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Chrysler 2004 Concorde Service Manual

Chrysler 2004 Concorde Service Manual

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GROUP TAB LOCATOR

Introduction

0

Lubrication & Maintenance

2

Suspension

3

Driveline

5

Brakes

7

Cooling

8A

Audio/Video

8B

Chime/Buzzer

8C

Clock

8E

Electronic Control Modules

8F

Engine Systems

8G

Heated Systems

8H

Horn

8I

Ignition Control

8J

Instrument Cluster

8L

Lamps

8M

Message Systems

8N

Power Systems

8O

Restraints

8P

Speed Control

8Q

Vehicle Theft Security

8R

Wipers/Washers

8W

Wiring

9

Engine

11

Exhaust System

13

Frame & Bumpers

14

Fuel System

19

Steering

21

Transaxle

22

Tires/Wheels

23

Body

24

Heating & Air Conditioning

25

Emissions Control

Component and System Index

Service Manual Comment Forms

(Rear of Manual)

Table of Contents

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Summary of Contents for Chrysler 2004 Concorde

Page 1 GROUP TAB LOCATOR Introduction Lubrication & Maintenance Suspension Driveline Brakes Cooling Audio/Video Chime/Buzzer Clock Electronic Control Modules Engine Systems Heated Systems Horn Ignition Control Instrument Cluster Lamps Message Systems Power Systems Restraints Speed Control Vehicle Theft Security Wipers/Washers Wiring Engine Exhaust System Frame &...
Page 3: Body Code Plate
INTRODUCTION INTRODUCTION TABLE OF CONTENTS page page BODY CODE PLATES TORQUE REFERENCES DESCRIPTION ......1 DESCRIPTION .
Page 4: Fastener Identification
DIGITS 20 DESCRIPTION Carline The SAE bolt strength grades range from grade 2 • C = Chrysler to grade 8. The higher the grade number, the greater • D = Dodge the bolt strength. Identification is determined by the • Y = Chrysler line marks on the top of each bolt head.
Page 5 INTRODUCTION FASTENER IDENTIFICATION (Continued) Fig. 3 FASTENER IDENTIFICATION...
Page 6 INTRODUCTION FASTENER IDENTIFICATION (Continued) Fig. 4 FASTENER STRENGTH...
Page 7 INTRODUCTION DESCRIPTION - THREADED HOLE REPAIR FASTENER USAGE Most stripped threaded holes can be repaired using a Helicoil . Follow the vehicle or Helicoil recommen- DESCRIPTION dations for application and repair procedures. DESCRIPTION - FASTENER USAGE INTERNATIONAL SYMBOLS WARNING: USE OF AN INCORRECT FASTENER DESCRIPTION MAY RESULT IN COMPONENT DAMAGE OR PER- SONAL INJURY.
Page 8: Metric System
INTRODUCTION The following chart will assist in converting metric METRIC SYSTEM units to equivalent English and SAE units, or vise versa. DESCRIPTION The metric system is based on quantities of one, ten, one hundred, one thousand and one million. CONVERSION FORMULAS AND EQUIVALENT VALUES MULTIPLY TO GET MULTIPLY...
Page 9 INTRODUCTION METRIC SYSTEM (Continued) Fig. 6 METRIC CONVERSION CHART...
Page 10 INTRODUCTION Chart for torque references not listed in the individual TORQUE REFERENCES torque charts (Fig. 7). DESCRIPTION Individual Torque Charts appear within many or the Groups. Refer to the Standard Torque Specifications Fig. 7 TORQUE SPECIFICATIONS...
Page 11: Vehicle Identification Number
CODE = DESCRIPTION Country of Origin 2 = Manufactured By DaimlerChrysler Canada Inc. Make B = Dodge C = Chrysler Vehicle Type 3 = Passenger Car Passenger Safety A = Restraint System - Active Driver and Side Airbags H = Restraint System - Active Driver and Passenger Airbags Car Line D = Concord (U.S.,Canada, Mexico, Bux)
Page 12: Certification Label
4 - AMENDMENT NUMBER VECI LABEL DESCRIPTION All models have a Vehicle Emission Control Infor- mation (VECI) Label. Chrysler permanently attaches the label in the engine compartment. It cannot be removed without defacing information and destroying the label. The label contains the vehicle’s emission specifica- tions and vacuum hose routings.
Page 13 INTRODUCTION MANUFACTURER PLATE DESCRIPTION The Manufacturer Plate (Fig. 11) is located in the engine compartment on the passenger side rear cor- ner of the hood. The plate contains five lines of infor- mation: 1. Vehicle Identification Number (VIN) 2. Gross Vehicle Mass (GVM) 3.
Page 15 LUBRICATION & MAINTENANCE 0 - 1 LUBRICATION & MAINTENANCE TABLE OF CONTENTS page page INTERNATIONAL SYMBOLS FLUID FILL/CHECK LOCATIONS DESCRIPTION ......1 DESCRIPTION .
Page 16 This symbol means that the oil has been certified mixtures. by the American Petroleum Institute (API). Diamler- Chrysler only recommend API Certified (GF-3) GEAR LUBRICANTS engine oils that meet the requirements of Material SAE ratings also apply to multigrade gear lubri- Standard MS-6395.
Page 17 LUBRICATION & MAINTENANCE 0 - 3 FLUID TYPES (Continued) quality of the lubricant. The following symbols indi- The use of aluminum cylinder blocks, cylinder cate the highest quality. heads, and water pumps requires special corrosion protection. Mopar Antifreeze/Coolant, Year/100,000 Mile Formula (MS-9769), or the equiva- lent ethylene glycol base coolant with hybrid organic corrosion inhibitors (called HOAT, for Hybrid Organic Additive Technology) is recommended.
Page 18 0 - 4 LUBRICATION & MAINTENANCE FLUID TYPES (Continued) has a unique odor that may change with age. Conse- may adversely affect the integrity of transmission quently, odor and color cannot be used to indi- seals. cate the fluid condition or the need for a fluid DESCRIPTION - FUEL REQUIREMENTS change.
Page 19: Fluid Capacities
LUBRICATION & MAINTENANCE 0 - 5 FLUID TYPES (Continued) • The use of leaded gas is prohibited by Federal MMT IN GASOLINE law. Using leaded gasoline can impair engine perfor- MMT is a manganese-containing metallic additive mance, damage the emission control system, and that is blended into some gasoline to increase octane.
Page 20: Lubrication Points
0 - 6 LUBRICATION & MAINTENANCE NOTE: Under no circumstances should oil change FLUID FILL/CHECK intervals exceed 6000 miles (10 000 km) or 6 LOCATIONS months whichever comes first. DESCRIPTION CAUTION: Failure to perform the required mainte- The fluid check/fill point locations are located in nance items may result in damage to the vehicle.
Page 21 LUBRICATION & MAINTENANCE 0 - 7 MAINTENANCE SCHEDULES (Continued) • Trailer towing. SCHEDULE “B” • Taxi, police or delivery service (commercial ser- Follow schedule “B” if you usually operate your vices). vehicle under one or more of the following conditions. •...
Page 22 0 - 8 LUBRICATION & MAINTENANCE MAINTENANCE SCHEDULES (Continued) Miles 57,000 60,000 63,000 66,000 69,000 72,000 (Kilometers) (91 000) (96 000) (101 000) (106 000) (110 000) (115 000) Change engine oil and engine oil filter. Inspect the air cleaner filter and replace if required.* Replace the air cleaner filter.
Page 23 LUBRICATION & MAINTENANCE 0 - 9 MAINTENANCE SCHEDULES (Continued) SCHEDULE “A” Miles 6,000 12,000 18,000 24,000 30,000 36,000 (Kilometers) (10 000) (19 000) (29 000) (38 000) (48 000) (58 000) [Months] [12] [18] [24] [30] [36] Change engine oil and engine oil filter. Inspect the air cleaner filter and replace if required.* Replace the air cleaner filter.*...
Page 24 0 - 10 LUBRICATION & MAINTENANCE MAINTENANCE SCHEDULES (Continued) Miles 78,000 84,000 90,000 96,000 102,000 (Kilometers) (125 000) (134 000) (144 000) (154 000) (163 000) [Months] [78] [84] [90] [96] [102] Check and replace, if necessary, the PCV valve.*‡ Replace the engine timing belt (Federal Emissions equipped vehicles only).
Page 25 LUBRICATION & MAINTENANCE 0 - 11 MAINTENANCE SCHEDULES (Continued) • Check the automatic transmission fluid level. At Each Oil Change • Check the coolant level, hoses, and clamps. • Change the engine oil filter. • Rotate the tires at each oil change interval •...
Page 26 0 - 12 LUBRICATION & MAINTENANCE MAINTENANCE SCHEDULES (Continued) • More than 50% of your driving is at sustained SCHEDULE “B” high speeds during hot weather, above 90° F (32° Follow schedule “B” if you usually operate your vehicle under one or more of the following conditions. •...
Page 27 LUBRICATION & MAINTENANCE 0 - 13 MAINTENANCE SCHEDULES (Continued) Kilometers 91 000 96 000 101000 106000 110000 115000 (Miles) (57,000) (60,000) (63,000) (66,000) (69,000) (72,000) Change engine oil and engine oil filter. Inspect the air cleaner filter and replace if required.* Replace the air cleaner filter.
Page 28: Jump Starting
0 - 14 LUBRICATION & MAINTENANCE HOISTING JUMP STARTING STANDARD PROCEDURE - HOISTING STANDARD PROCEDURE - JUMP STARTING Refer to Owner’s Manual provided with vehicle for WARNING: proper emergency jacking procedures. REVIEW ALL SAFETY PRECAUTIONS AND WARN- WARNING: THE HOISTING AND JACK LIFTING INGS.
Page 29 LUBRICATION & MAINTENANCE 0 - 15 JUMP STARTING (Continued) (2) When using another vehicle as a booster source, park the booster vehicle within cable reach without allow vehicles to touch. (3) Turn off all accessories, set the parking brake, place the automatic transmission in PARK, and turn the ignition OFF in both vehicles.
Page 30 0 - 16 LUBRICATION & MAINTENANCE TOWING (Continued) be sure the rear end of disabled vehicle has at least Always tow vehicle with front wheels off the 100 mm (4 inches) ground clearance. If minimum ground as shown (Fig. 9). ground clearance cannot be reached, use a towing dolly.
Page 31 SUSPENSION 2 - 1 SUSPENSION TABLE OF CONTENTS page page FRONT SUSPENSION ..... 1 WHEEL ALIGNMENT ..... 50 REAR SUSPENSION .
Page 32: Front Suspension
2 - 2 FRONT SUSPENSION suspension are allowed to pivot so the vehicle can be FRONT SUSPENSION steered in the direction preferred. Steering of the vehicle is provided through a rack and pinion steer- DESCRIPTION - FRONT SUSPENSION ing gear that is connected to a fixed steering arm on This vehicle uses a MacPherson strut type front each front strut.
Page 33: Specifications
FRONT SUSPENSION 2 - 3 FRONT SUSPENSION (Continued) CAUTION SPECIFICATIONS CAUTION: Only frame contact hoisting equipment FRONT SUSPENSION FASTENER TORQUE can be used on this vehicle. All vehicles have a fully independent rear suspension. The vehicles cannot be hoisted using equipment designed to lift DESCRIPTION N·m Lbs.
Page 34 2 - 4 FRONT SUSPENSION FRONT SUSPENSION (Continued) HUB / BEARING DESCRIPTION The front wheel bearing and front wheel hub of this vehicle are a hub and bearing unit type assem- bly. This unit combines the front wheel mounting hub (flange) and the front wheel bearing into a sealed one piece unit.
Page 35 FRONT SUSPENSION 2 - 5 HUB / BEARING (Continued) (3) Remove the 2 guide pin bolts mounting the cal- (5) Remove the hub and bearing retaining nut iper assembly to the steering knuckle (Fig. 3). (Fig. 5). Remove the caliper from the front steering knuckle. Refer to Disc Brake Caliper in Brakes.
Page 36 2 - 6 FRONT SUSPENSION HUB / BEARING (Continued) a pry bar between hub and bearing assembly and steering knuckle (Fig. 8) and gently pry hub and bearing from knuckle. If stub shaft is frozen to hub and bearing assembly, tap end of stub shaft with soft face hammer to free it from hub and bearing spline.
Page 37 FRONT SUSPENSION 2 - 7 HUB / BEARING (Continued) CAUTION: When installing hub and bearing assem- outer constant velocity (C/V) stub shaft is splined to bly into steering knuckle, be careful not to damage the center of the hub. the flinger disc (Fig. 9) on hub and bearing assem- OPERATION - STEERING KNUCKLE bly.
Page 38 2 - 8 FRONT SUSPENSION KNUCKLE (Continued) REMOVAL - STEERING KNUCKLE (1) Raise vehicle on jackstands or centered on a frame contact hoist. See Hoisting in the Lubrication and Maintenance section. (2) Remove the front wheel and tire assembly from the vehicle.
Page 39 FRONT SUSPENSION 2 - 9 KNUCKLE (Continued) Fig. 15 Hub And Bearing Retaining Nut 1 - HUB/BEARING ASSEMBLY 2 - NUT Fig. 17 Hub And Bearing Assembly Seal 1 - SEAL CAN MUST REMAIN TIGHT AGAINST HUB AND BEARING ASSEMBLY HERE 2 - SEAL 3 - FLINGER 4 - DO NOT ALLOW FLINGER TO BE BENT OR DAMAGED...
Page 40 2 - 10 FRONT SUSPENSION KNUCKLE (Continued) Fig. 18 Hub And Bearing Fig. 20 Control Arm To Steering Knuckle Attachment 1 - HUB/BEARING ASSEMBLY 2 - STEERING KNUCKLE 1 - LOWER CONTROL ARM 2 - BALL JOINT STUD 3 - CLAMP NUT AND BOLT Fig.
Page 41 FRONT SUSPENSION 2 - 11 KNUCKLE (Continued) CAUTION: When installing hub and bearing assem- bly into steering knuckle, be careful not to damage the flinger disc (Fig. 17) on hub and bearing assem- bly. If flinger disc becomes damaged, hub and bear- ing assembly MUST not be used and MUST be replaced with a new hub and bearing assembly.
Page 42 2 - 12 FRONT SUSPENSION LOWER BALL JOINT (Continued) The ball joint used in the lower control arm of this DIAGNOSIS AND TESTING - LOWER CONTROL vehicle is a sealed-for-life ball joint and requires no maintenance lubrication. The ball joint cannot be ser- Inspect the lower control arm for signs of damage viced separately from the lower control arm.
Page 43 FRONT SUSPENSION 2 - 13 LOWER CONTROL ARM (Continued) (4) Carefully insert a pry bar between lower con- (6) Loosen and remove lower control arm pivot trol arm and steering knuckle (Fig. 25). Push down bushing to cradle assembly pivot bolt (Fig. 27). on pry bar to separate ball joint stud from steering knuckle (Fig.
Page 44 2 - 14 FRONT SUSPENSION LOWER CONTROL ARM (Continued) Fig. 29 Lower Control Arm And Tension Strut Fig. 30 Lower Control Arm Pivot Bushing 1 - BALL JOINT STUD 1 - ARBOR PRESS RAM 2 - BALL JOINT SEAL 2 - SPECIAL TOOL 6644-2 3 - LOWER CONTROL ARM TENSION STRUT BUSHING 3 - SPECIAL TOOL MB990799 4 - NUT...
Page 45 FRONT SUSPENSION 2 - 15 LOWER CONTROL ARM (Continued) ASSEMBLY ASSEMBLY - LOWER CONTROL ARM (PIVOT BUSHING) (1) Position the lower control arm so it is sup- ported by Receiver, Special Tool MB-990799, as shown (Fig. 32). (2) Place new pivot bushing in lower control arm so it is square with the bushing hole.
Page 46: Stabilizer Bar
2 - 16 FRONT SUSPENSION LOWER CONTROL ARM (Continued) (4) Using the arbor press, press the tension strut (4) Install the lower control arm to cradle bracket bushing into the lower control arm. As the bushing is attaching pivot bolt and nut (Fig. 27). Do not being pressed into the control arm a pop noise will be tighten the lower control arm to cradle bracket heard.
Page 47 FRONT SUSPENSION 2 - 17 STABILIZER BAR (Continued) must be positioned toward the front of the vehicle when the stabilizer bar is installed. OPERATION Jounce and rebound movements affecting one wheel are partially transmitted to the opposite wheel of the vehicle through the stabilizer bar. This helps to minimize the body roll of the vehicle during sus- pension movement.
Page 48 2 - 18 FRONT SUSPENSION STABILIZER BAR (Continued) Fig. 41 Speed Sensor Cable Routing Bracket Fig. 39 Stabilizer Bar At Left Link 1 - STRUT ASSEMBLY 1 - LINK 2 - ROUTING BRACKET 2 - STABILIZER BAR 3 - SCREW 3 - LOWER ARM 4 - SPEED SENSOR CABLE 4 - NUT...
Page 49 FRONT SUSPENSION 2 - 19 STABILIZER BAR (Continued) Fig. 43 Structural Collar Fig. 45 Stabilizer Bar Isolator Bushing Attachment To Cradle 1 - TRANSAXLE 2 - MOUNTING BOLTS 1 - STABILIZER BAR 3 - ENGINE OIL PAN 2 - ATTACHING BOLTS 4 - STRUCTURAL COLLAR 3 - CRADLE 5 - STABILIZER BAR...
Page 50 2 - 20 FRONT SUSPENSION STABILIZER BAR (Continued) CAUTION: Be careful not to pull knuckle outward, (5) Install stabilizer bar isolator bushings onto sta- thus stretching halfshaft and possibly separating bilizer bar with slits facing forward and flat side fac- ing downward.
Page 51 FRONT SUSPENSION 2 - 21 STABILIZER BAR (Continued) CAUTION: The strut assembly to steering knuckle bolts are serrated were they go through strut assembly and steering knuckle. When installing bolts, turn nuts onto bolts DO NOT TURN BOLTS IN STEERING KNUCKLE. If bolts are turned damage to steering knuckle will result.
Page 52 2 - 22 FRONT SUSPENSION STABILIZER BAR BUSHINGS (Continued) • Jounce bumper • Jounce bumper cup • Coil spring • Upper spring isolator • Lower spring isolator • Strut Fig. 51 Stabilizer Bar Isolator Bushing 1 - STABILIZER BAR 2 - STABILIZER BAR ISOLATOR BUSHING 3 - CRADLE ASSEMBLY 4 - FRONT OF CAR 5 - SLIT...
Page 53 FRONT SUSPENSION 2 - 23 STRUT (Continued) DIAGNOSIS AND TESTING - STRUT ASSEMBLY (FRONT) (1) Inspect for damaged or broken coil springs. (2) Inspect for torn or damaged strut assembly dust boots. (3) Lift dust boot and inspect strut assembly for evidence of fluid running from the upper end of fluid reservoir.
Page 54 2 - 24 FRONT SUSPENSION STRUT (Continued) Fig. 55 Stabilizer Bar Link At Strut Fig. 57 Speed Sensor Cable Routing Bracket 1 - OUTER TIE ROD 1 - STRUT ASSEMBLY 2 - NUT 2 - ROUTING BRACKET 3 - STABILIZER BAR ATTACHING LINK 3 - SCREW 4 - STRUT ASSEMBLY 4 - SPEED SENSOR CABLE...
Page 55 FRONT SUSPENSION 2 - 25 STRUT (Continued) (7) Remove brake caliper assembly from steering knuckle and brake rotor. Refer to the Brakes. Sup- port caliper assembly by hanging it from frame of vehicle with wire or some other method (Fig. 59). Do not let caliper assembly hang by brake hose.
Page 56 2 - 26 FRONT SUSPENSION STRUT (Continued) WARNING: DO NOT REMOVE THE STRUT ASSEM- (3) Compress the coil spring until all coil spring BLY’S SHAFT NUT AT ANY TIME UNLESS THE COIL tension is removed from the upper mount. (4) Install Strut Nut Socket, Special Tool 6864, on SPRING HAS BEEN PROPERLY COMPRESSED FOLLOWING THE PROCEDURE LISTED HERE.
Page 57 FRONT SUSPENSION 2 - 27 STRUT (Continued) jounce bumper cup may also come off when the assembly is removed. Check inside the dust shield. NOTE: Before releasing the tension on the coil spring, note the position of the coil end on the upper end of the coil spring.
Page 58 2 - 28 FRONT SUSPENSION STRUT (Continued) built into the seat and upper spring isolator against the coil end of the coil spring. (4) Install the lower spring isolator on the lower spring seat of the strut (Fig. 65). The tabs on the iso- lator will align it on the strut spring seat.
Page 59 FRONT SUSPENSION 2 - 29 STRUT (Continued) CAUTION: The strut assembly to steering knuckle REMOVAL - TENSION STRUT bolts are serrated were they go through strut The tension strut is removed from the vehicle with assembly and steering knuckle. When installing the lower control arm, then separated.
Page 60 2 - 30 FRONT SUSPENSION TENSION STRUT CRADLE BUSHING (Continued) (3) Remove the remaining tension strut cradle INSTALLATION - TENSION STRUT CRADLE bushing halve from the engine cradle assembly (Fig. BUSHING 69). (1) Install tension strut cradle isolator bushing halve into front side of cradle mounting hole, until squarely seated against cradle (Fig.
Page 61 REAR SUSPENSION 2 - 31 REAR SUSPENSION TABLE OF CONTENTS page page REAR SUSPENSION REMOVAL - SPINDLE ....37 DESCRIPTION - REAR SUSPENSION .
Page 62 2 - 32 REAR SUSPENSION REAR SUSPENSION (Continued) Fig. 1 Rear Suspension 1 - STRUT ASSEMBLY 5 - HUB AND BEARING 2 - REAR SUSPENSION CROSSMEMBER 6 - STABILIZER BAR 3 - REAR SUSPENSION CROSSMEMBER BUSHING 7 - TRAILING ARM 4 - LATERAL LINKS 8 - SPINDLE CAUTION: If the vehicle is equipped with the Tire...
Page 63 REAR SUSPENSION 2 - 33 REAR SUSPENSION (Continued) SPECIFICATIONS HUB / BEARING REAR SUSPENSION FASTENER TORQUE DESCRIPTION The rear wheel bearing and rear wheel hub of this vehicle are a one piece sealed unit or hub and bear- DESCRIPTION N·m ing unit type assembly.
Page 64 2 - 34 REAR SUSPENSION HUB / BEARING (Continued) INSTALLATION - HUB AND BEARING (REAR) (1) Install the rear hub and bearing assembly on the rear spindle. Install hub and bearing assembly retaining washer and nut on spindle (Fig. 3). Tighten the hub and bearing retaining nut to a torque of 168 N·m (124 ft.
Page 65 REAR SUSPENSION 2 - 35 LATERAL LINK (Continued) REMOVAL - LATERAL LINKS The left forward lateral link requires a more involved removal and installation procedure in order to remove the attaching bolt at the crossmember. See separate procedures below for the proper lateral link service procedure.
Page 66 2 - 36 REAR SUSPENSION LATERAL LINK (Continued) CAUTION: The bolts attaching the forward lateral (8) Install the lateral links on the spindle. Install, links to the crossmember must be installed with the but DO NOT fully tighten the attaching bolt and nut at this time (Fig.
Page 67 REAR SUSPENSION 2 - 37 LATERAL LINK (Continued) (8) Tighten lateral arm to spindle attaching bolt and nut to 135 N·m (100 ft. lbs.). (9) Check and reset rear wheel toe to specifications if required. SPINDLE DESCRIPTION A forged rear spindle is mounted to each side of the rear suspension (Fig.
Page 68 2 - 38 REAR SUSPENSION SPINDLE (Continued) (6) If vehicle is equipped with antilock brakes, remove the speed sensor head from the rear disc brake adapter (Fig. 8). Fig. 10 Trailing Arm To Bracket Bolt 1 - SPINDLE 2 - TRAILING ARM BRACKET 3 - TRAILING ARM Fig.
Page 69 REAR SUSPENSION 2 - 39 SPINDLE (Continued) Fig. 12 Spindle Pinch Bolt Fig. 14 Removing Spindle From Strut 1 - PINCH BOLT 1 - BRASS DRIFT PUNCH 2 - STRUT ASSEMBLY 2 - STRUT ASSEMBLY 3 - REAR SPINDLE 3 - SPINDLE 4 - CENTER PUNCH 5 - HIT SPINDLE HERE 6 - LATERAL LINK...
Page 70 2 - 40 REAR SUSPENSION SPINDLE (Continued) (11) Tighten the lateral links to spindle attaching bar (Fig. 15). Remove the link from the stabilizer bar. bolt to a torque of 135 N·m (100 ft. lbs.). Repeat this procedure on the other side of the vehicle (12) Tighten the trailing arm to spindle bracket for the other attaching link.
Page 71 REAR SUSPENSION 2 - 41 STABILIZER BAR (Continued) member in place). Remove the stabilizer bar from the (4) Install the upper half of the retainer onto the vehicle. lower half. This is done by tapping the upper half, (5) Mount the stabilizer bar in a soft jawed vise starting with the large end, onto the lower half with with one of the two bushings mount just above the a hammer and brass drift punch (Fig.
Page 72 2 - 42 REAR SUSPENSION STABILIZER BAR (Continued) wrench and torque wrench in place of the wrench on the attaching nut.Be sure to use a wrench to hold the link stud in place while tightening each attaching nut. (10) Lower vehicle to the ground. STRUT DESCRIPTION - STRUT ASSEMBLY (REAR) The rear strut assemblies support the weight of...
Page 73 REAR SUSPENSION 2 - 43 STRUT (Continued) REMOVAL - STRUT ASSEMBLY (REAR) NOTE: When removing rear strut assembly from vehicle, access to the 3 rear strut assembly-to-strut tower attaching nuts is through the passenger com- partment of the vehicle. (1) Remove the rear seat cushion from the interior of the car.
Page 74 2 - 44 REAR SUSPENSION STRUT (Continued) Fig. 24 Spindle To Strut Attachment 1 - PINCH BOLT Fig. 22 Lateral Links To Spindle Attachment 2 - STRUT ASSEMBLY 1 - SPINDLE 3 - REAR SPINDLE 2 - LATERAL LINKS 3 - LATERAL LINK ATTACHING BOLT HEAD (15) Insert a center punch into the hole on the 4 - STRUT ASSEMBLY spindle (Fig.
Page 75 REAR SUSPENSION 2 - 45 STRUT (Continued) (21) Remove the nut, washers and rubber isolators securing the stabilizer bar link to the strut. (22) For disassembly of the strut assembly, refer to Disassembly. DISASSEMBLY - STRUT ASSEMBLY (REAR) The Strut assembly must be removed from the vehicle for it to be disassembled and assembled.
Page 76 2 - 46 REAR SUSPENSION STRUT (Continued) • Inspect the strut for any condition of shaft bind- (2) Install the lower spring isolator on strut ing over the full stroke of the shaft. matching the step in the isolator to the step in the •...
Page 77 REAR SUSPENSION 2 - 47 STRUT (Continued) (10) Install the strut assembly back into the vehi- attaching nut (Fig. 23). Tighten the stabilizer link to cle. Refer to Installation. stabilizer bar attaching nut to a torque of 95 N·m (70 ft.
Page 78 2 - 48 REAR SUSPENSION TRAILING ARM/LINK (Continued) Inspect the trailing arm for signs of contact with the ground or road debris which has bent or caused other damage to the trailing arm. If the trailing arm is bent or damaged the trailing arm will require replacement.
Page 79 REAR SUSPENSION 2 - 49 TRAILING ARM/LINK (Continued) (3) Install bolt attaching trailing arm to trailing (5) Lower vehicle to the ground. arm bracket on bottom of spindle (Fig. 30). Do not (6) Tighten the trailing arm to spindle bracket fully tighten attaching bolt at this time.
Page 80 2 - 50 WHEEL ALIGNMENT WHEEL ALIGNMENT TABLE OF CONTENTS page page WHEEL ALIGNMENT STANDARD PROCEDURE - WHEEL DESCRIPTION - WHEEL ALIGNMENT ..50 ALIGNMENT ......57 DIAGNOSIS AND TESTING STANDARD PROCEDURE - CURB HEIGHT DIAGNOSIS AND TESTING - SUSPENSION...
Page 81 WHEEL ALIGNMENT 2 - 51 WHEEL ALIGNMENT (Continued) CROSS CAMBER Cross camber is the difference between left and Toe is the inward or outward angle of the wheels right camber. To achieve the cross camber reading, as viewed from above the vehicle (Fig. 3). •...
Page 82 2 - 52 WHEEL ALIGNMENT WHEEL ALIGNMENT (Continued) TOE-OUT ON TURNS STEERING AXIS INCLINATION (S. A. I.) Toe-out on turns is the relative positioning of the Steering axis inclination is the angle between a front wheels while steering through a turn (Fig. 4). true vertical line starting at the center of the tire at This compensates for each front wheel’s turning the road contact point and a line drawn through the...
Page 83 WHEEL ALIGNMENT 2 - 53 WHEEL ALIGNMENT (Continued) THRUST ANGLE Improper tracking can cause undue tire wear, a lead or pull and a crooked steering wheel. Excessive Thrust angle is the averaged direction the rear thrust angle can usually be corrected by adjusting wheels are pointing in relation to the vehicle’s center the rear wheel toe so that each wheel has one-half of line (Fig.
Page 84: Diagnosis And Testing
2 - 54 WHEEL ALIGNMENT WHEEL ALIGNMENT (Continued) DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - SUSPENSION AND STEERING CONDITION POSSIBLE CAUSES CORRECTION Front End Whine On Turns 1. Defective wheel bearing 1. Replace wheel bearing 2. Incorrect wheel alignment 2. Check and reset wheel alignment 3.
Page 85 WHEEL ALIGNMENT 2 - 55 WHEEL ALIGNMENT (Continued) CONDITION POSSIBLE CAUSES CORRECTION Front End Clunk When 1. Worn or broken engine mount 1. Replace engine mount Accelerating Or Decelerating 2. Worn or defective transaxle gears or 2. Replace transaxle gears or bearings bearings 3.
Page 86 2 - 56 WHEEL ALIGNMENT WHEEL ALIGNMENT (Continued) DIAGNOSIS AND TESTING - VEHICLE Proceed with the Caster Bias procedure before attempting the Camber Bias procedure. LEAD/PULL To assure correct diagnosis, it is important to fol- CASTER BIAS low the steps outlined below in the order shown. On a vehicle that leads left, create more caster on Road test the vehicle before and after each step to the left than on the right.
Page 87 WHEEL ALIGNMENT 2 - 57 WHEEL ALIGNMENT (Continued) STANDARD PROCEDURE - WHEEL ALIGNMENT REAR WHEEL TOE ADJUSTMENT (1) Loosen lateral link, adjustment link jam nuts PRE-WHEEL ALIGNMENT INSPECTION (Fig. 7). Rotate adjustment links as required to set rear wheel Toe to specifications. Do not exceed the Before any attempt is made to change or correct maximum length dimensions of the lateral links the wheel alignment, the following inspection and...
Page 88 2 - 58 WHEEL ALIGNMENT WHEEL ALIGNMENT (Continued) (2) Tighten lateral link, adjustment link lock-nuts CAUTION: The bolts attaching the strut to the steer- to 88 N·m (65 ft. lbs.) torque. ing knuckle are serrated in the area where they go (3) Proceed to set the front wheel alignment.
Page 89 WHEEL ALIGNMENT 2 - 59 WHEEL ALIGNMENT (Continued) CAUTION: When torquing adjustment pinch bolt, the following procedure must be followed to ensure adequate retention of the adjustment sleeve. Not following this procedure, could result in the Toe Setting Adjustment changing and/or loosening of the inner or outer tie rod ends.
Page 90 2 - 60 WHEEL ALIGNMENT WHEEL ALIGNMENT (Continued) CURB HEIGHT SPECIFICATIONS VEHICLE FRONT REAR 739 mm ± 20 mm 754 mm ± 20 mm CONCORDE/300M 29.09 in. ± 0.79 in. 29.68 in. ± 0.79 in. 729 mm ± 20 mm 735 mm ±...
Page 91 DRIVELINE 3 - 1 DRIVELINE HALFSHAFT TABLE OF CONTENTS page page HALFSHAFT SPECIAL TOOLS DESCRIPTION ......1 DRIVELINE .
Page 92 3 - 2 HALFSHAFT HALFSHAFT (Continued) Fig. 1 Front Halfshaft Assemblies 1 - INNER BOOT 7 - INTERCONNECTING SHAFT 2 - INTERCONNECTING SHAFT 8 - OUTER RZEPPA JOINT 3 - OUTER BOOT 9 - INNER BOOT 4 - RIGHT HALF SHAFT 10 - LEFT HALF SHAFT 5 - TONE WHEEL 11 - OUTER BOOT...
Page 93 HALFSHAFT 3 - 3 HALFSHAFT (Continued) Fig. 2 Halfshaft Component Identification 1 - HOUSING ASM, RETAINER 11 - CLAMP, SEAL RETAINING 2 - RING, SPACER 12 - SHAFT, AXLE (RH SHOWN, LH SIMILAR) 3 - SPIDER, TRIPOD JOINT 13 - SEAL, DRIVE AXLE OUTBOARD 4 - RING, RETAINING 14 - CLAMP, SEAL RETAINING 5 - RETAINER, BALL &...
Page 94 3 - 4 HALFSHAFT HALFSHAFT (Continued) REMOVAL (1) Raise vehicle on jackstands or centered on a frame contact type hoist. (2) Remove the front wheel and tire assembly from the vehicle. (3) Remove the front caliper assembly from the front steering knuckle assembly (Fig. 3). Fig.
Page 95 HALFSHAFT 3 - 5 HALFSHAFT (Continued) Fig. 6 Hub And Bearing To Stub Axle Retaining Nut Fig. 8 Strut Assembly To Steering Knuckle Attaching Bolts 1 - HUB/BEARING ASSEMBLY 2 - NUT 1 - STRUT ASSEMBLY 2 - NUTS 3 - STRUT ASSEMBLY TO STEERING KNUCKLE ATTACHING BOLTS 4 - STEERING KNUCKLE Fig.
Page 96 3 - 6 HALFSHAFT HALFSHAFT (Continued) Fig. 12 Grease Applied To Inner Tripod Joint Housing Spline Fig. 10 Inner Tripod Joint Removal From Stub Shaft 1 - APPLY 1 MILLILITER BEAD OF GREASE HERE 1 - TRANSAXLE 2 - INNER TRIPOD JOINT HOUSING 2 - TRANSMISSION STUB SHAFT 3 - INNER TRIPOD JOINT Fig.
Page 97 HALFSHAFT 3 - 7 HALFSHAFT (Continued) (5) Hold outer C/V joint assembly with one hand. Grasp steering knuckle with other hand and rotate it out and to the rear of the vehicle. Install outer C/V joint into the hub and bearing assembly (Fig. 14). Fig.
Page 98 3 - 8 HALFSHAFT HALFSHAFT (Continued) (12) Install wheel and tire assembly on vehicle. Tighten the wheel mounting stud nuts in proper sequence (Fig. 19), until all nuts are tightened to half specification. Then repeat the tightening sequence to the full specified torque of 135 N·m (100 ft. lbs.). Fig.
Page 99 HALFSHAFT 3 - 9 HALFSHAFT (Continued) SPECIFICATIONS TORQUE TORQUE SPECIFICATIONS DESCRIPTION N·m Ft. Lbs. In. Lbs. Bolt, Caliper-to-Knuckle Bolt, Knuckle-to-Strut Nut, Front Wheel Lug Nut, Halfshaft Nut, Tie Rod End-to-Knuckle SPECIAL TOOLS DRIVELINE Boot Clamp Installer C-4975A CV BOOT-INNER Fig. 21 Inner Tripod Joint Sealing Boot Clamps 1 - SMALL CLAMP REMOVAL 2 - SEALING BOOT...
Page 100 3 - 10 HALFSHAFT CV BOOT-INNER (Continued) (1) Slide inner tripod joint seal boot retaining clamp, onto interconnecting shaft. Then slide replace- ment inner tripod joint sealing boot onto the inter- connecting shaft. Inner tripod joint seal boot MUST be positioned on interconnecting shaft, so only the thinnest (sight) groove on intercon- necting shaft is visible (Fig.
Page 101 HALFSHAFT 3 - 11 CV BOOT-INNER (Continued) Fig. 25 Spider Assembly Retaining Snap Ring Fig. 27 Crimping Tool Installed On Sealing Boot 1 - SNAP RING Clamp 2 - SEALING BOOT 1 - SPECIAL TOOL C-4975 3 - SPIDER ASSEMBLY 2 - SEALING BOOT CLAMP 4 - SNAP RING PLIERS 5 - INTERCONNECTING SHAFT...
Page 102 3 - 12 HALFSHAFT CV BOOT-INNER (Continued) Fig. 29 Boot and Clamp Positioning 1 - POSITION ON FLAT BETWEEN LOCATING SHOULDERS Fig. 30 Outer C/V Joint Seal Boot Clamps 2 - CLAMPS 1 - SMALL CLAMP (10) Install the halfshaft back into the vehicle. 2 - LARGE CLAMP (Refer to 3 - DIFFERENTIAL &...
Page 103 HALFSHAFT 3 - 13 CV BOOT-OUTER (Continued) INSTALLATION (1) Slide a new seal boot to interconnecting shaft retaining clamp, onto the interconnecting shaft. Then slide the replacement outer C/V joint assembly seal- ing boot onto the interconnecting shaft. (2) Install outer C/V joint assembly onto intercon- necting shaft.
Page 104 3 - 14 HALFSHAFT CV BOOT-OUTER (Continued) Fig. 37 Sealing Boot Retaining Clamp Installed Fig. 35 Sealing Boot Retaining Clamp Installed 1 - BOOT CLAMP 1 - SEALING BOOT 2 - SPECIAL TOOL C-4975 2 - SPECIAL TOOL C-4975 3 - SEALING BOOT 3 - CLAMP BRIDGE 4 - OUTER C/V JOINT (7) Clamp sealing boot onto outer C/V joint hous-...
Page 105 BRAKES 5 - 1 BRAKES TABLE OF CONTENTS page page BRAKES - BASE BRAKE SYSTEM ... . . 1 BRAKES - ANTILOCK BRAKE SYSTEM ..61 BRAKES - BASE BRAKE SYSTEM TABLE OF CONTENTS page...
Page 106: Table Of Contents
5 - 2 BRAKES - BASE BRAKE SYSTEM ASSEMBLY - CALIPER PISTON AND SEAL . . 33 DIAGNOSIS AND TESTING - INSTALLATION- REAR CALIPER ... . 34 PROPORTIONING VALVE ....46 FLUID ROTOR DIAGNOSIS AND TESTING - BRAKE FLUID...
Page 107 BRAKES - BASE BRAKE SYSTEM 5 - 3 lever pulls on cables that actuate parking brake BRAKES - BASE BRAKE shoes at each rear wheel. SYSTEM For more information on the operation of any indi- vidual base brake component, refer to that compo- DESCRIPTION - BASE BRAKES nent elsewhere in this section.
Page 108 5 - 4 BRAKES - BASE BRAKE SYSTEM BRAKES - BASE BRAKE SYSTEM (Continued) CAUTION: When handling the brake rotor and caliper, adequate removal of all trapped air from the brake be careful to avoid damaging the brake rotor and cal- hydraulic system.
Page 109 BRAKES - BASE BRAKE SYSTEM 5 - 5 BRAKES - BASE BRAKE SYSTEM (Continued) (5) Starting at the first wheel circuit as listed ear- lier, attach a clear hose to the bleeder screw at that wheels brake caliper or wheel cylinder and feed the other end of hose into a clear jar containing enough fresh brake fluid to submerge the end of the hose (Fig.
Page 110 5 - 6 BRAKES - BASE BRAKE SYSTEM BRAKES - BASE BRAKE SYSTEM (Continued) NOTE: Monitor the brake fluid level in the fluid res- BRAKE FASTENER TORQUE ervoir periodically to make sure it does not go too low. This will ensure that air does not reenter the brake hydraulic system.
Page 111 BRAKES - BASE BRAKE SYSTEM 5 - 7 BRAKES - BASE BRAKE SYSTEM (Continued) SPECIAL TOOLS BASE BRAKE SYSTEM Adapters, Brake Pressure Test 6892 Handle, Universal C-4171 Installer, Dust Boot C-4689 Adapters, Brake Pressure Test 8187 Dial Indicator C-3339 Gauge Set C-4007-A Tubes, Master Cylinder Bleed 8358...
Page 112 5 - 8 BRAKES - BASE BRAKE SYSTEM BRAKE FLUID LEVEL SWITCH HYDRAULIC/MECHANICAL DESCRIPTION DESCRIPTION The brake fluid level switch used on this vehicle’s master cylinder is internal to the master cylinder DESCRIPTION - FRONT DISC BRAKES fluid reservoir (Fig. 4). The vehicle wiring harness The front disc brake assembly used on this vehicle has a connector which plugs directly into the brake consists of the following components:...
Page 113 BRAKES - BASE BRAKE SYSTEM 5 - 9 HYDRAULIC/MECHANICAL (Continued) Fig. 5 Front Disc Brake Caliper Assembly 1 - GUIDE PIN BOLT 10 - OUTBOARD BRAKE SHOE 2 - SLEEVE 11 - INBOARD BRAKE SHOE 3 - BUSHING 12 - ANTI-RATTLE CLIP 4 - CALIPER 13 - BUSHING 5 - PISTON SEAL...
Page 114 5 - 10 BRAKES - BASE BRAKE SYSTEM HYDRAULIC/MECHANICAL (Continued) DESCRIPTION - REAR DISC BRAKES The adapter and disc shield are mounted to the rear suspension knuckles of vehicle. The adapter is The rear disc brakes are similar to front disc used to mount the brake shoes and actuating cables brakes, however, there are several distinctive fea- for the parking brake system.
Page 115 BRAKES - BASE BRAKE SYSTEM 5 - 11 HYDRAULIC/MECHANICAL (Continued) OPERATION OPERATION - FRONT DISC BRAKES Two machined abutments on the steering knuckle (Fig. 6) position and align the caliper fore-and-aft. The guide pin bolts, sleeves, and bushings control the side-to-side movement of the caliper.
Page 116 5 - 12 BRAKES - BASE BRAKE SYSTEM HYDRAULIC/MECHANICAL (Continued) BRAKE NOISE CONDITION POSSIBLE CAUSES CORRECTION DISC BRAKE CHIRP 1. Excessive brake rotor runout. 1. Follow brake rotor diagnosis and testing. Correct as necessary. 2. Lack of lubricant on brake caliper 2.
Page 117 BRAKES - BASE BRAKE SYSTEM 5 - 13 HYDRAULIC/MECHANICAL (Continued) CONDITION POSSIBLE CAUSES CORRECTION 4. Brake shoe lining transfer to brake 4. Reface or replace brake rotors as rotor. necessary. Replace brake shoes. EXCESSIVE PEDAL TRAVEL 1. Air in brake lines. 1.
Page 118: Brake Lines
5 - 14 BRAKES - BASE BRAKE SYSTEM OPERATION - BRAKE TUBES AND HOSES BRAKE LINES The purpose of the chassis brake tubes and flex hoses DESCRIPTION - BRAKE TUBES AND HOSES is to transfer the pressurized brake fluid developed by the master cylinder to the wheel brakes of the vehicle.
Page 119 BRAKES - BASE BRAKE SYSTEM 5 - 15 BRAKE PADS/SHOES - FRONT REMOVAL REMOVAL - FRONT DISC BRAKE SHOES (1) Raise vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCE- DURE) (2) Remove front wheel and tire assemblies from vehicle. (3) Remove the two caliper guide pin bolts (Fig.
Page 120 5 - 16 BRAKES - BASE BRAKE SYSTEM BRAKE PADS/SHOES - FRONT (Continued) (6) Remove outboard brake shoe by prying the REMOVAL - FRONT DISC BRAKE SHOES shoe retaining clip over raised area on caliper. Then (EXPORT) slide the brake shoe off the caliper (Fig. 14). (1) Raise vehicle.
Page 121 BRAKES - BASE BRAKE SYSTEM 5 - 17 BRAKE PADS/SHOES - FRONT (Continued) INSPECTION - DISC BRAKE SHOES Visually inspect brake shoes (pads) for uneven lining wear. Also inspect for excessive lining deterioration. Check the clearance between the tips of the wear indi- cators on the shoes (if equipped) and the brake rotors.
Page 122 5 - 18 BRAKES - BASE BRAKE SYSTEM BRAKE PADS/SHOES - FRONT (Continued) (11) Tighten the wheel mounting stud nuts in (9) Install the wheel and tire assemblies. proper sequence until all nuts are torqued to half (10) Tighten the wheel mounting stud nuts in specification.
Page 123 BRAKES - BASE BRAKE SYSTEM 5 - 19 BRAKE PADS/SHOES - REAR (Continued) (4) Remove caliper from adapter using the following (6) Remove the rear rotor from the hub by pulling procedure. First rotate top of caliper away from adapter. it straight off the wheel mounting studs (Fig.
Page 124 5 - 20 BRAKES - BASE BRAKE SYSTEM BRAKE PADS/SHOES - REAR (Continued) (8) Pull inboard brake shoe away from piston, wear indicators on the shoes (if equipped) and the until the retaining clip is free from the cavity in the brake rotors.
