-6) DRIVER AUTOMATIC AUTOMATIC POWER YL/DG DAY/ DAY/ MIRROR NIGHT NIGHT S212 MIRROR MIRROR (8W-62-4) (8W-12-6) OVERHEAD CONSOLE OTHERS C353 YL/DG C235 P114 P112 YL/DG YL/BK YL/WT S323...
Page 819 8W-44 INTERIOR LIGHTING 8W - 44 - 7 POWERTRAIN PARK/ CONTROL NEUTRAL MODUAL POSITION SWITCH SENSE FROM AUOMATIC DAY/ NIGHT FROM FROM C132 MIRROR S322 BK/WT (8W-44-6) (8W-44-6) (8W-44-6) S134 YL/DG BK/RD BK/WT PARK/ JUNCTION NEUTRAL BLOCK POSITION (8W-12-22) SWITCH BR/LG BR/LG C131...
Page 820 8W - 44 - 8 8W-44 INTERIOR LIGHTING BATT A7 (8W-10-12) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-12) FROM S214 (8W-44-12) COURTESY LAMP RELAY RADIO (8W-47-2) M112 BR/LG S220 (8W-15-17) RIGHT COURTESY BODY COURTESY C305 LAMP CONTROL LAMP (8W-44-2) RELAY MODULE CONTROL (8W-45-3) S216 BK/LB...
Page 821 8W-44 INTERIOR LIGHTING 8W - 44 - 9 BATT A250 (8W-10-10) JUNCTION BLOCK (8W-12-2) CIRCUIT BREAKER (8W-12-7) C334 DRIVER FUSED DOOR B (+) COURTESY MODULE LAMP (8W-60-2) DRIVER GROUND TWISTED PAIR VT/BR WT/BK LEFT C334 FULL POWER DOOR OPTION GROUP COURTESY VT/BR WT/BK...
Page 822 8W - 44 - 10 8W-44 INTERIOR LIGHTING BATT A250 (8W-10-10) JUNCTION BLOCK (8W-12-2) CIRCUIT BREAKER (8W-12-7) C351 PASSENGER FUSED DOOR B (+) COURTESY MODULE LAMP (8W-60-3) DRIVER GROUND TWISTED PAIR VT/BR WT/BK C351 RIGHT FULL DOOR OPTION OTHERS COURTESY VT/BR WT/BK LAMP...
Page 823 8W-44 INTERIOR LIGHTING 8W - 44 - 11 BODY HEADLAMP CONTROL SWITCH RECEIVER PANEL MODULE (8W-50-2) LAMP LAMP ILLUM. (8W-50-5) (8W-45-2) (8W-44-12) DRIVER LAMPS (8W-50-7) S214 (8W-44-12) S209 SWITCH INSTRUMENT CLUSTER ILLUMINATION CLUSTER (8W-40-2) C302 (8W-40-5) BK/OR S216 S205 (8W-15-17) (8W-15-18) FLOOR CONSOLE...
Page 824 8W - 44 - 12 8W-44 INTERIOR LIGHTING BODY CONTROL PANEL MODULE LAMP (8W-45-2) DRIVER S209 (8W-44-11) S214 MANUAL PREMIUM OVERHEAD HEATER CONSOLE OTHERS RECEIVER LAMP VEHICLE INFORMATION HEATER CENTER CONTROL (8W-46-4) (8W-42-5) GRAPHIC DISPLAY MODULE AUTOMATIC (8W-46-2) PANEL TEMPERATURE LAMP S220 CONTROL...
Page 825 8W-44 INTERIOR LIGHTING 8W - 44 - 13 BATT A6 JUNCTION BODY BLOCK CONTROL PANEL LAMP MODULE FUSE PANEL DIMMER LAMP SWITCH DRIVER SIGNAL PK/OR BK/WT S209 HEADLAMP SWITCH 0 OFF 1 HEAD ILLUMINATION 2 PARK LAMPS 3 AUTO S202 C301 G304 ZG004412...
Page 826 8W - 44 - 14 8W-44 INTERIOR LIGHTING BODY LEFT LEFT RIGHT RIGHT CONTROL FRONT REAR FRONT REAR MODULE DOOR DOOR DOOR DOOR LIFTGATE (8W-45-8) AJAR AJAR AJAR AJAR AJAR SWITCH SWITCH SWITCH SWITCH SWITCH SENSE SENSE SENSE SENSE SENSE TN/OR TN/RD TN/YL...
Page 827 8W - 44 INTERIOR LIGHTING 8W - 44 - 15 8W-44 INTERIOR LIGHTING INDEX page page DESCRIPTION AND OPERATION INTRODUCTION ......15 COURTESY LAMPS, CARGO LAMP, IGNITION OVERHEAD CONSOLE LAMPS .
Page 828 8W - 44 - 16 8W - 44 INTERIOR LIGHTING DESCRIPTION AND OPERATION (Continued) LIFTGATE COURTESY LAMP DISABLE OVERHEAD CONSOLE LAMPS SWITCH Circuit A7 from fuse 15 in the Power Distribution When closed, the liftgate disable switch provides Center (PDC) powers circuit M1 through fuse 16 in signal to the BCM on circuit M4 indicating a request the junction block.
Page 829 8W - 45 BODY CONTROL MODULE 8W - 45 - 1 8W-45 BODY CONTROL MODULE INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
Page 830 8W - 45 - 2 8W-45 BODY CONTROL MODULE RUN-ACC A31 RUN-ST A21 (8W-10-7) (8W-10-7) JUNCTION POWER BLOCK DISTRIBUTION FUSE (8W-12-2) CENTER FUSE (8W-10-3) (8W-10-13) (8W-10-14) (8W-12-4) DATA LINK BR/PK CONNECTOR S101 (8W-10-15) TWISTED VT/BR WT/BK PAIR S204 S203 C236 VT/BR WT/BK BODY...
Page 831 8W-45 BODY CONTROL MODULE 8W - 45 - 3 BATT A0 (8W-10-3) POWER DISTRIBUTION CENTER FUSE FUSE (8W-10-3) (8W-10-5) (8W-10-3) HORN RELAY (8W-39-6) (8W-41-2) A900 GY/OR OR/YL JUNCTION BLOCK COURTESY REAR (8W-12-2) LAMP WINDOW RELAY DEFOGGER RELAY (8W-44-8) (8W-12-9) (8W-48-2) S220 (8W-15-17) S216...
Page 832 8W - 45 - 4 8W-45 BODY CONTROL MODULE BATT A6 BATT A250 (8W-10-11) (8W-10-10) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-14) FUSE PARK (8W-12-8) LAMP RELAY S201 (8W-12-8) AUTOMATIC DB/RD HEADLAMP LIGHT SENSOR/ VTSS L109 L110 BK/LG OR/BK BODY PARK PARK FUSED VTSS ULTRALIGHT...
Page 833 8W-45 BODY CONTROL MODULE 8W - 45 - 5 HEADLAMP JUNCTION AUTOMATIC DIMMER BLOCK LAMP HEADLAMP SWITCH (8W-12-2) RELAY RELAY (8W-50-2) (8W-12-24) (8W-12-24) (8W-50-6) (8W-50-2) RD/OR C234 RD/OR S107 (8W-50-3) RD/OR C234 VT/OR RD/OR DG/YL BK/OR BODY DIMMER DIMMER AUTOMATIC CONTROL SWITCH SWITCH...
Page 834 8W - 45 - 6 8W-45 BODY CONTROL MODULE BODY SWITCHED CONTROL COURTESY MODULE LAMP FEED PK/LB HEADLAMP SWITCH (8W-50-5) 0 OFF 1 LOW 2 PARK 3 AUTO 4 DIMMER 5 FOG LAMP 6 COURTESY LAMP LAMP SWITCH (8W-50-7) S202 (8W-15-18) BR/WT BK/WT...
Page 835 8W-45 BODY CONTROL MODULE 8W - 45 - 7 RUN-ACC A31 (8W-10-7) JUNCTION BLOCK (8W-12-2) CIRCUIT BREAKER (8W-12-4) LG/BK LG/RD INTERMITTENT WIPER SWITCH S122 (PART OF (8W-12-4) MULTI-FUNCTION (8W-53-3) SWITCH) S207 (8W-53-2) INTERMITTENT LG/RD WIPER SWITCH C234 (PART OF MULTI-FUNCTION SWITCH) (8W-53-2) INTERMITTENT...
Page 836 8W - 45 - 8 8W-45 BODY CONTROL MODULE LIFTGATE RIGHT LEFT CYLINDER FRONT FRONT LOCK CYLINDER CYLINDER SWITCH LOCK LOCK (8W-39-5) SWITCH SWITCH (8W-39-5) (8W-39-5) VT/YL VT/YL VT/YL C321 C351 C334 VT/YL VT/YL VT/YL S305 (8W-39-5) VT/YL BODY VTSS LEFT LEFT RIGHT...
Page 837 8W-45 BODY CONTROL MODULE 8W - 45 - 9 BRAKE AUTOMATIC WARNING TEMPERATURE SWITCH CONTROL SELECT (8W-40-6) MODULE INPUT (8W-42-4) A/C HEATER CONTROL (8W-42-5) SELECT INPUT AMBIENT TEMPERATURE SENSOR GY/BK OTHERS DG/RD LG/WT MANUAL C234 C235 GY/BK S117 GY/BK (8W-40-6) LG/WT (8W-50-4) GY/BK...
Page 838 8W - 45 - 10 8W-45 BODY CONTROL MODULE CARGO INSTRUMENT FLOOR SWITCH LAMP CLUSTER CONSOLE RECEIVER LAMPS LAMP (8W-44-5) (8W-40-4) (8W-44-11) (8W-44-11) (8W-44-12) S214 C302 (8W-44-12) WT/LG S209 (8W-44-11) BODY LIFTGATE PANEL CONTROL COURTESY LAMP DISABLE LAMP DRIVER MODULE HOOD LIFTGATE AJAR...
Page 839 8W-45 BODY CONTROL MODULE 8W - 45 - 11 FROM C321 (8W-45-10) TN/BK S329 TN/BK TN/BK TN/BK LIFTGATE REAR LIFTGLASS AJAR WIPER AJAR SWITCH MODULE SWITCH (8W-53-4) S328 (8W-15-10) C325 S328 G300 (8W-15-11) ZG004510 J978W-3...
Page 840 8W - 45 - 12 8W - 45 BODY CONTROL MODULE 8W-45 BODY CONTROL MODULE INDEX page page DESCRIPTION AND OPERATION INTRODUCTION ......12 A/C SELECT SWITCH .
Page 841 8W - 45 BODY CONTROL MODULE 8W - 45 - 13 DESCRIPTION AND OPERATION (Continued) LIFTGATE COURTESY LAMP DISABLE SWITCH sounds an audible chime when the vehicle is moving if one of the doors, the hood, or liftgate opens. The When the courtesy lamp disable switch closes, it BCM also signals the VIC over the CCD bus.
