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Dodge 2000 DURANGO Service Manual

Dodge 2000 DURANGO Service Manual

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SERVICE MANUAL

2000

DURANGO

To order the special service tools used and

illustrated, please refer to the instructions on

inside back cover.

NO PART OF THIS PUBLICATION MAY BE

REPRODUCED,

STORED

IN

A

RETRIEVAL

SYSTEM, OR TRANSMITTED, IN ANY FORM OR

BY ANY MEANS, ELECTRONIC, MECHANICAL,

PHOTOCOPYING, RECORDING, OR OTHERWISE,

WITHOUT THE PRIOR WRITTEN PERMISSION

OF DAIMLERCHRYSLER CORPORATION.

DaimlerChrysler Corporation reserves the right to make changes in design or

to make additions to or improvements in its products without imposing any

obligations upon itself to install them on its products previously manufac-

tured.

Litho in U.S.A. Copyright © 1999 DaimlerChrysler Corporation

15M0799

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Summary of Contents for Dodge 2000 DURANGO

Page 1 SERVICE MANUAL 2000 DURANGO To order the special service tools used and illustrated, please refer to the instructions on inside back cover. NO PART OF THIS PUBLICATION MAY BE REPRODUCED, STORED RETRIEVAL SYSTEM, OR TRANSMITTED, IN ANY FORM OR BY ANY MEANS, ELECTRONIC, MECHANICAL, PHOTOCOPYING, RECORDING, OR OTHERWISE, WITHOUT THE PRIOR WRITTEN PERMISSION OF DAIMLERCHRYSLER CORPORATION.
Page 2 FOREWORD The information contained in this service manual has been prepared for the professional automotive tech- nician involved in daily repair operations. Information describing the operation and use of standard and optional equipment is included in the Owner’s Manual provided with the vehicle. Information in this manual is divided into groups.
Page 3 GROUP TAB LOCATOR Introduction Lubrication and Maintenance Suspension Differential and Driveline Brakes Cooling System Battery Starting Systems Charging System Ignition System Instrument Panel Systems Audio Systems Horn Systems Speed Control System Turn Signal and Hazard Warning Systems Wiper and Washer Systems Lamps Passive Restraint Systems Electrically Heated Systems...
Page 5 INTRODUCTION INTRODUCTION TABLE OF CONTENTS page page DESCRIPTION AND OPERATION FASTENER IDENTIFICATION ....3 VEHICLE IDENTIFICATION NUMBER (VIN) FASTENER USAGE ......6 PLATE .
Page 6 VIN DECODING INFORMATION POSITION INTERPRETATION CODE = DESCRIPTION Country of Origin 1= USA Make B = Dodge Vehicle Type 4 = Multipurpose Passenger Vehicle Gross Vehicle Weight Rating H = 6001-7000 lbs. R = Durango 4x2 Vehicle Line S = Durango 4x4...
Page 7 INTRODUCTION DESCRIPTION AND OPERATION (Continued) High Beam Rear Window Washer Fog Lamps Fuel Headlamp, Parking Lamps, Panel Lamps Engine Coolant Temperature Turn Warning Battery Charging Condition Hazard Warning Engine Oil Windshield Washer Seat Belt Windshield Wiper Brake Failure Windshield Wiper and Washer Parking Brake Windscreen Demisting and Defrosting Front Hood...
Page 8 INTRODUCTION DESCRIPTION AND OPERATION (Continued) FASTENER IDENTIFICATION...
Page 9 INTRODUCTION DESCRIPTION AND OPERATION (Continued) FASTENER STRENGTH...
Page 10 INTRODUCTION DESCRIPTION AND OPERATION (Continued) FASTENER USAGE THREADED HOLE REPAIR Most stripped threaded holes can be repaired using WARNING: USE OF AN INCORRECT FASTENER a Helicoil . Follow the manufactures recommenda- MAY RESULT IN COMPONENT DAMAGE OR PER- tions for application and repair procedures. SONAL INJURY.
Page 11 INTRODUCTION DESCRIPTION AND OPERATION (Continued) METRIC CONVERSION CHART...
Page 12 INTRODUCTION DESCRIPTION AND OPERATION (Continued) TORQUE SPECIFICATIONS...
Page 13 LUBRICATION AND MAINTENANCE 0 - 1 LUBRICATION AND MAINTENANCE TABLE OF CONTENTS page page LUBRICANTS ......1 JUMP STARTING, TOWING AND HOISTING .
Page 14 0 - 2 LUBRICATION AND MAINTENANCE SERVICE PROCEDURES (Continued) FLUID CAPACITIES Fuel Tank All ......95 L (25 gal.) Engine Oil W/Filter change 4.7 L .
Page 15 LUBRICATION AND MAINTENANCE 0 - 3 MAINTENANCE SCHEDULES TABLE OF CONTENTS page SERVICE PROCEDURES MAINTENANCE SCHEDULES ....3 SERVICE PROCEDURES the mileage specified to assure the continued proper functioning of the emission control system.
Page 16 0 - 4 LUBRICATION AND MAINTENANCE SERVICE PROCEDURES (Continued) 45,000 Miles (72 000 km) or at 36 months 90,000 Miles (144 000 km) or at 72 months • Change engine oil. • Change engine oil. • Replace engine oil filter. •...
Page 17 LUBRICATION AND MAINTENANCE 0 - 5 SERVICE PROCEDURES (Continued) Important: Inspection and service should also be 24,000 Miles (38 000 km) • Change engine oil. performed any time a malfunction is observed or sus- • Replace engine oil filter. pected. •...
Page 18 0 - 6 LUBRICATION AND MAINTENANCE SERVICE PROCEDURES (Continued) 48,000 Miles (77 000 km) 72,000 Miles (115 000 km) • Change engine oil. • Change engine oil. • Replace engine oil filter. • Replace engine oil filter. • Drain and refill automatic transmission fluid. •...
Page 19 LUBRICATION AND MAINTENANCE 0 - 7 SERVICE PROCEDURES (Continued) • Drain and refill transfer case fluid. 93,000 Miles (149 000 km) • Inspect front wheel bearings. • Change engine oil. • Lubricate • Replace engine oil filter. front suspension ball joints required.
Page 20 0 - 8 LUBRICATION AND MAINTENANCE JUMP STARTING, TOWING AND HOISTING TABLE OF CONTENTS page page SERVICE PROCEDURES TWO-WHEEL-DRIVE VEHICLE TOWING ..9 JUMP STARTING PROCEDURE....8 FOUR-WHEEL-DRIVE VEHICLE TOWING .
Page 21 LUBRICATION AND MAINTENANCE 0 - 9 SERVICE PROCEDURES (Continued) • Always use a safety chain system that is inde- pendent of the lifting and towing equipment. • Do not allow towing equipment to contact the disabled vehicle’s fuel tank. • Do not allow anyone under the disabled vehicle while it is lifted by the towing device.
Page 22 0 - 10 LUBRICATION AND MAINTENANCE SERVICE PROCEDURES (Continued) TWO WHEEL DRIVE TOWING-REAR END LIFTED CAUTION: Many vehicles are equipped with air dams, spoilers, and/or ground effect panels. To CAUTION: Do not use steering column lock to avoid component damage, a wheel-lift towing vehi- secure steering wheel during towing operation.
Page 23 LUBRICATION AND MAINTENANCE 0 - 11 SERVICE PROCEDURES (Continued) HOISTING RECOMMENDATIONS WARNING: THE HOISTING AND JACK LIFTING POINTS PROVIDED ARE FOR A COMPLETE VEHI- CLE. WHEN A CHASSIS OR DRIVETRAIN COMPO- NENT IS REMOVED FROM A VEHICLE, THE CENTER OF GRAVITY IS ALTERED MAKING SOME HOISTING CONDITIONS UNSTABLE.
Page 25 SUSPENSION 2 - 1 SUSPENSION TABLE OF CONTENTS page page ALIGNMENT ......1 FRONT SUSPENSION - 4x4 .
Page 26: Diagnosis And Testing
2 - 2 SUSPENSION DESCRIPTION AND OPERATION (Continued) • THRUST ANGLE is the angle of the rear axle relative to the centerline of the vehicle. Incorrect thrust angle can cause off-center steering and exces- sive tire wear. This angle is not adjustable, damaged component(s) must be replaced to correct the thrust angle.
Page 27 SUSPENSION 2 - 3 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION EXCESSIVE STEERING 1. Loose or worn steering gear. 1. Adjust or replace steering gear. EFFORT 2. Column coupler binding. 2. Replace coupler. 3. Tire pressure. 3. Adjust tire pressure. 4.
Page 28 2 - 4 SUSPENSION SERVICE PROCEDURES (Continued) CAMBER AND CASTER ADJUSTMENT CAMBER Camber and caster angle adjustments involve Move the front of the pivot bar in or out. This will changing the position of the upper suspension arm change the camber angle significantly and caster pivot bar (Fig.
Page 29: Specifications
SUSPENSION 2 - 5 SPECIFICATIONS ALIGNMENT VEHICLE CASTER ( 0.50°) CAMBER ( 0.50°) TOTAL TOE ( 0.06°) 3.10° −0.25° 0.10° 3.30° −0.25° 0.10° MAX RT to LT 0.50° 0.50° 0.06 DIFFERENCE THRUST ANGLE 0° 0.4° NOTE: All alignment specifications are in degrees.
Page 30 2 - 6 SUSPENSION FRONT SUSPENSION - 4x2 TABLE OF CONTENTS page page DESCRIPTION AND OPERATION COIL SPRING ......8 FRONT SUSPENSION - 4X2 .
Page 31 SUSPENSION 2 - 7 DESCRIPTION AND OPERATION (Continued) COIL SPRINGS DIAGNOSIS AND TESTING DESCRIPTION LOWER BALL JOINT The springs mount between the lower suspension (1) Raise the front of the vehicle. Place safety floor arms and frame rail spring seats. A rubber isolator stands under both lower suspension arms as far out- seats on top off the spring to help prevent noise.
Page 32: Removal And Installation
2 - 8 SUSPENSION DIAGNOSIS AND TESTING (Continued) UPPER BALL JOINT (1) Position a floor jack under the lower suspen- sion arm. Raise the wheel and allow the tire to lightly contact the floor (vehicle weight relieved from the tire). (2) Mount a dial indicator solidly on the upper sus- pension arm.
Page 33 SUSPENSION 2 - 9 REMOVAL AND INSTALLATION (Continued) INSTALLATION NOTE: The ramped or open end of the coil spring is the bottom of the spring. (1) Tape the isolator pad to the top of the coil spring. Position the spring in the lower suspension arm pocket.
Page 34 2 - 10 SUSPENSION REMOVAL AND INSTALLATION (Continued) Fig. 7 Lower Suspension Arm 1 – LOWER SUSPENSION ARM Fig. 6 Upper Ball Joint 2 – FRAME MOUNTS 1 – UPPER BALL JOINT 2 – REMOVER 3 – KNUCKLE (3) Install the shock absorber. (4) Install stabilizer bar link to the lower suspen- sion arm and tighten nut to 47 N·m (35 ft.
Page 35 SUSPENSION 2 - 11 REMOVAL AND INSTALLATION (Continued) Fig. 9 Stabilizer Bar 1 – RETAINER 2 – GROMMET 3 – STABILIZER LINK 4 – STABILIZER BAR Fig. 8 Upper Suspension Arm NOTE: Ensure the bar is center with equal spacing 1 –...
Page 36 2 - 12 SUSPENSION REMOVAL AND INSTALLATION (Continued) Fig. 10 Hub/Bearing Fig. 11 Wheel Stud Removal 1 – KNUCKLE 1 – REMOVER 2 – HUB/BEARING 2 – WHEEL STUD 3 – SPINDLE NUT SPECIFICATIONS (2) Install new spindle nut and tighten to 251 N·m (185 ft.
Page 37 SUSPENSION 2 - 13 SPECIAL TOOLS FRONT SUSPENSION Remover Ball Joint MB-991113 Compressor, Coil Spring DD-1278 Remover Ball Joint C-4150A Puller Tie Rod C-3894-A...
Page 38 2 - 14 SUSPENSION FRONT SUSPENSION - 4x4 TABLE OF CONTENTS page page DESCRIPTION AND OPERATION TORSION BAR ......17 SUSPENSION COMPONENTS 4x4.
Page 39 SUSPENSION 2 - 15 DESCRIPTION AND OPERATION (Continued) SHOCK ABSORBERS STABILIZER BAR DESCRIPTION DESCRIPTION The top of the low-pressure gas charged shock are The bar extends across the front underside of the bolted to the frame. The bottom of the shock are chassis and connects to the frame crossmember.
Page 40 2 - 16 SUSPENSION DIAGNOSIS AND TESTING (Continued) (5) Grasp the top of the tire and push inward and record the dial indicator reading. (6) If lateral movement is greater than 1.52 mm (0.060 in.), replace upper suspension arm. SHOCK DIAGNOSIS A knocking or rattling noise from a shock absorber may be caused by movement between mounting bushings and metal brackets or attaching compo-...
Page 41 SUSPENSION 2 - 17 REMOVAL AND INSTALLATION (Continued) Fig. 5 Torsion Bar 1 – SWIVEL 2 – ANCHOR 3 – BEARING 4 – ADJUSTMENT BOLT 5 – TORSION BAR 6 – LOWER SUSPENSION ARM Fig. 4 Shock Absorber 1 – NUT (2) Position anchor and bearing in frame cross- 2 –...
Page 42 2 - 18 SUSPENSION REMOVAL AND INSTALLATION (Continued) (8) Remove the lower ball joint cotter pin and nut. Separate the ball joint from the knuckle with Remover C-4150A (Fig. 8) and remove the knuckle. (9) Remove the hub/bearing from the steering knuckle.
Page 43 SUSPENSION 2 - 19 REMOVAL AND INSTALLATION (Continued) (9) Inspect lower ball joint seal and replace if dam- (4) Install the torsion bar. aged. Pry off old seal with screw driver if necessary. (5) Install shock absorber lower bolt and tighten to 108 N·m (80 ft.
Page 44 2 - 20 SUSPENSION REMOVAL AND INSTALLATION (Continued) Fig. 12 Upper Suspension Arm Fig. 13 Stabilizer Bar 1 – PIVOT BAR BOLT 1 – LOWER SUSPENSION ARM 2 – UPPER SUSPENSION ARM 2 – FLAG NUT 3 – STABILIZER BAR INSTALLATION 4 –...
Page 45 SUSPENSION 2 - 21 REMOVAL AND INSTALLATION (Continued) (7) Slid hub/bearing out of the steering knuckle and off the axle. Fig. 15 Wheel Stud Removal Fig. 14 Hub/Bearing 1 – REMOVER 1 – HUB BEARING 2 – WHEEL STUD 2 – STEERING KNUCKLE SPECIFICATIONS INSTALLATION (1) Install the hub/bearing into the steering...
Page 46 2 - 22 SUSPENSION SPECIAL TOOLS FRONT SUSPENSION Remover MB-991113 Puller Tie Rod C-3894-A Remover C-4150A...
Page 47 SUSPENSION 2 - 23 REAR SUSPENSION TABLE OF CONTENTS page page DESCRIPTION AND OPERATION STABILIZER BAR ......25 SUSPENSION COMPONENT .
Page 48 2 - 24 SUSPENSION DESCRIPTION AND OPERATION (Continued) LEAF SPRINGS ening the attaching nuts. If the noise persists, inspect for damaged and worn bushings, and attach- ing components. Repair as necessary if any of these DESCRIPTION conditions exist. The rear suspension system uses multi-leaf single A squeaking noise from the shock absorber may be stage springs and a solid drive axle.
Page 49 SUSPENSION 2 - 25 REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Install stabilizer bar bushings. (2) Install the stabilizer bar and center it with equal spacing on both sides. (3) Install stabilizer bar retainers and tighten bolts to 54 N·m (40 ft. lbs.). (4) Install link on the frame and the stabilizer bar.
Page 50: Special Tools
2 - 26 SUSPENSION REMOVAL AND INSTALLATION (Continued) ASSEMBLE (1) Press new bushing into the spring eye with an appropriate size driver. The bushing should be cen- tered in the spring eye. (2) Install the spring on the vehicle. SPECIFICATIONS TORQUE CHART DESCRIPTION TORQUE...
Page 51 DIFFERENTIAL AND DRIVELINE 3 - 1 DIFFERENTIAL AND DRIVELINE TABLE OF CONTENTS page page PROPELLER SHAFTS ..... . . 1 C205F AXLE .
Page 52 3 - 2 PROPELLER SHAFTS DESCRIPTION AND OPERATION (Continued) Fig. 1 Reference Marks on Yokes 1 – REFERENCE MARKS OPERATION The propeller shaft must operate through con- stantly changing relative angles between the trans- mission and axle. It must also be capable of changing Fig.
Page 53 PROPELLER SHAFTS 3 - 3 DESCRIPTION AND OPERATION (Continued) Fig. 3 Rear Propeller Shaft with Center Bearing 1 – REAR AXLE 3 – TRANSMISSION EXTENSION HOUSING 2 – REAR PROPELLER SHAFT 4 – CENTER BEARING Fig. 4 Rear Propeller Shaft 1 –...
Page 54 3 - 4 PROPELLER SHAFTS DESCRIPTION AND OPERATION (Continued) PROPELLER SHAFT JOINTS LUBRICATION The factory installed universal joints are lubricated DESCRIPTION for the life of the vehicle and do not need lubrication. All universal joints should be inspected for leakage Two different types of propeller shaft joints are and damage each time the vehicle is serviced.
Page 55 PROPELLER SHAFTS 3 - 5 DESCRIPTION AND OPERATION (Continued) Ideally the driveline system should have; DIAGNOSIS AND TESTING • Angles that are equal or opposite within 1 degree of each other. VIBRATION • Have a 3 degree maximum operating angle. Tires that are out-of-round, or wheels that are •...
Page 56 3 - 6 PROPELLER SHAFTS DIAGNOSIS AND TESTING (Continued) UNBALANCE NOTE: Removing and re-indexing the propeller shaft, 45° at a time, relative to the companion flange may eliminate some vibrations. If propeller shaft is suspected of being unbalanced, it can be verified with the following procedure: (1) Raise the vehicle.
Page 57: Service Procedures
PROPELLER SHAFTS 3 - 7 DIAGNOSIS AND TESTING (Continued) (4) Refer to Runout Specifications chart. ONE-PIECE PROPELLER SHAFT (5) If the propeller shaft runout is out of specifica- To accurately check driveline alignment, raise and tion, remove the propeller shaft, index the shaft 45°, support the vehicle at the axles as level as possible.
Page 58 3 - 8 PROPELLER SHAFTS SERVICE PROCEDURES (Continued) (6) Subtract smaller figure from larger (C minus B) to obtain axle Input Operating Angle. Refer to rules given below and the example in for additional information. • Good cancellation of U–joint operating angles (within 1°).
Page 59 PROPELLER SHAFTS 3 - 9 REMOVAL AND INSTALLATION (Continued) Fig. 14 Universal Joint Angle Example 1 – 4.9° Angle (C) 4 – 3.0° Angle (A) 2 – 3.2° Angle (B) 5 – Output Yoke 3 – Input Yoke Fig. 15 Universal Joint Angle—Two-Piece Shaft 1 –...
Page 60 3 - 10 PROPELLER SHAFTS REMOVAL AND INSTALLATION (Continued) (4) Remove the bolts holding the companion yoke REAR PROPELLER SHAFT to the companion flange (Fig. 16). (5) Remove the bolts holding the propeller shaft to REMOVAL the transfer case yoke. (1) Raise and support vehicle on safety stands.
Page 61 PROPELLER SHAFTS 3 - 11 REMOVAL AND INSTALLATION (Continued) CENTER BEARING REMOVAL (1) Remove rear propeller shaft. (2) Remove slip joint boot clamp and separate the two half-shafts. (3) Use hammer and punch to tap slinger away from shaft to provide room for bearing splitter. (4) Position Bearing Splitter Tool 1130 between slinger and shaft.
Page 62 3 - 12 PROPELLER SHAFTS DISASSEMBLY AND ASSEMBLY (Continued) (7) If the bearing cap will not pull out of the yoke by hand after pressing, tap the yoke ear near the bearing cap to dislodge the cap. (8) To remove the opposite bearing cap, turn the yoke over and straighten the cross in the open hole.
Page 63 PROPELLER SHAFTS 3 - 13 DISASSEMBLY AND ASSEMBLY (Continued) DOUBLE CARDAN JOINT DISASSEMBLY Individual components of cardan universal joints are not serviceable. If worn or leaking, they must be replaced as an assembly. (1) Remove the propeller shaft. (2) Using a soft drift, tap the outside of the bear- ing cap assembly to loosen snap ring.
Page 64 3 - 14 PROPELLER SHAFTS DISASSEMBLY AND ASSEMBLY (Continued) (7) Flip assembly and repeat Step 4, Step 5, and (3) Place a bearing cap over the trunnion and Step 6 to remove the opposite bearing cap. This will align the cap with the yoke bore (Fig. 28). Keep the then allow removal of the cross centering kit assem- needle bearings upright in the bearing assembly.
Page 65 PROPELLER SHAFTS 3 - 15 DISASSEMBLY AND ASSEMBLY (Continued) (6) Flip the propeller shaft yoke and install the (9) Install the centering kit assembly inside the bearing cap onto the opposite trunnion. Install a link yoke making sure the spring is properly posi- snap ring (Fig.
Page 66 3 - 16 PROPELLER SHAFTS DISASSEMBLY AND ASSEMBLY (Continued) (11) Press the remaining two bearing caps into place and install snap rings (Fig. 34). Fig. 36 Check Assembly CLEANING AND INSPECTION Fig. 34 Press In Bearing Cap PROPELLER SHAFT (12) Tap the snap rings to allow them to seat into (1) Clean all universal joint bores with cleaning the grooves (Fig.
Page 67 PROPELLER SHAFTS 3 - 17 ADJUSTMENTS (Continued) CENTER BEARING ADJUSTMENT SPECIAL TOOLS Drive away shudder is a vibration that occurs at PROPELLER SHAFT first acceleration from a stop. Shudder vibration usu- ally peaks at the engines highest torque output. Shudder is a symptom associated with vehicles using a two-piece propeller shaft.
Page 68 3 - 18 FRONT AXLE DRIVESHAFTS FRONT AXLE DRIVESHAFTS TABLE OF CONTENTS page page DESCRIPTION AND OPERATION C/V JOINT BOOTS ......21 FRONT AXLE DRIVESHAFTS.
Page 69 FRONT AXLE DRIVESHAFTS 3 - 19 DIAGNOSIS AND TESTING (Continued) Fig. 1 C/V Drive Shaft Components...
Page 70 3 - 20 FRONT AXLE DRIVESHAFTS DIAGNOSIS AND TESTING (Continued) 1 – RETAINER & HOUSING ASM 11 – RACE RETAINING RING 2 – C-CLIP 12 – SEAL RETAINING CLAMP 3 – TRIPOD JOINT SPIDER 13 – DRIVE AXLE OUTBOARD SEAL 4 –...
Page 71 FRONT AXLE DRIVESHAFTS 3 - 21 REMOVAL AND INSTALLATION (Continued) (7) Remove the brake caliper and rotor. Refer to (6) Install the bolts to hold the hub bearing to the Group 5, Brakes, for proper procedures. steering knuckle. Refer to Group 2, Suspension, for (8) Remove the ABS wheel speed sensor, if the proper torque.
Page 72 3 - 22 FRONT AXLE DRIVESHAFTS REMOVAL AND INSTALLATION (Continued) (a) Compress the inner hub down the connector shaft. (b) Use a small blunt drift between the large end and the boot seal to relieve the pressure. (c) The distance edge of the lip to the edge of the flange should be 181.00 mm (7.13 in.).
Page 73 FRONT AXLE DRIVESHAFTS 3 - 23 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 11 Inner C/V Joint Boot Fig. 9 Snap Retaining Ring Removal 1 – SMALL CLAMP 2 – SEALING BOOT 1 – SNAP RING 3 – LARGE CLAMP 2 – TRIPOD JOINT 4 –...
Page 74 3 - 24 FRONT AXLE DRIVESHAFTS DISASSEMBLY AND ASSEMBLY (Continued) (11) After the inner joint boot small clamp is (3) Clamp the shaft in a vise (with soft jaws). Sup- installed, the inboard hub must be set to a service port the outer C/V joint.
Page 75 FRONT AXLE DRIVESHAFTS 3 - 25 DISASSEMBLY AND ASSEMBLY (Continued) (8) Clamp the outer C/V joint in a vertical position. Place the stub shaft in a soft–jawed vise. (9) Press down on one side of the bearing cage/hub to tilt the cage. This will provide access to a ball at the opposite side of the cage.
Page 76 3 - 26 FRONT AXLE DRIVESHAFTS DISASSEMBLY AND ASSEMBLY (Continued) (3) Insert one of the bearing hub lands into a bear- ing cage window (Fig. 18). Roll the hub into the cage (Fig. 19). Rotate the bearing hub 90° to complete the installation (Fig.
Page 77 FRONT AXLE DRIVESHAFTS 3 - 27 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 23 Ball Installation In Raceway Fig. 25 Outer C/V Joint Installation 1 – CV JOINT HOUSING (OUTER) 1 – SNAP RING 2 – BEARING HUB (UP) 2 – SHAFT TAPER 3 –...
Page 78 3 - 28 FRONT AXLE DRIVESHAFTS CLEANING AND INSPECTION (Continued) Fig. 26 Drive Shaft Components...
Page 79 FRONT AXLE DRIVESHAFTS 3 - 29 CLEANING AND INSPECTION (Continued) 1 – RETAINER & HOUSING ASM 11 – RACE RETAINING RING 2 – C-CLIP 12 – SEAL RETAINING CLAMP 3 – TRIPOD JOINT SPIDER 13 – DRIVE AXLE OUTBOARD SEAL 4 –...
Page 80 3 - 30 C205F AXLE C205F AXLE TABLE OF CONTENTS page page DESCRIPTION AND OPERATION DIFFERENTIAL SIDE BEARINGS ... . . 40 C205F AXLE ......30 RING GEAR .
Page 81 C205F AXLE 3 - 31 DESCRIPTION AND OPERATION (Continued) CAUTION: If axle is submerged in water, lubricant When turning corners, the outside wheel must must be replaced immediately to avoid possible travel a greater distance than the inside wheel to complete a turn.
Page 82 3 - 32 C205F AXLE DIAGNOSIS AND TESTING (Continued) DIAGNOSTIC CHART Condition Possible Causes Correction Wheel Noise 1. Wheel loose. 1. Tighten loose nuts. 2. Faulty, brinelled wheel bearing. 2. Replace bearing. Axle Shaft Noise 1. Misaligned axle tube. 1. Inspect axle tube alignment. Correct as necessary.
Page 83 C205F AXLE 3 - 33 DIAGNOSIS AND TESTING (Continued) Condition Possible Causes Correction Differential Gears Scored 1. Insufficient lubrication. 1. Replace scored gears. Fill differential with the correct fluid type and quantity. 2. Improper grade of lubricant. 2. Replace scored gears. Fill differential with the correct fluid type and quantity.
Page 84 3 - 34 C205F AXLE DIAGNOSIS AND TESTING (Continued) Condition Possible Causes Correction Axle Noise 1. Insufficient lubricant. 1. Fill differential with the correct fluid type and quantity. 2. Improper ring gear and pinion 2. Check ring gear and pinion adjustment.
Page 85 C205F AXLE 3 - 35 DIAGNOSIS AND TESTING (Continued) • Damaged axle shaft bearing(s). • Loose pinion nut. • Excessive companion flange run out. • Bent axle shaft(s). Check for loose or damaged front–end components or engine/transmission mounts. These components can contribute to what appears to be a rear–end vibration.
Page 86 3 - 36 C205F AXLE REMOVAL AND INSTALLATION (Continued) (9) Remove bolts holding the axle to the engine INSTALLATION mounts (Fig. 4). (1) Raise the axle into position. Loosely install the (10) Remove bolts holding the axle to the pinion bolts and nuts to hold the axle to the engine mounts nose bracket (Fig.
Page 87 C205F AXLE 3 - 37 REMOVAL AND INSTALLATION (Continued) (5) Install seal with Installer C-3972-A and Handle C–4171 (Fig. 8). Fig. 8 Pinion Seal Installation 1 – SPECIAL TOOL C-4171 2 – SPECIAL TOOL C-3972–A (6) Install socket head bolts into two of the threaded holes in the companion flange, 180°...
Page 88 3 - 38 C205F AXLE REMOVAL AND INSTALLATION (Continued) (14) Align the installation reference marks on the propeller shaft and companion flange and install the propeller shaft. (15) Add gear lubricant to the differential housing, if necessary. Refer to the Lubricant Specifications for gear lubricant requirements.
Page 89 C205F AXLE 3 - 39 REMOVAL AND INSTALLATION (Continued) NOTE: The seal and bearing can be removed at the (8) Install a Pilot Stud L-4438 at the left side of same time with the bearing removal tool. the differential housing. Attach Dial Indicator C-3339 to pilot stud.
Page 90 3 - 40 C205F AXLE REMOVAL AND INSTALLATION (Continued) (1) Position Spreader W–129–B, with the Adapter (2) Remove the bearings from the differential case Plates 8142-A seated in the locating holes, on the with Puller/Press C-293-PA, C-293-48 Blocks, and axle and install the safety holddown clamps. Tighten Plug C-293-3 (Fig.
Page 91 C205F AXLE 3 - 41 REMOVAL AND INSTALLATION (Continued) INSTALLATION CAUTION: Do not reuse the bolts that held the ring gear to the differential case. The bolts can fracture causing extensive damage. (1) Invert the differential case and start two ring gear bolts.
Page 92 3 - 42 C205F AXLE REMOVAL AND INSTALLATION (Continued) (4) Separate the propeller shaft from the compan- ion flange and using suitable wire, tie the propeller shaft to the vehicle underbody. (5) Rotate the pinion gear three or four times. (6) Measure the amount of torque necessary to rotate the pinion with a (in.
Page 93 C205F AXLE 3 - 43 REMOVAL AND INSTALLATION (Continued) Fig. 21 Front Bearing Cup Removal Fig. 23 Collapsible Spacer 1 – REMOVER 1 – COLLAPSIBLE SPACER 2 – HANDLE 2 – SHOULDER 3 – PINION 4 – PINION DEPTH SHIM 5 –...
Page 94 3 - 44 C205F AXLE REMOVAL AND INSTALLATION (Continued) (2) Install the pinion rear bearing cup with (5) Install pinion front bearing, and oil slinger, if Installer D-145 and Driver Handle C–4171 (Fig. 25). equipped. Ensure cup is correctly seated. (6) Apply a light coating of gear lubricant on the lip of pinion seal.
Page 95 C205F AXLE 3 - 45 REMOVAL AND INSTALLATION (Continued) (14) Tighten the pinion nut until there is zero bearing end-play (Fig. 30). (15) Tighten the nut to 271 N·m (200 ft. lbs.). CAUTION: Never loosen pinion nut to decrease pin- ion bearing rotating torque and never exceed spec- ified preload torque.
Page 96 3 - 46 C205F AXLE REMOVAL AND INSTALLATION (Continued) Fig. 31 Check Pinion Rotating Torque Fig. 32 Typical Housing Cover With Sealant 1 – COMPANION FLANGE 1 – SEALING SURFACE 2 – INCH POUND TORQUE WRENCH 2 – CONTOUR OF BEAD 3 –...
Page 97 C205F AXLE 3 - 47 DISASSEMBLY AND ASSEMBLY (Continued) (6) Lubricate all differential components with hypoid gear lubricant. (7) Install ring gear. Fig. 33 Pinion Mate Shaft Removal 1 – PINION MATE GEAR 2 – PINION MATE SHAFT 3 – SIDE GEAR 4 –...
Page 98 3 - 48 C205F AXLE CLEANING AND INSPECTION (Continued) • Ring gear for damaged bolt threads. Replaced as a matched set only. • Companion flange for cracks, worn splines, pit- ted areas, and a rough/corroded seal contact surface. Repair or replace as necessary. •...
Page 99 C205F AXLE 3 - 49 ADJUSTMENTS (Continued) PINION GEAR DEPTH VARIANCE Original Replacement Pinion Gear Depth Variance Pinion Gear Depth −4 −3 −2 −1 Variance +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 −0.001 +0.006 +0.005...
Page 100 3 - 50 C205F AXLE ADJUSTMENTS (Continued) Fig. 40 Gauge Tools In Housing Fig. 41 Pinion Gear Depth Measurement 1 – ARBOR DISC 1 – ARBOR 2 – PINION BLOCK 2 – SCOOTER BLOCK 3 – ARBOR 3 – DIAL INDICATOR 4 –...
Page 101 C205F AXLE 3 - 51 ADJUSTMENTS (Continued) SHIM SELECTION NOTE: It is difficult to salvage the differential side bearings during the removal procedure. Install replacement bearings if necessary. (1) Remove side bearings from differential case. (2) Install ring gear, if necessary, on differential case and tighten bolts to specification.
Page 102 3 - 52 C205F AXLE ADJUSTMENTS (Continued) Fig. 48 Hold Differential Case and Read Dial Indicator 1 – READ DIAL INDICATOR 2 – FORCE DIFFERENTIAL CASE TO RING GEAR SIDE 3 – AXLE HOUSING Fig. 46 Differential Side play Measurement (14) Add the dial indicator reading to the starting point shim thicknesses to determine the total shim 1 –...
Page 103 C205F AXLE 3 - 53 ADJUSTMENTS (Continued) (27) Rotate dial indicator out of the way on guide stud. (28) Remove differential case, dummy bearings, and dummy shim from axle housing. (29) Install new side bearing cones and cups on differential case. (30) Install spreader W-129-B, utilizing Adapter Plates 8142-A, on axle housing and spread axle open- ing enough to receive differential case.
Page 104 3 - 54 C205F AXLE ADJUSTMENTS (Continued) Fig. 51 Gear Tooth Contact Patterns...
Page 105 C205F AXLE 3 - 55 SPECIFICATIONS C205F AXLE DESCRIPTION SPECIFICATION Axle Type ....Semi–Floating Hypoid Lubricant ..SAE Thermally Stable 80W–90 Lube Capacity .
Page 106 3 - 56 C205F AXLE SPECIAL TOOLS (Continued) Installer—D-129 Installer Screw—8112 Installer—D-145 Cup—8109 Remover—D-103 Handle—C-4171 Remover—8401 Installer—8236 Installer—6448...
Page 107 C205F AXLE 3 - 57 SPECIAL TOOLS (Continued) Bearing Remover—C-4660 Tool Set, Pinion Depth Cup—8150 Adapter Kit—6987A Installer—5063 Spreader—W-129-B Installer—8402 Guide Pin—C-3288-B Gauge Block—8177 Dial Indicator—C-3339...
Page 108 3 - 58 C205F AXLE SPECIAL TOOLS (Continued) Dummy Shim—8107 Dummy Bearing—8398...
Page 109 8 1/4 AND 9 1/4 AXLE 3 - 59 8 1/4 AND 9 1/4 AXLE TABLE OF CONTENTS page page DESCRIPTION AND OPERATION RING GEAR AND EXCITER RING ... . 75 8 1/4 AXLE .
Page 110 3 - 60 8 1/4 AND 9 1/4 AXLE DESCRIPTION AND OPERATION (Continued) Fig. 1 8 1/4 Axle OPERATION The axle receives power from the transmission/ transfer case through the rear propeller shaft. The rear propeller shaft is connected to the pinion gear which rotates the differential through the gear mesh with the ring gear bolted to the differential case.
Page 111 8 1/4 AND 9 1/4 AXLE 3 - 61 DESCRIPTION AND OPERATION (Continued) The removable, stamped steel cover provides a The differential case is a one-piece design. The dif- means for inspection and service without removing ferential pinion mate shaft is retained with a the complete axle from the vehicle.
Page 112 3 - 62 8 1/4 AND 9 1/4 AXLE DESCRIPTION AND OPERATION (Continued) Fig. 3 9 1/4 Axle...
Page 113 8 1/4 AND 9 1/4 AXLE 3 - 63 DESCRIPTION AND OPERATION (Continued) 1 – HUB 29 – PLUG 2 – AXLE SHAFT 30 – COVER BOLT 3 – VENT FITTING 31 – WASHER 4 – DIFFERENTIAL HOUSING 32 – CLIP 5 –...
Page 114 3 - 64 8 1/4 AND 9 1/4 AXLE DESCRIPTION AND OPERATION (Continued) STANDARD DIFFERENTIAL When turning corners, the outside wheel must travel a greater distance than the inside wheel to complete a turn. The difference must be compensated DESCRIPTION for to prevent the tires from scuffing and skidding The differential gear system divides the torque through turns.
Page 115 8 1/4 AND 9 1/4 AXLE 3 - 65 DESCRIPTION AND OPERATION (Continued) OPERATION The Trac-lok design provides the differential action needed for turning corners and for driving In operation, the Trac-lok clutches are engaged straight ahead during periods of unequal traction. by two concurrent forces.
Page 116 3 - 66 8 1/4 AND 9 1/4 AXLE DIAGNOSIS AND TESTING (Continued) DIAGNOSTIC CHART Condition Possible Causes Correction Wheel Noise 1. Wheel loose. 1. Tighten loose nuts. 2. Faulty, brinelled wheel bearing. 2. Replace bearing. Axle Shaft Noise 1. Misaligned axle tube. 1.
Page 117 8 1/4 AND 9 1/4 AXLE 3 - 67 DIAGNOSIS AND TESTING (Continued) Condition Possible Causes Correction Loss Of Lubricant 1. Lubricant level too high. 1. Drain lubricant to the correct level. 2. Worn axle shaft seals. 2. Replace seals. 3.
Page 118 3 - 68 8 1/4 AND 9 1/4 AXLE DIAGNOSIS AND TESTING (Continued) • Loose pinion nut. When road testing, first warm-up the axle fluid by • Excessive companion flange run out. driving the vehicle at least 5 miles and then acceler- •...
Page 119 8 1/4 AND 9 1/4 AXLE 3 - 69 DIAGNOSIS AND TESTING (Continued) The differential can be tested without removing the differential case by measuring rotating torque. Make sure brakes are not dragging during this measure- ment. (1) Place blocks in front and rear of both front wheels.
Page 120 3 - 70 8 1/4 AND 9 1/4 AXLE REMOVAL AND INSTALLATION (Continued) (7) Disconnect the brake hose at the axle junction (5) Loosen housing cover bolts. Drain lubricant block. Do not disconnect the brake hydraulic lines at from the housing and axle tubes. Remove housing the wheel cylinders.
Page 121 8 1/4 AND 9 1/4 AXLE 3 - 71 REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Lubricate bearing bore and seal lip with gear lubricant. Insert axle shaft through seal, bearing, and engage it into side gear splines. NOTE: Use care to prevent shaft splines from dam- aging axle shaft seal lip.
Page 122 3 - 72 8 1/4 AND 9 1/4 AXLE REMOVAL AND INSTALLATION (Continued) Fig. 14 Axle Shaft Seal and Bearing Installation 1 – HANDLE 2 – INSTALLER 3 – AXLE TUBE Fig. 15 Companion Flange Removal PINION SEAL 1 – COMPANION FLANGE 2 –...
Page 123 8 1/4 AND 9 1/4 AXLE 3 - 73 REMOVAL AND INSTALLATION (Continued) Fig. 16 8 1/4 Axle Pinion Seal Installation 1 – SPECIAL TOOL C-4735 2 – DIFFERENTIAL HOUSING 3 – SPECIAL TOOL C-4076-A (9) Seat companion flange on pinion shaft with Fig.
Page 124 3 - 74 8 1/4 AND 9 1/4 AXLE REMOVAL AND INSTALLATION (Continued) (15) Install the propeller shaft with the installa- tion reference marks aligned. (16) Tighten the companion flange bolts to 108 N·m (80 ft. lbs.). (17) Install the brake drums. (18) Install wheel and tire assemblies and lower the vehicle.
Page 125 8 1/4 AND 9 1/4 AXLE 3 - 75 REMOVAL AND INSTALLATION (Continued) (3) Install bearing cap bolts and tighten the upper bolts to 14 N·m (10 ft. lbs.). Tighten the lower bolts finger-tight until the bolt head is seated. (4) Perform the differential bearing preload and adjustment procedure.
Page 126 3 - 76 8 1/4 AND 9 1/4 AXLE REMOVAL AND INSTALLATION (Continued) INSTALLATION CAUTION: Do not reuse the bolts that held the ring gear to the differential case. The bolts can fracture causing extensive damage. (1) Invert the differential case. (2) Position exciter ring on differential case.
Page 127 8 1/4 AND 9 1/4 AXLE 3 - 77 REMOVAL AND INSTALLATION (Continued) REMOVAL (1) Remove differential from the axle housing. (2) Mark the companion flange and propeller shaft for installation alignment. (3) Disconnect the propeller shaft from the com- panion flange.
Page 128 3 - 78 8 1/4 AND 9 1/4 AXLE REMOVAL AND INSTALLATION (Continued) (13) Remove the rear bearing cup from housing (Fig. 30). Use: • Remover C-4307 and Handle C–4171 for the 8 1/4 axle. • Remover C-4309 and Handle C-4171 for the 9 1/4 axle.
Page 129 8 1/4 AND 9 1/4 AXLE 3 - 79 REMOVAL AND INSTALLATION (Continued) (6) Apply a light coating of gear lubricant on the lip of pinion seal. Install seal with: • Installer C-4076–B and Handle C-4735-1 for the 8 1/4 axle (Fig. 35). •...
Page 130 3 - 80 8 1/4 AND 9 1/4 AXLE REMOVAL AND INSTALLATION (Continued) (14) Install the companion flange washer and a new nut on the pinion and tighten the pinion nut until there is zero bearing end-play. It will not be possible at this point to achieve zero bearing end- play if a new collapsible spacer was installed.
Page 131 8 1/4 AND 9 1/4 AXLE 3 - 81 REMOVAL AND INSTALLATION (Continued) Fig. 39 Check pinion Rotating Torque Fig. 40 Typical Housing Cover With Sealant 1 – COMPANION FLANGE 1 – SEALING SURFACE 2 – INCH POUND TORQUE WRENCH 2 –...
Page 132 3 - 82 8 1/4 AND 9 1/4 AXLE DISASSEMBLY AND ASSEMBLY (Continued) (4) Remove the differential side gears and thrust washers. ASSEMBLY (1) Install the differential side gears and thrust washers. (2) Install the differential pinion gears and thrust washers.
Page 133 8 1/4 AND 9 1/4 AXLE 3 - 83 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 46 Mate Shaft Removal 1 – PINION MATE SHAFT 2 – SIDE GEAR 3 – DRIFT 4 – PINION MATE GEAR Fig. 44 Differential Case Holding Tool 1 –...
Page 134 3 - 84 8 1/4 AND 9 1/4 AXLE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 48 Threaded Adapter Installation Fig. 50 Remove Pinion Gear Thrust Washer 1 – SOCKET 2 – SLOT IN ADAPTER 1 – THRUST WASHER 3 – SCREWDRIVER 2 –...
Page 135 8 1/4 AND 9 1/4 AXLE 3 - 85 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 53 Clutch Disc Pack Fig. 52 Side Gear & Clutch Disc Removal 1 – CLUTCH PACK 1 – DIFFERENTIAL CASE 2 – RETAINER 2 – RETAINER 3 –...