Page 125 BRAKES - BASE BRAKE SYSTEM 5 - 21 BRAKE PADS/SHOES - REAR (Continued) CAUTION: When installing the caliper guide pin bolts extreme caution should be taken not to cross thread the guide pin bolts. (8) Install the caliper guide pin bolts. Tighten the guide pin bolts to a torque of 22 N·m (192 in.
Page 126 5 - 22 BRAKES - BASE BRAKE SYSTEM DISC BRAKE CALIPER - FRONT (Continued) (7) If required, remove rotor from hub by pulling it DISASSEMBLY straight off wheel mounting studs (Fig. 26). DISASSEMBLY - CALIPER GUIDE PIN BUSHINGS Before disassembling the brake caliper, clean and inspect it.
Page 127 BRAKES - BASE BRAKE SYSTEM 5 - 23 DISC BRAKE CALIPER - FRONT (Continued) Fig. 28 Removing Bushing From Caliper Fig. 29 Removing Caliper/Piston Dust Boot 1 - CALIPER 2 - BUSHING 1 - CALIPER 2 - SCREWDRIVER 3 - BOOT NOTE: The safest way to remove the piston from the caliper bore is to use the hydraulic pressure of (6) Using a soft tool such as a plastic trim stick,...
Page 128 5 - 24 BRAKES - BASE BRAKE SYSTEM DISC BRAKE CALIPER - FRONT (Continued) (7) Clean the piston bore and drilled passage ways CLEANING - CALIPER using alcohol or a suitable solvent. Wipe it dry using only a lint-free cloth. WARNING: DUST AND DIRT ACCUMULATING ON (8) Inspect the piston bore for scoring or pitting.
Page 129 BRAKES - BASE BRAKE SYSTEM 5 - 25 DISC BRAKE CALIPER - FRONT (Continued) (3) Unfold the bushing using your fingers or a ASSEMBLY wooden dowel until the bushing is fully seated into the caliper housing. The bushing flanges should be seated ASSEMBLY - CALIPER GUIDE PIN BUSHINGS evenly on both sides of the bushing hole (Fig.
Page 130 5 - 26 BRAKES - BASE BRAKE SYSTEM DISC BRAKE CALIPER - FRONT (Continued) (5) Install the guide pin sleeve into one end of bushing until the seal area of bushing is past the seal groove in the sleeve (Fig. 35). Fig.
Page 131 BRAKES - BASE BRAKE SYSTEM 5 - 27 DISC BRAKE CALIPER - FRONT (Continued) (4) Install piston into caliper bore pushing it past the piston seal until it bottoms in the caliper bore (Fig. 38). Fig. 39 Installing Dust Boot Fig.
Page 132 5 - 28 BRAKES - BASE BRAKE SYSTEM DISC BRAKE CALIPER - FRONT (Continued) (13) Road test the vehicle and make several stops (2) Remove rear wheel and tire assemblies from to wear off any foreign material off the brakes and to vehicle.
Page 133 BRAKES - BASE BRAKE SYSTEM 5 - 29 DISC BRAKE CALIPER - REAR (Continued) (5) Support caliper assembly firmly from rear strut to prevent weight of caliper from damaging the flex- ible brake hose (Fig. 42). Fig. 43 Removing / Installing Rear Rotor 1 - BRAKE ROTOR (DISC) 2 - DISC SHIELD 3 - HUB...
Page 134 5 - 30 BRAKES - BASE BRAKE SYSTEM DISC BRAKE CALIPER - REAR (Continued) (2) Using your fingers, collapse one side of the rub- beyond the first inch of pedal travel using a brake ber guide pin bushing. Pull the guide pin bushing out pedal holding tool.
Page 135 BRAKES - BASE BRAKE SYSTEM 5 - 31 DISC BRAKE CALIPER - REAR (Continued) Fig. 47 Removing Piston Seal 1 - PLASTIC TRIM STICK Fig. 48 Honing Brake Caliper Piston Bore 2 - CALIPER 3 - PISTON SEAL GROOVE 1 - CALIPER 4 - PISTON SEAL 2 - CALIPER BORE 3 - SPECIAL TOOL C-4095...
Page 136 5 - 32 BRAKES - BASE BRAKE SYSTEM DISC BRAKE CALIPER - REAR (Continued) (3) Unfold the bushing using your fingers or a ASSEMBLY wooden dowel until the bushing is fully seated into the caliper housing. The bushing flanges should be ASSEMBLY - CALIPER GUIDE PIN BUSHINGS seated evenly on both sides of the bushing hole (Fig.
Page 137 BRAKES - BASE BRAKE SYSTEM 5 - 33 DISC BRAKE CALIPER - REAR (Continued) (5) Install the guide pin sleeve into one end of bushing until the seal area of bushing is past the seal groove in the sleeve (Fig. 52). Fig.
Page 138 5 - 34 BRAKES - BASE BRAKE SYSTEM DISC BRAKE CALIPER - REAR (Continued) (4) Install piston into caliper bore pushing it past the piston seal until it bottoms in the caliper bore (Fig. 55). Fig. 56 Installing Dust Boot Fig.
Page 139: Brake Junction Block
BRAKES - BASE BRAKE SYSTEM 5 - 35 FLUID DIAGNOSIS AND TESTING - BRAKE FLUID CONTAMINATION Indications of fluid contamination are swollen or deteriorated rubber parts. Swollen rubber parts indicate the presence of petroleum in the brake fluid. To test for contamination, put a small amount of drained brake fluid in clear glass jar.
Page 140 5 - 36 BRAKES - BASE BRAKE SYSTEM BRAKE JUNCTION BLOCK (Continued) Later production junction blocks have the propor- tioning valves for the rear brakes mounted in them. One valve is mounted in each end (Fig. 58). The pro- portioning valves are not serviced separately from the junction block.
Page 141 BRAKES - BASE BRAKE SYSTEM 5 - 37 BRAKE JUNCTION BLOCK (Continued) (5) Remove nut and screw securing transmission control module to vehicle (Fig. 61). Fig. 62 Junction Block Fitting Identification 1 - FROM MASTER CYLINDER PRIMARY 2 - FROM MASTER CYLINDER SECONDARY 3 - TO LEFT FRONT BRAKE 4 - TO RIGHT REAR BRAKE Fig.
Page 142: Master Cylinder
5 - 38 BRAKES - BASE BRAKE SYSTEM BRAKE JUNCTION BLOCK (Continued) (6) Tighten the remaining junction block bracket- to-engine cradle crossmember mounting bolt to 26 N·m (230 in. lbs.) torque. (7) Install the four chassis brake tubes (going to each brake) to the junction block (Fig.
Page 143 BRAKES - BASE BRAKE SYSTEM 5 - 39 MASTER CYLINDER (Continued) NOTE: The master cylinder outlet ports use ISO (3) Fill reservoir with Mopar Brake Fluid or style flares and metric threads. Special Tool Pack- equivalent conforming to DOT 3 specifications. Make sure fluid level is above tips of bleeder tubes in res- age 8822 includes ISO style flare adapters with met- ric threads to be used in conjunction with Bleeder...
Page 144 5 - 40 BRAKES - BASE BRAKE SYSTEM MASTER CYLINDER (Continued) DISASSEMBLY (1) Remove the master cylinder from the power brake booster. (Refer to 5 - BRAKES/HYDRAULIC/ MECHANICAL/MASTER CYLINDER - REMOVAL) (2) Using an appropriate cleaner such as Mopar Brake Parts Cleaner, clean the master cylinder hous- ing and brake fluid reservoir.
Page 145 BRAKES - BASE BRAKE SYSTEM 5 - 41 MASTER CYLINDER (Continued) (4) Reconnect brake fluid level switch. (5) Check and adjust brake fluid level as necessary using Mopar Brake Fluid or equivalent. CAUTION: It will be necessary to bleed the entire base hydryaulic system if the brake system has been open to air for an excessive amount of time or air is present in the lines.
Page 146: Power Brake Booster
5 - 42 BRAKES - BASE BRAKE SYSTEM PEDAL (Continued) (5) Install the nut on the end of the brake pedal POWER BRAKE BOOSTER pivot shaft. Tighten the nut to a torque of 34 N·m (25 ft. lbs.). DESCRIPTION (6) Install the power brake booster input rod on The power brake booster assembly mounts on the the brake pedal pin.
Page 147 BRAKES - BASE BRAKE SYSTEM 5 - 43 POWER BRAKE BOOSTER (Continued) The power brake booster can be identified by the the primary piston of the master cylinder. As the pis- tag attached to the body of the booster assembly (Fig. tons in the master cylinder move forward this creates 73).
Page 148 5 - 44 BRAKES - BASE BRAKE SYSTEM POWER BRAKE BOOSTER (Continued) If the vacuum drop exceeds 1.0 inch Hg (3.3 kPa) in one minute, repeat the above steps to confirm the reading. The vacuum loss should be less than 1.0 inch Hg in one minute time span.
Page 149 BRAKES - BASE BRAKE SYSTEM 5 - 45 POWER BRAKE BOOSTER (Continued) (6) Disconnect the wire connector from the brake (11) Rotate screwdriver enough to allow retainer clip fluid level sensor on the right side of the master cyl- center tang to pass over end of brake pedal pin and pull inder reservoir.
Page 150: Proportioning Valve
5 - 46 BRAKES - BASE BRAKE SYSTEM POWER BRAKE BOOSTER (Continued) (6) Install and tighten the 2 master cylinder to DIAGNOSIS AND TESTING - PROPORTIONING booster mounting nuts (Fig. 78) to 28 N·m (250 in. VALVE lbs.) torque. Vehicles without Antilock Brakes have two propor- (7) Reconnect brake fluid level sensor connector.
Page 151 BRAKES - BASE BRAKE SYSTEM 5 - 47 PROPORTIONING VALVE (Continued) (8) Remove nut and screw securing transmission (12) If the left rear proportioning valve is suspect, control module to vehicle (Fig. 82). install Adapter, Special Tool 8494-3, in its place on the junction block.
Page 152 5 - 48 BRAKES - BASE BRAKE SYSTEM PROPORTIONING VALVE (Continued) (27) If no problem is found with the proportioning meeting OEM brake lining material specifications. valves, check the rear wheel brake shoe linings for These conditions can also cause premature rear contamination or for replacement brake shoes not wheel skid.
Page 153 BRAKES - BASE BRAKE SYSTEM 5 - 49 ROTOR (Continued) ROTOR THICKNESS VARIATION Thickness variation in a rotor’s braking surface can result in pedal pulsation, chatter and surge. This can also be caused by excessive runout in the rotor or the hub.
Page 154 5 - 50 BRAKES - BASE BRAKE SYSTEM ROTOR (Continued) NOTE: Clean the hub face surface before checking Hub runout should not exceed 0.03 mm (0.0012 runout. This provides a clean surface to get an inch). If runout exceeds this specification, the hub must be replaced.
Page 155 BRAKES - BASE BRAKE SYSTEM 5 - 51 ROTOR (Continued) STANDARD PROCEDURE - BRAKE ROTOR MACHINING NOTE: Refacing of the rotor is not required each time the brake pads are replaced. Any servicing of the rotor requires extreme care to maintain the rotor within service tolerances to ensure proper brake action.
Page 156 5 - 52 BRAKES - BASE BRAKE SYSTEM ROTOR (Continued) BRAKE ROTOR REFINISHING LIMITS Minimum Rotor Rotor Run Rotor Micro Braking Rotor Rotor Thickness Rotor Thickness Out* Finish Thickness Variation 25.87–26.13 mm 24.4 mm .013 mm .08 mm Front Rotor 15-80 RMS 1.019 -1.029 in.
Page 157: Parking Brake
BRAKES - BASE BRAKE SYSTEM 5 - 53 ROTOR (Continued) INSTALLATION INSTALLATION - BRAKE ROTOR (FRONT) (1) Install brake rotor over the wheel mounting studs onto hub (Fig. 93). (2) Install disc brake caliper and shoes following the procedure found in Brake Pads/Shoes. (Refer to 5 - BRAKES - BASE/HYDRAULIC/MECHANICAL/ BRAKE PADS/SHOES - INSTALLATION) (3) Pump the brake pedal several times to ensure...
Page 158: Parking Brake Cable Tensioner
5 - 54 BRAKES - BASE BRAKE SYSTEM PARKING BRAKE (Continued) NOTE: Leave park brakes applied until adjustment is complete. (11) Raise vehicle again. (12) Mark tensioner rod 6.35 mm (1/4 in.) from edge of tensioner bracket (Fig. 96). (13) Tighten adjusting nut at equalizer until mark on tensioner rod moves into alignment with tensioner bracket.
Page 159: Parking Brake Cable - Front
BRAKES - BASE BRAKE SYSTEM 5 - 55 PARKING BRAKE CABLE TENSIONER (Continued) (5) Verify the rear park brake shoes are properly adjusted. (6) Lower vehicle enough for access to park brake foot pedal. Fully apply park brakes. NOTE: Leave park brakes applied until adjustment is complete.
Page 160: Parking Brake Cable - Rear
5 - 56 BRAKES - BASE BRAKE SYSTEM (11) Remove the park brake actuator lever from PARKING BRAKE CABLE - the rear park brake cable. REAR (12) Using a screwdriver, carefully compress the retainer tabs securing the rear park brake cable to REMOVAL - REAR CABLE the disc brake adapter.
Page 161: Parking Brake Lever
BRAKES - BASE BRAKE SYSTEM 5 - 57 PARKING BRAKE LEVER REMOVAL - PARKING BRAKE LEVER AND CABLE NOTE: The parking brake lever assembly on this vehicle is serviced with the front cable installed on it. They should be removed, replaced, and installed as an assembly.
Page 162 5 - 58 BRAKES - BASE BRAKE SYSTEM PARKING BRAKE LEVER (Continued) (10) Remove the lower instrument panel cover from the instrument panel. It is attached by retain- ing clips along the top and right edge. (11) Remove the wiring harness connector from the trunk release switch in the lower instrument panel cover (Fig.
Page 163 BRAKES - BASE BRAKE SYSTEM 5 - 59 PARKING BRAKE LEVER (Continued) (21) Pull back floor carpeting on left side of pas- senger compartment to reveal front park brake cable. (22) Remove the screw securing the foot rest to the floor.
Page 164 5 - 60 BRAKES - BASE BRAKE SYSTEM PARKING BRAKE LEVER (Continued) (16) Reinstall the fuse panel cover on left side of INSTALLATION - PARKING BRAKE SHOES instrument panel. (1) Install front brake shoe and hold down clip. (17) Reinstall driver’s side kick panel (2) Install rear brake shoe and the upper brake (18) Reinstall driver’s door opening sill cover shoe to shoe return spring.
Page 165 BRAKES - ANTILOCK BRAKE SYSTEM 5 - 61 BRAKES - ANTILOCK BRAKE SYSTEM TABLE OF CONTENTS page page BRAKES - ANTILOCK BRAKE SYSTEM REAR WHEEL SPEED SENSOR DESCRIPTION DESCRIPTION ......68 DESCRIPTION - ANTILOCK BRAKES .
Page 166 5 - 62 BRAKES - ANTILOCK BRAKE SYSTEM BRAKES - ANTILOCK BRAKE SYSTEM (Continued) DESCRIPTION - ELECTRONIC VARIABLE rear wheels are controlled together for better vehicle stability. BRAKE PROPORTIONING The system can build and release pressure at each Vehicles equipped with ABS use electronic variable wheel, depending on signals generated by the wheel brake proportioning (EVBP) to balance front-to-rear speed sensors (WSS) at each wheel and received at...
Page 167 BRAKES - ANTILOCK BRAKE SYSTEM 5 - 63 BRAKES - ANTILOCK BRAKE SYSTEM (Continued) DRIVE-OFF CYCLE the end of EVBP braking (brakes released) the fluid in the LPA drains back to the master cylinder by switching When the vehicle is first driven off, a humming on the outlet valve and draining through the inlet valve may be heard or felt by the driver at approximately check valve.
Page 168 5 - 64 BRAKES - ANTILOCK BRAKE SYSTEM BRAKES - ANTILOCK BRAKE SYSTEM (Continued) CAUTION: Many components of the ABS System CAUTION are not serviceable and must be replaced as an assembly. Do not disassemble any component CAUTIONS which is not designed to be serviced. The ABS uses an electronic control module, the CAB.
Page 169 BRAKES - ANTILOCK BRAKE SYSTEM 5 - 65 BRAKES - ANTILOCK BRAKE SYSTEM (Continued) (6) Turn the key to the OFF position and then back to the ON position. Note whether the amber ABS warning lamp continues to stay on. (7) If the amber ABS warning indicator lamp stays on, shift into gear and drive the car to a speed of approximately 25 km/h (15 mph) to complete the ABS...
Page 170 5 - 66 BRAKES - ANTILOCK BRAKE SYSTEM BRAKES - ANTILOCK BRAKE SYSTEM (Continued) (4) Bleed the base brake system using the stan- FRONT WHEEL SPEED dard pressure or manual bleeding procedure. (Refer SENSOR to 5 - BRAKES - BASE - STANDARD PROCEDURE) (5) Using DRBIII , select...
Page 171 BRAKES - ANTILOCK BRAKE SYSTEM 5 - 67 FRONT WHEEL SPEED SENSOR (Continued) REMOVAL (1) Raise vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCE- DURE) (2) Remove the tire and wheel assembly from the vehicle. (3) Remove bolt securing the speed sensor cable routing bracket (Fig.
Page 172 5 - 68 BRAKES - ANTILOCK BRAKE SYSTEM REMOVAL REAR WHEEL SPEED SENSOR NOTE: When removing rear wheel speed sensor DESCRIPTION from vehicle, access to the wire harness connector This system uses two-wire wheel speed sensors is through the passenger compartment of the vehi- known as active wheel speed sensors.
Page 173 BRAKES - ANTILOCK BRAKE SYSTEM 5 - 69 REAR WHEEL SPEED SENSOR (Continued) (3) Guide the cable through the hole in the floor Check the gap between the speed sensor head and pan and install the grommet. the tone wheel to ensure it is within specifications. Install wheel and tire assembly on vehicle.
Page 174 5 - 70 BRAKES - ANTILOCK BRAKE SYSTEM HYDRAULIC/MECHANICAL (Continued) NORMAL BRAKING HYDRAULIC CIRCUIT AND SOLENOID VALVE FUNCTION (ABS WITHOUT TRACTION CONTROL) The hydraulic diagram (Fig. 7) shows the vehicle in the normal braking mode of the base brake hydraulic system.
Page 175 BRAKES - ANTILOCK BRAKE SYSTEM 5 - 71 HYDRAULIC/MECHANICAL (Continued) ABS HYDRAULIC CIRCUIT AND SOLENOID VALVE FUNCTION (ABS WITHOUT TRACTION CONTROL) The hydraulic diagram (Fig. 8) shows the vehicle in the ABS braking mode. The diagram shows one wheel is slipping because the driver is attempting to stop the vehicle at a faster rate than is allowed by the surface on which the tires are riding.
Page 176 5 - 72 BRAKES - ANTILOCK BRAKE SYSTEM HYDRAULIC/MECHANICAL (Continued) NORMAL BRAKING HYDRAULIC CIRCUIT, SOLENOID VALVE, AND SHUTTLE VALVE FUNCTION (ABS WITH TRACTION CONTROL) The hydraulic diagram (Fig. 9) shows a vehicle with traction control in the normal braking mode. The diagram shows no wheel spin or slip occurring relative to the speed of the vehicle.
Page 177 BRAKES - ANTILOCK BRAKE SYSTEM 5 - 73 HYDRAULIC/MECHANICAL (Continued) ABS BRAKING HYDRAULIC CIRCUIT, SOLENOID VALVE, AND SHUTTLE VALVE FUNCTION (ABS WITH TRACTION CONTROL) The hydraulic diagram (Fig. 10) shows the vehicle in the ABS braking mode. The diagram shows one wheel is slipping because the driver is attempting to stop the vehicle at a faster rate than is allowed by the surface on which the tires are riding.
Page 178 5 - 74 BRAKES - ANTILOCK BRAKE SYSTEM HYDRAULIC/MECHANICAL (Continued) ABS TRACTION CONTROL HYDRAULIC CIRCUIT, SOLENOID VALVE, AND SHUTTLE VALVE FUNCTION (ABS WITH TRACTION CONTROL) The hydraulic diagram (Fig. 11) shows the vehicle in the traction control (TC) mode. The diagram shows a drive wheel is spinning and brake pressure is required to reduce its speed.
Page 179 BRAKES - ANTILOCK BRAKE SYSTEM 5 - 75 BRAKE FLUID ACCUMULATORS HCU (HYDRAULIC CONTROL There are two fluid accumulators in the HCU, one UNIT) for the primary hydraulic circuit and one for the sec- ondary hydraulic circuit. Each hydraulic circuit uses DESCRIPTION a 5 cc accumulator.
Page 180 5 - 76 BRAKES - ANTILOCK BRAKE SYSTEM ICU (INTEGRATED CONTROL UNIT) DESCRIPTION The hydraulic control unit (HCU) and the control- ler antilock brake (CAB) used with this antilock brake system are combined (integrated) into one unit, which is called the integrated control unit (ICU) (Fig.
Page 181 BRAKES - ANTILOCK BRAKE SYSTEM 5 - 77 ICU (INTEGRATED CONTROL UNIT) (Continued) REMOVAL - ICU (1) Remove the remote ground cable from the ground stud on the right strut tower. (2) Correctly isolate remote ground cable when ser- vicing vehicle by installing the ground cable insulator on the strut tower ground stud as shown in (Fig.
Page 182 5 - 78 BRAKES - ANTILOCK BRAKE SYSTEM ICU (INTEGRATED CONTROL UNIT) (Continued) (8) Remove the primary and secondary brake tubes coming from the master cylinder, at the HCU, using a crow foot wrench (Fig. 17). Fig. 18 24-way CAB Connector Lock 1 - 24–WAY CAB CONNECTOR 2 - CONNECTOR LOCK Fig.
Page 183 BRAKES - ANTILOCK BRAKE SYSTEM 5 - 79 ICU (INTEGRATED CONTROL UNIT) (Continued) (3) Remove the 4 bolts (Fig. 20) attaching the CAB (INTEGRATED CONTROL UNIT) - INSTALLA- to the HCU. TION) INSTALLATION - ICU (1) Install the ICU back in the vehicle and attach it to its mounting bracket.
Page 185 COOLING 7 - 1 COOLING TABLE OF CONTENTS page page COOLING STANDARD PROCEDURE - COOLING DESCRIPTION - ENGINE COOLING SYSTEM . . 1 SYSTEM DRAINING ....8 OPERATION - ENGINE COOLING SYSTEM .
Page 186 7 - 2 COOLING COOLING (Continued) Fig. 1 COOLING SYSTEM FLOW 1 - BOTTLE SUPPLY HOSE 7 - RADIATOR LOWER OUTLET HOSE 2 - PRESSURE BOTTLE 8 - THERMOSTAT LOCATION 3 - HEATER SUPPLY TUBE 9 - BOTTLE RETURN 4 - RADIATOR UPPER INLET HOSE 10 - HEATER RETURN TUBE 5 - RADIATOR 11 - HEATER CORE...
Page 187 COOLING 7 - 3 COOLING (Continued) DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - COOLING SYSTEM CONDITION POSSIBLE CAUSES CORRECTION TEMPERATURE GAUGE 1. During cold weather operation 1. A normal condition. No correction is READING IS INCONSISTENT with the heater blower in the high necessary.
Page 188 7 - 4 COOLING COOLING (Continued) CONDITION POSSIBLE CAUSES CORRECTION COOLANT LOSS TO THE 1. Coolant leaks in radiator, cooling 1. Pressure test and repair as GROUND WITHOUT system hoses, water pump or necessary. (Refer to 7 - COOLING - PRESSURE CAP BLOWOFF.
Page 189 COOLING 7 - 5 COOLING (Continued) CONDITION POSSIBLE CAUSES CORRECTION INADEQUATE AIR 1. Radiator and/or A/C condenser is 1. Remove restriction and/or clean as CONDITIONER restricted, obstructed or dirty necessary. PERFORMANCE (COOLING (insects, leaves, etc.). SYSTEM SUSPECTED). 2. Electrical radiator fan not 2.
Page 190 7 - 6 COOLING COOLING (Continued) CONDITION POSSIBLE CAUSES CORRECTION 3. Radiator fan operating 3. (Refer to 7 - COOLING/ENGINE/ incorrectly. RADIATOR FAN - DIAGNOSIS AND TESTING) Repair as necessary. 4. Has undercoating been applied 4. Clean undercoating as necessary. to any unnecessary component? 5.
Page 191 COOLING 7 - 7 COOLING (Continued) • Combustion gas leaks into the coolant can also cause the above problems. DIAGNOSIS AND TESTING - COOLING SYSTEM DEAERATION As air is removed from the cooling system, it gath- ers in the coolant bottle. This pressure is released into the atmosphere through the pressure valve located in the pressure cap when pressure reaches 96 - 124 kPa (14 - 18 psi).
Page 192 7 - 8 COOLING COOLING (Continued) STANDARD PROCEDURE - COOLING SYSTEM DRAINING When servicing the cooling system, it is essential that coolant does not drip on the drive belts or pul- leys. If necessary, shield the belts with shop towels before working on the cooling system.
Page 193 COOLING 7 - 9 COOLING (Continued) Fig. 5 COOLING SYSTEM BLEEDING 1 - 2.7L ENGINE 6 - COOLANT CONTAINER 2 - 3.5L ENGINE 7 - HOSE 3 - BLEED VALVE 8 - TO COOLANT CONTAINER 4 - TO COOLANT CONTAINER 9 - BLEED VALVE 5 - SPECIAL TOOL 8195...
Page 194 7 - 10 COOLING COOLING (Continued) NOTE: IT IS IMPERATIVE THAT THE COOLING SYS- (9) Slowly fill the cooling system until a steady TEM AIR BLEED VALVE BE OPENED BEFORE ANY stream of coolant flows from the hose attached to the bleed valve (Fig.
Page 195 COOLING 7 - 11 COOLING (Continued) STANDARD PROCEDURE - ADDING SPECIFICATIONS ADDITIONAL COOLANT TORQUE CAUTION: Do not use well water, or suspect water supply in cooling system. Use only a 50/50 mixture DESCRIPTION N·m of the specified ethylene glycol type antifreeze/cool- Lbs.
Page 196 7 - 12 COOLING COOLING (Continued) SPECIAL TOOLS COOLING Coolant Refractometer 8286 Belt Tension Gauge 7198 Cooling System Tester 7700 Hose Clamp Pliers 8495 Hose Clamp Pliers 6094 Filling Aid Funnel 8195...
Page 197 ACCESSORY DRIVE 7 - 13 ACCESSORY DRIVE TABLE OF CONTENTS page page ACCESSORY DRIVE INSTALLATION ......15 DESCRIPTION .
Page 198 7 - 14 ACCESSORY DRIVE DRIVE BELTS - 2.7L REMOVAL GENERATOR/POWER STEERING BELT (1) Loosen tensioner pulley locking nut (Fig. 1). (2) Loosen belt adjusting bolt (Fig. 1). (3) Remove generator/power steering belt. Fig. 1 ACCESSORY DRIVE BELTS 1 - A/C DRIVE BELT 2 - LOCKING NUT 3 - GENERATOR/POWER STEERING DRIVE BELT 4 - ADJUSTING BOLT...
Page 199 ACCESSORY DRIVE 7 - 15 DRIVE BELTS - 2.7L (Continued) (8) Install the NEW belt by rotating the tensioner counterclockwise until the NEW belt can be installed on pulleys. See (Fig. 5) for belt routing. (9) Release tensioner and remove breaker bar. Belt is automatically adjusted with the tensioner’s torsion spring.
Page 200 7 - 16 ACCESSORY DRIVE DRIVE BELTS - 2.7L (Continued) (3) Remove pivot bolt, tensioner, and spring from BELT TENSION CHART—2.7/3.5L ENGINES front cover. (4) Insert spring into the USED belt position on POLY-V BELT GAUGE tensioner bracket (Fig. 4). Generator/Power New Belt: 836 ±44 N (5) Install spring, tensioner bracket, and pivot...
Page 201 ACCESSORY DRIVE 7 - 17 DRIVE BELTS - 3.5L (Continued) INSTALLATION NOTE: Use Special Tool 7198, Belt Tension Gauge to obtain proper tension on accessory drive belts. For Special Tool identification, (Refer to 7 - COOL- ING - SPECIAL TOOLS). For accessory drive belt tension specifications, (Refer to 7 - COOLING/AC- CESSORY DRIVE/DRIVE BELTS - ADJUSTMENTS).
Page 202 7 - 18 ENGINE ENGINE TABLE OF CONTENTS page page ENGINE INSTALLATION ......25 CLEANING ......18 HEATER SUPPLY TUBE - 3.5L INSPECTION .
Page 203 ENGINE 7 - 19 ENGINE (Continued) INSPECTION The green coolant MUST NOT BE MIXED with the orange or magenta coolants. When replacing cool- After performing cleaning/flush procedure, ant the complete system flush must be performed inspect all hoses, clamps and connections for deterio- before using the replacement coolant.
Page 204 7 - 20 ENGINE (4) Lubricate O-ring and insert heater tube assem- COOLANT OUTLET bly into outlet connector. Tighten screws to 3 N·m (30 CONNECTOR - 2.7L in. lbs.). (5) Install upper intake manifold (Refer to 9 - REMOVAL ENGINE/MANIFOLDS/INTAKE MANIFOLD INSTALLATION).
Page 205: Engine Block Heater
ENGINE 7 - 21 COOLANT RECOVERY PRESSURE CONTAINER (Continued) Fig. 3 COOLANT BOTTLE LOCATION Fig. 4 ENGINE BLOCK HEATER 1 - COOLANT RECOVERY PRESSURE BOTTLE 1 - BLOCK HEATER 2 - PRESSURE CAP 2 - ENGINE — RIGHT SIDE ENGINE BLOCK HEATER CAUTION: To prevent damage, the power cord must be secured in its retainer clips, and not positioned so it could contact linkages or exhaust manifolds.
Page 206 7 - 22 ENGINE ENGINE COOLANT TEMPERATURE SENSOR (Continued) ENGINE COOLANT THERMOSTAT DESCRIPTION The thermostat on the 2.7L and 3.5L engines are located on the lower left side of engine, near the front (Fig. 7) and (Fig. 8). The thermostat on both engines are on the inlet side of the water pump.
Page 207 ENGINE 7 - 23 ENGINE COOLANT THERMOSTAT (Continued) ENGINE COOLANT THERMOSTAT - 2.7L REMOVAL (1) Disconnect negative cable from remote jumper terminal. WARNING: DO NOT REMOVE PRESSURE CAP WITH THE SYSTEM HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM COOLANT CAN OCCUR.
Page 208 7 - 24 ENGINE ENGINE COOLANT THERMOSTAT - 2.7L (Continued) INSTALLATION NOTE: The OEM thermostat is staked in place at the factory. To ensure proper seating of replacement (1) Clean gasket sealing surfaces. thermostat, carefully remove the bulged metal from the thermostat housing using a suitable hand held NOTE: Install thermostat with the bleed valve grinder.
Page 209 ENGINE 7 - 25 HEATER SUPPLY TUBE - 2.7L REMOVAL WARNING: DO NOT REMOVE PRESSURE CAP WITH THE SYSTEM HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM COOLANT CAN OCCUR. (1) Drain cooling system. (Refer to 7 - COOLING - STANDARD PROCEDURE) (2) Remove radiator upper crossmember.
Page 210: Hose Clamps
7 - 26 ENGINE HEATER SUPPLY TUBE - 3.5L (Continued) Fig. 13 Spring Clamp Size Location 1 - SPRING CLAMP SIZE LOCATION HOSE CLAMP USAGE CHART SPRING CLAMP LOCATION 2.7L 3.5L Fig. 12 Heater Supply Tube - 3.2/3.5L Upper @ engine 39 mm 47 mm 1 - COOLANT TEMPERATURE SENSOR...
Page 211 ENGINE 7 - 27 RADIATOR REMOVAL NOTE: It is not necessary to discharge air condi- tioning system when removing the radiator. (1) Disconnect negative cable from remote jumper terminal. WARNING: DO NOT REMOVE THE CYLINDER BLOCK PLUG OR THE RADIATOR DRAINCOCK WITH THE SYSTEM HOT AND UNDER PRESSURE BECAUSE SERIOUS BURNS FROM COOLANT CAN OCCUR.
Page 212 7 - 28 ENGINE RADIATOR (Continued) (2) Attach air conditioning condenser to mounting clips on radiator. Install mounting screws and tighten to 5 N·m (45 in. lbs.) (Fig. 17) or (Fig. 18). (3) Install the radiator lower hose and clamp. (4) Install the transmission cooler line bracket and attaching fastener (Fig.
Page 213: Pressure Cap
ENGINE 7 - 29 RADIATOR DRAINCOCK (Continued) Fig. 20 PRESSURE CAP 1 - MAIN SPRING 2 - GASKET RETAINER Fig. 19 DRAINCOCK 3 - STAINLESS STEEL SWIVEL TOP 4 - RUBBER SEALS 1 - DRAINCOCK ASSEMBLY 5 - SPRING LOADED VALVE 6 - COOLANT PRESSURE BOTTLE (2) Position the draincock assembly horizontally to 7 - FILLER NECK...
Page 214: Radiator Fan
7 - 30 ENGINE PRESSURE CAP (Continued) Fig. 21 PRESSURE CAP 1 - MAIN SPRING 2 - GASKET RETAINER 3 - STAINLESS STEEL SWIVEL TOP Fig. 22 RADIATOR FAN 4 - RUBBER SEALS 1 - ELECTRICAL CONNECTOR 5 - SPRING LOADED VALVE 2 - FASTENERS 6 - COOLANT PRESSURE BOTTLE 3 - CLIPS...
Page 215 ENGINE 7 - 31 RADIATOR FAN (Continued) RADIATOR FAN OPERATION - 2.7L ENGINE INTAKE (CHARGE) ENGINE COOLANT TEMPERATURE TEMPERATURE Engine @ Idle < 13 Vehicle Speed < 45 A/C Off A/C On Km/h (8 MPH) Km/h (28 MPH)** Vehicle Speed Fan Speed High High...
Page 216 7 - 32 ENGINE RADIATOR FAN (Continued) RADIATOR FAN OPERATION - 3.5L ENGINE INTAKE (CHARGE) AIR ENGINE COOLANT TEMPERATURE TEMPERATURE Engine @ Idle < 13 Km/h (8 MPH) Vehicle Speed < 45 Km/h (28 A/C Off/On Vehicle Speed MPH) Fan Speed High High High...
Page 217: Water Pump
ENGINE 7 - 33 RADIATOR FAN RELAY (Continued) OPERATION 2.7L BASE The cooling system uses two fans. Both fans oper- ate at two different speeds, low and high. Depending on engine coolant temperature and A/C system high side pressure, the fans operate at either low or high speed.
Page 218 7 - 34 ENGINE WATER PUMP - 2.7L (Continued) (6) Remove bolts attaching water pump to block (Fig. 27). (7) Remove water pump and gasket. Fig. 26 WATER PUMP - 2.7L ENGINE 1 - WATER PUMP BODY 2 - IMPELLER 3 - GASKET NOTE: It is normal for the water pump to weep a small amount of coolant from the primary weep...
Page 219 ENGINE 7 - 35 WATER PUMP - 2.7L (Continued) NOTE: It is normal for the water pump to weep a small amount of coolant from the primary weep hole (black stain at weep passage). Do not replace the water pump if this condition exists. Replace the water pump if a heavy deposit or a steady flow of engine coolant is evident from the primary weep passage (Fig.
Page 220 7 - 36 ENGINE WATER PUMP - 3.5L DESCRIPTION The 3.5L water pump has a die cast aluminum housing and a plastic swept vane impeller. It bolts directly to the right rear timing belt cover using an O-ring for sealing (Fig. 32). The water pump is driven by the engine timing belt.
Page 221 ENGINE 7 - 37 WATER PUMP - 3.5L (Continued) INSTALLATION (1) Clean all O-ring surfaces on pump and cover. (2) Apply Mopar Dielectric Grease or the equiva- lent silicone grease to the O-ring to facilitate assem- bly. Install new O-ring on water pump (Fig. 32). Fig.
Page 222 7 - 38 TRANSMISSION TRANSMISSION TABLE OF CONTENTS page page TRANSMISSION OIL COOLER INSTALLATION ......39 DESCRIPTION .
Page 223 TRANSMISSION 7 - 39 TRANSMISSION OIL COOLER (Continued) REMOVAL CLEANING The in-tank transmission oil cooler is serviced with Check the external cooler for debris on the cooling the radiator (Refer to 7 - COOLING/ENGINE/RADI- fin surfaces. Clean as necessary. ATOR - REMOVAL). INSPECTION For removal of external trans cooler perform the following procedures:...
Page 224 7 - 40 TRANSMISSION TRANSMISSION OIL COOLER (Continued) (3) Reposition the A/C condenser to allow access to condenser rear surface. (4) Remove the previously cut-off cooler retaining straps. (5) Position and install the new retaining straps in the same locations on the condenser. (6) Reposition A/C condenser on the radiator upper retainers.
Page 225 TRANSMISSION 7 - 41 INSTALLATION TRANSMISSION OIL COOLER (1) Position cooler lines and connect to transmis- LINES sion. Torque flare nuts at transmission to 30 N·m (260 in. lbs.). REMOVAL (2) Connect cooler lines to supports. (1) Loosen hose clamps at radiator connections and (3) Connect cooler hoses to radiator (Fig.
Page 227 AUDIO/VIDEO 8A - 1 AUDIO/VIDEO TABLE OF CONTENTS page page AUDIO SYSTEM OPERATION ......8 DESCRIPTION .
Page 228 8A - 2 AUDIO/VIDEO AUDIO SYSTEM (Continued) Certain functions and features of the audio system and voice prompts. For complete operating instruc- rely upon resources shared with other electronic tions, refer to the manual included with the vehicle. modules in the vehicle over the Programmable Com- The audio system components operate on battery munication Interface (PCI) bus network.
Page 229 AUDIO/VIDEO 8A - 3 AUDIO SYSTEM (Continued) CONDITION POSSIBLE CAUSES CORRECTION NO SATELLITE RADIO 1. Subscription service has 1. Contact satellite radio provider. AUDIO (PERFORM ALL expired (with subscription DIAGNOSIS OUTDOORS) expired, one channel is still available) 2. Items on roof blocking 2.
Page 230 8A - 4 AUDIO/VIDEO AUDIO SYSTEM (Continued) CONDITION POSSIBLE CAUSES CORRECTION NO COMPACT DISC 1. Faulty CD. 1. Insert known good CD and test operation. OPERATION 2. Foreign material on CD. 2. Clean CD and test operation. 3. Condensation on CD or 3.
Page 231 AUDIO/VIDEO 8A - 5 AMPLIFIER (Continued) (5) Install the passenger side trunk liner. (6) Connect the battery negative cable. ANTENNA - SATELLITE RADIO DESCRIPTION The satellite radio antenna is secured by adhesive foam and two retainers which protrude through a hole in the roof panel.
Page 232 8A - 6 AUDIO/VIDEO ANTENNA - SATELLITE RADIO (Continued) (5) From inside the vehicle, and using a flat REMOVAL bladed tool, depress one of the retaining tabs on the (1) Disconnect and isolate the battery negative antenna. Push up the one side of the antenna con- cable.
Page 233 AUDIO/VIDEO 8A - 7 (5) Place center trim bezel into position and snap CD CHANGER into place. (6) Install ash receiver (if applicable). DESCRIPTION (7) Connect the negative battery cable remote ter- The 6 Disc In-Dash CD Changer (if equipped) is minal to the remote battery post.
Page 234 8A - 8 AUDIO/VIDEO RADIO (Continued) • AM/FM/CD with CD changer control (RBK sales code) • AM/FM/cassette/CD with CD changer control (RAD, RBT or RBY sales code) - export only • AM/FM/DVD with GPS navigation (RB1 sales code) All factory-installed radio receivers can communi- cate on the Programmable Communications Interface (PCI) data bus network.
Page 235 AUDIO/VIDEO 8A - 9 REAR WINDOW ANTENNA REMOVAL WARNING: OPERATE VEHICLE WITHIN 24 HOURS OF REAR WINDOW GLASS INSTALLATION. IT TAKES AT LEAST 24 HOURS FOR URETHANE ADHESIVE TO CURE. IF IT IS NOT CURED, THE REAR WINDOW GLASS MAY NOT PERFORM PROPERLY IN AN ACCIDENT.
Page 236 8A - 10 AUDIO/VIDEO REAR WINDOW ANTENNA MODULE (Continued) Before performing any antenna service procedures, (1) Check that the rear window adhesive does not verify that Rear Window Defogger is operating prop- come in contact with any portion of the grid lines or erly (Fig.
Page 237 AUDIO/VIDEO 8A - 11 REAR WINDOW ANTENNA MODULE (Continued) REMOVAL (1) Open hood and disconnect the negative battery cable remote terminal from the remote battery post. (2) Remove right upper quarter trim panel. (Refer to 23 - BODY/INTERIOR/UPPER QUARTER TRIM - REMOVAL).
Page 238 8A - 12 AUDIO/VIDEO REMOTE SWITCHES (Continued) WARNING: DISABLE AIRBAG SYSTEM Switch Switch Position Resistance BEFORE ATTEMPTING ANY STEERING WHEEL, Left STEERING COLUMN, SEAT BELT TENSIONER, SIDE Seek Up 0.261 Kilohms (Black) AIRBAG, OR INSTRUMENT PANEL COMPONENT Left DIAGNOSIS OR SERVICE. DISCONNECT AND ISO- Seek Down 0.681 Kilohms (Black)
Page 239 AUDIO/VIDEO 8A - 13 REMOTE SWITCHES (Continued) (2) Remove the driver side airbag module from the INSTALLATION steering wheel. (Refer to 8 - ELECTRICAL/RE- STRAINTS/DRIVER AIRBAG - REMOVAL). WARNING: DISABLE AIRBAG SYSTEM (3) Remove the speed control switch located on the BEFORE ATTEMPTING ANY STEERING WHEEL, same side of the steering wheel as the remote radio STEERING COLUMN, SEAT BELT TENSIONER, SIDE...
Page 240 8A - 14 AUDIO/VIDEO SATELLITE RECEIVER MODULE (Continued) • Two 6 x 9-inch, full-range speakers mounted in REMOVAL the rear shelf panel. (1) Disconnect and isolate the battery negative cable. MIDLINE SYSTEM (2) Remove instrument panel silencer (Refer to 23 The Midline System includes: BODY/INSTRUMENT PANEL/INSTRUMENT...
Page 241 AUDIO/VIDEO 8A - 15 SPEAKER (Continued) DIAGNOSIS AND TESTING - SPEAKER Step 6. If not OK, repair the shorted speaker feed (+) and/or return (-) circuits(s) to the speaker as Any diagnosis of the Audio system should required. begin with the use of the DRB III diagnostic (6) Disconnect wire harness connector at the inop- tool.
Page 242 8A - 16 AUDIO/VIDEO SPEAKER (Continued) (5) Pull speaker away from door and disconnect (3) Remove four retaining screws. wiring. (4) Remove speaker and disconnect wire connector. INSTRUMENT PANEL INSTALLATION (1) Disconnect and isolate the battery negative FRONT DOOR - LOWER cable.
Page 243 CHIME/BUZZER 8B - 1 CHIME/BUZZER TABLE OF CONTENTS page page CHIME/BUZZER DIAGNOSIS AND TESTING - EXTERIOR DESCRIPTION ......1 LAMPS ON .
Page 244 8B - 2 CHIME/BUZZER CHIME/BUZZER (Continued) No tone when key is left in ignition. Ignition DIAGNOSIS AND TESTING - EXTERIOR LAMPS switch is in the OFF position and driver’s door is open. To test the headlamps left on function, remove the (1) Using a DRB lll scan tool, check drivers door ignition key, turn exterior lamps on with driver’s ajar switch for good ground when driver’s door is...
Page 245 CLOCK 8C - 1 CLOCK TABLE OF CONTENTS page page CLOCK REMOVAL ......1 DESCRIPTION .
Page 247 ELECTRONIC CONTROL MODULES 8E - 1 ELECTRONIC CONTROL MODULES TABLE OF CONTENTS page page ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE STANDARD PROCEDURE - PCM/SKIM DESCRIPTION PROGRAMMING ..... . . 1 DESCRIPTION .
Page 248: Body Control Module
8E - 2 ELECTRONIC CONTROL MODULES ELECTRONIC CONTROL MODULES (Continued) NOTE: If three attempts are made to enter secure If ignition key programming is unsuccessful, the access mode using an incorrect PIN, secured DRB III will display one of the following messages: Programming Not Attempted - The DRB III access mode will be locked out for one hour.
Page 249 Block, Removal and Installation. lated (VPWM) signals. The PCI data bus speed is an average 10.4 Kilo-bits per second (Kbps). By compar- COMMUNICATION ison, the prior two-wire Chrysler Collision Detection (CCD) data bus system is designed to run at 7.8125 Kbps. DESCRIPTION...
Page 250 8E - 4 ELECTRONIC CONTROL MODULES COMMUNICATION (Continued) • In-Frame Response (IFR) byte(s) - If a els to generate signals. Low voltage is around zero volts and the high voltage is about seven and one- response is required from the target module(s), it can half volts.
Page 251: Data Link Connector
ELECTRONIC CONTROL MODULES 8E - 5 CONTROLLER ANTILOCK BRAKE (Continued) OPERATION CAB INPUTS • Wheel speed sensors (four) The primary functions of the controller antilock • Brake lamp switch brake (CAB) are to: • Ignition switch • Monitor the antilock brake system for proper •...