Page 843 8W - 46 MESSAGE CENTER 8W - 46 - 1 8W-46 MESSAGE CENTER INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
Page 844 8W - 46 - 2 8W-46 MESSAGE CENTER STANDARD BATT A0 (8W-10-3) POWER DISTRIBUTION CENTER FUSE (8W-10-3) (8W-10-12) BODY CONTROL PANEL YL/RD MODULE LAMP RUN A22 (8W-10-7) (8W-45-10) DRIVER JUNCTION BLOCK (8W-12-2) FUSE FUSE (8W-12-16) (8W-12-6) S209 (8W-44-11) YL/DG S212 S214 RD/WT (8W-12-6)
Page 845 8W-46 MESSAGE CENTER 8W - 46 - 3 STANDARD GRAPHIC DISPLAY MODULE PART FULL LAMP LAMP TIME TIME T106 LG/OR LB/RD YL/BK BK/RD GY/OR C212 LG/OR BK/RD C132 JUNCTION BLOCK (8W-12-2) T107 T106 LG/OR BK/RD GY/OR C131 C132 T107 T106 GY/OR LG/OR BK/RD...
Page 846: Overhead Console
8W - 46 - 4 8W-46 MESSAGE CENTER OVERHEAD CONSOLE BATT A0 (8W-10-3) POWER DISTRIBUTION CENTER FUSE (8W-10-3) (8W-10-12) BODY CONTROL YL/RD PANEL MODULE LAMP RUN A22 (8W-10-7) (8W-45-10) DRIVER JUNCTION BLOCK (8W-12-2) FUSE FUSE (8W-12-16) (8W-12-6) S209 (8W-44-11) YL/DG S212 S214 RD/WT...
Page 847 8W-46 MESSAGE CENTER 8W - 46 - 5 OVERHEAD CONSOLE VEHICLE INFORMATION CENTER PART FULL LAMP LAMP TIME TIME T106 LG/OR LB/RD YL/BK BK/RD GY/OR C212 LG/OR BK/RD C132 JUNCTION BLOCK (8W-12-2) T107 T106 LG/OR BK/RD GY/OR C131 C132 T107 T106 GY/OR LG/OR...
Page 848 8W - 46 - 6 8W-46 MESSAGE CENTER OVERHEAD CONSOLE BATT A6 (8W-10-11) JUNCTION BLOCK ELECTRONIC FLASHER (8W-12-2) FUSE (8W-52-6) (8W-12-14) PK/OR OR/BK HEADLAMP SWITCH 0 OFF 1 LOW TURN 2 PARK SIGNAL/ 3 AUTO HAZARD (8W-50-2) WARNING (8W-50-5) (8W-50-7) SWITCH DB/RD (8W-52-2)
Page 849 8W-46 MESSAGE CENTER 8W - 46 - 7 OVERHEAD CONSOLE VEHICLE INFORMATION CENTER TWISTED PAIR POWERTRAIN CONTROL MODULE (8W-30-18) (8W-30-18) (8W-30-19) (8W-30-19) VT/BR VT/BR WT/BK WT/BK TWISTED PAIR C235 TWISTED VT/BR WT/BK PAIR S204 S203 (8W-30-19) (8W-30-18) (8W-30-32) (8W-30-31) TWISTED PAIR VT/BR WT/BK...
Page 850 8W - 46 - 8 8W - 46 MESSAGE CENTER 8W-46 MESSAGE CENTER INDEX page page GENERAL INFORMATION VEHICLE INFORMATION CENTER ... 8 INTRODUCTION ......8 DESCRIPTION AND OPERATION GRAPHIC DISPLAY MODULE .
Page 851 8W - 46 MESSAGE CENTER 8W - 46 - 9 DESCRIPTION AND OPERATION (Continued) When the transfer case switch is in Part Time Z1. The VIC displays the Low Washer Fluid warning 4WD position, it connects circuit T107 from the VIC when the switch closes.
Page 853 8W - 47 AUDIO SYSTEM 8W - 47 - 1 8W-47 AUDIO SYSTEM INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
Page 854 8W - 47 - 2 8W-47 AUDIO SYSTEM BATT A6 RUN-ACC A31 BATT A7 (8W-10-11) (8W-10-9) (8W-10-12) JUNCTION BLOCK (8W-12-2) FUSE FUSE FUSE (8W-12-14) (8W-12-3) (8W-12-16) PARK LAMP RELAY (8W-50-7) (8W-50-8) ANTENNA DB/RD RD/GY RD/WT RADIO PANEL FUSED FUSED ANTENNA LAMP IGN.
Page 855 8W-47 AUDIO SYSTEM 8W - 47 - 3 LTD AND POWER AMP POWER RADIO AMPLIFIER RADIO RADIO (LTD+) OUTPUT OUTPUT DG/RD DG/RD BATT A7 (8W-10-12) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-11) POWER ANTENNA RELAY (EXPORT) 1 DOWN 2 UP S220 POWER (8W-15-17) ANTENNA (EXPORT)
Page 856 8W - 47 - 4 8W-47 AUDIO SYSTEM PREMIUM POWER RADIO AMPLIFIER RADIO RADIO (PREMIUM) OUTPUT OUTPUT DG/RD DG/RD BATT A7 (8W-10-12) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-11) POWER ANTENNA RELAY (EXPORT) 1 DOWN 2 UP S220 POWER (8W-15-17) ANTENNA (EXPORT) 1 DOWN 2 UP S216...
Page 857 8W-47 AUDIO SYSTEM 8W - 47 - 5 PREMIUM POWER AMPLIFIED AMPLIFIED AMPLIFIER LEFT RIGHT FRONT FRONT LG/RD LB/RD S300 S335 LG/RD LG/RD LB/RD LB/RD C307 C334 C307 C351 LG/RD LB/RD LEFT LEFT RIGHT RIGHT INSTRUMENT FRONT INSTRUMENT FRONT PANEL DOOR PANEL DOOR...
Page 858 8W - 47 - 6 8W-47 AUDIO SYSTEM POWER AMPLIFIED AMPLIFIED AMPLIFIER LEFT RIGHT FRONT FRONT LG/RD LB/RD S300 S335 LG/RD LG/RD LB/RD LB/RD C307 C334 C307 C351 LG/RD LB/BK LEFT LEFT RIGHT RIGHT INSTRUMENT FRONT INSTRUMENT FRONT PANEL DOOR PANEL DOOR SPEAKER...
Page 859 8W-47 AUDIO SYSTEM 8W - 47 - 7 PREMIUM POWER AMPLIFIED AMPLIFIED AMPLIFIER LEFT RIGHT REAR REAR WT/RD TN/RD C343 C345 DB/WT DB/WT LEFT RIGHT REAR REAR DOOR DOOR SPEAKER SPEAKER DB/OR DB/OR C343 C345 WT/BK TN/BK POWER AMPLIFIED AMPLIFIED AMPLIFIER RIGHT RIGHT...
Page 860 8W - 47 - 8 8W-47 AUDIO SYSTEM STANDARD LEFT RIGHT LEFT RIGHT FRONT FRONT REAR REAR DOOR DOOR DOOR DOOR SPEAKER SPEAKER SPEAKER SPEAKER TWISTED TWISTED TWISTED TWISTED PAIR PAIR PAIR PAIR BR/RD DB/RD BR/YL BR/LB DB/WT DB/OR C334 C351 C343 C345...
Page 861 8W-47 AUDIO SYSTEM 8W - 47 - 9 BATT A250 (8W-10-10) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-8) ANTENNA S318 POWER FUSED FUSED ANTENNA AMPLIFIER B (+) B (+) LEFT LEFT LEFT LEFT RIGHT RIGHT RIGHT RIGHT FRONT FRONT REAR REAR FRONT FRONT REAR REAR...
Page 862 8W - 47 - 10 8W-47 AUDIO SYSTEM PREMIUM BATT A250 (8W-10-10) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-8) ANTENNA S318 POWER FUSED FUSED ANTENNA AMPLIFIER B (+) B (+) LEFT LEFT LEFT LEFT RIGHT RIGHT RIGHT RIGHT FRONT FRONT REAR REAR FRONT FRONT REAR...
Page 863 8W-47 AUDIO SYSTEM 8W - 47 - 11 POWER AMPLIFIED AMPLIFIED AMPLIFIER LEFT RIGHT AMPLIFIED AMPLIFIED REAR REAR REAR REAR WT/RD TN/RD C343 C345 DB/OR BR/LB DB/WT DB/OR LEFT REAR RIGHT REAR SPEAKER REAR DOOR DOOR SPEAKER SPEAKER DB/OR DB/RD DB/WT BR/YL C343...
Page 864 8W - 47 - 12 8W-47 AUDIO SYSTEM BODY CONTROL RADIO MODULE CONTROL (8W-45-2) (8W-45-2) (8W-45-7) (8W-45-7) RADIO RD/BK VT/BR CLOCKSPRING VT/BR S204 (8W-30-19) VEHICLE (8W-30-32) SPEED CONTROL/ VT/BR LEFT RIGHT HORN RADIO RADIO SWITCH C235 REMOTE REMOTE 6 PRESET SWITCH SWITCH 7 SEEK DN...
Page 865 8W-47 AUDIO SYSTEM 8W - 47 - 13 REAR SPEAKER BR/YL BR/LB DB/OR DB/WT POWER LEFT LEFT RIGHT RIGHT AMPLIFIER REAR REAR REAR REAR HIGH HIGH HIGH HIGH (LTD+) ZG004712 J978W-3...
Page 866 8W - 47 - 14 8W - 47 AUDIO SYSTEM 8W-47 AUDIO SYSTEM INDEX page page GENERAL INFORMATION POWER ANTENNA—EXPORT ONLY ..15 INTRODUCTION ......14 RADIO ILLUMINATION .
Page 867 8W - 47 AUDIO SYSTEM 8W - 47 - 15 DESCRIPTION AND OPERATION (Continued) to the left instrument panel speaker and left front bar, mounted on the inside roof headliner just for- door speaker. Circuit X85 is the return from speakers ward of the liftgate.
Page 869 8W - 48 REAR WINDOW DEFOGGER 8W - 48 - 1 8W-48 REAR WINDOW DEFOGGER INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
Page 870 8W - 48 - 2 8W-48 REAR WINDOW DEFOGGER BATT A900 (8W-10-4) JUNCTION BLOCK REAR (8W-12-2) BK/WT WINDOW DEFOGGER C301 RELAY FUSE BK/WT (8W-12-9) C322 LIFTGLASS OTHERS BK/LB S332 WT/RD LB/YL BK/LB REAR WINDOW DEFOGGER REAR SWITCH WINDOW (PART OF DEFOGGER SWITCH POD) S328...
Page 871 8W - 48 REAR WINDOW DEFOGGER 8W - 48 - 3 8W-48 REAR WINDOW DEFOGGER DESCRIPTION AND OPERATION REAR WINDOW DEFOGGER The Body Control Module (BCM) operates the rear window defogger system through a relay located in the junction block. When the operator presses the rear window defogger switch, the switch connects cir- cuit C80 from the BCM to ground circuit Z1.
Page 873 8W - 49 OVERHEAD CONSOLE 8W - 49 - 1 8W-49 OVERHEAD CONSOLE INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
Page 874 8W - 49 - 2 8W-49 OVERHEAD CONSOLE RUN A22 (8W-10-8) JUNCTION POWERTRAIN BLOCK CONTROL (8W-12-2) MODULE FUSE (8W-30-18) (8W-30-19) (8W-12-6) TWISTED PAIR VT/BR WT/BK YL/DG C235 TWISTED PAIR S323 BODY (8W-12-7) CONTROL MODULE (8W-45-2) TWISTED YL/DG PAIR VT/BR WT/BK VT/BR WT/BK S204...