Page 136 3 - 86 8 1/4 AND 9 1/4 AXLE DISASSEMBLY AND ASSEMBLY (Continued) (13) Lubricate and install thrust washers behind pinion gears and align washers with a small screw driver. Insert mate shaft into each pinion gear to ver- ify alignment. (14) Remove Forcing Screw 6960-4, Step Plate 8140–2, and Threaded Adapter 8140-1.
Page 137 8 1/4 AND 9 1/4 AXLE 3 - 87 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 59 Mate Shaft Removal 1 – PINION MATE SHAFT 2 – SIDE GEAR 3 – DRIFT 4 – PINION MATE GEAR Fig. 57 Differential Case Holding Tool 1 –...
Page 138 3 - 88 8 1/4 AND 9 1/4 AXLE DISASSEMBLY AND ASSEMBLY (Continued) Fig. 61 Threaded Adapter Installation 1 – THREADED ADAPTER DISC 8139–1 Fig. 63 Remove Pinion Gear Thrust Washer 2 – SOCKET 1 – THRUST WASHER 3 – SLOT IN ADAPTER 2 –...
Page 139 8 1/4 AND 9 1/4 AXLE 3 - 89 DISASSEMBLY AND ASSEMBLY (Continued) Fig. 66 Clutch Disc Pack Fig. 65 Side Gear & Clutch Disc Removal 1 – CLUTCH PACK 1 – DIFFERENTIAL CASE 2 – RETAINER 2 – RETAINER 3 –...
Page 140 3 - 90 8 1/4 AND 9 1/4 AXLE DISASSEMBLY AND ASSEMBLY (Continued) • Smooth appearance with no broken/dented sur- faces on the bearing rollers or the roller contact sur- faces. • Bearing cups must not be distorted or cracked. •...
Page 141 8 1/4 AND 9 1/4 AXLE 3 - 91 Note where Old and New Pinion Marking columns ADJUSTMENTS intersect. Intersecting figure represents plus or minus the amount needed. 8 1/4 AXLE PINION GEAR DEPTH Note the painted number on the shaft of the pinion gear (–1, –2, 0, +1, +2, etc.).
Page 142 3 - 92 8 1/4 AND 9 1/4 AXLE ADJUSTMENTS (Continued) PINION GEAR DEPTH VARIANCE Original Pinion Replacement Pinion Gear Depth Variance Gear Depth −4 −3 −2 −1 Variance +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002...
Page 143 8 1/4 AND 9 1/4 AXLE 3 - 93 ADJUSTMENTS (Continued) Compensation pinion depth variance achieved with select shims. The shims are placed behind the rear pinion bearing (Fig. 74). Fig. 72 Gauge Tools In Housing 1 – ARBOR DISC 2 –...
Page 144 3 - 94 8 1/4 AND 9 1/4 AXLE ADJUSTMENTS (Continued) PINION GEAR DEPTH VARIANCE Original Pinion Replacement Pinion Gear Depth Variance Gear Depth −4 −3 −2 −1 Variance +0.008 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002 +0.001 +0.007 +0.006 +0.005 +0.004 +0.003 +0.002...
Page 145 8 1/4 AND 9 1/4 AXLE 3 - 95 ADJUSTMENTS (Continued) Fig. 77 Gauge Tools In Housing Fig. 78 Pinion Gear Depth Measurement 1 – ARBOR DISC 1 – ARBOR 2 – PINION BLOCK 2 – SCOOTER BLOCK 3 – ARBOR 3 –...
Page 146 3 - 96 8 1/4 AND 9 1/4 AXLE ADJUSTMENTS (Continued) (6) Tighten the right-side threaded adjuster to 102 N·m (75 ft. lbs.). Seat the bearing cups with the pro- cedure described above. Continue to tighten the right-side adjuster and seat bearing cups until the torque remains constant at 102 N·m (75 ft.
Page 147 8 1/4 AND 9 1/4 AXLE 3 - 97 ADJUSTMENTS (Continued) Fig. 81 Gear Tooth Contact Patterns...
Page 148 3 - 98 8 1/4 AND 9 1/4 AXLE ADJUSTMENTS (Continued) (2) Measure each side gear clearance. Insert a differential case without the C-lock installed and re- matched pair of feeler gauge blades between the gear measure the side gear clearance. and differential housing on opposite sides of the hub (6) Compare both clearance measurements.
Page 149 8 1/4 AND 9 1/4 AXLE 3 - 99 SPECIFICATIONS (Continued) 8 1/4 and 9 1/4 INCH AXLE DESCRIPTION TORQUE Diff. Cover Bolt ... . . 41 N·m (30 ft. lbs.) Bearing Cap Bolt—8 1/4 Axle .
Page 150 3 - 100 8 1/4 AND 9 1/4 AXLE SPECIAL TOOLS (Continued) Installer—C-4826 Adjustment Rod—C-4164 Holder—6719 Puller/Press—C-293–PA Puller—C-452 Adapters—C-293-48 Installer—C-3860-A Plug—SP-3289 Adapters—C-293-47 Installer—C-3718...
Page 151 8 1/4 AND 9 1/4 AXLE 3 - 101 SPECIAL TOOLS (Continued) Plug—C-293-3 Installer—C-4345 Installer—C-4340 Remover—C-4307 Remover—C-4309 Installer—C-4213 Adapters—C-293-37 Holder—8136 Installer—C-4308 Holder—8138...
Page 152 3 - 102 8 1/4 AND 9 1/4 AXLE SPECIAL TOOLS (Continued) Trac-lok Tools—8140 Installer—C-4310 Installer—D-130 Trac-lok Tools—6960 Installer—D-129 Trac-lok Tools—C-4487 Installer—6448 Trac-lok Tools—8139 Installer—C-3095 Pinion Gauge Block—8540...
Page 153 8 1/4 AND 9 1/4 AXLE 3 - 103 SPECIAL TOOLS (Continued) Arbor Discs—8541 Pinion Gauge Block—8542 Pinion Gauge Set...
Page 155 BRAKES 5 - 1 BRAKES TABLE OF CONTENTS page page BASE BRAKE SYSTEM ..... . 1 FOUR WHEEL ANTILOCK BRAKES... . 40 REAR WHEEL ANTILOCK BRAKES .
Page 156: Description And Operation
5 - 2 BRAKES cleaning materials recommended. If system contam- DESCRIPTION AND OPERATION ination is suspected, check the fluid for dirt, discol- oration, or separation into distinct layers. Also BRAKE SYSTEM check the reservoir cap seal for distortion. Drain and flush the system with new brake fluid if con- DESCRIPTION tamination is suspected.
Page 157 BRAKES 5 - 3 DESCRIPTION AND OPERATION (Continued) depressed. The speed control and brake sensor cir- malfunction. The reservoir compartments will retain cuits is closed until the plunger is depressed. enough fluid to operate the functioning hydraulic cir- cuit. RED BRAKE WARNING LAMP Care must be exercised when removing/installing the master cylinder connecting lines.
Page 158 5 - 4 BRAKES DESCRIPTION AND OPERATION (Continued) FRONT DISC BRAKES Application and release of the brake pedal gener- ates only a very slight movement of the caliper and piston. Upon release of the pedal, the caliper and pis- DESCRIPTION ton return to a rest position.
Page 159 BRAKES 5 - 5 DESCRIPTION AND OPERATION (Continued) tains a spring loaded mechanism to hold the pedal in the applied position. A rod and spring are used to release the ratchet mechanism and return the pedal to normal position. BRAKE HOSES AND LINES DESCRIPTION Flexible rubber hose is used at both front brakes and at the rear axle junction block.
Page 160: Tires
5 - 6 BRAKES DIAGNOSIS AND TESTING (Continued) and cups will also have to be replaced after flush- HARD PEDAL OR HIGH PEDAL EFFORT ing. Use clean brake fluid to flush the system. A hard pedal or high pedal effort may be due to (4) Check parking brake operation.
Page 161 BRAKES 5 - 7 DIAGNOSIS AND TESTING (Continued) BRAKE FADE BRAKE LINING CONTAMINATION Brake fade is usually a product of overheating Brake lining contamination is mostly a product of caused by brake drag. However, brake overheating leaking calipers or wheel cylinders, worn seals, driv- and resulting fade can also be caused by riding the ing through deep water puddles, or lining that has brake pedal, making repeated high deceleration stops...
Page 162 5 - 8 BRAKES DIAGNOSIS AND TESTING (Continued) steering, suspension, or engine components. However, The lamp illuminates for approximately 2-4 sec- calipers that bind on the slide surfaces can generate onds at every engine start up. This is a self test fea- a thump or clunk noise.
Page 163 BRAKES 5 - 9 DIAGNOSIS AND TESTING (Continued) COMBINATION VALVE Pressure Differential Switch (1) Have helper sit in drivers seat to apply brake pedal and observe red brake warning light. (2) Raise vehicle on hoist. (3) Connect bleed hose to a rear wheel cylinder and immerse hose end in container partially filled with brake fluid.
Page 164 5 - 10 BRAKES DIAGNOSIS AND TESTING (Continued) BRAKE DRUM The maximum allowable diameter of the drum braking surface is indicated on the drum outer edge. Generally, a drum can be machined to a maximum of 1.52 mm (0.060 in.) oversize. Always replace the drum if machining would cause drum diameter to exceed the size limit indicated on the drum.
Page 165 BRAKES 5 - 11 DIAGNOSIS AND TESTING (Continued) Swollen rubber parts indicate the presence of (4) Press cylinder pistons inward with wood dowel. petroleum in the brake fluid. Then release pistons and allow them to return under To test for contamination, put a small amount of spring pressure.
Page 166 5 - 12 BRAKES SERVICE PROCEDURES (Continued) (3) Attach one end of bleed hose to bleed screw NOTE: A hub mounted on-vehicle lathe is recom- and insert opposite end in glass container partially mended. This type of lathe trues the rotor to the filled with brake fluid (Fig.
Page 167 BRAKES 5 - 13 SERVICE PROCEDURES (Continued) (2) Remove any burrs from the inside of the tube. (3) Install tube nut on the tube. (4) Position the tube in the flaring tool flush with the top of the tool bar (Fig. 14). Then tighten the tool bar on the tube.
Page 168 5 - 14 BRAKES REMOVAL AND INSTALLATION (Continued) Fig. 15 Brake Lamp Switch & Bracket Fig. 16 Brake Pedal Mounting 1 – RELEASE LEVER 1 – PIVOT PIN 2 – BRACKET 2 – CLIP 3 – BRAKE PEDAL SUPPORT 3 – BUSHINGS 4 –...
Page 169 BRAKES 5 - 15 REMOVAL AND INSTALLATION (Continued) MASTER CYLINDER REMOVAL (1) Remove brake lines from the master cylinder (Fig. 17). (2) Remove mounting nuts from the master cylin- der (Fig. 17). (3) Remove master cylinder. Fig. 18 Booster Rod Clip 1 –...
Page 170 5 - 16 BRAKES REMOVAL AND INSTALLATION (Continued) DISC BRAKE CALIPER REMOVAL (1) Clean master cylinder reservoir and filler caps. (2) Remove reservoir filler cap and drain approxi- mately 1/4 of fluid from reservoir. Use clean suction gun or similar device to drain fluid. (3) Raise and support vehicle.
Page 171 BRAKES 5 - 17 REMOVAL AND INSTALLATION (Continued) (5) Install brake hose to caliper with new seal washers and tighten fitting bolt to 24 N·m (18 ft. lbs.). CAUTION: Verify brake hose is not twisted or kinked before tightening fitting bolt. (6) Bleed base brake system.
Page 172 5 - 18 BRAKES REMOVAL AND INSTALLATION (Continued) Fig. 26 Installing Outboard Shoe 1 – CALIPER 2 – OUTBOARD SHOE Fig. 28 Caliper Spring 1 – CALIPER 2 – ADAPTER 3 – CALIPER SPRING Fig. 27 Outboard Shoe Retainer Spring 1 –...
Page 173 BRAKES 5 - 19 REMOVAL AND INSTALLATION (Continued) (10) Remove support and lower vehicle. (11) Pump brake pedal to seat brake shoes. (12) Fill brake fluid reservoir. (13) Verify a firm brake pedal before moving vehi- cle. DISC BRAKE ROTOR REMOVAL (1) Raise and support vehicle.
Page 174 5 - 20 BRAKES REMOVAL AND INSTALLATION (Continued) (14) Remove secondary brake shoe from support plate. (15) Remove strut and spring (Fig. 31). (16) Remove parking brake lever retaining clip from the secondary shoe and remove the lever. (17) Remove primary shoe from support plate. (18) Disengage parking brake lever from parking brake cable.
Page 175 BRAKES 5 - 21 REMOVAL AND INSTALLATION (Continued) (14) Install shoe spring. Connect spring to second- (5) Install parking brake cable in support plate. ary shoe first. Then to primary shoe. (6) Install axle shaft, refer to Group 3 for proce- (15) Verify adjuster operation.
Page 176 5 - 22 BRAKES REMOVAL AND INSTALLATION (Continued) (6) Connect the cable to the tensioner. (7) Perform parking brake adjustment procedure. (8) Remove support and lower vehicle. REAR PARK BRAKE CABLES REMOVAL (1) Raise and support the vehicle. (2) Remove the rear wheel and tire assemblies. (3) Loosen tensioner adjuster nut.
Page 177 BRAKES 5 - 23 REMOVAL AND INSTALLATION (Continued) (9) Perform park brake adjustment procedure. (3) Remove pins that retain reservoir to master (10) Remove support and lower the vehicle. cylinder. Use hammer and pin punch to remove pins (Fig. 40). PARK BRAKE PEDAL ASSEMBLY Removal (1) Remove left side kick panel.
Page 178 5 - 24 BRAKES DISASSEMBLY AND ASSEMBLY (Continued) Fig. 42 Reservoir Removal 1 – RESERVOIR 2 – GROMMETS Fig. 44 Grommet Installation 1 – WORK NEW GROMMETS INTO PLACE USING FINGER PRESSURE ONLY Fig. 43 Grommet Removal 1 – MASTER CYLINDER BODY 2 –...
Page 179 BRAKES 5 - 25 DISASSEMBLY AND ASSEMBLY (Continued) CAUTION: Do not blow the piston out of the bore with sustained air pressure. This could result in a cracked piston. Use only enough air pressure to ease the piston out. WARNING: NEVER ATTEMPT TO CATCH THE PIS- TON AS IT LEAVES THE BORE.
Page 180 5 - 26 BRAKES DISASSEMBLY AND ASSEMBLY (Continued) (5) Slide new seal boot over piston until boot lip seats in piston groove (Fig. 49). (6) Push retainer part of boot forward until folds in boot snap into place (Fig. 50). Fig.
Page 181 BRAKES 5 - 27 DISASSEMBLY AND ASSEMBLY (Continued) (10) Install caliper bleed screw and bleed screw ASSEMBLY cap if removed (Fig. 53). (1) Lubricate wheel cylinder bore, pistons, piston cups and spring and expander with clean brake fluid. (2) Install first piston in cylinder bore. Then install first cup in bore and against piston.
Page 182 5 - 28 BRAKES CLEANING AND INSPECTION (Continued) Fig. 56 Polishing Piston Bore Fig. 55 Shoe Contact Surfaces 1 – SPECIAL HONE 1 – ANCHOR PIN 2 – CALIPER 2 – SUPPORT PLATE 3 – PISTON BORE 3 – SHOE CONTACT SURFACES INSPECTION CAUTION: Do not use gasoline, kerosene, paint Inspect the cylinder bore.
Page 183 BRAKES 5 - 29 ADJUSTMENTS (Continued) (3) Verify that left and right automatic adjuster (8) Install brake drums and wheels and lower levers and cables are properly connected. vehicle. (4) Insert brake gauge in drum. Expand gauge (9) Drive vehicle and make one forward stop fol- until gauge inner legs contact drum braking surface.
Page 184 5 - 30 BRAKES ADJUSTMENTS (Continued) (9) Repeat adjustment at opposite wheel. Be sure CAUTION: Do not loosen, or tighten the tensioner adjustment is equal at both wheels. adjusting nut for any reason after completing (10) Install support plate access hole plugs. adjustment.
Page 185 BRAKES 5 - 31 SPECIFICATIONS (Continued) BASE BRAKES SPECIAL TOOLS BASE BRAKES Disc Brake Caliper Type ......Sliding Bore .
Page 186 5 - 32 BRAKES REAR WHEEL ANTILOCK BRAKES TABLE OF CONTENTS page page DESCRIPTION AND OPERATION RWAL SERVICE PRECAUTIONS ... . . 36 REAR WHEEL ANTILOCK ....32 SERVICE PROCEDURES RWAL COMPONENT LOCATION .
Page 187 BRAKES 5 - 33 DESCRIPTION AND OPERATION (Continued) RWAL COMPONENT LOCATION DESCRIPTION COMPONENT LOCATION FUNCTION RWAL CONTROLLER Driver side inner fender on a Tests, monitors and controls the bracket. rear brake system. HYDRAULIC CONTROL UNIT/ Driver side inner fender on a Modulates hydraulic pressure to RWAL VALVE bracket.
Page 188 5 - 34 BRAKES DESCRIPTION AND OPERATION (Continued) OPERATION onds). The CAB will pulse the dump valve until rear wheel deceleration matches the desired slip rate pro- SYSTEM SELF-TEST grammed into the CAB. The system will switch to normal braking once wheel locking tendencies are no When the ignition switch is turned-on the micro- longer present.
Page 189 BRAKES 5 - 35 DESCRIPTION AND OPERATION (Continued) replacement procedure of the exciter ring, refer to Group 3 Differential and Driveline. Fig. 3 Exciter Ring Location 1 – EXCITER RING 2 – RING GEAR Fig. 4 Operation of the Wheel Speed Sensor 1 –...
Page 190 5 - 36 BRAKES DESCRIPTION AND OPERATION (Continued) receives the brake applied signal. The CAB then monitors the RWAL system to anticipate the need for an RWAL stop. DIAGNOSIS AND TESTING REAR WHEEL ANTILOCK Diagnosis of base brake conditions which are mechanical in nature should be performed first.
Page 191 BRAKES 5 - 37 SERVICE PROCEDURES REAR WHEEL ANTILOCK BRAKE BLEEDING Use Mopar brake fluid, or an equivalent quality fluid meeting SAE J1703-F and DOT 3 standards only. Use fresh, clean fluid from a sealed container at all times. Do not pump the brake pedal at any time while bleeding.
Page 192 5 - 38 BRAKES REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Position the valve on the bracket and install the mounting bolt. Tighten the mounting bolt to 20-27 N·m (15-20 ft. lbs.). (2) Install the brake lines and tighten to 19 N·m (170 in.
Page 193 BRAKES 5 - 39 REMOVAL AND INSTALLATION (Continued) EXCITER RING SPECIFICATIONS The exciter ring is mounted on the differential TORQUE CHART case. If the ring is damaged refer to Group 3 Differ- ential and Driveline for service procedures. DESCRIPTION TORQUE Controller Mounting Screws .
Page 194 5 - 40 BRAKES FOUR WHEEL ANTILOCK BRAKES TABLE OF CONTENTS page page DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION ANTILOCK BRAKE SYSTEM ....40 CONTROLLER ANTILOCK BRAKES ... 44 CONTROLLER ANTILOCK BRAKES .
Page 195 BRAKES 5 - 41 DESCRIPTION AND OPERATION (Continued) During normal braking, the master cylinder, power booster and wheel brake units all function as they would in a vehicle without ABS. The HCU compo- nents are not activated. The purpose of the antilock system is to prevent wheel lockup during periods of high wheel slip.
Page 196 5 - 42 BRAKES DESCRIPTION AND OPERATION (Continued) During normal braking, the HCU solenoid valves WHEEL SPEED SENSOR and pump are not activated. The master cylinder and power booster operate the same as a vehicle without DESCRIPTION an ABS brake system. The ABS brake system uses 3 wheel speed sensors.
Page 197 BRAKES 5 - 43 DESCRIPTION AND OPERATION (Continued) Fig. 4 Data Link Connector - Typical 1 – 16–WAY DATA LINK CONNECTOR OPERATION Fig. 3 Operation of the Wheel Speed Sensor If an ABS component exhibits a fault the CAB will illuminate the ABS warning lamp and register a 1 –...
Page 198 5 - 44 BRAKES SERVICE PROCEDURES BLEEDING ABS BRAKE SYSTEM ABS system bleeding requires conventional bleed- ing methods plus use of the DRB scan tool. The pro- cedure involves performing a base brake bleeding, followed by use of the scan tool to cycle and bleed the HCU pump and solenoids.
Page 199 BRAKES 5 - 45 REMOVAL AND INSTALLATION (Continued) Fig. 7 Controller Mounting Screws 1 – CAB 2 – MOUNTING LOCATIONS Fig. 9 Mounting Bracket REMOVAL 1 – ANTILOCK CONTROL ASSEMBLY (1) Disconnect battery negative cable. 2 – MOUNTING BRACKET (2) Remove the brake lines from HCU (Fig. 8). (3) Push the harness connector locks to release the INSTALLATION locks, (Fig.
Page 200 5 - 46 BRAKES REMOVAL AND INSTALLATION (Continued) (2) Secure sensor wire retaining clamps to control arm and fender panel. (3) In engine compartment, connect sensor wire to harness connector. Make sure wire is routed away from hot or rotating underhood components. (4) Turn steering wheel back and forth to verify that wire is clear of steering and suspension compo- nents.
Page 201 BRAKES 5 - 47 REMOVAL AND INSTALLATION (Continued) (2) Install O-ring on sensor (if removed). (3) Insert sensor in differential housing. (4) Install sensor shield. (5) Install the sensor mounting stud and tighten to 24 N·m (200 in. lbs.). (6) Install the brake line on the sensor stud and install the nut.
Page 203 COOLING SYSTEM 7 - 1 COOLING SYSTEM TABLE OF CONTENTS page page DESCRIPTION AND OPERATION COOLANT—ADDING ADDITIONAL... 23 COOLING SYSTEM ......2 COOLANT LEVEL CHECK .
Page 204: Cooling System
7 - 2 COOLING SYSTEM ating temperature as quickly as possible. It also DESCRIPTION AND OPERATION maintains normal operating temperature and pre- vents overheating. COOLING SYSTEM The cooling system also provides a means of heat- ing the passenger compartment and cooling the auto- DESCRIPTION matic transmission fluid (if equipped).
Page 205: Thermostat—5.2L/5.9L Engines
COOLING SYSTEM 7 - 3 DESCRIPTION AND OPERATION (Continued) Fig. 2 Engine Cooling System Flow—4.7L Engine—Typical 1 – LH CYL. HEAD 5 – RH BANK CYL. BLOCK 2 – BLEED 6 – LH BANK CYL. BLOCK 3 – THERMOSTAT LOCATION 7 –...
Page 206: Thermostat—4.7L Engine
7 - 4 COOLING SYSTEM DESCRIPTION AND OPERATION (Continued) Fig. 3 Upper Fan Shroud with Integral Coolant Reserve/Overflow System 1 – RADIATOR 2 – WASHER FLUID RESERVOIR Fig. 4 Thermostat—Typical 3 – COOLANT OVERFLOW/RESERVOIR 1 – THERMOSTAT HOUSING 4 – FAN SHROUD (UPPER) 2 –...
Page 207 COOLING SYSTEM 7 - 5 DESCRIPTION AND OPERATION (Continued) Fig. 5 Thermostat Cross Section View 4.7L Fig. 6 Radiator Pressure Cap—Typical 1 – FROM HEATER 1 – FILLER NECK SEAL 2 – FROM RADIATOR 2 – VACUUM VENT VALVE 3 – TO WATER PUMP 3 –...
Page 208: Water Pump Bypass—4.7L
7 - 6 COOLING SYSTEM DESCRIPTION AND OPERATION (Continued) WATER PUMP BYPASS—4.7L DESCRIPTION The 4.7L engine uses an internal water/coolant bypass system. The design uses galleries in the tim- ing chain cover to circulate coolant during engine warm-up preventing coolant from flowing through the radiator.
Page 209: Automatic Transmission Oil Coolers
COOLING SYSTEM 7 - 7 DESCRIPTION AND OPERATION (Continued) WATER PUMP BYPASS HOSE—5.2L/5.9L ENGINES DESCRIPTION A rubber water pump bypass hose (Fig. 10) is used between the intake manifold and water pump on all 5.2L/5.9L engines. Fig. 11 Oil Flow to Cooler—Top View (Typical) 1 –...
Page 210 7 - 8 COOLING SYSTEM DESCRIPTION AND OPERATION (Continued) not attempt to use a belt tension gauge on 4.7L, 5.2L The cord is attached to an engine compartment com- or 5.9L engines. ponent with tie-straps. The heater is mounted in a core hole of the engine cylinder block in place of a freeze plug with the heating element immersed in engine coolant.
Page 211 COOLING SYSTEM 7 - 9 DESCRIPTION AND OPERATION (Continued) Fig. 17 Fan Blade/Viscous Fan Drive—4.7L/5.2L/5.9L Engines 1 – VISCOUS FAN DRIVE Fig. 16 Spring Clamp Size Location 2 – FAN BLADE 1 – SPRING CLAMP SIZE LOCATION 3 – SCREW AND WASHER The spring type hose clamp applies constant ten- sion on a hose connection.
Page 212: On-Board Diagnostics (Obd)
7 - 10 COOLING SYSTEM PROLONGED IDLE, VERY HIGH AMBIENT DIAGNOSIS AND TESTING TEMPERATURE, SLIGHT TAIL WIND AT IDLE, SLOW TRAFFIC, TRAFFIC JAMS, HIGH SPEED, ON-BOARD DIAGNOSTICS (OBD) OR STEEP GRADES. Driving techniques that avoid overheating are: COOLING SYSTEM RELATED DIAGNOSTICS •...
Page 213 COOLING SYSTEM 7 - 11 DIAGNOSIS AND TESTING (Continued) COOLING SYSTEM DIAGNOSIS CHART CONDITION POSSIBLE CAUSES CORRECTION TEMPERATURE GAUGE 1. Has a Diagnostic Trouble Code 1. Refer to Group 25, Emission Systems READS LOW (DTC) been set indicating a stuck open for On-Board Diagnostics and DTC thermostat? information.
Page 214 7 - 12 COOLING SYSTEM DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION 7. Coolant level low in radiator but not 7. (a) Check condition of radiator cap in coolant reserve/overflow tank. This and cap seals. Refer to Radiator Cap in means the radiator is not drawing this Group.
Page 215 COOLING SYSTEM 7 - 13 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION TEMPERATURE GAUGE 1. During cold weather operation, with 1. A normal condition. No correction is READING IS the heater blower in the high position, necessary. INCONSISTENT the gauge reading may drop slightly. (FLUCTUATES, CYCLES 2.
Page 216 7 - 14 COOLING SYSTEM DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION DETONATION OR 1. Engine overheating. 1. Check reason for overheating and PRE-IGNITION (NOT repair as necessary. CAUSED BY IGNITION 2. Freeze point of coolant not correct. 2. Check coolant concentration. Refer to SYSTEM).
Page 217: Electric Cooling Fan
COOLING SYSTEM 7 - 15 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION INADEQUATE HEATER 1. Has a Diagnostic trouble Code (DTC) 1. Refer to Group 25, Emissions for PERFORMANCE. been set? correct procedures and replace THERMOSTAT FAILED IN thermostat if necessary OPEN POSITION 2.
Page 218: Cooling System—Testing For Leaks
7 - 16 COOLING SYSTEM DIAGNOSIS AND TESTING (Continued) Fig. 20 Power Distribution Center (PDC) 1 – POWER DISTRIBUTION CENTER (PDC) RADIATOR COOLANT FLOW CHECK Fig. 19 Electrical Cooling Fan Use the following procedure to determine if coolant 1 – RADIATOR is flowing through cooling system.
Page 219 COOLING SYSTEM 7 - 17 DIAGNOSIS AND TESTING (Continued) checked. If leaks are present, black light will cause additive to glow a bright green color. The black light can be used in conjunction with a pressure tester to determine if any external leaks exist (Fig.
Page 220 7 - 18 COOLING SYSTEM DIAGNOSIS AND TESTING (Continued) WARNING: WITH RADIATOR PRESSURE TESTER cooling system, bubbles will appear in coolant. If bub- TOOL INSTALLED ON RADIATOR, DO NOT ALLOW bles do not appear, internal combustion gas leakage is not present. PRESSURE TO EXCEED 110 KPA (20 PSI).
Page 221: Accessory Drive Belt Diagnosis
COOLING SYSTEM 7 - 19 DIAGNOSIS AND TESTING (Continued) ACCESSORY DRIVE BELT DIAGNOSIS VISUAL DIAGNOSIS When diagnosing serpentine accessory drive belts, small cracks that run across the ribbed surface of the belt from rib to rib (Fig. 23), are considered normal. These are not a reason to replace the belt.
Page 222 7 - 20 COOLING SYSTEM DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION LONGITUDAL BELT 1. Belt has mistracked from pulley 1. Replace belt CRACKING groove 2. Pulley groove tip has worn away 2. Replace belt rubber to tensile member GROOVE JUMPING”...
Page 223: Thermostat—Gas Engines
COOLING SYSTEM 7 - 21 DIAGNOSIS AND TESTING (Continued) THERMOSTAT—GAS ENGINES OVERFLOW HOSE INTO RESERVE/OVERFLOW TANK. SQUEEZE RADIATOR UPPER HOSE TO DETERMINE WHEN PRESSURE BEEN ON-BOARD DIAGNOSTICS RELEASED. WHEN COOLANT AND STEAM STOP All gasoline powered models are equipped with BEING PUSHED INTO TANK AND SYSTEM PRES- On-Board Diagnostics for certain cooling system com- SURE DROPS, REMOVE RADIATOR CAP COM-...
Page 224: Coolant—Low Level Aeration
7 - 22 COOLING SYSTEM DIAGNOSIS AND TESTING (Continued) CAUTION: Radiator pressure testing tools are very sensitive to small air leaks, which will not cause cooling system problems. A pressure cap that does not have a history of coolant loss should not be replaced just because it leaks slowly when tested with this tool.
Page 225: Coolant—Adding Additional
COOLING SYSTEM 7 - 23 SERVICE PROCEDURES (Continued) higher percentage will freeze at a warmer tempera- Chrysler Corporation recommends Mopar Antifreeze ture. Also, a higher percentage of antifreeze can or equivalent. If coolant becomes contaminated or cause the engine to overheat because the specific looses color, drain and flush cooling system and fill heat of antifreeze is lower than that of water.
Page 226 7 - 24 COOLING SYSTEM SERVICE PROCEDURES (Continued) (3) Place a drain pan under the thermostat hous- (2) Close radiator petcock. ing, then remove the thermostat housing and ther- (3) Fill cooling system with a 50/50 mixture of mostat (4.7L only). water and Mopar Antifreeze/Coolant.
Page 227: Water Pump—5.2L/5.9L Engines
COOLING SYSTEM 7 - 25 SERVICE PROCEDURES (Continued) from water pump and attach a lead-away hose to CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER water pump inlet fitting. 6094) (Fig. 38). SNAP-ON CLAMP TOOL (NUMBER HPC-20) MAY BE USED FOR LARGER CLAMPS. CAUTION: On vehicles equipped with a heater ALWAYS WEAR SAFETY GLASSES WHEN SERVIC- water control valve, be sure heater control valve is...
Page 228 7 - 26 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 29 Fan Blade and Viscous Fan Drive—5.2L/5.9L Engines 1 – WATER PUMP BYPASS HOSE 2 – FAN BLADE ASSEMBLY 3 – VISCOUS FAN DRIVE 4 – WATER PUMP AND PULLEY Fig.
Page 229: Water Pump 4.7L Engines
COOLING SYSTEM 7 - 27 REMOVAL AND INSTALLATION (Continued) Fig. 32 Belt Routing—5.2L/5.9L Engines Fig. 31 Coolant Return Tube—5.2L/5.9L Engines— 1 – IDLER PULLEY Typical 2 – GENERATOR PULLEY 1 – COOLANT RETURN TUBE 3 – A/C COMPRESSOR PULLEY 2 – WATER PUMP 4 –...
Page 230 7 - 28 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 34 Upper Fan Shroud, Coolant reservoir and Washer Fluid Reservoir 1 – RADIATOR 2 – WASHER FLUID RESERVOIR Fig. 33 Viscous Fan and Fan Drive 4.7L 3 – COOLANT OVERFLOW/RESERVOIR 1 –...
Page 231 COOLING SYSTEM 7 - 29 REMOVAL AND INSTALLATION (Continued) routing. Or, refer to the Belt Routing Label located in the engine compartment. The correct belt with correct length must be used. Fig. 35 Automatic Belt Tensioner—4.7L 1 – AUTOMATIC TENSIONER 2 –...
Page 232 7 - 30 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) WATER PUMP BYPASS HOSE—5.2L/5.9L ENGINES REMOVAL WITHOUT AIR CONDITIONING (1) Partially drain cooling system. Refer to COOL- ING SYSTEM—DRAINING and FILLING in this Section. Do not waste reusable coolant. If solution is clean, drain coolant into a clean container for reuse.
Page 233 COOLING SYSTEM 7 - 31 REMOVAL AND INSTALLATION (Continued) (2) Partially drain cooling system. Refer to COOL- ING SYSTEM—DRAINING and FILLING in this Section. Do not waste reusable coolant. If solution is clean, drain coolant into a clean container for reuse. (3) Remove upper radiator hose clamp (Fig.
Page 234: Thermostat—5.2L/5.9L Engine
7 - 32 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) (9) Install idler pulley. Tighten bolt to 54 N·m (40 THERMOSTAT—5.2L/5.9L ENGINE ft. lbs.) torque. (10) Relax tension from belt tensioner (Fig. 41). REMOVAL Install drive belt. WARNING: DO NOT LOOSEN RADIATOR DRAIN- CAUTION: When installing serpentine accessory COCK WITH SYSTEM HOT AND PRESSURIZED.
Page 235 COOLING SYSTEM 7 - 33 REMOVAL AND INSTALLATION (Continued) with 4WD, unplug 4WD indicator lamp wiring har- ness (located near rear of generator). (f) Remove generator. Position generator to gain access for thermostat gasket removal. Fig. 46 Thermostat—5.2L/5.9L Engines 1 – THERMOSTAT HOUSING 2 –...
Page 236: Thermostat— 4.7L Engine
7 - 34 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 48 Belt Routing—5.2L/5.9L Engines Fig. 47 Thermostat Position—5.2L/5.9L Engines 1 – IDLER PULLEY (b) Install support bracket (generator mounting 2 – GENERATOR PULLEY bracket-to-intake manifold) (Fig. 44). Tighten bolts 3 – A/C COMPRESSOR PULLEY 4 –...
Page 237 COOLING SYSTEM 7 - 35 REMOVAL AND INSTALLATION (Continued) Fig. 49 Thermostat and Thermostat Housing 4.7L 1 – THERMOSTAT HOUSING 3 – THERMOSTAT AND GASKET 2 – THERMOSTAT LOCATION 4 – TIMING CHAIN COVER (5) Install lower radiator hose on thermostat hous- ALWAYS WEAR SAFETY GLASSES WHEN SERVIC- ing.
Page 238 7 - 36 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 51 Clamp Number/Letter Location 1 – CONSTANT TENSION HOSE CLAMP 2 – CLAMP NUMBER/LETTER LOCATION Fig. 52 Radiator Upper Fan Shroud Removal/ 3 – HOSE Installation—Typical 1 – RADIATOR (3) Remove hose clamps (Fig. 50) and hoses from 2 –...
Page 239: Block Heater
COOLING SYSTEM 7 - 37 REMOVAL AND INSTALLATION (Continued) Fig. 54 Radiator Removal/Installation—Typical Fig. 55 Block Heater Removal/Installation—5.2L/5.9L 1 – CORE SUPPORT 1 – BLOCK HEATER POWER CORD 2 – LOWER ISOLATOR MOUNTS 2 – POWER CORD ROUTING CLIP (2) 3 –...
Page 240 7 - 38 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 58 Belt Routing—5.2L/5.9L Engine Fig. 57 Automatic Belt Tensioner—Belt Removal/ 1 – TENSIONER Installation 2 – GENERATOR PULLEY 1 – IDLER PULLEY 3 – IDLER PULLEY 2 – TENSIONER 4 – A/C COMPRESSOR PULLEY 3 –...
Page 241 COOLING SYSTEM 7 - 39 REMOVAL AND INSTALLATION (Continued) REMOVAL (2) Install new belt (Fig. 59). Route the belt around all pulleys except the idler pulley. Rotate the tensioner arm until it contacts it’s stop position. CAUTION: DO NOT LET TENSIONER ARM SNAP BACK TO THE FREEARM POSITION, SEVER DAM- Route the belt around the idler and slowly let the AGE MAY OCCUR TO THE TENSIONER.
Page 242 7 - 40 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 61 Automatic Belt Tensioner Removal/ Installation 5.2L/5.9L Engines 1 – AUTOMATIC TENSIONER 2 – COIL AND BRACKET 3 – SCREW AND WASHER (3) Connect all wiring to ignition coil. (4) Position coil to tensioner assembly, install two mounting screws.
Page 243 COOLING SYSTEM 7 - 41 REMOVAL AND INSTALLATION (Continued) Fig. 65 Draincock Assembled for Installation 1 – STEM 2 – BODY LOOSE ON STEM VISCOUS FAN DRIVE Fig. 63 Draincock Assembly 1 – BODY REMOVAL 2 – SEAL (1) Disconnect battery negative cable. 3 –...
Page 244: Radiator Cap
7 - 42 COOLING SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 68 Viscous Fan Drive and Fan Blade 1 – VISCOUS FAN DRIVE 2 – FAN BLADE 3 – SCREW AND WASHER Fig. 66 Fan Blade and Viscous Fan Drive Removal 1 –...
Page 245 COOLING SYSTEM 7 - 43 CLEANING AND INSPECTION (Continued) INSPECTION INSPECTION Hold cap at eye level, right side up. The vent valve WARNING: DO ATTEMPT BEND (Fig. 29) at bottom of cap should open. If rubber gas- STRAIGHTEN FAN BLADES IF FAN IS NOT WITHIN ket has swollen and prevents vent valve from open- SPECIFICATIONS.
Page 246 7 - 44 COOLING SYSTEM SPECIFICATIONS (Continued) COOLING SYSTEM SPECIAL TOOLS DESCRIPTION N·m COOLING Lbs. Lbs. Automatic Belt Tensioner to Mounting Bracket—Bolts(5.2L/5.9L) — Automatic Belt Tensioner to Block—Bolts (4.7L) — Automatic Belt Tensioner — Pulley—Bolt Block Heater—Bolt — Pliers Constant Pressure Hose Clamp—6094 Generator/Compressor Mounting Bracket—Bolts...
Page 247 BATTERY 8A - 1 BATTERY TABLE OF CONTENTS page page DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION BATTERY....... . 1 BATTERY HOLD DOWNS .
Page 248 8A - 2 BATTERY DESCRIPTION AND OPERATION (Continued) • Group Size plates are submerged in a sulfuric acid and water solution called an electrolyte. The outside dimensions and terminal placement of The factory-installed battery has a built-in test the battery conform to standards established by the indicator (hydrometer).
Page 249 BATTERY 8A - 3 DESCRIPTION AND OPERATION (Continued) charges deposited on the plates, and the voltage ing capacity. Refer to Wiring Diagrams in the index potential of the battery cells. For a battery to remain of this service manual for the location of the proper useful, it must be able to produce high-amperage cur- battery cable wire gauge information.
Page 250 8A - 4 BATTERY DESCRIPTION AND OPERATION (Continued) is also crimped onto the ends of two wires. One wire proper specifications. Improper hold down fastener has an eyelet terminal that connects the battery neg- tightness, whether too loose or too tight, can result in ative cable to the vehicle powertrain through a damage to the battery, the vehicle or both.
Page 251 BATTERY 8A - 5 DESCRIPTION AND OPERATION (Continued) DIAGNOSIS AND TESTING BATTERY DIAGNOSIS The battery, starting system and charging system in the vehicle operate with one another, and must be tested as a complete system. In order for the engine to start and the battery to charge properly, all of the components that are used in these systems must per- form within specifications.
Page 252 8A - 6 BATTERY DIAGNOSIS AND TESTING (Continued) WARNING: built-in test indicator, view the test indicator to • IF THE BATTERY SHOWS SIGNS OF FREEZ- determine the state-of-charge. If the battery has no test indicator but does have removable cell caps, per- ING, LEAKING, LOOSE POSTS, OR LOW ELECTRO- LYTE LEVEL, DO NOT TEST, ASSIST-BOOST, OR form the hydrometer test to determine the state-of-...
Page 253 BATTERY 8A - 7 DIAGNOSIS AND TESTING (Continued) Battery Diagnosis Condition Possible Causes Correction The battery seems weak or 1. The battery has an 1. Refer to Battery in the index of this service dead when attempting to start incorrect size or rating for manual for the location of the proper battery the engine.
Page 254 8A - 8 BATTERY DIAGNOSIS AND TESTING (Continued) Battery Diagnosis Condition Possible Causes Correction The battery state-of-charge 1. The battery has an 1. Refer to Battery in the index of this service cannot be maintained. incorrect size or rating for manual for the location of the proper battery this vehicle.
Page 255 BATTERY 8A - 9 DIAGNOSIS AND TESTING (Continued) TESTING Before testing, visually inspect the battery for any damage (a cracked case or cover, loose posts, etc.) BUILT-IN TEST INDICATOR that would cause the battery to be faulty. In order to obtain correct indications from the built-in test indi- A test indicator (hydrometer) built into the top of cator, it is important that the battery be level and...
Page 256 8A - 10 BATTERY DIAGNOSIS AND TESTING (Continued) See the instructions provided by the manufacturer of the hydrometer for recommendations on the cor- rect use of the hydrometer that you are using. Remove only enough electrolyte from the battery cell so that the float is off the bottom of the hydrometer barrel with pressure on the bulb released.
Page 257 BATTERY 8A - 11 DIAGNOSIS AND TESTING (Continued) (1) Determine the number of degrees above or THE BATTERY IS RETURNED TO SERVICE. PER- below 26.7° C (80° F): 26.6° C - -12.2° C = 38.8° C SONAL INJURY AND/OR VEHICLE DAMAGE MAY (80°...
Page 258 8A - 12 BATTERY DIAGNOSIS AND TESTING (Continued) Amperage (CCA) rating of the battery. See the label affixed to the battery case, or refer to Battery in the index of this service manual for the location of the proper factory-installed battery specifications to determine the battery CCA rating.
