Beruflich Dokumente
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INTRODUCTION
CONTENTS
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VEHICLE DESIGNATIONS
The Vehicle Code Designations chart lists the description and code for Dakota vehicles. Vehicle codes are used to identify vehicle types in charts, captions and procedure references. The codes are different from the Vehicle Identification Number (VIN) or designation reference.
Vehicle identification number (VIN). Type of vehicle. Month, day and hour (MDH) of final assembly. The label is located on the driver-side door shutface.
INTRODUCTION
VEHICLE IDENTIFICATION NUMBER (VIN) DECODING
INTRODUCTION
BODY CODE PLATE DECODING
VEHICLE DIMENSIONS
To view the body code plate: Move the seat forward as far as possible. Remove the jack cover and the jack. Fold the carpet over. Read the coded data. The Vehicle Exterior Dimensions chart provides the dimensions for each type of Dakota vehicle.
ENGINE/TRANSMISSION/PAYLOAD
The Engine/Transmission/Payload chart provides the maximum load specifications for each vehicle.
VEHICLE WEIGHTS
The Vehicle Weights chart provides: Gross vehicle weight rating (GVWR). Payload. Curb weight for each vehicle type/wheelbase.
INTRODUCTION
VEHICLE EXTERIOR DIMENSIONS
ENGINE/TRANSMISSION/PAYLOAD
INTRODUCTION
VEHICLE WEIGHTS
INTRODUCTION
TRAILER TOWING SPECIFICATIONS
INTRODUCTION
INTERNATIONAL CONTROL AND DISPLAY SYMBOLS
SPECIFICATION NOTATIONS
WARNING: THE USE OF INCORRECT ATTACHING HARDWARE CAN RESULT IN COMPONENT DAMAGE AND/OR PERSONAL INJURY. It is important to retain the original attaching hardware for assembly of the components. If the attaching hardware is not reusable, hardware with equivalent specifications must be used.
It is important to be aware that the torque values listed in the chart are based on clean and dry bolt threads. Reduce the torque value by 10 percent when the bolt threads are lubricated and by 20 percent if new.
TORQUE SPECIFICATIONS
TORQUE CHARTS A torque chart for fasteners is provided at the end of each group (of service information). Refer to the Standard Torque Specifications chart to determine torque values not listed in the group (Figs. 1 and 2).
INTRODUCTION
STANDARD TORQUE SPECIFICATIONS
A grade 5 bolt has 3 line marks on top of the bolt head A grade 7 bolt has 5 line marks on top of the bolt head A grade 8 bolt has 6 line marks on top of the bolt head The most commonly used metric bolt strength classes are 9.8 and 12.9. The metric strength class identification number is imprinted on the head of the bolt (Fig. 2). The higher the class number, the
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INTRODUCTION
METRIC CONVERSION
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INTRODUCTION
Lubrication and maintenance is divided into required and recommended service tasks. The required service tasks must be completed to verify the emission controls function correctly. The recommended service tasks should be completed to maintain safety and durability. This information will assist the service personnel in providing maximum protection for each owners vehicle. Conditions can vary with individual driving habits. It is necessary to schedule maintenance as a time interval as well as a distance interval. It is the owners responsibility to determine the applicable driving condition. Also to have the vehicle serviced according to the maintenance schedule, and to pay for the necessary parts and labor. Additional maintenance and lubrication information is listed in the Owners Manual.
INTERNATIONAL SYMBOLS
Chrysler Corporation uses international symbols to identify engine compartment lubricant and fluid inspection and fill locations (Fig. 1).
FUEL REQUIREMENTS
All gasoline engines require the use of unleaded fuel to reduce the potentially harmful effects of lead to the environment. Also unleaded fuel is necessary to prevent damage to the catalytic converter/O2 sensor. The fuel must have a minimum octane rating of 87 based on the (R + M)/2 calculation method.
CLASSIFICATION OF LUBRICANTS
Lubricating fluids and chassis lubricants are classified according to standards recommended by the: Society of Automotive Engineers (SAE). American Petroleum Institute (API).
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ENGINE OIL
API CERTIFICATION MARK For maximum engine protection during all driving conditions, install an engine oil that contains the API Certification Mark (Fig. 2). The API Certification Mark indicates that the oil is certified to meet the most critical requirements established by the manufacturer. Conformance to API specifications is determined by tests that measure the ability of an oil to control: Engine wear. Bearing corrosion. Sludge. Varnish. Oil thickening. Rust. Piston deposits.
CHASSIS COMPONENT AND WHEEL BEARING LUBRICANTS The chassis and wheel bearing lubricants that are recommended are identified by the NLGI Certification Symbol. The symbol contains a coded designation. This identifies the usage and quality of the lubricant. The letter G within the symbol designates wheel bearing lubricant. The letter L designates chassis lubricant. When the letters are combined, the lubricant can be used for dual applications. Use only lubricants that display the NLGI Certification Symbol (Fig. 4).
GEAR LUBRICANTS A dual grade is also used to specify the viscosity of multi-purpose gear lubricants.
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FLUID CAPACITIES
Fuel Tank Standard ................................................57 L (15 Optional .................................................83 L (22 Engine Oil W/Filter change 2.5L ......................................................4.2 L (4.5 3.9L ......................................................3.8 L (4.0 5.2L ......................................................4.8 L (5.0 Engine Oil W/O Filter change 2.5L ......................................................3.8 L (4.0 3.9L ......................................................3.3 L (3.5 5.2L ......................................................4.2 L (4.5 gal.) gal.) qts.) qts.) qts.) qts.) qts.) qts.)
Cooling System 2.5L ....................................................9.27 L (9.8 qts.) 3.9L ................................................13.25 L (14.0 qts.) 5.2L ................................................13.53 L (14.3 qts.) Automatic Transmission Dry fill capacity.* 42RH & 46RH ........................9.0-10.4 L (19-22 pts.) *Depending on type and size of internal cooler, length and inside diameter of cooler lines, or use of an auxiliary cooler, these figures may vary. Refer to Group-21, Transmission for proper fluid fill procedure. Manual Transmission NV3500 ................................................2.0 L (2.1 qts.) AX15.....................................................3.1 L (3.3 qts.) Transfer Case NP231 ..................................................1.2 L (2.5 pts.) Fill to bottom of fill hole. Front Axle N5 W/7-1/4 in......................................1.4 L (3.0 pts.) Rear Axle 7-1/4 in.................................................1.4 L (3.0 pts.) 8-1/4 in.................................................2.1 L (4.4 pts.) Power Steering N1(2WD) ............................................0.81 L (1.7 pts.) N5(4WD) ............................................1.18 L (2.5 pts.)
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There are two maintenance schedules that show proper service intervals for Dakota. Use the schedule that best describes the conditions the vehicle is operated under. When mileage and time is listed, follow the interval that occurs first. Schedule-A lists all the scheduled maintenance to be performed under normal operating conditions. Schedule-B is a schedule for vehicles that are usually operated under one or more of the following conditions. Frequent short trip driving less than 5 miles (8 km). Frequent driving in dusty conditions. Trailer towing or heavy load hauling. Frequent long periods of engine idling. Sustained high speed operation. Desert operation. Frequent starting and stopping. Cold climate operation. Off road driving. Commercial service. Snow plow operation. More than half of vehicle operation occurs in heavy city traffic during hot weather (above 90 F).
SCHEDULE-A
7,500 MILES (12 000KM) OR AT 6 MONTHS Change engine oil. 15,000 MILES (24 000KM) OR AT 12 MONTHS Change engine oil. Replace engine oil filter. Lubricate steering linkage (4x2). 22,500 MILES (36 000KM) OR AT 18 MONTHS Change engine oil. Inspect brake linings. Lubricate front suspension ball joints. Inspect front wheel bearings, clean and repack if required (4x2). 30,000 MILES (48 000KM) OR AT 24 MONTHS Change engine oil. Replace engine oil filter. Replace air cleaner element. Replace spark plugs. Inspect drive belt tension, adjust as required (2.5 L). Lubricate steering linkage (4x2). 37,500 MILES (60 000KM) OR AT 30 MONTHS Change engine oil. Drain and refill four wheel drive transfer case fluid. Drain and refill manual transmission fluid (Model AX-15 only). Drain and refill automatic transmission fluid. Replace filter and adjust bands. 45,000 MILES (72 000KM) OR AT 36 MONTHS Change engine oil. Replace engine oil filter. Inspect brake linings. Lubricate front suspension ball joints. Lubricate steering linkage (4x2). Inspect front wheel bearings, clean and repack if required (4x2). Flush and replace engine coolant at 36 months, regardless of mileage. 52,500 MILES (84 000KM) OR AT 42 MONTHS Change engine oil. Flush and replace engine coolant (if not done at 36 months). 60,000 MILES (96 000KM) OR AT 48 MONTHS Change engine oil. Replace engine oil filter. Replace air cleaner element. Replace distributor cap and rotor.
AT EACH STOP FOR GASOLINE Check engine oil level and add as required. Check windshield washer solvent and add as required. ONCE A MONTH Check tire pressure and look for unusual tire wear or damage. Check fluid levels of coolant reservoir, brake master cylinder, power steering and transmission. Add fluid as required. Check all lights and other electrical items for correct operation. Inspect battery and clean and tighten terminals as required. AT EACH OIL CHANGE Inspect exhaust system. Inspect brake hoses. Rotate the tires at each oil change interval shown on Schedule- A: (7,500 Miles) or every other interval shown on Schedule-B (6,000 Miles). Check engine coolant level, hoses, and clamps. If your mileage is less than 7,500 miles (12 000 km) yearly, replace the engine oil filter at each oil change. Lubricate 4x4 steering linkage.
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105,000 MILES (168 000KM) OR AT 84 MONTHS Change engine oil. Replace engine oil filter. Lubricate steering linkage (4x2). Flush and replace engine coolant if it has been 30,000 miles (48 000 km) or 24 months since last change. 112,500 MILES (180 000KM) OR AT 90 MONTHS Change engine oil. Drain and refill transfer case fluid. Inspect brake linings. Drain and refill manual transmission fluid (Model AX-15 only). Drain and refill automatic transmission fluid. Replace filter and adjust bands. Lubricate front suspension ball joints. Inspect front wheel bearings, clean and repack if required (4x2). Flush and replace engine coolant if it has been 30,000 miles (48 000 km) or 24 months since last change. 120,000 MILES (192 000KM) OR AT 96 MONTHS Change engine oil. Replace engine oil filter. Replace air cleaner element. Replace distributor cap and rotor. Replace ignition cables. Inspect PCV valve, replace if necessary.* Replace spark plugs. Replace drive belt (2.5 L). Replace fuel filter. Federal only (2.5 L). Lubricate steering linkage (4x2). Clean and relubricate crankcase inlet air cleaner. * This maintenance is recommended by Chrysler to the customer but it is not required to maintain warranty on the PCV valve.
67,500 MILES (108 000KM) OR AT 54 MONTHS Change engine oil. Inspect brake linings. Lubricate front suspension ball joints. Inspect front wheel bearings, clean and repack if required (4x2). 75,000 MILES (120 000KM) OR AT 60 MONTHS Change engine oil. Replace engine oil filter. Drain and refill transfer case fluid. Drain and refill manual transmission fluid (Model AX-15 only). Drain and refill automatic transmission fluid. Replace filter and adjust bands. Lubricate steering linkage (4x2). Flush and replace engine coolant if it has been 30,000 mile (48 000 km) or 24 month since last change. 82,500 MILES (132 000KM) OR AT 66 MONTHS Change engine oil. Flush and replace engine coolant if it has been 30,000 mile (48 000 km) or 24 month since last change. 90,000 MILES (144 000KM) OR AT 72 MONTHS Change engine oil. Replace engine oil filter. Replace air cleaner element. Replace spark plugs. Inspect belt tension, adjust if required (2.5 L). Inspect brake linings. Lubricate front suspension ball joints. Lubricate steering linkage (4x2). Inspect front wheel bearings, clean and repack if required (4x2). 97,500 MILES (156 000KM) OR AT 78 MONTHS Change engine oil.
SCHEDULE-B
3,000 MILES (4 800KM) Change engine oil. Lubricate steering linkage. 6,000 MILES (9 600KM) Change engine oil. Replace engine oil filter. Lubricate steering linkage. 9,000 MILES (14 400KM) Change engine oil. Lubricate steering linkage.
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12,000 MILES (19 200KM) Change engine oil. Replace engine oil filter. Drain and refill automatic transmission fluid. Replace filter and adjust bands. Change rear axle fluid. Change front axle fluid (4x4). Lubricate steering linkage. Lubricate front suspension ball joints. Inspect brake linings. 15,000 MILES (24 000KM) Change engine oil. Lubricate steering linkage. Inspect air cleaner element, replace as necessary. 18,000 MILES (29 000KM) Change engine oil. Replace engine oil filter. Drain and refill manual transmission fluid (Model AX-15 only). Lubricate steering linkage. 21,000 MILES (34 000KM) Change engine oil. Lubricate steering linkage. Lubricate front suspension ball joints. Inspect front wheel bearings, Clean and repack if required (4x2). 24,000 MILES (38 000KM) Change engine oil. Replace engine oil filter. Lubricate front suspension ball joints. Lubricate steering linkage. Drain and refill automatic transmission fluid. Replace filter and adjust bands. Change rear axle fluid. Change front axle fluid (4x4). Inspect brake linings. 27,000 MILES (43 000KM) Change engine oil. Lubricate steering linkage. 30,000 MILES (48 000KM) Change engine oil. Replace engine oil filter. Lubricate steering linkage. Replace spark plugs. Replace air cleaner element. Inspect PCV valve, replace as necessary.* Inspect drive belt tension, adjust as required (2.5 L). 33,000 MILES (53 000KM) Change engine oil. Lubricate steering linkage.
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84,000 MILES (134 400KM) Change engine oil. Replace engine oil filter. Lubricate front suspension ball joints. Lubricate steering linkage. Drain and refill automatic transmission fluid. Replace filter and adjust bands. Change rear axle fluid. Change front axle fluid (4x4). Inspect brake linings. Inspect front wheel bearings, Clean and repack if required (4x2). 87,000 MILES (140 000KM) Change engine oil. Lubricate steering linkage. 90,000 MILES (144 000KM) Change engine oil. Replace engine oil filter. Lubricate steering linkage. Replace spark plugs. Drain and refill manual transmission fluid (Model AX-15 only). Drain and refill automatic transmission fluid. Replace filter and adjust bands. Replace air cleaner element. Inspect drive belt tension, adjust as required (2.5 L). Inspect PCV valve, replace as necessary.* 93,000 MILES (149 000KM) Change engine oil. Lubricate steering linkage. 96,000 MILES (154 000KM) Change engine oil. Replace engine oil filter. Lubricate steering linkage. Lubricate front suspension ball joints. Change rear axle fluid. Change front axle fluid (4x4). Inspect brake linings. Inspect front wheel bearings, clean and repack if required (4x2). 99,000 MILES (158 400KM) Change engine oil. Lubricate steering linkage.
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102,000 MILES (163 000KM) Change engine oil. Replace engine oil filter. Lubricate steering linkage. 105,000 MILES (168 000KM) Change engine oil. Lubricate steering linkage. Inspect air cleaner element, replace as necessary. Inspect front wheel bearings, clean and repack if required (4x2). 108,000 MILES (172 800KM) Change engine oil. Replace engine oil filter. Lubricate steering linkage. Lubricate front suspension ball joints. Drain and refill manual transmission fluid (Model AX-15 only). Drain and refill automatic transmission fluid. Replace filter and adjust bands. Change rear axle fluid. Change front axle fluid (4x4). Drain and refill transfer case fluid. Inspect brake linings. 111,000 MILES (177 600KM) Change engine oil. Lubricate steering linkage. Flush and replace engine coolant. 114,000 MILES (182 400KM) Change engine oil. Replace engine oil filter. Lubricate steering linkage.
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page Towing Recommendations . . . . . . . . . . . . . . . . . . . 10 Towing When Keys Are Not Available . . . . . . . . . . 13 Two-Wheel-Drive Vehicle Towing . . . . . . . . . . . . . . 11 Fuel fumes or leakage, correct if necessary. CAUTION: If the cause of starting problem on disabled vehicle is severe, damage to booster vehicle charging system can result. (2) When using another vehicle as a booster source, turn off all accessories, place gear selector in park or neutral, set park brake and operate engine at 1200 rpm. (3) On disabled vehicle, place gear selector in park or neutral and set park brake. Turn off all accessories. (4) Connect jumper cables to booster battery. RED clamp to positive terminal (+). BLACK clamp to negative terminal (-) (Fig. 1). DO NOT allow clamps at opposite end of cables to touch, electrical arc will result. Review all warnings in this procedure. (5) On disabled vehicle, connect RED jumper cable clamp to positive (+) terminal. Connect BLACK jumper cable clamp to engine ground as close to the ground cable attaching point as possible (Fig. 1).
JUMP STARTING
WARNING: DO NOT ATTEMPT TO PUSH OR TOW A VEHICLE TO START THE ENGINE. UNBURNED FUEL COULD ENTER THE EXHAUST CATALYTIC CONVERTER AND IGNITE AFTER THE ENGINE IS STARTED. THIS COULD CAUSE THE CONVERTER TO OVERHEAT AND RUPTURE. WARNING: REVIEW ALL SAFETY PRECAUTIONS AND WARNINGS IN GROUP 8A, BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS. DO NOT JUMP START A FROZEN BATTERY, PERSONAL INJURY CAN RESULT. DO NOT JUMP START WHEN MAINTENANCE FREE BATTERY INDICATOR DOT IS YELLOW OR BRIGHT COLOR. DO NOT JUMP START A VEHICLE WHEN THE BATTERY FLUID IS BELOW THE TOP OF LEAD PLATES. DO NOT ALLOW JUMPER CABLE CLAMPS TO TOUCH EACH OTHER WHEN CONNECTED TO A BOOSTER SOURCE. DO NOT USE OPEN FLAME NEAR BATTERY. REMOVE METALLIC JEWELRY WORN ON HANDS OR WRISTS TO AVOID INJURY BY ACCIDENTAL ARCING OF BATTERY CURRENT. WHEN USING A HIGH OUTPUT BOOSTING DEVICE, DO NOT ALLOW BATTERY VOLTAGE TO EXCEED 16 VOLTS. REFER TO INSTRUCTIONS PROVIDED WITH DEVICE BEING USED. CAUTION: When using another vehicle as a booster, do not allow vehicles to touch. Electrical systems can be damaged on either vehicle.
TO JUMP START A DISABLED VEHICLE: (1) Raise hood on disabled vehicle and visually inspect engine compartment for: Battery cable clamp condition, clean if necessary. Frozen battery. Yellow or bright color test indicator, if equipped. Low battery fluid level. Generator drive belt condition and tension.
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start engine. If engine does not start within 15 seconds, stop cranking engine and allow starter to cool (15 min.), before cranking again. DISCONNECT CABLE CLAMPS AS FOLLOWS: Disconnect BLACK cable clamp from engine ground on disabled vehicle. When using a Booster vehicle, disconnect BLACK cable clamp from battery negative terminal. Disconnect RED cable clamp from battery positive terminal. Disconnect RED cable clamp from battery positive terminal on disabled vehicle.
PORTABLE STARTING UNIT There are many types of portable starting units available for starting engines. Follow the manufacturers instructions and observe the listed precautions when involved in any engine starting procedure.
HOIST A vehicle can be lifted with: A single-post, frame-contact hoist. A twin-post, chassis hoist. A ramp-type, drive-on hoist. When a frame-contact type hoist is used, verify that the lifting pads are positioned properly (Fig. 2).
WARNING: THE HOISTING AND JACK LIFTING POINTS PROVIDED ARE FOR A COMPLETE VEHICLE. WHEN A CHASSIS OR DRIVETRAIN COMPONENT IS REMOVED FROM A VEHICLE, THE CENTER OF GRAVITY IS ALTERED MAKING SOME HOISTING CONDITIONS UNSTABLE. PROPERLY SUPPORT OR SECURE VEHICLE TO HOISTING DEVICE WHEN THESE CONDITIONS EXIST.
HOISTING RECOMMENDATIONS
Refer to the Owners Manual for emergency vehicle lifting procedures.
FLOOR JACK When properly positioned, a floor jack can be used to lift a Dakota vehicle (Fig. 2). Support the vehicle in the raised position with jack stands at the front and rear ends of the frame rails.
TOWING RECOMMENDATIONS
A vehicle equipped with SAE approved sling-type towing equipment or a wheel-lift towing device can be used to tow all DAKOTA vehicles. When towing a 4WD vehicle, use tow dollies under the opposite end of the vehicle. A vehicle with a flat-bed device can also be used to transport a disabled vehicle (Fig. 3). A wooden crossbeam may be required for proper connection when using the sling-type, front-end towing method.
SAFETY PRECAUTIONS The following safety precautions must be observed when towing a vehicle. Secure loose and protruding parts. Always use a safety chain system that is independent of the lifting and towing equipment. Do not allow towing equipment to contact the disabled vehicles fuel tank. Do not allow anyone under the disabled vehicle while it is lifted by the towing device. Do not allow passengers to ride in a vehicle being towed. Always observe state and local laws regarding towing regulations. Do not tow a vehicle in a manner that could jeopardize the safety of the operator, pedestrians or other motorists.
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CAUTION: Do not use steering column lock to secure steering wheel during towing operation. 2WD vehicles can be towed with the front wheels on the surface for extended distances at speeds not exceeding 48 km/h (30 mph). (1) Attach the J-hooks around the axle shaft tubes outboard of the rear springs (Fig. 4). (2) Position and center the sling crossbar under and forward of the rear bumper. (3) Attach safety chains around the frame rails. (4) Turn the ignition switch to the OFF position to unlock the steering wheel. (5) Secure steering wheel in straight ahead position with a clamp device designed for towing. (6) Verify that steering components are in good condition. (7) Shift the transmission to NEUTRAL.
FLAT-BED TOWING RAMP ANGLE If a vehicle with flat-bed towing equipment is used, the approach ramp angle should not exceed 15 degrees.
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4WD TOWING-REAR END LIFTED (1) Raise the front of the vehicle off the ground and install tow dollies under front wheels. (2) Attach the J-hooks around the axle shaft tubes outboard of the rear springs (Fig. 6). (3) Position and center the sling crossbar under and forward of the rear bumper. (4) Attach safety chains around the frame rails. (5) Turn the ignition switch to the OFF position to unlock the steering wheel. (6) Secure steering wheel in straight ahead position with a clamp device designed for towing.
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Air Cleaner Element . . . . . . . Accessory Drive Belt . . . . . . . Air-Conditioner Compressor . . Battery . . . . . . . . . . . . . . . . . Crankcase Ventilation Systems Emission Control System . . . Engine Break-In . . . . . . . . . . Engine Cooling System . . . . .
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ENGINE BREAK-IN
CAUTION: Wide open throttle operation in low gears, before engine break-in period is complete, can damage engine. After first starting a new engine, allow it to idle for 15 seconds before shifting into a drive gear. Also: Drive the vehicle at varying speeds less than 88 km/h (55 mph) for the first 480 km (300 miles). Avoid fast acceleration and sudden stops. Do not drive at full-throttle for extended periods of time. Do not drive at constant speeds. Do not idle the engine excessively. A special break-in engine oil is not required. The original engine oil installed is a high quality, energy conserving lubricant. Special break-in oils are not recommended. These oils could interfere with the normal piston ring seating process. New engines tend to consume more fuel and oil until after the break-in period has ended.
ENGINE OIL
WARNING: NEW OR USED ENGINE OIL CAN BE IRRITATING TO THE SKIN. AVOID PROLONGED OR REPEATED SKIN CONTACT WITH ENGINE OIL. CONTAMINANTS IN USED ENGINE OIL, CAUSED BY INTERNAL COMBUSTION, CAN BE HAZARDOUS TO YOUR HEALTH. THOROUGHLY WASH EXPOSED SKIN WITH SOAP AND WATER. DO NOT WASH SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO NOT POLLUTE, DISPOSE OF USED ENGINE OIL PROPERLY. CONTACT YOUR DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR AREA.
ENGINE OIL ADDITIVES Chrysler Corporation recommends that Mopar Engine Oil Supplement or equivalent be used when friction and corrosion reducing materials added to the crankcase lubricant is desired.
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(4) Install dipstick and verify it is seated in the tube. (5) Remove dipstick, with handle held above the tip, take oil level reading. (6) Add oil only if level is below the ADD mark on dipstick.
TO CHANGE ENGINE OIL Run engine until achieving normal operating temperature. (1) Position the vehicle on a level surface and turn engine off. (2) Hoist and support vehicle on safety stands. Refer to Hoisting and Jacking Recommendations in this group. (3) Remove oil fill cap. (4) Place a suitable drain pan under crankcase drain. (5) Remove drain plug from crankcase and allow oil to drain into pan. Inspect drain plug threads for stretching or other damage. Replace drain plug and gasket if damaged. (6) Install drain plug in crankcase. (7) Lower vehicle and fill crankcase with specified type and amount of engine oil described in this section. (8) Install oil fill cap. (9) Start engine and inspect for leaks. (10) Stop engine and inspect oil level.
Fig. 3 Engine Oil Dipstick, Filter & Fill-Hole Cap3.9L & 5.2L Engines
CRANKCASE OIL LEVEL INSPECTION
CAUTION: Do not overfill crankcase with engine oil, oil foaming and oil pressure loss can result. Inspect engine oil level approximately every 800 kilometers (500 miles). Unless the engine has exhibited loss of oil pressure, run the engine for about five minutes before checking oil level. Checking engine oil level on a cold engine is not accurate. To maintain proper lubrication of an engine, the engine oil must be kept at an acceptable level. The acceptable level is located above the ADD mark and in the SAFE range on the dipstick. (1) Position vehicle on level surface. (2) With engine OFF, allow approximately ten minutes for oil to settle to bottom of crankcase, remove engine oil dipstick. (3) Wipe dipstick clean.
FILTER SPECIFICATION All engines are equipped with a high quality fullflow, throw-away type oil filter. The same type of filter is recommended when the filter is changed. OIL FILTER REMOVAL (1) Position a drain pan under the oil filter. (2) Using a suitable oil filter wrench loosen filter (Fig. 4).
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(4) When filter separates from adapter nipple, tip gasket end upward to minimize oil spill. Remove filter from vehicle. (5) With a wiping cloth, clean the gasket sealing surface of oil and grime (Fig. 5).
OIL FILTER INSTALLATION (1) Lightly lubricate oil filter gasket with engine oil or chassis grease. (2) Thread filter onto adapter nipple. When gasket makes contact with sealing surface, hand tighten filter one full turn, do not over tighten (Fig. 5). (3) Add oil, verify crankcase oil level and start engine. Inspect for oil leaks.
COOLING SYSTEM INSPECTION Coolant level should be inspected when other engine compartment service is performed or when coolant leak is suspected. With the engine at normal operating temperature, observe the coolant level in the coolant recovery bottle. The coolant level must be at least above the ADD mark and preferably at the FULL mark. Add coolant to the coolant recovery bottle only, if necessary. Cooling system freeze protection should be tested at the onset of the winter season or every 12 months. Service is required if coolant is low, contaminated, rusty or freeze protection is inadequate. To properly test cooling system, see Group 7, Cooling System. The cooling system factory fill is a mixture of 50% Ethylene Glycol based antifreeze and 50% water. Using a suitable hydrometer, measure antifreeze concentration in the radiator when the engine is cool. If the cooling system has recently been serviced, allow coolant to circulate for at least 20 minutes before taking hydrometer reading. Properly mixed coolant will protect the cooling system to -37C (-35F). If the freeze protection is above -28C (-20F), drain enough coolant from the cooling system to allow room to add antifreeze to achieve adequate protection. A mix table on the coolant container indicates the amount of antifreeze required to winterize the cooling system based on the capacity, see Capacity Chart in General Information section of this group. ANTIFREEZE SPECIFICATION Chrysler Corporation recommends Mopar Antifreeze/Coolant or a high quality, ethylene glycol base antifreeze/coolant, with a silicate inhibitor.
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FUEL SYSTEM
INSPECTION It is recommended that the fuel system filler cap, nozzle, tubes, hoses, and connections be inspected periodically. FUEL FILTER The fuel filter requires service only when a fuel contamination problem is suspected. For proper diagnostic and service procedures refer to Group 14, Fuel System. FUEL USAGE STATEMENTGASOLINE ENGINES Dakota vehicles are designed to meet all emission regulations and provide excellent fuel economy using high quality unleaded gasoline. Only use unleaded gasolines having a minimum posted octane of 87. If the vehicle develops occasional light spark knock (ping) at low engine speeds, this is not harmful. However, continued heavy knock at high speeds can cause damage and should be checked immediately.
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In addition to using unleaded gasoline with the proper octane rating, those that contain detergents, corrosion and stability additives are recommended.Using gasolines that have these additives will help improve fuel economy, reduce emissions and maintain vehicle performance. Poor quality gasoline can cause problems such as hard starting, stalling and stumble. If these problems occur, use another brand of gasoline before considering servicing the vehicle.
GASOLINE/OXYGENATE BLENDS Some fuel suppliers blend unleaded gasoline with materials that contain oxygen such as alcohol, MTBE and ETBE. The type and amount of oxygenate used in the blend is important. The following are generally used in gasoline blends:
ETHANOL Ethanol (Ethyl or Grain Alcohol) properly blended, is used as a mixture of 10 percent ethanol and 90 percent gasoline. Gasoline with ethanol may be used in your vehicle. METHANOL CAUTION: Do not use gasolines containing methanol. Use of methanol/gasoline blends may result in starting and driveability problems. In addition, damage may be done to critical fuel system components. Methanol (Methyl or Wood Alcohol) is used in a variety of concentrations blended with unleaded gasoline. You may encounter fuels containing 3 percent or more methanol along with other alcohols called cosolvents. Problems that are the result of using methanol/gasoline blends are not the responsibility of Chrysler Corporation. They may not be covered by the vehicle warranty. MTBE/ETBE Gasoline and MTBE (Methyl Tertiary Butyl Ether) blends are a mixture of unleaded gasoline and up to 15 percent MTBE. Gasoline and ETBE (Ethyl Tertiary Butyl Ether) are blends of gasoline and up to 17 percent ETBE. Gasoline blended with MTBE or ETBE may be used. CLEAN AIR GASOLINE Many gasolines are now being blended that contribute to cleaner air, especially in those areas of the country where air pollution levels are high. These new blends provide a cleaner burning fuel and some are referred to as Reformulated Gasoline.
IGNITION TIMING Test and adjust, if necessary, the timing at the time specified in the maintenance schedule. Refer to the specifications on the engine Emission Control label (located in the engine compartment). Refer to Group 8D, Ignition Systems and to Group 25, Emission Control Systems for additional service information.
SPARK PLUGS
Ignition spark plugs should be replaced at the mileage interval described in the Lubrication and Maintenance Schedules. Refer to the General Information section of this group. For proper service procedures refer to Group 8D, Ignition Systems.
BATTERY
WARNING: WEAR SAFETY GLASSES, RUBBER GLOVES AND PROTECTIVE CLOTHING WHEN HANDLING/SERVICING A BATTERY. THE BATTERY ELECTROLYTE CONTAINS SULFURIC ACID AND WILL CAUSE HARM IF IT CONTACTS SKIN, EYES OR CLOTHING. IT WILL ALSO DAMAGE PAINTED (AS WELL AS UN-PAINTED) SURFACES OF A VEHICLE. IF SULFURIC ACID CONTACTS ANY OF THESE, FLUSH IMMEDIATELY WITH LARGE AMOUNTS OF WATER. IF SULFURIC ACID CONTACTS SKIN OR EYES, GET IMMEDIATE MEDICAL ATTENTION. DO NOT SMOKE IN THE VICINITY OF A BATTERY. KEEP OPEN FLAMES AND SPARKS AWAY FROM BATTERY FILLER CAPS BECAUSE EXPLOSIVE GAS IS ALWAYS PRESENT. Inspect battery tray, hold down and terminal connections when other under hood service is performed. For proper diagnostic procedures refer to Group 8A, Battery/Starting/Charging System Diagnostics. For service and cleaning procedures refer to Group 8B, Battery/Starter Service.
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EXHAUST SYSTEM
The exhaust system should be inspected when under vehicle service is performed or as specified in the Lubrication and Maintenance Schedules.
RUBBER/PLASTIC COMPONENTS
CAUTION: Plastic hoses or wire harness covers will melt or deform when exposed to heat from exhaust system or engine manifolds. Position plastic or rubber components away from moving parts in engine compartment or under vehicle, or damage will result. Do not allow rubber engine mounts or other components to become oil contaminated, repair cause of oil contamination and clean area. All rubber and plastic components should be inspected when engine compartment or under vehicle service is performed. When evidence of deterioration exists, replacement is required. To reduce deterioration of rubber components, Chrysler Corporation recommends Mopar Foamy Engine Degreaser or equivalent be used to clean engine compartment of oil and road grime.
INSPECTION When inspecting an exhaust system, inspect for cracked or loose joints, stripped screw/bolt threads, corrosion damage, and worn or broken hangers (Slight cracking in rubber isolator or hanger is acceptable). Replace all components that are corroded or damaged. Do not attempt repair. Also, inspect for the following obvious conditions and correct as necessary: Exhaust system leaks, damage, misalignment. Contact with body panels metal or the frame. Catalytic converter bulging or excessive heat damage.
CAUTION: A catalytic converter will become contaminated if leaded gasoline is burned in the engine. If this occurs, the complete converter must be replaced. For proper service procedures see Group 11, Exhaust System and Intake Manifold.
AIR-CONDITIONER COMPRESSOR
The lubricant level in the air-conditioner compressor should be checked if there are indications that oil was lost. Loss of lubricating oil usually accompanies a loss of refrigerant. For additional information involving the A/C system, refer to Group 24, Heater And Air Conditioning.
ENGINE MOUNTS Inspect the rubber in the engine mounts for excessive wear. Slight wear at the ends will not affect the functioning of an engine mount. If excessive engine movement is detected, the engine mount(s) should be replaced.
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Automatic Transmission . . . . . . Clutch and Brake Pedal Bushings Clutch Master Cylinder . . . . . . . Drive Shafts . . . . . . . . . . . . . . .
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MANUAL TRANSMISSION
The manual transmission should be inspected for oil leaks and proper oil level when other under vehicle service is performed.
LUBRICANT SPECIFICATION When it becomes necessary to add to or change the lube oil in a Dakota manual transmission, use the following lubricant: AX-15SAE 75W-90, API Quality Grade GL-5 gear lubricant (MOPAR P/N 4649264). NV3500MOPAR Manual Trans. Lubricant (P/N 4761526). LUBRICANT LEVEL The fill-hole plug for the AX-15 manual transmissions is located on the left side of the case (Fig. 4) and the fill-hole plug for the NV3500 manual transmissions is located on the right side of the case (Fig. 5). Determine the lubricant level according to the following procedure.
LUBE OIL CHANGE When it becomes necessary to change manual transmission lube oil, use the following procedure. (1) Raise and support the vehicle. (2) Remove the fill-hole plug from the transmission. (3) Place a container to collect the lube oil under the transmission drain-hole plug. (4) Remove the drain-hole plug and drain the lube oil from the transmission into the container. Care should be exercised when disposing used lube oil after it has been drained from a transmission. (5) Install the drain-hole plug in the transmission. (6) Fill the transmission until the lube oil begins to drip out of the fill hole. (7) Install the fill-hole plug in the transmission. (8) Remove the support and lower the vehicle. SPECIAL ADDITIVES Do not add any additives to a transmission other than Black Light detection dye.
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AUTOMATIC TRANSMISSION
The automatic transmission fluid should be changed and bands adjusted at the intervals described in the Maintenance Schedules section of this Group. The automatic transmission should be inspected for fluid leaks and proper fluid level when other under hood service is performed. Refer to Group 21, Transmission for proper service procedures. CAUTION: To minimize fluid contamination, verify that dipstick is seated in the fill tube after fluid level reading is taken.
FLUID LEVEL The transfer case fill hole plug is located at the rear of the housing (Fig. 7).
AUTOMATIC TRANSMISSION FLUID SPECIFICATION When it becomes necessary to add fluid (ATF) or when the ATF is replaced, use MOPAR ATF PLUS (ATF Type 7176). Dexron III ATF can be used only if MOPAR ATF PLUS (ATF Type 7176) is not available.
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FLUID SPECIFICATION If it becomes necessary to add fluid (ATF) to a Dakota transfer case, use MOPAR ATF PLUS or an equivalent Dexron III ATF.
LUBRICANT SPECIFICATION MOPAR Hypoid Lubricant, SAE 80W-90 or equivalent should be used in all Dakota axles. In addition, a friction additive (friction modifier) must also be used in a limited-slip differential.
LUBRICANT LEVEL (1) Raise and support the vehicle. (2) The rear and front axles (4WD vehicles) differential housings have a rubber, PRESS-IN type fill hole plug (Figs. 8 and 9). Pry the fill hole plug from the differential housing. (3) The lubricant level should be within 10 mm (3/8 in.) of the bottom edge of the fill hole plug opening for rear axles. It should be between 10 mm (3/8 in.) and 13-mm (1/2-in.) below the bottom edge of the fill hole plug opening for front axles (4WD vehicles).
DRIVE SHAFTS
Lubricate at the intervals described in the Maintenance Schedule section of this Group. Refer to Group 16, Propeller Shafts for proper service procedures. CAUTION: It is very important that drive shafts be lubricated at periodic intervals and that the specified type of lubricant be used. Failure to properly lubricate could result in premature wear of drive shaft components.
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HOSE/TUBING INSPECTION Vehicle operating conditions determine the useable life of underbody hoses and tubing (Figs. 10 and 11). These conditions include: The extent and quality of vehicle maintenance. The geographic area of vehicle operation. The length of exposure time to excess heat and chemical contaminants. (1) Inspect all hose and tubing fittings for looseness and corrosion. Inspect the rubber hoses for brit-
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page . . . . . . . . . . . . . . . 27 26 29 25 28
STEERING LINKAGE
The steering linkage (Figs. 2 and 3) should be lubricated and inspected at the intervals described in the Maintenance Schedules section of this Group. Refer to Group 2, Front Suspension and Axles for proper service procedures.
LUBRICANT SPECIFICATION Use Mopar, Multi-purpose Grease or NLGI GC-LB lubricant equivalent to lubricate the steering linkage.
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INSPECTION/LUBRICATION Refer to Group 2, Front Suspension and Axle for inspection and service procedures. 4WD VEHICLES All 4WD Dakota vehicles are equipped with permanently sealed front wheel bearings. Refer to Group 2, Front Suspension for inspection and service procedures.
PRECAUTIONS Whenever a CV drive shaft is removed from the steering knuckle, be aware of the following precautions: Foreign particles must be prevented from the lubricated areas between the bearing and external seal, and from contacting the outer joint wear sleeve Inspect the lubricant on the external seal for adequate quantity and quality. If the lubricant is sparse or is contaminated, the seal should be cleaned and packed with lubricant Clean the face of the external seal. Replace any lubricant that was lost during seal cleaning or the disengagement of the shaft Clean the wear sleeve surface area completely and add approximately 3 grams of lubricant
LUBRICANT SPECIFICATION Use high temperature, multi-purpose NLGI GC-LB lubricant MOPAR Wheel Bearing Lubricant or an equivalent.
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The manual steering gear should be inspected for damage at the same time as the engine oil is changed and the oil filter is replaced. Refer to Group 19, Steering for additional information and service procedures.
BRAKE SYSTEM INSPECTION A brake system inspection should be included with all brake service procedures, and also each time the vehicle is lubricated. (1) Inspect the brake pads and linings for excessive wear, cracks, charred surfaces and broken rivets. (2) Inspect brake pads and linings for contamination from brake fluid, and/or other fluids.
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(3) Replace the brake pads linings if they are worn to within 0.78 mm (1/32 in) of the rivet head. (4) Operate the rear brake self-adjuster lever and pivot. Test the operation of the self-adjuster screw for ease of movement. (5) Inspect the self-adjuster components for wear or damage. (6) Inspect the disc brake caliper dust boot for damage and indications of brake fluid leakage. Inspect the bushings and pins for corrosion, tears and a binding condition. (7) Pull the rear wheel cylinder dust boot back to expose the wheel cylinder housing. Inspect for fluid leaks. Inspect the pistons and cylinder bores. (8) Inspect the brake differential warning valve and housing for indications of leakage.
INSPECTION Inspect the tires for excessive wear, damage. Test the tires for the recommended inflation pressure and adjust the pressure accordingly. Refer to the tire inflation pressure decal located on the left door face. Also to Group 22, Tires And Wheels for tire pressure charts, tire replacement, and tread wear indicators. ROTATION Tires/wheels should be rotated according to the recommended interval. The first tire/wheel rotation is the most important for establishing the prevention of uneven tread wear. After rotation, adjust the tire inflation pressure to the air pressure recommended on the decal located on the left door face. Refer to Group 22, Tires And Wheels for the recommended method of tire/wheel rotation.
BRAKE FLUID HOSES/TUBING The rubber brake fluid hoses should be inspected for: Correct length Severe surface cracking Swelling Pulling Scuffing Excessively worn areas If the hose has cracks or abrasions in the rubber cover, the hose should be replaced. (1) Inspect all the hoses for kinks, a distorted condition and fluid leakage. (2) Inspect the hose and tubing routing under the vehicle. Verify that no hose/tubing is rubbing against any exhaust or other underbody components. PARKING BRAKE (1) Engage the parking brake pedal and then release it. (2) Test it for smooth operation and vehicle-holding capability. (3) Inspect the parking brake cables. (4) With the parking brake released, the rear wheels should rotate without restriction. Adjust the parking brake cable tension, if necessary. (5) Repair any parking brake malfunctions. BRAKE OPERATIONAL TEST (1) Drive the vehicle and test for proper brake action. (2) Note any indication of drum/rotor overheating. (3) Evaluate any performance complaints received from the owner/operator. (4) Repair the brake system as necessary. Refer to Group 5, Brakes for additional information and service procedures.
BODY COMPONENTS
LUBRICATION REQUIREMENTS All Dakota cab and cargo box operating mechanisms and linkages should be lubricated when necessary. The door weatherstrip seals should be lubricated to prolong their life as well as to improve door sealing. LUBRICANT SPECIFICATIONS All applicable exterior and interior vehicle operating mechanisms should be: Inspected Cleaned Pivot/sliding contact areas on the mechanisms should then be lubricated. Multi-purpose NLGI GC-LB MOPAR Multi-Mileage Lubricant or an equivalent, should be used to lubricate the mechanisms. The door weatherstrip seals should be lubricated with silicone lubricant spray. Refer to the Body Lubricant Specifications chart below for additional lubricant applications. LUBRICATION (1) When necessary, lubricate the cab and cargo box operating mechanisms with the specified lubricants. (2) Apply silicone lubricant to a cloth and wipe it on door seals to avoid over-spray that can soil passenger clothing.
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(5) The door lock cylinders should be lubricated 2 times each year (preferably autumn and spring): Spray a small amount of lock cylinder lubricant directly into the lock cylinder. Apply a small amount to the key and insert it into the lock cylinder. Rotate it to the locked position and then back to the unlocked position several times. Remove the key. Wipe the lubricant from it with a clean cloth to avoid soiling of clothing.
HEADLAMPS
MAINTENANCE SCHEDULE Every six months check the headlamp beams to ensure that the headlamp beams are correctly positioned. AIM ADJUSTMENT Refer to Group 8L, Lamps for headlamp aim adjustment procedures.
SPEEDOMETER CABLE
SERVICE INFORMATION Speedometer cable lubrication is not necessary. For service information involving noisy cables, refer to Group 8E, Instrument Panel and Gauges.
(3) Before applying lubricant, the component should be wiped clean. After lubrication, any excess lubricant should be removed. (4) The hood latch, latch release mechanism, latch striker and safety latch should be lubricated periodically.
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7 1/4 INCH FRONT AXLE . . . . . . . . . . . . . . . . . 31 AXLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . 47 CV DRIVE SHAFT . . . . . . . . . . . . . . . . . . . . . . . 23 FRONT SUSPENSION2WD VEHICLES . . . . . . . 8 FRONT SUSPENSION4WD VEHICLES . . . . . . 14
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road noise by the use of replaceable bushings in the suspension arms. The upper suspension arm cross shaft also allows for caster and camber adjustment. The lower suspension arms use replaceable pressed in bushings to isolate road noise. The suspension arms are bolted to the frame and pivot through rubber bushings. The suspension arm travel (jounce or rebound) is limited through the use of rubber bumpers. All suspension components that use rubber bushings should be tightened with the vehicle at normal height. If springs are not at their normal ride position, vehicle ride comfort could be affected along with premature rubber bushing wear. Rubber bushings must never be lubricated. Vehicles equipped with 2WD use coil springs mounted up in a well (pocket) in a bracket that is part of the frame rail. There is a rubber (doughnut) isolator between the top of the spring and bracket. The bottom of the spring seats in the lower suspension arm. 4WD vehicles use torsion bars mounted to the back side of the lower suspension arm. The rearward end of the bar is mounted in a cam pivot that rests in the frame crossmember. The vehicle height is adjusted through the cams with screw jacks that increase the tension (twist) of the torsion bar. Ride control is accomplished through the use of dual-action shock absorbers. The shocks dampen the jounce and rebound as the vehicle travels over various road conditions. The top of the shock absorbers are bolted to the frame. The bottom of the shocks are bolted to the lower suspension arm. The stabilizer bar is used to minimize vehicle front sway during turns. The bar helps to maintain a flat attitude to the road surface. The bar extends across the front underside of the chassis and connects to the frame rails. The links are connected to the lower suspension brackets. All mounting points of the stabilizer bar are isolated by rubber bushings.
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GENERAL INFORMATION
Front wheel alignment involves the correct positioning of the tire contact patch in relation to the pavement. The positioning is accomplished through the suspension and steering linkage adjustments. An alignment is considered essential maintenance. It will maintain efficient steering, good directional stability and prevent abnormal tire wear. The most important factors of front end alignment are camber, caster and toe position. Routine inspection of the front suspension and steering components is a good preventative maintenance practice. Inspection also helps to ensure safe operation of the vehicle. CAMBER is the number of degrees the top of the wheel is tilted either inward or outward. An excessive negative camber angle will cause tread wear at the inside of the tire. An excessive positive camber angle will cause tread wear at the outside of the tire (Fig. 1). CASTER is the number of degrees of forward or rearward tilt of the steering knuckles. Forward tilt provides a negative caster angle. Rearward tilt provides a positive caster angle (Fig. 1). WHEEL TOE POSITION is the difference between the leading inside edges and trailing inside edges of the front tires (Fig. 1). Incorrect wheel toe position is the most common cause of unstable steering and uneven tire wear. The wheel toe position is the final front wheel alignment adjustment. STEERING AXIS INCLINATION ANGLE is measured in degrees and is the angle that the steering knuckles are tilted (Fig. 1). The inclination angle has a fixed relationship with the camber angle. This angle will not change except when a spindle or ball stud is damaged or bent. The angle is not adjustable and the damaged component(s) must be replaced to correct mis-alignment. CAUTION: Do not attempt to modify any suspension or steering component by heating and bending.
PRE-ALIGNMENT INSPECTION
Before starting a front wheel alignment, the following inspection and necessary corrections must be completed.
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bumper at the center and jounce the vehicle up and down several times. Always release the bumper when it is at the down position. Set the front end alignment to specifications while the vehicle is in its NORMALLY LOADED CONDITION.
SUSPENSION HEIGHT (4WD) The front suspension of a new vehicle will settle slightly during the first 2,000 miles/3,200 km of operation. To compensate for this, the front suspension height is slightly higher than the service specification height. A vehicle with less than 2,000 miles/3,200 km, SHOULD NOT be adjusted downward. The torsion bars have not set and can be no more than 0.5 inch (12.7 mm) higher than specifications. (1) Clean the surface areas where the suspension arm height will be measured (Fig. 2).
CAMBER AND CASTER ADJUSTMENT Camber and caster angle adjustments involve changing the position of the upper suspension arm pivot bar (Fig. 4).
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TOE POSITION The wheel toe position adjustment should be the final adjustment. (1) Start the engine and turn wheels both ways before straightening the wheels. Secure the steering wheel with the front wheels in the straight-ahead position. (2) Loosen the tie rod adjustment sleeve clamp bolts/nuts. Each front wheel should be adjusted for onehalf of the total toe position specification. This will ensure the steering wheel will be centered when the wheels are positioned straight-ahead. 29 (3) Adjust the wheel toe position by turning the tie rod adjustment sleeves as necessary (Fig. 5, 6). (3) Tighten the tie rod adjustment: 2WD: locknuts to 75 N m (55 ft. lbs.) torque 4WD: clamp bolts to 23 N m (17 ft. lbs.) torque. Position the clamp nut/bolt so that it does not extend above the top of the sleeve
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Coil Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Lower Ball Stud . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Lower Suspension Arm . . . . . . . . . . . . . . . . . . . . . 10 Service Information . . . . . . . . . . . . . . . . . . . . . . . . . 8 Shock Absorber . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SERVICE INFORMATION
Periodic lubrication of the front suspension (steering) system components is required. Refer to Group 0, Lubrication And Maintenance for the recommended maintenance schedule. CAUTION: Suspension components with rubber bushings should be tightened with the vehicle at normal height. It is important to have the springs supporting the weight of the vehicle when the fasteners are torqued. If springs are not at their normal ride position, vehicle ride comfort could be affected and premature bushing wear may occur. Rubber bushings must never be lubricated.
CLEANING AND INSPECTION (1) Thoroughly clean bearings and interior of hub/ rotor (Fig. 1). (2) To clean the bearings: Soak them in cleaning solvent Strike the flat of each bearing against a hardwood block several times
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INSTALLATION (1) Install the new bearing cup(s) with an appropriate installation tool. (2) Apply a coating of MOPAR Wheel Bearing Grease (or an equivalent lubricant) to entire inner surface area of hub/rotor. Install inner wheel bearing in the hub/rotor. Install a new bearing seal. (3) Inspect bearing and seal contact surfaces on spindle for burrs and/or roughness. (4) Remove all rough contact surfaces from spindle. Apply a coating of lubricant.
CAUTION: Use care to prevent inner wheel bearing and seal from contacting spindle threads during installation (Fig. 1). (5) Carefully slide the hub/rotor onto spindle (Fig. 1). Install outer wheel bearing, washer and retaining nut. (6) Tighten the nut to 41-54 N m (30-40 ft. lbs.) torque to preload bearing while rotating the hub/rotor. Stop hub/rotor and loosen nut to completely release bearing preload torque. Tighten the nut fingertight and install the nut lock. Install a new cotter pin. (7) The adjustment (above) should have 0 to 0.076 mm (0 to 0.003 in.) end play. (8) Clean the dust cap and apply a coating lubricant to the internal surface. Do not fill the dust cap with lubricant. Install the cap. (9) Install disc brake caliper. Refer to Group 5, Brakes. (10) Install the wheel and tire.
STABILIZER BAR
REMOVAL (1) Raise and support the vehicle. (2) Remove the nut and washer from the stabilizer bar link bolt at the lower suspension arm on each side of the vehicle (Fig. 3). (3) Remove the link bolt, retainers, insulators and spacer from each lower suspension arm (Fig. 3). (4) Remove the bolts from the U-shaped retainer. Remove the retainer, and stabilizer bar from the vehicle (Fig. 3). (5) If necessary, remove the bushings from the stabilizer bar (Fig. 3).
SHOCK ABSORBER
REMOVAL (1) Remove the hardware from the shock absorber stud (Fig. 2). (2) Raise the vehicle, remove the lower bolts and remove the shock absorber (Fig. 2).
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INSTALLATION (1) Tape the isolator pad to the top of the coil spring. Position the spring in the lower suspension arm well. Be sure that the coil spring is seated in the well (Fig. 2). The top of the spring is flat or closed with groves at the end of the coil. The ramped or open end of the coil spring is the bottom. (2) Install Spring Compressor DD-1278 up through the lower suspension arm and coil spring. (3) Tighten the tool nut to compress the coil spring. (4) Place two jack stands under the lower suspension arm immediately outward from where the bushings are located. Adjust the jack stands tight against the lower suspension arm. (5) Raise the jack stands until the isolator pad/coil spring is correctly seated top and bottom (Fig. 2). (6) Install the lower suspension arm bolts and nuts. Tighten the front nut to 176 N m (130 ft. lbs.) torque and the rear nut to 108 N m (80 ft. lbs.) torque. (7) Remove the spring compressor tool and the jack stands. (8) Install the stabilizer bar. (9) Install the shock absorber. (10) Install the wheel and tire.
COIL SPRING
REMOVAL (1) Raise and support the vehicle. (2) Remove the applicable front wheel. (3) Disconnect the stabilizer bar from the lower suspension arm. (4) Remove the shock absorber. (5) Install Spring Compressor DD-1278 up through the lower suspension arm and coil spring (Fig. 2). Spring Compressor DD-1278 will maintain the spring in a semi-compressed condition. This will retain the spring in place until the lower suspension arm is detached from and lowered for spring removal. (6) Tighten the tool nut to compress the coil spring.
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(5) Install Spring Compressor DD-1278. Use a piece of pipe to fabricate a spacer positioned between the tool and suspension arm. (6) Tighten tool nut against bell-shaped adapter tool finger-tight and loosen 1/2 of-a-turn. (7) Remove cotter pins and nuts from ball studs. (8) Position Ball Stud Remover C-3564-A as shown (Fig. 4). Rotate threaded portion of tool to apply force to the lower ball stud. (9) Strike steering knuckle sharply with a hammer to loosen ball stud from knuckle. Do not force ball stud out from knuckle with the tool. (10) Remove ball stud seal. Use Remover/Installer C-4212 to press the ball stud from lower suspension arm bore (Fig. 5).
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REMOVAL (1) Place a jack under outer end of lower suspension arm. Raise and support the vehicle. (2) Remove the wheel and tire. (3) Remove cotter pin and nut from upper ball stud. (4) Position Ball Stud Remover C-3564-A as shown (Fig. 7). Rotate threaded portion of tool to apply force to the upper ball stud. (5) Strike steering knuckle sharply with a hammer to loosen ball stud from knuckle. Do not force ball stud out from knuckle with the tool. (6) Remove ball stud seal. (7) Use Removal/Installation Tool C-3561 to unthread ball stud from suspension arm. INSTALLATION (1) Thread new ball stud in with Tool C-3561. Tighten ball stud to 170 N m (125 ft. lbs.) torque. The gap between ball stud Hex and suspension arm bore is 0.25 to 1.25mm (0.01 to 0.05 inch). (2) Install new seal over ball stud. Make sure seal is securely locked in-place. (3) Position steering knuckle on upper ball stud. Tighten the upper ball stud nut to 142 N m (105 ft. lbs.) torque. Install a new cotter pin. (4) Install the wheel and tire.
STEERING KNUCKLE
REMOVAL (1) Raise and support the vehicle. Place a jack under outer end of lower suspension arm. (2) Remove the wheel and tire. (3) Remove disc brake caliper. Refer to Group 5, Brakes. (4) Remove tie-rod from steering knuckle arm. Refer to Group 19, Steering. (5) Remove ABS sensor wire from lower suspension arm. Remove the rotor dust shield and ABS pick-up from knuckle (Fig. 9). (6) Remove cotter pins and nuts from upper and lower ball studs. (7) Use Ball Stud Remover C-3564-A to free upper and lower ball joints from steering knuckle (Fig. 4, 7). (8) Remove tool and steering knuckle assembly. (9) Remove steering arm from steering knuckle (Fig. 10). INSTALLATION (1) Install steering arm on knuckle. Tighten the nuts to 294 N m (217 ft. lbs.) torque (Fig. 10). (2) Position steering knuckle on upper and lower ball studs and install nuts. Tighten lower nut to 183 N m (135 ft. lbs.) torque. Tighten upper nut to 142 N m (105 ft. lbs.) torque. Install new cotter pins.
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Lower Suspension Arm Service Information . . . Shock Absorber . . . . . Stabilizer Bar . . . . . . . Steering Knuckle . . . . .
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SERVICE INFORMATION
Periodic lubrication of the front suspension (steering) system components is required. Refer to Group 0, Lubrication And Maintenance for the recommended maintenance schedule. CAUTION: Suspension components with rubber bushings should be tightened with the vehicle at normal height. It is important to have the springs supporting the weight of the vehicle when the fasteners are torqued. If springs are not at their normal ride position, vehicle ride comfort could be affected and premature bushing wear may occur. Rubber bushings must never be lubricated.
(4) Remove hub to steering knuckle bolts. Remove hub and bearing unit from the steering knuckle (Fig. 2).
REMOVAL (1) Remove the CV drive shaft. Refer to CV Drive Shaft Removal in this Group. (2) Remove disc brake caliper from steering knuckle and rotor. Refer to Group 5, Brakes. (3) Remove brake rotor from the hub (Fig. 1).
SHOCK ABSORBER
REMOVAL (1) Remove the hardware from the shock absorber stud (Fig. 3). (2) Raise the vehicle, remove the lower bolts and remove the shock absorber (Fig. 3). INSTALLATION (1) Install the lower retainer and grommet on the shock absorber stud. Insert the replacement shock absorber through the frame hole. Install the lower bolt (Fig. 3).
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TORSION BAR
SERVICE INFORMATION The left and right side torsion bars are NOT interchangeable. The bars are identified and stamped R or L, for right or left. The bars do not have a front or rear end and can be installed with either end facing forward. REMOVAL (1) Remove the suspension arm jounce bumpers before raising vehicle. (2) Raise and support the vehicle with the front suspension hanging. (3) Turn the adjustment bolt counterclockwise to release spring load (Fig. 5). Remove the adjustment bolt from swivel.
STABILIZER BAR
REMOVAL (1) Raise and support the vehicle. (2) Remove the bolts attaching the stabilizer bar rear support bracket to the frame crossmember bracket (Fig. 4). (3) Remove the bolts attaching the retainer to the lower suspension arm. Remove the retainer and stabilizer bar from the vehicle (Fig. 4). (4) If necessary, remove the rear support brackets and the bushings from the stabilizer bar (Fig. 4). INSTALLATION (1) If removed, install the bushings and the rear support brackets on the stabilizer bar (Fig. 4). (2) Place the stabilizer bar rear support brackets adjacent to the frame crossmember brackets (Fig. 4) and install the bolts. Tighten the bolts finger-tight. Check the alignment of the bar to ensure there is no interference with the either frame rail or chassis component. Spacing should be equal on both sides. (3) Attach the stabilizer bar to the lower suspension arm with the retainer and bolts (Fig. 4). Tighten the bolts to 27 N m (20 ft. lbs.) torque. (4) Tighten the rear support bracket bolts (Fig. 4) to 27 N m (20 ft. lbs.) torque.
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(5) Remove all foreign material from torsion bar mounting in anchor and suspension arm (Fig. 5). (6) Inspect adjustment bolt and swivel for severe corrosion or damage.
INSTALLATION (1) Insert torsion bar ends into anchor and suspension arm (Fig. 5). (2) Position anchor and bushing in frame crossmember. Install adjustment bolt through bushing and anchor and into swivel (Fig. 5). (3) Turn adjustment bolt clockwise to apply a spring load. (4) Lower vehicle and adjust the front suspension height. Refer to Wheel Alignment in this group. (5) Install suspension arm jounce bumpers.
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(8) Tighten upper suspension arm pivot bolts to 210 N m (155 ft. lbs.) torque. (9) Adjust alignment caster and camber. Refer to Front Wheel Alignment in this Group.
STEERING KNUCKLE
REMOVAL (1) Remove the CV drive shaft. Refer to CV Drive Shaft Removal in this Group. (2) Turn torsion bar adjustment bolt counter-clockwise to completely remove tension from torsion bar. Count the number of turns for installation reference. (3) Remove shock absorber lower bolt. (4) Disconnect the stabilizer bar from suspension arm.
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(5) Remove the wheel hub and bearings. Refer to Wheel Hub and Bearing Removal in this Group. (6) Remove tie-rod end stud from steering knuckle arm. Refer to Group 19, Steering. (7) Remove ABS sensor and wire from upper suspension arm (Fig. 9).
INSTALLATION (1) Position steering knuckle on upper and lower ball studs and install nuts. Tighten lower nut to 156
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GENERAL INFORMATION
Axle bearing problem conditions are usually caused by: Insufficient or incorrect lubricant Foreign matter/water contamination Incorrect bearing preload torque adjustment When serviced, the bearings must be cleaned thoroughly. They should be dried with lint-free shop towels. Never dry bearings with compressed air. This will overheat them and brinell the bearing surfaces. This will result in noisy operation after repair. Axle gear problem conditions are usually the result of: Insufficient lubrication Incorrect or contaminated lubricant Overloading (excessive engine torque) Incorrect clearance or backlash adjustment Insufficient lubrication is usually the result of a housing cover leak. It can also be from worn axle shaft or pinion gear seals. Check for cracks or porous areas in the housing or tubes. Using the wrong lubricant will cause overheating and gear failure. Gear tooth cracking and bearing spalling are indicators of this. Axle component breakage is most often the result of: Severe overloading Insufficient lubricant Incorrect lubricant Improperly tightened components Common causes of overloading is from full-throttle acceleration. Overloading happens when towing heavier-than-recommended loads. Component breakage can occur when the wheels are spun excessively. Insufficient or incorrect lubricants contribute to breakage through overheating. Loose differential components can also cause breakage. Incorrect bearing preload or gear backlash will not result in component breakage. Mis-adjustment will produce enough noise to cause service repair before a failure occurs. If a mis-adjustment condition is not corrected, component failure can result.
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level. Where axle bearing damage is slight, the noise is usually not noticeable at speeds above 30 mph.
DRIVELINE SNAP
A snap or clunk noise when the vehicle is shifted into gear (or the clutch engaged), can be caused by: High engine idle speed Loose engine/transmission/transfer case mounts Worn U-joints Loose spring shackles or U-bolts Loose pinion gear nut and yoke Excessive ring gear backlash Excessive differential side gear-to-case clearance With 2WD vehicles, a worn bushing in the transmission extension housing can also cause noise. The source of a snap or a clunk noise can be determined with the assistance of a helper. Raise the vehicle on a hoist with the wheels free to rotate. Instruct the helper to shift the transmission into gear. Listen for the noise, a mechanics stethoscope is helpful in isolating the source of a noise.
VIBRATION
Vibration at the rear of the vehicle is usually caused by a: Damaged drive shaft Missing drive shaft balance weight Worn, out-of-balance wheels Loose wheel lug nuts Worn U-joint Loose spring U-bolts Loose/broken rear springs or shackles Damaged axle shaft bearings Loose pinion gear nut Excessive pinion yoke run out Bent axle shaft 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. Do not overlook engine accessories, brackets and drive belts.
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SERVICE INFORMATION
The two constant velocity (CV) drive shafts are identical and interchangeable. They are comprised of three major components (Fig. 1): An inner, tripod CV joint A short, solid interconnecting shaft An outer, Rzeppa CV joint with stub shaft The axle shafts are equipped with ABS tone wheels. The sensors are attached to the knuckle assemblies and tone wheels are pressed on the axle shaft. Use care when removing axle shafts as NOT to damage the tone ring or sensor. The inner tripod-joints are attached to the axle shaft flanges (Fig. 1). The outer joint is splined and mates with the hub bearing on the knuckle. The lubricant amounts included with replacement rubber boots are different for inner and
outer CV joints. Apply only the specified lubricant amount to each CV joint. CAUTION: Proper CV joint boot sealing is critical for retaining the special lubricant. Prevent foreign material from entering and contaminating the CV joints. Mishandling a CV drive shaft can cause a boot to be punctured or damage within the joints. Always support both ends of the CV drive shaft during removal and installation to avoid damage. When replacing CV drive shaft components, ensure that only exact replacements parts are installed.
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SHAFT REMOVAL/INSTALLATION
REMOVAL (1) Remove the cotter pin, nut lock, and spring washer from the stub shaft (Fig. 2).
Fig. 4 Hub Nut & Washer Fig. 2 Cotter Pin, Nut Lock & Spring Washer Removal
(2) Loosen the lug nuts and hub nut while the vehicle is on the surface with the brakes applied (Fig. 3). (3) Clean all foreign material from the stub shaft threads. Install the hub nut and washer (Fig. 5). (4) Apply the brakes and tighten hub nut to 258 N m (190 ft. lbs.) torque. (5) Install the spring washer, nut lock and cotter pin on the stub shaft (Fig. 6). (6) Install the wheel and tire.
INNER CV JOINT
DISASSEMBLY (1) Remove the CV drive shaft. Refer to CV Drive Shaft Removal in this Group. (2) Place the inner CV joint housing in a vise. (3) Remove the inner rubber boot retaining clamps and clamp protector. Pull the inner boot back onto the interconnecting shaft. Discard the retaining clamps. (4) Pull the tripod and shaft straight out from the inner CV joint housing. (5) Move the snap retaining ring from the groove behind the tripod (Fig. 7). Slide the tripod toward the center of the shaft. Remove the C-clip on the outer end of the shaft (Fig. 8). (6) Remove the tripod from the shaft. Replace the boot as necessary. (7) Remove the lubricant from the interior of the housing and from the tripod. (8) Inspect the needle bearing raceways in the housing and tripod components for excessive wear and damage. Replace the tripod as a unit only if necessary. ASSEMBLY (1) Slide the boot down enough for work access. The inner boot will be marked and MUST only be used on the tripod end. (2) Install the snap ring past the ring grove (toward the center of the shaft). Slide the tripod onto the end of the interconnecting shaft. Be sure the chamfered end of the tripod is adjacent to the C-
INSTALLATION (1) Insert the CV drive shaft stub into the hub bearing. (2) Attach the inner joint flange to the axle shaft flange (Fig. 5). Tighten the bolts to 90 N m (65 ft. lbs.) torque.
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OUTER CV JOINT
If the outer CV joint is excessively worn, replace the entire CV joint and rubber boot.
DISASSEMBLY (1) Remove the CV drive shaft. Refer to CV Drive Shaft Removal in this Group. (2) Unsnap the clamp protectors (if installed). Remove retaining clamps from the outer CV joint and discard. Slide the boot off the outer joint and down the shaft. (3) Remove the lubricant to expose the outer CV joint components (Fig. 10).
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ASSEMBLY (1) Lightly apply lubricating oil to all the outer CV joint components (Fig. 9) before assembling them. (2) Align the bearing hub, cage and housing (Fig. 12) according to the alignment reference marks. (3) Insert one of the bearing hub lands into a bearing cage window (Fig. 15). Roll the hub into the cage. Rotate the bearing hub 90 to complete the installation (Fig. 16).
INSPECTION Inspect the lubricant for contamination. Inspect the outer CV joint components for defects according to the following instructions. (1) Clean all the components with an appropriate solvent and dry them with compressed air. (2) Inspect the ball raceways in the housing for excessive wear and scoring. (3) Examine the stub shaft splines and threads for damage. (4) Inspect the balls for pitting, cracks, scoring and excessive wear. A dull exterior surface is normal.
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Fig. 17 Assembled Bearing Cage & Hub Fig. 20 Ball Installation In Raceway
outer CV joint. Use installer tool L-4518-1 from tool set L-4518 and hammer slinger onto joint until it seats (Fig. 21). CAUTION: Prevent damage to the slinger after installation or a when a replacement outer CV joint is installed.
Fig. 21 Slinger Installation Fig. 19 Bearing Cage & Hub Installed In Housing
bricant equally between all the raceways. One packet of lubricant is sufficient to lubricate the complete CV joint. (6) Tilt the bearing hub and cage and install the balls in the raceways (Fig. 20). (7) Apply a small amount of lubricant to inner diameter of slinger. Place slinger squarely on the (8) Position the small-diameter end of the replacement rubber boot on the interconnecting shaft. Retain the boot with a replacement clamp. Refer to CV Joint Rubber Boots in this Section. (9) Align the shaft splines to the outer CV joint splines. Push the outer CV joint until the snap ring seats in the groove (Fig. 22).
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and outer large clamps. The clamps are installed according to the provided instructions below.
RUBBER BOOTS
HANDLING AND CLEANING PRECAUTIONS Extreme care must be exercised to avoid puncturing or tearing the boots. The rubber material in shaft boots is not compatible with oil, gasoline, or petroleum-based cleaning solvents. Do not expose the rubber boots to any of these fluids. Use only soap and water to clean the rubber boots. After cleaning, the rubber boot must be thoroughly rinsed and dried. INSPECTION Look for lubricant around the exterior of a boot. When a CV drive shaft is removed from the vehicle for service, the boot should be properly cleaned. Inspect for cracks, tears and scuffed areas on the surfaces. If any of these conditions exist, boot replacement is recommended. RETAINING CLAMPS Two different sizes of ladder type clamps are used to retain the rubber boots. The same size ladder clamp is used to retain the small-diameter end of the inner and outer CV Joint rubber boots. Clamp Installer/Remover C-4124 is used to compress and tighten the clamp (Fig. 23). Service replacement clamps use a protective plastic strap over both inner
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page . . . . . . . . . . . . . . . 31 33 31 38 34
GENERAL INFORMATION
The 7 1/4 inch front axle consists of a cast iron differential housing with axle shaft tubes extending from either side. The tubes are pressed into and welded to the differential housing to form a one-piece axle housing. The integral type housing, hypoid gear design has the centerline of the pinion set below the centerline of the ring gear. The axle has a fitting for a vent hose used to relieve internal pressure caused by lubricant vaporization and internal expansion. The axle shafts are retained by C-clips in the differential side gears. The cover provides a means for inspection and service of the differential without removing the axle. The axles have the gear ratio listed on a tag. The tag is attached to the housing cover. The differential case is a one-piece design. The differential pinion mate shaft is retained with a threaded roll pin. Differential bearing preload and ring gear backlash is adjusted by the use of threaded adjusters. The adjusters are located between the differential bearing cups and housing tubes. Pinion bearing preload is set and maintained by the use of a collapsible spacer. PINION GEAR DEPTH MEASUREMENT WITH GAUGE SET C-3715-B is used when; The axle/differential housing is being replaced The original pinion depth shim pack is lost or misplaced Replacing the differential case Replacing pinion and differential bearings
Refer to Group 0, Lubrication and Maintenance for additional information. CAUTION: If axle is submerged in water, lubricant must be replaced immediately to avoid possible premature axle failure.
LUBRICANT SPECIFICATIONS
Multi-purpose, hypoid gear lubricant should be used in the 7 1/4 inch axle. The lubricant should have MIL-L-2105C and API GL 5 quality specifications. MOPAR Hypoid Gear Lubricant conforms to both of these specifications. The factory installed lubricant for the 7 1/4 inch front axle is SAE 80W 90 gear lubricant The factory installed lubricant quantity is 48 1 fluid oz.
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LUBRICANT CHANGE
The gear lubricant will drain quicker if the vehicle has been recently driven. (1) Raise and support the vehicle. (2) Remove the lubricant fill hole plug from the differential housing cover. (3) Remove the differential housing cover and drain the lubricant from the housing. (4) Clean the housing cavity with a flushing oil, light engine oil or lint free cloth. Do not use water, steam, kerosene or gasoline for cleaning.
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Install the housing cover within 5 minutes after applying the sealant. If not installed the sealant must be removed and another bead applied. (7) Install the cover and any identification tag. Tighten the cover bolts in a criss-cross pattern to 47 N m (35 ft. lbs.) torque. (8) Refill the differential with MOPAR Hypoid Gear Lubricant within 13 mm (1/2 in.) below the fill plug hole. (9) Install the fill hole plug and lower the vehicle.
INSTALLATION (1) Apply a light coating of gear lubricant on the lip of pinion seal. Install seal with Installer C-4076-A and Handle C-4735.
CAUTION: Exercise care during the bearing preload torque adjustment. Do not over-tighten, or loosen and then re-tighten the nut. Do not exceed the bearing preload torque. The collapsible preload spacer on the pinion shaft will have to be replaced. The bearing preload torque will be re-adjusted afterward.
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RIGHT SIDE AXLE SHAFT REMOVAL (1) Raise and support the vehicle. (2) Remove CV drive shaft from axle shaft flange. Refer to CV Drive Shaft Removal. (3) Remove shock absorber. (4) Turn torsion bar adjustment bolt counter-clockwise to completely remove tension from torsion bar. Count the number of turns for installation reference.
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(5) Remove cotter pin and nut from lower ball stud. Separate ball stud from knuckle with Remover C-3564A. (6) Clean all the foreign material from housing cover area. (7) Loosen the housing cover bolts and drain the lubricant from the housing. Remove the housing cover. (8) Rotate the differential case so the differential pinion shaft lock screw is accessible. Remove the lock screw and pinion shaft from the differential case (Fig. 8). (9) Push the axle shaft in toward the center of the vehicle. Remove the axle shaft C-clip lock from the axle shaft (Fig. 9). (10) Lift knuckle and upper suspension arm up and remove the axle shaft. Use care to prevent damage to the axle shaft bearing, which will remain in the axle shaft tube. (11) Inspect the axle shaft bearing contact surface area for indications of brinelling, spalling, and pitting. (12) If any of these conditions exist, the axle shaft and bearing must be replaced. The normal appearance (from roller bearing contact) will be a dull gray surface area that could appear slightly dented.
BEARING AND SEAL INSTALLATION (1) Wipe the bore in the axle shaft tube clean. (2) Install bearing into axle shaft tube with Installer C-4198 and Handle C-4171.
CAUTION: DO NOT use the new axle shaft seal to position or seat the bearing in the axle shaft bore. (3) Install a new axle shaft seal (Fig. 11) with Installer C-4203 and Handle C-4171. The flat side of the installation tool must face the seal.
SEAL AND BEARING REMOVAL (1) Remove the axle shaft seals (Fig. 10) with a small pry bar.
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RING GEAR Do not remove the ring gear from case unless the runout must be measured. (1) Clamp the case (with the ring gear bolts facing upward). Use a vise equipped with soft jaws (brass). (2) Remove and discard the ring gear bolts. The bolts have left-hand threads. Use a hammer and a brass drift to force the ring gear loose from the case pilots. Remove the ring gear.
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runout must not exceed 0.003 inch (0.08 mm). If the runout exceeds the amount, replace the differential case. You can reduce excessive ring gear runout by positioning the ring gear runout mark 180 degrees opposite the flange runout mark. (5) Remove the differential bearing cap bolts. Remove the differential case from the differential housing.
DIFFERENTIAL CASE DISASSEMBLY (1) Rotate the side gears until the pinion gears are located at the differential case opening and remove them. (2) Remove the side gears and the thrust washers. (3) Remove the differential bearings from the case hubs with Puller C-293-PA and Adapter C-293-44 and Plug SP-3289 (Fig. 21).
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(4) Inspect the differential side and pinion gears. Replace any gear that is worn, cracked or chipped. (5) Inspect the differential case. Replace the case if cracked or damaged. Polish each axle shaft with No. 600 crocus cloth. This can remove slight surface damage. Do not reduce the diameter of the axle shaft seal contact surface. When polishing, the crocus cloth should be moved around the circumference of the shaft (not in-line with the shaft). When replacing a drive pinion gear bearing, always replace the bearing and cup as a matched set only. (6) Inspect the axle shaft C-clip locks for cracks and excessive wear. Replace them if necessary. (7) Test each threaded adjuster to determine if it rotates freely. (8) If an adjuster binds, repair the damaged threads or replace the adjuster.
DIFFERENTIAL CASE ASSEMBLY (1) Lubricate all the differential case components with gear lubricant. (2) Place the thrust washers on the differential side gears. Position the gears in the differential case counterbores. If replacement side gears or thrust washers are used, refer to Differential Side Gear Clearance Measurement And Adjustment. (3) Position the thrust washers on the differential pinion gears. Mesh the pinion gears with the side gears. Ensure that the pinion gears are exactly 180 degrees opposite each other. (4) Rotate the side gears to align the pinion gears and thrust washers. Align these components with the mate shaft bores in the case. (5) If the ring gear was removed, clean all contact surfaces. Use an Arkansas stone or fine file to remove any sharp areas from the chamfered inside diameter. (6) If removed, heat ring gear with a heat lamp or by immersing in a hot fluid. The temperature should not exceed 149C (300F). Do not use a torch to heat the ring. (7) Position heated gear on case. Use two equally spaced Pilot Studs C-3288-B to align the gear with the flange holes (Fig. 22). (8) Install replacement ring gear bolts (with left hand threads). Alternately and evenly tighten each bolt to 95 N m (70 ft. lbs.) torque.
CAUTION: When installing a differential bearing, never apply force to the bearing cage because bearing damage will result. (9) Place a differential bearing on each hub with Installer C-3716-A and Handle C-4171 (Fig. 23).
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(8) Center the tool. Place a piece of 0.002 inch shim stock at each end of the arbor. Position the bearing caps on the arbor tool. Install the bolts. Tighten the cap bolts to 14 N m (10 ft. lbs.) torque. (9) Trial fit depth shim(s) between the crossbore arbor and gauge block (Fig. 26). The depth shim(s) fit must be snug but not tight (drag friction of a feeler gauge blade).
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load torque is 1 N m (10 in. lbs.) torque in addition to the torque measured and recorded during disassembly.
DIFFERENTIAL CASE INSTALLATION (1) Apply a coating of hypoid gear lubricant to the differential bearings, bearing cups and threaded adjusters. A dab of grease can be used to keep the adjusters in position. Carefully position the assembled differential case in the housing. (2) Observe the reference marks and install the differential bearing caps at their original locations (Fig. 32). (3) Install the bearing cap bolts (Fig. 31). Tighten the upper bolts to 14 N m (10 ft. lbs.) torque. Tighten the lower bolts finger-tight until the bolt head is lightly seated. DIFFERENTIAL BEARING PRELOAD AND RING GEAR BACKLASH ADJUSTMENT The following must be considered when adjusting differential bearing preload torque and ring gear backlash: The maximum ring gear backlash variation is 0.003 inch (0.076 mm)
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SIDE GEAR CLEARANCE MEASUREMENT AND ADJUSTMENT When measuring side gear clearance, check each gear independently. One side gear can have an acceptable clearance and other side gear to have an unacceptable clearance. If it necessary to replace a side gear, replace both gears as a matched set. (1) Install the axle shafts and C-clip locks and pinion mate shaft. If necessary, refer to the installation located within this group. (2) Measure each side gear clearance. Insert a matched pair of feeler gauge blades between the gear and differential housing on opposite sides of the hub (Fig. 35).
RING GEAR TEETH CONTACT PATTERN ANALYSIS The ring gear teeth contact patterns will show if the pinion gear depth shim(s) have the correct thickness. It will also show if the ring gear backlash has been adjusted correctly. The backlash must be maintained within the specified limits until the correct teeth contact patterns are obtained. Excessive backlash is corrected by moving the ring gear teeth closer to the pinion gear teeth Insufficient backlash is corrected by moving the ring gear away from the pinion gear (1) Apply yellow ferrous (iron) oxide compound to both drive and coast sides of ring gear teeth. (2) Rotate the ring gear one complete revolution in both directions. (3) Note patterns in compound. Refer to (Fig. 37) for interpretation of contact patterns and adjust accordingly. (4) Install the axle shafts. Refer to Axle Shaft Installation in this group. (5) Install the housing cover. Refill the differential with lubricant. Refer to Axle Shaft Installation.
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Case Flange Runout ................0.076 mm (0.003 in.) Ring Gear Diameter .......................................18.41 cm (7.25 in.) Backlash....................0.07-0.15 mm (0.003-0.006 in.) Runout .......................................0.127 mm (0.005 in.) Pinion Bearing Preload....................................1-2 N m (10-20 in.lbs.)
CV DRIVE SHAFT
DESCRIPTION ................................................TORQUE Axle Shaft Flange Bolts.................................90 N m (65 ft. lbs.) Axle Nut...................................258 N m (190 ft. lbs.)
7 1/4 AXLE
DESCRIPTION ................................................TORQUE Diff. Cover Bolt ........................47 N m (35 ft. lbs.) Bearing Cap Bolt .....................61 N m (45 ft. lbs.) Ring Gear Bolt .........................95 N m (70 ft. lbs.)
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7 1/4 and 8 1/4 INCH AXLE . . . . . . . . . . . . . . . 12 AXLE NOISE/VIBRATION DIAGNOSIS . . . . . . . . . 8 AXLE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . 36 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1
AXLES
The 7 1/4 or 8 1/4 Inch axle housings consist of a cast iron center section. They also have two steel axle shaft tubes that are pressed into and welded to the differential housing.
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IDENTIFICATION The diameter of the ring gear can be determined from the size of the axle shaft tubes. The 7 1/4 Inch axle has shaft tubes that are 2.5inch (63.5-mm) diameter at the inner end. The outer end is 3.0-inch (76.2-mm) diameter The 8 1/4 Inch axle has axle shaft tubes that have a 3.0-inch (76.2-mm) diameter at both ends The axle differential covers can be used for identification (Fig. 2, 3).
STANDARD DIFFERENTIAL OPERATION The differential gear system divides the torque between the axle shafts. It allows the axle shafts to rotate at different speeds when turning corners. Each differential side gear is splined to an axle shaft. The pinion gears are mounted on a pinion mate shaft and are free to rotate on the shaft. The pinion gear is fitted in a bore in the differential case and is positioned at a right angle to the axle shafts. In operation, power flow occurs as follows: The pinion gear rotates the ring gear The ring gear (bolted to the differential case) rotates the case The differential pinion gears (mounted on the pinion mate shaft in the case) rotate the side gears The side gears (splined to the axle shafts) rotate the shafts During straight-ahead driving, the differential pinion gears do not rotate on the pinion mate shaft. This occurs because input torque applied to the gears is divided and distributed equally between the two side gears. As a result, the pinion gears revolve with the pinion mate shaft but do not rotate around it (Fig. 4). When turning corners, the outside wheel must
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SHOCK ABSORBER
REMOVAL (1) Raise and support the vehicle. (2) Remove the shock absorber lower nut and bolt from the axle bracket (Fig. 1, 2). (3) Remove the shock absorber upper nuts and bolts from the frame crossmember bracket (Fig. 1, 2). Remove the shock absorber. INSTALLATION (1) Install the shock absorber and upper fasteners on the frame bracket (Fig. 1, 2).
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LEAF SPRINGS
CAUTION: The rear of the vehicle must be lifted only with a jack or hoist. The lift must be placed under the frame rail crossmember located aft of the rear axle. Use care to avoid bending the side rail flange.
REMOVAL (1) Raise the vehicle at the frame. (2) Use a hydraulic jack to relieve the axle weight. (3) Remove the wheel and tire. (4) Remove the nuts, the U-bolts and spring bracket from the axle (Fig. 1, 2). (5) Remove the nut and bolt that attaches the spring rear eye to the shackle (Fig. 1, 2). (6) Remove the nut and bolt from the spring front eye (Fig. 1, 2). (7) Remove the spring from the vehicle.
INSTALLATION (1) If removed, install the spring shackle on the spring finger tight (Fig. 1, 2). (2) Position the spring on the rear axle pad. Make sure the spring center bolt is inserted in the pad locating hole (Fig. 1, 2). If 2WD, ensure the parking brake cable guide is properly positioned. (3) Align the spring front eye with the bolt hole in the rail front bracket. Install the spring eye bolt and nut (Fig. 1, 2). Tighten the spring eye nut fingertight. (4) Align the spring shackle eye with the bolt hole in the rail rear bracket. Install the bolt and nut (Fig. 1, 2). Tighten the spring shackle eye nut finger-tight. (5) Install the spring seat (2WD only), U-bolts, spring bracket, replacement washers and nuts (Fig. 1, 2). Tighten the nuts until the washers are compressed against the spring bracket. (6) Remove the support stands from under the frame rails. Lower the vehicle until the springs are supporting the weight of the vehicle. Tighten the Ubolt nuts (Fig. 1, 2): 2WD vehicles88 N m (65 ft. lbs.) torque 4WD vehicles149 N m (110 ft. lbs.) torque (7) Tighten the spring eye pivot bolt nut and all shackle nuts to 88 N m (65 ft. lbs.) torque (Fig. 1, 2). (8) Install the wheel and tire.
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(5) Remove the spring from the vise. Replace the broken/defective leaf. Insert a long drift or punch into the spring center bolt hole. (6) Position the spring between vise jaws and slowly tighten the vise jaws. Keep the spring leaves aligned with the long drift or punch. (7) Remove the drift from the spring center bolt hole. Install a replacement center bolt and nut (Fig. 3). (8) Tighten the nut to 40 N m (30 ft. lbs.) torque. An alternate way is to tighten the nut until the spring has no gaps between the leaves (maximum of 54 N m/40 ft. lbs. torque). (9) Install the alignment clips. (10) Pin the center bolt with a hammer to prevent the nut from backing off. (11) Install the spring in the vehicle. If necessary refer to the installation procedure.
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Driveline Snap . . . . . . Gear and Bearing Noise General Information . . Limited Slip Differential
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GENERAL INFORMATION
Axle bearing problem conditions are usually caused by: Insufficient or incorrect lubricant Foreign matter/water contamination Incorrect bearing preload torque adjustment When serviced, the bearings must be cleaned thoroughly. They should be dried with lint-free shop towels. Never dry bearings with compressed air. This will overheat them and brinell the bearing surfaces. This will result in noisy operation after repair. Axle gear problem conditions are usually the result of: Insufficient lubrication Incorrect or contaminated lubricant Overloading (excessive engine torque) Incorrect clearance or backlash adjustment Insufficient lubrication is usually the result of a housing cover leak. It can also be from worn axle shaft or pinion gear seals. Check for cracks or porous areas in the housing or tubes. Using the wrong lubricant or over filling will cause overheating and gear failure. Gear tooth cracking and bearing spalling are indicators of this. Axle component breakage is most often the result of: Severe overloading Insufficient lubricant Incorrect lubricant Improperly tightened components Common causes of overloading is from full-throttle acceleration. Overloading happens when towing heavier-than-recommended loads. Component breakage can occur when the wheels are spun excessively. Insufficient or incorrect lubricants contribute to breakage through overheating. Loose differential components can also cause breakage. Incorrect bearing preload or gear backlash will not result in component breakage. Mis-adjustment will produce enough noise to cause service repair before a failure occurs. If a mis-adjustment condition is not corrected, component failure can result.
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VIBRATION
Vibration at the rear of the vehicle is usually caused by a: Damaged drive shaft Missing drive shaft balance weight Worn, out-of-balance wheels Loose wheel lug nuts Worn U-joint Loose spring clamp bolts Loose/broken springs Damaged axle shaft bearings Loose pinion gear nut Excessive pinion yoke run out Bent axle shaft 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. Do not overlook engine accessories, brackets and drive belts. All driveline components should be examined before starting any repair. Refer to Group 22, Wheels and Tires for additional information.
DRIVELINE SNAP
A snap or clunk noise when the vehicle is shifted into gear (or the clutch engaged), can be caused by: High engine idle speed Loose engine/transmission/transfer case mounts Worn U-joints Loose spring mounts Loose pinion gear nut and yoke Excessive ring gear backlash Excessive differential side gear-to-case clearance The source of a snap or a clunk noise can be determined with the assistance of a helper. Raise the vehicle on a hoist with the wheels free to rotate. Instruct the helper to shift the transmission into gear. Listen for the noise, a mechanics stethoscope is helpful in isolating the source of a noise.
(2) Attach a one-inch long piece of masking tape at the center of each tire tread for use as reference marks. (3) Rotate the rear wheels until both reference marks face the front of the vehicle. Measure the distance between the outside edges of the two pieces of tape. Record this measurement as the front of tire (FTR) measurement. (4) Rotate the rear wheels until both reference marks face the rear of the vehicle. Measure the distance between the outside edges of the two pieces of tape. Record this measurement as the rear of tire (RTR) measurement. (5) Subtract the (RTR) measurement from the (FTR) measurement to obtain the amount of wheel toe. The acceptable rear wheel toe-in position is 1/16 inch (1.6 mm) to 3/16 inch (4.8 mm) toe-out. (6) Rotate the rear wheels until the reference marks are facing downward. Measure the distance between the outside edges of the two pieces of tape. Record this measurement as the bottom of tire (BTR) measurement. (7) Average the (FTR) and the (RTR) distance measurements. Subtract the (BTR) measurement from this average distance to obtain the camber. The acceptable amount of camber is 1/16 inch to 3/32 inch (1.6 to 2.4 mm). (FTR + RTR) DIVIDED BY 2 (TWO) MINUS BTR EQUALS CAMBER If the (BTR) distance measurement is less than the average FTR and RTR distance measurement, the camber will be positive ( + ). If the (BTR) distance measurement is greater than the average FTR and RTR distance, the camber will be negative ( - ). If the toe position or camber is not acceptable, a bent or deformed rear axle shaft is most likely the cause.
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REAR SUSPENSION AND AXLES 7 1/4 and 8 1/4 INCH AXLE INDEX
page page Lubricant Specifications . . . . . . . . . . . . . . . . . . . . . 12 Pinion Depth Measurement and Adjustment with Gauge Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Pinion Seal Replacement . . . . . . . . . . . . . . . . . . . 17 The factory installed lubricant for the 7 1/4 inch and 8 1/4 inch rear axles is SAE 80W 90 gear lubricant The factory installed lubricant quantity 7 1/4 inch, 46 1 fluid oz.. 8 1/4 Inch, 70 1 fluid oz.. Refer to Group 0, Lubrication and Maintenance for additional information. CAUTION: If axle is submerged in water, lubricant must be replaced immediately to avoid possible premature axle failure.
Axle Shaft, Seal and Bearing Service Differential Service . . . . . . . . . . . . . Drive Axle Assembly Replacement . . General Information . . . . . . . . . . . . Lubricant Change . . . . . . . . . . . . . .
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GENERAL INFORMATION
The 7 1/4 inch and 8 1/4 inch rear axle consists of a cast iron housing. Tubes are pressed into and welded to the housing to form a one-piece axle housing. The integral housing hypoid gear design, has the pinion set below the centerline of the ring gear. The axle uses a vent hose to relieve internal pressure caused by lubricant vaporization and expansion. The axles are equipped with semi-floating axle shafts, meaning that loads are supported by the axle shaft and bearings. The axle shafts are retained by C-clips in the differential side gears. The axles are equipped with RWAL brake sensors. The sensor is attached to the differential housing and the exciter ring is pressed on the differential carrier. Use care when removing the differential as NOT to damage the sensor. The removable cover provides a means for inspection and servicing the differential. The axles have the gear ratio listed on a tag. The tag is attached to the housing cover. The differential case is a one-piece design. The differential pinion mate shaft is retained with a threaded roll pin. Differential bearing preload and ring gear backlash is adjusted by the use of threaded adjusters. The adjusters are located between the differential bearing cups and housing tubes. Pinion bearing preload is set and maintained by the use of a collapsible spacer. PINION GEAR DEPTH MEASUREMENT WITH GAUGE SET C-3715-B is used when; The axle/differential housing is being replaced The original pinion depth shim pack is lost or misplaced Replacing the differential case Replacing pinion and differential bearings
LUBRICANT SPECIFICATIONS
Multi-purpose, hypoid gear lubricant should be used for the 7 1/4 inch and 8 1/4 inch rear axles. The lubricant should have MIL-L-2105C and API GL 5 quality specifications. Mopar Hypoid Gear Lubricant conforms to both of these specifications.