Page 875 8W-49 OVERHEAD CONSOLE 8W - 49 - 3 BATT A7 (8W-10-12) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-12) S321 (8W-12-13) OVERHEAD CONSOLE OVERHEAD CONSOLE OTHERS S322 S334 (8W-12-21) (8W-12-21) (8W-15-16) JUNCTION COURTESY BLOCK LAMP S216 (8W-12-2) RELAY (8W-15-17) (IN JB) (8W-44-8) S202 (8W-15-18) S220 (8W-15-17)
Page 876 8W - 49 - 4 8W - 49 OVERHEAD CONSOLE 8W-49 OVERHEAD CONSOLE DESCRIPTION AND OPERATION The overhead console contains a US/Metric switch. The switch selects which units to show on the dis- OVERHEAD CONSOLE play. The overhead console broadcasts the US/Metric selection on the CCD bus.
Page 877 8W - 50 FRONT LIGHTING 8W - 50 - 1 8W-50 FRONT LIGHTING INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
Page 878 8W - 50 - 2 8W-50 FRONT LIGHTING BATT A0 (8W-10-3) POWER DISTRIBUTION CENTER FUSE FUSE (8W-10-3) (8W-10-12) (8W-10-11) YL/RD RD/LB JUNCTION BLOCK (8W-12-2) AUTOMATIC FUSE HEADLAMP RELAY (8W-12-16) HEADLAMP SWITCH LG/BK TN/BK BK/OR TN/BK HEADLAMP DIMMER SWITCH (PART OF MULTI-FUNCTION SWITCH) 1 LOW...
Page 879 8W-50 FRONT LIGHTING 8W - 50 - 3 FROM FROM HEADLAMP HEADLAMP DIMMER DIMMER SWITCH SWITCH (8W-50-2) (8W-50-2) VT/OR RD/OR C234 C234 VT/OR RD/OR S108 S107 VT/OR VT/OR RD/OR RD/OR LEFT HEADLAMP RIGHT HEADLAMP S109 (8W-15-4) (8W-15-5) (8W-52-8) S104 (8W-15-6) C234 (8W-15-7) (8W-52-8)
Page 880 8W - 50 - 4 8W-50 FRONT LIGHTING BRAKE WARNING SWITCH (8W-40-6) C304 GY/BK S303 GY/BK GY/BK BODY PARK BRAKE CONTROL BRAKE SWITCH SENSE MODULE SWITCH (8W-45-9) J978W-3 ZG005003...
Page 881 8W-50 FRONT LIGHTING 8W - 50 - 5 BATT A6 (8W-10-11) HEADLAMP SWITCH CIRCUIT 1 AUTO BREAKER 0 OFF 2 PARK 3 LOW AUTOMATIC HEADLAMP RELAY (IN JB) TN/BK TN/BK LB/RD HEADLAMP DIMMER S202 S209 SWITCH (8W-15-18) (8W-44-11) (PART OF MULTI-FUNCTION SWITCH) AUTOMATIC...
Page 882 8W - 50 - 6 8W-50 FRONT LIGHTING BATT A0 (8W-10-3) POWER DISTRIBUTION CENTER FUSE (8W-10-3) (8W-10-13) JUNCTION BLOCK (8W-12-2) LAMP RELAY DG/YL S105 (8W-12-24) RIGHT LEFT LAMP LAMP LAMP SWITCH (8W-50-7) S104 (8W-52-8) BODY S109 DIESEL CONTROL (8W-52-8) LAMP RELAY MODULE CONTROL...
Page 883 8W-50 FRONT LIGHTING 8W - 50 - 7 BATT A6 (8W-10-11) JUNCTION FROM BLOCK (8W-12-2) PARK LAMP FUSE LAMP RELAY RELAY (8W-50-6) (8W-12-14) DB/RD PK/OR HEADLAMP SWITCH 1 AUTO 0 OFF 2 PARK LAMP 3 LOW SWITCH S202 (8W-15-18) BK/WT BR/WT C301 G304...
Page 884 8W - 50 - 8 8W-50 FRONT LIGHTING BATT A6 (8W-10-11) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-14) PARK LAMP RELAY DB/RD DB/RD DB/RD DB/RD DB/RD S103 VEHICLE INFORMATION CENTER DB/RD (8W-46-6) DB/RD RADIO (8W-47-2) C102 (8W-50-9) DB/RD DB/RD C150 (8W-50-10) BODY LAMP PARK PARK...
Page 885 8W-50 FRONT LIGHTING 8W - 50 - 9 TURN INSTRUMENT LEFT SIGNAL/ CLUSTER TURN HAZARD (8W-40-4) LEFT SIGNAL WARNING TURN INDICATOR SIGNAL SWITCH FEED (8W-52-2) LG/DB FROM S103 (8W-50-8) LG/DB C234 LG/DB S409 DB/RD (8W-15-5) LG/DB C102 DB/RD TN/DB S147 (8W-52-8) DB/RD LEFT...
Page 886 8W - 50 - 10 8W-50 FRONT LIGHTING INSTRUMENT TURN RIGHT CLUSTER SIGNAL/ TURN (8W-40-4) HAZARD RIGHT SIGNAL WARNING TURN INDICATOR SIGNAL SWITCH FEED (8W-52-2) FROM TN/DB S103 (8W-50-8) JUNCTION BLOCK (8W-12-2) DB/RD TN/DB S408 (8W-12-17) C150 TN/DB DB/RD C150 S150 (8W-52-8) TN/DB...
Page 887 8W-50 FRONT LIGHTING 8W - 50 - 11 LEFT RIGHT HEADLAMP HEADLAMP LEVELING LEVELING MOTOR MOTOR L101 L106 L105 L102 L103 L104 L104 L103 L102 L105 L106 L101 S114 S113 S112 S115 S110 S111 FROM L101 L106 L105 L102 L103 L104 JUNCTION BLOCK...
Page 888 8W - 50 - 12 8W - 50 FRONT LIGHTING 8W-50 FRONT LIGHTING INDEX page page DESCRIPTION AND OPERATION HEADLAMPS ......12 AUTO HEADLAMPS .
Page 889 8W - 50 FRONT LIGHTING 8W - 50 - 13 DESCRIPTION AND OPERATION (Continued) lamp high beam operation on circuit L3, it energizes When the fog lamp relay energizes, it connects cir- the fog lamp relay. The BCM energizes the relay by cuit F62 from fuse 19 in the Power Distribution Cen- grounding the relay coil on circuit L95.
Page 891 8W - 51 REAR LIGHTING 8W - 51 - 1 8W-51 REAR LIGHTING INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
Page 892 8W - 51 - 2 8W-51 REAR LIGHTING BATT A250 ST-RUN A21 BATT A6 (8W-10-10) (8W-10-8) (8W-10-11) JUNCTION BLOCK (8W-12-2) FUSE FUSE FUSE (8W-12-7) (8W-12-5) (8W-12-14) RD/LG WT/PK PK/OR HEADLAMP SWITCH STOP 1 AUTO LAMP 0 OFF SWITCH 2 PARK (8W-33-2) 3 LO (8W-50-2)
Page 893 8W-51 REAR LIGHTING 8W - 51 - 3 STOP LAMP SWITCH (8W-33-2) WT/TN S312 (8W-70-5) WT/TN WT/TN WT/TN WT/TN LAMP STOP STOP STOP STOP OUTAGE LAMP LAMP LAMP LAMP SWITCH SWITCH SWITCH SWITCH MODULE INPUT INPUT INPUT INPUT STOP STOP STOP STOP PARK...
Page 894 8W - 51 - 4 8W-51 REAR LIGHTING LAMP OUTAGE STOP PARK STOP PARK LAMP LAMP LAMP LAMP MODULE SWITCH RELAY SWITCH RELAY OUPUT OUTPUT OUPUT OUTPUT PK/WT LB/WT PK/BK C328 C328 C320 C320 PK/WT PK/BK LB/WT LEFT RIGHT TAIL/ TAIL/ STOP STOP...
Page 895 8W-51 REAR LIGHTING 8W - 51 - 5 VEHICLE RUN A22 (8W-10-8) INFORMATION REAR JUNCTION CENTER LAMP BLOCK (8W-46-6) (8W-12-2) INDICATOR FUSE (8W-12-6) BK/LB YL/DG C307 S212 (8W-12-6) LB/BK YL/DG LAMP REAR C235 OUTAGE LAMP STOP SPEED MODULE LAMP PROPORTIONAL INDICATOR SWITCH STEERING...
Page 896 8W - 51 - 6 8W-51 REAR LIGHTING FROM LAMP C131 PARK OUTAGE (8W-51-5) LAMP MODULE RELAY OUTPUT BR/LG DB/RD DB/RD JUNCTION C321 BLOCK (8W-12-2) DB/RD DB/RD AFTERMARKET C364 TRAILER BR/LG CONNECTOR DB/RD (8W-54-5) S311 C372 S418 (8W-12-17) BR/LG BR/LG DB/RD DB/RD C328...
Page 897 8W-51 REAR LIGHTING 8W - 51 - 7 BATT A6 BATT F61 (8W-10-11) (8W-10-9) JUNCTION BLOCK (8W-12-2) REAR FUSE FUSE LAMP (8W-12-14) (8W-12-20) RELAY PK/OR DG/YL LG/RD C307 HEADLAMP SWITCH LG/OR 1 AUTO 2 OFF 3 PARK LAMP 4 ON OUTAGE (8W-50-2) MODULE...
Page 898 8W - 51 - 8 8W - 51 REAR LIGHTING 8W-51 REAR LIGHTING REAR FOG LAMPS DESCRIPTION AND OPERATION The rear fog lamps are powered by the rear fog TAIL LAMPS, REAR LICENSE PLATE LAMPS AND lamp relay on circuit L36. The relay coil and contacts SIDE MARKER LAMPS are powered by circuit L95 from fuse 15 in the fuse block.
Page 899 8W - 52 TURN SIGNALS 8W - 52 - 1 8W-52 TURN SIGNALS INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
Page 900 8W - 52 - 2 8W-52 TURN SIGNALS BATT A7 RUN A22 (8W-10-12) (8W-10-8) JUNCTION BLOCK (8W-12-2) FUSE FUSE (8W-12-11) (8W-12-6) ELECTRONIC FUSED FUSED B(+) IGN. FLASHER (RUN) TURN HAZARD GROUND SIGNAL SIGNAL OR/BK OR/BK VT/TN TURN SIGNAL/ S220 HAZARD (8W-15-17) WARNING SWITCH...
Page 901 8W-52 TURN SIGNALS 8W - 52 - 3 GAS ENGINES FROM TURN SIGNAL/ HAZARD FROM WARNING JUNCTION SWITCH BLOCK (8W-52-2) (8W-52-2) (8W-52-8) C234 TN/DB LG/DB C150 C102 TN/DB TN/DB S408 S413 TN/DB TN/DB TN/DB TN/DB LEFT RIGHT FRONT FRONT LEFT RIGHT SIDE SIDE...
Page 902 8W - 52 - 4 8W-52 TURN SIGNALS RUN A22 (8W-10-8) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-6) ELECTRONIC FUSED FLASHER IGN. (8W-52-2) (RUN) TURN HAZARD SIGNAL SIGNAL OR/BK VT/TN TURN SIGNAL/ HAZARD WARNING SWITCH (PART OF MULTI-FUNCTION SWITCH) 1 RT TURN 2 LT TURN 0 OFF 4 HAZARD...