Page 259 BATTERY 8A - 13 DIAGNOSIS AND TESTING (Continued) (7) If the voltmeter reading falls below 9.6 volts, at a minimum battery temperature of 21° C (70° F), the battery is faulty and must be replaced. IGNITION-OFF DRAW TEST The term Ignition-Off Draw (IOD) identifies a nor- mal condition where power is being drained from the battery with the ignition switch in the Off position.
Page 260 8A - 14 BATTERY DIAGNOSIS AND TESTING (Continued) ELECTRONIC MODULE IGNITION-OFF DRAW (IOD) TIME OUT? IOD AFTER MODULE (IF YES, INTERVAL AND WAKE-UP INPUT) TIME OUT Powertrain Control 0.95 milliampere Module (PCM) ElectroMechanical Instrument Cluster 0.44 milliampere (EMIC) Combination Flasher 0.08 milliampere (2) Determine that the under-hood lamp is operat- rected, switch the multi-meter to progressively lower...
Page 261 BATTERY 8A - 15 DIAGNOSIS AND TESTING (Continued) you are reading the combined voltage drop in the ative lead of the voltmeter to the battery negative battery positive cable terminal clamp-to-terminal cable terminal clamp (Fig. 13). Rotate and hold the post connection and the battery positive cable.
Page 262 8A - 16 BATTERY DIAGNOSIS AND TESTING (Continued) (3) Connect the voltmeter to measure between the battery positive cable terminal clamp and the starter solenoid B(+) terminal stud (Fig. 15). Rotate and hold the ignition switch in the Start position. Observe the voltmeter.
Page 263 BATTERY 8A - 17 SERVICE PROCEDURES (Continued) CAUTION: peres. Such low current may not be detectable on the • Always disconnect and isolate the battery neg- ammeters built into many battery chargers. ative cable before charging a battery. Do not exceed sixteen volts while charging a battery.
Page 264 8A - 18 BATTERY SERVICE PROCEDURES (Continued) • Temperature necessary, use a battery terminal puller to remove A longer time will be needed to charge a battery at the terminal clamp from the battery post. -18° C (0° F) than at 27° C (80° F). When a fast bat- (4) Disconnect the battery positive cable terminal tery charger is connected to a cold battery, the cur- clamp from the battery positive terminal post.
Page 265 BATTERY 8A - 19 REMOVAL AND INSTALLATION (Continued) (3) Install and tighten the two hold down bolts TERY IS CRACKED OR LEAKING, THE ELECTRO- that secure the hold down strap/battery thermoguard LYTE CAN BURN THE SKIN AND EYES. unit to the U-nuts in the battery tray. Tighten the (7) Remove the battery from the battery tray.
Page 266 8A - 20 BATTERY REMOVAL AND INSTALLATION (Continued) (6) Reconnect the battery negative cable terminal (4) Remove the two screws that secure the out- clamp to the battery negative terminal post. Tighten board side of the battery tray to the front extension the terminal clamp pinch-bolt hex nut to 7.9 N·m (70 of the left front wheelhouse inner panel.
Page 267 BATTERY 8A - 21 REMOVAL AND INSTALLATION (Continued) tray support. Tighten the screws to 12.4 N·m (110 in. lbs.). (9) Install and tighten the one screw that secures the front of the battery tray to the front closure panel on the left side of the radiator yoke. Tighten the screw to 12.4 N·m (110 in.
Page 268 8A - 22 BATTERY CLEANING AND INSPECTION (Continued) cleaner, and a sodium bicarbonate (baking soda) and INSPECTION warm water cleaning solution (Fig. 24). (1) Inspect the battery cable terminal clamps for damage. Replace any battery cable that has a dam- aged or deformed terminal clamp.
Page 269 STARTING SYSTEMS 8B - 1 STARTING SYSTEMS TABLE OF CONTENTS page page DESCRIPTION AND OPERATION STARTER RELAY ......8 STARTING SYSTEM .
Page 270 8B - 2 STARTING SYSTEMS DESCRIPTION AND OPERATION (Continued) OPERATION STARTER MOTOR The starting system components form two separate DESCRIPTION circuits. A high-amperage feed circuit that feeds the starter motor between 150 and 350 amperes, and a The starter motors used for the 4.7L engines are low-amperage control circuit that operates on less not interchangeable with the starter motors used for than 20 amperes.
Page 271 STARTING SYSTEMS 8B - 3 DESCRIPTION AND OPERATION (Continued) STARTER RELAY nected in parallel with the electromagnetic coil in the relay, and helps to dissipate voltage spikes that are produced when the coil is de-energized. DESCRIPTION The starter relay is an electromechanical device that switches battery current to the pull-in coil of the DIAGNOSIS AND TESTING starter solenoid when the ignition switch is turned to...
Page 272 8B - 4 STARTING SYSTEMS DIAGNOSIS AND TESTING (Continued) Starting System Diagnosis CONDITION POSSIBLE CAUSE CORRECTION STARTER FAILS TO 1. Battery discharged or 1. Refer to Battery in the Diagnosis and Testing section of OPERATE. faulty. Group 8A - Battery. Charge or replace the battery, if 2.
Page 273 STARTING SYSTEMS 8B - 5 DIAGNOSIS AND TESTING (Continued) INSPECTION TESTING For complete circuit diagrams, refer to Starting COLD CRANKING TEST System in the Contents of Group 8W - Wiring Dia- grams. Before removing any unit from the starting For complete circuit diagrams, refer to Starting system for repair or diagnosis, perform the following System in the Contents of Group 8W - Wiring Dia- inspections:...
Page 274 8B - 6 STARTING SYSTEMS DIAGNOSIS AND TESTING (Continued) (b) If the voltage reads above 9.6 volts and the voltage is detected, correct the poor contact between current (amperage) draw reads below specifica- the cable clamp and the terminal post. tions, refer to Feed Circuit Test in this section.
Page 275 STARTING SYSTEMS 8B - 7 DIAGNOSIS AND TESTING (Continued) tighten the battery cable connection at the solenoid. voltmeter to the battery negative terminal post (Fig. Repeat the test. If the reading is still above 0.2 volt, 6). Rotate and hold the ignition switch in the Start replace the faulty battery positive cable.
Page 276 8B - 8 STARTING SYSTEMS DIAGNOSIS AND TESTING (Continued) System in the Specifications section of this group for the starter motor specifications. (1) Remove the starter motor from the vehicle. Refer to Starter Motor in the Removal and Instal- lation section of this group for the procedures. (2) Mount the starter motor securely in a soft- jawed bench vise.
Page 277 STARTING SYSTEMS 8B - 9 DIAGNOSIS AND TESTING (Continued) Testing section of Group 21 - Transmission for testing of the park/neutral position switch. REMOVAL AND INSTALLATION STARTER MOTOR TERMINAL LEGEND REMOVAL NUMBER IDENTIFICATION ALL 5.2L AND 5.9L ENGINE COMMON FEED COIL GROUND (1) Disconnect and isolate the battery negative cable.
Page 278 8B - 10 STARTING SYSTEMS REMOVAL AND INSTALLATION (Continued) enough to access and remove the nut that secures the battery positive cable eyelet terminal to the the battery positive cable eyelet terminal to the starter solenoid B(+) terminal stud. Always support starter solenoid B(+) terminal stud.
Page 279 STARTING SYSTEMS 8B - 11 REMOVAL AND INSTALLATION (Continued) 4.7L ENGINE (1) Position the starter motor to the automatic transmission torque converter housing. (2) Reconnect the battery positive cable solenoid terminal wire harness connector to the connector receptacle on the starter solenoid. Always support the starter motor during this process.
Page 280 8B - 12 STARTING SYSTEMS SPECIFICATIONS STARTING SYSTEM Starter Motor and Solenoid Manufacturer Denso Denso Part Number 56027702AC 56028715 Engine Application 5.2L, 5.9L 4.7L 1.4 Kilowatt 1.4 Kilowatt Power Rating (1.9 Horsepower (1.9 Horsepower Voltage 12 Volts 12 Volts Pinion Teeth Number of Fields Number of Poles Number of Brushes...
Page 281 CHARGING SYSTEM 8C - 1 CHARGING SYSTEM TABLE OF CONTENTS page page DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION CHARGING SYSTEM..... . . 1 GENERATOR .
Page 282 8C - 2 CHARGING SYSTEM DESCRIPTION AND OPERATION (Continued) The Y type stator winding connections deliver the within the PCM. This circuitry is connected in series induced alternating current to 3 positive and 3 negative with the generators second rotor field terminal and diodes for rectification.
Page 283 CHARGING SYSTEM 8C - 3 DIAGNOSIS AND TESTING (Continued) (4) Inspect generator mounting bolts for tightness. (6) Remove B+ terminal mounting nut at rear of Replace or tighten bolts if required. Refer to the Gen- generator (Fig. 3) or (Fig. 4). Disconnect terminal erator Removal/Installation section of this group for from generator.
Page 284 8C - 4 CHARGING SYSTEM REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Position generator to engine and snap field wire connector into rear of generator. (2) Install B+ terminal to generator mounting stud. Tighten mounting nut to 8.5 N·m (75 in. lbs.) torque.
Page 285 CHARGING SYSTEM 8C - 5 REMOVAL AND INSTALLATION (Continued) (2) Disconnect sensor pigtail harness from engine wire harness. Sensor pigtail harness is clipped to vehicle near its electrical connector. (3) Pry sensor straight up from battery tray mounting hole. INSTALLATION (1) Feed pigtail harness through hole in top of bat- tery tray and press sensor into top of battery tray.
Page 287 IGNITION SYSTEM 8D - 1 IGNITION SYSTEM TABLE OF CONTENTS page page DESCRIPTION AND OPERATION SPARK PLUGS ......11 IGNITION SYSTEM .
Page 288 8D - 2 IGNITION SYSTEM DESCRIPTION AND OPERATION (Continued) gle plug displaying an abnormal condition indicates that a problem exists in the corresponding cylinder. Replace spark plugs at the intervals recommended in Group O, Lubrication and Maintenance. Spark plugs that have low mileage may be cleaned and reused if not otherwise defective, carbon or oil fouled.
Page 289 IGNITION SYSTEM 8D - 3 DESCRIPTION AND OPERATION (Continued) IGNITION COIL—4.7L ENGINE DESCRIPTION The 4.7L V–8 engine uses 8 dedicated, and individ- ually fired coil (Fig. 2) for each spark plug. Each coil is mounted directly to the top of each spark plug (Fig.
Page 290 8D - 4 IGNITION SYSTEM DESCRIPTION AND OPERATION (Continued) OPERATION Engine speed and crankshaft position are provided through the crankshaft position sensor. The sensor generates pulses that are the input sent to the pow- ertrain control module (PCM). The PCM interprets the sensor input to determine the crankshaft posi- tion.
Page 291 IGNITION SYSTEM 8D - 5 DESCRIPTION AND OPERATION (Continued) This sync signal generator detects a rotating pulse located on a tonewheel. The tonewheel is located at ring (shutter) on the distributor shaft. The pulse ring the front of the camshaft for the right cylinder head rotates 180 degrees through the sync signal genera- (Fig.
Page 292 8D - 6 IGNITION SYSTEM DESCRIPTION AND OPERATION (Continued) lock cylinder is rotated to the LOCKED or ACCES- ing the cap through cracks). Replace any cap that SORY position. The interlock device within the steer- displays charred or eroded terminals. The machined ing column is not serviceable.
Page 293 IGNITION SYSTEM 8D - 7 DIAGNOSIS AND TESTING (Continued) on the end of the metal tip. The silicone-dielectric- varnish-compound applied to the rotor tip for radio interference noise suppression, will appear charred. This is normal. Do not remove the charred com- pound.
Page 294 8D - 8 IGNITION SYSTEM DIAGNOSIS AND TESTING (Continued) not remove cables from cap. Remove cable from spark plug. Connect ohmmeter to spark plug termi- nal end of cable and to corresponding electrode in distributor cap. Resistance should be 250 to 1000 Ohms per inch of cable.
Page 295 IGNITION SYSTEM 8D - 9 DIAGNOSIS AND TESTING (Continued) Fig. 16 Scavenger Deposits 1 – GROUND ELECTRODE COVERED WITH WHITE OR YELLOW DEPOSITS 2 – CENTER ELECTRODE CHIPPED ELECTRODE INSULATOR A chipped electrode insulator usually results from bending the center electrode while adjusting the Fig.
Page 296 8D - 10 IGNITION SYSTEM DIAGNOSIS AND TESTING (Continued) other operating conditions are causing engine over- IGNITION SWITCH AND KEY LOCK CYLINDER heating. (The heat range rating refers to the operat- ing temperature of a particular type spark plug. ELECTRICAL DIAGNOSIS Spark plugs are designed to operate within specific For ignition switch electrical schematics, refer to temperature ranges.
Page 297 IGNITION SYSTEM 8D - 11 DIAGNOSIS AND TESTING (Continued) necessary, the steering column assembly must be When replacing the spark plug and coil cables, replaced. Refer to Group 19, Steering for procedures. route the cables correctly and secure in the proper retainers.
Page 298 8D - 12 IGNITION SYSTEM REMOVAL AND INSTALLATION (Continued) (3) Remove spark plug from cylinder head using a INSTALLATION quality socket with a rubber or foam insert. If equipped with a 4.7L V-8 engine, also check condition CAUTION: The 4.7L V–8 engine is equipped with of coil o-ring and replace as necessary.
Page 299 IGNITION SYSTEM 8D - 13 REMOVAL AND INSTALLATION (Continued) 25) is used to seal the coil at the opening into the cyl- inder head. (1) Depending on which coil is being removed, the throttle body air intake tube or intake box may need to be removed to gain access to coil.
Page 300: L Engines
8D - 14 IGNITION SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 27 Crankshaft Position Sensor—3.9/5.2/5.9L Engines 1 – GROMMET Fig. 26 Ignition Coil Location—4.7L V–8 Engine 2 – MOUNTING BOLTS (2) 3 – CRANKSHAFT POSITION SENSOR 1 – IGNITION COIL 4 – RIGHT EXHAUST MANIFOLD 2 –...
Page 301 IGNITION SYSTEM 8D - 15 REMOVAL AND INSTALLATION (Continued) Fig. 29 Camshaft Position Sensor 1 – SYNC SIGNAL GENERATOR 2 – CAMSHAFT POSITION SENSOR 3 – PULSE RING 4 – DISTRIBUTOR ASSEMBLY (5) Install air cleaner assembly. Fig. 28 CKP Sensor Location/Removal/Installation— 4.7L V–8 Engine CAMSHAFT POSITION SENSOR—4.7L ENGINE 1 –...
Page 302 8D - 16 IGNITION SYSTEM REMOVAL AND INSTALLATION (Continued) REMOVAL damper is aligned to 0 degree (TDC) mark on timing chain cover (Fig. 31). It is easier to remove/install sensor from under vehicle. (1) Raise and support vehicle. (2) Disconnect electrical connector at CMP sensor (Fig.
Page 303 IGNITION SYSTEM 8D - 17 REMOVAL AND INSTALLATION (Continued) (11) Remove distributor holddown clamp bolt and (8) Connect camshaft position sensor wiring har- clamp (Fig. 33). Remove distributor from vehicle. ness to main engine harness. (9) Install distributor cap. Tighten mounting screws.
Page 304 8D - 18 IGNITION SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 35 Retaining Pin 1 – IGNITION SWITCH 2 – KEY/KEY CYLINDER (RUN POSITION) 3 – RETAINING PIN Fig. 34 Shroud Removal/Installation—Typical 1 – NUT 2 – STEERING WHEEL 3 – TILT LEVER 4 –...
Page 305 IGNITION SYSTEM 8D - 19 REMOVAL AND INSTALLATION (Continued) Fig. 37 Ignition Switch and Halo Lamp Connectors 1 – KEY-IN SWITCH & HALO LIGHT 2 – MULTI-FUNCTION SWITCH Fig. 39 Key Cylinder—Rear View 3 – TURN SIGNAL SWITCH & LEVER 1 –...
Page 306 8D - 20 IGNITION SYSTEM REMOVAL AND INSTALLATION (Continued) shifter must be in PARK position. The park lock dowel pin on rear of ignition switch (Fig. 41) must also be properly indexed into the park lock linkage (Fig. 42) before installing switch. Fig.
Page 307 IGNITION SYSTEM 8D - 21 REMOVAL AND INSTALLATION (Continued) erly installed in slot of park lock slider linkage. SPECIFICATIONS Remove ignition switch and reinstall. (11) Connect electrical connectors ignition IGNITION TIMING switch, halo lamp and (if equipped ), to “PRNDL”. Ignition timing is not adjustable on any engine.
Page 308 8D - 22 IGNITION SYSTEM SPECIFICATIONS (Continued) SPARK PLUGS ENGINE PLUG TYPE ELECTRODE GAP 3.9L V-6 RC12LC4 1.01 mm (.040 in.) 4.7L V-8 RC12MCC4 1.01 mm (.040 in.) 5.2L V-8 RC12LC4 1.01 mm (.040 in.) 5.9L V-8 RC12LC4 1.01 mm (.040 in.) SPARK PLUG CABLE RESISTANCE MINIMUM MAXIMUM...
Page 309 INSTRUMENT PANEL SYSTEMS 8E - 1 INSTRUMENT PANEL SYSTEMS TABLE OF CONTENTS page page DESCRIPTION AND OPERATION GEAR SELECTOR INDICATOR ....17 INSTRUMENT PANEL SYSTEM ....1 PARK BRAKE RELEASE HANDLE .
Page 310 8E - 2 INSTRUMENT PANEL SYSTEMS DESCRIPTION AND OPERATION (Continued) • Anti-lock Brake System (ABS) lamp greatly reduces the number of components used over • Brake warning lamp conventional instrument panel construction. • Check gauges lamp Modular instrument panel construction allows all •...
Page 311 INSTRUMENT PANEL SYSTEMS 8E - 3 DESCRIPTION AND OPERATION (Continued) cluster circuit board are faulty, the entire cluster park brake switch and by CCD data bus messages must be replaced. The cluster lens, the cluster hood, from the Controller Anti-lock Brake (CAB). The the rear cluster housing cover, and the incandescent instrument cluster circuitry uses CCD data bus mes- lamp bulbs and holders are available for service...
Page 312 8E - 4 INSTRUMENT PANEL SYSTEMS DESCRIPTION AND OPERATION (Continued) • Low washer fluid lamp warning CENTRAL TIMER MODULE • Seat belt reminder lamp warning • Transmission oil temperature lamp warning DESCRIPTION (automatic transmission) Two versions of the Central Timer Module (CTM) •...
Page 313 INSTRUMENT PANEL SYSTEMS 8E - 5 DESCRIPTION AND OPERATION (Continued) housing to the receptacle shell. If the cigar lighter from the instrument cluster. Refer to Steering Col- knob is pushed inward, the heat shield slides up umn in the Removal and Installation section of toward the knob exposing the heating element, and Group 19 - Steering for the mechanical gear selector the heating element extends from the housing toward...
Page 314 8E - 6 INSTRUMENT PANEL SYSTEMS battery negative cable. Check for battery voltage at DIAGNOSIS AND TESTING the fused B(+) circuit cavity of the instrument cluster wire harness connector A. If OK, refer to Instru- INSTRUMENT CLUSTER ment Cluster - Self-Diagnostic Test in the Diag- If all of the gauges and/or indicator lamps are inop- nosis and Testing section of this group.
Page 315 INSTRUMENT PANEL SYSTEMS 8E - 7 DIAGNOSIS AND TESTING (Continued) SELF-DIAGNOSTIC TEST (2) Depress the trip odometer reset button. (3) While holding the trip odometer reset button The instrument cluster self-diagnostic test will put depressed, turn the ignition switch to the On posi- the instrument cluster into its self-diagnostic mode.
Page 316 8E - 8 INSTRUMENT PANEL SYSTEMS DIAGNOSIS AND TESTING (Continued) (6) The instrument cluster will begin the odometer HARD WIRED LAMP DIAGNOSIS walking segment test. This test will require the oper- Each of the lamps found in this section depends ator to visually inspect each odometer segment as it upon a hard wired circuit input to the instrument is displayed to determine a pass or fail condition.
Page 317 INSTRUMENT PANEL SYSTEMS 8E - 9 DIAGNOSIS AND TESTING (Continued) should be no continuity. If OK, go to Step 5. If not lamps dimmer switch signal circuit cavity of the OK, repair the shorted park brake switch sense cir- instrument cluster wire harness connector B. Check cuit as required.
Page 318 8E - 10 INSTRUMENT PANEL SYSTEMS DIAGNOSIS AND TESTING (Continued) wheel drive lock indicator lamp should light. If OK, tem in the Diagnosis and Testing section of Group replace the faulty transfer case switch. If not OK, go 8K - Wiper and Washer Systems for more informa- to Step 5.
Page 319 INSTRUMENT PANEL SYSTEMS 8E - 11 DIAGNOSIS AND TESTING (Continued) cluster wire harness connector B and the washer TURN SIGNAL INDICATOR LAMP fluid level sensor wire harness connector. There The diagnosis found here addresses an inoperative should be continuity. If OK, replace the faulty bulb. turn signal indicator lamp condition.
Page 320 8E - 12 INSTRUMENT PANEL SYSTEMS DIAGNOSIS AND TESTING (Continued) (3) Turn the ignition switch to the Off position. (4) Check for battery voltage at the insulated con- Remove the cigar lighter knob and element from the tact located at the back of the power outlet recepta- cigar lighter receptacle.
Page 321 INSTRUMENT PANEL SYSTEMS 8E - 13 REMOVAL AND INSTALLATION (Continued) Fig. 1 Cluster Bezel Remove/Install 1 – SNAP CLIP RETAINERS 2 – CLUSTER BEZEL HEADLAMP SWITCH Fig. 2 Headlamp Switch Remove/Install WARNING: ON VEHICLES EQUIPPED WITH AIR- 1 – INSTRUMENT PANEL WIRE HARNESS CONNECTORS 2 –...
Page 322 8E - 14 INSTRUMENT PANEL SYSTEMS REMOVAL AND INSTALLATION (Continued) (3) Remove the four screws that secure the instru- (4) Install and tighten the four screws that secure ment cluster to the instrument panel (Fig. 3). the instrument cluster to the instrument panel. Tighten the screws to 2.2 N·m (20 in.
Page 323 INSTRUMENT PANEL SYSTEMS 8E - 15 REMOVAL AND INSTALLATION (Continued) reinstalled in the correct position. Always use the correct bulb size and type for replacement. An incor- rect bulb size or type may overheat and cause dam- age to the instrument cluster, the electronic circuit board and/or the gauges.
Page 324 8E - 16 INSTRUMENT PANEL SYSTEMS REMOVAL AND INSTALLATION (Continued) (2) Remove the instrument cluster from the instru- (3) Install and tighten the seven screws that ment panel. Refer to Instrument Cluster in the secure the lens and hood unit to the cluster housing. Removal and Installation section of this group for the Tighten the screws to 2.2 N·m (20 in.
Page 325 INSTRUMENT PANEL SYSTEMS 8E - 17 REMOVAL AND INSTALLATION (Continued) REMOVAL GEAR SELECTOR INDICATOR (1) Disconnect and isolate the battery negative The following service procedures apply only to the cable. mechanical gear selector indicator. The electronic (2) Remove the three screws that secure the lower gear selector indicator is integral to the instrument edge of the steering column opening cover to the cluster and can only be serviced by replacement of...
Page 326 8E - 18 INSTRUMENT PANEL SYSTEMS REMOVAL AND INSTALLATION (Continued) (5) Remove the steering column opening cover (7) Check the gear selector indicator for proper cal- from the instrument panel. Refer to Steering Col- ibration. If adjustment is needed, refer to Steering umn Opening Cover in the Removal and Installa- Column in the Removal and Installation section of tion section of this group for the procedures.
Page 327 INSTRUMENT PANEL SYSTEMS 8E - 19 REMOVAL AND INSTALLATION (Continued) lower reinforcement and lower the release handle to the floor. (4) Depress the latch tabs that secure the 16-way data link wire harness connector to the instrument panel lower reinforcement, and push the connector out of its mounting hole.
Page 328 8E - 20 INSTRUMENT PANEL SYSTEMS REMOVAL AND INSTALLATION (Continued) INSTRUMENT PANEL CENTER SUPPORT INSTALLATION (1) Position the center support bracket to the ACM BRACKET bracket on the floor panel transmission tunnel. (2) Install and tighten the two screws on the left, WARNING: ON VEHICLES EQUIPPED WITH AIR- and one screw on the right that secure the instru- BAGS,...
Page 329 INSTRUMENT PANEL SYSTEMS 8E - 21 REMOVAL AND INSTALLATION (Continued) REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Remove the cluster bezel from the instrument panel. Refer to Cluster Bezel in the Removal and Installation section of this group for the procedures. (3) Open the glove box.
Page 330 8E - 22 INSTRUMENT PANEL SYSTEMS REMOVAL AND INSTALLATION (Continued) (5) Install and tighten the two screws that secure (4) Look inside the cigar lighter or power outlet the lower edge of the lower bezel to the instrument receptacle base and note the position of the rectangu- panel.
Page 331 INSTRUMENT PANEL SYSTEMS 8E - 23 REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Install the cigar lighter or power outlet mount into the instrument panel lower bezel. (2) Align the splines on the outside of the cigar lighter or power outlet receptacle base connector receptacle with the grooves on the inside of the mount.
Page 332 8E - 24 INSTRUMENT PANEL SYSTEMS REMOVAL AND INSTALLATION (Continued) (3) Remove the two screws that secure the latch bumpers are beyond the stops, then release the sides striker to the instrument panel glove box opening of the bin. upper reinforcement (Fig. 18). (5) Reverse the roll down procedure to roll the glove box back up into the instrument panel.
Page 333 INSTRUMENT PANEL SYSTEMS 8E - 25 REMOVAL AND INSTALLATION (Continued) (3) Remove the two screws that secure each out- board flange of the glove box bin to the glove box door (Fig. 21). Fig. 20 Glove Box Hinge Pins 1 – GLOVE BOX OPENING 2 –...
Page 334 8E - 26 INSTRUMENT PANEL SYSTEMS REMOVAL AND INSTALLATION (Continued) CENTRAL TIMER MODULE Before replacing a high-line Central Timer Module (CTM), use a DRB scan tool to determine the current settings for the CTM programmable features. These settings should be duplicated in the replacement CTM using the DRB scan tool, before returning the vehicle to service.
Page 335 INSTRUMENT PANEL SYSTEMS 8E - 27 REMOVAL AND INSTALLATION (Continued) (2) Remove the trim from the right and left front door sills. Refer to Door Sill Trim Cover in the Removal and Installation section of Group 23 - Body for the procedures. (3) Remove the trim from the left and right cowl side inner panels.
Page 336 8E - 28 INSTRUMENT PANEL SYSTEMS REMOVAL AND INSTALLATION (Continued) (10) Remove the center support bracket from the ness connectors located on a bracket near the right instrument panel. Refer to Instrument Panel Cen- end of the instrument panel. ter Support Bracket in the Removal and Installa- (b) Disconnect the instrument panel wire har- tion section of this group for the procedures.
Page 337 INSTRUMENT PANEL SYSTEMS 8E - 29 REMOVAL AND INSTALLATION (Continued) Fig. 24 Instrument Panel Assembly Remove/Install 1 – CLIPS 5 – SCREW 2 – SCREW 6 – CENTER SUPPORT BRACKET 3 – INSTRUMENT PANEL 7 – SCREW 4 – SCREW (8) Reaching through the instrument panel glove box opening, perform the following: (a) Reconnect the two halves of the radio...
Page 338 8E - 30 INSTRUMENT PANEL SYSTEMS REMOVAL AND INSTALLATION (Continued) ter Support Bracket in the Removal and Installa- Removal and Installation section of Group 23 - Body tion section of this group for the procedures. for the procedures. (13) From under the driver side of the instrument (22) Reconnect the battery negative cable.
Page 339 INSTRUMENT PANEL SYSTEMS 8E - 31 REMOVAL AND INSTALLATION (Continued) Removal and Installation section of this group for the procedures. (13) Place the instrument panel on a suitable work surface. Be certain to take the proper precautions to protect the instrument panel from any possible cos- metic damage.
Page 340 8E - 32 INSTRUMENT PANEL SYSTEMS REMOVAL AND INSTALLATION (Continued) (15) Remove the screws around the perimeter of (5) Reach through the instrument panel heater- the top cover that secure it to the instrument panel A/C control opening to install and tighten the screw base.
Page 341 AUDIO SYSTEMS 8F - 1 AUDIO SYSTEMS TABLE OF CONTENTS page page DESCRIPTION AND OPERATION POWER AMPLIFIER ..... . . 8 AUDIO SYSTEM .
Page 342 8F - 2 AUDIO SYSTEMS DESCRIPTION AND OPERATION (Continued) on the steering wheel through a hard wired circuit. The IOD fuse should be checked if the radio or The CTM then sends the proper switch status mes- clock displays are inoperative. The IOD fuse is sages to the radio receiver.
Page 343 AUDIO SYSTEMS 8F - 3 DESCRIPTION AND OPERATION (Continued) els. The standard speakers in the rear doors are each replaced with an Infinity 16.5 centimeter (6.5 inch) diameter coaxial unit. The premium speaker system also includes an additional Infinity power amplifier. The total available power of the premium speaker system is about 100 watts.
Page 344 8F - 4 AUDIO SYSTEMS DESCRIPTION AND OPERATION (Continued) ANTENNA the radio receivers. These internal suppression devices are only serviced as part of the radio receiver. External suppression devices that are used on this DESCRIPTION vehicle to control RFI or EMI noise include the fol- All models use a black painted fixed-length stain- lowing: less steel rod-type antenna mast, installed on the...
Page 345 AUDIO SYSTEMS 8F - 5 DIAGNOSIS AND TESTING (Continued) Audio System Diagnosis CONDITION POSSIBLE CAUSE CORRECTION NO AUDIO 1. Fuse faulty. 1. Check radio fuses in junction block. Replace 2. Radio connector faulty. faulty fuses, if required. 3. Wiring faulty. 2.
Page 346 8F - 6 AUDIO SYSTEMS DIAGNOSIS AND TESTING (Continued) Audio System Diagnosis CONDITION POSSIBLE CAUSE 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.
Page 347 AUDIO SYSTEMS 8F - 7 DIAGNOSIS AND TESTING (Continued) (5) Check for continuity between the radio control mux circuit cavities of the remote radio switch wire harness connector and the 18-way CTM wire harness connector. There should be continuity. If OK, refer to the proper Diagnostic Procedures manual to test the CTM and the Chrysler Collision Detection (CCD) data bus.
Page 348 8F - 8 AUDIO SYSTEMS DIAGNOSIS AND TESTING (Continued) (4) Install a known good radio receiver. Connect (12) Turn the radio receiver off. Turn the ignition the battery negative cable. Turn the ignition switch switch to the Off position. Disconnect and isolate the to the On position.
Page 349 AUDIO SYSTEMS 8F - 9 DIAGNOSIS AND TESTING (Continued) The ohmmeter test lead connections for each test TEST 2 are shown in Antenna Tests (Fig. 3). Test 2 checks the antenna for an open circuit as follows: NOTE: This model has a special coating on the (1) Disconnect the antenna coaxial cable connector antenna mast which is not electrically conductive.
Page 350 8F - 10 AUDIO SYSTEMS DIAGNOSIS AND TESTING (Continued) For complete circuit diagrams, see Group 8W - REMOVAL AND INSTALLATION Wiring Diagrams. Inspect the ground paths and con- nections at the following locations: RADIO RECEIVER • Blower motor • Electric fuel pump WARNING: ON VEHICLES EQUIPPED WITH AIR- •...
Page 351 AUDIO SYSTEMS 8F - 11 REMOVAL AND INSTALLATION (Continued) REMOVAL (1) Disconnect and isolate the battery negative cable. (2) Remove the driver side airbag module from the steering wheel. Refer to Driver Side Airbag Mod- ule in the Removal and Installation section of Group 8M - Passive Restraint Systems for the procedures.
Page 352 8F - 12 AUDIO SYSTEMS REMOVAL AND INSTALLATION (Continued) (6) From the outside of the steering wheel rear trim cover, remove the remote radio switch from the trim cover mounting hole. INSTALLATION (1) Position the remote radio switch to the mount- ing hole on the outside of the steering wheel rear trim cover.
Page 353 AUDIO SYSTEMS 8F - 13 REMOVAL AND INSTALLATION (Continued) REAR DOOR SPEAKER (4) Install the trim panel onto the front door. Refer to Front Door Trim Panel in the Removal and (1) Disconnect and isolate the battery negative Installation section of Group 23 - Body for the proce- cable.
Page 354 8F - 14 AUDIO SYSTEMS REMOVAL AND INSTALLATION (Continued) POWER AMPLIFIER WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, REFER GROUP PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRE- CAUTIONS COULD RESULT IN ACCIDENTAL AIR- BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
Page 355 AUDIO SYSTEMS 8F - 15 REMOVAL AND INSTALLATION (Continued) (c) When the lower power amplifier mounting brackets are about 5 centimeters (2 inches) above the mounting holes for the lower brackets in the right cowl side inner panel, tilt the top of the power amplifier toward the right cowl side inner panel.
Page 356 8F - 16 AUDIO SYSTEMS REMOVAL AND INSTALLATION (Continued) Fig. 13 Antenna Mast Remove/Install - Typical 1 – ANTENNA MAST 2 – ADAPTER 3 – CAP NUT (7) Remove the antenna cap nut using an antenna nut wrench (Special Tool C-4816) (Fig. 14). Fig.
Page 357 AUDIO SYSTEMS 8F - 17 REMOVAL AND INSTALLATION (Continued) (6) Reach through the glove box opening to access panel. This cord will be used to pull or “fish” the and disengage the retainer that secures the antenna cable back into position. cable to the instrument panel structural support on (2) Using the cord or twine, pull the antenna cable the inboard side of the glove box opening.
Page 358 8F - 18 AUDIO SYSTEMS REMOVAL AND INSTALLATION (Continued) Fig. 16 Engine-To-Body Ground Strap Remove/ Install - Typical 1 – WELD STUDS 2 – LEFT GROUND STRAP 3 – NUT AND WASHER (2) 4 – RIGHT GROUND STRAP Fig. 18 Engine-To-Body Ground Strap Remove/ Install - 5.2L &...
Page 359 AUDIO SYSTEMS 8F - 19 REMOVAL AND INSTALLATION (Continued) Fig. 19 Engine-To-Body Ground Strap Remove/ Install - 4.7L Engine Only 1 – RIGHT FRONT FENDER Fig. 21 Exhaust System-To-Body Ground Strap 2 – TO RIGHT CYLINDER HEAD Remove/Install 3 – TO TRANSMISSION 1 –...
Page 360 8F - 20 AUDIO SYSTEMS REMOVAL AND INSTALLATION (Continued) wheelhouse inner panel. Tighten the nut to 11.8 N·m (2) Install and tighten the screw that secures the (105 in. lbs.). exhaust system-to-body ground strap eyelet terminal (7) Install and tighten the screw that secures the to the right body sill panel.
Page 361 HORN SYSTEMS 8G - 1 HORN SYSTEMS TABLE OF CONTENTS page page DESCRIPTION AND OPERATION HORN ........3 HORN SYSTEM.
Page 362 8G - 2 HORN SYSTEMS DESCRIPTION AND OPERATION (Continued) of the radiator. The high-note horn is connected in are the same as a conventional ISO relay. However, parallel with the low-note horn. The horns are con- the ISO micro-relay terminal pattern (or footprint) is nected to the vehicle electrical system through the different, the current capacity is lower, and the phys- headlamp and dash wire harness.
Page 363 HORN SYSTEMS 8G - 3 DESCRIPTION AND OPERATION (Continued) Steering Column in the Removal and Installation section of Group 19 - Steering for proper installation of the steering column. (3) Remove the driver side airbag module from the steering wheel. Disconnect the horn switch wire har- ness connectors from the driver side airbag module.
Page 364 8G - 4 HORN SYSTEMS INSTALLATION REMOVAL AND INSTALLATION (1) See the fuse and relay layout label affixed to HORN RELAY the inside of the fuse access panel for the proper horn relay location. WARNING: ON VEHICLES EQUIPPED WITH AIR- (2) Position the horn relay in the proper receptacle BAGS, DISABLE THE AIRBAG SYSTEM BEFORE in the JB.
Page 365 HORN SYSTEMS 8G - 5 REMOVAL AND INSTALLATION (Continued) (3) Remove the screw that secures the horn and (2) Install and tighten the screw that secures the mounting bracket unit to the front of the left vertical horn and mounting bracket unit to the radiator sup- member of the radiator support.
Page 367 SPEED CONTROL SYSTEM 8H - 1 SPEED CONTROL SYSTEM TABLE OF CONTENTS page page DESCRIPTION AND OPERATION VACUUM SUPPLY TEST ....4 SPEED CONTROL SYSTEM .
Page 368 8H - 2 SPEED CONTROL SYSTEM DESCRIPTION AND OPERATION (Continued) from an existing recorded target speed, momentarily SPEED CONTROL SOLENOID CIRCUITS depress the COAST switch. For each switch activa- tion, speed will be lowered approximately 1 mph. OPERATION When all of the speed control parameters are met, SPEED CONTROL SERVO and the SET button is pressed, the PCM actuates the vent solenoid and “duty-cycles”...
Page 369 The Vehicle Speed Sensor (VSS) is no longer used 12 volt signal to one of the normally closed contacts for any Dodge Truck. in the brake switch, which is returned to the PCM as Vehicle speed and distance covered are measured a brake switch state signal.
Page 370 8H - 4 SPEED CONTROL SYSTEM (4) If vacuum line to engine is not leaking, check DIAGNOSIS AND TESTING for leak at vacuum reservoir. To locate and gain access to reservoir, refer to Vacuum Reservoir Remov- ROAD TEST al/Installation in this group. Disconnect vacuum line Perform a vehicle road test to verify reports of at reservoir and connect a hand-operated vacuum speed control system malfunction.
Page 371 SPEED CONTROL SYSTEM 8H - 5 REMOVAL AND INSTALLATION (Continued) SPEED CONTROL SWITCHES REMOVAL WARNING: BEFORE BEGINNING ANY AIRBAG SYS- TEM COMPONENT REMOVAL OR INSTALLATION, REMOVE AND ISOLATE THE NEGATIVE (-) CABLE FROM THE BATTERY. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM.
Page 372 8H - 6 SPEED CONTROL SYSTEM REMOVAL AND INSTALLATION (Continued) SERVO CABLE (EXCEPT 4.7L ENGINE) (4) Lift accelerator cable from top of cable cam (Fig. 5). (5) Press tab (Fig. 6) to release plastic cable mount REMOVAL from bracket. Press on tab only enough to (1) Disconnect negative battery cable at battery.
Page 373 SPEED CONTROL SYSTEM 8H - 7 REMOVAL AND INSTALLATION (Continued) Fig. 6 Accelerator Cable Release Tab—4.7L V-8 Fig. 7 Speed Control Cable at Bracket—4.7L V-8 Engine Engine 1 – ACCELERATOR CABLE 1 – PLASTIC CABLE MOUNT 2 – PLASTIC CABLE MOUNT 2 –...