REMOVAL (1) Raise the vehicle to a comfortable working height that will permit support stands to be installed at the front of the rear springs. (2) Block the brake pedal in the up (non-depressed) position with a wooden block. (3) Remove the wheel and tire. Do not remove the brake drum retaining clips or the drums. (4) Disconnect the brake fluid tube fittings from the wheel cylinders. Cap the fittings to prevent loss of brake fluid. (5) Remove the vent hose from the brake tee nipple. (6) Remove the brake tee bolt. Carefully detach the brake fluid tubes from the clips. Disconnect the RWAL brake sensor. (7) Disconnect the parking brake cables. Mark the U-joint, pinion yoke, and pinion shaft for reference. (8) Disconnect the drive shaft from the pinion yoke. Secure the drive shaft in an upright position to prevent damage to the rear U-joint. (9) Remove the shock absorber lower nuts and bolts. Remove the rear spring U-bolts and spring brackets. (10) Remove the axle assembly from the vehicle.
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INSTALLATION (1) Support the vehicle at the front of the rear springs. Position the spring pads on the parking brake cable guides (2WD vehicles) or against the spring center bolts (4WD vehicles). Ensure the spring center bolts and holes in the spring pads are correctly aligned. (2) Install the spring U-bolts, brackets and nuts. Install the shock absorber lower bolts and nuts. 2WD vehicles88 N m (65 ft. lbs.) torque 4WD vehicles149 N m (110 ft. lbs.) torque (3) Tighten the spring U-bolt nuts finger-tight. Tighten the shock absorber nuts to 81 N m (60 ft. lbs.) torque. (4) Connect the parking brake cables. (5) Remove the block from the brake pedal. (6) Connect the brake tube fittings to the wheel cylinders, bleed and adjust the brakes. (7) Attach the brake tubes to the clips. (8) Install the brake tee bolt. Tighten it to 14 N m (10 ft. lbs./125 in. lbs.) torque. (9) Connect the vent hose to the brake tee nipple. (10) Install the drive shaft with the installation reference marks aligned. Tighten the U-joint yoke clamp screws to 19 N m (14 ft. lbs./170 in. lbs.) torque. (11) Install the wheel and tire. (12) Adjust the hoist so the vehicle is in a level position. Check the differential housing lubricant level. If necessary, add Mopar Hypoid Gear Lubricant to the correct level.
LUBRICANT CHANGE
The gear lubricant will drain quicker if the vehicle has been recently driven. (1) Raise and support the vehicle. (2) Remove the lubricant fill hole plug from the differential housing cover. (3) Remove the differential housing cover and drain the lubricant from the housing. (4) Clean the housing cavity with a flushing oil, light engine oil or lint free cloth. Do not use water, steam, kerosene or gasoline for cleaning. (5) Remove the sealant from the housing and cover surfaces. Use solvent to clean the mating surfaces. (6) Apply a bead of Mopar Silicone Rubber Sealant to the housing cover (Fig. 3). Allow the sealant to cure for a few minutes. Install the housing cover within 5 minutes after applying the sealant. If not installed the sealant must be removed and another bead applied.
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AXLE SHAFT REMOVAL (1) Raise and support the vehicle. (2) Remove the wheel and tire. (3) Remove the brake drum. (4) Clean all the foreign material from housing cover area. (5) Loosen the housing cover bolts. Drain the lubricant from the housing. Remove the housing cover. (6) Rotate the differential case so that the pinion mate gear shaft lock screw is accessible. Remove the lock screw and the pinion mate gear shaft from the case (Fig. 4).
SEAL AND BEARING REMOVAL (1) Remove the axle shaft seal with a small pry bar. (2) Remove the bearing if it appears damaged or the axle shaft shows any of the conditions described above.
BEARING AND SEAL INSTALLATION Do not install the original axle shaft seal. Always install a new seal. (1) Wipe the bore in the axle shaft tube clean. (2) If the original bearing is not reusable, install a new bearing. Place the axle shaft bearing on the pilot of Bearing Installer C-4198 and Handle C-4171.
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REMOVAL (1) Raise and support the vehicle. (2) Mark the U-joint, pinion yoke, and pinion shaft for reference. (3) Disconnect the drive shaft from the pinion yoke. Secure the drive shaft in an upright position to prevent damage to the rear U-joint. (4) Remove the rear wheels and tire and brake drums to prevent any drag. The drag can cause a possible false bearing preload torque measurement. (5) Use a Newton-meter or an inch-pound torque wrench to measure the pinion bearing preload. Rotate the pinion shaft several times with the torque wrench. Note the indicated torque as the wrench is moved through several revolutions. This measurement is important because bearing preload torque must be carefully re-adjusted after the seal installation. (6) Remove the pinion gear nut and washer. Use Puller C-452 and Wrench C-3281 to remove the pinion gear yoke (Fig. 8).
AXLE SHAFT INSTALLATION (1) Lubricate the bearing bore and seal lip. Insert the axle shaft and engage the splines with the side gear. Use care to prevent the shaft splines from damaging the axle shaft seal lip. (2) Insert the C-clip lock in the recessed groove (Fig. 2). Push the axle shaft outward to seat the Cclip lock. (3) Insert the pinion gear mate shaft in the case. Install through the thrust washers and pinion gears. Align the hole in the shaft with the lock screw hole. Install the lock screw with Loctite on the threads. Tighten the screw to 11 N m (8 ft. lbs.) torque (Fig. 1). (4) Clean the cover and apply a bead of sealant. Refer to the Drain and Refill in this section. (5) Install the brake drum. Install the wheel and tire. (6) Raise or lower the hoist until the vehicle is level. (7) Remove the fill hole plug. Fill the differential housing with lubricant. Refer to the Specifications chart for the type and the quantity. Install the fill hole plug. (8) Lower the vehicle and test the brakes and axle for correct operation.
INSTALLATION (1) Examine the splines on the pinion shaft for burrs or wear. (2) Remove any burrs and clean the shaft. (3) Inspect the pinion yoke for cracks, worn splines and a worn seal contact surface. Repair or replace the yoke as necessary. The outer perimeter of the seal is pre-coated with a special sealant. An additional application of sealant is not required. (4) Install the new pinion shaft seal (Fig. 10) with Seal Installer C-4076-A and Handle C-4735. The seal is correctly installed when the seal
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(3) Eliminate any side play in the differential case. Attach Dial Indicator to Pilot stud C-3288-B. Place the indicator plunger at a right angle (90) to the ring gear (Fig. 13). The plunger should exert a slight force against the gear face.
DIFFERENTIAL CASE REMOVAL (1) Remove the axle shafts, refer to Axle Shaft Removal. Side play and runout checks taken during disassembly will be very useful in reassembly. (2) Measure for differential side play. Position a screwdriver or pinch bar between left side of axle housing and case flange (Fig. 12). Use a prying motion to determine if any side play exists. There should be no side play.
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DIFFERENTIAL CASE DISASSEMBLY (1) Rotate the side gears until the pinion gears are located at the differential case opening and remove them. (2) Remove the side gears and the thrust washers. (3) Remove the differential bearings from the case hubs with Puller C-293-PA, Adapter and Plug SP-3289 (Fig. 21). 7 1/4 Inch axle use Adapter C-293-44 8 1/4 Inch axle use Adapter C-293-48 CLEANING AND INSPECTION (1) Clean all of the differential components in cleaning solvent. Allow the bearings to either air dry or dry them with a lint-free cloth. Dry the other components with compressed air. (2) Examine each component for wear or damage. (3) Replace shims, bearings and cups as a set only. Replace bearings and cups if either is galled, worn, cracked, or damaged. (4) Inspect the differential side and pinion gears. Replace any gear that is worn, cracked or chipped. (5) Inspect the differential case. Replace the case if cracked or damaged. Polish each axle shaft with No. 600 crocus cloth. This can remove slight surface damage. Do not reduce the diameter of the axle shaft seal contact surface. When polishing, the crocus cloth should be moved around the circumference of the shaft (not in-line with the shaft). When replacing a drive pinion gear bearing, always replace the bearing and cup as a matched set only.
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EXCITER RING REPLACEMENT The ring gear must be removed before the RWAL brake exciter ring can be replaced. (1) Remove exciter ring with a hammer and drift. (2) Heat the replacement exciter ring with a heat lamp or by immersing in a hot fluid. The temperature should not exceed 149C (300F). Do not use a torch to heat the ring. (3) After heating, quickly position the exciter ring on the differential case adjacent to the flange. DIFFERENTIAL CASE ASSEMBLY (1) Lubricate all the differential case components with gear lubricant. (2) Place the thrust washers on the differential side gears. Position the gears in the differential case counterbores. If replacement side gears or thrust washers are used, refer to Differential Side Gear Clearance Measurement And Adjustment.
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7 1/4 Inch axles (Fig. 24) Install Gauge Block SP-3250 at the end of SP-5385 Install Cap Screw (SP-536) and tighten with Wrench SP-531 8 1/4 Inch axles (Fig. 25) Install Gauge Block SP-5383 at the end of SP-5385 Install Cap Screw (SP-536) and tighten with Wrench SP-531 (7) Position Crossbore Arbor in the differential housing. 7 1/4 Inch axles (Fig. 24); (SP-3243) 8 1/4 Inch axles (Fig. 25); (SP-6029) (8) Center the tool. Place a piece of 0.002 inch shim stock at each end of the arbor. Position the bearing caps on the arbor tool. Install the bolts. Tighten the cap bolts to 14 N m (10 ft. lbs.) torque. (9) Trial fit depth shim(s) between the crossbore arbor and gauge block (Fig. 27). The depth shim(s) fit must be snug but not tight (drag friction of a feeler gauge blade). Depth shims are available in 0.001-inch increments from 0.020 inch to 0.038 inch. (10) Note the etched number on the face of the drive pinion gear. The numbers represent thousandsof-an-inch deviation from the standard. If the number is - (negative), add that value to the required thickness of the depth shim(s). If the number is + (positive), subtract that value from the thickness of the depth shim(s). If the number is 0, no change is necessary. (11) Remove the tools from the differential housing.
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CAUTION: Never loosen the pinion gear nut to decrease the pinion gear bearing preload torque. If the specified preload torque is exceeded, a replacement collapsible spacer must be installed. The torque sequence will have to be repeated. (23) Measure the pinion bearing preload torque by rotating pinion shaft with a Newton-meter or an inch-pound torque wrench. The correct bearing preload torque is 1 to 2 N m (10 to 20 in. lbs.). This torque value is with replacement bearings and pinion nut tightened to a minimum of 285 N m (210 ft. lbs.) torque (Fig. 32). When using original pinion rear bearing and a replacement front bearing. The correct preload torque is 1 N m (10 in. lbs.) plus the torque measured during disassembly.
DIFFERENTIAL CASE INSTALLATION (1) Apply a coating of hypoid gear lubricant to the differential bearings, bearing cups and threaded adjusters. A dab of grease can be used to keep the adjusters in position. Carefully position the assembled differential case in the housing. (2) Observe the reference marks and install the differential bearing caps at their original locations (Fig. 33).
DIFFERENTIAL BEARING PRELOAD AND RING GEAR BACKLASH ADJUSTMENT The following limitations must be considered when adjusting the preload torque and backlash: The maximum ring gear backlash variation is 0.003 inch (0.076 mm) Mark the gears so the same teeth are meshed during all backlash measurements Maintain the specified threaded-adjuster torque while adjusting the preload torque and backlash Excessive adjuster torque will introduce a high bearing load and cause premature bearing failure; insufficient adjuster torque can result in excessive differential case free-play and ring gear noise Insufficient adjuster torque can cause excessive differential case free-play and ring gear noise The differential bearing cups will not always immediately follow the threaded adjusters as they are moved during adjustment. Ensure accurate bearing cup responses to the adjustments. Maintain the gear teeth engaged (meshed) as marked. The bearings must be seated by rapidly rotating the pinion gear a half turn back and forth. Do this five to ten times each time the threaded adjusters are adjusted. (1) Use Wrench C-4164 to adjust each threaded adjuster inward (Fig. 34) until the differential bearing free-play is eliminated. Allow some ring gear backlash (approximately 0.01 inch/0.25 mm) between the ring and pinion gear. Seat the bearing cups with the procedure described above. (2) Install Dial Indicator (Fig. 35). Position the plunger against the drive side of a ring gear tooth. Measure the backlash at 4 positions (90 degrees
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7 1/4 Inch axles, 0.003 to 0.006 inch (0.076 to 0.152 mm) 8 1/4 Inch axles, 0.005 to 0.008 inch (0.127 to 0.203 mm) Continue increasing the torque at the right-side threaded adjuster until the specified backlash is obtained. The left-side threaded adjuster should have approximately 95 N m (70 ft. lbs.) torque. If the torque is considerably less, the complete adjustment procedure must be repeated. (8) Tighten the left-side threaded adjuster until 95 N m (70 ft. lbs.) torque is indicated. Seat the bearing rollers with the procedure described above. Do this until the torque remains constant. (9) Install the threaded adjuster locks . Ensure the lock finger is engaged with the adjuster hole. Tighten the lock screws to 10 N m (90 in. lbs.) torque.
SIDE GEAR CLEARANCE MEASUREMENT AND ADJUSTMENT When measuring side gear clearance, check each gear independently. One side gear can have an acceptable clearance and other side gear an unacceptable clearance. If it necessary to replace a side gear, replace both gears as a matched set. (1) Install the axle shafts and C-clip locks and pinion mate shaft. If necessary, refer to the installation located within this group. (2) Measure each side gear clearance. Insert a matched pair of feeler gauge blades between the gear and differential housing on opposite sides of the hub (Fig. 36).
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the axle shaft is not contacting the pinion gear mate shaft, the side gear clearance is acceptable. (4) If clearance is more than 0.005 inch (axle shaft not contacting mate shaft), record the side gear clearance. Remove the thrust washer and measure its thickness with a micrometer. Add the washer thickness to the recorded side gear clearance. The sum of gear clearance and washer thickness will determine required thickness of replacement thrust washer (Fig. 37).
RING GEAR TEETH CONTACT PATTERN ANALYSIS The ring gear teeth contact patterns will show if the pinion gear depth shim(s) have the correct thickness. It will also show if the ring gear backlash has been adjusted correctly. The backlash must be maintained within the specified limits until the correct teeth contact patterns are obtained. Excessive backlash is corrected by moving the ring gear teeth closer to the pinion gear teeth Insufficient backlash is corrected by moving the ring gear away from the pinion gear (1) Apply yellow ferrous (iron) oxide compound to both drive and coast sides of ring gear teeth. (2) Rotate the ring gear one complete revolution in both directions. (3) Note patterns in compound. Refer to (Fig. 38) for interpretation of contact patterns and adjust as necessary. (4) Install the axle shafts. Refer to Axle Shaft Installation within this group. (5) Install the housing cover. Refill the differential with lubricant. Refer to Axle Shaft Installation. (6) Install the RWAL brake speed sensor and cover onto the axle housing. Tighten the sensor to 24 N m (18 ft. lbs.) torque.
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GENERAL INFORMATION
The Trac-Loc differential is an option available in the 8 1/4 Inch rear axles (Fig. 1). In a conventional differential, the torque applied to the ring gear is transmitted to the axle shafts through the differential gears. During normal operation, the torque transmitted to each wheel is equal at all times. However, if one wheel spins, the opposite wheel will generate only as much torque as the spinning wheel. In the Trac-Lok differential, part of the ring gear torque is transmitted through clutch packs. The clutch packs contain multiple disc. The clutch will have radial grooves on the plates, and concentric grooves on the discs or bonded fiber material that is smooth appearance. In operation, the Trac-Lok clutches are engaged by two concurrent forces. The first being preload force exerted through Belleville spring washers. The second is from separating forces generated by the side gears (Fig. 1). The Trac-Lok design provides the normal differential action needed for turning corners. It also provides for the transmission of equal torque to both wheels when driving straight ahead. When one wheel loses traction, the clutch packs transfer torque to the wheel having the most traction. Trac-Lok differentials resist wheel spin on bumpy roads. It also provides more pulling power when one wheel loses traction. Pulling power is continuous until both wheels lose traction. If both wheels slip due to unequal traction, Trac-Lok operation is normal. In extreme cases of differences of traction, the wheel with the least traction may spin. This occurs after the Trac-Lok has transferred as much torque as possible to the non-spinning wheel.
NOISE DIAGNOSIS
If chatter occurs when turning corners, the most probable cause is incorrect or contaminated lubricant. Before removing the Trac-Lok unit for repair, drain, flush and refill the axle with the specified lubricant. Refer to Lubricant change in this Group. A container of Trac-Lok Lubricant (friction modifier) should be added after. Vehicles with a limited slip differential should be road tested by making 10 to 12 slow figure-eight turns. This maneuver will pump the lubricant through the clutch discs. Refer to Group 0, Lubrication and Maintenance for additional information.
DIFFERENTIAL TEST
WARNING: WHEN SERVICING VEHICLES WITH A LIMITED SLIP DIFFERENTIAL DO NOT USE THE EN-
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DIFFERENTIAL OVERHAUL
The Trac-Lok differential components are illustrated in (Fig. 3). Refer to this illustration during repair service.
DISASSEMBLY Service to the Trac-Lok differential requires the use of Tool Set C-4487 (J-23781). Refer to Axle section in this Group for Differential Removal and Installation. (1) Clamp one axle shaft in a vise equipped with soft jaws (Fig. 4). (2) Position the differential case on the axle shaft (Fig. 5). Place shop towels under the differential to avoid damage during removal of the ring gear (Fig. 5). (3) Remove and discard the ring gear bolts. Tap
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packs must be replaced. Lubricate each component with gear lubricant before assembly and installation. (2) Assemble the clutch discs into packs and secure disc packs with retaining clips (Fig. 14). (3) Position assembled clutch disc packs on the side gear hubs.
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BRAKES
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BRAKES
CONTENTS
page page
ABS BRAKE OPERATION AND SERVICE . . . . . . 51 ANTILOCK BRAKE SYSTEM DIAGNOSIS . . . . . . 8 DISC BRAKE ROTOR SERVICE . . . . . . . . . . . . . 41 DISC BRAKES2-WHEEL DRIVE . . . . . . . . . . . 27 DISC BRAKES4-WHEEL DRIVE . . . . . . . . . . . 34 DRUM BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . 20 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1 MASTER CYLINDERBRAKE FLUID BRAKELINES . . . . . . . . . . . . . . . . . . . . . . . . . . 12
PARKING BRAKES . . . . . . . . . . . . . . . . . . . . . . . 63 POWER BRAKE BOOSTERBRAKE PEDAL STOPLAMP SWITCH . . . . . . . . . . . . . . . . . . . 17 RWAL BRAKE OPERATION AND SERVICE . . . . 44 SERVICE BRAKE DIAGNOSIS . . . . . . . . . . . . . . . 3 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . 68
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BRAKES
HAZARD. NEVER CLEAN BRAKE COMPONENTS WITH COMPRESSED AIR OR BY DRY BRUSHING. USE A VACUUM CLEANER SPECIFICALLY DESIGNED TO REMOVE ASBESTOS FIBERS. IF A SUITABLE VACUUM CLEANER IS NOT AVAILABLE, PERFORM CLEANING OPERATIONS WITH A WATER DAMPENED CLOTH. DO NOT CREATE DUST BY SANDING, OR GRINDING BRAKELINING. DISPOSE OF ALL DUST AND DIRT SUSPECTED OF CONTAINING ASBESTOS FIBERS IN SEALED BAGS OR CONTAINERS. FOLLOW ALL RECOMMENDED PRACTICES PRESCRIBED BY THE OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA) AND THE ENVIRONMENTAL PROTECTION AGENCY (EPA) FOR HANDLING, PROCESSING, AND DISPOSITION OF MATERIAL THAT MAY CONTAIN ASBESTOS FIBERS.
CAUTION: Never use gasoline, kerosene, alcohol, motor oil, transmission fluid, or any fluid containing mineral oil to clean the system components. These fluids damage rubber cups and seals. If system contamination is suspected, check the fluid for dirt, discoloration, or separation into distinct layers. Drain and flush the system with new brake fluid if contamination is suspected.
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DIAGNOSIS PROCEDURES
The diagnosis information in this section covers service brake components only. Antilock brake component diagnosis is covered in the antilock brake diagnosis section. Service brake components include front/rear brakeshoes, disc brake calipers, wheel cylinders, brake drums, support plates, brakelines, master cylinder, power brake booster, and parking brake components. Brake diagnosis involves determining if the problem is related to a mechanical, hydraulic, vacuum, or electrically operated component. A preliminary check, road testing and component inspection can all be used to determine a problem cause. Road testing will either verify proper brake operation or confirm the existence of a problem. Component inspection will then identify the actual causal part.
(2) Inspect condition of tires and wheels. Damaged wheels and worn, damaged, or underinflated tires can cause pull, shudder, tramp, and a condition similar to grab. (3) If complaint was based on noise when braking, check suspension components. Jounce front and rear of vehicle and listen for noise that might be caused by loose, worn or damaged suspension or steering components. (4) Inspect brake fluid level and condition. Note that fluid level in disc brake reservoir section will decrease in proportion to lining wear. This is a normal condition. (a) If fluid level is abnormally low, look for evidence of leaks at calipers, wheel cylinders, brakelines and master cylinder. (b) If fluid appears contaminated, drain out a sample. If fluid is separated into layers, or obviously contains oil or a substance other than brake fluid, the system seals and cups will have to be replaced and the hydraulic system flushed. (5) Check parking brake operation. Verify free movement and full release of cables and foot pedal or hand lever. Also note if vehicle was being operated with parking brake partially applied. (6) Check brake pedal operation. Pedal should have adequate free play and not bind at any point of travel. If pedal lacks free play, check pedal and power booster for being loose or for bind condition. Do not road test until condition is corrected. (7) If components checked appear OK, and brake action is sufficient to stop vehicle, proceed to road test. However, if brake action is impaired, do not road test vehicle. Instead, raise vehicle on hoist and disassemble/repair as needed.
ROAD TESTING
A road test will confirm or deny the existence of a problem. The final diagnosis procedure involves road test analysis and a visual inspection of brake components. (1) If complaint involved low brake pedal, make several low speed stops and note if pedal returns to
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normal height. If pedal drops off, or brake action is impaired, immediately return to shop and begin repair. (2) Check brake pedal response with transmission in Neutral and engine running. Pedal should remain firm under steady foot pressure. (3) During road test, make normal and firm brake stops in 20-35 mph range. Note faulty brake operation such as pull, grab, drag, noise, low pedal, hard pedal, fade, pedal pulsation, etc. (4) Inspect brake components and refer to problem diagnosis information for causes of various brake conditions.
COMPONENT INSPECTION
Fluid leak points and dragging brake units can usually be located without removing any components. The area around a leak point will be wet with fluid. The components at a dragging brake unit (wheel, tire, rotor) will be quite warm or hot to the touch. Other brake problem conditions will require component removal for proper inspection. Raise the vehicle and remove the necessary wheel brake components for better visual access. During component inspection, pay particular attention to heavily rusted/corroded brake components (e.g. rotors, caliper pistons, brake return/holddown springs, support plates, etc.). Heavy accumulations of rust may be an indicator of rust and corrosion damage to a brake component. It is wise to remove surface rust in order to accurately determine the depth of rust penetration and damage. Light surface rust is fairly normal and not a major concern (as long as it is removed). However, heavy rust buildup, especially on high mileage vehicles, may actually cover structural damage to such important components as: brakelines; rotors; support plates; and brake booster.
SPONGY PEDAL A spongy pedal is most often caused by air in the system. Thin brake drums or substandard brake lines and hoses can also cause a spongy pedal. The proper course of action is to bleed the system and replace thin drums and suspect quality brake lines and hoses. HARD PEDAL OR HIGH PEDAL EFFORT A hard pedal or high pedal effort may be due to lining that is water soaked, contaminated, glazed, or badly worn. The power booster or check valve could also be faulty. Test the booster and valve as described in this section. BRAKE DRAG Brake drag occurs when the lining is in constant contact with the rotor or drum. Drag can occur at one wheel, all wheels, fronts only, or rears only. It is a product of incomplete brakeshoe release. Drag can be minor or severe enough to overheat the linings, rotors and drums. Brake drag also has a direct effect on fuel economy. If undetected, minor brake drag can be misdiagnosed as an engine or transmission/torque converter problem. Minor drag will usually cause slight surface charring of the lining. It can also generate hard spots in rotors and drums from the overheat-cool down process. In most cases, the rotors, drums, wheels and tires are quite warm to the touch after the vehicle is stopped. Severe drag can char the brake lining all the way through. It can also distort and score rotors and drums to the point of replacement. The wheels, tires and brake components will be extremely hot. In severe cases, the lining may generate smoke as it chars from overheating. Some common causes of brake drag are: seized or improperly adjusted parking brake cables loose or damaged wheel bearing seized caliper or wheel cylinder piston caliper binding on corroded bushings or rusted slide surfaces loose caliper mounting bracket drum brakeshoes binding on worn-damaged support plates misassembled components
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BRAKES DO NOT HOLD AFTER DRIVING THROUGH DEEP WATER PUDDLES This condition is generally caused by water soaked lining. If the lining is only wet, it can be dried by driving with the brakes lightly applied for a mile or two. However, if the lining is both wet and dirty, disassembly and cleaning will be necessary. BRAKE NOISE
Squeak/Squeal Brake squeak or squeal may be due to linings that are wet or contaminated with brake fluid, grease, or oil. Glazed linings and rotors with hard spots can also contribute to squeak. Dirt and foreign material embedded in the brake lining can also cause squeak/ squeal. A very loud squeak or squeal is frequently a sign of severely worn brake lining. If the lining has worn through to the brakeshoes in spots, metal-to-metal contact occurs. If the condition is allowed to continue, rotors can become so scored that replacement is necessary. Thump/Clunk Thumping or clunk noises during braking are frequently not caused by brake components. In many cases, such noises are caused by loose or damaged steering, suspension, or engine components. However, calipers that bind on the slide pins can generate a thump or clunk noise. In addition, worn out, improperly adjusted, or improperly assembled rear brakeshoes can also produce noise a thump noise. Chatter/Shudder Brake chatter, or shudder is usually caused by loose or worn components, or glazed/burned lining. Rotors with hard spots can also contribute to chatter. Additional causes of chatter are out-of-tolerance rotors, brake lining not securely attached to the shoes, loose wheel bearings and contaminated brake lining.
BRAKE FADE Brake fade is a product of overheating caused by brake drag. Brake overheat and fade can also be caused by riding the brake pedal, making repeated high deceleration stops in a short time span, or constant braking on steep mountain roads. Refer to the Brake Drag information in this section for causes. PEDAL PULSATION Pedal pulsation is caused by components that are loose, or beyond tolerance limits. Disc brake rotors with excessive lateral runout or thickness variation, or out of round brake drums are the primary causes of pulsation. Other causes are loose wheel bearings or calipers and worn, damaged tires. PULL A front pull condition could be the result of contaminated lining in one caliper, seized caliper piston, binding caliper, loose caliper, loose or corroded slide pins, improper brakeshoes, or a damaged rotor. A worn, damaged wheel bearing or suspension component are further causes of pull. A damaged front tire (bruised, ply separation) can also cause pull. A common and frequently misdiagnosed pull condition is where direction of pull changes after a few stops. The cause is a combination of brake drag followed by fade at one of the brake units. As the dragging brake overheats, efficiency is so reduced that fade occurs. Since the opposite brake unit is still functioning normally, its braking effect is magnified. This causes pull to switch direction in favor of the normally functioning brake unit. When diagnosing a change in pull condition, remember that pull will return to the original direction if the dragging brake unit is allowed to cool down (and is not seriously damaged). REAR BRAKE GRAB OR PULL Rear grab or pull is usually caused by an improperly adjusted or seized parking brake cable, contaminated lining, bent or binding shoes and support plates, or improperly assembled components. This is particularly true when only one rear wheel is involved. However, when both rear wheels are affected, the master cylinder or proportioning valve could be at fault.
BRAKELINING CONTAMINATION Brakelining contamination is usually a product of leaking calipers or wheel cylinders, driving through deep water puddles, or lining that has become covered with grease and grit during repair. WHEEL AND TIRE PROBLEMS Some conditions attributed to brake components may actually be caused by a wheel or tire problem. A damaged wheel can cause shudder, vibration and pull. A worn or damaged tire can also cause vibration or pull. Severely worn tires with very little tread left can produce a grab-like condition as the tires lose and recover traction.
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Flat-spotted tires can cause vibration and wheel tramp and generate shudder during brake operation. A tire with internal damage such as a severe bruise or ply separation can cause pull and vibration.
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ABS Diagnostic Connector Location . . . . . . . . . . . . 8 ABS System Normal and Fault Conditions . . . . . . . . 9 ABS/RWAL Control Module Diagnosis . . . . . . . . . . . 9 ABS/RWAL Fault Condition Causes . . . . . . . . . . . . 10 ABS/RWAL Warning Light Display . . . . . . . . . . . . . . 9 Antilock Valve Service and Diagnosis . . . . . . . . . . . 9 Clearing RWAL Fault Codes . . . . . . . . . . . . . . . . . 10
DIAGNOSIS PROCEDURES
ABS System Antilock diagnosis involves checking only those components that form the antilock system. Diagnosis involves three basic steps which are: observation of the warning light display visual examination for low fluid, leaks, or damaged wires circuit check with DRB scan tool Visual examination includes a check of reservoir fluid level and condition of the system components. This includes inspection of the sensor wires and electrical connections. Things to look for are leaks, loose connections, or obvious component damage. Circuit checking involves using the DRB scan tool to identify a faulty circuit or component. RWAL System An RWAL system malfunction will be indicated by illumination of the amber warning lamp. If a problem occurs, system diagnosis should begin with a fluid level check followed by a visual examination of the system electrical and hydraulic connections. If obvious defects (low fluid, leaks, loose connections, etc.) are not evident, road test the vehicle. A road test should help determine if a malfunction is actually related to an antilock component. During the road test, note if other conditions are evident such as a low pedal, pull, grab, or similar condition. Remember that brake malfunctions such as low fluid, system leaks, or parking brakes partially applied will affect antilock system operation. The idea is to determine if a malfunction is actually related to an antilock component. If a visual inspection and road test do not indicate the problem cause, check the system fault flash codes. Refer to the system fault code information in this section.
ANTILOCK BRAKE SYSTEM DIAGNOSIS ABS SYSTEM NORMAL AND FAULT CONDITIONS
Wheel/Tire Size And Input Signals Antilock system operation depends on accurate signals from the wheel speed sensors. Ideally, the vehicle wheels and tires should all be the same size and type to ensure accurate signals and satisfactory operation. Operating Sound Levels On the all wheel ABS system, the pump/motor and antilock valve solenoids may produce some sound as they cycle. This is a normal condition and should not be mistaken for faulty operation. Under most conditions, pump and solenoid valve operating sounds will not be audible. Vehicle Response In Antilock Mode During antilock braking, the front/rear solenoid valves cycle rapidly in response to antilock control module inputs. The driver may experience a slight pulsing sensation in the brake pedal and vehicle as the solenoid valves modulate fluid pressure as needed. This is a normal condition. Steering Response A modest amount of steering input is required during extremely high deceleration braking, or when braking on differing traction surfaces. An example of differing traction surfaces would be when the left side wheels are on ice and the right side wheels are on relatively dry pavement. Loss Of Sensor Input Wheel speed sensor malfunctions will most likely be due to loose connections, damaged sensor wires, or incorrect sensor air gap. An additional fault would be a result of sensor and tone ring misalignment or physical damage. A faulty sensor (open, shorted) can be located with the flash codes or the DRB scan tool on all wheel antilock models.
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Light Illuminates During Brake Stop A system fault such as loss of speed sensor signal or solenoid failure, will cause the amber warning light to illuminate. The most effective procedure here is to check for obvious damage first. Then check the electronic components with the DRB scan tool, or flash codes.
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TESTING 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. (4) Have helper press and hold brake pedal to floor and observe warning light.
(a) If warning light illuminates, switch is operating correctly. (b) If light fails to illuminate, check circuit fuse, bulb and wiring. Repair as necessary and repeat test steps (3) and (4). (5) If warning light still fails to illuminate, check brakelight and parking brake switches and wiring with test lamp. Repair or replace parts as necessary and test differential pressure switch operation again. (6) If warning light still does not illuminate, switch is faulty. Replace combination valve assembly, bleed brake system and verify proper switch and valve operation.
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Brake Fluid Contamination . . . . Brakelines and Hoses . . . . . . . . Correct Brake Fluid Level . . . . . General Service Information . . . Importance of Clean Brake Fluid
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Use new brake fluid only, to top off the master cylinder or refill the system. Never use reclaimed fluid, unmarked or unspecified fluid, fluid not meeting SAE/DOT standards, fluid marked 70R1, or fluid from a container that has been left open for any length of time. Using non recommended or unspecified fluid can result in brake failure after hard prolonged braking.
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(4) Note or mark position of reservoir before removal. Side of reservoir with fluid level information on it goes toward driver side of engine compartment. (5) Remove reservoir by firmly rocking it from side to side (Fig. 4). Continue rocking until reservoir comes out of grommets.
CYLINDER BLEEDING PROCEDURE (1) Remove protective caps from master cylinder outlet ports and mount master cylinder assembly in a vise. (2) Attach bleed tubes to cylinder outlet ports and insert bleed tubes in reservoir fluid compartments (Fig. 4). (3) Fill reservoir with fresh Mopar DOT 3 brake fluid. (4) Press cylinder pistons inward with wood dowel. Then release pistons and allow them to return under spring pressure.
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(5) Continue bleeding operations until air bubbles are no longer visible in fluid. (6) Remove bleed tubes. (7) If cylinder will not be installed right away, install protective caps in cylinder outlet ports. Caps will keep dirt out of cylinder.
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POWER BRAKE BOOSTERBRAKE PEDALSTOPLAMP SWITCH POWER BRAKE BOOSTERBRAKE PEDALSTOPLAMP SWITCH INDEX
page Brake Pedal Installation . . . . . . . . . . . . . . . . . . . . . 18 Brake Pedal Removal . . . . . . . . . . . . . . . . . . . . . . 18 General Service Information . . . . . . . . . . . . . . . . . 17
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page Power Brake Booster Installation . . . . . . . . . . . . . . 18 Power Brake Booster Removal . . . . . . . . . . . . . . . 17 Stoplamp Switch Adjustment . . . . . . . . . . . . . . . . . 18 A suspended-type brake pedal is used. The pedal is attached to the pedal support bracket with a pivot bolt and bushings (Fig. 1). The booster push rod is attached to the pedal with a clip. The pedal, bushings, pivot pin and support bracket are all serviceable components.
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SWITCH INITIAL ADJUSTMENT (1) Push and hold brake pedal in applied position. (2) Push switch forward until fully seated against bracket (Fig. 3). (3) Release brake pedal. (4) Lightly pull brake pedal rearward until master cylinder push rod bottoms against master cylinder internal stop. This action will set switch plunger at proper stroke length.
CAUTION: Do not use excessive force to move the pedal rearward and do not overextend the pedal and push rod. Stoplamp Switch Replacement (1) Remove steering column opening cover.
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(7) Work switch and bracket up toward pedal support and connect harness wires to switch. (8) Position switch and bracket in support. Install bracket retaining nut and washer. Tighten nut to 7 N m (60 in. lbs.) torque. Be sure bracket tang is seated in support. (9) Check switch operation before proceeding any further. If brakelights fail to illuminate or remain on, switch bracket is not seated, switch is not fully engaged in mounting bracket, switch plunger is not aligned with striker, or wire harness is not fully connected. Reposition switch, bracket or striker as needed. (10) Align and install air duct and steering column cover.
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Brake Drum Installation . . . . . . Brake Drum Refinish Limits . . . Brake Drum Refinishing . . . . . Brake Drum Removal . . . . . . . Brake Drum Runout . . . . . . . . Brake Support Plate Installation Brake Support Plate Removal . Brakeshoe Installation . . . . . . .
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GENERAL INFORMATION
The drum brake units used for all applications are dual shoe, internal expanding units with an automatic self adjusting mechanism (Figs. 1 and 2). Nine inch brakes are used on standard models. Ten inch brakes are used on models with heavy duty option packages. Cast wheel cylinders are used for all applications. The cylinders are serviceable components and can be overhauled. The cylinder bores can be lightly polished with crocus cloth but must not be honed.
BRAKESHOE REMOVAL
(1) Remove rear wheel and brake drum. (2) Remove shoe return springs with Brake Spring Plier Tool C-3785 (Fig. 3). (3) Remove adjuster cable. Slide cable eye off anchor pin. Then unhook and remove cable from adjuster lever.
DRUM BRAKES
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BRAKESHOE INSTALLATION
(1) Lubricate anchor pin and brakeshoe contact surfaces of support plate (Fig. 6). Use Mopar multipurpose grease, bearing grease, or Lubriplate. (2) Lubricate adjuster screw socket, nut, button and screw thread surfaces with Mopar spray lube or Lubriplate.
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DRUM BRAKES
marked L (left) and R (right) for identification (Fig. 8). The passenger side adjuster screw has left hand threads and the driver side screw has right hand threads.
Fig. 8 Adjuster Screw Components Fig. 6 Shoe Contact Surfaces On Support Plate
(3) Attach parking brake cable to lever. Then connect lever to secondary shoe. Use new U-clip to secure lever. (4) Install primary shoe on support plate. Secure shoe with new holddown spring, retainers and pin (Fig. 7). (5) Install spring on parking brake strut and engage strut in primary shoe (Fig. 7). (6) Install secondary shoe on support plate (Fig. 7). Insert strut in shoe and guide shoe onto anchor pin. Secure shoe with new holddown spring, retainers and pin. (10) Install adjuster lever spring on rear shoe pin. Position adjuster lever on pin and slide hooked end of spring over lever to hold it in place. (11) Raise adjuster lever upward and attach adjuster cable spring to lever. Be sure spring is securely attached to lever and that lever remains seated on shoe pin. (12) Connect the shoe spring to lower part of each brakeshoe. Hooked end of spring goes in rear shoe. (13) Install cable guide in secondary shoe and position cable around guide. (14) Insert hooked end of rear shoe return spring through cable guide and into spring hole in brakeshoe. Then seat spring on anchor pin with brake spring pliers. (15) Install front shoe return spring. (16) Verify adjuster operation. Pull adjuster cable upward. Cable should lift lever and rotate start wheel when cable is released. Be sure adjuster lever properly engages star wheel teeth. (17) Adjust brakeshoes to drum with brake gauge as described in Service Adjustments section.
DRUM BRAKES
drum outer edge (Fig. 9). Generally, a nine inch drum can be machined to a maximum of 230.1 mm (9.060 in.) and a ten inch drum to 255.5 mm (10.060 in.). Always replace the drum if machining would cause drum diameter to exceed indicated size limit.
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(2) Remove axle shaft and retainer. Refer to Group 3 for procedures. (3) Remove primary brakeshoe for access to parking brake cable if necessary. (4) Compress parking brake cable retainer tabs with a hose clamp (Fig. 10). Then push retainer and cable through and out of support plate.
Fig. 10 Removing Parking Brake Cable From Support Plate Fig. 9 Location Of Brake Drum Maximum Allowable Diameter
(5) Disconnect brake line at wheel cylinder. (6) Remove wheel cylinder and brakeshoes from support plate. (7) Remove bolts attaching support plate to axle and remove support plate.
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DRUM BRAKES
the cylinder if the bore is scored, pitted or heavily corroded. Honing the bore to restore the surface is not recommended. Inspect the cylinder pistons. The piston surfaces should be smooth and free of scratches, scoring and corrosion. Replace the pistons if worn, scored, or corroded. Do not attempt to restore the surface by sanding or polishing. Discard the old piston cups and the spring and expander. These parts are not reusable. The original dust boots may be reused but only if in good condition.
ASSEMBLING WHEEL CYLINDER (1) Lubricate wheel cylinder bore, pistons, piston cups and expander spring with fresh brake fluid. (2) Install first piston in cylinder bore. Then install cup in bore and against piston. Be sure lip of piston cup is facing inward (toward spring and expander) and flat side is against piston. (3) Install expander spring followed by remaining piston cup and piston. (4) Install boots on each end of cylinder and insert push rods in boots. Press boots onto cylinder ends in vise if necessary. (5) Install cylinder bleed screw.
ADJUSTMENT WITH BRAKE GAUGE (1) Verify that the left/right automatic adjuster lever and cable are properly connected. Also verify that the parking brakes are fully released and the cables are slack. (2) Insert the brake gauge in the drum. Expand the gauge until the gauge inner legs contact the drum braking surface. Then lock the gauge in position (Fig. 13).
DRUM BRAKES
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ADJUSTMENT WITH TOOL C-3784 (1) Release parking brakes fully, if applied. Be sure there is slack in the cables. (2) Raise vehicle so rear wheels are free to turn. (3) Remove rubber plugs from access holes in rear brake support plates. (4) Insert Drum Brake Adjusting Tool C-3784 through access hole and engage it in adjuster screw star wheel. Turn star wheel counterclockwise (move tool upward) until a slight drag is felt when road wheel is rotated. (5) Insert a thin screwdriver or length of welding rod into support plate access hole and push adjuster lever out of engagement with star wheel (Fig. 15). Do not bend the lever or distort the lever spring.
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DRUM BRAKES
The correct tightening sequence is important in avoiding drum distortion. The correct sequence is in a diagonal crossing pattern. Seat the wheel and install the wheel nuts finger tight. Tighten the nuts in sequence to 1/2 the required torque. Then repeat the tightening sequence to final specified torque.
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GENERAL INFORMATION
Two-wheel drive AN models are equipped with single piston disc brake calipers. The calipers move laterally on pins that attach the caliper to the mounting adapter. Abutment surfaces machined in the brakeshoes and mounting adapter maintain fore and aft alignment. The calipers are fully serviceable components and can be overhauled when necessary. Non metallic caliper pistons are used for all applications. The pistons are made of a phenolic resin material. Two-wheel drive models are equipped with a disc brake rotor and hub assembly. The rotor hub is supported on the steering knuckle spindle by the wheel bearings. The rotor braking surfaces are ventilated and can be machined to restore surface finish when necessary. The disc brakeshoes are held in position by retaining springs. The inboard shoe spring is an integral part of the shoe. The outboard shoe is spring is removable. Two slide pins secure the caliper to the caliper adapter. The adapter, which is also removable, is attached to the steering knuckle (Fig. 1).
DISC BRAKELINING WEAR COMPENSATION The caliper piston seal controls the amount of piston extension needed to compensate for normal lining wear. In operation, the seal is deflected outward under fluid pressure (Fig. 2). When fluid pressure is released, the seal relaxes and retracts the piston. The amount of retraction is determined by lining wear. Generally, the amount is just enough to maintain contact between the piston and inboard shoe and a zero or very slight clearance at the rotor. The fluid level in the disc brake reservoir will decrease as lining wear occurs. This is a normal condition and only requires that enough fluid be added to restore proper level. SHOE AND LINING WEAR LIMITS Combined shoe and lining thickness should be measured at the thinnest part of the assembly. Re-
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BRAKESHOE REMOVAL
(1) Clean master cylinder reservoir and filler caps. (2) Remove filler caps and drain approximately 1/4 of fluid from reservoir. Use clean suction gun or similar device to remove fluid. (3) Raise and support front of vehicle. (4) Remove front wheel and tire assemblies. (5) Remove outboard retaining spring from caliper (Fig. 3). Push spring ends downward and pull spring ends out of caliper to remove.
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BRAKESHOE INSTALLATION
(1) Clean and lubricate slide surfaces of caliper mounting adapter (Fig. 11). Use wire brush to clean surfaces. Then apply coating of Mopar multi mileage grease to slide surfaces and to threads of slide pin holes. (2) Clean caliper slide pins with brake cleaner or brake fluid. Then apply coating of silicone grease to pins. Minor rust or corrosion can be polished from pins with crocus cloth. However, replace
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CALIPER REMOVAL
Fig. 11 Caliper Adapter Slide Surfaces
the pins if severely rusted, or corroded. (3) Install caliper slide pin bushings and boots if removed (Fig. 10). (4) Install inboard shoe (Fig. 7). Be sure spring is fully seated in caliper piston. (5) Install outboard shoe in caliper mounting adapter. (6) Carefully lower caliper into place over rotor and outboard brakeshoe. (7) Align caliper in adapter and start caliper slide pins by hand. Do not cross thread pins. (8) Check position of brakeshoes (Fig. 12). Verify that shoe tabs are squarely seated on ledge surfaces of caliper adapter. (9) Final-tighten caliper slide pins to 25-35 N m (18-26 ft. lbs.). (1) Raise vehicle and remove front wheels. (2) Remove outboard shoe spring (Fig. 3). (3) Disconnect brake hose at caliper. Discard hose fitting washers if worn, or damaged (Fig. 14).
CALIPER DISASSEMBLY
(1) Remove brakeshoes from caliper (Figs. 6 and 7). Discard shoes if worn, or damaged. (2) Drain old brake fluid out of caliper into drain pan. (3) Remove piston dust boot (Fig. 15). Use screwdriver to push boot out of groove. (4) Pad outboard shoe side of caliper interior with a minimum 2.54 cm (1 in.) thickness of shop towels (Fig. 16). Towels will prevent piston damage when piston is comes out of bore. (5) Remove caliper piston with short bursts of compressed air. Apply air pressure through fluid inlet port of caliper (Fig. 16).
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(6) Remove caliper piston seal with wood pencil or plastic tool (Fig. 17). Do not use metal tools as they will scratch piston bore.
Fig. 17 Removing Caliper Piston Seal Fig. 15 Removing Piston Dust Boot
CAUTION: Do not blow the piston out of the caliper. This procedure will usually result in severe piston damage. Use only enough air pressure to ease the piston out of the bore. In addition, never attempt to catch the piston as it leaves the caliper bore. This practice will result in personal injury. (7) Remove caliper slide pin bushings and boots (Fig. 18).
Inspect the caliper bushings and boots. Replace the boots if cut or torn. Clean and lubricate the bushings with GE 661, Dow 111, or similar silicone grease if necessary.
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CALIPER ASSEMBLY
(1) Lubricate slide pin boots and bushings with GE, or Dow silicone grease. Then install boots and bushings in caliper. (2) Coat caliper piston bore, piston and new piston seal with fresh brake fluid. (3) Install new piston seal in caliper bore. Press seal into groove with finger (Fig. 19). Lubricate seal and caliper bore with additional, fresh brake fluid after seal installation.
(a) Slide boot over piston until boot lip seats in piston groove (Fig. 20). (b) Push retainer part of boot forward until folds in boot snap into place (Fig. 21).
CALIPER INSTALLATION
(1) Install brake shoes in caliper.
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Brakeshoe and Caliper Inspection Brakeshoe Installation . . . . . . . . . Brakeshoe Removal . . . . . . . . . . Caliper Assembly . . . . . . . . . . . . Caliper Cleaning and Inspection .
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GENERAL INFORMATION
Four-wheel drive AN models are equipped with single piston, slider type disc brake calipers. The calipers slide laterally on pins that attach the caliper to the steering knuckle (Fig. 1). The brakeshoes ride on ledges machined in the steering knuckle. The shoe mounting ears are notched to seat on these ledges. The notched ears also maintain fore and aft position of the shoes. A retainer spring on each brakeshoe maintains shoe position in the caliper. The single piston used in each caliper is non-metallic. The pistons are made of a phenolic resin material. Ventilated, disc brake rotors are used for all applications. The rotors are serviceable and can be machined to restore the surface finish when necessary. The calipers are fully serviceable components and can be overhauled when necessary. The brakeshoes
are replaceable components but must be replaced on both front wheels at the same time to maintain braking balance. Never replace the shoes on only one side.
BRAKELINING WEAR COMPENSATION The caliper piston seal controls the amount of piston extension needed to compensate for normal lining wear. In operation, the seal is deflected outward under fluid pressure (Fig. 2). When fluid pressure is released, the seal relaxes and retracts the piston. The amount of retraction is determined by lining wear. Generally, the amount is just enough to maintain contact between the piston and inboard shoe and a zero or very slight clearance at the rotor. The fluid level in the front brake reservoir will decrease as lining wear occurs. This is a normal condition and only requires adding enough fluid to restore proper level.
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BRAKESHOE REMOVAL
(1) Clean master cylinder reservoir and filler caps. (2) Remove reservoir filler caps and drain approximately 1/4 of fluid from reservoir. Use clean suction gun or similar device to drain fluid. (3) Raise and support vehicle. (4) Remove front wheel and tire assemblies. (5) Bottom caliper pistons in bores with large C-clamp. Position clamp frame on rear of caliper and clamp screw on outboard brakeshoe. (6) Remove caliper slide pins. (7) Remove caliper and brakeshoes (Fig. 3).
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BRAKESHOE INSTALLATION
(1) Clean slide surfaces of adapter ledges with a wire brush. Then lubricate surfaces with Mopar multi mileage grease. (2) Install new slide pin boots and sleeves if necessary.
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CALIPER REMOVAL
(1) Raise and support vehicle. (2) Remove front wheel and tire assemblies. (3) Disconnect brake hose at caliper. Discard hose fitting washers if worn, or damaged (Fig. 11).
CALIPER DISASSEMBLY
(1) Remove brakeshoes from caliper (Figs. 4 and 5). Discard shoes if worn, or damaged. (2) Drain old brake fluid out of caliper into drain pan. (3) Remove piston dust boot (Fig. 12). Use screwdriver to push boot out of groove. (4) Pad outboard shoe side of caliper interior with a minimum 1 inch thickness of shop towels (Fig. 13). Towels will prevent piston damage when piston is comes out of bore. (5) Remove caliper piston with short bursts of compressed air. Apply air pressure through fluid inlet port of caliper (Fig. 13). CAUTION: Do not blow the piston out of the caliper. This procedure will usually result in severe piston damage. Use only enough air pressure to ease the piston out of the bore. In addition, never attempt to catch the piston as it leaves the caliper bore. This practice will result in personal injury.
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CALIPER ASSEMBLY
(1) Lubricate slide pin boots and bushings with GE, or Dow silicone grease. Then install the boots and bushings in caliper. (2) Coat caliper piston bore, piston and new piston seal with clean brake fluid. (3) Install new piston seal in caliper bore. Press seal into groove with finger (Fig. 16). Lubricate seal and caliper bore with additional, fresh brake fluid after seal installation.
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CALIPER INSTALLATION
(1) Install brake shoes in caliper. (2) Install caliper and shoes over rotor and into ledges in steering knuckle. Be sure ends of brakeshoes are properly seated on slide surfaces of ledges. (3) Align caliper in adapter and start caliper slide pins into adapter by hand. (4) Tighten caliper slide pins to 30 N m (22 ft. lbs.) torque. (5) Connect brake hose to caliper. Use new washers to attach hose fitting if original washers are scored, worn, or damaged. (6) Fill and bleed brake hydraulic system. (7) Install wheel and tire assemblies. (8) Remove supports and lower vehicle. (9) Pump brake pedal to seat shoes and verify firm pedal before moving vehicle. (10) Check master cylinder fluid level again and top off if necessary.
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ROTOR TYPES
A disc brake rotor is used for 4-wheel drive applications (Fig. 1). A disc brake rotor and hub assembly is used for 2-wheel drive applications (Fig. 1). Both rotor types are cast metal with built in ventilating ribs between the rotor braking surfaces. The rotor braking surfaces on both rotor types can be sanded, or machined to restore surface finish when necessary. However, a rotor should be replaced if machining would cause rotor thickness to fall below usable minimum. On 2-wheel drive models with ABS brakes, the tone wheel for the front speed sensor is pressed onto the rotor hub. Because the tone wheel is only serviced as part of the complete rotor and hub assembly, extra care will be required in handling to avoid damage. Refer to the rotor removal and installation procedures in this section.
ROTOR REMOVAL
(1) Raise vehicle. (2) Remove wheel cover and wheel and tire assembly. (3) Remove caliper and brakeshoe assembly but do not disconnect brake line. Support caliper on stool, or box. Do not allow brake hose to support caliper weight. (4) On 2-wheel drive models, remove grease cap, cotter pin, nut lock,nut, thrust washer and outer wheel bearing. Then remove rotor and hub assembly (Fig. 1). CAUTION: On 2-wheel drive models with ABS brakes, the tone wheel for the front wheel sensor is located on the rotor hub (Fig. 2). Exercise care when handling the rotor during service. The entire rotor and hub assembly will have to be replaced if the tone wheel becomes damaged during handling. (5) On 4-wheel drive models, remove stamped rotor retainer nuts or clips and remove rotor (Fig. 1). (6) On 2-wheel drive models, if rotor will be refinished, remove wheel bearings from rotor hub so rotor can be mounted on brake lathe arbor.
ROTOR INSTALLATION
(1) On 4-wheel drive models: (a) Install rotor on wheel studs.
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Fig. 2 Front Sensor Tone Wheel Location (2-Wheel Drive Models With ABS)
(c) Install rotor on spindle and install bearing thrust washer and adjusting nut. (d) Install brakeshoes and caliper. Then install wheel and tire on rotor hub. (e) Adjust wheel bearings. Rotate wheel while tightening adjusting nut to properly seat bearings. Correct end play is from zero to maximum of 0.076 mm (0.003 in.). (f) Install nut lock and cotter pin (note preferred cotter pin position shown in Figure 1). Then apply coating of wheel bearing grease to interior of grease cap and seat cap in rotor hub. (3) On all models: (a) Install brakeshoes and caliper. (b) Lower vehicle. (c) Final tighten wheel nuts to 120 N m (88 ft. lbs.) torque.
ROTOR REFINISHING
Rotor braking surfaces can be refinished by sanding and/or machining in a disc brake lathe. The lathe must be capable of machining both rotor surfaces simultaneously with dual cutter heads (Fig. 2). Equipment capable of machining only one side at a time will produce a tapered rotor. The lathe should also be equipped with a grinder attachment or dual sanding discs for final cleanup or light refinishing (Fig. 3). If the rotor surfaces only need minor cleanup of rust, scale, or minor scoring, use abrasive discs to clean up the rotor surfaces. However, when a rotor is scored or worn, machining with cutting tools will be required. CAUTION: Do not refinish a rotor if machining would cause the rotor to fall below minimum allowable thickness. The final finish on the rotor should be a non-directional, cross hatch pattern (Fig. 4). Sanding discs will produce this finish.
ROTOR RUNOUT
Check rotor lateral runout with a dial indicator (Fig. 6). Excessive lateral runout will cause brake pedal pulsation and rapid, uneven wear of the brakeshoes. Maximum allowable rotor runout for all models is 0.102 mm (0.004 inch).
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A dial indicator, or machinist calipers can be used to check rotor taper. A tapered rotor is usually caused by improper machining and should be replaced.
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RWAL BRAKE OPERATION AND SERVICE RWAL BRAKE OPERATION AND SERVICE INDEX
page page Rear Antilock Valve Removal . . . . . . . . . . . . . . . RWAL System Brake Bleeding . . . . . . . . . . . . . . RWAL System Components . . . . . . . . . . . . . . . RWAL System Manual Brake Bleeding Procedure RWAL System Operation . . . . . . . . . . . . . . . . . . Speed Sensor Installation . . . . . . . . . . . . . . . . . Speed Sensor Removal . . . . . . . . . . . . . . . . . . . . 46 . . 48 . . 44 . 49 . . 45 . . 48 . . 48
Combination Valve Installation . . . . . Combination Valve Operation . . . . . Combination Valve Removal . . . . . . Electronic Control Module Installation Electronic Control Module Removal . General Information . . . . . . . . . . . . Rear Antilock Valve Installation . . . .
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47 46 47 48 48 44 47
GENERAL INFORMATION
The RWAL brake system is standard on all AN models. The system is controlled by a separate electronic control module. The RWAL system retards rear wheel lockup during periods of high wheel slip and deceleration. Retarding lockup is accomplished by modulating fluid pressure to the rear brake units. Rear brake fluid pressure is modulated according to wheel speed, degree of wheel slip and rate of deceleration. A sensor in the rear axle housing converts differential rotating speed into electronic signals. The signals are transmitted to the electronic control module for processing. The control module determines rate of deceleration and wheel slip from these signals.
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Fig. 3 Speed Sensor Location Fig. 2 Rear Brake Antilock And Combination Valves
Speed Sensor And Exciter Ring A speed sensor is used to transmit speed and rate of deceleration inputs to the electronic control module (Fig. 3). The sensor is actuated by an exciter ring on the differential case. The sensor is mounted at the top of the rear axle housing directly over the gear-type exciter ring (Fig. 3). The exciter ring is pressed onto the differential case adjacent to the ring gear. The exciter ring is the sensor trigger mechanism. Exciter ring rotation causes the teeth on the ring to interrupt the magnetic field around the sensor pole. The rate of interruption is converted into speed signals which are transmitted to the control module. The sensor is not adjustable and must be replaced whenever diagnosis indicates a fault has occurred. Antilock Warning Lamp The amber antilock warning lamp is located in the instrument cluster adjacent to the red service brake warning lamp. The antilock lamp illuminates only when an RWAL fault occurs. The antilock lamp is also used for troubleshooting purposes. The lamp is in circuit with the control module which has a self test program. If a system fault occurs, the program will flash the lamp when the diagnostic connector is grounded. The flash codes are used to identify a problem circuit, or component. Combination Valve A combination valve is used with the rear wheel antilock system. The valve is attached to a bracket bolted to the master cylinder mounting studs. The valve bracket is also used to secure the rear wheel antilock valve (Fig. 2). The mounting bracket and combination valve are serviced as an assembly. The valve is permanently attached to the bracket. The valve contains a front disc brake metering valve and a pressure differential valve and switch. The differential switch is in circuit with the red brake warning light.
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The module transmits the signal that activates the solenoid valves. The valves then decrease, or isolate fluid apply pressure to the rear wheel cylinders as needed to modulate fluid pressure. Closing the valves prevents further fluid flow to the rear wheel cylinders. This action isolates the rear brakes from the master cylinder. The net effect is to decrease rear brake apply pressure to the point where the wheels will continue to rotate but not lock. When rear brake pressure requirements return to normal levels, the solenoid valves are inactivated. This action allows the resumption of normal fluid flow to the wheel cylinders. Solenoid Valve Cycle Times Activation (opening/closing) of the solenoid valves is not static during antilock mode braking. Valve operation is continuous as they are rapidly cycled in response to sensor inputs and control module commands. Cycle times are measured in milliseconds. As the demand for antilock mode brake operation is decreased, the module deactivates the hydraulic valve components to restore normal brake operation.
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(5) Attach ground wire to combination valve bracket (Fig. 4). Make sure ground wire is securely attached and free of corrosion. A poor connection here will cause a system fault. (6) Connect brakelines to master cylinder, rear antilock valve and combination valve. (7) Tighten brakeline fittings to 16-23 N m (140-200 in. lbs.) torque. (8) Connect wire harnesses to antilock and combination valves. (9) Install and connect battery. (10) Bleed brakes as described at end of this section.
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VACUUM BLEEDING If vacuum bleeding equipment is being used, it is not necessary to hold the front brake metering valve open. Simply bleed the brakes following the bleed equipment manufacturers instructions. PRESSURE BLEEDING If pressure bleeding equipment will be used, the front brake metering valve will have to be held open to bleed the front brakes. The valve stem is located
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in the forward end of the combination valve. The stem must either be pressed inward, or held outward slightly. a spring clip tool or helper is needed to hold the valve stem in position. Follow the manufacturers instructions carefully when using pressure equipment. Some precautions are: Make sure the front brake metering valve in the combination is held open. A spring clip tool is best for securing the valve stem in an open position.
ABS BRAKE OPERATION AND SERVICE ABS BRAKE OPERATION AND SERVICE INDEX
page ABS Brake Bleeding Recommendations . . . . . . ABS Components . . . . . . . . . . . . . . . . . . . . . . ABS Electronic Control Module Installation . . . . ABS Electronic Control Module Removal . . . . . ABS Manual Brake Bleeding Procedure . . . . . . ABS Operation . . . . . . . . . . . . . . . . . . . . . . . . Combination Valve Installation . . . . . . . . . . . . . Combination Valve Operation . . . . . . . . . . . . . Combination Valve Removal . . . . . . . . . . . . . . Front Antilock Valve Installation . . . . . . . . . . . . Front Antilock Valve Removal . . . . . . . . . . . . . Front Brake Speed Sensor Installation (2-Wheel Drive Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 51 59 59 60 54 57 55 57 55 55
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page Front Brake Speed Sensor Installation (4-Wheel Drive Models) . . . . . . . . . . . . . . . . . . . . . . . . . . Front Brake Speed Sensor Removal (2-Wheel Drive Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Brake Speed Sensor Removal (4-Wheel Drive Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear Antilock Valve Installation . . . . . . . . . . . . . . . Rear Antilock Valve Removal . . . . . . . . . . . . . . . . . Rear Brake Speed Sensor Installation . . . . . . . . . . Rear Brake Speed Sensor Removal (All) . . . . . . . . Tone Wheel Service . . . . . . . . . . . . . . . . . . . . . . . 59 58 59 57 56 59 59 58
. . . 58 electrical harnesses combination valve diagnostic connector Front Antilock Valve The front antilock valve consists of a solenoid valve body and pump/motor unit combined into a single assembly (Fig. 2).
ABS COMPONENTS
The optionally available ABS system is an allwheel antilock brake system (Fig. 1). ABS system components include: rear antilock valve rear wheel speed sensor and exciter ring front wheel speed sensors and tone rings front antilock valve electronic control module
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The valve is mounted on the driver side inner fender panel. The valve and motor assembly are attached to a one piece mounting bracket. The valve body contains the solenoid valves that modulate brake fluid pressure during antilock braking. The valves are operated by the antilock system electronic control module. The front antilock valve provides two channel pressure control of the front brakes. One channel controls the left front brake and the second channel controls the right front brake. Each front brake is controlled independently. The solenoid valves are cycled open and closed as needed during antilock braking. The valves are not static. They are cycled rapidly and continuously to modulate pressure and control wheel slip and deceleration. The pump and motor unit are controlled by the electronic module. The pump supplies the additional fluid volume needed during antilock braking.
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The sensors convert wheel speed into an electrical signal. The signal is transmitted to the electronic control module for processing. The trigger mechanism for each front wheel sensor is a gear type, tone wheel. On 4-wheel drive models, the tone wheels are mounted on the axle shafts. On 2-wheel drive models, the tone wheels are mounted on the inboard side of the disc brake rotor hub (Fig. 6). A single sensor is used to monitor rear wheel speed and rate of deceleration. The sensor is mounted at the top of the rear axle housing (Fig. 7). The trigger mechanism for the sensor is an exciter ring pressed onto the differential case. The ring is pressed onto the case next to the ring gear. The teeth on the tone wheels and exciter ring interrupt the senor magnetic field as they rotate. Rate of interruption is converted into speed signals which are transmitted to the electronic control module. The front and rear sensors are fixed and not adjustable. A front or rear sensor must be replaced when diagnosis indicates a fault has occurred.
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ABS OPERATION IN NORMAL BRAKING MODE The ABS control module monitors wheel speed sensor inputs continuously while the vehicle is in motion. However, the module will not activate any ABS components as long as sensor inputs indicate normal braking. During normal braking, the master cylinder, power booster and wheel brake units all function as they would in a vehicle without ABS. The solenoid valves are not activated. ABS OPERATION IN ANTILOCK BRAKING MODE The ABS module activates the system whenever sensor signals indicate the onset of high wheel slip. High wheel slip can be described as the point where wheel rotation begins approaching zero (or lockup) during braking. The antilock system retards lockup during high slip conditions by modulating fluid apply pressure to the wheel brake units. Brake fluid apply pressure is modulated according to wheel speed, degree of slip and rate of deceleration. A sensor at each wheel converts wheel speed into electrical signals. These signals are transmitted to the module for processing and determination of wheel slip and deceleration rate. The ABS system has three fluid pressure control channels. The front brakes are controlled separately and the rear brakes in tandem. A speed sensor input signal indicating high slip conditions activates the control module antilock program. The solenoid valves are not static during antilock braking. They are cycled continuously to modulate pressure. Solenoid cycle time in antilock mode can be measured in milliseconds.
ABS OPERATION
The all-wheel ABS system is a three channel design. The front wheel brakes are controlled individually and the rear wheel brakes in tandem (Fig. 9). The ABS system is designed to retard wheel lockup during periods of high wheel slip when braking. Retarding wheel lockup is accomplished by modulating fluid pressure to the wheel brake units. The antilock electrical system is separate from other electrical circuits in the vehicle. A specially programmed electronic control module is used to operate the system components. The front and rear antilock valves contain electrically operated solenoid valves. The solenoid valves
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(4) Connect front brakelines to front antilock valve (Fig. 9). Tighten brakeline fittings to 16-23 N m (140200 in. lbs.). (5) Connect battery. (6) Bleed brake system as described at end of this section.
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(2) Disconnect rear brakeline at rear antilock valve (Fig. 11). (3) Disconnect line that connects front antilock valve to combination valve (Fig. 11). Disconnect line at combination valve fitting. (4) Disconnect harness connectors at antilock and combination valves (Fig. 12). (5) Disconnect ground wire at combination valve bracket (Fig. 12). (6) Remove nuts that attach combination valve bracket to brake booster studs (Fig. 12). (7) Disconnect lines from rear antilock valve to master cylinder (Fig. 13). (8) Slide combination valve bracket off master cylinder mounting studs (Fig. 13). Then remove rear antilock valve, combination valve and bracket and attached brakelines as assembly (Fig. 13). (9) Remove line that connects rear antilock valve to combination valve. (10) Remove bolt attaching rear antilock valve to combination valve bracket. (11) Remove rear brake antilock valve from combination valve bracket. (12) If combination valve will be replaced, remove connecting lines from valve. Retain lines as they will be transferred to new valve.
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(2) Install rear antilock valve on combination valve bracket (Fig. 14). Tighten valve attaching bolt securely. (3) Install line that connects front antilock valve to combination valve (Fig. 14). Do not fully tighten line fitting at this time. (4) Install valve and bracket assembly on booster studs (Fig. 13). (5) Install and tighten nuts that attach combination valve bracket to booster studs to 23-28 N m (200250 in. lbs.) torque. (6) Attach ground wire to combination valve bracket (Figs. 12 and 13). Make sure ground wire is securely attached and that connection is clean and free of corrosion. A poor ground connection will cause a system fault. (7) Connect brakelines to master cylinder, antilock valve and combination valve. (8) Tighten brakeline fittings at antilock valve to 13-20 N m (115-175 in. lbs.). Tighten all remaining line fittings to 16-23 N m (140-200 in. lbs.) torque. (9) Connect wire harnesses to antilock and combination valves. (10) Install and connect battery. (11) Bleed brake system as described in this section.
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(d) Tighten thumbscrew on bleed Tool 6670 just enough to push valve stem inward about 0.51 0.76 mm (0.020 - 0.030 in.). (e) Apply brake pedal. Pedal will fall off significantly when bleed plug is properly open and bleed valve stem is correctly unseated (pressed inward) by tool. (f) Stroke brake pedal rapidly 5-10 times. This action will fill upper and lower sections of valve rapidly. (g) Bleed new valve assembly at each brakeline fitting one at a time. Remember to close valve bleed plug before each brake pedal stroke. Continue bleeding until fluid flowing from fittings is clear and free of bubbles. (h) Remove depressor tool from valve stem and install cap on stem. Then tighten bleed plug to 7-9 N m (60-84 in. lbs.) torque. (6) If original front antilock valve assembly is being used, bleed plug and bleed valve do not have to be open during bleeding operations. Just bleed the valve assembly at each brakeline fitting one at a time. (7) Bleed first wheel brake unit. Start at left rear wheel and follow sequence recommended in step (3). Repeat bleeding operation at each wheel until fluid coming out of bleed screw is clear and free of bubbles. (8) Top off master cylinder reservoir fluid level. Then verify proper brake operation before moving vehicle.
VACUUM BLEEDING If vacuum bleeding equipment is being used, it is not necessary to hold the front brake metering valve open. Simply bleed the brakes following the equipment manufacturers instructions. PRESSURE BLEEDING If pressure bleeding equipment will be used, the front brake metering valve will have to be held open to bleed the front brakes. The valve stem is located in the forward end of the combination valve. The stem must either be pressed inward, or held outward slightly. a spring clip tool or helper is needed to hold the valve stem in position. Follow the manufacturers instructions carefully when using pressure equipment. Make sure the front brake metering valve in the combination is held open. A spring clip tool is best for securing the valve stem in an open position. Do pressure bleed without a proper master cylinder adapter. The wrong adapter can lead to leakage, or drawing air back into the system.
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Fig. 23 Location Of Front Antilock Valve Bleed Valve Stem And Plug
Fill the bleeder tank with recommended fluid and purge air from the tank lines before bleeding.
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GENERAL INFORMATION
The parking brakes are operated by a system of cables and levers attached to the rear brake secondary shoes. A foot pedal, cable tensioner, and four cables form the control system. The rear drum brakeshoes serve as the parking brakes. The shoes are moved into contact with the brake drum surface by a cable and lever mechanism attached to the trailing brakeshoe. A strut installed between the primary and secondary shoes maintains shoe position when the parking brakes are applied. The front parking brake cable is connected to the parking brake pedal and to an intermediate cable. The intermediate cable connects the front cable to the rear cables. The parking brake pedal assembly is mounted on the driver side cowl panel (Fig. 1). The front cable is directly attached to the assembly. The pedal assembly contains a spring loaded, ratchet-type mechanism to hold the pedal in the applied position. A cable and spring are used to release the ratchet mechanism and return the pedal to normal position. Parking brake cable adjustment is controlled by the cable tensioner. The tensioner, once adjusted at the factory, will not need further adjustment under normal circumstances. There are only two instances when adjustment is required. The first is when a new tensioner, or cables have been installed. And the second, is when the tensioner and cables are disconnected for access to other brake components.
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PARKING BRAKES
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PARKING BRAKES
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(8) Mark tensioner rod 6.5 mm (1/4 in.) from edge of tensioner bracket (Fig. 5). (9) Tighten adjusting nut at equalizer until mark on tensioner rod moves into alignment with tensioner bracket (Fig. 5). CAUTION: Do not loosen, or tighten the tensioner adjusting nut for any reason after completing adjustment. (10) Lower vehicle until rear wheels are 15-20 cm (6-8 in.) off shop floor. (11) Release parking brake foot pedal and verify that rear wheels rotate freely without drag. Then lower vehicle.
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CLUTCH
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CLUTCH
CONTENTS
page page
CLUTCH COMPONENTS
The clutch mechanism in AN models consists of a single, dry-type clutch disc and a diaphragm style clutch cover. A sleeve-type release bearing is used to engage and disengage the clutch cover pressure plate. The bearing is prelubricated during manufacture and is a sealed unit. The release bearing is operated by a pivoting release fork in the clutch housing. The fork pivots on a ball stud within the housing. The release fork is actuated by a hydraulic slave cylinder. The slave cylinder is operated by a clutch master cylinder connected to the clutch pedal. The clutch disc has cushion springs in the disc hub. The clutch disc facing is riveted to the hub. The facing is made from a non-asbestos material. The clutch cover pressure plate is a diaphragm type unit with a one-piece diaphragm spring and multiple release fingers. The pressure plate release fingers are preset during manufacture and are not adjustable. The transmission input shaft is supported in the crankshaft by a pilot bearing.
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CLUTCH
Do not apply grease to any part of the clutch cover or disc. Use Mopar multi mileage grease or a silicone grease for the clutch pedal bushings and pivot shaft. Use Mopar high temperature bearing grease or equivalent for the pilot bearing, release bearing bore, transmission input shaft and release fork components. Apply recommended amounts only and do not overlubricate. Refer to the Clutch Service section for specific information.
CLUTCH LUBRICATION
Proper clutch component lubrication is important to satisfactory operation. Using the correct lubricant and avoiding over lubrication are also equally important. During service, apply recommended lubricant sparingly. Do not overlubricate as this could result in clutch disc and pressure plate contamination. Clutch and transmission components requiring lubrication are: pilot bearing release lever pivot ball stud release lever pivot surfaces release bearing bore clutch pedal pivot bore and bushings. transmission input shaft splines and pilot hub release bearing slide surface of front bearing retainer
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page . . . . . . . . . . . . 3 3 3 4
GENERAL INFORMATION
Problem diagnosis will generally require a road test to determine the type of fault. Component inspection will then determine the problem cause after road testing. Drive the vehicle at normal speeds during the road test. Shift the transmission through all gear ranges and observe clutch action. If chatter, grab, slip, or improper release is experienced, remove and inspect the clutch components. However, if the problem is noise or hard shifting, further diagnosis may be needed. The transmission or another driveline component may actually be at fault. Careful observation during the test will help narrow the problem area.
Grease contamination is usually a product of excessive lubrication during clutch service. Apply only a small amount of grease to the input shaft splines, bearing retainer, pilot bearing, release fork and pivot stud. Excess grease can be thrown off during operation and contaminate the disc.
CLUTCH MISALIGNMENT
Clutch components must be in proper alignment with the crankshaft and transmission input shaft. Misalignment caused by excessive runout or warpage of any clutch component will cause grab, chatter and improper clutch release.
FLYWHEEL MISALIGNMENT
Common causes of misalignment are heat warping, mounting the flywheel on a dirty crankshaft flange, incorrect bolt tightening, improper seating on the crankshaft flange shoulder, or loose crankshaft or flywheel bolts.
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CLUTCH
loose housing bolts, missing alignment dowels, or housing damage. Only rarely is misalignment caused by housing mounting surfaces that are not parallel. If housing misalignment is suspected, the housing is probably not fully seated on either the engine, alignment dowels, or transmission front face. Since the AX 15 and NV3500 clutch housings are either attached, or an integral part of the transmission gear case, it will be necessary to remove the transmission and housing as an assembly to check seating. Be sure the housing mounting surface is clean. Also be sure the housing alignment dowels are securely in place in the engine block and are in good condition. Replace the dowels if distorted, damaged, or doubt exists about dowel condition.
Very light scoring on the flywheel face can be cleaned up by scuff sanding with 120/180 grit emery cloth or sandpaper. However, the flywheel should be replaced if warped, or severely scored. Do not machine the flywheel. The flywheel face is manufactured with a unique surface contour. Machining would negate this feature resulting in unsatisfactory operation. Clean the crankshaft flange before mounting the flywheel. Dirt and grease on the flange surface may cock the flywheel causing excessive runout. Use new bolts when remounting a flywheel and secure the bolts with Mopar Lock And Seal. Tighten flywheel bolts to specified torque only. Overtightening can distort the flywheel hub causing runout.
CLUTCH INSTALLATION METHODS AND PARTS USAGE Distortion of clutch components during installation or using non-standard components are additional causes of clutch malfunction. Improper clutch cover bolt tightening can distort the cover. The usual result is clutch grab, chatter and rapid wear. Tighten the cover bolts as described in Clutch Service section. Improperly seated flywheels and clutch housings are other causes of clutch failure. Improper seating will produce misalignment and clutch problems. Tighten all the clutch housing bolts to proper torque before installing any struts. Also be sure alignment dowels are in place and seated in the block and housing before bolt tightening. The use of non-standard or low quality parts can also lead to problems and wear. Use the recommended factory quality parts to avoid comebacks.
CLUTCH
CLUTCH INSPECTION CHART
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CLUTCH
CLUTCH SLIPS
CLUTCH
IMPROPER CLUTCH RELEASE
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CLUTCH
CLUTCH GRAB/CHATTER
CLUTCH
CLUTCH NOISE
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Cover and Disc Installation . . Cover and Disc Removal . . . Housing Replacement (AX 15) Hydraulic Linkage Installation Hydraulic Linkage Removal . .
10 10 11 13 12
CLUTCH
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CLUTCH
(3) Remove pilot bearing. Use blind hole puller tools such as those included in Snap-On set CG40CB to remove bearing. (4) Clean bearing bore with solvent and wipe dry with shop towel. (5) Lubricate new pilot bearing with Mopar high temperature grease. (6) Position and start new bearing in bearing bore by hand. Note that pilot bearing has seal at one end. Install bearing so seal is facing outward toward transmission. (7) Seat pilot bearing with clutch alignment tool (Fig. 7). Keep bearing straight during installation. Do not allow bearing to become cocked. Tap bearing into place until flush with edge of bearing bore. Do not recess bearing. (8) Install transmission assembly.
essary followed by a wax and grease remover, or similar solvent. Also clean engine block surface as well. (5) Position replacement clutch housing on transmission and install housing attaching bolts. Tighten bolts to 38 N m (28 ft. lbs.) torque. (6) Transfer release fork pivot ball stud to replacement housing if necessary. (7) Lubricate release bearing bore, release fork contact surfaces and release fork pivot stud with Mopar high temperature bearing grease. Also lubricate transmission input shaft splines, pilot hub and bearing retainer slide surface with light coat of same grease. (8) Install release fork and bearing in housing. Be sure release fork boot is properly seated in housing. (9) Install transmission as described in Group 21.
CLUTCH
(7) Remove retaining ring, flat washer and wave washer that attach clutch master cylinder push rod to clutch pedal (Fig. 8). (8) Slide clutch master cylinder push rod off clutch pedal pin. (9) Inspect condition of bushing on clutch pedal pin. Remove and replace bushing if worn or damaged. (10) Verify that cap on clutch master cylinder reservoir is tight. This is necessary to avoid undue spillage during removal. (11) Remove screws attaching clutch fluid reservoir to dash panel. (12) Pull clutch master cylinder rubber seal from dash panel (Fig. 8). (13) Rotate clutch master cylinder 45 counterclockwise to unlock it. Then remove cylinder from dash panel. (14) Remove hydraulic linkage components from vehicle.
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(3) Inspect bushing on the clutch pedal pin. Replace bushing if worn or damaged. (4) Remove snap ring and washer attaching clutch pedal to the pivot shaft. (5) Slide pedal off pivot shaft and remove pedal. (6) Remove and inspect bushings in pedal bore. Replace bushings if worn or cracked.
FLYWHEEL SERVICE
Inspect the flywheel whenever the clutch disc and cover are removed for service. Check condition of the flywheel face, hub, starter ring gear teeth, and flywheel bolts. Minor scratches, burrs, or glazing on the flywheel face can be reduced with 120/180 grit emery cloth. However, the flywheel should be replaced if the disc contact surface is severely scored, heat checked, cracked, or obviously worn. Cleanup of minor flywheel scoring should be performed with surface grinding equipment. Remove only enough material to reduce scoring (approximately 0.001 - 0.003 in.). Heavy stock removal is not recommended. The flywheel surface is manufactured with a unique contour which can be damaged by machining. Replace the flywheel if scoring is severe and deeper than 0.076 mm (0.003 in.). Excessive stock removal can also result in flywheel cracking or warpage after installation. It can also weaken the flywheel and interfere with proper clutch release. Check flywheel runout if misalignment is suspected. Runout should not exceed 0.08 mm (0.003 in.). Measure runout at the outer edge of the flywheel face with a dial indicator. Mount the dial indicator on a stud installed in place of one of the flywheel attaching bolts. Clean the crankshaft flange before mounting the flywheel. Dirt and grease on the flange surface may cock the flywheel causing runout. Check condition of the flywheel hub and attaching bolts. Replace the flywheel if the hub exhibits cracks in the area of the attaching bolt holes. Install new attaching bolts whenever the flywheel is replaced. Apply Mopar Lock-N-Seal, or Loctite 242 on the replacement bolt threads before installation.
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CLUTCH
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COOLING SYSTEM
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COOLING SYSTEM
CONTENTS
page page
GENERAL INFORMATION
Throughout this group, references are made to particular vehicle models by alphabetical designation or by the particular vehicle nameplate. A chart showing a breakdown of alphabetical designations is included in the Introduction section at the beginning of this manual.
COOLING SYSTEM
The cooling system regulates engine operating temperature. It allows the engine to reach normal oper-
ating temperature as quickly as possible. It also maintains normal operating temperature and prevents overheating. The cooling system also provides a means of heating the passenger compartment and cooling the automatic transmission fluid (if equipped). The cooling system is pressurized and uses a centrifugal water pump to circulate coolant throughout the system. An optional factory installed maximum duty cooling package is available on most models. This package will provide additional cooling capacity for vehicles used under extreme conditions such as trailer towing in high ambient temperatures.
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COOLING SYSTEM
Coolant reserve/overflow system Transmission oil cooler (if equipped with an automatic transmission) Coolant Water pump Hoses and hose clamps
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for eventual display to the service technician. If the problem is repaired or ceases to exist, the PCM cancels the DTC after 51 engine starts. Certain criteria must be met for a DTC to be entered into PCM memory. The criteria may be a specific range of engine rpm, engine temperature and/or input voltage to the PCM. A DTC indicates that the PCM has recognized an abnormal signal in a circuit or the system. A DTC may indicate the result of a failure, but never identify the failed component directly. It is possible that a DTC for a monitored circuit may not be entered into memory even though a malfunction has occurred. Refer to On-Board Diagnostics (OBD) in Group 14, Fuel Systems for additional information.
ACCESSING DIAGNOSTIC TROUBLE CODES A stored Diagnostic Trouble Code (DTC) can be displayed by cycling the ignition key On-Off-On-Off-On within three seconds and observing the malfunction indicator lamp. This lamp is displayed on the instrument panel as the CHECK ENGINE lamp (Fig. 3). They can also be displayed through the use of the Diagnostic Readout Box (DRB) scan tool. The DRB connects to the data link connector in the engine compartment (Fig. 4). For operation of the DRB, refer to the appropriate Powertrain Diagnostic Procedures service manual.
EXAMPLES: If the lamp (Fig. 3) flashes 1 time, pauses and flashes 2 more times, a flashing Diagnostic Trouble Code (DTC) number 12 is indicated. If this code is observed, it is indicating that the battery has been disconnected within the last 50 key-on cycles. It could also indicate that battery voltage has been disconnected to the PCM. In either case, other DTCs may have been erased. If the lamp flashes 1 time, pauses and flashes 7 more times, a flashing Diagnostic Trouble Code (DTC) number 17 is indicated. If the lamp flashes 3 times, pauses and flashes 5 more times, a flashing Diagnostic Trouble Code (DTC) number 35 is indicated.
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ERASING TROUBLE CODES After the problem has been repaired, use the DRB scan tool to erase a DTC. Refer to the appropriate Powertrain Diagnostic Procedures service manual for operation of the DRB scan tool.
PRELIMINARY CHECKS
ENGINE COOLING SYSTEM OVERHEATING Establish what driving conditions caused the complaint. Abnormal loads on the cooling system such as the following may be the cause:
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Automatic Transmission Oil Coolers . . . . . . . Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . Coolant Reserve/Overflow System . . . . . . . . Cooling System Cleaning/Reverse Flushing . Cooling System Fan2.5L 4-Cylinder Engine Cooling System Fan3.9L/5.2L Engine . . . . Cooling System Hoses . . . . . . . . . . . . . . . . Draining Cooling System . . . . . . . . . . . . . . . Pressure Testing Radiator Caps . . . . . . . . .
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32 23 27 25 33 36 32 24 28
WATER PUMPSREMOVAL/INSTALLATION
The water pump on all models can be removed without discharging the air conditioning system (if equipped).
2.5L 4-CYLINDER ENGINE The water pump used on 2.5L engines consists of a die-cast aluminum body and housing, and a stamped steel impeller. A gasket is used to seal between the pump body and housing. The water pump assembly bolts directly to the engine cylinder block. A rubber o-ring provides the seal between water pump and cylinder block (Fig. 1).
REMOVAL (1) Drain cooling system. (2) Remove accessory drive belt. (3) Remove generator. Refer to Group 8B, Battery/ Starter/Generator Service. CAUTION: If vehicle is equipped with air conditioning, the solid mount accessory drive bracket must be removed according to the following procedure:
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CAUTION: The solid mount accessory bracket fasteners must be tightened in following sequence. (e) Tighten bolt 1 (Fig. 2) to 3 N m (30 in. lbs.) torque. (f) Tighten nut 2 and bolt 3 (Fig. 2) to 54 N m (40 ft. lbs.) torque. (g) Tighten bolts 1, 4 and 5 (Fig. 2) to 54 N m (40 ft. lbs.) torque. (h) Tighten bolts 6 and 7 (Fig. 2) to 54 N m (40 ft. lbs.) torque. (i) Install air conditioning compressor. Tighten mounting bolts to 54 N m (40 ft. lbs.) torque. (3) Install generator. Refer to Group 8B, Battery/ Starter/ Generator Service. (4) Install accessory drive belts. Refer to the Engine Accessory Drive Belt section of this group for installation procedure and belt tension specifications. (5) Fill cooling system with coolant. Refer to the Refilling Cooling System section in this group. (6) Start and warm the engine. Check for leaks.
3.9L/5.2L ENGINE The water pump on 3.9L and 5.2L engines is bolted directly to the engine timing chain case/cover. A gasket is used as a seal between the water pump and timing chain case/cover. If water pump is replaced because of bearing/shaft damage, or leaking shaft seal, the mechanical cooling fan assembly should also be inspected. Inspect for fatigue cracks, loose blades, or loose rivets that could have resulted from excessive vibration. Replace fan if any of these conditions are found. Also check condition of the thermal Viscous Fan Drive. Refer to Viscous Fan Drive in this group.
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(10) Remove four water pump pulley-to-water pump hub bolts (Fig. 6) and remove pulley from vehicle. (11) Remove lower radiator hose clamp and remove lower hose at water pump. (12) Remove heater hose clamp (Fig. 3) and heater hose from heater hose coolant return tube. (13) Loosen heater hose coolant return tube mounting bolt (Fig. 8) and remove tube from water pump. Discard the old tube o-ring.
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wrong direction. Refer to (Fig. 17) for correct belt routing. The correct belt with correct length must be used.
THERMOSTAT
GENERAL INFORMATIONALL ENGINES On 2.5L 4-cylinder engines, the thermostat is located inside the water box at front of engine on radiator side (Fig. 18). This thermostat does not have an air bleed notch. On 3.9L and 5.2L engines, the thermostat is located beneath the thermostat housing at front of intake manifold (Fig. 19). This thermostat has an air bleed notch. All thermostats (2.5L, 3.9L and 5.2L engines) are of the wax-pellet-driven, reverse-poppet-choke-type. The wax pellet is located in a sealed container at spring end of thermostat. When heated, the pellet expands, overcoming closing spring tension and water pump pressure to force valve to open. Coolant leakage into pellet container will cause thermostat to fail in open position. Do not attempt to free a sticking thermostat with a prying device. The thermostat controls the operating temperature of the engine by controlling the amount of coolant flow to radiator. On all engines (2.5L, 3.9L and 5.2L), thermostat is closed below 88C (192F). When cool-
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If thermostat is being replaced, be sure that replacement is specified thermostat for vehicle model and engine type. Factory installed thermostat housings on 3.9L/5.2L engines are installed on a gasket with an anti-stick coating. This will aid in gasket removal and clean-up. (1) Disconnect negative battery cable at battery. (2) Drain cooling system until coolant level is below thermostat. Refer to Draining Cooling System in this group. (3) Air Conditioned vehicles: Remove support bracket (generator mounting bracket-to-intake manifold) located near rear of generator (Fig. 20).
INSTALLATION2.5L ENGINE If thermostat is being replaced, be sure that replacement is specified thermostat for vehicle model and engine type. (1) Dip replacement gasket in water and position on water box (Fig. 18). (2) Assemble the thermostat and thermostat housing as shown in (Fig. 18). Be sure the thermostat is centered into thermostat housing and that spring side is installed towards cylinder head.
CAUTION: Tightening housing unevenly or without thermostat centered, may result in a cracked housing. (3) Install housing stud/bolts. Tighten housing stud/bolts to 23 N m (200 in. lbs.) torque. (4) Install ignition coil/coil mounting bracket assembly. (5) Install upper radiator hose to thermostat housing. (6) Connect negative battery cable to battery. (7) Fill cooling system. Refer to Refilling Cooling System in this group.
REMOVAL3.9L/5.2L ENGINE
WARNING: DO NOT LOOSEN RADIATOR DRAINCOCK WITH SYSTEM HOT AND PRESSURIZED. SERIOUS BURNS FROM COOLANT CAN OCCUR. Do not waste reusable coolant. If solution is clean, drain coolant into a clean container for reuse.
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INSTALLATION3.9L/5.2L ENGINE (1) Clean mating areas of intake manifold and thermostat housing. (2) Install thermostat (spring side down) into recessed machined groove on intake manifold (Fig. 22). (3) Install gasket on intake manifold and over thermostat (Fig. 22). (4) Position thermostat housing to intake manifold. Note the word FRONT stamped on housing (Fig. 23). For adequate clearance, this must be placed towards
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coolant carries heat to radiator and heater core. Here it is transferred to ambient air passing through radiator and heater core fins. The coolant also removes heat from automatic transmission fluid in vehicles equipped with an automatic transmission.
COOLANT PERFORMANCE The required ethylene-glycol (antifreeze) and water mixture depends upon climate and vehicle operating conditions. The coolant performance of various mixtures follows: Pure Water-Water can absorb more heat than a mixture of water and ethylene-glycol. This is for purpose of heat transfer only. Water also freezes at a higher temperature and allows corrosion. 100% Ethylene-Glycol-The corrosion inhibiting additives in ethylene-glycol need the presence of water to dissolve. Without water, additives form deposits in system. These act as insulation causing temperature to rise to as high as 149C (300F). This temperature is hot enough to melt plastic and soften solder. The increased temperature can result in engine detonation. In addition, 100 percent ethyleneglycol freezes at -22C (-8F). 50/50 Ethylene-Glycol and Water-Is the recommended mixture, it provides protection against freezing to -37C (-35F). The antifreeze concentration must always be a minimum of 44 percent, yearround in all climates. If percentage is lower, engine parts may be eroded by cavitation. Maximum protection against freezing is provided with a 68 percent antifreeze concentration, which prevents freezing down to -67.7C (-90F). A higher percentage will freeze at a warmer temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because specific heat of antifreeze is lower than that of water.
CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can cause problems associated with 100 percent ethylene-glycol.
COOLANT SELECTION-ADDITIVES Coolant should be maintained at the specified level with a mixture of ethylene glycol-based antifreeze and low mineral content water. Only use an antifreeze containing ALUGARD 340-2 .
CAUTION: Do not use coolant additives that are claimed to improve engine cooling.
COOLANT
The cooling system is designed around the coolant. Coolant flows through the engine water jackets absorbing heat produced during engine operation. The
COOLANT SERVICE It is recommended that the cooling system be drained and flushed at 84,000 kilometers (52,500
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miles), or 3 years, whichever occurs first. Then every two years, or 48,000 kilometers (30,000 miles), whichever occurs first.