Page 903 8W-52 TURN SIGNALS 8W - 52 - 5 FACTORY TRAILER TOW TURN TURN SIGNAL/ SIGNAL/ HAZARD HAZARD WARNING WARNING SWITCH SWITCH (8W-52-4) (8W-52-4) C307 C372 C320 C328 RIGHT LEFT REAR REAR TURN TURN TRAILER TRAILER SIGNAL SIGNAL LAMP LAMP LEFT RIGHT TURN TURN...
Page 904 8W - 52 - 6 8W-52 TURN SIGNALS BATT A7 RUN A22 (8W-10-12) (8W-10-8) JUNCTION BLOCK FUSE FUSE (8W-12-2) (8W-12-11) (8W-12-6) ELECTRONIC FUSED FUSED FLASHER B(+) IGN. (RUN) TURN HAZARD GROUND SIGNAL SIGNAL OR/BK VEHICLE INFORMATION OR/BK VT/TN CENTER 8W-46-6) S220 TURN (8W-15-17)
Page 905 8W-52 TURN SIGNALS 8W - 52 - 7 AFTERMARKET TRAILER TOW BATT A250 (8W-10-10) TURN TURN (8W-39-3) JUNCTION SIGNAL/ SIGNAL/ BLOCK HAZARD HAZARD (8W-12-2) WARNING WARNING FUSE SWITCH SWITCH (8W-52-6) (8W-52-6) (8W-12-8) C307 C307 PK/BK C328 S315 S313 (8W-12-8) PK/BK C320 AFTERMARKET TRAILER...
Page 906: Diesel Engines
8W - 52 - 8 8W-52 TURN SIGNALS DIESEL ENGINES FROM TURN SIGNAL/ PARK HAZARD LAMP FROM JUNCTION WARNING RELAY BLOCK SWITCH (IN JB) (8W-52-2) (8W-52-2) (8W-50-7) (8W-50-8) LG/DB DB/RD C234 S103 LG/DB DB/RD DB/RD LG/DB S409 C102 C150 S412 LG/DB LG/DB DB/RD...
Page 907 8W - 52 TURN SIGNALS 8W - 52 - 9 8W-52 TURN SIGNALS DESCRIPTION AND OPERATION the flasher relay to circuits L60 and L64. Circuit L64 feeds the right front turn signal lamp and side ELECTRONIC FLASHER RELAY marker lamp. Circuit L60 feeds the right rear turn signal lamp.
Page 909 8W - 53 WIPERS 8W - 53 - 1 8W-53 WIPERS INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
Page 910 8W - 53 - 2 8W-53 WIPERS FROM (8W-10-9) RUN-ACC A31 INTERMITTENT JUNCTION WIPER BLOCK RELAY (8W-12-2) (8W-53-3) CIRCUIT BREAKER (8W-12-4) C234 LG/BK LG/RD S122 (8W-53-3) INTERMITTENT WIPER SWITCH (PART OF MULTI-FUNCTION SWITCH) 0 OFF 1 WASH 2 DELAY 3 HIGH 4 LOW 5 PARK BR/WT...
Page 911 8W-53 WIPERS 8W - 53 - 3 INTERMITTENT FROM JUNCTION WIPER BLOCK SWITCH (8W-53-2) (8W-53-2) LG/RD BR/WT RD/YL S122 LG/RD F86 16LG/RD INTERMITTENT C235 WIPER RELAY (IN PDC) C234 YL/LG C235 YL/LG C234 (8W-53-2) BODY INTERMITTENT CONTROL WIPER VT/WT MODULE RELAY CONTROL (8W-45-7)
Page 912 8W - 53 - 4 8W-53 WIPERS BATT A250 RUN-ACC A31 (8W-10-10) (8W-10-9) JUNCTION BLOCK FUSE FUSE (8W-12-8) (8W-12-4) PK/BK BR/PK S315 REAR (8W-12-8) WIPER/ WASHER PK/BK SWITCH C323 0 OFF 1 ON 2 INTERMITTENT PK/BK LIFTGLASS OTHERS BR/LG BR/OR WT/BK PK/BK C307...
Page 913 8W-53 WIPERS 8W - 53 - 5 VEHICLE FROM FROM REAR REAR WASHER INFORMATION FLUID WIPER WIPER CENTER FROM LEVEL MODULE MODULE C234 (8W-46-6) SENSE (8W-53-4) (8W-53-4) (8W-53-4) TN/BK WT/BK BK/TN S329 (8W-44-14) (8W-45-11) C234 TN/BK TN/BK BK/TN LIFT- LIFT- REAR WIPER GLASS...
Page 914 8W - 53 - 6 8W - 53 WIPERS 8W-53 WIPERS DESCRIPTION AND OPERATION Circuit A250 from fuse 11 in the PDC powers cir- cuit F70 through fuse 8 in the junction block. Circuit INTERMITTENT WIPER OPERATION F70 powers the rear wiper motor and the control module located internal to the motor assembly.
Page 915 8W - 54 TRAILER TOW 8W - 54 - 1 8W-54 TRAILER TOW INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
Page 916 8W - 54 - 2 8W-54 TRAILER TOW BATT A250 (8W-10-10) JUNCTION TRAILER PARK/ BLOCK BRAKE NEUTRAL (8W-12-2) PROVISION POSITION FUSE SWITCH (8W-44-6) (8W-12-8) BR/LG PK/BK S315 (8W-12-8) PK/BK C372 PK/BK C372 C131 TRAILER CIRCUIT CIRCUIT BREAKER BREAKER BR/LG JUNCTION TRAILER BLOCK (8W-12-2)
Page 917 8W-54 TRAILER TOW 8W - 54 - 3 TURN LAMP SIGNAL/ STOP OUTAGE LAMP HAZARD MODULE SWITCH WARNING (8W-51-3) OUTPUT SWITCH (8W-52-5) C307 WT/TN C372 WT/TN 94 18DG 94 18DG 95 18PK 95 18PK TRAILER TRAILER TRAILER RIGHT LEFT STOP TURN TURN LAMP...
Page 918 8W - 54 - 4 8W-54 TRAILER TOW BATT A250 (8W-10-10) JUNCTION TURN TRAILER BLOCK SIGNAL/ BRAKE (8W-12-2) HAZARD PROVISION WARNING FUSE SWITCH (8W-52-5) (8W-12-8) PARK/ LAMP NEUTRAL STOP OUTAGE PK/BK POSITION LAMP MODULE SWITCH SWITCH (8W-51-3) OUTPUT (8W-44-6) BR/LG C307 C131 C372...
Page 919 8W-54 TRAILER TOW 8W - 54 - 5 STOP BATT A250 (8W-10-10) HEADLAMP LAMP JUNCTION SWITCH SWITCH BLOCK (8W-50-7) (8W-33-2) (8W-12-2) FUSE WT/TN (8W-12-8) DB/RD C305 JUNCTION BLOCK (8W-12-2) PK/BK WT/TN S315 S312 (8W-12-8) (8W-70-5) PK/BK WT/TN WT/TN WT/TN WT/TN DB/RD DB/RD DB/RD...
Page 920 8W - 54 - 6 8W - 54 TRAILER TOW 8W-54 TRAILER TOW GENERAL INFORMATION normally CLOSED position to connect circuits 94 and L60. INTRODUCTION Circuit 94 is the feed for the contact side of the relay. Circuit L60 connects from the relay to the Two trailer tow packages are available;...
Page 921 8W - 60 POWER WINDOWS 8W - 60 - 1 8W-60 POWER WINDOWS INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
Page 922 8W - 60 - 2 8W-60 POWER WINDOWS BATT A250 (8W-10-10) JUNCTION BLOCK (8W-12-2) CIRCUIT BREAKER (8W-12-7) C334 DRIVER DOOR MODULE 1 UP 2 DOWN POWER FULL TWISTED GROUP OPTION VT/BR WT/BK PAIR C334 TWISTED VT/BR WT/BK PAIR S324 (8W-15-12) S306 S307 (8W-30-19)
Page 923 8W-60 POWER WINDOWS 8W - 60 - 3 BATT A250 (8W-10-10) JUNCTION BLOCK (8W-12-2) CIRCUIT BREAKER (8W-12-7) C351 PASSENGER DOOR MODULE 1 UP 2 DOWN POWER FULL TWISTED VT/BR WT/BK GROUP OPTION PAIR C351 VT/BR WT/BK S306 S307 (8W-30-19) (8W-30-18) (8W-30-32) (8W-30-31) S325...
Page 924 8W - 60 - 4 8W-60 POWER WINDOWS DRIVER PASSENGER LEFT LEFT LEFT RIGHT RIGHT RIGHT DOOR DOOR REAR REAR REAR REAR REAR REAR WINDOW WINDOW DOOR MODULE WINDOW WINDOW DOOR MODULE DRIVER DRIVER DRIVER DRIVER SWITCH SWITCH (UP) (UP) (DOWN) ILLUMINATION (DOWN)
Page 925 8W - 60 POWER WINDOWS 8W - 60 - 5 8W-60 POWER WINDOWS INDEX page page DESCRIPTION AND OPERATION POWER WINDOWS ..... . 5 INTRODUCTION .
Page 926 8W - 60 - 6 8W - 60 POWER WINDOWS DESCRIPTION AND OPERATION (Continued) For window UP operation the circuits are reversed. If the operator has selected the window lock-out The DDM powers circuit Q17 and grounds circuit feature, the Driver’s Door Module signals the PDM Q27.
Page 927 8W - 61 POWER DOOR LOCKS 8W - 61 - 1 8W-61 POWER DOOR LOCKS INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
Page 928 8W - 61 - 2 8W-61 POWER DOOR LOCKS BATT A250 (8W-10-10) JUNCTION BLOCK (8W-12-2) CIRCUIT BREAKER (8W-12-7) C334 DRIVER DOOR MODULE 1 UNLOCK 2 LOCK TWISTED PAIR PK/BK OR/VT VT/BR WT/BK C334 LEFT POWER FULL FRONT GROUP OPTION VT/BR WT/BK DOOR LOCK...
Page 929 8W-61 POWER DOOR LOCKS 8W - 61 - 3 BATT A250 (8W-10-10) JUNCTION BLOCK CIRCUIT (8W-12-2) BREAKER (8W-12-7) C351 PASSENGER DOOR MODULE 1 LOCK 2 UNLOCK TWISTED PAIR BK/WT PK/BK VT/BR WT/BK C351 S326 S327 VT/BR WT/BK (8W-61-4) (8W-61-4) S306 S307 POWER FULL...
Page 930 8W - 61 - 4 8W-61 POWER DOOR LOCKS FROM FROM PASSENGER PASSENGER DOOR DOOR MODULE MODULE (8W-61-3) (8W-61-3) BK/WT PK/BK S326 S327 BK/WT PK/BK BK/WT PK/BK C351 C351 RIGHT FRONT DOOR LOCK BK/WT PK/BK MOTOR S310 S308 BK/WT BK/WT PK/BK PK/BK BK/WT...
Page 931 8W-61 POWER DOOR LOCKS 8W - 61 - 5 BATT A250 (8W-10-10) JUNCTION BLOCK (8W-12-2) FUSE (8W-12-8) PK/BK S315 (8W-12-8) PK/BK C323 S328 PK/BK (8W-15-10) S336 (8W-45-11) (8W-12-8) PK/BK LIFTGLASS LIMIT SWITCH P101 C325 OR/PK LIFTGLASS PUSH BUTTON P100 OR/BR S316 (8W-15-11) LIFTGLASS...