Page 252 8E - 6 ELECTRONIC CONTROL MODULES DATA LINK CONNECTOR (Continued) OPERATION For diagnosis of the MHSMM or the PCI data bus, a DRB III scan tool and the Service/Diagnostic Pro- The data link connector (diagnostic connector) cedures manual are recommended. The Memory links the DRB scan tool with the Powertrain Control Heated Seat/Mirror Module cannot be adjusted or Module (PCM).
Page 253 ELECTRONIC CONTROL MODULES 8E - 7 MEMORY HEATED SEAT/MIRROR MODULE (Continued) The most reliable, efficient, and accurate means to (2) Check the vehicles battery open-circuit voltage diagnose the module requires the use of a DRB III and charging system performance. If the vehicles elec- scan tool and the Service and Body Diagnostic Proce- trical system is defective or weak it may not be suppling dures Manuals.
Page 254 8E - 8 ELECTRONIC CONTROL MODULES MEMORY HEATED SEAT/MIRROR MODULE (Continued) (4) Disconnect the module electrical connectors. NOTE: PCM Inputs: (5) Remove the module from drivers seat. • Air Conditioning Pressure Transducer • ASD Relay INSTALLATION • Battery Voltage (1) Position the module under the drivers seat. •...
Page 255 ELECTRONIC CONTROL MODULES 8E - 9 POWERTRAIN CONTROL MODULE (Continued) • Speed Control Relay • Storing and maintaining Clutch Volume Indices • Speed Control Vent Relay (CVI) • Speed Control Vacuum Relay • Storing and selecting appropriate Shift Sched- • Transmission Autostick Display (To Cluster) ules •...
Page 256 8E - 10 ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE (Continued) For example, if the input shaft is rotating at 1000 rpm and the output shaft is rotating at 500 rpm, then the PCM can determine that the gear ratio is 2:1.
Page 257 ELECTRONIC CONTROL MODULES 8E - 11 POWERTRAIN CONTROL MODULE (Continued) Schedule Condition Expected Operation Extreme Cold Oil temperature at start-up below Park, Reverse, Neutral and 2nd -16° F gear only (prevents shifting which may fail a clutch with frequent shifts) Cold Oil temperature at start-up above –...
Page 258 8E - 12 ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE (Continued) OPERATION - PCM GROUND STANDARD PROCEDURE - PINION FACTOR Ground is provided through multiple pins of the PROCEDURE PCM connector. There five different ground pins. The vehicle speed readings for the speedometer are There are engine power grounds and trans power taken from the output speed sensor.
Page 259 ELECTRONIC CONTROL MODULES 8E - 13 POWERTRAIN CONTROL MODULE (Continued) (4) Select Quick Learn Procedure. Follow the (1) Unbolt the washer bottle filler neck and repo- instructions of the DRB to perform the Quick Learn sition. Procedure. (2) Disconnect the 4 PCM electrical connector. (3) Reposition wiring harness out of the way (Fig.
Page 260 8E - 14 ELECTRONIC CONTROL MODULES POWERTRAIN CONTROL MODULE (Continued) (5) Remove PCM (Fig. 9). SENTRY KEY IMMOBILIZER MODULE DESCRIPTION Fig. 10 SENTRY KEY IMMOBILIZER MODULE The Sentry Key Immobilizer Module (SKIM) (Fig. 10) contains a Radio Frequency (RF) transceiver and Fig.
Page 261 ELECTRONIC CONTROL MODULES 8E - 15 SENTRY KEY IMMOBILIZER MODULE (Continued) system malfunction and/or that the SKIS has become inoperative. If the SKIM detects an invalid key when the igni- tion switch is turned to the ON position, it sends messages to flash the VTSS indicator LED.
Page 262 8E - 16 ELECTRONIC CONTROL MODULES SENTRY KEY IMMOBILIZER MODULE (Continued) (3) Remove the steering column upper and lower new SKIM and to program at least two Sentry Key shrouds. transponders. (4) Disengage the steering column wire harness (1) Slide the SKIM toward the steering column from the Sentry Key Immobilizer Module (SKIM).
Page 263 ENGINE SYSTEMS 8F - 1 ENGINE SYSTEMS TABLE OF CONTENTS page page BATTERY SYSTEM ......1 STARTING .
Page 264 8F - 2 BATTERY SYSTEM BATTERY SYSTEM (Continued) • Battery Heater Blanket - The battery heater the components that are used in these systems must blanket is used to improve battery cold start ability. perform within specifications. It is important that •...
Page 265 BATTERY SYSTEM 8F - 3 BATTERY SYSTEM (Continued) BATTERY SYSTEM DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION THE BATTERY SEEMS 1. The electrical system 1. Refer to the IGNITION-OFF DRAW TEST WEAK OR DEAD WHEN ignition-off draw is excessive. Standard Procedure for the proper test ATTEMPTING TO START procedures.
Page 266 8F - 4 BATTERY SYSTEM BATTERY SYSTEM (Continued) BATTERY SYSTEM DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION THE BATTERY STATE OF 1. The battery has an 1. Refer to Battery System Specifications for the CHARGE CANNOT BE incorrect size or rating for proper specifications.
Page 267 BATTERY SYSTEM 8F - 5 BATTERY SYSTEM (Continued) ponents. In addition to the maintenance schedules water cleaning solution using a stiff bristle parts found in this service manual and the owner’s man- cleaning brush to remove any acid film. ual, it is recommended that these procedures be per- (5) Clean any corrosion from the battery terminals formed any time the battery or related components with a wire brush or terminal cleaner, and a sodium...
Page 268 8F - 6 BATTERY SYSTEM BATTERY SYSTEM (Continued) rent (in amperes) the battery can deliver for thirty the battery fully-charged at 26.7° C (80° F). This rat- seconds at -18° C (0° F). Terminal voltage must not ing estimates how long the battery might last after a fall below 7.2 volts during or after the thirty second charging system failure, under minimum electrical discharge period.
Page 269 BATTERY SYSTEM 8F - 7 BATTERY (Continued) The battery is a device used to store electrical plates. If the battery cell caps cannot be removed, the energy potential in a chemical form. When an electri- battery must be replaced if the electrolyte level cal load is applied to the battery terminals, an elec- becomes low.
Page 270 8F - 8 BATTERY SYSTEM BATTERY (Continued) (3) Connect the tester (Fig. 3) to the battery or STANDARD PROCEDURE jumper posts, the red clamp to positive (+) and the black clamp to negative (–). STANDARD PROCEDURE - USING MICRO 420 (4) Using the ARROW key select in or out of vehi- BATTERY TESTER cle testing and press ENTER to make a selection.
Page 271 BATTERY SYSTEM 8F - 9 BATTERY (Continued) WARNING: NEVER EXCEED TWENTY AMPERES Clean and inspect the battery hold downs, tray, WHEN CHARGING A COLD (-1° C [30° F] OR terminals, posts, and top before completing battery service. Refer to Battery System Cleaning for the LOWER) BATTERY.
Page 272 8F - 10 BATTERY SYSTEM BATTERY (Continued) tery may be good and the charging should be STANDARD PROCEDURE - OPEN-CIRCUIT completed in the normal manner. VOLTAGE TEST A battery open-circuit voltage (no load) test will CHARGE RATE TABLE show the approximate state-of-charge of a battery. This test can be used in place of the hydrometer test Voltage Hours...
Page 273 BATTERY SYSTEM 8F - 11 BATTERY (Continued) STANDARD PROCEDURE - IGNITION-OFF Excessive IOD can be caused by: • Electrical items left on. DRAW TEST • Faulty or improperly adjusted switches. The term Ignition-Off Draw (IOD) identifies a nor- • Faulty or shorted electronic modules and compo- mal condition where power is being drained from the nents.
Page 274 8F - 12 BATTERY SYSTEM BATTERY (Continued) this service manual for complete PDC and JB fuse, (9) Slide the battery toward rear of vehicle. circuit breaker, and circuit identification. This will (10) Disconnect the negative battery cable from isolate each circuit and identify the circuit that is the the battery.
Page 275: Battery Cables
BATTERY SYSTEM 8F - 13 BATTERY HOLDDOWN (Continued) (4) Remove the air cleaner housing. Refer to the of the battery cable to the battery terminal posts. index for the location of the procedure. The terminal pinch bolts allow the female terminal (5) Remove battery splash shield.
Page 276 8F - 14 BATTERY SYSTEM BATTERY CABLES (Continued) • The battery is fully-charged and load tested. between the battery positive cable terminal clamp Refer to Standard Procedures for the proper battery and the battery positive terminal post. charging and load test procedures. •...
Page 277: Battery Tray
BATTERY SYSTEM 8F - 15 BATTERY CABLES (Continued) (4) Connect the voltmeter to measure between the BATTERY TRAY battery negative cable terminal clamp and a good clean ground on the engine block (Fig. 9). Rotate and DESCRIPTION hold the ignition switch in the Start position. The battery is placed in a steel tray located in the Observe the voltmeter.
Page 278 8F - 16 BATTERY SYSTEM BATTERY HEATER BLANKET (Continued) The heater blanket cannot be adjusted or repaired. (8) Disconnect the heater blanket from the vehicles If the blanket is faulty or damaged it must be electrical system. Using an Ohmmeter, connect the replaced.
Page 279 CHARGING 8F - 17 CHARGING TABLE OF CONTENTS page page CHARGING OPERATION ......19 DESCRIPTION - CHARGING SYSTEM .
Page 280 8F - 18 CHARGING CHARGING (Continued) • accessories being left on with the engine not The PCM uses the inlet air temperature sensor or ambient temperature sensor to control the charge running • a faulty or improperly adjusted switch that system voltage.
Page 281 CHARGING 8F - 19 CHARGING (Continued) SPECIFICATIONS GENERATOR Type Engine Minimun Test Amperage Denso 2.7L 105 Amp Denso 3.5L 125 Amps Test Specification: 1. Engine RPM : 2500 RPM ±20 RPM 2. Voltage Output : 14.0 V ± 0.5 V 3.
Page 282 8F - 20 CHARGING GENERATOR (Continued) REMOVAL - 3.5L REMOVAL (1) Disconnect negative battery cable (Fig. 2). REMOVAL - 2.7L (1) Disconnect negative battery cable. (2) Raise and support vehicle. (3) Remove lower plastic splash shield (Fig. 1). Fig. 2 GENERATOR 3.2L/3.5L (2) Loosen lower mounting bolt do not remove.
Page 283: Voltage Regulator
CHARGING 8F - 21 GENERATOR (Continued) INSTALLATION VOLTAGE REGULATOR INSTALLATION - 2.7L DESCRIPTION (1) Install generator. The Electronic Voltage Regulator (EVR) is not a (2) Install pivot bolt, leave loose. separate component. It is actually a voltage regulat- (3) Connect the generator field circuit plug. ing circuit located within the Powertrain Control (4) Install the B+ terminal nut and wire and Module (PCM).
Page 284 8F - 22 STARTING STARTING TABLE OF CONTENTS page page STARTING DESCRIPTION - 3.5L ....28 DESCRIPTION ......22 OPERATION OPERATION .
Page 285 STARTING 8F - 23 STARTING (Continued) • Starter Relay - Visually inspect the starter INSPECTION relay for indications of physical damage and loose or Before removing any unit from the starting system corroded wire harness connections. for repair or diagnosis, perform the following inspec- •...
Page 286 8F - 24 STARTING STARTING (Continued) CONDITION POSSIBLE CAUSE CORRECTION 2. STARTING CIRCUIT 2. REFER TO THE FEED CIRCUIT RESISTANCE TEST AND WIRING FAULTY. THE FEED CIRCUIT TEST IN THIS SECTION. REPAIR AS NECESSARY. 3. STARTER ASSEMBLY 3. IF ALL OTHER STARTING SYSTEM COMPONENTS AND FAULTY.
Page 287 STARTING 8F - 25 STARTING (Continued) DIAGNOSIS AND TESTING - CONTROL STARTER RELAY CIRCUIT TEST WARNING: CHECK TO ENSURE THAT THE TRANS- The starter control circuit has: MISSION IS IN THE PARK/NEUTRAL POSITION • Starter motor with integral solenoid WITH THE PARKING BRAKE APPLIED. •...
Page 288 8F - 26 STARTING STARTING (Continued) near zero engine speed (rpm) and low clutch inter- lock input and see near zero engine speed (rpm). To diagnose the Park Neutral switch of the trans range sensor refer to the transaxle section. Check for conti- nuity to ground while the ignition switch is in the start position and if equipped the clutch pedal depressed.
Page 289 STARTING 8F - 27 STARTING (Continued) ignition switch in the START position. Observe the still above 0.2 volt after correcting poor contacts, voltmeter. If voltage is detected, correct poor con- replace battery positive cable. tact between cable clamp and post. (b) If resistance tests do not detect feed circuit (b) Connect positive lead of the voltmeter to the failures, replace the starter motor.
Page 290: Starter Motor
8F - 28 STARTING STARTER MOTOR DESCRIPTION DESCRIPTION - 2.7L The Melco is a permanent magnet starter motor. DESCRIPTION - 3.5L The Nippondenso is a reduction gear-field coil starter motor. OPERATION OPERATION - 2.7L A planetary gear train transmits power between starter motor and pinion shaft.
Page 291: Starter Motor Relay
STARTING 8F - 29 STARTER RELAY CHART STARTER MOTOR RELAY DESCRIPTION The Starter Relay is a micro relay located in the Power Distribution Center (PDC), positioned in the left front corner of the engine compartment. OPERATION As battery power is applied to the relay from the ignition switch, battery power is applied to the starter motor through the relay to the starter sole- noid.
Page 292: Starter Solenoid
8F - 30 STARTING (3) Raise the vehicle. STARTER SOLENOID (4) Perform a visual inspection of the starter/ starter solenoid for corrosion, loose connections or DESCRIPTION faulty wiring. The Starter Solenoid is mounted directly to the (5) Lower the vehicle. Starter Motor, mounted on the left side of the engine.
Page 293 HEATED SYSTEMS 8G - 1 HEATED SYSTEMS TABLE OF CONTENTS page page HEATED GLASS ......1 HEATED SEAT SYSTEM .
Page 294 8G - 2 HEATED GLASS HEATED GLASS (Continued) Circuit protection is provided by a fusible link, located in the charging circuit, for the heated grid circuit and by a fuse for the relay control circuit. The MTC or the ATC head sends a signal to the BCM, which indicates to the BCM that the operator wants the rear window grid to heat.
Page 295 HEATED GLASS 8G - 3 HEATED GLASS (Continued) the BCM failed to complete the circuit to ground DEFOGGER RELAY - DIAGNOSIS AND TESTING). required to energize the EBL relay coil (Fig. 3). If the fuse is open, then go to Step 3. (2) Using a DC voltmeter with a 0-15 volt range, (3) Locate the ground lug that connects the nega- connect the negative lead to a known good vehicle...
Page 296 8G - 4 HEATED GLASS REAR WINDOW DEFOGGER GRID (Continued) sured on the positive rear window grid bus bar, then (2) Follow the instructions in the repair kit for the grid line is bad. The break in the grid can be preparing the damaged area.
Page 297: Rear Window Defogger Relay
HEATED GLASS 8G - 5 relay contact is held against one of the fixed contacts REAR WINDOW DEFOGGER (normally closed) by spring pressure. When the elec- RELAY tromagnetic coil is energized, it draws the movable contact away from the normally closed fixed contact, DESCRIPTION and holds it against the other (normally open) fixed The rear window defogger relay is an electrome-...
Page 298 8G - 6 HEATED GLASS REAR WINDOW DEFOGGER RELAY (Continued) VOLTAGE AT REAR WINDOW SYSTEM VOLTAGE AT REAR WINDOW DEFOGGER ON OR OFF DEFOGGER RELAY POINT TO GRID TO GOOD POTENTIAL PROBLEM WITH GOOD VEHICLE GROUND VEHICLE ENGINE GROUND RUNNING POOR CONNECTION BETWEEN MORE MORE...
Page 299: Rear Window Defogger Switch
HEATED GLASS 8G - 7 DIAGNOSIS AND TESTING - REAR WINDOW REAR WINDOW DEFOGGER DEFOGGER SWITCH SWITCH For instructions on how to use the DRB III scan tool or the a/c heater control self-diagnostics to test DESCRIPTION the control, (Refer to 24 - HEATING & AIR CONDI- The rear window defogger switch is integral to the TIONING - DIAGNOSIS AND TESTING - SELF a/c heater control, which is located in the instrument...
Page 300 8G - 8 HEATED MIRRORS HEATED MIRRORS TABLE OF CONTENTS page page HEATED MIRRORS DIAGNOSIS AND TESTING - HEATED DESCRIPTION ......8 MIRRORS .
Page 301 HEATED SEAT SYSTEM 8G - 9 HEATED SEAT SYSTEM TABLE OF CONTENTS page page HEATED SEAT SYSTEM REMOVAL ......14 DESCRIPTION .
Page 302: Heated Seat System Description
8G - 10 HEATED SEAT SYSTEM HEATED SEAT SYSTEM (Continued) The heated seat system also relies upon resources module will automatically turn off the heating ele- shared with other components in the vehicle over the ments if it detects an open or a HI/LOW short in the Programmable Communications Interface (PCI) data sensor circuit, or a open or LOW short in the heating bus network.
Page 303: Driver Heated Seat Switch Description
HEATED SEAT SYSTEM 8G - 11 HEATED SEAT SYSTEM (Continued) WARNING: REFER TO THE RESTRAINTS SECTION OF THIS MANUAL BEFORE ATTEMPTING ANY SEAT, STEERING WHEEL, STEERING COLUMN, OR 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 304: Diagnosis And Testing - Driver Heated Seat Switch
8G - 12 HEATED SEAT SYSTEM DRIVER HEATED SEAT SWITCH (Continued) port the new selection. If a heated seat switch is depressed a second time, the module interprets the second input as a request to turn the seat heater “OFF”. The HI and LO LED indicator lamps in the heated seat switches receive battery current through a fused ignition switch output (run) circuit when the ignition...
Page 305: Installation
HEATED SEAT SYSTEM 8G - 13 DRIVER HEATED SEAT SWITCH (Continued) Fig. 3 Heated, Memory and Power Seat Switch Locations 1 - DRIVER HEATED SEAT SWITCH 2 - DRIVER POWER SEAT SWITCH 3 - SEAT CUSHION SIDE SHIELD 4 - MEMORY SEAT SWITCH (3) Working from the underside of the switch, gen- tly rock the switch back and forth out of its mounting location.
Page 306: Diagnosis And Testing - Passenger Heated Seat Switch
8G - 14 HEATED SEAT SYSTEM PASSENGER HEATED SEAT SWITCH (Continued) lamps or headlamps are turned on, and their illumi- HEATED SEAT SWITCH PIN IDENTIFICATION nation intensity is controlled by the panel lamps dim- FUNCTION mer switch. LO LED DIAGNOSIS AND TESTING - PASSENGER OPEN HEATED SEAT SWITCH GROUND...
Page 307: Heated Seat Element Description
HEATED SEAT SYSTEM 8G - 15 temperature sensor cannot be adjusted or repaired HEATED SEAT ELEMENT and, if faulty or damaged, the heated seat element must be replaced. DESCRIPTION OPERATION The heated seat elements resist the flow of electri- cal current. When battery current is passed through the elements, the energy lost by the resistance of the elements is released in the form of heat.
Page 308: Removal
8G - 16 HEATED SEAT SYSTEM HEATED SEAT ELEMENT (Continued) DRIVER SEAT ELEMENT REMOVAL (1) Remove the driver front seat retaining fasten- Some LH models have heating elements that can- ers (Refer to 23 - BODY/SEATS/SEAT - REMOVAL). not be replaced without replacing the entire leather Do not disconnect the seat electrical connectors, sim- seat trim cover.
Page 309: Heated Seat Sensor Description
HEATED SEAT SYSTEM 8G - 17 HEATED SEAT ELEMENT (Continued) DIAGNOSIS AND TESTING - HEATED SEAT SENSOR For complete circuit diagrams, refer to the WIR- ING section of this manual. (1) Obtain a DRB III scan tool, if a DRB scan tool is not available a accurate voltmeter will also work.
Page 311 HORN 8H - 1 HORN TABLE OF CONTENTS page page HORN SYSTEM HORN RELAY DESCRIPTION ......1 DIAGNOSIS AND TESTING - HORN RELAY .
Page 312 8H - 2 HORN HORN SYSTEM (Continued) CONDITION POSSIBLE CAUSE CORRECTION 3. HORN RELAY CONTROL 3. REMOVE DRIVER AIRBAG CIRCUIT X3 SHORTING TO MODULE AND CHECK FOR GROUND INSIDE RUBBING, SHORTED OR LOOSE STEERING WHEEL. WIRE CONNECTOR AND REPAIR AS NECESSARY. 4.
Page 313 HORN 8H - 3 INSTALLATION HORN (1) Position both horns and the mounting bracket DIAGNOSIS AND TESTING - HORN onto the vehicle as a unit. (2) Install and tighten the screw that secures the (1) Disconnect wire connector at each horn. horn mounting bracket to vehicle.
Page 314: Horn Switch
8H - 4 HORN HORN RELAY (Continued) HORN SWITCH DIAGNOSIS AND TESTING - HORN SWITCH WARNING: DISABLE AIRBAG SYSTEM BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, SEAT BELT TENSIONER, SIDE AIRBAG, OR INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. DISCONNECT AND ISO- LATE THE BATTERY NEGATIVE (GROUND) CABLE, THEN WAIT TWO MINUTES FOR THE AIRBAG SYS- TEM CAPACITOR TO DISCHARGE BEFORE PER-...
Page 315 HORN 8H - 5 HORN SWITCH (Continued) REMOVAL FORMING FURTHER DIAGNOSIS OR SERVICE. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO TAKE THE PROPER PRE- WARNING: DISABLE AIRBAG SYSTEM CAUTIONS COULD RESULT IN ACCIDENTAL AIR- BEFORE ATTEMPTING ANY STEERING WHEEL, BAG DEPLOYMENT AND POSSIBLE PERSONAL STEERING COLUMN, SEAT BELT TENSIONER, SIDE...
Page 317 IGNITION CONTROL 8I - 1 IGNITION CONTROL TABLE OF CONTENTS page page IGNITION CONTROL IGNITION COIL DESCRIPTION - IGNITION SYSTEM ..1 DESCRIPTION ......5 OPERATION - IGNITION SYSTEM .
Page 318: Ignition Control
8I - 2 IGNITION CONTROL IGNITION CONTROL (Continued) SPECIFICATIONS TORQUE DESCRIPTION N·m Ft. Lbs. In. Lbs. 2.7L Camshaft Position Sensor Screw 3.5L Camshaft Position Sensor Screw Engine Coolant Sensor 2.7L Crankshaft Position Sensor Screw 3.5L Crankshaft Position Sensor Screw 2.7L Ignition Coil 3.5L Ignition Coil Knock Sensor 2.7L Map Sensor...
Page 319: Auto Shut Down Relay Description
IGNITION CONTROL 8I - 3 For both SBEC and NGC vehicles, the ASD relay AUTO SHUT DOWN RELAY also provides a sense circuit to the PCM for diagnos- tic purposes. If the PCM does not receive 12 volts DESCRIPTION from this input after grounding the control side of The relay is located in the Power Distribution Cen- the ASD relay, it sets a Diagnostic Trouble Code ter (PDC) (Fig.
Page 320: Operation
8I - 4 IGNITION CONTROL CAMSHAFT POSITION SENSOR (Continued) Fig. 3 CAMSHAFT POSITION SENSOR LOCATION Fig. 4 Camshaft Position Sensor 2.7L 3.5L 1 - CAMSHAFT SENSOR OPERATION The camshaft position sensor contains a hall effect device that provide cylinder identification to the Pow- ertrain Control Module (PCM) (Fig.
Page 321: Installation - 3.5L
IGNITION CONTROL 8I - 5 CAMSHAFT POSITION SENSOR (Continued) install and tighten the retaining bolt to 12 N·m (105 in. lbs.) torque. (2) Attach electrical connector to sensor. INSTALLATION - 3.5L The camshaft position sensor is installed in the timing belt housing cover above the left camshaft sprocket.
Page 322: Removal
8I - 6 IGNITION CONTROL IGNITION COIL (Continued) The coil’s low primary resistance (0.4 - 0.6 ohm) bility, the engine can run on crankshaft sensor or allows the PCM to fully charge the coil for each fir- camshaft sensor. Refer to Auto Shutdown (ASD) ing.
Page 323: Installation
IGNITION CONTROL 8I - 7 IGNITION COIL CAPACITOR (Continued) INSTALLATION REMOVAL (1) Install capacitor and tighten nut. The sensors screws into the cylinder block, directly (2) Attach electrical connector to capacitor. below the intake manifold. (3) Install the negative battery cable. (1) Remove intake manifold plenum refer to the Engine section.
Page 324: Installation
8I - 8 IGNITION CONTROL KNOCK SENSOR (Continued) INSTALLATION CAUTION: Cleaning of the platinum plug may dam- age the platinum tip. The sensors screws into the cylinder block, directly below the intake manifold. (1) Install knock sensor. Tighten knock sensor to 10 N·m (7 ft.
Page 325 INSTRUMENT CLUSTER 8J - 1 INSTRUMENT CLUSTER TABLE OF CONTENTS page page INSTRUMENT CLUSTER INSTALLATION ......4 DESCRIPTION .
Page 326: Instrument Cluster Description
8J - 2 INSTRUMENT CLUSTER INSTRUMENT CLUSTER (Continued) OPERATION attaching screws (four on Intrepid, Limited, and 300M, and five on Concorde). The gauges are the magnetic air-core type. When (8) Using a trim stick (special tool #C-4755), gently the ignition switch is OFF, the gauge pointers should pry out on the instrument panel cluster bezel, discon- rest at or below the low graduation.
Page 327: Anti-Lock Brake System Indicator Description
INSTRUMENT CLUSTER 8J - 3 NOTE: Tilt steering wheel down to gain access for ANTI-LOCK BRAKE SYSTEM instrument cluster removal. INDICATOR (10) Remove the instrument cluster from panel. DESCRIPTION The instrument panel wiring harness connectors are self-aligning, mounted directly to the rear panel. A The amber Anti-Lock Brake System (ABS) warning force of approximately 9 kilograms (30 lbs.) will be indicator lamp is located on the instrument panel in...
Page 328: Installation
8J - 4 INSTRUMENT CLUSTER INSTRUMENT CLUSTER MASK/LENS (Continued) INSTALLATION (5) Remove cluster mask/lens from instrument cluster. Refer to Mask/Lens Removal and Installa- (1) Align mask/lens with instrument cluster and tion. snap into place (Fig. 4). (6) Remove two screws to Vacuum Fluorescent (2) Snap seven retaining tabs holding mask/lens (VF) display Odometer and remove from cluster.
Page 329: Transmission Range Indicator (Prndl) Description
INSTRUMENT CLUSTER 8J - 5 TRANSMISSION RANGE CONDITION POSSIBLE CAUSE INDICATOR (PRNDL) ALL DISPLAY LIGHTS Normal transient condition between P&R and R&N gear positions DESCRIPTION The shift position indicator is located in the instru- Check shift lever linkage ment cluster. It indicates the position of the manual BCM malfunction valve lever by illuminating an LED located under the Check wiring and...
Page 331 LAMPS 8L - 1 LAMPS TABLE OF CONTENTS page page LAMPS/LIGHTING - EXTERIOR ....1 LAMPS/LIGHTING - INTERIOR ....47 LAMPS/LIGHTING - EXTERIOR TABLE OF CONTENTS page...
Page 332 8L - 2 LAMPS/LIGHTING - EXTERIOR HEADLAMP LEVELING MOTOR - EXPORT PARK/TURN SIGNAL LAMP DESCRIPTION ......23 REMOVAL .
Page 333: Lamps/Lighting - Exterior
LAMPS/LIGHTING - EXTERIOR 8L - 3 OPERATION - TURN SIGNAL & HAZARD LAMPS/LIGHTING - EXTERIOR WARNING SYSTEM The turn signal system operates on battery voltage DESCRIPTION received on a fused ignition switch output (RUN- ACC) circuit so that the turn signals will only oper- DESCRIPTION - POLICE with ignition...
Page 334: Specifications Exterior Lamps
8L - 4 LAMPS/LIGHTING - EXTERIOR LAMPS/LIGHTING - EXTERIOR (Continued) (3) Check for battery voltage at the fused B(+) fuse continuity. If OK, test the multi-function switch in the PDC. If OK, go to Step 4. If not OK, repair the (Refer to 8 - ELECTRICAL/LAMPS/LIGHTING - open B(+) circuit between the PDC and the battery EXTERIOR/MULTI-FUNCTION SWITCH - DIAG-...
Page 335: Back Up Lamp Removal
LAMPS/LIGHTING - EXTERIOR 8L - 5 LAMPS/LIGHTING - EXTERIOR (Continued) BACK UP LAMP UNIT LAMP MODEL BULB Tail/Brake/Turn ALL except 3157K REMOVAL Signal Concorde (1) Disconnect and isolate the battery negative Concorde 3057K cable. (2) Remove screws holding back up lamp unit to Tail Limited rear bumper.
Page 336: Diagnosis And Testing - Brake Lamp Switch
8L - 6 LAMPS/LIGHTING - EXTERIOR BRAKE LAMP SWITCH (Continued) • Speed control deactivation, and (3) Gently push the plunger on the brake lamp • Brake sense for ABS and brake transmission switch in until it stops. shift interlock (4) With the switch in the depressed position When the brake pedal is in the released position, (plunger pushed in), use an ohmmeter to test each of the plunger on the outside of the brake lamp switch...
Page 337: Adjustment - Brake Lamp Switch
LAMPS/LIGHTING - EXTERIOR 8L - 7 BRAKE LAMP SWITCH (Continued) (4) Mount the brake lamp switch into the bracket as follows: Depress the brake pedal as far down as possible. Install the switch in it’s bracket by aligning the index key on switch with the notch in the square mounting hole of the mounting bracket (Fig.
Page 338: Installation
8L - 8 LAMPS/LIGHTING - EXTERIOR CENTER HIGH MOUNTED STOP LAMP (Continued) (4) Disconnect lamp socket from housing (Fig. 6). INSTALLATION (5) Remove bulb from socket. CONCORDE (1) Install the bulb into the socket. (2) Install socket into CHMSL housing. (3) Connect the battery negative cable and close the hood.
Page 339: Installation
LAMPS/LIGHTING - EXTERIOR 8L - 9 CENTER HIGH MOUNTED STOP LAMP UNIT (Continued) COMBINATION FLASHER DESCRIPTION The Combination Flasher, also refered to as the combo-flasher, is mounted to the in-line bracket which is located to the right of the Junction Block. The flasher can be removed by pulling in a rearward direction.
Page 340: Lamps/Lighting - Interior
8L - 10 LAMPS/LIGHTING - EXTERIOR COMBINATION FLASHER (Continued) (2) Remove the left instrument panel silencer. DECKLID/TRUNK LAMP Refer to Body, Instrument Panel Silencer, Removal. (3) The flasher can be removed by pulling in a REMOVAL rearward direction. (1) Open hood, disconnect and isolate the battery negative cable.
Page 341 LAMPS/LIGHTING - EXTERIOR 8L - 11 FOG LAMP (Continued) FOG LAMP DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION FOG LAMPS ARE DIM 1. Loose or corroded battery cables. 1. Clean and secure battery cable clamps WITH ENGINE IDLING OR and posts. IGNITION TURNED OFF. 2.
Page 342 8L - 12 LAMPS/LIGHTING - EXTERIOR FOG LAMP (Continued) CONDITION POSSIBLE CAUSES CORRECTION FOG LAMPS DO NOT 1. Blown fuse for fog lamps. 1. Replace fuse, refer to Wiring Diagrams. ILLUMINATE 2. No Z1-ground at fog lamps. 2. Repair circuit ground, refer to Wiring Diagrams.
Page 343: Installation
LAMPS/LIGHTING - EXTERIOR 8L - 13 FOG LAMP (Continued) INSTALLATION FOG LAMP UNIT INTREPID/300M STANDARD PROCEDURE - FOG LAMP UNIT ALIGNMENT CAUTION: Do not touch the glass of halogen bulbs Prepare an alignment screen (Fig. 14). Refer to with fingers or other possibly oily surface, reduced Electrical, Lamps/Lighting - Exterior, Headlamp, bulb life will result.
Page 344: Removal
8L - 14 LAMPS/LIGHTING - EXTERIOR FOG LAMP UNIT (Continued) Fig. 18 FOG LAMP - INTREPID Fig. 16 FOG LAMP UNIT ADJUSTER SCREW - 1 - FOG LAMP CONCORDE 2 - SCREW 1 - UP/DOWN ADJUSTER SCREW 2 - FOG LAMP UNIT Fig.
Page 345: Front Position Lamp - Export Description
LAMPS/LIGHTING - EXTERIOR 8L - 15 FOG LAMP UNIT (Continued) (5) Verify fog lamp operation and alignment. Refer DIAGNOSIS AND TESTING - FRONT POSITION to Electrical, Exterior Lamps/Lighting, Fog Lamp, LAMP - EXPORT Adjustments. The following test is designed to diagnosis a faulty front position lamp.
Page 346: Headlamp Description
8L - 16 LAMPS/LIGHTING - EXTERIOR FRONT POSITION LAMP - EXPORT (Continued) windshield wipers have been in the intermittent, low or high mode of operation for more than ten seconds. When the windshield wipers are turned OFF the Body Control Module will determine if the instru- mentation and exterior illumination lamps should remain ON base upon the current ambient light level.
Page 347: Operation
LAMPS/LIGHTING - EXTERIOR 8L - 17 HEADLAMP (Continued) AUTO HEADLAMP SYSTEM Automatic headlamps are controlled by the Body Control Module (BCM). With the headlamp switch in the AUTO position (Automatic mode). The BCM will control the headlamp, parking, side marker, tail and instrumentation lamps based on ambient light levels.
Page 348: Diagnosis And Testing
8L - 18 LAMPS/LIGHTING - EXTERIOR HEADLAMP (Continued) • Igniter - The lamp assembly contains an igniter (Fig. 25) that controls the voltage applied to the lamp electrodes. The igniter uses the voltage supplied by the ballast and momentarily steps up the voltage to 25,000 volts to start the lamp.
Page 349 LAMPS/LIGHTING - EXTERIOR 8L - 19 HEADLAMP (Continued) 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 OR and posts. IGNITION TURNED OFF 2. Loose or worn generator drive 2.
Page 350: Diagnosis And Testing - High Intensity Discharge Headlamps - 300M Special
8L - 20 LAMPS/LIGHTING - EXTERIOR HEADLAMP (Continued) CONDITION POSSIBLE CAUSES CORRECTION HEADLAMPS DO NOT 1. No voltage to headlamps. 1. Repair open headlamp circuit, refer to ILLUMINATE Wiring Diagrams. 2. No Z1-ground at headlamps. 2. Repair circuit ground, refer to Wiring Diagrams.
Page 351: Removal
LAMPS/LIGHTING - EXTERIOR 8L - 21 HEADLAMP (Continued) REMOVAL CONCORDE/300M NOTE: Headlamp lens fogging is a normal condition and does not require service unless excessive or continual. Moisture will vent from tubes or vents located on the back of the lamp. (1) Remove headlamp unit.
Page 352: Installation
8L - 22 LAMPS/LIGHTING - EXTERIOR HEADLAMP (Continued) INSTALLATION CONCORDE/300M CAUTION: Do not touch the glass of halogen bulbs with fingers or other possibly oily surface, reduced bulb life will result. (1) Install the headlamp wiring connector. (2) Place lamp into socket and rotate retaining ring (High beam or Low beam) to headlamp housing.
Page 353: Headlamp Delay Description
LAMPS/LIGHTING - EXTERIOR 8L - 23 HEADLAMP (Continued) (3) Install the jackscrews attaching headlamp unit eling, be certain the headlamp leveling switch is in to crossmember. the “0” position before starting. Failure to do so will (4) Connect the battery negative cable. result in an incorrect headlamp alignment.
Page 354: Diagnosis And Testing
8L - 24 LAMPS/LIGHTING - EXTERIOR HEADLAMP LEVELING MOTOR - EXPORT (Continued) DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - HEADLAMP LEVELING MOTOR - EXPORT HEADLAMP LEVELING MOTOR DIAGNOSIS CONDITION POSSIBLE CAUSES CORRECTION ONE MOTOR DOES NOT 1. Poor electrical connection at 1.
Page 355: Installation
LAMPS/LIGHTING - EXTERIOR 8L - 25 HEADLAMP LEVELING MOTOR - EXPORT (Continued) INSTALLATION The Headlamp Leveling Switch is located next to the headlamp switch (Fig. 30) and is the primary (1) Be certain the replacement motor matches the controller of the headlamp leveling system. The lev- configuration of the motor removed.
Page 356: Removal
8L - 26 LAMPS/LIGHTING - EXTERIOR HEADLAMP LEVELING SWITCH - EXPORT (Continued) REMOVAL The headlamp leveling switch is integrated into the headlamp switch. If the headlamp leveling switch proves faulty the entire headlamp switch must be replaced. (Refer to 8 - ELECTRICAL/LAMPS/LIGHT- ING - EXTERIOR/HEADLAMP SWITCH - REMOV- AL).
Page 357: Removal
LAMPS/LIGHTING - EXTERIOR 8L - 27 HEADLAMP SWITCH (Continued) loads or vehicle ride height changes. The vehicle should always be on a level surface when headlamp unit alignments are checked or changed. Headlamp unit alignment should always be first attempted by using the bubble level.
Page 358 8L - 28 LAMPS/LIGHTING - EXTERIOR HEADLAMP UNIT (Continued) HEADLAMP UNIT ALIGNMENT MEASUREMENT TABLE LOW BEAM CENTERLINE TO DISTANCE BETWEEN CENTERS (LOW MODEL GROUND BEAM) CONCORDE 25.0 in. 635.4 mm 54.2 in. 1376 mm INTREPID 25.7 in. 652.4 mm 52.4 in. 1330 mm 25.0 in.
Page 359: Standard Procedure - Headlamp Unit Alignment - Export
LAMPS/LIGHTING - EXTERIOR 8L - 29 HEADLAMP UNIT (Continued) STANDARD PROCEDURE - HEADLAMP UNIT HEADLAMP UNIT ADJUSTMENT A properly aimed low beam headlamp will project a ALIGNMENT - EXPORT high intensity light pattern on the screen with the horizontal cut-off line aligned with the tape line 100 VEHICLE PREPARATION FOR HEADLAMP UNIT mm (4 in.) below the headlamp centerline (Fig.
Page 360 8L - 30 LAMPS/LIGHTING - EXTERIOR HEADLAMP UNIT (Continued) Fig. 34 HEADLAMP ALIGNMENT SCREEN - EXPORT 1 - CENTER OF VEHICLE 5 - 10 METERS (32.8 FT.) 2 - CENTER OF HEADLAMPS 6 - HORIZONTAL CUT-OFF LINE 3 - 15° CUT-OFF LINE 7 - 100 MM 4 - FRONT OF HEADLAMP •...
Page 361: Installation
LAMPS/LIGHTING - EXTERIOR 8L - 31 HEADLAMP UNIT (Continued) INSTALLATION (5) Connect the battery negative remote cable and close hood. (6) Verify headlamp operation and alignment. CONCORDE/300M CAUTION: Do not touch the glass of halogen lamps LICENSE PLATE LAMP with fingers or other possibly oily surface, reduced bulb life will result.
Page 362: Installation
8L - 32 LAMPS/LIGHTING - EXTERIOR LICENSE PLATE LAMP UNIT (Continued) (3) Connect the battery negative cable and close hood. (4) Verify park and front side marker lamp opera- tion. MARKER LAMP UNIT - CONCORDE REMOVAL (1) Loosen fascia as necessary to access lamp. (2) Remove bulb socket from lamp.
Page 363: Operation
LAMPS/LIGHTING - EXTERIOR 8L - 33 MULTI-FUNCTION SWITCH (Continued) • Hazard warning switch. When the system is activated, one of two indicator • Headlamp beam select switch. lamps mounted in the instrument cluster flashes in • Headlamp optical horn. unison with the turn signal lamps, indicating to the •...
Page 364 8L - 34 LAMPS/LIGHTING - EXTERIOR MULTI-FUNCTION SWITCH (Continued) CONDITION POSSIBLE CAUSES CORRECTION HAZARD WARNING 1. FAULTY FUSE. 1. REPLACE FUSE. MALFUNCTION/SYSTEM 2. FAULTY FLASHER UNIT. 2. REPLACE FLASHER UNIT. DOES NOT FLASH. 3. OPEN CIRCUIT IN FEED 3. REPLACE WIRING HARNESS. CHECK WIRE TO SWITCH.
Page 365: Removal
LAMPS/LIGHTING - EXTERIOR 8L - 35 MULTI-FUNCTION SWITCH (Continued) BEAM SELECT SWITCH CONTINUITY Fig. 40 TURN SIGNAL AND HAZARD SWITCH CONNECTOR PIN CALL OUT TURN SIGNAL AND HAZARD SWITCH CONTINUITY SWITCH POSITION CONTINUITY TURN HAZARD SIGNAL WARNING NEUTRAL 1 AND 2 LEFT 7 AND 6 RIGHT...
Page 366: Park/Turn Signal Lamp Removal
8L - 36 LAMPS/LIGHTING - EXTERIOR MULTI-FUNCTION SWITCH (Continued) Fig. 42 MULTI-FUNCTION SWITCH Fig. 43 PARKING, SIDE MARKER, AND TURN SIGNAL LAMP BULB - INTREPID 1 - MULTIFUNCTION SWITCH 2 - MOUNTING SCREW 1 - LOW BEAM BULB 3 - WIRING HARNESS 2 - PARK/TURN SIGNAL SOCKET 4 - STEERING COLUMN 3 - HIGH BEAM BULB...
Page 367: Rear Fog Lamp - Export Description
LAMPS/LIGHTING - EXTERIOR 8L - 37 PARK/TURN SIGNAL LAMP (Continued) 300M Rear fog lamps are standard equipment in certain parts of the world where excessive fog is experienced (1) Push bulb into socket (Fig. 44). Rotate socket. on a regular basis. (2) Reach under the fascia and place the socket into the lamp housing and rotate to lock.
Page 368: Operation
8L - 38 LAMPS/LIGHTING - EXTERIOR REAR FOG LAMP SWITCH - EXPORT (Continued) SIDE REPEATER LAMP - EXPORT DESCRIPTION Fig. 47 SIDE REPEATER LAMP Fig. 46 REAR FOG LAMP SWITCH 1 - SIDE REPEATER LAMP RETAINING TABS 2 - SIDE REPEATER LAMP HOUSING OPERATION 3 - FENDER With the rotation of the rear fog lamp switch, volt-...
Page 369: Installation
LAMPS/LIGHTING - EXTERIOR 8L - 39 SIDE REPEATER LAMP - EXPORT (Continued) (2) Reach up behind the side repeater lamp and (2) Install the side repeater lamp in the front depress the two lamp unit retaining tabs. Remove fender (Fig. 48). Be certain lamp is secure within the the lamp unit from the fender opening.
Page 370: Spot Lamp Assembly - Police Description
8L - 40 LAMPS/LIGHTING - EXTERIOR SPOT LAMP - POLICE (Continued) (3) Connect the electrical connector to the spot Each spot lamp assembly contains a 100 watt halo- lamp head assembly. gen bulb. The spot lamp assemblies are fused indi- (4) Tilt the sealed beam toward the spot lamp vidually and powered hot at all times.
Page 371: Removal
LAMPS/LIGHTING - EXTERIOR 8L - 41 SPOT LAMP ASSEMBLY - POLICE (Continued) (4) Check for B+ power at the spot lamp bulb with switch turned ON (Refer to 8 - ELECTRICAL/ LAMPS/LIGHTING - EXTERIOR/SPOT LAMP - REMOVAL). If there is B+ power at the spot lamp bulb connector, replace bulb.
Page 372: Installation