COOLANT LEVEL CHECK-ROUTINE Do not remove radiator cap for routine coolant level inspections. The coolant level can be checked at coolant reserve/overflow tank. The coolant reserve/overflow system provides a quick visual method for determining coolant level without removing radiator pressure cap. With engine idling and at normal operating temperature, observe coolant level in reserve/overflow tank. The coolant level should be between ADD and FULL marks. ADDING ADDITIONAL COOLANT-ROUTINE Do not remove radiator cap to add coolant to system. When adding coolant to maintain correct level, do so at coolant reserve/overflow tank. Use a 50/50 mixture of ethylene-glycol antifreeze containing Alugard 340-2 and low mineral content water. Remove radiator cap only for testing or when refilling system after service. Removing cap unnecessarily can cause loss of coolant and allow air to enter system, which produces corrosion. COOLANT LEVEL CHECK-SERVICE The cooling system is closed and designed to maintain coolant level to top of radiator.
WARNING: DO NOT OPEN RADIATOR DRAINCOCK WITH ENGINE RUNNING OR WHILE ENGINE IS HOT AND COOLING SYSTEM IS UNDER PRESSURE. When vehicle servicing requires a coolant level check in radiator, drain several ounces of coolant from radiator drain cock. Do this while observing coolant reserve/overflow system tank. The coolant level in reserve/overflow tank should drop slightly. If not, inspect for a leak between radiator and coolant reserve/overflow system connection. Remove radiator cap. The coolant level should be to top of radiator. If not, and if coolant level in reserve/overflow tank is at ADD mark, check for: An air leak in coolant reserve/overflow tank or its hose An air leak in radiator filler neck Leak in pressure cap seal to radiator filler neck
DEAERATION As the engine operates, any air trapped in cooling system gathers under the radiator cap. The next time the engine is operated, thermal expansion of coolant will push any trapped air past radiator cap into the coolant reserve/overflow tank. Here it escapes to the atmosphere into the tank. When the engine cools down the coolant, it will be drawn from the reserve/ overflow tank into the radiator to replace any removed air.
LOW COOLANT LEVEL-AERATION If the coolant level in radiator drops below top of radiator core tubes, air will enter cooling system. On 2.5L engines, air can gather in the water box containing the thermostat. Low coolant level can cause thermostat pellet to be suspended in air instead of coolant. This will cause thermostat to open later, which in turn causes higher coolant temperature. Air trapped in cooling system
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Allow radiator to fill with water. When radiator is filled, apply air in short blasts. Allow radiator to refill between blasts. Continue this reverse flushing until clean water flows out through rear of radiator cooling tube passages. Have radiator cleaned more extensively by a radiator repair shop.
REVERSE FLUSHING ENGINE Drain cooling system. Remove thermostat housing and thermostat. Install thermostat housing. Disconnect radiator upper hose from radiator and attach flushing gun to hose. Disconnect radiator lower hose from water pump and attach a lead-away hose to water pump inlet fitting.
CAUTION: On vehicles equipped with a heater water control valve, be sure heater control valve is closed (heat off). This will prevent coolant flow with scale and other deposits from entering heater core. Connect water supply hose and air supply hose to flushing gun. Allow engine to fill with water. When engine is filled, apply air in short blasts, allowing system to fill between air blasts. Continue until clean water flows through the lead away hose. Remove lead away hose, flushing gun, water supply hose and air supply hose. Remove thermostat housing and install thermostat. Install thermostat housing with a replacement gasket. Refer to Thermostat Replacement. Connect radiator hoses. Refill cooling system with correct antifreeze/water mixture. Refer to Refilling the Cooling System.
CHEMICAL CLEANING In some instances, use a radiator cleaner (Mopar Radiator Kleen or equivalent) before flushing. This will soften scale and other deposits and aid flushing operation.
CAUTION: Follow manufacturers instructions when using these products. Aluminum Hydroxide Deposition is a type of corrosion encountered in cooling system of engines that are of an aluminum composition. This would be on a 2.5L engine with aluminum cylinder head. It appears as dark grey when wet, but, when dry it is white. This type of corrosion can usually be removed with a commercially available two part cleaner (oxcilac acid and neutralizer). Follow manufacturers directions for use. However, it is recommended that engine be operated one extra hour if acid is in coolant.
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light (black light). Pour one ounce of additive into cooling system. Place heater control unit in HEAT position. Start and operate engine until radiator upper hose is warm to touch. Aim the commercially available black light tool at components to be 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. 26).
INTERNAL LEAKAGE INSPECTION Remove engine oil pan drain plug and drain a small amount of engine oil. If coolant is present in the pan, it will drain first because it is heavier than oil. An alternative method is to operate engine for a short period to churn the oil. After this is done, remove engine dipstick and inspect for water globules. Also inspect transmission dipstick for water globules and transmission fluid cooler for leakage.
WARNING: WITH RADIATOR PRESSURE TESTER TOOL INSTALLED ON RADIATOR, DO NOT ALLOW PRESSURE TO EXCEED 110 KPA (20 PSI). PRESSURE WILL BUILD UP QUICKLY IF A COMBUSTION LEAK IS PRESENT. TO RELEASE PRESSURE, ROCK TESTER FROM SIDE TO SIDE. WHEN REMOVING TESTER, DO NOT TURN TESTER MORE THAN 1/2 TURN IF SYSTEM IS UNDER PRESSURE.
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vides a convenient and safe method for checking coolant level and adjusting level at atmospheric pressure. This is done without removing the radiator pressure cap. The system also provides some reserve coolant to the radiator to cover minor leaks and evaporation or boiling losses. As the engine cools, a vacuum is formed in the cooling system of both the radiator and engine. Coolant will then be drawn from the coolant tank and returned to a proper level in the radiator.
COMBUSTION LEAKAGE TESTWITHOUT PRESSURE TESTER DO NOT WASTE reusable coolant. If solution is clean, drain coolant into a clean container for reuse.
WARNING: DO NOT REMOVE CYLINDER BLOCK DRAIN PLUGS OR LOOSEN RADIATOR DRAINCOCK WITH SYSTEM HOT AND UNDER PRESSURE. SERIOUS BURNS FROM COOLANT CAN OCCUR. Drain sufficient coolant to allow thermostat removal. Refer to Thermostat Replacement. Disconnect water pump drive belt. Add coolant to radiator to bring level to within 6.3 mm (1/4 in) of top of thermostat housing. CAUTION: Avoid overheating. Do not operate engine for an excessive period of time. Open draincock immediately after test to eliminate boil over. Start engine and accelerate rapidly three times, to approximately 3000 rpm while observing coolant. If internal engine combustion gases are leaking into cooling system, bubbles will appear in coolant. If bubbles do not appear, internal combustion gas leakage is not present.
TANK REMOVAL (1) Remove overflow hose at reserve/overflow tank. (2) Unsnap the coolant reserve/overflow tank from fan shroud. Lift straight up. The fan shroud is equipped with T-shaped slots to attach the tank. TANK INSTALLATION (1) Snap tank into fan shroud. (2) Install overflow hose to tank.
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spring-loaded pressure relief valve that opens when system pressure reaches release range of 97-124 kPa (14-18 psi).
RADIATOR CAP-TO-FILLER NECK SEAL PRESSURE RELIEF CHECK The pressure cap upper gasket (seal) pressure relief can be tested by removing overflow hose from radiator filler neck nipple. Attach hose of pressure tester tool 7700 (or equivalent) to nipple. It will be necessary to disconnect hose from its adapter for filler neck. Pump air into radiator. The pressure cap upper gasket should relieve at 69-124 kPa (10-18 psi) and hold pressure at a minimum of 55 kPa (8 psi).
WARNING: THE WARNING WORDS DO NOT OPEN HOT ON RADIATOR PRESSURE CAP, ARE A SAFETY PRECAUTION. WHEN HOT, PRESSURE BUILDS UP IN COOLING SYSTEM. TO PREVENT SCALDING OR INJURY, RADIATOR CAP SHOULD NOT BE REMOVED WHILE SYSTEM IS HOT AND/OR UNDER PRESSURE. Do not remove radiator cap at any time except for the following purposes: (1) Check and adjust antifreeze freeze point. (2) Refill system with new antifreeze. (3) Conducting service procedures.
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INSPECTION Hold cap at eye level, right side up. The vent valve (Fig. 29) at bottom of cap should open. If rubber gasket has swollen and prevents vent valve from opening, replace cap. Hold cap at eye level, upside down. If any light can be seen between vent valve and rubber gasket, replace cap. Do not use a replacement cap that has a spring to hold vent shut. A replacement cap must be the type designed for a coolant reserve/overflow system with a completely sealed diaphragm spring and a rubber gasket. This gasket is used to seal to radiator filler neck top surface. Use of proper cap will allow coolant return to radiator.
RADIATOR
The radiators used in these models are of the down-flow type (vertical tubes) and have plastic tanks. The radiator supplies sufficient heat transfer to cool engine. CAUTION: Although plastic radiator tanks are stronger than brass, they are more susceptible to damage from impact or excessive hose clamp torque. In the event of damage to a plastic radiator tank, replacement tanks and o-ring seals (Fig. 31) are available through the parts department. Tank repair should be performed by qualified personnel using proper equipment.
RADIATOR REMOVAL2.5L 4-CYLINDER ENGINE (1) Disconnect negative battery cable from battery.
WARNING: DO NOT REMOVE CYLINDER BLOCK DRAIN PLUGS OR LOOSEN RADIATOR DRAINCOCK WITH SYSTEM HOT AND UNDER PRESSURE. SERIOUS BURNS FROM COOLANT CAN OCCUR. (2) Drain cooling system. Refer to Draining Cooling System. WARNING: CONSTANT TENSION HOSE CLAMPS ARE USED ON MOST COOLING SYSTEM HOSES. WHEN REMOVING OR INSTALLING, USE ONLY TOOLS DESIGNED FOR SERVICING THIS TYPE OF CLAMP, SUCH AS SPECIAL CLAMP TOOL (NUMBER 6094) (FIG. 32). SNAP-ON CLAMP TOOL (NUMBER HPC-20) MAY BE USED FOR LARGER CLAMPS. ALWAYS WEAR SAFETY GLASSES WHEN SERVICING CONSTANT TENSION CLAMPS.
RADIATOR COOLANT FLOW CHECK Use the following procedure to determine if coolant is flowing through cooling system. (1) Idle engine until operating temperature is reached. If upper radiator hose is warm to the touch, thermostat is opening and coolant is flowing to radiator.
WARNING: HOT, PRESSURIZED COOLANT CAN CAUSE INJURY BY SCALDING. USING A RAG TO COVER RADIATOR PRESSURE CAP, OPEN RADIATOR CAP SLOWLY TO FIRST STOP. ALLOW ANY BUILT-UP PRESSURE TO VENT TO THE RESERVE/ OVERFLOW TANK. AFTER PRESSURE BUILD-UP HAS BEEN RELEASED, REMOVE CAP FROM FILLER NECK.
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CAUTION: A number or letter is stamped into the tongue of constant tension clamps (Fig. 33). If replacement is necessary, use only an original equipment clamp with matching number or letter.
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RADIATOR INSTALLATION3.9L/5.2L ENGINE The radiator has two alignment pins on bottom of lower tank. These fit into alignment holes in radiator lower support. (1) Lower radiator into engine compartment. Position alignment pins into alignment holes in radiator lower support. (2) Install two upper radiator bolts. (3) Install transmission cooler lines (if equipped). (4) Install both radiator hoses and hose clamps (Fig. 32). (5) Install fan shroud to radiator (two clips at toptwo bolts at bottom). (6) Install coolant reserve/overflow tank. Snaps into position. (7) Connect throttle cable to fan shroud. Snaps in. (8) Connect negative battery cable to battery. (9) Fill cooling system. Refer to Refilling Cooling System section in this group. (10) Start and warm the engine. Check for leaks.
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(2) Using a pair of needle nose pliers, compress draincock body and pull straight out of radiator (Fig. 36).
RADIATOR CLEANING The radiator and air conditioning fins should be cleaned when an accumulation of bugs, leaves etc. has occurred. Clean radiator fins are necessary for good heat transfer. With the engine cold, apply cold water and compressed air to the back (engine side) of the radiator to flush the radiator and/or A/C condenser of debris.
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AUXILIARY OIL-TO-AIR COOLER Oil-to-air transmission coolers are mounted ahead of radiator. They operate in conjunction with main cooler located in radiator lower tank (Fig. 41). The transmission oil is routed through main cooler in radiator lower tank first. It is then routed through auxiliary cooler before returning to transmission.
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TESTING ELECTRICAL COOLING FAN2.5L ENGINE The powertrain control module (PCM) will enter a diagnostic trouble code (DTC) number 35 in memory if it detects a problem in the electric cooling fan relay or circuit. This will be read as a flashing signal at the instrument panel mounted malfunction indicator lamp (displayed on the instrument panel as the CHECK ENGINE lampfigure 44). Refer to OnBoard Diagnostics in Group 14, Fuel Systems for more information on accessing a DTC. The DTC can also be accessed through the DRB scan tool. Refer to the appropriate Powertrain Diagnostic Procedures manual for diagnostic information and operation of the DRB scan tool. The cooling fan motor can be tested by applying 12 volts + to the fan motor connector. Disconnect fan motor connector from harness connector. Using 14gage wire and ensuring correct polarity (Fig. 42), connect battery voltage (12 volts) to fan motor connector. If fan operates normally, fan motor is functioning properly. If fan does not operate, replace fan. If motor has signs of being overheated such as melted wire insulation or charred contacts, the system charging voltage may be too high. Refer to Group 8A, Battery/ Starting/Charging System Diagnostics. RADIATOR FAN MOTOR INOPERATIVE Equipment Required: DRB Scan Tool Volt/Ohm meter Wiring Diagrams section of this manual Test Procedure
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If battery voltage is present, replace fan relay If voltage reading is 0, repair open or short in circuit-C27 (10) Turn ignition switch off. Connect 60-way connector to PCM. Test system operation.
FAN REMOVAL2.5L ENGINE The fan blade is not repairable. If the fan is bent, warped, cracked or damaged in any way, it must be replaced only with recommended replacement fan. This is done to be sure of adequate strength, performance and safety. (1) Disconnect negative battery cable from battery. (2) Disconnect fan motor wire connector. (3) Remove the two fan shroud mounting clips connecting the upper part of fan shroud to the radiator (Fig. 34). (4) Remove fan, shroud and motor from radiator as an assembly. (5) Support fan motor and shaft on a bench. Do not allow fan blades to contact bench. Remove fan retaining clip (Fig. 47).
REMOVAL (1) Disconnect negative battery cable from battery. (2) Remove throttle cable at top of fan shroud. (3) Unsnap coolant reserve/overflow tank from fan shroud and lay aside. The tank is held to shroud with T-shaped slots. Do not disconnect hose or drain coolant from tank. (4) The thermal viscous fan drive/fan blade assembly is attached (threaded) to water pump hub shaft (Fig. 48). Remove fan blade/viscous fan drive assembly from water pump by turning mounting nut counterclockwise as viewed from front. Threads on viscous fan drive are RIGHT HAND. A Snap-On 36 MM Fan Wrench (number SP346 from Snap-On Cummins Diesel Tool Set number 2017DSP) can be used. Place a bar or screwdriver between water pump pulley bolts (Fig. 48) to prevent pulley from rotating. Do not attempt to remove fan/viscous fan drive assembly from vehicle at this time.
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INSPECTION The fan blades cannot be repaired. If fan is damaged, it must be replaced. Inspect fan as follows: (1) Remove fan blade and viscous fan drive as an assembly from the engine. Refer to preceding Removal procedure. (2) Remove fan blade assembly from viscous fan drive unit (four bolts). (3) Lay fan on a flat surface with leading edge facing down. With tip of blade touching flat surface, replace fan if clearance between opposite blade and surface is greater than 2.0 mm (.090 inch). Rocking motion of opposite blades should not exceed 2.0 mm (.090 inch). Test all blades in this manner.
WARNING: DO NOT ATTEMPT TO BEND OR STRAIGHTEN FAN BLADES IF FAN IS NOT WITHIN SPECIFICATIONS. (4) Inspect fan assembly for cracks, bends, loose rivets or broken welds. Replace fan if any damage is found. CAUTION: If fan blade assembly is replaced because of mechanical damage, water pump and viscous fan drive should also be inspected. These components could have been damaged due to excessive vibration.
The thermal viscous fan drive (Figs. 48 or 49) is a silicone-fluid-filled coupling used to connect the fan blades to the water pump shaft. The coupling allows the fan to be driven in a normal manner. This is done at low engine speeds while limiting the top speed of the fan to a predetermined maximum level at higher engine speeds. A thermostatic bimetallic spring coil is located on the front face of the viscous fan drive unit (a typical viscous unit is shown in figure 49). This spring coil reacts to the temperature of the radiator discharge air. It engages the viscous fan drive for higher fan speed if the air temperature from the radiator rises above a certain point. Until additional engine cooling is necessary, the fan will remain at a reduced rpm regardless of engine speed.
INSTALLATION (1) Install fan blade assembly to viscous fan drive. Tighten bolts (Fig. 48) to 23 N m (17 ft. lbs.) torque. (2) Position fan shroud and fan blade/viscous fan drive assembly to vehicle as a complete unit. (3) Install fan shroud. (4) Install fan blade/viscous fan drive assembly to water pump shaft (Fig. 48). (5) Install coolant reserve/overflow tank to fan shroud. Snaps into position. (6) Install throttle cable to fan shroud. (7) Connect negative battery cable.
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CAUTION: If the viscous fan drive is replaced because of mechanical damage, the cooling fan blades should also be inspected. Inspect for fatigue cracks, loose blades, or loose rivets that could have resulted from excessive vibration. Replace fan blade assembly if any of these conditions are found. Also inspect water pump bearing and shaft assembly for any related damage due to a viscous fan drive malfunction. NOISE It is normal for fan noise to be louder (roaring) when: The underhood temperature is above the engagement point for the viscous drive coupling. This may occur when ambient (outside air temperature) is very high. Engine loads and temperatures are high such as when towing a trailer. Cool silicone fluid within the fan drive unit is being redistributed back to its normal disengaged (warm) position. This can occur during the first 15 seconds to one minute after engine start-up on a cold engine. LEAKS Viscous fan drive operation is not affected by small oil stains near the drive bearing. If leakage appears excessive, replace the fan drive unit. TESTING If the fan assembly free-wheels without drag (the fan blades will revolve more than five turns when spun by hand), replace the fan drive. This spin test must be performed when the engine is cool. For the following test, the cooling system must be in good condition. It also will ensure against excessively high coolant temperature. WARNING: BE SURE THAT THERE IS ADEQUATE FAN BLADE CLEARANCE BEFORE DRILLING. (1) Drill a 3.18-mm (1/8-in) diameter hole in the top center of the fan shroud. (2) Obtain a dial thermometer with an 8 inch stem (or equivalent). It should have a range of -18-to-
VISCOUS FAN DRIVE REMOVAL/ INSTALLATION Refer to the previous section on Cooling System Fan3.9L/5.2L Engine for removal and installation procedures of the viscous drive unit. Viscous Fan Drive Fluid Pump Out Requirement: After installing a new viscous fan drive, bring the engine speed up to approximately 2000 rpm and hold for approximately two minutes. This will ensure proper fluid distribution within the drive.
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BELT DIAGNOSIS
V-BELT DIAGNOSIS2.5L 4-CYLINDER ENGINE ONLY Refer to the V-Belt diagnosis chart. SERPENTINE DRIVE BELT DIAGNOSISALL ENGINES When diagnosing serpentine drive belts, small cracks that run across ribbed surface of belt from rib to rib (Fig. 1), are considered normal. These are not a reason to replace belt. However, cracks running along a rib (not across) are not normal. Any belt with cracks running along a rib must be replaced (Fig. 1). Also replace belt if it has excessive wear, frayed cords or severe glazing. Refer to the Serpentine Drive Belt Diagnosis charts for further belt diagnosis. Also refer to Automatic Belt Tensioner3.9L/5.2L Engine, proceeding in this group.
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2.5L 4-CYLINDER ENGINE ONLY There are different gauges for checking Poly-V serpentine (multi-ribbed) belts and conventional V-belts. Use correct gauge when checking belt tension. Place gauge in middle of section of belt being used to check tension. The gauge can only contact belt or a false reading may result. The edge of belt must be against stops on belt tension gauge. Release gauge handle rapidly for correct reading. Refer to the Belt Tension chart in the Specifications section at end of this group for tension specifications. A belt is considered used after 15 minutes of use. 3.9L/5.2L ENGINE ONLY It is not necessary to adjust belt tension on 3.9L (V-6) or 5.2L (V-8) engine. The engine is equipped with an automatic belt tensioner (Fig. 5). The tensioner maintains correct belt tension at all times. For other tensioner information and removal/installation procedures, refer to Automatic Belt Tensioner3.9L/ 5.2L Engine proceeding in this group. Due to use of this belt tensioner, do not attempt to use a belt tension gauge on 3.9L/5.2L engines.
BELT TENSION
ALL ENGINES Correct accessory drive belt tension is required to be sure of optimum performance of belt driven engine accessories. If specified tension is not maintained, belt slippage may cause; engine overheating, lack of
BELT REMOVAL/INSTALLATION
GENERATOR BELT2.5L ENGINE
REMOVAL (1) Disconnect negative battery cable from battery. (2) Loosen generator mounting bolt (Fig. 6).
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AIR CONDITIONING BELT2.5L ENGINE (1) Disconnect negative battery cable from battery. (2) Loosen idler bracket pivot screw and locking screws (Fig. 7) to remove or replace air conditioning belt. The lower locking screw must be removed to remove/install belt.
POWER STEERING BELT2.5L ENGINE (1) Disconnect negative battery cable from battery. (2) Loosen locking screw (Fig. 8). (3) Loosen pivot bolt (Fig. 8). (4) Loosen pivot nut at rear of power steering pump. (5) Remove or replace power steering belt. (6) The power steering pump adjusting bracket is equipped with a 1/2 inch square hole. Insert a 1/2 inch drive breaker bar into opening and adjust belt
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INSTALLATION (1) Install pulley and pulley bolt to tensioner. Tighten bolt to 61 N m (45 ft. lbs.). (2) Install tensioner assembly to mounting bracket. An indexing tab is located on back of tensioner. Align this tab to slot in mounting bracket. Tighten nut to 67 N m (50 ft. lbs.). (3) Connect all wiring to ignition coil. (4) Install coil to coil bracket. If nuts and bolts are used to secure coil to coil bracket, tighten to 11 N m (100 in. lbs.) torque. If coil mounting bracket has been tapped for coil mounting bolts, tighten bolts to 5 N m (50 in. lbs.) torque.
CAUTION: To prevent damage to coil case, coil mounting bolts must be torqued. (5) Position drive belt over all pulleys except idler pulley (located between generator and A/C compressor). CAUTION: When installing serpentine accessory drive belt, belt must be routed correctly. If not, engine may overheat due to water pump rotating in wrong direction. Refer to (Fig. 4) for correct 3.9L/ 5.2L engine belt routing. The correct belt with correct length must be used (6) Attach a socket/wrench to pulley mounting bolt of automatic tensioner (Fig. 9). (7) Rotate socket/wrench clockwise. Place belt over idler pulley. Let tensioner rotate back into place. Remove wrench. Be sure belt is properly seated on all pulleys. (8) Check belt indexing marks.
REMOVAL (1) Attach a socket/wrench to mounting bolt of automatic tensioner pulley bolt (Fig. 9). (2) Rotate tensioner assembly clockwise (as viewed from front) until tension has been relieved from belt. (3) Remove belt from idler pulley first. (4) Remove belt from other pulleys. (5) Disconnect wiring and secondary cable from ignition coil.
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REMOVAL (1) Disconnect negative battery cable from battery. (2) Drain coolant from radiator and cylinder block. Refer to Draining Cooling System in this group. (3) Remove power cord from block heater (Fig. 1). (4) Loosen screw at center of block heater. Remove heater assembly. INSTALLATION (1) Thoroughly clean cylinder block core hole and block heater seat. (2) Insert block heater assembly with element loop pointing down. (3) With block heater fully seated, tighten center screw to 2 N m (17 in. lbs.) torque. (4) Fill cooling system with recommended coolant. Refer to Filling Cooling System section in this group. (5) Start and warm the engine. Check for leaks.
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GENERAL INFORMATION
The following specifications are published from the latest information available at the time of publication. If anything differs between the specifications found on the Vehicle Emission Control Information (VECI) label and the following specifications, use specifications on VECI label. The VECI label is located in the engine compartment. Refer to Group 25, Emission System for more information on the VECI label.
TORQUE
COOLANT CAPACITIES
ELECTRICAL
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ELECTRICAL
GROUP INDEX
Group Group
AUDIO SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . BATTERY/STARTER/GENERATOR SERVICE . . . . BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . CHIME/BUZZER WARNING SYSTEMS . . . . . . . . HORN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IGNITION SYSTEMS . . . . . . . . . . . . . . . . . . . . . . INSTRUMENT PANEL AND GAUGES . . . . . . . . . LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OVERHEAD CONSOLE . . . . . . . . . . . . . . . . . . . .
8F 8B 8A 8U 8G 8D 8E 8L 8C
POWER LOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . 8P POWER MIRRORS . . . . . . . . . . . . . . . . . . . . . . . 8T POWER WINDOWS . . . . . . . . . . . . . . . . . . . . . . . 8S RESTRAINT SYSTEMS . . . . . . . . . . . . . . . . . . . 8M TURN SIGNAL AND HAZARD WARNING SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J VEHICLE SPEED CONTROL SYSTEM . . . . . . . . . 8H WIPER AND WASHER SYSTEMS . . . . . . . . . . . . 8K WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . 8W
nostic methods, to On-Board Diagnostics (OBD) built into the Powertrain Control Module (PCM). Use of an induction milliamp ammeter, volt/ohmmeter, battery charger, carbon pile rheostat (load tester), and 12volt test lamp will be required. All OBD-sensed systems are monitored by the PCM. Each monitored circuit is assigned a Diagnostic Trouble Code (DTC). The PCM will store a DTC in electronic memory for any failure it detects. See Using On-Board Diagnostic System in this group for more information.
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WARNING: DO NOT ATTEMPT TO ASSIST BOOST, CHARGE, OR TEST BATTERY WHEN ELECTROLYTE LEVEL IS BELOW THE TOP OF THE PLATES. PERSONAL INJURY MAY OCCUR.
BATTERY RATINGS Currently, there are 2 commonly accepted methods for rating and comparing battery performance. These ratings are called Cold Cranking Amperage (CCA), and Reserve Capacity (RC). Be certain that a replacement battery has CCA and RC ratings that equal or exceed the original equipment specification for the vehicle being serviced. See Battery Classifications and Ratings charts in Specifications at the back of this group.
COLD CRANKING AMPERAGE The Cold Cranking Amperage (CCA) rating specifies how much current (in amperes) the battery can deliver for 30 seconds at -17.7C (0F). Terminal voltage must not fall below 7.2 volts during or after the 30 second discharge. The CCA required is generally higher as engine displacement increases, depending also upon the starter current draw requirements. RESERVE CAPACITY The Reserve Capacity (RC) rating specifies the time (in minutes) it takes for battery terminal voltage to fall below 10.2 volts at a discharge rate of 25 amps. RC is determined with the battery fullycharged at 26.7C (80F). This rating estimates how long the battery might last after a charging system failure, under minimum electrical load.
DIAGNOSIS
The battery must be completely charged and the top, posts, and terminal clamps should be properly cleaned before diagnostic procedures are performed. Refer to Group 8B - Battery/Starter/Generator Service for more information. The condition of a battery is determined by two criteria: (1) State-Of-Charge This can be determined by viewing the built-in test indicator, by checking specific gravity of the electrolyte (hydrometer test), or by checking battery voltage (open circuit voltage test). (2) Cranking Capacity This can be determined by performing a battery load test, which measures the ability of the battery to supply high-amperage current. If the battery has a built-in test indicator, use this test first. If it has no test indicator, but has removable cell caps, perform the hydrometer test first. If cell caps are not removable, or a hydrometer is not available, perform the open circuit voltage test first. The battery must be charged before proceeding with a load test if:
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the built-in test indicator has a black or dark color visible the temperature corrected specific gravity is less than 1.235 the open circuit voltage is less than 12.4 volts. A battery that will not accept a charge is faulty and further testing is not required. A battery that is fully-charged, but does not pass the load test is faulty and must be replaced. Completely discharged batteries may take several hours to accept a charge. See Charging Completely Discharged Battery. A battery is fully-charged when: all cells are gassing freely during charging a green color is visible in the sight glass of the built-in test indicator three corrected specific gravity tests, taken at 1-hour intervals, indicate no increase in specific gravity open circuit voltage is 12.4 volts or greater.
ABNORMAL BATTERY DISCHARGING Any of the following conditions can result in abnormal battery discharging: (1) Corroded battery posts and terminals. (2) Loose or worn generator drive belt. (3) Electrical loads that exceed the output of the charging system, possibly due to equipment installed after manufacture or repeated short trip use. (4) Slow driving speeds (heavy traffic conditions) or prolonged idling with high-amperage draw systems in use. (5) Faulty circuit or component causing excessive ignition-off draw. See Ignition-Off Draw in this group for diagnosis. (6) Faulty charging system. (7) Faulty or incorrect battery. BUILT-IN TEST INDICATOR A test indicator (hydrometer) built into the top of the battery case, provides visual information for battery testing (Fig. 1). It is important when using the test indicator that the battery be level and have a clean sight glass to see correct indications. Additional light may be required to view indicator.
WARNING: DO NOT USE OPEN FLAME AS A SOURCE OF ADDITIONAL LIGHT FOR VIEWING TEST INDICATOR. EXPLOSIVE HYDROGEN GAS MAY BE PRESENT IN THE AREA SURROUNDING BATTERY. Like a hydrometer, the built-in test indicator measures the specific gravity of the electrolyte. Specific gravity will indicate battery state-of-charge. However, the test indicator will not indicate cranking capacity of the battery. See Load Test in this group for more information. Look into the sight glass and note the color of the indicator (Fig. 2). Refer to the following description, as the color indicates:
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HYDROMETER TEST The hydrometer test reveals the battery state-ofcharge by measuring the specific gravity of the electrolyte. This test cannot be performed on batteries with non-removable cell caps. If battery has non-removable cell caps, see Built-In Test Indicator or Open Circuit Voltage Test. Specific gravity is a comparison of the density of the electrolyte to the density of pure water. Pure water has a specific gravity of 1.000, and sulfuric acid has a specific gravity of 1.835. Sulfuric acid makes up approximately 35% of the electrolyte by weight, or 24% by volume. In a fully-charged battery the electrolyte will have a temperature corrected specific gravity of 1.260 to 1.290. However, a specific gravity of 1.235 or above is satisfactory for battery load testing and/or return to service. Before testing, visually inspect battery for any damage (cracked case or cover, loose posts, etc.) that would cause the battery to be faulty. Then remove cell caps and check electrolyte level. Add distilled water if electrolyte level is below the top of the battery plates. To use the hydrometer correctly, hold it with the top surface of the electrolyte at eye level. Refer to the hydrometer manufacturers instructions for correct use of hydrometer. Remove only enough electrolyte from the battery so the float is off the bottom of the hydrometer barrel with pressure on the bulb released. Exercise care when inserting the tip of the hydrometer into a cell to avoid damaging the plate separators. Damaged plate separators can cause premature battery failure. Hydrometer floats are generally calibrated to indicate the specific gravity correctly only at 26.7C (80F). When testing the specific gravity at any other temperature, a correction factor is required. The correction factor is approximately a specific gravity value of 0.004, referred to as 4 points of specific gravity. For each 5.5C above 26.7C (10F above 80F), add 4 points. For each 5.5C below 26.7C (10F below 80F), subtract 4 points. Always correct the specific gravity for temperature variation. Test the specific gravity of the electrolyte in each battery cell. Example: A battery is tested at -12.2C (10F) and has a specific gravity of 1.240. Determine the actual specific gravity as follows: (1) Determine the number of degrees above or below 26.7C (80F): 26.6C - -12.2C = 38.8C (80F - 10F = 70F) (2) Divide the result from step 1 by 5.5 (10): 38.8C/5.5 = 7 (70F/10 = 7)
OPEN CIRCUIT VOLTAGE TEST A battery open circuit voltage (no load) test will show state-of-charge of a battery. This test can be used in place of the hydrometer test if a hydrometer is not available, or for maintenance-free batteries with non-removable cell caps. Before proceeding with this test or load test, completely charge battery as described in Battery Charging in this group. Test battery open circuit voltage as follows: (1) Before measuring open circuit voltage the surface charge must be removed from the battery. Turn headlamps on for 15 seconds, then allow up to 5 minutes for voltage to stabilize. (2) Remove both battery cables, negative first. (3) Using a voltmeter connected to the battery posts (refer to instructions provided with voltmeter) measure open circuit voltage (Fig. 3).
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LOAD TEST A battery load test will verify battery cranking capacity. The test is based on the Cold Cranking Amperage (CCA) rating of the battery. See Battery Classifications and Ratings chart in Specifications, at the back of this group.
WARNING: IF BATTERY SHOWS SIGNS OF FREEZING, LEAKING, LOOSE POSTS, OR LOW ELECTROLYTE LEVEL, DO NOT LOAD TEST. PERSONAL INJURY AND/OR VEHICLE DAMAGE MAY RESULT. Before performing load test, the battery must be FULLY-CHARGED. (1) Remove both battery cables, negative first. Battery top and posts should be clean. (2) Connect a suitable volt-ammeter-load tester (Fig. 4) to the battery posts (Fig. 5). Refer to operating instructions provided with the tester being used. Check the open circuit voltage (no load) of the battery. Open circuit voltage must be 12.4 volts or greater.
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(6) Voltage drop will vary with battery temperature at the time of the load test. Battery temperature can be estimated by the ambient temperature over the past several hours. If the battery has been charged, boosted, or loaded a few minutes prior to test, the battery will be somewhat warmer. See Load Test Temperature chart for proper loaded voltage reading. (7) If the voltmeter reading falls below 9.6 volts, at a minimum battery temperature of 21C (70F), replace the battery.
BATTERY CHARGING
A battery is fully-charged when: all cells are gassing freely during charging a green color is visible in sight glass of built-in test indicator three corrected specific gravity tests, taken at 1-hour intervals, indicate no increase in specific gravity open circuit voltage is 12.4 volts or above. WARNING: DO NOT ASSIST BOOST OR CHARGE A BATTERY THAT HAS LOW ELECTROLYTE LEVEL OR IS FROZEN. BATTERY MAY ARC INTERNALLY AND EXPLODE. WARNING: EXPLOSIVE HYDROGEN GAS FORMS IN AND AROUND BATTERY. DO NOT SMOKE, USE FLAME, OR CREATE SPARKS NEAR BATTERY. WARNING: POISONOUS AND CAUSTIC. BATTERY CONTAINS SULFURIC ACID. AVOID CONTACT WITH SKIN, EYES, OR CLOTHING. IN EVENT OF CONTACT, FLUSH WITH WATER AND CALL PHYSICIAN IMMEDIATELY. KEEP OUT OF REACH OF CHILDREN. CAUTION: Always disconnect the battery negative cable before charging battery to avoid damage to
After the battery has been charged to 12.4 volts or greater, perform a load test to determine cranking capacity. If the battery will endure a load test, return the battery to use. If the battery will not endure a load test, it must be replaced. Clean and inspect battery holddowns, tray, terminals, posts, and top before completing service. Refer to Group 8B - Battery/Starter/Generator Service for more information.
CHARGING TIME REQUIRED The time required to charge a battery will vary, depending upon the following factors: (1) Battery CapacityA completely discharged heavy-duty battery requires twice the recharging time of a small capacity battery.
WARNING: NEVER EXCEED 20 AMPS WHEN CHARGING A COLD (-1C/30F) BATTERY. PERSONAL INJURY MAY RESULT. (2) TemperatureA longer time will be needed to charge a battery at -18C (0F) than at 27C (80F).
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CHARGING COMPLETELY DISCHARGED BATTERY The following procedure should be used to recharge a completely discharged battery. Unless this procedure is properly followed, a good battery may be needlessly replaced. (1) Measure voltage at battery posts with a voltmeter, accurate to 1/10 (0.10) volt (Fig. 8). If the reading is below 10 volts, the charge current will be low. It could take some time before the battery accepts a current greater than a few milliamperes. Such low current may not be detectable on ammeters built into many chargers. (2) Disconnect battery negative cable. Connect charger leads. Some battery chargers are equipped with polarity sensing circuitry. This circuitry protects the charger and/or battery from being damaged if improperly connected. If the battery state-of-charge is too low for the polarity sensing circuitry to detect, the charger will not operate. This makes it appear that the battery will not accept charging current. Refer to the instructions provided with the battery charger to bypass the polarity sensing circuitry.
CHARGE RATE
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GENERAL INFORMATION
Ignition-Off Draw (IOD) refers to power being drained from the battery with the ignition switch turned OFF. A normal vehicle electrical system will draw from 5 to 20 milliamps (0.005 - 0.020 amps). This is with the ignition switch in the OFF position, and all non-ignition controlled circuits in proper working order. The 20 milliamps are needed to supply PCM memory, digital clock memory, and electronically-tuned radio memory. A vehicle that has not been operated for approximately 20 days, may discharge the battery to an inadequate level. When a vehicle will not be used for 20 days or more (stored), remove the IOD fuse in the Power Distribution Center (PDC). This will reduce battery discharging. Excessive battery drain can be caused by: electrical items left on faulty or improperly adjusted switches internally shorted generator intermittent shorts in the wiring. If the IOD is over 20 milliamps, the problem must be found and corrected before replacing a battery. In most cases, the battery can be charged and returned to service.
DIAGNOSIS
Testing for high-amperage IOD must be performed first to prevent damage to most milliamp meters. (1) Verify that all electrical accessories are off. Turn off all lamps, remove ignition key, and close all doors. If the vehicle is equipped with illuminated entry or electronically-tuned radio, allow the systems to automatically shut off (time out). This may take up to 3 minutes. (2) Determine that the underhood lamp is operating properly, then disconnect or remove bulb. (3) Disconnect negative cable from battery. (4) Connect a typical 12-volt test lamp (low-wattage bulb) between the negative cable clamp and the battery negative terminal. Make sure that the doors remain closed so that illuminated entry is not activated.
The test lamp may light brightly for up to 3 minutes, or may not light at all, depending upon the vehicles electrical equipment. The term brightly, as used throughout the following tests, implies the brightness of the test lamp will be the same as if it were connected across the battery. The test lamp must be securely clamped to the negative cable clamp and battery negative terminal. If the test lamp becomes disconnected during any part of the IOD test, the electronic timer function will be activated and all tests must be repeated. (5) After 3 minutes the test lamp should turn off or be dimly lit, depending upon the vehicles electrical equipment. If the test lamp remains brightly lit, do not disconnect it. Remove each fuse or circuit breaker (refer to Group 8W - Wiring Diagrams) until test lamp is either off or dimly lit. This will isolate each circuit and identify the source of the high-amperage draw. If the test lamp is still brightly lit after disconnecting each fuse and circuit breaker, disconnect the wiring harness from the generator. If test lamp now turns off or is dimly lit, see Charging System in this group to diagnose faulty generator. Do not disconnect the test lamp. After high-amperage IOD has been corrected, lowamperage IOD may be checked. It is now safe to install a milliamp meter to check for low-amperage IOD. (6) With test lamp still connected securely, clamp a milliamp meter between battery negative terminal and negative cable clamp. Do not open any doors or turn on any electrical accessories with the test lamp disconnected or the milliamp meter may be damaged. (7) Disconnect test lamp. Observe milliamp meter. The current draw should not exceed 0.020 amp. If draw exceeds 20 milliamps, isolate each circuit by removing circuit breakers and fuses. The milliamp meter reading will drop when the source of the draw is disconnected. Repair this circuit as necessary, whether a wiring short, incorrect switch adjustment or a component failure is found.
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tery terminal of the starter relay only if the clutch pedal is depressed while the ignition switch is turned to the START position. If the vehicle is equipped with an automatic transmission, the park/neutral position switch provides a ground path to the starter relay coil ground terminal. This switch provides ground only with the transmission in NEUTRAL or PARK. If the vehicle is equipped with a manual transmission, the starter relay coil ground terminal is always grounded. With the starter relay coil now energized, the normally open relay contacts close. The relay contacts connect the relay common feed terminal to the relay normally open terminal. The closed relay contacts energize the starter solenoid coil windings. The energized solenoid coils pull-in and hold-in the solenoid plunger. The solenoid plunger pulls the shift lever in the starter. This engages the starter overrunning clutch and pinion gear with the flywheel/drive plate ring gear. As the solenoid plunger reaches the end of its travel, the solenoid contact disc completes the highamperage starter feed circuit. Current now flows between the solenoid battery terminal and the starter motor, energizing the starter. Once the engine starts, the overrunning clutch protects the starter from damage by allowing the starter pinion gear to spin faster than the pinion shaft. When the driver releases the ignition switch to the ON position the starter relay coil is de-energized. This causes the relay contacts to open. When the relay contacts open, the starter solenoid coil is de-energized. When the solenoid coil is de-energized, the solenoid plunger return spring returns the plunger to its relaxed position. This causes the contact disc to open the starter feed circuit, and the shift lever to disengage the overrunning clutch and pinion gear from the ring gear. The starter motor and solenoid are serviced only as a complete assembly. If either component fails, the entire assembly must be replaced.
DIAGNOSIS
Before removing any unit from the starting system for repair, perform the following inspections:
INSPECTION
BATTERY INSPECTION To determine condition of the battery, see Battery in this group.
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WIRING INSPECTION Inspect wiring for damage. Inspect all connections at: starter solenoid park/neutral position switch (automatic transmission) clutch pedal position switch (manual transmission) ignition switch starter relay battery (including all ground connections). Clean, tighten and repair all connections as required. SOLENOID, RELAY AND SWITCH INSPECTIONS Inspect the solenoid, relay and ignition switch to determine their condition. Also, if equipped with automatic transmission, inspect condition of the park/ neutral position switch. If equipped with manual transmission, inspect condition of the clutch pedal position switch. Testing information can be found in the following pages.
COLD CRANKING TEST (1) Battery must be fully-charged and load tested before proceeding. See Battery, in this group. (2) Connect a suitable volt-ampere tester to the battery terminals (Fig. 2). Refer to the operating instructions provided with the tester being used.
FEED CIRCUIT TESTS The starter feed circuit tests (voltage drop method) will determine if there is excessive resistance in the high-amperage circuit. When performing these tests, it is important that the voltmeter be connected properly. Connect voltmeter leads to the terminals that the cable connectors or clamps are attached to, not to the cable connectors or clamps. For example: When testing between the battery and solenoid, touch the voltmeter leads to the battery post and the solenoid threaded stud. The following operation will require a voltmeter accurate to 1/10 (0.10) volt. Before performing the tests, be certain the following procedures are accomplished: unplug Auto Shut-Down (ASD) relay from Power Distribution Center (PDC) to prevent engine from starting place transmission in NEUTRAL (manual transmission) or PARK (automatic transmission) install a jumper wire between two clutch pedal position switch connectors (manual transmission) parking brake is applied battery is fully-charged (see Battery, in this group). (1) Connect positive lead of voltmeter to battery negative post. Connect negative lead of voltmeter to battery negative cable clamp (Fig. 3). Rotate and hold ignition switch in the START position. Observe voltmeter. If voltage is detected, correct poor contact between cable clamp and post.
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(5) Connect positive lead of voltmeter to starter housing. Connect negative lead of voltmeter to battery negative terminal (Fig. 6). Rotate and hold ignition switch in the START position. Observe voltmeter. If voltage reads above 0.2 volt, correct poor starter to engine ground. If resistance tests detect no feed circuit problems, remove the starter and see Solenoid Test in this group.
Fig. 6 Test Starter Ground (Typical) Fig. 4 Test Battery Positive Cable Resistance (Typical)
(4) Connect voltmeter to measure between the battery negative post and a good clean ground on the engine block (Fig. 5). Rotate and hold ignition switch in the START position. Observe voltmeter. If voltage reads above 0.2 volt, correct poor contact at battery negative cable attaching point. Repeat test. If reading is still above 0.2 volt, replace battery negative cable.
CONTROL CIRCUIT TESTS The starter control circuit consists of: starter solenoid starter relay ignition switch park/neutral position switch (automatic transmission) clutch pedal position switch (manual transmission) wiring harness and connections. Test procedures for these components are as follows, and should be followed in the order described.
CAUTION: Before performing any test, unplug Auto Shut-Down (ASD) relay from Power Distribution Center (PDC) to prevent engine from starting. SOLENOID TEST Refer to Group 8B - Battery/Starter/Generator Service for starter removal procedures. (1) Disconnect solenoid field coil wire from field coil terminal. (2) Check for continuity between solenoid terminal and field coil terminal with a continuity tester. There should be continuity (Fig. 7 or 8).
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Fig. 7 Continuity Test Between Solenoid Terminal and Field Coil Terminal (Bosch)
RELAY TEST The starter relay is in the Power Distribution Center (PDC)(Fig. 11). Refer to the underside of the PDC cover for relay location. Remove starter relay from PDC to perform the following tests: (1) A relay in the de-energized position should have continuity between terminals 87A and 30, and no continuity between terminals 87 and 30. If OK, go to next step. If not OK, replace faulty relay. (2) Resistance between terminals 85 and 86 (electromagnet) should be 75 5 ohms. If OK, go to next step. If not OK, replace faulty relay. (3) Connect a battery to terminals 85 and 86. There should now be continuity between terminals 30 and 87, and no continuity between terminals 87A and 30. If OK, go to Relay Circuit Test. If not OK, replace faulty relay.
Fig. 8 Continuity Test Between Solenoid Terminal and Field Coil Terminal (Nippondenso)
(3) Check for continuity between solenoid terminal and solenoid case. There should be continuity (Fig. 9 or 10).
Fig. 9 Continuity Test Between Solenoid Terminal and Solenoid Case (Bosch)
Fig. 10 Continuity Test Between Solenoid Terminal and Solenoid Case (Nippondenso)
(4) If there is continuity, solenoid is good. If there is no continuity in either test, solenoid has an open circuit and is faulty. Replace starter assembly. (5) Connect solenoid field coil wire to field coil terminal. (6) Install starter as described in Group 8B - Battery/Starter/Generator Service.
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RELAY CIRCUIT TEST (1) The common feed terminal (30) is connected to battery voltage and should be hot at all times. If OK, go to next step. If not OK, check circuit to fuse B in Power Distribution Center (PDC). Repair as required. (2) The normally closed terminal (87A) is connected to terminal 30 in the de-energized position, but is not used for this application. Go to next step. (3) The normally open terminal (87) is connected to the battery terminal (30) in the energized position. This terminal supplies battery voltage to the starter solenoid field coils. There should be continuity between cavity for relay terminal 87 and the starter solenoid terminal at all times. If OK, go to next step. If not OK, repair circuit to solenoid as required. (4) The coil battery terminal (86) is connected to the electromagnet in the relay. It is energized when the ignition switch is in the START position. Check for battery voltage at cavity for relay terminal 86 with ignition switch in the START position. If OK, go to next step. If not OK and vehicle has automatic transmission, refer to Group 8D - Ignition Systems for testing and service of the ignition switch. If not OK and vehicle has manual transmission, refer to Group 6 - Clutch for testing and service of the clutch pedal position switch.
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DIAGNOSIS
When the ignition switch is turned to the ON position, battery potential will register on the voltmeter. During engine cranking a lower voltage will appear on the meter. With the engine running, a voltage reading higher than the first reading (ignition in ON) should register. The following procedures may be used to diagnose the charging system if: the voltmeter does not operate properly an undercharged or overcharged battery condition occurs. Remember that an undercharged battery is often caused by: accessories being left on with the engine not running a faulty or improperly adjusted switch that allows a lamp to stay on (see Ignition-Off Draw in this group).
INSPECTION (1) Inspect condition of battery cable terminals, battery posts, connections at engine block, starter solenoid and relay. They should be clean and tight. Repair as required. (2) Inspect all fuses in the fuseblock module and Power Distribution Center (PDC) for tightness in re-
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ceptacles. They should be properly installed and tight. Repair or replace as required. (3) Inspect the electrolyte level in the battery. If cell caps are removable, add water if required. If cell caps are not removable, replace battery if electrolyte level is low. (4) Inspect generator mounting bolts for tightness. Replace or tighten bolts, if required. Refer to Group 8B - Battery/Starter/Generator Service for torque specifications. (5) Inspect generator drive belt condition and tension. Tighten or replace belt as required. Refer to Belt Tension Specifications in Group 7 - Cooling System. (6) Inspect connections at generator field, battery output, and ground terminals. Also check ground connection at engine. They should all be clean and tight. Repair as required.
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RESULTS If a higher voltage drop is indicated, inspect, clean and tighten all connections. This includes any connection between generator battery output terminal and battery positive post. A voltage drop test may be performed at each connection to locate the connection with excessive resistance. If resistance tests satisfactorily, reduce engine speed, turn OFF carbon pile and turn OFF ignition switch. (1) Disconnect negative cable from battery. (2) Remove test ammeter, voltmeter, carbon pile, and tachometer. (3) Remove jumper wire. (4) Connect generator output wire to generator battery output terminal. Tighten nut to 8.5 1.5 N m (75 15 in. lbs.). (5) Connect negative cable to battery. (6) Use DRB scan tool to erase DTC.
CURRENT OUTPUT TEST The generator current output test determines whether generator can deliver its rated current output.
PREPARATION (1) Before starting test make sure vehicle has a fully-charged battery. See Battery in this group for more information. (2) Disconnect negative cable from battery. (3) Disconnect generator output wire at the generator battery output terminal.
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(4) Connect a 0-150 ampere scale DC ammeter (Fig. 3). Install in series between generator battery output terminal and disconnected generator output wire. Connect positive lead to generator battery output terminal and negative lead to disconnected generator output wire. (5) Connect positive lead of a test voltmeter (range 0-18 volts minimum) to generator battery output terminal. (6) Connect negative lead of test voltmeter to a good ground. (7) Connect an engine tachometer, then connect battery negative cable to battery. (8) Connect a variable carbon pile rheostat between battery terminals. Be sure carbon pile is in OPEN or OFF position before connecting leads. See Load Test in this group for instructions. (9) Connect one end of a jumper wire to ground and with other end probe green K20 field wire at back of generator (Fig. 3). This will generate a DTC. CAUTION: Do not connect green/orange A142 (w/3.9L or 5.2L engine) or blue A21 (w/2.5L engine) field wire to ground. Refer to Group 8W - Wiring Diagrams for more information. TEST (1) Start engine. Immediately after starting, reduce engine speed to idle.
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to be set. Therefore, it is important that the test procedures be followed in sequence, to understand what caused a DTC to be set. See Generator Diagnostic Trouble Code chart for DTCs which apply to the charging system. Refer to the Powertrain Diagnostic Procedures manual to diagnose an on-board diagnostic system trouble code.
DIAGNOSTIC TROUBLE CODES Diagnostic Trouble Codes (DTC) are two-digit numbers flashed on the malfunction indicator (Check Engine) lamp that identify which circuit is bad. A DTC description can also be read using the DRB scan tool. Refer to Group 14 - Fuel Systems for more information. A DTC does not identify which component in a circuit is bad. Thus, a DTC should be treated as a symptom, not as the cause for the problem. In some cases, because of the design of the diagnostic test procedure, a DTC can be the reason for another DTC
RETRIEVING DIAGNOSTIC TROUBLE CODES To start this function, cycle the ignition switch ONOFF-ON-OFF-ON within 5 seconds. This will cause any DTC stored in the PCM memory to be displayed. The malfunction indicator (Check Engine) lamp will display a DTC by flashing on and off. There is a short pause between flashes and a longer pause between digits. All DTCs displayed are two-digit numbers, with a four-second pause between codes. An example of a DTC is as follows: (1) Lamp on for 2 seconds, then turns off. (2) Lamp flashes 4 times pauses and then flashes 1 time. (3) Lamp pauses for 4 seconds, flashes 4 times, pauses, then flashes 7 times. The two DTCs are 41 and 47. Any number of DTCs can be displayed, as long as they are in memory. The lamp will flash until all stored DTCs are displayed (55 = end of test).
8A - 22
BATTERY SPECIFICATIONS
BATTERY CLASSIFICATIONS AND RATINGS
8A - 23
BATTERY/STARTER/GENERATOR SERVICE
8B - 1
BATTERY/STARTER/GENERATOR SERVICE
CONTENTS
page page
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
GENERAL INFORMATION
Group 8B covers battery, starter and generator service procedures. For diagnosis of these components and their related systems, refer to Group 8A - Bat-
tery/Starting/Charging Systems Diagnostics. Refer to Group 8W - Wiring Diagrams for complete circuit descriptions and diagrams.
GENERAL INFORMATION
BATTERY
This section covers battery service procedures only. For battery maintenance procedures, refer to Group 0 - Lubrication and Maintenance. While battery charging can be considered a service or maintenance procedure, this information is located in Group 8A Battery/Starting/Charging Systems Diagnostics. This was done because the battery must be fully charged before any diagnosis can be performed. It is important that the battery, starting, and charging systems be thoroughly tested and inspected any time a battery needs to be charged or replaced. The cause of abnormal discharge, over-charging, or premature failure of the battery must be diagnosed and corrected before a battery is replaced or returned to service. Refer to Group 8A - Battery/Starting/ Charging Systems Diagnostics. The factory-installed maintenance-free battery (Fig. 1) has non-removable battery vent caps. Water cannot be added to this battery. The chemical composition within the maintenance-free battery reduces battery gassing and water loss at normal charge and discharge rates. Therefore, the battery should not require additional water in normal service. The factory-installed battery also has a built-in test indicator (hydrometer). The color visible in the sight glass of the indicator will reveal the battery condition, as follows: GreenBattery is fully charged. Black or DarkBattery is discharged. Yellow or BrightElectrolyte level is low. If battery electrolyte level becomes low, the battery must be replaced. However, low electrolyte can be caused by an over-charging condition. Be certain to diagnose charging system before returning vehicle to service. Refer to Group 8A - Battery/Starting/Charging Systems Diagnostics for more information.
BATTERY REMOVE/INSTALL
(1) Turn ignition switch to OFF position. Make sure all electrical accessories are off. (2) Loosen the cable terminal clamps and remove both battery cables, negative cable first. If necessary, use a puller to remove terminal clamps from battery posts (Fig. 2). (3) Inspect the cable terminals for corrosion and damage. Remove corrosion using a wire brush or post and terminal cleaning tool, and a sodium bicarbonate (baking soda) and warm water cleaning solution (Fig. 3). Replace cables that have damaged or deformed terminals. WARNING: WEAR A SUITABLE PAIR OF RUBBER GLOVES (NOT THE HOUSEHOLD TYPE) WHEN REMOVING A BATTERY BY HAND. SAFETY GLASSES SHOULD ALSO BE WORN. IF THE BATTERY IS CRACKED OR LEAKING, THE ELECTROLYTE CAN BURN THE SKIN AND EYES.
8B - 2
BATTERY/STARTER/GENERATOR SERVICE
BATTERY/STARTER/GENERATOR SERVICE
(9) Clean corrosion from battery posts (Fig. 6) with a wire brush or post and terminal cleaner, and sodium bicarbonate (baking soda) and warm water cleaning solution.
8B - 3
8B - 4
GENERAL INFORMATION
This section covers starter and starter relay service procedures only. For diagnostic procedures, refer to Group 8A - Battery/Starting/Charging Systems Diagnostics. Service procedures for other starting system components can be found as follows: battery - see Battery, in this group ignition switch - refer to Group 8D - Ignition Systems clutch pedal position switch - refer to Group 6 Clutch park/neutral position switch (automatic transmission) - refer to Group 21 - Transmission and Transfer Case. wiring harness and connectors - refer to Group 8W - Wiring Diagrams.
Distribution Center (PDC). The PDC is attached to the drivers side inner fender shield, next to the battery. See underside of PDC cover for relay identification and location.
STARTER REMOVE/INSTALL2.5L
(1) Disconnect battery negative cable. Raise and support vehicle. (2) Remove starter heat shield clamp and heat shield (Fig. 1).
STARTER The starter motor incorporates several features to create a reliable, efficient, compact and lightweight unit. A planetary gear system (intermediate transmission) is used between the electric motor and pinion gear. This feature makes it possible to reduce the dimensions of the starter. At the same time, it allows higher armature rotational speed and delivers increased torque through the pinion gear to the flywheel or drive plate ring gear. The use of a permanent magnet field on 2.5L engine starters also reduces size and weight. This field contains high-strength permanent magnets. The magnets are aligned according to their polarity and are permanently fixed in the starter field frame. The starter motors for all engines are activated by a solenoid mounted to the overrunning clutch housing. However, the starter motor/solenoid are serviced only as a complete assembly. If either component fails, the entire assembly must be replaced. Permanent magnet starters are highly sensitive to hammering, shocks and external pressure.
CAUTION: The 2.5L engine starter motor MUST NOT BE CLAMPED in a vise by the starter field frame. Doing so may damage the magnets. Starter may be clamped by the mounting flange ONLY. CAUTION: Do not connect 2.5L engine starter motor incorrectly when tests are being performed. The permanent magnets may be damaged and rendered unserviceable.
STARTER REMOVE/INSTALL3.9L/5.2L
TWO-WHEEL DRIVE MODELS (1) Disconnect battery negative cable. Raise and support vehicle.
STARTER RELAY The starter relay is an International Standards Organization (ISO) type relay. It is located in the Power
BATTERY/STARTER/GENERATOR SERVICE
(2) Remove starter lower mounting nut and lock washer. Then remove starter upper mounting bolt (Fig. 2).
8B - 5
FOUR-WHEEL DRIVE MODELS (1) Remove battery negative cable. Raise and support vehicle. (2) Remove front axle skid plate, if so equipped. Refer to Group 13 - Frame and Bumpers for procedure. (3) Remove lower starter mounting nut and lock washer (Fig. 2). Access from front of vehicle with a long extension. (4) Lower vehicle and remove the 15mm intermediate steering shaft coupler bolt (Fig. 5). (5) Rotate coupler clip on the steering shaft and slide upper half of shaft toward the rear of vehicle. (6) Remove upper starter mounting bolt.
8B - 6
8B - 7
GENERATOR REMOVE/INSTALL2.5L
WARNING: DISCONNECT NEGATIVE CABLE FROM BATTERY BEFORE REMOVING BATTERY OUTPUT WIRE FROM GENERATOR. FAILURE TO DO SO CAN RESULT IN INJURY. (1) Disconnect battery negative cable. (2) Remove generator drive belt. Refer to Group 7 Cooling System for procedure. (3) Remove the generator pivot and mounting bolts (Fig. 1 or 2). Position generator for access to wire connectors. (4) Remove nuts from harness holddown, battery terminal, ground terminal and 2 field terminals (Fig. 3). Remove wire connectors. (5) Remove the generator. (6) Reverse removal procedure to install. Torque generator hardware as follows: generator mounting bolt - 54 N m (40 ft. lbs.) generator pivot bolt - 54 N m (40 ft. lbs.) battery terminal nut - 8.5 N m (75 in. lbs.) ground terminal nut - 8.5 N m (75 in. lbs.) harness holddown nut - 8.5 N m (75 in. lbs.) field terminal nuts - 2.8 N m (25 in. lbs.) CAUTION: Never force a belt over a pulley rim using a screwdriver. The synthetic fiber of the belt can be damaged. CAUTION: When installing a serpentine accessory drive belt, the belt MUST be routed correctly. The water pump will be rotating in the wrong direction if
GENERATOR REMOVE/INSTALL3.9L/5.2L
WARNING: DISCONNECT NEGATIVE CABLE FROM BATTERY BEFORE REMOVING BATTERY OUTPUT WIRE FROM GENERATOR. FAILURE TO DO SO CAN RESULT IN INJURY. (1) Disconnect battery negative cable.
8B - 8
BATTERY/STARTER/GENERATOR SERVICE
(4) Remove nuts from harness holddown, battery terminal, ground terminal and 2 field terminals (Fig. 5). Remove wire connectors.
8B - 9
8B - 10
BATTERY/STARTER/GENERATOR SERVICE
OVERHEAD CONSOLE
8C - 1
OVERHEAD CONSOLE
CONTENTS
page page
SERVICE PROCEDURES
................... 5
GENERAL INFORMATION
Following are general descriptions of major components used in the Dakota overhead console. Refer to Group 8W - Wiring Diagrams for complete circuit descriptions and diagrams. circles, on level ground, in not less than 48 seconds. This will reorient the unit to its vehicle. The unit also will compensate for magnetism the body of the vehicle may acquire during normal use. However, avoid placing anything magnetic directly on the roof of the vehicle. Magnetic mounts for an antenna, a repair order hat, or a funeral procession flag can exceed the compensating ability of the compass unit if placed on the roof panel. Magnetic bit drivers used on the fasteners that hold the assembly to the roof header can also affect compass operation. If the vehicle roof should become magnetized, the demagnetizing and calibration procedures may be required to restore proper operation.
THERMOMETER
The thermometer displays the outside ambient temperature. The temperature displayed can be changed from Fahrenheit to Celsius using the US/ METRIC button. The displayed temperature is not an instant reading of conditions, but an average temperature. It may take the unit several minutes to react to a major temperature change such as driving out of a heated garage into winter temperatures. When the ignition switch is turned OFF, the last displayed temperature reading stays in memory. When the ignition switch is turned ON again, the thermometer will display the memory temperature for one minute; then update the display to the current average temperature reading within five minutes.
COMPASS
The compass will display the direction in which the vehicle is pointed using the eight major compass headings (Examples: north is N, northeast is NE). It does not display the headings in actual degrees. The display is turned on or off using the COMP/TEMP button to the left of the display. The self-calibrating compass unit requires no adjusting in normal use. The only calibration that may prove necessary is to drive the vehicle in 3 complete
8C - 2
The transmitter is mounted within the compartment with an adhesive-backed hook and loop fastener patch. Then one to three pegs are selected and mounted in a slot on the inside of the storage compartment door. The pegs may be stacked, if necessary. The peg(s) selected must be long enough to activate the button of the transmitter each time the storage compartment door is depressed.
OVERHEAD CONSOLE
8C - 3
COMPASS/THERMOMETER DIAGNOSIS
8C - 4
OVERHEAD CONSOLE
SENSOR TEST (1) Turn the ignition switch to OFF. Unplug sensor connector. (2) Measure resistance of sensor. At -40F the resistance is 336K ohms. At 140F the resistance is 2.488K ohms. Sensor resistance should read between these two values. If OK, go to Sensor Circuit Test. If not OK, replace the sensor. SENSOR CIRCUIT TEST (1) Turn ignition switch to OFF. Unplug sensor connector. (2) Short the pins on the body half of connector using a jumper wire. (3) Remove the overhead console as described in Service Procedures. (4) Check continuity between cavities 6 and 8 of overhead console harness connector (Fig. 2). There should be continuity. If OK, go to next step. If not OK, repair open circuit as required.
THERMOMETER DIAGNOSIS
The thermometer function is supported by a temperature sensor, a wiring circuit and a portion of the overhead console display. The sensor is mounted at the center of the vehicle on the support brace, behind the grille (Fig. 1).
8C - 5
ity of the compass. DO NOT use magnetic tools when servicing the overhead console. The compass features a self-calibrating design, which simplifies the calibration procedure. This feature automatically updates the compass calibration while the vehicle is being driven. This takes into account small changes in residual magnetism the vehicle may acquire during normal use. Do not attempt to calibrate the compass near large metal objects such as other vehicles, large buildings or bridges. Whenever the compass is calibrated manually, the variation number must also be reset. See Variation Adjustment Procedure, in this group. Calibrate the compass manually as follows: (1) Start the engine. (2) Depress both the US/METRIC and COMP/ TEMP buttons. Hold down until CAL is displayed. This takes about 10 seconds and appears about 5 seconds after VAR is displayed. (3) Release both buttons. (4) Drive vehicle on a level surface that is away from large metal objects through 3 or more complete circles in not less than 48 seconds. The CAL message will disappear to indicate that the compass is now calibrated. If CAL message remains in display, either there is excessive magnetism near the compass or the unit is faulty. Repeat the demagnetizing and calibration procedures at least one more time. If the wrong direction is still indicated, the area selected may be too close to a strong magnetic field. Repeat the calibration procedure in another location.
COMPASS DEMAGNETIZING
The tool used to degauss or demagnetize the roof panel is the Miller Tool 6029. Equivalent units must be rated as continuous duty for 110/115 volts and 60Hz. They must also have a field strength of over 350 gauss at 1/4-inch beyond the tip of the probe. The degaussing tool is used to demagnetize the roof panel, as follows: (1) Be sure the ignition switch is in the OFF position before you begin the demagnetizing procedure. (2) Place an 8-1/2 X 11 inch piece of paper, oriented lengthwise from front to rear, on the center line of the roof at the windshield header (Fig. 2). The purpose of the paper is to protect the roof panel from scratches and define the area to be demagnetized. (3) Plug in the degaussing tool, while keeping the tool at least 2 feet away from the compass unit.
COMPASS CALIBRATION
CAUTION: DO NOT place any external magnets such as magnetic roof mount antennas, in the vicin-
8C - 6
OVERHEAD CONSOLE
OVERHEAD CONSOLE
(4) Push front of compass/thermometer module back to release forward mounting tabs (Fig. 6).
8C - 7
8C - 8
OVERHEAD CONSOLE
the diagonal tang on hinge spring. Then insert rear of bin into left rear corner of bin opening and slide towards right rear corner of opening until rear pivot pin snaps into place.
Fig. 13 Storage Bin Hinge Spring Fig. 11 GDO Storage Door Remove/Install
(3) To install, snap door pivot pins into place.
VISCOUS DAMPER REMOVE/INSTALL (1) Remove overhead console. See Overhead Console Remove/Install. (2) Remove 2 screws securing damper to overhead console bezel (Fig. 9) at right rear corner of bin housing. (3) Remove viscous damper. (4) Reverse removal procedure to install. LATCH SPRING REMOVE/INSTALL (1) Remove overhead console. See Overhead Console Remove/Install. (2) Open sunglasses storage bin door. (3) Release latch spring from 3 clips molded into left front corner of bin housing (Fig. 9). (4) Rotate latch spring 90 and remove. (5) Reverse removal procedure to install. HINGE SPRING REMOVE/INSTALL See Overhead Console Bezel Remove/Install for service of this component.
READING/COURTESY LAMPS
LENS OR BULB REMOVE/INSTALL (1) Insert a long flat-bladed tool at the notch on the curved edge of the lens. Carefully pry the lens from the housing and pivot the lens down. It may be necessary to move the tool along the edge to free the lens. (2) Remove bulb by pulling straight down. (3) Install new bulb by pushing firmly into socket. (4) Pivot lens up into position and snap into place. Test by depressing lens to check for proper switching and lighting.
OVERHEAD CONSOLE
SWITCH SPRING REMOVE/INSTALL (1) Remove overhead console. See Overhead Console Remove/Install. (2) Snap switch from lamp housing (Fig. 14) by sliding towards rear of console. (3) Remove switch spring from switch. (4) Reverse removal procedure to install.
8C - 9
IGNITION SYSTEMS
8D - 1
IGNITION SYSTEMS
CONTENTS
page page
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5 5 5 5 5 5
GENERAL INFORMATION
Throughout this group, references are made to particular vehicle models by alphabetical designation or by the particular vehicle nameplate. A chart showing a breakdown of alphabetical designations is included in the Introduction group at the beginning of this manual. This section of the group, Component Identification/System Operation, will discuss ignition system operation and will identify ignition system components. For diagnostic procedures and adjustments, refer to the Diagnostics/Service Procedures section of this group. For removal and installation of ignition system components, refer to the Component Removal/Installation section of this group. For other useful information, refer to On-Board Diagnostics in the General Diagnosis sections of Group 14, Fuel System in this manual. For operation of the DRB Scan Tool, refer to the appropriate Powertrain Diagnostic Procedures service manual. An Ignition specifications section is included at the end of this group. A general Maintenance Schedule (mileage intervals) for ignition related items can be found in Group 0, Lubrication and Maintenance. This schedule can also be found in the Owners Manual.
IGNITION SYSTEMS Two different ignition operating systems are used. One system is used on the 2.5L 4-cylinder engine. The other is used on the 3.9L V-6 and 5.2L V-8 engine. Similarities and differences between the two systems will be discussed. A single-port, fuel injection system is used on the 2.5L 4-cylinder engine. A multi-port, fuel injection system is used on the 3.9L/5.2L engine. The ignition system is controlled by the powertrain control module (PCM) on all engines. The PCM was formerly referred to as the SBEC or engine controller. The ignition system consists of: Spark Plugs Ignition Coil Secondary Ignition Cables Distributor2.5L engine. Contains rotor and hall effect switch Distributor3.9L/5.2L engine. Contains rotor and camshaft position sensor Powertrain Control Module (PCM) Crankshaft Position Sensor3.9L/5.2L engine only
8D - 2
IGNITION SYSTEMS
The interruption of magnetic field causes the voltage to switch high resulting in a sync signal of approximately 5 volts. When the trailing edge of the pulse ring (shutter) leaves the sync signal generator, the following occurs: The change of the magnetic field causes the sync signal voltage to switch low to 0 volts. For component testing, refer to the Diagnostics/Service Procedures section of this group. For removal and installation of this component, refer to the Component Removal/Installation section of this group.
age to the ignition coil. The ground circuit for the ASD relay is controlled by the powertrain control module (PCM). The PCM regulates ASD relay operation by switching the ground circuit on-and-off.
Fig. 3 Crankshaft Position Sensor3.9L/5.2L Engine Fig. 2 Camshaft Position Sensor3.9L/5.2L Engine
The camshaft position sensor contains a hall effect device called a sync signal generator to generate a fuel sync signal. This sync signal generator detects a rotating pulse ring (shutter) on the distributor shaft. The pulse ring rotates 180 degrees through the sync signal generator. Its signal is used in conjunction with the crankshaft position sensor to differentiate between fuel injection and spark events. It is also used to synchronize the fuel injectors with their respective cylinders. When the leading edge of the pulse ring (shutter) enters the sync signal generator, the following occurs: Engine speed and crankshaft position are provided through the crankshaft position sensor. The sensor generates pulses that are the input sent to the powertrain control module (PCM). The PCM interprets the sensor input to determine the crankshaft position. The PCM then uses this position, along with other inputs, to determine injector sequence and ignition timing. The sensor is a hall effect device combined with an internal magnet. It is also sensitive to steel within a certain distance from it.
IGNITION SYSTEMS
SENSOR OPERATION3.9L ENGINE The flywheel/drive plate has groups of notches at its outer edge. On 3.9L V-6 engines, there are three sets of double notches and three sets of single notches (Fig. 4). The notches cause a pulse to be generated when they pass under the sensor. The pulses are the input to the PCM. The engine will not operate if the PCM does not receive a crankshaft position sensor input. For component testing, refer to the Diagnostics/Service Procedures section of this group. For removal and installation of this sensor, refer to the Component Removal/Installation section of this group.
8D - 3
2.5L ENGINE The 2.5L 4-cylinder engine is equipped with a mechanical distributor containing a shaft driven distributor rotor. It is driven by the timing belt through an intermediate shaft. The distributor uses a hall effect pick-up (Fig. 6). This supplies engine piston position and rpm information to the powertrain control module (PCM). Refer to Hall Effect Pick-Up in this section for additional information.
DISTRIBUTORS
For component testing, refer to the Diagnostics/Service Procedures section of this group.
8D - 4
IGNITION SYSTEMS
3.9L/5.2L ENGINES All 3.9L V-6 and 5.2L V-8 engines are equipped with a camshaft driven mechanical distributor, containing a shaft driven distributor rotor. They are equipped with an internal camshaft position (fuel sync) sensor. This sensor provides fuel injection synchronization and cylinder identification. The distributors on the 3.9L/5.2L engines do not have built in centrifugal or vacuum assisted advance. Base ignition timing and all timing advance is controlled by the powertrain control module (PCM). Because ignition timing is controlled by the PCM, base ignition timing is not adjustable on any of these engines. The distributor is held to the engine in the conventional method using a holddown clamp and bolt. Although the distributor on the 3.9L/5.2L engine can be rotated, it will have no effect on ignition timing. All distributors contain an internal oil seal that prevents oil from entering the distributor housing. The seal is not serviceable. For removal and installation of this component, refer to the Component Removal/Installation section of this group.
IGNITION COIL
Battery voltage is supplied to the ignition coil positive terminal from the ASD relay. The powertrain control module (PCM) opens and closes the ignition coil ground circuit for ignition coil operation. Base ignition timing is not adjustable on the 3.9L/5.2L engine. By controlling the coil ground circuit, the PCM is able to set the base timing and adjust the ignition timing advance. This is done to meet changing engine operating conditions. The ignition coil is not oil filled. The windings are embedded in an epoxy compound. This provides heat and vibration resistance that allows the ignition coil to be mounted on the engine. 2.5L engine: The coil is mounted on a bracket, to the thermostat housing, in front of the coolant temperature sensor (Fig. 7). 3.9L or 5.2L engines: The coil is mounted to a bracket that is bolted to the front of the right engine cylinder head (Fig. 8). This bracket is also used to mount the automatic belt tensioner. For component testing, refer to the Diagnostics/Service Procedures section of this group. For removal and installation of this component, refer to the Component Removal/Installation section of this group.
IGNITION SYSTEMS
through the pick-up, they interrupt the magnetic field. The hall effect device in the pick-up senses the change in the magnetic field. It then switches on and off, which creates pulses generating the input signal to the PCM. The PCM calculates engine speed through the number of pulses generated.
8D - 5
8D - 6
Automatic Shutdown (ASD) Relay Test . Camshaft Position Sensor Test . . . . . . . Crankshaft Position Sensor Test . . . . . . Distributor Cap . . . . . . . . . . . . . . . . . . . Distributor Rotor . . . . . . . . . . . . . . . . . . DRB Scan Tool . . . . . . . . . . . . . . . . . . . Engine Coolant Temperature Sensor Test General Information . . . . . . . . . . . . . . . Ignition Coil . . . . . . . . . . . . . . . . . . . . . Ignition Secondary Circuit Diagnosis . . .
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6 6 7 7 7 8 8 6 8 9
GENERAL INFORMATION
This section of the group, Diagnostics/Service Procedures, will discuss basic ignition system diagnostics and service adjustments. For system operation and component identification, refer to the Component Identification/System Operation section of this group. For removal or installation of ignition system components, refer to the Component Removal/Installation section of this group. For other useful information, refer to On-Board Diagnostics in the General Diagnosis sections of Group 14, Fuel System in this manual. For operation of the DRB Scan Tool, refer to the appropriate Powertrain Diagnostic Procedures service manual.
(2) Connect the negative (-) voltmeter lead into the ground wire. For wire identification, refer to Group 8W, Wiring Diagrams. (3) Set the voltmeter to the 15 Volt DC scale. (4) Remove distributor cap from distributor (two screws). Rotate (crank) the engine until the distributor rotor is pointed towards the rear of vehicle. The movable pulse ring should now be within the sensor pickup. (5) Turn ignition key to ON position. Voltmeter should read approximately 5.0 volts. (6) If voltage is not present, check the voltmeter leads for a good connection. (7) If voltage is still not present, check for voltage at the supply wire. For wire identification, refer to Group 8W, Wiring Diagrams. (8) If voltage is not present at supply wire, check for voltage at pin-7 of powertrain control module (PCM) 60-way connector. Leave the PCM connector connected for this test. (9) If voltage is still not present, perform vehicle test using the DRB scan tool. (10) If voltage is present at pin-7, but not at the supply wire: (a) Check continuity between the supply wire. This is checked between the distributor connector and pin-7 at the PCM. If continuity is not present, repair the harness as necessary. (b) Check for continuity between the camshaft position sensor output wire and pin-44 at the PCM. If continuity is not present, repair the harness as necessary. (c) Check for continuity between the ground circuit wire at the distributor connector and ground. If continuity is not present, repair the harness as necessary. (11) While observing the voltmeter, crank the engine with ignition switch. The voltmeter needle should fluctuate between 0 and 5 volts while the engine is cranking. This verifies that the camshaft position sensor in the distributor is operating properly
IGNITION SYSTEMS
and a sync pulse signal is being generated. If sync pulse signal is not present, replacement of the camshaft position sensor is necessary. For removal or installation of ignition system components, refer to the Component Removal/Installation section of this group. For system operation and component identification, refer to the Component Identification/System Operation section of this group.
8D - 7
DISTRIBUTOR ROTOR
Visually inspect the rotor (Fig. 5) for cracks, evidence of corrosion, or the effects of arcing on the metal tip. Also check for evidence of mechanical interference with the cap. Some charring is normal 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 compound. Test the spring for insufficient tension. Replace a rotor that displays any of these adverse conditions.
DISTRIBUTOR CAP
INSPECTION Remove the distributor cap and wipe it clean with a dry lint free cloth. Visually inspect the cap for cracks, carbon paths, broken towers, or damaged rotor button (Figs. 3 and 4). Also check for white depos-
8D - 8
IGNITION SYSTEMS
IGNITION COIL
To perform a complete test of the ignition coil and its circuitry, refer to the DRB scan tool. Also refer to the appropriate Powertrain Diagnostics Procedures manual. To test the coil only, refer to the following: The ignition coil (Figs. 6 or 7) is designed to operate without an external ballast resistor. Inspect the ignition coil for arcing. Test the coil according to coil tester manufacturers instructions. Test the coil primary and secondary resistance. Replace any coil that does not meet specifications. Refer to the Ignition Coil Resistance chart.
IGNITION SYSTEMS
IGNITION COIL RESISTANCE
8D - 9
8D - 10
IGNITION SYSTEMS
that the ignition secondary system is operating correctly. (note that if the ignition coil cable is removed for this test, instead of a spark plug cable, the spark intensity will be much higher.) If steady arcing occurs at the spark plug cables, but the engine will not start, connect the DRB scan tool. Refer to the Powertrain Diagnostic Procedures service manual.
FAILURE TO START TEST To prevent unnecessary diagnostic time and wrong test results, the previous Checking For Spark test should be performed prior to this test.
WARNING: SET PARKING BRAKE OR BLOCK THE DRIVE WHEELS BEFORE PROCEEDING WITH THIS TEST. (1) Unplug the ignition coil harness connector at the coil (Figs. 11 or 12).
IGNITION SYSTEMS
8D - 11
IGNITION TIMING
2.5L ENGINE
WARNING: APPLY PARKING BRAKE AND/OR BLOCK WHEELS BEFORE PERFORMING IGNITION TIMING ADJUSTMENT, OR ANY TESTS WITH A RUNNING ENGINE. Proper ignition timing is required to obtain optimum engine performance. The distributor must be correctly indexed to provide correct initial ignition timing. (1) Set the gearshift selector in park or neutral and apply the parking brake. All lights and accessories must be off. (2) If a magnetic timing unit is being used, insert the pickup probe into the open receptacle on the transmission bell housing. This is located next to the upper, left mounting bolt. If a magnetic timing unit is not available, use a conventional timing light connected to the number one cylinder spark plug cable. Use the timing scale on the transmission dust cover (Fig. 15).
high resistance. In addition, breaking the rubber insulation may permit secondary current to arc to ground. (3) Turn selector switch to the appropriate cylinder position. (4) Start engine and run until normal operating temperature is obtained. (a) If using the DRB scan tool: Connect the DRB tool. Refer to the appropriate Powertrain Diagnostic Procedures service manual. (b) If not using the DRB tool: Disconnect the coolant temperature sensor (Fig. 16). When the sensor is disconnected, the radiator (electrical) cooling fan should operate and the malfunction indicator lamp (displayed on the instrument panel as the CHECK ENGINE lampfigure 17) should be lit.
8D - 12
SPARK PLUGS
For spark plug removal, cleaning, gap adjustment and installation, refer to the Component Removal/Installation section of this group. 3.9L/5.2L Engine: Spark plug cable boot heat shields are pressed into the cylinder head to surround each cable boot and spark plug (Fig. 20). These shields protect the spark plug boots from damage (due to intense engine heat generated by the exhaust manifolds) and should not be removed. After the spark plug cable has been installed, the lip of the cable boot should have a small air gap to the top of the heat shield (Fig. 20). Faulty carbon and/or gas fouled plugs generally cause hard starting, but they will clean up at higher
IGNITION SYSTEMS
8D - 13
CONDITION
NORMAL OPERATING The few deposits present on the spark plug will probably be light tan or slightly gray in color. This is evident with most grades of commercial gasoline (Fig. 21). There will not be evidence of electrode burning. Gap growth will not average more than approximately 0.025 mm (.001 in) per 1600 km (1000 miles) of operation. Spark plugs that have normal wear can usually be cleaned, have the electrodes filed, have the gap set and then be installed. Some fuel refiners in several areas of the United States have introduced a manganese additive (MMT) for unleaded fuel. During combustion, fuel with MMT causes the entire tip of the spark plug to be coated with a rust colored deposit. This rust color can be misdiagnosed as being caused by coolant in the combustion chamber. Spark plug performance is not affected by MMT deposits.
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IGNITION SYSTEMS
IGNITION SYSTEMS
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Fig. 29 Spark Plug Cable Removal/Installation2.5L Engine Fig. 27 Spark Plug Overheating
TESTING Spark plug cables are sometimes referred to as secondary ignition cables or secondary wires. The cables transfer electrical current from the distributor to in-
dividual spark plugs at each cylinder. The spark plug cables are of nonmetallic construction and have a built in resistance. The cables provide suppression of radio frequency emissions from the ignition system. Check the high-tension cable connections for good contact at the ignition coil, distributor cap towers and spark plugs. Terminals should be fully seated. The terminals and spark plug covers should be in good condition. Terminals should fit tightly to the ignition coil, distributor cap and spark plugs. The spark plug cover (boot) of the cable should fit tight around the spark plug insulator. Loose cable connections can cause corrosion and increase resistance, resulting in shorter cable service life. Clean the high tension cables with a cloth moistened with a nonflammable solvent and wipe dry. Check for brittle or cracked insulation. When testing secondary cables for damage with an oscilloscope, follow the instructions of the equipment manufacturer. If an oscilloscope is not available, spark plug cables may be tested as follows:
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IGNITION SYSTEMS
rotor button (center contact) of distributor cap and terminal at ignition coil end of cable. If resistance is not within specifications as found in the Spark Plug Cable Resistance chart, remove the cable from the distributor cap. Connect the ohmmeter to the terminal ends of the cable. If resistance is not within specifications as found in the Spark Plug Cable Resistance chart, replace the cable. Inspect the ignition coil tower for cracks, burns or corrosion. For removal and installation of spark plug cables, refer to Spark Plug Secondary Cables in the Component Removal/Installation section.
CAUTION: Do not leave any one spark plug cable disconnected for longer than necessary during testing. This may cause possible heat damage to the catalytic converter. Total test time must not exceed ten minutes. With the engine running, remove spark plug cable from spark plug (one at a time) and hold next to a good engine ground. If the cable and spark plug are in good condition, the engine rpm should drop and the engine will run poorly. If engine rpm does not drop, the cable and/or spark plug may not be operating properly and should be replaced. Also check engine cylinder compression. With the engine not running, connect one end of a test probe to a good ground. Start the engine and run the other end of the test probe along the entire length of all spark plug cables. If cables are cracked or punctured, there will be a noticeable spark jump from the damaged area to the test probe. The cable running from the ignition coil to the distributor cap can be checked in the same manner. Cracked, damaged or faulty cables should be replaced with resistance type cable. This can be identified by the words ELECTRONIC SUPPRESSION printed on the cable jacket. Use an ohmmeter to test for open circuits, excessive resistance or loose terminals. Remove the distributor cap from the distributor. Do not remove cables from cap. Remove cable from spark plug. Connect ohmmeter to spark plug terminal end of cable and to corresponding electrode in distributor cap. Resistance should be 250 to 1000 Ohms per inch of cable. If not, remove cable from distributor cap tower and connect ohmmeter to the terminal ends of cable. If resistance is not within specifications as found in the Spark Plug Cable Resistance chart, replace the cable. Test all spark plug cables in this manner.
ON-BOARD DIAGNOSTICS
FOR CERTAIN IGNITION SYSTEM COMPONENTS The powertrain control module (PCM) performs an On-Board Diagnostic (OBD) check for certain ignition system components on all vehicles. This is done by setting a diagnostic trouble code (DTC). A DTC can be obtained in two different ways. One of the ways is by connecting the DRB scan tool to the data link connector. This connector is located in the engine compartment (Fig. 30). Refer to the appropriate Powertrain Diagnostic Procedures service manual for operation of the DRB scan tool. The other way is to cycle the ignition key and observe the malfunction indicator lamp (MIL). The MIL lamp is displayed on the instrument panel as the CHECK ENGINE lamp (Fig. 31). This lamp will flash a numeric code. If a numeric code number 11 (for the crankshaft position sensor) or 42 (for the ASD relay) is observed, a problem has been found in the ignition system. Note that the CHECK ENGINE lamp will illuminate initially for approximately two seconds each time the ignition key is turned to the ON position. This is done for a bulb test.
To test ignition coil-to-distributor cap cable, do not remove the cable from the cap. Connect ohmmeter to
IGNITION SYSTEMS
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Automatic Shutdown (ASD) Relay . Camshaft Position Sensor . . . . . . . Crankshaft Position Sensor . . . . . . Distributor2.5L Engine . . . . . . . . Distributor3.9L/5.2L Engine . . . . Engine Coolant Temperature Sensor General Information . . . . . . . . . . . Hall Effect Pick-Up2.5L Engine . .
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18 18 19 20 21 20 18 23
GENERAL INFORMATION
This section of the group, Component Removal/Installation, will discuss the removal and installation of ignition system components. For basic ignition system diagnostics and service adjustments, refer to the Diagnostics/Service Procedures section of this group. For system operation and component identification, refer to the Component Identification/System Operation section of this group.
REMOVAL3.9L/5.2L ENGINE Distributor removal is not necessary to remove camshaft position sensor. (1) Disconnect negative battery cable at battery. (2) Remove distributor cap from distributor (two screws). (3) Disconnect camshaft position sensor wiring harness from main engine wiring harness.
INSTALLATION (1) Install camshaft position sensor to distributor. Align sensor into notch on distributor housing. (2) Connect wiring harness. (3) Install rotor. (4) Install distributor cap. Tighten mounting screws.
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IGNITION SYSTEMS
DISTRIBUTOR2.5L ENGINE
Also refer to Hall Effect Pick-Up in this section for removal and installation.
REMOVAL (1) Disconnect distributor pick-up lead wire at wiring harness connector (Fig. 5).
INSTALLATION (1) Position distributor in engine. Make certain that the O-ring is properly seated on distributor. If O-ring is cracked or nicked, replace O-ring. (2) Carefully engage distributor drive with auxiliary shaft drive. When distributor is installed properly, rotor will be pointing toward cylinder block. If engine has been cranked while distributor is removed, it will be necessary to establish proper relationship between the distributor shaft and number one piston position as follows: (a) Rotate the crankshaft until number one piston is at top of compression stroke. Pointer on
IGNITION SYSTEMS
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Before distributor is removed, the number-one cylinder must be brought to the top dead center (TDC) firing position. (4) Attach a socket to the Crankshaft Vibration Damper mounting bolt. (5) Slowly rotate engine clockwise, as viewed from front, until indicating mark on crankshaft vibration damper is aligned to 0 degree (TDC) mark on timing chain cover (Fig. 10).
DISTRIBUTOR3.9L/5.2L ENGINE
REMOVAL
CAUTION: Base ignition timing is not adjustable on any 3.9L V-6 or 5.2L V-8 engine. Distributors do not have built in centrifugal or vacuum assisted advance. Base ignition timing and timing advance are controlled by the powertrain control module (PCM). Because a conventional timing light can not be used to adjust distributor position after installation, note position of distributor before removal. (1) Disconnect negative battery cable at battery. (2) Remove distributor cap from distributor (two screws). (3) Mark the position of distributor housing in relationship to engine or dash panel. This is done to aid in installation.
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IGNITION SYSTEMS
CHECKING DISTRIBUTOR POSITION To verify correct distributor rotational position, connect the DRB scan tool to the data link connector. The data link connector is located in the engine compartment. Gain access to the SET SYNC screen on the DRB. WARNING: WHEN PERFORMING THE FOLLOWING TEST, THE ENGINE WILL BE RUNNING. BE CAREFUL NOT TO STAND IN LINE WITH THE FAN BLADES OR FAN BELT. DO NOT WEAR LOOSE CLOTHING. Follow the directions on the DRB screen and start the engine. With the engine running, the words IN RANGE should appear on the screen along with 0. This indicates correct distributor position. If a plus (+) or a minus (-) is displayed next to the degree number, and/or the degree displayed is not zero, loosen but do not remove the distributor holddown clamp bolt. Rotate the distributor until IN RANGE appears on the screen. Continue to rotate the distributor until achieving as close to 0 as possible. After adjustment, tighten clamp bolt to 22.5 N m (200 in. lbs.) torque. The degree scale on the SET SYNC screen of the DRB is referring to fuel synchronization only. It is not referring to ignition timing. Because of this, do not attempt to adjust ignition timing using this method. Rotating the distributor will have no effect on ignition timing. All ignition timing values are controlled by the powertrain control module (PCM).
INSTALLATION If engine has been cranked while distributor is removed, establish the relationship between distributor shaft and number one piston position as follows: Rotate crankshaft in a clockwise direction, as viewed from front, until number-one cylinder piston is at top of compression stroke (compression should be felt on finger with number one spark removed). Then continue to slowly rotate engine clockwise until indicating mark (Fig. 10) is aligned to 0 degree (TDC) mark on timing chain cover. (1) Clean top of cylinder block for a good seal between distributor base and block. (2) Lightly oil the rubber O-ring seal on the distributor housing. (3) Install rotor to distributor shaft. (4) Position distributor into engine to its original position. Engage tongue of distributor shaft with slot in distributor oil pump drive gear. Position rotor to the number one spark plug cable position. (5) Install distributor holddown clamp and clamp bolt. Do not tighten bolt at this time. (6) Rotate the distributor housing until rotor is aligned to CYL. NO. 1 alignment mark on the camshaft position sensor (Fig. 11). (7) Tighten clamp holddown bolt (Fig. 12) to 22.5 N m (200 in. lbs.) torque. (8) Connect camshaft position sensor wiring harness to main engine harness. (9) Install distributor cap. Tighten mounting screws. (10) Refer to the following Checking Distributor Position.
IGNITION COIL
The ignition coil is an epoxy filled type. If the coil is replaced, it must be replaced with the same type.
REMOVAL2.5L ENGINE The coil is mounted on a bracket, to the thermostat housing, in front of the coolant temperature sensor (Fig. 13). (1) Disconnect the ignition coil secondary cable from ignition coil (Fig. 13). (2) Disconnect engine harness connector from ignition coil. (3) Remove ignition coil mounting screws. Remove coil. INSTALLATION2.5L ENGINE (1) Install ignition coil to bracket on cylinder block with mounting screws. (2) Connect engine harness connector to coil. (3) Connect ignition coil cable to ignition coil. REMOVAL3.9L/5.2L ENGINE The ignition coil is mounted to a bracket near the front of the right engine cylinder head on 3.9L/5.2L engines (Fig. 14).