Page 374 8H - 8 SPEED CONTROL SYSTEM REMOVAL AND INSTALLATION (Continued) (9) Remove cowl plenum cover/grille panel from vehicle. (10) Remove three reservoir mounting screws (Fig. (11) Remove vacuum reservoir from vehicle. INSTALLATION (1) Install vacuum reservoir and three mounting screws to plastic cowl cover. Tighten three screws to 2.2 N·m (20 in.
Page 375 SPEED CONTROL SYSTEM 8H - 9 SPECIFICATIONS TORQUE CHART Description Torque Servo Mounting Bracket-to-Servo Nuts . . . 8.5 N·m (75 in. lbs.) Servo Mounting Bracket-to-Body Nuts . . 7–10 N·m (63–94 in. lbs.) Switch Module Mounting Screws ..1.5 N·m (14 in.
Page 377 TURN SIGNAL AND HAZARD WARNING SYSTEMS 8J - 1 TURN SIGNAL AND HAZARD WARNING SYSTEMS TABLE OF CONTENTS page page DESCRIPTION AND OPERATION TURN SIGNAL SWITCH AND HAZARD TURN SIGNAL SYSTEM ....1 WARNING SWITCH .
Page 378 8J - 2 TURN SIGNAL AND HAZARD WARNING SYSTEMS DESCRIPTION AND OPERATION (Continued) lamps, and rear tail/stop/turn signal lamps to flash ard warning functions. For information relative to on and off in unison. the other systems that are controlled by and circuits See the owner’s manual in the vehicle glove box for that are integral to the multi-function switch, see the more information on the features, use and operation...
Page 379 TURN SIGNAL AND HAZARD WARNING SYSTEMS 8J - 3 DESCRIPTION AND OPERATION (Continued) rotor. The clockspring mechanism provides turn sig- combination flasher is believed to be faulty, test the nal cancellation as well as a constant electrical con- turn signal system and hazard warning system cir- nection between the horn switch, driver side airbag cuits as described in this group.
Page 380 8J - 4 TURN SIGNAL AND HAZARD WARNING SYSTEMS DESCRIPTION AND OPERATION (Continued) WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, REFER GROUP PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRE- CAUTIONS COULD RESULT IN ACCIDENTAL AIR- BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
Page 381 TURN SIGNAL AND HAZARD WARNING SYSTEMS 8J - 5 DIAGNOSIS AND TESTING (Continued) and fuse block and a good ground. There should be REMOVAL AND INSTALLATION continuity. If OK, go to Step 9. If not OK, repair the open ground circuit to ground as required. COMBINATION FLASHER (9) Disconnect the instrument panel wire harness connector from the multi-function switch connector...
Page 382 8J - 6 TURN SIGNAL AND HAZARD WARNING SYSTEMS REMOVAL AND INSTALLATION (Continued) SWITCH POSITIONS TURN SIGNAL HAZARD WARNING CONTINUITY BETWEEN NEUTRAL 12 AND 14 AND 15 LEFT 15 AND 16 AND 17 LEFT 12 AND 14 LEFT 22 AND 23 WITH OPTIONAL CORNER LAMPS RIGHT 11 AND 12 AND 17 RIGHT...
Page 383 TURN SIGNAL AND HAZARD WARNING SYSTEMS 8J - 7 REMOVAL AND INSTALLATION (Continued) Fig. 6 Multi-Function Switch Connector 1 – WIRE HARNESS CONNECTORS 2 – SCREW Fig. 5 Steering Column Shrouds Remove/Install - 3 – WIRE HARNESS CONNECTOR Typical 4 – MULTI-FUNCTION SWITCH 1 –...
Page 385 WIPER AND WASHER SYSTEMS 8K - 1 WIPER AND WASHER SYSTEMS TABLE OF CONTENTS page page GENERAL INFORMATION WASHER NOZZLE AND PLUMBING ... 5 INTRODUCTION ......1 DIAGNOSIS AND TESTING WINDSHIELD WIPER SYSTEM .
Page 386 8K - 2 WIPER AND WASHER SYSTEMS GENERAL INFORMATION (Continued) The washers will operate only when the ignition If the squeegees are damaged, worn, or contami- switch is in the Accessory or On positions. A fuse nated, the entire wiper blade assembly must be located in the junction block protects the circuitry of replaced.
Page 387 WIPER AND WASHER SYSTEMS 8K - 3 DESCRIPTION AND OPERATION (Continued) • Turn signals WIPER MOTOR • Hazard warning • Headlamp beam selection FRONT • Headlamp optical horn The two-speed permanent magnet wiper motor has • Windshield wipers an integral transmission and park switch. The motor •...
Page 388 8K - 4 WIPER AND WASHER SYSTEMS DESCRIPTION AND OPERATION (Continued) also has an integral illumination lamp with a ser- of the instrument panel glove box opening. Refer to viceable bulb. Both the rear wiper and rear washer Central Timer Module in the Removal and Installa- motors will operate continuously for as long as the tion section of Group 8E - Instrument Panel Systems switch is held in the momentary Wash position.
Page 389 WIPER AND WASHER SYSTEMS 8K - 5 DESCRIPTION AND OPERATION (Continued) WASHER PUMP The wye fitting includes an integral check valve to prevent the washer fluid from draining from the noz- The washer pumps and motors are mounted on the zles back to the reservoir or from leaking out of the right end of the upper radiator shroud near the bot- nozzles after washer operation is complete.
Page 390 8K - 6 WIPER AND WASHER SYSTEMS DIAGNOSIS AND TESTING (Continued) WARNING: ON VEHICLES EQUIPPED WITH AIR- (8) Test the wiper switch. See Wiper Switch and BAGS, REFER GROUP PASSIVE Washer Switch in the Diagnosis and Testing section of this group for the procedures. If the switch tests RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL,...
Page 391 WIPER AND WASHER SYSTEMS 8K - 7 DIAGNOSIS AND TESTING (Continued) WARNING: ON VEHICLES EQUIPPED WITH AIR- pod wire harness connector. There should be continu- BAGS, REFER GROUP PASSIVE ity. If OK, replace the faulty rear wiper motor. If not OK, repair the open circuit as required.
Page 392 8K - 8 WIPER AND WASHER SYSTEMS DIAGNOSIS AND TESTING (Continued) (5) Turn the ignition switch to the Off position. (4) Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Disconnect and isolate the battery negative cable. Move the Central Timer Module (CTM) from its Unplug the rear wiper and washer switch wire har- mounting position far enough so that the CTM wire...
Page 393 WIPER AND WASHER SYSTEMS 8K - 9 DIAGNOSIS AND TESTING (Continued) REAR WINDOW SWITCH POD SWITCH POSITION CONTINUITY BETWEEN 3 & 4 (LAMPS) WIPER SWITCH ON 2 & 7 WASHER SWITCH 7 & 8 ON DEPRESSED Fig. 2 Multi-Function Switch Continuity WARNING: ON VEHICLES EQUIPPED WITH AIR- LAMPS 3 &...
Page 394 8K - 10 WIPER AND WASHER SYSTEMS DIAGNOSIS AND TESTING (Continued) and the proper Diagnostic Procedures manual for diagnosis of the high-line version CTM. If not OK, repair the open circuit to the CTM as required. REMOVAL AND INSTALLATION WIPER BLADE TERMINAL LEGEND NUMBER IDENTIFICATION...
Page 395 WIPER AND WASHER SYSTEMS 8K - 11 REMOVAL AND INSTALLATION (Continued) REAR (7) Release the rear wiper arm and slide the rear wiper blade towards the tip of the wiper arm until the pivot of the blade retainer is engaged in the NOTE: The notched retainer end of the wiper ele- ment should always be oriented towards the end of U-shaped formation on the tip of the wiper arm.
Page 396 8K - 12 WIPER AND WASHER SYSTEMS REMOVAL AND INSTALLATION (Continued) Fig. 10 Rear Wiper Arm Remove/Install Fig. 8 Wiper Arm Puller 1 – WIPER ARM AND BLADE 1 – WIPER ARM 2 – NUT CAP 2 – WIPER PIVOT 3 –...
Page 397 WIPER AND WASHER SYSTEMS 8K - 13 REMOVAL AND INSTALLATION (Continued) WIPER MOTOR (4) Remove the four plastic nuts that secure the cowl plenum cover/grille panel to the studs on the cowl top panel near the base of the windshield (Fig. 12). FRONT (5) Remove the one plastic rivet that secures the (1) Disconnect and isolate the battery negative cable.
Page 398 8K - 14 WIPER AND WASHER SYSTEMS REMOVAL AND INSTALLATION (Continued) (13) Move the wiper module as required to access the wiper motor wire harness connector. (14) Unplug the wiper motor wire harness connec- tor from the wiper motor. (15) Remove the wiper module from the cowl ple- num.
Page 399 WIPER AND WASHER SYSTEMS 8K - 15 REMOVAL AND INSTALLATION (Continued) (4) Remove the nut that secures the rear wiper (3) Refer to the label on the PDC cover for inter- motor output shaft to the outer liftgate panel. mittent wipe relay identification and location. (5) Pull the bezel and grommet off of the rear (4) Unplug the intermittent wipe relay from the wiper motor output shaft.
Page 400 8K - 16 WIPER AND WASHER SYSTEMS REMOVAL AND INSTALLATION (Continued) Fig. 18 Multi-Function Switch Connector 1 – WIRE HARNESS CONNECTORS 2 – SCREW Fig. 17 Steering Column Shrouds Remove/Install - 3 – WIRE HARNESS CONNECTOR Typical 4 – MULTI-FUNCTION SWITCH 1 –...
Page 401 WIPER AND WASHER SYSTEMS 8K - 17 REMOVAL AND INSTALLATION (Continued) WASHER SYSTEM WASHER RESERVOIR The washer reservoir is integral to the right end of the upper radiator shroud in the engine compartment (Fig. 20). Refer to Group 7 - Cooling System for the proper upper radiator shroud service procedures.
Page 402 8K - 18 WIPER AND WASHER SYSTEMS REMOVAL AND INSTALLATION (Continued) WASHER NOZZLE (1) Remove the right upper D-pillar trim. Refer to Group 23 - Body for the procedures. FRONT (2) Disconnect the washer supply hoses from the barbed nipples on each end of the rear washer sys- (1) Remove the cowl plenum cover/grille panel tem check valve.
Page 403 LAMPS 8L - 1 LAMPS TABLE OF CONTENTS page page SAFETY PRECAUTIONS ..... 1 LAMP SERVICE......15 LAMP DIAGNOSIS .
Page 404 8L - 2 LAMPS LAMP DIAGNOSIS TABLE OF CONTENTS page DIAGNOSIS AND TESTING SYSTEM DIAGNOSIS ..... . 2 DIAGNOSIS AND TESTING when it comes in contact with the metal body, or through a separate ground wire.
Page 405 LAMPS 8L - 3 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION HEADLAMPS (HIGH & 1. No voltage at either headlamp. 1. Voltage should always be present. Trace LOW) DO NOT short circuit and replace BOTH headlamp ILLUMINATE fuses. Refer to Group 8W. Check wiring circuit from Right headlamp fuse to headlamp.
Page 406 8L - 4 LAMPS DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION HEADLAMP SWITCH ON 1. Headlamp feed circuit shorted to 1. Check wiring circuit from right headlamp (LOW BEAMS ON), ONE ground. fuse to headlamp. Repeat for left side. LOW BEAM ON AND Trace short circuit in wiring and repair.
Page 407 LAMPS 8L - 5 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION FOG LAMPS FLASH 1. Poor lighting circuit Z3-ground. 1. Test for voltage drop across Z3-ground RANDOMLY locations. Refer to Group 8W. 2. High resistance in fog lamp circuit. 2.
Page 408 8L - 6 LAMPS HEADLAMP ALIGNMENT TABLE OF CONTENTS page page SERVICE PROCEDURES HEADLAMP ALIGNMENT ....7 HEADLAMP ALIGNMENT ....6 FOG LAMP ALIGNMENT .
Page 409 LAMPS 8L - 7 SERVICE PROCEDURES (Continued) Fig. 1 Headlamp Alignment Screen—Typical 1 – CENTER OF VEHICLE 3 – 7.62 METERS (25 FT.) 2 – CENTER OF HEADLAMP 4 – FRONT OF HEADLAMP HEADLAMP ALIGNMENT A properly aimed low beam headlamp will project top edge of high intensity pattern on screen from 50 mm (2 in.) above to 50 mm (2 in.) below headlamp centerline.
Page 410 8L - 8 LAMPS SERVICE PROCEDURES (Continued) Fig. 3 Fog Lamp Alignment —Typical 1 – VEHICLE CENTERLINE 5 – 100 mm (4 in.) 2 – CENTER OF VEHICLE TO CENTER OF FOG LAMP LENS 6 – 7.62 METERS (25 FEET) 3 –...
Page 411 LAMPS 8L - 9 SPECIAL TOOLS HEADLAMP ALIGNMENT Headlamp Aiming Kit C-4466–A...
Page 412 8L - 10 LAMPS LAMP BULB SERVICE TABLE OF CONTENTS page page REMOVAL AND INSTALLATION TAIL, BRAKE, TURN SIGNAL AND BACK-UP HEADLAMP BULB ......10 LAMP BULB .
Page 413 LAMPS 8L - 11 REMOVAL AND INSTALLATION (Continued) PARK AND TURN SIGNAL LAMP BULBS CENTER HIGH MOUNTED STOP LAMP (CHMSL) BULB REMOVAL (1) Remove park and turn signal lamp. REMOVAL (2) Rotate bulb socket 1/4 turn counterclockwise (1) Remove CHMSL from liftgate. and pull turn signal lamp socket from back of lamp (2) Turn bulb socket 1/4 turn counterclockwise.
Page 414 8L - 12 LAMPS REMOVAL AND INSTALLATION (Continued) Fig. 6 License Plate Lamp Bulb Fig. 4 Tail, Brake, Turn Signal and Back-up Lamp 1 – SOCKET Bulb 2 – BULB 1 – TAIL, STOP AND TURN SIGNAL LAMP 3 – LICENSE PLATE LAMP 2 –...
Page 415 LAMPS 8L - 13 REMOVAL AND INSTALLATION (Continued) Fig. 9 Lamp Lens Fig. 8 Underhood Lamp Bulb 1 – FLAT BLADE 1 – BULB 2 – LENS 2 – DEPRESS TERMINAL INWARD 3 – BULB WIRE LOOP 4 – LAMP BASE INSTALLATION (1) Engage the replacement bulb wire loop to the terminal closest to the lamp base wire connector.
Page 416 8L - 14 LAMPS REMOVAL AND INSTALLATION (Continued) OVERHEAD CONSOLE READING LAMP BULB REMOVAL (1) Using a small flat blade, carefully pry forward edge of reading lamp lens downward from lamp. (2) Disengage lamp lens from pivots on overhead console. (3) Rotate bulb holder and pull bulb from lamp.
Page 417 LAMPS 8L - 15 LAMP SERVICE TABLE OF CONTENTS page page DESCRIPTION AND OPERATION LIFTGATE/CARGO LAMP ....17 LAMP SYSTEMS ......15 TAIL, BRAKE, TURN SIGNAL AND BACK-UP REMOVAL AND INSTALLATION LAMP .
Page 418 8L - 16 LAMPS (2) Remove the bolts attaching the fog lamp to the REMOVAL AND INSTALLATION bumper (Fig. 2). (3) Separate fog lamp from bumper. HEADLAMP REMOVAL (1) Open hood. (2) Remove the bolts attaching headlamp to the inner fender panel (Fig. 1). (3) Grasp the headlamp and firmly pull the head- lamp to disengage it from the panel.
Page 419 LAMPS 8L - 17 REMOVAL AND INSTALLATION (Continued) Fig. 5 Center High Mounted Stop Lamp Fig. 3 Park Lamp Screw 1 – LIFTGATE 1 – HEADLAMP 2 – CHMSL 2 – HIDDEN SCREW 3 – LIFTGATE TRIM 3 – PARK LAMP INSTALLATION (1) Position socket in lamp.
Page 420 8L - 18 LAMPS REMOVAL AND INSTALLATION (Continued) Fig. 8 Tail Lamp Connector Fig. 6 Liftgate/Cargo Lamp 1 – TAIL, STOP AND TURN SIGNAL LAMP 1 – LIFTGATE 2 – WIRE CONNECTOR 2 – LIFTGATE LAMP 3 – POSITIVE LOCK (7) Depress lock tab on the side of the body har- (6) Position inner end of lamp into quarter panel.
Page 421 LAMPS 8L - 19 REMOVAL AND INSTALLATION (Continued) Fig. 10 Front Dome Lamp Fig. 9 Underhood Lamp Removal 1 – DOME LAMP 1 – HOOD 2 – HEADLINER 2 – UNDERHOOD LAMP INSTALLATION (1) Install bulb. (2) Install lamp lens. (3) Position the underhood lamp on the hood inner panel.
Page 422 8L - 20 LAMPS REMOVAL AND INSTALLATION (Continued) (2) Allow the lens to hang down this will disen- INSTALLATION gage the forward edge of the lamp from the head- (1) Position lamp at headliner. liner. (2) Connect lamp wire connector to body wire har- (3) Pull the forward edge of the lamp down and ness.
Page 423 LAMPS 8L - 21 LAMP SYSTEMS TABLE OF CONTENTS page REMOVAL AND INSTALLATION DAYTIME RUNNING LAMP MODULE (DRLM) . . . 21 REMOVAL AND INSTALLATION INSTALLATION (1) Connect the electrical connector. DAYTIME RUNNING LAMP MODULE (DRLM) (2) Insert the tab on the DRLM into the slot on the left inner fender.
Page 424 8L - 22 LAMPS BULB APPLICATION TABLE OF CONTENTS page page SPECIFICATIONS INTERIOR LAMPS ......22 EXTERIOR LAMPS......22 SPECIFICATIONS The following Bulb Application Tables lists the lamp title on the left side of the column and trade...
Page 425 PASSIVE RESTRAINT SYSTEMS 8M - 1 PASSIVE RESTRAINT SYSTEMS TABLE OF CONTENTS page page DESCRIPTION AND OPERATION DRIVER SIDE AIRBAG MODULE TRIM AIRBAG SYSTEM ......1 COVER .
Page 426 8M - 2 PASSIVE RESTRAINT SYSTEMS DESCRIPTION AND OPERATION (Continued) the status of the airbag system. If the airbag indica- MOPAR PARTS CATALOG. SUBSTITUTE PARTS tor lamp comes on at any time other than during the MAY APPEAR INTERCHANGEABLE, BUT INTERNAL bulb test, it indicates that there is a problem in the DIFFERENCES MAY RESULT IN INFERIOR OCCU- airbag system circuits.
Page 427 PASSIVE RESTRAINT SYSTEMS 8M - 3 DESCRIPTION AND OPERATION (Continued) trim cover has locking blocks molded into it that AIRBAG CONTROL MODULE engage a lip on the airbag module metal housing. Two stamped metal retainers then fit over the infla- DESCRIPTION tor mounting studs on the back of the airbag module The Airbag Control Module (ACM) is secured with...
Page 428 8M - 4 PASSIVE RESTRAINT SYSTEMS DESCRIPTION AND OPERATION (Continued) CLOCKSPRING DIAGNOSIS AND TESTING DESCRIPTION AIRBAG SYSTEM The clockspring assembly is secured with two inte- A DRB scan tool is required for diagnosis of the gral plastic latches onto the steering column lock airbag system.
Page 429 PASSIVE RESTRAINT SYSTEMS 8M - 5 DIAGNOSIS AND TESTING (Continued) onds, and then back to the On position. Observe the Other vehicle components should closely airbag indicator lamp in the instrument cluster. It inspected, but are to be replaced only as required by should light for six to eight seconds, and then go out.
Page 430 8M - 6 PASSIVE RESTRAINT SYSTEMS SERVICE PROCEDURES (Continued) Removal and Installation section of this group for the TEM CAPACITOR TO DISCHARGE BEFORE FUR- procedures. THER SYSTEM SERVICE. THIS IS THE ONLY SURE Use a vacuum cleaner to remove any residual pow- WAY TO DISABLE THE AIRBAG SYSTEM.
Page 431 PASSIVE RESTRAINT SYSTEMS 8M - 7 REMOVAL AND INSTALLATION (Continued) Fig. 4 Driver Side Airbag Module Remove/Install 1 – AIRBAG MODULE 4 – STEERING WHEEL 2 – HORN SWITCH CONNECTOR 5 – SCREW 3 – AIRBAG CONNECTOR INSTALLATION carefully for a distinct audible click as the connector snaps into place.
Page 432 8M - 8 PASSIVE RESTRAINT SYSTEMS REMOVAL AND INSTALLATION (Continued) WARNING: • THE AIRBAG SYSTEM IS A SENSITIVE, COM- PLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIR- BAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE.
Page 433 PASSIVE RESTRAINT SYSTEMS 8M - 9 REMOVAL AND INSTALLATION (Continued) Fig. 7 Driver Side Airbag Trim Cover Remove/Install 1 – RETAINER SLOTS 2 – RETAINER SLOTS 3 – HORN SWITCH Fig. 8 Driver Side Airbag Trim Cover Locking 4 – LOCKING BLOCKS Blocks Engaged 1 –...
Page 434 8M - 10 PASSIVE RESTRAINT SYSTEMS REMOVAL AND INSTALLATION (Continued) WARNING: • THE AIRBAG SYSTEM IS A SENSITIVE, COM- PLEX ELECTROMECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE OR SERVICE ANY AIR- BAG SYSTEM OR RELATED STEERING WHEEL, STEERING COLUMN, OR INSTRUMENT PANEL COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE.
Page 435 PASSIVE RESTRAINT SYSTEMS 8M - 11 REMOVAL AND INSTALLATION (Continued) • THE PASSENGER SIDE AIRBAG DOOR MUST WARNING: DO NOT USE A DRILL TO REMOVE THE RIVETS. SPARKS CREATED WHEN DRILLING NEVER BE PAINTED. REPLACEMENT INSTRUMENT COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY- PANEL ASSEMBLIES AND TOP COVERS ARE SER- MENT AND POSSIBLE PERSONAL INJURY.
Page 436 8M - 12 PASSIVE RESTRAINT SYSTEMS REMOVAL AND INSTALLATION (Continued) AIRBAG CONTROL MODULE WARNING: • THE AIRBAG CONTROL MODULE CONTAINS THE IMPACT SENSOR, WHICH ENABLES THE SYS- TEM TO DEPLOY THE AIRBAG. BEFORE ATTEMPT- ING TO DIAGNOSE OR SERVICE ANY AIRBAG SYSTEM OR RELATED STEERING WHEEL, STEER- ING COLUMN, OR INSTRUMENT PANEL COMPO- NENTS YOU MUST FIRST DISCONNECT AND...
Page 437 PASSIVE RESTRAINT SYSTEMS 8M - 13 REMOVAL AND INSTALLATION (Continued) CLOCKSPRING The clockspring cannot be repaired. It must be replaced if faulty or damaged, or if the driver side airbag has been deployed. WARNING: THE AIRBAG SYSTEM IS A SENSITIVE, COMPLEX ELECTROMECHANICAL UNIT.
Page 438 8M - 14 PASSIVE RESTRAINT SYSTEMS REMOVAL AND INSTALLATION (Continued) (2) Reconnect the lower clockspring wire harness connector to the instrument panel wire harness. Be certain that the wire harness locator clips are prop- erly seated on the outside of the wiring trough and that the connector latches are fully engaged.
Page 439 PASSIVE RESTRAINT SYSTEMS 8M - 15 ADJUSTMENTS (Continued) indexes the clockspring tape to other steering compo- nents so that it can operate within its designed travel limits. The rotor of a centered clockspring can be rotated two and one-half turns in either direction from the centered position, without damaging the clockspring tape.
Page 441 ELECTRICALLY HEATED SYSTEMS 8N - 1 ELECTRICALLY HEATED SYSTEMS TABLE OF CONTENTS page page GENERAL INFORMATION DIAGNOSIS AND TESTING INTRODUCTION ......1 DEFOGGER SYSTEM .
Page 442 8N - 2 ELECTRICALLY HEATED SYSTEMS which is located near the center of the lower instru- DESCRIPTION AND OPERATION ment panel, below the heater and air conditioner con- trols. REAR GLASS HEATING GRID The rear window switch pod also contains the rear The heated rear window glass has two electrically window defogger logic and timer circuitry, an amber conductive vertical bus bars and a series of horizon-...
Page 443 ELECTRICALLY HEATED SYSTEMS 8N - 3 DIAGNOSIS AND TESTING (Continued) (2) Using a 12-volt DC voltmeter, contact the ver- tical bus bar on the right side of the vehicle with the negative lead. With the positive lead, contact the ver- tical bus bar on the left side of the vehicle.
Page 444 8N - 4 ELECTRICALLY HEATED SYSTEMS DIAGNOSIS AND TESTING (Continued) not OK, repair the circuit to the junction block fuse as required. (5) Turn the ignition switch to the Off position. Disconnect and isolate the battery negative cable. Plug the wire harness connector into the rear win- dow switch pod.
Page 445 ELECTRICALLY HEATED SYSTEMS 8N - 5 REMOVAL AND INSTALLATION DEFOGGER SWITCH WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, REFER GROUP PASSIVE RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE PROPER PRE- CAUTIONS COULD RESULT IN ACCIDENTAL AIR- BAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
Page 447 POWER DISTRIBUTION SYSTEMS 8O - 1 POWER DISTRIBUTION SYSTEMS TABLE OF CONTENTS page page DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION POWER DISTRIBUTION SYSTEM... . . 1 POWER DISTRIBUTION CENTER ... . . 4 POWER DISTRIBUTION CENTER .
Page 448 8O - 2 POWER DISTRIBUTION SYSTEMS DESCRIPTION AND OPERATION (Continued) front corner of the engine compartment, just behind nals. The generator cartridge fuse cannot be repaired the battery. The PDC houses the generator cartridge and, if faulty or damaged, it must be replaced. fuse and up to ten maxi-type cartridge fuses, which OPERATION replace all in-line fusible links.
Page 449 POWER DISTRIBUTION SYSTEMS 8O - 3 DESCRIPTION AND OPERATION (Continued) houses up to nineteen blade-type fuses (two stan- dard-type and seventeen mini-type), up to two blade- type automatic resetting circuit breakers, and two International Standards Organization (ISO) relays (one standard-type and one micro-type). The molded plastic JB housing has integral mount- ing brackets that are secured with two screws to the left instrument panel end bracket.
Page 450 8O - 4 POWER DISTRIBUTION SYSTEMS DESCRIPTION AND OPERATION (Continued) The IOD fuse can be used by the vehicle owner as The relay and fuse block components are accessed a convenient means of reducing battery depletion for service by removing the steering column opening when a vehicle is to be stored for periods not to cover from the instrument panel.
Page 451 POWER DISTRIBUTION SYSTEMS 8O - 5 REMOVAL AND INSTALLATION (Continued) (6) Disconnect the engine wire harness in-line con- nector from the PDC connector receptacle (Fig. 5). Fig. 5 Engine Wire Harness In-Line Connector Fig. 6 Battery and Generator Connections to PDC 1 –...
Page 452 8O - 6 POWER DISTRIBUTION SYSTEMS REMOVAL AND INSTALLATION (Continued) (1) Position the PDC and the headlamp and dash REMOVAL wire harness unit in the engine compartment. (1) Disconnect and isolate the battery negative (2) Install the two PDC mounts onto the two stan- cable.
Page 453 POWER DISTRIBUTION SYSTEMS 8O - 7 REMOVAL AND INSTALLATION (Continued) (8) Reach through the outboard side of the instru- ment panel steering column opening to remove the JB from the left instrument panel end bracket. INSTALLATION NOTE: If the Junction Block (JB) is being replaced with a new unit, be certain to transfer each of the fuses, circuit breakers and relays from the faulty JB to the proper cavities of the replacement JB.
Page 454 8O - 8 POWER DISTRIBUTION SYSTEMS REMOVAL AND INSTALLATION (Continued) RELAY AND FUSE BLOCK The relay and fuse block is serviced as a unit with the instrument panel wire harness. If any internal circuit of the relay and fuse block or the relay and fuse block housing is faulty or damaged, the entire instrument panel...
Page 455 POWER DISTRIBUTION SYSTEMS 8O - 9 REMOVAL AND INSTALLATION (Continued) (1) Position the relay and fuse block and the instrument panel wire harness onto the instrument panel. (2) Install the relay and fuse block by engaging its mounting slots onto the tabs on the Junction Block (JB).
Page 457 POWER LOCK SYSTEMS 8P - 1 POWER LOCK SYSTEMS TABLE OF CONTENTS page page GENERAL INFORMATION POWER LOCK SWITCH ....5 INTRODUCTION .
Page 458 8P - 2 POWER LOCK SYSTEMS GENERAL INFORMATION (Continued) Unlock button to unlock just the driver door, and a also uses inputs from the door ajar switches, the second press within five seconds to unlock all doors headlamp switch and the key-in ignition switch to and the liftgate.
Page 459 POWER LOCK SYSTEMS 8P - 3 DESCRIPTION AND OPERATION (Continued) depressed a second time. A vehicle speed of about 24 Testing section of Group 8U for diagnosis of the base kilometers-per-hour (15 miles-per-hour) will also can- version of the CTM. For diagnosis of the high-line cel the panic event.
Page 460 8P - 4 POWER LOCK SYSTEMS DESCRIPTION AND OPERATION (Continued) Each transmitter has a different vehicle access The driver unlock relay is located in the relay and code, which must be programmed into the memory of fuse block attached to the back of the junction block, the RKE receiver in the vehicle in order to operate under the left side of the instrument panel in the the RKE system.
Page 461 POWER LOCK SYSTEMS 8P - 5 (1) Check the fuse in the junction block. If OK, go DIAGNOSIS AND TESTING to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. POWER LOCK SYSTEM AND REMOTE (2) Check for battery voltage at the fuse in the KEYLESS ENTRY SYSTEM junction block.
Page 462 8P - 6 POWER LOCK SYSTEMS DIAGNOSIS AND TESTING (Continued) (1) Check the fuses in the junction block. If OK, go to Step 2. If not OK, repair the shorted circuit or component as required and replace the faulty fuse. (2) Check for battery voltage at the fuse in the junction block.
Page 463 POWER LOCK SYSTEMS 8P - 7 DIAGNOSIS AND TESTING (Continued) with the power lock switch, see Remote Keyless the power lock motor and the CTM as required. If Entry Transmitter in the Diagnosis and Testing sec- not OK, replace the faulty power lock motor. tion of this group.
Page 464 8P - 8 POWER LOCK SYSTEMS DIAGNOSIS AND TESTING (Continued) Remove the relay (Fig. 3) from the PDC, JB or the REMOTE KEYLESS ENTRY TRANSMITTER relay and fuse block as described in this group to PROGRAMMING perform the following tests: To program the Remote Keyless Entry (RKE) (1) A relay in the de-energized position should transmitter access codes into the RKE receiver in the...
Page 465 POWER LOCK SYSTEMS 8P - 9 REMOVAL AND INSTALLATION (Continued) (2) Remove the trim panel from the inner liftgate the relay and fuse block on the back of the junction panel. Refer to Group 23 - Body for the procedures. block (Fig.
Page 466 8P - 10 POWER LOCK SYSTEMS REMOVAL AND INSTALLATION (Continued) Fig. 6 Power Distribution Center 1 – CLIP 2 – BATTERY 3 – TRAY 4 – NEGATIVE CABLE Fig. 7 Horn Relay Remove/Install 5 – POSITIVE CABLE 1 – INSTRUMENT PANEL 6 –...
Page 467 VEHICLE THEFT/SECURITY SYSTEMS 8Q - 1 VEHICLE THEFT/SECURITY SYSTEMS TABLE OF CONTENTS page page GENERAL INFORMATION HORN RELAY ......4 INTRODUCTION .
Page 468 8Q - 2 VEHICLE THEFT/SECURITY SYSTEMS GENERAL INFORMATION (Continued) The VTSS will not arm if the doors are locked using out (about fifteen minutes). This feature alerts the the key in the lock cylinder or using the mechanical vehicle operator that the VTSS was activated while lock button.
Page 469 VEHICLE THEFT/SECURITY SYSTEMS 8Q - 3 DESCRIPTION AND OPERATION (Continued) tion section of Group 8E - Instrument Panel Systems this input and its internal programming to control for the service procedures. the proper Vehicle Theft Security System (VTSS) and For diagnosis of the high-line version of the CTM power lock system outputs.
Page 470 8Q - 4 VEHICLE THEFT/SECURITY SYSTEMS DESCRIPTION AND OPERATION (Continued) HORN RELAY The Vehicle Theft Security System (VTSS) and the Chrysler Collision Detection (CCD) data bus network The horn relay is a International Standards Orga- should be diagnosed using a DRB scan tool and the nization (ISO) micro-relay.
Page 471 VEHICLE THEFT/SECURITY SYSTEMS 8Q - 5 DIAGNOSIS AND TESTING (Continued) (2) Using an ohmmeter, perform the switch resis- tance checks between the two cavities of the liftgate lock cylinder switch wire harness connector. Actuate the switch by rotating the key in the liftgate lock cyl- inder to test for the proper resistance values in each of the three switch positions, as shown in the Lift- gate Lock Cylinder Switch chart.
Page 472 8Q - 6 VEHICLE THEFT/SECURITY SYSTEMS REMOVAL AND INSTALLATION (Continued) (4) Unplug the liftgate lock cylinder switch wire harness connector. (5) Remove the liftgate lock cylinder switch from the liftgate. (6) Reverse the removal procedures to install. HEADLAMP RELAY WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS, REFER GROUP...
Page 473 VEHICLE THEFT/SECURITY SYSTEMS 8Q - 7 REMOVAL AND INSTALLATION (Continued) HORN RELAY (1) Disconnect and isolate the battery negative cable. (2) Remove the fuse access panel from the left end of the instrument panel (Fig. 5). (3) Refer to the label on the inside of the fuse access panel for horn relay identification and loca- tion.
Page 475 POWER SEAT SYSTEMS 8R - 1 POWER SEAT SYSTEMS TABLE OF CONTENTS page page GENERAL INFORMATION DIAGNOSIS AND TESTING INTRODUCTION ......1 POWER SEAT SYSTEM .
Page 476 8R - 2 POWER SEAT SYSTEMS (1) Disconnect and isolate the battery negative DIAGNOSIS AND TESTING cable. (2) Remove the power seat switch from the power POWER SEAT SYSTEM seat. Before any testing of the power seat system is (3) Use an ohmmeter to test the continuity of the attempted, the battery should be fully-charged and power seat switches in each position.
Page 477 POWER SEAT SYSTEMS 8R - 3 REMOVAL AND INSTALLATION POWER SEAT SWITCH (1) Disconnect and isolate the battery negative cable. (2) Remove the screw that secures the recliner lever to the recliner mechanism release shaft on the outboard side of the driver side front seat. (3) Pull the recliner lever off of the recliner mech- anism release shaft.
Page 479 POWER WINDOW SYSTEMS 8S - 1 POWER WINDOW SYSTEMS TABLE OF CONTENTS page page GENERAL INFORMATION CIRCUIT BREAKER ......3 INTRODUCTION .
Page 480 8S - 2 POWER WINDOW SYSTEMS DESCRIPTION AND OPERATION (Continued) POWER WINDOW MOTOR erly. If the glass is not free to move up and down, the motor will overload and trip the integral circuit A permanent magnet reversible motor moves the breaker.
Page 481 POWER WINDOW SYSTEMS 8S - 3 DIAGNOSIS AND TESTING (Continued) Motor in the Diagnosis and Testing section of this (4) Test the power window switch continuity. See group. If not OK, repair the open circuit(s) as the Power Window Switch Continuity charts to deter- required.
Page 482 8S - 4 POWER WINDOW SYSTEMS DIAGNOSIS AND TESTING (Continued) NOTE: Because this switch contains active elec- motor will not operate in that direction by design. If tronic elements for the Auto-down feature, this OK, repair the circuits from the power window motor to the power window switch as required.
Page 483 POWER MIRROR SYSTEMS 8T - 1 POWER MIRROR SYSTEMS TABLE OF CONTENTS page page EXTERIOR MIRRORS ..... . . 1 INTERIOR MIRRORS .
Page 484 8T - 2 POWER MIRROR SYSTEMS DESCRIPTION AND OPERATION (Continued) POWER MIRROR SWITCH (6) Connect the battery negative cable. Turn the ignition switch to the On position. Turn on the rear Both the right and left power outside mirrors are window defogger system.
Page 485 POWER MIRROR SYSTEMS 8T - 3 DIAGNOSIS AND TESTING (Continued) MIRROR SELECTOR KNOB IN “L” POSITION MOVE LEVER CONTINUITY BETWEEN Pins 3 and 8, 1 and 7, 4 and 7 RIGHT Pins 3 and 7, 2 and 8, 5 and 8 DOWN Pins 3 and 7, 1 and 8, 4 and 8 LEFT...
Page 486 8T - 4 POWER MIRROR SYSTEMS REMOVAL AND INSTALLATION (Continued) (6) Unplug the power mirror switch wire harness connector (Fig. 6). Fig. 7 Mirror Flag Seal Remove/Install 1 – WATER DAM 2 – MIRROR FLAG SEAL Fig. 6 Door Trim Panel Wire Harness Connectors 1 –...
Page 487 POWER MIRROR SYSTEMS 8T - 5 INTERIOR MIRRORS TABLE OF CONTENTS page page GENERAL INFORMATION DIAGNOSIS AND TESTING INTRODUCTION ......5 AUTOMATIC DAY/NIGHT MIRROR .
Page 488 8T - 6 POWER MIRROR SYSTEMS DIAGNOSIS AND TESTING (Continued) position. Check for battery voltage at the fused igni- NOTE: The ambient photocell sensor must be cov- tion switch output (run/start) circuit cavity of the ered completely, so that no light reaches the sen- automatic day/night mirror wire harness connector.
Page 489 CHIME/BUZZER WARNING SYSTEMS 8U - 1 CHIME/BUZZER WARNING SYSTEMS TABLE OF CONTENTS page page GENERAL INFORMATION DIAGNOSIS AND TESTING INTRODUCTION ......1 CENTRAL TIMER MODULE .
Page 490 8U - 2 CHIME/BUZZER WARNING SYSTEMS DESCRIPTION AND OPERATION (Continued) programming, and a hard-wired chime request input DRIVER DOOR AJAR SWITCH from the instrument cluster circuitry to detect when The driver door ajar switch is integral to the driver a chime tone is required. side front door latch.
Page 491 CHIME/BUZZER WARNING SYSTEMS 8U - 3 DESCRIPTION AND OPERATION (Continued) The driver seat belt switch cannot be repaired and, and a good ground. In each case, there should be con- if faulty or damaged, the entire driver seat belt and tinuity.
Page 492 8U - 4 CHIME/BUZZER WARNING SYSTEMS DIAGNOSIS AND TESTING (Continued) Removal and Installation section of Group 8E - CTM wire harness connector and a good ground. Instrument Panel Systems procedures. There should be no continuity. If OK, go to Step 5. If Unplug the 14-way CTM wire harness connector.
Page 493 CHIME/BUZZER WARNING SYSTEMS 8U - 5 DIAGNOSIS AND TESTING (Continued) (4) Check for continuity between the driver door 8W-40 - Instrument Cluster or 8W-45 - Central ajar switch sense circuit terminal and the key-in Timer Module in Group 8W - Wiring Diagrams. ignition switch sense circuit terminal of the head- WARNING: ON VEHICLES EQUIPPED WITH AIR- lamp switch.
Page 495 OVERHEAD CONSOLE SYSTEMS 8V - 1 OVERHEAD CONSOLE SYSTEMS TABLE OF CONTENTS page page DESCRIPTION AND OPERATION COMPASS DEMAGNETIZING ....7 OVERHEAD CONSOLE SYSTEM ....1 REMOVAL AND INSTALLATION OVERHEAD CONSOLE .
Page 496 8V - 2 OVERHEAD CONSOLE SYSTEMS DESCRIPTION AND OPERATION (Continued) faced tape to the inside surface of the roof panel. A for all other compass mini-trip computer functions, single electrical connection joins the overhead console including VFD dimming level, is received through wire harness to the roof wire harness.
Page 497 OVERHEAD CONSOLE SYSTEMS 8V - 3 DESCRIPTION AND OPERATION (Continued) switch is turned to the On position again, the ther- The overhead console reading and courtesy lamps mometer will display the memory temperature if the operate on battery current that is provided at all engine coolant temperature is above about 52°...
Page 498 8V - 4 OVERHEAD CONSOLE SYSTEMS DESCRIPTION AND OPERATION (Continued) for service replacement. The door unit includes the slot in the rear flange of the overhead console read- spring-loaded latch mechanism. If any of these com- ing and courtesy lamp housing to provide a smooth ponents is damaged or faulty, the garage door opener opening action and an open detent position for the storage bin door unit must be replaced.
Page 499 OVERHEAD CONSOLE SYSTEMS 8V - 5 (1) With the ignition switch in the Off position, DIAGNOSIS AND TESTING simultaneously depress and hold the Step button and the U.S./Metric button. COMPASS MINI-TRIP COMPUTER (2) Turn the ignition switch to the On position. If the problem with the compass mini-trip com- (3) Continue to hold both buttons depressed until puter module is an “OC”...
Page 500 8V - 6 OVERHEAD CONSOLE SYSTEMS DIAGNOSIS AND TESTING (Continued) AMBIENT TEMPERATURE SENSOR nector. Check for continuity between the sensor return circuit cavity of the roof wire harness over- The thermometer function is supported by the head console connector and a good ground. There ambient temperature sensor, a wiring circuit, and a should be no continuity.
Page 501 OVERHEAD CONSOLE SYSTEMS 8V - 7 SERVICE PROCEDURES (Continued) Fig. 2 Variance Settings The electronic compass unit features a self-cali- seconds, and appears about five seconds after “VAR” brating design, which simplifies the calibration pro- is displayed. cedure. This feature automatically updates the (3) Release both of the push buttons.