8L - 42 LAMPS/LIGHTING - EXTERIOR SPOT LAMP ASSEMBLY - POLICE (Continued) (10) Loosen the clamp screw at the base of the spot lamp head assembly (Fig. 55). Fig. 57 SPOT LAMP MOUNTING BRACKET - REMOVE/INSTALL INSTALLATION Fig. 55 SPOT LAMP HEAD ASSEMBLY 1 - SPOT LAMP HEAD CLAMP SCREW CAUTION: Make sure that fuse F (master spot lamp (11) Carefully remove the spot lamp head with the...
Page 373: Tail Lamp Removal
LAMPS/LIGHTING - EXTERIOR 8L - 43 SPOT LAMP ASSEMBLY - POLICE (Continued) (a) Position the spot lamp handle in the operat- TAIL LAMP ing (downward close to vertical) position to the outer tube. REMOVAL (b) There are two detent positions to which the (1) Release decklid latch and open decklid.
Page 374: Tail Lamp Unit Removal
8L - 44 LAMPS/LIGHTING - EXTERIOR TAIL LAMP (Continued) Fig. 60 TAIL LAMP - 300M Fig. 62 TAIL LAMP - INTREPID (6) Connect the battery negative cable and close INSTALLATION hood. (7) Verify lamp operation. (1) Connect tail lamp unit wire connector to body wire harness.
Page 375: Underhood Lamp - Police Removal
LAMPS/LIGHTING - EXTERIOR 8L - 45 TURN SIGNAL LAMP UNIT - CONCORDE/300M (Continued) Fig. 63 FRONT PARKING, SIDE MARKER/TURN SIGNAL LAMP UNIT UNDERHOOD LAMP - POLICE Fig. 65 UNDERHOOD LAMP 1 - BULB 2 - DEPRESS TERMINAL INWARD REMOVAL 3 - BULB WIRE LOOP (1) Open hood, disconnect and isolate the battery 4 - LAMP BASE negative remote terminal or pull fuse Y in the PDC.
Page 376: Installation
8L - 46 LAMPS/LIGHTING - EXTERIOR UNDERHOOD LAMP UNIT - POLICE (Continued) INSTALLATION (1) Position the underhood lamp unit on the hood inner panel. (2) Install the push-pin fastener attaching the lamp unit base to the inner hood panel. (3) Install the lamp unit and press into place. (4) Connect the wire harness connector.
Page 377 LAMPS/LIGHTING - INTERIOR 8L - 47 LAMPS/LIGHTING - INTERIOR TABLE OF CONTENTS page page LAMPS/LIGHTING - INTERIOR GLOVE BOX LAMP SWITCH SPECIFICATIONS REMOVAL ......49 INTERIOR LAMPS .
Page 378: Interior Lamps
8L - 48 LAMPS/LIGHTING - INTERIOR LAMPS/LIGHTING - INTERIOR (Continued) INTERIOR LAMPS INDICATOR COLOR BULB #/LED Service procedures for most of the lamps in the fol- HIGH BEAM BLUE lowing list can be found in Body. Some components TURN SIGNALS GREEN have lamps that can only be serviced by an Autho- rized Service Center (ASC) after the component is...
Page 379: Courtesy Lamp Description
LAMPS/LIGHTING - INTERIOR 8L - 49 COURTESY LAMP DESCRIPTION The Body Control Module (BCM) illuminates the courtesy lamps whenever a door is opened. When the last door is closed, the BCM “fades-to-OFF” the cour- tesy lamps in five seconds if not in illuminated entry mode.
Page 380: Diagnosis And Testing - Illuminated Entry
8L - 50 LAMPS/LIGHTING - INTERIOR ILLUMINATED ENTRY (Continued) DIAGNOSIS AND TESTING - ILLUMINATED TRANSMISSION RANGE ENTRY INDICATOR ILLUMINATION When testing the system, all doors must be closed to prevent courtesy lamps from lighting. Verify that DESCRIPTION remote keyless entry system is operating properly The floor console mounted Transmission Range before testing illuminated entry circuits.
Page 381 MESSAGE SYSTEMS 8M - 1 MESSAGE SYSTEMS TABLE OF CONTENTS page page OVERHEAD CONSOLE REMOVAL ......9 DESCRIPTION .
Page 382: Overhead Console
8M - 2 MESSAGE SYSTEMS OVERHEAD CONSOLE (Continued) TENT problem may be present. You must than attempt to find the intermittent problem, such as running a tire pressure monitoring system self test. Refer to the Tires/Wheels section for more informa- tion.
Page 383: Standard Procedure
MESSAGE SYSTEMS 8M - 3 OVERHEAD CONSOLE (Continued) The electronic compass unit features a self-cali- brating design, which simplifies the calibration pro- cedure. This feature automatically updates the compass calibration while the vehicle is being driven. This allows the compass unit to compensate for small changes in the residual magnetism that the vehicle may acquire during normal use.
Page 384: Standard Procedure - Compass Variation Adjustment
8M - 4 MESSAGE SYSTEMS OVERHEAD CONSOLE (Continued) continuous duty for 110/115 volts and 60 Hz. They must also have a field strength of over 350 gauss at 7 millimeters (0.25 inch) beyond the tip of the probe. To demagnetize the roof panel and the overhead console forward mounting screw, proceed as follows: (1) Be certain that the ignition switch is in the Off position, before you begin the demagnetizing proce-...
Page 385: Standard Procedure - Electronic Vehicle Information Center Programming
MESSAGE SYSTEMS 8M - 5 OVERHEAD CONSOLE (Continued) Fig. 6 Variance Settings (4) Release the Reset push button. “VARIANCE =XX ” (2) Depress and release the Menu push button. will remain in the display. “XX” equals the current vari- The first item in the programmable features menu ance zone setting.
Page 386 8M - 6 MESSAGE SYSTEMS OVERHEAD CONSOLE (Continued) • DISPLAY U.S. OR METRIC? - The options Unlock signal from an RKE transmitter. When No is include U.S. and M. The default is U.S. This feature selected, no lamp flash will occur with the RKE Lock toggles the trip computer temperature, fuel economy or Unlock event.
Page 387: Removal - Overhead Console
MESSAGE SYSTEMS 8M - 7 OVERHEAD CONSOLE (Continued) ture can be obtained by enabling the EASY EXIT (3) Using your fingertips, grasp the sides of the SEAT feature and disabling the REMOTE LINKED overhead console and pull straight down evenly to TO MEMORY feature.
Page 388: Compass/Mini-Trip Computer Description
8M - 8 MESSAGE SYSTEMS RESET BUTTON COMPASS/MINI-TRIP Pressing the RESET button resets the function COMPUTER currently on the display, provided that function can be reset. The functions which can be reset are Aver- DESCRIPTION age fuel economy, Trip odometer and Elapsed time. The Compass Mini-Trip Computer (CMTC) is a The RESET button is also used to set the variance module located within the overhead console.
Page 389: Overhead Console
MESSAGE SYSTEMS 8M - 9 COMPASS/MINI-TRIP COMPUTER (Continued) TRIP ODOMETER (6) If Compass Mini-Trip Computer displays bUS, check for an open or a short in the PCI bus commu- Compass Mini-Trip Computer receives trip odome- nication circuit. ter information from the Cluster over the PCI bus (7) Press the C/T or the STEP button to exit self- line.
Page 390: Electronic Vehicle Info Center Description
8M - 10 MESSAGE SYSTEMS buttons is transmitting, and when the transceiver is ELECTRONIC VEHICLE INFO cleared. CENTER If the vehicle is equipped with the optional Tire Pressure Monitoring System, the EVIC will also DESCRIPTION display messages and an icon indicating when the The Electronic Vehicle Information Center (EVIC) tire air pressure falls below a given set-point, and is located in the overhead console on models...
Page 391: Operation
MESSAGE SYSTEMS 8M - 11 ELECTRONIC VEHICLE INFO CENTER (Continued) for an antenna, a repair order hat, or a funeral pro- mode. While in the compass/temperature/trip com- cession flag can exceed the compensating ability of puter display mode, momentarily depressing and the compass unit if placed on the roof panel.
Page 392: Standard Procedure - Tire Pressure System Test
8M - 12 MESSAGE SYSTEMS ELECTRONIC VEHICLE INFO CENTER (Continued) • NOT RECEIVING J1850 MESSAGE - The (3) Check the fused ignition switch output (run/ start) fuse in the junction block. If OK, go to Step 4. EVIC module is not receiving proper message input If not OK, repair the shorted circuit or component as through the PCI data bus.
Page 393: Removal
MESSAGE SYSTEMS 8M - 13 ELECTRONIC VEHICLE INFO CENTER (Continued) NOTE: Pressing the RESET button during the test (3) Install the overhead console onto the headliner will sound a beep and reset all the counter values (Refer to 8 - ELECTRICAL/OVERHEAD CONSOLE - INSTALLATION).
Page 394: Operation
8M - 14 MESSAGE SYSTEMS UNIVERSAL TRANSMITTER (Continued) The EVIC module displays messages and a small (3) The red signal detection LEDs will light and house-shaped icon with one, two or three dots corre- the tool will beep if a radio signal is detected. Repeat sponding to the three transmitter buttons to indicate this test three times.
Page 395: Ambient Temperature Sensor Description
MESSAGE SYSTEMS 8M - 15 UNIVERSAL TRANSMITTER (Continued) (4) When the red light on the universal transmit- The PCM then sends the proper ambient tempera- ter begins to flash rapidly (this may take as long as ture messages to the EVIC over the PCI data bus. 60 seconds), release both buttons.
Page 396: Installation
8M - 16 MESSAGE SYSTEMS AMBIENT TEMPERATURE SENSOR (Continued) INSTALLATION (3) Connect the negative battery cable. (1) Connect the ambient temperature sensor elec- trical connector. (2) Install the ambient temperature sensor retain- ing screw.
Page 397 POWER SYSTEMS 8N - 1 POWER SYSTEMS TABLE OF CONTENTS page page POWER LOCKS ......1 POWER SEATS .
Page 398: Power Locks
8N - 2 POWER LOCKS POWER LOCKS (Continued) NOTE: The Power Door Lock Motor is not serviced HORN CHIRP TOGGLE separately. It is part of the door latch assembly. Once the transmitters have been programmed, the Refer to Body, Door - Front, Front Door Latch, or horn chirp can be enabled/disabled by sending the Body, Door - Rear, Rear Door Latch, Removal and horn chirp toggle operation code to the Body Control...
Page 399: Diagnosis And Testing - Power Locks
POWER LOCKS 8N - 3 POWER LOCKS (Continued) CHILD PROTECTION LOCK DIAGNOSIS AND TESTING - POWER LOCKS The lock when engaged, will disable the inside door The most reliable, efficient, and accurate handle from opening the door. The lock is part of the means to diagnose the power lock system latch/lock assembly.
Page 400: Installation
8N - 4 POWER LOCKS DECK LID RELEASE SOLENOID (Continued) INSTALLATION (1) Install the two mounting motor screws and remote key cable retainers and motor. (2) Install the cover and latch cover attaching screws. (3) Connect and isolate the negative battery cable remote terminal onto the remote battery post.
Page 401: Keyless Entry Transmitter
POWER LOCKS 8N - 5 DOOR LOCK SWITCH (Continued) KEYLESS ENTRY TRANSMITTER DIAGNOSIS AND TESTING - KEYLESS ENTRY TRANSMITTER Using special tool 9001, first test to ensure that the transmitter is functioning. Typical testing distance is 2.5 centimeters (1 inch) for Asian transmitters and 30.5 centimeters (12 inches) for all others.
Page 402: Specifications
8N - 6 POWER LOCKS KEYLESS ENTRY TRANSMITTER (Continued) Transmitter programming by the customer is done REMOTE KEYLESS ENTRY by continually pressing the unlock button, on a pro- MODULE grammed fob, for a minimum of 4 seconds to a max- imum of 10 seconds with the ignition switch ON.
Page 403 POWER MIRRORS 8N - 7 POWER MIRRORS TABLE OF CONTENTS page page POWER MIRRORS POWER MIRROR SWITCH DESCRIPTION ......7 DESCRIPTION .
Page 404 8N - 8 POWER MIRRORS POWER MIRRORS (Continued) grams, proper wire and connector repair procedures, details of wire harness routing and retention, connec- tor pin-out information and location views for the various wire harness connectors, splices and grounds. (1) Remove the door trim panel (Refer to 23 - BODY/DOOR - FRONT/TRIM PANEL - REMOVAL).
Page 405: Operation
POWER MIRRORS 8N - 9 block. If OK, go to Step 3. If not OK, repair the open AUTOMATIC DAY / NIGHT circuit to the ignition switch as required. MIRROR (3) Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. DESCRIPTION Unplug the wire harness connector from the auto- The automatic day/night mirror uses a thin layer...
Page 406: Power Mirror Switch Description
8N - 10 POWER MIRRORS MIRROR SWITCH TEST POWER MIRROR SWITCH DESCRIPTION SWITCH POSITION CONTINUITY BETWEEN MOVE BUTTON TERMINALS The mirror switch on the door trim panel operates both the outside rear view mirrors. On vehicles MIRROR IN L POSITION equipped with Memory/Heated Seats, the Memory PIN 11 TO 12 Heated Seat Mirror Module (MHSMM) activates the...
Page 407 POWER SEATS 8N - 11 POWER SEATS TABLE OF CONTENTS page page POWER SEATS DRIVER POWER SEAT SWITCH DESCRIPTION DESCRIPTION ......15 DESCRIPTION - POWER SEAT SYSTEM .
Page 408: Power Seats
8N - 12 POWER SEATS POWER SEATS (Continued) • Power Seat Recliner - Two power seat reclin- The memory system includes the following compo- ers are used per vehicle. One seat recliner is used for nents: • Memory each front seat. The power seat recliner replaces the Heated Seat Mirror...
Page 409: Operation - Power Seat System
POWER SEATS 8N - 13 POWER SEATS (Continued) Other vehicle equipped electronic modules that DIAGNOSIS AND TESTING may affect memory system operation are as follows: • Body Control Module (BCM) - Refer to Body DIAGNOSIS AND TESTING - POWER SEATS Control Module in Electronic Control Modules for The following tests will help to diagnose the hard more information.
Page 410: Diagnosis And Testing - Memory Seat System
8N - 14 POWER SEATS POWER SEATS (Continued) the dome lamp does not dim, proceed with testing of (3) Press momentarily and release memory switch the individual components and circuits. (4) Press momentarily and release memory switch TESTING VOLTAGE TO SEAT 1 or 2.
Page 411: Operation
POWER SEATS 8N - 15 MEMORY SET SWITCH (Continued) OPERATION RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. When the memory set/selector switch is depressed, (2) Remove the drivers seat cushion side shield a resistance signal is sent to the memory heated seat from the seat (Fig.
Page 412: Diagnosis And Testing - Driver Power Seat Switch
8N - 16 POWER SEATS DRIVER POWER SEAT SWITCH (Continued) tion until the switch is released, or until the travel DRIVER SEAT SWITCH TEST limit of the adjuster is reached. When the switch is moved in the opposite direction, the battery feed and SWITCH CONTINUITY BETWEEN ground path to the motor are reversed through the...
Page 413: Installation
POWER SEATS 8N - 17 DRIVER POWER SEAT SWITCH (Continued) (2) Remove seat cushion side shield (Fig. 4). Refer PASSENGER POWER SEAT to the Body section for the procedure. SWITCH DESCRIPTION Vehicles equipped with power seats utilize a eight/ four-way passenger power seat switch. This eight/ four-way power seat switch features two knobs ganged together on the outboard seat cushion side shield.
Page 414: Removal
8N - 18 POWER SEATS PASSENGER POWER SEAT SWITCH (Continued) present, If OK go to Step 4 , If NOT OK repair the REMOVAL open voltage supply circuit as required. (1) Open hood, disconnect and isolate the negative (4) Using an ohmmeter, perform the Seat Switch battery cable remote terminal from the remote bat- Continuity Test table using (Fig.
Page 415: Power Seat Track Description
POWER SEATS 8N - 19 PASSENGER POWER SEAT SWITCH (Continued) The front and rear (if equipped) of the seat are operated by two separate vertical adjustment motors. These motors can be operated independently of each other, tilting the entire seat assembly forward or rearward;...
Page 416: Removal
8N - 20 POWER SEATS POWER SEAT TRACK (Continued) Fig. 9 Power Seat Wire Harness Pin Call-Out 1 - BLUE 2 - VIEWED FROM BODY HARNESS END REMOVAL WARNING: SOME VEHICLES ARE EQUIPPED WITH SEATBACK MOUNTED AIRBAGS. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY SEAT OR POWER SEAT SYSTEM COMPONENT YOU MUST FIRST DISCONNECT AND ISOLATE THE Fig.
Page 417 POWER WINDOWS 8N - 21 POWER WINDOWS TABLE OF CONTENTS page page POWER WINDOWS INSTALLATION ......22 DESCRIPTION .
Page 418 8N - 22 POWER WINDOWS POWER WINDOWS (Continued) (3) Connect negative (-) lead from test battery to (5) Disconnect wiring connector from motor. remaining motor terminal. (6) Secure the sector gear and mounting plate with (4) The motor should now rotate in one direction to a C clamp or similar clamping tool.
Page 419 POWER WINDOWS 8N - 23 WINDOW SWITCH DIAGNOSIS AND TESTING - WINDOW SWITCH For switch testing, remove the switch from its mounting, refer to Switch Removal. Using an ohm- meter, refer to Window Switch Continuity Charts to determine if continuity is correct (Fig. 2) and (Fig. 3). If the results are not obtained, replace the switch.
Page 420 8N - 24 POWER WINDOWS WINDOW SWITCH (Continued) REAR DOOR SWITCHES (4) Connect negative battery cable remote termi- nal. (1) Open hood and disconnect the negative battery cable remote terminal from the remote battery post. LHS and 300M (2) Open rear door. (1) Install wire connector to switch.
Page 421 RESTRAINTS 8O - 1 RESTRAINTS TABLE OF CONTENTS page page RESTRAINTS OPERATION ......15 DESCRIPTION - SIDE IMPACT AIRBAG OCCUPANT RESTRAINT CONTROLLER SYSTEM...
Page 422: Restraints
AIRBAG FACING UP. IF NOT, A PREMATURE WARNING DEPLOYMENT CAN RESULT. IF THE DRIVER/PASSENGER AIRBAG IS DEFEC- WARNING TIVE AND DEPLOYED, REFER TO CHRYSLER COR- PORATIONS CURRENT RETURN LIST FOR PROPER WARNING: THIS SYSTEM IS A SENSITIVE, COM- HANDLING PROCEDURES. PLEX ELECTRONIC UNIT. DISCONNECT AND ISO-...
Page 423 RESTRAINTS 8O - 3 RESTRAINTS (Continued) Fig. 1 SIDE AIRBAG LOCATION - TYPICAL...
Page 424: Warning - Airbag Deployment Zones - Police
8O - 4 RESTRAINTS RESTRAINTS (Continued) 1 - FRONT SEAT BACK PANEL 5 - SEAT BACK TRIM COVERS 2 - LEFT SEAT AIRBAG MODULE 6 - SEAT BACK CUSHIONS 3 - HOLE PROVIDED IN SEAT BACK FOAM FOR SEAT AIRBAG 7 - SEAT BACK FRAMES MODULE 4 - SIDE AIRBAG MODULE NYLON SLEEVE...
Page 425: Diagnosis And Testing - Airbag System
RESTRAINTS 8O - 5 RESTRAINTS (Continued) Fig. 5 PASSENGER AIRBAG LATERAL DEPLOYMENT ZONE 1 - 333 MM 2 - CENTER OF PASSENGER AIRBAG 3 - PASSENGER AIRBAG DEPLOYMENT ZONE Fig. 3 DRIVER AIRBAG LATERAL DEPLOYMENT 4 - 217 MM 5 - REFERENCE POINT - TOP OF INTREPID LOGO ZONE 1 - SEATING REFERENCE DIAGNOSIS AND TESTING - AIRBAG SYSTEM...
Page 426: Standard Procedure Standard Procedure - Handling Airbags
8O - 6 RESTRAINTS RESTRAINTS (Continued) If you find that the cleanup is irritating your skin, run cool water over the affected area. Also, if you experience nasal or throat irritation, exit the vehicle for fresh air until the irritation ceases. If irritation continues, see a physician.
Page 427: Child Restraint Anchor Description
RESTRAINTS 8O - 7 RESTRAINTS (Continued) SEAT BELTS AND RETRACTORS ter and the two outboard seating positions, but does not have the child restraint lower anchors. All seat belts should be closely inspected for cuts, Vehicles manufactured for sale in North America tears, fraying, or damage in any way following any also have two lower anchors for each rear outboard frontal impact or airbag deployment.
Page 428: Operation
8O - 8 RESTRAINTS CHILD RESTRAINT ANCHOR (Continued) INSTALLATION CLOCK SPRING WARNING: DURING, AND FOLLOWING, ANY CHILD DESCRIPTION RESTRAINT ANCHOR SERVICE, DUE TO IMPACT EVENT OR VEHICLE REPAIR, CAREFULLY INSPECT ALL MOUNTING HARDWARE, TETHER STRAPS AND ANCHORS PROPER INSTALLATION, OPERATION, OR DAMAGE. IF A CHILD RESTRAINT ANCHOR IS FOUND DAMAGED IN ANY WAY, THE ANCHOR MUST BE REPLACED.
Page 429 RESTRAINTS 8O - 9 CLOCK SPRING (Continued) (3) Keeping locking mechanism disengaged, rotate the clock spring rotor until a yellow dot appears in centering window and black arrow lines up with drive pin. (4) Reinstall steering wheel upside down with wheels turned 180°...
Page 430: Installation
8O - 10 RESTRAINTS CLOCK SPRING (Continued) (12) Remove two mounting screws and pull clock DRIVER AIRBAG spring assembly from steering shaft. The clock spring cannot be repaired, and must be replaced if faulty. DESCRIPTION INSTALLATION (1) Confirm that: • The steering wheel position is a half turn (180°) to the right (clockwise).
Page 431: Removal
RESTRAINTS 8O - 11 DRIVER AIRBAG (Continued) The protective trim cover is fitted to the front of (a) If equipped with remote radio switches, only the airbag and forms a decorative cover in the center the 4-way connector between the steering wheel of the steering wheel.
Page 432 8O - 12 RESTRAINTS DRIVER AIRBAG TRIM COVER (Continued) Fig. 13 DRIVER AIRBAG TRIM COVER BLADE CONNECTOR - REMOVAL 1 - HORN SWITCH FEED WIRE 4 - NUTS 2 - HORN SWITCH GROUND WIRE 5 - WIRE RETAINER 3 - TRIM COVER RETAINER BRACKET Fig.
Page 433 RESTRAINTS 8O - 13 DRIVER AIRBAG TRIM COVER (Continued) Fig. 15 DRIVER AIRBAG, HOUSING, AND INFLATOR 1 - INFLATOR 2 - DRIVER AIRBAG HOUSING Fig. 16 DRIVER AIRBAG TRIM COVER 1 - LOCKING BLOCKS 3 - HORN GROUND WIRE 2 - TRIM COVER RETAINER BRACKET 4 - LOCKING BLOCKS...
Page 434: Front Seat Belt & Retractor Removal
8O - 14 RESTRAINTS DRIVER AIRBAG TRIM COVER (Continued) FRONT SEAT BELT & RETRACTOR REMOVAL WARNING: INSPECT THE CONDITION OF THE SHOULDER/LAP BELT. REPLACE THE RETRACTOR IF THE BELT IS CUT, FRAYED, TORN, OR DAM- AGED IN ANY WAY. (1) If necessary, move the front seat all the way forward for access.
Page 435: Installation
RESTRAINTS 8O - 15 FRONT SEAT BELT & RETRACTOR (Continued) INSTALLATION OCCUPANT RESTRAINT CONTROLLER WARNING: INSPECT THE CONDITION OF THE SHOULDER/LAP BELT. REPLACE THE RETRACTOR DESCRIPTION IF THE BELT IS CUT, FRAYED, TORN, OR DAM- The Occupant Restraint Controller (ORC) is also AGED IN ANY WAY.
Page 436: Installation
8O - 16 RESTRAINTS OCCUPANT RESTRAINT CONTROLLER - 5 PASSENGER VEHICLES (Continued) (11) With the ORC now exposed, slide the red Con- WARNING: DO NOT CONNECT THE BATTERY NEG- nector Position Assurance (CPA) tab out. Press down ATIVE CABLE REMOTE TERMINAL. REFER TO on the locking latch and disconnect the ORC 23-way ELECTRICAL, RESTRAINTS, DIAGNOSIS AND TEST- connector.
Page 437: Installation
RESTRAINTS 8O - 17 OCCUPANT RESTRAINT CONTROLLER - 6 PASSENGER VEHICLES (Continued) INSTALLATION WARNING: THE ORC IS A SAFETY MODULE. FAIL- URE TO INSTALL AND SECURE IT PROPERLY COULD CAUSE THE MODULE TO MALFUNCTION AND CAUSE PERSONAL INJURY. (1) Position the ORC (arrow pointing forward in vehicle) on the ORC mounting bracket.
Page 438 8O - 18 RESTRAINTS PASSENGER AIRBAG (Continued) REMOVAL (12) If equipped with console, remove the left instrument panel side cover. (13) If not equipped with center console, remove NON DEPLOYED AIRBAG the center lower instrument panel floor bin. Use this procedure when removing an airbag for (14) Remove the two center instrument panel any reason OTHER THAN DEPLOYMENT.
Page 439 RESTRAINTS 8O - 19 PASSENGER AIRBAG (Continued) (1) Open hood and disconnect the negative battery cable remote terminal from the remote battery post. (2) Wait two minutes for the system reserve capac- itor to discharge before servicing any airbag compo- nents.
Page 440: Removal
8O - 20 RESTRAINTS PASSENGER AIRBAG (Continued) (17) Lift the steering column into position and (4) Install the five screws attaching the passenger install the four steering column nuts. airbag assembly to retainer. Torque screws to 2 N·m (18) Connect the two center instrument panel (20 in.
Page 441: Rear Seat Belt & Retractor - Center Removal
RESTRAINTS 8O - 21 REAR SEAT BELT & RETRACTOR (Continued) Fig. 23 REAR SEAT BELT RETRACTOR 1 - TURNING LOOP 2 - REAR SEAT BELT RETRACTOR 3 - SEAT BACK 4 - ANCHOR NUT Fig. 24 REAR SEAT BELT RETRACTOR - CENTER (2) Install the bolt to attach the seat belt retractor 1 - CENTER REAR SEAT BELT RETRACTOR to the quarter panel.
Page 442: Seat Airbag Description
8O - 22 RESTRAINTS REAR SEAT BELT & RETRACTOR - CENTER (Continued) OPERATION Only the Side Impact Airbag Control Module (SIACM) can deploy the side airbags. When supplied with the proper electrical signal the seat airbag infla- tor will produce a gas and discharge the bag directly between the occupant and the side of the vehicle, protecting the occupant.
Page 443: Installation
RESTRAINTS 8O - 23 SEAT AIRBAG (Continued) bracket. Install airbag retaining nuts. Torque to 10.7 ± 1 N·m (94.7 in. lbs.). (3) Position the upper seat back trim cover and cushion over the seat back frame. (4) Connect the side airbag electrical connector. After the initial connector is installed, be certain the yellow locking tab is in the upper “LOCKED”...
Page 444: Installation
8O - 24 RESTRAINTS SEAT AIRBAG WIRING HARNESS (Continued) (5) Disengage seat back trim cover J-strap from the upper, lower and airbag side of seat back. (6) Disconnect the side airbag electrical connector. Slide yellow locking tab down to unlock. Then with two fingers, push two side retaining tabs in and pull connector straight from side airbag.
Page 445: Seat Belt Buckle - Rear Seat Removal
RESTRAINTS 8O - 25 SEAT BELT BUCKLE - REAR SEAT BELT BUCKLE - FRONT SEAT SEAT CENTER OCCUPIED - CONCORDE/INTREPID REMOVAL (1) Remove the rear seat cushion. REMOVAL (2) Remove the seat belt anchor nut (Fig. 30). (1) Move or remove the front seat as necessary to gain access to seat belt buckle anchor bolt.
Page 446: Side Impact Airbag Control Module Description
8O - 26 RESTRAINTS OPERATION SIDE IMPACT AIRBAG Each Side Impact Airbag Control Module (SIACM) CONTROL MODULE serves as the impact sensor for its seat mounted air- bag. The right side SIACM controls the right seat DESCRIPTION airbag (Fig. 33). The left side SIACM controls the left seat airbag (Fig.
Page 447: Installation
RESTRAINTS 8O - 27 SIDE IMPACT AIRBAG CONTROL MODULE (Continued) Fig. 33 SIDE IMPACT AIRBAG SYSTEM COMPONENT LOCATION 1 - RIGHT SIDE IMPACT AIRBAG CONTROL MODULE (SIACM) 4 - LEFT SEAT AIRBAG MODULE 2 - VEHICLE BODY B-PILLAR 5 - LEFT SIDE IMPACT AIRBAG CONTROL MODULE (SIACM) 3 - RIGHT SEAT AIRBAG MODULE 6 - OCCUPANT RESTRAINT CONTROLLER INSTALLATION...
Page 449 SPEED CONTROL 8P - 1 SPEED CONTROL TABLE OF CONTENTS page page SPEED CONTROL INSTALLATION - 3.5L ....4 DESCRIPTION ......1 SERVO OPERATION DESCRIPTION...
Page 450: Speed Control
8P - 2 SPEED CONTROL SPEED CONTROL (Continued) NOTE: Turning the system off by depressing the throttle opening, while inhibiting/delaying down- OFF switch or turning off the ignition switch will shifts. erase the set speed stored in the PCM. OPERATION For added safety, the speed control system is pro- If opening the throttle alone cannot maintain the grammed to disengage for any of the following condi-...
Page 451: Description
SPEED CONTROL 8P - 3 SPEED CONTROL (Continued) OPERATION tem. The cause of any speedometer problems should be corrected before proceeding. Refer to the Instru- The Powertrain Control Module (PCM) first senses ment Cluster for speedometer diagnosis. that the speed control is set. If the set speed is If a road test verifies an inoperative system, and exceeded by more than 4 mph (6.5 km/hr) and the the speedometer operates properly, check for:...
Page 452: Cable Description
8P - 4 SPEED CONTROL (2) Rotate the throttle cam forward to the wide CABLE open position and install speed control cable clasp (Fig. 2). DESCRIPTION (3) Rotate the throttle cam forward to the wide The speed control servo cable is connected between open position and install throttle cable clasp.
Page 453: Servo Description
SPEED CONTROL 8P - 5 INSTALLATION SERVO (1) With throttle in full open position align hole in DESCRIPTION speed control cable sleeve with hole in servo pin and install retaining clip. The servo unit consists of a solenoid valve body, (2) Connect vacuum hose to servo.
Page 454: Installation
8P - 6 SPEED CONTROL SWITCH (Continued) (3) Remove two screws from side of the switch. highest available vacuum level in the servo, reservoir (4) Rock switch away from airbag and steering and vacuum hoses. When engine vacuum drops, as in wheel.
Page 455 VEHICLE THEFT SECURITY 8Q - 1 VEHICLE THEFT SECURITY TABLE OF CONTENTS page page VEHICLE THEFT SECURITY SKIS INDICATOR LAMP DESCRIPTION ......1 DESCRIPTION .
Page 456: Vehicle Theft Security
8Q - 2 VEHICLE THEFT SECURITY VEHICLE THEFT SECURITY (Continued) NOTE: The ignition switch can be turned to the SENTRY KEY IMMOBILIZER SYSTEM accessory position without triggering alarm system. The SKIS includes two valid Sentry Key transpon- ders from the factory. These two Sentry Keys can be OPERATION used to program additional non-coded blank Sentry Keys.
Page 457: Diagnosis And Testing - Vehicle Theft Security System
VEHICLE THEFT SECURITY 8Q - 3 VEHICLE THEFT SECURITY (Continued) (2) Disconnect and isolate the battery negative remote cable from the remote terminal. Unplug the wire harness connector at the SKIM. Check for con- tinuity between the ground circuit cavity of the SKIM wire harness connector and a good ground.
Page 458: Skis Indicator Lamp Description
8Q - 4 VEHICLE THEFT SECURITY DECKLID SECURITY SWITCH (Continued) sends messages to the BCM to flash the VTSS indi- cator LED. The SKIM can also send messages to the BCM to flash the LED and to generate a single audible chime tone.
Page 459: Operation
VEHICLE THEFT SECURITY 8Q - 5 TRANSPONDER KEY (Continued) OPERATION (2) Insert one of the two valid Sentry Key tran- sponders into the ignition switch and turn the igni- Each Sentry Key transponder has a unique tran- tion switch to the ON position. sponder identification code programmed into it by the (3) After the ignition switch has been in the ON manufacturer.
Page 460: Operation
8Q - 6 VEHICLE THEFT SECURITY VTSS INDICATOR (Continued) OPERATION tone. These functions serve as an indication to the customer that the SKIS has been placed in its “Cus- The SKIM sends messages to the BCM to turn the tomer Learn” programming mode. See Sentry Key LED on for about three seconds when the ignition Immobilizer System Transponder Programming in switch is turned to the ON position as a bulb test.
Page 461 WIPERS/WASHERS 8R - 1 WIPERS/WASHERS TABLE OF CONTENTS page page WIPERS/WASHERS INSTALLATION ......16 DESCRIPTION ......2 WASHER PUMP MOTOR - INTREPID OPERATION .
Page 462: Wipers/Washers Description
8R - 2 WIPERS/WASHERS The intermittent wiper system, in addition to low WIPERS/WASHERS and high speed, has a delay mode. The delay mode has a range of 1/2 to 18 seconds. The wiper delay DESCRIPTION times will double to a range of 1 to 36 seconds when the vehicle speed is less than 10 mph.
Page 463: Diagnosis And Testing - Windshield Washers
WIPERS/WASHERS 8R - 3 WIPERS/WASHERS (Continued) DIAGNOSIS AND TESTING - WINDSHIELD WASHERS Whenever a windshield washer malfunction occurs, first verify that the windshield washer wire harness is properly connected to all connectors before starting normal diagnosis and repair procedures. Refer to Windshield Washer Test table.
Page 464 8R - 4 WIPERS/WASHERS WIPERS/WASHERS (Continued) CONDITION POSSIBLE CAUSE CORRECTION WASHER SYSTEM WILL 1. NO WASHER FLUID IN 1. FILL RESERVOIR. NOT FLOW WASHER RESERVOIR. FLUID. 2. JUNCTION BLOCK FUSE 2. SHORT CIRCUIT BETWEEN JUNCTION #5 BLOWN. BLOCK FUSE #5 AND WIPER SWITCH TERMINAL #1.
Page 465 WIPERS/WASHERS 8R - 5 WIPERS/WASHERS (Continued) CONDITION POSSIBLE CAUSE CORRECTION HOOD NOZZLE WILL NOT 1. FROZEN NOZZLE. 1. DE-ICE NOZZLE BY ALLOWING TIME FOR FLOW. UNDERHOOD ENGINE HEAT TO THAW NOZZLE. IF NOT OK, MOVE VEHICLE INTO HEATED AREA. ASSURE WASHER FLUID IS PROPERLY BLENDED FOR AMBIENT OUTSIDE TEMPERATURES.
Page 466: Diagnosis And Testing - Wiper System Conditions
8R - 6 WIPERS/WASHERS WIPERS/WASHERS (Continued) CONDITION POSSIBLE CAUSE CORRECTION WASHER FLUID LEVEL 1. LOOSE FLUID LEVEL 1. PROPERLY SEAT CONNECTOR TO SWITCH. INDICATOR INOPERATIVE. SENSOR CONNECTOR. 2. OPEN POWER CIRCUIT 2. OPEN OR DEFECTIVE CIRCUIT BETWEEN TO SWITCH. INSTRUMENT CLUSTER CONNECTOR TERMINAL #B4 AND LOW FLUID LEVEL SENSOR CONNECTOR TERMINAL.
Page 467 WIPERS/WASHERS 8R - 7 WIPERS/WASHERS (Continued) (5) Place the wiper switch in the ON position. When replacing motor crank nut tighten to 15-20 Using a voltmeter, check for battery voltage at termi- N·m (130-177 in. lbs.) torque. nal D and A of the intermittent wiper relay in the (a) If average amp meter reading is more than Power Distribution Center.
Page 468: Headlamp Washers - Export Description
8R - 8 WIPERS/WASHERS WIPERS/WASHERS (Continued) (3) Check for faulty HI-LO wiper relay. Check for WIPER WILL RUN CONTINUOUSLY WITH SWITCH crossed wires in harness from HI-LO relay to motor. IN THE INTERMITTENT POSITION. WHEN COLUMN (4) Disconnect C3 bone 12-way connector from the SWITCH IS TURNED OFF, WIPERS STOP BCM and remove the HI/LO wiper relay.
Page 469: Operation
WIPERS/WASHERS 8R - 9 HEADLAMP WASHERS - EXPORT (Continued) OPERATION DIAGNOSIS AND TESTING - HEADLAMP The headlamp washer system utilizes a separate WASHER - EXPORT high pressure pump that is attached to the wind- Whenever a headlamp washer malfunction occurs, shield washer reservoir.
Page 470 8R - 10 WIPERS/WASHERS HEADLAMP WASHERS - EXPORT (Continued) CONDITION POSSIBLE CAUSE CORRECTION WASHER SYSTEM WILL 1. JUNCTION BLOCK FUSE 1. SHORT CIRCUIT BETWEEN JUNCTION NOT FLOW WASHER #5 BLOWN. BLOCK FUSE #5 AND WIPER SWITCH FLUID. TERMINAL #1. SHORT IN WIPER SWITCH. IF NOT OK, REPAIR CIRCUIT OR REFER TO WIPER/WASHER SWITCH DIAGNOSTIC PROCEDURES.
Page 471 WIPERS/WASHERS 8R - 11 HEADLAMP WASHERS - EXPORT (Continued) CONDITION POSSIBLE CAUSE CORRECTION WIPER WILL NOT CYCLE 1. OPEN OR DEFECTIVE 1. OPEN OR DEFECTIVE CIRCUIT BETWEEN WHEN WASHER SWITCH IS WASHER SYSTEM WIPER/WASHER SWITCH CONNECTOR DEPRESSED. CONTROL CIRCUIT. TERMINAL #2 AND BCM #C2 BLACK CONNECTOR TERMINAL #7.
Page 472 8R - 12 WIPERS/WASHERS HEADLAMP WASHERS - EXPORT (Continued) CONDITION POSSIBLE CAUSE CORRECTION HEADLAMP WASHER 1. NO WASHER FLUID IN 1. FILL RESERVOIR. SYSTEM WILL NOT FLOW RESERVOIR. WASHER FLUID. 2. JUNCTION BLOCK FUSE 2. SHORT CIRCUIT BETWEEN JUNCTION #5 BLOWN. BLOCK FUSE #5 AND WIPER SWITCH TERMINAL #1.
Page 473: Standard Procedure - Headlamp Washer System Priming - Export
WIPERS/WASHERS 8R - 13 HEADLAMP WASHERS - EXPORT (Continued) STANDARD PROCEDURE - HEADLAMP WASHER SYSTEM PRIMING - EXPORT The headlamp washer system may loose it’s prime when the system is serviced. The following procedure must be used to prime the headlamp washer system. A DRB III scan tool must be used for this priming procedure.
Page 474: Headlamp Washer Nozzle - Export Removal
8R - 14 WIPERS/WASHERS Standard Procedures - Headlamp Washer System HEADLAMP WASHER NOZZLE Priming. - EXPORT HEADLAMP WASHER PUMP - REMOVAL (1) Hoist vehicle. EXPORT (2) Partially remove the front fascia to gain access to the headlamp assembly. Refer to Body for Removal REMOVAL procedures.
Page 475: Installation
WIPERS/WASHERS 8R - 15 HEADLAMP WASHER PUMP - EXPORT (Continued) INSTALLATION (6) Connect the negative battery cable remote ter- minal to the remote battery post. (1) Install the headlamp washer motor in the windshield/headlamp washer pump. (2) Connect the headlamp washer pump hose and WASHER FLUID LEVEL electrical connector.
Page 476: Installation
8R - 16 WIPERS/WASHERS WASHER HOSES (Continued) INSTALLATION INSTALLATION (1) Route washer hose up through engine compart- (1) Install new rubber grommet in reservoir. ment. (2) Carefully install pump motot into reservoir. (2) Connect washer hose to top of reservoir and to Care must be taken not to puncture reservoir (Fig.
Page 477: Washer Reservoir
WIPERS/WASHERS 8R - 17 WASHER PUMP MOTOR - INTREPID (Continued) (7) Install the four retaining bolts to the washer (8) Remove washer reservoir from vehicle. reservoir (Fig. 7). (9) Transfer fluid level sensor, pump, and washer (8) Install the left headlamp assembly. Refer to fluid to new reservoir (Fig.
Page 478: Washer Reservoir - Intrepid
8R - 18 WIPERS/WASHERS WASHER RESERVOIR - WASHER RESERVOIR FILLER INTREPID TUBE REMOVAL REMOVAL (1) Open hood and disconnect the negative battery (1) Open hood and disconnect the negative battery cable remote terminal from the remote battery post. cable remote terminal from the remote battery post. (2) Remove the left headlamp assembly and set (2) Hoist vehicle.
Page 479: Wiper Arms
WIPERS/WASHERS 8R - 19 WIPER ARMS WIPER BLADES STANDARD PROCEDURE - WIPER ARM DESCRIPTION ALIGNMENT The wiper blades are a rubber element with a steel vertebrae that are mounted on the end of the wind- The wiper system does not have an indexing fea- shield wiper arm and sweep across the front wind- ture designed into the arm and blade assembly.
Page 480: Wiper Blade Element Removal
8R - 20 WIPERS/WASHERS WIPER BLADES (Continued) WIPER LINKAGE REMOVAL There a two serviceable link assemblies in the wiper module (Fig. 13). The Master Link connects the motor output crank to the drivers side pivot. The Slave link connects the driver side pivot to the pas- senger side pivot.
Page 481: Wiper Module Removal
WIPERS/WASHERS 8R - 21 WIPER LINKAGE (Continued) (1) Install “U” nut to body (if necessary). (2) Install the module linkage mounting grommets. NOTE: When assembling master link or slave link to module frame, use channel locks wrapped in cloth to prevent damage to ball and socket joint. Apply light pressure to assemble socket to ball.
Page 482: Wiper Motor
8R - 22 WIPERS/WASHERS WIPER MODULE (Continued) (5) Start rear outboard screw first, rear inboard (13) Install the driver and passenger side wiper screw second, and forward outboard screw last. arms. Refer to Electrical, Wipers and Washers, Wiper (6) Start all module mounting screws and bolt by Arm Removal.
Page 483 WIPERS/WASHERS 8R - 23 WIPER MOTOR (Continued) CONDITION POSSIBLE CAUSE CORRECTION WIPER OPERATES IN HIGH 1. DEFECTIVE HI/LO 1. CHECK WIPER HI/LO RELAY WITH KNOWN SPEED ONLY. RELAY. GOOD RELAY. REPLACE IF NOT OK. 2. DEFECTIVE CONTROL 2. CONTINUOUS SHORT BETWEEN HI/LO CIRCUIT TO BCM.
Page 484 8R - 24 WIPERS/WASHERS WIPER MOTOR (Continued) CONDITION POSSIBLE CAUSE CORRECTION WIPER RUNS 1. DEFECTIVE ON/OFF 1. CHECK WIPER ON/OFF RELAY WITH CONTINUOUSLY OR RELAY. KNOWN GOOD RELAY. IF NOT OK, REPLACE INTERMITTENTLY IN LOW RELAY. SPEED WITH IGNITION OR 2.
Page 485 WIPERS/WASHERS 8R - 25 WIPER MOTOR (Continued) CONDITION POSSIBLE CAUSE CORRECTION 6. BCM CONNECTORS B 6. CHECK BCM CONNECTORS B AND C AND C (LOOSE, BENT OR FOR BENT, LOOSE, OR CORRODED CORRODED). CONNECTORS. 7. OPEN OR DEFECTIVE 7. OPEN OR DEFECTIVE CIRCUIT BETWEEN CONTROL CIRCUIT TO ON/OFF RELAY CAVITY C AND BCM BCM.
Page 486: Removal
8R - 26 WIPERS/WASHERS WIPER MOTOR (Continued) CONDITION POSSIBLE CAUSE CORRECTION DRIVER AND/OR 1. LOOSE ARM TO PIVOT 1. CHECK ARM TO PIVOT SHAFT PASSENGER ARM WILL SHAFT. CONNECTION FOR LOOSENESS. TORQUE NOT CYCLE (OPERATE). NUT TO SPECIFICATION. 2. STRIPPED ARM TO 2.
Page 487: Wiper Switch