IGNITION SYSTEMS
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INSTALLATION3.9L/5.2L ENGINE (1) Install the ignition coil to coil bracket. If nuts and bolts are used to secure coil to coil bracket, tighten to 11 N m (100 in. lbs.) torque. If the coil mounting bracket has been tapped for coil mounting bolts, tighten bolts to 5 N m (50 in. lbs.) torque. (2) Connect all wiring to ignition coil.
REMOVAL (1) Remove shield and distributor cap. Refer to Distributor Removal2.5L Engine. (2) Remove rotor from shaft (Fig. 15).
INSTALLATION (1) Place hall effect pick-up assembly into distributor housing (Fig. 16).
CAUTION: The hall effect pick-up assembly leads may be damaged if not properly installed (Fig. 16). (2) Install rotor (Fig. 15). (3) Install cap and splash shield. Refer to Distributor Installation2.5L Engine.
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IGNITION SYSTEMS
INSTALLATION (1) Check pins in 60-way PCM connector for damage. Repair as necessary. (2) Connect 60-Way electrical connector to the PCM (Fig. 17). (3) Mount PCM to inside right front fender (Fig. 17). Tighten screws to 4 N m (35 in. lbs.) torque. (4) Install air cleaner duct to the PCM (2.5L only). (5) Connect negative battery cable to battery.
SPARK PLUGS
3.9L/5.2L ENGINE. Spark plug cable heat shields are pressed into the cylinder head to surround each cable boot and spark plug (Fig. 18). These shields protect the spark plug boots from damage (due to intense engine heat generated by the exhaust manifolds) and should not be removed. After the spark plug cable has been installed, the lip of the cable boot should have a small air gap to the top of the heat shield (Fig. 18). If removal of the heat shield(s) is necessary, remove the spark plug cable and compress the sides of shield for removal. Each shield is slotted to allow for compression and removal. To install the shields, align shield to machined opening in cylinder head and tap into place with a block of wood.
IGNITION SYSTEMS
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PLUG CLEANING The plugs may be cleaned using commercially available spark plug cleaning equipment. After cleaning, file the center electrode flat with a small point file or jewelers file before adjusting gap.
CAUTION: Never use a motorized wire wheel brush to clean the spark plugs. Metallic deposits will remain on the spark plug insulator and will cause plug misfire.
PLUG GAP ADJUSTMENT Check the spark plug gap with a gap gauge tool. If the gap is not correct, adjust it by bending the ground electrode (Fig. 20). Never attempt to adjust the gap by bending the center electrode. SPARK PLUG GAP 2.5L Engine Spark Plug Gap: .89 mm (.035 in). 3.9L/5.2L Engine Spark Plug Gap: .89 mm (.035 in). PLUG INSTALLATION Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting in a change in the spark plug gap or a cracked porcelain insulator. When replacing the spark plug and ignition coil cables, route the cables correctly and secure them in the appropriate retainers. Failure to route the cables properly can cause the radio to reproduce ignition noise. It could cause cross ignition of the spark plugs, or short circuit the cables to ground. (1) Start the spark plug into the cylinder head by hand to avoid cross threading.
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IGNITION SYSTEMS
spark plug cable has been installed, the lip of the cable boot should have a small air gap to the top of the heat shield (Fig. 24).
IGNITION SYSTEMS
1995 AN Dakota Publication No. 81-370-5110 TSB 23-44-94 June 3, 1994
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GENERAL INFORMATION
The ignition switch is located in the steering column. The Key-In- Switch and Halo Light are integral with the ignition switch. Refer to Group 8U for KeyIn-Switch and Halo Light diagnosis.
TYPE 1 WITH RETAINING PIN (7) To remove the lock cylinder with retaining pin from the ignition switch:
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IGNITION SYSTEMS
1995 AN Dakota Publication No. 81-370-5110 TSB 23-44-94 June 3, 1994
(b) Rotate key clockwise to the OFF position. Lock cylinder will unseat from ignition switch (Fig. 4). When lock cylinder is unseated, it will be approximately 1/8 inch away from ignition switch halo light ring. Do not attempt to remove lock cylinder at this time. (c) With lock cylinder in unseated position, rotate key counterclockwise to the lock position and remove key. (d) Remove lock cylinder from ignition switch (Fig. 7).
IGNITION SYSTEMS
1995 AN Dakota Publication No. 81-370-5110 TSB 23-44-94 June 3, 1994
8D - 28A
INSTALLATION TYPE II (1) Connect electrical connectors to the ignition switch. Make sure that the switch locking tabs are fully seated in the wiring connectors. (2) Before attaching the ignition switch to a tilt steering column, the transmission shifter must be in the Park position. Also the park lock dowel pin and the column lock flag must be properly indexed before installing the switch (Fig. 8). (a) Place the transmission shifter in the PARK position. (b) Place the ignition switch in the lock position. The switch is in the lock position when the column lock flag is parallel to the ignition switch terminals (Fig. 8). (c) Position ignition switch park lock dowel pin so it will engage the steering column park lock slider linkage (Fig. 9). (d) Apply a light coating of grease to the column lock flag and the park lock dowel pin. (3) Place the ignition switch against the lock housing opening on the steering column. Ensure that the ignition switch park lock dowel pin enters the slot in the park lock slider linkage in the steering column. (4) Install retaining bracket and ignition switch mounting screws. Tighten screws to 3 5 N m (26 4 in. lbs.) torque. (5) Install ignition lock cylinder: (a) With the lock cylinder and the ignition switch in the Lock position, insert the lock cylinder into the ignition switch until it bottoms. (b) Insert ignition key into lock cylinder. While gently pushing the lock cylinder in toward the ignition switch, rotate the ignition key to the end of travel. (6) Install retaining screw into bracket and lock cylinder. Tighten screw to 3 5 N m (26 4 in. lbs.) torque. (7) Install steering column covers. Tighten screws to 2 N m (17 in. lbs.) torque. (8) If vehicle is equipped with a tilt steering column, install tilt lever. (9) Connect negative cable to battery. (10) Check for proper operation of the halo light, shift lock (if applicable), and column lock. Also check for proper operation of the ignition switch accessory, lock, off, run, and start positions.
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IGNITION SYSTEMS
SPARK PLUGS
SENSOR
TORQUE
8E - 1
GENERAL INFORMATION
Following are general descriptions of major instrument panel components. Refer to Group 8W - Wiring Diagrams for complete circuit descriptions and diagrams.
INSTRUMENT PANEL
Modular instrument panel construction allows all gauges and controls to be serviced from the front of the panel. In addition, most instrument panel wiring or heater and air conditioning components can be accessed without complete instrument panel removal. If necessary, the instrument panel can be rolled-down and removed from the vehicle as an assembly. Removal of the instrument cluster bezel allows access to the cluster assembly, switches, the climate controls, and the radio. Removal of the cluster assembly allows access to the individual gauges, illumination and indicator lamp bulbs, printed circuits, and most wiring. Removal of the lower instrument panel allows access to heater and air conditioning components, and other wiring and electrical components. Removal of the steering column cover provides access to the steering column mounts, the intermittent wipe module, and the gear selector (auto trans) indicator cable. Models equipped with a drivers-side airbag restraint have a knee blocker and reinforcement behind the steering column cover.
INSTRUMENT CLUSTERS
Two basic instrument cluster options are offered on Dakota models. One is referred to as a standard cluster (Fig. 1), and the other is referred to as a optional cluster (Fig. 2). Each cluster is served by a printed circuit and two wiring connectors. Some variations of each cluster exist due to optional equipment and regulatory requirements. The standard cluster includes the following gauges: coolant temperature gauge fuel gauge gear selector indicator (auto trans) oil pressure gauge speedometer/odometer trip odometer
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low fuel warning lamp low oil pressure warning lamp low washer fluid warning lamp malfunction indicator (Check Engine) lamp seat belt reminder lamp transmission oil temperature warning lamp (snow plow prep package w/auto trans - located on steering column cover) turn signal indicator lamps upshift indicator lamp. The optional cluster includes all of the gauges and indicator lamps found in the standard cluster, but adds a analog tachometer. Some of the standard cluster gauges and indicator lamps have different positions or sizes in the optional cluster to accommodate the tachometer.
GAUGES
With the ignition switch in the ON or START position, voltage is supplied to all gauges through the instrument cluster printed circuit. With the ignition switch in the OFF position, voltage is not supplied to the gauges. A gauge pointer may remain within the gauge scale after the ignition switch is OFF. However, the gauges do not accurately indicate any vehicle condition unless the ignition switch is ON. All gauges except the odometer are air core magnetic units. Two fixed electromagnetic coils are located within the gauge. These coils are wrapped at right angles to each other around a movable permanent magnet. The movable magnet is suspended within the coils on one end of a shaft. The gauge needle is attached to the other end of the shaft. One of the coils has a fixed current flowing through it to maintain a constant magnetic field strength. Current flow through the second coil changes, which causes changes in its magnetic field strength. The current flowing through the second coil can be changed by: a variable resistor-type sending unit (fuel level, coolant temperature, or oil pressure) changes in electrical system voltage (voltmeter) electronic control circuitry (speedometer/odometer, tachometer). The gauge needle moves as the movable permanent magnet aligns itself to the changing magnetic fields created around it by the electromagnets.
COOLANT TEMPERATURE GAUGE The coolant temperature gauge gives an indication of engine coolant temperature. The coolant temperature sending unit is a thermistor that changes electrical resistance with changes in engine coolant temperature. High sending unit resistance causes low coolant temperature readings. Low resistance causes high coolant temperature readings. Sending unit resistance values are shown in a chart in Specifications.
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TRIP ODOMETER The trip odometer is driven by the same electronic integrated circuit as the speedometer/odometer. However, by depressing the trip odometer reset knob on the face of the speedometer, the trip odometer can be reset to zero. The trip odometer is serviced only as a part of the speedometer/odometer gauge assembly. VOLTMETER The voltmeter is connected in parallel with the battery. With the ignition switch ON, the voltmeter indicates battery or generator output voltage, whichever is greater.
two halves of the split brake hydraulic system are unequal. With the ignition switch turned ON, battery voltage is supplied to one side of the indicator bulb. A ground path for the bulb is provided by 3 switches. The bulb will light when: the brake warning switch is closed (indicating unequal brake system hydraulic pressures possibly due to brake fluid leakage) the ignition switch is in the START position (bulb test) the parking brake switch is closed (parking brake is applied). Refer to Group 5 - Brakes for more information.
INDICATOR LAMPS
Indicator lamps are located in several areas of the cluster and instrument panel, depending upon equipment. Those lamps within the cluster area are served by the cluster printed circuit and cluster connectors.
FOUR-WHEEL DRIVE INDICATOR LAMP On vehicles with four-wheel drive, the indicator lamp lights when the transfer case is engaged in the 4H or 4L position. The lamp is located on the transfer case shift lever bezel on the floor of the vehicle. Voltage is supplied to one side of the indicator bulb. A switch in the transfer case is connected to the other side of the indicator bulb. When the switch is closed, a path to ground is provided and the indicator bulb lights. HEADLAMP HIGH BEAM INDICATOR LAMP The high beam indicator lamp is controlled by the headlamp dimmer (multi-function) switch. One side of the indicator bulb is grounded at all times. The other side of the bulb receives battery feed through the contacts of the dimmer switch when the multifunction switch stalk is actuated to turn the headlamp high beams on. Refer to Group 8L - Lamps for more information. LOW FUEL WARNING LAMP The low fuel warning lamp will light when the fuel level falls below approximately 4 gallons. One side of the low fuel warning bulb is grounded at all times. A low fuel warning module attached to the rear of the gauge cluster provides battery voltage to the lamp when the fuel level is low. The low fuel warning module receives a signal from the fuel level sending unit that is directly opposite the signal used for the fuel gauge. In other words, when the fuel level is low, sending unit resistance is low. LOW OIL PRESSURE WARNING LAMP The low oil pressure warning lamp lights with the ignition switch in the ON position and the engine not running. The lamp should be off when the engine is running. Battery voltage is supplied to one side of the indicator bulb when the ignition switch is turned ON. The warning lamp side of the combination oil pressure sending unit is connected to the other side of the bulb. When normal engine oil pressure is applied to the sending unit, resistance on the warning lamp side is high and the lamp goes off. When engine
AIRBAG INDICATOR LAMP The airbag indicator lamp is switched to ground by the Airbag Control Module (ACM). The lamp lights for 6 to 8 seconds each time the ignition switch is turned to the ON position as a bulb test and to indicate a system self-test is in process. If the lamp remains on after the self-test or comes on while driving, it may indicate that the ACM has detected a system malfunction or that the system has become inoperative. Refer to Group 8M - Restraint Systems for more information. ANTI-LOCK BRAKE SYSTEM LAMP The Anti-Lock Brake System (ABS) or Rear Wheel Anti-Lock (RWAL) lamp is switched to ground by the ABS or RWAL module. The module lights the lamp when the ignition switch is turned to the START position as a bulb test. The lamp will stay on for 3 to 5 seconds after vehicle start-up to indicate a system self-test is in process. If the lamp remains on after start-up, or comes on and stays on while driving, it may indicate that the ABS or RWAL module has detected a system malfunction or that the system has become inoperative. Refer to Group 5 - Brakes for more information. BRAKE WARNING LAMP The brake warning lamp warns the driver that the parking brake is applied or that the pressures in the
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oil pressure is too low, resistance on the warning lamp side of the sending unit is low, which causes the bulb to light.
LOW WASHER FLUID WARNING LAMP The low washer fluid warning lamp indicates when the fluid level in the washer reservoir is too low. The washer fluid level sensor uses a float in the reservoir to monitor fluid level. The action of the float opens or closes the switch within the sensor that provides a ground path to the lamp bulb. Refer to Group 8K Wiper and Washer Systems for more information. MALFUNCTION INDICATOR LAMP The CHECK ENGINE or Malfunction Indicator Lamp (MIL) lights each time the ignition switch is turned ON, and stays on for 3 seconds as a bulb test. If the Powertrain Control Module (PCM) receives an incorrect signal or no signal from certain fuel or emission system related circuits or components, the lamp is turned on. This will indicate that the PCM has recorded a Diagnostic Trouble Code (DTC) in electronic memory for a circuit or component malfunction. Refer to Group 14 - Fuel System for more information. SEAT BELT REMINDER LAMP The seat belt reminder lamp lights for 4 to 8 seconds after the ignition switch is turned to the ON position. A timer in the chime/buzzer module controls ignition-switched battery feed to the lamp. Refer to Group 8U - Chime/Buzzer Warning Systems for more information. TRANSMISSION OIL TEMPERATURE WARNING LAMP The transmission oil temperature warning lamp lights to indicate that the transmission oil is overheating. One side of the lamp bulb receives battery voltage when the ignition switch is turned to the ON position. The other side of the bulb is grounded by a switch mounted to the transmission cooler line when transmission oil temperature is too high. This lamp
TURN SIGNAL INDICATOR LAMPS The left and right turn signal indicator lamps are controlled by the turn signal and hazard warning (multi-function) switches. One side of the bulb for each lamp is grounded at all times. The other side of the bulb receives battery feed through the contacts of the multi-function switch when the turn signal lever (multi-function switch stalk) or hazard warning button are actuated. Refer to Group 8J - Turn Signal and Hazard Warning Systems for more information. UPSHIFT INDICATOR LAMP Vehicles equipped with manual transmissions (except cab and chassis models) have an optional upshift indicator lamp. Ground feed for the lamp is switched by the Powertrain Control Module (PCM). The lamp lights to indicate when the driver should shift to the next highest gear for best fuel economy. The PCM will turn the lamp off after 3 to 5 seconds if the upshift is not performed. The lamp will remain off until the vehicle stops accelerating and is brought back to the range of lamp operation, or until the transmission is shifted into another gear. The indicator lamp is normally on when the ignition switch is turned ON and is turned off when the engine is started. The lamp will be turned on during vehicle operation according to engine speed and load.
DIAGNOSIS GAUGES
If an individual gauge is inoperative, see the diagnostic procedure under the heading for that gauge. If more than one gauge is inoperative, perform the following: (1) Check fuse 14 in the fuseblock module. If OK, go to next step. If not OK, replace fuse. (2) Check for battery voltage at fuse 14 with ignition switch in ON position. If OK, go to next step. If not OK, repair open in circuit from ignition switch and/or refer to Group 8D - Ignition Systems for testing of ignition switch. (3) Turn ignition switch to OFF. Disconnect battery negative cable. Remove instrument cluster bezel and cluster assembly. Disconnect gauge cluster connector 2 (red connector on left side of cluster). (4) Connect battery negative cable. Turn ignition switch to ON. Check for battery voltage at cavity D of cluster connector 2. If OK, go to next step. If not OK, repair open in circuit from fuse 14 as required. (5) Turn ignition switch to OFF. Disconnect battery negative cable. Probe cavity F of cluster connector 2. Check for continuity to a good ground. There should
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COOLANT TEMPERATURE GAUGE The diagnosis found here addresses an inoperative gauge condition. If the problem being diagnosed is related to gauge accuracy, be certain to confirm that problem is with gauge and not with cooling system performance. Actual engine coolant temperature should be checked with a test gauge or thermometer and compared to gauge readings before you proceed with gauge diagnosis. Refer to Group 7 - Cooling System for more information. (1) Turn ignition switch to ON. Disconnect coolant temperature sending unit connector (Figs. 1 or 2). The gauge needle should move to low end of gauge scale. If OK, go to next step. If not OK, go to step 3. (2) Install a jumper wire from sending unit wiring
(3) Turn ignition switch to OFF. Disconnect battery negative cable. Remove instrument cluster bezel and cluster assembly. Disconnect cluster connector 1 (gray connector on right side of cluster). (4) Probe cavity B of cluster connector 1. Check for continuity to a good ground. There should be no continuity. If OK, go to next step. If not OK, repair short in circuit as required. (5) Still probing cavity B of cluster connector 1, check for continuity to sending unit wiring connector. There should be continuity. If OK, replace gauge. If not OK, repair open in circuit as required.
FUEL GAUGE The diagnosis found here addresses an inoperative gauge condition. If the problem being diagnosed is related to gauge accuracy, be certain to confirm that problem is with gauge and not with fuel tank. Inspect fuel tank for signs of damage or distortion that could affect sending unit performance before you proceed with gauge diagnosis. Refer to Group 14 - Fuel System for more information. (1) Turn ignition switch to ON. Disconnect fuel gauge sending unit connector. Connector is located on top of the fuel tank. The gauge needle should move to low end of gauge scale. If OK, go to next step. If not OK, go to step 4. (2) Connect a jumper wire between sending unit ground cavity and fuel sensor input cavity in the body half of the fuel gauge sending unit connector (Fig. 3). The gauge needle should move to high end of gauge scale. If OK, refer to Group 14 - Fuel System for procedure to replace sending unit. If not OK, remove jumper wire and go to next step.
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(5) Probe cavity D of cluster connector 1. Check for continuity to a good ground. There should be no continuity. If OK, go to next step. If not OK, repair short circuit as required. (6) Still probing cavity D of cluster connector 1, check for continuity to fuel sensor input cavity of sending unit body half connector. There should be continuity. If OK, replace gauge. If not OK, repair open circuit as required.
GEAR SELECTOR INDICATOR Refer to Group 21 - Transmission and Transfer Case for diagnosis, service, and adjustment of this component. OIL PRESSURE GAUGE The diagnosis found here addresses an inoperative gauge condition. If the problem being diagnosed is related to gauge accuracy, be certain to confirm that problem is with gauge and not with engine oiling system performance. Actual engine oil pressure should be checked with a test gauge and compared to gauge readings before you proceed with gauge diagnosis. Refer to Group 9 - Engines for more information. (1) Turn ignition switch to ON. Disconnect oil pressure sending unit connector (Figs. 4 or 5). The gauge needle should move to low end of gauge scale. If OK, go to next step. If not OK, go to step 3.
SPEEDOMETER/ODOMETER The diagnosis found here addresses an inoperative gauge condition. If the problem being diagnosed is related to gauge accuracy, be certain to confirm that problem is with gauge and not with incorrect speedometer pinion, axle ratio or tire size. Refer to Group 21 - Transmission and Transfer Case for more information. (1) Perform vehicle speed sensor test as described in the appropriate Powertrain Diagnostic Procedures manual. If OK, go to next step. If not OK, replace vehicle speed sensor. (2) Disconnect battery negative cable. Unplug vehi-
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INDICATOR LAMPS
If an individual indicator lamp is inoperative, see the diagnostic procedure under the heading for that lamp. If more than one indicator lamp or a combination of lamps and gauges in the instrument cluster is inoperative, see Gauges in this section for diagnosis.
ANTI-LOCK BRAKE SYSTEM LAMP The diagnosis found here addresses an inoperative lamp condition. If the ABS lamp stays on with the ignition switch in the ON position, or comes on and stays on while driving, refer to Group 5 - Brakes for diagnosis. If no ABS problem is found, the following procedure will help locate a short or open in the ABS lamp circuit. (1) Disconnect battery negative cable. Remove instrument cluster bezel and cluster assembly. On models with ABS, remove ABS relay from fuseblock module. Disconnect ABS/RWAL control module connector. (2) Install a jumper wire between cavity J of cluster connector 2 (red connector on left side of cluster) and a good ground. Connect battery negative cable and turn ignition switch to ON. Lamp should light. If OK, remove jumper wire and go to next step. If not OK, replace bulb. (3) Turn ignition switch to OFF. Disconnect battery negative cable and unplug cluster connector 2. Check for continuity between cavity J of cluster connector 2 and a good ground. There should be no continuity. If OK, go to next step. If not OK, repair short circuit as required. (4) Check continuity between cavity J of cluster connector 2 and cavity 2 of RWAL control module connector (Fig. 10), or cavity 24 of ABS control module connector (Fig. 11). There should be continuity. If OK, refer Group 5 - Brakes for diagnosis of RWAL or ABS control module. If not OK, repair open circuit as required.
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open circuit to fuse 16 as required. (5) Turn ignition switch to OFF position. Transfer case switch connector still unplugged. Check for continuity between cavity 1 (dark green/gray wire) of lamp socket to a good ground. There should be no continuity. If OK, go to next step. If not OK, repair short circuit as required. (6) Check for continuity between cavity 1 (dark green/gray wire) of lamp socket and cavity l (dark green/yellow wire) of transfer case switch connector. There should be continuity. If OK, replace bulb. If not OK, repair open circuit to transfer case switch as required.
HEADLAMP HIGH BEAM INDICATOR LAMP (1) Check that headlamp high beams are functional. If OK, go to next step. If not OK, refer to Group 8L - Lamps for diagnosis of headlamp system. (2) Disconnect battery negative cable. Remove instrument cluster bezel and cluster assembly. Unplug cluster connector 1 (gray connector on right side of cluster. Connect battery negative cable. Turn headlamps on and select high beam. Check for battery voltage at cavity G of cluster connector 1. If OK, replace indicator bulb. If not OK, repair circuit to headlamp dimmer (multi-function) switch as required. LOW FUEL WARNING LAMP (1) Check that fuel gauge is operating as designed. See Fuel Gauge Calibration chart in Specifications. If OK, go to next step. If not OK, see Fuel Gauge in this section for diagnosis. (2) Disconnect battery negative cable. Unplug fuel gauge sending unit connector. Remove instrument cluster bezel and instrument cluster. Unplug cluster connector 1 (gray connector on right side of cluster). Check for continuity between cavity E of cluster connector 1 and a good ground. There should be no continuity. If OK, go to next step. If not OK, repair short circuit as required. (3) Check for continuity between cavity E of cluster connector 1 and center cavity of fuel gauge sending unit connector (Fig. 13). There should be continuity. If OK, go to next step. If not OK, repair open circuit as required.
FOUR-WHEEL DRIVE INDICATOR LAMP (1) Turn ignition switch to ON position. Unplug transfer case switch connector. Install a jumper wire between the two cavities of harness half of switch connector. Lamp should light. Remove jumper and lamp should go off. If OK, replace transfer case switch. If not OK, go to next step. (2) Turn ignition switch to OFF position. Check for continuity between cavity 2 (black wire) of transfer case switch connector and a good ground. There should be continuity. If OK, go to next step. If not OK, repair open circuit to ground as required. (3) With ignition switch in ON position, check for battery voltage at fuse 16 in fuseblock module. If OK, go to next step. If not OK, repair open circuit to ignition switch or replace fuse as required. (4) Unsnap transfer case shift lever bezel from floor. Unplug lamp socket from lamp housing on underside of shift lever bezel. Remove bulb from lamp socket. With ignition switch in ON position, check for battery voltage at cavity 2 (dark blue/white wire) of lamp socket. If OK, go to next step. If not OK, repair
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(4) Reinstall cluster connector 1. Install a jumper wire between cavity E of cluster connector 1 and a good ground. Connect battery negative cable. Turn ignition switch to ON and wait 30 seconds. Connect a voltmeter to battery and ground terminals of low fuel warning bulb. Meter should read battery voltage. If OK, replace faulty bulb. If not OK, replace faulty low fuel warning lamp module (Fig. 14).
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cable. Turn ignition switch to ON. Lamp should light. If OK, go to next step. If not OK, replace bulb. (3) Turn ignition switch to OFF. Disconnect battery negative cable. Unplug cluster connector 2. Check for continuity between cavity A of cluster connector 2 and a good ground. There should be no continuity. If OK, go to next step. If not OK, repair short circuit to PCM as required. (4) Check continuity between cavity A of cluster connector 2 and cavity 32 of PCM connector. There should be continuity. If not OK, repair open circuit to PCM as required.
MALFUNCTION INDICATOR LAMP The diagnosis found here addresses an inoperative lamp condition. If the lamp comes on and stays on with engine running, refer to Group 14 - Fuel System for diagnosis. If no fuel or emission system problem is found, the following procedure will help locate a short or open in the lamp circuit. (1) Disconnect battery negative cable. Unplug PCM connector. Install a jumper wire from cavity 32 of PCM connector (Fig. 18) to a good ground. Connect battery negative cable. Turn ignition switch to ON. Lamp should light. Remove jumper wire and lamp should go OFF. If OK, refer to Powertrain Diagnostic Procedures to check PCM. If not OK, go to next step.
SEAT BELT REMINDER LAMP (1) Refer to Group 8U - Chime/Buzzer Warning Systems to check chime/buzzer module operation. If OK, go to next step. If not OK, replace chime/buzzer module. (2) Disconnect battery negative cable. Remove instrument cluster bezel and cluster assembly. Unplug cluster connector 2 (red connector on left side of cluster). Check for continuity between cavity F of cluster connector 2 and a good ground. There should be continuity. If OK, plug cluster connector 2 back into cluster and go to next step. If not OK, repair open circuit to ground as required. (3) Connect battery negative cable. Install a jumper wire between a 12-volt battery feed and cavity C of cluster connector 2. Lamp should light. If OK, go to next step. If not OK, replace bulb. (4) Disconnect battery negative cable. Unplug chime/buzzer module from fuseblock module. Unplug cluster connector 2. Check for continuity between cavity C of cluster connector 2 and a good ground. There should be no continuity. If OK, go to next step. If not OK, repair short circuit to chime/buzzer module as required. (5) Check continuity between cavity C of cluster connector 2 and cavity for terminal A3 of chime/ buzzer module (Fig. 19) in fuseblock module. There should be continuity. If not OK, repair open circuit to chime/buzzer module as required. TRANSMISSION OIL TEMPERATURE WARNING LAMP The diagnosis found here addresses an inoperative lamp condition. If the problem being diagnosed is related to lamp accuracy, be certain to confirm that problem is with lamp and not with transmission oil cooling system. Proper transmission oil flow and cooler operation should be checked before you proceed with lamp diagnosis. The switch should close when fluid temperature at the switch is approximately 130C (270F), and should open at 115C (240F). Refer to Group 21 - Transmission and Transfer Case for more information. (1) Unplug transmission oil temperature switch connector. Install a jumper wire between 2 cavities of
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UPSHIFT INDICATOR LAMP (1) Disconnect battery negative cable. Unplug PCM connector. Connect battery negative cable. Turn ignition switch to ON. Install a jumper wire from cavity 54 of PCM connector (Fig. 18) to a good ground. Lamp should light. Remove jumper from ground. Lamp should go off. If OK, refer to Powertrain Diagnostic Procedures manual to diagnose PCM. If not OK, turn ignition switch to OFF and go to next step. (2) Disconnect battery negative cable. Remove instrument cluster bezel and cluster assembly. Install a jumper wire from cavity K of cluster connector 2 (red connector on left side of cluster) to a good ground. Connect battery negative cable. Turn ignition switch to ON. Lamp should light. If OK, go to next step. If not OK, replace bulb. (3) Turn ignition switch to OFF. Disconnect battery negative cable. Unplug cluster connector 2. Check for continuity between cavity K of cluster connector 2 and a good ground. There should be no continuity. If OK, go to next step. If not OK, repair short circuit as required. (4) Check for continuity between cavity K of cluster connector 2 and cavity 54 of PCM connector. There should be continuity. If not OK, repair open circuit as required.
TURN SIGNAL INDICATOR LAMPS (1) Disconnect battery negative cable. Remove instrument cluster bezel and cluster assembly. Probe cavity F of cluster connector 2 (red connector on left side of cluster). Check for continuity to a good ground. There should be continuity. If OK, go to next step. If not OK, repair open circuit to ground. (2) Connect battery negative cable. Install a jumper wire from cavity H (left indicator) or cavity J (right indicator) of cluster connector 1 (gray connector on right side of cluster) to a 12-volt battery feed. Lamp should light. If OK, continue to next step. If not OK, replace bulb.
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(5) Probe cavity F of cluster connector 2. Check for continuity to ground. There should be continuity. If OK, replace illumination bulb(s). If not OK, repair open circuit as required.
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GAUGES REMOVE/INSTALL
When removing gauge assemblies from cluster, gauge must be pulled straight out, not twisted, or damage to gauge pins may result. (1) Remove cluster lens and mask as described in Cluster Lens and Mask Remove/Install. (2) Remove retaining screws from gauge (Figs. 5, 6 and 7) and pull gauge straight out.
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(a) Remove power mirror switch knob by pulling straight back from switch. (b) Remove switch mounting plate screws 2 on back side of switch bezel. (c) Remove retaining ring holding switch to mounting plate.
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Fig. 27 Lower Instrument Panel Module Remove/ Install Fig. 25 Intermittent Wipe Module Remove/Install
(12) Reverse removal procedures to install.
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(11) On vehicles with automatic transmissions, disconnect gear selector indicator cable from column. (12) Remove steering column support nuts, lower steering column, then remove steering column attaching studs. (13) Disconnect wiring at ignition switch and headlamp dimmer switch on steering column. (14) Remove windshield pillar and cowl side trim panels. (15) Loosen the instrument panel pivot bolts (Fig 28). (16) Remove 5 screws at base of windshield and roll panel down. Attach a hook from fence line to center panel mount to hold instrument panel in position. (17) Disconnect wiring for stereo speakers, door switches and A/C-heater blower motor. (18) Disconnect radio antenna cable, A/C-heater control vacuum harness and temperature control cable. (19) Disconnect demister hoses at A/C-heater unit. (20) Remove instrument panel from vehicle. (21) Reverse removal procedures to install.
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AUDIO SYSTEMS
8F - 1
AUDIO SYSTEMS
CONTENTS
page page
SERVICE PROCEDURES
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GENERAL INFORMATION
Following are general descriptions of major components used in Dakota audio systems. Refer to Group 8W - Wiring Diagrams for complete circuit descriptions and diagrams.
RADIOS
Radio options for the Dakota models include an AM/FM, an AM/FM/cassette, an AM/FM/CD, or an AM/FM/cassette with graphic equalizer. All receivers are stereo Electronically-Tuned Radios (ETR) and include a clock function. For more information on radio features, setting procedures, and control functions refer to the Sound System manual. The Sound System manual is included with the owners manual in the vehicle glove box.
ANTENNA
All models use a fixed-length stainless steel rodtype antenna mast, installed at the right front fender of the vehicle. The antenna mast is connected to the center wire of the coaxial antenna cable and is not grounded to any part of the vehicle. To eliminate static, the antenna base must have a good ground. The coaxial antenna cable shield (the outer wire mesh of the cable) is grounded to the antenna base and the radio chassis. The factory installed ETRs automatically compensate for radio antenna trim. Therefore, no antenna trimmer adjustment is required or possible when replacing the receiver or the antenna.
SPEAKERS
Speaker system options include two or four speaker locations. On two-speaker systems, one full range speaker is located in each door. Four-speaker systems add one full range speaker in each B pillar. The premium speaker option upgrades all the speakers in the above locations to Infinity bi-amplified models. Each Infinity speaker features an integral amplifier and frequency filter unit. The amplifier of the radio is used to drive the tweeters at each speaker location. The speaker-mounted amplifiers drive the woofers at each speaker location.
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AUDIO SYSTEMS
munications. However, this unit will not resolve complaints of RFI in the commercial AM or FM radio frequency ranges.
Fleet vehicles are available with an extra-cost RFIsuppressed Powertrain Control Module (PCM). This unit reduces interference generated by the PCM on some radio frequencies used in two-way radio com-
DIAGNOSIS RADIO
(1) Check fuse 12 in fuseblock module and fuse F2 in Power Distribution Center (PDC). If OK, go to next step. If not OK, replace fuse. (2) Check for battery voltage at fuse F2 in PDC. If OK, go to next step. If not OK, repair circuit to cartridge fuse F2 in PDC. (3) Turn ignition switch to ON position. Check for battery voltage at fuse 12. If OK, go to next step. If not OK, repair circuit to ignition switch as required. (4) Turn ignition switch to OFF position. Disconnect battery negative cable. Remove instrument cluster bezel. Remove radio, but do not unplug any connections. Check for continuity between the radio chassis and a good ground. There should be continuity. If OK, go to next step. If not OK, repair radio ground circuit as required. (5) Connect battery negative cable. Turn ignition switch to ON position. See Radio and Speaker Connectors chart. Check for battery voltage at cavity 6 of left (gray) radio connector. If OK, go to next step. If not OK, repair circuit to fuse 12 as required. (6) Turn ignition switch to OFF position. Check for battery voltage at cavity 7 of left (gray) radio connector. If OK, replace radio. If not OK, repair circuit to fuse F2 in PDC as required.
AUDIO SYSTEMS
RADIO DIAGNOSIS CHART
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AUDIO SYSTEMS
RADIO AND SPEAKER CONNECTORS
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(2) Check for battery voltage at fuse 6 in fuseblock module. If OK, go to next step. If not OK, repair circuit to Power Distribution Center as required. (3) Remove lower instrument panel module and unplug choke/relay connector. See Radio and Speaker Connectors chart. Check for battery voltage at cavity 1 of choke/relay connector. If OK, go to next step. If not OK, repair circuit to fuse 6 as required. (4) Probe cavity 4 of choke/relay connector. Check for continuity to a good ground. There should be continuity. If OK, go to next step. If not OK, repair open circuit to ground as required. (5) Turn ignition switch to ON position and turn radio on. Check for battery voltage at cavity 3 of choke/relay connector. If OK, go to next step. If not OK, repair circuit to cavity 1 of right (black) radio connector as required. (6) Turn radio and ignition switches to OFF position. Connect choke/relay connector. Check voltage at cavity 2 of choke/relay connector. There should be zero volts. Turn ignition and radio switches to ON position. There should now be battery voltage at cavity 2 of choke/relay connector. If OK, repair circuit from cavity 2 of choke/relay connector to speaker amplifiers as required. If not OK, replace choke/relay.
ANTENNA
The following four tests are used to diagnose the antenna with an ohmmeter: mast to ground test (Test 1) tip-of-mast to tip-of-conductor test (Test 2) body ground to battery ground test (Test 3) body ground to coaxial shield test (Test 4). Ohmmeter test lead connections for each test are shown in Figure 1.
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AUDIO SYSTEMS
TEST 4 Test 4 checks condition of the ground between the antenna base and vehicle body as follows: (1) Connect one ohmmeter test lead to the fender and the other lead to the crimp on the coaxial antenna cable shield. (2) Resistance should be less then one ohm. (3) If resistance is more then one ohm, clean and/or tighten antenna base to fender mounting hardware.
TEST 1 Test 1 determines if the antenna mast is insulated from the base. Proceed as follows: (1) Disconnect antenna cable lead from radio chassis and isolate. (2) Connect one ohmmeter lead to tip of antenna mast and the other lead to the antenna base. Check for continuity. (3) There should be no continuity. If continuity is found, replace defective or damaged antenna base and cable assembly. TEST 2 Test 2 checks the antenna for an open circuit as follows: (1) Disconnect the antenna cable lead from the radio chassis. (2) Connect one ohmmeter test lead to tip of antenna mast. Connect remaining lead to tip of antenna cable lead (the part inserted into the radio). (3) Continuity should exist (ohmmeter should only register a fraction of an ohm). High or infinite resistance indicates damage to the base and cable assembly. Replace if required. TEST 3 Test 3 checks condition of the vehicle body ground connection as follows: (1) Connect one ohmmeter test lead to the vehicle fender and the other lead to the battery negative post. (2) Resistance should be less than one ohm. (3) If resistance is more than one ohm, check the braided ground strap connected to the engine and vehicle body for being loose, corroded, or damaged. Repair as necessary.
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SPEAKERS REMOVE/INSTALL
FRONT DOOR (1) Unscrew door lock knob. (2) Remove window regulator handle (if equipped). (3) Squeeze the ends of the power switch housing while pulling the switch housing away from the door trim panel. (4) Remove 2 screws from the power switch bezel. (5) Remove trim plug at top of trim panel.
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AUDIO SYSTEMS
REAR PILLAR - STANDARD CAB (1) Remove the rear pillar upper seat belt mounting bolt. (2) Remove the 4 trim panel screws. (3) When pulling trim panel away from pillar, remove wiring connector from speaker (Fig. 6).
REAR PILLAR - EXTENDED CAB (1) Carefully pry the speaker grille off the trim panel. There is a lock tab at each corner of the grille. (2) Remove speaker attaching hardware. (3) Disconnect speaker connector and remove speaker. (4) Reverse removal procedures to install.
AUDIO SYSTEMS
(13) Move module rearward and down until there is room over top of module to remove wiring harness trough attaching screws (Fig. 10).
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ANTENNA REMOVE/INSTALL
(1) Disconnect battery negative cable. (2) Remove glove box. (3) Reach behind instrument panel and unplug antenna cable from radio (Fig. 13).
HORN
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HORN
CONTENTS
page page
SERVICE PROCEDURES
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GENERAL INFORMATION
Following are general descriptions of the major components in the Dakota horn system. Refer to Group 8W - Wiring Diagrams for complete circuit descriptions and diagrams. column. One side of the horn relay electromagnetic coil receives battery voltage at all times. When a horn switch is depressed, the other side of the relay coil is grounded. The energized relay coil causes the normally open relay contacts to close, providing battery voltage to the horn. If a problem is encountered with a continuously sounding horn, it can usually be quickly resolved by removing the horn relay from the fuseblock module until further diagnosis is completed.
HORN SWITCH
Two horn switches are installed in the steering wheel, one on each side of the center-mounted drivers airbag module. When either switch is depressed it completes a circuit to ground for the coil side of the horn relay. The steering wheel and steering column must be properly grounded for the horn switches to function. The horn switches are only serviced as a set with their wiring. If either switch should fail, both switches must be replaced.
HORN
The single, lo-note, diaphragm-type horn is located in the engine compartment on the upper left corner of the radiator closure panel just forward of the battery. It is grounded to the closure panel and receives battery feed through the closed contacts of the horn relay.
HORN RELAY
The horn relay is installed in the fuseblock module under the instrument panel and left of the steering
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HORN DIAGNOSIS
WARNING: ON VEHICLES EQUIPPED WITH AN AIRBAG, REFER TO GROUP 8M - RESTRAINT SYSTEMS BEFORE ATTEMPTING STEERING WHEEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
HORN RELAY
RELAY TESTS (1) Remove horn relay from fuseblock module. The de-energized relay should have continuity between terminals 1 and 3 (Fig. 1). There should be no continuity between terminals 2 and 3. If OK, go to next step. If not OK, replace faulty relay. (2) Connect relay terminal 1 to a good ground and terminal 3 to a battery feed. There should now be battery voltage at terminal 2. If OK, go to Circuit Test. If not OK, replace faulty relay.
Still probing horn relay cavity 1, depress either horn switch, there should now be continuity to ground. If OK, go to next step. If not OK, see diagnosis for horn switch. (4) Unplug connector at horn. Check for continuity between horn relay cavity 2 and a good ground. There should be no continuity. If OK, go to next step. If not OK, repair short circuit as required. (5) Check for continuity between horn relay cavity 2 and horn connector. There should be continuity. If OK, see diagnosis for horn. If not OK, repair open circuit as required.
HORN SWITCH
(1) Disconnect battery negative cable. Remove knee blocker. Check for continuity between metal steering column jacket and a good ground. There should be continuity. If OK, go to next step. If not OK, refer to Group 19 - Steering and check for proper installation of steering column ground clip. (2) Remove horn relay from fuseblock module. Access horn switch wire connector as described in Horn Switch Remove/Install. Unplug horn wire connector. Check for continuity between steering column half of horn wire connector and a good ground. There should be no continuity. If OK, go to next step. If not OK, repair short circuit as required. (3) Check for continuity between steering column half of horn wire connector and horn relay cavity 1. There should be continuity. If OK, go to next step. If not OK, repair open circuit as required. (4) Check for continuity between horn switch half of horn wire connector and a good ground. There should be no continuity. If OK, go to next step. If not OK, replace faulty horn switches. (5) Depress one horn switch and check for continuity between horn switch half of horn wire connector and a good ground. There should be continuity. Repeat test for other horn switch. If either switch is not OK, replace faulty horn switches.
HORN
(1) Measure resistance between the horn mounting bracket and a good ground. There should be zero ohms. If not OK, repair horn ground. (2) Disconnect horn connector. Depress horn switch. There should be battery voltage at the horn connector. If OK, replace horn. If not OK, repair open circuit to horn relay.
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8G - 4
HORN
HORN REMOVE/INSTALL
(1) Raise and support the hood. (2) Make sure ignition switch is in OFF position and all battery feed accessories are OFF. (3) Disconnect and remove battery cables at battery, negative cable first.
HORN
CAUTION: The horn connector is a self locking connector. To remove it, grasp and pull the insulator only. DO NOT pull on the wire. (5) Remove the wire connector from the horn (Fig. 10).
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(6) From the front of the vehicle remove the horn mounting bolt while removing the horn (Fig. 11).
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SERVICE PROCEDURES
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GENERAL INFORMATION
The vehicle speed control system (Fig. 1) is an available option on Dakota models equipped with a 3.9L or 5.2L engine. The system is electronically controlled and vacuum operated. Following are general descriptions of the major components in the Dakota speed control system. Refer to Group 8W - Wiring Diagrams for complete circuit descriptions and diagrams. control linkage to open or close the throttle valve in response to movement of the vacuum servo diaphragm.
VACUUM RESERVOIR
The vacuum reservoir is mounted to the speed control servo mounting bracket on the passenger side dash panel in the engine compartment. The reservoir contains a one-way check valve to trap engine vacuum in the reservoir. When engine vacuum drops, as in climbing a grade while driving, the reservoir supplies the vacuum needed to maintain proper speed control operation. The vacuum reservoir cannot be repaired and must be replaced if faulty.
SERVO CABLE
The speed control servo cable is connected between the speed control vacuum servo diaphragm and the throttle control linkage. This cable causes the throttle
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symptom, not as the cause for the problem. In some cases, because of the design of the diagnostic test procedure, a DTC can be the reason for another DTC to be set. Therefore, it is important that the test procedures be followed in sequence, to understand what caused a DTC to be set. See Speed Control Diagnostic Trouble Code chart for DTCs which apply to the speed control system. Refer to the Powertrain Diagnostic Procedures manual to diagnose an on-board diagnostic system trouble code.
RETRIEVING DIAGNOSTIC TROUBLE CODES To start this function, cycle the ignition switch ONOFF-ON-OFF-ON within 5 seconds. This will cause any DTC stored in the PCM memory to be displayed. The malfunction indicator (Check Engine) lamp will display a DTC by flashing on and off. There is a short pause between flashes and a longer pause between digits. All DTCs displayed are two-digit numbers, with a four-second pause between codes. An example of a DTC is as follows: (1) Lamp on for 2 seconds, then turns off. (2) Lamp flashes 1 time pauses and then flashes 5 times. (3) Lamp pauses for 4 seconds, flashes 3 times, pauses, then flashes 4 times. The two DTCs are 15 and 34. Any number of DTCs can be displayed, as long as they are in memory. The lamp will flash until all stored DTCs are displayed (55 = end of test). If a DTC 15 is observed, see diagnosis for Vehicle Speed Sensor in this group. If a DTC 34 is observed, see diagnosis for Speed Control Servo and Powertrain Control Module in this group. Correct any problems found in your diagnosis, then recheck for DTC after corrections are completed.
DIAGNOSTIC TROUBLE CODES Diagnostic Trouble Codes (DTC) are two-digit numbers flashed on the malfunction indicator (Check Engine) lamp that identify which circuit is bad. A DTC description can also be read using the DRB scan tool. Refer to Group 14 - Fuel Systems for more information. A DTC does not identify which component in a circuit is bad. Thus, a DTC should be treated as a
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(1) Disconnect battery negative cable. Wait 2 minutes for airbag system capacitor to discharge. Remove speed control switch from steering wheel. (2) Check speed control switch continuity as shown in chart (Fig. 2). If OK, reinstall switch. If not OK, replace switch.
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terminal locations. Touch the positive lead of the voltmeter to the terminal in cavity number 33. With the speed control switch in the OFF position, the voltmeter should read zero volts. With the speed control switch in the ON position, the voltmeter should read battery voltage. If not, repair the main harness as necessary.
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8J - 1
SERVICE PROCEDURES
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GENERAL INFORMATION
Following are general descriptions of the major components in the Dakota turn signal and hazard warning systems. Refer to Group 8W - Wiring Diagrams for complete circuit descriptions and diagrams. The standard flasher is designed to handle the current flow requirements of the factory installed lighting. If supplemental lighting is added to the turn signal circuits such as when towing a trailer with lights, the current flow through the flasher increases. This causes the flash rate to increase. It is recommended that the standard flasher be replaced with a heavy-duty (hazard warning) flasher when supplemental lighting is added. However, when a turn signal bulb fails with a standard flasher, the remaining bulbs in that circuit will light, but not flash. This will give the driver an indication to check the turn signal bulbs. Because a heavy-duty flasher has different internal circuitry, a failed bulb will not prevent the remaining bulbs in the circuit from flashing. Therefore, it is recommended that an occasional visual inspection of exterior turn signal lamp operation be performed when a heavy-duty flasher is installed.
TURN SIGNAL FLASHER The turn signal flasher is located in the fuseblock module (Fig. 1). It contains one fixed contact point and one contact point attached to a flexible bimetal arm. The contact points are normally closed. When a turn signal is activated, current flows through the flasher. As the current flows through the bimetal arm it heats and flexes to pull the contact points open, stopping current flow. As the bimetal arm cools it straightens, until the contact points close and the cycle repeats.
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HAZARD WARNING FLASHER The hazard warning flasher is located in the fuseblock module (Fig. 1). The hazard warning flasher contains two normally open contact points mounted to two flexible arms. A bimetal strip is attached between the two arms. When the hazard warning is activated, current flows through the flasher. As the current flows through the bimetal strip it heats and pulls the flexible arms together until the contact points close, allowing current flow to the lamps. As the bimetal strip cools, the contact points are pushed open and the cycle repeats. MULTI-FUNCTION SWITCH The multi-function switch assembly (Fig. 2) is mounted to the left side of the steering column. This switch contains electrical circuitry for the following functions: turn signals hazard warning headlamp beam selection headlamp optical horn windshield wipers windshield washers. The information contained in this group addresses only the switch functions for the turn signal and hazard warning circuits. For information relative to other switch functions, refer to the appropriate group. However, the multi-function switch can not be repaired. If any function of the switch is faulty, the entire switch assembly must be replaced. TURN SIGNAL INDICATOR LAMPS These lamps are located in the instrument cluster. They flash with the exterior turn signal lamps to
TURN SIGNAL LAMPS The exterior lamps included in the turn signal and hazard warning circuits include: the front park/turn signal, the front side marker, and the rear tail/stop/ turn signal. For diagnosis and service of these lamps, refer to Group 8L - Lamps.
DIAGNOSIS
When diagnosing the turn signal or hazard warning circuits, remember that high generator output can burn out bulbs rapidly and repeatedly. If this is a problem on the vehicle being diagnosed, refer to Group 8A - Battery/Starting/Charging Systems Diagnostics to test charging system. WARNING: ON VEHICLES EQUIPPED WITH AN AIRBAG, REFER TO GROUP 8M - RESTRAINT SYSTEMS BEFORE ATTEMPTING STEERING WHEEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. comes on but does not flash, check for a turn signal bulb that is not lit. Replace that bulb or repair circuits to that lamp, as required. Test operation. If turn indicator does not light or still doesnt flash, continue to next step. (2) Remove and inspect fuse 11 in fuseblock module. Replace fuse, if required. (3) With ignition switch in ON position, check for battery voltage at fuse 11. If OK, go to next step. If not OK, repair circuit to ignition switch as required. (4) With ignition switch in ON position, place turn signal lever in neutral position. There should be battery voltage at the fuse side of the turn signal flasher (L5 circuit). If OK, go to next step. If not OK, repair circuit between fuse and bottom terminal of turn signal flasher. (5) Replace turn flasher with known good unit of the same rating. The lamps should flash. If OK, discard faulty flasher. If not OK, re-install original flasher and go to next step.
TURN SIGNAL
(1) Turn ignition switch to ON position. Move turn signal lever down for left turn signal problem, or up for right turn signal problem. Observe the turn indicator lamp in the instrument cluster. If the lamp
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HAZARD WARNING
(1) Check fuse F1 in power distribution center. If OK, go to next step. If not OK, replace fuse. (2) Check for battery voltage at the fuse side of the hazard warning flasher (L9 circuit). If OK, go to next step. If not OK, repair open circuit between fuse and flasher. (3) Replace hazard flasher with known good unit of the same rating. The lamps should flash. If OK, dis-
card faulty flasher. If not OK, re-install original flasher and go to next step. (4) Locate the multi-function switch connector. See diagnosis for Multi-Function Switch, in this group. Check for battery voltage at the multi-function switch connector cavity 13. If OK, replace multi-function switch. If not OK, repair open circuit to flasher (L19 circuit).
MULTI-FUNCTION SWITCH
(1) Access multi-function switch connector and remove. See service procedures for Multi-Function Switch, in this group. (2) Using an ohmmeter, perform switch continuity checks at the switch terminals as shown in the chart (Fig. 3).
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WARNING: ON VEHICLES EQUIPPED WITH AN AIRBAG, REFER TO GROUP 8M - RESTRAINT SYSTEMS BEFORE ATTEMPTING STEERING WHEEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
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SERVICE PROCEDURES
................... 7
GENERAL INFORMATION
Following are general descriptions of the major components in the Dakota wiper and washer systems. Refer to Group 8W - Wiring Diagrams for complete circuit descriptions and diagrams. cloth and a mild detergent or non-abrasive cleaner. If the squeegees continue to streak or smear, they should be replaced. The blades are mounted to two spring-loaded wiper arms. Spring tension of the wiper arms controls the pressure applied to the blades on the windshield. The wiper arms are attached by an integral latch to the two wiper pivots on the cowl grille panel at the base of the windshield. The wiper arms and blades can not be adjusted or repaired. If faulty, they must be replaced.
WIPER LINKAGE AND PIVOTS The wiper pivots are fastened to the cowl top panel with screws beneath the cowl cover/grille panel. Each pivot assembly can be replaced by removing the cowl grille panel, unsnapping the linkage bushing(s) from the pivot crank arm pins, and removing the mounting screws. The two pivot cranks are joined by a connecting link, and a drive link connects the motor crank to the drive link near the left pivot. Pressed-in plastic bushings in the ends of the links can be replaced if worn or damaged. WIPER MOTOR The two-speed permanent magnet wiper motor has an integral transmission and park switch. The motor is mounted to the engine side of the cowl panel with a reinforcement/stud plate and a rubber-isolated mounting bracket. The wiper motor output shaft passes through the cowl panel into the cowl plenum area, where a crank arm attached to the output shaft drives the wiper drive link. Wiper speed is controlled by current flow to the appropriate set of brushes. The wiper motor completes its wipe cycle when the switch is turned OFF, and parks the blades in the lowest portion of the wipe pattern. The wiper motor assembly can not be repaired. If faulty, the entire motor assembly must be replaced. The crank arm, mounting bracket, and reinforcement/stud plate are available for service.
WIPER ARMS, BLADES, AND ELEMENTS All Dakota models have two 18-inch wiper blades with replaceable rubber elements (squeegees). Blades are supplied by two manufacturers and are interchangeable as assemblies. However, replacement squeegees are not interchangeable between blade types. Caution should be exercised to protect the rubber squeegees from any petroleum-based cleaners or contaminants, which will rapidly deteriorate the squeegee rubber. If squeegees are damaged, worn or contaminated they must be replaced. Wiper squeegees exposed to the weather for a long time tend to lose their wiping effectiveness. Periodic cleaning of the squeegees is suggested to remove deposits of salt and road film. The wiper blades, arms and windshield should be cleaned with a sponge or
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WIPER/WASHER SWITCH Controls for the windshield wiper and washer systems are contained in the multi-function switch control lever. The multi-function switch is mounted on the left side of the steering column between the steering wheel and the instrument panel. This switch also controls many other functions. The multi-function switch can not be repaired. If any function of the switch is faulty, the entire switch must be replaced. INTERMITTENT WIPE MODULE In addition to low and high speed, the intermittent wipe system has a delay mode. The delay mode has a range of 2 to 15 seconds. The length of the delay is selected with a variable resistor in the wiper switch and is accomplished by electronic circuitry within the intermittent wipe module. If the washer knob is depressed while the wiper switch is in the OFF position, the intermittent wipe module will operate the wiper motor for approximately 2 wipes and automatically turn the motor off. The intermittent wipe module is mounted to the instrument panel, behind the knee blocker and to the right of the steering column. The module can not be repaired.
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(5) Disconnect motor wiring connector and replace fuse. If fuse does not blow, motor is defective. If fuse blows, wiper/washer switch or wiring is at fault.
CONDITION Motor runs slowly at all speeds. PROCEDURE (1) Disconnect wiring harness connector at motor. Remove wiper arms and blades. Connect an ammeter between battery and terminal L on motor (Fig. 2). If motor runs and average ammeter reading is more than 6 amps, continue to next step. If motor runs and average ammeter reading is less than 6 amps, go to step 3.
CONDITION Motor will not run in any wiper/washer switch position. PROCEDURE (1) Check fuse 10 in the fuseblock module. If OK, go to step 3. If not OK, replace fuse and go to next step. (2) Check motor operation in all wiper/washer switch positions. If not OK and fuse blows, go to step 5. If not OK and fuse is OK, go to next step. (3) Place wiper/washer switch in LOW position and listen to motor. If you cannot hear it running, go to next step. If motor is running, check motor output shaft. If output shaft is not turning, replace motor assembly. If it is turning, drive link to output shaft or linkage is not properly connected. Replace worn parts and/or properly connect drive link to the motor output shaft. (4) Connect a voltmeter between motor terminal L and ground strap (Fig. 1). If there is little or no voltage (less than 1 volt), move negative test lead from the ground strap to battery negative terminal. If an increase in voltage is noticed, the problem is a bad ground circuit. Make sure the motor mounting is free of paint and that mounting fasteners are tight. If there is still no indication of voltage, the problem is an open in wiring or faulty wiper/washer switch. If a small increase (greater than 3 volts) in voltage is observed, the problem is a faulty motor assembly.
CONDITION Motor will run at high speed, but not at low speed. Motor will run at low speed, but not at high speed.
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(2) Connect second jumper from terminal P1 to battery. If motor runs to park position and stops, wiper/washer switch is faulty. If motor keeps running and does not park, replace motor assembly.
CONDITION Motor will stop wherever it is, when wiper/ washer switch is put in OFF position. (Wipers do not continue running to park position.) PROCEDURE (1) Remove motor wiring connector and clean terminals. Reconnect connector and test motor. If not OK, go to step 2. (2) Put wiper/washer switch in OFF position. Disconnect motor wiring connector. Connect a voltmeter or test lamp to the motor ground strap. Connect the other lead to terminal P1 of wiring connector. If voltage is not present, check for an open circuit in the wiring harness or wiper/washer switch. If voltage is present, go to next step. (3) Connect an ohmmeter or continuity tester between terminals L and P2 (Fig. 5). If there is continuity between these terminals, the problem is a defective motor. If there is no continuity, the problem is an open in wiring or a faulty wiper/washer switch.
CONDITION Motor will keep running with wiper/washer switch in OFF position. PROCEDURE (1) Disconnect wiring harness connector at motor. Connect jumper from terminal P2 to terminal L of wiper motor (Fig. 4).
Fig. 4 One Jumper Wire Between Terminal P2 and L. One Jumper Wire Between Terminal P1 and B+.
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WIPER/WASHER SWITCH
Use an ohmmeter to test for continuity (no resistance) between the terminals of the switch as shown in the Multi-Function Switch Continuity chart (Fig. 6).
CONDITION In DELAY mode wipers run continually when wash is operated, but do not provide an extra wipe when the washer switch is released. PROCEDURE Replace the intermittent wipe module. CONDITION Wipers start erratically during DELAY mode. PROCEDURE (1) Verify that the ground connection at the instrument panel is making good connection (free from paint) and is tight. (2) Verify that the motor ground strap is making good contact and that the motor mounting bolts are tight. (3) Verify that the wiring ground connections for the intermittent wipe module and the wiper/washer switch are tight. (4) If condition is not corrected, replace intermittent wipe module.
CONDITION Excessive delay (more than 30 seconds) or inadequate variation in delay. PROCEDURE Variations in delay should be as follows: (1) Minimum delay (wiper/washer switch to extreme counter-clockwise position before LOW detent) 1/2 to 2 seconds. (2) Maximum delay (wiper/washer switch to extreme clockwise position before OFF detent) 10 to 30 seconds.
WASHER PUMP
(1) Check for continuity between black wire of pump connector and a good ground. There should be continuity. If OK, go to next step. If not OK, repair ground circuit as required. (2) Turn ignition switch to ON position. Check for battery voltage at brown wire of pump connector with washer switch depressed. If OK, replace pump. If not OK, see diagnosis for Wiper/Washer Switch in this group. If switch tests OK, repair wiring between switch and pump as required.
WIPER AND WASHER SYSTEMS SERVICE PROCEDURES WIPER BLADES OR ELEMENTS REMOVE/INSTALL
There are two types of wiper blade assemblies. The assemblies are identified as Type A (Fig. 8) and Type B (Figs. 9 and 10).
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WIPER MOTOR
(1) Disconnect battery negative cable.
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(2) Disconnect electrical connector from wiper motor. (3) Remove 3 motor mounting nuts. (4) Remove wiper arms. (5) Remove cowl grille panel mounting screws (Fig. 13). There is a screw in the center of the grille to the right of the right pivot assembly.
LINKAGE REMOVE/INSTALL
(1) Remove wiper arms as described in Wiper Arms Remove/Install. (2) Remove cowl grille panel mounting screws (Fig. 13). There is a screw in the center of the grille to the right of right pivot assembly. (3) Disengage rear of cowl panel from windshield weatherstrip by pulling forward and remove cowl grille panel. (4) Remove screen by carefully prying up clips. (5) Remove crank arm from drive link by prying retainer bushing from crank arm pin with a suitable size screwdriver. (6) Remove pivot mounting screws. (7) Working through access holes, remove linkage and pivots as an assembly. (8) Remove drive link from pivots by prying retainer bushing from pivot pin with a suitable size screwdriver. (9) Reverse removal procedures to install. Use channel-lock pliers to reinstall linkage retainer bushings on pivot and crank pins. Tighten pivot mounting screws to 7 N m (60 in. lbs.) torque.
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8K - 10
LAMPS
8L - 1
LAMPS
CONTENTS
page page
SERVICE PROCEDURES
................... 6
GENERAL INFORMATION
Each vehicle is equipped with various lamp assemblies. A good ground is necessary for proper lighting operation. Grounding is provided by the lamp socket when it comes in contact with the metal body, or through a separate ground wire. When changing lamp bulbs check the socket for corrosion. If corrosion is present, clean it with a wire brush and coat the inside of the socket lightly with Mopar Multi-Purpose Grease or equivalent. Aero headlamps use a replaceable bulb that is mounted in a molded plastic lens. connections, charging system, headlamp bulbs, wire connectors, relay, high beam dimmer switch and headlamp switch. Refer to Group 8W, Wiring Diagrams for component locations and circuit information. Always begin any diagnosis by testing all of the fuses and circuit breakers in the system. Refer to Group 8W, Wiring Diagrams. Conventional and halogen headlamps are interchangeable. It is recommended that they not be intermixed on a given vehicle.
DIAGNOSTIC PROCEDURES
When a vehicle experiences problems with the headlamp system, verify the condition of the battery
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LAMPS
HEADLAMP DIAGNOSIS
LAMPS
FOG/OFF ROAD LAMP DIAGNOSIS
8L - 3
8L - 4
LAMPS
(2) Remove screws along bottom edge of steering column (Fig. 1). (3) Pull knee blocker down to disengage slide tabs and remove. (4) Remove tilt lever. (5) Remove upper and lower column shrouds to gain access to the switch connector (Fig. 2). (6) Remove lower fixed column shroud. (7) Loosen steering column upper bracket nuts. Do not remove nuts. (8) Move upper fixed column shroud to gain access to rear of multi-function switch. (9) Remove switch connector (Fig. 3 and 4).
LAMPS
(10) Use an ohmmeter to test for continuity between the terminals of the switch as shown in the continuity chart (Fig. 5). (11) Refer to Service Procedures for assembly.
8L - 5
8L - 6
Aero Headlamp Bulb Replacement . . . . . . . . . . . . . 7 Aero Headlamp Lens Replacement . . . . . . . . . . . . . 7 Backup Lamp Switch . . . . . . . . . . . . . . . . . . . . . . . 11 Backup Lamps (Fig. 12) . . . . . . . . . . . . . . . . . . . . 11 Center High Mounted Stop Lamp (CHMSL) . . . . . . 11 Daytime Running Light Module (DRLM) . . . . . . . . . 12 Fog Lamp Switch Replacement . . . . . . . . . . . . . . . 10 Fog Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Front Side Marker Lamp . . . . . . . . . . . . . . . . . . . . . 9 Headlamp Alignment . . . . . . . . . . . . . . . . . . . . . . . . 6 Headlamp Alignment Preparation . . . . . . . . . . . . . . . 6 Headlamp Switch . . . . . . . . . . . . . . . . . . . . . . . . . 10 Headlamp/Fog Lamp Adjustment Using Alignment Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
HEADLAMP ALIGNMENT
Headlamps can be aligned using the screen method provided in this section. Alignment Tool C4466-A or equivalent can also be used. Refer to instructions provided with the tool for proper procedures. The preferred headlamp alignment setting is 0 for the left/right adjustment and 1 down for the up/down adjustment.
(5) Jounce front suspension three times by pushing downward on front bumper and releasing. (6) Measure the distance from the center of headlamp lens to the floor. Transfer measurement to the alignment screen (with tape). Use this line for up/ down adjustment reference. (7) Measure distance from the centerline of the vehicle to the center of each headlamp being aligned. Transfer measurements to screen (with tape) to each side of vehicle centerline. Use these lines for left/ right adjustment reference.
HEADLAMP ADJUSTMENT (FIG. 2 OR 3) A properly aimed low beam headlamp will project the top edge of high intensity pattern on the alignment screen from 50 mm (2 in.) above to 50 mm (2 in.) below the headlamp centerline. The side-to-side outboard edge of high intensity pattern should be from 50 mm (2 in.) left to 50 mm (2 in.) right of headlamp centerline (Fig. 1). The preferred headlamp alignment is 0 for the up/down adjustment and 1 down for the left/right adjustment. The high beams on a vehicle with aero headlamps cannot be aligned. The high beam pattern should be correct when the low beams are aligned properly. To adjust headlamp aim, rotate alignment screws to achieve the specified high intensity pattern (Fig. 2 or 3). FOG LAMP ADJUSTMENT (FIG. 4) Prepare an alignment screen. Refer to Alignment Screen Preparation paragraph in this section. A properly aligned fog lamp will project a pattern on the alignment screen 100 mm (4 in.) below the fog lamp centerline and straight ahead.
LAMPS
8L - 7
8L - 8
LAMPS
FOG LAMPS
Fog lamps are turned OFF by the circuit relay when the high beam driving lamps are turned ON. Fog lamps may be operated ONLY when low beam headlamps are ON. If the headlamps are switched to high beam, the low beam lamps and fog lamps will
LAMPS
turn OFF. The fog lamps will go back on when the high beams are switched OFF. The indicator lamp on the fog lamp switch will go: OFF when the high beams lamps are switched ON. ON when the high beam lamps are switched OFF.
8L - 9
Fig. 8 Headlamp, Park and Turn Signal, and Front Side Marker Lamp
(3) To install, reverse the removal procedures.
8L - 10
LAMPS
HEADLAMP SWITCH
To remove or replace the headlamp switch. Refer to Group 8E, Instrument Panel and Gauges.
LAMPS
(2) Mount multi-function switch to column and torque screws to 2 N m (17 in. lbs.). (3) Position upper fixed column shroud. (4) Tighten steering column upper bracket nuts to 12 N m (110 in. lbs.). (5) Install lower fixed shroud and upper and lower lock shrouds. (6) Install tilt lever (tilt column only). (7) Install battery negative cable. (8) Check all functions of switch for proper operation.
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UNDERHOOD LAMP
When equipped, the underhood lamp is installed on the hood left, rear panel for all Dakota vehicles (Fig. 15). The lamp is illuminated when the hood is opened via the liquid ON/OFF switch that is integral with the lamp base (Fig. 14).
8L - 12
LAMPS
8L - 13
EXTERIOR LAMPS
Back-up .................................................................1156 Center High Mounted Stoplamp ..........................922 Fog............................................................................H3 Front Side Marker.................................................194 Headlamp/Sealed Beam .................................HP4666 Headlamp/Aero-Style ...........................................9004 License Plate ..........................................................168 Off-Road Lamp ........................................................H3 Park/Turn Signal..................................................2057 Tail/Stop/Turn Signal...........................................2057
INTERIOR LAMPS
DIMMER CONTROLLED LAMPS Service procedures for most of the lamps in the instrument panel, Instrument cluster and switches are located in Group 8E, Instrument Panel and Gauges. Some components have lamps that can only be serviced by an Authorized Service Center (ASC) after the component is removed from the vehicle. Contact local dealer for location of nearest ASC. Ash Receiver...........................................................161 Cigar Lighter..........................................................161
INDICATOR LAMPS Service procedures for most of the lamps in the instrument panel, instrument cluster and switches are located in Group 8E, Instrument Panel and Gauges. A/C Control...............................................................74 Airbag.................................................................PC194 Anti-lock Brake .................................................PC194 Brake Warning ..................................................PC194 Check Engine ....................................................PC194 EGR Reminder ..................................................PC194 Engine Oil Pressure .........................................PC194 Fasten Seat Belts .............................................PC194 Four Wheel Drive ..................................................161 Heater Control .......................................................158 High Beam.........................................................PC194 Illumination .......................................................PC194 Low Fuel ............................................................PC194 Low Washer Fluid.............................................PC194 Maintenance Required......................................PC194 Temperature Indicator......................................PC194 Turn Signal........................................................PC194 Upshift .................................................................PC74 NON-DIMMING LAMPS Service procedures for most of the lamps in the following list can be found in Group 23, Body. Dome ....................................................................211-2 Glove Compartment...............................................194 Overhead Console ...............................................212-2 Under Hood ............................................................105
RESTRAINT SYSTEMS
8M - 1
RESTRAINT SYSTEMS
CONTENTS
page page
AIRBAG SYSTEM
WARNING: THIS SYSTEM IS A SENSITIVE, COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL THE AIRBAG SYSTEM OR RELATED STEERING WHEEL AND STEERING COLUMN COMPONENTS YOU MUST FIRST DISCONNECT AND ISOLATE THE BATTERY NEGATIVE (GROUND) CABLE. THEN WAIT 2 MINUTES FOR SYSTEM CAPACITOR TO DISCHARGE BEFORE FURTHER SYSTEM SERVICE. FAILURE TO DO SO COULD RESULT IN ACCIDENTAL DEPLOYMENT AND POSSIBLE PERSONAL INJURY. WARNING: THE AIRBAG MODULE INFLATOR ASSEMBLY CONTAINS SODIUM AZIDE AND POTASSIUM NITRATE. THESE MATERIALS ARE POISONOUS AND EXTREMELY FLAMMABLE. CONTACT WITH ACID, WATER OR HEAVY METALS MAY PRODUCE HARMFUL AND IRRITATING GASES (SODIUM HYDROXIDE IS FORMED IN THE PRESENCE OF MOISTURE) OR COMBUSTIBLE COMPOUNDS. DO NOT ATTEMPT TO DISMANTLE THE MODULE OR TAMPER WITH ITS INFLATOR. DO NOT PUNCTURE, INCINERATE OR BRING INTO CONTACT WITH ELECTRICITY. DO NOT STORE AT TEMPERATURES EXCEEDING 200F. WARNING: REPLACE AIRBAG SYSTEM COMPONENTS WITH PARTS SPECIFIED IN THE CHRYSLER MOPAR PARTS CATALOG ONLY. SUBSTITUTE PARTS MAY APPEAR INTERCHANGEABLE, BUT INTERNAL DIFFERENCES MAY RESULT IN INFERIOR OCCUPANT PROTECTION. THE FASTENERS, SCREWS, AND BOLTS ORIGINALLY USED FOR THE AIRBAG COMPONENTS HAVE SPECIAL COATINGS AND ARE SPECIFICALLY DESIGNED FOR THE AIRBAG SYSTEM. THEY MUST NEVER BE REPLACED WITH ANY SUBSTITUTES. ANYTIME A NEW FASTENER IS NEEDED, REPLACE WITH THE CORRECT FASTENERS PROVIDED IN THE SERVICE PACKAGE OR SPECIFIED IN THE CHRYSLER MOPAR PARTS CATALOG. WARNING: WHEN A STEERING COLUMN HAS AN AIRBAG MODULE ATTACHED, NEVER PLACE THE COLUMN ON THE FLOOR OR OTHER SURFACE WITH THE STEERING WHEEL OR AIRBAG MODULE FACE DOWN.
GENERAL INFORMATION
The airbag system is a standard equipment safety device on Dakota models. It is designed to protect the driver from serious injury, caused by a frontal impact of the vehicle. To inspect this system use Airbag System - Body Diagnostic Procedures manual. If the airbag module assembly is defective and non-deployed, refer to Chrysler Corporation current return list for proper handling procedures. Following are general descriptions of the major components in the Dakota airbag system. Refer to Group 8W - Wiring Diagrams for complete circuit descriptions and diagrams.
AIRBAG MODULE
The airbag module protective cover is the most visible part of the system. The module is mounted directly to the steering wheel. Under the airbag module cover, the airbag cushion and its supporting components are contained. The airbag module contains a housing to which the cushion and inflator are attached and sealed. The airbag module is non-serviceable, and must be replaced if deployed or damaged in any way. The inflator assembly is mounted to the back of the module. The inflator seals the hole in the airbag cushion so it can discharge the gas it produces directly into the cushion when supplied with the
8M - 2
proper electrical signal. The protective cover is fitted to the front of the airbag module and forms a decorative cover in the center of the steering wheel. Upon airbag deployment, this cover will split horizontally.
STORAGE The airbag module must be stored in its original, special container until used for service. Also, it must be stored in a clean, dry environment; away from sources of extreme heat, sparks, and high electrical energy. Always place or store the module on a surface with the trim cover facing up to minimize movement in case of accidental deployment.
IMPACT SENSOR
The impact sensors provide verification of the direction and severity of the impact. Three impact sensors are used. One is called a safing sensor. It is located inside the airbag control module (ACM), which is mounted to a bracket under the instrument panel above the heater and A/C housing. The other two sensors are mounted on the radiator closure panel on the left and right side of the vehicle. The impact sensors are threshold sensitive switches that complete an electrical circuit when an impact provides a sufficient deceleration force to close the switch. The sensors are calibrated for the specific vehicle, and react to the severity and direction of the impact.
DIAGNOSIS
A DRB scan tool is required for diagnosis of the airbag system. Refer to Airbag System - Body Diagnostic Procedures manual for more information. (6) Read and record any stored DTC. (7) Refer to the Airbag System - Body Diagnostic Test Procedures manual, if any DTC is found in steps 5 or 6. (8) Erase stored DTC, if there are no active fault codes. If problems remain, DTC will not erase. (9) With the ignition switch in the ON position, make sure nobody is in the vehicle. (10) From right side of vehicle, turn the ignition switch to OFF then ON. Observe airbag warning lamp on the instrument cluster. It should light for 6 to 8 seconds, then go out; indicating system is functioning normally. If the airbag warning lamp fails to light, or lights and stays on, there is a system malfunction. Refer to the Airbag System - Body Diagnostic Test Procedures manual to diagnose the problem.
8M - 3
CLEANUP PROCEDURE
Begin cleanup by putting tape over the airbag exhaust vent (Fig. 2) so that no more powder will find its way into the vehicle interior. Then remove the airbag and airbag module from the vehicle.
8M - 4
RESTRAINT SYSTEMS
(10) Do not connect negative battery cable at this time. See Airbag System Check for proper procedure.
LEFT SIDE (1) Disconnect battery negative cable and isolate. If airbag module is undeployed, wait 2 minutes for system capacitor to discharge before further service. (2) Remove battery holddown (Fig. 8) and move battery rearward. (3) Unplug connector from sensor. (4) Remove 3 nuts holding left sensor to closure panel support (Fig. 9) and remove sensor.
RESTRAINT SYSTEMS
8M - 5
RIGHT SIDE (1) Disconnect battery negative cable and isolate. If airbag module is undeployed, wait 2 minutes for system capacitor to discharge before further service. (2) Pull air cleaner inlet tube off radiator support. (3) Unplug connector from right sensor. (4) Remove 3 nuts holding right sensor to radiator support (Fig. 9) and remove sensor. If stud plate needs to be replaced, remove push nut from stud and discard. Always use new push nut (Fig. 9) when installing stud plate. (5) When installing, mount sensor (arrow pointed forward) using 3 nuts provided with new sensor. Torque nuts to 3 to 4 N m (24 - 36 in. lbs.). (6) Connect sensor wiring lead from harness to connector on body of sensor. (7) Install air cleaner inlet tube to radiator support. (8) Do not connect negative battery cable at this time. See Airbag System Check for proper procedure.
8M - 6
RESTRAINT SYSTEMS
CLOCKSPRING REMOVE/INSTALL
(1) Place the front wheels in the straight-ahead position before starting the repair. (2) Disconnect battery negative cable and isolate. If airbag is undeployed, wait 2 minutes for system capacitor to discharge before further service. (3) Remove the airbag module. See Airbag Module Remove/Install. (4) Remove speed control switch and connector, if equipped.
RESTRAINT SYSTEMS
(5) Remove the steering wheel with steering wheel puller tool (C-3428B). (6) Unplug wiring connectors from horn switches. (7) Remove upper and lower steering column shrouds to gain access to clockspring wiring (Fig. 13). (8) Disconnect the 2-way connector between the
8M - 7
(15) Install the airbag module, and torque nuts to 9 to 11 N m (80 to 100 in. lb.). (16) Do not connect negative battery cable at this time. See Airbag System Check for proper procedure.
CLOCKSPRING CENTERING
If the rotating tape within the clockspring is not positioned properly in relation to the steering wheel and the front wheels, the clockspring may fail during use. The clockspring MUST BE CENTERED, if it is not known to be properly positioned, or if the front wheels were moved from the straight-ahead position. (1) Place front wheels in the straight-ahead position. (2) Disconnect battery negative cable and isolate. If airbag is undeployed, wait 2 minutes for system capacitor to discharge before further service. (3) Remove airbag module. Remove steering wheel with steering wheel puller tool (C-3428B). (4) Depress the two plastic auto-locking tabs (Fig. 14).
POWER LOCKS
8P - 1
POWER LOCKS
CONTENTS
page page
SERVICE PROCEDURES
................... 2
GENERAL INFORMATION
Power door locks are optional equipment on Dakota models. Both doors can be locked or unlocked electrically by operating the switch on either door panel. The power door locks operate with battery power supplied independent of the ignition switch. Following are general descriptions of the major components in the Dakota power door lock system. Refer to Group 8W - Wiring Diagrams for complete circuit descriptions and diagrams. switch controls both the battery and ground feeds to the door lock motors. The battery and ground feeds are reversed between the LOCK and UNLOCK switch positions. The door lock switches can not be repaired. If faulty, the entire switch must be replaced.
8P - 2
POWER LOCKS
Disconnect each motor connector, one at a time, and re-check both lock and unlock functions while operating the door lock switch. If both motors are still inoperative after above test, repair wire harness between motor and switch as required. If disconnecting one motor causes the other motor to become functional, go back to step 2 to test the disconnected motor.
connector at the motor. Apply 12 volts across the motor terminals to check its operation in one direction. Reverse the polarity to check the operation in the other direction. If OK, repair wire harness from the motor to the switch as required. If not OK, replace the motor. (3) If both motors are inoperative, the problem may be caused by one shorted motor. Disconnecting a shorted motor will allow the good motor to operate.
POWER WINDOWS
8S - 1
POWER WINDOWS
CONTENTS
page page
SERVICE PROCEDURES
................... 3
GENERAL INFORMATION
Power door windows are optional equipment on Dakota models. The power windows operate only with the ignition switch in the ON position. This group covers diagnosis and service of the electrical components peculiar to the power window system. For service of mechanical components such as the regulator, lift plate or window tracks refer to Group 23 - Body Components. Following are general descriptions of the major components in the Dakota power window system. Refer to Group 8W - Wiring Diagrams for complete circuit descriptions and diagrams. positive and negative battery connection to the two motor terminals will cause the motor to rotate in one direction. Reversing current through these same two connections will cause the motor to rotate in the opposite direction. The power window motor and gearbox assembly cannot be repaired. If faulty, the entire assembly must be replaced.
CIRCUIT BREAKER
An automatic re-setting circuit breaker in the fuseblock module is used to protect the power window system circuit. The circuit breaker can protect the system from a short circuit, and can also protect the system from an overload condition caused by an obstructed or stuck window glass or regulator. The circuit breaker can not be repaired. If faulty, it must be replaced.
DIAGNOSIS
It is necessary that the window be free to slide up and down for the power window system to function properly. If the window is not free to move up and down, the motor will overload and trip the circuit breaker. To determine if the glass is free, disconnect regulator plate from the glass and slide window up and down by hand. An alternate method is to shake the glass in the door, with the glass positioned between the up and down stop positions. Check that the glass can be moved slightly from side to side, front to rear, and up and down. Then check that window is not bound tight in the tracks. If window is free, proceed with diagnosis that follows. If window is not free, refer to Group 23 - Body Components for service procedures.
CIRCUIT BREAKER
Locate correct circuit breaker in fuseblock module. Pull out slightly, but be sure that circuit breaker terminals still contact terminals in fuseblock module. Turn ignition switch to ON position. Connect ground wire of voltmeter to a good ground. With probe of voltmeter positive lead, check both terminals of circuit breaker for battery voltage. If only one terminal has battery voltage, circuit breaker is faulty and must be replaced. If neither terminal has battery voltage, repair circuit from ignition switch as required.
8S - 2
POWER WINDOWS
(1) Remove switch from door trim panel. See Power Window Switch Remove/Install. Carefully separate multiple terminal block on wiring harness from switch body. (2) Check for continuity between connector cavity for left switch pin 2 (Fig. 1) or connector cavities for right switch pins 2 and 4 (Fig. 2) and a good ground. There should be continuity. If OK, go to next step. If not OK, repair ground circuit as required. Note that right switch gets ground feed through the left switch. (3) Turn ignition switch to ON position. Check for battery voltage at connector cavity for switch pin 5 (Fig. 1 or 2). If OK, go to next step. If not OK, repair wiring to circuit breaker as required. (4) Test switch continuity. See Switch Continuity charts (Fig. 1 or 2) to determine if continuity is correct in the OFF, UP and DOWN switch positions. If OK, go to Power Window Motor diagnosis. If not OK, replace the switch.
8S - 3
(7) Using a trim stick or other suitable widebladed flat tool, gently pry trim panel away from door. (8) Roll door watershield away from lower rear corner of door to reveal inside panel access opening. (9) Raise window to full up position and keep it there at all times while replacing motor. Place a window block in door that will positively prevent window from dropping into door. (10) Disconnect wiring connector for motor (Fig. 4). (11) Remove 3 mounting screws that hold motor
POWER MIRRORS
8T - 1
POWER MIRRORS
CONTENTS
page page
SERVICE PROCEDURES
................... 3
GENERAL INFORMATION
This group covers power outside mirrors and the automatic day/night inside rear view mirror, which are available options on Dakota models. Following are general descriptions of the major components in the Dakota power outside mirror and automatic day/ night inside rear view mirror systems. Refer to Group 8W - Wiring Diagrams for complete circuit descriptions and diagrams.
POWER MIRRORS
The power mirrors are connected to battery feed at all times. Each mirror head contains two electric motors, two drive mechanisms and the mirror glass. One motor and drive controls mirror up-and-down movement, and the other controls right-and-left movement. The mirror glass is the only serviced replacement part for the power mirror assembly. If any other component of the mirror unit is faulty or damaged, the entire assembly must be replaced.
8T - 2
POWER MIRRORS
(1) Check fuse F1 in Power Distribution Center (PDC). If OK, go to next step. If not OK, replace fuse. (2) Check for battery voltage at fuse F1 in PDC. If OK, go to next step. If not OK, repair circuit to fusible link cartridge fuse F in PDC. (3) Remove power mirror switch from the instrument panel. See Power Mirror Switch Remove/Install. (4) Disconnect wiring harness connector from switch. Check for battery voltage at pink wire. If OK, go to next step. If not OK, repair circuit to fuse F1 in PDC. (5) Check for continuity between black wire in switch harness connector and a good ground. There should be continuity. If OK, go to next step. If not OK, repair circuit to ground. (6) Check switch continuity as shown in the Mirror Switch Continuity chart (Fig. 2). If OK, go to next step. If not OK, replace switch.
(2) Turn ignition switch to the ON position. Check for battery voltage at fuse 3 in fuseblock module. If OK, go to next step. If not OK, repair circuit from fuse to ignition switch as required. (3) Unplug harness connector from mirror (Fig. 3). Check for battery voltage at connector cavity with white wire. If OK, go to next step. If not OK, repair circuit to fuse 3 as required.
POWER MIRRORS
pletely so that no light reaches the sensor. Use only one finger pressed tightly against sensor, or cover sensor completely with electrical tape. (7) Shine a light into the rear facing sensor. The mirror should darken. If OK, go to next step. If not OK, replace mirror
8T - 3
(8) With the mirror darkened, place the transmission gear selector in Reverse. The mirror should return to its normal condition. If not OK, replace mirror.
8T - 4
POWER MIRRORS
8U - 1
SERVICE PROCEDURES
................... 3
GENERAL INFORMATION
This group covers the buzzer warning system, which is standard equipment on Dakota models. The system provides an audible warning to the driver when it monitors the following conditions: key is in ignition switch with the drivers door open head or park lamps are on with drivers door open drivers seat belt is not buckled with ignition switch in ON position. Following are general descriptions of the major components in the Dakota buzzer warning system. Refer to Group 8W - Wiring Diagrams for complete circuit descriptions and diagrams.
BUZZER MODULE
The buzzer module is located on the fuseblock module (Fig. 1). It receives battery voltage at all times from fuse 7 in the fuseblock module. It also receives a second battery feed through fuse 16 that is switched on when the ignition switch is in the ON or START position. Other inputs to the module include the drivers door jamb switch, the drivers seat belt switch, the ignition key-in switch, and the headlamp switch. The only output of the module is a timed 4 to 8 second feed to the seat belt reminder lamp in the instrument cluster. The timer function begins after the ignition switch is turned to the ON position. The buzzer module can not be repaired. If faulty, it must be replaced.
HEADLAMP SWITCH
The headlamp switch is located in the instrument panel. It closes a path to ground when the park or headlamps are on and the drivers door jamb switch is closed (door open). The switch opens the ground path when the park and headlamps are turned off. The headlamp switch can not be repaired. If faulty, it must be replaced. Refer to Group 8E - Instrument Panel and Gauges for service procedures.
8U - 2
BUZZER MODULE
(1) Check fuse 7 and fuse 16 in the fuseblock module. If fuses are OK, go to next step. If not OK, replace fuses as required. (2) Check for battery voltage at fuse 7 in fuseblock module. If OK, go to next step. If not OK, repair feed circuit from power distribution center as required. (3) Turn ignition switch to ON position. Check for battery voltage at fuse 16 in the fuseblock module. If OK, go to next step. If not OK, repair feed from ignition switch as required. (4) Turn ignition switch to OFF position. Replace buzzer module with a known good unit and test operation. If not OK, remove buzzer module and go to next step. (5) Check for battery voltage at cavity for buzzer terminal 7 in fuseblock module (Fig. 2). If OK, go to next step. If not OK, repair circuit to fuse 7.
8U - 3
HEADLAMP SWITCH
(1) Remove headlamp switch from instrument panel (refer to Group 8E - Instrument Panel and Gauges for procedure). Unplug headlamp switch connector. Open drivers door. Check for continuity between connector cavity with black/light blue wire to a good ground. There should be continuity until drivers door is closed. If OK, go to next step. If not OK, repair circuit from headlamp switch to drivers door jamb switch as required. (2) Check for continuity between connector cavity with light blue wire and cavity for terminal 6 of buzzer module in fuseblock module. There should be continuity. If OK, go to next step. If not OK, repair circuit from headlamp switch to fuseblock module as required. (3) Check continuity between headlamp switch terminal for connector cavity with black/light blue wire and terminal for cavity with light blue wire. There should be no continuity with switch in off position, and there should be continuity with switch in park lamps or headlamps on position. If not OK, replace headlamp switch.
belt anchor on floor. Check for continuity between two cavities of seat belt half of connector. There should be continuity with seat belt unbuckled, and no continuity with seat belt buckled. If OK, go to next step. If not OK, replace seat belt buckle-half assembly. (2) Check for continuity between cavity with black wire in harness half of seat belt switch connector and a good ground. There should be continuity. If OK, go to next step. If not OK, repair circuit to ground as required. (3) Check for continuity between cavity with light green/red wire in harness half of seat belt switch connector and cavity for terminal 4 of buzzer module in fuseblock module. There should be continuity. If not OK, repair circuit from seat belt switch connector to fuseblock module as required.
SERVICE PROCEDURES
Service procedures for components of the buzzer system can be found in the appropriate group as follows: drivers door jamb switch - refer to Group 8L - Lamps ignition key-in switch - refer to Group 8D - Ignition Systems headlamp switch - refer to Group 8E - Instrument Panel and Gauges drivers seat belt switch - refer to Group 23 - Body Components.
WIRING DIAGRAMS
8W - 1
WIRING DIAGRAMS
CONTENTS
page page
8W-01 GENERAL INFORMATIONWIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . 8W-01-1 8W-10 FUSE BLOCK . . . . . . . . . . . . . . . . . 8W-10-1 8W-11 POWER DISTRIBUTION . . . . . . . . 8W-11-1 8W-15 GROUND DISTRIBUTION . . . . . . . 8W-15-1 8W-20 CHARGING SYSTEM . . . . . . . . . . 8W-20-1 8W-21 STARTING SYSTEM . . . . . . . . . . . 8W-21-1 8W-30 FUEL/IGNITION . . . . . . . . . . . . . . 8W-30-1 8W-31 TRANSMISSION CONTROLS . . . . 8W-31-1 8W-32 ANTI-LOCK BRAKES . . . . . . . . . . 8W-32-1 8W-33 VEHICLE SPEED CONTROL . . . . . 8W-33-1 8W-40 INSTRUMENT CLUSTER . . . . . . . 8W-40-1 8W-41 HORN/CIGAR LIGHTER . . . . . . . . . 8W-41-1 8W-42 AIR CONDITIONING/HEATER . . . . 8W-42-1 8W-43 AIRBAG SYSTEM . . . . . . . . . . . . . 8W-43-1 HOW TO USE THIS GROUP
The purpose of this group is to show the electrical circuits in a clear, simple fashion and to make troubleshooting easier. Components that work together are shown together. All electrical components used in a specific system are shown on one diagram. The feed for a system is shown at the top of the page. All wires, connectors, splices, and components are shown in the flow of current to the bottom of the page. Wiring which is not part of the circuit represented is referenced to another page/section, where the complete circuit is shown. In addition, all switches, components, and modules are shown in the at rest position with the doors closed and the key removed from the ignition. If a component is part of several different circuits, it is shown in the diagram for each. For example, the headlamp switch is the main part of the exterior lighting, but it also affects the interior lighting and the chime warning system. It is important to realize that no attempt is made on the diagrams to represent components and wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a long one. In addition, switches and other components are shown as simply as possible, with regard to function only. Both the standard cab and club cab models are shown in this section. If there is a difference in sys-
8W-44 8W-47 8W-49 8W-50 8W-51 8W-52 8W-53 8W-54 8W-60 8W-61 8W-62 8W-70 8W-80 8W-90 8W-95
INTERIOR LIGHTING . . . . . . . . . . AUDIO SYSTEM . . . . . . . . . . . . . . OVERHEAD CONSOLE . . . . . . . . . FRONT LIGHTING . . . . . . . . . . . . . REAR LIGHTING . . . . . . . . . . . . . . TURN SIGNALS . . . . . . . . . . . . . . WIPERS . . . . . . . . . . . . . . . . . . . . TRAILER TOW . . . . . . . . . . . . . . . POWER WINDOWS . . . . . . . . . . . POWER DOOR LOCKS . . . . . . . . . POWER MIRRORS . . . . . . . . . . . . SPLICE INFORMATION . . . . . . . . CONNECTOR PIN OUTS . . . . . . . CONNECTOR LOCATIONS . . . . . . SPLICE LOCATIONS . . . . . . . . . . .
8W-44-1 8W-47-1 8W-49-1 8W-50-1 8W-51-1 8W-52-1 8W-53-1 8W-54-1 8W-60-1 8W-61-1 8W-62-1 8W-70-1 8W-80-1 8W-90-1 8W-95-1
tems or components between the models, an identifier is placed next to the component.