Page 502 8V - 8 OVERHEAD CONSOLE SYSTEMS SERVICE PROCEDURES (Continued) (1) Be certain that the ignition switch is in the Off (7) Connect the degaussing tool to an electrical position, before you begin the demagnetizing proce- outlet, while keeping the tool at least 61 centimeters dure.
Page 503 OVERHEAD CONSOLE SYSTEMS 8V - 9 REMOVAL AND INSTALLATION (Continued) (2) Remove the screw that secures the front of the overhead console to the front of the overhead console bracket (Fig. 5). Fig. 5 Overhead Console Remove/Install 1 – HEADLINER 2 –...
Page 504 8V - 10 OVERHEAD CONSOLE SYSTEMS REMOVAL AND INSTALLATION (Continued) (3) Remove the headliner from the roof panel. (6) Install and tighten the screw that secures the Refer to Headliner in the Removal and Installation front of the overhead console housing to the overhead section of Group 23 - Body for the procedures.
Page 505 OVERHEAD CONSOLE SYSTEMS 8V - 11 REMOVAL AND INSTALLATION (Continued) (5) Disengage the overhead console wire harness (4) Pull the compass mini-trip computer module connector from the mount on the paperclip by push- away from the overhead console far enough to access ing the connector firmly toward the left side of the the wire harness connectors.
Page 506 8V - 12 OVERHEAD CONSOLE SYSTEMS REMOVAL AND INSTALLATION (Continued) (3) Remove the two screws that secure the reading the reading and courtesy lamp housing until they and courtesy lamp housing to the overhead console snap into place. housing (Fig. 8). (3) Install both reading and courtesy lamp bulbs into their bulb holders by pushing them straight into the holders.
Page 507 OVERHEAD CONSOLE SYSTEMS 8V - 13 REMOVAL AND INSTALLATION (Continued) GARAGE DOOR OPENER STORAGE BIN DOOR (4) Position the garage door opener storage bin door pivot and bumper block onto the overhead con- sole housing. REMOVAL (5) Install and tighten the two screws that secure (1) Disconnect and isolate the battery negative the garage door opener storage bin door pivot and cable.
Page 508 8V - 14 OVERHEAD CONSOLE SYSTEMS REMOVAL AND INSTALLATION (Continued) INSTALLATION SPECIAL TOOLS (1) Position the ambient temperature sensor onto OVERHEAD CONSOLE SYSTEMS the radiator yoke. (2) Install and tighten the one screw that secures the ambient temperature sensor bracket to the radi- ator yoke.
Page 510 ENGINE 9 - 1 ENGINE TABLE OF CONTENTS page page 4.7L ENGINE......1 5.9L ENGINE.
Page 511 9 - 2 4.7L ENGINE OIL PUMP ......69 CYLINDER HEADS......75 ENGINE OIL PRESSURE SENDING UNIT .
Page 512 4.7L ENGINE 9 - 3 DESCRIPTION AND OPERATION (Continued) firing order is 1–8–4–3–6–5–7–2. The engine serial number is located at the right front side of the engine block (Fig. 1) ENGINE LUBRICATION SYSTEM DESCRIPTION The lubrication system (Fig. 2) is a full flow filtra- tion pressure feed type.
Page 513 9 - 4 4.7L ENGINE DESCRIPTION AND OPERATION (Continued) Fig. 2 Engine Oil Lubrication System 1 – LEFT CYLINDER HEAD OIL GALLERY 7 – TO CRANKSHAFT MAIN JOURNALS 2 – OIL PRESSURE SENSOR LOCATION 8 – RIGHT CYLINDER HEAD OIL GALLERY 3 –...
Page 514 4.7L ENGINE 9 - 5 2000 DN Service Manual DESCRIPTION AND OPERATION (Continued) Publication No. 81-370-0016 TSB 26-12-99 December, 1999 ENGINE LUBRICATION FLOW CHART—CYLINDER HEADS: TABLE 2 FROM Cylinder Head Oil Port (in bolt hole) Diagonal Cross Drilling to Main Oil Gallery Main Oil Gallery (drilled through head from rear to front) 1.
Page 515 9 - 6 4.7L ENGINE DESCRIPTION AND OPERATION (Continued) VALVE SPRING There are two secondary drive chains, both are inverted tooth type, one to drive the camshaft in each SOHC cylinder head. There are no shaft speed DESCRIPTION changes in the secondary chain drive system. Each The valve springs are made from high strength secondary chain drives a thirty tooth cam sprocket chrome silicon steel.
Page 516 4.7L ENGINE 9 - 7 DESCRIPTION AND OPERATION (Continued) OIL PAN mance. The exhaust manifolds are made of high silicon molybdenum cast iron. A perforated core graphite exhaust manifold gasket is used to improve DESCRIPTION sealing to the cylinder head. The exhaust manifolds The engine oil pan is made of laminated steel and are covered by a three layer laminated heat shield has a single plane sealing surface.
Page 517: Service Diagnosis—Performance
9 - 8 4.7L ENGINE DIAGNOSIS AND TESTING (Continued) SERVICE DIAGNOSIS—PERFORMANCE CONDITION POSSIBLE CAUSE CORRECTION ENGINE WILL NOT START 1. Weak battery 1. Charge or replace as necessary. 2. Corroded or loose battery 2. Clean and tighten battery connections. connections. Apply a coat of light mineral grease to the terminals.
Page 518 4.7L ENGINE 9 - 9 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSE CORRECTION ENGINE LOSS OF POWER 1. Incorrect ignition timing. 1. Refer to Group 8D, Ignition System. 2. Worn or burned distributor rotor. 2. Replace distributor rotor. 3. Worn distributor shaft. 3.
Page 519: Service Diagnosis—Mechanical
9 - 10 4.7L ENGINE DIAGNOSIS AND TESTING (Continued) SERVICE DIAGNOSIS—MECHANICAL CONDITION POSSIBLE CAUSES CORRECTIONS NOISY VALVES 1. High or low oil level in 1. Refer to Group 0, Lubrication and crankcase. Maintenance. 2. Thin or diluted oil. 2. Change oil and filter. 3.
Page 520: Service Diagnosis—Lubrication
4.7L ENGINE 9 - 11 DIAGNOSIS AND TESTING (Continued) SERVICE DIAGNOSIS—LUBRICATION CONDITION POSSIBLE CAUSES CORRECTION OIL LEAKS 1. Gaskets and O-Rings. (a) Misaligned or damaged. (a) Replace as necessary. (b) Loose fasteners, broken or (b) Tighten fasteners, Repair or porous metal parts. replace metal parts.
Page 521 9 - 12 4.7L ENGINE DIAGNOSIS AND TESTING (Continued) Otherwise the indicated compression pressures may COOLING SYSTEM TESTER METHOD not be valid for diagnosis purposes. (1) Clean the spark plug recesses with compressed WARNING: WITH COOLING SYSTEM TESTER IN PLACE, PRESSURE WILL BUILD UP FAST. EXCES- air.
Page 522 4.7L ENGINE 9 - 13 DIAGNOSIS AND TESTING (Continued) CYLINDER COMBUSTION PRESSURE LEAKAGE DIAGNOSIS CHART CONDITION POSSIBLE CAUSE CORRECTION AIR ESCAPES THROUGH Intake valve bent, burnt, or not Inspect valve and valve seat. THROTTLE BODY seated properly Reface or replace, as necessary AIR ESCAPES THROUGH Exhaust valve bent, burnt, or not Inspect valve and valve seat.
Page 523 9 - 14 4.7L ENGINE DIAGNOSIS AND TESTING (Continued) filter runoff, and main bearing cap to cylinder crankshaft seal surface is damaged. The seal area on block mating surfaces. the crankshaft could have minor nicks or scratches (4) If no leaks are detected, pressurize the crank- that can be polished out with emery cloth.
Page 524 4.7L ENGINE 9 - 15 DIAGNOSIS AND TESTING (Continued) CHECKING ENGINE OIL PRESSURE have different properties and cannot be used inter- changeably. (1) Remove oil pressure sending unit (Fig. 3) and install gauge assembly C-3292. MOPAR SILICONE RUBBER ADHESIVE SEALANT Mopar Silicone Rubber Adhesive Sealant, normally black in color, is available in 3 ounce tubes.
Page 525 9 - 16 4.7L ENGINE SERVICE PROCEDURES (Continued) locating dowel is recommended during assembly to ENERGY CONSERVING OIL prevent smearing the material off location. An Energy Conserving type oil is recommended for gasoline engines. The designation of ENERGY CON- ENGINE OIL SERVING is located on the label of an engine oil con- tainer.
Page 526 4.7L ENGINE 9 - 17 SERVICE PROCEDURES (Continued) CRANKCASE OIL LEVEL INSPECTION OIL FILTER REMOVAL (1) Position a drain pan under the oil filter. CAUTION: Do not overfill crankcase with engine oil, (2) Using a suitable oil filter wrench loosen filter. pressure loss or oil foaming can result.
Page 527 9 - 18 4.7L ENGINE SERVICE PROCEDURES (Continued) The hone marks should INTERSECT at 50° to 60° for proper seating of rings (Fig. 9). Fig. 8 Oil Filter Sealing Surface—Typical 1 – SEALING SURFACE 2 – RUBBER GASKET 3 – OIL FILTER Damaged or worn threads can be repaired.
Page 528: Engine Timing—Verification
4.7L ENGINE 9 - 19 SERVICE PROCEDURES (Continued) (6) Identify the fluid in the cylinders (i.e. coolant, fuel, oil, etc.). (7) Make sure all fluid has been removed from the cylinders. (8) Repair engine or components as necessary to prevent this problem from occurring again. (9) Squirt engine oil into the cylinders to lubricate the walls.
Page 529 9 - 20 4.7L ENGINE SERVICE PROCEDURES (Continued) SINGLE CAMSHAFT TIMING NOTE: to adjust the timing on one camshaft, pre- form the following procedure. (1) Using Chain Tensioner Wedge, special tool 8350, stabilize the secondary chain drive. For refer- ence purposes, mark the chain-to-sprocket position (Fig.
Page 530 4.7L ENGINE 9 - 21 SERVICE PROCEDURES (Continued) Fig. 12 Camshaft Sprocket V8 Marks 1 – LEFT CYLINDER HEAD 2 – RIGHT CYLINDER HEAD Fig. 13 Securing Timing Chain Tensioners Using Timing Chain Wedge 1 – LEFT CYLINDER HEAD 3 – SPECIAL TOOL 8350 WEDGE 2 –...
Page 531: Timing Chain—Measuring Wear
9 - 22 4.7L ENGINE SERVICE PROCEDURES (Continued) Fig. 14 Camshaft Dowel To Sprocket Alignment 1 – ADJUSTABLE PLIERS 2 – CAMSHAFT DOWEL TIMING CHAIN—MEASURING WEAR Fig. 15 Camshaft Sprocket Installation—Left NOTE: This procedure must be performed with the Cylinder Head timing chain cover removed.
Page 532 4.7L ENGINE 9 - 23 SERVICE PROCEDURES (Continued) Fig. 18 Moly Coated Piston 1 – MOLY COATED Fig. 16 Camshaft Sprocket Installation—Right 2 – MOLY COATED Cylinder Head 1 – TORQUE WRENCH 2 – SPECIAL TOOL 6958 WITH ADAPTER PINS 8346 3 –...
Page 533 9 - 24 4.7L ENGINE 2000 DN Service Manual SERVICE PROCEDURES (Continued) Publication No. 81-370-0016 TSB 26-12-99 December, 1999 PISTON RINGS—FITTING RING END GAP Before reinstalling used rings or installing new rings, the ring clearances must be checked. (1) Wipe the cylinder bore clean. (2) Insert the ring in the cylinder bore.
Page 534 4.7L ENGINE 9 - 25 SERVICE PROCEDURES (Continued) NOTE: Piston rings are installed in the following order: • Oil ring expander. • Upper oil ring side rail. • Lower oil ring side rail. • No. 2 Intermediate piston ring. • No. 1 Upper piston ring. (8) Install the oil ring expander.
Page 535 9 - 26 4.7L ENGINE SERVICE PROCEDURES (Continued) Fig. 25 Connecting Rod Bearing Inspection 1 – UPPER BEARING HALF 2 – MATING EDGES 3 – GROOVES CAUSED BY ROD BOLTS SCRATCHING JOURNAL DURING INSTALLATION 4 – WEAR PATTERN — ALWAYS GREATER ON UPPER BEARING 5 –...
Page 536 4.7L ENGINE 9 - 27 SERVICE PROCEDURES (Continued) Fig. 30 Checking Connecting Rod Side Clearance— Fig. 29 Measuring Bearing Clearance with Typical Plastigage 1 – PLASTIGAGE SCALE 2 – COMPRESSED PLASTIGAGE Bearing SIZE USED WITH Mark JOURNAL SIZE .025 US .025 mm 50.983-50.967 mm (.001 in.)
Page 537: Engine Mounts—Left And Right
9 - 28 4.7L ENGINE SERVICE PROCEDURES (Continued) nal diameter specification (Main Bearing Fitting Chart). Select inserts required to obtain the specified bearing-to-journal clearance. Install the crankshaft into the cylinder block. Refer to Crankshaft in this section for procedure. CRANKSHAFT MAIN BEARING SELECTION (1) Service main bearings are available in three grades.
Page 538 4.7L ENGINE 9 - 29 REMOVAL AND INSTALLATION (Continued) (4) Remove the four bolts and washers retaining the mount to the transmission (4x4 automatic trans- mission only) (Fig. 38). (5) Raise the transmission enough to remove the through bolt (Manual transmission and 4x2 auto- matic transmission only) (Fig.
Page 539: Structural Cover
9 - 30 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) STRUCTURAL COVER REMOVAL (1) Raise vehicle on hoist. (2) Remove the left hand exhaust pipe from exhaust manifold. Refer to Group 11, Exhaust Sys- tem. (3) Loosen the right hand exhaust manifold-to-ex- haust pipe retaining bolts.
Page 540 4.7L ENGINE 9 - 31 REMOVAL AND INSTALLATION (Continued) SEQUENCE ITEM TORQUE BOLT 54 N·m (Qty 4) (40 ft. lbs.) BOLT 54 N·m (Qty 2) (40 ft. lbs.) BOLT 54 N·m (Qty 2) (40 ft. lbs.) ENGINE ASSEMBLY REMOVAL NOTE: This procedure applies to both the 4X2 and 4X4 vehicles, steps that apply to the 4X4 vehicle only, are identified.
Page 541 9 - 32 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 41 Engine Mount Through Bolt and Nut Removal / Installation—4X4 Vehicles 1 – ENGINE MOUNT BRACKET (2) Fig. 42 Axle Isolator Bracket Removal / 2 – THROUGH BOLT (2) 3 – LOCKNUT AND WASHER (2) Installation—4X4 Vehicles With Automatic 4 –...
Page 542 4.7L ENGINE 9 - 33 REMOVAL AND INSTALLATION (Continued) Fig. 45 Heater Hoses and Tubes Removal / Installation Fig. 43 Crankshaft Position Sensor 1 – HEATER HOSES AND TUBES 1 – CRANKSHAFT POSITION SENSOR 2 – ROUTING/RETAINING CLIPS 2 – CYLINDER HEAD COVER 3 –...
Page 543 9 - 34 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 46 Throttle Body Connection Points 1 – THROTTLE BODY 2 – TPS 3 – IAC MOTOR Fig. 47 Engine Lifting Fixture Attachment Locations 4 – IAT SENSOR 1 – ATTACHING LOCATION 5 –...
Page 544 4.7L ENGINE 9 - 35 REMOVAL AND INSTALLATION (Continued) INTAKE MANIFOLD REMOVAL (1) Disconnect negative cable from battery. (2) Remove resonator assembly and air inlet hose. (3) Disconnect throttle and speed control cables. (4) Disconnect electrical connectors for the follow- ing components: Refer to FUEL SYSTEM for compo- nent locations.
Page 545: Exhaust Manifolds
9 - 36 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) (12) Connect electrical connectors for the following components: • Manifold Absolute Pressure (MAP) Sensor • Intake Air Temperature (IAT) Sensor • Throttle Position (TPS) Sensor • Coolant Temperature (CTS) Sensor • Idle Air Control (IAC) Motor •...
Page 546 4.7L ENGINE 9 - 37 REMOVAL AND INSTALLATION (Continued) Fig. 52 Exhaust Manifold—Right ITEM DESCRIPTION TORQUE ITEM DESCRIPTION TORQUE Stud (Qty 2) Nut (Qty 2) 8 N·m (72 in. lbs.), then 25 N·m loosen 45 Bolt (Qty 4) Nut (Qty 2) (18 ft.
Page 547 9 - 38 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) (9) Install A/C compressor and fasteners. (5) Disconnect the left side breather tube and (10) Install accessory drive belt. remove the breather tube. (11) Install air cleaner assembly, resonator assem- (6) Remove the cylinder head cover mounting bly and air inlet hose.
Page 548 4.7L ENGINE 9 - 39 REMOVAL AND INSTALLATION (Continued) Fig. 53 Exhaust Manifold—Left ITEM DESCRIPTION TORQUE ITEM DESCRIPTION TORQUE Stud (Qty 2) Nut (Qty 2) 8 N·m (72 in. lbs.), then loosen 25 N·m (18 ft. Bolt (Qty 4) Nut (Qty 2) 45 degrees lbs.) Stud (Qty 2)
Page 549 9 - 40 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) (5) Connect injector, ignition coil electrical connec- tors and harness retaining clips. (6) Install the oil fill tube. (7) Install PCV hose. (8) Install heater hoses. (9) Install air conditioning compressor retaining bolts.
Page 550 4.7L ENGINE 9 - 41 REMOVAL AND INSTALLATION (Continued) (11) Rotate the crankshaft until the damper timing mark is aligned with TDC indicator mark (Fig. 57). Fig. 56 Rocker Arm—Removal 1 – CAMSHAFT 2 – SPECIAL TOOL 8516 Fig. 57 Engine Top Dead Center (TDC) Indicator Mark (4) For rocker arm installation on cylinders 1 and 1 –...
Page 551 9 - 42 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) CAUTION: Do not overlook the four smaller bolts at the front of the cylinder head. Do not attempt to remove the cylinder head without removing these four bolts. NOTE: The cylinder head is attached to the cylinder block with fourteen bolts.
Page 552 4.7L ENGINE 9 - 43 REMOVAL AND INSTALLATION (Continued) (21) Remove the cylinder head retaining bolts. (22) Remove the cylinder head and gasket. Discard the gasket. CAUTION: Do not lay the cylinder head on its gas- ket sealing surface, due to the design of the cylin- der head gasket any distortion to the cylinder head sealing surface may prevent the gasket from prop- erly sealing resulting in leaks.
Page 553 9 - 44 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) (14) Remove the timing chain cover. Refer to Tim- ing Chain Cover in this section. (15) Lock the secondary timing chains to the idler sprocket using Special Tool 8515 (Fig. 58). NOTE: Mark the secondary timing chain prior to removal to aid in installation.
Page 554 4.7L ENGINE 9 - 45 REMOVAL AND INSTALLATION (Continued) NOTE: The cylinder head is attached to the cylinder (2) Position the new cylinder head gasket on the block with fourteen bolts. locating dowels. (21) Remove the cylinder head retaining bolts. CAUTION: When installing cylinder head, use care (22) Remove the cylinder head and gasket.
Page 555 9 - 46 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) (14) Install crankshaft damper. Tighten NOTE: All eight valve springs and seals are damper bolt 175 N·m (130 Ft. Lbs.). removed in the same manner; this procedure only (15) Install accessory drive belt. covers one valve seal and valve spring.
Page 556: Crankshaft Damper
4.7L ENGINE 9 - 47 REMOVAL AND INSTALLATION (Continued) Fig. 68 Valve Assembly Configuration Fig. 69 Fan Assembly—Removal/Installation 1 – VALVE LOCKS (3–BEAD) 1 – SPECIAL TOOL 6958 SPANNER WRENCH WITH ADAPTER 2 – RETAINER PINS 8346 3 – VALVE STEM OIL SEAL 2 –...
Page 557: Timing Chain Cover
9 - 48 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 72 Crankshaft Damper—Installation Fig. 70 Crankshaft Damper—Removal 1 – SPECIAL TOOL 8512 1 – SPECIAL TOOL 8513 INSERT 2 – SPECIAL TOOL 1026 (6) Install radiator upper shroud and tighten fas- teners to 11 N·m (95 in.
Page 558 4.7L ENGINE 9 - 49 REMOVAL AND INSTALLATION (Continued) (9) Fill cooling system. Refer to Group 7, Cooling System for procedures. (10) Connect the battery negative cable. TIMING CHAIN AND SPROCKETS REMOVAL (1) Disconnect negative cable from battery. (2) Drain cooling system. Refer to Group 7, Cooling System for procedures.
Page 559 9 - 50 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 76 Camshaft Sprocket V8 Marks 1 – LEFT CYLINDER HEAD 2 – RIGHT CYLINDER HEAD Fig. 77 Cylinder Head Access Plug Location 1 – RIGHT CYLINDER HEAD ACCESS PLUG 2 – LEFT CYLINDER HEAD ACCESS PLUG Fig.
Page 560 4.7L ENGINE 9 - 51 REMOVAL AND INSTALLATION (Continued) Fig. 79 Camshaft Position Sensor—Removal Fig. 80 Camshaft Rotation—Left Side 1 – CRANKSHAFT POSITION SENSOR 1 – CAMSHAFT SPROCKET AND CHAIN 2 – CYLINDER HEAD COVER 2 – ADJUSTABLE PLIERS 3 – CAMSHAFT POSITION SENSOR 3 –...
Page 561 9 - 52 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 82 Timing Chain System 1 – RIGHT CAMSHAFT SPROCKET AND SECONDARY CHAIN 7 – PRIMARY CHAIN 2 – SECONDARY TIMING CHAIN TENSIONER 8 – IDLER SPROCKET 3 – SECONDARY TENSIONER ARM 9 –...
Page 562 4.7L ENGINE 9 - 53 REMOVAL AND INSTALLATION (Continued) the secondary timing chains are installed, position special tool 8515 to hold chains in place for installa- tion (Fig. 84). (8) Align primary chain double plated links with the timing mark at 12 o’clock on the idler sprocket. Align the primary chain single plated link with the timing mark at 6 o’clock on the crankshaft sprocket (Fig.
Page 563 9 - 54 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 85 Installing Idler Gear, Primary and Secondary Timing Chains 1 – SPECIAL TOOL 8515 2 – PRIMARY CHAIN IDLER SPROCKET 3 – CRANKSHAFT SPROCKET (13) Remove Special Tool 8515, then attach both sprockets to camshafts.
Page 564: Idler Shaft—Timing Drive
4.7L ENGINE 9 - 55 REMOVAL AND INSTALLATION (Continued) (25) Install the oil fill housing. (26) Install access plug in left cylinder head (Fig. 77). (27) Install power steering pump. Refer to Group 19, Steering for procedure. (28) Install radiator fan shroud. Refer to Group 7, Cooling System for procedure.
Page 565: Camshafts—In Vehicle
9 - 56 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) CAUTION: When removing the cam sprocket, tim- ing chains or camshaft, Failure to use Special Tool 8350 will result in hydraulic tensioner ratchet over extension, requiring timing chain cover removal to reset the tensioner ratchet.
Page 566 4.7L ENGINE 9 - 57 REMOVAL AND INSTALLATION (Continued) Fig. 91 Securing Timing Chain Tensioners Using Timing Chain Wedge 1 – LEFT CYLINDER HEAD 3 – SPECIAL TOOL 8350 WEDGE 2 – RIGHT CYLINDER HEAD 4 – SPECIAL TOOL 8350 WEDGE INSTALLATION (1) Lubricate camshaft journals with clean engine oil.
Page 567 9 - 58 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) (8) Remove excess oil from bolt, then install the camshaft sprocket retaining bolt and hand tighten. (9) Remove Special Tool 8350 timing chain wedge (Fig. 91). (10) Using Special Tool 6958 spanner wrench with adapter pins 8346 (Fig.
Page 568 4.7L ENGINE 9 - 59 REMOVAL AND INSTALLATION (Continued) Fig. 95 Camshaft Sprocket Installation 1 – ADJUSTABLE PLIERS 2 – CAMSHAFT DOWEL (2) Set engine to TDC cylinder #1, camshaft sprocket V8 marks at the 12 o’clock position. Fig. 96 Tightening Left Side Cam Sprocket (3) Mark one link on the secondary timing chain Retaining Bolt on both sides of the V8 mark on the camshaft...
Page 569 9 - 60 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 97 Securing Timing Chain Tensioners Using Timing Chain Wedge 1 – LEFT CYLINDER HEAD 3 – SPECIAL TOOL 8350 WEDGE 2 – RIGHT CYLINDER HEAD 4 – SPECIAL TOOL 8350 WEDGE Fig.
Page 570 4.7L ENGINE 9 - 61 REMOVAL AND INSTALLATION (Continued) INSTALLATION (8) Remove excess oil from camshaft sprocket bolt, then install the camshaft sprocket retaining bolt and (1) Lubricate camshaft journals with clean engine hand tighten. oil. (9) Remove timing chain wedge special tool 8350 NOTE: Position the right side camshaft so that the (Fig.
Page 571 9 - 62 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 101 Timing Chain to Sprocket Alignment 1 – LEFT CYLINDER HEAD 2 – RIGHT CYLINDER HEAD Fig. 103 Tightening Right Side Cam Sprocket Retaining Bolt 1 – TORQUE WRENCH Fig. 102 Camshaft Sprocket Installation 2 –...
Page 572 4.7L ENGINE 9 - 63 REMOVAL AND INSTALLATION (Continued) Fig. 105 Checking Crankshaft End Play—Typical CRANKSHAFT END PLAY SPECIFICATION CHART Fig. 104 Main Bearing Markings on Target Wheel New Part: 0.052 - 0.282mm 1 – REARMOST CRANKSHAFT COUNTER WEIGHT Specification (0.002 - 0.011 in.) 2 –...
Page 573 9 - 64 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) (15) Start engine and check for leaks. OIL PAN 4X4 VEHICLE REMOVAL NOTE: 4X4 vehicles equipped with a 4.7L engine must have the front axle removed before the oil pan can be removed. (1) Remove the front axle from vehicle.
Page 574 4.7L ENGINE 9 - 65 REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Clean the oil pan gasket mating surface of the bedplate and oil pan. (2) Position the oil pan gasket and pickup tube with new o-ring. Install the mounting bolt and nuts. Tighten bolt and nuts to 28 N·m (20 ft.
Page 575 9 - 66 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 114 Piston Ring End Gap Position Fig. 112 Side Rail—Installation 1 – SIDE RAIL UPPER 1 – SIDE RAIL END 2 – NO. 1 RING GAP 3 – PISTON PIN 4 –...
Page 576 4.7L ENGINE 9 - 67 REMOVAL AND INSTALLATION (Continued) CRANKSHAFT REMOVAL NOTE: To remove the crankshaft from the engine, the engine must be removed from the vehicle. (1) Remove the engine. Refer to Engine Assembly in this section for procedure. (2) Remove the engine oil pump.
Page 577 9 - 68 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) (1) Lubricate upper main bearing halves with clean engine oil. CAUTION: When installing crankshaft, use care not to damage bearing surfaces on the crankshaft. NOTE: Apply sealant to the tone wheel retaining screws prior to installation.
Page 578 4.7L ENGINE 9 - 69 REMOVAL AND INSTALLATION (Continued) • Tighten bolts A1– A6 to 27 N·m (20 ft. lbs.) (8) Measure crankshaft end play. Refer to Crank- shaft Main Bearings in this section for procedure. (9) Install the connecting rods and measure side clearance.
Page 579 9 - 70 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 121 Bedplate Tightening Sequence Fig. 122 Oil Pan Tightening Sequence ENGINE OIL PRESSURE SENDING UNIT REMOVAL (1) Disconnect the negative cable from the battery. (2) Raise vehicle on hoist. (3) Remove front splash shield. (4) Disconnect oil pressure sender wire (Fig.
Page 580 4.7L ENGINE 9 - 71 REMOVAL AND INSTALLATION (Continued) (4) Drain cooling system. Refer to Group 7, Cooling System for procedure. (5) Remove upper radiator hose. (6) Using Special Tools 6958 Spanner with Adapter Pins 8346 loosen fan and viscous assembly from water pump (Fig.
Page 581 9 - 72 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 127 Crankshaft Damper—Removal Fig. 129 Crankshaft Front Seal—Installation 1 – SPECIAL TOOL 8513 INSERT 1 – TIMING CHAIN COVER 2 – SPECIAL TOOL 1026 2 – SPECIAL TOOL 8348 3 – SPECIAL TOOL 8512 (2) Assemble Special Tool 8512 as follows, The nut is threaded onto the shaft first.
Page 582 4.7L ENGINE 9 - 73 REMOVAL AND INSTALLATION (Continued) (1) If being preformed in vehicle, remove the transmission. Refer to Group 21, Transmission and Transfer Case. (2) Remove the flexplate. Refer to procedure in this section. NOTE: The crankshaft oil seal CAN NOT be reused after removal.
Page 583 9 - 74 4.7L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 135 Engine Core Plug Removal 1 – CYLINDER BLOCK 2 – REMOVE PLUG WITH PLIERS Fig. 133 Crankshaft Rear Oil Seal Guide Special 3 – STRIKE HERE WITH HAMMER Tool 8349–2 and Oil Seal 4 –...
Page 584 4.7L ENGINE 9 - 75 DISASSEMBLY AND ASSEMBLY (Continued) NOTE: Once the oil pressure relief valve, cup plug, (3) Inspect the manifold to exhaust pipe mating and pin are removed, the pump assembly must be surface for cracks, gouges, or other damage that would prevent sealing.
Page 585 9 - 76 4.7L ENGINE CLEANING AND INSPECTION (Continued) PISTON AND CONNECTING ROD (1) Clean all parts thoroughly. Mating surface of the oil pump housing should be smooth. If the pump cover is scratched or grooved the oil pump assembly CLEANING should be replaced.
Page 586 4.7L ENGINE 9 - 77 CLEANING AND INSPECTION (Continued) Fig. 137 Checking Oil Pump Cover Flatness 1 – STRAIGHT EDGE 2 – FEELER GAUGE 3 – OIL PUMP COVER Fig. 140 Measuring Outer Rotor Clearance in Housing 1 – FEELER GAUGE 2 –...
Page 587 9 - 78 4.7L ENGINE CLEANING AND INSPECTION (Continued) (4) Determine taper by subtracting the smaller diameter from the larger diameter. (5) Rotate measuring device 90° and repeat steps above. (6) Determine out-of-roundness by comparing the difference between each measurement. (7) If cylinder bore taper does not exceed 0.025 mm (0.001 inch) and out-of-roundness does not exceed 0.025 mm (0.001 inch), the cylinder bore can...
Page 588 4.7L ENGINE 9 - 79 SPECIFICATIONS (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION No. 3 83.88 - 84.08 mm Bearing Bore Out of 0.004 mm Round (3.302 - 3.310 in.) (MAX) (0.0002 in.) PISTON PINS Total Weight (Less 578 grams (20.388 Type Pressed Fit Bearing) ounces)
Page 589 9 - 80 4.7L ENGINE 2000 DN Service Manual SPECIFICATIONS (Continued) Publication No. 81-370-0016 TSB 26-12-99 December, 1999 DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Spring Force (Valve Exhaust Closed) Opens (BTDC) 232.5° Intake and Exhaust 315.5 - 352.5 N @ 40.89 Closes (ATDC) 21.2°...
Page 590 4.7L ENGINE 9 - 81 SPECIFICATIONS (Continued) DESCRIPTION SPECIFICATION DESCRIPTION N·m OIL PUMP Lbs. Lbs. Clearance Over Rotors .035 -.095 mm Flexplate—Bolts — (MAX) Engine Mount Bracket to — (0.0014 - 0.0038 in.) Block—Bolts Cover Out - of -Flat .025 mm (0.001 in.) Rear Mount to —...
Page 591 9 - 82 4.7L ENGINE SPECIAL TOOLS 4.7L ENGINE Front Crankshaft Seal Remover 8511 Spanner Wrench 6958 Front Crankshaft Seal Installer 8348 Adapter Pins 8346 Engine Lifting Studs 8400 Handle C-4171 Engine Lift Fixture 8347 Rear Crankshaft Seal Installer 8349...
Page 592 4.7L ENGINE 9 - 83 SPECIAL TOOLS (Continued) Crankshaft Damper Removal Insert 8513 Rear Crankshaft Seal Remover 8506 Connecting Rod Guides 8507 Chain Tensioner Wedge 8350 Crankshaft Damper Installer 8512 Chain Tensioner Pins 8514 Puller 1026 Secondary Chain Holder 8515...
Page 593 9 - 84 4.7L ENGINE SPECIAL TOOLS (Continued) Valve Spring Tester C-647 Remover, Rocker Arm 8516 Dial Indicator C-3339 Valve Spring Compressor 8387 Valve Spring Compressor C-3422-B Idler Shaft Remover 8517 Bore Size Indicator C-119 Valve Spring Compressor Adapters 8519 Oil Pressure Gauge C-3292...
Page 594 4.7L ENGINE 9 - 85 SPECIAL TOOLS (Continued) Pressure Tester Kit 7700 Piston Ring Compressor C-385 Bloc–Chek–Kit C-3685–A...
Page 595 9 - 86 5.2L ENGINE 5.2L ENGINE TABLE OF CONTENTS page page DESCRIPTION AND OPERATION CYLINDER HEAD ......107 ENGINE .
Page 596 5.2L ENGINE 9 - 87 DESCRIPTION AND OPERATION (Continued) Fig. 3 Positive Displacement Oil Pump—Typical 1 – INNER ROTOR AND SHAFT 2 – BODY 3 – DISTRIBUTOR DRIVESHAFT (REFERENCE) Fig. 1 Firing Order 4 – COTTER PIN 5 – RETAINER CAP 6 –...
Page 597 9 - 88 5.2L ENGINE DESCRIPTION AND OPERATION (Continued)
Page 598: Exhaust Manifold
5.2L ENGINE 9 - 89 DESCRIPTION AND OPERATION (Continued) 1 – OIL DEFLECTOR TAB 14 – OIL PUMP 2 – BOLT 15 – OIL FILTER 3 – ROCKER ARM PIVOT 16 – CRANKSHAFT 4 – ROCKER ARM 17 – FROM OIL PUMP 5 –...
Page 599 9 - 90 5.2L ENGINE DESCRIPTION AND OPERATION (Continued) CYLINDER HEAD COVER GASKET OPERATION The cylinder head closes the combustion chamber DESCRIPTION allowing the pistons to compress the air fuel mixture to the correct ratio for ignition. The valves located in The cylinder head cover gasket is a steel-backed the cylinder head open and close to either allow clean silicone gasket, designed for long life usage (Fig.
Page 600 5.2L ENGINE 9 - 91 DESCRIPTION AND OPERATION (Continued) CRANKSHAFT MAIN BEARINGS DESCRIPTION Main bearings are located in the cylinder block. One half of the main bearing is located in the crank- shaft main bore the other half of the matching bear- ing is located in the main bearing cap (Fig.
Page 601 9 - 92 5.2L ENGINE SERVICE PROCEDURES (Continued) Scrape or wire brush all gasket surfaces to remove (9) Inspect crankcase ventilation system as out all loose material. Inspect stamped parts to ensure lined in Group 0, Lubrication and Maintenance. For gasket rails are flat.
Page 602 5.2L ENGINE 9 - 93 SERVICE PROCEDURES (Continued) particular ambient temperature range and variation To ensure proper lubrication of an engine, the (Fig. 12). engine oil must be maintained at an acceptable level. The acceptable levels are indicated between the ADD and SAFE marks on the engine oil dipstick.
Page 603 9 - 94 5.2L ENGINE SERVICE PROCEDURES (Continued) • Tapping the hole with a special Heli-Coil Tap, or equivalent. • Installing an insert into the tapped hole to bring the hole back to its original thread size. CYLINDER BORE—HONING Before honing, stuff plenty of clean shop towels under the bores and over the crankshaft to keep abrasive materials from entering the crankshaft area.
Page 604 5.2L ENGINE 9 - 95 SERVICE PROCEDURES (Continued) (4) A controlled hone motor speed between 200 and (2) Insert a 6.350 mm (1/4 inch) spacer between 300 RPM is necessary to obtain the proper cross- rocker arm pad and stem tip of No.1 intake valve. hatch angle.
Page 605 9 - 96 5.2L ENGINE SERVICE PROCEDURES (Continued) (2) Attach Dial Indicator Tool C-3339 to cylinder head and set it at right angle of valve stem being measured (Fig. 18). Fig. 18 Measuring Valve Guide Wear Fig. 19 Valve Face and Seat Angles 1 –...
Page 606 5.2L ENGINE 9 - 97 SERVICE PROCEDURES (Continued) (4) When seat is properly positioned the width of intake seats should be 1.016-1.524 mm (0.040-0.060 inch). The width of the exhaust seats should be 1.524-2.032 mm (0.060-0.080 inch). VALVE SPRING INSPECTION Whenever valves have been removed for inspection, reconditioning or replacement, valve springs should be tested.
Page 607 9 - 98 5.2L ENGINE SERVICE PROCEDURES (Continued) sprocket bolt, crankshaft should not be permitted to move. It may be necessary to block the crankshaft to prevent rotation. (3) Hold a scale with dimensional reading even with the edge of a chain link. With cylinder heads installed, apply 14 N·m (30 ft.
Page 608 5.2L ENGINE 9 - 99 SERVICE PROCEDURES (Continued) PISTON MEASUREMENT CHART up (toward top of piston) and chamfer facing down. An identification mark on the ring is a drill point, a stamped letter “O”, an oval depression or the PISTON A DIA = PISTON BORE word TOP (Fig.
Page 609 9 - 100 5.2L ENGINE SERVICE PROCEDURES (Continued) The bearing shells must be installed so that the tangs are in the machined grooves in the rods and caps. Limits of taper or out-of-round on any crankshaft journals should be held to 0.025 mm (0.001 inch). Bearings are available in 0.025 mm (0.001 inch), 0.051 mm (0.002 inch), 0.076 mm (0.003 inch), 0.254 mm (0.010 inch) and 0.305 mm (0.012 inch) under-...
Page 610 5.2L ENGINE 9 - 101 REMOVAL AND INSTALLATION (Continued) (1) Disconnect the negative cable from the battery. (2) Raise vehicle on hoist. (3) Install engine lifting (support) fixture. (4) Remove front axle assembly. (Refer to Group 3, Differential and Driveline in this publication.) (5) Left mount insulator only.
Page 611 9 - 102 5.2L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 33 Engine Mount Insulator at Frame 1 – NUT 2 – ENGINE SUPPORT BRACKET Fig. 34 Rear Mount Insulator 3 – INSULATOR 4 – NUT 1 – AUTOMATIC TRANSMISSION 5 – THROUGH BOLT 2 –...
Page 612 5.2L ENGINE 9 - 103 REMOVAL AND INSTALLATION (Continued) (9) Disconnect the accelerator linkage. (11) Install the generator (refer to Group 8B, Bat- (10) Remove throttle body. tery/Starter/Generator Service). (11) Perform the Fuel System Pressure release (12) Install starter motor (refer to Group 8B, Bat- procedure (refer to Group 14, fuel System).
Page 613 9 - 104 5.2L ENGINE REMOVAL AND INSTALLATION (Continued) (13) Disconnect the heater hoses and bypass hose. (14) Remove the closed crankcase ventilation and evaporation control systems. (15) Remove intake manifold bolts. (16) Lift the intake manifold and throttle body out of the engine compartment as an assembly.
Page 614 5.2L ENGINE 9 - 105 REMOVAL AND INSTALLATION (Continued) • Step 1—Tighten bolts 1 thru 4, in sequence, to 8 N·m (72 in. lbs.) torque. Tighten in alternating steps 1.4 N·m (12 in. lbs.) torque at a time. • Step 2—Tighten bolts 5 thru 12, in sequence, to 8 N·m (72 in.
Page 615 9 - 106 5.2L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 42 Exhaust Manifold Installation—5.9L Engine Fig. 40 Exhaust Manifold Heat Shield—Right Side 1 – EXHAUST MANIFOLD (LEFT) 2 – BOLTS & WASHERS 1 – WASHER 3 – NUTS & WASHERS 2 –...
Page 616 5.2L ENGINE 9 - 107 REMOVAL AND INSTALLATION (Continued) (2) Position the cylinder head cover onto the gas- (3) Remove coil wire from distributor and secure to ket. Tighten the bolts to 11 N·m (95 in. lbs.) torque. good ground to prevent engine from starting. (3) Install closed crankcase ventilation system and (4) Using suitable socket and flex handle at crank- evaporation control system.
Page 617 9 - 108 5.2L ENGINE REMOVAL AND INSTALLATION (Continued) (15) Remove intake manifold and throttle body as (10) Connect the heater hoses and bypass hose. an assembly. Discard the flange side gaskets and the (11) Install distributor cap and wires. front and rear cross-over gaskets.
Page 618 5.2L ENGINE 9 - 109 REMOVAL AND INSTALLATION (Continued) spring seat in cylinder head to the bottom surface of (3) Remove the cooling system fan. spring retainer. If spacers are installed, measure (4) Remove the serpentine belt (refer to Group 7, from the top of spacer.
Page 619 9 - 110 5.2L ENGINE REMOVAL AND INSTALLATION (Continued) (7) Position the fan shroud and install the bolts. Tighten the retainer bolts to 11 N·m (95 in. lbs.) torque. (8) Connect the negative cable to the battery. TIMING CHAIN COVER (1) Disconnect the negative cable from the battery.
Page 620 5.2L ENGINE 9 - 111 REMOVAL AND INSTALLATION (Continued) the crankshaft to align timing marks as shown in (Fig. 52). (4) Remove camshaft sprocket attaching bolt and remove timing chain with crankshaft and camshaft sprockets. INSTALLATION (1) Place both camshaft sprocket and crankshaft sprocket on the bench with timing marks on exact imaginary center line through both camshaft and crankshaft bores.
Page 621 9 - 112 5.2L ENGINE REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Lubricate camshaft lobes and camshaft bearing journals and insert the camshaft to within 51 mm (2 inches) of its final position in cylinder block. (2) Install Camshaft Gear Installer Tool C-3509 with tongue back of distributor drive gear (Fig.