WIPERS/WASHERS 8R - 27 WIPER MOTOR (Continued) Fig. 18 WIPER SWITCH LOCATION 1 - WINDSHIELD WASHER BUTTON 2 - CONTROL STALK (BEAM SELECT) 3 - HAZARD WARNING BUTTON 4 - MULTI-FUNCTION SWITCH 5 - WINDSHIELD WIPER CONTROL Fig. 17 WIPER MOTOR RETAINING BOLTS 1 - CRANK ARM NUT 2 - WIPER MOTOR RETAINING BOLTS WIPER SWITCH...
Page 488 8R - 28 WIPERS/WASHERS WIPER SWITCH (Continued) WIPER/WASHER SWITCH RESISTANCE SWITCH POSITION TERMINALS RESISTANCE VALUE PINS 1 T0 3 OPEN > 300 K OHMS PINS 1 TO 3 9.72 K OHMS DELAY PINS 1 TO 3 8.22 K OHMS LEVEL PINS 1 TO 3 6.61 K OHMS PINS 1 TO 3...
Page 489 WIRING 8W - 1 WIRING TABLE OF CONTENTS page page WIRING DIAGRAM INFORMATION..8W-01-1 BODY CONTROL MODULE ... . . 8W-45-1 COMPONENT INDEX ....8W-02-1 AUDIO SYSTEM .
Page 491 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 1 8W-01 WIRING DIAGRAM INFORMATION TABLE OF CONTENTS page page WIRING DIAGRAM INFORMATION STANDARD PROCEDURE - TESTING FOR A DESCRIPTION SHORT TO GROUND ....9 DESCRIPTION - HOW TO USE WIRING STANDARD PROCEDURE - TESTING FOR A DIAGRAMS .
Page 492: Wiring Diagram Information
8W - 01 - 2 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) Fig. 1 WIRING DIAGRAM EXAMPLE 1...
Page 493 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 3 WIRING DIAGRAM INFORMATION (Continued) Fig. 2 WIRING DIAGRAM EXAMPLE 2...
Page 494 8W - 01 - 4 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) Fig. 3 WIRING DIAGRAM SYMBOLS...
Page 495: Description - Circuit Information
8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 5 WIRING DIAGRAM INFORMATION (Continued) TERMINOLOGY WIRE COLOR CODE CHART This is a list of terms and definitions used in the wiring diagrams. COLOR CODE COLOR BLUE LHD ....Left Hand Drive Vehicles BLACK RHD .
Page 496: Description - Circuit Functions
8W - 01 - 6 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) DESCRIPTION - CIRCUIT FUNCTIONS DESCRIPTION - SECTION IDENTIFICATION AND All circuits in the diagrams use an alpha/numeric INFORMATION code to identify the wire and it’s function. To identify The wiring diagrams are grouped into individual which circuit code applies to a system, refer to the sections.
Page 497: Description - Connector, Ground And Splice Information
8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 7 WIRING DIAGRAM INFORMATION (Continued) DESCRIPTION - CONNECTOR, GROUND AND WARNING: BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE SPLICE INFORMATION PROCEDURE REQUIRES IT TO BE ON. CAUTION: Not all connectors are serviced.
Page 498: Standard Procedure Standard Procedure - Electrostatic Discharge (Esd) Sensitive Devices
8W - 01 - 8 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) • Ohmmeter - Used to check the resistance factory items added to the vehicle before doing any between two points of a circuit. Low or no resistance diagnosis.
Page 499: Standard Procedure - Testing Of Voltage Potential
8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 9 WIRING DIAGRAM INFORMATION (Continued) STANDARD PROCEDURE - TESTING OF STANDARD PROCEDURE - TESTING FOR VOLTAGE POTENTIAL CONTINUITY (1) Connect the ground lead of a voltmeter to a (1) Remove the fuse for the circuit being checked known good ground (Fig.
Page 500: Standard Procedure - Testing For Ashort To Ground On Fuses Powering Several Loads
8W - 01 - 10 8W-01 WIRING DIAGRAM INFORMATION WIRING DIAGRAM INFORMATION (Continued) STANDARD PROCEDURE - TESTING FOR A SPECIAL TOOLS SHORT TO GROUND ON FUSES POWERING WIRING/TERMINAL SEVERAL LOADS (1) Refer to the wiring diagrams and disconnect or isolate all items on the suspected fused circuits. (2) Replace the blown fuse.
Page 501: Connector Removal
8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 11 INSTALLATION CONNECTOR (1) Insert the removed terminal in the same cavity REMOVAL on the repair connector. (2) Repeat steps for each terminal in the connec- (1) Disconnect battery. tor, being sure that all wires are inserted into the (2) Release Connector Lock (Fig.
Page 502 8W - 01 - 12 8W-01 WIRING DIAGRAM INFORMATION CONNECTOR (Continued) Fig. 11 EXAMPLES OF CONNECTOR SECONDARY TERMINAL LOCKS 1 - Secondary Terminal Lock...
Page 503 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 13 CONNECTOR (Continued) Fig. 12 TERMINAL REMOVAL 1 - TYPICAL CONNECTOR 7 - MOLEX CONNECTOR 2 - PICK FROM SPECIAL TOOL KIT 6680 8 - SPECIAL TOOL 6742 3 - APEX CONNECTOR 9 - THOMAS AND BETTS CONNECTOR 4 - PICK FROM SPECIAL TOOL KIT 6680 10 - SPECIAL TOOL 6934...
Page 504: Diode Removal
8W - 01 - 14 8W-01 WIRING DIAGRAM INFORMATION DIODE TERMINAL REMOVAL REMOVAL (1) Disconnect the battery. (1) Follow steps for removing terminals described (2) Locate the diode in the harness, and remove in the connector removal section. the protective covering. (2) Cut the wire 6 inches from the back of the con- (3) Remove the diode from the harness, pay atten- nector.
Page 505: Standard Procedure - Wire Splicing
8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 15 (5) Solder the connection together using rosin core WIRE type solder only (Fig. 16). STANDARD PROCEDURE - WIRE SPLICING CAUTION: DO NOT USE ACID CORE SOLDER. When splicing a wire, it is important that the cor- rect gage be used as shown in the wiring diagrams.
Page 507 8W-02 COMPONENT INDEX 8W - 02 - 1 8W-02 COMPONENT INDEX Component Page Component Page A/C Compressor Clutch Relay ... . 8W-42 Fog Lamp Relay ..... . 8W-50 A/C Compressor Clutch .
Page 508 8W - 02 - 2 8W-02 COMPONENT INDEX Component Page Component Page Overhead Map/Courtesy Lamp ... 8W-44 Sentry Key Immobilizer Module ..8W-39 Overhead Travel Information System .
Page 509 8W-10 POWER DISTRIBUTION 8W - 10 - 1 8W-10 POWER DISTRIBUTION Component Page Component Page A/C Compressor Clutch ....8W-10-12 Fuse K ......8W-10-8, 18 A/C Compressor Clutch Relay .
Page 539 8W-11 FUSE BLOCK 8W - 11 - 1 8W-11 FUSE BLOCK Component Page Component Page Fuse 1 ......8W-11-5 ISO Relay No.
Page 545 8W-12 JUNCTION BLOCK 8W - 12 - 1 8W-12 JUNCTION BLOCK Component Page Component Page A/C Compressor Clutch Relay ....8W-12-24 Left Back-Up Lamp ..... . 8W-12-31 Airbag Control Module (ORC) .
Page 579 8W-15 GROUND DISTRIBUTION 8W - 15 - 1 8W-15 GROUND DISTRIBUTION Component Page Component Page A/C Compressor Clutch ....8W-15-5 Left Side Impact Airbag Control Module ..8W-15-10 Airbag Control Module (ORC) .
Page 601 8W-18 BUS COMMUNICATIONS 8W - 18 - 1 8W-18 BUS COMMUNICATIONS Component Page Component Page Airbag Control Module (ORC) ..8W-18-3 Junction Block ..... . 8W-18-2 Automatic Temperature Control Head .
Page 605 8W-20 CHARGING SYSTEM 8W - 20 - 1 8W-20 CHARGING SYSTEM Component Page Component Page Auto Shut Down Relay ....8W-20-3 Generator ......8W-20-2 Battery .
Page 609 8W-21 STARTING SYSTEM 8W - 21 - 1 8W-21 STARTING SYSTEM Component Page Component Page Battery ......8W-21-2 Power Distribution Center .
Page 611 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 1 8W-30 FUEL/IGNITION SYSTEM Component Page Component Page A/C Compressor Clutch Relay ..8W-30-16 Fuse V ......8W-30-21 A/C Pressure Transducer .
Page 637 8W-31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 1 8W-31 TRANSMISSION CONTROL SYSTEM Component Page Component Page Automatic Day/Night Mirror ... 8W-31-5 G300 ......8W-31-8 Autostick Switch .
Page 645 8W-33 VEHICLE SPEED CONTROL 8W - 33 - 1 8W-33 VEHICLE SPEED CONTROL Component Page Component Page Body Control Module ....8W-33-2 G201 ......8W-33-3 Brake Lamp Switch .
Page 649 8W-35 ANTILOCK BRAKES 8W - 35 - 1 8W-35 ANTILOCK BRAKES Component Page Component Page Body Control Module ....8W-35-2 G103 ......8W-35-2 Brake Lamp Switch .
Page 653 8W-39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 1 8W-39 VEHICLE THEFT SECURITY SYSTEM Component Page Component Page Body Control Module ..8W-39-2, 3, 4, 5, 6 Ignition Switch ..... . 8W-39-2 Driver Cylinder Lock Switch .
Page 659 8W-40 INSTRUMENT CLUSTER 8W - 40 - 1 8W-40 INSTRUMENT CLUSTER Component Page Component Page Analog Clock ..... . 8W-40-10 G201 .
Page 669 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET 8W - 41 - 1 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET Component Page Component Page Body Control Module ....8W-41-2 G200 ......8W-41-2 Cigar Lighter .
Page 673 8W-42 AIR CONDITIONING-HEATER 8W - 42 - 1 8W-42 AIR CONDITIONING-HEATER Component Page Component Page A/C Compressor Clutch ....8W-42-6 G105 ......8W-42-7, 8 A/C Compressor Clutch Relay .
Page 683 8W-43 OCCUPANT RESTRAINT SYSTEM 8W - 43 - 1 8W-43 OCCUPANT RESTRAINT SYSTEM Component Page Component Page Airbag Control Module (ORC) ..8W-43-2 G300 ......8W-43-3 Body Control Module .
Page 687 8W-44 INTERIOR LIGHTING 8W - 44 - 1 8W-44 INTERIOR LIGHTING Component Page Component Page Analog Clock ..... . . 8W-44-6 Junction Block .
Page 695 8W-45 BODY CONTROL MODULE 8W - 45 - 1 8W-45 BODY CONTROL MODULE Component Page Component Page Airbag Control Module (ORC) ..8W-45-15 Left Rear Reading/Courtesy Lamp ..8W-45-4 Automatic Temperature Control Head .
Page 711 8W-47 AUDIO SYSTEM 8W - 47 - 1 8W-47 AUDIO SYSTEM Component Page Component Page Body Control Module ... 8W-47-2, 3, 7, 8 Left Remote Radio Switch ... . . 8W-47-7 Center Instrument Panel Speaker .
Page 725 8W-48 REAR WINDOW DEFOGGER 8W - 48 - 1 8W-48 REAR WINDOW DEFOGGER Component Page Component Page Body Control Module ....8W-48-2 Passenger Power Mirror ....8W-48-4 Driver Power Mirror .
Page 729 8W-49 OVERHEAD CONSOLE 8W - 49 - 1 8W-49 OVERHEAD CONSOLE Component Page Component Page Body Control Module ....8W-49-2 G201 ......8W-49-2 Fuse 14 .
Page 731 8W-50 FRONT LIGHTING 8W - 50 - 1 8W-50 FRONT LIGHTING Component Page Component Page Accessory No. 1 ..... 8W-50-16 Headlamp Switch .
Page 747 8W-51 REAR LIGHTING 8W - 51 - 1 8W-51 REAR LIGHTING Component Page Component Page Automatic Day/Night Mirror ..8W-51-4, 5 Left Rear Side Marker Lamp ... 8W-51-8 Body Control Module .
Page 757 8W-52 TURN SIGNALS 8W - 52 - 1 8W-52 TURN SIGNALS Component Page Component Page Combination Flasher ....8W-52-2 Left Front Side Marker Lamp ..8W-52-5 Fuse 9 .
Page 763 8W-53 WIPERS 8W - 53 - 1 8W-53 WIPERS Component Page Component Page Body Control Module ... . . 8W-53-2, 4, 5 G106 ......8W-53-5 Front Washer Pump Motor .
Page 769 8W-60 POWER WINDOWS 8W - 60 - 1 8W-60 POWER WINDOWS Component Page Component Page Circuit Breaker No. 1 ....8W-60-2 Left Rear Power Window Switch ..8W-60-3, 4 Driver Power Window Motor .
Page 773 8W-61 POWER DOOR LOCKS 8W - 61 - 1 8W-61 POWER DOOR LOCKS Component Page Component Page Body Control Module ... 8W-61-2, 3, 4, 5 Fuse 19 ......8W-61-2, 5 Circuit Breaker No.
Page 779 8W-62 POWER MIRRORS 8W - 62 - 1 8W-62 POWER MIRRORS Component Page Component Page Automatic Day/Night Mirror ... 8W-62-7 Junction Block ....8W-62-2, 3, 4, 6, 7 Driver Power Mirror .
Page 787 8W-63 POWER SEAT 8W - 63 - 1 8W-63 POWER SEAT Component Page Component Page Body Control Module ....8W-63-8 Driver Power Seat Switch ... 8W-63-2, 4 Circuit Breaker No.
Page 795 8W-64 POWER SUNROOF 8W - 64 - 1 8W-64 POWER SUNROOF Component Page Component Page Fuse 14 ......8W-64-2 Power Distribution Center .
Page 797 8W-65 SPEED PROPORTIONAL STEERING 8W - 65 - 1 8W-65 SPEED PROPORTIONAL STEERING Component Page Component Page Body Control Module ....8W-65-2 Junction Block ..... . 8W-65-2 Fuse 19 .
Page 799 8W-70 SPLICE INFORMATION 8W - 70 - 1 8W-70 SPLICE INFORMATION Component Page Component Page S100 ....... . 8W-15-4 S218 .
Page 803 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 1 8W-80 CONNECTOR PIN-OUTS Component Page Component Page A/C Compressor Clutch ....8W-80-5 C204 ......8W-80-21 A/C Pressure Transducer .
Page 804 8W - 80 - 2 8W-80 CONNECTOR PIN-OUTS Component Page Component Page C322 ......8W-80-36 Driver Power Seat Recliner Motor Sensor (Memory) .
Page 805 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 3 Component Page Component Page Left Front Park/Turn Signal Lamp Mode Door Actuator ....8W-80-69 (Concorde) ..... . 8W-80-59 Multi-Function Switch .
Page 806 8W - 80 - 4 8W-80 CONNECTOR PIN-OUTS Component Page Component Page Right Back-Up Lamp (Concorde/LTD) . . . 8W-80-84 Right Side Repeater Lamp (Export) ..8W-80-91 Right Back-Up Lamp (Dodge) ..8W-80-85 Right Speed Control Switch .
Page 807 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 5 A/C COMPRESSOR CLUTCH - BLACK 2 WAY CIRCUIT FUNCTION C2 14DB/BK A/C CLUTCH RELAY OUTPUT Z1 14BK GROUND A/C PRESSURE TRANSDUCER - GRAY 4 WAY CIRCUIT FUNCTION K4 20BK/LB SENSOR GROUND K6 20VT/WT 5 VOLT SUPPLY C18 20DB A/C PRESSURE SIGNAL...
Page 808 8W - 80 - 6 8W-80 CONNECTOR PIN-OUTS AMBIENT TEMPERATURE SENSOR - BLACK 2 WAY CIRCUIT FUNCTION K25 20VT/LG AAT SIGNAL K4 20BK/LB SENSOR GROUND ANALOG CLOCK (LTD/300M) - NATURAL 4 WAY CIRCUIT FUNCTION M1 20PK FUSED B(+) Z2 20BK/LG GROUND E2 20OR PANEL LAMPS DRIVER...
Page 809 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 7 AUTOSTICK SWITCH (DODGE/300M) - NATURAL 4 WAY CIRCUIT FUNCTION T44 20YL/LB AUTOSTICK DOWNSHIFT SWITCH SENSE T5 20LG/RD AUTOSTICK UPSHIFT SWITCH SIGNAL Z1 20BK GROUND F11 20RD/WT FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) BLEND DOOR ACTUATOR - BLACK 5 WAY CIRCUIT FUNCTION C33 22DB/RD...
Page 810 8W - 80 - 8 8W-80 CONNECTOR PIN-OUTS BODY CONTROL MODULE C1 - GRAY 14 WAY CIRCUIT FUNCTION P1 20BK/WT DECKLID RELEASE SWITCH OUTPUT C32 22GY/DB RECIRCULATION DOOR DRIVER C33 22DB/RD BLEND AIR DOOR DRIVER D25 20VT/YL PCI BUS (ATC) D25 20VT/YL PCI BUS (RADIO) F13 20DB...
Page 811 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 9 BODY CONTROL MODULE C3 - NATURAL 12 WAY CIRCUIT FUNCTION D25 18VT/YL PCI BUS (PCM) D25 18VT/YL (ABS) PCI BUS (CAB) V55 20TN/RD FRONT WIPER PARK SWITCH SENSE V14 20RD/VT FRONT WIPER ON/OFF RELAY CONTROL Z1 18BK (EXCEPT EXPORT) 12 VOLT V58 20BR/YL (EXPORT)
Page 812 8W - 80 - 10 8W-80 CONNECTOR PIN-OUTS BRAKE LAMP SWITCH - GRAY 6 WAY CIRCUIT FUNCTION K29 20WT/PK BRAKE SWITCH SIGNAL Z2 18BK/LG GROUND V32 20YL/RD S/C SUPPLY V30 20DB/RD SPEED CONTROL BRAKE SWITCH OUTPUT L50 16WT/TN BRAKE LAMP SWITCH OUTPUT F32 16PK/DB FUSED B(+) BRAKE TRANSMISSION SHIFT INTERLOCK SOLENOID - WHITE 2 WAY...
Page 813 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 11 C101 - BLACK (HEADLAMP/DASH SIDE) CIRCUIT F42 16DG/LG K236 18GY/PK (3.5L H.O.) Z12 14BK/TN C2 14DB/BK Z1 14BK T40 12BR G6 20GY Z1 16BK/WT C18 20DB K4 20BK/LB K4 20BK/LB C103 - GREEN (HEADLAMP/DASH SIDE) CIRCUIT V37 20RD/LG V32 20YL/RD...
Page 814 8W - 80 - 12 8W-80 CONNECTOR PIN-OUTS C103 - GREEN (INSTRUMENT PANEL SIDE) CIRCUIT V37 20RD/LG V32 20YL/RD V30 20DB/RD K29 20WT/PK G29 22BK/TN G6 22GY D21 20PK/TN D20 20LG G9 20GY/BK (POLICE PACKAGE/SPE- CIAL SERVICE) K4 20BK/LB L96 18LG/RD (EXPORT) A101 16RD/TN (POLICE PACKAGE) A105 18DB/RD (EXCEPT POLICE PACK- AGE)
Page 815 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 13 C105 - YELLOW (BODY SIDE) CIRCUIT L13 18BR/YL A141 12DG/WT A4 10BK/PK C105 - YELLOW (HEADLAMP/DASH SIDE) CIRCUIT A4 10BK/PK A141 12DG/WT L13 18BR/YL (EXPORT) C106 - NATURAL (BODY SIDE) CIRCUIT B4 18LG B3 18LG/DB B2 18YL B1 18YL/DB...
Page 816 8W - 80 - 14 8W-80 CONNECTOR PIN-OUTS C107 - LT. GRAY (HEADLAMP/DASH SIDE) CIRCUIT K399 18BR/GY L1 20VT/BK F20 20WT T1 20LG/BK T3 20VT T42 20VT/WT T41 20BK/WT T54 20VT/PK T13 20DB/BK K904 18DB/DG K341 20PK/WT K141 20TN/WT T52 20RD/BK T14 20LG/WT C107 - LT.
Page 817 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 15 C108 - LT. GRAY (TRANSMISSION SIDE) CIRCUIT T9 16OR/BK T19 16WT Z1 18BK T60 16BR T59 16PK T50 16DG T47 16YL/BK K199 18BR/VT T20 16LB T16 16RD C109 - BLACK (FRONT FASCIA SIDE) CIRCUIT L60 18TN (300M/EXPORT) L60 20TN (EXCEPT 300M/EXPORT)
Page 818 8W - 80 - 16 8W-80 CONNECTOR PIN-OUTS C111 (EXPORT) - GRAY (HEADLAMP MODULE SIDE) CIRCUIT L43 20VT L7 20BK/YL Z1 20BK L13 20BR/YL L33 20RD C112 (EXPORT) - GRAY (HEADLAMP MODULE SIDE) CIRCUIT L44 16VT/RD L7 20BK/YL Z1 16BK L13 20BR/YL L34 20RD/OR C112 (EXPORT) - GRAY (HEADLIGHT LEVELING...
Page 819 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 17 C115 (EXCEPT 2.7L BASE) - BLACK (RADIATOR MOTOR SIDE) CIRCUIT Z1 12BK Z1 12BK C23 12RD C25 12RD C120 (POLICE PACKAGE/SPECIAL SERVICE) - (HEADLAMP/DASH SIDE) CIRCUIT L99 20GY/BK (EXCEPT SPECIAL SER- VICE/CANADIAN POLICE PACKAGE) G9 20GY/BK (SPECIAL SERVICE/CANA- DIAN POLICE PACKAGE) C120 (POLICE PACKAGE/SPECIAL SERVICE) -...
Page 820 8W - 80 - 18 8W-80 CONNECTOR PIN-OUTS C200 - BLUE (INSTRUMENT PANEL SIDE) CIRCUIT G78 20TN/BK Z2 20BK/LG L13 18BR/YL L95 18DG/YL (EXPORT) F14 18LG/YL (EXCEPT POLICE PACK- AGE) X60 20DG/RD (EXCEPT DODGE) P112 18TN/OR (EXCEPT DODGE) X12 20RD (POLICE PACKAGE) G9 20GY/BK (POLICE PACKAGE) P114 18TN/WT (EXCEPT DODGE) C80 20DB/WT...
Page 821 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 19 C201 - NATURAL (INSTRUMENT PANEL SIDE) CIRCUIT F62 16RD X51 18BR/YL X52 18DB/WT X53 18DG X54 18VT X55 18BR/RD X57 18BR/LB X58 18DB/OR X56 18DB/RD X88 18PK/RD (EXCEPT BASE) X89 18PK/BK (EXCEPT BASE) X60 20DG/RD F62 16RD/WT C202 (MTC) - NATURAL (HVAC SIDE)
Page 822 8W - 80 - 20 8W-80 CONNECTOR PIN-OUTS C203 (ATC) - NATURAL (HVAC SIDE) CIRCUIT C34 20BR/WT C35 22DG/YL C33 22DB/RD C32 20GY/DB C57 20DB/GY C26 22PK/DB C1 12DG C12 20LG/BK C36 22RD/WT C37 22YL/WT Z1 12BK C56 22RD/LG C203 (ATC) - NATURAL (INSTRUMENT PANEL SIDE) CIRCUIT C34 22BR/WT...
Page 823 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 21 C204 - NATURAL (HEADLINER SIDE) CIRCUIT Q41 20WT A130 16VT/RD Z1 16BK G5 20DB/WT Q43 20VT Q42 20LB C204 - NATURAL (SUNROOF SIDE) CIRCUIT Q41 20WT A130 16VT/RD Z1 16BK G5 20DB/WT Q43 20VT Q42 20LB C205 (EXCEPT POLICE PACKAGE) - NATURAL...
Page 824 8W - 80 - 22 8W-80 CONNECTOR PIN-OUTS C206 (EXCEPT POLICE PACKAGE) - NATURAL (HEADLINER SIDE) CIRCUIT P112 18BK/TN P114 18BK/YL C206 (EXCEPT POLICE PACKAGE) - NATURAL (INSTRUMENT PANEL SIDE) CIRCUIT P112 18TN/OR P114 18TN/WT C300 - NATURAL (BODY SIDE) CIRCUIT Q17 14DB/WT X81 18YL/BK...
Page 825 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 23 C300 - NATURAL (LEFT FRONT DOOR SIDE) CIRCUIT Q17 14DB/WT X81 18YL/BK P33 16OR Q26 14VT/WT Q18 14GY/BK X87 18LG/VT X83 18YL/RD P55 16DB Q16 14BR/WT M2 22YL (EXCEPT DODGE) F21 14TN Q27 14RD/BK X85 18LG/BK Q28 14DG/WT...
Page 826 8W - 80 - 24 8W-80 CONNECTOR PIN-OUTS C301 - NATURAL (LEFT FRONT DOOR SIDE) CIRCUIT G5 20DB/WT C16 20LB/YL M1 20PK P72 20YL/BK P70 20WT P74 20DB G73 20LG/OR P97 20WT/DG P64 20YL/OR P65 20DB/YL P69 20WT/RD P71 20YL (MEMORY) P75 20BK/WT (MEMORY) P73 20YL/PK (MEMORY) G75 20TN...
Page 827 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 25 C302 - NATURAL (RIGHT FRONT DOOR SIDE) CIRCUIT X84 18OR/BK P33 16OR Q26 14VT/WT X80 18LB/BK X86 18OR/RD P34 16PK/BK Q16 14BR/WT M2 22YL Q1 14YL Z1 20BK X82 18LB/RD L60 18TN C303 - NATURAL (BODY SIDE) CIRCUIT C16 20LB/YL...
Page 828 8W - 80 - 26 8W-80 CONNECTOR PIN-OUTS C303 - NATURAL (RIGHT FRONT DOOR SIDE) CIRCUIT C16 22LB/YL M1 20PK P72 20YL/BK P70 20WT P74 20DB P96 20WT/LG G74 20TN/RD C304 - NATURAL (BODY SIDE) CIRCUIT Z1 20BK X95 18WT/VT (PREMIUM II) P33 16OR X97 18WT/DG (PREMIUM II) P34 16PK/BK...
Page 829 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 27 C305 - NATURAL (BODY SIDE) CIRCUIT Z1 20BK X98 18TN/VT (PREMIUM II AUDIO) P33 16OR X96 18TN/DG (PREMIUM II AUDIO) P34 16PK/BK Q28 14DG/WT G74 20TN/RD Q1 14YL (EXCEPT POLICE PACKAGE) Q18 14GY/BK C305 - NATURAL (REAR DOOR SIDE) CIRCUIT Z1 20BK...
Page 830 8W - 80 - 28 8W-80 CONNECTOR PIN-OUTS C307 - BLACK (BODY SIDE) CIRCUIT Z1 16BK (HEATED SEATS) F35 16RD C307 - GREEN (POWER SEAT SIDE) CIRCUIT Z1 16BK F35 16RD C308 - BLACK (BODY SIDE) CIRCUIT K106 18WT/DG Z1 12BK G4 20DB K107 20OR/RD A141 12DG/WT...
Page 831 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 29 C309 - YELLOW (SAB OVERLAY SIDE) CIRCUIT R31 20LG/OR R33 20LG/WT C310 - YELLOW (SAB JUMPER SIDE) CIRCUIT R32 20LB/OR R34 20LB/WT C310 - YELLOW (SAB OVERLAY SIDE) CIRCUIT R32 20LB/OR R34 20LB/WT C311 - RED (BODY SIDE) CIRCUIT G78 20TN/BK...
Page 832 8W - 80 - 30 8W-80 CONNECTOR PIN-OUTS C312 (300M/DODGE) - BLACK (BODY SIDE) CIRCUIT L7 18BK/YL Z1 18BK C312 (300M/DODGE) - BLACK (REAR FASCIA SIDE) CIRCUIT L7 18BK/YL Z1 18BK C313 (CONCORDE/DODGE/300M) - GRAY (BODY SIDE) CIRCUIT L50 16WT/TN L60 16TN L7 18BK/YL L1 20VT/BK...
Page 833 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 31 C313 (EXPORT) - GRAY (BODY SIDE) CIRCUIT L50 16WT/TN L60 16TN L95 16DG/YL (EXPORT) L7 18BK/YL L1 20VT/BK (EXPORT) Z1 16BK C313 (EXPORT) - GRAY (TAIL LAMPS SIDE) CIRCUIT L50 18WT/TN L60 18LG/TN L95 18DG/YL (EXPORT) L7 18BK/YL L1 18VT/BK (EXPORT)
Page 834 8W - 80 - 32 8W-80 CONNECTOR PIN-OUTS C314 (EXPORT) - GRAY (BODY SIDE) CIRCUIT L50 16WT/TN L61 16LG L95 16DG/YL (EXPORT) L7 18BK/YL L1 20 VT/BK (EXPORT) Z1 16BK C314 (EXPORT) - GRAY (TAIL LAMPS SIDE) CIRCUIT L50 18WT/TN L61 18LG/TN L95 18DG/YL (EXPORT) L7 18BK/YL...
Page 835 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 33 C316 - BLACK (INSTRUMENT PANEL SIDE) 12 CIRCUIT X160 18YL X112 22RD Z140 18BK/OR X480 22DG/LB X607 22BK X17 22GY/OR D25 22BK X481 22DG/YL X917 22DG/WT X166 22GY/WT C318 (MEMORY) - NATURAL (BODY SIDE) CIRCUIT P130 16RD/TN P142 20TN/DB...
Page 836 8W - 80 - 34 8W-80 CONNECTOR PIN-OUTS C319 (MEMORY) - NATURAL (BODY SIDE) CIRCUIT D25 20VT/YL G5 20DB/WT P70 20WT P72 20YL/BK P74 20DB P142 20TN/DB P130 16RD/TN P144 20BK/LG P134 20TN/LG P140 20VT/BK P138 20VT/LG P71 20YL P75 20BK/WT P73 20YL/PK P64 20YL/OR P65 20DB/YL...
Page 837 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 35 C320 (CONCORDE/LTD) - NATURAL (BODY SIDE) CIRCUIT L50 16WT/TN Z1 16BK C320 (CONCORDE/LTD) - NATURAL (CHMSL SIDE) CIRCUIT L50 18WT/TN Z1 18BK C321 (300M) - BLACK (CHMSL SIDE) CIRCUIT L50 18WT/TN Z1 18BK C321 (300M) - NATURAL (DECKLID SIDE) CIRCUIT L50 18WT/TN...
Page 838 8W - 80 - 36 8W-80 CONNECTOR PIN-OUTS C322 - BLACK (SAB JUMPER SIDE) CIRCUIT F14 20LG/YL Z2 20BK/LG D25 20VT/YL C325 (POLICE PACKAGE) - GREEN (AUXILIARY LIGHTING SIDE) CIRCUIT M1 20PK Z1 20BK C325 (POLICE PACKAGE) - GREEN (BODY SIDE) CIRCUIT M1 20PK Z1 20BK...
Page 839 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 37 CAMSHAFT POSITION SENSOR - BLACK 3 WAY CIRCUIT FUNCTION K6 20VT/WT 5 VOLT SUPPLY K4 20BK/LB SENSOR GROUND K44 20TN/YL CMP SIGNAL CENTER HIGH MOUNTED STOP LAMP (300M) - 2 WAY CIRCUIT FUNCTION Z1 18BK GROUND...
Page 840 8W - 80 - 38 8W-80 CONNECTOR PIN-OUTS CENTER HIGH MOUNTED STOP LAMP NO. 2 (CONCORDE/LTD) - GRAY 2 WAY CIRCUIT FUNCTION L50 18WT/TN BRAKE LAMP SWITCH OUTPUT L50 18WT/TN BRAKE LAMP SWITCH OUTPUT Z1 18BK GROUND Z1 18BK GROUND CENTER HIGH MOUNTED STOP LAMP NO.
Page 841 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 39 CLOCKSPRING C1 - NATURAL 5 WAY CIRCUIT FUNCTION V37 20RD/LG S/C SWITCH SIGNAL K4 20BK/LB SENSOR GROUND X3 16BK/RD HORN RELAY CONTROL X20 20GY/WT RADIO CONTROL MUX X920 20GY/OR RADIO CONTROL MUX RETURN CLOCKSPRING C2 - YELLOW 2 WAY CIRCUIT FUNCTION...
Page 842 8W - 80 - 40 8W-80 CONNECTOR PIN-OUTS COIL ON PLUG NO. 3 - BLACK 2 WAY CIRCUIT FUNCTION F42 16DG/LG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT K93 16TN/OR COIL CONTROL NO. 3 COIL ON PLUG NO. 4 - BLACK 2 WAY CIRCUIT FUNCTION F42 16DG/LG...
Page 843 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 41 COMPACT DISC CHANGER - BLACK 8 WAY CIRCUIT FUNCTION X40 22GY/WT AUDIO OUT RIGHT E14 22OR/TN PANEL LAMPS DIMMER SIGNAL D25 22VT/YL PCI BUS (CD CHANGER) X112 22RD FUSED IGNITION SWITCH OUTPUT (RUN-ACC) X41 22DG/WT AUDIO OUT LEFT Z140 22BK/OR (EXCEPT SATELLITE...
Page 844 8W - 80 - 42 8W-80 CONNECTOR PIN-OUTS CRANKSHAFT POSITION SENSOR - BLACK 3 WAY CIRCUIT FUNCTION K6 20VT/WT 5 VOLT SUPPLY K4 20BK/LB SENSOR GROUND K24 20GY/BK CKP SIGNAL DATA LINK CONNECTOR - BLACK 16 WAY CIRCUIT FUNCTION D25 20VT/YL PCI BUS (DLC) Z1 20BK GROUND...
Page 845 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 43 DRIVER AIRBAG SQUIB - YELLOW 2 WAY CIRCUIT FUNCTION DRIVER SQUIB 1 LINE 2 DRIVER SQUIB 1 LINE 1 DRIVER CYLINDER LOCK SWITCH - GRAY 2 WAY CIRCUIT FUNCTION G73 20LG/OR DRIVER CYLINDER LOCK SWITCH MUX M1 20PK FUSED B(+) DRIVER DOOR LOCK MOTOR/AJAR SWITCH - BLACK 4 WAY...
Page 846 8W - 80 - 44 8W-80 CONNECTOR PIN-OUTS DRIVER HEATED SEAT CUSHION - BLACK 4 WAY CIRCUIT FUNCTION P131 16RD/TN (EXCEPT MEMORY) DRIVER SEAT HEATER B(+) DRIVER P131 16RD/DG (MEMORY) DRIVER SEAT HEATER B(+) DRIVER P88 16BR/BK HEATED SEAT DRIVER P141 20TN/LB DRIVER SEAT TEMPERATURE SENSOR INPUT P143 20BK/LG (EXCEPT MEMORY)
Page 847 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 45 DRIVER POWER SEAT FRONT RISER MOTOR - RED 2 WAY CIRCUIT FUNCTION P19 16YL/LG (EXCEPT MEMORY DRIVER SEAT FRONT UP SEATS) P119 16YL/LG (MEMORY SEATS) SEAT FRONT UP DRIVER P21 16RD/LG (EXCEPT MEMORY DRIVER SEAT FRONT DOWN SEATS) P121 16RD/LG (MEMORY SEATS)
Page 848 8W - 80 - 46 8W-80 CONNECTOR PIN-OUTS DRIVER POWER SEAT REAR RISER MOTOR SENSOR (MEMORY) - NATURAL 3 WAY CIRCUIT FUNCTION P29 20BR/WT SEAT SENSOR 5 VOLT SUPPLY P27 20LB/RD REAR RISER POSITION SIGNAL P28 20BR/RD SEAT POSITION SENSOR GROUND DRIVER POWER SEAT RECLINER MOTOR - GREEN 2 WAY CIRCUIT FUNCTION...
Page 849 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 47 DRIVER POWER WINDOW MOTOR - RED 2 WAY CIRCUIT FUNCTION Q21 16WT DRIVER WINDOW DRIVER (DOWN) Q11 16LB DRIVER WINDOW DOWN (UP) DRIVER POWER WINDOW SWITCH - BLUE 12 WAY CIRCUIT FUNCTION F21 14TN FUSED IGNITION SWITCH OUTPUT (RUN) Q17 14DB/WT...
Page 850 8W - 80 - 48 8W-80 CONNECTOR PIN-OUTS EVAP/PURGE SOLENOID - BLACK 2 WAY CIRCUIT FUNCTION K52 18PK/BK EVAP PURGE CONTROL K108 18DG/LG EVAP PURGE RETURN EVAPORATOR TEMPERATURE SENSOR - BLACK 2 WAY CIRCUIT FUNCTION C12 20LG/BK EVAPORATOR TEMPERATURE SENSOR SIGNAL C57 20DB/GY SENSOR GROUND FRONT WASHER PUMP MOTOR - BLACK 2 WAY...
Page 851 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 49 FUEL INJECTOR NO. 1 - BLACK 2 WAY CIRCUIT FUNCTION K11 18WT/DB INJECTOR CONTROL NO. 1 F42 18DG/LG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT FUEL INJECTOR NO. 2 - BLACK 2 WAY CIRCUIT FUNCTION K12 18TN/WT...
Page 852 8W - 80 - 50 8W-80 CONNECTOR PIN-OUTS FUEL INJECTOR NO. 6 - BLACK 2 WAY CIRCUIT FUNCTION K58 18BR/DB INJECTOR CONTROL NO. 6 F42 18DG/LG FUSED AUTOMATIC SHUT DOWN RELAY OUTPUT FUEL PUMP MODULE - GRAY 4 WAY CIRCUIT FUNCTION Z1 12BK GROUND...
Page 853 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 51 HEADLAMP FLASHER CAP (POLICE PACKAGE) - BLACK 6 WAY CIRCUIT FUNCTION L33 20RD FUSED LEFT HIGH BEAM OUTPUT L34 20OR FUSED RIGHT HIGH BEAM OUTPUT L33 20RD FUSED LEFT HIGH BEAM OUTPUT L34 20OR FUSED RIGHT HIGH BEAM OUTPUT HEADLAMP SWITCH - BLUE 13 WAY...
Page 854 8W - 80 - 52 8W-80 CONNECTOR PIN-OUTS IDLE AIR CONTROL MOTOR - BLACK 2 WAY CIRCUIT FUNCTION K39 18GY/RD IAC MOTOR CONTROL K60 18YL/BK IAC RETURN IGNITION SWITCH - BLACK 10 WAY CIRCUIT FUNCTION A81 14DG/RD IGNITION SWITCH OUTPUT (OFF-RUN-START) G26 22LB KEY-IN IGNITION SWITCH SENSE Z2 20BK/LG...
Page 855 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 53 INSTRUMENT CLUSTER C2 - BLUE 10 WAY CIRCUIT FUNCTION G5 18DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) G9 22GY/BK BRAKE WARNING INDICATOR DRIVER G29 22BK/TN WASHER FLUID LEVEL SWITCH SENSE L61 22LG LEFT TURN SIGNAL Z1 22BK GROUND B27 20RD/YL...
Page 856 8W - 80 - 54 8W-80 CONNECTOR PIN-OUTS JUNCTION BLOCK C1 - BLACK 6 WAY CIRCUIT FUNCTION F32 16PK/DB FUSED B(+) A21 12DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) A31 12BK/WT FUSED IGNITION SWITCH OUTPUT (RUN-ACC) F30 18RD FUSED B(+) C1 12DG BLOWER MOTOR FEED JUNCTION BLOCK C2 - GRAY 16 WAY CIRCUIT...
Page 857 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 55 JUNCTION BLOCK C4 - GREEN 12 WAY CIRCUIT FUNCTION L7 18BK/YL (EXPORT) HEADLAMP SWITCH OUTPUT M1 20PK (EXCEPT POLICE PACKAGE) FUSED B(+) F33 18PK/RD FUSED B(+) F33 18PK/RD FUSED B(+) L324 18WT/LG SWITCHED HIGH BEAM RELAY CONTROL F62 16RD FUSED B(+)
Page 858 8W - 80 - 56 8W-80 CONNECTOR PIN-OUTS JUNCTION BLOCK C7 - NATURAL 12 WAY CIRCUIT FUNCTION G9 20GY/BK BRAKE WARNING INDICATOR DRIVER P2 20BK/WT DECKLID RELEASE CONTROL F35 16RD FUSED B(+) F35 16RD FUSED B(+) M1 20PK FUSED B(+) M1 20PK FUSED B(+) G5 20DB/WT...
Page 859 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 57 JUNCTION BLOCK C10 - GRAY 13 WAY CIRCUIT FUNCTION L60 18TN RIGHT TURN SIGNAL L61 18LG LEFT TURN SIGNAL G9 20GY/BK BRAKE WARNING INDICATOR DRIVER L34 20RD/OR FUSED RIGHT HIGH BEAM OUTPUT L1 20VT/BK BACK-UP LAMP FEED F18 20LG/BK...
Page 860 8W - 80 - 58 8W-80 CONNECTOR PIN-OUTS LEFT BACK-UP LAMP (CONCORDE/LTD) - NATURAL 2 WAY CIRCUIT FUNCTION L1 18VT/BK BACK-UP LAMP FEED Z1 18BK GROUND LEFT BACK-UP LAMP (DODGE) - GRAY 2 WAY CIRCUIT FUNCTION Z1 18BK GROUND L1 18VT/BK BACK-UP LAMP FEED LEFT FOG LAMP (CONCORDE/LTD) - BLACK 2 WAY CIRCUIT...
Page 861 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 59 LEFT FRONT DOOR SPEAKER - BLACK 3 WAY CIRCUIT FUNCTION X87 18LG/VT AMPLIFIED LEFT DOOR SPEAKER (+) X85 18LG/BK AMPLIFIED LEFT DOOR SPEAKER (-) LEFT FRONT PARK/TURN SIGNAL LAMP (CONCORDE) - BLACK 3 WAY CIRCUIT FUNCTION L61 18LG...
Page 862 8W - 80 - 60 8W-80 CONNECTOR PIN-OUTS LEFT FRONT WHEEL SPEED SENSOR - BLACK 2 WAY CIRCUIT FUNCTION B9 18RD LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUP- B9 18RD/DB LEFT FRONT WHEEL SPEED SENSOR SIGNAL LEFT HEADLAMP LEVELING MOTOR (EXPORT) - BLACK 3 WAY CIRCUIT FUNCTION L7 20BK/YL...
Page 863 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 61 LEFT LOW BEAM HEADLAMP (EXCEPT EXPORT) - GRAY 2 WAY CIRCUIT FUNCTION L43 16VT FUSED LEFT LOW BEAM OUTPUT Z1 16BK GROUND LEFT REAR DOOR LOCK MOTOR/AJAR SWITCH - BLACK 4 WAY CIRCUIT FUNCTION G74 20TN/RD...
Page 864 8W - 80 - 62 8W-80 CONNECTOR PIN-OUTS LEFT REAR POWER WINDOW MOTOR - RED 2 WAY CIRCUIT FUNCTION Q23 16DG LEFT REAR POWER WINDOW DRIVER DOWN Q13 16GY WINDOW LEFT REAR B(+) UP LEFT REAR POWER WINDOW SWITCH - BLUE 6 WAY CIRCUIT FUNCTION Q23 16DG...
Page 865 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 63 LEFT REAR SIDE MARKER LAMP (DODGE) - NATURAL 2 WAY CIRCUIT FUNCTION Z1 18BK GROUND L7 18BK/YL PARK LAMP RELAY OUTPUT LEFT REAR TURN SIGNAL LAMP (300M/EXPORT) - 3 WAY CIRCUIT FUNCTION L61 18LG/TN LEFT TURN SIGNAL Z1 18BK...
Page 866 8W - 80 - 64 8W-80 CONNECTOR PIN-OUTS LEFT REMOTE RADIO SWITCH - BLACK 2 WAY CIRCUIT FUNCTION X20 22GY/WT RADIO CONTROL MUX X920 22GY/OR RADIO CONTROL MUX RETURN LEFT SEAT AIRBAG SQUIB - YELLOW 2 WAY CIRCUIT FUNCTION R31 20LG/OR LEFT SEAT SQUIB 1 LINE 1 R33 20LG/WT LEFT SEAT SQUIB 1 LINE 2...
Page 867 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 65 LEFT TAIL LAMP (300M/EXPORT) - NATURAL 3 WAY CIRCUIT FUNCTION Z1 18BK GROUND L7 18BK/YL PARK LAMP RELAY OUTPUT LEFT TAIL LAMP (CONCORDE) - WHITE 2 WAY CIRCUIT FUNCTION Z1 18BK GROUND L7 18BK/YL PARK LAMP RELAY OUTPUT LEFT TAIL/STOP LAMP (CONCORDE) - BLACK 3 WAY...
Page 868 8W - 80 - 66 8W-80 CONNECTOR PIN-OUTS LEFT TAIL/STOP LAMP NO. 2 (300M) - NATURAL 3 WAY CIRCUIT FUNCTION Z1 18BK GROUND L7 18BK/YL PARK LAMP RELAY OUTPUT L50 18WT/TN BRAKE LAMP SWITCH OUTPUT LEFT TAIL/STOP LAMP NO. 2 (DODGE) - BLACK 3 WAY CIRCUIT FUNCTION L50 18WT/TN...
Page 869 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 67 MANIFOLD TUNING VALVE (3.5L HIGH OUTPUT) - BLACK 2 WAY CIRCUIT FUNCTION Z12 18BK/TN GROUND K36 18VT/RD MTV CONTROL MANUAL TEMPERATURE CONTROL HEAD C1 - NATURAL 12 WAY CIRCUIT FUNCTION C48 20VT/PK A/C LED INDICATOR SIGNAL C80 20DB/WT REAR WINDOW DEFOGGER RELAY CONTROL...
Page 870 8W - 80 - 68 8W-80 CONNECTOR PIN-OUTS MEMORY HEATED SEAT/MIRROR MODULE C1 - 26 WAY CIRCUIT FUNCTION P69 20WT/RD DRIVER MIRROR SENSOR GROUND P25 20VT/RD SEAT HORIZONTAL POSITION SIGNAL P27 20LB/RD REAR RISER POSITION SIGNAL P141 20TN/LB DRIVER SEAT TEMPERATURE SENSOR INPUT P134 20TN/LG PASSENGER SEAT HEATER MUX SWITCH P64 20YL/OR...
Page 871 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 69 MEMORY HEATED SEAT/MIRROR MODULE C3 - WHITE 12 WAY CIRCUIT FUNCTION P111 16YL/WT SEAT REAR UP DRIVER P115 16YL/DB SEAT HORIZONTAL FORWARD DRIVER P119 16YL/LG SEAT FRONT UP DRIVER P113 16RD/WT SEAT REAR DOWN DRIVER P121 16RD/LG SEAT FRONT DOWN DRIVER P130 16RD/TN...
Page 872 8W - 80 - 70 8W-80 CONNECTOR PIN-OUTS MULTI-FUNCTION SWITCH - BLACK 7 WAY CIRCUIT FUNCTION F13 20DB FUSED IGNITION SWITCH OUTPUT (RUN-ACC) V10 20BR FRONT WASHER PUMP MOTOR CONTROL V52 20DG/RD FRONT WIPER MUX SWITCH SIGNAL L40 18BR/WT FUSED LOW BEAM RELAY OUTPUT F33 18PK/RD FUSED B(+) L324 18WT/LG...
Page 873 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 71 OVERHEAD TRAVEL INFORMATION SYSTEM (PREMIUM) - BLACK 6 WAY CIRCUIT FUNCTION G5 20BK/DB FUSED IGNITION SWITCH OUTPUT (RUN-START) Z2 20BK/LG GROUND M1 20PK FUSED B(+) D25 20VT/YL PCI BUS (OTIS) OXYGEN SENSOR 1/1 RIGHT BANK UP - GRAY 4 WAY CIRCUIT FUNCTION Z1 18BK...
Page 874 8W - 80 - 72 8W-80 CONNECTOR PIN-OUTS OXYGEN SENSOR 2/2 LEFT BANK DOWN - BLACK 4 WAY CIRCUIT FUNCTION Z1 18BK GROUND K399 18BR/GY O2 2/2 HEATER CONTROL K904 18DB/DG O2 RETURN (DOWN) K341 20PK/WT O2 2/2 SIGNAL PASSENGER AIRBAG SQUIB - YELLOW 2 WAY CIRCUIT FUNCTION R42 18BK/YL...
Page 875 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 73 PASSENGER HEATED SEAT CUSHION - BLACK 4 WAY CIRCUIT FUNCTION P130 16RD/TN PASSENGER SEAT HEATER B(+) DRIVER P88 16BR/BK HEATED SEAT DRIVER P142 20TN/DB PASSENGER SEAT TEMPERATURE SENSOR INPUT P144 20BK/LG PASSENGER SEAT TEMPERATURE 5VOLT SUPPLY PASSENGER HEATED SEAT SWITCH - 6 WAY CIRCUIT FUNCTION...
Page 876 8W - 80 - 74 8W-80 CONNECTOR PIN-OUTS PASSENGER POWER SEAT FRONT RISER MOTOR - RED 2 WAY CIRCUIT FUNCTION P18 16YL/LG PASSENGER SEAT FRONT UP P20 16RD/LG PASSENGER SEAT FRONT DOWN PASSENGER POWER SEAT HORIZONTAL MOTOR - BLACK 2 WAY CIRCUIT FUNCTION P14 16YL/LB...
Page 877 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 75 PASSENGER POWER WINDOW MOTOR - RED 2 WAY CIRCUIT FUNCTION Q22 16VT PASSENGER WINDOW DRIVER (DOWN) Q12 16BR PASSENGER WINDOW DRIVER (UP) PASSENGER POWER WINDOW SWITCH - BLUE 6 WAY CIRCUIT FUNCTION Q22 16VT PASSENGER WINDOW DRIVER (DOWN) Q16 14BR/WT...
Page 878 8W - 80 - 76 8W-80 CONNECTOR PIN-OUTS POWER AMPLIFIER C2 - WHITE 22 WAY CIRCUIT FUNCTION F62 16RD/WT FUSED B(+) Z2 16BK/LG GROUND X60 20DG/RD RADIO 12 VOLT OUTPUT X54 18VT RIGHT FRONT SPEAKER (+) X53 18DG LEFT FRONT SPEAKER (+) X52 18DB/WT RIGHT REAR SPEAKER (+) X51 18BR/YL...
Page 879 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 77 POWER OUTLET (LTD/300M) - BLACK 3 WAY CIRCUIT FUNCTION A105 18DB/RD FUSED B(+) Z1 18BK GROUND POWERTRAIN CONTROL MODULE C1 - BLACK 38 WAY CIRCUIT FUNCTION Z12 18BK/TN GROUND F12 20DB/WT FUSED IGNITION SWITCH OUTPUT (RUN-START) F11 20RD/WT FUSED IGNITION SWITCH OUTPUT (OFF-RUN-START) K236 18GY/PK (3.5L HIGH OUTPUT)
Page 880 8W - 80 - 78 8W-80 CONNECTOR PIN-OUTS POWERTRAIN CONTROL MODULE C2 - 38 WAY CIRCUIT FUNCTION K96 16TN/LB COIL CONTROL NO. 6 K95 16TN/DG COIL CONTROL NO. 5 K94 16TN/LG COIL CONTROL NO. 4 K58 18BR/DB INJECTOR CONTROL NO. 6 K38 18GY INJECTOR CONTROL NO.
Page 881 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 79 POWERTRAIN CONTROL MODULE C3 - WHITE 38 WAY CIRCUIT FUNCTION K51 20DB/YL AUTOMATIC SHUT DOWN RELAY CONTROL C27 20DB/PK HIGH SPEED RAD FAN RELAY CONTROL V35 20LG/RD S/C VENT CONTROL C24 20DB/PK LOW RAD FAN RELAY CONTROL V32 20YL/RD S/C SUPPLY...
Page 882 8W - 80 - 80 8W-80 CONNECTOR PIN-OUTS POWERTRAIN CONTROL MODULE C4 - GREEN 38 WAY CIRCUIT FUNCTION T60 16BR OVERDRIVE SOLENOID CONTROL T59 16PK UNDERDRIVE SOLENOID CONTROL T19 16WT 2-4 SOLENOID CONTROL T20 16LB LOW/REVERSE SOLENOID CONTROL Z14 16BK/YL GROUND Z13 16BK/RD GROUND...
Page 883 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 81 RADIATOR FAN - BLACK 4 WAY CIRCUIT FUNCTION Z1 12BK GROUND Z1 12BK GROUND C23 12DG LOW SPEED RAD FAN RELAY OUTPUT C25 12YL HIGH SPEED RAD FAN RELAY OUTPUT RADIATOR FAN MOTOR NO. 1 (EXCEPT 2.7L BASE) - 2 WAY CIRCUIT FUNCTION Z1 12BK...
Page 884 8W - 80 - 82 8W-80 CONNECTOR PIN-OUTS RADIATOR FAN RELAY NO. 2 (AT FAN) (EXCEPT 2.7L BASE) CIRCUIT FUNCTION 12BK GROUND C25 12RD HIGH SPEED RADIATOR FAN RELAY OUTPUT C25 12RD HIGH SPEED RADIATOR FAN RELAY OUTPUT Z1 12BK RADIATOR FAN MOTOR NO.
Page 885 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 83 RADIO C2 (CD CHANGER) - 10 WAY CIRCUIT FUNCTION X40 22GY/WT AUDIO OUT RIGHT Z140 22BK/OR GROUND C235 WT/LB RADIO-COMPACT DISC SHIELD D25 22VT/YL PCI BUS (CD CHANGER) X112 22RD FUSED IGNITION SWITCH OUTPUT (RUN-ACC) X41 22DG/WT AUDIO OUT LEFT Z141 22BK/TN...
Page 886 8W - 80 - 84 8W-80 CONNECTOR PIN-OUTS REAR WINDOW DEFOGGER/ANTENNA MODULE - BLACK 3 WAY CIRCUIT FUNCTION X60 20DG/RD RADIO 12 VOLT OUTPUT C15 10BK/WT REAR WINDOW DEFOGGER RELAY OUTPUT RECIRCULATION DOOR ACTUATOR - NATURAL 5 WAY CIRCUIT FUNCTION C32 20GY/DB RECIRCULATION DOOR DRIVER C34 20BR/WT...
Page 887 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 85 RIGHT BACK-UP LAMP (DODGE) - GRAY 2 WAY CIRCUIT FUNCTION Z1 18BK GROUND L1 18VT/BK BACK-UP LAMP FEED RIGHT FOG LAMP (CONCORDE/LTD) - BLACK 2 WAY CIRCUIT FUNCTION L39 20LB FOG LAMP RELAY OUTPUT Z1 20BK GROUND RIGHT FOG LAMP (DODGE/300M/EXPORT) - GRAY 2 WAY...
Page 888 8W - 80 - 86 8W-80 CONNECTOR PIN-OUTS RIGHT FRONT PARK/TURN SIGNAL LAMP (DODGE) - BLACK 3 WAY CIRCUIT FUNCTION Z1 18BK GROUND L7 18BK/YL PARK LAMP RELAY OUTPUT L60 18TN RIGHT TURN SIGNAL RIGHT FRONT PARK/TURN SIGNAL LAMP (EXCEPT DODGE/300M) - BLACK 3 WAY CIRCUIT FUNCTION L60 18TN...
Page 889 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 87 RIGHT HEADLAMP LEVELING MOTOR (EXPORT) - BLACK 3 WAY CIRCUIT FUNCTION L7 20BK/YL PARK LAMP RELAY OUTPUT L13 20BR/YL HEADLAMP ADJUST SIGNAL Z1 20BK GROUND RIGHT HIGH BEAM HEADLAMP (EXCEPT EXPORT) - BLACK 2 WAY CIRCUIT FUNCTION L34 20RD/OR (EXCEPT POLICE PACK-...
Page 890 8W - 80 - 88 8W-80 CONNECTOR PIN-OUTS RIGHT REAR DOOR LOCK MOTOR/AJAR SWITCH - BLACK 4 WAY CIRCUIT FUNCTION G74 20TN/RD DOOR AJAR SWITCH SENSE Z1 20BK GROUND P34 16PK/BK UNLOCK RELAY OUTPUT P33 16OR LOCK RELAY OUTPUT RIGHT REAR DOOR SPEAKER (PREMIUM) - BLACK 2 WAY CIRCUIT FUNCTION X96 18TN/DG...
Page 891 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 89 RIGHT REAR POWER WINDOW SWITCH - BLUE 6 WAY CIRCUIT FUNCTION Q24 16DG WINDOW RIGHT REAR B (+) DOWN Q18 14GY/BK RIGHT REAR WINDOW DRIVER (UP) Q28 14DG/WT RIGHT REAR WINDOW DRIVER DOWN Q14 16GY WINDOW RIGHT REAR B(+) UP Q1 14YL...
Page 892 8W - 80 - 90 8W-80 CONNECTOR PIN-OUTS RIGHT REAR SIDE MARKER LAMP (DODGE) - NATURAL 2 WAY CIRCUIT FUNCTION Z1 18BK GROUND L7 18BK/YL PARK LAMP RELAY OUTPUT RIGHT REAR TURN SIGNAL LAMP (300M/EXPORT) - 3 WAY CIRCUIT FUNCTION L60 18LG/TN RIGHT TURN SIGNAL Z1 18BK...