SECTION IDENTIFICATION
Sections in Group 8W are organized by sub-systems. The sections contain circuit operation descriptions, helpful information, and system diagrams. The intention is to organize information by system, consistently from year to year.
CONNECTOR LOCATIONS
Section 8W-90 contains Connector Location illustrations. The illustrations contain the connector number and component identification. Connector Location charts in Section 8W-90 reference the illustration number for components and connectors. Section 8W-80 shows each connector and the circuits involved with that connector. The connectors are identified using the number on the Diagram pages.
SPLICE LOCATIONS
Splice Location charts in Section 8W-70 show the entire splice, and provide references to other sections the splice serves. Section 8W-95 contains illustrations that show the general location of the splices in each harness. The illustrations show the splice by number, and provide a written location.
8W - 01 - 1
TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER. DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS PRESENT IN AND AROUND THE BATTERY. ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE CLOTHING.
8W - 01 - 2
CIRCUIT IDENTIFICATION
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function (Fig. 3). To identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This chart shows the main circuits only and does not show the secondary codes that may apply to some models.
CONNECTORS
Connectors shown in the diagrams are identified using the international standard arrows for male and female terminals (Fig. 4). A connector identifier is placed next to the arrows to indicate the connector number (Fig. 4). For viewing connector pin outs, with two terminals or greater, refer to section 8W-80. This section identifies the connector by number and provides terminal numbering, circuit identification, wire colors, and functions. All connectors are viewed from the terminal end unless otherwise specified. To find the connector location in the vehicle refer to section 8W-90. This section uses the connector identification number from the wiring diagrams to provide a figure number reference.
SYMBOLS
Various symbols are used throughout the Wiring Diagrams. These symbols can be identified by referring to the symbol identification chart (Fig. 5).
TAKE OUTS
The abbreviation T/O is used in the component location section to indicate a point in which the wiring harness branches out to a component.
8W - 01 - 3
8W - 01 - 4
(1) Always touch a known good ground before handling the part. This should be repeated while handling the part and more frequently after sliding across a seat, sitting down from a standing position, or walking a distance. (2) Avoid touching electrical terminals of the part, unless instructed to do so by a written diagnostic procedure. (3) When using a voltmeter, be sure to connect the ground lead first. (4) Do not remove the part from its protective packing until it is time to install the part. (5) Before removing the part from its package, ground the package to a known good ground on the vehicle.
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit there are several common tools necessary. These tools are listed and explained below. Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass an open in a circuit. WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR, CONNECTED BETWEEN A BATTERY FEED AND GROUND. Voltmeter - Used to check for voltage on a circuit. Always connect the black lead to a known good ground and the red lead to the positive side of the circuit. CAUTION: Most of the electrical components used in todays vehicle are solid state. When checking voltages in these circuits use a meter with a 10-megohm or greater impedance. Ohmmeter - Used to check the resistance between two points of a circuit. Low or no resistance in a circuit means good continuity. CAUTION: - Most of the electrical components used in todays vehicle are Solid State. When checking resistance in these circuits use a meter with a 10megohm or greater impedance. In addition, make
TROUBLESHOOTING TESTS
Before beginning any tests on a vehicles electrical system, use the Wiring Diagrams and study the circuit. Also refer to the Troubleshooting Wiring Problems section in this section.
TESTING FOR VOLTAGE (1) Connect the ground lead of a voltmeter to a known good ground (Fig. 8). (2) Connect the other lead of the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check voltage. Refer to the appropriate test procedure.
8W - 01 - 5
TESTING FOR A SHORT TO GROUND (1) Remove the fuse and disconnect all items involved with the fuse. (2) Connect a test light or a voltmeter across the terminals of the fuse. (3) Starting at the fuse block, wiggle the wiring harness about six to eight inches apart and watch the voltmeter/test lamp. (4) If the voltmeter registers voltage or the test lamp glows, there is a short to ground in that general area of the wiring harness. TESTING FOR A SHORT TO GROUND ON FUSES POWERING SEVERAL LOADS (1) Refer to the wiring diagrams and disconnect or isolate all items on the fused circuit. (2) Replace the blown fuse. (3) Supply power to the fuse by turning ON the ignition switch or re-connecting the battery. (4) Start connecting the items in the fuse circuit one at a time. When the fuse blows the circuit with the short to ground has been isolated.
8W - 01 - 6
are listed and explained below. Always check for nonfactory items added to the vehicle before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify these add-on items are not the cause of the problem. (1) Verify the problem. (2) Verify any related symptoms. Do this by performing operational checks on components that are in the same circuit. Refer to the wiring diagrams. (3) Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the problem most likely is occurring and where the diagnosis will continue. (4) Isolate the problem area. (5) Repair the problem. (6) Verify proper operation. For this step, check for proper operation of all items on the repaired circuit. Refer to the wiring diagrams.
WIRING REPAIR
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation. (1) Disconnect battery negative cable. (2) Remove 1 inch of insulation from each end of the wire. (3) Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. (4) Spread the strands of the wire apart on each part of the exposed wires (Fig. 11 example 1).
8W - 01 - 7
8W - 01 - 8
(10) Push the two ends of wire together until the strands of wire are close to the insulation (Fig. 11 example 2). (11) Twist the wires together (Fig. 11 example 3). (12) Solder the connection together using rosin core type solder only. Do not use acid core solder. (13) Center the heat shrink tubing over the joint and heat using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both ends of the tubing. (14) Repeat steps 8 through 13 for each wire. (15) Re-tape the wire harness starting 1-1/2 inches behind the connector and 2 inches past the repair. (16) Re-connect the repaired connector. (17) Connect the battery, and test all affected systems.
DIODE REPLACEMENT
(1) Disconnect the battery. (2) Locate the diode in the harness, and remove the protective covering. (3) Remove the diode from the harness, pay attention to the current flow direction (Fig. 18).
TERMINAL REPLACEMENT
(1) Disconnect battery. (2) Disconnect the connector being repaired from its mating half. (3) Remove connector locking wedge, if required (Fig. 14). (4) Position the connector locking finger away from the terminal using the proper pick from special tool kit 6680. Pull on the wire to remove the terminal from the connector (Figs. 15 and 16). (5) Cut the wire 6 inches from the back of the connector. (6) Remove 1 inch of insulation from the wire on the harness side. (7) Select a wire from the terminal repair assembly that best matches the color wire being repaired. (8) Cut the repair wire to the proper length and remove 1 inch of insulation. (9) Place a piece of heat shrink tubing over one side of the wire. Make sure the tubing will be long enough to cover and seal the entire repair area. (10) Spread the strands of the wire apart on each part of the exposed wires (Fig. 11 example 1). (11) Push the two ends of wire together until the strands of wire are close to the insulation (Fig. 11 example 2). (12) Twist the wires together (Fig. 11 example 3). (13) Solder the connection together using rosin core type solder only. Do not use acid core solder.
8W - 10 - 1
FUSE BLOCK
GENERAL INFORMATION
This section covers the Fuse Block and all circuits involved with it. For additional information on system operation, refer to the appropriate section of the wiring diagrams.
DIAGRAM INDEX
Component Page ABS Warning Lamp Relay . . . . . . . . . . . . . . . . . . . . . . . .2 Buzzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Circuit Breaker Cavity 2 . . . . . . . . . . . . . . . . . . . . . . . . .4 Clutch Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . .3 Fuse 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Fuse 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Fuse 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Fuse 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Fuse 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Fuse 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Fuse 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Fuse 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Fuse 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Fuse 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Fuse 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Fuse 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Fuse 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Fuse 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Fuse 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Fuse 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Fuse Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Hazard Flasher Relay . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Headlamp Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Horn Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3, 4 Time Delay Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Turn Signal Flasher . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
8W - 11 - 1
POWER DISTRIBUTION
GENERAL INFORMATION
This section covers the Power Distribution Center (PDC) and all circuits involved with it. For additional information on system operation, refer to the appropriate section of the wiring diagrams.
DIAGRAM INDEX
Component Page A/C Compressor Clutch Relay . . . . . . . . . . . . . . .8W-11-3, 5 ABS Power Relay . . . . . . . . . . . . . . . . . . . . . .8W-11-3, 8 ABS Warning Lamp Relay . . . . . . . . . . . . . . . . . . .8W-11-8 Automatic Shut Down Relay . . . . . . . . . . . . . . . .8W-11-3, 6 Buss Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-11-2 Clutch Pedal Position Switch . . . . . . . . . . . . . . . . .8W-11-4 Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-11-5 Engine Starter Relay . . . . . . . . . . . . . . . . . . . . .8W-11-3, 4 Fuel Pump Relay . . . . . . . . . . . . . . . . . . . . . . .8W-11-3, 7 Fuse Block Fuse 1 . . . . . . . . . . . . . . . . . . . . . . . .8W-11-9 Fuse Block Fuse 2 . . . . . . . . . . . . . . . . . . . . . . . .8W-11-9 Fuse Block Fuse 3 . . . . . . . . . . . . . . . . . . . . . . . .8W-11-9 Fuse Block Fuse 4 . . . . . . . . . . . . . . . . . . . . . . . .8W-11-8 Fuse Block Fuse 4 . . . . . . . . . . . . . . . . . . . . . . . .8W-11-9 Fuse Block Fuse 14 . . . . . . . . . . . . . . . . . . .8W-11-5, 6, 7 Fuse Block Fuse 15 . . . . . . . . . . . . . . . . . . .8W-11-5, 6, 7 Fuse Block Fuse 16 . . . . . . . . . . . . . . . . . . .8W-11-5, 6, 7 Fuse F1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-11-2, 8 Fuse F2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-11-2, 9 Fuse A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-11-8 Fuse B . . . . . . . . . . . . . . . . . . . . . . . . . .8W-11-4, 5, 6, 7 Fuse C . . . . . . . . . . . . . . . . . . . . . . . . . .8W-11-4, 5, 6, 7 Fuse E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-11-9 Fuse F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-11-9 Fuse G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-11-9 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-11-2 Ignition Switch . . . . . . . . . . . . . . . . . . .8W-11-4, 5, 6, 7, 9 Power Distribution Center . . . . . . . . . . . . . . . . . . .8W-11-2 Radiator Fan Control Relay . . . . . . . . . . . . . . . .8W-11-3, 5
8W - 15 - 1
GROUND DISTRIBUTION
GENERAL INFORMATION
This section identifies the grounds, splices that connect to those grounds, and the components that connect those grounds. For additional information on system operation, refer to the appropriate section of the wiring diagrams. For an illustration of the physical location of each ground, refer to group 8W-90.
DIAGRAM INDEX
Component G101 . . . G102 . . . G103 . . . G104 . . . G105 . . . G106 . . . G107 . . . G108 . . . G109 . . . G110 . . . G111 . . . G201 . . . G202 . . . G203 . . . G301 . . . G302 . . . G303 . . . G304 . . . S101 . . . S113 . . . S121 . . . S129 . . . S141 . . . S142 . . . S204 . . . S306 . . . S308 . . . S310 . . . S401 . . . S403 . . . S404 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page .8W-15-2 .8W-15-2 .8W-15-2 .8W-15-2 .8W-15-2 .8W-15-3 .8W-15-3 .8W-15-3 .8W-15-4 .8W-15-4 .8W-15-4 .8W-15-4 .8W-15-4 .8W-15-4 .8W-15-5 .8W-15-5 .8W-15-5 .8W-15-5 .8W-15-2 .8W-15-2 .8W-15-3 .8W-15-3 .8W-15-4 .8W-15-4 .8W-15-4 .8W-15-5 .8W-15-5 .8W-15-5 .8W-15-5 .8W-15-5 .8W-15-5
1995 AN Dakota Publication No. 81-370-5110 TSB 08-55-94 October 14, 1994
8W - 20 - 1
CHARGING SYSTEM
CHARGING SYSTEM
2.5L ENGINE The charging system is an integral part of the battery and starting systems. Because all these systems work in conjunction, diagnose and test them together. Circuit A11 connects to the generator output terminal and splices to circuit A0. Circuit A0 connects to the battery. A fusible link in circuit A11 between the battery and the generator protects the charging system. Circuit Z1 provides ground for the generator at terminal 4 of the generator connector. Circuit Z1 attaches to the top of the left side of the engine. When the ignition switch is in either the START or RUN positions it connects battery voltage from circuit A1 to the A21 circuit. Circuit A21 connects to the generator field terminal (terminal 2). Circuit A1 originates in the Power Distribution Center (PDC) and is connected to battery voltage. 40 amp fuse C in the PDC protects the A1 circuit. The Powertrain Control Module (PCM) has an internal voltage regulator that controls generator output. Circuit K20 connects to generator terminal 1 and PCM cavity 20. The PCM controls the generator field on the K20 circuit. When the engine operates and there is current in the generator field, the generator produces a B+ voltage. The generator supplies B+ voltage to the battery through the A11 and A0 circuits.
HELPFUL INFORMATION Circuit A21 splices to supply battery voltage to the coil side of the Automatic Shutdown (ASD) relay. If battery voltage is not present on the A21 circuit at the ASD relay, the PCM will not be able to energize the relay. The ASD relay supplies battery voltage for the fuel injectors, fuel pump module, ignition coil, and the heated oxygen sensor. Ground circuit Z1 also supplies ground for the A/C compressor clutch. Circuit Z1 provides ground for the generator. The Z1 circuit terminates the rear of the A/C compressor. When the ignition switch is in either the START or RUN positions, it connects battery voltage from circuit A1 to the A21 circuit. Circuit A21 connects to the coil side of the Automatic Shutdown (ASD) relay. Circuit A1 originates in the PDC and is connected to battery voltage. 40 amp fuse C in the PDC protects the A1 circuit. When the ASD relay energizes, it connects circuit A14 from the PDC to circuit A142. Circuit A142 splices to connect to terminal 2 of the generator 3-way connector supplying battery voltage to the generator field. The Powertrain Control Module (PCM) has an internal voltage regulator that controls generator output. Circuit K20 connects to generator terminal 1 and PCM cavity 20. The PCM controls the generator field on the K20 circuit. When the engine operates and there is current in the generator field, the generator produces a B+ voltage. The generator supplies B+ voltage to the battery through the A11 and A0 circuits. HELPFUL INFORMATION Circuit A14 connects to fuse D in the PDC. Circuit A0 from the battery supplies voltage to a bus bar in the PDC that fuse D connects to. From the ASD relay, circuit A142 splices to supply voltage to the fuel injectors, ignition coil, fuel pump module, and the heated oxygen sensor.
DIAGRAM INDEX2.5L
Component Battery . . . . . . . . . . . . Fuse F1 . . . . . . . . . . . . Fusible Link . . . . . . . . . Generator . . . . . . . . . . . Powertrain Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page .8W-20-2 .8W-20-2 .8W-20-2 .8W-20-2 .8W-20-2
3.9L AND 5.2L ENGINES The charging system is an integral part of the battery and starting systems. Because all these systems work in conjunction, diagnose and test them together. Circuit A0 from the battery connects to a bus bar in the Power Distribution Center (PDC). Circuit A11 connects to the PDC buss bar and the output terminal of the generator. A fusible link in circuit A11 between the PDC and the generator protects the charging system.
DIAGRAM INDEX3.9L/5.2L
Component Battery . . . . . . . . . . . . Fuse F1 . . . . . . . . . . . . Fusible Link . . . . . . . . . Generator . . . . . . . . . . . Power Distribution Center Powertrain Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page .8W-20-3 .8W-20-3 .8W-20-3 .8W-20-3 .8W-20-3 .8W-20-3
8W - 21 - 1
STARTING SYSTEM
INDEX
page 2.5L Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3.9L and 5.2L Engines . . . . . . . . . . . . . . . . . . . . . . 1 page Diagram Index2.5L . . . . . . . . . . . . . . . . . . . . . . . . 2 Diagram Index3.9L/2.5L . . . . . . . . . . . . . . . . . . . . 2
2.5L ENGINE
The Power Distribution Center (PDC) supplies battery voltage to the engine starter motor solenoid on circuit T40 when the coil side of the engine starter motor relay energizes. Circuit A0 from the battery is double crimped at the battery positive post. One branch of circuit A0 (battery positive cable) connects to the engine starter motor. The other A0 branch supplies voltage to a bus bar in the PDC. Fuse B (30 amp) connects to the bus bar protects circuit C26. Circuit C26 splices to circuit A0 which connects to the contact side of the engine starter motor relay. In the START position, the ignition switch connects battery voltage from the PDC on circuit A1 with circuit A41. Circuit A41 feeds the coil side of the engine starter motor relay. Circuit Z1 provides ground for the coil side of the relay. The engine starter motor relay is located in the PDC. Manual transmission equipped vehicles use a clutch pedal position switch in circuit A41 between the ignition switch and the engine starter motor relay. Before the relay will energize, the operator has to depress the clutch pedal to close the clutch pedal position switch. When the engine starter motor relay energizes and the contacts close, circuit T40 supplies battery voltage to the starter motor solenoid. Circuit A0 from the battery supplies voltage to the engine starter motor when the solenoid energizes.
HELPFUL INFORMATION Circuit C26 splices to feed the contact sides of the radiator fan relay and the A/C compressor clutch relay. Fuse C, 40 amp, protects circuits A1 and A41. Fuse C is located in the PDC. Circuit Z1 also provides ground for the vehicle speed sensor, A/C compressor clutch, 4x4 switch, speed control, heated oxygen sensor, and PCM. The engine will not start if the vehicle loses this ground. The grounding point for the Z1 ground is the left fender side shield.
8W - 21 - 2
MANUAL TRANSMISSION The Power Distribution Center (PDC) supplies battery voltage to the engine starter motor solenoid on circuit T40 when the coil side of the engine starter motor relay energizes. Circuit A0 from the battery is double crimped at the positive battery post. One branch of circuit A0 (battery positive cable) connects to the starter motor. The other A0 branch supplies voltage to a bus bar in the PDC. Fuse B (30 amp) connects to the bus bar and protects circuit C26. Circuit C26 splices to circuit A0 which connects to the contact side of the starter motor relay. The ignition switch supplies battery voltage to the coil side of the engine starter motor relay on circuit A41 when the key is moved to the START position and the operator depresses the clutch pedal. When the operator depresses the clutch pedal, the clutch pedal position switch closes. Ground for the coil side of the engine starter motor relay is supplied on circuit T41. This circuit is spliced with circuit Z1. The Z1 circuit terminates at the left fender side shield. When the starter motor relay energizes, and the contacts close, circuit T40 supplies battery voltage to the starter motor solenoid. Circuit A0 from the battery supplies voltage to the starter motor when the solenoid energizes.
HELPFUL INFORMATION Circuit Z1 also provides ground for the vehicle speed sensor, A/C compressor clutch, 4x4 switch, vehicle speed control, heated oxygen sensor, and PCM. The engine will not start if the vehicle loses this ground. The grounding point for the Z1 ground is the left fender side shield.
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DIAGRAM INDEX3.9L/5.2L
Component Page Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-21-4, 5 Clutch Pedal Position Switch . . . . . . . . . . . . . . . . .8W-21-4 Fuse 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-21-5 Fuse B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-21-4 Fuse C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-21-4 Fuse E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-21-5 Engine Starter Motor . . . . . . . . . . . . . . . . . . . . . .8W-21-4 Engine Starter Relay . . . . . . . . . . . . . . . . . . . . . .8W-21-4 Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . .8W-21-4, 5 Park/Neutral Position Switch . . . . . . . . . . . . . . . . .8W-21-5 Power Distribution Center . . . . . . . . . . . . . . . . . . .8W-21-4 Powertrain Control Module . . . . . . . . . . . . . . . . . .8W-21-5
8W-30 FUEL/IGNITION
8W - 30 - 1
FUEL/IGNITION
CONTENTS
page page
IGNITION SWITCH
When the ignition switch is in the RUN position, it connects circuit A2 from the Power Distribution Center (PDC) to circuit A22. A 50 amp fuse in cavity E of the PDC protects the A2 and A22 circuits. Circuit A22 connects to a bus bar in the fuse block. The bus bar feeds circuits C1, F21, F20, and A20. Circuits C1, F20, and A20 are protected by separate fuses. A circuit breaker protects circuit F21. Fuse 1, 30 amp, protects circuit C1. Circuit C1 feeds the blower motor switch. The 30 amp circuit breaker in cavity 2 of the fuse block protects circuit F21. The F21 circuit feeds the power window switches. Fuse 3, 15 amp, protects circuit F20. The F20 circuit is double crimped at the fuse. One branch of circuit F20 feeds just the Airbag Control Module (ACM). The other branch feeds the overhead console, Powertrain Control Module (PCM), and the back-up lamp switch. Fuse 4, 5 amp, is only used on vehicles with ABS. The fuse protects circuit A20. Circuit A20 provides an
input to the ABS control module. Circuit A20 also splices to the ABS power relay and the ABS warning lamp relay. In the START position, the ignition switch connects circuit A1 from the PDC to circuit A41. Circuit A41 connects to the coil side of the engine starter motor relay. If the vehicle is equipped with a manual transmission, circuit A41 connects to the clutch pedal position switch before reaching the starter motor relay. Also in the START position, the ignition switch provides ground for the brake lamp switch, parking brake lamp switch, and connects to the ABS module or Rear Wheel Anti-Lock (RWAL) module. In the START or RUN positions, the ignition switch connects circuit A1 from the PDC with circuit A21. Circuit A1 connects to fuse C in the PDC. The A21 circuit is double crimped at the fuse block. The branch from the fuse block is spliced to the Automatic Shut Down (ASD) relay, radiator fan relay and the daytime running lamps (DRL) module. At the fuse block, circuit A21 connects to a bus bar that feeds circuits F14, V34, and G5. Each circuit is protected by a separate fuse.
8W - 30 - 2
Fuse 16, 5 amp, feeds circuit G5. The G5 circuit powers the combination buzzer and the overdrive lamp. Fuse 15, 2 amp, feeds circuit V34. Circuit V34 powers the vehicle speed control switch. Fuse 14, 15 amp, feeds circuit F14. Circuit F14 is double crimped at fuse 14. One branch of circuit F14 connects to the instrument cluster. The other branch of circuit F14 connects to the ACM. In the ACCESSORY position, the ignition switch connects circuit A1 from the PDC with circuit A31. Circuit A31 connects to a bus bar in the fuse block that feeds circuits X22, V6, L5, and X12. Each circuit is protected by a separate fuse. Fuse 9, 15 amp, feeds circuit X22. Circuit X22 powers the cigar lighter. Fuse 10, 20 amp, feeds circuit V6. Circuit V6 powers the wiper system. Fuse 11, 20 amp, feeds circuit L5. Circuit L5 is double crimped at fuse 11. One branch of circuit L5 connects to the RWAL module (if equipped). The other L5 branch connects to the turn signal flasher in the fuse block. Fuse 12, 10 amp, feeds circuit X12 which powers the radio.
HELPFUL INFORMATION Circuit A142 splices to supply voltage to the fuel injector, distributor ignition coil, and heated oxygen sensor. The A142 circuit also feeds circuit A141 which in turn feeds circuit A61. Circuit A61 supplies voltage to the fuel pump module. For information regarding fuel injector operation, refer to Group 14.
IGNITION COIL
When the Powertrain Control Module (PCM) grounds the Automatic Shut Down (ASD) relay and the contacts close, circuits A14 and A142 are connected. A 30 amp fuse, in cavity D of the PDC, protects the A14 and A142 circuits. Circuit A142 supplies battery voltage to the distributor ignition coil. The PCM controls the ground path for the ignition coil on circuit K19. Circuit K19 connects to cavity 19 of the PCM.
HELPFUL INFORMATION Circuit A142 splices to supply voltage to the fuel injector, distributor ignition coil, and heated oxygen sensor. The A142 circuit also feeds circuit A141 which feeds circuit A61. Circuit A61 supplies voltage to the fuel pump module.
BATTERY FEED
Circuit A14 from the Power Distribution Center (PDC) supplies battery voltage to cavity 3 of the Powertrain Control Module (PCM). A 30 amp fuse in the PDC, cavity D, protects circuit A14.
HELPFUL INFORMATION Circuit A14 supplies power to the contact side of the ASD relay.
FUEL INJECTOR
When the Powertrain Control Module (PCM) grounds the Automatic Shut Down (ASD) relay, the contacts close and connect circuits A14 and A142. A 30 amp fuse in cavity D of the PDC protects the A14 and A142 circuits.
FUEL LEVEL SENSOR The fuel level sensor is a variable resistor. Circuit G4 connects the fuel level sensor to the fuel gauge in the instrument cluster. Circuit F14 from the 15 amp fuse in cavity 14 of the fuse block supplies voltage to
8W - 30 - 3
HELPFUL INFORMATION Circuit A142 splices to supply voltage to the fuel injector, distributor ignition coil, and heated oxygen sensor. The A142 circuit also feeds circuit A141 which feeds circuit A61. Circuit A61 supplies voltage to the fuel pump module. Circuit K4 splices to supply ground for the signals from the following: Heated oxygen sensor Distributor Pick-up coil Throttle position sensor Manifold absolute pressure sensor Engine coolant temperature sensor Throttle body temperature sensor Circuit Z12 also supplies ground for the data link connector and the PCM. Circuit Z12 connects to cavities 11 and 12 of the PCM.
DISTRIBUTOR PICK-UP
The Powertrain Control Module (PCM) supplies 8 volts to the distributor pick-up coil on circuit K7. Circuit K7 connects to cavity 7 of the PCM. The PCM receives the engine speed signal from the distributor pick-up coil on circuit K24. Circuit K24 connects to cavity 24 of the PCM. The PCM provides a ground for the distributor pick-up coil (circuit K24) through circuit K4. Circuit K4 connects to cavity 4 of the PCM connector.
HELPFUL INFORMATION Circuit G7 splices to the speedometer, combination buzzer, and Daytime Running Lamps (DRL) module . Circuit K7 splices to supply 8 volts to the pick-up coil in the distributor. Circuit K4 splices to supply ground for the signals from the following: Heated oxygen sensor Distributor Pick-up coil Throttle position sensor Manifold absolute pressure sensor
HELPFUL INFORMATION Circuit K7 splices to supply 8 volts to the vehicle speed sensor. Circuit K4 splices to supply ground for the signals from the following: Heated oxygen sensor Distributor Pick-up coil Throttle position sensor Manifold absolute pressure sensor
8W - 30 - 4
Engine coolant temperature sensor Throttle body temperature sensor
HELPFUL INFORMATION Circuit K4 splices to supply ground for the signals from the following: Heated oxygen sensor Distributor Pick-up coil Throttle position sensor Manifold absolute pressure sensor Engine coolant temperature sensor Throttle body temperature sensor
HELPFUL INFORMATION Refer to Group 14 for MAP sensor operation. Circuit K6 splices to supply 5 volts to the throttle position sensor. Circuit K4 splices to supply ground for the signals from the following: Heated oxygen sensor Distributor Pick-up coil Throttle position sensor Manifold absolute pressure sensor Engine coolant temperature sensor Throttle body temperature sensor
HELPFUL INFORMATION Refer to Group 14 for throttle position sensor operation. Circuit K6 splices to supply 5 volts to the manifold absolute pressure sensor. Circuit K4 splices to supply ground for the signals from the following: Heated oxygen sensor Distributor Pick-up coil Throttle position sensor Manifold absolute pressure sensor Engine coolant temperature sensor Throttle body temperature sensor
HELPFUL INFORMATION Circuit K4 splices to supply ground for the signals from the following: Heated oxygen sensor Distributor Pick-up coil Throttle position sensor Manifold absolute pressure sensor Engine coolant temperature sensor Throttle body temperature sensor
EGR SOLENOID
The Powertrain Control Module (PCM) operates the Exhaust Gas Recirculation (EGR) solenoid by providing a ground path on circuit K35. Circuit K35 connects to PCM cavity 35. Circuit A21 supplies battery voltage to the EGR solenoid.
HELPFUL INFORMATION In the RUN or START position, the ignition switch connects circuit A1 from the fuse block and circuit A21. Circuit A1 connects to battery voltage and is protected by a 40 amp fuse in cavity C of the Power Distribution Center (PDC). Circuit A21 is double crimped at fuse 14 in fuse block. This circuit splices to supply battery voltage to
8W - 30 - 5
EVAP/PURGE SOLENOID
The Powertrain Control Module (PCM) operates the EVAP/purge solenoid by providing a ground path on circuit K52. Circuit K52 connects to PCM cavity 52. Circuit A21 supplies battery voltage to the EVAP/ Purge solenoid.
Internal to the PCM, the power (device) ground circuit connects to the PCM sensor return circuit (from circuit K4).
HELPFUL INFORMATION In the RUN or START position, the ignition switch connects circuit A1 from the fuse block and circuit A21. Circuit A1 connects to battery voltage and is protected by a 40 amp fuse in cavity C of the Power Distribution Center (PDC). Circuit A21 is double crimped at fuse 14 in fuse block. This circuit splices to supply battery voltage to the EVAP purge solenoid, EGR solenoid, generator field, data link connector and provides an input to the PCM.
HELPFUL INFORMATION The grounding point for circuit Z12 is the right rear of the cylinder head. Circuit Z12 also supplies a ground for the PCM high current drivers and the heated oxygen sensor. If the system loses ground for the ganged circuits at the right rear of the cylinder head, the vehicle will not operate. Check the connection at the gangedground circuit eyelet.
DIAGRAM INDEX
Component Page Automatic Shut-Down Relay . . . . . . . . .8W-30-14, 15, 16, 17 Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-13 Data Link Connector . . . . . . . . . . . . . . . . . . . . . .8W-30-15 Distributor . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-19 Distributor Ignition Coil . . . . . . . . . . . . . . . . . . . .8W-30-17 EGR Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-17 Engine Coolant Temperature Sensor . . . . . . . . . . . .8W-30-19 Engine Oil Pressure Sending Unit . . . . . . . . . . . . . .8W-30-17 EVAP/Purge Solenoid . . . . . . . . . . . . . . . . . . . . .8W-30-17 Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-14 Fuse 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-13 Fuse 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-13 Fuse 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-13 Fuse 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-12 Fuse 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-12 Fuse 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-12 Fuse 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-12 Fuse 14 . . . . . . . . . . . . . . . . . . . . . . . .8W-30-12, 16, 17 Fuse 15 . . . . . . . . . . . . . . . . . . . . . . . .8W-30-12, 16, 17 Fuse 16 . . . . . . . . . . . . . . . . . . . . . . . .8W-30-12, 16, 17 Fuse C . . . . . . . . . . . . . . . . . . . . . . .8W-30-12, 15, 16, 17 Fuse D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-16 Fuse E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-13 Heated Oxygen Sensor . . . . . . . . . . . . . . . . . . . .8W-30-15 Idle Air Control Motor . . . . . . . . . . . . . . . . . . . . .8W-30-18 Ignition Switch . . . . . . . . . . . . . . . . .8W-30-12, 13, 16, 17 MAP Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-19 Powertrain Control Module . . . .8W-30-14, 15, 16, 17, 18, 19 Throttle Body Temperature Sensor . . . . . . . . . . . . .8W-30-14 Throttle Position Sensor . . . . . . . . . . . . . . . . . . .8W-30-14 Vehicle Speed Sensor . . . . . . . . . . . . . . . . . . . . .8W-30-18
HELPFUL INFORMATION The grounding point for circuit Z12 is the right rear of the cylinder head. Circuit Z12 also supplies a ground for the PCM high current drivers and the heated oxygen sensor. If the system loses ground for the ganged circuits at the right rear of the cylinder head, the vehicle will not operate. Check the connection at the gangedground circuit eyelet.
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8W-30 FUEL/IGNITION3.9L AND 5.2L ENGINES FUEL/IGNITION3.9L AND 5.2L ENGINES INDEX
page page Idle Air Control (IAC) Motor . . . . . . . . . . . . . . . . . . . 8 Ignition Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Intake Air Temperature Sensor . . . . . . . . . . . . . . . 10 Manifold Absolute Pressure Sensor . . . . . . . . . . . . . 9 Overdrive Solenoid . . . . . . . . . . . . . . . . . . . . . . . . 10 Park/Neutral Position Switch . . . . . . . . . . . . . . . . . 10 Power (Device) Ground . . . . . . . . . . . . . . . . . . . . . 11 TCC Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Throttle Position Sensor . . . . . . . . . . . . . . . . . . . . . 9 Upshift Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Vehicle Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . 8 branch from the fuse block connection is spliced to the A/C compressor clutch relay, PCM, and the Daytime Running Lamps (DRL) module. At the fuse block, circuit A21 connects to a bus bar that feeds circuits F14, V34, and G5. Each circuit is protected by a separate fuse. Fuse 16, 5 amp, feeds circuit G5. The G5 circuit powers the combination buzzer, overdrive switch, transmission oil temperature lamp, and 4 x 4 lamp. Fuse 15, 2 amp, feeds circuit V34. Circuit V34 powers the vehicle speed control switch. Fuse 14, 15 amp, feeds circuit F14. Circuit F14 is double crimped at fuse 14. One branch of circuit F14 connects to the instrument cluster. The other branch, of circuit F14 connects to the ACM. In the ACCESSORY position, the ignition switch connects circuit A1 from the PDC with circuit A31. Circuit A31 connects to a bus bar in the fuse block that feeds circuits X22, V6, L5, and X12. Each circuit is protected by a separate fuse. Fuse 9, 15 amp, feeds circuit X22. Circuit X22 powers the cigar lighter. Fuse 10, 20 amp, feeds circuit V6. Circuit V6 powers the wiper system. Fuse 11, 20 amp, feeds circuit L5. Circuit L5 is double crimped at fuse 11. One branch of circuit L5 connects to the RWAL module (if equipped). The other L5 branch connects to the turn signal flasher in the fuse block. Fuse 12, 10 amp, feeds circuit X12 which powers the radio.
Automatic Shut Down (ASD) Relay . . . . . . . . . . . . . 6 Battery Feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Camshaft Position Sensor . . . . . . . . . . . . . . . . . . . . 8 Crankshaft Position Sensor . . . . . . . . . . . . . . . . . . . 9 Data Link Connector . . . . . . . . . . . . . . . . . . . . . . . 11 Diagram Index . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 EGR Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Engine Coolant Temperature Sensor . . . . . . . . . . . . 9 EVAP/Purge Solenoid . . . . . . . . . . . . . . . . . . . . . . 10 Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Fuel Pump Module . . . . . . . . . . . . . . . . . . . . . . . . . 7 Fuel Pump Relay . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Heated Oxygen Sensor . . . . . . . . . . . . . . . . . . . . . . 8
IGNITION SWITCH
When the ignition switch is in the RUN position, it connects circuit A2 from the Power Distribution Center (PDC) to circuit A22. A 50 amp fuse link in cavity E of the PDC protects the A2 and A22 circuits. Circuit A22 connects to a bus bar in the fuse block. The bus bar feeds circuits C1, F21, F20, and A20. Circuits C1, F20, and A20 are protected by separate fuses. A circuit breaker protects circuit F21. Fuse 1, 30 amp, protects circuit C1. Circuit C1 feeds the blower motor switch. A 30 amp circuit breaker in cavity 2 of the fuse block protects circuit F21. The F21 circuit feeds the power window switches. Fuse 3, 15 amp, protects circuit F20. The F20 circuit is double crimped at the fuse. One branch of circuit F20 feeds the Airbag Control Module (ACM). The other branch feeds the overhead console, Powertrain Control Module (PCM), and the back-up lamp switch or park/neutral switch, depending on transmission. Fuse 4, 5 amp, is only used on vehicles with ABS. The fuse protects circuit A20. Circuit A20 provides an input to the ABS control module and splices to the ABS power relay and the ABS warning lamp relay. In the START position, the ignition switch connects circuit A1 from the PDC to circuit A41. Circuit A41 connects to the coil side of the starter motor relay. If the vehicle is equipped with a manual transmission, circuit A41 connects to the clutch pedal position switch before reaching the starter motor relay. Also in the START position, the ignition switch provides ground for the brake lamp switch, parking brake lamp switch, and connects to the ABS module or Rear Wheel Anti-Lock (RWAL) module. In the START or RUN positions, the ignition switch connects circuit A1 from the PDC with circuit A21. Circuit A1 connects to fuse C in the PDC. The A21 circuit is double crimped at the fuse block. The
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HELPFUL INFORMATION Circuit A142 splices to supply voltage to the fuel injectors, ignition coil, and heated oxygen sensor. One of the splices in circuit A142 connects directly to injectors 1, 3, 5, 7 and also connects to a splice that feeds injectors 2, 4, 6, and 8. Refer to the diagrams. For information about fuel injector operation, refer to Group 14.
HELPFUL INFORMATION Along with supplying voltage to the ASD relay contacts, circuit A14 splices to supply voltage to the contact side of the fuel pump relay. Circuit A21 splices to supply battery voltage to the coil side of the ASD relay and fuel pump relay.
IGNITION COIL
When the Powertrain Control Module (PCM) grounds the Automatic Shut Down (ASD) relay and the contacts close, they connect circuits A14 and A142. A 30 amp fuse in cavity D of the Power Distribution Center (PDC) protects the A14 and A142 circuits. Circuit A142 supplies battery voltage to the ignition coil. The PCM controls the ground path for the ignition coil on circuit K19. Circuit K19 connects to cavity 19 of the PCM.
BATTERY FEED
Circuit A14 from the Power Distribution Center (PDC) supplies battery voltage to cavity 3 of the Powertrain Control Module (PCM). A 30 amp fuse in cavity D of the PDC protects circuit A14.
HELPFUL INFORMATION Circuit A14 supplies power to the contact sides of the Automatic Shut Down (ASD) relay and fuel pump relay.
HELPFUL INFORMATION Circuit A142 splices to supply voltage to the fuel injectors, ignition coil, and heated oxygen sensor.
FUEL INJECTORS
When the Automatic Shut Down (ASD) relay contacts close, they connect circuits A14 and A142. Circuit A142 supplies voltage to the fuel injectors. Each injector has a separate ground circuit controlled by the Powertrain Control Module (PCM). Circuit K11 provides ground for injector number one. The K11 circuit connects to cavity 11 of the PCM. Circuit K12 provides ground for injector number two. The K12 circuit connects to cavity 15 of the PCM. Circuit K13 provides ground for injector number three. The K13 circuit connects to cavity 14 of the PCM. Circuit K14 provides ground for injector number four. The K14 circuit connects to cavity 13 of the PCM. Circuit K15 provides ground for injector number five. The K15 circuit connects to cavity 38 of the PCM. Circuit K16 provides ground for injector number six. The K16 circuit connects to cavity 58 of the PCM. On the 5.2L engine, circuit K17 provides ground for injector number seven. The K17 circuit connects to cavity 17 of the PCM. Also on the 5.2L engine, circuit K18 provides ground for injector number eight. The K18 circuit connects to cavity 18 of the PCM.
HELPFUL INFORMATION Along with supplying voltage to the fuel pump relay contacts, circuit A14 splices to supply voltage to the contact side of the ASD relay. Circuit A21 splices to supply battery voltage to the coil sides of the ASD relay and fuel pump relay.
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HELPFUL INFORMATION Circuit A14 splices to supply voltage to the contact side of the Automatic Shut Down (ASD) relay. Circuit A142 connects to circuit A14 when the ASD relay contacts close.
FUEL LEVEL SENSOR The fuel level sensor is a variable resistor. Circuit G4 connects the fuel level sensor to the fuel gauge in the instrument cluster. Circuit F14 from fuse 14 in the fuse block supplies voltage to the fuel gauge. The fuel level sensor draws voltage from circuit F14 through the fuel gauge on circuit G4. Circuit G40 connects the fuel level sensor to the low fuel relay in the instrument cluster. For low fuel warning lamp operation, refer to group 8E. Circuit Z1 provides the ground path for the fuel level sensor. The grounding point for circuit Z1 is instrument panel left inner fender panel.
HELPFUL INFORMATION As current flows through the coils in the fuel gauge, it creates a magnetic field. The magnetic field controls the position of the fuel gauge pointer. The fuel level sensor contains a variable resistor. As the position of the float arm on the fuel level sensor changes, the resistor changes the current flow through the fuel gauge circuit. A change in current flow alters the magnetic field in the fuel gauge, which changes the pointer position.
HELPFUL INFORMATION Along with supplying voltage to the ASD relay contacts, circuit A14 splices to supply voltage to the contact side of the fuel pump relay. Circuit A142 splices to supply voltage to the fuel injectors, ignition coil, and heated oxygen sensor. Circuit K4 splices to supply ground for the signals from the following: Camshaft position sensor Crankshaft position sensor Intake air temperature sensor Throttle position sensor Manifold absolute pressure sensor Engine coolant temperature sensor Vehicle speed sensor Circuit Z1 also supplies ground for the 4WD switch, A/C compressor clutch, vehicle speed sensor, speed control, starter relay (manual transmission), and PCM.
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HELPFUL INFORMATION Circuit K7 splices to supply 8 volts to the crankshaft position sensor and the vehicle speed sensor. Circuit K4 splices to supply ground for the signals from the following: Heated oxygen sensor Crankshaft position sensor Intake air temperature sensor Throttle position sensor Manifold absolute pressure sensor Engine coolant temperature sensor Vehicle speed sensor
HELPFUL INFORMATION Circuit K4 splices to supply ground for the signals from the following: Heated oxygen sensor Camshaft position sensor Crankshaft position sensor Intake air temperature sensor Throttle position sensor Manifold absolute pressure sensor Vehicle speed sensor
HELPFUL INFORMATION Circuit K7 splices to supply 8 volts to the camshaft position sensor and the vehicle speed sensor. Circuit K4 splices to supply ground for the signals from the following: Heated oxygen sensor Camshaft position sensor Intake air temperature sensor Throttle position sensor Manifold absolute pressure sensor Engine coolant temperature sensor Vehicle speed sensor
HELPFUL INFORMATION Refer to Group 14 for throttle position sensor operation. Circuit K6 splices to supply 5 volts to the manifold absolute pressure sensor. Circuit K4 splices to supply ground for the signals from the following: Heated oxygen sensor Camshaft position sensor Crankshaft position sensor Intake air temperature sensor Manifold absolute pressure sensor Engine coolant temperature sensor Vehicle speed sensor
HELPFUL INFORMATION Refer to Group 14 for MAP sensor operation. Circuit K6 splices to supply 5 volts to the throttle position sensor. Circuit K4 splices to supply ground for the signals from the following: Heated oxygen sensor Camshaft position sensor Crankshaft position sensor Intake air temperature sensor
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Throttle position sensor Engine coolant temperature sensor Vehicle speed sensor
UPSHIFT LAMP
On vehicles equipped with a manual transmission, the Powertrain Control Module (PCM) provides a ground path for the instrument cluster upshift lamp on circuit K54. Circuit F14 provides battery voltage to the lamp.
OVERDRIVE SOLENOID
The overdrive solenoid and TCC solenoid are molded together. They are only used on automatic transmissions. The Powertrain Control Module (PCM) operates the overdrive solenoid by providing a ground path on circuit T60. Circuit T60 connects to PCM cavity 55. Circuit A21 supplies battery voltage to the overdrive solenoid.
HELPFUL INFORMATION Circuit K4 splices to supply ground for the signals from the following: Heated oxygen sensor Camshaft position sensor Crankshaft position sensor Throttle position sensor Manifold absolute pressure sensor Engine coolant temperature sensor Vehicle speed sensor
HELPFUL INFORMATION In the START or RUN position, the ignition switch connects circuit A1 from the fuse block and circuit A21. Circuit A1 connects to battery voltage and is protected by a 40 amp fuse in cavity C of the Power Distribution Center (PDC). Circuit A21 is double crimped at fuse 14 in fuse block. The A21 branch from fuse 14 splices to supply battery voltage to the EVAP/Purge solenoid, EGR solenoid, TCC solenoid, overdrive solenoid, data link connector and provides an input to the PCM.
EGR SOLENOID
The Powertrain Control Module (PCM) operates the Exhaust Gas Recirculation (EGR) solenoid by providing a ground path on circuit K35. Circuit K35 connects to PCM cavity 35. Circuit A21 supplies battery voltage to the EGR solenoid.
HELPFUL INFORMATION In the START position, the ignition switch connects circuit A1 from the Power Distribution Center (PDC) to circuit A41. A 40 amp fuse in cavity C of the PDC protects circuits A1 and A41.
TCC SOLENOID
The TCC solenoid and overdrive solenoid are molded together. They are only used on automatic transmissions. The Powertrain Control Module (PCM) operates the TCC solenoid by providing a ground path on circuit K54. Circuit K54 connects to PCM cavity 54. Circuit A21 supplies battery voltage to the TCC solenoid.
HELPFUL INFORMATION In the START or RUN position, the ignition switch connects circuit A1 from the fuse block and circuit A21. Circuit A1 connects to battery voltage and is protected by a 40 amp fuse in cavity C of the Power Distribution Center (PDC). Circuit A21 is double crimped at fuse 14 in fuse block. The A21 branch from fuse 14 splices to supply battery voltage to the EVAP/Purge solenoid, EGR solenoid, TCC solenoid, overdrive solenoid, data link connector and provides an input to the PCM.
HELPFUL INFORMATION In the START or RUN position, the ignition switch connects circuit A1 from the fuse block and circuit
EVAP/PURGE SOLENOID
The Powertrain Control Module (PCM) operates the EVAP/Purge solenoid by providing a ground path
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HELPFUL INFORMATION In the START or RUN position, the ignition switch connects circuit A1 from the fuse block and circuit A21. Circuit A1 connects to battery voltage and is protected by a 40 amp fuse in cavity C of the Power Distribution Center (PDC). Circuit A21 is double crimped at fuse 14 in fuse block. The A21 branch from fuse 14 splices to supply battery voltage to the EVAP/Purge solenoid, EGR solenoid, TCC solenoid, overdrive solenoid, data link connector and provides an input to the PCM.
HELPFUL INFORMATION The grounding point for circuit Z12 is the rear of the right cylinder head. Circuit Z12 also supplies a ground for the PCM high current drivers and the heated oxygen sensor. If the system loses ground for the Z12 circuits at the right rear of the cylinder head, the vehicle will not operate. Check the connection at the gangedground circuit eyelet.
DIAGRAM INDEX
Component Page Automatic Shut Down Relay . . . . . . . . . . . . . . . . .8W-30-22 Camshaft Position Sensor . . . . . . . . . . . . . . . . . .8W-30-25 Crankshaft Position Sensor . . . . . . . . . . . . . . . . .8W-30-24 Data Link Connector . . . . . . . . . . . . . . . . . . . . . .8W-30-23 Distributor Ignition Coil . . . . . . . . . . . . . . . . . . . .8W-30-21 Engine Coolant Temperature Sensor . . . . . . . . . . . .8W-30-25 EVAP/Purge Solenoid . . . . . . . . . . . . . . . . . . . . .8W-30-23 Exhaust Gas Recirculation Solenoid . . . . . . . . . . . .8W-30-23 Fuel Injector #1 . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-20 Fuel Injector #2 . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-21 Fuel Injector #3 . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-20 Fuel Injector #4 . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-21 Fuel Injector #5 . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-20 Fuel Injector #6 . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-21 Fuel Injector #7 . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-20 Fuel Injector #8 . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-21 Fuel Pump Relay . . . . . . . . . . . . . . . . . . . . .8W-30-22, 27 Fuel Tank Gauge Level Sending Unit . . . . . . . . . . .8W-30-27 Fuse 14 . . . . . . . . . . . . . . . . . . . . . . . .8W-30-22, 23, 27 Fuse 15 . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-22, 27 Fuse 16 . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-22, 27 Fuse C . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-22, 27 Fuse D . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-22, 27 Heated Oxygen Sensor . . . . . . . . . . . . . . . . . . . .8W-30-24 Idle Air Control Motor . . . . . . . . . . . . . . . . . . . . .8W-30-20 Ignition Switch . . . . . . . . . . . . . . . . . . . . . . .8W-30-22, 27 Intake Air Temperature Sensor . . . . . . . . . . . . . . .8W-30-25 MAP Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-30-26 Powertrain Control Module . . . . . . . . . . . .8W-30-20, 21, 22, 23, 24, 25, 26, 27 Throttle Position Sensor . . . . . . . . . . . . . . . . . . .8W-30-24 Vehicle Speed Sensor . . . . . . . . . . . . . . . . . . . . .8W-30-26
HELPFUL INFORMATION The grounding point for circuit Z12 is the rear of the right cylinder head. Circuit Z12 also supplies a ground for the PCM high current drivers. If the system loses ground for the Z12 circuits at the rear of the right cylinder head, the vehicle will not operate. Check the connection at the gangedground circuit eyelet.
1995 AN Dakota Publication No. 81-370-5110 TSB 08-55-94 October 14, 1994
1995 AN Dakota Publication No. 81-370-5110 TSB 08-55-94 October 14, 1994
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TRANSMISSION CONTROLS
OVERDRIVE SWITCH
Automatic transmission equipped vehicles may have an overdrive switch. The operator disables or enables overdrive when the switch is depressed. The overdrive switch consists of a switch connected to the Powertrain Control Module (PCM), an illumination lamp and an overdrive ON/OFF indicator lamp. If overdrive is currently enabled, it is disabled when the operator depresses the overdrive switch. Conversely, if the operator already disabled overdrive, it is enabled when the switch is depressed. Circuit T6 from the overdrive switch connects to cavity 10 of the PCM and provides the overdrive signal. Circuit Z1 provides ground for the switch. The grounding point for circuit Z1 is the instrument panel left support. The PCM turns the overdrive ON/OFF indicator lamp ON or OFF by providing a ground for the lamp on circuit T61. Power for the lamp is supplied by circuit G5 from fuse 16 in the fuse block. When the headlamps or parking lamps are ON, circuit E2 from fuse 13 in the fuse block powers the illumination lamp in the overdrive switch. Circuit E1 from the headlamp switch feeds fuse 13. Circuit Z1 provides ground for the illumination lamp in the overdrive switch. The grounding point for circuit Z1 is the instrument panel left support.
UPSHIFT LAMP
On vehicles equipped with a manual transmission, the Powertrain Control Module (PCM) provides a ground path for the instrument cluster upshift lamp on circuit K54. Circuit F14 provides battery voltage to the lamp.
OVERDRIVE SOLENOID
The overdrive solenoid and TCC solenoid are molded together. They are only used on automatic transmissions. The Powertrain Control Module (PCM) operates the overdrive solenoid by providing a ground path on circuit T60. Circuit T60 connects to PCM cavity 55. Circuit A21 supplies battery voltage to the overdrive solenoid.
HELPFUL INFORMATION In the START or RUN position, the ignition switch connects circuit A1 from the Power Distribution Center (PDC) and circuit A21. Circuit A1 connects to battery voltage and is protected by a 40 amp fuse in cavity C of the PDC. Circuit A21 is double crimped at fuse 14 in fuse block. The A21 branch from fuse 14 splices to supply battery voltage to the EVAP/Purge solenoid, EGR solenoid, TCC solenoid, overdrive solenoid, data link connector and provides an input to the PCM.
TCC SOLENOID
The TCC solenoid and overdrive solenoid are molded together. They are only used on automatic transmissions. The Powertrain Control Module (PCM) operates the TCC solenoid by providing a ground path on circuit K54. Circuit K54 connects to PCM cavity 54. Circuit A21 supplies battery voltage to the TCC solenoid.
DIAGRAM INDEX
Component Page 4WD Indicator Lamp . . . . . . . . . . . . . . . . . . . . . .8W-31-2 4WD Indicator Switch . . . . . . . . . . . . . . . . . . . . . .8W-31-2 Fuse 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-31-3 Fuse 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-31-2, 3 Fuse C . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-31-2, 3 Headlamp Switch . . . . . . . . . . . . . . . . . . . . . . . . .8W-31-3 Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . .8W-31-2, 3 Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . .8W-31-3 Overdrive Solenoid . . . . . . . . . . . . . . . . . . . . . . . .8W-31-3 Powertrain Control Module . . . . . . . . . . . . . . . . . .8W-31-3 TCC Solenoid . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-31-3 Transmission Oil Temperature Lamp . . . . . . . . . . . .8W-31-2 Transmission Oil Temperature Sensor . . . . . . . . . . . .8W-31-2 Transmission Overdrive Switch . . . . . . . . . . . . . . . .8W-31-3
HELPFUL INFORMATION In the START or RUN position, the ignition switch connects circuit A1 from the Power Distribution Center (PDC) and circuit A21. Circuit A1 connects to battery voltage and is protected by a 40 amp fuse in cavity C of the PDC. Circuit A21 is double crimped at fuse 14 in fuse block. The A21 branch from fuse 14 splices to supply battery voltage to the EVAP/Purge solenoid, EGR solenoid, TCC solenoid, overdrive solenoid, data link connector and provides an input to the PCM.
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ANTI-LOCK BRAKES
CONTENTS
page page
... 3
(RWAL) system. When referring to the circuit descriptions or wiring diagrams, ensure that you use the ones for the appropriate system.
GENERAL INFORMATION
Four fuses supply power for the Anti-Lock Brake System (ABS); fuses A, F and E in the Power Distribution Center (PDC) and fuse 4 in the fuse block. Fuses A, F and E in the PDC are connected directly to battery voltage and are HOT all times. Fuse 4 is HOT when the ignition switch is the RUN position. In the RUN position, the ignition switch connects circuit A2 from a 20 amp fuse in cavity E of the PDC with circuit A22. Circuit A22 connects to a bus bar in the fuse block. The bus bar feeds circuit A20 through fuse 4. Fuse 4 is a 5 amp fuse. Circuit A20 is double crimped at the coil side of the ABS warning lamp relay. The A20 circuit from the ABS warning lamp relay splices to supply voltage to pins 7 and 12 of the ABS control module and the coil side of the ABS power relay. Circuits Z7 and Z8 provide ground for the ABS control module. Both grounds terminate on the left fender side shield. Circuit Z7 connects to cavity 20 of the 37-way ABS control module connector. Circuit Z8 connects to cavity 1 of the two-way connector.
rear wheels and individual sensors for the front wheels. The single sensor used for the rear wheels mounts on the top of the rear axle differential housing. Each sensor converts wheel speed into an electrical signal that it transmits to the ABS control module. A pair of twisted wires connect to each sensor and provide signals to the ABS control module. Circuits B6 and B7 provide signals to ABS control module from right front wheel speed sensor. Circuit B6 which provides the LOW signal, connects to cavity 15 of the ABS control module. Circuit B7 connects to cavity 2 of the module and provides the HIGH signal. Circuits B8 and B9 provide signals to ABS control module from left front wheel speed sensor. Circuit B8 which provides the LOW signal, connects to cavity 16 of the ABS control module. Circuit B9 connects to cavity 3 of the module and provides the HIGH signal. Circuit B114 connects to cavity 14 of the ABS control module and to circuit B2 of the rear wheel speed sensor at the sensor connector. Circuit B113 connects to cavity 1 of the ABS control module and to circuit B1 at the rear wheel speed sensor connector. Circuit B114 provide the rear wheel speed sensor HIGH input while circuit B113 provides the LOW input.
When the ABS control module grounds the ABS power relay on circuit B116, the relay contacts close connecting circuit A10 from the Power Distribution Center (PDC) and circuit B120. Circuit A10 connects to fuse A in the PDC. Circuit A20 from the fuse 4 in the fuse block splices to feed the coil side of the ABS power relay. From the ABS power relay, circuit B120 splices to supply voltage to the ABS pump motor and all solenoids in the front brake anti-lock valve. Circuit B120 also supplies power to the solenoids in the rear antilock valve. Additionally, circuit B120 provides an input to cavity 34 of the ABS module. The input tells the module that voltage has been supplied to the pump motor.
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module connect to the data link connector. Circuit D12 connects to cavity 10 of the ABS control module. The ABS control module transmits data to the DRB scan tool on circuit D12. The DRB scan tool receives data from the ABS control module on circuit D11. Circuit D11 connects to cavity 11 of the ABS control module. Circuit A14 from fuse F in the Power Distribution Center (PDC) splices to circuit M1. Circuit M1 supplies battery voltage to pin 2 of the ABS data link connector. Ground circuit Z11 connects to pin 8 of the ABS data link connector. The grounding point for circuit Z11 is the instrument panel left support.
DIAGRAM INDEX
Component Page ABS Control Module . . . . . . . . . . . . . . . . .8W-32-5, 6, 7, 8 ABS Front Hydraulic Valve . . . . . . . . . . . . . . . . . . .8W-32-6 ABS Power Relay . . . . . . . . . . . . . . . . . . . . . . . .8W-32-5 ABS Rear Hydraulic Valve . . . . . . . . . . . . . . . . . . .8W-32-6 ABS Rear Wheel Sensor . . . . . . . . . . . . . . . . . . . .8W-32-7 ABS Warning Lamp Relay . . . . . . . . . . . . . . . . . . .8W-32-5 Brake Warning Lamp Switch . . . . . . . . . . . . . . . . .8W-32-7 Data Link Connector . . . . . . . . . . . . . . . . . . . . . .8W-32-8 Fuse A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-32-5 Fuse E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-32-5 Fuse F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-32-8 Fuse F2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-32-8 4-WD Switch . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-32-7 Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . .8W-32-5, 7 Left Front Wheel Sensor . . . . . . . . . . . . . . . . . . . .8W-32-8 Right Front Wheel Sensor . . . . . . . . . . . . . . . . . . .8W-32-8 Stop Lamp Switch . . . . . . . . . . . . . . . . . . . . . . . .8W-32-8
GENERAL INFORMATION
Four fuses supply power for the Rear Wheel AntiLock (RWAL) Brake System. They are fuses C, and G in the Power Distribution Center (PDC) and fuses 7 and 11 in the fuse block. Fuses C and G in the PDC are connected directly to battery voltage and are HOT all times. Fuse 11 in the fuse block is HOT when the ignition switch is the RUN Position. In the RUN position, the ignition switch connects circuit A1 from a 40 amp fuse in cavity C of the PDC with circuit A31. Circuit A31 connects to a bus bar in the fuse block. The bus bar feeds circuit L5 through fuse 11. Fuse 11 is a 20 amp fuse. Circuit L5 is double crimped at fuse 11 and connects to cavity 3 of the RWAL control module. The L5 input tells the RWAL module when the vehicle is running. The other wire connects to the turn signal flasher. Circuit F32 provides battery voltage to the RWAL module at cavity 9. Circuit F32 is HOT at all times. Fuse 7 in the fuse block protects circuit F32. Circuit
A3 from the PDC feeds the fuse block bus bar that powers fuse 7 and circuit F32. Fuse G in the PDC protects circuit A3. Circuit Z2 provides ground for the RWAL control module. The Z2 circle terminates at the instrument panel left support. If the vehicle has intermittent wipers, circuit Z2 also provides ground for the intermittent wiper module.
The rear anti-lock valve contains an isolation solenoid, a dump solenoid and a reset switch. Each is powered by the Rear Wheel Anti-Lock (RWAL) module on separate circuits. Circuit B108 from cavity 8 of the RWAL module feeds the dump solenoid. The isolation solenoid is powered on circuit B101 from cavity 1 of the RWAL module. Circuit Z9 provides ground for both solenoids. Circuit Z9 terminates in the engine compartment at the left fender side shield. Circuit B111 from cavity 11 of the RWAL module connects to the reset switch. The case grounded rear anti-lock valve provides ground for the reset switch.
WARNING LAMP
The Rear Wheel Anti-Lock (RWAL) module provides ground for the instrument cluster Check AntiLock warning lamp on circuit B102. Circuit F14 provides voltage to the instrument cluster to feed the warning lamp.
1995 AN Dakota Publication No. 81-370-5110 TSB 08-55-94 October 14, 1994
8W - 33 - 1
HELPFUL INFORMATION The grounding point for circuit Z1 (speed control servo ground) is left fender side shield. The grounding point for circuit Z1 from the stop lamp switch is the instrument panel right lower reinforcement support. Circuit V40 also connects to the ABS control module on vehicles with all wheel anti-lock brakes. Circuit V40 also connects to the RWAL control module on vehicles with rear wheel anti-lock brakes.
DIAGRAM INDEX
Component Page ABS Control Module . . . . . . . . . . . . . . . . . . . . . .8W-33-3 Fuse 15 Fuse C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-33-2 Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . .8W-33-2 Powertrain Control Module . . . . . . . . . . . . . . . . .8W-33-2, 3 RWAL Control Module . . . . . . . . . . . . . . . . . . . . .8W-33-3 Stop Lamp Switch . . . . . . . . . . . . . . . . . . . . . . . .8W-33-3 Vehicle Speed Control Servo . . . . . . . . . . . . . . . . .8W-33-2 Vehicle Speed Control Switch . . . . . . . . . . . . . . . . .8W-33-2
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INSTRUMENT CLUSTER
INDEX
page Diagram Index ............................ 3 Instrument Cluster page ......................... 3
INSTRUMENT CLUSTER
The instrument cluster contains the gauges and warning lamps. All gauges have magnetic movements. When the ignition switch is in the START or RUN position, circuit A21 feeds circuit F14 through a bus bar in the fuse block and fuse 14. Circuit A1 from fuse C in the Power Distribution Center (PDC) supplies voltage to circuit A21. Circuit A21 is HOT at all times. Circuit F14 connects to cavity D of the left cluster connector. Circuit F14 provides battery voltage for the warning lamps (except seat belt indicator lamp), transmission up shift lamp, and all gauges. Circuit E2 from fuse 13 in the fuse block feeds the illumination lamps. Circuit E1 from the headlamp switch powers fuse 13 when the parking lamps or headlamp are ON. Circuit Z1 provides ground for illumination and indicator lamps. The grounding point for circuit Z1 is the instrument panel lower right reinforcement support.
flow alters the magnetic field in the fuel gauge, which changes the pointer position. Circuit Z1 provides the ground path for the fuel level sensor. The grounding point for circuit Z1 is instrument panel lower right reinforcement support.
LOW FUEL WARNING LAMP Circuit G40 connects the fuel level sensor to the low fuel relay in the instrument cluster. When the fuel level in the fuel tank reaches a calibrated level, the low fuel warning lamp relay illuminates the lamp. OIL PRESSURE GAUGE The case grounded oil pressure sensor is a variable resistor that connects to circuits G60 and G6. Circuit G60 connects to the oil pressure gauge. Circuit G6 connects to the oil pressure warning lamp. Circuit F14 connects to the instrument cluster at the left connector and supplies battery voltage to oil pressure gauge. The gauge uses two coils. Current passing through the coils creates a magnetic field. Position of the gauge needle is controlled by the amount of current passing through the coils to ground at the sensor. OIL PRESSURE WARNING LAMP The case grounded oil pressure sensor is a variable resistor that connects to circuits G60 and G6. Circuit G60 connects to the oil pressure gauge. Circuit G6 connects to the oil pressure warning lamp. Circuit F14 connects to the instrument cluster at the left connector and supplies battery voltage to oil pressure lamp. TACHOMETER Tachometers are available on vehicles equipped with 3.9L and 5.2L engines only. The tachometer module in the instrument cluster operates the tachometer. The Powertrain Control Module (PCM) signals the tachometer module on circuit G21. The PCM provides engine speed information to the tachometer module. Circuit X1 from the horn relay provides voltage for the tachometer module. Circuit F14 also supplies voltage to the tachometer module.
ENGINE COOLANT TEMPERATURE GAUGE Circuit G20 connects the engine coolant temperature gauge to the engine coolant temperature sensor. The sensor is a variable resistor and case grounded to the engine. Circuit F14 connects to the instrument cluster left connector and supplies voltage for the gauge. The gauge uses two coils. Current passing through the coils creates a magnetic field. Position of the gauge needle is controlled by the amount of current passing through the coils to ground at the sensor. FUEL GAUGE Circuit G4 connects the fuel level sensor to the fuel gauge in the instrument cluster. Circuit F14 from fuse 14 in the fuse block supplies voltage to the fuel gauge. The fuel level sensor draws voltage from circuit F14 through the fuel gauge on circuit G4. As current flows through the coils in the fuel gauge, it creates a magnetic field. The magnetic field controls the position of the fuel gauge pointer. The fuel level sensor contains a variable resistor. As the position of the float arm on the fuel level sensor changes, the resistor changes the current flow through the fuel gauge circuit. A change in current
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Circuit Z1 provides ground for the tachometer module. The grounding point for circuit Z1 is the instrument cluster lower right reinforcement support.
SPEEDOMETER The speedometer and odometer receive a signal from the vehicle speed sensor on circuit G7. Circuit G7 connects to the Powertrain Control Module (PCM). ABS WARNING LAMP
ALL-WHEEL ANTI-LOCK BRAKES The ABS module controls the ABS warning lamp through the ABS warning lamp relay. When the ABS module grounds the warning lamp relay on circuit B47, the relay contacts close and complete the ground path for the ABS warning lamp. Circuit B47 connects to pin 13 of the ABS module and the coil side of the relay. Circuit A20 from fuse 4 in the fuse block supplies power to the coil side of the relay. Circuit G19 from the ABS warning lamp in the instrument cluster is double crimped at the contact side of the ABS warning lamp relay. Power for the bulb is supplied by circuit F14. REAR WHEEL ANTI-LOCK (RWAL) BRAKES The RWAL module provides ground for the instrument cluster Check Anti-Lock warning lamp on circuit B102. Circuit F14 provides voltage to the instrument cluster to feed the warning lamp.
MALFUNCTION INDICATOR LAMP (MIL) The Powertrain Control Module (PCM) provides ground for the MIL on circuit G3. Circuit G3 connects to cavity 32 of the PCM. For information regarding diagnostic trouble code access using the MIL, refer to Group 14, Fuel Systems. LOW WASHER FLUID Circuit G29 connects the low washer fluid switch to the warning lamp in the instrument cluster. Circuit F14 supplies battery voltage to the lamp. When the low washer fluid switch closes, it connects circuits G29 and Z1. Circuit Z1 provides a ground path, illuminating the warning lamp. Circuit Z1 also provides ground for the windshield washer pump motor. The grounding point for circuit Z1 is the left fender side shield. SEAT BELT INDICATOR WARNING LAMP The seat belt indicator warning lamp is activated by the combination buzzer on circuit G13. Circuit G13 supplies power to instrument cluster for the lamp. Circuit Z1 provides ground for the lamp. The Z1 circuit terminates a the instrument panel right lower reinforcement support.
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8W - 41 - 1
HORN/CIGAR LIGHTER
HORN
The horn system uses two switches and a horn relay. The horn switches are in the steering wheel along with the speed control switches (if equipped). Circuit A3 from fuse G in the Power Distribution Center (PDC) feeds a fuse block bus bar that powers circuit X1 through fuse 6. Circuit X1 is HOT at all times and powers the coil and contact sides of the horn relay. When the horn switch is depressed, circuit X3 provides ground for the coil side of the relay and the contacts close. When the contacts close, circuit X2 supplies voltage to the horn.
HELPFUL INFORMATION In the ACCESSORY or RUN position,the ignition switch connects circuit A1 from Power Distribution Center (PDC) with circuit A31. Circuit A1 is protected by fuse C. Circuit Z1 terminates at the instrument panel lower right reinforcement support.
DIAGRAM INDEX
Component Cigar Lighter . Fuse 6 . . . . . Fuse 9 Fuse C . . . . . Fuse G . . . . . Horn . . . . . . . Horn Relay . . . Horn Switches Ignition Switch Page . . . . . . . . . . . . . . . . . . . . . . . . . .8W-41-2 . . . . . . . . . . . . . . . . . . . . . . . . . .8W-41-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-41-2 .8W-41-2 .8W-41-2 .8W-41-2 .8W-41-2 .8W-41-2
HELPFUL INFORMATION The horn switch is grounded to the steering wheel. Circuit X1 is double crimped at the horn relay. The circuit connects to the instrument cluster and supplies power to the tachometer module (if equipped).
CIGAR LIGHTER
In the ACCESSORY or RUN position, the ignition switch supplies voltage to fuse 9 in the fuse block on circuit A31. Fuse 9 feeds circuit X22 which connects to the cigar lighter. When the lighter is depressed, the contacts inside of the lighter element close and voltage flows to ground on circuit Z1.
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AIR CONDITIONING/HEATER
CONTENTS
page page
GENERAL INFORMATION
Several fuses supply power for the air conditioning/ heater system. Fuse B from the Power Distribution Center (PDC) supplies battery voltage on circuit C26 to the contact sides of the A/C compressor clutch relay and radiator fan relay. Circuit C26 is HOT at all times. In the START or RUN positions, the ignition switch connects circuit A1 from fuse C in the PDC to circuit A21. Circuit A21 feeds the coil side of the radiator fan relay and fuse 16 in the fuse block. In the RUN position only, the ignition switch connects circuit A2 from fuse E in the PDC to circuit A22. Circuit A22 supplies voltage to a bus bar in the fuse block. Fuse 1 connects to bus bar and protects circuit C1 which feeds the blower motor. Circuit E2 from fuse 13 in the fuse block powers the illumination lamps in the A/C heater control switch.
BLOWER MOTOR
When the ignition switch is in the RUN position, circuit A2 from fuse E in the Power Distribution Center (PDC) connects with circuit A22. Circuit A22 supplies voltage to a bus bar in the fuse block that
powers fuse 1. Fuse 1 protects circuit C1 which supplies battery voltage to the blower motor. The ground path for the blower motor is through circuit H6 to the blower motor resistor block and then through the fan switch in the A/C heater controls to circuit Z1. The blower motor resistor block consists of four resistors connected in series. Ground circuit Z1, which is the ground circuit, terminates at the instrument panel lower right reinforcement. Each resistor in the blower motor resistor block is spliced to the fan switch on separate circuits; C4, C5, C6, and C7. Depending on fan switch position, voltage passes through one or more resistors to ground. Blower motor fan speed is controlled by the number of resistors voltage passes through to ground. When the fan switch is in the LOW position, circuit C4 provides the ground path. In the M1 position, circuit C5 provides ground. In the M2 position, the ground path is through circuit C6. Circuit C7 provides path for ground when the switch is in the HIGH position.
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ertrain Control Module (PCM) receives an A/C request signal on circuit C20. Circuit C20 connects to cavity 27 of the PCM. After receiving the A/C request signal, the PCM supplies ground for the radiator fan relay and the A/C clutch relay. The coil side of the A/C clutch relay is powered from contact side of the radiator fan relay. The PCM supplies ground for the coil side of the radiator fan relay on circuit C27. Circuit C27 connects to cavity 31 of the PCM. Circuit A21 from fuse 16 in the fuse block supplies battery voltage to the coil side of the radiator fan relay. Circuit C26 from fuse B in the Power Distribution Center (PDC) supplies voltage to the contact side of the relay. When the PCM grounds the radiator fan relay, the contacts close and connect circuits C26 and C25. Circuit C25 supplies power to the radiator fan motor and the coil side of the A/C compressor clutch relay. The PCM controls ground for the A/C clutch relay on circuit C13. Circuit C13 connects to cavity 34 of the PCM and splices to circuit C12. Circuit C12 connects to the coil side of the relay. Circuit C12 has an in-line diode. Circuit C26 provides voltage to the contact side of the relay. When the relay contacts close, circuit C26 connects to circuit C3. Circuit C3 feeds the A/C compressor clutch. Ground for the compressor clutch is provided on circuit Z1 which terminates on the engine at left rear of the cylinder head. The A/C compressor clutch connector has a built-in diode. The diode controls the induced voltage that results from the magnetic field collapsing when the clutch disengages. The diode provides a current path to protect other components and systems.
HELPFUL INFORMATION Circuit C26 also powers the coil side of the A/C compressor clutch relay.
DIAGRAM INDEX
Component Page A/C Compressor Clutch . . . . . . . . . . . . . . . . . . . . .8W-42-4 A/C Compressor Clutch Relay . . . . . . . . . . . . . . . .8W-42-4 A/C High Pressure Switch . . . . . . . . . . . . . . . . . . .8W-42-6 A/C Low Pressure Switch . . . . . . . . . . . . . . . . . . .8W-42-6 Blower Motor . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-4 Blower Motor Resistor . . . . . . . . . . . . . . . . . . . . .8W-42-6 Diode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-4 Fuse 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-4 Fuse 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-6 Fuse 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-6 Fuse 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-5 Fuse B . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-4, 5 Fuse C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-5 Fuse E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-4 Fuse G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-6 Headlamp Switch . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-6 HVAC Switch . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-6 Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . .8W-42-4, 5 Powertrain Control Module . . . . . . . . . . . . . . .8W-42-4, 5, 6 Radiator Fan Control Relay . . . . . . . . . . . . . . . . . .8W-42-5 Radiator Fan Motor . . . . . . . . . . . . . . . . . . . . . . .8W-42-5
HELPFUL INFORMATION Circuit C21 from the A/C heater control switch connects to the low pressure switch. Circuit C22 from the low pressure switch connects to the high pressure switch. Circuit C20 connects to the high pressure switch and the PCM.
8W-42 AIR CONDITIONING/HEATER3.9L AND 5.2L ENGINES AIR CONDITIONING/HEATER3.9 AND 5.2L ENGINES GENERAL INFORMATION
Several fuses supply power for the air conditioning/ heater system. Fuse B from the Power Distribution Center (PDC) supplies battery voltage on circuit C26 to the contact side of the A/C compressor clutch relay. Circuit C26 is HOT at all times. In the START or RUN positions, the ignition switch connects circuit A1 from fuse C in the PDC to circuit A21. Circuit A21 feeds the coil side of the A/C compressor clutch relay. In the RUN position only, the ignition switch connects circuit A2 from fuse E in the PDC to circuit A22. Circuit A22 supplies voltage to a bus bar in the fuse block. Fuse 1 connects to the bus bar and protects circuit C1 which feeds the blower motor. Circuit E2 from fuse 13 in the fuse block powers the illumination lamps in the A/C heater control switch.
8W - 42 - 3
After receiving the A/C request signal, the PCM supplies ground for the coil side of the A/C clutch relay on circuit C13. Circuit C13 connects to cavity 34 of the PCM. Circuit A21 supplies battery voltage to the coil side of the relay. Circuit C26 from fuse B in the Power Distribution Center (PDC) supplies voltage to the contact side of the relay. When the PCM grounds the A/C compressor clutch relay, the contacts close and connect circuits C26 and C3. Circuit C3 supplies voltage to the A/C compressor clutch. Ground for the compressor clutch is provided on circuit Z1 which terminates at the left fender side shield. The A/C compressor clutch connector has a built-in diode. The diode controls the induced voltage that results from the magnetic field collapsing when the clutch disengages. The diode provides a current path to protect other components and systems.
BLOWER MOTOR
When the ignition switch is in the RUN position, circuit A2 from fuse E in the Power Distribution Center (PDC) connects with circuit A22. Circuit A22 supplies voltage to a bus bar in the fuse block that supplies powers fuse 1. Fuse 1 protects circuit C1 which supplies battery voltage to the blower motor. The ground path for the blower motor is through circuit H6 to the blower motor resistor block and then through the fan switch in the A/C heater controls to circuit Z1. The blower motor resistor block consists of four resistors connected in series. Ground circuit Z1 terminates at the instrument panel lower right reinforcement. Each resistor in blower motor resistor block is spliced to the fan switch on separate circuits; C4, C5, C6, and C7. Depending on fan switch position, voltage passes through one or more resistors to ground. Blower motor fan speed is controlled by the number of resistors voltage passes through to ground. When the fan switch is in the LOW position, circuit C4 provides the ground path. In the M1 position, circuit C5 provides ground. In the M2 position, the ground path is through circuit C6. Circuit C7 provides path for ground when the switch is in the HIGH position.
HELPFUL INFORMATION Circuit C21 from the A/C heater control switch connects to the low pressure switch. Circuit C22 from the low pressure switch connects to the high pressure switch. Circuit C20 connects to the high pressure switch and the PCM. Circuit A21 splices to circuit A0 which connects to contact side of the starter motor relay.
DIAGRAM INDEX
Component Page A/C Compressor Clutch . . . . . . . . . . . . . . . . . . . . .8W-42-7 A/C Compressor Clutch Relay . . . . . . . . . . . . . . . .8W-42-7 A/C High Pressure Switch . . . . . . . . . . . . . . . . . . .8W-42-8 A/C Low Pressure Switch . . . . . . . . . . . . . . . . . . .8W-42-8 Blower Motor . . . . . . . . . . . . . . . . . . . . . . . .8W-42-7, 10 Blower Motor Resistor . . . . . . . . . . . . . . . . . .8W-42-8, 10 Fuse 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-7, 10 Fuse 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-8, 10 Fuse 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-8, 10 Fuse 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-7, 9 Fuse B . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-7, 9 Fuse C . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-7, 9 Fuse E . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-7, 10 Fuse G . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-8, 10 Headlamp Switch . . . . . . . . . . . . . . . . . . . . . .8W-42-8, 10 HVAC Switch . . . . . . . . . . . . . . . . . . . . . . . . .8W-42-8, 10 Ignition Switch . . . . . . . . . . . . . . . . . . . . . .8W-42-7, 9, 10 Powertrain Control Module . . . . . . . . . . . . . . .8W-42-7, 8, 9 Radiator Fan Motor . . . . . . . . . . . . . . . . . . . . . . .8W-42-9 Radiator Fan Relay . . . . . . . . . . . . . . . . . . . . . . .8W-42-9
8W - 43 - 1
AIRBAG SYSTEM
AIRBAG CONTROL MODULE (ACM)
Two circuits provide battery voltage to the Airbag Control Module (ACM); F14 and F20. Circuits F14 and F20 are connected to separate bus bars in the fuse block. Different circuits from the Power Distribution Center (PDC) and the ignition switch supply battery voltage to the fuse block bus bars. Circuit F20 supplies battery voltage to the ACM only when the ignition switch is in the RUN position. Circuit F14 circuit powers the ACM when the ignition switch is in either the START or RUN position. In either the START or RUN positions, the ignition switch connects circuit A21 circuit with circuit A1 from fuse C in the PDC. Circuit A21 circuit supplies battery voltage to the fuse block bus bar that feeds circuit F14. Fuse 14 in the fuse block protects circuit F14. Circuit F14 connects to cavity 1 of the ACM. When the ignition switch is in the RUN position, it connects circuit A2 from fuse E in the PDC to circuit A22. Circuit A22 supplies battery voltage to the fuse block bus bar that feeds circuit F20. Fuse 3 in the fuse block protects circuit F20. Circuit F20 connects to cavity 2 of the ACM. The ACM is case grounded and has an external dedicated ground, circuit Z6. Circuit Z6 connects to the right fender side shield.
HELPFUL INFORMATION Circuit F14 is double crimped at fuse 14 in the fuse block to feed the instrument cluster.
DIAGRAM INDEX
Component Airbag Control Module Clock Spring . . . . . . Data Link Connector . Fuse 3 . . . . . . . . . . Fuse 14 . . . . . . . . . . Fuse C . . . . . . . . . . Fuse E . . . . . . . . . . Ignition Switch . . . . . Instrument Cluster . . . Left Impact Sensor . . Right Impact Sensor . Squib . . . . . . . . . . . Page .8W-43-2 .8W-43-2 .8W-43-2 .8W-43-2 .8W-43-3 .8W-43-2 .8W-43-2 .8W-43-2 .8W-43-2 .8W-43-2 .8W-43-2 .8W-43-2
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1995 AN Dakota Publication No. 81-370-5110 TSB 08-55-94 October 14, 1994
8W - 44 - 1
INTERIOR LIGHTING
INDEX
page Ash Receiver Lamp and Cigar Lamp . . . Combination Buzzer . . . . . . . . . . . . . . . . Courtesy Lamp and Ignition Switch Lamp Day/Night Mirror . . . . . . . . . . . . . . . . . . Diagram Index . . . . . . . . . . . . . . . . . . . ... ... .. ... ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2 1 2 2 Dome Lamp . . . . . General Information Glove Box Lamp . . Time Delay Relay . Underhood Lamp . .. . .. .. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page . . . . . . . . . . 1 1 1 1 1
GENERAL INFORMATION
Circuit M1 supplies power to the underhood lamp, glove box lamp, dome lamp, and the time delay relay. Circuit M50 from the time delay relay powers the courtesy lamp and ignition switch lamp. Circuit E2 supplies power to the ash receiver and cigar lighter lamp. Fuse 13 in the fuse block protects circuit E2. Circuit M1 is protected by the ignition off draw (IOD) fuse (fuse F2) in the Power Distribution Center (PDC).
HELPFUL INFORMATION Circuit M1 splices to supply voltage to the glove box lamp, dome lamp, overhead console, ABS diagnostic connector, power mirror switch, and radio.
HELPFUL INFORMATION Circuit E2 splices to supply voltage to illumination lamps in the instrument cluster.
UNDERHOOD LAMP
Circuit M1 from the IOD fuse in the Power Distribution Center (PDC) supplies battery voltage for the underhood lamp. A mercury switch, in series after the lamp, connects the lamp to ground on circuit Z1. When the hood is raised, mercury inside the switch moves to a position where it connects circuit M1 to ground circuit Z1, illuminating the lamp. Circuit Z1 terminates at the left fender side shield. The underhood lamp is wired in parallel with other components on circuit M1.
DOME LAMP
Circuit M1, from the IOD fuse (fuse F2) in the Power Distribution Center (PDC), supplies power to
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the dome lamp. This circuit is HOT at all times. The ground path for the lamp is provided in two different ways. One way is through the door ajar switches. Circuit M2 connects to the door ajar switches from the dome lamp. The switches are case-grounded to the body. When a door is opened, the plunger in the switch closes, completing a path to ground. The second ground path is through the headlamp switch. Circuit M2 is spliced in with the door ajar switches. When the operator turns the headlamp switch to the dome lamp ON position, a ground path is provided through the switch.
DAY/NIGHT MIRROR
The day/night mirror receives power from circuit F20 when the ignition switch is in the RUN position. Circuit Z1 provides ground for the day/night mirror. The grounding point for circuit Z1 is the windshield header. When the back-up lamps switch closes, circuit L1 provides a signal to the day/night mirror. The day night mirror turns OFF when the vehicle is in reverse.
HELPFUL INFORMATION Circuit F32 also powers the stop lamp switch. Circuit G5 is double crimped at the combination buzzer. The G5 branch from the buzzer splices to power the four-wheel drive lamp and the overdrive lamp.
DIAGRAM INDEX
Component Page Ash Receiver Lamp . . . . . . . . . . . . . . . . . . . . . . .8W-44-4 Cigar Lighter Lamp . . . . . . . . . . . . . . . . . . . . . . .8W-44-4 Combination Buzzer . . . . . . . . . . . . . . . . . . . . . . .8W-44-5 Courtesy Lamp . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-3 Day/Night Mirror. . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-6 Dome Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-3 Door Ajar Switch . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-5 Fuse 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-6 Fuse 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-5 Fuse 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-4 Fuse 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-4 Fuse 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-5 Fuse C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-5 Fuse F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-3, 4 Fuse F2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-3, 4 Fuse G . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-4, 5 Glove Box Lamp . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-4 Headlamp Switch . . . . . . . . . . . . . . . . . . . . .8W-44-3, 4, 5 Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . .8W-44-5, 6 Ignition Switch Lamp . . . . . . . . . . . . . . . . . . . . . .8W-44-3 Overhead Console . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-6 Key-In Switch . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-3 Seat Belt Switch . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-5 Time Delay Relay . . . . . . . . . . . . . . . . . . . . . . . .8W-44-3 Underhood Lamp . . . . . . . . . . . . . . . . . . . . . . . . .8W-44-4
COMBINATION BUZZER
The conbination buzzer module sounds an audible warning tone. The tone sounds for seat belt warning and when the ignition key is in the ignition switch while the drivers door is open. The tone also sounds when the ignition key is in the ON position while the drivers side seat belt is not buckled. Refer to Group 8U for buzzer operation. Fuses 7 and 16 in the fuse block protect the combination buzzer. Fuse 7 powers circuit F32 which connects to the buzzer. Circuit A3 from fuse G in the Power Distribution Center (PDC) supplies power to the fuse block for fuse 7 and circuit F32. Circuit G5 from fuse 16 also provides voltage to the combination buzzer when the ignition switch is in the START or RUN positions. The ignition switch connects circuit A1 from fuse C in the PDC to circuit A21. Circuit A21 connects to the fuse block. When the parking lamps or headlamps are ON, the headlamp switch connects circuit G16 from the drivers side door jamb switch to circuit G26. Circuit G26
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AUDIO SYSTEM
GENERAL INFORMATION
Two radio systems are available in this vehicle; the radio with standard speaker system and a radio with premium speaker system. The premium speaker system uses a power amplifier and radio choke relay not used on the standard speaker system. When referencing the circuit descriptions or the diagrams, ensure that you use the correct ones. fuse G in the Power Distribution Center (PDC) connects to the fuse block bus bar that feeds circuit X1 through fuse 6. Circuits A3 and X1 are HOT at all times. When the radio supplies power for the relay, the contact close and connect circuits X1 and X13. Circuit X13 supplies voltage to the amplifier circuits in the speakers. Circuit X15 provides ground for the amplifier circuit of the speakers.
RADIO OPERATION
In the ACCESSORY or RUN position, the ignition switch connects circuit A1 from fuse C in the Power Distribution Center (PDC) with circuit A31. Circuit A31 powers a bus bar in the fuse block that feeds circuit X12 through fuse 12. Circuit X12 supplies battery voltage to the radio. The radio is case grounded.
SPEAKERSSTANDARD RADIO
Circuit X53 feeds the speaker in the left front door. Circuit X55 is the return from the speaker to the radio. Circuit X54 feeds the right front door speaker. Circuit X56 is the return from the speaker to the radio. Circuit X51 feeds the speaker in the left rear of the vehicle. Circuit X57 is the return from the speaker to the radio. Circuit X52 feeds the right rear speaker. Circuit X58 is the return from the speaker to the radio.
RADIO MEMORY
Circuit M1 from the Ignition Off Draw (IOD) fuse (fuse F2) in the Power Distribution Center (PDC) supplies power for the radio memory. The IOD fuse is removed during vehicle shipping to prevent excessive battery draw. Circuit A4 from fuse F in the PDC supplies voltage to the IOD fuse. Circuit A4 is HOT at all times.
SPEAKERSPREMIUM RADIO
When the radio choke relay energizes, circuit X13 supplies voltage to the amplifier circuits in each speaker. Circuit X15 supplies ground for the amplifier circuit. Circuit X15 grounds to the rear of the radio. Circuit X53 feeds the speaker in the left front of the vehicle. Circuit X55 is the return from the speaker to the radio. Circuit X54 feeds the right front door speaker. Circuit X56 is the return from the speaker to the radio. Circuit X51 feeds the speaker in the left rear of the vehicle. Circuit X57 is the return from the speaker to the radio. Circuit X52 feeds the right rear speaker. Circuit X58 is the return from the speaker to the radio.
RADIO ILLUMINATION
When the parking lamps or headlamps are on, circuits E2 and L7 from the headlamp switch power the radio illumination lamps. Fuse 13 in the fuse block powers circuit E2 which feeds the radio illumination lamp. Circuit E1 from the headlamp switch supplies power to fuse 13. Circuit L7 supplies voltage for the radio lamps. The radio case ground completes the ground path for the illumination and park lamp circuits.
HELPFUL INFORMATION When the headlamp switch is in the park lamps or headlamp ON position, it connects circuit F33 from fuse 8 in the fuse block with circuits E1 and L7. Circuit E1 is powered by a variable resistor in the headlamp switch used to adjust illumination lamp brightness. Circuit A3 from fuse G in the PDC feeds the fuse block bus bar that powers circuit F33 through fuse 8. Circuits A3 and F33 are HOT at all times.
DIAGRAM INDEX
Component Page Fuse 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-47-6 Fuse 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-47-3, 5 Fuse C . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-47-3, 5 Fuse F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-47-2, 4 Fuse G . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-47-2, 4, 6 Headlamp Switch . . . . . . . . . . . . . . . . . . . . . . .8W-47-2, 4 Ignition Off-Draw Fuse (Fuse F2) . . . . . . . . . . . . .8W-47-2, 4 Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . .8W-47-3, 5 Left Door Speaker . . . . . . . . . . . . . . . . . . . . . .8W-47-3, 6 Left Rear Speaker . . . . . . . . . . . . . . . . . . . . . .8W-47-3, 6 Radio . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-47-2, 3, 4, 5 Radio Choke Relay . . . . . . . . . . . . . . . . . . . . . . .8W-47-6 Right Door Speaker . . . . . . . . . . . . . . . . . . . . .8W-47-3, 6 Right Rear Speaker . . . . . . . . . . . . . . . . . . . . .8W-47-3, 6
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OVERHEAD CONSOLE
OVERHEAD CONSOLE
When the ignition switch is in the RUN position, circuit F20 from fuse 3 in the fuse block supplies power to the overhead console. If the vehicle is equipped with Daytime Running Lamps (DRL), circuit F20 is double crimped at the overhead console and connects to the DRL module. When the headlamps or parking lamps are ON, circuits L7 and E2 provide voltage to the overhead console for illumination. Voltage on circuit L7 informs the overhead console that the headlamps or parking lamps are ON. Circuit E2 from fuse 13 in the fuse block powers the illumination lamps in the overhead console. Circuit E1 from the headlamp switch feeds fuse 13 and circuit E2. Circuit Z2 provides ground for the compass. The grounding point for circuit Z2 is the windshield header.
HELPFUL INFORMATION If the vehicle has DRL, circuit Z1 also provides ground for the DRL module. Circuit M1 splices to supply voltage for the radio memory, courtesy lamp, time delay relay, underhood lamp, and glove box lamp. Circuit E2 splices to provide voltage to the instrument cluster illumination lamps, the ash receiver lamp, cigar lighter lamp and radio lamp. Circuit A3 from fuse G in the PDC supplies power to fuse 8 in the fuse block. Circuit F33 from fuse 8 supplies voltage to the headlamp switch for circuits L7 and E1. Circuit E1 supplies power to circuit E2 through fuse 13. In the RUN position, the ignition switch connects circuit A2, from fuse E in the PDC, with circuit A2. Circuit A2 powers circuit F20 through fuse 3 in the fuse block.
AMBIENT TEMPERATURE SENSOR The ambient temperature sensor is a variable resistor. Circuit G31 supplies voltage from the overhead console to the sensor. Circuit G32 is the signal return from the sensor to the overhead console. LAMPS Circuit M1 supplies voltage for the reading lamps and dome lamp in the overhead console. The ignition off draw (IOD) fuse (fuse F2) in the Power Distribution Center (PDC) supplies voltage to circuit M1. Circuit A4 from fuse F in PDC feeds the IOD fuse. Circuit Z1 grounds the reading lamps. The grounding point for circuit Z1 is the windshield header. Circuit M2 also provides ground for the reading lamps and dome lamp. The M2 circuit supplies ground for the overhead console lamp in two ways. One way is through the door jamb switches. Circuit M2 connects to the door jamb switches. The switches are case-grounded to the body. When a door is opened, the plunger in the switch closes, completing a path to ground. The second ground path is through the headlamp switch. When the operator turns the headlamp switch to the dome lamp ON position, a ground path provided on circuit M2 through the switch.