Page 622 5.2L ENGINE 9 - 113 REMOVAL AND INSTALLATION (Continued) Fig. 56 Alignment of Timing Marks Fig. 57 Camshaft Bearings Removal/Installation with 1 – TIMING MARKS Tool C-3132-A 1 – SPECIAL TOOL C-3132–A (13) Install distributor and distributor drive shaft. 2 – MAIN BEARING OIL HOLE (14) Install push rods and tappets.
Page 623 9 - 114 5.2L ENGINE REMOVAL AND INSTALLATION (Continued) INSTALLATION Only one main bearing should be selectively fitted while all other main bearing caps are properly tight- ened. All bearing capbolts removed during service pro- cedures are to be cleaned and oiled before installation. When installing a new upper bearing shell, slightly chamfer the sharp edges from the plain side.
Page 624 5.2L ENGINE 9 - 115 2000 DN Service Manual REMOVAL AND INSTALLATION (Continued) Publication No. 81-370-0016 TSB 26-12-99 December, 1999 Fig. 62 Position of Oil Pump Shaft Slot 1 – DISTRIBUTOR DRIVE After the distributor has been installed, its rota- tional position must be set using the SET SYNC mode of the DRB scan tool.
Page 625 9 - 115A 5.2L ENGINE 2000 DN Service Manual REMOVAL AND INSTALLATION (Continued) Publication No. 81-370-0016 TSB 26-12-99 December, 1999 (8) Install the drain plug. Tighten drain plug to 34 N·m (25 ft. lbs.) torque. (9) Lower transmission onto crossmember. (10) Install rear support cushion mounting bolts.
Page 626 9 - 116 5.2L ENGINE REMOVAL AND INSTALLATION (Continued) PISTON AND CONNECTING ROD ASSEMBLY (4) Install connecting rod bolt protectors on rod bolts, the long protector should be installed on the numbered side of the connecting rod. REMOVAL (5) Rotate crankshaft so that the connecting rod (1) Remove the engine from the vehicle.
Page 627 5.2L ENGINE 9 - 117 REMOVAL AND INSTALLATION (Continued) INSTALLATION Apply enough sealant until a small amount is squeezed out. Withdraw nozzle and wipe excess seal- (1) Clean Gasket Maker residue and sealant from ant off the oil pan seal groove. the cylinder block and rear cap mating surface.
Page 628 9 - 118 5.2L ENGINE REMOVAL AND INSTALLATION (Continued) interference. If tool does not fit, the cover must be removed and installed properly. (4) Place a suitable tool behind the lips of the oil seal to pry the oil seal outward. Be careful not to damage the crankshaft seal bore of cover.
Page 629 5.2L ENGINE 9 - 119 REMOVAL AND INSTALLATION (Continued) (2) Lightly oil the new upper seal lips with engine oil. (3) Install the new upper rear bearing oil seal with the white paint facing towards the rear of the engine. (4) Position the crankshaft into the cylinder block.
Page 630 9 - 120 5.2L ENGINE REMOVAL AND INSTALLATION (Continued) (6) To align the bearing cap, use cap slot, align- ENGINE CORE OIL AND CAMSHAFT PLUGS ment dowel and cap bolts. DO NOT remove excess Engine core plugs have been pressed into the oil material after assembly.
Page 631 5.2L ENGINE 9 - 121 REMOVAL AND INSTALLATION (Continued) (2) Attach Dial Indicator Tool C-3339 to cylinder head and set it at right angle of valve stem being measured (Fig. 76). Fig. 74 Core Hole Plug Removal 1 – CYLINDER BLOCK 2 –...
Page 632 9 - 122 5.2L ENGINE DISASSEMBLY AND ASSEMBLY (Continued) REFACING VALVES AND VALVE SEATS The intake and exhaust valves have a 43-1/4° to 43-3/4° face angle and a 44-1/4° to 44-3/4° seat angle (Fig. 77). Fig. 78 Intake and Exhaust Valves 1 –...
Page 633 5.2L ENGINE 9 - 123 DISASSEMBLY AND ASSEMBLY (Continued) (2) Measure the concentricity of valve seat using a OIL PUMP dial indicator. Total runout should not exceed 0.051 mm (0.002 inch) total indicator reading. DISASSEMBLE (3) Inspect the valve seat with Prussian blue to (1) Remove the relief valve as follows: determine where the valve contacts the seat.
Page 634 9 - 124 5.2L ENGINE DISASSEMBLY AND ASSEMBLY (Continued) CLEANING AND INSPECTION CYLINDER HEAD COVER CLEANING Clean cylinder head cover gasket surface. Clean head rail, if necessary. INSPECTION Inspect cover for distortion and straighten, if nec- essary. Check the gasket for use in head cover installation. If damaged, use a new gasket.
Page 635 5.2L ENGINE 9 - 125 CLEANING AND INSPECTION (Continued) Clean oil pan in solvent and wipe dry with a clean cloth. Clean oil screen and pipe thoroughly in clean sol- vent. Inspect condition of screen. INSPECTION Inspect oil drain plug and plug hole for stripped or damaged threads.
Page 636 9 - 126 5.2L ENGINE CLEANING AND INSPECTION (Continued) Fig. 85 Measuring Outer Rotor Thickness Fig. 88 Measuring Clearance Between Rotors 1 – OUTER ROTOR 2 – FEELER GAUGE 3 – INNER ROTOR Place a straightedge across the face of the pump, between bolt holes.
Page 637 5.2L ENGINE 9 - 127 CLEANING AND INSPECTION (Continued) • The cylinder bores show a taper of more than If oil pressure was low and pump is within specifi- cations, inspect for worn engine bearings or other 0.254 mm (0.010 inch). •...
Page 638 9 - 128 5.2L ENGINE SPECIFICATIONS DESCRIPTION SPECIFICATION 5.2L ENGINE SPECIFICATIONS No. 5 39.688 – 39.713 mm ENGINE SPECIFICATIONS (1.5625 – 1.5635 in.) Bearing Journal Diameter DESCRIPTION SPECIFICATION No. 1 50.749 – 50.775 mm GENERAL SPECIFICATIONS (1.998 – 1.999 in.) No.
Page 639 5.2L ENGINE 9 - 129 SPECIFICATIONS (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Main Bearing Journal CYLINDER HEAD Diameter 63.487 – 63.513 mm Valve Seat (2.4995 – 2.5005 in.) Angle 44.25° – 44.75° Out of Round (Max.) 0.127 mm Runout (Max.) 0.0762 mm (0.001 in.) (0.003 in.) Taper (Max.)
Page 640 9 - 130 5.2L ENGINE SPECIFICATIONS (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION VALVE SPRINGS OIL PUMP Free Length 49.962 mm Clearance over Rotors 0.0381 mm (Max.) (1.967 in.) (0.0015 in.) Spring Tension Inner Rotor Thickness 20.955 mm valve closed 378 N @ 41.66 mm (Min.) (85 lbs.
Page 641 5.2L ENGINE 9 - 131 SPECIFICATIONS (Continued) OVERSIZE AND UNDERSIZE ENGINE DESCRIPTION SPECIFICATION PISTON PIN COMPONENT MARKINGS CHART Clearance in Piston 0.00635 – 0.01905 mm U/S-O/S Item Identification Identification (0.00025 – 0.00075 in.) Location Diameter 24.996 – 25.001 mm Rod/ R or M R-1-4 Milled flat on (0.9841 –...
Page 642 9 - 132 5.2L ENGINE SPECIFICATIONS (Continued) TORQUE SPECIFICATIONS DESCRIPTION N·m TORQUE CHART 5.2L ENGINE Lbs. Lbs. Rear Insulator to — DESCRIPTION N·m Transmission— Lbs. Lbs. Bolts (4WD) Camshaft Sprocket—Bolt — Rear Insulator Bracket—Bolts — Camshaft Thrust Plate—Bolts — (4WD Automatic) Chain Case Cover—Bolts —...
Page 643 5.2L ENGINE 9 - 133 SPECIAL TOOLS (Continued) Engine Support Fixture C-3487–A Dial Indicator C-3339 Valve Spring Compressor MD-998772–A Puller C-3688 Adapter 6633 Front Oil Seal Installer 6635 Adapter 6716A Cam Bearing Remover/Installer C-3132–A Valve Guide Sleeve C-3973 Camshaft Holder C-3509...
Page 644 9 - 134 5.2L ENGINE SPECIAL TOOLS (Continued) Crankshaft Main Bearing Remover C-3059 Distributor Bushing Puller C-3052 Distributor Bushing Driver/Burnisher C-3053 Cylinder Bore Gauge C-119 Piston Ring Compressor C-385...
Page 645 5.9L ENGINE 9 - 135 5.9L ENGINE TABLE OF CONTENTS page page DESCRIPTION AND OPERATION ENGINE REAR SUPPORT ....160 ENGINE ....... 136 ENGINE ASSEMBLY.
Page 646 9 - 136 5.9L ENGINE ENGINE LUBRICATION SYSTEM DESCRIPTION AND OPERATION ENGINE DESCRIPTION A gear-type positive displacement pump (Fig. 3) is DESCRIPTION mounted at the underside of the rear main bearing cap. The pump uses a pick-up tube and screen The 5.9 Liter (360 CID) eight-cylinder engine is a assembly to gather engine oil from the oil pan.
Page 647 5.9L ENGINE 9 - 137 DESCRIPTION AND OPERATION (Continued) The hydraulic valve tappets receive oil directly tappets, which pass oil through hollow push rods to a from the main oil gallery. The camshaft bearings hole in the corresponding rocker arm. Oil from the receive oil from the main bearing galleries.
Page 648 9 - 138 5.9L ENGINE DESCRIPTION AND OPERATION (Continued)
Page 649 5.9L ENGINE 9 - 139 DESCRIPTION AND OPERATION (Continued) 1 – OIL DEFLECTOR TAB 14 – OIL PUMP 2 – BOLT 15 – OIL FILTER 3 – ROCKER ARM PIVOT 16 – CRANKSHAFT 4 – ROCKER ARM 17 – FROM OIL PUMP 5 –...
Page 650 9 - 140 5.9L ENGINE DESCRIPTION AND OPERATION (Continued) CYLINDER HEAD COVER GASKET OPERATION The cylinder head closes the combustion chamber DESCRIPTION allowing the pistons to compress the air fuel mixture to the correct ratio for ignition. The valves located in The cylinder head cover gasket is a steel-backed the cylinder head open and close to either allow clean silicone gasket, designed for long life usage (Fig.
Page 651 5.9L ENGINE 9 - 141 DESCRIPTION AND OPERATION (Continued) CRANKSHAFT MAIN BEARINGS DESCRIPTION Main bearings are located in the cylinder block. One half of the main bearing is located in the crank- shaft main bore the other half of the matching bear- ing is located in the main bearing cap (Fig.
Page 652: Service Diagnosis—Gasoline Engines
9 - 142 5.9L ENGINE DIAGNOSIS AND TESTING (Continued) SERVICE DIAGNOSIS—GASOLINE ENGINES PERFORMANCE DIAGNOSIS CHART—GASOLINE ENGINES CONDITION POSSIBLE CAUSES CORRECTION ENGINE WILL 1. Weak or dead battery 1. Charge/Replace Battery. Refer to Group 8A, NOT CRANK Battery, for correct procedures. Check charging system.
Page 653 5.9L ENGINE 9 - 143 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION 3. Worn or incorrectly gapped spark 3. Replace or clean and re-gap spark plugs (Refer to plugs group 8D, Ignition System) 4. Worn or burned distributor rotor 4.
Page 654 9 - 144 5.9L ENGINE DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION CONNECTING 1. Insufficient oil supply 1. Check engine oil level. (Refer to group 0, Lubrication and ROD NOISE Maintenance) 2. Low oil pressure 2. Check engine oil level. If ok, Perform oil pressure test. Refer to this group for engine oil pressure test/specifications 3.
Page 655 5.9L ENGINE 9 - 145 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION OIL LEAKS 1. Misaligned or 1. Replace gasket deteriorated gaskets 2. Loose fastener, 2. Tighten, repair or replace the part broken or porous metal part 3. Front or rear 3.
Page 656 9 - 146 5.9L ENGINE DIAGNOSIS AND TESTING (Continued) Ensure the battery is completely charged and the COOLING SYSTEM TESTER METHOD engine starter motor is in good operating condition. Otherwise, the indicated compression pressures may WARNING: WITH COOLING SYSTEM TESTER IN PLACE, PRESSURE WILL BUILD UP FAST.
Page 657 5.9L ENGINE 9 - 147 DIAGNOSIS AND TESTING (Continued) All gauge pressure indications should be equal, (12) Clean the oil off the suspect oil leak area with no more than 25% leakage. using a suitable solvent. Drive the vehicle at various FOR EXAMPLE: At 552 kPa (80 psi) input pres- speeds approximately 24 km (15 miles).
Page 658 9 - 148 5.9L ENGINE DIAGNOSIS AND TESTING (Continued) HYDRAULIC TAPPETS plunger partially sticking in the tappet body cylinder. The tappet should be replaced. A heavy click is Before disassembling any part of the engine to cor- caused by a tappet check valve not seating, or by for- rect tappet noise, check the oil pressure.
Page 659 5.9L ENGINE 9 - 149 DIAGNOSIS AND TESTING (Continued) MOPAR GASKET MAKER Mopar Gasket Maker, normally red in color, is available in 6 cc tubes. This anaerobic type gasket material cures in the absence of air when squeezed between smooth machined metallic surfaces. It will not cure if left in the uncovered tube.
Page 660 9 - 150 5.9L ENGINE SERVICE PROCEDURES (Continued) (2) Check intake manifold bolt torque. (3) Perform cylinder compression test. Refer to Cylinder Compression Pressure Test in the Engine Diagnosis area of this section. (4) Clean or replace spark plugs as necessary and adjust gap as specified in Electrical Group 8D.
Page 661 5.9L ENGINE 9 - 151 SERVICE PROCEDURES (Continued) (7) Lower vehicle and fill crankcase with specified type and amount of engine oil described in this sec- tion. (8) Install oil fill cap. (9) Start engine and inspect for leaks. (10) Stop engine and inspect oil level. ENGINE OIL FILTER CHANGE FILTER SPECIFICATION All engines are equipped with a high quality full-...
Page 662 9 - 152 5.9L ENGINE SERVICE PROCEDURES (Continued) The hone marks should INTERSECT at 50° to 60° for proper seating of rings (Fig. 17). Fig. 16 Oil Filter Sealing Surface—Typical 1 – SEALING SURFACE 2 – RUBBER GASKET 3 – OIL FILTER Damaged or worn threads can be repaired.
Page 663 5.9L ENGINE 9 - 153 SERVICE PROCEDURES (Continued) (6) Identify the fluid in the cylinders (i.e. coolant, VALVE GUIDES fuel, oil, etc.). Measure valve stem guide clearance as follows: (7) Make sure all fluid has been removed from the (1) Install Valve Guide Sleeve Tool C-3973 over cylinders.
Page 664 9 - 154 5.9L ENGINE SERVICE PROCEDURES (Continued) REAMER SIZES VALVE FACE AND VALVE SEAT ANGLE CHART REAMER O/S VALVE GUIDE SIZE ITEM DESCRIPTION SPECIFICATION 0.076 mm (0.003 in.) 8.026 - 8.052 mm SEAT WIDTH– 1.016 - 1.524 mm (0.316 - 0.317 in.) INTAKE (0.040 - 0.060 in.) 0.381 mm (0.015 in.)
Page 665 5.9L ENGINE 9 - 155 SERVICE PROCEDURES (Continued) Fig. 23 Testing Valve Spring for Compressed Fig. 22 Refacing Valve Seats Length 1 – STONE 1 – TORQUE WRENCH 2 – PILOT 2 – VALVE SPRING TESTER 3 – VALVE SEAT 4 –...
Page 666 9 - 156 5.9L ENGINE SERVICE PROCEDURES (Continued) (7) Place timing chain around both sprockets. (8) Turn crankshaft and camshaft to line up with keyway location in crankshaft sprocket and in cam- shaft sprocket. (9) Lift sprockets and chain (keep sprockets tight against the chain in position as described).
Page 667 5.9L ENGINE 9 - 157 SERVICE PROCEDURES (Continued) PISTON MEASUREMENT CHART PISTON A DIA = PISTON BORE SIZE DIAMETER DIAMETER MIN. MAX. MIN. MAX. mm (in.) (in.) (in.) (in.) — — — — 101.580 101.592 101.605 101.618 Fig. 27 Second Compression Ring Identification (3.9992) (3.9997) (4.0002)
Page 668 9 - 158 5.9L ENGINE SERVICE PROCEDURES (Continued) Fig. 29 Compression Ring Chamfer Location (Typical) 1 – CHAMFER 2 – TOP COMPRESSION RING Fig. 31 Main Bearing Identification 3 – SECOND COMPRESSION RING 4 – PISTON REMOVAL AND INSTALLATION 5 – CHAMFER ENGINE FRONT MOUNTS REMOVAL—2WD (1) Disconnect the negative cable from the battery.
Page 669 5.9L ENGINE 9 - 159 REMOVAL AND INSTALLATION (Continued) Fig. 32 Engine Right Front Insulator Mount—2WD Vehicles Fig. 34 Engine Mount Insulator at Frame 1 – HEAT SHIELD 1 – NUT 2 – INSULATOR 2 – INSULATOR 3 – FRAME 4 –...
Page 670 9 - 160 5.9L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 36 Left Engine Mount Insulator and Support Fig. 35 Right Engine Mount Insulator and Support Bracket—4WD Vehicles Bracket—4WD Vehicles 1 – ENGINE SUPPORT BRACKET 1 – ENGINE SUPPORT BRACKET 2 – INSULATOR 2 –...
Page 671 5.9L ENGINE 9 - 161 REMOVAL AND INSTALLATION (Continued) Fig. 38 Rear Insulator—2WD Vehicles 1 – ENGINE SUPPORT BRACKET 2 – THROUGH BOLT Fig. 37 Engine Mount Insulator at Frame—4WD 3 – CROSSMEMBER Vehicles 4 – INSULATOR 5 – TRANSMISSION EXTENSION 1 –...
Page 672 9 - 162 5.9L ENGINE REMOVAL AND INSTALLATION (Continued) through insulators and support brackets. Separate the engine as follows: • LEFT SIDE —Remove 2 bolts attaching (engine/pinion nose/transmission) bracket to trans- mission bell housing. Remove 2 bracket to pinion nose adaptor bolts. Separate engine from insulator by removing upper nut washer assembly and bolt from engine support bracket.
Page 673 5.9L ENGINE 9 - 163 REMOVAL AND INSTALLATION (Continued) INTAKE MANIFOLD INSTALLATION (1) If the plenum pan was removed, position pan REMOVAL gasket and pan. (2) Install plenum pan retaining bolts. (Fig. 41). (1) Disconnect the battery negative cable. (3) Tighten plenum pan mounting bolts as follows: (2) Drain the cooling system.
Page 674 9 - 164 5.9L ENGINE REMOVAL AND INSTALLATION (Continued) Fig. 42 Cross-Over Gaskets 1 – FRONT CROSS-OVER GASKET 2 – REAR CROSS-OVER GASKET place, inspect to make sure seals are in place. Remove alignment studs if used. Fig. 43 Intake Manifold Flange Gasket Alignment (9) The following torque sequence duplicates the 1 –...
Page 675 5.9L ENGINE 9 - 165 REMOVAL AND INSTALLATION (Continued) EXHAUST MANIFOLD REMOVAL (1) Disconnect the battery negative cable. (2) Raise the vehicle. (3) Remove the exhaust pipe to manifold nuts. (4) Lower the vehicle. (5) Remove three nuts, heat shield and washers from the right side exhaust manifold, if necessary (Fig.
Page 676 9 - 166 5.9L ENGINE REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Rotate the crankshaft until the “V8” mark lines up with the TDC mark on the timing chain case cover. This mark is located 147° ATDC from the No.1 firing position. (2) Install the push rods in the same order as removed.
Page 677 5.9L ENGINE 9 - 167 REMOVAL AND INSTALLATION (Continued) CYLINDER HEAD REMOVAL (1) Disconnect the battery negative cable. (2) Drain cooling system Refer to COOLING SYS- TEM. (3) Remove intake manifold-to-generator bracket support rod. Remove the generator. (4) Remove closed crankcase ventilation system. (5) Disconnect the evaporation control system.
Page 678 9 - 168 5.9L ENGINE REMOVAL AND INSTALLATION (Continued) (4) Before removing valves, remove any burrs from (7) Install rocker arm. valve stem lock grooves to prevent damage to the (8) Install cylinder head cover. valve guides. Identify valves to ensure installation in (9) Install air cleaner assembly and air inlet hose.
Page 679 5.9L ENGINE 9 - 169 REMOVAL AND INSTALLATION (Continued) (2) Place installing tool, part of Puller Tool Set C-3688 in position and press the vibration damper onto the crankshaft (Fig. 52). Fig. 53 Removal of Front Crankshaft Oil Seal (3) Using a new cover gasket, carefully install chain case cover to avoid damaging oil pan gasket.
Page 680 9 - 170 5.9L ENGINE REMOVAL AND INSTALLATION (Continued) (12) Install water pump and housing assembly using new gaskets (refer to Group 7, Cooling Sys- tem). Tighten bolts to 41 N·m (30 ft. lbs.) torque. (13) Install power steering pump (refer to Group 19, Steering).
Page 681 5.9L ENGINE 9 - 171 REMOVAL AND INSTALLATION (Continued) Fig. 57 Alignment of Timing Marks 1 – TIMING MARKS Fig. 59 Timing Chain Oil Tab Installation 1 – THRUST PLATE FRONT SIDE 2 – CHAIN OIL TAB 3 – THRUST PLATE REAR SIDE Fig.
Page 682 9 - 172 5.9L ENGINE REMOVAL AND INSTALLATION (Continued) torque. Top edge of tab should be flat against thrust CAMSHAFT BEARINGS plate in order to catch oil for chain lubrication. (5) Place both camshaft sprocket and crankshaft REMOVAL sprocket on the bench with timing marks on exact imaginary center line through both camshaft and NOTE: This procedure requires that the engine is crankshaft bores.
Page 683 5.9L ENGINE 9 - 173 REMOVAL AND INSTALLATION (Continued) (4) Hold puller screw and tighten puller nut until bushing is removed. Fig. 65 Burnishing Distributor Driveshaft Bushing 1 – SPECIAL TOOL C-3053 2 – BUSHING Fig. 63 Distributor Driveshaft Bushing Removal 1 –...
Page 684 9 - 174 5.9L ENGINE 2000 DN Service Manual REMOVAL AND INSTALLATION (Continued) Publication No. 81-370-0016 TSB 26-12-99 December, 1999 CRANKSHAFT MAIN BEARINGS (4) Disconnect distributor cap and position away from cowl. (5) Remove the fan shroud. Refer to COOLING REMOVAL SYSTEM.
Page 685 5.9L ENGINE 9 - 175 2000 DN Service Manual REMOVAL AND INSTALLATION (Continued) Publication No. 81-370-0016 TSB 26-12-99 December, 1999 INSTALLATION (12) Remove through bolts from frame brackets and lower engine. Install mount insulator through bolts and tighten to 95 N·m (70 ft. lbs.). (13) Install starter.
Page 686 9 - 176 5.9L ENGINE REMOVAL AND INSTALLATION (Continued) INSTALLATION CRANKSHAFT (1) Be sure that compression ring gaps are stag- A crankshaft which has undersize journals will be gered so that neither is in-line with oil ring rail gap. stamped with 1/4 inch letters on the milled flat on (2) Before installing the ring compressor, make the No.3 crankshaft counterweight (Fig.
Page 687 5.9L ENGINE 9 - 177 REMOVAL AND INSTALLATION (Continued) (7) Remove and discard the crankshaft rear oil seals. (8) Remove and discard the front crankshaft oil seal. INSPECTION OF JOURNALS The crankshaft connecting rod and main journals should be checked for excessive wear, taper and scor- ing.
Page 688 9 - 178 5.9L ENGINE REMOVAL AND INSTALLATION (Continued) (2) Hold the oil pump base flush against mating surface on No.5 main bearing cap. Finger tighten pump attaching bolts. Tighten attaching bolts to 41 N·m (30 ft. lbs.) torque. (3) Install the oil pan. CRANKSHAFT OIL SEAL—FRONT The oil seal can be replaced without removing the timing chain cover provided the cover is not mis-...
Page 689 5.9L ENGINE 9 - 179 REMOVAL AND INSTALLATION (Continued) CRANKSHAFT OIL SEALS—REAR (8) To align the bearing cap, use cap slot, align- ment dowel and cap bolts. DO NOT remove excess The service seal is a 2 piece, viton seal. The upper material after assembly.
Page 690 9 - 180 5.9L ENGINE REMOVAL AND INSTALLATION (Continued) least the 2 main bearing caps forward of the rear allow the sealant to contact the rubber seal. Assem- bearing cap. ble bearing cap to cylinder block immediately after (3) Rotate the new upper seal into the cylinder sealant application.
Page 691 5.9L ENGINE 9 - 181 REMOVAL AND INSTALLATION (Continued) Fig. 80 Core Hole Plug Removal Fig. 81 Oil Pressure Relief Valve 1 – CYLINDER BLOCK 1 – OIL PUMP ASSEMBLY 2 – REMOVE PLUG WITH PLIERS 2 – COTTER PIN 3 –...
Page 692 9 - 182 5.9L ENGINE DISASSEMBLY AND ASSEMBLY (Continued) ASSEMBLE Check the pistons for taper and elliptical shape before they are fitted into the cylinder bore (Fig. 83). (1) Install pump rotors and shaft, using new parts as required. (2) Position the oil pump cover onto the pump body.
Page 693 5.9L ENGINE 9 - 183 CLEANING AND INSPECTION (Continued) PISTON MEASUREMENT CHART PISTON A DIA = PISTON BORE SIZE DIAMETER DIAMETER MIN. MAX. MIN. MAX. mm (in.) (in.) (in.) (in.) — — — — 101.580 101.592 101.605 101.618 (3.9992) (3.9997) (4.0002) (4.0007) 101.592...
Page 694 9 - 184 5.9L ENGINE CLEANING AND INSPECTION (Continued) Slide outer rotor into pump body. Press rotor to the side with your fingers and measure clearance between rotor and pump body (Fig. 87). If clearance is 0.356 mm (0.014 inch) or more, replace oil pump assembly.
Page 695 5.9L ENGINE 9 - 185 CLEANING AND INSPECTION (Continued) CYLINDER BLOCK SPECIFICATIONS CLEANING 5.9L ENGINE SPECIFICATIONS Clean cylinder block thoroughly and check all core hole plugs for evidence of leaking. DESCRIPTION SPECIFICATION INSPECTION Engine Type 90° V-8 OHV Examine block for cracks or fractures. Bore and Stroke 101.6 x 90.9 mm The cylinder walls should be checked for out-of-...
Page 696 9 - 186 5.9L ENGINE SPECIFICATIONS (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Bearing Journal Diameter Bearing Clearance No. 1 50.749 – 50.775 mm #1 Journal 0.013 – 0.038 mm (1.998 – 1.999 in.) (0.0005 – 0.0015 in.) No. 2 50.343 – 50.368 mm Service Limit (1.982 –...
Page 697 5.9L ENGINE 9 - 187 SPECIFICATIONS (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION Valves HYDRAULIC TAPPETS Face Angle 43.25° – 43.75° Body Diameter 22.949 – 22.962 mm Head Diameter – Intake 47.752 mm (1.88 in.) (0.9035 – 0.9040 in.) Head Diameter – 41.072 (1.617 in.) Clearance (to bore) 0.0279 –...
Page 698 9 - 188 5.9L ENGINE SPECIFICATIONS (Continued) DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION PISTONS Oil Ring (Steel Rails) – 0.447 –0.473 mm Max. Clearance at Top of Skirt 0.013 – 0.038 mm (0.018 – 0.019 in.) (0.0005 – 0.0015 in.) VALVE TIMING Land Clearance (Diam.) 0.508 –...
Page 699 5.9L ENGINE 9 - 189 SPECIFICATIONS (Continued) SPECIFICATIONS DESCRIPTION N·m TORQUE CHART 5.9L ENGINE Lbs. Lbs. Rear Insulator to — DESCRIPTION N·m Transmission— Lbs. Lbs. Bolts (4WD) Camshaft Sprocket—Bolt — Rear Insulator Bracket—Bolts — Camshaft Thrust Plate—Bolts — (4WD Automatic) Timing Chain Case Cover—...
Page 700 9 - 190 5.9L ENGINE SPECIAL TOOLS (Continued) Engine Support Fixture C-3487–A Dial Indicator C-3339 Valve Spring Compressor MD-998772–A Puller C-3688 Adapter 6633 Puller 1026 Adapter 6716A Crankshaft Damper Removal Insert 8513 Valve Guide Sleeve C-3973 Front Oil Seal Installer 6635...
Page 701 5.9L ENGINE 9 - 191 SPECIAL TOOLS (Continued) Cam Bearing Remover/Installer C-3132–A Piston Ring Compressor C-385 Camshaft Holder C-3509 Crankshaft Main Bearing Remover C-3059 Distributor Bushing Puller C-3052 Cylinder Bore Gauge C-119 Distributor Bushing Driver/Burnisher C-3053 Pressure Tester Kit 7700 Bloc–Chek–Kit C-3685–A...
Page 703 EXHAUST SYSTEM 11 - 1 EXHAUST SYSTEM TABLE OF CONTENTS page page DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION EXHAUST SYSTEM......1 EXHAUST PIPE .
Page 704 11 - 2 EXHAUST SYSTEM DESCRIPTION AND OPERATION (Continued) CATALYTIC CONVERTER DESCRIPTION California emissions vehicles incorporate mini cat- alytic converters into the exhaust system. The pipes and catalytic converters are made of stainless steel designed to operate at extremely high temperatures (Fig.
Page 705 EXHAUST SYSTEM 11 - 3 DESCRIPTION AND OPERATION (Continued) OPERATION The muffler is designed to muffle the sound of the exhaust as if leaves the engine. TAILPIPE DESCRIPTION The tailpipe is made of stainless steel and attaches to the muffler (Fig. 5). Fig.
Page 706 11 - 4 EXHAUST SYSTEM DIAGNOSIS AND TESTING EXHAUST SYSTEM EXHAUST SYSTEM DIAGNOSIS CHART CONDITION POSSIBLE CAUSE CORRECTION EXCESSIVE EXHAUST NOISE OR 1. Leaks at pipe joints. 1. Tighten clamps/bolts to specified LEAKING EXHAUST GASES torque at leaking joints. 2. Rusted or blown out muffler. 2.
Page 707 EXHAUST SYSTEM 11 - 5 REMOVAL AND INSTALLATION (Continued) (4) Lower the vehicle. (5) Start the engine and inspect for exhaust leaks and exhaust system contact with the body panels. Adjust the alignment, if needed. CATALYTIC CONVERTER NOTE: Neither the inline catalytic converter nor the mini catalytic converters (California emission vehi- cles only) are serviceable separately from the exhaust pipe.
Page 708 11 - 6 EXHAUST SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 10 Muffler Removal/Installation Fig. 11 Tailipipe Removal/Installation 1 – CATALYTIC CONVERTER WITH PIPE 2 – REAR MUFFLER HANGER 1 – MUFFLER 3 – MUFFLER 2 – TAILPIPE HANGER INSULATOR 4 – CLAMP 3 –...
Page 709 EXHAUST SYSTEM 11 - 7 REMOVAL AND INSTALLATION (Continued) Fig. 12 Front and Rear Floor Pan/Converter Shields Fig. 14 Left and Right Dash Heat Shield 1 – REAR FLOOR PAN/CONVERTER SHIELD 1 – LEFT DASH HEAT SHIELD 2 – FRONT FLOOR PAN/CONVERTER SHIELD 2 –...
Page 710 11 - 8 EXHAUST SYSTEM SPECIFICATIONS TORQUE SPECIFICATIONS DESCRIPTION N·m Lbs. Lbs. Exhaust Clamp—Nuts (All) — Exhaust Pipe to Manifold— — Nuts Heat Shield—Nuts — Muffler Hanger—Bolts — Tailpipe Hanger—Bolt —...
Page 711 FRAME AND BUMPERS 13 - 1 FRAME AND BUMPERS TABLE OF CONTENTS page page BUMPERS ....... . 1 FRAME .
Page 712 13 - 2 FRAME AND BUMPERS REMOVAL AND INSTALLATION (Continued) Fig. 1 Front Bumper 1 – FOG LAMP 5 – FRAME 2 – FRONT BUMPER 6 – INNER BUMPER BRACKET 3 – OUTER BUMPER BRACKET 7 – FASCIA BRACKET 4 – U-NUT FRONT BUMPER INNER BRACKET (2) Remove the bolts attaching the fascia to the bumper.
Page 713 FRAME AND BUMPERS 13 - 3 REMOVAL AND INSTALLATION (Continued) Fig. 2 Rear Bumper 1 – BUMPER BEAM 7 – SHIELD 2 – PUSH—PIN 8 – BLIND RIVET 3 – STEP PAD 9 – FASCIA BRACKET 4 – PUSH—PIN 10 – BUMPER BRACKET 5 –...
Page 714 13 - 4 FRAME AND BUMPERS REMOVAL AND INSTALLATION (Continued) (6) Remove the bumper fascia from the bumper INSTALLATION (Fig. 2). (1) Position the bumper fascia on the bumper (Fig. (2) Install upper push pin. (3) Align all holes and install the lower push pins. (4) Position step pad on fascia and press into place.
Page 715 FRAME AND BUMPERS 13 - 5 FRAME TABLE OF CONTENTS page page DESCRIPTION AND OPERATION FUEL TANK SKID PLATE—4WD VEHICLES ..7 FRAME ....... . . 5 SPARE TIRE WINCH .
Page 716 13 - 6 FRAME AND BUMPERS SERVICE PROCEDURES (Continued) replacement bolts that are used to join the frame members should conform to the same specifications as the original bolts. FRAME REPAIRS DRILLING HOLES Do not drill holes in frame side rail top and bottom flanges, metal fatigue can result causing frame fail- ure.
Page 717 FRAME AND BUMPERS 13 - 7 REMOVAL AND INSTALLATION (Continued) Fig. 4 Transfer Case Skid Plate Fig. 3 Front Axle Skid Plate 1 – U—NUT 1 – U-NUT 2 – U—NUT 2 – BRACKET 3 – FRAME 3 – SKID PLATE CROSSMEMBER 4 –...
Page 718 13 - 8 FRAME AND BUMPERS REMOVAL AND INSTALLATION (Continued) REMOVAL (1) Remove spare tire. (2) Raise and support vehicle on hoist. (3) Remove bolts attaching spare tire winch to frame. Fig. 7 Trailer Hitch Harness Connector 1 – TRAILER HARNESS CONNECTOR 2 –...
Page 719 FRAME AND BUMPERS 13 - 9 SPECIFICATIONS (Continued)
Page 720 13 - 10 FRAME AND BUMPERS SPECIFICATIONS (Continued) TORQUE SPECIFICATIONS DESCRIPTION TORQUE Front axle skid plate-to-front x-member bolt ... . 23 N·m (17 ft. lbs.) Front axle skid plate-to-trans x-member bolt ... . 23 N·m (17 ft. lbs.) Front bumper brkt-to-frame nut .
Page 721 FUEL SYSTEM 14 - 1 FUEL SYSTEM TABLE OF CONTENTS page page FUEL DELIVERY SYSTEM....1 FUEL INJECTION SYSTEM ....27 FUEL DELIVERY SYSTEM TABLE OF CONTENTS page...
Page 722 14 - 2 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) • Fuel gauge sending unit (fuel level sensor) FUEL DELIVERY SYSTEM • Fuel supply line connection at filter/regulator • A metal lockring to retain pump module to fuel DESCRIPTION tank The fuel delivery system consists of: •...
Page 723 Output voltages will vary from about.6 volts at FULL, to about 8.6 volts at EMPTY (Jeep models), or, about 7.0 volts at EMPTY (Dodge Truck models). NOTE: For diagnostic purposes, this voltage can only be verified with the fuel gauge sending unit circuit closed (i.e.
Page 724 14 - 4 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) vapor flow controls are required for all fuel tank con- nections. A rollover valve(s) is mounted into the top of the fuel tank (or pump module). Refer to Emission Con- trol System for rollover valve information. An evaporation control system is connected to the rollover valve(s) to reduce emissions of fuel vapors into the atmosphere.
Page 725 FUEL SYSTEM 14 - 5 DESCRIPTION AND OPERATION (Continued) The engine wiring harness connector for each fuel CAUTION: The left and right sections of the fuel rail injector is equipped with an attached numerical tag are connected with a flexible connecting hose. Do (INJ 1, INJ 2 etc.).
Page 726 14 - 6 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) BEFORE SERVICING ANY FUEL SYSTEM HOSES, FITTINGS OR LINES, THE FUEL SYSTEM PRES- SURE MUST BE RELEASED. REFER TO THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE IN THIS GROUP. The lines/tubes/hoses used on fuel injected vehicles are of a special construction.
Page 727 FUEL SYSTEM 14 - 7 DIAGNOSIS AND TESTING (Continued) to 0 psi (cold fluid contracts), but liquid gasoline will Capacity, Fuel Pump Amperage or Fuel Pressure remain in fuel supply line between the check valve Leak Down Tests were not met, replace fuel pump fuel injectors.
Page 728 14 - 8 FUEL SYSTEM DIAGNOSIS AND TESTING (Continued) flow back into the tank and to maintain fuel supply line pressure (engine warm) when pump is not oper- ational. It is also used to keep the fuel supply line full of gasoline when pump is not operational. After the vehicle has cooled down, fuel pressure may drop to 0 psi (cold fluid contracts), but liquid gasoline will remain in fuel supply line between the check valve...
Page 729 FUEL SYSTEM 14 - 9 DIAGNOSIS AND TESTING (Continued) the temperature of the fuel tank is above 50° F (10° WARNING: BEFORE PROCEEDING TO NEXT STEP, NOTE THE FUEL PUMP WILL BE ACTIVATED AND The DRB Scan Tool along with the DRB Low Cur- SYSTEM PRESSURE WILL BE PRESENT.
Page 730 14 - 10 FUEL SYSTEM DIAGNOSIS AND TESTING (Continued) TERMINAL LEGEND NUMBER IDENTIFICATION COMMON FEED COIL GROUND TERMINAL LEGEND COIL BATTERY NUMBER IDENTIFICATION NORMALLY OPEN COIL BATTERY NORMALLY CLOSED COIL GROUND COMMON FEED Fig. 10 Type–1 Relay NORMALLY CLOSED NORMALLY OPEN Fig.
Page 731 FUEL SYSTEM 14 - 11 SERVICE PROCEDURES (Continued) (4) Attempt restarting engine until it will no fuel line. If repair is necessary, replace complete longer run. fuel line assembly. (5) Turn ignition key to OFF position. (1) Perform fuel pressure release procedure. Refer to Fuel Pressure Release Procedure in this group.
Page 732 14 - 12 FUEL SYSTEM SERVICE PROCEDURES (Continued) Fig. 16 Typical Two-Tab Type Quick-Connect Fitting Fig. 14 Disconnecting Single-Tab Type Fitting 1 – TAB(S) 1 – PULL TAB 2 – QUICK-CONNECT FITTING 2 – SCREWDRIVER 3 – QUICK-CONNECT FITTING Fig. 15 Removing Pull Tab 1 –...
Page 733 FUEL SYSTEM 14 - 13 SERVICE PROCEDURES (Continued) Fig. 18 Latch Clip—Type 1 Fig. 20 Fuel Line Disconnection Using Special Tool 1 – TETHER STRAP 1 – SPECIAL FUEL LINE TOOL 2 – FUEL LINE 2 – FUEL LINE 3 – SCREWDRIVER 3 –...
Page 734 14 - 14 FUEL SYSTEM SERVICE PROCEDURES (Continued) (6) Verify a locked condition by firmly pulling on fuel tube and fitting (15-30 lbs.). (7) Latch Clip Equipped: Install latch clip (snaps into position). If latch clip will not fit, this indi- cates fuel line is not properly installed to fuel rail (or other fuel line).
Page 735 FUEL SYSTEM 14 - 15 REMOVAL AND INSTALLATION (Continued) (1) Drain fuel tank and remove tank. Refer to Fuel Tank Removal/Installation in this group. (2) Thoroughly wash and clean area around pump module to prevent contaminants from entering tank. (3) Part of Fuel Tank Removal Procedure: Discon- nect EVAP line at pump module (Fig.
Page 736 14 - 16 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) (1) Using a new gasket, position fuel pump module INSTALLATION into opening in fuel tank. Be sure rubber gasket (1) Snap new filter to bottom of module. Be sure remains in place. Rotate pump module assembly o-ring is in correct position.
Page 737 FUEL SYSTEM 14 - 17 REMOVAL AND INSTALLATION (Continued) Fig. 29 Fuel Rail Assembly—3.9/5.2/5.9L Engine— Fig. 28 Fuel Gauge Sending Unit Lock Tab/Tracks Typical 1 – FUEL GAUGE SENDING UNIT 1 – FUEL RAIL CONNECTING HOSE 2 – LOCK TAB 2 –...
Page 738 14 - 18 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 32 Fuel Injector Mounting—Typical 1 – CLIP 2 – INJECTOR 3 – FUEL RAIL Fig. 31 Remove/Install Injector Connector red colored slider away from injector (1). While push- ing slider, depress tab (2) and remove connector (3) from injector.
Page 739 FUEL SYSTEM 14 - 19 REMOVAL AND INSTALLATION (Continued) rail down until fuel injectors have bottomed on injec- tor shoulder. (6) Install fuel rail mounting bolts. (7) Connect electrical connector to intake manifold air temperature sensor. (8) Connect electrical connectors at all fuel injec- tors.
Page 740 14 - 20 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) colored slider (2). Verify connector is locked to injec- tor by lightly tugging on connector. (11) Connect vacuum lines to throttle body. (12) Connect fuel line latch clip and fuel line to fuel rail.
Page 741 FUEL SYSTEM 14 - 21 REMOVAL AND INSTALLATION (Continued) activation procedures. Before disconnecting fuel line at fuel rail, release fuel pressure. Refer to the Fuel System Pressure Release Procedure in this group for procedures. Attach end of special test hose tool num- ber 6541, 6539, 6631 or 6923 at fuel rail disconnec- tion (tool number will depend on model and/or engine application).
Page 742 14 - 22 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) If fuel pump module is being installed, refer to Fuel Pump Module Removal/Installation. Be sure fuel filter/fuel pressure regulator inlet fitting is pointed towards front of vehicle. (2) Place and secure fuel tank on top of transmis- sion jack.
Page 743 FUEL SYSTEM 14 - 23 REMOVAL AND INSTALLATION (Continued) Fig. 39 Index Tab and Slot 1 – INDEX TAB 2 – INDEX SLOT 3 – CABLE RETAINER 4 – PEDAL ARM Fig. 40 Throttle Cable at Throttle Body—Typical (V-8 THROTTLE CABLE Shown) 1 –...
Page 744 14 - 24 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) (6) Install air tube to throttle body. THROTTLE CABLE—4.7L V-8 ENGINE REMOVAL CAUTION: Be careful not to damage or kink the cable core wire (within the cable sheathing) while servicing accelerator pedal or throttle cable. (1) From inside vehicle, hold up accelerator pedal.