Page 932 8W - 61 - 6 8W - 61 POWER DOOR LOCKS 8W-61 POWER DOOR LOCKS DESCRIPTION AND OPERATION CCD Bus. When the DRIVERS door lock switch acti- vates, the DDM sends the appropriate signal to the INTRODUCTION PDM. After receiving a LOCK signal, the DDM supplies The Drivers Door Module (DDM) powers the driv- battery voltage to the left front door lock motor on ers door lock motor.
Page 933 8W - 62 POWER MIRRORS 8W - 62 - 1 8W-62 POWER MIRRORS INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
Page 934 8W - 62 - 2 8W-62 POWER MIRRORS (8W-10-10) BATT A250 JUNCTION BLOCK (8W-12-2) CIRCUIT BREAKER (8W-12-7) C334 DRIVER FUSED DOOR B (+) MODULE GROUND VT/BR WT/BK POWER FULL GROUP OPTION C334 VT/BR WT/BK S306 S307 (8W-30-19) (8W-30-18) (8W-30-32) (8W-30-31) S324 (8W-15-12) VT/BR...
Page 935 8W-62 POWER MIRRORS 8W - 62 - 3 (8W-10-10) BATT A250 JUNCTION BLOCK (8W-12-2) CIRCUIT BREAKER (8W-12-7) C351 PASSENGER FUSED DOOR B (+) MODULE GROUND VT/BR WT/BK POWER FULL GROUP OPTION C351 VT/BR WT/BK S306 S307 (8W-30-19) (8W-30-18) (8W-30-32) (8W-30-31) S325 (8W-15-14) VT/BR...
Page 936 8W - 62 - 4 8W-62 POWER MIRRORS AUTOMATIC AUTO AUTO DAY/ NIGHT NIGHT NIGHT MIRROR MIRROR MIRROR (8W-44-6) (8W-44-7) P114 P112 BK/YL BK/WT DRIVER DOOR MODULE HORIZONTAL VERTICAL POSITION POSITION HEATER HEATER HORIZONTAL COMMON VERTICAL SENSOR SENSOR SENSOR SWITCHED SIGNAL SIGNAL DRIVER...
Page 937 8W-62 POWER MIRRORS 8W - 62 - 5 PASSENGER HORIZONTAL DOOR VERTICAL POSITION POSITION HEATER HEATER MODULE HORIZONTAL COMMON VERTICAL SENSOR SENSOR SENSOR SWITCHED DRIVER DRIVER DRIVER SIGNAL GROUND SIGNAL GROUND SUPPLY PASSENGER POWER MIRROR ZG006204 J978W-3...
Page 938 8W - 62 - 6 8W - 62 POWER MIRRORS 8W-62 POWER MIRRORS DESCRIPTION AND OPERATION power to the left mirror UP/DOWN motor on circuit F71 and grounds circuit F73. INTRODUCTION When a DOWN adjustment is made, the polarity reveres. The DDM supplies power to circuit F73 and The Drivers Door Module (DDM) controls both grounds circuit F71.
Page 939 8W - 63 POWER SEAT 8W - 63 - 1 8W-63 POWER SEAT INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
Page 940 8W - 63 - 2 8W-63 POWER SEAT BATT A7 (8W-10-12) JUNCTION BLOCK (8W-12-2) CIRCUIT BREAKER (8W-12-18) C329 S403 (8W-12-18) DRIVER LUMBAR SWITCH 1 FILL 2 VENT P105 P104 LG/DB YL/RD MEMORY FUSED FUSED LUMBAR LUMBAR SEAT B (+) B (+) FORWARD BACKWARD SWITCH...
Page 941 8W-63 POWER SEAT 8W - 63 - 3 BATT A7 (8W-10-12) JUNCTION BLOCK (8W-12-2) CIRCUIT BREAKER (8W-12-18) C329 S403 (8W-12-18) DRIVER LUMBAR SWITCH 1 FILL 2 VENT P106 P107 DG/WT OR/BK S402 (8W-15-15) C329 DRIVER LUMBAR MOTOR S304 (8W-15-15) G305 (8W-15-15) ZG006302 J978W-3...
Page 942 8W - 63 - 4 8W-63 POWER SEAT BATT A7 (8W-10-12) JUNCTION BLOCK (8W-12-2) CIRCUIT BREAKER (8W-12-18) C335 S405 (8W-12-18) PASSENGER LUMBAR SWITCH 1 FILL 2 VENT P106 P107 DG/WT OR/BK S406 (8W-15-13) C335 PASSENGER LUMBAR MOTOR S333 (8W-15-14) S304 (8W-15-15) G305 (8W-15-15)
Page 943 8W-63 POWER SEAT 8W - 63 - 5 MEMORY SEAT MODULE LUMBAR LUMBAR LUMBAR SENSOR POSITION SENSOR VENT FILL SUPPLY SENSOR GROUND DRIVER DRIVER P103 P106 P107 BR/WT DB/WT BR/RD DG/WT OR/BK S401 S400 (8W-63-6) (8W-70-4) BR/WT BR/RD DRIVER LUMBAR SENSOR/ MOTOR ZG006304...
Page 944 8W - 63 - 6 8W-63 POWER SEAT DRIVER MEMORY DRIVER DRIVER LUMBAR SEAT POWER POWER SENSOR/ MODULE SEAT SEAT SENSOR MOTOR (8W-63-5) FRONT REAR SUPPLY (8W-63-5) RISER RISER MOTOR MOTOR SENSOR SENSOR (8W-63-7) (8W-63-7) BR/WT BR/WT BR/WT BR/WT S401 BR/WT BR/WT DRIVER...
Page 945 8W-63 POWER SEAT 8W - 63 - 7 MEMORY SEAT MODULE SENSOR (8W-63-5) SUPPLY BR/WT S401 (8W-63-6) BR/WT BR/WT DRIVER DRIVER POWER POWER SEAT SEAT REAR FRONT RISER RISER MOTOR MOTOR SENSOR SENSOR LB/RD BR/RD BR/RD S400 (8W-70-4) BR/RD MEMORY REAR SENSOR FRONT...
Page 946 8W - 63 - 8 8W-63 POWER SEAT BATT A7 (8W-10-12) JUNCTION BLOCK (8W-12-2) CIRCUIT BREAKER (8W-12-18) C329 S403 (8W-12-18) DRIVER POWER SEAT SWITCH 1 BACK 2 FWD 3 UP 4 DOWN RD/LG YL/LG RD/WT YL/WT YL/LB RD/LB GY/WT GY/LB S402 (8W-15-15) C329...
Page 947 8W-63 POWER SEAT 8W - 63 - 9 BATT A7 (8W-10-12) JUNCTION BLOCK (8W-12-2) CIRCUIT BREAKER (8W-12-18) C335 S405 (8W-12-18) PASSENGER POWER SEAT SWITCH 1 BACK 2 FWD 3 UP 4 DOWN RD/LG YL/LG RD/WT YL/WT YL/LB RD/LB GY/WT GY/LB S406 (8W-15-13) PASSENGER...
Page 948 8W - 63 - 10 8W-63 POWER SEAT BATT A7 (8W-10-12) JUNCTION BLOCK (8W-12-2) CIRCUIT BREAKER (8W-12-18) C335 S403 (8W-12-18) DRIVER POWER SEAT SWITCH 1 BACK 2 FWD 3 UP 4 DOWN RD/LG YL/LG RD/WT YL/WT YL/LB RD/LB GY/WT GY/LB S402 DRIVER (8W-15-15)
Page 949: Heated Seat
8W-63 POWER SEAT 8W - 63 - 11 HEATED SEAT DRIVER HEATED DRIVER SEAT HEATED SEAT SEAT HEATED HEATER SWITCH SWITCH SEAT CONTROL (8W-63-14) OUTPUT DRIVER GROUND MODULE LB/BK BK/OR C301 LB/BK C329 LB/BK S407 LB/BK DRIVER HEATED SEAT CUSHION BR/BK DRIVER HEATED...
Page 950 8W - 63 - 12 8W-63 POWER SEAT HEATED SEAT PASSENGER HEATED PASSENGER SEAT SEAT HEATED HEATER SEAT HEATED SWITCH SWITCH SEAT CONTROL (8W-63-13) OUTPUT DRIVER GROUND MODULE LB/WT BK/OR LB/WT C301 LB/WT C335 S404 LB/WT PASSENGER HEATED SEAT CUSHION BR/BK PASSENGER HEATED...
Page 951 8W-63 POWER SEAT 8W - 63 - 13 HEATED SEAT BATT A7 RUN A22 (8W-10-12) (8W-10-8) JUNCTION BLOCK (8W-12-2) CIRCUIT FUSE BREAKER (8W-12-10) (8W-12-18) PK/DG S218 (8W-12-10) PK/DG PK/DG HEATED SEAT SWITCH C302 (PART OF SWITCH POD) 1 HIGH 2 LOW 0 OFF PK/DG S317...
Page 952 8W - 63 - 14 8W-63 POWER SEAT HEATED SEAT BATT A7 RUN A22 (8W-10-12) (8W-10-8) JUNCTION BLOCK (8W-12-2) CIRCUIT FUSE BREAKER (8W-12-10) (8W-12-18) PK/DG S218 (8W-12-10) PK/DG PK/DG HEATED SEAT SWITCH C302 (PART OF SWITCH POD) 1 HIGH 2 LOW 0 OFF PK/DG S317...
Page 953 8W-63 POWER SEAT 8W - 63 - 15 MEMORY SEAT MEMORY SEAT MODULE VT/BR WT/BK C329 VT/BR WT/BK S306 S307 (8W-30-19) (8W-30-18) (8W-30-32) (8W-30-31) VT/BR VT/BR WT/BK WT/BK C351 C334 C334 VT/BR WT/BK PASSENGER VT/BR WT/BK DOOR MODULE (8W-60-3) (8W-61-3) (8W-62-3) DRIVER DOOR...
Page 954 8W - 63 - 16 8W - 63 POWER SEAT 8W-63 POWER SEAT INDEX page page DESCRIPTION AND OPERATION MEMORY SEATS ..... . . 17 HEATED SEATS .
Page 955 8W - 63 POWER SEAT 8W - 63 - 17 DESCRIPTION AND OPERATION (Continued) A bus bar internal to the switch connects circuit P12 To operate the seat motor(s), the control module to ground on circuit Z1. supplies the power and ground. The following is a list For REAR VERTICAL DOWN function the circuits of the circuits that connect from the control module are reversed.
Page 956 8W - 63 - 18 8W - 63 POWER SEAT DESCRIPTION AND OPERATION (Continued) When the ignition switch is in the RUN position, it circuit F71 passes through the resistor to circuit P7 connects circuit A1 from fuse 8 in the PDC to circuit or P8.
Page 957 8W - 64 POWER SUNROOF 8W - 64 - 1 8W-64 POWER SUNROOF INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
Page 958 8W - 64 - 2 8W-64 POWER SUNROOF BATT A7 RUN-ACC A31 (8W-10-12) (8W-10-9) JUNCTION BLOCK (8W-12-2) FUSE CIRCUIT BREAKER (8W-12-11) (8W-12-4) ELECTRONIC FUSED FLASHER B (+) (8W-52-2) (8W-52-6) GROUND LG/BK S220 C231 (8W-15-17) LG/BK S216 S322 S320 (8W-12-5) (8W-15-17) (8W-15-16) LG/BK LG/BK...