DIAGRAM INDEX
Component Page Ambient Temperature Sensor . . . . . . . . . . . . . . . . .8W-49-3 Automatic Day/Night Mirror . . . . . . . . . . . . . . . . . .8W-49-3 Fuse 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-49-2 Fuse 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-49-2 Fuse 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-49-2 Fuse E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-49-2 Fuse F . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-49-2 Fuse F2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-49-2 Fuse G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-49-2 Headlamp Switch . . . . . . . . . . . . . . . . . . . . . . . . .8W-49-2 Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . .8W-49-2 Left Door Jamb Switch . . . . . . . . . . . . . . . . . . . . .8W-49-3 Overhead Console . . . . . . . . . . . . . . . . . . . . . .8W-49-2, 3 Right Door Jamb Switch . . . . . . . . . . . . . . . . . . . .8W-49-3 Time Delay Relay . . . . . . . . . . . . . . . . . . . . . . . .8W-49-2 Transmission Range/Back-Up Lamp Switch . . . . . . . .8W-49-3
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FRONT LIGHTING
INDEX
page Daytime Running Lamp (DRL) Module . . . . . . . . . . . 2 Diagram Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Fog Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 page Headlamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Off-Road Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Parking Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 The headlamp switch has an internal circuit breaker. For the left front parking lamp, turn signal, side marker lamp, and left headlamp, the Z1 circuit grounding point is on the dash panel, near the blower motor resistor block. For the right front parking lamp, turn signal, side marker lamp, and right headlamp, the Z1 circuit grounding point is on the right fender side shield. For the left and rear parking lamps, turn signals, side marker lamps, and the rear license plate lamp, the Z1 circuit grounding point is the left inner fender panel. The Z1 circuit also provides ground for the fuel level sensor.
HEADLAMPS
The headlamp switch has three positions: ON, PARK (parking lamps) and OFF. Two circuits, L2 and L20, connect the headlamp switch to the headlamp dimmer/optical horn switch located in the multi-function switch. The multi-function switch feeds the low and high beams of the headlamps.
HEADLAMP SWITCH IN OFF OR PARKING LAMP POSITION Circuit A3 from fuse G in the Power Distribution Center (PDC) supplies battery voltage to the headlamp switch. The headlamp switch has an internal circuit breaker that connects circuit A3 to circuit L20. In the OFF and PARK positions, the headlamp switch feeds circuit L20 which connects to the multifunction switch. Circuit L20 powers the high-beam circuit when the operator flashes the headlamps with the turn signal stalk of the multi-function switch. The multi-function switch connects circuit L20 to circuit L3. Circuit L3 feeds the high beam of the headlamps. HEADLAMP SWITCH IN ON POSITION When the headlamp switch is in the ON position, the A3 circuit from the Power Distribution Center (PDC) connects to circuit L2. Circuit L2 connects to the multi-function switch and feeds the L4 circuit. The L4 circuit powers the low beam of the headlamps. When the operator selects high beam operation, with the turn signal stalk of the multi-function switch, circuit L2 connects to the L3 circuit. Circuit L3 powers high beam operation. HEADLAMP GROUND Although circuit Z1 provides ground for both the right and left headlamps, it has different termination points for each. For the right headlamp, the Z1 circuit terminates at the dash panel, near the blower motor resistor block. For the left headlamp, the Z1 circuit terminates at the left fender side shield. HELPFUL INFORMATION Check fuse G in the PDC.
PARKING LAMPS
Circuit A3 in the Power Distribution Center (PDC) connects to a bus bar in the fuse block. One of the four circuits powered by the bus bar is circuit F33. Circuit F33 connects to the headlamp switch. Fuse G in the PDC protects the A3 circuit. Fuse 8 in the fuse block protects circuit F33. The headlamp switch has three positions: ON, PARK (parking lamps) and OFF, plus a dimmer switch. When the headlamp switch is in the PARK or ON position, the switch connects circuit F33 to circuit L7. From the headlamp switch, circuit L7 branches to power the front parking lamps and rear tail lamps, side marker lamps, and rear license plate lamps.
GROUND CIRCUIT Circuit Z1 provides a ground for the parking lamps, tail lamps, and rear license plate lamps. The grounding point for circuit Z1 is the dash panel, left of the brake master cylinder. HELPFUL INFORMATION If the vehicle is equipped with factory installed fog lamps, circuit L7 splices to feed the park lamp relay. Check fuse G in PDC. Check fuse 8 in the fuse block. Circuit L7 also feeds the radio, if equipped. When the headlamp switch is in the PARK or ON position, the dimmer circuit, F33, also connects to circuit E1. Circuit E1 feeds circuit E2, which powers
8W - 50 - 2
the ash receiver lamp, instrument cluster illumination lamps, under hood lamp, glove box lamp and radio lamp. Fuse 13 in the fuse block protects circuits E1 and E2.
FOG LAMPS
The fog lamps are controlled by the fog lamp switch, park lamp relay and high beam relay. The fog lamps operate only when the headlamp switch is in the ON position, and the operator has selected lowbeam operation. When the headlamps are in highbeam operation, the fog lamps will not operate. Circuit A3 from fuse G in the Power Distribution Center (PDC) supplies voltage to circuit F39 through fuse 20 in the fuse block, Circuit F39 splices to supply power to the contact side of the park lamp relay. Circuit L7 supplies power to the coil side of the park lamp relay. Circuit L35 connects to the coil side of the relay and to circuit Z1 through the fog lamp switch. Ground for the coil side of the relay is provided on circuit Z1 through the fog lamp switch. When the fog lamp switch closes, the park lamp relay contacts close connecting circuits F39 and L36. Circuit L36 powers the contact side of the high beam relay. When the headlamp high beams are off, the high beam relay is not energized and voltage flows through the normally closed contacts to circuit L39. Circuit L39 supplies voltage to the fog lamps and the illumination lamp in the fog lamp switch. Circuit Z1 provides ground for the fog lamps. If the high beam lamps are on, circuit L3 from the headlamp switch energizes the high beam relay. When the high beam relay energizes, the contacts open and power is not supplied to the fog lamps. Circuit Z1 provides ground for the coil side of the high beam relay. The grounding point for circuit Z1 is the left fender side shield.
DIAGRAM INDEX
Component Page Daytime Running Lamps (DRL) Module . . . . . . . . . .8W-50-6 Dimmer Switch . . . . . . . . . . . . . . . . . . . . . . . . . .8W-50-3 Fog Lamp Switch . . . . . . . . . . . . . . . . . . . . . . . .8W-50-7 Fog Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-50-8 Fuse 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-50-6 Fuse G . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-50-3, 6, 7 Fuse 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-50-3 Fuse 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-50-7 Headlamp Switch . . . . . . . . . . . . . . . . . . . . . . . . .8W-50-3 Headlamps2.5L . . . . . . . . . . . . . . . . . . . . . . . .8W-50-4 Headlamps3.9L/5.2L . . . . . . . . . . . . . . . . . . . . .8W-50-5 High Beam Relay . . . . . . . . . . . . . . . . . . . . . . . . .8W-50-7 Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . .8W-50-6 Off-Road Lamp Switch . . . . . . . . . . . . . . . . . . . . .8W-50-7 Off-Road Lamps . . . . . . . . . . . . . . . . . . . . . . . . .8W-50-8 Park Lamp Relay . . . . . . . . . . . . . . . . . . . . . . . . .8W-50-7 Park/Turn Signal Lamps3.9L/5.2L . . . . . . . . . . . . .8W-50-5 Park/Turn Signal Lamps2.5L . . . . . . . . . . . . . . . .8W-50-4 Side Marker Lamps3.9L/5.2L . . . . . . . . . . . . . . .8W-50-5 Side Marker Lamps2.5L . . . . . . . . . . . . . . . . . . .8W-50-4
HELPFUL INFORMATION Circuit L3 powers the high beam circuit of the headlamps.
OFF-ROAD LAMPS
Circuit A3 from fuse G in the Power Distribution Center (PDC) supplies voltage to circuit F39 through fuse 20 in the fuse block. Circuit F39 splices to supply power to the off-road lamp switch. When the off road lamp switch closes, circuit F39 powers the illumination lamp in the switch and circuit L31. Circuit L31 feeds the off-road lamps. Circuit Z1 provides ground for the off-road lamps. The grounding point for circuit Z1 is the left fender side shield.
1995 AN Dakota Publication No. 81-370-5110 TSB 08-55-94 October 14, 1994
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REAR LIGHTING
INDEX
page Diagram Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Back-up Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 page Stop Lamps and CHMSL Lamps . . . . . . . . . . . . . . . 1 Tail Lamps and Rear License Plate Lamps . . . . . . . 1
GROUND CIRCUIT Circuit Z1 provides a ground for the parking lamps, tail lamps, and rear license plate lamps. The grounding point for circuit Z1 is the left inner fender panel. There are two different license plate lamp systems; a one lamp system or a two lamp system. If the vehicle is not equipped with a step bumper, it has the one lamp system. Circuit H4 from the license plate lamp connects to circuit Z1. If the vehicle has a step bumper, it uses the two lamp license plate lamp system. Circuit X2 from each lamp connects to circuit Z1. HELPFUL INFORMATION If the vehicle is equipped with factory installed fog lamps, circuit L7 splices to feed the park lamp relay. If the vehicle is equipped with factory installed trailer tow, circuit L7 splices to the trailer tow harness. Check fuse G in PDC. Check fuse 8 in the fuse block. Circuit L7 also feeds the radio, if equipped. When the headlamp switch is in the PARK or ON position, the dimmer circuit, F33, also connects to circuit E1. Circuit E1 feeds circuit E2, which powers the ash receiver lamp, instrument cluster illumination lamps, under hood lamp, glove box lamp and radio lamp. Fuse 13 protects circuits E1 and E2.
GROUND CIRCUIT Circuit Z1 provides a ground for the stop lamps, back-up lamps and CHMSL lamps. The Z1 circuit has more than one branch. Circuit Z1 also supplies ground path for the tail lamps, parking lamps, side marker lamps, rear license plate lamp, back-up lamps, and turn signals. Both branches of circuit Z1 terminate at the dash panel, left of the brake master cylinder. HELPFUL INFORMATION Check for blown fuse in circuit F32. Check for continuity across the stop lamp switch when it is closed. If the vehicle is equipped with Rear Wheel AntiLock (RWAL) brakes, circuit F32 connects to the RWAL module.
BACK-UP LAMPS
In the RUN position, the ignition switch connects circuit A2 from fuse E in the Power Distribution Center (PDC) to circuit A22. Circuit A22 feeds a bus bar in the fuse block that powers circuit F20 through fuse 3. Circuit F20 supplies power to the back-up lamp switch. On automatic transmission equipped vehicles, the back-up lamp switch is part of an assembly that includes the PARK/NEUTRAL position switch.
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When the operator puts the transmission in REVERSE, the back-up lamp switch connects circuit F20 to circuit L1. Circuit L1 feeds the back-up lamps. If the vehicle is equipped with trailer tow, a jumper harness connects circuit B2 in line with circuit L1. Circuit B2 splices to the trailer tow harness.
GROUND CIRCUIT Circuit Z1 provides ground for the back-up lamps. Circuit Z1 also supplies a ground path for the tail lamps, parking lamps, CHMSL lamps, rear license plate lamp, stop lamps, and turn signals. The grounding point for circuit Z1 is the dash panel, left of the brake master cylinder. HELPFUL INFORMATION Check for blown fuses in circuits A2 and F20. Check for continuity across the back-up lamp switch when it is closed. Circuit F20 feeds the overhead console and airbag control module. Circuit L1 also connects to the day/night mirror.
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TURN SIGNALS
TURN SIGNALS
In the ACCESSORY or RUN position, the ignition switch connects circuit A1 from fuse C in the Power Distribution Center (PDC) to circuit A31. Circuit A31 feeds circuit L5 through fuse 11 in the fuse block. Circuit L5 powers the turn signal flasher. Circuit L6 from the flasher connects to the multi-function switch to supply power to the turn signals. The multi-function switch connects to the turn signal and side marker lamps on circuits L60, L61, L62 and L63. Circuit L9 from the hazard flasher fuse supplies battery voltage to the hazard warning flasher. Circuit L19 from the flasher connects to the multi-function switch. When the operator depress the hazard flasher button, the multi-function switch connects circuit L19 to circuits L60, L61, L62, and L63. Circuit L62 powers the right rear turn signal/stop lamp. Circuit L63 powers the left rear turn signal/stop lamp. Circuit L60 powers the right indicator lamp. Circuit L61 powers the left indicator lamp. Circuit L60 also splices to feed the instrument cluster right indicator lamp. Circuit L61 splices to feed the instrument cluster left indicator lamp.
RIGHT TURN SIGNAL When the operator selects the right turn signal, the multi-function switch connects power from circuit L6 to circuits L60 and L62. Circuit L62 feeds the right rear turn signal/hazard flasher/stop lamp. Circuit L60 feeds the right front turn signal/hazard flasher lamp and side marker lamp. Circuit L60 also splices to power the turn signal indicator lamp on the instrument cluster. LEFT TURN SIGNAL When the operator selects the left turn signal, the multi-function switch connects power from circuit L6 to circuits L61 and L63. Circuit L63 feeds the left rear turn signal/hazard flasher/stop lamp. Circuit L61 feeds the left front turn signal/hazard flasher lamp and side marker lamp. Circuit L61 also splices to power the turn signal indicator lamp on the instrument cluster. GROUND CIRCUIT Circuit Z1 provides a ground for the parking lamps, turn/tail/stop lamps, and rear license plate lamps. The grounding point for circuit Z1 is the dash panel, left of the brake master cylinder. HELPFUL INFORMATION Check fuse C in the PDC. Check fuse 11 in the fuse block. If the vehicle is equipped with Rear Wheel AntiLock (RWAL) brakes, circuit L4 also feeds the RWAL module.
GROUND CIRCUIT Circuit Z1 provides a ground for the parking lamps, turn/tail/stop lamps, and rear license plate lamps at the left inner fender panel. Circuit Z1 also provides a ground for the back-up lamps and Center High Mounted Stop Lamp (CHMSL) at the left inner fender panel. Circuit Z1 also provide ground for the indicator lamps, and side marker lamps at the left inner fender panel. HELPFUL INFORMATION Check the fusible link in the A15 circuit.
DIAGRAM INDEX
Component Fuse G . . . . . . . . . . . . Fuse 7 . . . . . . . . . . . . Fuse F2 (IOD Fuse) . . . . Fuse C . . . . . . . . . . . . Fusible Link . . . . . . . . . Hazard Flasher . . . . . . . Ignition Switch . . . . . . . RWAL Module . . . . . . . Stop Lamp Switch . . . . . Turn Signal/Hazard Flasher Turn Signal Flasher . . . . Page . . . . . . . . . . . . . .8W-52-3 . . . . . . . . . . . . . .8W-52-3 . . . . . . . . . . . . . .8W-52-2 . . . . . . . . . . . . . .8W-52-2 . . . . . . . . . . . . . .8W-52-2 . . . . . . . . . . . . . .8W-52-2 . . . . . . . . . . . . . .8W-52-2 . . . . . . . . . . . . . .8W-52-3 . . . . . . . . . . . . . .8W-52-3 . . . . . . . . . . . .8W-52-3, 4 . . . . . . . . . . . . . .8W-52-2
..... ..... ..... ..... ..... ..... ..... ..... ..... Switch .....
HAZARD FLASHERS
Circuit A15 from the battery positive post supplies power to the hazard flasher fuse (fuse F1) in the Power Distribution Center (PDC). Circuit A15 has an in-line fusible link.
8W-53 WIPERS
8W - 53 - 1
WIPERS
INDEX
page Diagram Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Low Washer Fluid Warning Lamp . . . . . . . . . . . . . . 2 page WipersIntermittent . . . . . . . . . . . . . . . . . . . . . . . . 1 WipersStandard . . . . . . . . . . . . . . . . . . . . . . . . . . 1 control module. Circuit Z2 terminates at the instrument panel lower right reinforcement support. When the operator moves the wiper switch to the LOW speed position, the switch passes voltage to circuit V3. Circuit V3 feeds the wiper motor LOW speed brushes. If the operator selects wiper HIGH speed operation, the wiper switch passes current to circuit V4. Circuit V4 feeds the wiper motor HIGH speed brushes. If the operator selects wiper DELAY operation, the wiper switch provides an input to the intermittent wiper control module on circuit V8. The DEALY portion of the wiper switch contains a variable resistor. The variable resistor connects to the intermittent wiper module on circuit V9. Voltage for the resistor is supplied by circuit V6 through the wiper switch. The amount of delay selected by the operator determines the voltage drop through the resistor and the voltage level received by the intermittent wiper module. After the intermittent wiper control module determines the amount of delay selected, it cycles the wipers by periodically energizing circuit V17 which connects to circuit V3 through the wiper switch. Circuit V3 powers the wiper motor LOW speed brushes. As the windshield wiper motor turns, the park switch, internal to the motor, moves from its grounded position (down) to the powered RUN (up) position. Circuit V7 provides an input to the intermittent wiper control module when the wiper switch is in the OFF position. The intermittent wiper control module powers the park switch in the wiper motor on circuit V5. The intermittent windshield wiper system is also equipped with a pulse wipe feature. To activate this feature, the operator presses the washer switch momentarily. When the washer switch closes, voltage from circuit V6 passes through the switch to circuit V10. Circuit V10 provides a signal to the intermittent wiper control module and supplies voltage for the windshield washer pump. When the control module receives the signal on circuit V10, it cycles the wipers on circuit V3 while the washer fluid pump operates. The washer motor operates whenever the washer switch closes and supplies voltage to the motor on
WIPERSSTANDARD
Fuse 10 in the fuse block powers the standard wiper system. The standard wiper system operates at either LOW or HIGH speeds. In the ACCESSORY or RUN position, the ignition switch connects circuit A1 from fuse C in the Power Distribution Center (PDC) with circuit A31. Circuit A31 supplies voltage to circuit V6 through fuse 10 in the fuse block. Circuit V6 splices to supply power to the wiper switch circuitry in the multi-function switch and to the park switch in the wiper motor. The wiper system is case grounded at the wiper motor. When the operator moves the wiper switch to the LOW position, battery voltage passes through the switch to circuit V3. Circuit V3 feeds the wiper motor LOW speed brushes. If the operator selects wiper HIGH speed operation, the wiper switch passes current to circuit V4. Circuit V4 feeds the wiper motor HIGH speed brushes. As the windshield wiper motor turns, the park switch, internal to the motor, moves from its DOWN position to the UP position. When the wiper switch is turned OFF, the V5 circuit prevents the wipers from stopping in any position but park. The windshield washer uses a pump motor located inside the windshield washer fluid reservoir. When the washer switch is pressed, power is supplied through the wiper switch to the pump motor on circuit V10. Circuit Z1 provides ground for the pump motor. The Z1 circuit terminates at the left headlamp ground at the left fender side shield.
WIPERSINTERMITTENT
Fuse 10 in the fuse block powers the intermittent wiper system. The intermittent wiper system operates at either DELAY, LOW or HIGH speeds. In the ACCESSORY or RUN position, the ignition switch connects circuit A1 from fuse C in the Power Distribution Center (PDC) with circuit A31. Circuit A31 supplies voltage to circuit V6 through fuse 10 in the fuse block. Circuit V6 splices to supply power to the wiper switch circuitry in the multi-function switch, the intermittent wiper module and the park switch in the wiper motor. The wiper motor is case grounded. Circuit Z2 provides ground for the intermittent wiper
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circuit V10. Circuit Z1 provides ground for the pump motor. Circuit Z1 terminates at the left fender side shield.
HELPFUL INFORMATION Circuit V3 is double crimped at the multi-function switch to allow either the wiper switch or intermittent wiper control module to power the wiper motor LOW speed brushes. Ground circuit Z2 is double crimped at the intermittent wiper control module to provide ground for the Rear Wheel Anti-Lock (RWAL) module.
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TRAILER TOW
TRAILER TOW
The trailer tow jumper harness connects to the circuits for the stop lamps, turn signals, tail lamps and back-up lamps. The harness wires are taped back and sealed at the time of vehicle delivery. Circuit D7 connects to circuit L62 which powers the right turn signal/stop lamp. Circuit D8 connects to circuit L63 which supplies power to left turn signal/stop lamp. Circuit B2 connects to circuit L1 for the back-up lamps. The trailer tow harness also contains tail lamp circuit L7, and circuit X2. Circuit X2 is connected to ground circuit Z1.
DIAGRAM INDEX
Component Page Back-Up Lamps . . . . . . . . . . . . . . . . . . . . . . . . . .8W-54-2 Tail, Stop and Turn Signal Lamps . . . . . . . . . . . . . .8W-54-2 Trailer Tow Harness . . . . . . . . . . . . . . . . . . . . . . .8W-54-2
8W - 60 - 1
POWER WINDOWS
POWER WINDOWS
In the RUN position, the ignition switch connects circuit A2 from fuse E in the Power Distribution Center (PDC) to circuit A22. Circuit A22 powers circuit F21 through the circuit breaker in cavity 2 of the fuse block. Circuit F21 supplies battery voltage to the left and right power window switches. Circuit Z1 provides ground for the system through the left power window switch. The grounding point for circuit Z1 is the instrument panel lower right panel reinforcement support. The left power door switch contains two switches for the left and right windows. The right power window switch on the passengers side of the vehicle only operates the right window. Q12 back through the passenger side switch to circuit Q16, through the drivers side switch to ground on circuit Z1. When the drivers side switch is put in the UP position, the switch supplies voltage to circuit Q16. Circuit Q16 connects to the UP side of the passenger side switch. Voltage passes through the passengers side switch to the window motor on circuit Q12. The ground path from the motor is on circuit Q22 back through the passengers side switch to circuit Q26, through the drivers side switch to ground on circuit Z1. PASSENGER SIDE SWITCH OPERATION Circuit F21 splices to supply voltage to the right window switch on the passenger side of the vehicle. When the passenger side switch is put in the DOWN position, the switch supplies voltage to the motor on circuit Q22. The ground path from the motor is on circuit Q12 back through the passenger side switch to circuit Q16, through the drivers side switch to ground on circuit Z1. In the UP position, the passenger side switch supplies voltage to the window motor on circuit Q12. The ground path from the motor is on circuit Q22 back through the passenger side switch to circuit Q26, through the drivers side switch to ground on circuit Z1.
LEFT POWER WINDOW Circuit F21 supplies voltage to the left power window switch. When the switch for the left window is put in the DOWN position, the switch supplies voltage to the left power window motor on circuit Q21. The ground path from the motor is on circuit Q11 back through the switch to ground on circuit Z1. When the left power window switch is put in the UP position, circuit Q11 supplies voltage to the power window motor. The ground path from the motor is on circuit Q21 back through switch to ground on circuit Z1. RIGHT POWER WINDOW The right power window can be operated by either the right power window switch on the drivers side or the switch on the passenger side. The switch on the passengers side of the vehicle is wired in series between the drivers side switch and the motor.
DRIVER SIDE SWITCH OPERATION Circuit F21 supplies voltage to the right power window switches for raising and lowering the windows. When the drivers side switch is put in the DOWN position, the switch supplies voltage to circuit Q26. Circuit Q26 connects to the down side of the passenger side switch. Voltage passes through the passenger side switch to the window motor on circuit Q22. The ground path from the motor is on circuit
HELPFUL INFORMATION Check fuse E in the PDC. Check the circuit breaker in cavity 2 of the fuse block.
DIAGRAM INDEX
Component Page Circuit Breaker (Cavity 2 of Fuse Block) . . . . . . . .8W-60-2, 3 Fuse E . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-60-2, 3 Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . .8W-60-2, 3 Left Window Lift Motor . . . . . . . . . . . . . . . . . . . .8W-60-2 Left Door Power Window Switch . . . . . . . . . . . . . .8W-60-2 Right Window Lift Motor . . . . . . . . . . . . . . . . . . .8W-60-3 Right Door Power Window Switch . . . . . . . . . . . . .8W-60-3
8W - 61 - 1
LEFT DOOR SWITCH OPERATION (LOCK) When the left door lock switch is moved to the LOCK position, voltage is supplied on circuit P35 to the LOCK bus bar inside the right door switch. Battery voltage is passed through the right door switch to both door lock motors on circuit P33. The ground path for each motor is through circuit P34 to the right door switch. The ground circuit continues through the UNLOCK bus bar in the right door switch to circuit P36. From circuit P36 the ground circuit passes through the UNLOCK bus bar in the left door switch and then to ground on circuit Z1. LEFT DOOR SWITCH OPERATION (UNLOCK) When the left door lock switch is moved to the UNLOCK position, voltage is supplied on circuit P36 to the UNLOCK bus bar inside the right door switch. Battery voltage is passed through the right door switch to both door lock motors on circuit P34. The ground path for each motor is through circuit P33 to the right door switch. The ground circuit continues through the LOCK bus bar in the right door switch to circuit P35. From circuit P35 the ground circuit passes through the LOCK bus bar in the left door switch and then to ground on Z1 circuit.
RIGHT DOOR SWITCH OPERATION (LOCK) When the right door switch is moved to the LOCK position, voltage is supplied to both door lock motors on circuit P33. The ground path for each motor is through circuit P34 to the right door switch. The ground circuit continues through the UNLOCK bus bar in the right door switch to circuit P36. From circuit P36 the ground circuit passes through the UNLOCK bus bar in the left door switch and then to ground on circuit Z1 RIGHT DOOR SWITCH OPERATION (UNLOCK) When the right door switch is moved to the UNLOCK position, voltage is supplied to both door lock motors on circuit P34. The ground path for each motor is through circuit P33 to the right door switch. The ground circuit continues through the LOCK bus bar in the right door switch to circuit P35. From circuit P35 the ground circuit passes through the LOCK bus bar in the left door switch and then to ground on circuit Z1. HELPFUL INFORMATION Check fuse G in the PDC. Check fuse 5 in the fuse block.
DIAGRAM INDEX
Component Page Fuse G . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-61-2, 3 Fuse 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-61-2, 3 Left Door Motor . . . . . . . . . . . . . . . . . . . . . . . . .8W-61-3 Left Door Lock Switch . . . . . . . . . . . . . . . . . . . . .8W-61-2 Right Door Lock Switch . . . . . . . . . . . . . . . . . . . .8W-61-3 Right Door Motor . . . . . . . . . . . . . . . . . . . . . . . .8W-61-3
8W - 62 - 1
POWER MIRRORS
POWER MIRRORS
A single switch operates both the left and right power mirrors. Each mirror has two motors; a LEFT/ RIGHT motor and a UP/DOWN motor. The motors switch polarity to allow mirror adjustment. Circuit A4 from fuse F in the Power Distribution Center (PDC) supplies battery voltage to the Ignition Off-Draw (IOD) fuse (fuse F2) in the PDC. The IOD fuse powers the power mirror switch on circuit M1. Circuit Z1 connects to the power mirror switch and supplies ground for the power mirror system. The grounding point for circuit Z1 is the instrument panel lower right reinforcement support. made. Circuit P71 provides the ground path the for RIGHTWARD adjustments. When the operator makes LEFTWARD adjustment, polarity reverses. For LEFTWARD adjustments, the switch supplies battery voltage the left mirror LEFT/ RIGHT motor on circuit P71. Circuit P73 supplies ground for LEFTWARD adjustments. During UPWARD adjustments, the switch supplies voltage to the left mirror UP/DOWN motor on circuit P75. Circuit P73 supplies ground during UPWARD adjustments. For DOWNWARD adjustments, the polarity is reversed, the switch powers the left mirror UP/DOWN motor on circuit P73. Circuit P75 supplies the ground path.
RIGHT POWER MIRROR OPERATION In the RIGHT position, the power mirror switch supplies power to the right mirror LEFT/RIGHT motor on circuit P70 when a rightward adjustment is made. Circuit P74 provides the ground path the for rightward adjustments. When the operator makes a leftward adjustment, polarity reverses. For leftward adjustments, the switch supplies battery voltage the right mirror LEFT/RIGHT motor on circuit P74. Circuit P70 supplies ground for leftward adjustments. During UPWARD adjustments, the switch supplies voltage to the right mirror UP/DOWN motor on circuit P72. Circuit P70 supplies ground during UPWARD adjustments. For DOWNWARD adjustments, the polarity is reversed, the switch powers the right mirror UP/ DOWN motor on circuit P70. Circuit P72 supplies the ground path. LEFT POWER MIRROR OPERATION In the LEFT position, the power mirror switch supplies power to the left mirror LEFT/RIGHT motor on circuit P73 when a RIGHTWARD adjustment is
HELPFUL INFORMATION Check fuse F in the PDC. Check the IOD fuse (fuse F2) in the PDC. Circuit M1 supplies voltage to the radio memory, lamp, underhood lamp, time delay relay, dome lamp, overhead console lamps and glove box lamp. Check for proper operation of these items. Move the switch to its various positions and listen for the motors to click or try to move. Some movement or clicking indicates a poor connection or a mechanical problem with a mirror.
DIAGRAM INDEX
Component Fuse F . . . . . . . . . Fuse F2 (IOD Fuse) . Left Mirror Motors . . Power Mirror Switch Right Mirror Motors . Page .8W-62-2 .8W-62-2 .8W-62-2 .8W-62-2 .8W-62-2
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8W - 70 - 1
SPLICE INFORMATION
GENERAL INFORMATION
This section identifies all splices shown in the diagrams. It also shows the splices in their entirety. All circuits that are part of the splices are shown, and the systems they affect are referenced. For viewing the location of each splice in the vehicle, refer to Section 8W-95.
SPLICE INDEX
Component Page S101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-2 S102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-2 S103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-2 S104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-2 S105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-3 S106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-3 S107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-3 S108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-4 S109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-4 S110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-4 S111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-4 S112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-4 S113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-5 S114 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-5 S115 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-5 S116 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-5 S117 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-6 S118 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-6 S119 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-6 S120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-6 S121 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-7 S122 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-7 S123 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-7 S124 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-7 S125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-8 S126 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-8 S127 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-8 S128 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-8 S129 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-9 S130 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-9 S131 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-9 S132 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-10 S133 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-10 S134 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-10 S135 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-11 S136 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-11 S137 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-11 S138 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-11 S139 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-11 S140 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-12 S141 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-12 S142 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-70-12 Component S143 . . . . S144 . . . . S145 . . . . S201 . . . . S202 . . . . S203 . . . . S204 . . . . S205 . . . . S206 . . . . S207 . . . . S208 . . . . S209 . . . . S210 . . . . S211 . . . . S212 . . . . S213 . . . . S214 . . . . S215 . . . . S216 . . . . S301 . . . . S302 . . . . S303 . . . . S304 . . . . S305 . . . . S306 . . . . S307 . . . . S308 . . . . S309 . . . . S310 . . . . S311 . . . . S312 . . . . S313 . . . . S314 . . . . S315 . . . . S316 . . . . S317 . . . . S318 . . . . S401 . . . . S402 . . . . S403 . . . . S404 . . . . S405 . . . . Page .8W-70-12 .8W-70-12 .8W-70-13 .8W-70-13 .8W-70-13 .8W-70-13 .8W-70-14 .8W-70-14 .8W-70-14 .8W-70-15 .8W-70-15 .8W-70-15 .8W-70-15 .8W-70-16 .8W-70-16 .8W-70-16 .8W-70-17 .8W-70-17 .8W-70-17 .8W-70-17 .8W-70-17 .8W-70-18 .8W-70-18 .8W-70-18 .8W-70-19 .8W-70-19 .8W-70-19 .8W-70-19 .8W-70-20 .8W-70-20 .8W-70-20 .8W-70-20 .8W-70-21 .8W-70-21 .8W-70-21 .8W-70-21 .8W-70-22 .8W-70-22 .8W-70-22 .8W-70-22 .8W-70-23 .8W-70-23
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1995 AN Dakota Publication No. 81-370-5110 TSB 08-55-94 October 14, 1994
1995 AN Dakota Publication No. 81-370-5110 TSB 08-55-94 October 14, 1994
8W - 80 - 1
CONNECTOR LOCATIONS
Component Page C101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-3 C102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-3 C103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-3 C104 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-3 C105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-3 C106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-4 C107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-4 C108 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-4 C109 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-4 C110 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-4 C111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-5 C112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-5 C113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-5 C114 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-5 C115 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-5 C116 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-6 C117 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-7 C118 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-7 C119 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-7 C120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-8 C121 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-8 C122 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-8 C123 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-8 C124 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-8 C125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-8 C126 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-9 C127 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-9 C128 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-9 C129 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-9 C130 (2.5L) . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-10 C130 (3.9L/5.2L) . . . . . . . . . . . . . . . . . . . . . . . .8W-80-11 C131 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-12 C132 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-12 C133 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-12 C134 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-12 C135 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-12 C136 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-12 C137 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-13 C138 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-13 C139 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-13 C140 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-13 C141 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-13 C142 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-13 C143 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-13 C144 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-14 C145 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-14 C146 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-14 C147 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8W-80-14 Component C148 . . . . C149 . . . . C150 . . . . C151 . . . . C152 . . . . C153 . . . . C154 . . . . C155 . . . . C156 . . . . C157 . . . . C158 . . . . C159 . . . . C160 . . . . C161 . . . . C162 . . . . C163 . . . . C164 . . . . C165 . . . . C166 . . . . C167 . . . . C168 . . . . C201 . . . . C202 . . . . C203 . . . . C204 . . . . C205 . . . . C206 . . . . C207 . . . . C208 . . . . C209 . . . . C210 . . . . C211 . . . . C212 . . . . C213 . . . . C214 . . . . C215 . . . . C216 . . . . C217 . . . . C218 . . . . C219 . . . . C220 . . . . C221 . . . . C222 . . . . C223 . . . . C224 . . . . C225 . . . . C226 . . . . C227 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page .8W-80-14 .8W-80-14 .8W-80-15 .8W-80-15 .8W-80-15 .8W-80-15 .8W-80-15 .8W-80-15 .8W-80-16 .8W-80-16 .8W-80-16 .8W-80-16 .8W-80-16 .8W-80-16 .8W-80-17 .8W-80-17 .8W-80-17 .8W-80-17 .8W-80-18 .8W-80-18 .8W-80-18 .8W-80-19 .8W-80-19 .8W-80-19 .8W-80-19 .8W-80-20 .8W-80-20 .8W-80-20 .8W-80-20 .8W-80-21 .8W-80-21 .8W-80-21 .8W-80-21 .8W-80-21 .8W-80-22 .8W-80-22 .8W-80-22 .8W-80-22 .8W-80-22 .8W-80-23 .8W-80-23 .8W-80-23 .8W-80-23 .8W-80-24 .8W-80-24 .8W-80-24 .8W-80-24 .8W-80-24
8W - 80 - 2
Component C228 . . . . C229 . . . . C230 . . . . C231 . . . . C232 . . . . C233 . . . . C234 . . . . C235 . . . . C236 . . . . C301 . . . . C302 . . . . C303 . . . . C304 . . . . C305 . . . . C306 . . . . C307 . . . . C308 . . . . C309 . . . . C310 . . . . C311 . . . . C312 . . . . C313 . . . . C314 . . . . C315 . . . . C316 . . . . C317 . . . . C318 . . . . C319 . . . . C320 . . . . C321 . . . . C322 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1995 AN Dakota Publication No. 81-370-5110 TSB 08-55-94 October 14, 1994
1995 AN Dakota Publication No. 81-370-5110 TSB 08-55-94 October 14, 1994
1995 AN Dakota Publication No. 81-370-5110 TSB 08-55-94 October 14, 1994
1995 AN Dakota Publication No. 81-370-5110 TSB 08-55-94 October 14, 1994
1995 AN Dakota Publication No. 81-370-5110 TSB 08-55-94 October 14, 1994
8W - 90 - 1
CONNECTOR LOCATIONS
GENERAL INFORMATION
This section provides illustrations identifying component and connector locations in the vehicle. A connector index is provided. Use the wiring diagrams in each section for connector number identification. Refer to the index for the proper figure number.
CONNECTOR LOCATIONS
Connector # C101 . . . . . C102 . . . . . C103 . . . . . C104 . . . . . C105 . . . . . C106 . . . . . C107 . . . . . C108 . . . . . C109 . . . . . C110 . . . . . C111 . . . . . C112 . . . . . C113 . . . . . C114 . . . . . C115 . . . . . C116 . . . . . C117 . . . . . C118 . . . . . C119 . . . . . C120 . . . . . C121 . . . . . C122 . . . . . C123 . . . . . C124 . . . . . C125 . . . . . C126 . . . . . C127 . . . . . C128 . . . . . C129 . . . . . C130 . . . . . C131 . . . . . C132 . . . . . C133 . . . . . C133 . . . . . C133 . . . . . C134 . . . . . C134 . . . . . C134 . . . . . C135 . . . . . C135 . . . . . C135 . . . . . C136 . . . . . C137 . . . . . C138 . . . . . C139 . . . . . C140 . . . . . C140 . . . . . C141 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Color BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . GY . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Location Fig. Rear of Right Headlamp . . . . . . . . . 2 Right Side Marker Lamp . . . . . . . .2 Right Front Turn Signal Lamp . . .. . .2 Airbag Right Impact Sensor . . . . . .1 Right Fender Side Shield3.9L, 5.2L .1 Right Fender Side Shield3.9L, 5.2L .1 Right Fender Side Shield . . . . . . . .1 Right Fender Side Shield Right Fender Side Shield . . . . . . . .1 Windshield Wiper Motor . . . . . . . . .2 Left Side of Dash Panel . . . . . . . .21 Near Bulkhead Connector Washer Fluid Reservoir . . . . . . . . .2 Washer Fluid Reservoir . . . . . . . . .2 Below Master Cylinder . . . . . . . . . .2 Left of Vacuum Brake Booster . .2, 10 ABS Hydraulic Unit . . . . . . . . . . . .2 ABS Hydraulic Unit . . . . . . . . . . . .2 ABS Hydraulic Unit . . . . . . . . . . . .2 Near Battery . . . . . . . . . . . . . . . .2 Near Battery, Below PDC Below ABS Hydraulic Unit . . . . . . . .2 Below Battery Tray . . . . . . . . . . . .3 Rear of Left Headlamp . . . . . . . . . .2 Air Bag Left Impact Sensor . . . . . . .1 Left Front Turn Signal Lamp . . . . . .2 Left Front Side Marker Lamp . . . . . .2 Right Fender Side Shield2.5L . . . .1 Right Fender Side Shield3.9L, 5.2L .1 At PCM, Right Fender Side Shield . .1 Near Blower Motor Resistor Block . .1 On Receiver/Drier . . . . . . . . . . . . .1 Right Side of Dash Panel2.5L . . . .1 Rear of Fuel Rail3.9L . . . . . . . . .6 Rear of Fuel Rail5.2L . . . . . . . . .7 Right Side of Dash Panel2.5L . . . .1 Right of Distributor3.9L . . . . . . .6 Right of Distributor5.2L . . . . . . .7 Right Side of Dash Panel2.5L . . . .1 On Throttle Body3.9L . . . . . . . . .6 On Throttle Body5.2L . . . . . . . . .7 Below Windshield Wiper Motor . . . .5 Below Windshield Wiper Motor Radiator Fan Motor . . . . . . . . . . . .3 Speed Control Servo . . . . . . . . . . .1 No. 2 Injector3.9L . . . . . . . . . . .6 No. 2 Injector5.2L . . . . . . . . . . .7 No. 4 Injector3.9L . . . . . . . . . . .6 Connector # C141 . . . . . C142 . . . . . C142 . . . . . C143 . . . . . C144 . . . . . C144 . . . . . C145 . . . . . C145 . . . . . C146 . . . . . C146 . . . . . C147 . . . . . C148 . . . . . C148 . . . . . C148 . . . . . C149 . . . . . C149 . . . . . C150 . . . . . C150 . . . . . C150 . . . . . C151 . . . . . C151 . . . . . C151 . . . . . C152 . . . . . C153 . . . . . C153 . . . . . C153 . . . . . C154 . . . . . C154 . . . . . C154 . . . . . C155 . . . . . C156 . . . . . C156 . . . . . C156 . . . . . C157 . . . . . C157 . . . . . C158 . . . . . C159 . . . . . C160 . . . . . C161 . . . . . C162 . . . . . C163 . . . . . C164 . . . . . C164 . . . . . C164 . . . . . C165 . . . . . C166 . . . . . C167 . . . . . C168 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Color BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Location No. 4 Injector5.2L . . . . . . . . No. 6 Injector3.9L . . . . . . . . No. 6 Injector5.2L . . . . . . . . No. 8 Injector5.2L . . . . . . . . No. 1 Injector3.9L . . . . . . . . No. 1 Injector5.2L . . . . . . . . No. 3 Injector3.9L . . . . . . . . No. 3 Injector5.2L . . . . . . . . No. 5 Injector3.9L . . . . . . . . No. 5 Injector5.2L . . . . . . . . No. 7 Injector5.2L . . . . . . . . Rear of Generator2.5L . . . . . Rear of Generator3.9L . . . . . Rear of Generator5.2L . . . . . Near No.2 Injector3.9L . . . . . Near No.2 Injector5.2L . . . . . On Thermostat Housing2.5L . . Next to Generator3.9L . . . . . . Next to Generator5.2L . . . . . . Side of A/C Compressor2.5L . Side of A/C Compressor3.9L . Side of A/C Compressor5.2L . On A/C Line at Compressor Side of Throttle Body2.5L . . . Rear of Throttle Body3.9L . . . Rear of Throttle Body5.2L . . . On Throttle Body2.5L . . . . . . On Throttle Body3.9L . . . . . . On Throttle Body5.2L . . . . . . Rear of Engine . . . . . . . . . . . . Rear Left of Engine Block2.5L Near Distributor3.9L . . . . . . . Near Distributor5.2L . . . . . . . Distributor3.9L . . . . . . . . . . Distributor5.2L . . . . . . . . . . Left Side of Transmission . . . . . Left Side of Transmission . . . . . Back-up Lamp Switch . . . . . . . Top Front of Engine . . . . . . . . Top of Transmission . . . . . . . . On Transfer Case . . . . . . . . . . Ignition Coil2.5L . . . . . . . . . Ignition Coil3.9L . . . . . . . . . Ignition Coil5.2L . . . . . . . . . Starter Motor . . . . . . . . . . . . . On Throttle Body2.5L . . . . . . On Throttle Body2.5L . . . . . . Distributor2.5L . . . . . . . . . . Fig. . . .7 . . .6 . . .7 . . .7 . . .6 . . .7 . . .6 . . .7 . . .6 . . .7 . . .7 . . .5 . . .6 . . .7 . . .6 . . .7 . . .5 . . .6 . . .7 . . .5 . . .6 . . .7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 .6 .7 .5 .6 .7 .8 .5 .6 .7 .6 .7 .8 .8 .8 .8 .8 .8 .5 .6 .7 .4 .5 .5 .5
8W - 90 - 2
Connector # C201 . . . . . C202 . . . . . C203 . . . . . C204 . . . . . C205 . . . . . C206 . . . . . C207 . . . . . C208 . . . . . C209 . . . . . C210 . . . . . C211 . . . . . C212 . . . . . C213 . . . . . C214 . . . . . C215 . . . . . C216 . . . . . C217 . . . . . C218 . . . . . C219 . . . . . C220 . . . . . C221 . . . . . C222 . . . . . C223 . . . . . C224 . . . . . C225 . . . . . C226 . . . . . C227 . . . . . C228 . . . . . C229 . . . . . C230 . . . . . C231 . . . . . C232 . . . . . C233 . . . . . C234 . . . . . C235 . . . . . C236 . . . . . C301 . . . . . C302 . . . . . C303 . . . . . C304 . . . . . C305 . . . . . C306 . . . . . C307 . . . . . C308 . . . . . C309 . . . . . C310 . . . . . C311 . . . . . C312 . . . . . C313 . . . . . C314 . . . . . C315 . . . . . C316 . . . . . C317 . . . . . C318 . . . . . C319 . . . . . C320 . . . . . C321 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Color BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . GY . BK . GY . BK . BK . BK . BK . BK . BK . GY . RD . BK . BK . BK . BK . BK . BK . BK BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . RD . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . BK . . BK . BK . BK . BK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
D102. . . . . . . . . . . . . D102 . . . . . . . . . . . . D201 G101 G102 G103 G104 G105 G106 G107 G107 G108 G108 G109 G109 G110 G111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8W - 90 - 3
Color Location Fig. . . . . . . . Center of Windshield Header . . . . .12 . . . . . . . Near PDC . . . . . . . . . . . . . . . . .18 . . . . . . . Dash Panel, Left of Master Cylinder . . . . . . . . . . . . . . . . . .2
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8W - 95 - 1
SPLICE LOCATIONS
GENERAL INFORMATION
The illustrations referenced in this section show the general location of each splice. Individual splice numbers are referenced on diagram pages throughout Group 8W.
SPLICE LOCATIONS
Splice Number S101. . . S102 . . S103 . . S104 . . S105 . . S106 . . S107 . . S108 . . S109 . . S110 . . S111 . . S112 . . S113 . . S114 . . S115 . . S116 . . S117 . . S118 . . S119 . . S120 . . S121 . . Splice Number S141 . . . . . S142 . . . . . S143 . . . . . S144 . . . . . S145 . . . . . S201 . . . . . S202 S203 S204 S205 S206 . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
S122 . . . . . S123 . . . . . S124 . . . . . S125 . . . . . S126 S127 S128 S129 S130 S131 S132 S133 S134 S135 S135 S136 S137 S138 S139 S140 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Locations Fig. . Below Coolant Reservoir . . . . . . . . . . . . .1, 2 . After Coolant Reservoir . . . . . . . . . . . . . . .1 . After Coolant Reservoir . . . . . . . . . . . . .1, 2 . Before T/O for Right Headlamp Ground . . . . .1 . After Wiper Motor T/O . . . . . . . . . . . . . .1, 2 . Before Bulkhead Connector . . . . . . . . . . .1, 2 . Near Washer Fluid Reservoir . . . . . . . . . .1, 2 . Below Washer Fluid Reservoir . . . . . . . . .1, 2 . Below Washer Fluid Reservoir . . . . . . . . .1, 2 . Below Washer Fluid Reservoir . . . . . . . . .1, 2 . Below Washer Fluid Reservoir . . . . . . . . .1, 2 . Between Washer Fluid Reservoir and PDC .1, 2 . Before T/O for Left Headlamp Ground . . . .1, 2 . Before T/O for Left Headlamp Ground . . . .1, 2 . After T/O for Left Headlamp Ground . . . . . . .1 . Below PDC . . . . . . . . . . . . . . . . . . . . .1, 2 . Below PDC . . . . . . . . . . . . . . . . . . . . . . .1 . Near PDC Connector . . . . . . . . . . . . . . .1, 2 . Before Wiper Motor T/O . . . . . . . . . . . . . . .2 . Near Blower Motor Resistor Block . . . . . . . .2 . Between PCM and Blower Motor Resistor Block . . . . . . . . . . . . . . . . . . . . . . . .2, 3 . After PCM . . . . . . . . . . . . . . . . . . . . . . . .2 . After T/O for Injector No. 1 . . . . . . . . . . .2, 3 . Between Blower Motor Resistor and Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . .2 . Between Data Link Connector T/O and Speed Control Servo T/O . . . . . . . . . . . . .3 . Before T/O for Low Washer Fluid Level Sensor .2 . Below PDC . . . . . . . . . . . . . . . . . . . . . . .2 . Near PCM Connector . . . . . . . . . . . . . . . . .3 . Between PCM and Blower Motor Resistor Block . . . . . . . . . . . . . . . . . . . . . . . . .3 . Near Blower Motor Resistor Block . . . . . . . .3 . Near Blower Motor Resistor Block . . . . . . . .3 . After T/O for Injector No. 6 . . . . . . . . . . . .3 . Between Take Outs for Injector No. 4 and No. 6 . . . . . . . . . . . . . . . . . . . . . .3 . Before T/O For IAC Motor . . . . . . . . . . . . . .3 . Near T/O for Injector No. 7, 3.9L/5.2L . . . . . .3 . After T/O for Temperature Sensor, 2.5L . . . . .4 . Between T/O for Injector No. 7 and T/O for Oil Pressure Sending Unit . . . . . . . . . .3 . Above Bulkhead Connector . . . . . . . . . . . . .2 . Between PCM and A/C Compressor Clutch Relay . Between PCM and A/C Compressor Clutch Relay . After Battery Positive Post . . . . . . . . . . . . .4
S207 . . . . . S208 S209 S210 S211 S212 S213 S214 S215 S216 S301 S302 S303 S304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
S305 . . . . . S306 . . . . . S307 S308 S309 S310 S311 S312 S313 S314 S315 S316 S317 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Locations Fig. . Before T/O for Temperature Sending Unit . . . .4 . Before T/O for Oil Pressure Sending Unit . . . .4 . Before Oil Pressure Sending Unit T/O and Engine Ground T/O . . . . . . . . . . . . . . . .4 . Before T/O for IAC Motor . . . . . . . . . . . . . .4 . Before T/O for Ignition Coil . . . . . . . . . . . . .4 . Between Radio Take Outs and Stop Lamp Switch Take Out . . . . . . . . . . . . . . . . . .5 . Before T/O for Stop Lamp Switch . . . . . . . .5 . Before T/O for A/C-Heater Controls . . . . . . . .5 . In A/C-Heater Controls T/O . . . . . . . . . . . . .5 . After A/C-Heater Controls T/O . . . . . . . . . . .5 . Between A/C-Heater Controls T/O and IP Cluster T/Os . . . . . . . . . . . . . . . . . . .5 . Between A/C-Heater Controls T/O and IP Cluster T/Os . . . . . . . . . . . . . . . . . . .5 . Before IP Cluster Take Outs . . . . . . . . . . . .5 . In T/O for Overdrive Switch . . . . . . . . . . . .5 . Near Overdrive Switch T/O . . . . . . . . . . . . .5 . After Overdrive Switch T/O . . . . . . . . . . . . .5 . Near Fuse Block . . . . . . . . . . . . . . . . . . . .5 . Near Fuse Block . . . . . . . . . . . . . . . . . . . .5 . Diode Before Bulkhead Connector . . . . . . . . .5 . Diode Before Bulkhead Connector . . . . . . . . .5 . Before Park Brake Switch T/O . . . . . . . . . . .5 . Near T/O for Left Door Speaker . . . . . . . . . .6 . Before T/O for Right Door Speaker . . . . . . . .6 . After T/O for Right Door Speaker . . . . . . . . .6 . Between CHMSL T/O and Fuel Pump Module T/O . . . . . . . . . . . . . . . . . . . . .7 . Between CHMSL T/O and Fuel Pump Module T/O . . . . . . . . . . . . . . . . . . . . .7 . Between CHMSL T/O and Fuel Pump Module T/O . . . . . . . . . . . . . . . . . . . . .7 . Before T/O for Stop Lamp Switch . . . . . . . .7 . Before Overhead Console and T/O for Ground .9 . Before Take Outs for Fog Lamps . . . . . . . . .8 . After T/O for Fog Lamp Ground . . . . . . . . . .8 . After Fog Lamp Switch T/O . . . . . . . . . . . . .8 . Before Park Lamp Relay and High Beam Relay .8 . In Fog Lamp Switch T/O . . . . . . . . . . . . . .8 . In Trailer Tow Harness . . . . . . . . . . . . . . . .7 . In Trailer Tow Harness . . . . . . . . . . . . . . . .7 . In Trailer Tow Harness . . . . . . . . . . . . . . . .7 . In Trailer Tow Harness . . . . . . . . . . . . . . . .7
8W - 95 - 2
Splice Number S318 . . . . . S401 . . . . . S402 . . . . .
Locations Fig. . In Trailer Tow Harness . . . . . . . . . . . . . . . .7 . Before T/O for Right Back-Up Lamp . . . . . .11 . In CHMSL Harness, Before Lamps . . . . . . .10
Locations Fig. . In CHMSL Harness, Before Lamps . . . . . . .10 . Before T/O for Left Back-Up Lamp . . . . . . .11 . Between License Plate Lamps . . . . . . . . . .11
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ENGINE
9 - 1
ENGINE
CONTENTS
page page
3.9L ENGINE SERVICE PROCEDURES . . . . . . . 49 5.2L ENGINE SERVICE PROCEDURES . . . . . . . 82 STANDARD SERVICE PROCEDURES . . . . . . . . . 1
FORM-IN-PLACE GASKETS
There are several places where form-in-place gaskets are used on the engine. DO NOT use form-inplace gasket material unless specified. Care must be taken when applying form-in-place gaskets. Bead size, continuity and location are of great importance. Too thin a bead can result in leakage while too much can result in spill-over. A continuous bead of the proper width is essential to obtain a leak-free joint. Two types of form-in-place gasket materials are used in the engine area (Mopar Silicone Rubber Adhesive Sealant and Mopar Gasket Maker). Each have different properties and cannot be used interchangeably.
SURFACE PREPARATION Parts assembled with form-in-place gaskets may be disassembled without unusual effort. In some instances, it may be necessary to lightly tap the part with a mallet or other suitable tool to break the seal between the mating surfaces. A flat gasket scraper may also be lightly tapped into the joint but care must be taken not to damage the mating surfaces. Scrape or wire brush all gasket surfaces to remove all loose material. Inspect stamped parts to ensure gasket rails are flat. Flatten rails with a hammer on a flat plate, if required. Gasket surfaces must be free of oil and dirt. Make sure the old gasket material is removed from blind attaching holes. GASKET APPLICATION Assembling parts using a form-in-place gasket requires care. Mopar Silicone Rubber Adhesive Sealant should be applied in a continuous bead approximately 3 mm (0.12 inch) in diameter. All mounting holes must be circled. For corner sealing, a 3 or 6 mm (1/8 or 1/4 inch) drop is placed in the center of the gasket contact area. Uncured sealant may be removed with a shop towel. Components should be torqued in place while the sealant is still wet to the touch (within 10 minutes). The use of a locating dowel is recommended during assembly to prevent smearing the material off location. Mopar Gasket Maker should be applied sparingly to one gasket surface. The sealant diameter should be 1.00 mm (0.04 inch) or less. Be certain the material surrounds each mounting hole. Excess material
MOPAR SILICONE RUBBER ADHESIVE SEALANT Mopar Silicone Rubber Adhesive Sealant, normally black in color, is available in 3 ounce tubes. Moisture in the air causes the sealant material to cure. This material is normally used on flexible metal flanges. It has a shelf life of a year and will not properly cure if over aged. Always inspect the package for the expiration date before use. 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. DO NOT use on flexible metal flanges.
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ENGINE
bled to determine the cause of low compression unless some malfunction is present. (4) Clean or replace spark plugs as necessary. Adjust gap (refer to Group 8D, Ignition System for gap adjustment and torque). (5) Test resistance of spark plug cables (refer to Group 8D, Ignition System). (6) Inspect the primary wire. Test coil output voltage, primary and secondary resistance. Replace parts as necessary (refer to Group 8D, Ignition System and make necessary adjustment). (7) Set ignition timing to specifications (refer to Specification Label on engine compartment hood). (8) Perform a combustion analysis. (9) Test fuel pump for pressure (refer to Group 14, Fuel System for the proper specifications). (10) Inspect air filter element (refer to Group 0, Lubrication and Maintenance for the proper procedure). (11) Inspect crankcase ventilation system (refer to Group 0, Lubrication and Maintenance for the proper procedure). (12) For emission controls, refer to Group 25, Emission Controls System for service procedures. (13) Inspect and adjust accessory belt drives (refer to Group 7, Cooling System for the proper adjustments). (14) Road test vehicle as a final test.
can easily be wiped off. Components should be torqued in place within 15 minutes. The use of a locating dowel is recommended during assembly to prevent smearing the material off location.
ENGINE PERFORMANCE
To provide best vehicle performance and lowest vehicle emissions, it is most important that the tune-up be done accurately. Use the specifications listed on the Vehicle Emission Control Information label found on the engine compartment hood. (1) Test cranking amperage draw (refer to Group 8B, Battery/Starter/Generator Service for the proper procedures). (2) Tighten the intake manifold bolts (refer to Group 11, Exhaust System and Intake Manifold for the proper specifications). (3) Perform cylinder compression test: (a) Check engine oil level and add oil, if necessary. (b) Drive the vehicle until engine reaches normal operating temperature. (c) Select a route free from traffic and other forms of congestion, observe all traffic laws and briskly accelerate through the gears several times. The higher engine speed may help clean out valve seat deposits which can prevent accurate compression readings. CAUTION: DO NOT overspeed the engine. (d) Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for abnormal firing indicatorsfouled, hot, oily, etc. Record cylinder number of spark plug for future reference. (e) Disconnect coil wire from distributor and secure to good ground to prevent a spark from starting a fire. (f) Be sure throttle blades are fully open during the compression check. (g) Insert compression gage adaptor into the No.1 spark plug hole. Crank engine until maximum pressure is reached on gauge. Record this pressure as No.1 cylinder pressure. (h) Repeat Step 3g for all remaining cylinders. (i) Compression should not be less than 689 kPa (100 psi) and not vary more than 172 kPa (25 psi) from cylinder to cylinder. (j) If cylinder(s) have abnormally low compression pressures, repeat steps 3a through 3h. (k) If the same cylinder(s) repeat an abnormally low reading, it could indicate the existence of a problem in the cylinder. The recommended compression pressures are to be used only as a guide to diagnosing engine problems. An engine should NOT be disassem-
ENGINE
The hone marks should INTERSECT at 50 to 60 for proper seating of rings (Fig. 1). (4) A controlled hone motor speed between 200 and
9 - 3
CHECK NO.3 BEARING: Shim No.2 and No.4 main bearing. CHECK NO.4 BEARING: Shim No.3 main bearing (3.9L). Shim No.3 and No.5 main bearing (2.5L and 5.2L). CHECK NO.5 BEARING: Shim No.4 main bearing (2.5L and 5.2L). Remove all shims before assembling engine. METHOD - 2 (ALTERNATIVE)The weight of the crankshaft is supported by a jack under the counterweight adjacent to the bearing being checked. (3) Place a piece of Plastigage across the entire width of the bearing cap shell (Fig. 2). Position the Plastigage approximately 6.35 mm (1/4 inch) off center and away from the oil holes. In addition, suspect areas can be checked by placing the Plastigage in that area. Tighten the bearing cap bolts of the bearing being checked to 41 N m (30 ft. lbs.) torque plus 1/4 turn (2.5L Engine). Tighten the bearing cap bolts of the bearing being checked to 115 N m (85 ft. lbs.) torque (3.9L and 5.2L Engines). DO NOT rotate the crankshaft or the Plastigage may be smeared, giving inaccurate results. (4) Remove the bearing cap and compare the width
CONNECTING ROD BEARING CLEARANCE Engine connecting rod bearing clearances can be determined by use of Plastigage, or equivalent. The following is the recommended procedures for the use of Plastigage: (1) Remove oil film from surface to be checked. Plastigage is soluble in oil.
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ENGINE
CAUTION: Be sure that the tapped holes maintain the original center line. Heli-Coil tools and inserts are readily available from automotive parts jobbers.
HYDROSTATIC LOCK
When an engine is suspected of hydrostatic lock (regardless of what caused the problem), follow the steps below. (1) Perform the Fuel Pressure Release Procedure (refer to Group 14, Fuel System). (2) Disconnect the negative cable from the battery. (3) Inspect air cleaner, induction system and intake manifold to ensure system is dry and clear of foreign material. (4) Place a shop towel around the spark plugs to catch any fluid that may possibly be under pressure in the cylinder head. Remove the plugs from the engine. CAUTION: DO NOT use the starter motor to rotate the crankshaft. Severe damage could occur. (5) With all spark plugs removed, rotate the crankshaft using a breaker bar and socket. (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. This will prevent damage on restart. (10) Install new spark plugs. Tighten the 2.5L engine spark plugs to 27 N m (20 ft. lbs.) torque. Tighten the 3.9L or 5.2L engine spark plugs to 41 N m (30 ft. lbs.) torque. (11) Drain engine oil. Remove and discard the oil filter. (12) Install the drain plug. Tighten the 2.5L engine drain plug to 27 N m (20 ft. lbs.) torque. Tighten the 3.9L or 5.2L engine drain plug to 34 N m (25 ft. lbs.) torque. (13) Install a new oil filter. (14) Fill engine crankcase with the specified amount and grade of oil (refer to Group 0, Lubrication and Maintenance). (15) Connect the negative cable to the battery. (16) Start the engine and check for any leaks.
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GENERAL INFORMATION
Engine diagnosis is helpful in determining the causes of malfunctions not detected and remedied by routine tune-ups. These malfunctions may be classified as either mechanical (e.g., a strange noise), or performance (e.g., engine idles rough and stalls). Refer to the Service DiagnosisMechanical Chart and the Service DiagnosisPerformance Chart for possible causes and corrections of malfunctions. Refer to Group 14, Fuel System for the fuel system diagnosis. Additional tests and diagnostic procedures may be necessary for specific engine malfunctions that can not be isolated with the Service Diagnosis charts. Information concerning additional tests and diagnosis is provided within the following diagnosis: Cylinder Compression Pressure Test. Cylinder Combustion Pressure Leakage Test. Engine Cylinder Head Gasket Failure Diagnosis. Intake Manifold Leakage Diagnosis.
Ensure the battery is completely charged and the engine starter motor is in good operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis purposes. (1) Clean the spark plug recesses with compressed air. (2) Remove the spark plugs. (3) Secure the throttle in the wide-open position. (4) Disconnect the ignition coil. (5) Insert a compression pressure gauge and rotate the engine with the engine starter motor for three revolutions. (6) Record the compression pressure on the 3rd revolution. Continue the test for the remaining cylinders. Refer to Engine Specifications for the correct engine compression pressures.
CYLINDER-TO-CYLINDER LEAKAGE TEST To determine if an engine cylinder head gasket is leaking between adjacent cylinders; follow the procedures outlined in Cylinder Compression Pressure Test. An engine cylinder head gasket leaking between adjacent cylinders will result in approximately a 5070% reduction in compression pressure. CYLINDER-TO-WATER JACKET LEAKAGE TEST
WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING. DO NOT STAND IN A DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE PULLEYS, BELTS OR THE FAN. DO NOT WEAR LOOSE CLOTHING. Remove the radiator cap. Start the engine and allow it to warm up until the engine thermostat opens. If a large combustion/compression pressure leak exists, bubbles will be visible in the coolant.
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ENGINE
(2) Add an oil soluble dye (use as recommended by manufacturer). Start the engine and let idle for approximately 15 minutes. Check the oil dipstick to make sure the dye is thoroughly mixed as indicated with a bright yellow color under a black light. (3) Using a black light, inspect the entire engine for fluorescent dye, particularly at the suspected area of oil leak. If the oil leak is found and identified, repair per service manual instructions. (4) If dye is not observed, drive the vehicle at various speeds for approximately 24km (15 miles), and repeat step (3). If the oil leak source is not positively identified at this time, proceed with the air leak detection test method as follows: (1) Disconnect the breather cap to air cleaner hose at the breather cap end. Cap or plug breather cap nipple. (2) Remove the PCV valve from the cylinder head cover. Cap or plug the PCV valve grommet. (3) Attach an air hose with pressure gauge and regulator to the dipstick tube. CAUTION: Do not subject the engine assembly to more than 20.6 kpa (3 PSI) of test pressure. (4) Gradually apply air pressure from 1 psi to 2.5 psi maximum while applying soapy water at the suspected source. Adjust the regulator to the suitable test pressure that provide the best bubbles which will pinpoint the leak source. If the oil leak is detected and identified, repair per service manual procedures. (5) If the leakage occurs at the rear oil seal area, refer to the section, Inspection for Rear Seal Area Leak. (6) If no leaks are detected, turn off the air supply and remove the air hose and all plugs and caps. Install the PCV valve and breather cap hose. Proceed to step 7. (7) Clean the oil off the suspect oil leak area using a suitable solvent. Drive the vehicle at various speeds approximately 24 km (15 miles). Inspect the engine for signs of an oil leak by using a black light.
If bubbles are not visible, install a radiator pressure tester and pressurize the coolant system. If a cylinder is leaking combustion pressure into the water jacket, the tester pointer will pulsate with every combustion stroke of the cylinder.
INSPECTION FOR REAR SEAL AREA LEAKS Since it is sometimes difficult to determine the source of an oil leak in the rear seal area of the engine, a more involved inspection is necessary. The following steps should be followed to help pinpoint the source of the leak. If the leakage occurs at the crankshaft rear oil seal area: (1) Disconnect the battery. (2) Raise the vehicle. (3) Remove torque converter or clutch housing cover and inspect rear of block for evidence of oil. Use a black light to check for the oil leak:
ENGINE
(a) Circular spray pattern generally indicates seal leakage or crankshaft damage. (b) Where leakage tends to run straight down, possible causes are a porous block, distributor seal, camshaft bore cup plugs oil galley pipe plugs, oil filter runoff, and main bearing cap to cylinder block mating surfaces. See Group 9, Engines for proper repair procedures of these items. (4) If no leaks are detected, pressurized the crankcase as outlined in the, Inspection (Engine oil Leaks in general) CAUTION: Do not exceed 20.6 kPa (3 psi). (5) If the leak is not detected, very slowly turn the crankshaft and watch for leakage. If a leak is detected between the crankshaft and seal while slowly turning the crankshaft, it is possible the crankshaft seal surface is damaged. The seal area on the crankshaft could have minor nicks or scratches that can be polished out with emery cloth. CAUTION: Use extreme caution when crankshaft polishing is necessary to remove minor nicks and
9 - 7
scratches. The crankshaft seal flange is especially machined to complement the function of the rear oil seal. (6) For bubbles that remain steady with shaft rotation, no further inspection can be done until disassembled. Refer to the service DiagnosisMechanical, under the Oil Leak row for components inspections on possible causes and corrections. (7) After the oil leak root cause and appropriate corrective action have been identified, Refer to Group 9, EnginesCrankshaft Rear Oil Seals, for proper replacement procedures.
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ENGINE
SERVICE DIAGNOSISPERFORMANCE
ENGINE
SERVICE DIAGNOSISMECHANICAL
9 - 9
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ENGINE
SERVICE DIAGNOSISLUBRICATION
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page Engine Front Mounts . . . . . . . . . . . . . . . . . . . . . . . Engine Lubrication System . . . . . . . . . . . . . . . . . . Engine Mounts . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Rear Support . . . . . . . . . . . . . . . . . . . . . . . General Information . . . . . . . . . . . . . . . . . . . . . . . . Intermediate Shaft Service . . . . . . . . . . . . . . . . . . Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Pump Service . . . . . . . . . . . . . . . . . . . . . . . . . Solid Mount Compressor Bracket Service . . . . . . . Timing System and Seals Service . . . . . . . . . . . . . Valve ServiceCylinder Head Removed . . . . . . . . 13 39 13 13 11 32 45 42 42 15 16 25
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18 44 28 29 30 34 24 19 21 14 38
GENERAL INFORMATION
SPECIFICATION
ENGINE IDENTIFICATION NUMBER OR CODE The engine identification number is located on the rear of the cylinder block just below the cylinder head (Fig. 1). BLOCK: The four cylinder cast iron blocks have cast-in recesses in the bottom of each cylinder bore to provide connecting rod clearance; especially for 2.5L engines. The bores are also siamese to minimize engine length. A partial open deck is used for cooling and weight reduction with oil filter, water pump, and distributor mounting bosses molded into the front (radiator side) of the block. Nominal wall thickness is 4.5 mm (0.177 in.). Five main bearing bulkheads and
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2.5L ENGINE
through a sintered iron sprocket mounted on the nose of the accessory shaft. The accessory shaft in turn drives the oil pump and distributor. VALVES: The valves are actuated by roller cam followers which pivot on stationary hydraulic lash adjusters. The valve train with 40.6 mm (1.60 in.) diameter intake valves and 35.4 mm (1.39 in.) diameter exhaust valves employ viton rubber valve stem seals. Valve springs, spring retainers, and locks are conventional. INTAKE MANIFOLDS: The intake manifold is a four branch design aluminum casting. The long branch fan design enhances low and midspeed torque and also features an integrally cast water crossover passage to warm incoming fuel/air mixture, plus EGR mounting boss and PCV inlet. EXHAUST MANIFOLDS: All exhaust manifolds are made of nodular cast iron for strength and high temperatures. All naturally aspirated engines exit exhaust gasses through a machined, articulated joint connection to the exhaust pipe. All manifolds intermesh with the intake manifold at the cylinder head. 2.5L engines use a four branch design with cylinders one and four joined and cylinder two and three joined to exit at the outlet. ENGINE LUBRICATION: System is full flow filtration, pressure feed type. The oil pump is mounted within the crankcase and driven by the auxiliary shaft. Pressurized oil is routed through the main oil gallery, to the main and rod bearings, then to the lower balance shaft assemblies. Pistons are lubricated from directed holes in connecting rod assemblies. Camshaft and valve mechanisms are lubricated from a full-length cylinder head oil gallery supplied from the crankcase main oil gallery.
sprocket is mounted on the crankshaft nose. This sprocket provides motive power; via timing belt to the camshaft and intermediate shaft sprockets (also sintered iron) providing timed valve, distributor, and oil pump actuation. PISTONS: The 2.5L TBI pistons have valve cuts to provide valve clearance and also have cast-in steel struts at the pin bosses for autothermic control. The 2.5L engine is designed for 8.9:1 compression ratio. The standard 2.5L piston is dished and is a lightweight design to further enhance engine smoothness. All TBI 2.5L engines use pressed-in piston pins to attach forged steel connecting rods. CYLINDER HEAD: The cylinder head is cast aluminum with in-line valves arranged with alternating exhaust and intake. The intake and exhaust ports are located in the rearward, facing side of the head. The intake ports feed fast-burn design combustion chambers with spark plugs located close to the center line of the combustion chamber for optimum efficiency. An integral oil gallery within the cylinder head supplies oil to the hydraulic lash adjusters, camshaft, and valve mechanisms. CAMSHAFT: The nodular iron camshaft has five bearing journals. Flanges at the rear journal control camshaft end play. A sintered iron timing belt sprocket is mounted on the cam nose, and a hydrodynamic oil seal is used for oil control at the front of the camshaft. ACCESSORY SHAFT: The iron accessory shaft has two bearing journals and is housed in the forward facing side of the block. A hydrodynamic seal, installed in an aluminum housing attached to the block, provides retention, shaft thrust, and oil control. The accessory shaft is driven by the timing belt
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(4) Install and tighten the thru-bolt nut to 68 N m (50 ft. lbs.) torque (Fig. 2). (5) Remove lifting fixture or jack. (6) Lower the vehicle. (7) Connect the negative cable to the battery.
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(16) Disconnect the starter motor wires. (17) Remove upper transmission housing bolts. (18) Lower the vehicle. (19) Support transmission with a transmission stand. (20) Install an engine lifting fixture. Attach a chain hoist to fixture eyebolt. (21) Loosen engine mount through bolts. (22) Remove engine to transmission struts and bolts. (23) Raise engine until front mount insulators clear the crossmember retaining brackets. Move engine forward until drive pinion shaft clears the clutch disc. (24) Remove engine from engine compartment and install on engine repair stand. (25) Remove the engine lifting fixture.
ENGINE ASSEMBLY
REMOVAL (1) Scribe the hood hinge outlines on the hood. Remove the hood. (2) Drain cooling system (refer to Group 7, Cooling System for the proper procedure). (3) Remove the battery. (4) Remove the air cleaner. (5) Disconnect the radiator and heater hoses. Remove electric cooling fan and radiator (refer to Group 7, Cooling System). (6) Remove air conditioning compressor mounting bolts and set compressor aside (if equipped). (7) Remove the vacuum lines. (8) Disconnect the accelerator linkage and speed control (if equipped). (9) Perform the Fuel System Pressure Release procedure (refer to Group 14, Fuel System). (10) Disconnect the fuel lines and brackets. (11) If equipped, remove the power steering hoses and cap ends of open hoses. (12) Disconnect the body wiring harness. (13) Raise the vehicle on a hoist. (14) Disconnect exhaust pipe at manifold. (15) Remove starter motor.
INSTALLATION (1) Attach an engine lifting fixture to the engine. Attach a chain hoist to fixture eyebolt. (2) Remove engine from repair stand and position in engine compartment. (3) Move engine rearward until drive pinion shaft engages the clutch disc or torque converter. (4) Install engine to transmission struts and bolts. (5) Loose install engine mount through bolts and nuts. (6) lower engine mount into mount brackets. Tighten the thru-bolt nuts to 68 N m (50 ft. lbs.) torque. (7) Remove transmission stand from the transmission. (8) Raise the vehicle on a hoist. (9) Install transmission to clutch housing bolts. Tighten the bolts to 41 N m (30 ft. lbs.) torque. (10) Connect the starter motor wires. (11) Install starter motor. (12) Install exhaust pipe to manifold. Tighten the bolts to 27 N m (20 ft. lbs.). (13) Lower the vehicle. (14) Install vacuum lines. (15) Connect the fuel lines and brackets. (16) Connect the accelerator linkage and speed control (if equipped). (17) Position and install the radiator. Install the fan shroud (refer to Group 7, Cooling System). Connect the radiator and heater hoses. (18) Connect body wiring harness. (19) Connect power steering hoses, if so equipped. (20) If equipped, install the air conditioning compressor to bracket. If system was opened, evacuate and charge the air conditioning system (refer to Group 24, Heater and Air Conditioning). (21) Fill the cooling system (refer to Group 7, Cooling System for the proper procedure). (22) Install battery. (23) Install the air cleaner. (24) Start the engine and warm to operating temperature. Adjust the engine, if necessary.
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ACCESSORIES REMOVAL (1) Disconnect the negative cable from the battery. (2) Remove (and install/adjust) belts, Refer to Accessory Drive Belts in Cooling System, Group 7. (3) Remove air conditioning compressor (in vehicle with lines and set aside) (Fig. 4). (4) Remove generator pivot bolt and remove generator (in vehicle: turn wiring side up and disconnect). (5) Remove air conditioner compressor belt idler. SOLID MOUNT BRACKETREMOVAL (1) Remove five side mounting bolts #1, #4 , #5, #6, and #7 (Fig. 4). (2) Remove front mounting nut, #2, and remove (or loosen) front bolt #3*. *In vehicle: fully loosen bolt and remove with assembly.
SOLID MOUNT BRACKETINSTALLATION (1) Front mounting bolt and spacer need to be installed simultaneously with bracket. (2) Install bracket on front (#2 nut) mounting stud and slide bracket over timing belt cover into position. (3) Loosen assembly bracket to engine fasteners (numbered #1 through #7 in Fig. 4).
CAUTION: Fasteners MUST BE TIGHTENED IN SEQUENCE and to specified torque. (4) Tighten in the following alphabetical sequence: (a) Bolt #1 to 30 N m (30 in. lbs.) (b) Nut #2 and Bolt #3 to 54 N m (40 ft. lbs.). (c) Tighten Bolts #1 (second tightening) #4 and #5 to 54 N m (40 ft. lbs.). (d) Bolts #6 and #7 to 54 N m (40 ft. lbs.). (5) Install generator and A/C compressor. Tighten compressor mounting bracket bolts to 54 N m (40 ft. lbs.). (6) Connect the negative cable to the battery.
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(3) Remove nuts holding cover to cylinder head. (4) Remove screws holding cover to cylinder block. (5) Remove both halves of timing belt cover and lay aside (Fig. 3)
TIMING BELT SERVICE (1) Remove Solid Mount Compressor Bracket. Refer to procedure outlined in this section. (2) Remove screws retaining water pump pulley and bolts retaining crankshaft pulley (Fig. 2) and lay pulley aside.
2.5L ENGINE
(6) Loosen timing belt tensioner screw (Fig. 4) and remove timing belt.
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(4) Hold engine sprocket with Special Tool C-4687 (with adaptor Tool C-4687-1) while removing/installing screw (Fig. 6).
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2.5L ENGINE
(3) Install timing belt.
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(10) Position both halves of timing belt cover together (Fig. 4). (11) Install fasteners holding cover to cylinder head and block. Tighten fasteners to 4 N m (40 in. lbs.) torque. (12) Valve Timing Check; (timing belt cover installed). With number one cylinder at TDC, small hole in sprocket must be centered in timing belt cover hole (Fig. 10). If hole is not aligned correctly perform procedure again. (13) Install spark plugs.
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CLEANING Before installation, clean cylinder head and cover mating surfaces. CURTAIN INSTALLATION Install curtain manifold side first with cutouts over cam towers and contacting cylinder head floor, then press opposite distributor side into position below cylinder head rail. Curtain is retained in position with rubber bumpers (Fig. 1). COVER INSTALLATION Before installation, clean cylinder head and cover mating surfaces. Make certain rails are flat. (1) Install a new gasket on valve cover.
CAUTION: Do not allow oil or solvents to contact the timing belt as they can deteriorate the rubber and cause tooth skipping. (2) Install curtain, cover and gasket assembly to head and tighten to 12 N m (105 in.lbs.). (3) Install timing belt cover (refer to Timing Belt Service in this section). (4) Connect the negative cable from the battery.
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2.5L ENGINE
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CAMSHAFT SERVICE Refer to TIMING SYSTEM AND SEALS for camshaft timing belt and sprocket removal and installation, and CYLINDER HEAD In Vehicle Service. REMOVAL (1) Disconnect the negative cable from the battery. (2) Remove timing belt cover (refer to Timing Belt Service in this section).
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2.5L ENGINE
Fig. 7 Camshaft
CAMSHAFT END PLAY (1) Oil camshaft journals and install camshaft without cam followers. Tighten screws to specified torque. (2) Using a suitable tool, move camshaft as far rearward as it will go. (3) Zero dial indicator (Fig. 8). (4) Move camshaft as far forward as it will go. (5) End play travel: 0.13 - 0.33 mm (0.005 - 0.013 in.) (6) Remove bearing caps and camshaft.
INSPECTION Check bearing cap and oil feed holes for blockage. Inspect bearing cap and cylinder head journals for wear and/or oversize, Refer to CYLINDER HEAD, Inspect and Specifications.
INSTALLATION (1) Install cam followers in correct order as removed. (2) Apply Mopar Gasket Maker to No.1 and No.5 bearing cap (Fig. 9). (3) Align camshaft bearing caps in proper sequence with Cap No. 1 at timing belt end and Cap No. 5 at transmission end. Arrows on Caps No. 1, 2, 3, 4 must point toward timing belt to prevent cap breakage (Fig. 10). (4) Caps must be installed before camshaft seals are installed.
2.5L ENGINE
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VALVE SPRINGS AND VALVE STEM SEALS REMOVAL (1) Remove rocker arms as previously outlined in this section. (2) Rotate crankshaft until piston is at TDC on compression. (3) With air hose attached to adapter tool installed in spark plug hole, apply 90-120 psi air pressure. (4) Using Special Tool C-4682 (Fig. 11) compress valve springs and remove valve locks. (5) Remove valve spring. (6) Remove valve stem seal by gently prying sideto-side with a screwdriver blade. Once dislodged from guide post, seal may be easily removed. INSTALLATION (1) Install valve seals (Fig. 12) as outlined in step (2) of Valve Gear Reassembly - After Valve Service in this section. (2) Using Special Tool C-4682 compress valve springs only enough to install locks. Correct alignment of tool is necessary to avoid nicking valve stems (air pressure required), piston at TDC. (3) Install rocker arms as previously outlined in this section.
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2.5L ENGINE
CYLINDER HEAD
REMOVAL (1) Perform fuel system pressure release procedure before attempting any repairs. Refer to Fuel System Group 14. (2) Disconnect negative battery cable. Drain cooling system. Refer to Cooling System, Group 7. (3) Remove air cleaner and disconnect all vacuum lines, electrical wiring and fuel lines from throttle body. (4) Remove throttle linkage. (5) Loosen power steering pump and remove belt. (6) Remove power brake vacuum hose from intake manifold. (7) Remove water hoses from water crossover. (8) Raise vehicle and remove exhaust pipe from manifold. (9) Remove power steering pump assembly and set aside. (10) Disconnect coil wiring connector and coil wire from coil. (11) Disconnect dipstick tube from thermostat housing and ROTATE bracket from stud.DO NOT bend the bracket. (12) Refer to Solid Mount Compressor Bracket removal in, this Group. (13) Remove cylinder head cover and curtain from head. (14) Remove cylinder head bolts. INSPECT HEAD AND CAMSHAFT BEARING JOURNALS (1) Cylinder head must be flat within 0.1 mm (.004 in.)(Fig. 13). (2) Inspect camshaft journals for scoring and journal caps for oversize markings. When servicing cylinder head or camshaft, it is necessary to be certain that oversized camshafts are used only in oversized heads. Identify oversize components follows:
CLEANING Remove all gasket material from cylinder head and block. Be careful not gouge or scratch aluminum head sealing surface. INSTALLATION
CAUTION: Head bolt diameter is 11 mm. These bolts are identified with 11 on the head of the bolt. 10 mm bolts will thread into the 11 mm hole but will strip the cylinder block bolt hole. Since the Cylinder head bolts are torqued using a new procedure they should be examined BEFORE reuse. If the threads are necked down the bolts should be replaced. (Fig. 14). Necking can be checked by holding a scale or straight edge against the threads. If all the threads do not contact the scale the bolt should be replaced.
2.5L ENGINE
(2) Tighten the cylinder head bolts in the sequence shown in (Fig. 15). Using the 4 step torque turn method, tighten according to the following values: First All to 61 N m (45 ft. lbs.) Second All to 88 N m (65 ft. lbs.) Third All (again) to 88 N m (65 ft. lbs.) Fourth + 1/4 Turn Do use a not torque wrench for this step. Bolt torque after 1/4 turn should be over 90 ft. lbs. If not, replace the bolt. (3) Rotate dipstick tube on bracket. (4) Tighten bracket retaining nut to 23 N m (200 in. lbs.) (5) Install cylinder head cover and curtain. Refer to cover sealing of this group for procedure.
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amount specified in (Fig. 17). Readings should be taken for lengthwise and crosswise (with respect to cylinder head) movement for each valve. Ream the guides for valves with oversize stems if dial indicator reading is excessive or if the stems are scuffed or scored.
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2.5L ENGINE
Valve seats which are worn or burned can be reworked, provided that correct angle and seat width are maintained. Otherwise cylinder head must be replaced. (6) When seat is properly positioned the width of intake seats should be 1.75 to 2.25 mm (0.69 to .088 in.) The width of the exhaust seats should be 1.50 to 2.00 mm (0.059 to 0.078 in.) (Fig. 22 Dimension 1). (7) Check valve tip to valve spring seat dimensions after grinding to seats or faces. Grind valve tip to give 49.76 to 51.04 mm (1.960 to 2.009 in.) over valve spring seat when installed in the head (Fig. 23). The valve tip diameter should be no less than 7.0 mm (0.275 in.), if necessary, the tip chamfer should be reground to prevent seal damage when the valve is installed. (8) Check the valve spring installed height after refacing the valve and seat (Fig. 24). CAUTION: If more than 0.5 mm (0.020 in.) must be ground from the valve tip, check the clearance between the rocker arm and the valve spring retainer. If the clearance is below 1.25 mm (0.050 in.), grind the rocker arm ears until proper clearance is obtained.
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CLEANING Clean all valve guides, valves and valve spring assemblies thoroughly suitable cleaning solution before reassembling. VALVE GEAR REASSEMBLY AFTER VALVE SERVICE (1) Coat valve stems with lubrication oil and insert in cylinder head. (2) Install new valve stem seals on all valves. The valve stem seals should be pushed firmly and squarely over valve guide. The lower edge of the seal should be resting on the valve guide boss.
CAUTION: When oversize valves are used, the corresponding oversize valve seal must also be used. Excessive guide wear may result if oversize seals are not used with oversize valves. (3) Install valve spring seats and springs and retainers. Compress valve springs only enough to install locks, taking care not to misalign the direction of compression. Nicked valve stems may result from misalignment of the valve spring compressor. CAUTION: When depressing the valve spring retainers with Special Tool C-3422-B the locks can become dislocated. Check to make sure both locks are in their correct location after removing tool.
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2.5L ENGINE
in.). To completely collapse adjuster for dry lash measurement, pry off retainer cap, disassemble, drain the adjuster of oil, reassemble, and install. After performing dry lash check, refill adjuster with oil (do not reuse retainer cap/s) and allow 10 minutes for adjuster/s to bleed down before rotating cam.
(either side of valve tip) of the rocker arms and the valve spring retainers. At least 1.25 mm (0.050 in.) clearance must be present, if necessary, the rocker arm ears may be ground to obtain this clearance (Fig. 24). (6) Checking dry lash. Dry lash is the amount of clearance that exists between the base circle of an installed cam and the rocker arm roller when the adjuster is drained of oil and completely collapsed. Specified dry lash is 0.62 to 1.52 mm (0.024 to 0.060
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2.5L ENGINE
MAIN BEARING SERVICECRANKSHAFT NOT REMOVED
REMOVAL (1) Remove oil pan and identify bearing caps before removal. (2) Remove bearing caps one at a time. Remove upper half of bearing by inserting Special Main Bearing Tool C-3059 (Fig. 8) into the oil hole of crankshaft. (3) Slowly rotate crankshaft clockwise, forcing out upper half of bearing shell.
CRANKSHAFT SERVICE
CRANKSHAFT MAIN BEARINGS Bearing caps are not interchangeable and should be marked at removal to insure correct assembly. Upper and lower bearing halves are NOT interchangeable. Lower main bearing halves of 1, 2, 4 and 5 are interchangeable. Upper main bearing halves of 1, 2, 4 and 5 are interchangeable. CRANKSHAFT MAIN JOURNALS The crankshaft journals should be checked for excessive wear, taper and scoring. Limits of taper or out-of-round on any crankshaft journals should be held to 0.025 mm (.001 in.). Journal grinding should not exceed 0.305 mm (0.012 in.) under the standard journal diameter. Do NOT grind thrust faces of Number 3 main bearing. Do NOT nick crank pin or bearing fillets. After grinding, remove rough edges from crankshaft oil holes and clean out all passages.
CAUTION: With the nodular cast iron crankshafts used it is important that the final paper or cloth polish after any journal regrind be in the same direction as normal rotation in the engine. Upper and lower Number 3 bearing halves are flanged to carry the crankshaft thrust loads and are NOT interchangeable with any other bearing halves in the engine (Fig. 7). All bearing cap bolts removed during service procedures are to be cleaned and oiled before installation. Bearing shells are available in standard and the following undersized: 0.025 mm (0.001 in.), 0.051 mm (.002 in.), 0.076 mm (0.003 in.), 0.254 mm (0.010 in.), and 0.305 mm (0.012 in.). Never install an undersize bearing that will reduce clearance below specifications.
Fig. 8 Removing and Installing Upper Main Bearing With Special Tool C-3059
INSTALLATION Only one main bearing should be selectively fitted while all other main bearing caps are properly tightened. When installing a new upper bearing shell, slightly chamfer the sharp edges from the plain side. (1) Start bearing in place, and insert Main Bearing Tool C-3059 into oil hole of crankshaft (Fig. 8). (2) Slowly rotate crankshaft counter-clockwise sliding the bearing into position. Remove Special Main Bearing Tool C-3059.
CHECKING CRANKSHAFT END PLAY (1) Mount a dial indicator to front of engine, locating probe on nose of crankshaft (Fig. 9). (2) Move crankshaft all the way to the rear of its travel. (3) Zero the dial indicator. (4) Move crankshaft all the way to the front and read the dial indicator. Refer to (Fig. 10) for specifications.
OPTIONAL CRANKSHAFT END PLAY CHECK (1) Move crankshaft all the way to the rear of its travel using the appropriate tool inserted between a
2.5L ENGINE
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2.5L ENGINE
INSTALLATION (1) Lubricate distributor drive gear when installing. (2) Apply Mopar Gasket Maker as shown in (Fig. 18) and install intermediate shaft retainer. (3) Install retaining screws and torque to 12 N m (105 in. lbs.).
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(2) Install front bushing using Special Tool C-4697-1 and Special Tool Handle C-4171 until tool is flush with block. (3) Remove rear bushing using Special Tool C-4686-2 and Special Tool Handle C-4171 (Fig. 20). (4) Install rear bushing using Special Tool C-4686-1 and Special Tool Handle C-4171 until tool is flush with block.
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tained. Refer to Honing Cylinder Bores outlined in the Standard Service Procedures for specification and procedures. Measure the cylinder bore at three levels in directions A and B (Fig. 5). Top measurement should be 10 mm ( 3/8 in.) down and bottom measurement should be 10 mm ( 3/8 in.) up from bottom of bore. Refer to (Fig. 6) for specifications.
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2.5L ENGINE
(2) Check piston ring to groove clearance: (Fig. 10).
bore and transverse to the engine crankshaft center line shown in (Fig. 5). Refer to (Fig. 6) for specifications. Pistons and cylinder bores should be measured at normal room temperature, 70F. (21C).
PISTON RINGREMOVAL (1) ID mark on face of upper and intermediate piston rings must point toward piston crown. (2) Using a suitable ring expander, remove upper and intermediate piston rings (Fig. 8).
FITTING RINGS (1) Wipe cylinder bore clean. Insert ring and push down with piston to ensure it is square in bore. The ring gap measurement must be made with the ring positioning at least 12 mm (0.50 in.) from bottom of cylinder bore. Check gap with feeler gauge (Fig. 9).
2.5L ENGINE
(4) Install No. 2 piston ring and then No. 1 piston ring (Fig. 8).
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CONNECTING RODS (1) Follow procedure specified in the Standard Service Procedures Section for Measuring Main Bearing Clearance and Connecting Rod Bearing Clearance (Fig. 16). Refer to specifications (Fig. 19).
CAUTION: Do not rotate crankshaft or the Plastigage may be smeared. The rod bearing bolts should be examined before reuse. If the threads are necked down the bolts should be replaced. (Fig. 17)
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2.5L ENGINE
INSTALLATION Thoroughly clean inside of cup plug hole in cylinder block or head. Be sure to remove old sealer. Lightly coat inside of cup plug hole with sealer. Make certain the new plug is cleaned of all oil or grease. Using proper drive plug, drive plug into hole so that the sharp edge of the plug is at least 0.5 mm (0.020 in.) inside the lead-in chamfer (Fig. 20). It is in not necessary to wait for curing of the sealant. The cooling system can be refilled and the vehicle placed in service immediately.
2.5L ENGINE
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cylinder block (Fig. 2). Modified oil pickup, pump and check valve provide increased oil flow to the main oil gallery.
MAIN/ROD BEARINGS A diagonal hole in each bulkhead feeds oil to each main bearing. Drilled passages within the crankshaft route oil from main bearing journals to crankpin journals (Fig. 2). ACCESSORY SHAFT Two separate holes supply oil to the accessory shaft. CAMSHAFT/HYDRAULIC LIFTERS A vertical hole at the number five bulkhead routes (through a restrictor) pressurized oil up past a cylinder head bolt to an oil gallery running the length of the cylinder head. Hydraulic adjusters are supplied directly from this gallery while diagonal holes supply oil to the camshaft journals. The camshaft journals are partially slotted to allow a predetermined amount of pressurized oil to pass into the bearing cap cavities with small holes directed to spray lubricate the camshaft lobes. SPLASH LUBRICATION Oil returning to the pan from pressurized components supplies lubrication to the valve stems. Cylinder bores and wrist pins are splash lubricated from directed holes in the connecting rods.