Page 745 FUEL SYSTEM 14 - 25 SPECIFICATIONS (Continued) ates, and are specifically blended to reduce vehicle emissions and improve air quality. We strongly supports the use of reformulated gas- oline. Properly blended reformulated gasoline will provide excellent performance and durability for the engine and fuel system components.
Page 746 14 - 26 FUEL SYSTEM SPECIFICATIONS (Continued) CAUTION: If the Malfunction Indicator Lamp (MIL), help prevent spark knock. If spark knock persists, Check Engine or Service Engine Soon light is flash- lighten the load, or engine piston damage may result. •...
Page 747 FUEL SYSTEM 14 - 27 FUEL INJECTION SYSTEM TABLE OF CONTENTS page page DESCRIPTION AND OPERATION THROTTLE BODY ......39 POWERTRAIN CONTROL MODULE (PCM) .
Page 748 14 - 28 FUEL SYSTEM tion (automatic transmission), vehicle speed and the DESCRIPTION AND OPERATION brake switch. The PCM adjusts idle speed based on inputs it POWERTRAIN CONTROL MODULE (PCM) receives from sensors that react to: throttle position, vehicle speed, transmission gear selection, engine DESCRIPTION coolant temperature and from inputs it receives from The Powertrain Control Module (PCM) (Fig.
Page 749 FUEL SYSTEM 14 - 29 DESCRIPTION AND OPERATION (Continued) • Five volt sensor supply (primary) • Ignition switch OFF • Five volt sensor supply (secondary) The ignition switch On, engine start-up (crank), • Fuel injectors engine warm-up, acceleration, deceleration and wide •...
Page 750 14 - 30 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) • Voltage is applied to the fuel injectors with the The PCM determines the proper ignition timing according to input received from the crankshaft posi- ASD relay via the PCM. The PCM will then control tion sensor.
Page 751 FUEL SYSTEM 14 - 31 DESCRIPTION AND OPERATION (Continued) DECELERATION MODE IGNITION SWITCH OFF MODE When the engine is at operating temperature, this When ignition switch is turned to OFF position, is an Open Loop mode. During hard deceleration, the the PCM stops operating the injectors, ignition coil, PCM receives the following inputs.
Page 752: Fuel Level Sensor—Pcm Input
14 - 32 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) • supply a reference voltage for the Throttle Posi- ENGINE COOLANT TEMPERATURE SENSOR— tion Sensor (TPS) sensor. PCM INPUT • supply the required 5 volt power source to the oil pressure sensor. DESCRIPTION •...
Page 753 FUEL SYSTEM 14 - 33 DESCRIPTION AND OPERATION (Continued) upon intake manifold temperature. At key-on, a During key-on (engine not running) the sensor 5–volt power circuit is supplied to the sensor from reads (updates) barometric pressure. A normal range the PCM. The sensor is grounded at the PCM can be obtained by monitoring a known good sensor.
Page 754: Oil Pressure Sensor—Pcm Input
14 - 34 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) OIL PRESSURE SENSOR—PCM INPUT age output is high; if the oxygen content is high the output voltage is low. The PCM uses this information adjust injector pulse-width achieve DESCRIPTION 14.7–to–1 air/fuel ratio necessary for proper engine The 2–wire, electrical/mechanical engine oil pres- operation and to control emissions.
Page 755: Power Grounds
FUEL SYSTEM 14 - 35 DESCRIPTION AND OPERATION (Continued) the PCM has determined will make the downstream POWER GROUNDS sensor output (oxygen content) correct. The upstream oxygen sensor also provides an input OPERATION to determine catalytic convertor efficiency. The Powertrain Control Module (PCM) has 2 main Downstream Sensor (Certain Non-California grounds.
Page 756: Sensor Return—Pcm Input
14 - 36 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) OPERATION sensors, the PCM uses the TPS input to determine current engine operating conditions. In response to The power steering pressure switch provides an engine operating conditions, the PCM will adjust fuel input to the Powertrain Control Module (PCM).
Page 757: Ccd Bus (+/-) Circuits-Pcm Outputs
FUEL SYSTEM 14 - 37 DESCRIPTION AND OPERATION (Continued) • the ignition key is left in the ON position. This injector pulse width based on various inputs it is if the engine has not been running for approxi- receives. mately 1.8 seconds. Battery voltage (12 volts +) is supplied to the injec- •...
Page 758 14 - 38 FUEL SYSTEM DESCRIPTION AND OPERATION (Continued) The PCM uses the IAC motor to control idle speed can anticipate A/C compressor loads. This is accom- (along with timing) and to reach a desired MAP dur- plished by delaying compressor operation for approx- ing decel (keep engine from stalling).
Page 759: Visual Inspection—3.9/5.2/5.9L Engines
FUEL SYSTEM 14 - 39 DESCRIPTION AND OPERATION (Continued) coolant temperature drops to approximately 98°C (208°F). Refer to Cooling Systems for additional information. Equipped With A/C: In addition to using coolant temperatures to control cooling fan operation, the cooling fan will also be engaged when the air conditioning system has been activated.
Page 760 14 - 40 FUEL SYSTEM DIAGNOSIS AND TESTING (Continued) Fig. 5 Ignition Coil Fig. 6 PCV Valve Hose Connections 1 – ACCESSORY DRIVE BELT TENSIONER 1 – PCV VALVE 2 – COIL CONNECTOR 2 – PCV VALVE HOSE CONNECTIONS 3 – IGNITION COIL 4 –...
Page 761 FUEL SYSTEM 14 - 41 DIAGNOSIS AND TESTING (Continued) (19) Verify wire harness connector is firmly con- nected to engine coolant temperature sensor (Fig. 10). Fig. 8 Sensor and IAC Motor Location—Typical (V-8 Fig. 10 Engine Coolant Temperature Sensor Shown) 1 –...
Page 762 14 - 42 FUEL SYSTEM DIAGNOSIS AND TESTING (Continued) TERMINAL LEGEND Fig. 12 Downstream Oxygen Sensor NUMBER IDENTIFICATION 1 – DOWNSTREAM OXYGEN SENSOR 2 – FRAME RAIL COMMON FEED 3 – CATALYTIC CONVERTER COIL GROUND COIL BATTERY (23) Inspect for exhaust system restrictions such NORMALLY OPEN as pinched exhaust pipes, collapsed muffler or NORMALLY CLOSED...
Page 763 FUEL SYSTEM 14 - 43 DIAGNOSIS AND TESTING (Continued) (5) Connect one end of a jumper wire (16 gauge or smaller) to relay terminal 85. Connect the other end of the jumper wire to the ground side of a 12 volt power source.
Page 764 14 - 44 FUEL SYSTEM DIAGNOSIS AND TESTING (Continued) (5) Disconnect the idle purge vacuum line from fit- REMOVAL AND INSTALLATION ting at throttle body. This vacuum line is located on the front of throttle body next to the MAP sensor AUTOMATIC SHUTDOWN (ASD) RELAY (Fig.
Page 765: Throttle Body—3.9/5.2/5.9L Engines
FUEL SYSTEM 14 - 45 REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Install relay to PDC. (2) Install cover to PDC. OXYGEN SENSOR HEATER RELAYS The oxygen sensor heater relays are located in the Power Distribution Center (PDC) (Fig. 17). Refer to label on PDC cover for relay location.
Page 766: Throttle Position Sensor (Tps)—4.7L
14 - 46 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) plate. Never attempt to adjust the engine idle (8) Install air duct/air box at throttle body. speed using this screw. All idle speed functions are THROTTLE POSITION SENSOR (TPS)—3.9/5.2/ controlled by the Powertrain Control Module (PCM). 5.9L ENGINES REMOVAL (1) Remove the air duct and air resonator box at...
Page 767 FUEL SYSTEM 14 - 47 REMOVAL AND INSTALLATION (Continued) INSTALLATION The throttle shaft end of throttle body slides into a socket in TPS (Fig. 24). The TPS must be installed so that it can be rotated a few degrees. If sensor will not rotate, install sensor with throttle shaft on other side of socket tangs.
Page 768 14 - 48 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) Fig. 25 Mounting Bolts (Screws)—IAC Motor—3.9/ 5.2/5.9L Engines 1 – MOUNTING SCREWS 2 – IDLE SPEED MOTOR Fig. 26 MAP Sensor Location—3.9/5.2/5.9L Engines 1 – MAP SENSOR (2) Install and tighten two mounting bolts (screws) 2 –...
Page 769 FUEL SYSTEM 14 - 49 REMOVAL AND INSTALLATION (Continued) (2) Position sensor to throttle body while guiding POWERTRAIN CONTROL MODULE (PCM) rubber fitting over throttle body vacuum nipple. The PCM is located in the engine compartment (3) Install MAP sensor mounting bolts (screws). (Fig.
Page 770 14 - 50 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) OXYGEN SENSOR REMOVAL Never apply any type of grease to the oxygen sensor electrical connector, or attempt any sol- dering of the sensor wiring harness. For sensor operation, it must have a comparison source of oxygen from outside the exhaust system.
Page 771 FUEL SYSTEM 14 - 51 REMOVAL AND INSTALLATION (Continued) Fig. 32 Oxygen Sensor Locations—4.7L V-8 Engine REMOVAL INSTALLATION (1) Install sensor. WARNING: HOT, PRESSURIZED COOLANT CAN (2) Tighten to 11 N·m (8 ft. lbs.) torque. CAUSE INJURY BY SCALDING. COOLING SYSTEM (3) Use long needlenose pliers to connect electrical MUST BE PARTIALLY DRAINED BEFORE REMOV- connector to sensor.
Page 772 14 - 52 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) The ECT sensor is located near the front of the intake manifold (Fig. 35). (1) Partially drain cooling system. Refer to Group 7, Cooling. (2) Disconnect electrical connector from ECT sen- sor.
Page 773: Intake Manifold Air Temperature
FUEL SYSTEM 14 - 53 REMOVAL AND INSTALLATION (Continued) Fig. 36 Intake Manifold Air Temperature Sensor— 3.9/5.2/5.9L Engines—Typical 1 – INTAKE MANIFOLD AIR TEMPERATURE SENSOR 2 – ELECTRICAL CONNECTOR INSTALLATION (1) Install sensor to intake manifold. Tighten to 28 N·m (20 ft. lbs.) torque. (2) Install electrical connector.
Page 774 14 - 54 FUEL SYSTEM REMOVAL AND INSTALLATION (Continued) POWER STEERING PRESSURE SWITCH SPECIFICATIONS This switch is used only with 4.7L V-8 engine. TORQUE CHART The power steering pressure switch is installed in the power steering high-pressure hose (Fig. 38). DESCRIPTION TORQUE Engine Coolant Temperature...
Page 775 FUEL SYSTEM 14 - 55 SPECIAL TOOLS (Continued) O2S (Oxygen Sensor) Remover/Installer—C-4907 Test Kit, Fuel Pressure—5069 Fuel Line Removal Tool—6782 Test Kit, Fuel Pressure—C-4799-B...
Page 777 STEERING 19 - 1 STEERING TABLE OF CONTENTS page page POWER STEERING ......1 RACK & PINION STEERING GEAR ... . 11 POWER STEERING PUMP .
Page 778 19 - 2 STEERING DESCRIPTION AND OPERATION (Continued) Fig. 2 Steering Pump, Gear And Oil Cooler - 4.7L 1 – HYDRAULIC PUMP 2 – RACK AND PINION GEAR 3 – OIL COOLER DIAGNOSIS AND TESTING POWER STEERING SYSTEM STEERING NOISE There is some noise in all power steering systems.
Page 779 STEERING 19 - 3 DIAGNOSIS AND TESTING (Continued) CONDITION POSSIBLE CAUSES CORRECTION WHINE OR GROWL 1. Low fluid level. 1. Fill to proper level. 2. Pressure hose in contact with other 2. Reposition hose. components. 3. Internal pump noise. 3. Replace pump. SUCKING AIR SOUND 1.
Page 780 19 - 4 STEERING DIAGNOSIS AND TESTING (Continued) LOOSE STEERING AND VEHICLE LEAD CONDITION POSSIBLE CAUSE CORRECTION EXCESSIVE PLAY IN STEERING 1. Worn or loose suspension or 1. Inspect and repair as necessary. WHEEL steering components. 2. Worn or loose wheel bearings. 2.
Page 781 STEERING 19 - 5 DIAGNOSIS AND TESTING (Continued) (12) Close valve fully three times and record high- est pressure indicated each time. All three read- ings must be above specifications and within 345 kPa (50 psi) of each other. • Pressures above specifications but not within 345 kPa (50 psi) of each other, replace pump.
Page 782 19 - 6 STEERING POWER STEERING PUMP TABLE OF CONTENTS page page DESCRIPTION AND OPERATION POWER STEERING PUMP - 4.7L....8 POWER STEERING PUMP ....6 DISASSEMBLY AND ASSEMBLY DIAGNOSIS AND TESTING PUMP PULLEY .
Page 783 STEERING 19 - 7 DESCRIPTION AND OPERATION (Continued) Wipe filler cap clean, then check the fluid level. The dipstick should indicate COLD when the fluid is at normal temperature. (1) Turn steering wheel all the way to the left (2) Fill the pump fluid reservoir to the proper level and let the fluid settle for at least two (2) minutes.
Page 784 19 - 8 STEERING REMOVAL AND INSTALLATION (Continued) POWER STEERING PUMP - 4.7L REMOVAL (1) Remove the serpentine drive belt, refer to Group 7 Cooling. (2) Remove return hose from the pump reservoir and drain the pump. (3) Remove power steering pressure switch connec- tor and remove pressure line from the bottom of the pump.
Page 785 STEERING 19 - 9 (3) Install pump assembly. DISASSEMBLY AND ASSEMBLY (4) With Serpentine Belts; Run engine until warm (5 min.) and note any belt chirp. If chirp exists, move PUMP PULLEY pulley outward approximately 0.5 mm (0.020 in.). If noise increases, press on 1.0 mm (0.040 in.).
Page 786 19 - 10 STEERING SPECIAL TOOLS (Continued) Installer, Power Steering Pulley C-4063–B Puller C-4333...
Page 787 STEERING 19 - 11 RACK & PINION STEERING GEAR TABLE OF CONTENTS page page DESCRIPTION AND OPERATION DISASSEMBLY AND ASSEMBLY RACK & PINION STEERING GEAR ... 11 BOOT SEAL ......14 REMOVAL AND INSTALLATION SPECIFICATIONS TIE ROD END .
Page 788 19 - 12 STEERING REMOVAL AND INSTALLATION (Continued) (5) Remove support and lower vehicle. (6) Adjust the wheel toe position, Refer to Group 2 Suspension. RACK & PINION STEERING GEAR - 4x2 REMOVAL (1) Raise and support the vehicle. (2) Remove the nuts from the tie rod ends. (3) Separate tie rod ends from the knuckles with Puller C-3894-A (Fig.
Page 789 STEERING 19 - 13 REMOVAL AND INSTALLATION (Continued) (2) Remove the splash shield from under the front end to gain access to the gear. (3) Remove the nuts from the tie rod ends. (4) Separate tie rod ends from the knuckles with Puller C-3894-A (Fig.
Page 790 19 - 14 STEERING INSTALLATION DISASSEMBLY AND ASSEMBLY (1) Lubricate the boot outer groove (tie rod) with BOOT SEAL silicone type lubricant. Ensure that the boot is not twisted. REMOVAL (2) On 4x2 vehicles align the breather tube with the reference mark on the steering gear. (1) Remove steering gear.
Page 791 STEERING 19 - 15 STEERING COLUMN TABLE OF CONTENTS page page DESCRIPTION AND OPERATION GEAR SHIFT LEVER ..... . 18 STEERING COLUMN .
Page 792 19 - 16 STEERING DIAGNOSIS AND TESTING (Continued) Fig. 4 Steering Column Flash Removal Fig. 2 Observe Cautions 1 – FILE THIS AREA TO REMOVE FLASHING AND PROVIDE CLEARANCE TO ELIMINATE BINDING 1 – CAUTION: NEVER REMOVE SHAFT LOCK PLATE 2 –...
Page 793 STEERING 19 - 17 REMOVAL AND INSTALLATION (Continued) CAUTION: Failure to follow Group 8 Electrical pro- cedure for clockspring removal, may damage the clockspring plastic latches. Fig. 5 Shift Cable 1 – SHIFT LEVER 2 – STEERING COLUMN 3 – SHIFT CABLE Fig.
Page 794 19 - 18 STEERING REMOVAL AND INSTALLATION (Continued) (7) Install the lower and upper shrouds. (8) Install the PRNDL cable (column shift vehi- cles). Place shifter in Park position. If indicator needs adjusting turn thumb screw on cable retainer to adjust cable.
Page 795 STEERING 19 - 19 REMOVAL AND INSTALLATION (Continued) SPECIFICATIONS TORQUE CHART DESCRIPTION TORQUE Steering Column Steering Wheel Nut ..47 N·m (35 ft. lbs.) Column Bracket Nuts ..12 N·m (105 in. lbs.) Shaft Coupler Bolts .
Page 797: Table Of Contents
TIRES AND WHEELS 22 - 1 TIRES AND WHEELS TABLE OF CONTENTS page page TIRES ........1 WHEELS .
Page 798: Radial-Ply Tires
22 - 2 TIRES AND WHEELS DESCRIPTION AND OPERATION (Continued) SPARE TIRE–TEMPORARY DESCRIPTION The temporary spare tire is designed for emer- gency use only. The original tire should be repaired or replaced at the first opportunity, then reinstalled. Do not exceed speeds of 50 M. P. H. when using the temporary spare tire.
Page 799: Tire Pressure For High Speed
TIRES AND WHEELS 22 - 3 DESCRIPTION AND OPERATION (Continued) Improper inflation can cause: REPLACEMENT TIRES • Uneven wear patterns • Reduced tread life DESCRIPTION • Reduced fuel economy The original equipment tires provide a proper bal- • Unsatisfactory ride ance of many characteristics such as: •...
Page 800: Tire Noise Or Vibration
22 - 4 TIRES AND WHEELS DIAGNOSIS AND TESTING (Continued) SERVICE PROCEDURES ROTATION Tires on the front and rear operate at different loads and perform different steering, driving, and braking functions. For these reasons they wear at unequal rates and tend to develop irregular wear patterns.
Page 801: Repairing Leaks
TIRES AND WHEELS 22 - 5 SERVICE PROCEDURES (Continued) Fig. 6 Tire Rotation Pattern stem location. This reference will ensure that it is remounted in the original position on the wheel. (1) Remove the tire and wheel assembly from the vehicle and mount on a service dynamic balance machine.
Page 802: Cleaning And Inspection Cleaning Tires
22 - 6 TIRES AND WHEELS SERVICE PROCEDURES (Continued) Fig. 10 Tire Repair Area 1 – REPAIRABLE AREA Fig. 9 Remount Tire 90 Degrees In Direction of Arrow 1 – 2ND HIGH SPOT ON TIRE NOTE: DO NOT use gasoline, mineral oil, oil-based 2 –...
Page 803 TIRES AND WHEELS 22 - 7 WHEELS TABLE OF CONTENTS page page DESCRIPTION AND OPERATION SERVICE PROCEDURES WHEEL ....... . . 7 WHEEL INSTALLATION .
Page 804 22 - 8 TIRES AND WHEELS DIAGNOSIS AND TESTING (Continued) • STEEL WHEELS: Radial runout 0.040 in., Lat- eral runout 0.045 in. (maximum) • ALUMINUM WHEELS: Radial runout 0.030 in., Lateral runout 0.035 in. (maximum) (3) If point of greatest wheel lateral runout is near original chalk mark, remount tire 180 degrees.
Page 805 TIRES AND WHEELS 22 - 9 SERVICE PROCEDURES (Continued) WHEEL REPLACEMENT Wheels must be replaced if they have: • Excessive runout • Bent or dented • Leak air through welds • Have damaged bolt holes Wheel repairs employing hammering, heating, or welding are not allowed.
Page 806 22 - 10 TIRES AND WHEELS SERVICE PROCEDURES (Continued) Fig. 6 Static Unbalance & Balance 1 – HEAVY SPOT 4 – CORRECTIVE WEIGHT LOCATION 2 – CENTER LINE OF SPINDLE 5 – TIRE OR WHEEL TRAMP, OR WHEEL HOP 3 – ADD BALANCE WEIGHTS HERE Fig.
Page 807 TIRES AND WHEELS 22 - 11 CAUTION: DO NOT USE CHROME PLATED LUG SPECIFICATIONS NUTS WITH CHROME PLATED WHEELS. TORQUE CHART DESCRIPTION TORQUE Wheel Lug Nut ..115 to 157 N·m (85 to 115 ft. lbs.)
Page 809 BODY 23 - 1 BODY TABLE OF CONTENTS page page SAFETY PRECAUTIONS ..... 1 SEATS ........10 PAINT .
Page 810 23 - 2 BODY PAINT TABLE OF CONTENTS page page DESCRIPTION AND OPERATION PAINTED SURFACE TOUCH-UP ....2 PAINT CODE ......2 AFTERMARKET REPAIR PRODUCTS .
Page 811 BODY 23 - 3 DESCRIPTION AND OPERATION (Continued) (4) Cover the filler/primer with color touch-up described in Step 4. Allow clear top coat to dry hard. paint. Do not overlap touch-up color onto the original If desired, Step 5 can be performed on clear top coat. color coat around the scratch or chip.
Page 812 23 - 4 BODY DESCRIPTION AND OPERATION (Continued) INTERIOR PAINT CODES AND SUPPLIER STOCK NUMBERS AKZO INTERIOR CHRY S-W** SPIES DuPONT NOBEL ICI** COLOR CODE M-S** HECKER SIKKENS 9856 CHALAZI 75016 7WC8 Agate C9208 45994 2–1461 35799 CHARC3I 74339 7WB2 Mist Gray C9507 50508...
Page 813 BODY 23 - 5 STATIONARY GLASS TABLE OF CONTENTS page page DESCRIPTION AND OPERATION REAR DOOR STATIONARY GLASS ... . 7 STATIONARY GLASS ..... . . 5 QUARTER WINDOW GLASS .
Page 814 23 - 6 BODY REMOVAL AND INSTALLATION (Continued) (4) Apply clear glass primer 25 mm (1 in.) wide around perimeter of windshield and wipe with a new clean and dry lint- free cloth. (5) Apply the header molding to the windshield. (6) Apply pinchweld primer 15 mm (.75 in.) wide around the windshield fence.
Page 815 BODY 23 - 7 REMOVAL AND INSTALLATION (Continued) Fig. 5 Applicator Tip 1 – APPLICATOR TIP (8) Separate rearward channel/stationary glass from door. Fig. 3 Center Windshield and Mark at Support (9) Pull to separate stationary glass from run Spacers channel.
Page 816 23 - 8 BODY REMOVAL AND INSTALLATION (Continued) QUARTER WINDOW GLASS Ensure the butyl tape is wrapped around the mount- ing studs. (2) Place glass into opening and insert mounting REMOVAL studs through holes in pinchweld. (1) Remove quarter panel trim. (3) Install nuts attaching quarter window glass to (2) Carefully pull down headliner to access upper pinchweld.
Page 817 BODY 23 - 9 REMOVAL AND INSTALLATION (Continued) (5) Apply a 12 mm (0.4 in.) bead of urethane around window opening fence. Position backlite into window opening (Fig. 9). Fig. 9 Liftgate Backlite 1 – BACKLITE 2 – LIFTGATE Fig. 8 Liftgate Backlite Seals 1 –...
Page 818: Description And Operation Seat Systems
23 - 10 BODY SEATS TABLE OF CONTENTS page page DESCRIPTION AND OPERATION 2ND ROW SEAT BACK ....13 SEAT SYSTEMS......10 2ND ROW SEAT BACK COVER .
Page 819: Towel Bar
BODY 23 - 11 REMOVAL AND INSTALLATION (Continued) BUCKET SEAT BACK COVER/CUSHION NOTE: CLOTH TRIM IS BONDED TO THE CUSHION FOAM. REMOVAL (1) Position seat in full forward position. (2) Disengage J-strap at base of seat back. (3) Using a trim stick, carefully pry off lumbar handle (driver’s side only).
Page 820: Bucket Seat Recliner
23 - 12 BODY REMOVAL AND INSTALLATION (Continued) Fig. 3 Buckle Anchor Bolt Fig. 4 Center Seat/Armrest 1 – ANCHOR BOLT 1 – DRIVERS SEAT 2 – SEAT TRACK 2 – PASSENGER SEAT 3 – SEAT CUSHION 3 – CENTER SEAT 4 –...
Page 821: Center Seat Cushion/Cover
BODY 23 - 13 REMOVAL AND INSTALLATION (Continued) INSTALLATION 2ND ROW SEAT BACK (1) Install the upper latch cover onto the upper REMOVAL latch inertia arm. Ensure the check strap loops under the stud on the side of the lower stanchion/ (1) Tumble seat forward.
Page 822: 2Nd Row Seat Back Cover
23 - 14 BODY REMOVAL AND INSTALLATION (Continued) INSTALLATION (3) Install seat to frame. Refer to 2nd Row Seat Cushion for installation procedures. (1) Position seat back in vehicle. (4) Install latch side shield. (2) Install bolts attaching hinge to seat back. (5) Install tumble release handle.
Page 823: 2Nd Row Center Seat Cushion Cover
BODY 23 - 15 REMOVAL AND INSTALLATION (Continued) (3) Remove bolts attaching outboard tumble latch (3) Install bolts attaching floor latch to seat cush- to seat cushion frame. ion frame (Fig. 11). Tighten bolts to 27 N·m (19 ft. (4) Remove bolts attaching inboard tumble latch to lbs.) torque.
Page 824: 2Nd Row Center Seat Back
23 - 16 BODY REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Transfer applicable components. (2) Install outboard seats. (3) Install 2nd row seat assembly. 2ND ROW CENTER SEAT BACK REMOVAL (1) Tumble outboard seats forward. (2) Remove screw attaching cover to hinge. (3) Using a trim stick, pry trim covers from center seat back to center seat cushion hinge (Fig.
Page 825: Head Restraint Sleeve
BODY 23 - 17 REMOVAL AND INSTALLATION (Continued) INSTALLATION 3RD ROW SEAT BACK (1) Position seat cushion/frame in vehicle. REMOVAL (2) Install the bolts attaching seat cushion/frame to lift bar. Tighten bolts to 24 N·m (17 ft. lbs.) torque. (1) Lift seat cushion upward and move into cargo (3) Place seat cushion in seating position.
Page 826 23 - 18 BODY BODY COMPONENT SERVICE TABLE OF CONTENTS page page DESCRIPTION AND OPERATION REAR DOOR HINGE ..... . 40 BODY COMPONENTS .
Page 827: Body Components
BODY 23 - 19 FLOOR CONSOLE ......62 DOOR ....... . . 67 FLOOR CARPET .
Page 828: Service Procedures
23 - 20 BODY DIAGNOSIS AND TESTING (Continued) • If a leak occurs with the vehicle parked in a sealed location, water could enter through the open- steady light rain, flood the leak area with an open- ing. ended garden hose. •...
Page 829: Removal And Installation
BODY 23 - 21 SERVICE PROCEDURES (Continued) (2) Bend or move the trim panel components at INSTALLATION the heat staked joints. Observe the heat staked loca- (1) Position grille on hood. tions and/or component seams for looseness. (2) Install nuts attaching grille to hood. (3) Heat stake the components.
Page 830: Hood Silencer Pad
23 - 22 BODY REMOVAL AND INSTALLATION (Continued) HOOD SILENCER PAD REMOVAL (1) Raise the hood. (2) Remove the retainers attaching the silencer pad to the hood (Fig. 3). (3) Remove the silencer pad from the hood. Fig. 4 Hood Hinge 1 –...
Page 831: Hood Latch
BODY 23 - 23 REMOVAL AND INSTALLATION (Continued) Fig. 5 Hood Safety Latch Fig. 7 Hood Release Cable 1 – HOOD 1 – HOOD RELEASE CABLE 2 – SAFETY LATCH 2 – HOOD LATCH 3 – HINGE 3 – BOTTOM FLANGE HOOD LATCH (2) Position hood latch on crossmember.
Page 832: Cowl Grille
23 - 24 BODY REMOVAL AND INSTALLATION (Continued) Fig. 8 Hood Release Cable 1 – DASH PANEL Fig. 9 Cowl Grille 2 – HOOD RELEASE CABLE 3 – HOOD RELEASE HANDLE 1 – STUD 4 – INSTRUMENT PANEL 2 – PLASTIC NUT 3 –...
Page 833: Hood Seal
BODY 23 - 25 REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Position cowl seal on flange and press into place. HOOD SEAL REMOVAL (1) Remove push-in fasteners attaching hood seal to inner hood panel (Fig. 11). (2) Separate hood seal from vehicle. INSTALLATION (1) Position hood seal on inner hood panel.
Page 834: Left Front Fender
23 - 26 BODY REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Position liner in wheelhouse. (2) Install plastic rivets attaching wheelhouse liner to wheelhouse. (3) Install wheel opening molding. (4) Install the front wheel. (5) Remove the support and lower the vehicle. LEFT FRONT FENDER REMOVAL (1) Remove battery.
Page 835 BODY 23 - 27 REMOVAL AND INSTALLATION (Continued) (10) Remove bolt attaching fender to lower rocker panel. (11) Remove bolts attaching fender to lower radia- tor closure panel (Fig. 15). (12) Remove bolts attaching fender to hood hinge support bracket. (13) Remove bolts attaching fender to upper cowl.
Page 836: Running Board
23 - 28 BODY REMOVAL AND INSTALLATION (Continued) (10) Install right headlamp module. EXTERIOR NAMEPLATES (11) Install wheelhouse liner. (12) Install wheel opening molding. REMOVAL (13) Install right front wheel. (14) Remove the support and lower the vehicle. NOTE: Exterior nameplates are attached to body (15) Connect battery negative cable.
Page 837 BODY 23 - 29 REMOVAL AND INSTALLATION (Continued) Fig. 17 Running Boards 1 – SCREW 2 – BOLT Fig. 18 Hood/Fender Nameplates 1 – HOOD NAMEPLATE 2 – ENGINE NAMEPLATE...
Page 838: Decals
23 - 30 BODY REMOVAL AND INSTALLATION (Continued) DECALS REMOVAL (1) Warm the panel to approximately 38°C (100°F) using a suitable heat lamp or heat gun. (2) Peel decal from body panel (Fig. 19) and (Fig. 20) using an even pressure pull. (3) Remove adhesive residue from body panel using a suitable adhesive removing solvent.
Page 839: Front Door Trim Panel
BODY 23 - 31 REMOVAL AND INSTALLATION (Continued) Fig. 23 Window Crank—Typical Fig. 22 Side View Mirror Connectors 1 – WINDOW CRANK REMOVAL TOOL 2 – WINDOW CRANK 1 – ELECTRIC FOLD AWAY SIDEVIEW MIRROR 2 – DOOR 3 – ELECTRIC SIDEVIEW MIRROR (4) Engage power mirror wire connector from door harness, if equipped.
Page 840: Front Door
23 - 32 BODY REMOVAL AND INSTALLATION (Continued) Fig. 27 Speaker And Power Mirror Connector Fig. 25 Trim Panel Screw 1 – POWER MIRROR CONNECTOR 1 – INNER DOOR PANEL 2 – TRIM PANEL 2 – INSIDE DOOR HANDLE BRACKET 3 –...
Page 841: Front Door Hinge
BODY 23 - 33 REMOVAL AND INSTALLATION (Continued) FRONT DOOR HINGE REMOVAL (1) Release door latch and open door. (2) Support door on a suitable lifting device. (3) Using a suitable marker, mark the outline of the door hinge on the hinge pillar and door end frame to aid installation.
Page 842 23 - 34 BODY REMOVAL AND INSTALLATION (Continued) Fig. 31 Access Plug 1 – ACCESS PLUG Fig. 33 Lock Cylinder 2 – DOOR 1 – LOCK CYLINDER TO LATCH ROD 2 – STUD 3 – OUTSIDE HANDLE (3) Disengage lock cylinder to latch rod from the 4 –...
Page 843: Lock Cylinders
BODY 23 - 35 REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Push lock cylinder into lock cylinder housing/ outside handle. Ensure the lock cylinder is fully seated in the handle. (2) Install lock cylinder retaining clip. Ensure the clip is fully seated. (3) Engage lock cylinder to latch rod to the lock cylinder.
Page 844: Front Door Inner Belt Weatherstrip
23 - 36 BODY REMOVAL AND INSTALLATION (Continued) FRONT DOOR OUTER BELT WEATHERSTRIP REMOVAL (1) Lower glass. (2) Lift rearward corner of weatherstrip and slide weatherstrip rearward (Fig. 36). INSTALLATION (1) Lightly lubricate weatherstrip with silicone and slide weatherstrip behind mirror. (2) Push weatherstrip down to seat onto door.
Page 845: Front Door Window Regulator
BODY 23 - 37 REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Slowly lower glass into door. (2) Position glass in regulator arm. (3) Install front glass run channel. (4) Install screws attaching glass channel to regu- lator arm. (5) Ensure glass is aligned in run channels and tighten run channel bolts.
Page 846: Front Door Glass Run Weatherstrip
23 - 38 BODY REMOVAL AND INSTALLATION (Continued) (3) Remove door sill trim. (4) Loosen upper and lower B-pillar trim to access weatherstrip. (5) Pull weatherstrip from pinch flange around door opening (Fig. 41). Fig. 40 Lower Glass Run Channels 1 –...
Page 847 BODY 23 - 39 REMOVAL AND INSTALLATION (Continued) (4) Remove screws attaching trim panel to door (Fig. 43). CAUTION: Do not forcibly pull trim panel from door, damage to trim panel may occur. (5) Simultaneously lift upward and outward to release retainer steps from inner door panel (Fig.
Page 848: Rear Door Waterdam
23 - 40 BODY REMOVAL AND INSTALLATION (Continued) (7) Install window crank, if equipped. REAR DOOR WATERDAM REMOVAL (1) Remove door trim panel. (2) Peel the waterdam from the door. (3) Route the latch rods and wire harnesses through the waterdam. (4) Separate the waterdam from the door inner panel (Fig.
Page 849: Rear Door Latch
BODY 23 - 41 REMOVAL AND INSTALLATION (Continued) (4) Disconnect the latch harness connector. (5) Remove screws attaching latch to rear door (Fig. 51). Fig. 48 Latch Rod 1 – OUTSIDE HANDLE 2 – LATCH 3 – LATCH ROD Fig. 50 Rear Door Latch Rods 1 –...
Page 850: Rear Door Inside Handle Actuator
23 - 42 BODY REMOVAL AND INSTALLATION (Continued) (2) Remove bolts attaching striker and shim to C-pillar (Fig. 52). (3) Separate striker from C-pillar. Fig. 53 Inner/Outer Belt Weatherstrip 1 – OUTER BELT WEATHERSTRIP 2 – INNER BELT WEATHERSTRIP Fig. 52 Rear Door Latch Striker INSTALLATION 1 –...
Page 851: Rear Door Glass Run Weatherstrip
BODY 23 - 43 REMOVAL AND INSTALLATION (Continued) Fig. 54 Door Opening Weatherstrip Fig. 56 Rear Door Window Regulator—Power 1 – UPPER BODY SEAL 1 – REAR DOOR POWER REGULATOR 2 – PRIMARY DOOR SEAL 2 – NUT (4) Disengage glass from regulator lift channel. (6) Tighten bolts attaching the regulator to the (5) Position glass up into door frame (rest glass on inner door panel.
Page 852: Rear Door Glass Run Channels
23 - 44 BODY REMOVAL AND INSTALLATION (Continued) INSTALLATION (6) Remove bolts attaching door glass to regulator (Fig. 58). (1) Position weatherstrip in door frame and divider (7) Separate door glass from door. bar channel. (8) Remove bolt attaching bottom of reward run (2) Install outer beltline weatherstrip.
Page 853: Rear Door Secondary Seal
BODY 23 - 45 REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Clean the contact area with Mopar Super Kleen or equivalent. (2) Remove the carrier for the seal (3) Align the seal on the door and press into place. REAR DOOR SECONDARY SEAL REMOVAL (1) Separate the secondary seal from the inner door panel...
Page 854: Wheel Opening Molding
23 - 46 BODY REMOVAL AND INSTALLATION (Continued) (2) Warm the effected stick-on molding and body metal to approximately 38°C (100°F) using a suitable heat lamp or heat gun. (3) Pull stick-on molding from painted surface (Fig. 63). INSTALLATION (1) Clean body surface with MOPAR Super Kleen solvent or equivalent.
Page 855: Fuel Filler Door
BODY 23 - 47 REMOVAL AND INSTALLATION (Continued) FUEL FILLER DOOR REMOVAL (1) Open the fuel filler door. (2) Remove the screws attaching the door to the quarter panel (Fig. 65). (3) Remove the door from the panel. Fig. 66 Wheelhouse Liner 1 –...
Page 856: Liftgate Hinge
23 - 48 BODY REMOVAL AND INSTALLATION (Continued) LIFTGATE HINGE (3) Remove bolt attaching liftgate support cylinder to liftgate (Fig. 70). (4) Remove liftgate support cylinder from liftgate. REMOVAL (1) Remove liftgate upper trim. (2) Remove D-pillar trim. (3) Support liftgate on a suitable lifting device. (4) Using a wax crayon or equivalent, mark the position of the hinge on the liftgate and roof panel.
Page 857: Liftgate
BODY 23 - 49 REMOVAL AND INSTALLATION (Continued) LIFTGATE (3) Lift liftgate watershield to expose liftgate han- dle. (4) Disconnect vehicle security harness connector, REMOVAL if equipped. (1) Remove liftgate upper trim. (5) Disconnect latch rod and actuator rod. (2) Remove D-pillar trim. (6) Remove nuts attaching outside handle to lift- (3) Disconnect liftgate wire harness from body gate (Fig.
Page 858: Liftgate Latch
23 - 50 BODY REMOVAL AND INSTALLATION (Continued) Fig. 74 Liftgate Latch Fig. 73 Liftgate Lock Cylinder 1 – LIFTGATE TO OUTSIDE HANDLE ROD 1 – OUTSIDE HANDLE 2 – LATCH 2 – LOCK CYLINDER 3 – LIFTGATE 3 – ACTUATOR LEVER 4 –...
Page 859: Liftgate Molding
BODY 23 - 51 REMOVAL AND INSTALLATION (Continued) (3) Pull weatherstrip from liftgate opening (Fig. 76). Fig. 77 Liftgate Molding—Typical 1 – LIFTGATE 2 – MOLDING Fig. 76 Liftgate Opening Weatherstrip 1 – LIFTGATE OPENING WEATHERSTRIP (4) Lift one edge of each skid strip with a putty knife and peel it from roof panel.
Page 860: Cowl Trim Cover
23 - 52 BODY REMOVAL AND INSTALLATION (Continued) (3) Remove the carrier backing and press each skid strip onto roof panel with a roller. NOTE: Apply 3M Drip-Chek Sealant (or an equiva- lent product) to side rail screw threads. (4) Position luggage rack on roof. (5) Install screws attaching side rail to roof panel (Fig.
Page 861: B-Pillar Trim
BODY 23 - 53 REMOVAL AND INSTALLATION (Continued) Fig. 81 Rear Door Sill Trim 1 – GROMMET Fig. 82 B-Pillar Trim 2 – DOOR SILL TRIM 1 – TURNING LOOP 3 – REAR DOOR SILL 2 – ADJUSTER 3 – UPPER B-PILLAR TRIM B-PILLAR TRIM 4 –...
Page 862: D-Pillar Trim
23 - 54 BODY REMOVAL AND INSTALLATION (Continued) Fig. 83 C-Pillar Trim 1 – ADJUSTER 6 – BELT ANCHOR 2 – C-PILLAR TRIM 7 – ANTI-RATTLE CUP 3 – TURNING LOOP 8 – RETRACTOR 4 – QUARTER PANEL TRIM 9 – C-PILLAR 5 –...
Page 863: Quarter Panel Trim
BODY 23 - 55 REMOVAL AND INSTALLATION (Continued) Fig. 85 D-Pillar Trim 1 – D-PILLAR 6 – STUD 2 – RETRACTOR 7 – BELT ANCHOR 3 – ANTI-RATTLE CUP 8 – TURNING LOOP 4 – BUCKLE 9 – D-PILLAR TRIM 5 –...
Page 864: Liftgate Scuff Plate
23 - 56 BODY REMOVAL AND INSTALLATION (Continued) LIFTGATE SCUFF PLATE REMOVAL (1) Remove screws attaching cargo tie downs to liftgate scuff plate (Fig. 86). (2) Grasp scuff plate and lift upward to disengage spring clips. (3) Separate scuff plate from liftgate opening. Fig.
Page 865: Front Seat Belt Buckle
BODY 23 - 57 REMOVAL AND INSTALLATION (Continued) (7) Install turning loop cover. (2) Remove bolt attaching seat belt anchor to floor (8) Install front seat belt anchor bolt (Fig. 88). panel. Tighten to 23 N·m (17 ft. lbs.) torque. (3) Remove bolt attaching retractor to C-pillar (9) Install front seat side shield, if equipped.
Page 866 23 - 58 BODY REMOVAL AND INSTALLATION (Continued) Fig. 90 2nd Row Retractor 1 – ADJUSTER 6 – BELT ANCHOR 2 – C-PILLAR TRIM 7 – ANTI-RATTLE CUP 3 – TURNING LOOP 8 – RETRACTOR 4 – QUARTER PANEL TRIM 9 –...
Page 867: 3Rd Row Seat Belt Buckle
BODY 23 - 59 REMOVAL AND INSTALLATION (Continued) Fig. 92 3rd Row Seat Belt Retractor 1 – D-PILLAR 6 – STUD 2 – RETRACTOR 7 – BELT ANCHOR 3 – ANTI-RATTLE CUP 8 – TURNING LOOP 4 – BUCKLE 9 – D-PILLAR TRIM 5 –...
Page 868 23 - 60 BODY REMOVAL AND INSTALLATION (Continued) Fig. 93 3rd Row Seat Belt Buckle 1 – 3RD ROW SEAT BELT BUCKLE 2 – FLOOR PAN Fig. 94 Bucket Seat 1 – COVER 6 – COVER (POWER SEAT) 2 – COVER 7 –...
Page 869: 3Rd Row Seat
BODY 23 - 61 REMOVAL AND INSTALLATION (Continued) (II) Passenger’s front inboard (III) Driver’s front inboard (IV) Passenger’s front outboard Tighten bolts attaching front seat track to floor pan to 28 N·m (20 ft. lbs.) torque. (4) Install front screws attaching trim cover to seat track.
Page 870: Floor Console
23 - 62 BODY REMOVAL AND INSTALLATION (Continued) (c) Left rear bolt (d) Right rear bolt (3) Tighten bolts to 27 N·m (20 ft. lbs.) torque. (4) Move and latch 3rd row seat cushion to seating position. (5) Move and latch 2nd row seat to seating posi- tion.
Page 871: Floor Carpet