Page 959 8W-64 POWER SUNROOF 8W - 64 - 3 SLIDING SLIDING ROOF ROOF POSITION MOTOR SWITCH SUNROOF SLIDING SLIDING SLIDING SLIDING SLIDING ROOF ROOF ROOF ROOF ROOF CONTROL POSITION POSITION POSITION MOTOR MOTOR MODULE SWITCH SWITCH SWITCH DRIVER DRIVER OUTPUT OUTPUT OUTPUT ZG006402 J978W-3...
Page 960 8W - 64 - 4 8W - 64 POWER SUNROOF 8W-64 POWER SUNROOF INDEX page DESCRIPTION AND OPERATION POWER SUNROOF ..... . 4 sensor is used to prevent the sunroof from being DESCRIPTION AND OPERATION moved to far in any one direction.
Page 961 8W - 65 SPEED PROPORTIONAL STEERING 8W - 65 - 1 8W-65 SPEED PROPORTIONAL STEERING INDEX page SCHEMATICS AND DIAGRAMS ............1 DESCRIPTION AND OPERATION .
Page 962 8W - 65 - 2 8W-65 SPEED PROPORTIONAL STEERING GAS ENGINES RUN A22 (8W-10-8) JUNCTION VEHICLE BLOCK SPEED (8W-12-2) SENSOR FUSE (8W-33-3) (8W-33-3) (8W-12-6) DATA LINK CONNECTOR YL/DG WT/OR (8W-30-2) S212 S131 (8W-12-6) (8W-70-2) YL/DG BK/PK WT/OR C235 C234 C235 C132 YL/DG BK/PK...
Page 963 8W-65 SPEED PROPORTIONAL STEERING 8W - 65 - 3 GAS ENGINES SPEED PROPORTIONAL STEERING CONTROL CONTROL SOLENOID HIGH STEERING WHEEL SPEED SENSOR GROUND SIGNAL A SIGNAL B SUPPLY BK/YL BK/LG PK/WT C235 BK/YL BK/LG PK/WT SPEED CONTROL CONTROL GROUND SIGNAL A SIGNAL B PROPORTIONAL HIGH...
Page 964 8W - 65 - 4 8W - 65 SPEED PROPORTIONAL STEERING 8W-65 SPEED PROPORTIONAL STEERING INDEX page page DESCRIPTION AND OPERATION SPEED PROPORTIONAL STEERING CONTROL DATA LINK CONNECTOR ....4 MODULE .
Page 965 8W - 70 SPLICE INFORMATION 8W - 70 - 1 8W-70 SPLICE INFORMATION INDEX page SCHEMATICS AND DIAGRAMS ............1 Component Page Component...
Page 966 8W - 70 - 2 8W-70 SPLICE INFORMATION UPSTREAM MANIFOLD ENGINE INTAKE HEATED ABSOLUTE COOLANT OXYGEN PRESSURE TEMPERATURE TEMPERATURE SENSOR SENSOR SENSOR SENSOR (8W-30-14) (8W-30-9) (8W-30-9) (8W-30-9) BK/LB BK/LB BK/LB BK/LB S127 (4.0L) BK/LB BK/LB BK/LB S135 POWERTRAIN THROTTLE TRANSMISSION (8W-70-3) CONTROL POSITION...
Page 967 8W-70 SPLICE INFORMATION 8W - 70 - 3 GAS ENGINES POWERTRAIN BATTERY TRANSMISSION CONTROL TEMPERATURE SOLENOID MODULE SENSOR ASSEMBLY (8W-30-6) (8W-30-16) (8W-31-3) (8W-30-7) (8W-30-8) (8W-30-9) (8W-30-13) (8W-30-14) BK/LB BK/LB (8W-30-16) (8W-30-17) S102 S127 (8W-70-6) (4.0L) (8W-70-2) VEHICLE SPEED PRESSURE BK/LB SENSOR SENSOR (8W-33-3)
Page 968 8W - 70 - 4 8W-70 SPLICE INFORMATION CRANKSHAFT CAMSHAFT MANIFOLD THROTTLE POSITION POSITION ABSOLUTE POSITION SENSOR SENSOR PRESSURE SENSOR (8W-30-7) (8W-30-7) SENSOR (8W-30-8) (8W-31-4) (8W-30-8) FROM S135 (8W-70-3) BK/LB BK/LB BK/LB BK/LB BK/LB S136 (5.2L) BK/LB BK/LB ENGINE INTAKE COOLANT TEMPERATURE TEMPERATURE...
Page 969 8W-70 SPLICE INFORMATION 8W - 70 - 5 LEFT CONTROLLER RIGHT TAIL/ CONTROLLER ANTI-LOCK TAIL/ STOP BRAKE STOP (8W-30-29) LAMP (8W-35-3) LAMP (8W-51-4) (8W-51-4) PK/WT WT/TN PK/WT DIESEL LAMP LAMP C328 C132 C320 OUTAGE OUTAGE MODULE MODULE (8W-51-3) (8W-51-3) PK/WT WT/TN WT/TN WT/TN...
Page 970 8W - 70 - 6 8W-70 SPLICE INFORMATION GAS ENGINE FUEL COOLANT SENDER LEVEL UNIT SENSOR (8W-30-28) (8W-30-29) K167 K167 BR/YL BR/YL C304 K167 BR/YL S102 K167 BR/YL C132 K167 BR/YL S141 (8W-70-9) K167 BR/YL POWERTRAIN CONTROL MODULE (8W-30-24) (8W-30-28) (8W-30-29) J978W-3 ZG007005...
Page 971 8W-70 SPLICE INFORMATION 8W - 70 - 7 DIESEL ENGINE FUEL CONTROLLER PUMP (8W-30-22) MODULE (8W-30-26) A142 A142 A142 A142 A142 DG/OR DG/OR DG/OR DG/OR DG/OR S128 A142 A142 DG/OR DG/OR GENERATOR (8W-20-2) POWERTRAIN GLOW AUTOMATIC CONTROL SOLENOID PLUG SHUT MODULE (8W-30-28) RELAY...
Page 972 8W - 70 - 8 8W-70 SPLICE INFORMATION DIESEL ENGINE ENGINE MASS COOLANT CONTROLLER TEMPERATURE FLOW (8W-30-29) SENSOR MODULE (8W-30-29) (8W-30-26) BK/LB BK/LB BK/LB S136 BK/LB BK/LB C131 FUEL PUMP MODULE BK/LB (8W-30-26) S119 BK/LB BK/LB C234 C236 CONNECTION BK/LB S211 BK/LB BK/LB...
Page 973 8W-70 SPLICE INFORMATION 8W - 70 - 9 DIESEL ENGINE VEHICLE WATER POWERTRAIN SPEED CONTROL SENSOR FUEL MODULE (8W-33-5) SENSOR (8W-30-24) (8W-30-28) (8W-30-24) (8W-30-29) K167 K167 K167 BR/YL BR/YL BR/YL S141 K167 K167 BR/YL BR/YL C917 C132 K167 K167 BR/YL BR/YL S102 K167...
Page 975 8W - 80 CONNECTOR PIN-OUTS 8W - 80 - 1 8W-80 CONNECTOR PIN-OUTS INDEX page SCHEMATICS AND DIAGRAMS ............1 Component Page Component...
Page 976 8W - 80 - 2 8W - 80 CONNECTOR PIN-OUTS DESCRIPTION AND OPERATION (Continued) Component Page Component Page Dome/Reading Lamp ....8W-80-29 Idle Air Control Motor (with 4.0L Engine). .8W-80-40 Downstream Heated Oxygen Sensor .
Page 977 8W - 80 CONNECTOR PIN-OUTS 8W - 80 - 3 DESCRIPTION AND OPERATION (Continued) Component Page Component Page Left Rear Fog Lamp ....8W-80-51 Radio - C2 .
Page 978 8W - 80 - 4 8W - 80 CONNECTOR PIN-OUTS DESCRIPTION AND OPERATION (Continued) Component Page Component Page Underhood Lamp.....8W-80-79 Water In-Fuel Sensor (Diesel) .
Page 979 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 5 BLACK CIRCUIT FUNCTION C4 14TN LOW BLOWER MOTOR DRIVER C5 14LG M1 BLOWER MOTOR DRIVER C7 12BK/TN HIGH BLOWER MOTOR DRIVER C1 14DG GROUND C6 14LB M2 BLOWER MOTOR DRIVER A/C HEATER CONTROL - C1 CIRCUIT FUNCTION...
Page 980 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 6 BLACK CIRCUIT FUNCTION R45 18DG/LB DRIVER AIRBAG LINE 2 R43 18BK/LB DRIVER AIRBAG LINE 1 R42 18BK/YL PASSENGER AIRBAG LINE 1 R44 18DG/YL PASSENGER AIRBAG LINE 2 Z6 16BK/PK GROUND AIRBAG CONTROL MODULE G5 18DB/WT FUSED IGNITION SWITCH OUTPUT (RUN/START) D2 18WT/BK...
Page 981 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 7 CIRCUIT FUNCTION C37 20YL MODE DOOR MOTOR DRIVER C35 20DG/YL BLEND AIR DOOR MOTOR DRIVER C39 20WT MODE DOOR MOTOR POSITION SENSE C90 20LG A/C SELECT INPUT C40 20BR/WT 5 VOLT SUPPLY C43 18YL/BR BLOWER POWER MODULE OUTPUT D1 18VT/BR...
Page 982 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 8 BLACK CIRCUIT FUNCTION C40 20DG/YL 5 VOLT SUPPLY C36 20DB/RD BLEND AIR DOOR FEEDBACK SIGNAL D41 20LG/WT SENSOR RETURN C35 20DB/WT BLEND AIR DOOR MOTOR DRIVER BLEND DOOR ACTUATOR C34 20VT/WT BLEND AIR DOOR MOTOR DRIVER (WITH AUTOMATIC TEMPERATURE CONTROL) BLACK...
Page 983 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 9 BLACK CIRCUIT FUNCTION C42 12BR/RD BLOWER MOTOR DRIVER A19 10RD FUSED B(+) C43 18BR/YL BLOWER POWER MODULE OUTPUT Z4 18BK GROUND BLOWER POWER MODULE CIRCUIT FUNCTION V51 18WT WINDSHIELD WIPER SWITCH SIGNAL D41 20LG/WT SENSOR RETURN C8 20DG/RD...
Page 984 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 10 CIRCUIT FUNCTION L109 20WT ULTRALIGHT SENSOR DRIVER 709 20RD/BK RADIO CONTROL MUX V66 16VT/WT WIPER PARK SWITCH SENSE M112 20BR/LG COURTESY LAMP RELAY CONTROL C90 20LG A/C SELECT INPUT WHITE F75 18VT FUSED B(+) L110 20OR/BK ULTRALIGHT SENSOR SIGNAL...
Page 985 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 11 CIRCUIT FUNCTION G78 20TN/BK LEFTGATE AJAR SWITCH SENSE G9 20GY/BK PARK BRAKE SENSE BLACK G76 18TN/YL RIGHT REAR DOOR AJAR SWITCH SENSE G75 18TN LEFT FRONT DOOR AJAR SWITCH SENSE M4 20WT/LG LIFTGATE COURTESY LAMP DISABLE Z2 18BK/OR GROUND...