2.5L ENGINE
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REMOVAL (1) Disconnect the negative cable from the battery. (2) Disconnect air pump relief valve rubber hose. (3) Raise vehicle and drain engine oil. (4) Remove clutch housing to block strut and housing lower cover (Fig. 3).
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(2) Limits: 0.03 mm (0.001 in.) min 0.09 mm (0.0035 in.) max. (3) Thickness: 23.96 mm (0.9435 in.) min. Outer Diameter: 62.7 mm (2.469 in.) min (Fig. 9). (4) Install with large chamfered edge in pump body (Fig. 9).
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2.5L ENGINE
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Fig. 19 Engine Oil Filter and Antidrain Back Valve Fig. 17 Oil Pump Shaft Alignment
(2) Warm engine at high idle until thermostat opens. CAUTION: If oil pressure is 0 at idle, Do Not Run engine at 3000 RPM. (3) Oil Pressure: Curb Idle 25 kPa (4 psi) minimum 3000 RPM 170-550 kPa (25-80 psi).
FILTER
CAUTION: When servicing the oil filter (Fig. 19) avoid deforming the filter can by installing the remove/install tool band strap against the can-to-base lock seam. The lock-seam joining the can to the base is reinforced by the base plate. (1) Using Tool C-4065, turn filter counter-clockwise to remove from base. Properly discard filter. (2) Wipe base clean, then inspect gasket contact surface. (3) Lubricate gasket of new filter with clean engine oil. (4) Install new filter until gasket contacts base. Tighten filter 1 turn or 20 N m (15 ft. lbs.). Use filter wrench if necessary. (5) Start engine and check for leaks.
OIL FILTER
ANTI-DRAIN BACK VALVE Installation: Apply liquid (Teflon Type) sealant to valve-to-block threads (Fig. 19). Tighten assembly to 55 N m (40 ft. lbs.).
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ENGINE SPECIFICATIONS
2.5L ENGINE
ENGINE SPECIFICATIONSCONT.
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2.5L ENGINE
TORQUE SPECIFICATIONS
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GENERAL INFORMATION
The 3.9 Liter (238 CID) six-cylinder engine is a VType, lightweight, single cam, overhead valve engine with hydraulic roller tappets (Fig. 1).
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3.9L ENGINE
CAUTION: DO NOT lift the engine by the intake manifold. (3) Install engine lifting fixture. (4) Raise vehicle on hoist. (5) Remove bolts and washers holding front support insulator assembly and the strut to the engine block (Figs. 4 and 5). Move the strut out of the way. (6) Remove the insulator thru-bolt (Figs. 4 and 5). (7) Raise engine with lifting fixture SLIGHTLY. Remove the insulator assembly.
3.9L ENGINE
(7) Remove the thru-bolt and nut from the front support assembly and the engine front support bracket. Remove the stud nut and washer assembly attaching front support assembly to the engine front support bracket (Figs. 7 and 8). (8) Remove thru-bolts attaching front support assembly to front axle housing (Fig. 7) or axle disconnect housing (Fig. 8). (9) Remove front support assembly to frame mount bracket thru-bolt. Raise engine slightly to clear front support assembly stud (Figs. 7 and 8). Remove the front support assembly.
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MANUAL Install the insulator onto crossmember. Tighten the stud nuts to 41 N m (30 ft. lbs) torque. Lower the transmission and engine while aligning the insulator studs into the transmission extension. Install the stud nuts. Tighten the stud nuts to 41 N m (30 ft. lbs) torque. (3) Remove transmission jack. (4) Lower the vehicle. (5) Connect the negative cable to the battery.
REMOVAL4WD (1) Disconnect the negative cable from the battery. (2) Raise the vehicle on a hoist. (3) Support the transmission with a transmission jack. (4) TRANSMISSION AUTOMATIC Remove stud nuts holding the insulator to the crossmember (Fig. 11). Raise rear of transmission SLIGHTLY. Remove bolts holding the insulator to the insulator bracket (Fig. 11). Remove the insulator.
3.9L ENGINE
Remove bolts holding the insulator to the transmission (Fig. 12). Remove the insulator.
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ENGINE ASSEMBLY
REMOVAL (1) Scribe hood hinge outlines on hood. Remove the hood. (2) Remove the battery. (3) Drain cooling system (refer to Group 7, Cooling System for the proper procedure). (4) Remove the air cleaner. (5) Disconnect the radiator and heater hoses. Remove radiator (refer to Group 7, Cooling System). (6) Set fan shroud aside. (7) Remove the vacuum lines. (8) Remove the distributor cap and wiring. (9) Disconnect the accelerator linkage. (10) Remove throttle body. (11) Disconnect the fuel line. (12) Disconnect the starter wires. (13) Disconnect the oil pressure wire. (14) Discharge the air conditioning system, if equipped (refer to Group 24, Heating and Air Conditioning for service procedures). (15) Disconnect the air conditioning hoses. (16) Disconnect the power steering hoses, if equipped. (17) Remove starter motor (refer to Group 8B, Battery/Starter/Generator Service). (18) Remove the generator (refer to Group 8B, Battery/Starter/Generator Service). (19) Raise and support the vehicle on a hoist. (20) Disconnect exhaust pipe at manifold. (21) Refer to Group 21, Transmissions for transmission removal.
CAUTION: DO NOT lift the engine by the intake manifold. (22) Install an engine lifting fixture. (23) 2WD VEHICLESRemove engine front mount bolts. (24) 4WD VEHICLESThe engine and front driving axle (engine/axle/transmission) are connected through insulators and support brackets. Separate the engine as follows: LEFT SIDERemove 2 bolts attaching (engine/ pinion nose/transmission) bracket to transmission 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. RIGHT SIDERemove 2 bracket to axle (disconnect housing) bolts and 1 bracket to bell housing bolt. Separate engine from insulator by removing upper nut washer assembly and bolt from engine support bracket. (25) Lower the vehicle. (26) On automatic transmission vehicles, disconnect the engine from the torque converter drive plate.
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On manual transmission vehicles, move engine forward until drive pinion shaft clears the clutch disc. Remove engine from engine compartment. (27) Install engine assembly on engine repair stand.
INSTALLATION (1) Remove engine from the repair stand and position in the engine compartment. (2) Install an engine support fixture. (3) Raise and support the vehicle on a hoist. (4) Refer to Group 21, Transmissions for transmission installation. (5) Install the front engine mounts. (6) Lower the vehicle. (7) Remove engine lifting fixture. (8) Install the generator (refer to Group 8B, Battery/Starter/Generator Service). (9) Install starter motor (refer to Group 8B, Battery/Starter/Generator Service). (10) Connect power steering hoses, if equipped. (11) Connect air conditioning hoses. (12) Evacuate and charge the air conditioning system, if equipped (refer to Group 24, Heater and Air Conditioning for service procedures). (13) Using a new gasket, install throttle body. Tighten the throttle body bolts to 23 N m (200 in. lbs.) torque. (14) Connect the accelerator linkage. (15) Connect the starter wires. (16) Connect the oil pressure wire. (17) Install the distributor cap and wiring. (18) Connect the vacuum lines. (19) Connect the fuel line. (20) Install the radiator (refer to Group 7, Cooling System). Connect the radiator hoses and heater hoses. (21) Install fan shroud in position. (22) Fill cooling system (refer to Group 7, Cooling System for the proper procedure). (23) Install the air cleaner. (24) Install the battery. (25) Warm engine and adjust. (26) Install hood and line up with the scribe marks. (27) Road test vehicle.
VALVE COMPONENTS REPLACECLYINDER HEAD NOT REMOVED ROCKER ARMS AND PUSH RODS
REMOVAL (1) Disconnect spark plug wires by pulling on the boot straight out in line with plug. (2) Remove cylinder head cover and gasket. (3) Remove the rocker arm bolts and pivots (Fig. 2). Place them on a bench in the same order as removed. (4) Remove the push rods and place them on a bench in the same order as removed. INSTALLATION (1) Rotate the crankshaft until the V6 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.
REMOVAL (1) Disconnect the negative cable from the battery. (2) Disconnect closed ventilation system and evaporation control system from cylinder head cover. (3) Remove cylinder head cover and gasket. The gasket may be used again.
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valve stem as a guide. DO NOT force seal against top of guide. When installing the valve retainer locks, compress the spring only enough to install the locks. (11) Follow the same procedure on the remaining 5 cylinders using the firing sequence 1-6-5-4-3-2. Make sure piston in cylinder is at TDC on the valve spring that is being removed. (12) Remove adapter from the No.1 spark plug hole. (13) Install rocker arms. (14) Install covers and coil wire to distributor. (15) Install air cleaner. (16) Road test vehicle.
CYLINDER HEADS
The alloy cast iron cylinder heads (Fig. 3) are held in place by 8 bolts. The spark plugs are located in the peak of the wedge between the valves.
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(15) Remove cylinder head covers and gaskets. (16) Remove intake manifold and throttle body as an assembly. Discard the flange side gaskets and the front and rear cross-over gaskets. (17) Remove exhaust manifolds. (18) Remove rocker arm assemblies and push rods. Identify to ensure installation in original locations. (19) Remove the head bolts from each cylinder head and remove cylinder heads. Discard the cylinder head gasket. (20) Remove spark plugs.
CLEANING Clean all surfaces of cylinder block and cylinder heads. Clean cylinder block front and rear gasket surfaces using a suitable solvent. INSPECTION Inspect all surfaces with a straightedge if there is any reason to suspect leakage. If out-of-flatness exceeds 0.00075 mm/mm (0.00075 inch/inch) times the span length in any direction, either replace head or lightly machine the head surface. FOR EXAMPLE:A 305 mm (12 inch) span is 0.102 mm (0.004 inch) out-of-flat. The allowable outof-flat is 305 x 0.00075 (12 x 0.00075) equals 0.23 mm (0.009 inch). This amount of out-of-flat is acceptable. The cylinder head surface finish should be 1.78-3.00 microns (70-125 microinches). Inspect push rods. Replace worn or bent rods. INSTALLATION (1) Position the new cylinder head gaskets onto the cylinder block. (2) Position the cylinder heads onto head gaskets and cylinder block. (3) Starting at top center, tighten all cylinder head bolts, in sequence, to 68 N m (50 ft. lbs.) torque (Fig. 4). Repeat procedure, tighten all cylinder head bolts to 143 N m (105 ft. lbs.) torque. Repeat procedure to confirm that all bolts are at 143 N m (105 ft. lbs.) torque.
CAUTION: When tightening the rocker arm bolts, make sure the piston in that cylinder is NOT at TDC. Contact between the valves and piston could occur. CAUTION: DO NOT rotate or crank the engine during or immediately after rocker arm installation. Allow the hydraulic roller tappets adequate time to bleed down (about 5 minutes). (4) Install push rods and rocker arm assemblies in their original position. Tighten the bolts to 28 N m (21 ft. lbs.) torque.
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This procedure requires the removal of the cylinder head.
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REMOVAL (1) Remove the cylinder head. (2) Compress valve springs using Valve Spring Compressor Tool MD-998772-A (3) Remove valve retaining locks, valve spring retainers, valve stem seals and valve springs. (4) Before removing valves, remove any burrs from valve stem lock grooves to prevent damage to the valve guides. Identify valves to ensure installation in original location. VALVE CLEANING Clean valves thoroughly. Discard burned, warped and cracked valves. Remove carbon and varnish deposits from inside of valve guides with a reliable guide cleaner. VALVE INSPECTION Measure valve stems for wear. If wear exceeds 0.051 mm (0.002 inch), replace the valve. VALVE GUIDES Measure valve stem guide clearance as follows: (a) Install Valve Guide Sleeve Tool C-3973 over valve stem and install valve (Fig. 5). The special sleeve places the valve at the correct height for checking with a dial indicator.
REFACING VALVES / 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. 8).
VALVES Inspect the remaining margin after the valves are refaced (Fig. 9). Valves with less than 1.190 mm (0.047 inch) margin should be discarded. VALVE SEATS CAUTION: DO NOT un-shroud valves during valve seat refacing (Fig. 10). (1) When refacing valve seats, it is important that the correct size valve guide pilot be used for reseating stones. A true and complete surface must be obtained. (2) Measure the concentricity of valve seat using a dial indicator. Total runout should not exceed 0.051 mm (0.002 inch) total indicator reading.
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(2) If valves or seats are reground, check valve stem height. If valve is too long, replace cylinder head. (3) Install new seals on all valve guides. Install valve springs and valve retainers. (4) Compress valve springs with Valve Spring Compressor Tool MD-998772-A, install locks and release tool. If valves and/or seats are ground, measure the installed height of springs. Make sure the measurement is taken from bottom of spring seat in cylinder head to the bottom surface of spring retainer. If spacers are installed, measure from the top of spacer. If height is greater than 42.86 mm (1-11/16 inches), install a 1.587 mm (1/16 inch) spacer in head counterbore. This should bring spring height back to normal 41.27 to 42.86 mm (1-5/8 to 1-11/16 inch).
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HYDRAULIC TAPPETS
Before disassembling any part of the engine to correct tappet noise, check the oil pressure. If vehicle has no oil pressure gauge, install a reliable gauge at the pressure sending unit. The pressure should be between 207-552 kPa (30-80 psi) at 3,000 RPM. Check the oil level after the engine reaches normal operating temperature. Allow 5 minutes to stabilize oil level, check dipstick. The oil level in the pan should never be above the FULL mark or below the ADD OIL mark on dipstick. Either of these 2 conditions could be responsible for noisy tappets.
OIL LEVEL
HIGH If oil level is above the FULL mark, it is possible for the connecting rods to dip into the oil. With the engine running, this condition could create foam in the oil pan. Foam in oil pan would be fed to the hydraulic tappets by the oil pump causing them to lose length and allow valves to seat noisily. LOW Low oil level may allow oil pump to take in air. When air is fed to the tappets, they lose length which allows valves to seat noisily. Any leaks on intake side of oil pump through which air can be drawn will create the same tappet action. Check the lubrication system from the intake strainer to the pump cover, including the relief valve retainer cap. When tappet noise is due to aeration, it may be intermittent or constant, and usually more than 1 tappet will be noisy. When oil level and leaks have been corrected, operate the engine at fast idle. Run engine for a sufficient time to allow all of the air inside the tappets to be bled out.
TAPPET NOISE DIAGNOSIS (1) To determine source of tappet noise, operate engine at idle with cylinder head covers removed. (2) Feel each valve spring or rocker arm to detect noisy tappet. The noisy tappet will cause the affected spring and/or rocker arm to vibrate or feel rough in operation. Worn valve guides or cocked springs are sometimes mistaken for noisy tappets. If such is the case, noise may be dampened by applying side thrust on the valve spring. If noise is not appreciably reduced, it can be assumed the noise is in the tappet. Inspect the rocker arm push rod sockets and push rod ends for wear. (3) Valve tappet noise ranges from light noise to a heavy click. A light noise is usually caused by excessive leak down around the unit plunger or by the plunger partially sticking in the tappet body cylinder. The tappet should be replaced. A heavy click is caused by a tappet check valve not seating or by foreign particles becoming wedged between the plunger and the tappet body. This will cause the plunger to stick in the down position. This heavy click will be accompanied by excessive clearance between the valve stem and rocker arm as valve closes. In either case, tappet assembly should be removed for inspection and cleaning. The valve train generates a noise very much like a light tappet noise during normal operation. Care must be taken to ensure that tappets are making the noise. In general, if more than one tappet seems to be noisy, its probably not the tappets. REMOVAL (1) Remove the air cleaner. (2) Remove cylinder head cover. (3) Remove rocker assembly and push rods. Identify push rods to ensure installation in original location. (4) Remove intake manifold. (5) Remove yoke retainer and aligning yokes. (6) Slide Hydraulic Tappet Remover/Installer Tool C-4129-A through opening in cylinder head and seat tool firmly in the head of tappet. (7) Pull tappet out of bore with a twisting motion. If all tappets are to be removed, identify tappets to ensure installation in original location. (8) If the tappet or bore in cylinder block is scored, scuffed, or shows signs of sticking, ream the bore to next oversize. Replace with oversize tappet.
CAUTION: The plunger and tappet bodies are not interchangeable. The plunger and valve must always be fitted to the original body. It is advisable to work on one tappet at a time to avoid mixing of parts. Mixed parts are not compatible. DO NOT disassemble a tappet on a dirty work bench.
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(2) Insert a 6.350 mm (1/4 inch) spacer between rocker arm pad and stem tip of No.1 intake valve. Allow spring load to bleed tappet down giving in effect a solid tappet. (3) Install a dial indicator so plunger contacts valve spring retainer as nearly perpendicular as possible. Zero the indicator. (4) Rotate the crankshaft clockwise (normal running direction) until the valve has lifted 0.254 mm (0.010 inch). The timing of the crankshaft should now read from 10 before top dead center to 2 after top dead center. Remove spacer. CAUTION: DO NOT turn crankshaft any further clockwise as valve spring might bottom and result in serious damage. (5) If reading is not within specified limits: (a) Check sprocket index marks. (b) Inspect timing chain for wear. (c) Check accuracy of DC mark on timing indicator.
DISASSEMBLE (1) Pry out plunger retainer spring clip (Fig. 12). (2) Clean varnish deposits from inside of tappet body above plunger cap. (3) Invert tappet body and remove plunger cap, plunger, check valve, check valve spring, check valve retainer and plunger spring (Fig. 12). Check valve could be flat or ball. ASSEMBLE (1) Clean all tappet parts in a solvent that will remove all varnish and carbon. (2) Replace tappets that are unfit for further service with new assemblies. (3) If plunger shows signs of scoring or wear, install a new tappet assembly. If valve is pitted, or valve seat on end of plunger is prevented from seating, install a new tappet assembly. (4) Assemble tappets (Fig. 12).
VIBRATION DAMPER
REMOVAL (1) Disconnect the negative cable from the battery. (2) Remove fan shroud retainer bolts and set shroud back over engine. (3) Remove the cooling system fan. (4) Remove the serpentine belt (refer to Group 7, Cooling System). (5) Remove the vibration damper pulley. (6) Remove vibration damper bolt and washer from end of crankshaft. (7) Install bar and screw from Puller Tool Set C-3688. Install 2 bolts with washers through the puller tool and into the vibration damper (Fig. 1).
VALVE TIMING
(1) Turn crankshaft until the No.6 exhaust valve is closing and No.6 intake valve is opening.
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(2) Place installing tool, part of Puller Tool Set C-3688 in position and press the vibration damper onto the crankshaft (Fig. 2).
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(10) Slide both sprockets evenly over their respective shafts and use a straightedge to check alignment of timing marks (Fig. 5).
CLEANING Be sure mating surfaces of chain case cover and cylinder block are clean and free from burrs. The water pump mounting surface must be cleaned. INSTALLATION (1) Using a new cover gasket, carefully install chain case cover to avoid damaging oil pan gasket. Use a small amount of Mopar Silicone Rubber Adhesive Sealant, or equivalent, at the joint between timing chain cover gasket and the oil pan gasket. Finger tighten the timing chain cover bolts at this time.
CAUTION: If chain cover is replaced for any reason, make sure the oil hole (passenger side of cover) is plugged. (2) Place the smaller diameter of the oil seal over Front Oil Seal Installation Tool 6635 (Fig. 6). Seat the oil seal in the groove of the tool. (3) Position the seal and tool onto the crankshaft (Fig. 7). (4) Tighten the 4 lower chain case cover bolts to 13N m (10 ft.lbs.) to prevent the cover from tipping during seal installation. (5) Using the vibration damper bolt, tighten the bolt to draw the seal into position on the crankshaft (Fig. 8). (6) Loosen the 4 bolts tightened in step 4 to allow realignment of front cover assembly. (7) Tighten the 4 lower chain case cover bolts to 13N m (10 ft.lbs.) to prevent the cover from tipping during seal installation.
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CAMSHAFT
This procedure requires that the engine is removed from the vehicle. The camshaft has an integral oil pump and distributor drive gear (Fig. 9).
REMOVALBEARING (1) With engine completely disassembled, drive out rear cam bearing core hole plug. (2) Install proper size adapters and horseshoe washers (part of Camshaft Bearing Remover/Installer
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(3) Hold tool in position with a distributor lockplate bolt. This tool will restrict camshaft from being pushed in too far and prevent knocking out the welch plug in rear of cylinder block. Tool should remain installed until the camshaft and crankshaft sprockets and timing chain have been installed. (4) Install camshaft thrust plate and chain oil tab. Make sure tang enters lower right hole in thrust plate. Tighten bolts to 24 N m (210 in. lbs.) torque. Top edge of tab should be flat against thrust plate in order to catch oil for chain lubrication. (5) Place both camshaft sprocket and crankshaft sprocket on the bench with timing marks on exact imaginary center line through both camshaft and crankshaft bores. (6) Place timing chain around both sprockets. (7) Turn crankshaft and camshaft to line up with keyway location in crankshaft sprocket and in camshaft sprocket. (8) Lift sprockets and chain (keep sprockets tight against the chain in position as described). (9) Slide both sprockets evenly over their respective shafts and use a straightedge to check alignment of timing marks (Fig. 13).
Tool C-3132-A) at back of each bearing shell. Drive out bearing shells (Fig. 11).
DISTRIBUTOR BUSHING
DISTRIBUTER REMOVAL Refer to Group 8D, Ignition Systems for the proper procedure. REMOVALDRIVE SHAFT BUSHING (1) Insert Distributor Drive Shaft Bushing Puller Tool C-3052 into old bushing and thread down until a tight fit is obtained (Fig. 14).
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(2) Hold puller screw and tighten puller nut until bushing is removed.
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DISTRIBUTOR INSTALLATION Refer to the Component Removal/Installation section of Group 8D, Ignition Systems for the proper procedure. See Distributor. After the distributor has been installed, its rotational position must be set using the SET SYNC mode of the DRB scan tool. Refer to Checking Distributor Position following the Distributor Installation section in Group 8D, Ignition system. Do not attempt to adjust ignition timing by rotating the distributor. It has no effect on ignition timing. Adjusting distributor position will effect fuel synchronization only. Before installing the distributor, the oil pump drive shaft must be aligned to number one cylinder. (1) Rotate crankshaft until No.1 cylinder is at top dead center on the firing stroke. (2) When in this position, the timing mark on vibration damper should be under 0 on the timing indicator. (3) Install the shaft so that after the gear spirals into place, it will index with the oil pump shaft. The slot on top of oil pump shaft should be aligned towards left front intake manifold attaching bolt hole (Fig. 17).
OIL PAN
REMOVAL2WD (1) Disconnect the negative cable from the battery. (2) Remove engine oil dipstick. (3) Disconnect distributor cap and position away from cowl. (4) Raise vehicle. (5) Drain engine oil. (6) Remove exhaust pipe. (7) Loosen side engine mount bolts. (8) Raise engine by way of oil pan using a block of wood between the jack and oil pan. (9) When engine is high enough, place bolts (similar in size to the engine mount bolts) in the engine mount attaching points on the frame brackets.
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(10) Lower engine so bottom of engine mounts rest on the replacement bolts placed in the engine mount frame brackets. (11) Remove oil pan and one-piece gasket.
REMOVAL4WD (1) Disconnect the negative cable from the battery. (2) Remove engine oil dipstick. (3) Raise vehicle. (4) Drain engine oil. (5) Remove front driving axle (refer to Group 3, Drive Axles and Group 2, Front Suspension for the proper procedures). (6) Remove exhaust pipe. (7) Remove transmission lower (dust) cover. (8) Remove oil pan and one-piece gasket. CLEANING Clean the block and pan gasket surfaces. Trim or remove excess sealant film in the rear main cap oil pan gasket groove. DO NOT remove the sealant inside the rear main cap slots. If present, trim excess sealant from inside the engine. Clean oil pan in solvent and wipe dry with a clean cloth. Clean oil screen and pipe thoroughly in clean solvent. Inspect condition of screen. INSPECTION Inspect oil drain plug and plug hole for stripped or damaged threads. Repair as necessary. Inspect oil pan mounting flange for bends or distortion. Straighten flange, if necessary. INSTALLATION2WD (1) Fabricate 4 alignment dowels from 1 1/2 x 5/16 inch bolts. Cut the head off the bolts and cut a slot into the top of the dowel. This will allow easier installation and removal with a screwdriver (Fig. 1).
INSTALLATION4WD (1) Fabricate 4 alignment dowels from 1 1/2 x 5/16 inch bolts. Cut the head off the bolts and cut a slot into the top of the dowel. This will allow easier installation and removal with a screwdriver (Fig. 1). (2) Install the dowels in the cylinder block (Fig. 2). (3) Apply small amount of Mopar Silicone Rubber Adhesive Sealant, or equivalent in the corner of the cap and the cylinder block. (4) Slide the one-piece gasket over the dowels and onto the block. (5) Position the oil pan over the dowels and onto the gasket.
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(6) Install the oil pan bolts. Tighten the bolts to 24 N m (215 in. lbs.) torque. (7) Remove the dowels. Install the remaining oil pan bolts. Tighten these bolts to 24 N m (215 in. lbs.) torque. (8) Install the drain plug. Tighten drain plug to 34 N m (25 ft. lbs.) torque. (9) Install front driving axle (refer to Group 3, Drive Axles and Group 2, Front Suspension for the proper procedures). (10) (11) (12) (13) (14) (15)
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Install exhaust pipe. Lower vehicle Connect the distributor cap. Install dipstick. Connect the negative cable to the battery. Fill crankcase with oil to proper level.
LUBRICATION SYSTEM
A geartype positive displacement pump is mounted at the underside of the rear main bearing cap. The pump draws oil through the screen and inlet tube from the sump at the rear of the oil pan. The oil is driven between the drive and idler gears and pump body, then forced through the outlet to the block. An oil gallery in the block channels the oil to the inlet side of the full flow oil filter. After passing through the filter element, the oil passes from the center outlet of the filter through an oil gallery that channels the oil up to the main gallery which extends the entire length on the right side of the block. The oil then goes down to the No. 1 main bearing, back up to the left side of the block and into the oil gallery on the left side of the engine. Galleries extend downward from the main oil gallery to the upper shell of each main bearing. The crankshaft is drilled internally to pass oil from the main bearing journals to the connecting rod journals. Each connecting rod bearing has half a hole in it, oil passes through the hole when the rods rotate and the hole lines up, oil is then thrown off as the rod rotates. This oil throwoff lubricates the camshaft lobes, distributor drive gear, cylinder walls, and piston pins. The hydraulic valve tappets receive oil directly from the main oil gallery. The camshaft bearings receive oil from the main bearing galleries. The front camshaft bearing journal passes oil through the camshaft sprocket to the timing chain. Oil drains back to the oil pan under the number one main bearing cap. The oil supply for the rocker arms and bridged pivot assemblies is provided by the hydraulic valve tappets which pass oil through hollow push rods to a hole in the corresponding rocker arm. Oil from the rocker arm lubricates the valve train components. The oil then passes down through the push rod guide holes, and the oil drain back passages in the cylinder head past the valve tappet area, and returns to the oil pan.
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REMOVAL (1) Remove the oil pan. (2) Remove the oil pump from rear main bearing cap. DISASSEMBLE (1) Remove the relief valve as follows: (a) Remove cotter pin. Drill a 3.175 mm (1/8 inch) hole into the relief valve retainer cap and insert a self-threading sheet metal screw into cap. (b) Clamp screw into a vise and while supporting oil pump, remove cap by tapping pump body using a soft hammer. Discard retainer cap and remove spring and relief valve (Fig. 3).
INSPECTION Mating surface of the oil pump cover should be smooth. Replace pump assembly if cover is scratched or grooved. Lay a straightedge across the pump cover surface (Fig. 5). If a 0.038 mm (0.0015 inch) feeler gauge can be inserted between cover and straightedge, pump assembly should be replaced.
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Fig. 10 Measuring Clearance Over Rotors Fig. 7 Measuring Inner Rotor Thickness
Inspect oil pressure relief valve plunger for scoring and free operation in its bore. Small marks may be removed with 400-grit wet or dry sandpaper. The relief valve spring has a free length of approximately 49.5 mm (1.95 inches). The spring should test between 19.5 and 20.5 pounds when compressed to 34 mm (1-11/32 inches). Replace spring that fails to meet these specifications (Fig. 11). If oil pressure was low and pump is within specifications, inspect for worn engine bearings or other reasons for oil pressure loss.
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(2) Hold the oil pump base flush against mating surface on No.4 main bearing cap. Finger tighten pump attaching bolts. Tighten attaching bolts to 41 N m (30 ft. lbs.) torque. (3) Install the oil pan.
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REMOVAL (1) Remove the engine from the vehicle. (2) Remove the cylinder head. (3) Remove the oil pan. (4) Remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be sure to keep tops of pistons covered during this operation. (5) Be sure the connecting rod and connecting rod cap are identified with the cylinder number. Remove connecting rod cap. Install connecting rod bolt guide set on connecting rod bolts. (6) Pistons and connecting rods must be removed from top of cylinder block. When removing piston and connecting rod assemblies, rotate crankshaft to center the connecting rod in the cylinder bore and at BDC. Be careful not to nick crankshaft journals. (7) After removal, install bearing cap on the mating rod. INSPECTION All measurements are at 21C (70 33F). Check the crankshaft connecting rod journal for excessive wear, taper and scoring. Check the cylinder block bore for out-of-round, taper, scoring and scuffing. Check the pistons for taper and elliptical shape before they are fitted into the cylinder bore (Fig. 1). FITTING PISTONS Piston and cylinder wall must be clean and dry. Specified clearance between the piston and the cylinder wall is 0.013-0.038 mm (0.0005-0.0015 inch) at 21C (70F). Piston diameter should be measured at the top of skirt, 90 to piston pin axis. Cylinder bores should be
FITTING RINGS (1) Measurement of end gaps: (a) Measure piston ring gap 2 inches from bottom of cylinder bore. An inverted piston can be used to push the rings down to ensure positioning rings squarely in the cylinder bore before measuring. (b) Insert feeler gauge in the gap. The top compression ring gap should be between 0.254-0.508 mm (0.010-0.020 inch). The second compression ring gap should be between 0.508-0.762 mm (0.0200.030 inch). The oil ring gap should be 0.254-1.270 mm (0.010-0.050 inch). (c) Rings with insufficient end gap may be filed to the correct dimension. Rings with excess gaps should not be used. (2) Install rings and confirm ring side clearance: (a) Install oil rings being careful not to nick or scratch the piston. (b) Install the compression rings using Installation Tool C-4184. The top compression may be installed with either side up. The second compression ring must be installed with the identification mark face up (toward top of piston) and the chamfer should face down. An identification mark on the ring is a drill point, a stamped letter O, an oval depression or the word TOP. (c) Measure side clearance between piston ring and ring land (Fig. 2). Clearance should be 0.038-
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tion of the cylinder wall in the opposite bank. 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) undersize. Install the bearings in pairs. DO NOT use a new bearing half with an old bearing half. DO NOT file the rods or bearing caps.
0.076 mm (0.0015-0.0030 inch) for the compression rings. The steel rail oil ring should be free in groove, but should not exceed 0.203 mm (0.0080 inch) side clearance.
INSTALLATION (1) Be sure that compression ring gaps are staggered so that neither is in-line with oil ring rail gap. (2) Before installing the ring compressor, make sure the oil ring expander ends are butted and the rail gaps located properly (Fig. 3). (3) Immerse the piston head and rings in clean engine oil. Slide Piston Ring Compressor Tool C-385 over the piston and tighten with the special wrench (part of Tool C-385). Be sure position of rings does not change during this operation. (4) Install connecting rod bolt protectors on rod bolts, the long protector should be installed on the numbered side of the connecting rod. (5) Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Be sure connecting rod and cylinder bore number are the same. Insert rod and piston into cylinder bore and guide rod over the crankshaft journal. (6) Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod into position on crankshaft journal. (7) The notch or groove on top of piston must be pointing toward front of engine. The larger chamfer of the connecting rod bore must be installed toward crankshaft journal fillet. (8) Install rod caps. Be sure connecting rod, connecting rod cap and cylinder bore number are the same. Install nuts on cleaned and oiled rod bolts and tighten nuts to 61 N m (45 ft. lbs.) torque. (9) Install the oil pan. (10) Install the cylinder head. (11) Install the engine into the vehicle.
CRANKSHAFT
A crankshaft which has undersize journals will be stamped with 1/4 inch letters near the notch of the No.6 crankshaft counterweight (Fig. 4). FOR EXAMPLE: R2 stamped on the No.6 crankshaft counterweight indicates that the No.2 rod journal is 0.025 mm (0.001 in) undersize. M4 indicates that the No.4 main journal is 0.025 mm (0.001 in) undersize. R3 M2 indicates that the No.3 rod journal and the No.2 main journal are 0.025 mm (0.001 in) undersize.
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CLEANING Clean Loctite 515 residue and sealant from the cylinder block and rear cap mating surface. Do this before applying the Loctite drop and the installation of rear cap. INSTALLATION (1) Lightly oil the new upper seal lips with engine oil. (2) Install the new upper rear bearing oil seal with the white paint facing towards the rear of the engine. (3) Position the crankshaft into the cylinder block. (4) Lightly oil the new lower seal lips with engine oil. (5) Install the new lower rear bearing oil seal into the bearing cap with the white paint facing towards the rear of the engine. (6) Apply 5 mm (0.20 in) drop of Loctite 515, or equivalent, on each side of the rear main bearing cap (Fig. 5). DO NOT over apply sealant or allow the sealant to contact the rubber seal. Assemble bearing cap to cylinder block immediately after sealant application.
REMOVAL (1) Remove the oil pan. (2) Remove the oil pump from the rear main bearing cap. (3) Remove the vibration damper. (4) Remove the timing chain cover. (5) Identify bearing caps before removal. Remove bearing caps and bearings one at a time. (6) Lift the crankshaft out of the block. (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 scoring. The maximum taper or out-of-round on any crankshaft journal is 0.025 mm (0.001 inch). Journal grinding should not exceed 0.305 mm (0.012 inch) under the standard journal diameter. DO NOT grind thrust faces of No.2 main bearing. DO NOT nick crank pin or bearing fillets. After grinding, remove rough edges from crankshaft oil holes and clean out all oil passages.
CAUTION: After any journal grind, it is important that the final paper or cloth polish be in the same direction as the engine rotates.
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(5) Slowly rotate crankshaft clockwise, forcing out upper half of bearing shell.
Fig. 8 Upper Main Bearing Removal and Installation with Tool C-3059
INSTALLATION Install the bearings in pairs. DO NOT use a new bearing half with an old bearing half. Only one main bearing should be selectively fitted while all other main bearing caps are properly tightened. All bearing capbolts removed during service procedures are to be cleaned and oiled before installation. When installing a new upper bearing shell, slightly chamfer the sharp edges from the plain side. (1) Start bearing in place, and insert Crankshaft Main Bearing Remover/Installer Tool C-3059 into oil hole of crankshaft (Fig. 8). (2) Slowly rotate crankshaft counterclockwise sliding the bearing into position. Remove Tool C-3059. (3) Install the bearing caps. Clean and oil the bolts. Tighten the capbolts to 115 N m (85 ft. lbs.) torque. (4) Install the oil pump. (5) Install the oil pan.
UPPER SEAL REPLACEMENTCRANKSHAFT REMOVED (1) Remove the crankshaft. Discard the old upper seal. (2) Clean the cylinder block rear cap mating surface. Make sure the seal groove is free of debris.
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(3) Lightly oil the new upper seal lips with engine oil. (4) Install the new upper rear bearing oil seal with the white paint facing towards the rear of the engine. (5) Position the crankshaft into the cylinder block. (6) Lightly oil the new lower seal lips with engine oil. (7) Install the new lower rear bearing oil seal into the bearing cap with the white paint facing towards the rear of the engine. (8) Apply 5 mm (0.20 in) drop of Loctite 515, or equivalent, on each side of the rear main bearing cap (Fig. 5). DO NOT over apply sealant or allow the sealant to contact the rubber seal. Assemble bearing cap to cylinder block immediately after sealant application. (9) To align the bearing cap, use cap slot, alignment dowel and cap bolts. DO NOT remove excess material after assembly. DO NOT strike rear cap more than 2 times for proper engagement. (10) Clean and oil all cap bolts. Install all main bearing caps. Install all cap bolts and alternately tighten to 115 N m (85 ft. lbs.) torque. (11) Install oil pump. (12) Apply Mopar Silicone Rubber Adhesive Sealant, or equivalent, at bearing cap to block joint to provide cap to block and oil pan sealing (Fig. 6). Apply enough sealant until a small amount is squeezed out. Withdraw nozzle and wipe excess sealant off the oil pan seal groove. (13) Install new front crankshaft oil seal. (14) Immediately install the oil pan.
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(9) Apply 5 mm (0.20 in) drop of Loctite 515, or equivalent, on each side of the rear main bearing cap (Fig. 5). DO NOT over apply sealant or allow the sealant to contact the rubber seal. Assemble bearing cap to cylinder block immediately after sealant application. Be sure the white paint faces toward the rear of the engine. (10) To align the bearing cap, use cap slot, alignment dowel and cap bolts. DO NOT remove excess material after assembly. DO NOT strike rear cap more than 2 times for proper engagement. (11) Install the rear main bearing cap with cleaned and oiled cap bolts. Alternately tighten ALL cap bolts to 115 N m (85 ft. lbs.) torque. (12) Install oil pump. (13) Apply Mopar Silicone Rubber Adhesive Sealant, or equivalent, at bearing cap to block joint to provide cap to block and oil pan sealing (Fig. 6). Apply enough sealant until a small amount is squeezed out. Withdraw nozzle and wipe excess sealant off the oil pan seal groove. (14) Immediately install the oil pan.
UPPER SEAL REPLACEMENTCRANKSHAFT INSTALLED (1) Remove the oil pan. (2) Remove the oil pump from the rear main bearing cap. (3) Remove the rear main bearing cap. Remove and discard the old lower oil seal. (4) Carefully remove and discard the old upper oil seal. (5) Clean the cylinder block mating surfaces before oil seal installation. Check for burr at the oil hole on the cylinder block mating surface to rear cap. (6) Lightly oil the new upper seal lips with engine oil. To allow ease of installation of the seal, loosen at least the 2 main bearing caps forward of the rear bearing cap. (7) Rotate the new upper seal into the cylinder block being careful not to shave or cut the outer surface of the seal. To assure proper installation, use the installation tool provided with the kit. Install the new seal with the white paint facing towards the rear of the engine. (8) Install the new lower rear bearing oil seal into the bearing cap with the white paint facing towards the rear of the engine.
LOWER SEAL REPLACEMENT (1) Remove the oil pan. (2) Remove the oil pump from the rear main bearing cap. (3) Remove the rear main bearing cap and discard the old lower seal. (4) Clean the rear main cap mating surfaces including the oil pan gasket groove. (5) Carefully install a new upper seal (refer to Upper Seal Replacement - Crankshaft Installed procedure above). (6) Lightly oil the new lower seal lips with engine oil. (7) Install a new lower seal in bearing cap with the white paint facing the rear of engine. (8) Apply 5 mm (0.20 in) drop of Loctite 515, or equivalent, on each side of the rear main bearing cap (Fig. 5). DO NOT over apply sealant or allow the sealant to contact the rubber seal. Assemble bearing cap to cylinder block immediately after sealant application. (9) To align the bearing cap, use cap slot, alignment dowel and cap bolts. DO NOT remove excess material after assembly. DO NOT strike rear cap more than 2 times for proper engagement. (10) Install the rear main bearing cap with cleaned and oiled cap bolts. Alternately tighten the cap bolts to 115 N m (85 ft. lbs.) torque. (11) Install oil pump. (12) Apply Mopar Silicone Rubber Adhesive Sealant, or equivalent, at bearing cap to block joint to provide cap to block and oil pan sealing (Fig. 6). Apply enough sealant until a small amount is squeezed out. Withdraw nozzle and wipe excess sealant off the oil pan seal groove.
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3.9L ENGINE
CYLINDER BLOCK
Remove the engine assembly from the vehicle.
DISASSEMBLE (1) Remove the cylinder head. (2) Remove the oil pan. (3) Remove the piston/connecting rod assemblies. CLEANING Clean cylinder block thoroughly and check all core hole plugs for evidence of leaking. INSPECTION Examine block for cracks or fractures. The cylinder walls should be checked for out-ofround and taper with Cylinder Bore Indicator Tool C-119. The cylinder block should be bored and honed with new pistons and rings fitted if: The cylinder bores show more than 0.127 mm (0.005 inch) out-of-round. The cylinder bores show a taper of more than 0.254 mm (0.010 inch). The cylinder walls are badly scuffed or scored. Boring and honing operation should be closely coordinated with the fitting of pistons and rings so specified clearances may be maintained. Refer to Standard Service Procedures in the beginning of this Group for the proper honing of cylinder bores. OIL LINE PLUG The oil line plug is located in the vertical passage at the rear of the block between the Oil-To-Filter and Oil-From-Filter passages (Fig. 9). Improper installation or plug missing could cause erratic, low or no oil pressure. The oil plug must come out the bottom. Use flat dowel, down the oil pressure sending unit hole from the top, to remove oil plug. (1) Remove oil pressure sending unit from back of block. (2) Insert a 3.175 mm (1/8 inch) finish wire or equivalent into passage. (3) Plug should be 190.0 to 195.2 mm (7-1/2 to 7-11/16 inches) from machined surface of block (Fig. 9). If plug is too high, use a suitable flat dowel to position properly. (4) If plug is to low, remove oil pan and rear main bearing cap. Use suitable flat dowel to position properly. Coat outside diameter of new plug with Mopar (Stud and Bearing Mount Adhesive), or equivalent. Plug should be 54.0 to 57.7 mm (2-1/8 to 2-5/16 inches) from bottom of the block. (5) Assemble engine and check oil pressure.
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INSTALLATION (1) Coat edges of plug and core hole with Mopar Gasket Maker, or equivalent. CAUTION: DO NOT drive cup plug into the casting as restricted coolant flow can result and cause serious engine problems. (2) Using proper plug driver, drive cup plug into hole. The sharp edge of the plug should be at least 0.50 mm (0.020 inch) inside the lead-in chamfer. It is not necessary to wait for curing of the sealant. The cooling system can be filled and the vehicle placed in service immediately.
ASSEMBLE (1) Install the (2) Install the (3) Install the (4) Install the
piston/connecting rod assembly. oil pan. cylinder head. engine into the vehicle.
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ENGINE SPECIFICATIONS
3.9L ENGINE
ENGINE SPECIFICATIONSCONT.
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ENGINE SPECIFICATIONSCONT.
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TORQUE SPECIFICATIONS
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Camshaft . . . . . . . . . . . . . . . . . . . . . . Cylinder Head Cover . . . . . . . . . . . . . . Cylinder Heads . . . . . . . . . . . . . . . . . . Distributor . . . . . . . . . . . . . . . . . . . . . . Engine Assembly . . . . . . . . . . . . . . . . Engine Front Mounts . . . . . . . . . . . . . . Engine Rear Support . . . . . . . . . . . . . . Front Crankshaft Oil Seal Replacement General Information . . . . . . . . . . . . . . Hydraulic Tappets . . . . . . . . . . . . . . . .
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GENERAL INFORMATION
The 5.2 Liter (318 CID) eight-cylinder engine is a V-Type lightweight, single cam, overhead valve engine with hydraulic roller tappets (Fig. 1).
5.2L ENGINE
CAUTION: DO NOT lift the engine by the intake manifold. (3) Install engine lifting fixture. (4) Raise vehicle on hoist. (5) Remove bolts and washers holding front support insulator assembly and the strut to the engine block (Figs. 4 and 5). Move the strut out of the way. (6) Remove the insulator thru-bolt (Figs. 4 and 5). (7) Raise engine with lifting fixture SLIGHTLY. Remove the insulator assembly.
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(7) Remove the thru-bolt and nut from the front support assembly and the engine front support bracket. Remove the stud nut and washer assembly attaching front support assembly to the engine front support bracket (Figs. 7 and 8). (8) Remove thru-bolts attaching front support assembly to front axle housing (Fig. 7) or axle disconnect housing (Fig. 8). (9) Remove front support assembly to frame mount bracket thru-bolt. Raise engine slightly to clear front support assembly stud (Figs. 7 and 8). Remove the front support assembly.
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REMOVAL4WD (1) Disconnect the negative cable from the battery. (2) Raise the vehicle on a hoist. (3) Support the transmission with a transmission jack. (4) Remove stud nuts holding the insulator to the crossmember (Fig. 10). (5) Raise rear of transmission SLIGHTLY. (6) Remove bolts holding the insulator to the insulator bracket (Fig. 10). Remove the insulator. INSTALLATION4WD (1) If the insulator bracket was removed, install the bracket to the transmission (Fig. 10). Tighten the bolts to 28 N m (250 in. lbs.) torque. (2) Install the bolts holding insulator to insulator bracket. Tighten the bolts to 28 N m (250 in. lbs.) torque. (3) Lower rear of transmission while aligning the insulator studs into the mounting support bracket. Install stud nuts and tighten to 28 N m (250 in. lbs.) torque. (5) Remove the transmission jack. (6) Lower the vehicle. (7) Connect the negative cable to the battery.
ENGINE ASSEMBLY
REMOVAL (1) Scribe hood hinge outlines on hood. Remove the hood. (2) Remove the battery. (3) Drain cooling system (refer to Group 7, Cooling
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5.2L ENGINE
(25) Install the radiator (refer to Group 7, Cooling System). Connect the radiator hoses and heater hoses. (26) Install fan shroud in position. (27) Fill cooling system (refer to Group 7, Cooling System for the proper procedure). (28) Install the air cleaner. (29) Install the battery. (30) Warm engine and adjust. (31) Install hood and line up with the scribe marks. (32) Road test vehicle.
CAUTION: DO NOT lift the engine by the intake manifold. (23) Install an engine lifting fixture. (24) 2WD VEHICLESRemove engine front mount bolts. (25) 4WD VEHICLESThe engine and front driving axle (engine/axle/transmission) are connected through insulators and support brackets. Separate the engine as follows: LEFT SIDERemove 2 bolts attaching (engine/ pinion nose/transmission) bracket to transmission 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. RIGHT SIDERemove 2 bracket to axle (disconnect housing) bolts and a bracket to bell housing bolt. Separate engine from insulator by removing upper nut washer assembly and bolt from engine support bracket. (26) Lower the vehicle. (27) Install engine assembly on engine repair stand.
INSTALLATION (1) Remove engine from the repair stand and position in the engine compartment. (2) Install an engine support fixture. (3) Raise and support the vehicle on a hoist. (5) Install the engine front mounts. Refer to Group, 21 Transmissions for transmission installation (8) Install the inspection plate. (9) Remove transmission support. (10) Install exhaust pipe to manifold. (11) Lower the vehicle. (12) Remove engine lifting fixture. (13) Install the generator (refer to Group 8B, Battery/Starter/Generator Service). (14) Install starter motor (refer to Group 8B, Battery/Starter/Generator Service). (15) Connect power steering hoses, if equipped. (16) Connect air conditioning hoses. (17) Evacuate and charge the air conditioning system, if equipped (refer to Group 24, Heater and Air Conditioning for service procedures). (18) Using a new gasket, install throttle body. Tighten the throttle body bolts to 23 N m (200 in. lbs.) torque. (19) Connect the accelerator linkage. (20) Connect the starter wires. (21) Connect the oil pressure wire. (22) Install the distributor cap and wiring. (23) Connect the vacuum lines. (24) Connect the fuel lines.
5.2L ENGINE VALVE COMPONENTS REPLACECLYINDER HEAD NOT REMOVED ROCKER ARMS AND PUSH RODS
REMOVAL (1) Disconnect spark plug wires by pulling on the boot straight out in line with plug. (2) Remove cylinder head cover and gasket. (3) Remove the rocker arm bolts and pivots (Fig. 2). Place them on a bench in the same order as removed. (4) Remove the push rods and place them on a bench in the same order as removed.
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(6) Remove rocker arms. (7) With air hose attached to an adapter installed in No.1 spark plug hole, apply 620-689 kPa (90-100 psi) air pressure. (8) Using Valve Spring Compressor Tool MD998772-A, compress valve spring and remove retainer valve locks and valve spring. (9) Install seals on the exhaust valve stem and position down against valve guides. (10) The intake valve stem seals should be pushed firmly and squarely over the valve guide using the valve stem as a guide. DO NOT force seal against top of guide. When installing the valve retainer locks, compress the spring only enough to install the locks. (11) Follow the same procedure on the remaining 7 cylinders using the firing sequence 1-8-4-3-6-5-7-2. Make sure piston in cylinder is at TDC on the valve spring that is being removed. (12) Remove adapter from the No.1 spark plug hole. (13) Install rocker arms. (14) Install covers and coil wire to distributor. (15) Install air cleaner. (16) Road test vehicle.
CYLINDER HEADS
The alloy cast iron cylinder heads (Fig. 3) are held in place by 10 bolts. The spark plugs are located in the peak of the wedge between the valves. The 5.2L cylinder head is identified by the foundry mark NH.
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5.2L ENGINE
(7) Perform fuel system pressure release procedure (before attempting any repairs Refer to Group 14, Fuel Systems). (8) Disconnect the fuel lines. (9) Disconnect accelerator linkage and if so equipped, the speed control and transmission kickdown cables. (10) Remove the return spring. (11) Remove distributor cap and wires. (12) Disconnect the coil wires. (13) Disconnect heat indicator sending unit wire. (14) Disconnect heater hoses and bypass hose. (15) Remove cylinder head covers and gaskets. (16) Remove intake manifold and throttle body as an assembly. Discard the flange side gaskets and the front and rear cross-over gaskets. (17) Remove exhaust manifolds. (18) Remove rocker arm assemblies and push rods. Identify to ensure installation in original locations. (19) Remove the head bolts from each cylinder head and remove cylinder heads. Discard the cylinder head gasket. (20) Remove spark plugs.
CLEANING Clean all surfaces of cylinder block and cylinder heads. Clean cylinder block front and rear gasket surfaces using a suitable solvent. INSPECTION Inspect all surfaces with a straightedge if there is any reason to suspect leakage. If out-of-flatness exceeds 0.00075 mm/mm (0.00075 inch/inch) times the span length in inches in any direction, either replace head or lightly machine the head surface. FOR EXAMPLE: A 305 mm (12 inch) span is 0.102 mm (0.004 inch) out-of-flat. The allowable outof-flat is 305 x 0.00075 (12 x 0.00075) equals 0.23 mm (0.009 inch). This amount of out-of-flat is acceptable. The cylinder head surface finish should be 1.78-3.00 microns (70-125 microinches). Inspect push rods. Replace worn or bent rods. INSTALLATION (1) Apply Perfect Sealant No.5, or equivalent, to both sides of the gasket (Fig. 4). (2) Position the new cylinder head gaskets onto the cylinder block. (3) Position the cylinder heads onto head gaskets and cylinder block. (4) Starting at top center, tighten all cylinder head bolts, in sequence, to 68 N m (50 ft. lbs.) torque (Fig. 5). Repeat procedure, tighten all cylinder head bolts to 143 N m (105 ft. lbs.) torque. Repeat procedure to confirm that all bolts are at 143 N m (105 ft. lbs.) torque.
5.2L ENGINE
(14) Connect the accelerator linkage and if so equipped, the speed control and transmission kickdown cables. (15) Install the fuel lines. (16) Install the generator and drive belt. Tighten generator mounting bolt to 41 N m (30 ft. lbs.) torque. Tighten the adjusting strap bolt to 23 N m (200 in. lbs.) torque. Refer to Group 7, Cooling System for adjusting the belt tension. (17) Install the intake manifold-to-generator bracket support rod. Tighten the bolts. (18) Place the cylinder head cover gaskets in position and install cylinder head covers. Tighten the bolts to 11 N m (95 in. lbs.) torque. (19) Install closed crankcase ventilation system. (20) Connect the evaporation control system. (21) Install the air cleaner. (22) Install the heat shields. Tighten the bolts to 41 N m (30 ft. lbs.) torque. (23) Fill cooling system (refer to Group 7, Cooling System for proper procedure). (24) Connect the negative cable to the battery.
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REMOVAL (1) Remove the cylinder head. (2) Compress valve springs using Valve Spring Compressor Tool MD-998772-A. (3) Remove valve retaining locks, valve spring retainers, valve stem seals and valve springs. (4) Before removing valves, remove any burrs from valve stem lock grooves to prevent damage to the valve guides. Identify valves to ensure installation in original location. VALVE CLEANING Clean valves thoroughly. Discard burned, warped and cracked valves. Remove carbon and varnish deposits from inside of valve guides with a reliable guide cleaner. VALVE INSPECTION Measure valve stems for wear. If wear exceeds 0.051 mm (0.002 inch), replace the valve.
VALVE GUIDES
Measure valve stem guide clearance as follows: (a) Install Valve Guide Sleeve Tool C-3973 over valve stem and install valve (Fig. 6). The special sleeve places the valve at the correct height for checking with a dial indicator.
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5.2L ENGINE
VALVE SEATS CAUTION: DO NOT un-shroud valves during valve seat refacing (Fig. 11).
Use a 2 step procedure so the valve guides are reamed true in relation to the valve seat: Step 1Ream to 0.0763 mm (0.003 inch). Step 2Ream to 0.381 mm (0.015 inch).
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. 9).
VALVE SPRING INSPECTION Whenever valves have been removed for inspection, reconditioning or replacement, valve springs should be tested. As an example the compression length of the spring to be tested is 1-5/16 inch. Turn table of Universal Valve Spring Tester Tool until surface is in line with the 1-5/16 inch mark on the threaded stud. Be sure the zero mark is to the front (Fig. 12). Place spring over stud on the table and lift compressing lever to set tone device. Pull on torque wrench until ping is heard. Take reading on torque wrench at this instant. Multiply this reading by 2. This will give the spring load at test length. Fractional measurements are indicated on the table for finer adjustments. Re-
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fer to specifications to obtain specified height and allowable tensions. Discard the springs that do not meet specifications.
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OIL LEVEL
HIGH If oil level is above the FULL mark, it is possible for the connecting rods to dip into the oil. With the engine running this condition could create foam in the oil pan. Foam in oil pan would be fed to the hydraulic tappets by the oil pump causing them to lose length and allow valves to seat noisily. LOW Low oil level may allow oil pump to take in air. When air is fed to the tappets, they lose length which allows valves to seat noisily. Any leaks on intake side of oil pump through which air can be drawn will create the same tappet action. Check the lubrication system from the intake strainer to the pump cover, including the relief valve retainer cap. When tappet noise is due to aeration, it may be intermittent or constant, and usually more than 1 tappet will be noisy. When oil level and leaks have been corrected, operate the engine at fast idle. Run engine for a sufficient time to allow all of the air inside the tappets to be bled out.
HYDRAULIC TAPPETS
Before disassembling any part of the engine to correct tappet noise, check the oil pressure. If vehicle has no oil pressure gauge, install a reliable gauge at the pressure sending unit. The pressure should be between 207-552 kPa (30-80 psi) at 3,000 RPM. Check the oil level after the engine reaches normal operating temperature. Allow 5 minutes to stabilize oil level, check dipstick. The oil level in the pan should never be above the FULL mark or below the ADD OIL mark on dipstick. Either of these 2 conditions could be responsible for noisy tappets.
TAPPET NOISE DIAGNOSIS (1) To determine source of tappet noise, operate engine at idle with cylinder head covers removed. (2) Feel each valve spring or rocker arm to detect noisy tappet. The noisy tappet will cause the affected spring and/or rocker arm to vibrate or feel rough in operation. Worn valve guides or cocked springs are sometimes mistaken for noisy tappets. If such is the case, noise may be dampened by applying side thrust on the valve spring. If noise is not appreciably reduced, it can be assumed the noise is in the tappet. Inspect the rocker arm push rod sockets and push rod ends for wear. (3) Valve tappet noise ranges from light noise to a heavy click. A light noise is usually caused by excessive leak-down around the unit plunger or by the plunger partially sticking in the tappet body cylinder. The tappet should be replaced. A heavy click is caused by a tappet check valve not seating or by foreign particles becoming wedged between the plunger and the tappet body. This will cause the plunger to stick in the down position. This heavy click will be accompanied by excessive clearance between the valve stem and rocker arm as valve closes. In either case, tappet assembly should be removed for inspection and cleaning. The valve train generates a noise very much like a light tappet noise during normal operation. Care must be taken to ensure that tappets are making the noise. In general, if more than one tappet seems to be noisy, its probably not the tappets.
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5.2L ENGINE
INSTALLATION (1) Lubricate tappets. (2) Install tappets and push rods in their original positions. Ensure that the oil feed hole in the side of the tappet body faces up (away from the crankshaft). (3) Install aligning yokes with ARROW toward camshaft. (4) Install yoke retainer. Tighten the bolts to 23 N m (200 in. lbs.) torque. Install intake manifold. (5) Install push rods in original positions. (6) Install rocker arm. (7) Install cylinder head cover. (8) Start and operate engine. Warm up to normal operating temperature.
CAUTION: To prevent damage to valve mechanism, engine must not be run above fast idle until all hydraulic tappets have filled with oil and have become quiet.
REMOVAL (1) Remove the air cleaner. (2) Remove cylinder head cover. (3) Remove rocker assembly and push rods. Identify push rods to ensure installation in original location. (4) Remove intake manifold. (5) Remove yoke retainer and aligning yokes. (6) Slide Hydraulic Tappet Remover/Installer Tool C-4129-A through opening in cylinder head and seat tool firmly in the head of tappet. (7) Pull tappet out of bore with a twisting motion. If all tappets are to be removed, identify tappets to ensure installation in original location. (8) If the tappet or bore in cylinder block is scored, scuffed, or shows signs of sticking, ream the bore to next oversize. Replace with oversize tappet.
CAUTION: The plunger and tappet bodies are not interchangeable. The plunger and valve must always be fitted to the original body. It is advisable to work on one tappet at a time to avoid mixing of parts. Mixed parts are not compatible. DO NOT disassemble a tappet on a dirty work bench.
VALVE TIMING
(1) Turn crankshaft until the No.6 exhaust valve is closing and No.6 intake valve is opening. (2) Insert a 6.350 mm (1/4 inch) spacer between rocker arm pad and stem tip of No.1 intake valve. Allow spring load to bleed tappet down giving in effect a solid tappet. (3) Install a dial indicator so plunger contacts valve spring retainer as nearly perpendicular as possible. Zero the indicator. (4) Rotate the crankshaft clockwise (normal running direction) until the valve has lifted 0.254 mm (0.010 inch). The timing of the crankshaft should now read from 10 before top dead center to 2 after top dead center. Remove spacer. CAUTION: DO NOT turn crankshaft any further clockwise as valve spring might bottom and result in serious damage. (5) If reading is not within specified limits: (a) Check sprocket index marks. (b) Inspect timing chain for wear. (c) Check accuracy of DC mark on timing indicator.
DISASSEMBLE (1) Pry out plunger retainer spring clip (Fig. 13). (2) Clean varnish deposits from inside of tappet body above plunger cap. (3) Invert tappet body and remove plunger cap, plunger, check valve, check valve spring, check valve retainer and plunger spring (Fig. 13). Check valve could be flat or ball. ASSEMBLE (1) Clean all tappet parts in a solvent that will remove all varnish and carbon. (2) Replace tappets that are unfit for further service with new assemblies. (3) If plunger shows signs of scoring or wear, install a new tappet assembly. If valve is pitted, or valve seat on end of plunger is prevented from seating, install a new tappet assembly. (4) Assemble tappets (Fig. 13).
VIBRATION DAMPER
REMOVAL (1) Disconnect the negative cable from the battery. (2) Remove fan shroud retainer bolts and set shroud back over engine. (3) Remove the cooling system fan. (4) Remove the serpentine belt (refer to Group 7, Cooling System). (5) Remove the vibration damper pulley.
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(6) Remove vibration damper bolt and washer from end of crankshaft. (7) Install bar and screw from Puller Tool Set C-3688. Install 2 bolts with washers through the puller tool and into the vibration damper (Fig. 1).
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(2) Drain cooling system (refer to Group 7, Cooling System). (3) Remove the serpentine belt (refer to Group 7, Cooling System). (4) Remove water pump (refer to Group 7, Cooling System). (5) Remove power steering pump (refer to Group 19, Steering). (6) Remove vibration damper. (7) Remove fuel lines (refer to Group 14, Fuel System). (8) Loosen oil pan bolts and remove the front bolt at each side. (9) Remove the cover bolts. (10) Remove chain case cover and gasket using extreme caution to avoid damaging oil pan gasket. (11) 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 surface of cover (Fig. 3).
INSTALLATION (1) Position the vibration damper onto the crankshaft. (2) Place installing tool, part of Puller Tool Set C-3688 in position and press the vibration damper onto the crankshaft (Fig. 2).
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sive Sealant, or equivalent, at the joint between timing chain cover gasket and the oil pan gasket. Finger tighten the timing chain cover bolts at this time. (2) Place the smaller diameter of the oil seal over Front Oil Seal Installation Tool 6635 (Fig. 6). Seat the oil seal in the groove of the tool.
CLEANING Be sure mating surfaces of chain case cover and cylinder block are clean and free from burrs. The water pump mounting surface must be cleaned. INSTALLATION (1) Using a new cover gasket, carefully install chain case cover to avoid damaging oil pan gasket. Use a small amount of Mopar Silicone Rubber Adhe-
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(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 surface of cover. (5) Place the smaller diameter of the oil seal over Front Oil Seal Installation Tool 6635 (Fig. 6). Seat the oil seal in the groove of the tool. (6) Position the seal and tool onto the crankshaft (Fig. 7). (7) Using the vibration damper bolt, tighten the bolt to draw the seal into position on the crankshaft (Fig. 8). (8) Remove the vibration damper bolt and seal installation tool. (9) Inspect the seal flange on the vibration damper. (10) Install the vibration damper. (11) Connect the negative cable to the battery.
CAMSHAFT
This procedure requires that the engine is removed from the vehicle. The camshaft has an integral oil pump and distributor drive gear (Fig. 9).
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Whenever an engine has been rebuilt, a new camshaft and/or new tappets installed, add 1 pint of Mopar Crankcase Conditioner, or equivalent. The oil mixture should be left in engine for a minimum of 805 km (500 miles). Drain at the next normal oil change. (2) Install Camshaft Gear Installer Tool C-3509 with tongue back of distributor drive gear (Fig. 12).
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DISTRIBUTOR
REMOVAL Refer to Group 8D, Ignition Systems for the proper procedure. REMOVALDRIVE SHAFT BUSHING (1) Remove the intake manifold (refer to Group 11, Exhaust System and Intake Manifold). (2) Insert Distributor Drive Shaft Bushing Puller Tool C-3052 into old bushing and thread down until a tight fit is obtained (Fig. 14). (3) Hold puller screw and tighten puller nut until bushing is removed.
OIL PAN
REMOVAL2WD (1) Disconnect the negative cable from the battery. (2) Remove engine oil dipstick. (3) Disconnect distributor cap and position away from cowl.
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INSTALLATION2WD (1) Fabricate 4 alignment dowels from 1 1/2 x 5/16 inch bolts. Cut the head off the bolts and cut a slot into the top of the dowel. This will allow easier installation and removal with a screwdriver (Fig. 1).
REMOVAL4WD (1) Disconnect the negative cable from the battery. (2) Remove engine oil dipstick. (3) Raise vehicle. (4) Drain engine oil. (5) Remove front driving axle (refer to Group 3, Drive Axles and Group 2, Front Suspension for the proper procedures). (6) Remove exhaust pipe. (7) Remove transmission lower (dust) cover. (8) Remove oil pan and one-piece gasket. CLEANING Clean the block and pan gasket surfaces. Trim or remove excess sealant film in the rear main cap oil pan gasket groove. DO NOT remove the sealant inside the rear main cap slots. If present, trim excess sealant from inside the engine. Clean oil pan in solvent and wipe dry with a clean cloth. Clean oil screen and pipe thoroughly in clean solvent. Inspect condition of screen. INSPECTION Inspect oil drain plug and plug hole for stripped or damaged threads. Repair as necessary. Inspect oil pan mounting flange for bends or distortion. Straighten flange, if necessary.
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(9) Raise engine by way of oil pan with a wood block placed between jack and oil pan. (10) Remove temporary bolts from frame brackets and lower engine. Tighten side engine mount bolts to specifications. (11) Install exhaust pipe. (12) Lower vehicle. (13) Connect the distributor cap. (14) Install dipstick. (15) Connect the negative cable to the battery. (16) Fill crankcase with oil to proper level.
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INSTALLATION4WD (1) Fabricate 4 alignment dowels from 1 1/2 x 5/16 inch bolts. Cut the head off the bolts and cut a slot into the top of the dowel. This will allow easier installation and removal with a screwdriver (Fig. 1). (2) Install the dowels in the cylinder block (Fig. 2). (3) Apply small amount of Mopar Silicone Rubber Adhesive Sealant, or equivalent in the corner of the cap and the cylinder block.
(4) Slide the one-piece gasket over the dowels and onto the block. (5) Position the oil pan over the dowels and onto the gasket. (6) Install the oil pan bolts. Tighten the bolts to 24 N m (215 in. lbs.) torque. (7) Remove the dowels. Install the remaining oil pan bolts. Tighten these bolts to 24 N m (215 in. lbs.) torque. (8) Install the drain plug. Tighten drain plug to 34 N m (25 ft. lbs.) torque. (9) Install front driving axle (refer to Group 3, Drive Axles and Group 2, Front Suspension for the proper procedures). (10) Install exhaust pipe. (11) Lower vehicle (12) Connect the distributor cap. (13) Install dipstick. (14) Connect the negative cable to the battery. (15) Fill crankcase with oil to proper level.
LUBRICATION SYSTEM
A geartype positive displacement pump is mounted at the underside of the rear main bearing cap. The pump draws oil through the screen and inlet tube from the sump at the rear of the oil pan. The oil is driven between the drive and idler gears and pump body, then forced through the outlet to the block. An oil gallery in the block channels the oil to the inlet side of the full flow oil filter. After passing through the filter element, the oil passes from the center outlet of the filter through an oil gallery that channels the oil up to the main gallery which extends the entire length on the right side of the block. The oil then goes down to the No. 1 main bearing, back up to the left side of the block and into the oil gallery on the left side of the engine. Galleries extend downward from the main oil gallery to the upper shell of each main bearing. The crankshaft is drilled internally to pass oil from the main bearing journals to the connecting rod journals. Each connecting rod bearing has half a hole in it, oil passes through the hole when the rods rotate and the hole lines up, oil is then thrown off as the rod rotates. This oil throwoff lubricates the camshaft lobes, distributor drive gear, cylinder walls, and piston pins. The hydraulic valve tappets receive oil directly from the main oil gallery. The camshaft bearings receive oil from the main bearing galleries. The front camshaft bearing journal passes oil through the camshaft sprocket to the timing chain. Oil drains back to the oil pan under the number one main bearing cap. The oil supply for the rocker arms and bridged pivot assemblies is provided by the hydraulic valve tappets which pass oil through hollow push rods to a hole in the corresponding rocker arm. Oil from the rocker arm lubricates the valve train components. The oil then passes down through the push rod guide holes, and the oil drain back passages in the cylinder head past the valve tappet area, and returns to the oil pan.
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REMOVAL (1) Remove the oil pan. (2) Remove the oil pump from rear main bearing cap. DISASSEMBLE (1) Remove the relief valve as follows: (a) Remove cotter pin. Drill a 3.175 mm (1/8 inch) hole into the relief valve retainer cap and insert a self-threading sheet metal screw into cap. (b) Clamp screw into a vise and while supporting oil pump, remove cap by tapping pump body using a soft hammer. Discard retainer cap and remove spring and relief valve (Fig. 3).
INSPECTION Mating surface of the oil pump cover should be smooth. Replace pump assembly if cover is scratched or grooved. Lay a straightedge across the pump cover surface (Fig. 5). If a 0.038 mm (0.0015 inch) feeler gauge can be inserted between cover and straightedge, pump assembly should be replaced.
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Fig. 10 Measuring Clearance Over Rotors Fig. 7 Measuring Inner Rotor Thickness
Inspect oil pressure relief valve plunger for scoring and free operation in its bore. Small marks may be removed with 400-grit wet or dry sandpaper. The relief valve spring has a free length of approximately 49.5 mm (1.95 inches). The spring should test between 19.5 and 20.5 pounds when compressed to 34 mm (1-11/32 inches). Replace spring that fails to meet these specifications (Fig. 11). If oil pressure was low and pump is within specifications, inspect for worn engine bearings or other reasons for oil pressure loss.
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(2) Hold the oil pump base flush against mating surface on No.4 main bearing cap. Finger tighten pump attaching bolts. Tighten attaching bolts to 41 N m (30 ft. lbs.) torque. (3) Install the oil pan.
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REMOVAL (1) Remove the engine from the vehicle. (2) Remove the cylinder head. (3) Remove the oil pan. (4) Remove top ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be sure to keep tops of pistons covered during this operation. (5) Be sure the connecting rod and connecting rod cap are identified with the cylinder number. Remove connecting rod cap. Install connecting rod bolt guide set on connecting rod bolts. (6) Pistons and connecting rods must be removed from top of cylinder block. When removing piston and connecting rod assemblies, rotate crankshaft to center the connecting rod in the cylinder bore and at BDC. Be careful not to nick crankshaft journals. (7) After removal, install bearing cap on the mating rod. INSPECTION Check the crankshaft connecting rod journal for excessive wear, taper and scoring. Check the cylinder block bore for out-of-round, taper, scoring and scuffing. Check the pistons for taper and elliptical shape before they are fitted into the cylinder bore (Fig. 1). Pistons and cylinder bores should be measured at normal room temperature, 21C (70F). FITTING PISTONS Piston and cylinder wall must be clean and dry. Specified clearance between the piston and the cylinder wall is 0.013-0.038 mm (0.0005-0.0015 inch) at 21C (70F). Piston diameter should be measured at the top of skirt, 90 to piston pin axis. Cylinder bores should be
FITTING RINGS (1) Measurement of end gaps: (a) Measure piston ring gap 2 inches from bottom of cylinder bore. An inverted piston can be used to push the rings down to ensure positioning rings squarely in the cylinder bore before measuring. (b) Insert feeler gauge in the gap. The top compression ring gap should be between 0.254-0.508 mm (0.010-0.020 inch). The second compression ring gap should be between 0.508-0.762 mm (0.0200.030 inch). The oil ring gap should be 0.254-1.270 mm (0.010-0.050 inch). (c) Rings with insufficient end gap may be properly filed to the correct dimension. Rings with excess gaps should not be used. (2) Install rings and confirm ring side clearance: (a) Install oil rings being careful not to nick or scratch the piston. (b) Install the compression rings using Installation Tool C-4184. The top compression may be installed with either side up. The second compression ring must be installed with the identification mark face up (toward top of piston) and the chamfer should face down. An identification mark on the ring is a drill point, a stamped letter O, an oval depression or the word TOP. (c) Measure side clearance between piston ring and ring land (Fig. 2). Clearance should be 0.038-
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tion of the cylinder wall in the opposite bank. 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) undersize. Install the bearings in pairs. DO NOT use a new bearing half with an old bearing half. DO NOT file the rods or bearing caps.
0.076 mm (0.0015-0.0030 inch) for the compression rings. The steel rail oil ring should be free in groove, but should not exceed 0.203 mm (0.0080 inch) side clearance.
INSTALLATION (1) Be sure that compression ring gaps are staggered so that neither is in-line with oil ring rail gap. (2) Before installing the ring compressor, make sure the oil ring expander ends are butted and the rail gaps located properly (Fig. 3). (3) Immerse the piston head and rings in clean engine oil. Slide Piston Ring Compressor Tool C-385 over the piston and tighten with the special wrench (part of Tool C-385). Be sure position of rings does not change during this operation. (4) Install connecting rod bolt protectors on rod bolts, the long protector should be installed on the numbered side of the connecting rod. (5) Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Be sure connecting rod and cylinder bore number are the same. Insert rod and piston into cylinder bore and guide rod over the crankshaft journal. (6) Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide connecting rod into position on crankshaft journal. (7) The notch or groove on top of piston must be pointing toward front of engine. The larger chamfer of the connecting rod bore must be installed toward crankshaft journal fillet. (8) Install rod caps. Be sure connecting rod, connecting rod cap and cylinder bore number are the same. Install nuts on cleaned and oiled rod bolts and tighten nuts to 61 N m (45 ft. lbs.) torque. (9) Install the oil pan. (10) Install the cylinder head. (11) Install the engine into the vehicle.
CRANKSHAFT
A crankshaft which has undersize journals will be stamped with 1/4 inch letters on the milled flat on the No.8 crankshaft counterweight (Fig. 4). FOR EXAMPLE: R2 stamped on the No.8 crankshaft counterweight indicates that the No.2 rod journal is 0.025 mm (0.001 in) undersize. M4 indicates that the No.4 main journal is 0.025 mm (0.001 in) undersize. R3 M2 indicates that the No.3 rod journal and the No.2 main journal are 0.025 mm (0.001 in) undersize.
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INSTALLATION (1) Lightly oil the new upper seal lips with engine oil. (2) Install the new upper rear bearing oil seal with the white paint facing towards the rear of the engine. (3) Position the crankshaft into the cylinder block. (4) Lightly oil the new lower seal lips with engine oil. (5) Install the new lower rear bearing oil seal into the bearing cap with the white paint facing towards the rear of the engine. (6) Apply 5 mm (0.20 in) drop of Loctite 515, or equivalent, on each side of the rear main bearing cap (Fig. 5). DO NOT over apply sealant or allow the sealant to contact the rubber seal. Assemble bearing cap to cylinder block immediately after sealant application.
REMOVAL (1) Remove the oil pan. (2) Remove the oil pump from the rear main bearing cap. (3) Remove the vibration damper. (4) Remove the timing chain cover. (5) Identify bearing caps before removal. Remove bearing caps and bearings one at a time. (6) Lift the crankshaft out of the block. (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 scoring. The maximum taper or out-of-round on any crankshaft journal is 0.025 mm (0.001 inch). Journal grinding should not exceed 0.305 mm (0.012 inch) under the standard journal diameter. DO NOT grind thrust faces of No.3 main bearing. DO NOT nick crank pin or bearing fillets. After grinding, remove rough edges from crankshaft oil holes and clean out all oil passages.
CAUTION: After any journal grind, it is important that the final paper or cloth polish be in the same direction as the engine rotates.
CLEANING Clean Loctite 515 residue and sealant from the cylinder block and rear cap mating surface. Do this before applying the Loctite drop and the installation of rear cap.
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Fig. 8 Upper Main Bearing Removal and Installation with Tool C-3059
INSTALLATION Install the bearings in pairs. DO NOT use a new bearing half with an old bearing half. Only one main bearing should be selectively fitted while all other main bearing caps are properly tightened. All bearing capbolts removed during service procedures are to be cleaned and oiled before installation. When installing a new upper bearing shell, slightly chamfer the sharp edges from the plain side. (1) Start bearing in place, and insert Crankshaft Main Bearing Remover/Installer Tool C-3059 into oil hole of crankshaft (Fig. 8). (2) Slowly rotate crankshaft counterclockwise sliding the bearing into position. Remove Tool C-3059. (3) Install the bearing caps. Clean and oil the bolts. Tighten the capbolts to 115 N m (85 ft. lbs.) torque. (4) Install the oil pump. (5) Install the oil pan.
UPPER SEAL REPLACEMENTCRANKSHAFT REMOVED (1) Remove the crankshaft. Discard the old upper seal. (2) Clean the cylinder block rear cap mating surface. Make sure the seal groove is free of debris. Check for burr at the oil hole on the cylinder block mating surface to rear cap. (3) Lightly oil the new upper seal lips with engine oil.
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(4) Install the new upper rear bearing oil seal with the white paint facing towards the rear of the engine. (5) Position the crankshaft into the cylinder block. (6) Lightly oil the new lower seal lips with engine oil. (7) Install the new lower rear bearing oil seal into the bearing cap with the white paint facing towards the rear of the engine. (8) Apply 5 mm (0.20 in) drop of Loctite 515, or equivalent, on each side of the rear main bearing cap (Fig. 5). DO NOT over apply sealant or allow the sealant to contact the rubber seal. Assemble bearing cap to cylinder block immediately after sealant application. (9) To align the bearing cap, use cap slot, alignment dowel and cap bolts. DO NOT remove excess material after assembly. DO NOT strike rear cap more than 2 times for proper engagement. (10) Clean and oil all cap bolts. Install all main bearing caps. Install all cap bolts and alternately tighten to 115 N m (85 ft. lbs.) torque. (11) Install oil pump. (12) Apply Mopar Silicone Rubber Adhesive Sealant, or equivalent, at bearing cap to block joint to provide cap to block and oil pan sealing (Fig. 6). Apply enough sealant until a small amount is squeezed out. Withdraw nozzle and wipe excess sealant off the oil pan seal groove. (13) Install new front crankshaft oil seal. (14) Immediately install the oil pan.
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(9) Apply 5 mm (0.20 in) drop of Loctite 515, or equivalent, on each side of the rear main bearing cap (Fig. 5). DO NOT over apply sealant or allow the sealant to contact the rubber seal. Assemble bearing cap to cylinder block immediately after sealant application. Be sure the white paint faces toward the rear of the engine. (10) To align the bearing cap, use cap slot, alignment dowel and cap bolts. DO NOT remove excess material after assembly. DO NOT strike rear cap more than 2 times for proper engagement. (11) Install the rear main bearing cap with cleaned and oiled cap bolts. Alternately tighten ALL cap bolts to 115 N m (85 ft. lbs.) torque. (12) Install oil pump. (13) Apply Mopar Silicone Rubber Adhesive Sealant, or equivalent, at bearing cap to block joint to provide cap to block and oil pan sealing (Fig. 6). Apply enough sealant until a small amount is squeezed out. Withdraw nozzle and wipe excess sealant off the oil pan seal groove. (14) Immediately install the oil pan.
UPPER SEAL REPLACEMENTCRANKSHAFT INSTALLED (1) Remove the oil pan. (2) Remove the oil pump from the rear main bearing cap. (3) Remove the rear main bearing cap. Remove and discard the old lower oil seal. (4) Carefully remove and discard the old upper oil seal. (5) Clean the cylinder block mating surfaces before oil seal installation. Check for burr at the oil hole on the cylinder block mating surface to rear cap. (6) Lightly oil the new upper seal lips with engine oil. To allow ease of installation of the seal, loosen at least the 2 main bearing caps forward of the rear bearing cap. (7) Rotate the new upper seal into the cylinder block being careful not to shave or cut the outer surface of the seal. To assure proper installation, use the installation tool provided with the kit. Install the new seal with the white paint facing towards the rear of the engine. (8) Install the new lower rear bearing oil seal into the bearing cap with the white paint facing towards the rear of the engine.
LOWER SEAL REPLACEMENT (1) Remove the oil pan. (2) Remove the oil pump from the rear main bearing cap. (3) Remove the rear main bearing cap and discard the old lower seal. (4) Clean the rear main cap mating surfaces including the oil pan gasket groove. (5) Carefully install a new upper seal (refer to Upper Seal Replacement - Crankshaft Installed procedure above). (6) Lightly oil the new lower seal lips with engine oil. (7) Install a new lower seal in bearing cap with the white paint facing the rear of engine. (8) Apply 5 mm (0.20 in) drop of Loctite 515, or equivalent, on each side of the rear main bearing cap (Fig. 5). DO NOT over apply sealant or allow the sealant to contact the rubber seal. Assemble bearing cap to cylinder block immediately after sealant application. (9) To align the bearing cap, use cap slot, alignment dowel and cap bolts. DO NOT remove excess material after assembly. DO NOT strike rear cap more than 2 times for proper engagement. (10) Install the rear main bearing cap with cleaned and oiled cap bolts. Alternately tighten the cap bolts to 115 N m (85 ft. lbs.) torque. (11) Install oil pump. (12) Apply Mopar Silicone Rubber Adhesive Sealant, or equivalent, at bearing cap to block joint to provide cap to block and oil pan sealing (Fig. 6). Apply enough sealant until a small amount is squeezed out. Withdraw nozzle and wipe excess sealant off the oil pan seal groove.
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CYLINDER BLOCK
Remove the engine assembly from the vehicle.
DISASSEMBLE (1) Remove the cylinder head. (2) Remove the oil pan. (3) Remove the piston/connecting rod assembly. CLEANING Clean cylinder block thoroughly and check all core hole plugs for evidence of leaking. INSPECTION Examine block for cracks or fractures. The cylinder walls should be checked for out-ofround and taper with Cylinder Bore Indicator Tool C-119. The cylinder block should be bored and honed with new pistons and rings fitted if: The cylinder bores show more than 0.127 mm (0.005 inch) out-of-round. The cylinder bores show a taper of more than 0.254 mm (0.010 inch). The cylinder walls are badly scuffed or scored. Boring and honing operation should be closely coordinated with the fitting of pistons and rings so specified clearances may be maintained. Refer to Standard Service Procedures in the beginning of this Group for the proper honing of cylinder bores. OIL LINE PLUG The oil line plug is located in the vertical passage at the rear of the block between the Oil-To-Filter and Oil-From-Filter passages (Fig. 9). Improper installation or plug missing could cause erratic, low or no oil pressure. The oil plug must come out the bottom. Use flat dowel, down the oil pressure sending unit hole from the top, to remove oil plug. (1) Remove oil pressure sending unit from back of block. (2) Insert a 3.175 mm (1/8 inch) finish wire or equivalent into passage. (3) Plug should be 190.0 to 195.2 mm (7-1/2 to 7-11/16 inches) from machined surface of block (Fig. 9). If plug is too high, use a suitable flat dowel to position properly. (4) If plug is too low, remove oil pan and rear main bearing cap. Use suitable flat dowel to position properly. Coat outside diameter of new plug with Mopar (Stud and Bearing Mount Adhesive), or equivalent. Plug should be 54.0 to 57.7 mm (2-1/8 to 2-5/16 inches) from bottom of the block. (5) Assemble engine and check oil pressure.
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INSTALLATION (1) Coat edges of plug and core hole with Mopar Gasket Maker, or equivalent. CAUTION: DO NOT drive cup plug into the casting as restricted coolant flow can result and cause serious engine problems. (2) Using proper plug drive, drive cup plug into hole. The sharp edge of the plug should be at least 0.50 mm (0.020 inch) inside the lead-in chamfer. It is not necessary to wait for curing of the sealant. The cooling system can be filled and the vehicle placed in service immediately.
ASSEMBLE (1) Install the (2) Install the (3) Install the (4) Install the
piston/connecting rod assembly. oil pan. cylinder head. engine into the vehicle.
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ENGINE SPECIFICATIONS
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ENGINE SPECIFICATIONSCONT.
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ENGINE SPECIFICATIONSCONT.
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TORQUE SPECIFICATIONS
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CATALYTIC CONVERTER
The stainless steel catalytic converter body is designed to last the life of the vehicle. Excessive heat can result in bulging or other distortion, but excessive heat will not be the fault of the converter. If unburned fuel enters the converter, overheating may occur. If a converter is heat-damaged, correct the cause of the damage at the same time the converter
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is replaced. Also, inspect all other components of the exhaust system for heat damage. Unleaded gasoline must be used to avoid contaminating the catalyst core.
HEAT SHIELDS
Heat shields are needed to protect both the vehicle and the environment from the high temperatures developed by the catalytic converter. The catalytic converter releases additional heat into the exhaust system. Under severe operating conditions, the temperature increases in the area of the converter. Such conditions can exist when the engine misfires or otherwise does not operate at peak efficiency. DO NOT remove spark plug wires from plugs or by any other means short out cylinders. Failure of the catalytic converter can occur due to a temperature increase caused by unburned fuel passing through the converter.
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EXHAUST PIPE
REMOVAL (1) Raise and support the vehicle. (2) Saturate the bolts and nuts with heat valve lubricant. Allow 5 minutes for penetration. (3) Remove the exhaust manifold-to-exhaust pipe nuts (Fig. 1). (4) On manual transmission vehicles, remove the
Fig. 2 Exhaust Pipe-to-Support BracketManual Transmission Fig. 1 Exhaust Pipe-to-Exhaust Manifold Connection
clamp bolt nuts holding the exhaust pipe to the support bracket and spacer (Fig. 2). (5) Disconnect the exhaust pipe from the catalytic converter front flange and the exhaust manifold. (6) Remove the exhaust pipe.
INSTALLATION (1) Align and connect the exhaust pipe to the catalytic converter flange (Fig. 3). (2) Connect the exhaust pipe to the exhaust manifold. Tighten the nuts to 27 N m (20 ft. lbs.) torque. (3) On manual transmission vehicles, position the spacer and clamp bolt onto the support bracket. Install the clamp bolt nuts and tighten to 47 N m (35 ft. lbs.) torque. (4) Lower the vehicle.
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(5) Start the engine and inspect for exhaust leaks and exhaust system contact with the body panels. Adjust the alignment, if needed.
CATALYTIC CONVERTER
REMOVAL (1) Raise and support the vehicle. (2) Saturate the bolts and nuts with heat valve lubricant. Allow 5 minutes for penetration. (3) Remove the clamp nuts holding the catalytic converter flange to the exhaust pipe (Fig. 3). (4) Remove the clamp nuts holding the catalytic converter flange to the extension pipe (Fig. 4) or muffler (Fig. 5 or 6). (5) Remove the catalytic converter. You may have to loosen up other sections of the exhaust system. INSTALLATION (1) Align and connect the catalytic converter flange to the exhaust pipe (Fig. 3). (2) Install the catalytic converter flange into the extension pipe (Fig. 4) or muffler (Fig. 5 or 6). (3) If other sections of the exhaust system where loosened in removal, refer to that section for the tightening procedures. (4) At the catalytic converter flange connections, install the clamp and nuts. Tighten the clamp nuts to 47 N m (35 ft. lbs.) torque. (5) Lower the vehicle. (6) Start the engine and inspect for exhaust leaks and exhaust system contact with the body panels. Adjust the alignment, if needed.
MUFFLER
REMOVAL (1) Raise and support the vehicle. (2) Saturate the clamp nuts with heat valve lubricant. Allow 5 minutes for penetration. (3) Remove the muffler clamp nuts from the front (Fig. 5 or 6) and rear hanger (Fig. 7 or 8). (4) Disconnect the muffler from the tailpipe. The
EXTENSION PIPE
REMOVAL (1) Raise and support the vehicle. (2) Saturate the clamp nuts with heat valve lubricant. Allow 5 minutes for penetration. (3) Remove the front (Fig. 4) and rear clamp nuts (Fig. 5 or 6). (4) It may be necessary to loosen other sections of the exhaust system to remove the extension pipe. INSTALLATION (1) Position the extension pipe in the muffler (Fig. 5 or 6) and the catalytic converter flange (Fig. 4). (2) If other sections of the exhaust system where loosened in removal, refer to the section for tightening procedures. (3) Install the clamps and nuts. Tighten the nuts to 47 N m (35 ft. lbs.) torque. (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.
INSTALLATION (1) If the 2.5L engine front muffler support assembly (Fig. 5) was removed, install the bolts into the frame. Tighten the bolts to 23 N m (200 in. lbs.) torque. (2) If the 3.9L or 5.2L engine upper front muffler hanger (Fig. 6) was removed, install the bolts into
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TAILPIPE
REMOVAL (1) Raise and support the vehicle. (2) Saturate the clamp nuts with heat valve lubricant. Allow 5 minutes for penetration. (3) Loosen the nuts on the muffler rear hanger clamp. (Fig. 7 or 8). (4) Remove the tailpipe hanger clamp bolt. (Fig. 9). (5) Remove the tailpipe.
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frame bracket, install the hanger (Fig. 9). Tighten the bolt to 23 N m (200 in. lbs.) torque. Install the tailpipe clamp hanger bolt. Tighten the bolt to 23 N m (200 in. lbs.) torque. (3) Tighten the muffler rear hanger nuts to 47 N m (35 ft. lbs.) torque. (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.
REMOVAL (1) Disconnect the negative cable from the battery. (2) Drain the cooling system (refer to Group 7, Cooling System for the proper procedure). (3) Remove the air cleaner and disconnect all vacuum lines, electrical wiring and fuel lines from the throttle body. (4) Remove throttle linkage. (5) Remove the throttle body mounting bolts and lift the throttle body and gasket from the intake manifold (Fig. 14). Discard the gasket. (6) Remove power steering and air pump support bracket. (7) Remove power brake vacuum hose from intake manifold. (8) Remove diverter valve assembly and disconnect air injection tube assembly from the exhaust manifold. (9) Remove water hoses from water crossover. (10) Raise vehicle and remove exhaust pipe from the exhaust manifold. (11) Remove the EGR tube (Fig. 15).
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CLEANING AND INSPECTION Discard the gaskets. Clean all gasket surfaces on both manifolds and on cylinder head. Check gasket surfaces of the manifolds for flatness using a straight edge. Surfaces must be flat within 0.15 mm per 300 mm (0.006 in. per foot) of manifold length. Inspect the manifolds for cracks and distortion.
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(a) Turn the intake manifold upside down. Support the manifold. (b) Remove the bolts and lift the pan off the manifold. Discard the gasket.
REMOVAL (1) Disconnect the negative cable from the battery. (2) Drain the cooling system (refer to Group 7, Cooling System for the proper procedures). (3) Remove the generator (refer to Group 8B Battery/Starting/Charging Systems). (4) Remove the air cleaner. (5) Remove the fuel lines and fuel rail (refer to Group 14, Fuel System). (6) Disconnect the accelerator linkage and, if so equipped, the speed control and transmission kickdown cables. (7) Remove the return spring. (8) Remove the distributor cap and wires. (9) Disconnect the coil wires. (10) Disconnect the heat indicator sending unit wire. (11) Disconnect the heater hoses and bypass hose. (12) Remove the closed crankcase ventilation and evaporation control systems. (13) Remove intake manifold bolts. (14) Lift the intake manifold and throttle body out of the engine compartment as an assembly. (15) Remove and discard the flange side gaskets and the front and rear cross-over gaskets. (16) Remove the throttle body bolts and lift the throttle body off the intake manifold (Fig. 17). Discard the throttle body gasket.
CLEANING Clean manifold in solvent and blow dry with compressed air. Clean cylinder block front and rear gasket surfaces using a suitable solvent. The plenum pan rail must be clean and dry (free of all foreign material). INSPECTION Inspect manifold for cracks. Inspect mating surfaces of manifold for flatness with a straightedge. INSTALLATION (1) Install the plenum pan, if removed, as follows: (a) Turn the intake manifold upside down. Support the manifold. (b) Place a new plenum pan gasket onto the seal rail of the intake manifold. Position the pan over the gasket. Align all the gasket and pan holes with the intake manifold. (c) Hand start all bolts. (d) Tighten the bolts, in sequence (Fig. 18), as follows:
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Step 4Check that all bolts are tightened to 9.5 N m (84 in. lbs.) torque. (2) Using a new gasket, install the throttle body onto the intake manifold. Tighten the bolts to 23 N m (200 in. lbs.) torque. (3) Place the 4 plastic locator dowels into the holes in the block. (4) Apply a bead of Mopar Silicone Rubber Adhesive Sealant, or equivalent, to the four corner joints. The sealant bead height should be slightly higher than the cross-over gaskets, approx. 5 mm (0.2 in). An excessive amount of sealant is not required to ensure a leak proof seal, and an excessive amount of sealant may reduce the effectiveness of the flange gasket. (5) Install the front and rear cross-over gaskets onto the dowels (Fig. 19).