Page 893 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 91 RIGHT REMOTE RADIO SWITCH - BLACK 2 WAY CIRCUIT FUNCTION X20 22GY/WT RADIO CONTROL MUX X920 22GY/OR RADIO CONTROL MUX RETURN RIGHT SEAT AIRBAG SQUIB - YELLOW 2 WAY CIRCUIT FUNCTION R32 20LB/OR RIGHT SEAT SQUIB 1 LINE 1 R34 20LB/WT RIGHT SEAT SQUIB 1 LINE 2...
Page 894 8W - 80 - 92 8W-80 CONNECTOR PIN-OUTS RIGHT TAIL LAMP (300M/EXPORT) - NATURAL 3 WAY CIRCUIT FUNCTION Z1 18BK GROUND L7 18BK/YL PARK LAMP RELAY OUTPUT RIGHT TAIL LAMP (CONCORDE) - WHITE 2 WAY CIRCUIT FUNCTION Z1 18BK GROUND L7 18BK/YL PARK LAMP RELAY OUTPUT RIGHT TAIL/STOP LAMP (CONCORDE) - BLACK 3 WAY...
Page 895 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 93 RIGHT TAIL/STOP LAMP NO. 1 (DODGE) - BLACK 3 WAY CIRCUIT FUNCTION Z1 18BK GROUND L7 18BK/YL PARK LAMP RELAY OUTPUT L50 18WT/TN BRAKE LAMP SWITCH OUTPUT RIGHT TAIL/STOP LAMP NO. 2 (300M) - GREEN 3 WAY CIRCUIT FUNCTION L50 18WT/TN...
Page 896 8W - 80 - 94 8W-80 CONNECTOR PIN-OUTS SATELLITE RADIO MULTIPLEXER C1 - BLACK 22 WAY CIRCUIT FUNCTION X417 22GY/OR AUDIO MUX LEFT X416 22GY/WT AUDIO MUX RIGHT X916 22DG/WT AUDIO RETURN D25 22VT/YL PCI BUS (MULTIPLEXER) X112 22RD FUSED IGNITION SWITCH OUTPUT (RUN-ACC) X112 22RD FUSED IGNITION SWITCH OUTPUT (RUN-ACC) X166 22GY/WT...
Page 897 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 95 SATELLITE RECEIVER MODULE C1 - BLACK 12 WAY CIRCUIT FUNCTION X160 18YL FUSED B(+) X112 22RD FUSED IGNITION SWITCH OUTPUT (RUN-ACC) Z140 18BK/OR GROUND X480 22DG/LB AUDIO MUX ENABLE X17 22GY/OR AUDIO SIGNAL LEFT (+) D25 22BK PCI BUS (SATELLITE RECEIVER) X481 22DG/YL...
Page 898 8W - 80 - 96 8W-80 CONNECTOR PIN-OUTS SPEED CONTROL SERVO - BLACK 4 WAY CIRCUIT FUNCTION V36 18TN/RD S/C VACUUM CONTROL V35 20LG/RD S/C VENT CONTROL V30 20DB/RD SPEED CONTROL BRAKE SWITCH OUTPUT Z1 20BK GROUND SPEED PROPORTIONAL STEERING SOLENOID - LT. GRAY 2 WAY CIRCUIT FUNCTION S76 18LG/PK...
Page 899 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 97 SUN SENSOR/VTSS LED - BLACK 4 WAY CIRCUIT FUNCTION M1 20PK FUSED B(+) G69 22BK/OR VTSS INDICATOR DRIVER C57 20DB/GY SENSOR GROUND C38 20DB SUN SENSOR SIGNAL SUNROOF CONTROL MODULE - WHITE 10 WAY CIRCUIT FUNCTION Q6 16DB...
Page 900 8W - 80 - 98 8W-80 CONNECTOR PIN-OUTS SUNROOF SWITCH - NATURAL 4 WAY CIRCUIT FUNCTION Q41 20WT SUNROOF OPEN Q42 20LB SUNROOF CLOSE Z1 20BK GROUND Q43 20VT SUNROOF VENT THROTTLE POSITION SENSOR (2.7L) - BLACK 3 WAY CIRCUIT FUNCTION K6 20VT/WT 5 VOLT SUPPLY...
Page 901 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 99 TRANSMISSION RANGE SENSOR - LT. GREEN 10 WAY CIRCUIT FUNCTION F20 20WT FUSED IGNITION SWITCH OUTPUT (RUN) T13 20DB/BK SPEED SENSOR GROUND T54 20VT/PK TRANSMISSION TEMPERATURE SENSOR SIGNAL L1 20VT/BK BACK-UP LAMP FEED T1 20LG/BK TRS T1 SENSE T3 20VT...
Page 902 8W - 80 - 100 8W-80 CONNECTOR PIN-OUTS TURN SIGNAL/HAZARD SWITCH - BLACK 8 WAY CIRCUIT FUNCTION Z1 20BK GROUND L91 22DB/PK COMBINATION FLASHER SWITCHED GROUND L61 22LG LEFT TURN SIGNAL L32 18RD COMBINATION FLASHER OUTPUT L60 22TN RIGHT TURN SIGNAL UNDERHOOD LAMP (POLICE PACKAGE) - BLACK 2 WAY CIRCUIT FUNCTION...
Page 903 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 1 8W-91 CONNECTOR/GROUND/SPLICE LOCATION TABLE OF CONTENTS page CONNECTOR/GROUND/SPLICE LOCATION DESCRIPTION ......1 Use the wiring diagrams in each section for connec- CONNECTOR/GROUND/SPLICE tor, ground, and splice identification.
Page 904 8W - 91 - 2 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. Body Control Module C3 Left Side of Instrument Panel Body Control Module C4 Left Side of Instrument Panel Brake Fluid Level Switch At Master Cylinder Brake Lamp Switch Top of Brake Pedal Brake Transmission Shift...
Page 905 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 3 CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. C317 Right B Pillar 21, 24 C318 Under Passenger Seat C319 Under Drivers Seat C320 Left Side Shelf Panel 28, 30 C321 (300M) Deck Lid C322 Left B Pillar C325...
Page 906 8W - 91 - 4 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. Driver Door Lock Motor/Ajar Left Front Door Switch Driver Door Unlock Relay — In Junction Block Driver Heated Seat Back At Driver Seat Driver Heated Seat Cushion At Driver Seat Driver Heated Seat Switch At Driver Seat...
Page 907 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 5 CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. Fusible Link — Near Battery 8, 9 Generator Rear of Generator 8, 9 Generator Output — Rear of Generator Glove Box Lamp At Lamp Headlamp Flasher (Police Behind Park Brake Lever Package)
Page 908 8W - 91 - 6 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. Left Front Door Sail Speaker At Left Front Door, see Right Front Door Figure Left Front Door Speaker Left Front Door, see Right Front Door Panel Figure Left Front Park/Turn Signal Lamp At Lamp...
Page 909 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 7 CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. Left Side Repeater Lamp Left Fender Side Shield, See Right side figure Left Speed Control Switch Steering Wheel Left Tail Lamp (300M Export) At Lamp Left Tail Lamp (Concorde) At Lamp Left Tail / Stop Lamp (Concorde)
Page 910 8W - 91 - 8 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. Overhead Travel Information Headliner System Oxygen Sensor 1/1 Right Bank Right Exhaust manifold 8, 9 Oxygen Sensor 1/2 Right Bank Right Exhaust - Post Convertor Down Oxygen Sensor 2/1 Left Bank Up Left Exhaust Manifold...
Page 911 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 9 CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. Radiator Fan Motor No.1 (Except Rear of Fan Motor Base 2.7L) Radiator Fan Motor No.2 (Except Rear of Fan Motor Base 2.7L) Radiator Fan Relay No.1 (Except —...
Page 912 8W - 91 - 10 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. Right High Beam Headlamp At Lamp Right Horn At Horn Right License Lamp (Export) At Lamp Right Low Beam Headlamp At Lamp Right Rear Door Lock Motor/Ajar At Door Switch Right Rear Door Speaker...
Page 913 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 11 CONNECTOR/GROUND/SPLICE LOCATION (Continued) CONNECTOR NAME/NUMBER COLOR LOCATION FIG. Satellite Radio Antenna C2 LTBL Above Headliner 8 forward of Backlite Satellite Radio Multiplexer C1 At Back of Multiplexer Satellite Radio Multiplexer C2 At Back of Multiplexer Satellite Radio Receiver C1 AT Receiver 17, 19...
Page 914 8W - 91 - 12 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) GROUNDS CONNECTOR NAME/NUMBER LOCATION FIG. G100 Rear of Block Right Side 8, 9 G101 Rear of Block Left Side 8, 9 G102 Near Left Headlamp, Behind the PDC G103 Near Left Headlamp, In Front of the PDC G104 Left Headlamp...
Page 915 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 13 CONNECTOR/GROUND/SPLICE LOCATION (Continued) SPLICE LOCATION FIG. NUMBER S124 Headlamp and Dash in Power Distribution Center S125 Headlamp and Dash in Power Distribution Center S128 Headlamp and Dash in Power Distribution Center S130 Front Lighting Near T/O for Left Front Lamps S131 Front Lighting Near T/O for Left Front Lamps...
Page 916 8W - 91 - 14 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) SPLICE LOCATION FIG. NUMBER S209 Instrument Panel Right Side in T/O to C201 S210 A/C Heater Harness Near T/O to Blend Door Actuator S211 A/C Heater Harness Near T/O to Blend Door Actuator S212 A/C Heater Harness Near T/O to Blend Door Actuator S214...
Page 917 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 15 CONNECTOR/GROUND/SPLICE LOCATION (Continued) SPLICE LOCATION FIG. NUMBER S326 Headliner Harness Near T/O to Right Rear Door Courtesy Lamp S327 Headliner Harness Near T/O to Right Rear Door Courtesy Lamp S328 Power Seat Harness at Seat S331 Body Harness, Left Side Body S334...
Page 918 8W - 91 - 16 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 1 RIGHT FRONT BATTERY COMPARTMENT...
Page 919 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 17 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 920 8W - 91 - 18 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 3 RIGHT FRONT LAMPS Fig. 4 RIGHT FRONT WHEEL SPEED SENSOR...
Page 921 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 19 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 5 RIGHT REPEATER LAMP...
Page 922 8W - 91 - 20 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 923 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 21 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 924 8W - 91 - 22 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 925 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 23 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 926 8W - 91 - 24 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 927 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 25 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 928 8W - 91 - 26 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 929 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 27 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 13 HVAC CONNECTIONS Fig. 14 LEFT INSTRUMENT PANEL END CAP...
Page 930 8W - 91 - 28 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 931 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 29 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 16 ACCESSORY EQUIPMENT CONNECTOR Fig. 17 SATELLITE RADIO CONNECTORS...
Page 932 8W - 91 - 30 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 18 SATELLITE RADIO MUX...
Page 933 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 31 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 934 8W - 91 - 32 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 20 HEADLAMP FLASHER - POLICE...
Page 935 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 33 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 936 8W - 91 - 34 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 22 LEFT SIDE BODY REAR...
Page 937 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 35 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 938 8W - 91 - 36 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 939 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 37 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 25 RIGHT FRONT DOOR Fig. 26 RIGHT FRONT DOOR PANEL...
Page 940 8W - 91 - 38 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 27 RIGHT REAR DOOR PANEL Fig. 28 SHELF PANEL...
Page 941 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 39 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 29 AUXILIARY LIGHT CONNECTOR Fig. 30 DECK LID...
Page 942 8W - 91 - 40 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 31 LICENSE LAMP Fig. 32 CENTER HIGH MOUNTED STOP LAMP (300M)
Page 943 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 41 CONNECTOR/GROUND/SPLICE LOCATION (Continued) Fig. 33 CENTER HIGH MOUNTED STOP LAMP (DODGE) Fig. 34 RIGHT TRUNK, REAR POWER AND ACCESSORIES...
Page 944 8W - 91 - 42 8W-91 CONNECTOR/GROUND/SPLICE LOCATION CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 945 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 43 CONNECTOR/GROUND/SPLICE LOCATION (Continued)
Page 947 8W-97 POWER DISTRIBUTION 8W - 97 - 1 8W-97 POWER DISTRIBUTION TABLE OF CONTENTS page page POWER DISTRIBUTION OPERATION ......3 DESCRIPTION .
Page 948: Power Distribution
8W - 97 - 2 8W-97 POWER DISTRIBUTION POWER DISTRIBUTION (Continued) • Junction Block (JB) • Accessories that draw higher power (i.e. cool- • Accessory power outlet. ers, vacuum cleaners, lights, etc.), will degrade the battery even more quickly. Only use these intermit- NOTE: DO NOT ATTEMPT TO SWAP POWER DIS- tently and with greater caution.
Page 949: Operation
8W-97 POWER DISTRIBUTION 8W - 97 - 3 CIGAR LIGHTER/POWER OUTLET (Continued) (3) Using external snap ring pliers with 90 degree CIRCUITS INCLUDED WITH IOD FUSE • Cluster tips. Insert pliers with tips against bosses and squeeze forcing bosses out of base. •...
Page 950 8W - 97 - 4 8W-97 POWER DISTRIBUTION IOD FUSE (Continued) (2) Remove the fuse access panel by unsnapping it The JB is positioned on a mounting bracket up and from the outboard end of the instrument panel. under the left instrument panel. It is secured by four (3) Grasp the outer tabs of the IOD fuse in cavity screws.
Page 951: Power Distribution Center
8W-97 POWER DISTRIBUTION 8W - 97 - 5 JUNCTION BLOCK (Continued) (4) Remove left knee blocker. (5) Remove under column ducts. (6) Remove Junction Block/BCM four mounting screws. (7) Remove wire harness connectors from Junction Block/BCM. (8) Remove Junction Block/BCM. (9) Disconnect BCM wire connectors and RKE antenna connector.
Page 952 8W - 97 - 6 8W-97 POWER DISTRIBUTION POWER DISTRIBUTION CENTER (Continued) AND TESTING) for more information on the loca- tion for the proper power distribution center cavity tions of the affected connectors. assignments. (3) Remove the fasteners that secure each of the (1) Position the PDC over the mounting bracket in engine compartment wire harness ground eyelets to the engine compartment.
Page 953 ENGINE 9 - 1 ENGINE TABLE OF CONTENTS page page ENGINE 3.5L CAMSHAFT(S) DESCRIPTION ......3 DESCRIPTION .
Page 954 9 - 2 ENGINE INSTALLATION LEFT MOUNT INSTALLATION - CYLINDER HEAD OFF ..39 REMOVAL ......58 INSTALLATION - CYLINDER HEAD ON .
Page 955 ENGINE 9 - 3 INTAKE MANIFOLD - UPPER INSTALLATION ......80 REMOVAL ......71 TIMING BELT TENSIONER &...
Page 956: Engine 3.5L
9 - 4 ENGINE ENGINE 3.5L (Continued) Fig. 1 3.5L Engine...
Page 957: Diagnosis And Testing
ENGINE 9 - 5 ENGINE 3.5L (Continued) DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - INTRODUCTION Engine diagnosis is helpful in determining the causes of malfunctions not detected and remedied by routine maintenance. These malfunctions may be classified as either mechanical (e.g., a strange noise), or performance (e.g., engine idles rough and stalls).
Page 958: Diagnosis And Testing - Engine Diagnosis - Mechanical
9 - 6 ENGINE ENGINE 3.5L (Continued) DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICAL CONDITION POSSIBLE CAUSES CORRECTION NOISY VALVES 1. High or low oil level in 1. Check and correct engine oil crankcase. level. 2. Thin or diluted oil. 2.
Page 959 ENGINE 9 - 7 ENGINE 3.5L (Continued) CONDITION POSSIBLE CAUSES CORRECTION MAIN BEARING NOISE 1. Insufficient oil supply. 1. Check engine oil level. 2. Low oil pressure. 2. Check engine oil level. Inspect oil pump relief valve and spring. 3. Thick / Thin or diluted oil. 3.
Page 960: Diagnosis And Testing - Engine Diagnosis - Performance
9 - 8 ENGINE ENGINE 3.5L (Continued) CONDITION POSSIBLE CAUSES CORRECTION OIL CONSUMPTION OR SPARK 1. PCV system malfunction. 1. Check system and repair as PLUGS FOULED necessary. (Refer to Appropriate Diagnostic Manual) 2. Worn, scuffed or broken rings. 2. Hone cylinder bores. Install new rings.
Page 961 ENGINE 9 - 9 ENGINE 3.5L (Continued) CONDITION POSSIBLE CAUSE CORRECTION ENGINE STALLS OR IDLES 1. Idle speed too low. 1. Test minimum air flow. (Refer to ROUGH Appropriate Diagnostic Information) 2. Incorrect fuel mixture. 2. (Refer to Appropriate Diagnostic Information) 3.
Page 962: Diagnosis And Testing - Cylinder Compression Pressure Test
9 - 10 ENGINE ENGINE 3.5L (Continued) • Leaks between adjacent cylinders or into water DIAGNOSIS AND TESTING - CYLINDER jacket. COMPRESSION PRESSURE TEST • Any causes for combustion/compression pressure The results of a cylinder compression pressure test loss. can be utilized to diagnose several engine malfunc- tions.
Page 963: Standard Procedure - Engine Gasket Surface Preparation
ENGINE 9 - 11 ENGINE 3.5L (Continued) specially designed black silicone rubber RTV that may be removed with a shop towel. Components retains adhesion sealing properties when should be torqued in place while the sealant is still exposed to engine oil. Moisture in the air causes the wet to the touch (within 10 minutes).
Page 964: Standard Procedure - Hydrostatic Locked Engine
9 - 12 ENGINE ENGINE 3.5L (Continued) (8) Install new spark plugs. (9) Drain engine oil and remove oil filter. (10) Install a new oil filter. (11) Fill engine with specified amount of approved oil. (12) Connect negative battery cable. (13) Start engine and check for any leaks.
Page 965: Standard Procedure - Measuring Bearing Clearance Using Plastigage
ENGINE 9 - 13 ENGINE 3.5L (Continued) STANDARD PROCEDURE - MEASURING REMOVAL - ENGINE ASSEMBLY BEARING CLEARANCE USING PLASTIGAGE (1) Release fuel pressure. (Refer to 14 - FUEL SYSTEM/FUEL DELIVERY - STANDARD PROCE- Engine crankshaft bearing clearances can be deter- DURE) mined by use of Plastigage or equivalent.
Page 966: Installation - Engine Assembly
9 - 14 ENGINE ENGINE 3.5L (Continued) (27) Disconnect all vacuum hoses. (28) Disconnect ground straps at both cylinder heads. CAUTION: Upper Intake manifold is a composite design. Therefore, manifold should be removed before lifting engine or damage to the manifold could occur.
Page 967: Specifications 3.5L Engine
ENGINE 9 - 15 ENGINE 3.5L (Continued) (6) Tighten engine mount fastener to 61 N·m (45 (33) Attach air conditioning condenser to radiator. ft. lbs.). (34) Install power steering line bracket to radiator. (7) Align flex plate to torque converter and install (35) Connect engine oil and transmission cooler mounting bolts.
Page 968 9 - 16 ENGINE ENGINE 3.5L (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Pistons Ring Width Type Material Aluminum (Full Floating Top Compression Ring 1.17–1.19 mm Pins) (0.0461–0.0469 in.) Piston Diameter 95.98 ± 0.019 mm 2nd Compression Ring 1.47–1.49 mm (3.7788 ± 0.0008 in.) (0.058–0.059 in.) Clearance at Size –0.007 to +0.047 mm...
Page 969 ENGINE 9 - 17 ENGINE 3.5L (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Camshaft Head Diameter—Exhaust 28.87–29.13 mm Bore Diameter 43.038–43.059 mm (1.1366–1.1469 in.) (1.6944–1.6952 in.) Length—Intake (Overall) 114.41–114.99 mm Bearing Journal Diameter 42.939–42.960 mm (4.5043–4.5272 in.) (1.6905–1.6913 in.) Length—Exhaust 125.67–126.25 mm (Overall) Diametrical Clearance 0.078–0.12 mm...
Page 970: Torque
9 - 18 ENGINE ENGINE 3.5L (Continued) TORQUE DESCRIPTION SPECIFICATION Spring Force—Intake 836–907 N @ 29.85 mm N·m (Valve Open) (188–204 lbs. @ 1.1594 DESCRIPTION Lbs. Lbs. in.) A/C Compressor Bracket to — Spring Force—Exhaust 579–640 N @ 31.47 mm Engine—Bolts (Valve Open) (130–144 lbs.
Page 971: 3.5L Engine
ENGINE 9 - 19 ENGINE 3.5L (Continued) N·m DESCRIPTION Lbs. Lbs. Oil Pan —M6 Bolts — —M8 Bolts — Oil Pan Drain Plug — Oil Filter — Crankshaft Damper Remover Insert C-4685-C2 Oil Pump to Block—Bolts — Oil Pump Cover—Bolts —...
Page 972 9 - 20 ENGINE ENGINE 3.5L (Continued) Crankshaft Seal Remover Camshaft Seal Remover C-3981B Crankshaft Seal Installer 6342 Camshaft Seal Installer 6052 Crankshaft Sprocket Installer 6641 Dial Indicator C-3339 Valve Spring Compressor C-3422-D Camshaft Alignment 6642 Camshaft Seal Protector 6788 Valve Spring Adapter 6526...
Page 973 ENGINE 9 - 21 ENGINE 3.5L (Continued) Crankshaft Rear Seal Guide 6926-1 & Installer 6926-2 Valve Spring Tester C-647 Valve Spring Compressor MD-998772-A Driver Handle C-4171 Valve Spring Adapter 6527 Crankshaft Rear Seal Retainer Alignment Fixture 8225 Indicator Bore Size C-119 Release Probe 8351 Main Bearing Remover/Installer C-3059...
Page 974: Air Cleaner Element
9 - 22 ENGINE ENGINE 3.5L (Continued) Cooling System Tester 7700 Pressure Gauge C-3292 Adapter 8406 Combustion Leak Tester C-3685-A AIR CLEANER ELEMENT REMOVAL (1) Remove air cleaner lid. Lift lid off of air cleaner housing. (2) Remove filter element (Fig. 9). DRB III with PEP Module –...
Page 975: Cylinder Head Description
ENGINE 9 - 23 COOLING SYSTEM TESTER METHOD CYLINDER HEAD WARNING: WITH COOLING SYSTEM TESTER IN DESCRIPTION PLACE, PRESSURE WILL BUILD UP FAST. EXCES- The aluminum alloy cylinder heads feature cross- SIVE PRESSURE BUILT UP, BY CONTINUOUS flow type intake and exhaust ports. Valve guides and ENGINE OPERATION, MUST BE RELEASED TO A seat inserts are powdered metal.
Page 976: Cleaning
9 - 24 ENGINE CYLINDER HEAD (Continued) DURE). Be careful not to gouge or scratch the alumi- num head sealing surface. Clean all engine oil passages. INSPECTION (1) Before cleaning, check for leaks, damage and cracks. (2) Clean cylinder head and oil passages. (3) Check cylinder head for flatness (Fig.
Page 977 ENGINE 9 - 25 CYLINDER HEAD (Continued) (4) Before installing bolts, lubricate threads with engine oil. (5) Tighten the cylinder head bolts in the sequence shown in (Fig. 15). Using the 4 step torque-turn method, tighten according to the following torque val- ues: •...
Page 978: Camshaft Oil Seal(S) Removal
9 - 26 ENGINE CAMSHAFT OIL SEAL(S) REMOVAL (1) Remove camshaft sprocket(s). (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL) (2) Use Special Tool C-3981B to remove camshaft oil seal (Fig. 16). Fig. 17 Camshaft Oil Seal Protector Sleeve 1 - SPECIAL TOOL 6788 Fig.
Page 979: Cleaning
ENGINE 9 - 27 CAMSHAFT(S) (Continued) (6) If end play is excessive, check cylinder head and camshaft for wear; replace as necessary. Fig. 19 Camshaft End Play - Typical REMOVAL Fig. 20 Cylinder Head, Camshaft, and Rocker Arms Camshafts are removed from the rear of each cyl- inder head.
Page 980: Cylinder Head Cover(S)
9 - 28 ENGINE CAMSHAFT(S) (Continued) (2) Install cylinder head(s). (Refer to 9 - ENGINE/ (7) Remove cylinder head cover bolts and remove CYLINDER HEAD - INSTALLATION) cover (Fig. 24). (3) Install the rocker arm assembly. (Refer to 9 - ENGINE/CYLINDER HEAD/ROCKER ADJUSTER ASSY - INSTALLATION)
Page 981: Intake/Exhaust Valves & Seats
ENGINE 9 - 29 CYLINDER HEAD COVER(S) (Continued) INTAKE/EXHAUST VALVES & SEATS DESCRIPTION Valves are made of highly heat-resistant steel and are chrome plated to prevent stem scuffing. The intake valve is a one-piece forging, while the exhaust valve has a forged head with a welded stem for lock groove hardenability.
Page 982: Removal
9 - 30 ENGINE INTAKE/EXHAUST VALVES & SEATS (Continued) Fig. 28 Valve Face and Seat 1 - SEAT WIDTH 2 - FACE ANGLE 3 - SEAT ANGLE 4 - SEAT CONTACT AREA (3) Inspect the valve seat with Prussian blue to determine where the valve contacts the seat.
Page 983: Cleaning
ENGINE 9 - 31 INTAKE/EXHAUST VALVES & SEATS (Continued) Fig. 32 Intake and Exhaust Valves 1 - MARGIN 2 - FACE 3 - STEM 4 - VALVE SPRING RETAINER LOCK GROOVES Fig. 31 Valve Seal and Spring - Installation NOTE: Replace cylinder head if stem-to-guide clear- 1 - VALVE ance exceeds specifications, or if guide is loose in 2 - VALVE RETAINING LOCKS...
Page 984: Rocker Arm / Adjuster Assembly
9 - 32 ENGINE INTAKE/EXHAUST VALVES & SEATS (Continued) Fig. 34 Checking Valve Tip Height and Valve Spring Installed Height 1 - SPRING RETAINER 2 - GARTER SPRING 3 - VALVE SPRING SEAT TOP 4 - CYLINDER HEAD SURFACE Fig. 35 Rocker Arm Assembly ROCKER ARM / ADJUSTER 1 - RETAINER ASSEMBLY...
Page 985 ENGINE 9 - 33 ROCKER ARM / ADJUSTER ASSEMBLY (Continued) POSSIBLE NOISE SOURCES POSSIBLE NOISE MISDIAGNOSIS SOURCES Spongy/soft/aerated lash adjusters. SRV valve axle chatter. Missing lash adjuster swivel contact pads. Exhaust rocker arm-to-cylinder head cover contact. Intake rocker-to-camshaft bearing journal contact. Piston pin bore fit.
Page 986: Standard Procedure - Hydraulic Lash Adjuster Bleeding
9 - 34 ENGINE ROCKER ARM / ADJUSTER ASSEMBLY (Continued) STANDARD PROCEDURE - HYDRAULIC LASH (b) Gently unseat BOTH lash adjuster’s internal check ball at the same time. ADJUSTER BLEEDING (c) While internal check ball held Use this procedure to manually bleed aerated oil unseated, press the rocker arm into the valve tip, from the lash adjuster and remove sponginess.
Page 987: Disassembly
ENGINE 9 - 35 ROCKER ARM / ADJUSTER ASSEMBLY (Continued) DISASSEMBLY (1) Remove rocker arm and shafts. (Refer to 9 - ENGINE/CYLINDER HEAD/ROCKER ADJUSTER ASSY - REMOVAL) (2) Remove dowel pin using a 4 mm screw, nut, spacer, and washer installed into the pin (Fig. 40). Thread the screw into the pin, then loosen the nut on the screw.
Page 988: Assembly
9 - 36 ENGINE ROCKER ARM / ADJUSTER ASSEMBLY (Continued) ASSEMBLY CAUTION: New dowel pins must be installed when reassembling. (1) Install the rocker arms, and pedestals onto the shaft. (2) Install dowel pins (Fig. 43). Dowel pins pass through the pedestal into the exhaust rocker shafts. Dowel pins should be pressed in until they bottom- out against the rocker shaft in the pedestal.
Page 989: Spark Plug Tube
ENGINE 9 - 37 ROCKER ARM / ADJUSTER ASSEMBLY (Continued) Fig. 46 Servicing Spark Plug Tubes Fig. 44 Camshaft Sprockets Neutral Position 1 - SPARK PLUG TUBE 2 - LOCKING PLIERS (4) Install cylinder head cover(s). (Refer to 9 - ENGINE/CYLINDER HEAD/CYLINDER HEAD...
Page 990: Valve Springs
9 - 38 ENGINE VALVE STEM SEALS (Continued) CAUTION: Do not remove garter spring around the seal at the top of the valve stem seal (Fig. 48). (2) Install valve spring. (Refer to 9 - ENGINE/ CYLINDER HEAD/VALVE SPRINGS - INSTALLA- TION) Fig.
Page 991: Installation
ENGINE 9 - 39 VALVE SPRINGS (Continued) sure piston is at TDC in each cylinder of the spring seat to the bottom surface of spring valve spring that is being removed. retainer. If height is greater than 38.75 mm (1.5256 (13) Remove spark plug adapter tool.
Page 992: Installation - Cylinder Head On
9 - 40 ENGINE VALVE SPRINGS (Continued) INSTALLATION - CYLINDER HEAD ON ENGINE BLOCK (1) Compress valve spring using Special Tool MD DESCRIPTION 998772A with Adaptor 6527 only enough to install retainer and locks. The cylinder block (Fig. 53) is made of heat treated (2) After installing locks, release tension on valve aluminum with cast-in-place iron liners.
Page 993: Cleaning
ENGINE 9 - 41 ENGINE BLOCK (Continued) (2) Deglazing of the cylinder walls may be done CLEANING using a cylinder surfacing hone, recommended tool Clean cylinder block thoroughly using a suitable C-3501 or equivalent, equipped with 280 grit stones, cleaning solvent. if the cylinder bore is straight and round.
Page 994: Connecting Rod Bearings
9 - 42 ENGINE CONNECTING ROD BOLTS CONNECTING ROD BEARINGS (1) Examine connecting rod bolts for stretching. Stretching can be checked by holding a scale or STANDARD PROCEDURE - CONNECTING RODS straight edge against the threads. If all the threads AND BEARINGS do not contact the scale the bolt must be replaced.
Page 995: Standard Procedure - Crankshaft End Play
ENGINE 9 - 43 CRANKSHAFT (Continued) (7) Remove front main timing belt cover. (8) Remove front left side timing belt cover. (9) Remove timing belt tensioner and timing belt. (10) Remove crankshaft sprocket. (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT/CHAIN AND SPROCKETS - REMOVAL) (11) Tap dowel pin out of crankshaft.
Page 996: Installation
9 - 44 ENGINE CRANKSHAFT (Continued) INSTALLATION CAUTION: Main bearings are select fit. (Refer to 9 - ENGINE/ENGINE BLOCK/CONNECTING ROD BEAR- INGS - STANDARD PROCEDURE) (1) Install crankshaft main bearings (Fig. 63). (Refer to 9 - ENGINE/ENGINE BLOCK/CRANK- SHAFT MAIN BEARINGS - STANDARD PROCE- DURE) (2) Install the crankshaft to cylinder block.
Page 997: Crankshaft Main Bearings
ENGINE 9 - 45 CRANKSHAFT (Continued) (9) Install connecting rods and measure side clear- ance. (Refer to 9 - ENGINE/ENGINE BLOCK/CON- NECTING BEARINGS STANDARD PROCEDURE) (10) Install windage tray. Lubricate bolts with engine oil and tighten to 27 N·m + 1/4 turn (20 ft. lbs.
Page 998 9 - 46 ENGINE CRANKSHAFT MAIN BEARINGS (Continued) The marks for the cylinder block main bore grade are located on the left side pan rail, just rear of the left engine mount bracket (Fig. 65). These grade marks (1, 2, or 3) are read left to right, corresponding to main bore 1, 2, 3, 4.
Page 999: Removal
ENGINE 9 - 47 CRANKSHAFT MAIN BEARINGS (Continued) MAIN BEARING SELECTION CHART—3.2/3.5L Main Bearing Bore Grade Marks (2) +003 +0.006 standard (+0.0002 (+0.0003 in.) in.) (2) +003 Crankshaft -0.003 Main Journal standard (+0.0002 Grade Marks (-0.0002 in.) in.) Fig. 69 Removing and Installing Upper Main Bearing -0.006 -0.003 With Special Tool C- 3059...
Page 1000: Crankshaft Oil Seal - Front
9 - 48 ENGINE CRANKSHAFT MAIN BEARINGS (Continued) When installing a new upper bearing shell, slightly (8) Measure crankshaft end play. (Refer to 9 - chamfer the sharp edges from the plain side. ENGINE/ENGINE BLOCK/CRANKSHAFT - STAN- (1) Lubricate main bearing with clean engine oil. DARD PROCEDURE) (2) Start bearing in place, and insert Main Bearing (9) Install windage tray.
Page 1001: Installation
ENGINE 9 - 49 CRANKSHAFT OIL SEAL - FRONT (Continued) (4) Shaft seal lip surface must be free of varnish, CRANKSHAFT OIL SEAL - dirt or nicks. Polish with 400 grit paper if necessary. REAR REMOVAL (1) Remove transaxle from vehicle. (Refer to 21 - TRANSMISSION/TRANSAXLE/AUTOMATIC - 42LE - REMOVAL) (2) Remove drive plate.
Page 1002: Crankshaft Rear Oil Seal Retainer Removal
9 - 50 ENGINE CRANKSHAFT OIL SEAL - REAR (Continued) (1) Place Special Tool 6926-1 Guide on crankshaft NOTE: Seal retainer gasket is bonded to the (Fig. 76). This is a pilot tool with a magnetic base. retainer and must be replaced as an assembly. (2) Position seal over pilot tool.
Page 1003: Flex Plate
ENGINE 9 - 51 CRANKSHAFT REAR OIL SEAL RETAINER (Continued) Fig. 79 FLEX PLATE 1 - FLEX PLATE 2 - BOLT (QTY. 8) 3 - BACKING PLATE PISTON & CONNECTING ROD DESCRIPTION NOTE: Valve reliefs were removed from the pistons for the 2003MY.
Page 1004: Installation
9 - 52 ENGINE PISTON & CONNECTING ROD (Continued) Fig. 80 Piston Measurements (2) Remove the oil pan. (Refer to 9 - ENGINE/LU- BRICATION/OIL PAN - REMOVAL) Fig. 82 Connecting Rod Guides and Crankshaft (3) Remove top ridge of cylinder bores with a reli- Protectors able ridge reamer before removing pistons from cyl- 1 - COVER ROD BOLTS WITH A SUITABLE COVERING WHEN...
Page 1005 ENGINE 9 - 53 PISTON & CONNECTING ROD (Continued) (3) Before installing pistons and connecting rod (6) Rotate crankshaft so that the connecting rod assemblies into the bore, ensure that compression journal is on the center of the cylinder bore. Insert ring gaps are staggered so that neither is in line with rod and piston into cylinder bore and guide rod over oil ring rail gap (Fig.
Page 1006: Piston Rings
9 - 54 ENGINE PISTON & CONNECTING ROD (Continued) Fig. 87 Piston and Connecting Rod Positioning (Front View of Engine) 2 - OIL SQUIRT HOLE 1 - MAJOR THRUST SIDE OF PISTON PISTON RINGS STANDARD PROCEDURE - PISTON RING FITTING (1) Wipe cylinder bore clean.
Page 1007: Removal
ENGINE 9 - 55 PISTON RINGS (Continued) (3) Install the side rail by placing one end between the piston ring groove and the expander. Hold end firmly and press down the portion to be installed until side rail is in position. Do not use a piston ring expander during this step (Fig.
Page 1008: Structural Collar / Cover Removal
9 - 56 ENGINE PISTON RINGS (Continued) STRUCTURAL COLLAR / COVER REMOVAL (1) Raise vehicle on hoist. (2) Remove bolts attaching structural collar to oil pan and transmission housing (Fig. 94). (3) Remove collar (Fig. 94). Fig. 92 UPPER AND INTERMEDIATE RINGS (4) Install upper side rail first and then the lower side rail.
Page 1009: Installation
ENGINE 9 - 57 VIBRATION DAMPER (Continued) (4) Remove the accessory drive belts. (Refer to 7 - ing from 6792, and 6792-1 Installer (Fig. 97). Install COOLING/ACCESSORY DRIVE/DRIVE BELTS - center bolt and tighten to 115 N·m (85 ft. lbs.) (Fig. REMOVAL) 95).
Page 1010: Inspection
9 - 58 ENGINE ENGINE MOUNTING (Continued) INSPECTION INSTALLATION Engine hydro-mounts may show surface cracks. (1) Install isolator mount with heat shield onto the This will not effect performance and mount should frame. not be replaced. Only replace the engine hydro- (2) Lower the engine onto the isolator mount.
Page 1011: Rear Mount Removal
ENGINE 9 - 59 REAR MOUNT RIGHT MOUNT REMOVAL REMOVAL (1) Raise vehicle on hoist. (1) Raise vehicle on hoist. (2) Support transaxle with a jack. (2) Remove the isolator attaching nuts from top of (3) Remove isolator nuts from the mount to trans- the mounting bracket (Fig.
Page 1012: Lubrication Description
9 - 60 ENGINE LUBRICATION DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - ENGINE OIL LEAK DESCRIPTION INSPECTION System is a full-flow filtration, pressure feed type. The oil pump body is mounted to the engine block. Begin with a thorough visual inspection of the The pump inner rotor is driven by the crankshaft.
Page 1013: Diagnosis And Testing - Checking Engine Oil Pressure
ENGINE 9 - 61 LUBRICATION (Continued) (4) If dye is not observed, drive the vehicle at var- present in this area, remove transmission for further ious speeds for approximately 24 km (15 miles), and inspection. repeat inspection. (a) Circular spray pattern generally indicates (5) If the oil leak source is not positively seal leakage or crankshaft damage.
Page 1014: Oil Description
9 - 62 ENGINE PROPERLY. CONTACT YOUR DEALER OR GOVERN- MENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA. DESCRIPTION For engine oil type and capacity (Refer to LUBRI- TO CHANGE ENGINE OIL CATION & MAINTENANCE/FLUID TYPES (1) Run engine until achieving normal operating DESCRIPTION - ENGINE OIL) temperature.
Page 1015: Removal
ENGINE 9 - 63 OIL COOLER & LINES (Continued) 138–207 kPa (20–30 psi) and an internal orifice lim- (3) Remove valve from engine block by unscrewing its oil flow to a maximum of 11.3 LPM (3 GPM). The fitting. engine oil exits the cooler through the oil return line INSTALLATION and is returned to the engine oil pan (Fig.
Page 1016: Oil Filter Removal
9 - 64 ENGINE OIL COOLER & LINES (Continued) (b) Position control valve to fitting. Push line INSTALLATION into fitting until it locks in place. Ensure proper (1) Wipe base clean, then inspect gasket contact connection is made by pulling in-and-out on valve. surface.
Page 1017: Installation
ENGINE 9 - 65 OIL PAN (Continued) Fig. 105 OIL PAN 1 - GASKET 5 - BOLT-M8 2 - OIL PAN 6 - BOLT-M8 3 - BOLT-M6 7 - BOLT-M6 4 - NUT-M6 INSTALLATION (1) Apply a 1/8 inch bead of Mopar Engine RTV GEN II at the parting line of the oil pump housing and the rear seal retainer (Fig.
Page 1018: Oil Pressure Relief Valve Removal
9 - 66 ENGINE (2) Install valve, spring and retainer cap (Fig. OIL PRESSURE RELIEF VALVE 107). (3) Install new cotter pin. REMOVAL (4) Install the oil pan. (Refer to 9 - ENGINE/LU- (1) Remove the oil pan. (Refer to 9 - ENGINE/LU- BRICATION/OIL PAN - INSTALLATION) BRICATION/OIL PAN - REMOVAL) (2) To remove the relief valve, proceed as follows:...
Page 1019: Oil Pump Removal
ENGINE 9 - 67 OIL PRESSURE SWITCH (Continued) Fig. 109 OIL PUMP - REMOVAL/INSTALLATION 1 - OIL PUMP 2 - GASKET DISASSEMBLY (1) To remove the relief valve, proceed as follows: (2) Remove cotter pin. Drill a 3.175 mm (1/8 inch.) Fig.
Page 1020: Cleaning
9 - 68 ENGINE OIL PUMP (Continued) (4) Measure thickness and diameter of outer rotor. If outer rotor thickness measures 14.299 mm (0.563 in.) or less (Fig. 113), or if the diameter is 79.78 mm (3.141 inches.) or less, replace outer rotor. Fig.
Page 1021: Assembly
ENGINE 9 - 69 OIL PUMP (Continued) Fig. 117 Measuring Clearance Over Rotors Fig. 115 Measuring Outer Rotor Clearance in Housing 1 - STRAIGHT EDGE 2 - FEELER GAUGES 1 - FEELER GAUGE 2 - OUTER ROTOR Fig. 118 Oil Pressure Relief Valve 1 - RELIEF VALVE Fig.
Page 1022: Installation
9 - 70 ENGINE OIL PUMP (Continued) INSTALLATION The aluminum lower intake manifold attaches to each cylinder head and uses a gasket for sealing (Fig. (1) Prime oil pump before installation by filling 120). The manifold coolant passage allows coolant to rotor cavity with engine oil.
Page 1023: Diagnosis And Testing - Intake Manifold Leaks
ENGINE 9 - 71 INTAKE MANIFOLD (Continued) Fig. 120 LOWER INTAKE MANIFOLD 1 - BOLT 6 - GASKET 2 - HEATER SUPPLY TUBE 7 - BOLT 3 - BOLT 8 - O-RING 4 - BOLT 9 - INTAKE MANIFOLD-LOWER 5 - KNOCK SENSOR DIAGNOSIS AND TESTING - INTAKE INTAKE MANIFOLD - UPPER MANIFOLD LEAKS...
Page 1024 9 - 72 ENGINE INTAKE MANIFOLD - UPPER (Continued) Fig. 123 INTAKE MANIFOLD SUPPORT - LEFT 1 - SUPPORT BRACKET (7) Remove support brackets at intake manifold front corners and at MTV (Fig. 124). Fig. 121 AIR CLEANER WITH INLET HOSE 1 - AIR CLEANER ASSEMBLY WITH AIR INLET HOSE 2 - THROTTLE BODY (5) Disconnect vacuum hoses from the following:...
Page 1025: Inspection
ENGINE 9 - 73 INTAKE MANIFOLD - UPPER (Continued) Fig. 126 UPPER INTAKE MANIFOLD TIGHTENING (5) Install right side (Fig. 122) and left side (Fig. 123) intake manifold supports. (6) Install manifold support brackets at front cor- ners and at MTV (Fig. 124). (7) Tighten fastener attaching throttle body to sup- Fig.
Page 1026: Intake Manifold - Lower Removal
9 - 74 ENGINE INSPECTION INTAKE MANIFOLD - LOWER Check manifold for: • Damage and cracks REMOVAL • Gasket surface damage or warpage (1) Perform fuel pressure release procedure. (Refer • Damaged fuel injector ports to 14 - FUEL SYSTEM/FUEL DELIVERY - STAN- If the manifold exihibits any of these conditions, DARD PROCEDURE) replace the manifold.
Page 1027 ENGINE 9 - 75 INTAKE MANIFOLD - LOWER (Continued) Fig. 128 LOWER INTAKE MANIFOLD 1 - BOLT 6 - GASKET 2 - HEATER SUPPLY TUBE 7 - BOLT 3 - BOLT 8 - O-RING 4 - BOLT 9 - INTAKE MANIFOLD-LOWER 5 - KNOCK SENSOR...
Page 1028: Exhaust Manifold Description
9 - 76 ENGINE INTAKE MANIFOLD - LOWER (Continued) Fig. 130 EXHAUST MANIFOLD 1 - BOLT - HEAT SHIELD 2 - HEAT SHIELD 3 - GASKET 4 - EXHAUST MANIFOLD 5 - BOLT - EXHAUST MANIFOLD 6 - HEAT SHIELD EXHAUST MANIFOLD - RIGHT REMOVAL (1) Disconnect negative cable from remote jumper...
Page 1029: Inspection
ENGINE 9 - 77 EXHAUST MANIFOLD - RIGHT (Continued) NOTE: Do not reuse V-Band clamp. INSPECTION (1) Inspect exhaust manifolds for damage or (9) Remove the A/C compressor attaching bolts and cracks. set compressor aside. (2) Check manifold flatness. (10) Remove engine oil dipstick tube. (3) Inspect the exhaust manifold gasket for obvi- (11) Remove the A/C compressor bracket.
Page 1030: Exhaust Manifold - Left Removal