BODY 23 - 63 REMOVAL AND INSTALLATION (Continued) (4) Install screws attaching floor console to floor (5) Install B-pillar trim. pan (Fig. 98). (6) Install lower cowl trim. (5) Install forward and rearward cup holder inserts. (7) Tighten gas pedal bracket. (8) Install 3rd row seats, if equipped.
Page 872: Floor Cargo Storage Door
23 - 64 BODY REMOVAL AND INSTALLATION (Continued) FLOOR CARGO STORAGE DOOR (5) Apply adhesive accelerator to the bracket con- tact surface on the windshield glass. Allow the accel- The floor cargo storage door is attached to the erator to dry for one minute. Do not touch the glass cargo area carpet.
Page 873: Coat Hook
BODY 23 - 65 REMOVAL AND INSTALLATION (Continued) Fig. 101 Sunvisor Fig. 103 Coat Hook Removal 1 – SUNVISOR 1 – HEADLINER 2 – COAT HOOK Fig. 102 Sunvisor Support 1 – SUNVISOR SUPPORT BASE Fig. 104 Coat Hook 2 – ROOF PANEL 1 –...
Page 874: Headliner
23 - 66 BODY REMOVAL AND INSTALLATION (Continued) Fig. 105 Overhead Assist Handle Fig. 106 Headliner 1 – RIV-NUT 1 – HEADLINER 2 – OVERHEAD ASSIST HANDLE HEADLINER REMOVAL (1) Disconnect battery negative cable. (2) Remove sunvisors and sunvisor arm supports. (3) Remove coat hooks.
Page 875: Hood Latch Striker
BODY 23 - 67 ADJUSTMENTS (Continued) (3) Close the hood. Adjust the fore/aft position. (5) Test handle button and lock cylinder for proper (4) Raise the hood. Tighten the hinge arm-to-hood operation. panel bolts. (5) Tighten the latch screws. (6) Lower the hood. Inspect clearance between the hood and the cowl cover.
Page 876: Specifications
23 - 68 BODY SPECIFICATIONS WELD LOCATIONS FRONT FENDER AND INNER WHEELHOUSE...
Page 877 BODY 23 - 69 SPECIFICATIONS (Continued) COWL AND DASH PANEL...
Page 878 23 - 70 BODY SPECIFICATIONS (Continued) COWL AND DASH PANEL...
Page 879 BODY 23 - 71 SPECIFICATIONS (Continued) COWL AND DASH PANEL...
Page 880 23 - 72 BODY SPECIFICATIONS (Continued) COWL AND DASH PANEL ROOF PANEL AND ROOF BOWS...
Page 881 BODY 23 - 73 SPECIFICATIONS (Continued) ROOF PANEL AND ROOF BOWS...
Page 882 23 - 74 BODY SPECIFICATIONS (Continued) ROOF PANEL AND ROOF BOWS...
Page 883 BODY 23 - 75 SPECIFICATIONS (Continued) ROOF PANEL AND ROOF BOWS...
Page 884 23 - 76 BODY SPECIFICATIONS (Continued) BODY SIDE APERTURE...
Page 885 BODY 23 - 77 SPECIFICATIONS (Continued) BODY SIDE APERTURE...
Page 886 23 - 78 BODY SPECIFICATIONS (Continued) BODY SIDE APERTURE...
Page 887 BODY 23 - 79 SPECIFICATIONS (Continued) BODY SIDE APERTURE...
Page 888 23 - 80 BODY SPECIFICATIONS (Continued) BODY SIDE APERTURE...
Page 889 BODY 23 - 81 SPECIFICATIONS (Continued) BODY SIDE APERTURE...
Page 890 23 - 82 BODY SPECIFICATIONS (Continued) BODY SIDE APERTURE...
Page 891 BODY 23 - 83 SPECIFICATIONS (Continued) BODY SIDE APERTURE...
Page 892 23 - 84 BODY SPECIFICATIONS (Continued) BODY SIDE APERTURE...
Page 893 BODY 23 - 85 SPECIFICATIONS (Continued) BODY SIDE APERTURE...
Page 894 23 - 86 BODY SPECIFICATIONS (Continued) BODY SIDE APERTURE...
Page 895 BODY 23 - 87 SPECIFICATIONS (Continued) BODY SIDE APERTURE...
Page 896 23 - 88 BODY SPECIFICATIONS (Continued) FLOOR PAN...
Page 897 BODY 23 - 89 SPECIFICATIONS (Continued) FLOOR PAN...
Page 898 23 - 90 BODY SPECIFICATIONS (Continued) FLOOR PAN...
Page 899 BODY 23 - 91 SPECIFICATIONS (Continued) FLOOR PAN...
Page 900 23 - 92 BODY SPECIFICATIONS (Continued) FLOOR PAN...
Page 901 BODY 23 - 93 SPECIFICATIONS (Continued) FLOOR PAN...
Page 902 23 - 94 BODY SPECIFICATIONS (Continued) FLOOR PAN...
Page 903 BODY 23 - 95 SPECIFICATIONS (Continued) FLOOR PAN...
Page 904 23 - 96 BODY SPECIFICATIONS (Continued) FLOOR PAN...
Page 905 BODY 23 - 97 SPECIFICATIONS (Continued) LIFTGATE OPENING...
Page 906 23 - 98 BODY SPECIFICATIONS (Continued) LIFTGATE OPENING...
Page 907 BODY 23 - 99 SPECIFICATIONS (Continued) LIFTGATE OPENING...
Page 908: Structural Adhesive Locations
23 - 100 BODY SPECIFICATIONS (Continued) STRUCTURAL ADHESIVE LOCATIONS ROOF PANEL...
Page 909: Body Sealing Locations
BODY 23 - 101 SPECIFICATIONS (Continued) BODY SEALING LOCATIONS APPLICATION METHODS...
Page 910 23 - 102 BODY SPECIFICATIONS (Continued) COWL AND DASH PANEL...
Page 911 BODY 23 - 103 SPECIFICATIONS (Continued) COWL AND DASH PANEL...
Page 912 23 - 104 BODY SPECIFICATIONS (Continued) A—PILLAR AND FRONT BODY AREA...
Page 913 BODY 23 - 105 SPECIFICATIONS (Continued) B—PILLAR AND FLOOR AREA...
Page 914 23 - 106 BODY SPECIFICATIONS (Continued) FLOOR PAN ROOF PANEL...
Page 915 BODY 23 - 107 SPECIFICATIONS (Continued) RIGHT OUTER WHEELHOUSE AND REAR UNDERBODY...
Page 916 23 - 108 BODY SPECIFICATIONS (Continued) RIGHT OUTER WHEELHOUSE...
Page 917 BODY 23 - 109 SPECIFICATIONS (Continued) FLOOR AND INNER QUARTER AREA...
Page 918 23 - 110 BODY SPECIFICATIONS (Continued) LEFT OUTER WHEELHOUSE...
Page 919 BODY 23 - 111 SPECIFICATIONS (Continued) LEFT OUTER WHEELHOUSE...
Page 920 23 - 112 BODY SPECIFICATIONS (Continued) LEFT INNER QUARTER AREA...
Page 921 BODY 23 - 113 SPECIFICATIONS (Continued) LIFTGATE OPENING AREA TAIL LAMP AREA...
Page 922 23 - 114 BODY SPECIFICATIONS (Continued) FRONT DOORS...
Page 923 BODY 23 - 115 SPECIFICATIONS (Continued) REAR DOOR...
Page 924 23 - 116 BODY SPECIFICATIONS (Continued) LIFTGATE...
Page 925: Body Gap And Flush Measurements
BODY 23 - 117 SPECIFICATIONS (Continued) BODY GAP AND FLUSH MEASUREMENTS FRONT GAP AND FLUSH MEASUREMENTS LOCATION FLUSH Front Door to Windshield Pillar Front Door to Roof Front Door to Rear Door Front Door to Aperture at Sill Front Door to Fender Hood to Fender Headlamp to Fender Headlamp to Grille...
Page 926 23 - 118 BODY SPECIFICATIONS (Continued) REAR GAP AND FLUSH MEASUREMENTS LOCATION FLUSH Rear Door to Aperture Liftgate to Roof Liftgate to Aperture Liftgate to Fascia 19.0 Taillamp to Liftgate Taillamp to Quarter Panel Aperture to Rear Fascia 17.3 3.0 Rear Door to Quarter Panel...
Page 927: Body Opening Dimensions
BODY 23 - 119 SPECIFICATIONS (Continued) BODY OPENING DIMENSIONS WINDSHIELD OPENING DOOR OPENING...
Page 928 23 - 120 BODY SPECIFICATIONS (Continued) QUARTER WINDOW OPENING ENGINE COMPARTMENT OPENING...
Page 929 BODY 23 - 121 SPECIFICATIONS (Continued) BACKLITE OPENING LIFTGATE OPENING...
Page 930: Torque Specifications
23 - 122 BODY SPECIFICATIONS (Continued) TORQUE SPECIFICATIONS DESCRIPTION TORQUE Side rear view mirror ..7 N·m (65 in. lbs.) BODY COMPONENTS Tumble latch to seat cushion frame bolt . . . 27 N·m (19 ft.
Page 931 HEATING AND AIR CONDITIONING 24 - 1 HEATING AND AIR CONDITIONING TABLE OF CONTENTS page page DESCRIPTION AND OPERATION DUAL FUNCTION HIGH PRESSURE BLOWER MOTOR ......2 SWITCH/HIGH PRESSURE CUT-OFF BLOWER MOTOR RELAY .
Page 932: Description And Operation Blower Motor
24 - 2 HEATING AND AIR CONDITIONING UNDERBODY REFRIGERANT LINE... 69 SPECIFICATIONS VACUUM CHECK VALVE ....70 A/C APPLICATION TABLE .
Page 933: Blower Motor Resistor
HEATING AND AIR CONDITIONING 24 - 3 DESCRIPTION AND OPERATION (Continued) plastic inside the glove box opening, next to the left- side energy-absorbing bracket (Fig. 1). Refer to the PDC label for blower motor relay identification and location. The blower motor relay (VRR) cannot be repaired and, if faulty or damaged, it must be replaced.
Page 934: Blower Motor Switch
24 - 4 HEATING AND AIR CONDITIONING DESCRIPTION AND OPERATION (Continued) The blower motor resistor cannot be repaired and, OPERATION if faulty or damaged, it must be replaced. The compressor is driven by the engine through an electric clutch, drive pulley and belt arrangement. BLOWER MOTOR SWITCH The compressor is lubricated by refrigerant oil that is circulated throughout the refrigerant system with the...
Page 935: Compressor Clutch Relay
HEATING AND AIR CONDITIONING 24 - 5 DESCRIPTION AND OPERATION (Continued) energized, it magnetically draws the clutch into con- OPERATION tact with the pulley and drives the compressor shaft. When the refrigerant gas gives up its heat, it con- When the coil is not energized, the pulley freewheels denses.
Page 936: Evaporator Coil
24 - 6 HEATING AND AIR CONDITIONING DESCRIPTION AND OPERATION (Continued) EVAPORATOR COIL EXPANSION VALVE FRONT FRONT DESCRIPTION DESCRIPTION The evaporator coil is located in the heater-A/C The front “H” valve-type thermal expansion valve housing, under the instrument panel. The evaporator (TXV) is located at the dash panel between the liquid coil is positioned in the heater-A/C housing so that and suction lines, and the evaporator coil.
Page 937: Heater And Air Conditioner
HEATING AND AIR CONDITIONING 24 - 7 DESCRIPTION AND OPERATION (Continued) OPERATION on the heater-A/C control panel. The air intake open- ings must be kept free of snow, ice, leaves, and other The filter-drier performs a filtering action to pre- obstructions for the heater-A/C system to receive a vent foreign material in the refrigerant from contam- sufficient volume of outside air.
Page 938: Heater And Air Conditioner Control
24 - 8 HEATING AND AIR CONDITIONING DESCRIPTION AND OPERATION (Continued) heated air. This air conditioning system uses a ther- HIGH PRESSURE CUT-OFF SWITCH mal expansion valve between the condenser and the evaporator coil to meter refrigerant flow to the evap- DESCRIPTION orator coil.
Page 939: Low Pressure Cut-Off Switch
HEATING AND AIR CONDITIONING 24 - 9 DESCRIPTION AND OPERATION (Continued) turbed. The valve is only serviced as a part of the adjustable outlet barrels toward the rear of the unit. compressor assembly. A condensate tray is integral to the lower unit hous- ing, and water is drained out of the unit through LOW PRESSURE CUT-OFF SWITCH hoses located behind the trim on each of the B-pil-...
Page 940: Refrigerant Line Couplers
24 - 10 HEATING AND AIR CONDITIONING DESCRIPTION AND OPERATION (Continued) refrigerant hoses are made from lightweight alumi- num or steel, and commonly use braze-less fittings. Any kinks or sharp bends in the refrigerant plumb- ing will reduce the capacity of the entire air condi- tioning system.
Page 941: Refrigerant System Service Ports
HEATING AND AIR CONDITIONING 24 - 11 DESCRIPTION AND OPERATION (Continued) REFRIGERANT SYSTEM SERVICE PORTS OPERATION Engine vacuum is stored in the vacuum reservoir. DESCRIPTION The stored vacuum is used to operate the vacuum- controlled vehicle accessories during periods of low The two refrigerant system service ports are used engine vacuum such as when the vehicle is climbing to charge, recover/recycle, evacuate, and test the air...
Page 942 24 - 12 HEATING AND AIR CONDITIONING DIAGNOSIS AND TESTING (Continued) Review the Service Warnings and Precautions in headliner for testing of the rear unit. Operate the the General Information section near the front of this engine for five minutes. group before performing this procedure.
Page 943 HEATING AND AIR CONDITIONING 24 - 13 DIAGNOSIS AND TESTING (Continued) A/C Diagnosis CONDITION POSSIBLE CAUSE CORRECTION RAPID COMPRESSOR 1. Low refrigerant system 1. See Refrigerant System Leaks in the Diagnosis and CLUTCH CYCLING (TEN charge. Testing section of this group. Test the refrigerant system OR MORE CYCLES PER 2.
Page 944 24 - 14 HEATING AND AIR CONDITIONING DIAGNOSIS AND TESTING (Continued) A/C Diagnosis CONDITION POSSIBLE CAUSE CORRECTION LOW SIDE PRESSURE 1. Low refrigerant system 1. See Refrigerant System Leaks in the Diagnosis and IS NORMAL OR charge. Testing section of this group. Test the refrigerant system SLIGHTLY LOW, AND 2.
Page 945: Blower Motor
HEATING AND AIR CONDITIONING 24 - 15 DIAGNOSIS AND TESTING (Continued) BLOWER MOTOR front blower is the source of the noise, unplug the front blower motor wire harness connector and oper- ate the heater-A/C system. If the noise goes away, WARNING: ON VEHICLES EQUIPPED WITH AIR- possible causes include: BAGS, REFER TO PASSIVE RESTRAINT SYSTEMS...
Page 946: Blower Motor Resistor
24 - 16 HEATING AND AIR CONDITIONING DIAGNOSIS AND TESTING (Continued) for the relay electromagnetic coil. There should be continuity between the PDC cavity for relay terminal 85 and a good ground at all times. If not OK, repair the open circuit as required. ADDITIONAL RELAY CIRCUIT TESTING •...
Page 947: Blower Motor Switch
HEATING AND AIR CONDITIONING 24 - 17 DIAGNOSIS AND TESTING (Continued) (2) Unplug the wire harness connector from the (1) Turn the ignition switch to the Off position. blower motor resistor. Disconnect and isolate the battery negative cable. (3) Check for continuity between each of the Remove the rear blower motor switch from the head- blower motor switch input terminals of the resistor liner.
Page 948: Compressor Clutch Coil
24 - 18 HEATING AND AIR CONDITIONING DIAGNOSIS AND TESTING (Continued) clutch plate and pulley are properly aligned and have repair as required. If there is no voltage reading at the correct air gap. See Compressor and Compressor the clutch coil, use a DRB scan tool and the proper Clutch in the Removal and Installation section of this Diagnostic Procedures manual for testing of the com- group for the procedures.
Page 949: Electronic Cycling Clutch Switch (Front Unit Only)
HEATING AND AIR CONDITIONING 24 - 19 DIAGNOSIS AND TESTING (Continued) ing Diagrams. Use a volt/ohmmeter to test the elec- tronic cycling clutch switch. Verify that refrigerant system has the correct refrigerant charge. Check that both the low and high pressure cut-off switches are functional as described in the Diagnosis and Testing section of this group before testing the electronic cycling clutch switch.
Page 950: Heater-A/C Control
24 - 20 HEATING AND AIR CONDITIONING DIAGNOSIS AND TESTING (Continued) FRONT (ONLY) sufficient reheat to load the front and rear evapora- tors. The discharge pressure (high side) at the service (1) Attach a manifold gauge set. Close the vehicle port should reach 966 to 1656 kPa (140 to 240 psi).
Page 951: Heater Performance
HEATING AND AIR CONDITIONING 24 - 21 DIAGNOSIS AND TESTING (Continued) knob travel in each direction, with no spring-back of to normal idle. The vacuum will be high at low idle the knob. If not OK, inspect the condition, routing, and the vacuum actuators should respond quickly.
Page 952: Dual Function High Pressure Switch/High Pressure Cut-Off Switch
24 - 22 HEATING AND AIR CONDITIONING DIAGNOSIS AND TESTING (Continued) • A faulty, obstructed or improperly installed heater-A/C control panel, the following could require blend-air door. service: • The temperature control cable is not connected, • A faulty heater-A/C control. •...
Page 953: Refrigerant System Leaks
HEATING AND AIR CONDITIONING 24 - 23 DIAGNOSIS AND TESTING (Continued) (1) Disconnect and isolate the battery negative SYSTEM EMPTY cable. (1) Evacuate the refrigerant system. See Refriger- (2) Unplug the low pressure cut-off switch wire ant System Evacuate in the Service Procedures sec- harness connector from the switch on the suction line tion of this group.
Page 954: Refrigerant System Service Equipment
24 - 24 HEATING AND AIR CONDITIONING DIAGNOSIS AND TESTING (Continued) the lowest speed position, and the mode control switch to the recirculation mode (Max-A/C). REFRIGERANT SYSTEM SERVICE EQUIPMENT WARNING: EYE PROTECTION MUST BE WORN WHEN SERVICING AN AIR CONDITIONING REFRIG- ERANT SYSTEM.
Page 955 HEATING AND AIR CONDITIONING 24 - 25 DIAGNOSIS AND TESTING (Continued) exact 27 kPa (8 in. Hg.) setting. Otherwise, a false return to the 27 kPa (8 in. Hg.) setting shortly after reading will be obtained during testing. each selection is made. If not OK, a component or vacuum line in the vacuum circuit of the selected mode has a leak.
Page 956 24 - 26 HEATING AND AIR CONDITIONING DIAGNOSIS AND TESTING (Continued) (3) Determine the vacuum line color of the vacuum each connection is made. If OK, replace the faulty circuit that is leaking. To determine the vacuum line disconnected component. If not OK, go to Step 6. colors, see the Vacuum Circuits chart (Fig.
Page 957 HEATING AND AIR CONDITIONING 24 - 27 DIAGNOSIS AND TESTING (Continued) VACUUM CIRCUIT LEGEND I.D. FUNCTION COLOR Recirculation Actuator Light Green (Door Closed) Floor-Defrost Actuator Yellow (Mid Position Panel-Defrost Actuator Brown (Full Position) Floor-Defrost Actuator Blue (Full Position) Vacuum Supply Black (Reservoir) Panel-Defrost Actuator...
Page 958: Service Procedures Refrigerant Oil Level
24 - 28 HEATING AND AIR CONDITIONING REFRIGERANT RECOVERY SERVICE PROCEDURES REFRIGERANT OIL LEVEL WARNING: REVIEW THE WARNINGS AND CAU- TIONS IN THE GENERAL INFORMATION SECTION When an air conditioning system is assembled at NEAR THE FRONT OF THIS GROUP BEFORE the factory, all components except the compressor are RECOVERING REFRIGERANT.
Page 959: Removal And Installation
HEATING AND AIR CONDITIONING 24 - 29 SERVICE PROCEDURES (Continued) • AVOID BREATHING THE REFRIGERANT AND (1) Connect a R-134a refrigerant recovery/recy- cling/charging station that meets SAE Standard REFRIGERANT OIL VAPOR OR MIST. EXPOSURE J2210 and a manifold gauge set to the refrigerant MAY IRRITATE THE EYES, NOSE, AND/OR THROAT.
Page 960 24 - 30 HEATING AND AIR CONDITIONING REMOVAL AND INSTALLATION (Continued) CAUTION: after using. Store refrigerant oil only in a clean, air- • Liquid refrigerant is corrosive to metal sur- tight, and moisture-free container. • Keep service tools and the work area clean. faces.
Page 961: B-Pillar Refrigerant Line
HEATING AND AIR CONDITIONING 24 - 31 REMOVAL AND INSTALLATION (Continued) as a fitting is loosened, tighten the fitting and refrigerant line coupler at the B-pillar suction line. recover the refrigerant from the system again. See Refrigerant Line Coupler in the Removal and Do not discharge refrigerant into the atmosphere.
Page 962: Blower Motor
24 - 32 HEATING AND AIR CONDITIONING REMOVAL AND INSTALLATION (Continued) (4) Position the B-pillar refrigerant line clamp and seal over the hole in the floor panel and secure it with two screws. Tighten the mounting screws to 2.2 N·m (20 in. lbs.). (5) Position the B-pillar refrigerant line over the mounting holes in the inner B-pillar and secure with a screw.
Page 963 HEATING AND AIR CONDITIONING 24 - 33 REMOVAL AND INSTALLATION (Continued) (4) Pull the blower motor wiring through the hole from the dash panel side of the heater-A/C housing until the grommet is seated, while positioning the blower motor and blower wheel assembly inside the housing.
Page 964: Blower Motor Relay
24 - 34 HEATING AND AIR CONDITIONING REMOVAL AND INSTALLATION (Continued) (4) Remove the nine screws that secure the lower (9) Remove the four screws that secure the rear housing cover to the rear overhead A/C unit. blower motor, wheel and housing unit to the rear (5) Release the lower housing cover snap retainer overhead A/C unit upper housing cover.
Page 965: Blower Motor Resistor
HEATING AND AIR CONDITIONING 24 - 35 REMOVAL AND INSTALLATION (Continued) (3) Using a short or 90 degree screwdriver, remove the front blower motor resistor to the cowl plenum the screw that secures the blower motor relay (VRR) panel. to the steel clip in the instrument panel plastic flange.
Page 966 24 - 36 HEATING AND AIR CONDITIONING REMOVAL AND INSTALLATION (Continued) (3) Disconnect the B-pillar drain hoses from the (6) Feed the rear blower motor switch wire har- wye fittings on each side of the rear overhead A/C ness and connector through the hole in the right end unit (Fig.
Page 967: Compressor
HEATING AND AIR CONDITIONING 24 - 37 REMOVAL AND INSTALLATION (Continued) (5) Be certain that the lower housing cover snap REMOVAL retainer near the center of the outlet side (rear) of (1) Recover the refrigerant from the refrigerant the rear overhead A/C unit is engaged. system.
Page 968: Compressor Clutch
24 - 38 HEATING AND AIR CONDITIONING REMOVAL AND INSTALLATION (Continued) INSTALLATION NOTE: If replacement compressor being installed, be certain to check the refrigerant oil level. See Refrigerant Oil Level in the Service Pro- cedures section of this group. Use only refrigerant oil of the type recommended for the compressor in the vehicle.
Page 969 HEATING AND AIR CONDITIONING 24 - 39 REMOVAL AND INSTALLATION (Continued) Fig. 30 Clutch Coil Lead Wire Harness Fig. 28 Shaft Protector and Puller 1 – CLIP 1 – PULLER SHAFT PROTECTOR 2 – JAWS Fig. 31 Clutch Field Coil Snap Ring Remove 1 –...
Page 970 24 - 40 HEATING AND AIR CONDITIONING REMOVAL AND INSTALLATION (Continued) Check the clutch pulley bearing for roughness or excessive leakage of grease. Replace the bearing, if required. INSTALLATION (1) Install the clutch field coil and snap ring. (2) Install the clutch coil lead wire harness retain- ing clip on the compressor front housing and tighten the retaining screw.
Page 971: Compressor Clutch Relay
HEATING AND AIR CONDITIONING 24 - 41 REMOVAL AND INSTALLATION (Continued) tion, add or subtract shims as required. The air gap specification is 0.41 to 0.79 millimeter (0.016 to 0.031 inch). If the air gap is not consistent around the cir- cumference of the clutch, lightly pry up at the mini- mum variations.
Page 972 24 - 42 HEATING AND AIR CONDITIONING REMOVAL AND INSTALLATION (Continued) (3) Disconnect the refrigerant line fitting that secures the discharge line to the condenser inlet (Fig. 37). Install plugs in, or tape over all of the opened refrigerant line fittings. Fig.
Page 973: Ducts And Outlets
HEATING AND AIR CONDITIONING 24 - 43 REMOVAL AND INSTALLATION (Continued) NOTE: If the condenser is replaced, add 30 millili- ters (1 fluid ounce) of refrigerant oil to the refriger- ant system. Use only refrigerant oil of the type recommended for the compressor in the vehicle. DUCTS AND OUTLETS WARNING: ON VEHICLES EQUIPPED WITH AIR- BAGS,...
Page 974 24 - 44 HEATING AND AIR CONDITIONING REMOVAL AND INSTALLATION (Continued) REAR SEAT FLOOR DUCT CONTROL REAR SEAT FLOOR DUCT The rear seat floor duct damper door is only ser- SPLIT BENCH SEAT viced as part of the rear seat floor duct on bench seat (1) Remove the three retainers that secure the models, or the center seat floor duct on bucket seat HVAC rear bezel to the brackets near the back of the...
Page 975 HEATING AND AIR CONDITIONING 24 - 45 REMOVAL AND INSTALLATION (Continued) Fig. 42 Rear Seat Floor Duct Control - Bucket Seat 1 – SCREW 6 – DAMPER DOOR PIVOT 2 – SCREW 7 – BASE PLATE 3 – UPPER REAR PANEL 8 –...
Page 976 24 - 46 HEATING AND AIR CONDITIONING REMOVAL AND INSTALLATION (Continued) Fig. 44 Rear Seat Floor Ducts Remove/Install - Bucket Seat 1 – RETAINER 4 – RETAINER 2 – FRONT TUNNEL DUCT 5 – CENTER SEAT FLOOR DUCT 3 – REAR SEAT FLOOR DUCT (5) Remove the demister duct hose from the demis- ter duct tee near the underside of the instrument panel top cover.
Page 977 HEATING AND AIR CONDITIONING 24 - 47 REMOVAL AND INSTALLATION (Continued) Fig. 46 Demister Ducts Remove/Install Fig. 47 Heater-A/C Housing Plenum Adapter 1 – DEMISTER DUCT TEE Remove/Install 2 – INSTRUMENT PANEL TOP COVER 1 – PLENUM PANEL 3 – LEFT DEMISTER DUCT 2 –...
Page 978: Electronic Cycling Clutch Switch
24 - 48 HEATING AND AIR CONDITIONING REMOVAL AND INSTALLATION (Continued) (2) Remove the rear overhead A/C outlet bezel (2) Install the electronic cycling clutch switch to from the headliner mounting hole. the expansion valve and secure it with a new fas- (3) Reverse the removal procedures to install.
Page 979 HEATING AND AIR CONDITIONING 24 - 49 REMOVAL AND INSTALLATION (Continued) INSTALLATION (1) Insert the front evaporator coil into the bottom of the heater-A/C housing. (2) Reassemble and reinstall the heater-A/C hous- ing in the vehicle. See Heater-A/C Housing in the Removal and Installation section of this group for the procedures.
Page 980 24 - 50 HEATING AND AIR CONDITIONING REMOVAL AND INSTALLATION (Continued) Fig. 53 Rear Overhead A/C Unit Lower Housing Fig. 55 Rear Evaporator Coil Remove/Install Cover Remove/Install 1 – BLOWER WHEEL AND HOUSING 1 – REAR OVERHEAD A/C UNIT LOWER HOUSING COVER 2 –...
Page 981: Expansion Valve
HEATING AND AIR CONDITIONING 24 - 51 REMOVAL AND INSTALLATION (Continued) EXPANSION VALVE of the expansion valve. Install the expansion valve to the evaporator tube mounting flange and secure with two screws. Tighten the mounting screws to 11.4 N·m FRONT (100 in.
Page 982: Filter-Drier
24 - 52 HEATING AND AIR CONDITIONING REMOVAL AND INSTALLATION (Continued) and outlet (Fig. 58). Disengage the block fittings from the filter-drier. Install plugs in, or tape over all of the opened refrigerant line fittings. Fig. 57 REAR EXPANSION VALVE REMOVAL/ INSTALL Fig.
Page 983: Heater-A/C Control
HEATING AND AIR CONDITIONING 24 - 53 REMOVAL AND INSTALLATION (Continued) (6) Evacuate the refrigerant system. See Refriger- ant System Evacuate in the Service Procedures sec- tion of this group. (7) Charge the refrigerant system. See Refrigerant System Charge in the Service Procedures section of this group.
Page 984: Heater-A/C Housing
24 - 54 HEATING AND AIR CONDITIONING REMOVAL AND INSTALLATION (Continued) (2) Connect the temperature control cable housing (4) Remove the front expansion valve from the flag retainer to the receptacle on the back of the evaporator tube mounting flange. See Expansion heater-A/C control.
Page 985 HEATING AND AIR CONDITIONING 24 - 55 REMOVAL AND INSTALLATION (Continued) Fig. 61 Heater-A/C Housing Remove/Install 1 – STUD 4 – NUT 2 – BRACE 5 – NUT 3 – HEATER-A/C HOUSING Fig. 62 Heater-A/C Housing Floor Outlet Screws Fig. 63 Blend-Air Door Lever Remove/Install 1 –...
Page 986 24 - 56 HEATING AND AIR CONDITIONING REMOVAL AND INSTALLATION (Continued) (12) Gently pry off the push nut that secures the heater-A/C housing cover to the heater-A/C housing post. (13) Using a trim stick or another suitable wide flat-bladed tool, gently pry the panel-defrost door lever off of the panel-defrost door pivot shaft (Fig.
Page 987: Heater-A/C Housing Door
HEATING AND AIR CONDITIONING 24 - 57 REMOVAL AND INSTALLATION (Continued) drain tube and the housing mounting studs are inserted into their correct mounting holes. (2) Install the nut that secures the heater-A/C housing mounting brace to the stud on the passenger compartment side of the dash panel.
Page 988 24 - 58 HEATING AND AIR CONDITIONING REMOVAL AND INSTALLATION (Continued) Fig. 68 Blend-Air Door Remove/Install 1 – BLEND-AIR DOOR 2 – EVAPORATOR COIL Fig. 69 Floor-Defrost Door Remove/Install FLOOR-DEFROST DOOR 1 – PUSH-NUT 2 – ACTUATOR LINK (1) Remove the heater-A/C housing from the vehi- 3 –...
Page 989: Heater Core
HEATING AND AIR CONDITIONING 24 - 59 REMOVAL AND INSTALLATION (Continued) (3) Lift the lower end of the recirculation air door up far enough so that the door lever is clear of the recirculation air intake grille, then twist the door to remove the door pivots from the pivot holes in the blower motor housing cover (Fig.
Page 990: Liquid Line
24 - 60 HEATING AND AIR CONDITIONING REMOVAL AND INSTALLATION (Continued) Install plugs in, or tape over all of the opened refrig- erant line fittings. (4) Disconnect the front liquid line refrigerant line coupler at the condenser outlet. See Refrigerant Line Coupler in the Removal and Installation section of this group for the procedures.
Page 991 HEATING AND AIR CONDITIONING 24 - 61 REMOVAL AND INSTALLATION (Continued) Fig. 74 Liquid Line Remove/Install 1 – FRONT LIQUID LINE 9 – LIQUID LINE EXTENSION 2 – SCREW 10 – NUT 3 – HIGH PRESSURE SERVICE PORT 11 – EXPANSION VALVE 4 –...
Page 992: Low Pressure Cut-Off Switch
24 - 62 HEATING AND AIR CONDITIONING REMOVAL AND INSTALLATION (Continued) outlet and secure the connection with a screw. (4) Remove the O-ring seal from the suction line Tighten the mounting screw to 13.5 N·m (120 in. jumper fitting and discard. lbs.).
Page 993: Rear Blower Motor Switch
HEATING AND AIR CONDITIONING 24 - 63 REMOVAL AND INSTALLATION (Continued) Fig. 77 Panel-Defrost Door Actuator 1 – VACUUM CONNECTOR 2 – SCREW 3 – PANEL-DEFROST DOOR ACTUATOR Fig. 76 Floor-Defrost Door Actuator Remove/Install 4 – SCREW 5 – DEMISTER DUCT ADAPTER 1 –...
Page 994: Rear Overhead A/C Unit
24 - 64 HEATING AND AIR CONDITIONING REMOVAL AND INSTALLATION (Continued) (4) Remove the rear blower motor switch from the headliner. INSTALLATION (1) Plug the wire harness connector into the back of the rear blower motor switch. (2) Tuck the wire harness back through the rear blower motor switch mounting hole in the headliner.
Page 995 HEATING AND AIR CONDITIONING 24 - 65 REMOVAL AND INSTALLATION (Continued) Fig. 82 Rear Overhead A/C Unit Remove/Install 1 – ROOF PANEL Fig. 80 Rear Overhead A/C Unit Refrigerant Line 2 – SCREWS Remove/Install 3 – REAR OVERHEAD A/C UNIT 1 –...
Page 996: Refrigerant Line Coupler
24 - 66 HEATING AND AIR CONDITIONING REMOVAL AND INSTALLATION (Continued) NOTE: If the rear overhead A/C unit is replaced, NOTE: The garter spring may not release if the A/C add 30 milliliters (1 fluid ounce) of refrigerant oil to line disconnect tool is cocked while pushing it into the refrigerant system.
Page 997: Suction Line Jumper
HEATING AND AIR CONDITIONING 24 - 67 REMOVAL AND INSTALLATION (Continued) High pressures are produced in the refrigerant sys- tem when the air conditioning compressor is operat- ing. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free.
Page 998: Temperature Control Cable
24 - 68 HEATING AND AIR CONDITIONING REMOVAL AND INSTALLATION (Continued) (5) Remove the rear liquid line from the engine tion section of Group 8E - Instrument Panel Systems compartment. See Liquid Line in the Removal and for the procedures. Installation section of this group for the procedures.
Page 999 HEATING AND AIR CONDITIONING 24 - 69 REMOVAL AND INSTALLATION (Continued) Fig. 86 Temperature Control Cable Self-Adjuster Clip 1 – SELF-ADJUSTER CLIP 3 – HEATER-A/C CONTROL CABLE HOUSING FLAG RETAINER- CONTROL END 2 – HEATER-A/C CONTROL CABLE HOUSING FLAG RETAINER- HOUSING END 4 –...
Page 1000 24 - 70 HEATING AND AIR CONDITIONING REMOVAL AND INSTALLATION (Continued) Fig. 87 Underbody Refrigerant Line Remove/Install 1 – SUCTION LINE JUMPER 8 – CLIP 2 – FRONT EXPANSION VALVE 9 – B-PILLAR REFRIGERANT LINES 3 – LIQUID LINE EXTENSION 10 –...
Page 1001 HEATING AND AIR CONDITIONING 24 - 71 REMOVAL AND INSTALLATION (Continued) Fig. 88 Vacuum Supply 1 – VACUUM CHECK VALVE 4 – VACUUM SUPPLY LINE 2 – CLIP 5 – TO SPEED CONTROL SERVO 3 – TO HEATER-AC CONTROLS 6 – GROMMET (3) Remove the weatherstrip along the front edge cowl top panel near the base of the windshield (Fig.
Page 1002 24 - 72 HEATING AND AIR CONDITIONING REMOVAL AND INSTALLATION (Continued) Fig. 90 Cowl Plenum Cover/Grille Panel Remove/Install 1 – IN-LINE WASHER SUPPLY HOSE CONNECTOR 5 – COWL PLENUM COVER/GRILLE PANEL 2 – STUD 6 – PLASTIC RIVET 3 – PUSH-IN PLASTIC RETAINER 7 –...
Page 1003 HEATING AND AIR CONDITIONING 24 - 73 ADJUSTMENTS (Continued) in the Removal and Installation section of this group SPECIFICATIONS for the procedures. (2) Rotate the temperature control knob on the A/C APPLICATION TABLE heater-A/C control so that the knob pointer is in the 12 o’clock position.
Page 1005: On-Board Diagnostics
EMISSION CONTROL SYSTEMS 25 - 1 EMISSION CONTROL SYSTEMS TABLE OF CONTENTS page page ON-BOARD DIAGNOSTICS ....1 EVAPORATIVE EMISSION CONTROLS ..24 ON-BOARD DIAGNOSTICS TABLE OF CONTENTS page...
Page 1006: Description And Operation
25 - 2 EMISSION CONTROL SYSTEMS DESCRIPTION AND OPERATION (Continued) Technicians must retrieve stored DTC’s by connect- an open circuit, a short circuit, or a defective switch. ing the DRB scan tool (or an equivalent scan tool) to If the State Display screen shows the change from the 16–way data link connector (Fig.
Page 1007: Diagnostic Trouble Code Descriptions
EMISSION CONTROL SYSTEMS 25 - 3 DESCRIPTION AND OPERATION (Continued) DIAGNOSTIC TROUBLE CODE DESCRIPTIONS Malfunction Indicator Lamp (MIL) illuminated during engine operation if this DTC was recorded (depending if required by CARB and/or EPA). MIL is displayed as an engine icon on instrument panel.
Page 1008 25 - 4 EMISSION CONTROL SYSTEMS DESCRIPTION AND OPERATION (Continued) Malfunction Indicator Lamp (MIL) illuminated during engine operation if this DTC was recorded (depending if required by CARB and/or EPA). MIL is displayed as an engine icon on instrument panel. Generator lamp illuminated P0134 (M) 1/1 O2 Sensor Stays at Center...
Page 1009 EMISSION CONTROL SYSTEMS 25 - 5 DESCRIPTION AND OPERATION (Continued) Malfunction Indicator Lamp (MIL) illuminated during engine operation if this DTC was recorded (depending if required by CARB and/or EPA). MIL is displayed as an engine icon on instrument panel. Generator lamp illuminated P0171 (M) 1/1 Fuel System Lean...
Page 1010 25 - 6 EMISSION CONTROL SYSTEMS DESCRIPTION AND OPERATION (Continued) Malfunction Indicator Lamp (MIL) illuminated during engine operation if this DTC was recorded (depending if required by CARB and/or EPA). MIL is displayed as an engine icon on instrument panel. Generator lamp illuminated P0215 Fuel Injection Pump Control Circuit...
Page 1011 EMISSION CONTROL SYSTEMS 25 - 7 DESCRIPTION AND OPERATION (Continued) Malfunction Indicator Lamp (MIL) illuminated during engine operation if this DTC was recorded (depending if required by CARB and/or EPA). MIL is displayed as an engine icon on instrument panel. Generator lamp illuminated P0320 (M) No RPM Signal to PCM (Crankshaft...
Page 1012 25 - 8 EMISSION CONTROL SYSTEMS DESCRIPTION AND OPERATION (Continued) Malfunction Indicator Lamp (MIL) illuminated during engine operation if this DTC was recorded (depending if required by CARB and/or EPA). MIL is displayed as an engine icon on instrument panel. Generator lamp illuminated P0404 EGR Position Sensor Rationality...
Page 1013 EMISSION CONTROL SYSTEMS 25 - 9 DESCRIPTION AND OPERATION (Continued) Malfunction Indicator Lamp (MIL) illuminated during engine operation if this DTC was recorded (depending if required by CARB and/or EPA). MIL is displayed as an engine icon on instrument panel. Generator lamp illuminated P0545 A/C Clutch Relay Circuit...
Page 1014 25 - 10 EMISSION CONTROL SYSTEMS DESCRIPTION AND OPERATION (Continued) Malfunction Indicator Lamp (MIL) illuminated during engine operation if this DTC was recorded (depending if required by CARB and/or EPA). MIL is displayed as an engine icon on instrument panel. Generator lamp illuminated P0720 (M) Low Output Spd Sensor RPM Above...
Page 1015 EMISSION CONTROL SYSTEMS 25 - 11 DESCRIPTION AND OPERATION (Continued) Malfunction Indicator Lamp (MIL) illuminated during engine operation if this DTC was recorded (depending if required by CARB and/or EPA). MIL is displayed as an engine icon on instrument panel. Generator lamp illuminated P1197 1/2 O2 Sensor Slow During Catalyst...
Page 1016 25 - 12 EMISSION CONTROL SYSTEMS DESCRIPTION AND OPERATION (Continued) Malfunction Indicator Lamp (MIL) illuminated during engine operation if this DTC was recorded (depending if required by CARB and/or EPA). MIL is displayed as an engine icon on instrument panel. Generator lamp illuminated P1297 (M) No Change in MAP From Start To...
Page 1017 EMISSION CONTROL SYSTEMS 25 - 13 DESCRIPTION AND OPERATION (Continued) Malfunction Indicator Lamp (MIL) illuminated during engine operation if this DTC was recorded (depending if required by CARB and/or EPA). MIL is displayed as an engine icon on instrument panel. Generator lamp illuminated P1486 Evap Leak Monitor Pinched Hose...
Page 1018 25 - 14 EMISSION CONTROL SYSTEMS DESCRIPTION AND OPERATION (Continued) Malfunction Indicator Lamp (MIL) illuminated during engine operation if this DTC was recorded (depending if required by CARB and/or EPA). MIL is displayed as an engine icon on instrument panel. Generator lamp illuminated P1598 A/C Pressure Sensor Volts Too High...
Page 1019 EMISSION CONTROL SYSTEMS 25 - 15 DESCRIPTION AND OPERATION (Continued) Malfunction Indicator Lamp (MIL) illuminated during engine operation if this DTC was recorded (depending if required by CARB and/or EPA). MIL is displayed as an engine icon on instrument panel. Generator lamp illuminated P1695 No CCD/J1850 Message From Body...
Page 1020: Task Manager-Gasoline Powered Engines Only
25 - 16 EMISSION CONTROL SYSTEMS DESCRIPTION AND OPERATION (Continued) Malfunction Indicator Lamp (MIL) illuminated during engine operation if this DTC was recorded (depending if required by CARB and/or EPA). MIL is displayed as an engine icon on instrument panel. Generator lamp illuminated P1764 (M) Governor Pressure Sensor Volts Too...

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