Page 986 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 12 CIRCUIT CIRCUIT T20 18LB T20 18LB BLACK F99 20OR F99 18OR BLACK A142 18DG/OR A142 18DG/OR F5 14RD/YL F5 14RD/YL L10 18BR/LG L10 18BR/LG C2 18DB/YL C2 18DB/YL G28 20LG/OR G28 20LG/OR C131 C131 (GAS)
Page 987 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 13 CIRCUIT CIRCUIT C2 18DB/YL C2 18DB/YL D83 20BK/WT D83 20BK/PK D84 20BK/WT K95 20PK K95 20PK C21 18DB/OR C21 18DB/OR T40 12LB/BK T40 12LB/BK K95 20PK V32 20YL/RD C21 18DB/OR C141 C141 T40 12LG/BK (DIESEL) (DIESEL)
Page 988 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 14 CIRCUIT CIRCUIT C7 12BK/TN C7 12BK/TN C6 14LB C6 14LB C5 14LG C5 14LG BLACK C4 14TN C4 14TN BLACK C36 20DB/RD C36 20DB/RD F71 20PK/DG F71 20PK/DG C34 20VT/WT C34 20VT/WT C206 C1 14DG Z4 12BK...
Page 989 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 15 CIRCUIT CIRCUIT G28 20LG/OR G42 20LG/RD 107 20BK/RD T10 20YL/BK C212 C212 BLACK BLACK CIRCUIT CIRCUIT A41 14YL T141 14YL/RD C229 T141 14YL/RD T141 14YL/RD C229 (MANUAL TRANS ONLY) CIRCUIT CIRCUIT BLACK D1 18VT/BR D1 18VT/BR BLACK...
Page 990 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 16 CIRCUIT CIRCUIT V11 18TN/BK V11 18TN/BK L3 16RD/OR L3 16RD/OR L4 16VT/OR L4 16VT/OR V4 18RD/YL V4 18RD/YL G9 16GY/BK* G9 16GY/BK WHITE BLACK G9 18GY/BK** G18 16PK/BK* G18 16PK/BK* G29 20BK/TN G118 16PK/DB** K4 18BK/LB G29 16BK/TN...
Page 991 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 17 CIRCUIT CIRCUIT L101 20RD L101 20RD WHITE 9 18 L102 20WT L102 20WT L103 20LB L103 20LB WHITE 9 18 L104 20LG L104 20LG L105 20PK L105 20PK L106 20YL L106 20YL F99 20OR** F99 20OR 1 10...
Page 992 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 18 CIRCUIT CIRCUIT G9 20GY/BK* G9 20GY/BK G9 20GY/BK* BLACK BLACK B1 20YL/DB G9 18GY/BK** B2 20YL B1 20YL/DB B2 20YL B41 20YL/VT B42 20TN/WT B41 20YL/VT B43 20PK/OR B42 20TN/WT C304 C304 B43 20PK/OR G40 18LB/BK G40 18LB/BK...
Page 993 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 19 CIRCUIT CIRCUIT V24 18BR/OR V24 18BR/OR V20 18BK/WT V20 18WT/BK X55 16BR/RD X55 20BR/RD X55 16BR/RD X53 16DG X53 20DG X53 16DG X54 16VT X54 20VT/YL X54 16VT BLACK X56 16DB X56 20DB X56 16DB Z5 14BK/LB Z5 16BK...
Page 994 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 20 CIRCUIT CIRCUIT L36 18LG/OR L36 18LG/OR L36 18LG/OR L50 18WT/TN L50 18WT/TN L90 18DB/RD* L90 18DB/RD BLACK L90 20DB/RD L90 18DB/RD BLACK L90 18DB/RD L22 18LB L90 18DB/RD L21 18LB/WT L90 18DB/RD L74 18PK/BK L50 18WT/TN C316...
Page 995 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 21 BLACK CONNECTOR RETAINER CIRCUIT CIRCUIT C15 12BK/WT C15 12BK/LB BLACK C322 C322 CONNECTOR GRAY RETAINER CIRCUIT CIRCUIT P2 16BK/WT F70 14PK/BK F70 16PK/BK P2 14BKWT C323 GRAY C323 CONNECTOR RETAINER CIRCUIT CIRCUIT BLACK V13 18BR/LG V13 18BR/LG...
Page 996 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 22 GRAY GRAY CIRCUIT CIRCUIT L73 18PK/WT L74 18PK/BK L21 18LB/WT L21 18LB/WT L10 18BR/LG L10 18BR/LG Z1 18BK Z1 18BK L61 18LG L61 18LG C328 L61 18LG L36 18LG/BK C328 L36 18LG/OR BLACK BLACK CIRCUIT...
Page 997 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 23 CIRCUIT CIRCUIT Z1 12BK Z1 12BK F81 10TN F81 12TN BLACK BLACK E21 18OR/RD E21 18OR Q17 14DB/WT Q17 16DB/WT X53 16DG** X53 20DG X87 16LG/RD* Q27 14RD/BK Q27 16RD/BK X55 16BR/RD** X55 20BR/RD X85 16LG/BK* C334...
Page 998 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 24 CIRCUIT CIRCUIT BLACK X94 16TN/RD* BLACK X52 20DB/WT X52 16DB/WT** X92 16TN/BK* X58 20DB/OR X58 16DB/OR** P2 16BK/WT P2 18BK/WT Z1 16BK Z1 16BK C345 C345 E20 18OR/DB E20 20OR/DG CIRCUIT CIRCUIT Z1 12BK Z1 12BK F81 12TN...
Page 999 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 25 BLACK BLACK CIRCUIT CIRCUIT L87 20DG/WT L87 18DG/WT Z1 20BK Z1 18BK C359 C359 BLACK BLACK CIRCUIT CIRCUIT Z1 20BK Z1 20BK L90 20DB/RD L90 20DB/RD C364 C364 BLACK BLACK CIRCUIT CIRCUIT Z1 16BK Z1 16BK Q41 16WT...
Page 1000 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 26 CIRCUIT CIRCUIT T40 14LG/BK T40 12LG/BK G60 20GY/YL G60 20GY/YL K167 20BR/YL K167 20BR/YL C917 C917 (DIESEL) (DIESEL) BLACK CIRCUIT FUNCTION K25 20WT/BK 5 VOLT SUPPLY K4 20BK/LB SENSOR GROUND K24 18GY/BK CAMSHAFT POSITION SENSOR SIGNAL CAMSHAFT POSITION SENSOR...
Page 1001 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 27 BLACK CIRCUIT FUNCTION L87 20DG/WT STOP LAMP SWITCH OUTPUT L87 20DG/WT STOP LAMP SWITCH OUTPUT Z1 20BK GROUND Z1 20BK GROUND CENTER HIGH MOUNTED STOP LAMP NO. 3 BLACK CIRCUIT FUNCTION F30 18RD/DB FUSED IGNITION SWITCH OUTPUT (ACC/RUN) Z1 18BK GROUND...
Page 1002 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 28 BLACK CIRCUIT FUNCTION G18 16PK/BK ENGINE COOLANT LEVEL SENSE Z1 16BK GROUND COOLANT LEVEL SENSOR BLACK CIRCUIT FUNCTION K4 20BK/LB SENSOR GROUND K24 20GY/BK CRANKSHAFT POSITION SENSOR SIGNAL CRANKSHAFT POSITION SENSOR (DIESEL) BLACK CIRCUIT FUNCTION...
Page 1003 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 29 NATURAL CIRCUIT FUNCTION Z1 20BK GROUND M2 2OYL COURTESY LAMP RELAY OUTPUT M1 20PK FUSED B(+) DOME/READING LAMP BLACK CIRCUIT FUNCTION A142 18DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT Z12 18BK/TN GROUND DOWNSTREAM K4 18BK/LB SENSOR GROUND HEATED OXYGEN...
Page 1004 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 30 CIRCUIT FUNCTION BLACK Z1 20BK GROUND P22 20BR 5 VOLT SUPPLY G49 20OR SET LED DRIVER M1 20GY SWITCHED MUX LED SUPPLY DRIVER DOOR MODULE - C3 BLACK CIRCUIT FUNCTION Z1 16BK GROUND P88 16BR/BK HEATED SEAT DRIVER...
Page 1005 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 31 CIRCUIT FUNCTION P121 16RD/GY* FRONT RISER DOWN DRIVER P21 16RD/LG FRONT RISER DOWN SWITCH SENSE P119 16YL/RD* FRONT RISER UP DRIVER P19 16YL/LG FRONT RISER UP SWITCH SENSE DRIVER POWER SEAT FRONT RISER MOTOR BLACK CIRCUIT FUNCTION...
Page 1006 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 32 BLACK CIRCUIT FUNCTION P104 20YL/RD* LUMBAR REARWARD SWITCH SENSE P107 18OR/BK LUMBAR FORWARD DRIVER Z1 18BK GROUND F35 18RD FUSED B(+) Z1 18BK GROUND LUMBAR FORWARD SWITCH SENSE P105 20LG/DB* LUMBAR FORWARD SWITCH SENSE P106 18DG/WT LUMBAR REWARD DRIVER DRIVER POWER SEAT...
Page 1007 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 33 BLACK CIRCUIT FUNCTION P29 20BR/WT 6 VOLT SENSOR SUPPLY P47 20LB HORIZONTAL POSITION SENSE P28 20BR/RD SENSOR GROUND DRIVER POWER SEAT RECLINER MOTOR SENSOR CIRCUIT FUNCTION Z1 16BK GROUND P40 18GY/LB* RECLINER UP SWITCH SENSE P43 16GY/LB RECLINER UP DRIVER P17 18RD/LB*...
Page 1008 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 34 YELLOW CIRCUIT FUNCTION R45 18DG/LB DRIVER AIR BAG LINE 2 R43 18BK/LB DRIVER AIR BAG LINE 1 DRIVER SIDE AIRBAG BLACK CIRCUIT FUNCTION F99 20OR IGNITION SWITCH OUTPUT (START/RUN) K52 18PK/BK EVAPORATIVE EMISSION SOLENOID CONTROL DUTY CYCLE EVAP/PURGE SOLENOID CIRCUIT...
Page 1009 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 35 BLACK CIRCUIT FUNCTION A0 6RD B(+) A0 2RD** B(+) T40 12LG/BK ENGINE STARTER MOTOR RELAY OUTPUT T40 14LG/BK** ENGINE STARTER MOTOR RELAY OUTPUT ENGINE STARTER MOTOR BLACK CIRCUIT FUNCTION F99 20OR FUSED IGNITION SWITCH OUTPUT (START/RUN) J95 18DG/RD VAPOR CANISTER SOLENOID DRIVER J96 18VT/RD...
Page 1010 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 36 CIRCUIT FUNCTION BLACK K134 20LB/BK SLEEVE POSITION SENSOR (-) K57 20LG/OR CONT SLEEVE POSITION SENSOR K135 20WT/BK SLEEVE POSITION SENSOR (+) K4 20BK/LB SENSOR GROUND K238 16VT FUEL TIMING SHUTOFF SOLENOID K153 20OR SHUTOFF FEED K156 20GY FUEL TEMP SENSOR SIGNAL...
Page 1011 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 37 BLACK CIRCUIT FUNCTION B43 20PK/OR G SWITCH GROUND B41 20YL/VT G SWITCH NO. 1 SENSE B42 20TN/WT G SWITCH NO. 2 SENSE G-SWITCH CIRCUIT FUNCTION A142 16DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT K20 18DG/YL GENERATOR FIELD DRIVER GENERATOR...