9 - 78 ENGINE INSPECTION EXHAUST MANIFOLD - LEFT (1) Inspect exhaust manifolds for damage or REMOVAL cracks. (2) Check manifold flatness. (1) Disconnect negative cable from remote jumper (3) Inspect the exhaust manifold gasket for obvi- terminal. ous discoloration or distortion. (2) Raise the vehicle on hoist.
Page 1031: Standard Procedure - Valve Timing Verification
ENGINE 9 - 79 VALVE TIMING (Continued) Fig. 133 TIMING DRIVE SYSTEM 1 - TIMING BELT COVER - RIGHT REAR 8 - BOLT-CRANKSHAFT DAMPER 2 - TENSIONER-TIMING BELT 9 - TIMING BELT COVER-LOWER 3 - CAMSHAFT SPROCKET 10 - TIMING BELT COVER-RIGHT 4 - BOLT-CAMSHAFT SPROCKET 11 - TIMING BELT COVER-LEFT 5 - TIMING BELT...
Page 1032: Installation
9 - 80 ENGINE TIMING BELT COVER(S) - FRONT (Continued) (6) Remove the lower belt cover located behind the crankshaft vibration damper (Fig. 135). (7) Remove the A/C belt guide/lift bracket (Fig. 134). Fig. 136 TIMING BELT COVER SEALER 1 - SEALER (2) Install the right stamped steel cover (Fig.
Page 1033 ENGINE 9 - 81 TIMING BELT COVER(S) - REAR (Continued) (2) Clean right rear timing belt cover O-ring seal- ing surfaces and grooves (Fig. 139). Lubricate new O-rings with Mopar Dielectric Grease or equivalent to facilitate assembly. (3) Position NEW O-rings on cover (Fig. 139). Fig.
Page 1034: Installation
9 - 82 ENGINE TIMING BELT COVER(S) - REAR (Continued) (4) Install rear timing belt covers (Fig. 140) and TIMING BELT/CHAIN SPROCKETS (Fig. 141). Tighten bolts to the following specified INSTALLATION) torque: • M10—54 N·m (40 ft. lbs.) TIMING BELT TENSIONER & •...
Page 1035: Installation - Tensioner
ENGINE 9 - 83 TIMING BELT TENSIONER & PULLEY (Continued) INSTALLATION - TENSIONER (1) For timing belt tensioner installation procedure (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT AND SPROCKETS - INSTALLATION - TIM- ING BELT). TIMING BELT AND SPROCKETS REMOVAL REMOVAL - TIMING BELT CAUTION: The following procedure can only be used when the camshaft sprockets HAVE NOT...
Page 1036: Removal - Camshaft Sprockets
9 - 84 ENGINE TIMING BELT AND SPROCKETS (Continued) CAUTION: Align the camshaft sprockets between the marks on rear belt covers before timing belt removal or damage to valve and/or pistons could occur. (9) Using a ink or paint marker; mark the exact position of the camshaft sprocket timing mark rela- tive to the two timing marks on the rear timing cover.
Page 1037 ENGINE 9 - 85 TIMING BELT AND SPROCKETS (Continued) CAUTION: When camshaft sprocket bolts are loos- ened or removed, the camshafts must be re-timed to the engine. Also, the camshaft sprocket bolts must NOT be reused. (1) Remove front timing belt covers. (Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT / CHAIN COVER(S) - REMOVAL) (2) Position crankshaft sprocket to the TDC mark...
Page 1038: Removal - Crankshaft Sprocket
9 - 86 ENGINE TIMING BELT AND SPROCKETS (Continued) (8) Loosen and remove bolt and washer. To remove (h) Vehicle mileage or time at component main- the camshaft sprocket bolts with engine in the vehi- tenance requirement. (Refer to LUBRICATION & cle, it may be necessary to lift the engine to allow MAINTENANCE/MAINTENANCE SCHEDULES - bolt removal clearance.
Page 1039: Installation - Camshaft Sprockets
ENGINE 9 - 87 TIMING BELT AND SPROCKETS (Continued) (2) Align the camshaft sprockets (to reference (10) Install the radiator fan. (Refer to 7 - COOL- mark made upon removal) between the marks on the ING/ENGINE/RADIATOR FAN - INSTALLATION) rear covers (Fig. 144). (11) Install upper radiator crossmember.
Page 1040 9 - 88 ENGINE TIMING BELT AND SPROCKETS (Continued) • Left side = 115 N·m (85 ft. lbs.) +90° turn Fig. 154 Camshaft Sprocket Timing Marks 1 - ALIGN CAMSHAFT SPROCKET TIMING MARK BETWEEN MARKS ON REAR TIMING BELT COVER 2 - CRANKSHAFT AT TDC Fig.
Page 1041: Installation - Crankshaft Sprocket
ENGINE 9 - 89 TIMING BELT AND SPROCKETS (Continued) (13) Install accessory drive belts. (Refer to 7 - COOLING/ACCESSORY DRIVE/DRIVE BELTS - INSTALLATION) (14) Fill cooling system. (Refer to 7 - COOLING - STANDARD PROCEDURE) INSTALLATION - CRANKSHAFT SPROCKET CAUTION: To ensure proper installation depth of crankshaft sprocket, Special Tool 6641 must be used.
Page 1043 EXHAUST SYSTEM 11 - 1 EXHAUST SYSTEM TABLE OF CONTENTS page page EXHAUST SYSTEM CATALYTIC CONVERTER - RIGHT DESCRIPTION ......1 REMOVAL - RIGHT SIDE .
Page 1044 11 - 2 EXHAUST SYSTEM EXHAUST SYSTEM (Continued) Fig. 1 Exhaust System 1 - V-BAND CLAMPS 5 - MUFFLER 2 - BAND CLAMPS 6 - BAND CLAMP 3 - FRONT RESONATOR 7 - LEFT REAR RESONATOR/PIPE ASSEMBLY 4 - INTERMEDIATE PIPE 8 - CATALYTIC CONVERTERS Fig.
Page 1045: Exhaust System
EXHAUST SYSTEM 11 - 3 EXHAUST SYSTEM (Continued) DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING - EXHAUST SYSTEM CONDITION POSSIBLE CAUSES CORRECTION EXCESSIVE EXHAUST NOISE 1. Exhaust manifold cracked or 1. Replace manifold. (UNDER HOOD) broken. 2. Manifold to cylinder head leak. 2.
Page 1046: Removal - Exhaust System
11 - 4 EXHAUST SYSTEM EXHAUST SYSTEM (Continued) (7) If pressure exceeds maximum limits, inspect exhaust system for restricted component. For further catalytic converter inspection procedures, (Refer to 11 - EXHAUST SYSTEM/CATALYTIC CONVERTER - INSPECTION). Replace component(s) as necessary. EXHAUST BACK PRESSURE LIMITS Exhaust Back Pressure Limit (Max) Vehicle in Park/Neutral 3.45 Kpa (0.5 psi)
Page 1047: Adjustments
EXHAUST SYSTEM 11 - 5 EXHAUST SYSTEM (Continued) Fig. 4 Exhaust System Supports 3 - ISOLATORS 1 - SUPPORTS 2 - MUFFLER component to maintain position and proper clearance (3) Tighten all clamps and brackets once align- with underbody parts. ment and clearances are achieved.
Page 1048: Special Tools
11 - 6 EXHAUST SYSTEM EXHAUST SYSTEM (Continued) SPECIAL TOOLS EXHAUST SYSTEM DRB III & PEP Module - OT-CH6010A Fig. 5 Catalytic Converters 1 - V-BAND CLAMPS 2 - RIGHT CATALYTIC CONVERTER 3 - LEFT CATALYTIC CONVERTER verted into water (H2O) and carbon dioxide (CO2). Back Pressure Test Adapter - CH8519 Oxides of Nitrogen (NOx) are converted into elemen- tal Nitrogen (N) and water.
Page 1049: Inspection
EXHAUST SYSTEM 11 - 7 CATALYTIC CONVERTER(S) (Continued) plug wires from plugs or by any other means short CATALYTIC CONVERTER - out cylinders, if exhaust system is equipped with a RIGHT catalytic converter. Failure of the catalytic converter can occur due to temperature increases caused by REMOVAL - RIGHT SIDE unburned fuel passing through the converter.
Page 1050 11 - 8 EXHAUST SYSTEM CATALYTIC CONVERTER - RIGHT (Continued) (9) Disconnect ground strap at right frame rail/ shock tower area. (10) Remove air cleaner resonator support bracket from right cylinder head. (11) Disconnect downstream oxygen sensor connec- tor and remove sensor from converter pipe (Refer to 14 - FUEL SYSTEM/FUEL INJECTION/O2 SENSOR - REMOVAL).
Page 1051: Installation - Right Side
EXHAUST SYSTEM 11 - 9 CATALYTIC CONVERTER - RIGHT (Continued) NOTE: To allow enough clearance for catalytic con- lbs.). Torque front cradle bolts to 109 N·m (80 ft. lbs.) verter removal, remove hanger bracket from hanger (Fig. 8). (7) Remove jack stands and transmission jack. (Fig.
Page 1052: Installation - Left Side
11 - 10 EXHAUST SYSTEM CATALYTIC CONVERTER - LEFT (Continued) (5) Loosen or remove nut attaching left pipe to (2) Loosen clamp and separate left rear resonator/ transaxle bracket (Fig. 5). pipe from muffler/front resonator assembly (Fig. 1) or (Fig. 2). CAUTION: Care should be taken when removing (3) 300M Special: Remove nuts securing right converter not to damage driveshaft boot.
Page 1053: Resonator - Right Rear (300M Special)
EXHAUST SYSTEM 11 - 11 Do Not use a petroleum-based lubricant on the iso- RESONATOR - RIGHT REAR lators. This will damage the rubber material. (300M SPECIAL) (3) Remove the rubber isolator from the rear sup- port bracket on body. REMOVAL (4) Remove right rear resonator/pipe nuts (Fig.
Page 1055 FRAME & BUMPERS 13 - 1 FRAME & BUMPERS TABLE OF CONTENTS page page FRONT BUMPER REINFORCEMENT SPECIFICATIONS - TORQUE ... . . 9 REMOVAL ......1 ENGINE CRADLE CROSSMEMBER INSTALLATION .
Page 1056: Removal
13 - 2 FRAME & BUMPERS FRONT FASCIA REMOVAL REMOVAL (1) Release hood latch and open hood. (2) Remove large rubber grommet (70 mm x 168 mm) from splash shield to gain access to fascia fas- teners (Fig. 2). (3) Remove fasteners attaching fascia to the front fender and splash shield.
Page 1057: Installation
FRAME & BUMPERS 13 - 3 FRONT FASCIA (Continued) (6) Install nut on fascia stud through the splash shield access hole, on each side. (7) Install fasteners attaching fascia to the front fender and splash shield. (8) Install grommet. (9) Install the fasteners attaching the fascia to the lower crossmember.
Page 1058: Rear Fascia - Intrepid
13 - 4 FRAME & BUMPERS REAR FASCIA (Continued) (2) Partially remove trunk carpet to gain access to (2) Remove fasteners attaching fascia to rear quar- fascia attaching nuts and remove nuts. ter and splash shields. (3) 300M only, remove both tail lamp housings to (3) Remove fasteners attaching fascia to lower gain access to fascia attaching fasteners and remove trunk panel.
Page 1059 FRAME & BUMPERS 13 - 5 2004 LH Service Manual FRAME (Continued) Publication No. 81-270-04027 04LH13-5 June, 2003 INDEX DESCRIPTION FIGURE ENGINE COMPARTMENT TOP VIEW ENGINE COMPARTMENT SIDE VIEW FORWARD FRAME SECTION AND ENGINE CRADLE REAR FRAME SECTION Fig. 11 ENGINE COMPARTMENT TOP VIEW...
Page 1060 13 - 6 FRAME & BUMPERS FRAME (Continued) Fig. 12 ENGINE COMPARTMENT SIDE VIEW...
Page 1061 FRAME & BUMPERS 13 - 7 FRAME (Continued)
Page 1062 13 - 8 FRAME & BUMPERS FRAME (Continued) Fig. 14 REAR FRAME SECTION...
Page 1063: Specifications - Torque
FRAME & BUMPERS 13 - 9 FRAME (Continued) SPECIFICATIONS - TORQUE TORQUE SPECIFICATIONS DESCRIPTION N·m Lbs. Lbs. Rear bumber reinforcement — attaching nut Front suspension crossmember — front attaching bolt Front suspension crossmember — rear attaching bolt Radiator support crossmember —...
Page 1064: Installation
13 - 10 FRAME & BUMPERS FRONT TOW EYE (Continued) (2) Open hood and disconnect the negative battery cable remote terminal from the battery post. (3) Hoist vehicle. (4) Partially remove the front fascia to gain access to the windshield/headlamp washer reservoir. Refer to Body for the procedure.
Page 1065 FRAME & BUMPERS 13 - 11 REAR CROSSMEMBER (Continued) Fig. 18 REAR SUSPENSION CROSSMEMBER 3 - LATERAL LINKS 1 - LATERAL LINKS 2 - REAR CROSSMEMBER ISOLATOR BUSHINGS be easily removed. (Fig. 19). Notice the forward attaching bolts face rearward. CAUTION: The bolts attaching the forward lateral links to the crossmember must be installed with the bolts pointing rearward (Fig.
Page 1066: Disassembly
13 - 12 FRAME & BUMPERS REAR CROSSMEMBER (Continued) (18) Remove the final 2 bolts attaching the rear suspension crossmember to the frame rails. These are located at the rear corners of the crossmember (Fig. 21). (19) Lower rear suspension crossmember as low as possible to allow for removal of lateral link attaching bolt at left front corner of crossmember.
Page 1067: Installation
FRAME & BUMPERS 13 - 13 REAR CROSSMEMBER (Continued) Fig. 23 SPECIAL TOOLS Fig. 22 BUSHING REMOVAL 1 - SPECIAL TOOL 8173–1 1 - SPECIAL TOOL C-4212F 2 - SPECIAL TOOL C-4212F 2 - REAR SUSPENSION CROSSMEMBER 3 - SPECIAL TOOL 8173–4 3 - BUSHING 4 - SPECIAL TOOL 8173–1 5 - SPECIAL TOOL 8173–2...
Page 1068 13 - 14 FRAME & BUMPERS REAR CROSSMEMBER (Continued) 2 rearward attaching bolts attach the front corners of the rear suspension crossmember in place). Tighten the forward stabilizer bar isolator bushing retainer attaching bolts to 40 N·m (30 ft. lbs.). Tighten the 2 rearward stabilizer bar isolator bushing retainer attaching bolts (which also serve as the front cross- member attaching bolts) to 100 N·m (75 ft.
Page 1069: Rear Tow Eye Removal
FRAME & BUMPERS 13 - 15 REAR TOW EYE REMOVAL (1) Hoist and support vehicle. Refer to Lubrication and Maintenance, for proper lifting procedure. (2) Remove bolts holding rear tow eye bracket to rear frame rail (Fig. 25). (3) Remove rear tow eye bracket from vehicle. INSTALLATION (1) Position rear tow eye bracket on vehicle.
Page 1071 FUEL SYSTEM 14 - 1 FUEL SYSTEM TABLE OF CONTENTS page page FUEL DELIVERY ......1 FUEL INJECTION .
Page 1072: Fuel Delivery
14 - 2 FUEL DELIVERY • Ignition voltage FUEL DELIVERY • Crankshaft Position (CKP) sensor • Camshaft Position (CMP) sensor DESCRIPTION The front wheel drive car uses a plastic fuel tank DIAGNOSIS AND TESTING - FUEL DELIVERY located rear center of the vehicle. SYSTEM The Fuel Delivery System consists of: the following (Refer to Appropriate Diagnostic Information)
Page 1073: Special Tools
FUEL DELIVERY 14 - 3 FUEL DELIVERY (Continued) SPECIAL TOOLS FUEL O2S (Oxygen Sensor) Remover/Installer—C-4907 Pressure Gauge Assembly C–4799–B O2S (Oxygen Sensor) Remover/Installer - 8439 FLOW MANAGEMENT VALVE DESCRIPTION It is a plastic valve inline between the fuel tank and the EVAP canister. OPERATION Fuel Pressure Test Adapter 6539 The flow management valve meters the flow of fuel...
Page 1074: Removal
14 - 4 FUEL DELIVERY FUEL LEVEL SENDING UNIT / SENSOR (Continued) REMOVAL Remove fuel pump module. Refer to Fuel Pump Module in this section. (1) Depress the retaining tab and remove the fuel pump/level sensor connector from the bottom of the fuel pump module electrical connector (Fig.
Page 1075: Fuel Lines
FUEL DELIVERY 14 - 5 FUEL LEVEL SENDING UNIT / SENSOR (Continued) Fig. 5 Fuel Level Sensor Removal Fig. 7 LEVEL SENSOR 1 - LEVEL SENSOR 1 - STANDPIPE OPENING 2 - INSTALLATION CHANNEL 2 - GROOVE 3 - BACK OF LEVEL SENSOR (7) Install fuel pump module.
Page 1076: Fuel Pressure Regulator
14 - 6 FUEL DELIVERY FUEL LINES (Continued) cracked, scuffed, or swelled hoses. Replace hoses that rub against other vehicle components or show sign of wear. Fuel injected vehicles use specially constructed hoses. When replacing hoses, only use hoses marked EFM/EFI.
Page 1077: Operation
OPERATION The Chrysler fuel pump modul is an in-tank unit with an integral fuel level sensor and pressure regu- lator. The pump is driven by a 12 volt DC motor any time the fuel pump relay is energized.
Page 1078: Fuel Rail
14 - 8 FUEL DELIVERY FUEL PUMP MODULE (Continued) the fuel tank mounted fuel pump module. Refer to Fuel Filter/Fuel Pressure Regulator in the Fuel Delivery System section of this group for information. The fuel rail is not repairable. REMOVAL - 2.7/3.5L WARNING: RELEASE FUEL SYSTEM PRESSURE BEFORE SERVICING FUEL RAIL.
Page 1079: Installation - 2.7L
FUEL DELIVERY 14 - 9 FUEL RAIL (Continued) All models are equipped with either one or two INSTALLATION rollover valves mounted into the top of the fuel tank (or pump module). INSTALLATION - 2.7L An evaporation control system is connected to the (1) Lightly lubricate the fuel injector O-rings with rollover valve(s)/control valve(Refer to 25 - EMIS- a couple drops of clean engine oil.
Page 1080 14 - 10 FUEL DELIVERY FUEL TANK (Continued) (3) Remove rear seat, refer to the Body section for (7) Loosen the rear stabilizer bar brackets from more information. body. Swing stabilizer bar toward rear of vehicle (Fig. (4) Disconnect fuel pump electrical connector (Fig. 14). 16) and (Fig.
Page 1081 FUEL DELIVERY 14 - 11 FUEL TANK (Continued) Fig. 20 HARNESS ON TANK PIN 1 - Pin 2 - Wiring Harness Fig. 18 Fuel and EVAP Lines 1 - EVAP LINES 2 - BRAKE LINES 3 - FUEL LINE (12) Remove the wiring harness from the heat shield, if needed (Fig.
Page 1082: Fuel Tank Filler Tube
14 - 12 FUEL DELIVERY FUEL TANK FILLER TUBE REMOVAL (1) Disconnect negative cable from battery. (2) Drain fuel tank. (3) Remove 3 screws from filler neck to quarter panel. (4) Raise and support vehicle on host. (5) Loosen clamps at filler neck. (6) Remove filler neck.
Page 1083 FUEL DELIVERY 14 - 13 QUICK CONNECT FITTING (Continued) INSTALLATION plied for disconnecting the quick-connect fitting from component being serviced. CAUTION: Never install a quick-connect fitting with- out the retainer being either on the fuel tube or already in the quick-connect fitting. In either case, ensure the retainer locks securely into the quick- connect fitting by firmly pulling on fuel tube and fit- ting to ensure it is secured.
Page 1084 14 - 14 FUEL DELIVERY QUICK CONNECT FITTING (Continued) CAUTION: When the quick-connect fitting was dis- CAUTION: The interior components (O-rings, spac- connected, the plastic retainer will remain on the ers, retainers) of this type of quick-connect fitting component being serviced. If this retainer must be are not serviced separately.
Page 1085 FUEL INJECTION 14 - 15 FUEL INJECTION TABLE OF CONTENTS page page FUEL INJECTION INSTALLATION ......27 OPERATION MANIFOLD TUNE VALVE OPERATION - INJECTION SYSTEM...
Page 1086: Fuel Injection
14 - 16 FUEL INJECTION sensor diagnostics (they are checked for shorted con- FUEL INJECTION ditions at all times). During CLOSED LOOP modes the PCM monitors OPERATION the inputs from the upstream and downstream heated oxygen sensors. The upstream heated oxygen OPERATION - INJECTION SYSTEM sensor input tells the PCM if the calculated injector pulse width resulted in the ideal air-fuel ratio of 14.7...
Page 1087 FUEL INJECTION 14 - 17 FUEL INJECTION (Continued) • Camshaft position 1 second. Therefore, battery voltage is not supplied to • Knock sensor the fuel pump, ignition coil, fuel injectors and heated • Throttle position oxygen sensors. • A/C switch status ENGINE START-UP MODE •...
Page 1088: Fuel Correction Or Adaptive Memories
14 - 18 FUEL INJECTION FUEL INJECTION (Continued) • All monitored components (refer to the Emission WIDE-OPEN-THROTTLE MODE section for On-Board Diagnostics). This is an OPEN LOOP mode. During wide-open- The PCM compares the upstream and downstream throttle operation, the following inputs are used by heated oxygen sensor inputs to measure catalytic the PCM: •...
Page 1089: Programmable Communications Interface (Pci) Bus
FUEL INJECTION 14 - 19 FUEL INJECTION (Continued) opposite preset limit or switch point. The process As the engine enters one of these cells the PCM then repeats itself in the opposite direction. looks at the amount of short term correction being Short term fuel correction will keep increasing or used.
Page 1090: System Diagnosis
14 - 20 FUEL INJECTION FUEL INJECTION (Continued) • Instrument Panel system, the PCM stores a Diagnostic Trouble Code • Body Control Module (DTC) in memory. • Air Bag System Diagnostic Module For DTC information see On-Board Diagnostics • Full ATC Display Head (if equipped) (Refer to 8 - ELECTRICAL/ELECTRONIC CON- •...
Page 1091: Special Tools
FUEL INJECTION 14 - 21 FUEL INJECTION (Continued) SPECIAL TOOLS FUEL O2S (Oxygen Sensor) Remover/Installer—C-4907 Pressure Gauge Assembly C–4799–B O2S (Oxygen Sensor) Remover/Installer - 8439 ACCELERATOR PEDAL REMOVAL (1) Working from the engine compartment, hold the throttle body throttle lever in the wide open posi- tion.
Page 1092: Installation
14 - 22 FUEL INJECTION ACCELERATOR PEDAL (Continued) Fig. 4 CARPET AND INSULATION PLACEMENT 1 - PEDAL BASE 2 - CARPET 3 - INSULATION Fig. 2 RETAINER CLIP 4 - FLOOR PAN (3) Working from the passenger compartment, CRANKSHAFT POSITION remove nuts from accelerator pedal base (Fig.
Page 1093: Operation
FUEL INJECTION 14 - 23 CRANKSHAFT POSITION SENSOR (Continued) OPERATION tial housing. The bottom of the sensor sits above the drive plate. Engine speed and crankshaft position are provided (1) Disconnect electrical connector from crankshaft through the crankshaft position sensor. The sensor position sensor.
Page 1094: Removal - 2.7L
14 - 24 FUEL INJECTION FUEL INJECTOR (Continued) Fig. 9 FUEL INJECTOR - TYPICAL Fig. 7 Fuel Injector - Typical 1 - FUEL INJECTOR 2 - NOZZLE 3 - TOP (FUEL ENTRY) REMOVAL REMOVAL - 2.7L (1) Release fuel system pressure. Refer to Fuel System Pressure Release Procedure in this section.
Page 1095: Installation - 2.7L
FUEL INJECTION 14 - 25 FUEL INJECTOR (Continued) (3) Remove intake manifold plenum. Refer to the (7) Install intake manifold plenum. Refer to the Engine section for information. Engine section for information. (4) Remove intake manifold plenum mounting (8) Connect the battery cable. bolts.
Page 1096: Operation
14 - 26 FUEL INJECTION IDLE AIR CONTROL MOTOR (Continued) OPERATION The PCM adjusts engine idle speed through the idle air control motor to compensate for engine load, coolant temperature or barometric pressure changes. The throttle body has an air bypass passage that provides air for the engine during closed throttle idle.
Page 1097: Inlet Air Temperature Sensor
FUEL INJECTION 14 - 27 INLET AIR TEMPERATURE MANIFOLD TUNE VALVE SENSOR REMOVAL - 3.5L (1) Disconnect negative battery cable. REMOVAL (2) Disconnect electrical connector (Fig. 13). (1) Remove the negative battery cable. (2) Disconnect electrical connector from sensor. (3) Remove sensor from clean air hose to throttle body.
Page 1098 14 - 28 FUEL INJECTION MAP SENSOR (Continued) because as air pressure changes the barometric pres- sure changes. Barometric pressure and altitude have a direct inverse correlation, as altitude goes up baro- metric pressure goes down. The first thing that hap- pens as the ignition key is rolled on, before reaching the crank position, the PCM powers up, and looks at the MAP voltage, and based upon the voltage it sees,...
Page 1099: Removal - 2.7L
FUEL INJECTION 14 - 29 MAP SENSOR (Continued) sure drops .10 in. Hg. If a storm goes through it can either add, high pressure, or decrease, low pressure, from what should be present for that altitude.You should make a habit of knowing what the average pressure and corresponding barometric pressure is for your area.
Page 1100: Operation
14 - 30 FUEL INJECTION O2 SENSOR (Continued) less efficient catalyst. To monitor catalytic convertor deterioration, the fuel injection system uses two heated oxygen sensors. One sensor upstream of the catalytic convertor, one downstream of the convertor. The PCM compares the reading from the sensors to calculate the catalytic convertor oxygen storage capacity and converter efficiency.
Page 1101: Removal - Upstream 1/1 Or 2/1
FUEL INJECTION 14 - 31 O2 SENSOR (Continued) UPSTREAM OXYGEN SENSOR The input from the upstream heated oxygen sensor tells the PCM the oxygen content of the exhaust gas. Based on this input, the PCM fine tunes the air-fuel ratio by adjusting injector pulse width. The sensor input switches from 0 to 1 volt, depend- ing upon the oxygen content of the exhaust gas in the exhaust manifold (this is offset by 2.5 voltage on...
Page 1102: Installation - Upstream 1/1 Or 2/1
14 - 32 FUEL INJECTION O2 SENSOR (Continued) (2) Raise and support the vehicle. (3) Disconnect the wire connector from the O2 sen- sors. CAUTION: When disconnecting the sensor electrical connector, do not pull directly on wire going into sensor. (4) Remove the O2 sensors.
Page 1103: Installation - 3.5L
FUEL INJECTION 14 - 33 SHORT RUNNER VALVE (Continued) INSTALLATION - 3.5L (1) Install 3 bolts and tighten to 6.7 N·m ( 60 in. lbs.). (2) Install link. (3) Install electrical connector. (4) Install the negative battery cable. THROTTLE BODY DESCRIPTION The throttle body is located on the intake manifold (Fig.
Page 1104: Installation - 2.7L
14 - 34 FUEL INJECTION THROTTLE BODY (Continued) (3) From inside the vehicle, hold up the pedal and INSTALLATION install throttle cable and cable retainer in the upper end of the pedal shaft (Fig. 1). INSTALLATION - 2.7L (4) At the dash panel, install the cable retainer (1) Install throttle body and bolts.
Page 1105: Removal - 2.7L
FUEL INJECTION 14 - 35 THROTTLE POSITION SENSOR (Continued) Fig. 28 THROTTLE POSITION SENSOR 3.2/3.5L Fig. 29 Throttle Position Sensor—2.7L Engine ENGINE 1 - TPS SENSOR 2 - THROTTLE BODY 1 - TPS 3 - PCV VALVE 2 - IAC 4 - EGR TUBE ating conditions.
Page 1107 STEERING 19 - 1 STEERING TABLE OF CONTENTS page page STEERING DIAGNOSIS AND TESTING - SPEED DESCRIPTION - POWER STEERING SYSTEM . . 1 PROPORTIONAL POWER STEERING ..10 OPERATION - POWER STEERING SYSTEM . . . 1 SPECIFICATIONS WARNING .
Page 1108: Caution
19 - 2 STEERING STEERING (Continued) CAUTION: If the vehicle is equipped with the Tire (1) Assemble hoses on Power Steering Analyzer, Pressure Monitoring (TPM) System, the tire/wheel Special Tool 6815, as shown. Install Pressure Hose, Special Tool 6905 (in 6893 kit), in the inlet fitting on assembly needs to be reinstalled in the same loca- tion it is removed from or the TPM System (sen- Power Steering Analyzer.
Page 1109 STEERING 19 - 3 STEERING (Continued) Disconnect the power steering fluid pressure (4) 2.7L engine — Connect Adapter Fitting, Spe- hose from the power steering pump (Fig. 3) (Fig. 4). cial Tool 6844 (Fig. 5), attached to pressure hose from inlet (gauge end) of Power Steering Analyzer to the pressure fitting on the power steering pump.
Page 1110: Diagnosis And Testing - Steering
19 - 4 STEERING STEERING (Continued) • Power steering pump pressures above specifica- (6) Connect vehicle power steering fluid pressure hose to Adapter Fitting, Special Tool 6826, which tions but not within 345 kPa (50 psi) of each other, should be already installed in the outlet hose (valve replace pump.
Page 1111 STEERING 19 - 5 STEERING (Continued) POWER STEERING NOISE CONDITION POSSIBLE CAUSES CORRECTION OBJECTIONABLE HISS OR 1. Damaged or mispositioned steering 1. Reposition or replace steering column WHISTLE* column shaft/coupling dash panel seal. shaft/coupling dash panel seal. 2. Noisy valve in power steering gear. 2.
Page 1112 19 - 6 STEERING STEERING (Continued) CONDITION POSSIBLE CAUSES CORRECTION WHINE OR GROWL 1. Low fluid level. 1. Fill power steering fluid reservoir to (POWER STEERING proper level and check for leaks (make PUMP)** sure all air is bled from the system fluid). 2.
Page 1113 STEERING 19 - 7 STEERING (Continued) STEERING WHEEL FEEL CONDITION POSSIBLE CAUSES CORRECTION STEERING WHEEL/ 1. Loose steering coupling pinch 1. Replace pinch bolt and torque to COLUMN CLICKING, bolt. specifications. CLUNKING OR RATTLING. 2. Steering column bearings. 2. Replace steering column. STEERING WHEEL HAS 1.
Page 1114 19 - 8 STEERING STEERING (Continued) CONDITION POSSIBLE CAUSES CORRECTION 10. Excessive friction in power 10. Replace power steering gear. steering gear. 11. Worn/binding seat and bearing in 11. Replace seat and bearing in front strut front strut assembly. assembly. STIFF, HARD TO TURN, 1.
Page 1115 STEERING 19 - 9 STEERING (Continued) CONDITION POSSIBLE CAUSES CORRECTION EXCESSIVE STEERING 1. Air in the fluid of the power 1. Bleed air from system following the the WHEEL KICKBACK OR steering system. power steering pump initial operation TOO MUCH STEERING service procedure.* WHEEL FREE PLAY.
Page 1116: Diagnosis And Testing - Speed Proportional Power Steering
19 - 10 STEERING STEERING (Continued) POWER STEERING FLUID CONDITION POSSIBLE CAUSES CORRECTION LOW FLUID LEVEL WITH 1. Loose power steering hose 1. Tighten the fitting to its specified torque. VISIBLE LEAK. fittings. 2. Damaged or missing fitting seal, 2. Replace as necessary. gasket, or O-ring.
Page 1117: Steering Column Fastener Torque
STEERING 19 - 11 STEERING (Continued) STEERING COLUMN FASTENER TORQUE DESCRIPTION N·m Lbs. Lbs. Airbag Module Mounting — Bolts Speed Control Switch — Screws Puller C-4333 Steering Column Coupler Pinch Bolt Steering Column Mounting — Bolts Steering Column Mounting — Nuts Steering Wheel Retaining —...
Page 1118 19 - 12 COLUMN COLUMN TABLE OF CONTENTS page page COLUMN LOCK CYLINDER HOUSING DESCRIPTION ......12 REMOVAL .
Page 1119: Column
COLUMN 19 - 13 COLUMN (Continued) Fig. 1 Steering Column 1 - SHIFT LEVER (COLUMN SHIFT ONLY) 4 - STEERING COLUMN MOUNTING BRACKET 2 - TILT HOUSING 5 - STEERING COLUMN COUPLER 3 - TILT MECHANISM ACTUATOR 6 - STEERING COLUMN LOWER MOUNTING BRACKET WARNING: THE AIR BAG SYSTEM IS A SENSITIVE, WARNING: WHEN HANDLING AN UNDEPLOYED COMPLEX ELECTRO-MECHANICAL UNIT.
Page 1120: Diagnosis And Testing - Steering
19 - 14 COLUMN COLUMN (Continued) (1) Remove remote ground cable from ground stud CAUTION on shock tower and isolate ground cable from vehicle by installing isolator on stud (Fig. 2). CAUTIONS CAUTION: Disconnect the negative (ground) cable from the battery, before servicing any column com- ponent.
Page 1121 COLUMN 19 - 15 COLUMN (Continued) (3) Remove the 2 screws behind the fuse panel cover attaching the lower instrument panel cover to the instrument panel (Fig. 4). Fig. 6 Park Brake Release Cable 1 - PARK BRAKE RELEASE CABLE 2 - PARK BRAKE RELEASE HANDLE 3 - LOWER INSTRUMENT PANEL COVER Fig.
Page 1122 19 - 16 COLUMN COLUMN (Continued) (8) Before beginning removal of steering column (10) Remove the 2 bolts attaching the driver air- assembly from vehicle, be sure front wheels of vehicle bag to the steering wheel (Fig. 10). are in the STRAIGHT-AHEAD position. CAUTION: When removing the steering wheel, use care not to damage the steering wheel finish.
Page 1123 COLUMN 19 - 17 COLUMN (Continued) (15) Remove the steering wheel attaching nut from CAUTION: Do not bump or hammer on steering the steering column shaft (Fig. 12). wheel or steering column shaft when removing steering wheel from steering column. (17) Remove steering wheel from steering column shaft.
Page 1124 19 - 18 COLUMN COLUMN (Continued) (20) Remove the two screws attaching the lower (22) Remove the two screws (Fig. 17) mounting the shroud to the steering column (Fig. 15). Remove the clockspring to the steering column. Remove the clock- lower shroud from the steering column.
Page 1125 COLUMN 19 - 19 COLUMN (Continued) (25) Remove the 2 screws (Fig. 19) mounting the (27) If the vehicle is equipped with a steering col- ignition switch to the steering column. Remove the umn mounted shift lever, remove the brake transmis- ignition switch, with the wiring harness attached, sion shift interlock (BTSI) solenoid from the shift from the steering column.
Page 1126 19 - 20 COLUMN COLUMN (Continued) (28) If the vehicle is equipped with a steering col- (30) Remove the 2 air ducts (Fig. 25) from under umn mounted shift lever, remove the shift cable from the steering column. the shifter mechanism. Unlock the cable lock, then, the shift cable is removed by inserting a screwdriver between the shift cable and the shifter mechanism and prying the cable off the pin (Fig.
Page 1127: Installation - Steering Column
COLUMN 19 - 21 COLUMN (Continued) (32) Remove the 2 steering column upper mount- (5) If the vehicle is equipped with a floor shifter, ing bracket to support bracket nuts (Fig. 27). Then install the shifter/ignition interlock cable (Fig. 20) in loosen the 2 bolts attaching the steering column the lock cylinder housing.
Page 1128 19 - 22 COLUMN COLUMN (Continued) (b) Slide the solenoid completely onto the shift (10) If the vehicle is equipped with a steering col- lever mounting stud aligning the plastic guide umn mounted shift lever and if a new ignition shift formed into the solenoid housing with the flange on interlock cassette has been installed, the interlock the shift lever mechanism bracket (Fig.
Page 1129 COLUMN 19 - 23 COLUMN (Continued) CAUTION: If any doubt is present as to whether the (25) If optional audio control switches are present clockspring is properly centered, This clockspring on the rear of the steering wheel, connect the 4-way connector lead from the clockspring to the steering centering procedure MUST be performed prior to installing steering wheel assembly.
Page 1130: Ignition Switch Removal
19 - 24 COLUMN COLUMN (Continued) • Connect DRBIII scan tool to diagnostic connec- tor below the column. • Turn ignition key to ON position. Exit vehicle with the DRBIII scan tool. • Ensuring that there are no occupants in the vehicle, connect negative cable to negative post of the battery.
Page 1131: Intermediate Shaft
COLUMN 19 - 25 INTERMEDIATE SHAFT DIAGNOSIS AND TESTING - STEERING COLUMN INTERMEDIATE SHAFT The steering column (to steering gear) intermedi- ate shaft has an integrated lower coupler with uni- versal joint. The entire assembly MUST be replaced whenever any of the following conditions exist. •...
Page 1132: Installation
19 - 26 COLUMN KEY/LOCK CYLINDER (Continued) INSTALLATION (4) Turn key to Off position. Remove key. (5) If the vehicle has column shift and a new lock The lock cylinder is inserted in the end of the cylinder was used, install and adjust a new interlock housing opposite the ignition switch.
Page 1133: Installation
COLUMN 19 - 27 LOCK CYLINDER HOUSING (Continued) (7) Lift off multifunction switch, then disconnect two wiring connectors and remove switch. (8) Remove two torx-head screws securing ignition switch in place (Fig. 40). Remove switch from col- umn. allow switch to hang by wiring harness. Fig.
Page 1134: Shroud - Lower Removal
19 - 28 COLUMN (4) Remove the wiring harness connector from the SHROUD - LOWER trunk release switch in the lower instrument panel cover (Fig. 44). REMOVAL (1) Remove the fuse panel cover from the left end of the instrument panel (Fig. 42). Fig.
Page 1135: Installation
COLUMN 19 - 29 SHROUD - LOWER (Continued) (6) Remove the upper shroud from the steering col- (2) Install the tilt lever on the steering column and umn using the following procedure: install the mounting screw (Fig. 46). (a) On the right side of the steering column, (3) Install the upper shroud on the steering col- push in on seam between the upper and lower umn by snapping it onto the lower shroud.
Page 1136: Steering Coupling
19 - 30 COLUMN STEERING COUPLING DIAGNOSIS AND TESTING - STEERING COLUMN SHAFT UPPER COUPLER If the steering column shaft upper coupler is diag- nosed to be defective due to any of the following con- ditions: seized bearing, loose bearing stake or a bearing not fully seated in the yoke of the coupler assembly, the coupler can be serviced as a separate component of the steering column assembly.
Page 1137: Installation
COLUMN 19 - 31 STEERING WHEEL (Continued) (7) If optional audio control switches are present STEERING COLUMN GEAR on the rear of the steering wheel, disconnect the SHIFT LEVER 4-way connector between the clockspring and steer- ing wheel wiring harness. REMOVAL (8) Remove steering wheel retaining nut.
Page 1138 19 - 32 COLUMN STEERING COLUMN GEAR SHIFT LEVER (Continued) (4) Remove the tilt lever and the upper and lower steering column shrouds from steering column assembly (Fig. 51). Then remove center outlet bezel. Fig. 53 Solenoid Retainer Clip 1 - SOLENOID 2 - MOUNTING STUD 3 - RETAINER CLIP (6) Remove the gear shift cable from the attaching...
Page 1139: Installation
COLUMN 19 - 33 STEERING COLUMN GEAR SHIFT LEVER (Continued) INSTALLATION (1) Install new shift lever assembly on tilt housing of steering column. Install and securely tighten the 3 Torx head screws attaching shift lever assembly to tilt housing. (2) Install the gear shift cable onto the cable attaching pin on shift lever assembly.
Page 1140 19 - 34 COLUMN STEERING COLUMN GEAR SHIFT LEVER (Continued) (7) Adjust the ignition interlock system by pushing (8) Install upper and lower shroud on steering col- in on the adjustment tab until it stops (Fig. 58). The umn assembly (Fig. 51). adjustment tab will click as it moves into position.
Page 1141 GEAR 19 - 35 GEAR TABLE OF CONTENTS page page GEAR OPERATION - SOLENOID CONTROL VALVE . . 45 DESCRIPTION REMOVAL - SOLENOID CONTROL VALVE ..45 DESCRIPTION - POWER STEERING GEAR . 35 INSTALLATION - SOLENOID CONTROL VALVE . 46 DESCRIPTION - SPEED PROPORTIONAL TIE ROD - INNER STEERING GEAR .
Page 1142 19 - 36 GEAR GEAR (Continued) Fig. 1 Power Steering Gear 1 - STEERING GEAR FLUID LINES 6 - ADJUSTMENT SLEEVE 2 - STEERING GEAR BOOT 7 - INNER TIE ROD 3 - RACK AND PINION STEERING GEAR 8 - ADJUSTMENT SLEEVE 4 - CLAMP 9 - TIE ROD END 5 - TIE ROD END...
Page 1143: Steering Gear
GEAR 19 - 37 GEAR (Continued) REMOVAL - POWER STEERING GEAR OPERATION (1) Remove the battery ground cable from the OPERATION - POWER STEERING GEAR ground stud on the shock tower and isolate the ground cable by installing the cable isolator on the Turning of the steering wheel is converted into lat- ground stud (Fig.
Page 1144 19 - 38 GEAR GEAR (Continued) CAUTION: Before removing the steering column (7) Remove the wiper arms from the pivots. Wiper coupler from the intermediated steering shaft be arms are removed from the pivots by rocking them back and force on the pivots until they can be pulled sure the steering wheel is locked from rotating (Fig.
Page 1145 GEAR 19 - 39 GEAR (Continued) (10) Remove the in-line resonator and inlet hose (Fig. 9) from the throttle body and air let hose com- ing from the lid of the air cleaner housing. Fig. 11 Master Cylinder To Vacuum Booster Mounting 1 - MOUNTING NUT 2 - MASTER CYLINDER 3 - MOUNTING NUT...
Page 1146 19 - 40 GEAR GEAR (Continued) (17) Remove the bolts, mounting plate and washers (20) Remove the two bolts attaching the left side of attaching the tie rods to the steering gear (Fig. 13). Lay the steering gear to the crossmember (Fig. 15). the tie rods on top of the transaxle bell housing.
Page 1147 GEAR 19 - 41 GEAR (Continued) NOTE: It may be necessary to loosen the two mounting bolts (Fig. 17) attaching the right mount- ing bracket to the steering gear in order to clear the air conditioning lines. Fig. 18 Steering Coupler Roll Pin 1 - SPECIAL TOOL 6831–A 2 - DASH PANEL SEAL &...
Page 1148 19 - 42 GEAR GEAR (Continued) (28) Remove the tie rod end from the steering arm of the strut using Puller, Special Tool C-3894–A (Fig. 20). Fig. 22 Steering Gear Through Tie Rod Hole 1 - FENDER 2 - TIE ROD HOLE Fig.
Page 1149: Disassembly - Power Steering Gear (Housing Bushings)
GEAR 19 - 43 GEAR (Continued) DISASSEMBLY - POWER STEERING GEAR toms in the recessed area of the steering gear hous- ing. (HOUSING BUSHINGS) The power steering gear must be removed from the vehicle for the bushings to be serviced. Refer to REMOVAL in this section.