Page 1012 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 38 CIRCUIT FUNCTION G18 20PK/BK ENGINE COOLANT LEVEL SWITCH SENSE F60 20RD/WT FUSED B(+) Z2 20BK/OR GROUND L5 18OR/BK TURN SIGNAL BLACK G46 20BK/LB REAR LAMP OUT INDICATOR DRIVER D1 18VT/BR CCD BUS (+) D2 18WT/BK CCD BUS (-) E2 20OR...
Page 1013 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 39 CIRCUIT FUNCTION E2 20OR PANEL LAMP DRIVER Z1 16BK GROUND M11 20PK/LB SWITCHED COURTESY LAMP FEED L39 20LB FOG LAMP RELAY OUTPUT Z1 16BK GROUND L35 20BR/WT FOG LAMP SWITCH OUTPUT BLACK L96 20LG/RD COIL DRIVER #6 707 20BK/WT...
Page 1014 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 40 BLACK CIRCUIT FUNCTION K60 16YL/BK IDLE AIR CONTROL NO. 2 DRIVER K59 16VT/BK IDLE AIR CONTROL NO. 4 DRIVER K40 16BR/WT IDLE AIR CONTROL NO. 3 DRIVER K39 16GY/RD IDLE AIR CONTROL NO. 1 DRIVER IDLE AIR CONTROL MOTOR (4.0L I-6)
Page 1015 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 41 GRAY CIRCUIT FUNCTION A142 18DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT K11 18WT/DB INJECTOR NO.1 DRIVER FUEL INJECTOR NO.1 GRAY CIRCUIT FUNCTION A142 18DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT K12 18TN INJECTOR NO. 2 DRIVER FUEL INJECTOR NO.2 GRAY...
Page 1016 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 42 GRAY CIRCUIT FUNCTION A142 18DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT K58 18BR/YL INJECTOR NO. 6 DRIVER FUEL INJECTOR NO.6 GRAY CIRCUIT FUNCTION A142 18DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT K17 18DB/WT INJECTOR NO. 7 DRIVER FUEL INJECTOR NO.7 (WITH 5.2L ENG)
Page 1017 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 43 GRAY CIRCUIT FUNCTION A21 12DB/GY IGNITION SWITCH OUTPUT (START/RUN) A7 12YL/RD FUSED B(+) A900 12OR/YL FUSED B(+) A250 10RD FUSED B(+) JUNCTION BLOCK - C2 CIRCUIT FUNCTION X4 20GY/OR HORN RELAY CONTROL BLUE G28 20LG/OR 2-WHEEL DRIVE LAMP/LOW RANGE...
Page 1018 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 44 BLACK CIRCUIT FUNCTION A31 12RD/BK FUSED IGNITION SWITCH OUTPUT (ACC/RUN) A21 12DB/GY FUSED IGNITION SWITCH OUTPUT (START/RUN) C15 12BK/WT REAR WINDOW DEFOGGER RELAY OUTPUT F61 16WT/OR FUSED B(+) JUNCTION BLOCK - C6 CIRCUIT FUNCTION X12 18RD/GY...
Page 1019 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 45 CIRCUIT FUNCTION C16 20LB/YL REAR WINDOW DEFOGGER LAMP DRIVER F38 18OR FUSED B(+) LIGHT GRAY F71 20DG/PK* FUSED IGNITION SWITCH OUTPUT (RUN) F60 20RD/WT FUSED B(+) F87 20BK/WT FUSED IGNITION SWITCH OUTPUT (START/RUN) F71 20PK/DG* FUSED IGNITION SWITCH OUTPUT (RUN) JUNCTION BLOCK - C9...
Page 1020 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 46 CIRCUIT FUNCTION BLACK L10 18BR/LG BACK-UP LAMP SWITCH OUTPUT G5 18DB/WT FUSED IGNITION SWITCH OUTPUT (START/RUN) M2 20YL COURTESY LAMP RELAY OUTPUT X60 18DG/RD RADIO 12 VOLT OUTPUT F81 10TN FUSED B(+) F70 14PK/BK FUSED B(+) JUNCTION BLOCK...
Page 1021 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 47 CIRCUIT FUNCTION L36 18LG/OR NOT USED L50 18WT/TN STOP LAMP SWITCH OUTPUT BLACK L90 18DB/RD PARK LAMP RELAY OUTPUT L90 18DB/RD PARK LAMP RELAY OUTPUT L90 18DB/RD PARK LAMP RELAY OUTPUT L90 18DB/RD PARK LAMP RELAY OUTPUT LAMP OUTAGE MODULE - C1 L90 18DB/RD...
Page 1022 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 48 BLACK CIRCUIT FUNCTION L10 18BR/LG BACK-UP LAMP SWITCH OUTPUT Z1 18BK GROUND LEFT BACK-UP LAMP BLACK CIRCUIT FUNCTION M1 20PK FUSED B(+) M2 20YL COURTESY LAMP RELAY OUTPUT LEFT COURTESY LAMP BLACK CIRCUIT FUNCTION M1 20PK...
Page 1023 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 49 BLACK CIRCUIT FUNCTION P34 18PK/BK LEFT FRONT DOOR UNLOCK DRIVER P35 18OR/VT LEFT FRONT DOOR LOCK DRIVER LEFT FRONT DOOR LOCK MOTOR BLACK CIRCUIT FUNCTION X53 20DG LEFT FRONT (+) X55 20BR/RD LEFT FRONT (-) LEFT FRONT DOOR SPEAKER...
Page 1024 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 50 BLACK CIRCUIT FUNCTION L64 18TN/DB TURN SIGNAL SWITCH OUTPUT Z1 18BK GROUND LEFT FRONT TURN SIGNAL LAMP BLACK CIRCUIT FUNCTION B8 20RD/DB LEFT FRONT WHEEL SPEED SENSOR (-) B9 20RD LEFT FRONT WHEEL SPEED SENSOR (+) LEFT FRONT WHEEL SPEED SENSOR BLACK...
Page 1025 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 51 NATURAL CIRCUIT FUNCTION L90 20DB/RD PARK LAMP RELAY OUTPUT Z1 20BK GROUND LEFT LICENSE LAMP CIRCUIT FUNCTION L90 18DB/RD PARK LAMP RELAY Z1 18BK GROUND LEFT PARK LAMP BLACK CIRCUIT FUNCTION L65 18LG/DB LEFT FRONT T.S.
Page 1026 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 52 BLACK CIRCUIT FUNCTION Q12 16BR LEFT REAR WINDOW DRIVER (UP) Q22 16VT LEFT REAR WINDOW DRIVER (DOWN) LEFT REAR POWER WINDOW MOTOR BLUE CIRCUIT FUNCTION Q18 16GY/BK LEFT REAR WINDOW DRIVER (UP) Q12 16BR LEFT REAR WINDOW DRIVER (UP) E20 20OR/DG...
Page 1027 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 53 BLACK CIRCUIT FUNCTION L74 18PK/BK STOP LAMP SWITCH OUTPUT L21 18LB/WT PARK LAMP SWITCH OUTPUT Z1 18BK GROUND LEFT TAIL/STOP LAMP BLACK CIRCUIT FUNCTION M1 20PK FUSED B(+) Z1 20BK GROUND LEFT VISOR/ VANITY MIRROR BLACK CIRCUIT...
Page 1028 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 54 BLACK CIRCUIT FUNCTION Z1 20BK GROUND G78 20TN/BK LIFTGLASS AJAR SWITCH SENSE LIFTGLASS AJAR SWITCH NATURAL CIRCUIT FUNCTION F70 16PK/BK FUSED B(+) P101 16OR/PK LIFTGLASS LIMIT SWITCH OUTPUT LIFTGLASS LIMIT SWITCH BLACK CIRCUIT FUNCTION P100 14OR/BR...
Page 1029 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 55 CIRCUIT FUNCTION Z1 20BK GROUND K4 20BK/LB SENSOR GROUND A142 18DG/OR FUSED (B+) K155 20DB AIR FLOW METER SIGNAL MASS AIR FLOW MODULE CIRCUIT FUNCTION Z12 14BK/TN POWER GROUND G21 20GY/LB TACHOMETER SIGNAL K185 18OR/LB WAIT TO START LAMP K140 16TN/WT...
Page 1030 8W-80 CONNECTOR PIN-OUTS 8W - 80 -56 CIRCUIT FUNCTION P29 20BR/WT 6 VOLT SENSOR SUPPLY P28 20BR/RD SENSOR GROUND P25 20VT/RD HORIZONTAL POSITION SENSE P26 20BR FRONT RISER POSITION SENSE P27 20LB/RD REAR RISER POSITION SENSE BLACK P47 20LB RECLINER POSITION SENSE P103 20DB/WT LUMBAR POSITION SENSE P21 18RD/LG...
Page 1031 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 57 CIRCUIT FUNCTION F83 20YL/DG FUSED IGNITION SWITCH OUTPUT (RUN) Z1 20BK GROUND D1 18VT/BR CCD BUS(+) M2 20YL COURTESY LAMP RELAY OUTPUT D2 18WT/BK CCD BUS(-) M1 20PK FUSED B(+) MINI OVERHEAD CONSOLE CIRCUIT FUNCTION...
Page 1032 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 58 CIRCUIT FUNCTION K67 20BR/BK NEEDLE MOVEMENT SENSOR (+) K68 20LG/YL NEEDLE MOVEMENT SENSOR (-) NEEDLE SENSOR (DIESEL) BLACK CIRCUIT FUNCTION K4 20BK/LB SENSOR GROUND G60 20GY/YL* OIL PRESSURE SENSOR SIGNAL G6 18GY/WT OIL PRESSURE SENSOR SIGNAL OIL PRESSURE SENSOR...
Page 1033 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 59 BLACK CIRCUIT FUNCTION L10 18BR/LG BACK-UP LAMP SWITCH OUTPUT T41 20BK/WT PARK/NEUTRAL POSITION SWITCH SENSE F83 18YL/DG FUSED IGNITION SWITCH OUTPUT (RUN) PARK/NEUTRAL POSITION SWITCH YELLOW CIRCUIT FUNCTION R44 18DB PASSENGER AIRBAG LINE 2 R42 18VT PASSENGER AIRBAG LINE 1 PASSENGER...
Page 1034 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 60 GREEN CIRCUIT FUNCTION Z1 16BK GROUND P88 16BR/BK HEATED SEAT DRIVER PASSENGER HEATED SEAT BACK BLACK CIRCUIT FUNCTION P87 16BK/OR HEATED SEAT DRIVER P88 16BR/BK HEATED SEAT DRIVER P8 18LB/WT PASSENGER HEATED SEAT SWITCH OUTPUT PASSENGER HEATED Z1 20BK GROUND...
Page 1035 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 61 CIRCUIT FUNCTION P20 16RD/LG FRONT RISER DOWN SWITCH SENSE P18 16YL/LG FRONT RISER UP SWITCH SENSE PASSENGER POWER SEAT FRONT RISER MOTOR BLACK CIRCUIT FUNCTION P14 16YL/LB HORIZONTAL FORWARD SWITCH SENSE P16 16RD/LB HORIZONTAL REARWARD SWITCH SENSE PASSENGER POWER SEAT HORIZONTAL MOTOR...

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