Page 1150 19 - 44 GEAR GEAR (Continued) (8) Using roll pin Installer, Special Tool 6831A, (11) Install the bolts mounting the right side install the roll pin in the flex joint of the intermedi- mounting bracket for the steering gear to the cross- ate shaft (Fig.
Page 1151: Speed Proportional Steering Solenoid
GEAR 19 - 45 GEAR (Continued) (16) Align center take off on steering gear with the (23) Install the wiper arms (Fig. 6) on the pivots. tie rod assemblies. Install tie rod attaching bolts and Install and securely tighten the wiper arm to pivot washers into steering gear assembly.
Page 1152: Installation - Solenoid Control Valve
19 - 46 GEAR SPEED PROPORTIONAL STEERING SOLENOID (Continued) Fig. 31 Loosening Solenoid Control Valve 1 - SOLENOID CONTROL VALVE 2 - RETURN HOSE Fig. 29 Wiring Harness 3 - 15/16 CROW FOOT 4 - STEERING GEAR 1 - SPEED PROPORTIONAL STEERING SOLENOID CONNECTOR INSTALLATION - SOLENOID CONTROL VALVE 2 - MASTER CYLINDER RESERVOIR...
Page 1153: Tie Rod - Inner
GEAR 19 - 47 SPEED PROPORTIONAL STEERING SOLENOID (Continued) (4) Reconnect the power steering hoses at the gear (Fig. 30). Tighten both hose tube nuts to 31 N·m (275 in lbs.). (5) Route the solenoid control valve wire harness over the top of the gear and clip it into place on the gear end cap.
Page 1154 19 - 48 GEAR TIE ROD - INNER (Continued) (6) Remove the in-line resonator and inlet hose (10) Remove the tie rod end from the steering arm from the throttle body and air let hose coming from of the strut using Puller, Special Tool C-3894–A (Fig. the lid of the air cleaner housing (Fig.
Page 1155: Installation - Inner Tie Rod
GEAR 19 - 49 TIE ROD - INNER (Continued) (13) Remove the bolt fastening the inner tie rod requiring service to the steering gear (Fig. 41). Be careful not to loose the washer behind the tie rod. (14) Loosen the bolt fastening the opposite inner tie rod to the gear, but do not fully remove it.
Page 1156: Tie Rod - Outer
19 - 50 GEAR TIE ROD - INNER (Continued) (4) Align the inner tie rod with the mounting hole attaching nuts. Install the caps on the wiper arms in the center take off on steering gear. Rotate the covering the pivot nuts. mounting plate into position over the tie rod.
Page 1157: Removal - Outer Tie Rod
GEAR 19 - 51 TIE ROD - OUTER (Continued) (6) Equally tighten both nuts on the U-bolt until a torque of 2.7 N·m (24 in. lbs.) is achieved on each nut. (7) Note the tie rod socket end play. New ball joint end play should not be greater then 0.100 inches.
Page 1158: Bushing - Inner Tie Rod
19 - 52 GEAR TIE ROD - OUTER (Continued) Check the front wheel toe setting on vehicle (1) Remove the battery ground cable from the and make required changes. When making front ground stud on the shock tower and isolate the wheel toe adjustments, be sure the maximum ground cable by installing the cable isolator on the exposed thread requirements (Fig.
Page 1159 GEAR 19 - 53 BUSHING - INNER TIE ROD (Continued) (4) Remove the wiper module cover and cowl cover from the vehicle (Fig. 52). Fig. 52 Wiper Module And Cowl Cover 1 - COWL COVER 2 - WIPER MODULE COVER (5) Remove the eight bolts attaching the cowl rein- Fig.
Page 1160: Installation - Inner Tie Rod Bushing
19 - 54 GEAR BUSHING - INNER TIE ROD (Continued) (10) Remove the tie rod end from the steering arm (14) Loosen the bolt fastening the opposite inner of the strut using Puller, Special Tool C-3894–A (Fig. tie rod to the gear, but do not fully remove it. 56).
Page 1161 GEAR 19 - 55 BUSHING - INNER TIE ROD (Continued) (3) With Receiver, Special Tool 8438–1, mounted in the vise as shown (Fig. 61), assemble the Special Tool 8438 in the following manner to install the new bushing. (a) Place the inner tie rod end in Receiver as shown (Fig.
Page 1162 19 - 56 GEAR BUSHING - INNER TIE ROD (Continued) (4) Remove the Screw, Remover/Installer and Sizer, then remove the tie rod from the Receiver. (5) Inspect the bushing. It will appear slightly off- center in the tie rod (Fig. 62). This is a normal con- dition.
Page 1163 GEAR 19 - 57 BUSHING - INNER TIE ROD (Continued) (9) Tighten both tie rod to steering gear bolts to a (16) Install the reinforcement on the vehicle (Fig. torque of 100 N·m (74 ft. lbs.). 53). Install the eight bolts attaching the cowl rein- (10) Bend retaining tabs against heads of tie rod forcement to the strut towers.
Page 1164 19 - 58 PUMP PUMP TABLE OF CONTENTS page page PUMP REMOVAL ......66 DESCRIPTION .
Page 1165: Operation
PUMP 19 - 59 PUMP (Continued) valve ball from its seat and allows oil to flow through a trigger orifice located in the outlet fitting. This reduces pressure on the spring end of the flow con- trol valve which then opens and allows the oil to return to the intake side of the pump.
Page 1166: Removal - Pump (2.7L Engine)
19 - 60 PUMP PUMP (Continued) REMOVAL REMOVAL - PUMP (2.7L ENGINE) (1) Remove the battery ground cable from the ground stud on the shock tower and isolate the ground cable by installing the cable isolator on the ground stud (Fig. 3). Fig.
Page 1167: Removal - Pump (3.5L Engine)
PUMP 19 - 61 PUMP (Continued) (7) Let remaining power steering fluid drain from the power steering pump. (8) Loosen the lock-nut (Fig. 6) on the front of the pulley for the serpentine drive belt tensioner. Fig. 7 Tensioner Bracket To Power Steering Pump Sleeve 1 - SCREWDRIVER 2 - POWER STEERING PUMP...
Page 1168 19 - 62 PUMP PUMP (Continued) (2) Using a siphon pump, remove as much power steering fluid as possible from the power steering fluid reservoir. (3) Raise vehicle. (Refer to LUBRICATION & MAINTENANCE/HOISTING - STANDARD PROCE- DURE) (4) Remove the power steering fluid supply hose (Fig.
Page 1169: Disassembly - Pump (Pulley)
PUMP 19 - 63 PUMP (Continued) (13) Remove the power steering pump from the engine. The power steering pump and pulley are removed as an assembly from the engine. The power steering pump is removed from the bottom of the engine between the radiator lower support and the cradle (Fig.
Page 1170: Installation - Pump (2.7L Engine)
19 - 64 PUMP PUMP (Continued) the Installer into the end of the power steering pump sure the sleeve is fully seated against the power shaft (Fig. 15). Tighten the installer into pump shaft. steering pump. (4) Holding the Pulley Installer with one wrench (3) Tighten the power steering pump mounting so it will not rotate, turn hex nut down threaded rod bolts to a torque of 28 N·m (250 in.
Page 1171: Specifications
PUMP 19 - 65 PUMP (Continued) SPECIFICATIONS POWER STEERING PUMP FLOW SPECIFICATIONS DESCRIPTION SPECIFICATION Flow At 1500 RPM And 8.0 – 9.5 Liters/Min. Minimum Pressure 2.1 – 2.5 GPM Control Valve Relief 8618 – 9308 kPa Pressure 1250 – 1350 psi FLUID STANDARD PROCEDURE - POWER STEERING Fig.
Page 1172: Removal
19 - 66 PUMP FLUID COOLER (Continued) heat from the cooler which it has absorbed from the (6) Remove the 6 clips (Fig. 21) mounting the air power steering fluid flowing through it. The cooler is dam to the radiator lower support. placed in series with the power steering fluid return line, between the steering gear and the power steer- ing fluid reservoir.
Page 1173: Hoses Description
PUMP 19 - 67 FLUID COOLER (Continued) hose clamps are installed on hose past the upset bead on the power steering cooler. (5) 300M only - Reinstall front fascia. (6) Lower the vehicle to a point where front tires are just off the ground. (7) Perform Power Steering Pump Initial Opera- tion procedure (Refer to 19 - STEERING/PUMP - STANDARD PROCEDURE).
Page 1174 19 - 68 PUMP HOSES (Continued) (7) Remove the 8 bolts, attaching the reinforce- ment (Fig. 26)to the strut towers and the 1 bolt (Fig. 26) attaching the wiper module to the reinforcement. Remove the reinforcement from the vehicle. Fig. 28 Steering Wheel Lock Installed (Typical) 1 - STEERING WHEEL Fig.
Page 1175 PUMP 19 - 69 HOSES (Continued) (11) Bend back the retaining tabs on the mounting (13) Using a siphon pump, remove as much power plate for the tie rod to steering gear mounting bolts steering fluid as possible from the power steering (Fig.
Page 1176 19 - 70 PUMP HOSES (Continued) (18) Remove the 2 bolts attaching the left side of (20) Move the steering gear to clear the pressure the steering gear to the crossmember (Fig. 34). and return lines. (21) Remove the bolts mounting the power steer- ing hoses to the left frame rail (Fig.
Page 1177: Installation - Pressure And Return Hoses
PUMP 19 - 71 HOSES (Continued) (25) Lower the vehicle. (8) Loosely install the bolts mounting the left side (26) Remove the power steering fluid hoses from of the steering gear to the crossmember (Fig. 34). the vehicle. The power steering fluid hoses are CAUTION: Tightening the steering gear to cross- removable from the back of the engine compartment member mounting bolts to the proper torque is very...
Page 1178: Reservoir Description
19 - 72 PUMP HOSES (Continued) (12) Align center take-off on steering gear with the (19) Install the covers over the wiper module and tie rod assemblies. Install tie rod attaching bolts and the cowl (Fig. 25). Install and securely tighten the washers into steering gear.
Page 1179: Removal - Reservoir (2.7L Engine)
PUMP 19 - 73 RESERVOIR (Continued) REMOVAL REMOVAL - RESERVOIR (2.7L ENGINE) The 2.7 liter engine uses a power steering fluid reservoir that is integral to the power steering pump. To replace the power steering fluid reservoir used on this power steering pump the power steering pump will need to be removed from the engine.
Page 1180: Installation - Reservoir (3.5L Engine)
19 - 74 PUMP RESERVOIR (Continued) (3) Install and securely tighten the three bolts INSTALLATION mounting the power steering fluid reservoir to the power steering pump. Tighten bolt on pulley side to INSTALLATION - RESERVOIR (2.7L ENGINE) 13 N·m (115 in. lbs.). Tighten bolts on rear to 24 N·m (1) Lubricate the O-ring seal on the power steering (212 in.
Page 1181 TRANSAXLE 21 - 1 TRANSAXLE TABLE OF CONTENTS page page 42LE AUTOMATIC TRANSAXLE STANDARD PROCEDURE - FLUID/FILTER DESCRIPTION ......2 SERVICE .
Page 1182: 42Le Automatic Transaxle
21 - 2 TRANSAXLE SHIFT INTERLOCK SOLENOID INSTALLATION ......145 REMOVAL ......134 TORQUE CONVERTER INSTALLATION .
Page 1183 TRANSAXLE 21 - 3 42LE AUTOMATIC TRANSAXLE (Continued) Fig. 1 42LE Transaxle 1 - DIFFERENTIAL 7 - OUTPUT GEAR 13 - UNDERDRIVE CLUTCH 2 - TRANSFER SHAFT 8 - OUTPUT SPEED SENSOR 14 - INPUT SPEED SENSOR 3 - TRANSFER GEAR 9 - LOW/REVERSE CLUTCH 15 - CONVERTER CLUTCH 4 - FRONT PLANET CARRIER...
Page 1184: Operation
21 - 4 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) TRANSAXLE IDENTIFICATION The 42LE transaxle identification code is a series of digits printed on a bar-code label that is fixed to the transaxle case as shown in (Fig. 2). For example, the identification code K 821 1125 1316 can be broken down as follows: •...
Page 1185: Diagnosis And Testing - Road Test
TRANSAXLE 21 - 5 42LE AUTOMATIC TRANSAXLE (Continued) • Dynamic conditions (acceleration, deceleration, During the road test, the transaxle should be oper- upshift, cornering) ated in each position to check for slipping and any • Elements in use when condition occurs (what variation in shifting.
Page 1186: Diagnosis And Testing - Hydraulic Pressure Tests
21 - 6 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) DIAGNOSIS AND TESTING - HYDRAULIC TEST TWO-SELECTOR IN DRIVE (Second Gear) PRESSURE TESTS NOTE: This test checks the underdrive clutch Pressure testing is a very important step in the hydraulic circuit as well as the shift schedule. diagnostic procedure.
Page 1187 TRANSAXLE 21 - 7 42LE AUTOMATIC TRANSAXLE (Continued) TEST FIVE-SELECTOR IN OVERDRIVE (Fourth TEST SIX-SELECTOR IN REVERSE Gear, CC on) NOTE: This test checks the reverse clutch hydraulic circuit. NOTE: These tests check the torque converter clutch hydraulic circuit. (1) Attach gauge to the reverse and low/reverse clutch tap.
Page 1188: Diagnosis And Testing - Clutch Air Pressure Tests
21 - 8 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) DIAGNOSIS AND TESTING - CLUTCH AIR to the low/reverse or the 2/4 clutches. This locks the output shaft. Use a piece of rubber hose wrapped PRESSURE TESTS around the input shaft and a pair of clamp-on pliers Inoperative clutches can be located by substituting to turn the input shaft.
Page 1189 TRANSAXLE 21 - 9 42LE AUTOMATIC TRANSAXLE (Continued) ATF is dyed red, while differential hypoid oil is brown in color and has a distinctive odor. There are two seals at the boundary of the two sumps. There is a weep hole in the right side of the transaxle case (Fig.
Page 1190: Standard Procedure - Aluminum Thread Repair
21 - 10 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) FLUID LEAKAGE—DIFFERENTIAL HOUSING AREA MODULES/POWERTRAIN CONTROL MODULE STANDARD PROCEDURE) The differential uses Mopar 75w-90 Fuel Saving The transaxle can be removed without having to petroleum based hypoid gear lube. It can be distin- remove the engine.
Page 1191: Disassembly
TRANSAXLE 21 - 11 42LE AUTOMATIC TRANSAXLE (Continued) (18) Disconnect transmission range sensor connec- torque converter location to ensure that the torque tor. Disconnect input and output speed sensor con- converter is reinstalled correctly. nector. CAUTION: The drive plate to torque converter bolts (19) Disconnect and plug transaxle cooler lines at and the drive plate to crankshaft bolts must not be the transaxle.
Page 1192 21 - 12 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) for reference when reassembling the transaxle. If (3) Remove transaxle oil pan (Fig. 14). endplay exceeds the specified range, the #4 thrust plate needs to be inspected and changed if necessary. Fig. 14 Remove Transaxle Oil Pan 1 - TRANSAXLE OIL PAN (4) Remove transaxle oil filter (Fig.
Page 1193 TRANSAXLE 21 - 13 42LE AUTOMATIC TRANSAXLE (Continued) (5) Remove seven valve body-to-case bolts (Fig. NOTE: For valve body recondition procedure, (Refer 16). to 21 - TRANSMISSION/TRANSAXLE/AUTOMATIC - 42LE/VALVE BODY - DISASSEMBLY). (7) Remove underdrive accumulator and spring (Fig. 18) (Fig. 20). Fig.
Page 1194 21 - 14 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) CAUTION: Tag the springs for the Overdrive Accu- (10) Remove the low/reverse accumulator plug mulator so that they are not confused with the (Fig. 22). springs in the Low/Reverse Accumulator. Fig. 22 Remove Low/Reverse Accumulator Plug Fig.
Page 1195 TRANSAXLE 21 - 15 42LE AUTOMATIC TRANSAXLE (Continued) (13) Remove long stub shaft and bearing from bell- housing using Tools 8420A and C-3752 (Fig. 26). Fig. 24 Low/Reverse Accumulator Components 1 - ACCUMULATOR PISTON 2 - SEAL RINGS 3 - RETURN SPRINGS Fig.
Page 1196 21 - 16 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) (15) Remove oil pump using C-3752 Pullers (Fig. (17) Remove oil pump gasket (Fig. 30). 28). Fig. 30 Remove Oil Pump Gasket Fig. 28 Oil Pump Pullers 1 - BELL HOUSING 2 - OIL PUMP GASKET 1 - OIL PUMP 2 - PULLERS CAUTION: By-pass valve must be replaced if trans-...
Page 1197 TRANSAXLE 21 - 17 42LE AUTOMATIC TRANSAXLE (Continued) (19) Remove #1 caged needle bearing (Fig. 32). (21) Remove #4 thrust plate (Fig. 34). Fig. 34 Remove #4 Thrust Plate Fig. 32 Remove No. 1 Caged Needle Bearing 1 - OVERDRIVE SHAFT ASSEMBLY 2 - #4 THRUST PLATE (SELECT) 1 - #1 CAGED NEEDLE BEARING 3 - 3 DABS OF PETROLATUM FOR RETENTION...
Page 1198 21 - 18 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) (23) Remove front carrier/rear annulus and #6 nee- NOTE: The number seven needle bearing has three dle bearing (Fig. 36). antireversal tabs and is common with the number five and number two position. The orientation should allow the bearing to seat flat against the rear sun gear (Fig.
Page 1199 TRANSAXLE 21 - 19 42LE AUTOMATIC TRANSAXLE (Continued) (26) Remove 2/4 clutch retainer (Fig. 40) (Fig. 41). (27) Remove 2/4 clutch return spring (Fig. 42). Fig. 40 Remove 2/4 Clutch Retainer Fig. 42 Remove 2/4 Clutch Return Spring 1 - 2/4 CLUTCH RETAINER 1 - 24 CLUTCH RETURN SPRING (28) Remove 2/4 clutch pack (Fig.
Page 1200 21 - 20 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) (29) Remove tapered snap ring (Fig. 44). (31) Remove one (1) low/reverse clutch disc to facil- itate snap ring removal (Fig. 46). Fig. 44 Remove Tapered Snap Ring Fig. 46 Remove One Disc 1 - LOW/REVERSE CLUTCH REACTION PLATE 1 - ONE DISC FROM LOW/REVERSE CLUTCH 2 - LONG TAB...
Page 1201 TRANSAXLE 21 - 21 42LE AUTOMATIC TRANSAXLE (Continued) (33) Remove low/reverse clutch pack (Fig. 48). (35) Stand trans upright on bellhousing. (36) Remove chain oiler (Fig. 50). Fig. 50 Remove Chain Oiler Fig. 48 Remove Low/Reverse Clutch Pack 1 - CHAIN SNUBBER 1 - CLUTCH PLATES (5) 2 - CHAIN OILER 2 - CLUTCH DISCS (5)
Page 1202 21 - 22 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) (38) Remove transfer and output shaft sprocket (39) Install Tool 6550 and apply a light amount of snap rings and wave washers (Fig. 52) (Fig. 53). pressure to facilitate removal (Fig. 54). Fig.
Page 1203 TRANSAXLE 21 - 23 42LE AUTOMATIC TRANSAXLE (Continued) (41) Remove output shaft sprocket spacer (Fig. 56). CAUTION: Failure to grind and open stakes of the output shaft nut and transfer shaft nut will result in thread damage to the shafts during nut removal. WARNING: WEAR SAFETY...
Page 1204 21 - 24 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) (44) Using a small chisel, carefully open stakes on (46) Remove output shaft from case using a shop nut (Fig. 60). press (Fig. 62). Fig. 60 Opening Nut Stakes Fig. 62 Use Arbor Press to Remove Output Shaft 1 - CHISEL from Case 2 - NUT STAKE...
Page 1205 TRANSAXLE 21 - 25 42LE AUTOMATIC TRANSAXLE (Continued) (47) Use special tool 6597 and handle C-4171 and (49) Install and load compressor (Fig. 66) as shown C-4171-2 to press rear output shaft bearing cup rear- in (Fig. 67). ward (Fig. 64). Fig.
Page 1206 21 - 26 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) (50) Remove snap ring (Fig. 68). (52) Remove park sprag pivot retaining screw (Fig. 70). Fig. 68 Remove Snap Ring Fig. 70 Remove Parking Sprag Pivot Retaining 1 - SNAP RING OPENING MUST BE BETWEEN SPRING LEVERS (AS SHOWN) Screw 2 - SNAP RING PLIERS...
Page 1207 TRANSAXLE 21 - 27 42LE AUTOMATIC TRANSAXLE (Continued) (54) Remove guide bracket pivot shaft (Fig. 72). (55) Remove low/reverse clutch piston (Fig. 74). Inspect all components (Fig. 73) for wear and replace if necessary. Fig. 74 Remove Low/Reverse Clutch Piston 1 - LOW/REVERSE CLUTCH PISTON 2 - D-RING SEAL Fig.
Page 1208: Assembly
21 - 28 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) (57) Remove low/reverse piston retainer (Fig. 76). (1) Install the output bearing cups, use Special Tool # 5050A (Fig. 78). Fig. 78 Bearing Cup Installation Special Tool 5050A (2) Install low/reverse piston retainer gasket (Fig. 79).
Page 1209 TRANSAXLE 21 - 29 42LE AUTOMATIC TRANSAXLE (Continued) (4) Install low/reverse piston retainer-to-case (6) Assemble guide bracket assembly as shown in screws (Fig. 81) and torque to 5 N·m (45 in. lbs.). (Fig. 83) (Fig. 84). Fig. 81 Install Retainer Attaching Screws 1 - LOW/REVERSE CLUTCH PISTON RETAINER 2 - SCREWDRIVER 3 - TORX-LOC SCREWS...
Page 1210 21 - 30 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) (7) Install guide bracket pivot shaft (Fig. 85). Fig. 87 Install Low/Reverse Piston Return Spring 1 - LOW/REVERSE PISTON RETURN SPRING 2 - PISTON Fig. 85 Install Guide Bracket Pivot Shaft 1 - PIVOT PIN 2 - GUIDE BRACKET ASSEMBLY CAUTION: When installing, be sure guide bracket and split sleeve touch the rear of the transaxle...
Page 1211 TRANSAXLE 21 - 31 42LE AUTOMATIC TRANSAXLE (Continued) (11) Install snap ring and remove compressor tool (13) Check output bearing preload. Output bear- (Fig. 90). ing preload must be checked and/or adjusted if any of the following items have been replaced: •...
Page 1212 21 - 32 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) (d) Install shim on output shaft (Fig. 94). Apply small amount of petrolatum onto the shim to hold it in place. Use the original shim as a starting point. If original shim is not available, use the thickest shim available.
Page 1213 TRANSAXLE 21 - 33 42LE AUTOMATIC TRANSAXLE (Continued) (h) The new nut must be staked after the correct (14) Apply Mopar ATF RTV (MS-GF41) as shown turning torque is obtained (Fig. 97) (Fig. 98). Use in (Fig. 99). Install main sump baffle to transaxle special tool 6639 to stake output shaft nut and spe- case (Fig.
Page 1214 21 - 34 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) CAUTION: When reinstalling drive chains, the blue (17) Remove chain spreader (Fig. 103). link must face outward. (15) Install output sprocket spacer (Fig. 101). Fig. 103 Remove Chain Spreader 1 - OUTPUT SPROCKET 2 - SPECIAL TOOL 6550 3 - TRANSFER SPROCKET Fig.
Page 1215 TRANSAXLE 21 - 35 42LE AUTOMATIC TRANSAXLE (Continued) (20) Install chain oiler (Fig. 107) and torque screw to 5 N·m (45 in. lbs.). Fig. 105 Install Output Shaft Sprocket Snap Ring and Wave Washer 1 - WAVE WASHER Fig. 107 Install Chain Oiler 2 - SNAP RING 1 - CHAIN SNUBBER 2 - CHAIN OILER...
Page 1216 21 - 36 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) (23) Install low/reverse clutch pack (Fig. 109). (25) Install one low/reverse clutch disc (Fig. 111). Leave uppermost disc out to facilitate snap ring installation. Fig. 111 Install One Disc 1 - ONE DISC FROM LOW/REVERSE CLUTCH Fig.
Page 1217 TRANSAXLE 21 - 37 42LE AUTOMATIC TRANSAXLE (Continued) (27) Install tapered snap ring (tapered side out) as (28) Measure low/reverse clutch pack. Set up dial shown in (Fig. 113) (Fig. 114). indicator as shown in (Fig. 115). Press down clutch pack with finger and zero dial indicator.
Page 1218 21 - 38 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) (30) Install 2/4 clutch pack (Fig. 116). Stagger 2/4 (31) Install 2/4 clutch belleville spring (Fig. 118) clutch disc pads as shown in (Fig. 117). (Fig. 119). Fig. 118 Install 2/4 Clutch Return Spring Fig.
Page 1219 TRANSAXLE 21 - 39 42LE AUTOMATIC TRANSAXLE (Continued) (32) Install 2/4 clutch retainer (Fig. 120). Fig. 122 Check 2/4 Clutch Clearance Fig. 120 Install 2/4 Clutch Retainer 1 - DIAL INDICATOR 2 - HOOK TOOL 1 - 24 CLUTCH RETAINER 3 - DIAL INDICATOR TIP TOOL 6268 2 - 24 CLUTCH RETURN SPRING (35) Install the #7 needle bearing to the rear sun...
Page 1220 21 - 40 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) (36) Install rear sun gear and #7 needle bearing (38) Install front sun gear assembly and #4 thrust (Fig. 124). washer (Fig. 126). Fig. 126 Install Front Sun Gear Assembly Fig. 124 Install Rear Sun Gear 1 - FRONT SUN GEAR ASSEMBLY 1 - #7 NEEDLE BEARING 2 - #4 THRUST WASHER (FOUR TABS)
Page 1221 TRANSAXLE 21 - 41 42LE AUTOMATIC TRANSAXLE (Continued) (c) Install input clutch assembly. Ensure the (g) Measure input shaft end play. Input shaft input clutch assembly is completely seated by view- end play must be .005 to .025 inch. For exam- ing position through input speed sensor hole (Fig.
Page 1222 21 - 42 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) (40) Install input clutch assembly with proper (42) Replace cooler by-pass valve if transmission thrust plate (Fig. 131). failure has occurred (Fig. 133). CAUTION: By-pass valve must be replaced if trans- mission failure occurs. Fig.
Page 1223 TRANSAXLE 21 - 43 42LE AUTOMATIC TRANSAXLE (Continued) (44) Install oil pump and torque oil pump-to-case NOTE: Install new halfshaft retainer clips. bolts to 28 N·m (250 in. lbs.) (Fig. 135). (46) Install long stub shaft bearing retaining snap ring (Fig. 137). Replace halfshaft retainer clips. Fig.
Page 1224 21 - 44 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) (48) Install low/reverse accumulator plug (Fig. 139). Fig. 141 Accumulator Locations 1 - OVERDRIVE ACCUMULATOR LOCATION 2 - UNDERDRIVE ACCUMULATOR LOCATION 3 - LOW/REVERSE ACCUMULATOR Fig. 139 Install Low/Reverse Accumulator Plug (Cover) 1 - ADJUSTABLE PLIERS 2 - PLUG (49) Install low/reverse accumulator snap ring...
Page 1225 TRANSAXLE 21 - 45 42LE AUTOMATIC TRANSAXLE (Continued) (52) Install seven (7) valve body-to-case bolts (Fig. 145) and torque to 12 N·m (105 in. lbs.). Fig. 143 Install Overdrive Accumulator and Springs 1 - OVERDRIVE ACCUMULATOR PISTON 2 - RETURN SPRINGS 3 - SEAL RING Fig.
Page 1226: Installation
21 - 46 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) Fig. 147 Install Transaxle Oil Pan 1 - TRANSAXLE OIL PAN Fig. 149 Measure Input Shaft End Play Using Tool 8266—Typical 1 - TOOL 8266–8 2 - TOOL 8266–2 3 - TOOL C-3339 the collar is flush against transmission and oil pan before torquing to specifications.
Page 1227: Schematics And Diagrams - 42Le Transaxle
TRANSAXLE 21 - 47 42LE AUTOMATIC TRANSAXLE (Continued) SCHEMATICS AND DIAGRAMS - 42LE TRANSAXLE...
Page 1228 21 - 48 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued)
Page 1229 TRANSAXLE 21 - 49 42LE AUTOMATIC TRANSAXLE (Continued)
Page 1230 21 - 50 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued)
Page 1231 TRANSAXLE 21 - 51 42LE AUTOMATIC TRANSAXLE (Continued)
Page 1232 21 - 52 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued)
Page 1233 TRANSAXLE 21 - 53 42LE AUTOMATIC TRANSAXLE (Continued)
Page 1234 21 - 54 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued)
Page 1235 TRANSAXLE 21 - 55 42LE AUTOMATIC TRANSAXLE (Continued)
Page 1236 21 - 56 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued)
Page 1237 TRANSAXLE 21 - 57 42LE AUTOMATIC TRANSAXLE (Continued)
Page 1238 21 - 58 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued)
Page 1239 TRANSAXLE 21 - 59 42LE AUTOMATIC TRANSAXLE (Continued)
Page 1240: Specifications
21 - 60 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) SPECIFICATIONS 42LE AUTOMATIC TRANSAXLE GENERAL SPECIFICATIONS Four-Speed Automatic, Longitudinally Mounted, Electronically Controlled, Fully Adaptive, Electronically Transaxle Type Modulated Torque Converter, Integrated Differential with Unique Oil Sump Lubrication Method Pump (internal - external gear-type) Water Heat Exchanger and/or Air-to-Oil Heat Cooling Method Exchanger...
Page 1241 TRANSAXLE 21 - 61 42LE AUTOMATIC TRANSAXLE (Continued) FLUID, TRANSMISSION & DIFFERENTIAL Location Type Metric Capacity Standard Capacity Transmission Sump Mopar ATF+4 Type 9602 9.29L 9.81 Qts. Differential Sump Mopar Fuel Saving 0.95L 32 oz. 75W-90 Petroleum-Based Hypoid Gear Lube INPUT SHAFT Description Metric...
Page 1242 21 - 62 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) TORQUE SPECIFICATIONS Description N·m Ft. Lbs. In. Lbs. Bolt, Converter-to-Driveplate Bolt, Differential Assembly Partial Bolt, Differential Case Cover Bolt, Differential Ring Gear-to-Case Bolt, Differential Vent Baffle Bolt, Driveplate-to-Crankshaft Bolt, End Cover-to-Case Bolt, Fluid Filter-to-Valve Body Bolt, L/R Clutch Retainer-to-Case Bolt, Main Sump Vent Bolt, Manual Valve Lever-to-Manual Valve...
Page 1243: Special Tools
TRANSAXLE 21 - 63 42LE AUTOMATIC TRANSAXLE (Continued) SPECIAL TOOLS 42LE AUTOMATIC TRANSAXLE Dial Indicator C-3339 Puller Press Extension C-293-3 Slide Hammer C-3752 Adapter Blocks C-293–48 Seal Puller C-3981B Puller Press C-293–PA Pressure Gauge (High) C-3293SP Universal Handle C-4171...
Page 1244 21 - 64 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) Handle Extension C-4171-2 Bearing Splitter P-334 Seal Installer C-4193A Puller Set 5048 Installer C-4340 Installer 5050A Adapter C-4996 Compressor 5058A Adapter Set L-4559...
Page 1245 TRANSAXLE 21 - 65 42LE AUTOMATIC TRANSAXLE (Continued) Compressor 5059-A Tip 6268 Installer 5067 Remover/Installer 6301 Installer 6052 Remover/Installer 6302 Remover 6310 Disk 6057 Installer 6494...
Page 1246 21 - 66 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) Remover 6495 Installer 6522 Wrench 6497 Puller Jaws 6545 Wrench 6498 Turning Fork 6548 Pinion Gauge Tool Set 6549 Remover 6502B Remover 6550 Wrench 6503...
Page 1247 TRANSAXLE 21 - 67 42LE AUTOMATIC TRANSAXLE (Continued) Installer 6558 Seal Protector 6591 Installer 6560 Seal Protector 6592 Seal Installer 6567A Fixture 6595 Remover 6577 Remover 6596 Staking Tool 6589 Remover 6597...
Page 1248 21 - 68 TRANSAXLE 42LE AUTOMATIC TRANSAXLE (Continued) Plate Set 6599 End Play Set 8266 Support Plate 6618A Pressure Fixture 8391 Staking Tool 6639 Cooler Flusher 6906 Remover 8420A...
Page 1249: Accumulator Description
TRANSAXLE 21 - 69 ACCUMULATOR DESCRIPTION The 42LE underdrive, overdrive, low/reverse, and 2/4 clutch hydraulic circuits each contain an accumu- lator. An accumulator assembly typically consists of a piston, seals, return spring(s), and a cover or plug (Fig. 150). Fig. 151 Overdrive, Underdrive and Low/Reverse Accumulator Location 1 - OVERDRIVE ACCUMULATOR LOCATION 2 - UNDERDRIVE ACCUMULATOR LOCATION...
Page 1250: Autostick Switch Description
21 - 70 TRANSAXLE stick mode. Speed control will be deactivated if the AUTOSTICK SWITCH transaxle is shifted to 2nd gear. Shifting into OD position cancels the Autostick mode, and the trans- DESCRIPTION axle resumes the OD shift schedule. Autostick is a driver-interactive transmission fea- ture that offers manual gear shifting capability to DEACTIVATION provide you with more control.
Page 1251: Bearing Adjustment Procedures
TRANSAXLE 21 - 71 Used (original) bearing may lose up to 50 percent BEARINGS of the original drag torque after break-in. NOTE: All bearing adjustments must be made with ADJUSTMENTS no other component interference or gear inter- mesh, except the transfer gear bearing. BEARING ADJUSTMENT PROCEDURES Take extreme care when removing and installing Oil all bearings before checking turning torque.
Page 1252 21 - 72 TRANSAXLE BEARINGS (Continued) Fig. 153 Master Shim Chart...
Page 1253: Driving Clutches Description
TRANSAXLE 21 - 73 UNDERDRIVE CLUTCH DRIVING CLUTCHES The underdrive clutch is hydraulically applied in first, second, and third (direct) gears by pressurized DESCRIPTION fluid against the underdrive piston. When the under- Three hydraulically applied input clutches are used drive clutch is applied, the underdrive hub drives the to drive planetary components.
Page 1254: Disassembly
21 - 74 TRANSAXLE FINAL DRIVE (Continued) OPERATION (2) Remove chain oiler (Fig. 157). The differential assembly is driven by the transfer shaft by way of the differential ring gear. The ring gear drives the differential case, and the case drives the driveshafts through the differential gears.
Page 1255 TRANSAXLE 21 - 75 FINAL DRIVE (Continued) (4) Remove output shaft sprocket snap ring and (6) Install chain spreader 6550 and expand to wave washer (Fig. 159). facilitate sprocket and chain removal (Fig. 161). Fig. 159 Remove Output Shaft Sprocket Snap Ring Fig.
Page 1256 21 - 76 TRANSAXLE FINAL DRIVE (Continued) (8) Using suitable snap ring pliers, remove long (10) Remove inner differential adjuster lock (Fig. stub shaft snap ring (Fig. 163). 165). Fig. 165 Remove Inner Differential Adjuster Lock Fig. 163 Remove Long Stub Shaft Snap Ring 1 - INNER DIFFERENTIAL ADJUSTER LOCK 1 - SNAP RING 2 - INNER DIFFERENTIAL ADJUSTER...
Page 1257 TRANSAXLE 21 - 77 FINAL DRIVE (Continued) (12) Loosen outer adjuster (Fig. 167). DIFFERENTIAL DISASSEMBLY (1) Remove ring gear-to-carrier bolts (Fig. 169). Fig. 167 Loosen Outer Adjuster Fig. 169 Remove Ring Gear Bolts 1 - OUTER ADJUSTER 2 - SPECIAL TOOL 6503 1 - RING GEAR BOLTS 2 - RING GEAR (13) Remove differential side cover, and carrier/...
Page 1258 21 - 78 TRANSAXLE FINAL DRIVE (Continued) (3) Using suitable pry tools, pry differential carrier (5) Using a suitable punch, remove pinion shaft apart (Fig. 171). roll pin (Fig. 173). Fig. 171 Pry Differential Carrier Apart 1 - DIFFERENTIAL CARRIER 2 - PRY TOOL 3 - PRY TOOL (4) Remove stub shaft C-clip (Fig.
Page 1259 TRANSAXLE 21 - 79 FINAL DRIVE (Continued) (7) Using tool C-293-PA, adapters C-293-48, and (15) Remove differential vent baffle (Fig. 177). adapter C-4996, remove differential carrier bearings (Fig. 175). Fig. 177 Differential Vent Baffle 1 - RETAINING SCREWS 2 - VENT BAFFLE W/SHIELD CAUTION: Failure to grind and open stakes on the transfer shaft nut will result in thread damage to transfer shaft during nut removal.
Page 1260 21 - 80 TRANSAXLE FINAL DRIVE (Continued) Fig. 179 Stake Grinding Pattern 1 - TRANSFER SHAFT 2 - TRANSFER SHAFT NUT (17) Using a small chisel, carefully open stakes on nut (Fig. 180) Fig. 181 Press Transfer Shaft Downward to Remove Rear Cone 1 - TRANSFER SHAFT 2 - ARBOR PRESS...
Page 1261 TRANSAXLE 21 - 81 FINAL DRIVE (Continued) (20) Remove transfer shaft preload shim (Fig. CAUTION: If the transfer shaft is removed from the 183). If transfer shaft bearings are to be reused, the transaxle case for any reason, both seals must be original shim must also be reused.
Page 1262: Assembly / Bearing Adjustment Procedure
21 - 82 TRANSAXLE FINAL DRIVE (Continued) (24) Support special tool P-334 on press table so that pinion head of transfer shaft can be pressed through table (Fig. 187). Fig. 187 Remove Front Transfer Shaft Bearing And Pinion Depth Shim 1 - ARBOR PRESS 2 - TRANSFER SHAFT Fig.
Page 1263 TRANSAXLE 21 - 83 FINAL DRIVE (Continued) (3) Install new front bearing (actual bearing to be used during reassembly) onto gauge disc (special tool 6549-3) (Fig. 190). Fig. 192 Disc Installation 1 - SPECIAL TOOL 6494–2 Fig. 190 Gauge Disc and Bearing 1 - FRONT TRANSFER SHAFT BEARING 2 - SPECIAL TOOL 6549–3 (4) Install gauge disc and bearing into case using...
Page 1264 21 - 84 TRANSAXLE FINAL DRIVE (Continued) NOTE: The dial indicator used to make this mea- (10) Compress the dial indicator slightly and surement must have a face that shows 0-50-0 (Spe- insert dial indicator pin into centering block (Fig. 197).
Page 1265 TRANSAXLE 21 - 85 FINAL DRIVE (Continued) (12) To determine the required shim thickness, the pinion depth measurement must be adjusted. The pinion shim adjustment number is the first of seven digits ink stamped on the shank of the transfer shaft (Fig.
Page 1266 21 - 86 TRANSAXLE FINAL DRIVE (Continued) (17) Press front transfer shaft bearing onto trans- fer shaft (special tool 6052). The shim must be in place before pressing on bearing (Fig. 200). Fig. 201 Outer Adjuster Removal 1 - SPECIAL TOOL 6503 2 - OUTER DIFFERENTIAL ADJUSTER 3 - SIDE COVER Fig.
Page 1267 TRANSAXLE 21 - 87 FINAL DRIVE (Continued) (24) Screw in the inner adjuster using special tool (2) Install differential pinion and side gears, and 6502B (Fig. 203). The inner adjuster should be pinion shaft (Fig. 205). screwed in until under-flush with inside of the case (viewed from differential side).
Page 1268 21 - 88 TRANSAXLE FINAL DRIVE (Continued) (4) Install side gear, stub shaft, and c-clip to differ- (25) Install differential assembly into the transaxle ential support plate (Fig. 207). case (Fig. 209). Fig. 207 Install Side Gear, Stub Shaft, and C-Clip 1 - SIDE GEAR 2 - STUB SHAFT 3 - “C”...
Page 1269 TRANSAXLE 21 - 89 FINAL DRIVE (Continued) (27) Install seal protector (special tool 6591) as shown in (Fig. 211). Apply a thin film of gear oil on the protector. Fig. 213 Special Tool 6548 1 - SPECIAL TOOL 6548 ⁄ EXTENSION 3 - TORQUE WRENCH Fig.
Page 1270 21 - 90 TRANSAXLE FINAL DRIVE (Continued) Fig. 215 Transfer Shaft Installation 1 - TRANSFER SHAFT Fig. 216 Transfer Shaft Support Fixture 1 - SUPPORT FIXTURE (6595) Fig. 214 Determining Turning Torque 1 - FT. LBS. TORQUE WRENCH 3 - IN. LBS. TORQUE WRENCH 2 - SPECIAL TOOL 6548 4 - SPECIAL TOOL 6503...
Page 1271 TRANSAXLE 21 - 91 FINAL DRIVE (Continued) (35) Install transfer shaft seal protector (special (37) Install seal with special tool 6567A (Fig. 219). tool 6592) (Fig. 217). Apply thin film of gear oil to Use a press to install seal. The installation tool will protector.
Page 1272 21 - 92 TRANSAXLE FINAL DRIVE (Continued) (39) Install rear transfer shaft cup into case (Fig. the thickest shim as a starting point. Refer to Trans- 221). fer Shaft Rear Shim Chart for available sizes. Fig. 223 Transfer Preload Shim Installation 1 - TRANSFER SHAFT PRELOAD SHIM 2 - TRANSFER SHAFT Fig.
Page 1273 TRANSAXLE 21 - 93 FINAL DRIVE (Continued) (44) Install a new transfer shaft nut (Fig. 224). CAUTION: A press and special tool 6589 must be Tighten nut to 271 N·m (200 ft. lbs.). Use special used when staking the transfer shaft nut. Do not tools 6497 holder and 6498 shaft socket to tighten use a hammer and the special tool to stake nut.
Page 1274 21 - 94 TRANSAXLE FINAL DRIVE (Continued) CAUTION: Failure to stake the transfer shaft nut correctly may allow the nut to loosen during trans- axle operation. This will cause transaxle failure. (47) At this point the transfer shaft, new oil seals, pinion depth and transfer shaft preload have been set.
Page 1275 TRANSAXLE 21 - 95 FINAL DRIVE (Continued) (52) Apply a 1/8 inch bead of sealant to differential (54) Install outer adjuster with new O-ring (Fig. cover flange. Then install differential cover with seal- 233). Torque the outer adjuster (special tool 6503) to ant (Fig.
Page 1276 21 - 96 TRANSAXLE FINAL DRIVE (Continued) (56) If there is too much backlash, loosen the outer to be sure that the fluid level check is accurate. The adjuster with special tool 6503. Then turn the inner engine should be running at idle speed for at adjuster so that it moves away from the ring least one minute, with the vehicle on level gear.
Page 1277: Standard Procedure - Fluid/Filter Service
TRANSAXLE 21 - 97 FLUID (Continued) Fig. 236 42LE Fluid Temperature Chart 2 - MIN. LEVEL 1 - MAX. LEVEL In either case, air bubbles can cause overheating DIFFERENTIAL SUMP and/or fluid oxidation, and varnishing. This can The differential sump is checked separately from interfere with normal valve, clutch, and accumulator the transmission.
Page 1278: Standard Procedure - Differential Sump Drain And Refill
21 - 98 TRANSAXLE FLUID (Continued) NOTE: The 42LE Transaxle has separate transmis- sion and differential fluid sumps. Only fluids of the type labeled Mopar ATF+4 (Automatic Transmis- sion Fluid) should be used in the transaxle sump. A filter change should be made at the time of the transmission oil change.

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