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REMOVAL (1) Disconnect the negative cable from the battery. (2) Raise the vehicle. (3) Remove the bolts and nuts attaching the exhaust pipe to the exhaust manifold. (4) Lower the vehicle. (5) Remove bolts, nuts and washers attaching manifold to cylinder head. (6) Remove manifold from the cylinder head. CLEANING Clean mating surfaces on cylinder head and manifold, wash with solvent and blow dry with compressed air. Inspect manifold for cracks. INSPECTION Inspect mating surfaces of manifold for flatness with a straight edge. Seal surfaces must be flat within 0.1 mm (0.004 inch) overall. INSTALLATION
CAUTION: If the studs came out with the nuts when removing the exhaust manifold, install new studs. (1) Position the exhaust manifolds on the two studs located on the cylinder head. Install conical washers and nuts on these studs (Figs. 23 and 24). (2) Install new bolt and washer assemblies in the remaining holes (Figs. 23 and 24). Start at the center arm and work outward. Tighten the bolts and nuts to 24 N m (18 ft. lbs.) torque. (3) Raise the vehicle.
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(5) Lower the vehicle. (6) Connect the negative cable to the battery.
TORQUE SPECIFICATIONS
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BUMPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
REAR BUMPER
Dakota rear bumpers are attached to the frame rails with support brackets, braces, bolts and nuts.
TEMPORARY BUMPER REMOVAL (1) Support the bumper. (2) Remove the bumper support bracket attaching nuts and bolts from the frame rails. (3) Remove the support and remove the bumper from the vehicle. STEP BUMPER
SERVICE INFORMATION The rear step bumper includes the bumper rail, the support brackets and braces, and the license plate lamps. Each of the step bumper components can be serviced separately. BUMPER REMOVAL (1) Remove the wire harness clip retainers, disconnect the bulb sockets from each license plate lamp and detach the wire harness from the step bumper (Fig. 3).
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page Snow Plow Malfunction Diagnosis and Tests . . . . . . 4 Snow Plow Pivot Bracket . . . . . . . . . . . . . . . . . . . 16 Snow Plow Wiring Diagrams . . . . . . . . . . . . . . . . . . 4 System Description and Operation . . . . . . . . . . . . . . 3 Sector shear pinSelf-locking pin that locks the moldboard in either a straight ahead or an angled plowing position If the blade impacts obstructions, the pin will shear to protect the snow plow and the vehicle from damage. The pin is not used with power angle plowing. Power angling cylindersEnable the operator to move the moldboard either straight ahead or to the side Hinge pinsAllows the A-Frame to pivot up and down. The pins act as attaching points. Cutting edgeReplaceable blade edge extends the life of the blade RunnersAdjustable runners retain the cutting edge at the proper height Sno-Flo paintSpecially developed high-visibility, yellow paint provides fast, smooth snow-rolling action Hydraulic pump and motor (Electro-Touch)Hydraulically raises, lowers and angles the snow plow A-frameProvides the means for attaching the snow plow to the vehicle Lift armRaises and lowers the snow plow.
SERVICE INFORMATION
A snow plow is optionally available for Dakota Truck vehicles. The primary mechanical components are illustrated in Figure 1.
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With power applied, the solenoid retracts and pulls the poppet valve into the OPEN position. When power is turned off, the spring forces the solenoid back to its normal, CLOSED position. SOLENOID VALVE A The solenoid valve A cartridge contains a poppet valve. This valve is normally de-energized in the CLOSED position. When closed, the valve retains pressure in the lift cylinder. When it is energized (valve opened), it allows the fluid to flow from the lift cylinder back to the reservoir. This enables the plow blade to lower via gravity. Solenoid valve A is designed to remain energized (valve open) during plowing to provide a floating blade position. This ensures that the plow blade is guided up-down by the surface deviations. SOLENOID VALVE B The solenoid valve B cartridge contains a spool valve. This valve is normally in the de-energized CLOSED position. This allows the fluid to flow to the C solenoid. In the energized OPEN position, the fluid is diverted to the lift cylinder. This causes the plow blade to be raised. SOLENOID VALVE C The solenoid valve C cartridge contains a spool valve that is normally in the de-energized CLOSED position. This allows the fluid to flow to the rightside power angling cylinder. This angles the blade to the left. At the same time, it allows the fluid from the retracting left-side power angling cylinder to return to the pump reservoir. Energizing the solenoid valve will route fluid to the left side angling cylinder. This angles the plow blade to the right. Also, the fluid is forced from the retracting right side cylinder. It flows through the C cartridge valve and returns to the pump reservoir.
SYSTEM OPERATION Refer to Figures 2 through 5 for voltage application and hydraulic fluid flow for each snow plow function. Each figure shows the components that are actuated for each function.
MECHANICAL HYDRAULIC VALVES The mechanical hydraulic valves all have the same function: they control the direction of the hydraulic fluid flow.
CHECK VALVES Check valves allow fluid to flow freely in one direction while preventing fluid from flowing in the opposite direction. A pump check valve is used to prevent fluid from leaking back through the pump to the reservoir. Two additional check valves are necessary because solenoid valves B and C have some leakage. One check valve is located between solenoid valve B and the lift cylinder. It prevents fluid in the lift cylinder from leaking back through solenoid valve B. If fluid leaks back, it could angle the blade to the left. This would force fluid through solenoid valve C into the right side cylinder.
SOLENOID VALVE COIL FUNCTIONAL TEST Test the coils for proper operation, according to the following procedure. (1) Hold a screwdriver blade about 1/8 inch above the nut on the coil to be tested. (2) Have a helper operate the control switch that energizes the applicable coil.
CAUTION: Do not connect an ohmmeter to a coil when it is applied. This can cause internal damage to the ohmmeter. (3) If the coil is working, the electromagnetic action will pull the screwdriver down to the retaining nut. If this does not occur, use an ohmmeter to check the coil for continuity.
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Fig. 3 Lower & Float BladeVoltage Application & Hydraulic Fluid Flow
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(23) Disassemble the three-way valve (Fig. 9). Discard the O-ring seal. (24) Remove and clean solenoid valve C with special tool J-25399 (Fig. 9). Inspect the solenoid valve for external damage. (25) Disassemble the four-way valve (Fig. 12). Discard the O-ring seals (Fig. 12). (26) Test solenoid valve B and C coils for electrical continuity. The normal coil DC resistance is 3.7 ohms. (27) Remove the pilot check valve plug, the spring and the ball from the bottom of the valve block. (28) Inspect the spring for damage and the ball seat for nicks. (29) Remove the acorn nut for access to the crossover valve components (Fig. 9). (30) Remove the crossover valve components (Fig. 13). Inspect for external damage. Discard the O-ring seals. (31) Clean the block with compressed air to remove all foreign material.
ASSEMBLY Verify that all components are thoroughly clean and free of foreign material. Use replacement gaskets and seals during assembly. Petroleum jelly should used for installing the rubber O-ring seals. (1) Install the crossover valve components in the valve block with replacement O-ring seals (Fig. 13). (2) Install the ball, spring and pressure plug with a replacement O-ring seal in the bottom of the valve block (Fig. 13). (3) Assemble solenoid valve C with replacement Oring seals and nylon retainer rings (Fig. 12). (4) Install solenoid valve C with Tool J-25399 (Fig. 9). (5) Assemble solenoid valve B with replacement Oring seals. (6) Install the ball, spring and solenoid valve B with Tool J-25399 (Fig. 9). (7) Install the valve block and the replacement Oring seals on the pump base. (8) Install the retainer, the spring, the ball, the insert valve and the pump housing with replacement O-ring seals (Fig. 11). Tighten the pump housing base nuts to 11.3 N m (100 in. lbs.) torque. (9) Install the filters and the plugs with replacement O-ring seals (Fig. 9). (10) Install solenoid valve A cartridge in the pump base with replacement O-ring seals (Fig. 9). (11) Install solenoid valve A coil (Fig. 9). (12) Install the motor on the pump housing (Fig. 9). Engage the gear shaft tang with the notch in the motor output shaft. Tighten the motor housing capscrews to 5 N m (45 in. lbs.) torque. (13) Install the ram and piston with replacement O-ring seals (Fig. 9). (14) Position the cover on the reservoir. Secure it with locknuts (Fig. 9). Tighten the locknuts to 11.3 N m (100 in. lbs.) torque.
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INSTALLATION (1) Position and support the pivot bracket at the vehicle frame rails with the bolt holes aligned (Fig. 16). (2) Install the pivot bracket attaching bolts, washers and nuts finger-tight (Fig. 16). (3) Install the support strap attaching bolts and nuts (Fig. 15). Tighten the nuts to 68 N m (50 ft. lbs.) torque. (4) Tighten the pivot bracket attaching nuts to 68 N m (50 ft. lbs.) torque. (5) Remove the support from under the pivot bracket.
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ASSEMBLY/INSTALLATION (1) Insert the auxiliary headlamp switch in the switch cover opening. Carefully push inward until it is completely seated against the cover face (Fig. 18).
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and through-bolts. The cargo box or bed is attached to the frame with bolts. Refer to Group 23, Body for cargo box service procedures. The frame is designed for independent front suspension with the front suspension crossmember being a part of the frame (Fig. 1). The engine front mount support brackets are welded to the frame rails on a 4x4 vehicle and bolted to the crossmember on a 4x2 vehicle. The front suspension attaching brackets are welded to the side rails (Fig. 1). The rear suspension attaching brackets are riveted to the side rails. The frame (Fig. 1) is the foundation and the structural center of a Dakota vehicle. It is designed to absorb and dissipate flexing and twisting due to acceleration, braking, cornering and road surface variances without bending when subjected to normal driving conditions. The frame is the mounting platform for the following systems and components. Front and rear suspension systems. Engine, transmission, and transfer case. Steering gear and linkage. Fuel cell and fuel line tubing. Front end sheet metal and radiator closure panel. Passenger cab. Cargo box or bed. Front and rear bumper systems.
FRAME STRAIGHTENING
When necessary, a conventional frame that is bent or twisted can be straightened by application of heat. The temperature must not exceed 566C (1050F). The metal will have a dull red glow at the desired temperature. Excessive heat will decrease the strength of the metal and result in a weakened frame. Welding the joints around riveted cross members and frame side rails is not recommended. A straightening repair process should be limited to frame members that are not severely damaged. The replacement bolts, nuts and rivets that are used to join the frame members should conform to the same specifications as the original bolts, nuts and rivets.
GENERAL INFORMATION
Dakota vehicles have a ladder-type frame (Fig. 1) that has: A box-section front. A dropped center. Open-channel side rails in the rear. As applicable, the frame crossmembers are securely attached to the side rails by either rivets, welds or bolts to form a ladder-shaped frame (Fig. 1). The cab is attached from the frame with rubber load cushions
FRAME REPAIRS
DRILLING HOLES Do not drill holes in frame side rail top and bottom
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WELDING Use MIG, TIG or arc welding equipment to repair welded frame components. Frame components that have been damaged should be inspected for cracks before returning the vehicle to use. If cracks are found in accessible frame components perform the following procedures. (1) Drill a hole at each end of the crack with a 3 mm (O.125 in.) diameter drill bit. (2) Using a suitable die grinder with 3 inch cut off wheel, V-groove the crack to allow 100% weld penetration. (3) Weld the crack. (4) If necessary when a side rail is repaired, grind the weld smooth and install a reinforcement channel (Fig. 2) over the repaired area. If a reinforcement channel is required, the top and bottom flanges should be 0.250 inches narrower than the side rail flanges. Weld only in the areas indicated (Fig. 2). FRAME FASTENERS Bolts, nuts and rivets can be used to repair frames or to install a reinforcement section on the frame. Bolts can be used in place of rivets. When replacing rivets with bolts, install the next larger size diameter bolt to assure proper fit. If necessary, drill the hole out just enough to receive the bolt.
FRAME DIMENSIONS
Frame dimensions are listed in inch scale. All dimensions are from center to center of Principal Locating Point (PLP), or from center to center of PLP and fastener location (Fig. 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, and 14).
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Drive Shaft Center Bearing Support Crossmember . 35 Engine Splash Shield/Air Deflector4WD Vehicles . 34
SERVICE INFORMATION
It may be necessary to refer to the component removal procedure for service access.
SKID PLATES
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REMOVAL (1) At each side of the vehicle, remove the nuts and bolts that attach the support crossmember to the frame side rail (Fig. 5).
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(2) At each side of the vehicle, install the bolts and nuts to attach the crossmember rod to the frame side rail (Fig. 5).
FUEL SYSTEM
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FUEL SYSTEM
CONTENTS
page page
ACCELERATOR PEDAL AND THROTTLE CABLE . 18 FUEL DELIVERY SYSTEM . . . . . . . . . . . . . . . . . . 3 FUEL TANKS . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1 MULTI-PORT FUEL INJECTION (MFI) COMPONENT DESCRIPTION/SYSTEM OPERATION3.9L/5.2L ENGINE . . . . . . . . . . 52 MULTI-PORT FUEL INJECTION (MFI) COMPONENT REMOVAL/INSTALLATION 3.9L/5.2L ENGINE . . . . . . . . . . . . . . . . . . . . . 83
MULTI-PORT FUEL INJECTIONGENERAL DIAGNOSIS3.9L/5.2L ENGINE . . . . . . . . . . SINGLE-PORT FUEL INJECTIONCOMPONENT DESCRIPTION/SYSTEM OPERATION2.5L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SINGLE-PORT FUEL INJECTIONCOMPONENT REMOVAL/INSTALLATION2.5L ENGINE . . . SINGLE-PORT FUEL INJECTIONGENERAL DIAGNOSIS2.5L ENGINE . . . . . . . . . . . . . . SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . .
67 21 43 32 92
GENERAL INFORMATION
Throughout this group, references are made to particular vehicle models by alphabetical designation or by the particular vehicle nameplate. A chart showing a breakdown of the alphabetical designations is included in the Introduction section at the beginning of this manual. All vehicles are equipped with either: a 2.5L 4-cylinder, a 3.9L V-6 or a 5.2L (V-8) engine. The Fuel System consists of: the fuel tank, an electric (fuel tank mounted) fuel pump, a separate frame mounted fuel filter (2.5L engine only), a combination fuel filter/pressure regulator (3.9L and 5.2L engines only), the pressure relief/rollover valve and a pressure-vacuum fuel filler cap. It also consists of fuel tubes/lines/hoses, vacuum hoses, throttle body and fuel injector(s). The Fuel Delivery System consists of: the electric fuel pump, fuel filter, fuel tubes/lines/hoses, fuel rail, fuel injectors and fuel pressure regulator. On 3.9L V-6 and 5.2L V-8 engines, a combination fuel filter and fuel pressure regulator are mounted to the top of the fuel pump module. A Fuel Return System is used on all vehicles (all engines). On the 2.5L 4-cylinder engine, the system consists of a throttle body mounted fuel pressure regulator and the fuel tubes/lines/hoses that route fuel from the engine and return it to the fuel tank. On 3.9L or 5.2L engines, fuel is returned through the fuel pump module and back into the fuel tank through the fuel filter/fuel pressure regulator. A separate fuel return line from the engine to the tank is no longer used on any 3.9L V-6 or 5.2L V-8 engine. The Fuel Tank Assembly consists of: the fuel tank, the filler tube, a fuel gauge sending unit/electric fuel pump module, a combination fuel filter/pressure regulator (3.9L and 5.2L engines), a pressure relief/rollover valve and a pressure-vacuum filler cap. Also to be considered part of the fuel system is the Evaporation Control System. This is designed to reduce the emission of fuel vapors into the atmosphere. The description and function of the Evaporative Control System is found in Group 25, Emission Control Systems.
GASOLINE/OXYGENATE BLENDS Some fuel suppliers blend unleaded gasoline with materials that contain oxygen such as alcohol, MTBE
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FUEL SYSTEM
MTBE/ETBE Gasoline and MTBE (Methyl Tertiary Butyl Ether) blends are a mixture of unleaded gasoline and up to 15 percent MTBE. Gasoline and ETBE (Ethyl Tertiary Butyl Ether) are blends of gasoline and up to 17 percent ETBE. Gasoline blended with MTBE or ETBE may be used in your vehicle. CLEAN AIR GASOLINE Many gasolines are now being blended that contribute to cleaner air, especially in those areas of the country where air pollution levels are high. These new blends provide a cleaner burning fuel and some are referred to as Reformulated Gasoline. In areas of the country where carbon monoxide levels are high, gasolines are being treated with oxygenated materials such as MTBE, ETBE and ethanol. Chrysler Corporation supports these efforts toward cleaner air and recommends that you use these gasolines as they become available.
and ETBE. The type and amount of oxygenate used in the blend is important. The following are generally used in gasoline blends: ETHANOL Ethanol (Ethyl or Grain Alcohol) properly blended, is used as a mixture of 10 percent ethanol and 90 percent gasoline. Gasoline with ethanol may be used in your vehicle. METHANOL CAUTION: DO NOT USE GASOLINES CONTAINING METHANOL. Use of methanol/gasoline blends may result in starting and driveability problems. In addition, damage may be done to critical fuel system components. Methanol (Methyl or Wood Alcohol) is used in a variety of concentrations blended with unleaded gasoline. You may encounter fuels containing 3 percent or more methanol along with other alcohols called cosolvents. Problems that are the result of using methanol/gasoline blends are not the responsibility of Chrysler Corporation. They may not be covered by the vehicle warranty.
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page Fuel Pump Module3.9L/5.2L Engine . . . . . . . . . . . 3 Fuel System Pressure Release . . . . . . . . . . . . . . . . 7 Fuel System Pressure Test2.5L Engine . . . . . . . . 8 Fuel System Pressure Test3.9L/5.2L Engine . . . . . 8 Fuel Tubes/Lines/Hoses and Clamps . . . . . . . . . . . 10 Quick-Connect Fittings . . . . . . . . . . . . . . . . . . . . . 10
ELECTRIC FUEL PUMP The fuel pump used in this system has a permanent magnet electric motor. The pump is part of the fuel pump module (Fig. 4). The fuel pump module is suspended in fuel in the fuel tank. Fuel is drawn in through a filter and pushed through the electric motor to the outlet. The pump contains a check valve. This valve is located near the pump outlet. It re-
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FUEL FILTER
2.5L ENGINE ONLY
REMOVAL WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE OFF). BEFORE SERVICING THE FUEL FILTER, THE FUEL SYSTEM PRESSURE MUST BE RELEASED. (1) Perform the Fuel System Pressure Release procedure. (2) Disconnect negative battery cable from battery. (3) Raise and support the vehicle. (4) Remove filter retaining bolt and remove filter assembly from mounting plate (Fig. 6). (5) Loosen hose clamps on filter and hoses (Fig. 6). (6) Wrap a shop towel around hoses to absorb fuel. Remove hoses at filter and fuel tube and remove filter from vehicle. (7) Discard hose clamps. INSTALLATION CAUTION: The tubes/hoses used on fuel injected vehicles are of a special construction. This is due to the higher fuel pressures and the possibility of contaminated fuel in this system. If it is necessary to replace these tubes/hoses, only tubes/hoses marked EFM/EFI may be used. CAUTION: The hose clamps used on fuel injected vehicles are of a special rolled edge construction to prevent the edge of the clamp from cutting into the hose. Only these rolled edge type clamps may be used in this system. All other types of clamps may cut into the hoses and cause high-pressure fuel leaks.
3.9L OR 5.2L ENGINE Refer to Fuel Filter/Fuel Pressure Regulator for information.
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The regulator is calibrated to maintain fuel system operating pressure of approximately 241-310 kPa (35-45 psi) at the fuel injectors. It contains a diaphragm, calibrated springs and a fuel return valve. The internal fuel filter (Fig. 7) is also part of the assembly. Fuel is supplied to the filter/regulator by the electric fuel pump through an opening tube at the bottom of filter/regulator (Fig. 7). The filter/regulator contains a check valve to maintain some fuel pressure when the engine is not operating. This will help to start the engine. If fuel pressure at the pressure regulator exceeds approximately 45 psi, an internal diaphragm closes and excess fuel pressure is routed back into the tank through the pressure regulator. A separate fuel return line is not used with any 3.9L or 5.2L engine.
INSTALLATION (1) Install a new clamp over the plastic fuel tube.
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2.5L ENGINE (1) Loosen fuel tank filler tube cap to release fuel tank pressure. (2) Disconnect fuel injector wiring harness from engine harness. (3) Connect one end of a jumper wire (18 gauge or smaller) to ground terminal number-1 of the injector harness (Fig. 13). Connect the other end of jumper to engine ground. (4) Connect one end of a jumper wire (18 gauge or smaller) to the positive terminal number-2 of the injector harness (Fig. 13). Touch the other end of jumper to positive battery post for no longer than 5 seconds. This releases fuel system pressure. (5) Remove jumper wires. (6) Continue fuel system service.
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3.9L/5.2L ENGINE (1) Disconnect negative battery cable. (2) Remove the fuel tank filler tube cap to release fuel tank pressure. (3) Remove protective cap from pressure test port on the fuel rail (Fig. 14).
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priate Powertrain Diagnostic Procedures service manual for DRB operation. (5) A good fuel pump will deliver at least 1 liter of fuel per minute.
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(9) Again, start engine and bring to normal operating temperature. (10) Shut engine off. (11) Checking for fuel injector leakage: Clamp off the rubber hose portion of either tool 6539 or 6631 between the disconnected fuel tube (line) and test port inlet. If pressure now holds at or above 24 psi, a fuel injector or the fuel rail is leaking. Checking for fuel pressure regulator or fuel tube leakage: Clamp off the rubber hose portion of either tool 6539 or 6631 between the fuel rail and test port inlet. If pressure now holds at or above 24 psi, a leak can be found at a fuel tube/line. If no leaks are found at fuel tubes or lines, replace the fuel filter/fuel pressure regulator.
QUICK-CONNECT FITTINGS
Also refer to the previous Fuel Tubes/Lines/Hoses and Clamps section. Different types of quick-connect fittings are used to attach various fuel system components. These are: a single-tab type, a two-tab type or a plastic retainer ring type.
MECHANICAL MALFUNCTIONS Mechanical malfunctions are more difficult to diagnose with this system. The powertrain control module (PCM) has been programmed to compensate for some mechanical malfunctions such as incorrect cam timing, vacuum leaks, etc. If engine performance problems are encountered and diagnostic trouble codes are not displayed, the problem may be mechanical rather than electronic.
SINGLE-TAB TYPE This type of fitting is equipped with a single pull tab (Fig. 17). The tab is removable. After the tab is removed, the quick-connect fitting can be separated from the fuel system component.
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and component. Clean the parts with a lint-free cloth. Lubricate them with clean engine oil. (10) Insert the quick-connect fitting into the fuel tube or fuel system component until the built-on stop on the fuel tube or component rests against back of fitting. (11) Obtain a new pull tab. Push the new tab down until it locks into place in the quick-connect fitting. (12) Verify a locked condition by firmly pulling on fuel tube and fitting (15-30 lbs.). (13) Connect negative cable to battery. (14) Start engine and check for leaks.
TWO-TAB TYPE FITTING This type of fitting is equipped with tabs located on both sides of the fitting (Fig. 20). These tabs are supplied for disconnecting the quick-connect fitting from component being serviced.
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(2) Perform the fuel pressure release procedure. Refer to the Fuel Pressure Release Procedure in this section. (3) Clean the fitting of any foreign material before disassembly. (4) To disconnect the quick-connect fitting, squeeze the plastic retainer tabs against the sides of the quick-connect fitting with your fingers. Tool use is not required for removal and may damage plastic retainer. Pull the fitting from the fuel system component being serviced. The plastic retainer will remain on the component being serviced after fitting is disconnected. The o-rings and spacer will remain in the quick-connect fitting connector body. (5) Inspect the quick-connect fitting body and component for damage. Replace as necessary. CAUTION: When the quick-connect fitting was disconnected, the plastic retainer will remain on the component being serviced. If this retainer must be removed, very carefully release the retainer from the component with two small screwdrivers. After removal, inspect the retainer for cracks or any damage. (6) Prior to connecting the quick-connect fitting to component being serviced, check condition of fitting and component. Clean the parts with a lint-free cloth. Lubricate them with clean engine oil. (7) Insert the quick-connect fitting to the component being serviced and into the plastic retainer. When a connection is made, a click will be heard. (8) Verify a locked condition by firmly pulling on fuel tube and fitting (15-30 lbs.). (9) Connect negative cable to battery. (10) Start engine and check for leaks.
PLASTIC RETAINER RING TYPE FITTING This type of fitting can be identified by the use of a full-round plastic retainer ring (Fig. 21) usually black in color.
CAUTION: The interior components (o-rings, spacers, retainers) of this type of quick-connect fitting are not serviced separately. Do not attempt to repair damaged fittings or fuel lines/tubes. If repair is necessary, replace the complete fuel tube/quick-connect fitting assembly. WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE OFF). BEFORE SERVICING ANY FUEL SYSTEM HOSES, FITTINGS OR LINES, THE FUEL SYSTEM PRESSURE MUST BE RELEASED. REFER TO THE FUEL SYSTEM PRESSURE RELEASE PROCEDURE IN THIS GROUP.
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Gauge Sending Unit . . . . . PumpRemoval/Installation Reservoir . . . . . . . . . . . . . Tank Capacities . . . . . . . . . Tank Filler Tube Cap . . . . .
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16 16 16 15 15
GENERAL INFORMATION
These vehicles pass a full 360 degree rollover test without fuel leakage. To accomplish this, fuel and vapor flow controls are required for all fuel tank connections. All models are equipped with a pressure relief/rollover valve mounted in the top of the fuel pump module (Figs. 1 or 2). On 2.5L 4-cylinder engines, the return line from the fuel pump to the fuel tank contains a one-way check valve.
FUEL TANKS
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HEAT SHIELDS
The sheet metal heat shields must be removed when servicing the fuel tank, fuel lines or vapor vent line. The heat shields must be installed to protect the lines and tank from the heat of the exhaust system. Refer to Group 11, Exhaust System and Intake Manifold for proper installation.
FUEL TANKS
The standard equipment fuel tank on all models is located between the left frame structure and the pro-
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FUEL TANKS
fuel filler hose to absorb any spilled fuel. Disconnect filler hose from filler neck. Drain fuel tank through filler hose.
REMOVAL (1) Disconnect negative cable from battery. (2) Remove fuel tank filler tube cap before disconnecting any fuel or vent lines. The fuel tank could be under a small pressure. (3) Drain fuel tank. Refer to Draining Fuel Tank in this section.
WARNING: WRAP SHOP TOWELS AROUND FUEL FILLER HOSES TO ABSORB ANY GASOLINE THAT MIGHT SPILL. (4) Raise vehicle on hoist and disconnect all vent hoses and filler hose (Fig. 4). Remove the vent hoses from hose routing bracket attached to the top of the frame rail.
FUEL PUMPREMOVAL/INSTALLATION
The electric fuel pump is not serviceable. If the fuel pump needs replacement, the complete fuel pump module must be replaced. Refer to Fuel Pump Module in the Fuel Delivery System section of this group.
FUEL RESERVOIR
The fuel reservoir (Fig. 6) is part of the lower end of the fuel pump module. The purpose of the reservoir is to provide fuel at the pump intake during all driving conditions. This is when low fuel levels are present. The fuel return line directs fuel into the reservoir (2.5L engine only).
INSTALLATION (1) Place fuel tank on top of transmission jack. Raise tank up enough to connect the fuel tubes (lines) to the fuel pump module. Refer to Quick-Connect Fittings in the Fuel Delivery System section.
FUEL TANKS
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(2) Disconnect the vapor line (hose) at the valve. (3) Wedge the blade of a screwdriver between the rubber grommet and the fuel tank where the support rib is located. Do not wedge between the valve and the grommet or damage to the valve may result upon removal. (4) Use a second screwdriver as a support and pry the valve and grommet assembly from the tank. (5) To remove the grommet from the valve, place the valve upright on a flat surface. Push down on the grommet peeling it down off the valve.
INSTALLATION (1) Install the rubber grommet in the fuel tank and work it around the curled lip. (2) Lubricate the grommet with power steering fluid and push the valve downward into the grommet. Twist valve until properly positioned. (3) Install fuel tank. Refer to Fuel Tank Installation in this section of the group.
REMOVAL (1) Remove fuel tank. Refer to Fuel Tank draining and removal in this section of the group.
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ACCELERATOR PEDAL AND THROTTLE CABLE ACCELERATOR PEDAL AND THROTTLE CABLE INDEX
page page Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
GENERAL INFORMATION
All engines are equipped with torsion return springs located on the throttle body shaft. 3.9L V-6 and 5.2L V-8 engines equipped with a manual transmission have an additional pedal return spring (Fig. 1). All of these springs are designed to give positive throttle return while meeting safety requirements.
Fig. 2 Accelerator PedalRemoval or Installation Fig. 1 Throttle Return Spring3.9L/5.2L Engines with Man. Trans.
(2) Remove two accelerator pedal/bracket nuts (Fig. 2) and remove pedal/bracket assembly from vehicle.
ACCELERATOR PEDAL
CAUTION: Be careful not to damage or kink the cable core wire (within the cable sheathing) while servicing accelerator pedal or cables.
REMOVAL (1) From inside the vehicle, hold up accelerator pedal. Remove plastic cable retainer and throttle cable core wire from upper end of pedal arm (Fig. 2). Plastic cable retainer snaps into pedal arm.
INSTALLATION (1) Position pedal/bracket assembly over the two dash panel mounting studs and install retaining nuts. (2) Tighten nuts to 7 N m (65 in. lbs.) torque. (3) From inside the vehicle, hold up the accelerator pedal. Install the throttle cable core wire and plastic cable retainer into the upper end of the pedal arm. The plastic retainer is snapped into the pedal arm. When installing the plastic retainer to the accelerator pedal arm, note the index tab on the pedal arm (Fig. 3). Align the index slot (Fig. 3) on the plastic cable retainer to this index tab.
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THROTTLE CABLE
CAUTION: Be careful not to damage or kink the cable core wire (within the cable sheathing) while servicing accelerator pedal or cables.
REMOVAL (1) From inside the vehicle, hold up accelerator pedal. Remove plastic cable retainer and throttle cable core wire from upper end of pedal arm (Fig. 2). Plastic cable retainer snaps into pedal arm. (2) Remove the cable core wire at the pedal arm. (3) From inside the vehicle, pinch both sides of the cable housing retainer at the dash panel (Fig. 2). Remove cable housing from dash panel and pull into the engine compartment. (4) 2.5L Engine: (a) Remove the cable slug from the throttle body cam. (b) Separate the cable mounting bracket with wide-jaw pliers by compressing the end-fitting tabs (Fig. 4). 3.9L/5.2L Engine: (a) Remove the air cleaner housing. (b) Operate the throttle body cam (by hand) to the full open throttle position (Fig. 5). (c) Slip the pin on the end of cable from the hole in the throttle body cam (Fig. 5). (d) Remove cable from cam. (e) Remove cable housing at throttle body mounting bracket by pressing forward on release tab with a small screwdriver (Fig. 6). To prevent cable housing breakage, press on the tab only enough to release the cable from the bracket. (f) Lift the cable housing straight up from bracket while pressing on release tab. (g) Disconnect cable from radiator fan shroud routing clip. (5) Remove cable from vehicle.
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GENERAL INFORMATION
The Single-Port Electronic Fuel Injection System (Fig. 1) used in vehicles equipped with the 2.5L engine is a computer regulated system. It provides a precise air/fuel ratio for all driving conditions. Fuel is supplied to the engine through a fuel injector located in the throttle body. The fuel injection system is controlled by the powertrain control module (PCM). The PCM was formerly referred to as the SBEC or engine controller. The PCM is a pre-programmed, microprocessor digital computer. It regulates ignition timing, air-fuel ratio, emission control devices, charging system, engine cooling fan, idle speed, air conditioning, fuel pump and the tachometer. The PCM can adapt its programming to meet changing operating conditions. Various sensors provide the inputs necessary for the PCM to correctly regulate fuel flow at the injector. These include the manifold absolute pressure, throttle position, exhaust gas oxygen content, engine coolant temperature, throttle body temperature, engine speed and vehicle speed sensors. In addition to the sensors, various switches and relays provide important information and system control. These include the air conditioning switch, brake switch and automatic shutdown relay. All inputs to the PCM are converted into signals. Air-fuel ratio, ignition timing and other controlled outputs are adjusted based on these inputs. The PCM adjusts the air-fuel ratio by changing the injector pulse width. Injector pulse width is the period of time that the injector is energized by the PCM.
SYSTEM DIAGNOSIS The powertrain control module (PCM) tests many of its own input and output circuits. If a Diagnostic Trouble Code (DTC) is found in a major system, this information is stored in the PCM memory. Refer to On-Board Diagnostics in the Single-Port Fuel InjectionGeneral Diagnosis2.5L Engine section of this group for DTC information.
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energized). This is done to compensate for increased amount of time needed to energize the injector due to lower voltage.
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magnetic field. The Hall effect device in the pick-up senses the change in the magnetic field and switches on and off (which creates pulses). These generate the input signal to the powertrain control module (PCM). The PCM calculates engine speed through the number of pulses generated. Refer to Distributors in Group 8D, Ignition System for more information.
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GENERATORPCM OUTPUT
The powertrain control module (PCM) regulates the charging system voltage within a range of 12.9 to 15.0 volts. Refer to Group 8A for charging system information.
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MODES Open Loop Closed Loop During Open Loop modes, the powertrain control module (PCM) receives input signals and responds only according to preset internal programming. Input from the oxygen (O2S) sensor is not monitored during Open Loop modes. During Closed Loop modes, the powertrain control module (PCM) will monitor the oxygen (O2S) sensor input. This input indicates to the PCM whether or not the calculated injector pulse width results in the ideal air-fuel ratio. This ratio is 14.7 parts air to 1 part fuel. By monitoring the exhaust oxygen content through the O2S sensor, the PCM can fine tune the
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Determines the number of engine revolutions since cranking was initiated. Monitors the engine coolant temperature sensor, distributor pick-up, MAP sensor and throttle position sensor. This will determine correct ignition timing.
IGNITION SWITCH (KEY-ON) MODE This is an Open Loop mode. When the single-port fuel injection system is activated by the ignition switch, the following actions occur: Powertrain control module (PCM) determines atmospheric air pressure from the Manifold Absolute Pressure (MAP) sensor input to determine basic fuel strategy. The PCM monitors the engine coolant temperature sensor input. The PCM modifies fuel strategy based on this input. When the key is in the On position, the auto shutdown (ASD) relay is not energized. Battery voltage is not supplied to the fuel pump, ignition coil, fuel injector or oxygen sensor heating relay. ENGINE START-UP MODE This is an Open Loop mode. The following actions occur when the starter motor is engaged: If the powertrain control module (PCM) receives a distributor signal it will energize the auto shutdown (ASD) relay. This is done to supply battery voltage to the fuel pump, fuel injector, ignition coil and oxygen sensor heating element. If the PCM does not receive a distributor input within 0.5 seconds, the ASD relay will be de-energized. When the engine is operating and idling within 64 rpm of target rpm, the PCM compares current MAP value with atmospheric pressure value it received. This is done during the Key-On mode. If a minimum difference between the two is not detected, a pneumatic trouble code is set into memory. Once the ASD relay has been energized, the PCM: Supplies a ground path to the injector. The injector is pulsed four times per engine revolution instead of the normal two pulses per revolution. Determines injector pulse width based on engine coolant temperature and barometric pressure (MAP sensor).
ENGINE WARM-UP MODE This is a Open Loop mode. The following inputs are received by the powertrain control module (PCM): Engine coolant temperature Manifold absolute pressure (MAP) Engine speed (distributor pick-up) Throttle position Air Conditioning (A/C) switch Battery voltage The PCM provides a ground path for the injector to precisely control injector pulse width. This is done by switching the ground on and off. It then fires the injector twice per engine revolution. The PCM adjusts engine idle speed, throttle stop angle and ignition timing. The up-shift indicator lamp (manual transmission only) is illuminated by the PCM according to engine speed and load. CRUISE OR IDLE MODE When the engine is at operating temperature, this is a Closed Loop mode. During cruising speed and at idle, the following inputs are received by the powertrain control module (PCM): Engine coolant temperature Manifold absolute pressure Engine speed Throttle position Exhaust gas oxygen content Air Conditioning (A/C) control positions The PCM provides a ground path for the injector to precisely control injector pulse width. It fires the injector twice per engine revolution. The PCM regulates engine idle speed, throttle stop angle and ignition timing. The PCM adjusts the air/fuel ratio according to the oxygen content in the exhaust gas. The up-shift indicator lamp (manual transmission only) is illuminated by the PCM according to engine speed and load. ACCELERATION MODE This is a Closed Loop mode. The powertrain control module (PCM) recognizes an abrupt increase in throttle position or MAP pressure as a demand. This demand is used for increased engine output and vehicle acceleration. The PCM increases injector pulse width in response to increased fuel demand. The PCM will de-energize the A/C clutch relay. This is done if the air conditioning is on and a wide open throttle (WOT) condition is sensed.
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DECELERATION MODE This is a Closed Loop mode. During deceleration, the following inputs are received by the powertrain control module (PCM): Engine coolant temperature Manifold absolute pressure Engine speed Throttle position Exhaust gas oxygen content Vehicle speed sensor Air Conditioning (A/C) control positions A closed throttle input, along with an abrupt decrease in manifold pressure, indicates to the PCM that the vehicle is in a hard deceleration. The PCM may reduce injector firing to just once per engine revolution to lean the air-fuel mixture. This is sensed through the O2S sensor during hard deceleration. The PCM grounds the EGR and EVAP purge solenoids. This stops EGR operation and EVAP canister purge functions. WIDE OPEN THROTTLE MODE This is an Open Loop mode. During wide-openthrottle operation, the following inputs are received by the powertrain control module (PCM): Engine coolant temperature Manifold absolute pressure Engine speed Throttle position When the PCM senses wide open throttle condition through the throttle position sensor (TPS), it will provide a ground for the EGR solenoid. This will prevent any EGR functions. The exhaust gas oxygen content input is not accepted by the PCM. It will adjust injector pulse width to supply a predetermined amount of additional fuel. IGNITION SWITCH OFF-MODE This is an Open Loop mode. When the ignition switch is turned to the Off position, the powertrain control module (PCM) ceases to provide a ground for the auto shutdown (ASD) relay. Battery voltage is disconnected from the fuel pump, fuel injector, ignition coil and oxygen sensor heating element. This is done when the ASD relay is not energized. All fuel injection stops.
THROTTLE BODY
The throttle body assembly (Fig. 16) is mounted on top of the intake manifold. It contains: The fuel injector The fuel pressure regulator The throttle position sensor (TPS) The idle air control (IAC) motor The throttle body temperature sensor Air flow through the throttle body is controlled by a cable operated throttle blade. This throttle is located in the base of the throttle body. The throttle body itself provides the chamber for metering, atomizing and mixing fuel with the air entering the engine.
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. . . .
GENERAL INFORMATION
The fuel injection system is managed by the powertrain control module (PCM). The PCM was formerly referred to as the SBEC or engine controller. The PCM receives inputs from various switches and sensors (Fig. 1). Based on these inputs, the PCM adjusts ignition timing and idle speed through output devices. Refer to the previous section of this group for system operation and component descriptions.
VISUAL INSPECTION
A visual inspection for loose, disconnected, or incorrectly routed wires and hoses should be made. This should be done before attempting to diagnose or service the fuel injection system. A visual check will help spot these faults and save unnecessary test and diagnostic time. A thorough visual inspection will include the following checks:
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Fig. 4 EVAP Canister Purge Solenoid and EGR Solenoid Vacuum Connections
(8) Verify that the engine ground strap is properly attached. Refer to Group 8, Wiring for schematics and ground locations. (9) Check ignition coil electrical connections. (10) Verify that the throttle body wiring connection to main harness is attached. (11) Check transmission electrical connection. (12) Verify that 4-way connector is attached to Idle Air Control (IAC) Motor (Fig. 5).
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(13) Verify that the 3-way connector is attached to the throttle position sensor (Fig. 5). (14) Verify that the 2-way connector is attached to the throttle body temperature sensor (Fig. 5). (15) Verify that the 2-way connector is attached to the fuel injector (Fig. 5). (16) Verify that hose from PCV valve is securely attached to the intake manifold vacuum port (Fig. 6). Also verify orifice plug is in valve cover nipple.
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a DTC. If the MAP sensor output circuit shorts to ground when the engine rpm is above 2400 rpm, a 0 volt input will be seen by the PCM. A DTC will not be entered into memory because the condition does not occur within the specified rpm range. A DTC indicates that the powertrain control module (PCM) has recognized an abnormal signal in a circuit or the system. A DTC may indicate the result of a failure, but never identify the failed component directly. There are several operating conditions that the PCM does not monitor and set a DTC for. Refer to the following Monitored Circuits and Non-Monitored Circuits in this section.
MONITORED CIRCUITS The powertrain control module (PCM) can detect certain problems in the fuel injection system. Open or Shorted Circuit - The PCM can determine if sensor output (which is the input to PCM) is within proper range. It also determines if the circuit is open or shorted. Output Device Current Flow - The PCM senses whether the output devices are hooked up. If there is a problem with the circuit, the PCM senses whether the circuit is open, shorted to ground (-), or shorted to (+) voltage. Oxygen Sensor - The PCM can determine if the oxygen sensor is switching between rich and lean. This is, once the system has entered Closed Loop. Refer to Open Loop/Closed Loop Modes Of Operation in the Component Description/System Operation section for an explanation of the Closed (or Open) Loop operation. NON-MONITORED CIRCUITS The PCM does not monitor the following circuits, systems or conditions that could have malfunctions that result in driveability problems. A Diagnostic Trouble Code (DTC) may not be displayed for these conditions. Fuel Pressure Fuel pressure is controlled by the fuel pressure regulator. The PCM cannot detect a clogged fuel pump inlet filter, clogged in-line fuel filter, or a pinched fuel supply or return line. However, these could result in a rich or lean condition causing an oxygen sensor DTC to be stored in the PCM. Secondary Ignition Circuit: The PCM cannot detect an inoperative ignition coil, fouled or worn spark plugs, ignition cross firing, or open circuited spark plug cables. Engine Timing: The PCM cannot detect an incorrectly indexed timing chain, camshaft sprocket or crankshaft sprocket. The PCM also cannot detect an incorrectly indexed distributor. However, these could result in a rich or lean condition causing an oxygen sensor DTC to be stored in the PCM.
HIGH AND LOW LIMITS The powertrain control module (PCM) compares input signal voltages from each input device. It will establish high and low limits that are programmed into it for that device. If the input voltage is not within specifications and other Diagnostic Trouble Code (DTC) criteria are met, a DTC will be stored in memory. Other DTC criteria might include engine rpm limits or input voltages from other sensors or switches. The other inputs might have to be sensed by the PCM when it senses a high or low input voltage from the control system device in question. ACCESSING DIAGNOSTIC TROUBLE CODES Stored diagnostic trouble codes can be displayed by cycling the ignition key On-Off-On-Off-On within three seconds and observing the malfunction indicator lamp. This lamp is displayed on the instrument panel as the CHECK ENGINE lamp (Fig. 17). They can also be displayed through use of the Diagnostic Readout Box (DRB scan tool). The DRB connects to the data link connector in the vehicle (Fig. 18). The circuits of the data link connector are shown
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ERASING TROUBLE CODES The DRB scan tool must be used to erase a Diagnostic Trouble Code (DTC). Refer to the appropriate Powertrain Diagnostic Procedures service manual for operation of the DRB scan tool.
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No Crank Reference Signal at PCM Battery Disconnect No Change in MAP From Start to Run
No crank reference signal detected during engine cranking. Direct battery input to PCM was disconnected within the last 50 Key-on cycles. No difference recognized between the engine MAP reading and the barometric (atmospheric) pressure reading at start-up. MAP sensor input below minimum acceptable voltage.
14**
MAP Sensor Voltage Too Low or MAP Sensor Voltage Too High
MAP sensor input above maximum acceptable voltage. No vehicle distance (speed) sensor signal detected during road load conditions. Engine coolant temperature remains below normal operating temperatures during vehicle travel (thermostat). Neither rich or lean condition detected from the oxygen sensor input.
15** 17*
21**
Oxygen sensor input voltage maintained above the normal operating range. Engine coolant temperature sensor input above maximum acceptable voltage.
22**
ECT Sensor Voltage Too High or ECT Sensor Voltage Too Low
Engine coolant temperature sensor input below minimum acceptable voltage. Intake manifold air temperature sensor input below the minimum acceptable voltage.
23**
Intake Air Temp Sensor Voltage Low or Intake Air Temp Sensor Voltage High
Intake manifold air temperature sensor input above the maximum acceptable voltage. Throttle position sensor input above the maximum acceptable voltage.
24**
Throttle Position Sensor Voltage High or Throttle Position Sensor Voltage Low
* Check Engine Lamp will not illuminate at all times if this Diagnostic Trouble Code was recorded. Cycle Ignition key as described in manual and observe code flashed by Check Engine lamp. ** Check Engine Lamp will illuminate during engine operation if this Diagnostic Trouble Code was recorded.
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Description of Diagnostic Trouble Code A shorted condition detected in one or more of the idle air control motor circuits. Injector #1 output driver does not respond properly to the control signal.
An open or shorted condition detected in the EVAP solenoid circuit. An open or shorted condition detected in the EGR solenoid circuit.
A mechanical problem found in EGR system (vacuum line leak, defective EGR valve, plugged EGR tube, etc.) An open or shorted condition detected in the A/C clutch relay circuit. An open or shorted condition detected in the Speed Control vacuum or vent solenoid circuits.
33* 34*
or Speed Control Switch Always Low or Speed Control Switch Always High 35* 41** 42* Rad Fan Control Relay Circuits Generator Field Not Switching Properly Auto Shutdown Relay Control Circuit Speed Control switch input above the maximum acceptable voltage. An open or shorted condition detected in the radiator fan relay circuit. An open or shorted condition detected in the generator field control circuit. An open or shorted condition detected in the auto shutdown relay circuit. Speed Control switch input below the minimum acceptable voltage.
* Check Engine Lamp will not illuminate at all times if this Diagnostic Trouble Code was recorded. Cycle Ignition key as described in manual and observe code flashed by Check Engine lamp. ** Check Engine Lamp will illuminate during engine operation if this Diagnostic Trouble Code was recorded.
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Description of Diagnostic Trouble Code An open or shorted condition exists in the engine coolant temperature sensor circuit or a problem exists in the PCMs battery temperature voltage circuit. Battery voltage sense input above target charging voltage during engine operation. Battery voltage sense input below target charging during engine operation. Also, no significant change detected in battery voltage during active test of generator output. Oxygen sensor signal input indicates lean air/ fuel ratio condition during engine operation. Oxygen sensor signal input indicates rich air/ fuel ratio condition during engine operation. PCM Internal fault condition detected.
46** 47**
Charging System Voltage Too High Charging System Voltage Too Low
O2S Signal Stays Below Center (Lean) O2S Signal Stays Above Center (Rich) Internal PCM Failure or PCM Failure SRI Communications
PCM Internal fault condition detected. Completion of diagnostic trouble code display on the Malfunction Indicator Lamp (Check Engine Lamp). Unsuccessful attempt to update SRI (service reminder indicator) miles in the PCM EEPROM. Unsuccessful attempt to write to an EEPROM location by the PCM.
55*
62*
63*
* Check Engine Lamp will not illuminate at all times if this Diagnostic Trouble Code was recorded. Cycle Ignition key as described in manual and observe code flashed by Check Engine lamp. ** Check Engine Lamp will illuminate during engine operation if this Diagnostic Trouble Code was recorded.
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BRAKE SWITCH
Refer to Group 5, Brakes for removal/installation procedures.
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REMOVAL (1) Partially drain cooling system. Refer to Group 7, Cooling System. (2) Disconnect electrical connector from sensor (Fig. 3). (3) Remove sensor.
FUEL FILTER
Refer to the Fuel Delivery System section of this group for removal/installation procedures.
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FUEL SYSTEM COMPONENT REMOVAL/INSTALLATION2.5L ENGINE FUEL SYSTEM PRESSURE RELEASE PROCEDURE
WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE OFF) OF APPROXIMATELY 100 KPA (14.5 PSI). BEFORE SERVICING THE FUEL PUMP, FUEL LINES, FUEL FILTER, THROTTLE BODY OR FUEL INJECTOR, THE FUEL SYSTEM PRESSURE MUST BE RELEASED. Refer to the Fuel Delivery System section of this group. See Fuel Pressure Release procedure.
FUEL TANKS
Fig. 10 Servicing Fuel Pressure Regulator
INSTALLATION (1) Place new gasket on pressure regulator and carefully install new o-ring. (2) Position pressure regulator on throttle body. Press into place. Install screws and tighten to 5 N m (40 in. lbs.) torque. (3) Connect battery cable to battery. (4) Test for leaks using DRB scan tool. With key in the Run position, use DRB Special Functions Test ASD Fuel System Test. This will activate pump and pressurize the system. Check for leaks. (5) Install air cleaner assembly. Refer to the Fuel Tank section of this group for removal/installation procedures.
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REMOVAL The oxygen sensor is installed in the exhaust manifold (Fig. 15).
CAUTION: When disconnecting the sensor electrical connector, do not pull directly on wire going into sensor. Damage to sensor may result. Use care in working around sensor as the exhaust manifold may be extremely hot. (1) Disconnect O2S electrical connector (Fig. 15). (2) Remove the O2S sensor from the exhaust manifold. Snap-On oxygen sensor wrench (number YA 8875) may be used for removal and installation. (3) When the sensor is removed, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap.
IGNITION COIL
Refer to Group 8D, Ignition Systems for removal/ installation procedures.
INTAKE MANIFOLD
Refer to Group 11, Exhaust System and Intake Manifold for removal/installation procedures.
INSTALLATION If the same sensor is to be installed, the sensor threads must be coated with an anti-seize compound such as Loctite 771-64 or equivalent. New factory sensors are packaged with compound on the threads. Additional compound is not required. The sensor must be tightened to 27 N m (20 ft. lbs.) torque.
PARK/NEUTRAL SWITCH
Refer to Group 21, Transmission and Transfer Case for removal/installation procedures.
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QUICK-CONNECT FITTINGS
Refer to the Fuel Delivery System section of this group for removal/installation procedures.
THROTTLE BODY
REMOVAL
WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE OFF) OF APPROXIMATELY 100 KPA (14.5 PSI). BEFORE SERVICING THE THROTTLE BODY OR FUEL INJECTOR THE FUEL SYSTEM PRESSURE MUST BE RELEASED. (1) Remove air cleaner (Fig. 17).
REMOVAL (1) Disconnect negative battery cable at battery. (2) Remove air cleaner air duct from PCM. (3) Remove 60-way wiring connector from module. (4) Remove PCM mounting screws. Remove module.
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REMOVAL (1) Remove air cleaner assembly. (2) Perform Fuel System Pressure Release. (3) Disconnect negative battery cable at battery.
WARNING: DO NOT ALLOW FUEL TO SPILL ONTO THE ENGINE INTAKE OR EXHAUST MANIFOLDS. PLACE SHOP TOWELS UNDER THE FUEL SYSTEM HOSES ABSORB ANY RESIDUAL FUEL WHEN DISCONNECTING THEM FROM THE FUEL FITTINGS. (4) Loosen fuel intake and return hose clamps. Wrap a shop towel around each hose. Twist and pull on each hose for removal. (5) Remove each fitting and note inlet diameter. The fuel inlet fitting nipple diameter is larger than the fuel inlet fittings (Fig. 20). Remove and discard the copper washers on the fittings.
REMOVAL (1) Remove air cleaner. (2) Disconnect throttle cables from throttle body linkage. (3) Remove throttle cable bracket mounting screws and lay bracket aside. (4) Disconnect throttle body temperature sensor electrical connector. (5) Unscrew sensor (Fig. 19). INSTALLATION (1) Apply heat transfer compound (provided with new factory sensor) to tip portion of new sensor (Fig. 19). (2) Install sensor and tighten to 9-13.5 N m (80-120 in. lbs.) torque. (3) Connect wiring connector. (4) Install throttle cable bracket. Tighten mounting screws. (5) Connect throttle cables to throttle body linkage and install clips. (6) Install air cleaner.
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INSTALLATION (1) Install new replacement washers on fuel fittings. (2) Install fuel fittings in proper fuel passage ports. Tighten to 20 N m (175 in. lbs.) torque. (3) Using new original equipment type hose clamps, install fuel return and supply hoses. Tighten hose clamps to 1 N m (10 in. lbs.) torque. (4) Connect battery cable. (5) Test for leaks using Diagnostic Readout Box II (DRB) scan tool. With key in the Run position, use Special Functions Test ASD Fuel System Test. This will activate pump and pressurize the system. Check for leaks. (6) Install air cleaner assembly.
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. . . . . 58 . . . . . 62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 64 59 59 60 53 60 56 60 63 60 63 60 63 63 63 60 60
GENERAL INFORMATION
All 3.9L (V-6) and 5.2L (V-8) engines are equipped with sequential Multi-Port Fuel Injection (MFI). The MFI system provides precise air/fuel ratios for all driving conditions. The powertrain control module (PCM) operates the fuel system. The PCM was formerly referred to as the SBEC or engine controller. The PCM is a pre-programmed, dual microprocessor digital computer. It regulates ignition timing, air-fuel ratio, emission control devices, charging system, speed control, air conditioning compressor clutch engagement and idle speed. The PCM can adapt its programming to meet changing operating conditions. Powertrain Control Module (PCM) Inputs represent the instantaneous engine operating conditions. Air-fuel mixture and ignition timing calibrations for various driving and atmospheric conditions are preprogrammed into the PCM. The PCM monitors and analyzes various inputs. It then computes engine fuel and ignition timing requirements based on these inputs. Fuel delivery control and ignition timing will then be adjusted accordingly. Other inputs to the PCM are provided by the brake switch, air conditioning select switch and the speed control switches. All inputs to the PCM are converted into signals.
Electrically operated fuel injectors spray fuel in precise metered amounts into the intake port directly above the intake valve. The injectors are fired in a specific sequence by the PCM. The PCM maintains an air/fuel ratio of 14.7 to 1 by constantly adjusting injector pulse width. Injector pulse width is the length of time that the injector opens and sprays fuel into the chamber. The PCM adjusts injector pulse width by opening and closing the ground path to the injector. Manifold absolute pressure (air density) and engine rpm (speed) are the primary inputs that determine fuel injector pulse width. The PCM also monitors other inputs when adjusting air-fuel ratio. Inputs That Effect Fuel Injector Pulse Width Exhaust gas oxygen content (O2S) Coolant temperature Manifold absolute pressure (MAP) Engine speed Throttle position Battery voltage Air conditioning selection Transmission gear selection (automatic transmissions only) Speed control The powertrain control module (PCM) adjusts ignition timing by controlling ignition coil operation. The ignition coil receives battery voltage when the ignition key is in the run or starter position. The PCM
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information is stored in the PCM memory. Refer to On-Board Diagnostics in the Multi-Port Fuel InjectionGeneral Diagnosis3.9L/5.2L Engine section of this group for DTC information.
SYSTEM DIAGNOSIS The powertrain control module (PCM) tests many of its own input and output circuits. If a Diagnostic Trouble Code (DTC) is found in a major system, this
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Refer to Camshaft Position Sensor in Group 8D, Ignition System for more information.
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FUEL SYSTEM COMPONENT DESCRIPTION/SYSTEM OPERATION3.9L/5.2L ENGINE MANIFOLD ABSOLUTE PRESSURE (MAP) SENSORPCM INPUT
The MAP sensor reacts to absolute pressure in the intake manifold. It provides an input voltage to the powertrain control module (PCM). As engine load changes, manifold pressure varies. The change in manifold pressure causes MAP sensor voltage to change. The change in MAP sensor voltage results in a different input voltage to the PCM. The input voltage level supplies the PCM with information about ambient barometric pressure during engine start-up (cranking) and engine load while the engine is running. The PCM uses this input along with inputs from other sensors to adjust air-fuel mixture. The MAP sensor is mounted on the side of the engine throttle body (Fig. 9). The sensor is connected to the throttle body with a rubber L-shaped fitting.
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The oxygen sensor is equipped with a heating element that keeps the sensor at proper operating temperature during all operating modes. Maintaining correct sensor temperature at all times allows the system to enter into closed loop operation sooner. In Closed Loop operation, the powertrain control module (PCM) monitors the O2S sensor input (along with other inputs). It then adjusts the injector pulse width accordingly. During Open Loop operation, the PCM ignores the O2S sensor input and adjusts injector pulse width to a preprogrammed value (based on other sensor inputs).
OVERDRIVE/OVERRIDE SWITCH
On vehicles equipped with an automatic transmission and overdrive, the powertrain control module (PCM) regulates the 3-4 overdrive up-shift and downshift through the overdrive solenoid. This solenoid is located in the transmission. An overdrive/override push-button switch is located on the instrument panel. The PCM circuit for overdrive is controlled by inputs from the engine coolant temperature sensor and vehicle speed sensor. If coolant temperature and vehicle speed are not within the preset PCM specifications, the PCM will not allow the transmission to shift into overdrive. These preset PCM specifications must be met before the push-button switch will be allowed to control overdrive operation. The overdrive/override push-button switch is normally closed (overdrive allowed) when the lamp is not illuminated. It opens (overdrive not allowed) when the operator presses the switch and the lamp is illuminated. The switch will revert to its normally closed position (lamp off) each time the ignition switch in turned on. The transmission downshifts if the operator presses the override switch while in overdrive. Refer to Group 21 for more transmission information.
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POWER GROUND
The power ground is used to control ground circuits for the following powertrain control module (PCM) loads: Generator Field Winding 8 volt (PCM) power supply Fuel Injectors Ignition Coil
FUEL SYSTEM COMPONENT DESCRIPTION/SYSTEM OPERATION3.9L/5.2L ENGINE AIR CONDITIONING (A/C) CLUTCH RELAYPCM OUTPUT
The powertrain control module (PCM) activates the A/C compressor through the A/C clutch relay. The PCM regulates A/C compressor operation by switching the ground circuit for the A/C clutch relay on and off. The relay is located in the power distribution center (PDC) (Fig. 12). For the location of the relay within the PDC, refer to label under PDC cover.
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tle body. Fuel is sprayed into the manifold by the fuel injectors. The throttle body is mounted on the intake manifold. It contains an air control passage (Fig. 18) controlled by an idle air control (IAC) motor. The air control passage is used to supply air for idle conditions. A throttle valve (plate) is used to supply air for above idle conditions.
FUEL RAIL
The fuel rail supplies the necessary fuel to each individual fuel injector and is mounted to the intake manifold (Fig. 19). The fuel pressure regulator is no longer mounted to the fuel rail on the 3.9L V-6 or 5.2L V-8 engine. It is now located on the fuel tank mounted fuel pump module. Refer to Fuel Filter/Fuel Pressure Regulator in the Fuel Delivery System section of this group for information. The fuel rail is not repairable.
TACHOMETERPCM OUTPUT
The powertrain control module (PCM) supplies engine rpm values to the instrument cluster tachometer. Refer to Group 8E for tachometer information.
THROTTLE BODY
Filtered air from the air cleaner enters the intake manifold through the throttle body (Fig. 17). Fuel does not enter the intake manifold through the throt-
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MODES Open Loop Closed Loop During Open Loop modes, the powertrain control module (PCM) receives input signals and responds only according to preset PCM programming. Input from the oxygen (O2S) sensor is not monitored during Open Loop modes. During Closed Loop modes, the PCM will monitor the oxygen (O2S) sensor input. This input indicates to the PCM whether or not the calculated injector pulse width results in the ideal air-fuel ratio. This ratio is 14.7 parts air-to-1 part fuel. By monitoring the exhaust oxygen content through the O2S sensor, the PCM can fine tune the injector pulse width. This is done to achieve optimum fuel economy combined with low emission engine performance. The fuel injection system has the following modes of operation: Ignition switch ON Engine start-up (crank) Engine warm-up Idle Cruise Acceleration Deceleration Wide open throttle (WOT) Ignition switch OFF The ignition switch On, engine start-up (crank), engine warm-up, acceleration, deceleration and wide open throttle modes are Open Loop modes. The idle and cruise modes, (with the engine at operating temperature) are Closed Loop modes. IGNITION SWITCH (KEY-ON) MODE This is an Open Loop mode. When the fuel system is activated by the ignition switch, the following actions occur: The powertrain control module (PCM) pre-positions the idle air control (IAC) motor. The PCM determines atmospheric air pressure from the MAP sensor input to determine basic fuel strategy. The PCM monitors the engine coolant temperature sensor input. The PCM modifies fuel strategy based on this input. Intake manifold air temperature sensor input is monitored Throttle position sensor (TPS) is monitored The auto shutdown (ASD) relay is energized by the PCM for approximately three seconds.
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ENGINE START-UP MODE This is an Open Loop mode. The following actions occur when the starter motor is engaged. The powertrain control module (PCM) receives inputs from: Battery voltage Engine coolant temperature sensor Crankshaft position sensor Intake manifold air temperature sensor Manifold absolute pressure (MAP) sensor Throttle position sensor (TPS) Starter motor relay Camshaft position sensor signal The PCM monitors the crankshaft position sensor. If the PCM does not receive a crankshaft position sensor signal within 3 seconds of cranking the engine, it will shut down the fuel injection system. The fuel pump is activated by the PCM through the fuel pump relay. Voltage is applied to the fuel injectors with the PCM. The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM determines the proper ignition timing according to input received from the crankshaft position sensor. ENGINE WARM-UP MODE This is an Open Loop mode. During engine warmup, the powertrain control module (PCM) receives inputs from: Battery voltage Crankshaft position sensor Engine coolant temperature sensor Intake manifold air temperature sensor Manifold absolute pressure (MAP) sensor Throttle position sensor (TPS) Camshaft position sensor signal (in the distributor) Park/Neutral Switch (gear indicator signalauto. trans. only) Air conditioning select signal (if equipped) Air conditioning request signal (if equipped) Based on these inputs the following occurs: Voltage is applied to the fuel injectors with the powertrain control module (PCM). The PCM will
then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM adjusts engine idle speed through the idle air control (IAC) motor and adjusts ignition timing. The PCM operates the A/C compressor clutch through the clutch relay. This is done if A/C has been selected by the vehicle operator and requested by the A/C thermostat. If the vehicle has a manual transmission, the upshift lamp is operated by the PCM. When engine has reached operating temperature, the PCM will begin monitoring O2S sensor input. The system will then leave the warm-up mode and go into closed loop operation.
IDLE MODE When the engine is at operating temperature, this is a Closed Loop mode. At idle speed, the powertrain control module (PCM) receives inputs from: Air conditioning select signal (if equipped) Air conditioning request signal (if equipped) Battery voltage Crankshaft position sensor Engine coolant temperature sensor Intake manifold air temperature sensor Manifold absolute pressure (MAP) sensor Throttle position sensor (TPS) Camshaft position sensor signal (in the distributor) Battery voltage Park/Neutral Switch (gear indicator signalauto. trans. only) Oxygen sensor Based on these inputs, the following occurs: Voltage is applied to the fuel injectors with the powertrain control module (PCM). The PCM will then control injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM monitors the O2S sensor input and adjusts air-fuel ratio by varying injector pulse width. It also adjusts engine idle speed through the idle air control (IAC) motor. The PCM adjusts ignition timing by increasing and decreasing spark advance. The PCM operates the A/C compressor clutch through the clutch relay. This happens if A/C has been selected by the vehicle operator and requested by the A/C thermostat. CRUISE MODE When the engine is at operating temperature, this is a Closed Loop mode. At cruising speed, the powertrain control module (PCM) receives inputs from: Air conditioning select signal (if equipped) Air conditioning request signal (if equipped)
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Battery voltage Engine coolant temperature sensor Crankshaft position sensor Intake manifold air temperature sensor Manifold absolute pressure (MAP) sensor Throttle position sensor (TPS) Camshaft position sensor signal (in the distributor) Park/Neutral switch (gear indicator signalauto. trans. only) Oxygen (O2S) sensor Based on these inputs, the following occurs: Voltage is applied to the fuel injectors with the PCM. The PCM will then adjust the injector pulse width by turning the ground circuit to each individual injector on and off. The PCM monitors the O2S sensor input and adjusts air-fuel ratio. It also adjusts engine idle speed through the idle air control (IAC) motor. The PCM adjusts ignition timing by turning the ground path to the coil on and off. The PCM operates the A/C compressor clutch through the clutch relay. This happens if A/C has been selected by the vehicle operator and requested by the A/C thermostat.
ACCELERATION MODE This is an Open Loop mode. The powertrain control module (PCM) recognizes an abrupt increase in throttle position or MAP pressure as a demand for increased engine output and vehicle acceleration. The PCM increases injector pulse width in response to increased throttle opening. DECELERATION MODE When the engine is at operating temperature, this is an Open Loop mode. During hard deceleration, the powertrain control module (PCM) receives the following inputs. Air conditioning select signal (if equipped) Air conditioning request signal (if equipped) Battery voltage Engine coolant temperature sensor Crankshaft position sensor Intake manifold air temperature sensor Manifold absolute pressure (MAP) sensor Throttle position sensor (TPS) Camshaft position sensor signal (in the distributor) Park/Neutral switch (gear indicator signalauto. trans. only) If the vehicle is under hard deceleration with the proper rpm and closed throttle conditions, the PCM
WIDE OPEN THROTTLE MODE This is an Open Loop mode. During wide open throttle operation, the powertrain control module (PCM) receives the following inputs. Battery voltage Crankshaft position sensor Engine coolant temperature sensor Intake manifold air temperature sensor Manifold absolute pressure (MAP) sensor Throttle position sensor (TPS) Camshaft position sensor signal (in the distributor) During wide open throttle conditions, the following occurs: Voltage is applied to the fuel injectors with the powertrain control module (PCM). The PCM will then control the injection sequence and injector pulse width by turning the ground circuit to each individual injector on and off. The PCM ignores the oxygen sensor input signal and provides a predetermined amount of additional fuel. This is done by adjusting injector pulse width. The PCM adjusts ignition timing by turning the ground path to the coil on and off. The PCM opens the ground circuit to the A/C clutch relay to disengage the A/C compressor clutch. This will be done for approximately 15 seconds (if the air conditioning system is operating). If the vehicle has a manual transmission, the upshift lamp is operated by the PCM. IGNITION SWITCH OFF MODE When ignition switch is turned to OFF position, the PCM stops operating the injectors, ignition coil, ASD relay and fuel pump relay.
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VISUAL INSPECTION
A visual inspection for loose, disconnected, or incorrectly routed wires and hoses should be made. This should be done before attempting to diagnose or service the fuel injection system. A visual check will help spot these faults and save unnecessary test and diagnostic time. A thorough visual inspection will include the following checks: (1) Verify that the 60-way connector is fully inserted into the connector of the powertrain control module (PCM) (Fig. 1). Verify that the connector mounting screw is tightened to 4 N m (35 in. lbs.) torque.
power distribution center (PDC) (Fig. 2). For the location of the relays within the PDC, refer to label under PDC cover.
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Fig. 9 Oxygen Sensor Location Fig. 7 Rubber L-Shaped FittingMAP Sensor-toThrottle Body
(18) Verify harness connectors are firmly connected to idle air control (IAC) motor, throttle position sensor (TPS) and manifold absolute pressure (MAP) sensor (Fig. 6). (19) Verify that wire harness connector is firmly connected to the engine coolant temperature sensor (Fig. 8). (25) Verify that the harness connector is firmly connected to the vehicle speed sensor (Fig. 10).
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SYSTEM SCHEMATICS
Refer to PCM Schematics in the Multi-Port Fuel Injection (MFI)Component Description/System Operation3.9L/5.2L Engine section of this group.
tor terminal. Also test continuity of wire harness terminal 4 to the sensor connector terminal. Repair the wire harness if an open circuit is indicated. (4) After tests are completed, connect electrical connector to sensor. The sensor connector is symmetrical (not indexed). It can be installed to the sensor in either direction.
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FUEL SYSTEM GENERAL DIAGNOSIS3.9L/5.2L ENGINE OXYGEN (O2S) SENSOR HEATING ELEMENT TEST
To perform a complete test of O2S sensor and its circuitry, refer to DRB scan tool and appropriate Powertrain Diagnostics Procedures manual. To test the O2S only, refer to the following: The O2S sensor is located on the right exhaust down pipe (Fig. 17). The O2S heating element can be tested with an ohmmeter as follows: Disconnect the O2S sensor connector. Connect the ohmmeter test leads across the white wire terminals of the sensor connector. Resistance should be between 5 and 7 ohms. Replace the sensor if the ohmmeter displays an infinity (open) reading.
(6) Test the MAP sensor ground circuit at the PCM connector between terminal/pin-4 and terminal/ pin-11 with an ohmmeter. If the ohmmeter indicates an open circuit, inspect for a defective sensor ground connection. Refer to Group 8W, Wiring Diagrams for location of this connection. If the ground connection is good, replace the PCM. If terminal/pin-4 has a short circuit to 12 volts +, correct this condition before replacing the PCM.
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(3) Disconnect the vacuum line at the PCV valve (Fig. 21).
RELAYSOPERATION/TESTING
Fig. 22 Idle Purge Line
(6) Connect the DRB scan tool to the data link connector (Fig. 23) on the vehicle. Refer to the appropriate Powertrain Diagnostic Procedures service manual for DRB operation. (7) Start the engine.
OPERATION The following operations/tests apply to these relays only: Automatic Shutdown (ASD) and Fuel Pump. For operations/tests on all other relays, refer to the appropriate section of this service manual. These relays are located in the power distribution center (PDC) (Fig. 24). For the location of the relay within the PDC, refer to label under PDC cover.
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tion. Terminal number 87 then supplies battery voltage to the component being operated. Terminal number 86 is connected to a switched (+) power source. Terminal number 85 is grounded by the powertrain control module (PCM).
TESTING (1) Remove relay before testing. (2) Using an ohmmeter, perform a resistance test between terminals 85 and 86. Resistance value (ohms) should be 75 5 ohms for resistor equipped relays. (3) Connect the ohmmeter between terminals number 87A and 30. Continuity should be present at this time. (4) Connect the ohmmeter between terminals number 87 and 30. Continuity should not be present at this time. (5) Use a set of jumper wires (16 gauge or smaller). Connect one jumper wire between terminal number 85 (on the relay) to the ground side (-) of a 12 Volt power source. (6) Attach the other jumper wire to the positive side (+) of a 12V power source. Do not connect this jumper wire to relay at this time.
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CAUTION: DO NOT ALLOW THE OHMMETER TO CONTACT TERMINALS 85 OR 86 DURING THESE TESTS. DAMAGE TO OHMMETER MAY RESULT. (7) Attach the other jumper wire (12V +) to terminal number 86. This will activate the relay. Continuity should now be present between terminals number 87 and 30. Continuity should not be present between terminals number 87A and 30. (8) Disconnect jumper wires from relay and 12 Volt power source. If continuity or resistance tests did not pass, replace relay. If tests passed, refer to Group 8W, Wiring Diagrams for (fuel system) relay wiring schematics and for additional circuit information.
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There are several operating conditions that the PCM does not monitor and set a DTC for. Refer to the following Monitored Circuits and Non-Monitored Circuits in this section.
MONITORED CIRCUITS The powertrain control module (PCM) can detect certain problems in the fuel injection system. Open or Shorted Circuit - The PCM can determine if sensor output (which is the input to PCM) is within proper range. It also determines if the circuit is open or shorted. Output Device Current Flow - The PCM senses whether the output devices are hooked up. If there is a problem with the circuit, the PCM senses whether the circuit is open, shorted to ground (-), or shorted to (+) voltage. Oxygen Sensor - The PCM can determine if the oxygen sensor is switching between rich and lean. This is, once the system has entered Closed Loop. Refer to Open Loop/Closed Loop Modes Of Operation in the Component Description/System Operation section for an explanation of Closed (or Open) Loop operation. NON-MONITORED CIRCUITS The PCM does not monitor the following circuits, systems or conditions that could have malfunctions that result in driveability problems. A Diagnostic Trouble Code (DTC) may not be displayed for these conditions. Fuel Pressure: Fuel pressure is controlled by the vacuum assisted fuel pressure regulator. The PCM cannot detect a clogged fuel pump inlet filter, clogged in-line fuel filter, or a pinched fuel supply or return line. However, these could result in a rich or lean condition causing an oxygen sensor DTC to be stored in the PCM. Secondary Ignition Circuit: The PCM cannot detect an inoperative ignition coil, fouled or worn spark plugs, ignition cross firing, or open circuited spark plug cables. Engine Timing: The PCM cannot detect an incorrectly indexed timing chain, camshaft sprocket or crankshaft sprocket. The PCM also cannot detect an incorrectly indexed distributor. However, these could result in a rich or lean condition causing an oxygen sensor DTC to be stored in the PCM. Cylinder Compression: The PCM cannot detect uneven, low, or high engine cylinder compression. Exhaust System: The PCM cannot detect a plugged, restricted or leaking exhaust system. Fuel Injector Malfunctions: The PCM cannot determine if the fuel injector is clogged, or the wrong injector is installed. However, these could result in a rich or lean condition causing an oxygen sensor DTC to be stored in the PCM.
HIGH AND LOW LIMITS The powertrain control module (PCM) compares input signal voltages from each input device. It will establish high and low limits that are programmed into it for that device. If the input voltage is not within specifications and other Diagnostic Trouble Code (DTC) criteria are met, a DTC will be stored in memory. Other DTC criteria might include engine rpm limits or input voltages from other sensors or switches. The other inputs might have to be sensed by the PCM when it senses a high or low input voltage from the control system device in question. ACCESSING DIAGNOSTIC TROUBLE CODES A stored Diagnostic Trouble Code (DTC) can be displayed by cycling the ignition key On-Off-On-Off-On within three seconds and observing the malfunction indicator lamp. This lamp is displayed on the instrument panel as the CHECK ENGINE lamp (Fig. 28). They can also be displayed through the use of the Diagnostic Readout Box (DRB) scan tool. The DRB connects to the data link connector in the vehicle (Fig. 29). For operation of the DRB, refer to the appropriate Powertrain Diagnostic Procedures service manual.
EXAMPLES: If the lamp (Fig. 28) flashes 1 time, pauses and flashes 2 more times, a flashing Diagnostic Trouble Code (DTC) number 12 is indicated. If this code is observed, it is indicating that the battery has been disconnected within the last 50 key-on cycles. It
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After any stored DTC information has been observed, the display will end with a flashing DTC number 55. This will indicate the end of all stored information. Refer to the Diagnostic Trouble Code (DTC) charts for DTC identification. If the problem is repaired or ceases to exist, the powertrain control module (PCM) cancels the DTC after 51 engine starts. Diagnostic trouble codes indicate the results of a failure, but never identify the failed component directly. The circuits of the data link connector are shown in (Fig. 30).
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No Crank Reference Signal at PCM Battery Disconnect No Change in MAP From Start to Run
No crank reference signal detected during engine cranking. Direct battery input to PCM was disconnected within the last 50 Key-on cycles. No difference recognized between the engine MAP reading and the barometric (atmospheric) pressure reading at start-up. MAP sensor input below minimum acceptable voltage.
14**
MAP Sensor Voltage Too Low or MAP Sensor Voltage Too High
MAP sensor input above maximum acceptable voltage. No vehicle distance (speed) sensor signal detected during road load conditions. Engine coolant temperature remains below normal operating temperatures during vehicle travel (thermostat). Neither rich or lean condition detected from the oxygen sensor input.
15** 17*
21**
Oxygen sensor input voltage maintained above the normal operating range. Engine coolant temperature sensor input above maximum acceptable voltage.
22**
ECT Sensor Voltage Too High or ECT Sensor Voltage Too Low
Engine coolant temperature sensor input below minimum acceptable voltage. Intake manifold air temperature sensor input below the minimum acceptable voltage.
23**
Intake Air Temp Sensor Voltage Low or Intake Air Temp Sensor Voltage High
Intake manifold air temperature sensor input above the maximum acceptable voltage. Throttle position sensor input above the maximum acceptable voltage.
24**
Throttle Position Sensor Voltage High or Throttle Position Sensor Voltage Low
Throttle position sensor input below the minimum acceptable voltage. A shorted condition detected in one or more of the idle air control motor circuits.
25**
* Check Engine Lamp will not illuminate at all times if this Diagnostic Trouble Code was recorded. Cycle Ignition key as described in manual and observe code flashed by Check Engine lamp. ** Check Engine Lamp will illuminate during engine operation if this Diagnostic Trouble Code was recorded.
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27*
Injector #1 Control Circuit or Injector #2 Control Circuit or Injector #3 Control Circuit or Injector #4 Control Circuit or Injector #5 Control Circuit or Injector #6 Control Circuit or Injector #7 Control Circuit or Injector #8 Control Circuit
Injector #1 output driver does not respond properly to the control signal.
Injector #2 output driver does not respond properly to the control signal.
Injector #3 output driver does not respond properly to the control signal.
Injector #4 output driver does not respond properly to the control signal.
Injector #5 output driver does not respond properly to the control signal.
Injector #6 output driver does not respond properly to the control signal.
Injector #7 output driver does not respond properly to the control signal.
Injector #8 output driver does not respond properly to the control signal. An open or shorted condition detected in the EVAP solenoid circuit. An open or shorted condition detected in the EGR solenoid circuit.
31** 32**
A mechanical problem found in EGR system (vaccum line leak, defective EGR valve, plugged EGR tube, etc.). An open or shorted condition detected in the A/C clutch relay circuit. An open or shorted condition detected in the Speed Control vacuum or vent solenoid circuits.
33* 34*
or Speed Control Switch Always Low Speed Control switch input below the minimum acceptable voltage.
* Check Engine Lamp will not illuminate at all times if this Diagnostic Trouble Code was recorded. Cycle Ignition key as described in manual and observe code flashed by Check Engine lamp. ** Check Engine Lamp will illuminate during engine operation if this Diagnostic Trouble Code was recorded.
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or Speed Control Switch Always High 41** 42* 44* Generator Field Not Switching Properly Auto Shutdown Relay Control Circuit Battery Temp Sensor Volts out of Limit Speed Control switch input above the maximum acceptable voltage. An open or shorted condition detected in the generator field control circuit. An open or shorted condition detected in the auto shutdown relay circuit. An open or shorted condition exists in the engine coolant temperature sensor circuit or a problem exists in the PCMs battery temperature voltage circuit. Battery voltage sense input above target charging voltage during engine operation. Battery voltage sense input below target charging during engine operation. Also, no significant change detected in battery voltage during active test of generator output. Oxygen sensor signal input indicates lean air/ fuel ratio condition during engine operation. Oxygen sensor signal input indicates rich air/ fuel ratio condition during engine operation. PCM Internal fault condition detected.
46** 47**
Charging System Voltage Too High Charging System Voltage Too Low
O2S Signal Stays Below Center (Lean) O2S Signal Stays Above Center (Rich) Internal PCM Failure or PCM Failure SRI Communications
PCM Internal fault condition detected. No fuel sync (camshaft signal) detected during engine cranking. Completion of diagnostic trouble code display on the Malfunction Indicator Lamp (Check Engine Lamp). Unsuccessful attempt to update SRI (service reminder indicator) miles in the PCM EEPROM. Unsuccessful attempt to write to an EEPROM location by the PCM.
54* 55*
No Cam Sync Signal at PCM Display not shown on DRB scan tool
62*
63*
* Check Engine Lamp will not illuminate at all times if this Diagnostic Trouble Code was recorded. Cycle Ignition key as described in manual and observe code flashed by Check Engine lamp. ** Check Engine Lamp will illuminate during engine operation if this Diagnostic Trouble Code was recorded.
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INSTALLATION (1) Position air cleaner housing to throttle body. (2) If housing-to-throttle body mounting stud (Fig. 3) is being installed, tighten to 10 N m (90 in. lbs.) torque. (3) Tighten wingnut to 1.5 N m (15 in. lbs.) torque. (4) Push crankcase breather/filter into valve cover. (5) Install air intake tube to housing.
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BRAKE SWITCH
Refer to Group 5, Brakes for removal/installation procedures.
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FUEL FILTER
3.9L and 5.2L Engine: The fuel filter and fuel pressure regulator are one combined part. A separate in-line fuel filter is not used with the 3.9L or 5.2L engine. Refer to Fuel Filter/Fuel Pressure Regulator in the Fuel Delivery System section of this group for removal and installation procedures.
FUEL INJECTOR(S)
WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE TURNED OFF). BEFORE SERVICING THE FUEL INJECTOR(S), THE FUEL SYSTEM PRESSURE MUST BE RELEASED. To release fuel pressure, refer to the Fuel Delivery System section of this group. See Fuel System Pressure Release. To remove one or more fuel injectors, the fuel rail assembly must be removed from engine.
INSTALLATION (1) Apply a small amount of engine oil to each fuel injector o-ring. This will help in fuel rail installation. (2) Install injector(s) and injector clip(s) to fuel rail. (3) Install fuel rail assembly. Refer to Fuel Rail installation. (4) Install air cleaner. (5) Start engine and check for leaks.
REMOVAL (1) Remove air cleaner assembly. (2) Remove fuel rail assembly. Refer to Fuel Rail removal in this section.
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Fuel Filter/Fuel Pressure Regulator in the Fuel Delivery System section of this group for removal and installation procedures.
FUEL RAIL
WARNING: THE FUEL SYSTEM IS UNDER A CONSTANT PRESSURE (EVEN WITH THE ENGINE TURNED OFF). BEFORE SERVICING THE FUEL RAIL ASSEMBLY, THE FUEL SYSTEM PRESSURE MUST BE RELEASED.
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(3) Position the fuel rail/fuel injector assembly to the injector openings on the intake manifold. (4) Guide each injector into the intake manifold. Be careful not to tear the injector o-ring. (5) Push the right fuel rail down until fuel injectors have bottomed on injector shoulder. Push the left fuel rail down until fuel injectors have bottomed on injector shoulder. (6) Install fuel rail mounting bolts. (7) Install EVAP canister purge solenoid to intake manifold. (8) Connect electrical connector to intake manifold air temperature sensor. (9) Connect wiring to all fuel injectors. The injector wiring harness is numerically tagged. (10) Install the A/C support bracket (if equipped). (11) Install throttle body to intake manifold. Refer to Throttle Body installation in this section of the group. (12) Install fuel line at fuel rail. Install latch clip to fuel line. Refer to Fuel Tubes/Lines/Hoses and Clamps in the Fuel Delivery System section of this group for procedures. (13) Install air cleaner. (14) Connect battery cable to battery. (15) Start engine and check for leaks.
INSTALLATION (1) Apply a small amount of engine oil to each fuel injector o-ring. This will help in fuel rail installation. (2) Install injector(s) and injector clip(s) to fuel rail.
FUEL TANKS
Refer to the Fuel Tank section of this group for removal/installation procedures.
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INTAKE MANIFOLD
Refer to Group 11, Exhaust System and Intake Manifold for removal/installation procedures.
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REMOVAL
WARNING: THE EXHAUST MANIFOLD BECOMES VERY HOT DURING ENGINE OPERATION. ALLOW ENGINE TO COOL BEFORE REMOVING OXYGEN SENSOR. (1) Raise and support the vehicle. (2) Disconnect the wire connector from the O2S sensor. CAUTION: When disconnecting the sensor electrical connector, do not pull directly on wire going into sensor. (3) Remove the O2S sensor from the exhaust manifold. Snap-On oxygen sensor wrench (number YA 8875) may be used for removal and installation.
REMOVAL (1) Disconnect negative battery cable at battery. (2) Carefully remove 60-way wiring connector from PCM (one screw) (Fig. 17). (3) Remove three mounting screws (Fig. 17). (4) Remove PCM from vehicle. INSTALLATION (1) Install PCM to inner fender. (2) Check inside of 60-way wiring harness connector for bent pins or corrosion. Repair as necessary. (3) Install 60-way connector to PCM. Tighten mounting screw to 4 N m (35 in. lbs.). torque. (4) Install battery cable to battery.
QUICK-CONNECT FITTINGS
Refer to the Fuel Delivery System section of this group for removal/installation procedures.
THROTTLE BODY
Fig. 16 Oxygen Sensor
INSTALLATION Threads of new oxygen sensors are factory coated with anti-seize compound to aid in removal. DO NOT add any additional anti-seize compound to the threads of a new oxygen sensor. (1) Install the O2S sensor into the exhaust manifold. Tighten to 30 N m (22 ft. lbs.) torque. (2) Connect the O2S sensor wire connector. (3) Lower the vehicle.
A (factory adjusted) set screw is used to mechanically limit the position of the throttle body throttle plate. Never attempt to adjust the engine idle speed using this screw. All idle speed functions are controlled by the powertrain control module (PCM).
PARK/NEUTRAL SWITCH
Refer to Group 21, Transmission and Transfer Case for removal/installation procedures.
REMOVAL (1) Remove the air cleaner. (2) Disconnect throttle body electrical connectors at MAP sensor, IAC motor and TPS (Fig. 18). (3) Remove vacuum line at throttle body. (4) Remove all control cables from throttle body (lever) arm. Refer to the Accelerator Pedal and Throttle Cable section of this group for additional information. (5) Remove four throttle body mounting bolts (Fig. 19). (6) Remove throttle body from intake manifold. (7) Discard old throttle body-to-intake manifold gasket.
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INSTALLATION The throttle shaft end of the throttle body slides into a socket in the TPS (Fig. 21). The TPS must be installed so that it can be rotated a few degrees. If the sensor will not rotate, install the sensor with the throttle shaft on the other side of the socket tangs. The TPS will be under slight tension when rotated.
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(2) Clean the area around the sensor before removal. (3) Disconnect the electrical connector from the sensor (Fig. 23).
REMOVAL
INSTALLATION (1) Install new sensor into speedometer gear adapter. (2) Tighten sensor mounting bolt. To prevent damage to sensor or speedometer adapter, be sure the sensor is mounted flush to the adapter before tightening. (3) Connect electrical connector to sensor.
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GENERAL INFORMATION
The following specifications are published from the latest information available at the time of publication. If anything differs between the specifications found on the Vehicle Emission Control Information (VECI) label and the following specifications, use specifications on VECI label. The VECI label is located in the engine compartment.
SENSOR
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PROPELLER SHAFTS
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PROPELLER SHAFTS
CONTENTS
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PROPELLER SHAFTS
CENTER BEARINGS
Vehicles equipped with a two-piece propeller shaft uses a rubber insulated center bearing. The bearing is used to support the shafts where they are joined together.
UNIVERSAL JOINTS
The rear propeller shaft uses a 7290 series cardan joint. This joint is used on 2WD and 4WD vehicles. The 4WD front shaft uses a 1310 series double cardan joint at the transfer case end. At the front axle end a 1310/7260 hybrid joint is used. Two different types of universal joints systems are used: Single cardan universal joint (Fig. 2). Double cardan universal joint (Fig. 3).
LUBRICATION
The slip yoke on the front shaft is equipped with a zerk type lubrication fitting. Use a multi-purpose NLGI Grade 2 EP lubricant. Refer to Group 0, Lubrication and Maintenance for additional information. The factory installed U-joints are lubricated for the life of the vehicle and do not need re-lubrication. All
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PRECAUTIONS
Propeller shafts are balanced by the manufacturer to prevent vibration. Before undercoating a vehicle, the propeller shaft and the U-joints should be covered. This will prevent the undercoating from causing an unbalanced condition and vibration. Use exact replacement hardware for attaching the propeller shafts. Exact replacement will ensure safe operation. The specified torque must always be applied when tightening the fasteners.
Propeller shaft vibration will increase as the vehicle speed is increased. A vibration that occurs within a specific speed range is not caused by propeller shaft unbalance. Defective U-joints or an incorrect propeller shaft angle are usually the cause.
UNBALANCE
If propeller shaft unbalance is suspected, it can be verified with the following procedure. Removing and re-indexing the propeller shaft 180 may eliminate some vibrations. (1) Raise and support the vehicle. (2) Clean all foreign material from propeller shaft and U-joints. (3) Inspect propeller shaft for missing balance weights, broken welds, and bent areas. If the propeller shaft is bent, it must be replaced. (4) Ensure the U-joints are not worn and are properly installed. (5) Check the U-joint clamp screws torque. (6) Remove wheels and tires. Install wheel lug nuts to retain brake drums in place.
VIBRATION
Tires that are out-of-round or wheels that are unbalanced will cause a low frequency vibration. Refer to Group 22, Tires And Wheels for service information. Brake drums that are unbalanced will cause harsh, low frequency vibration. Refer to Group 5, Brakes for service information. Driveline vibration can also result from loose or damaged engine mounts. Refer to Group 21, Transmissions for additional information.
DRIVELINE VIBRATION
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PROPELLER SHAFTS
(7) Mark and number the propeller shaft tube at four positions 90 apart, and six inches from the yoke weld. (8) Run and accelerate the vehicle until vibration occurs. Note the intensity and speed the vibration occurred. Stop the engine. (9) Install a screw clamp at position 1 (Fig. 1).
RUNOUT
(1) Clean propeller shaft surface where the dial indicator contacts the shaft. (2) Measure propeller shaft runout at the center and ends of the shaft. (3) Mount a dial indicator perpendicular to the shaft surface. (4) Rotate shaft several times and not reading. Refer to Runout Specifications chart. (5) Replace the propeller shaft if the runout exceeds the limit.
RUNOUT SPECIFICATIONS
INFORMATION When two shafts intersect at any common universal joint, the bend that is formed is called the working or operating angle. The larger the operating angle, the larger the amount of acceleration and deceleration of the joint. This speeding up and slowing down of the joint must be cancelled to produce a
PROPELLER SHAFTS
smooth power flow. This is done through phasing and proper universal joint working angles. A propeller shaft is properly phased when the yoke ends are on the same plane or in line. A twisted shaft will throw the yokes out of phase and cause a noticeable vibration. When taking universal joint angle measurements or checking phasing with two piece shafts, consider each shaft separately. On 4WD vehicles, the front shaft input (pinion shaft) angle has priority over the caster angle. Ideally the driveline system should have: Angles that are in equal or opposite within 1 degree of each other Have a 3 degree maximum operating angle Have at least a 1/2 degree continuous operating (propeller shaft) angle Engine speed (R.P.M.) is the main factor though in determining maximum allowable operating angles. As a guide to maximum normal operating angles refer to the chart listed (Fig. 4).
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Always make measurements from front to rear. (2) Place Inclinometer on yoke bearing (A) parallel to the shaft (Fig. 5). Center bubble in sight glass and record measurement. This measurement will give you the transmission or OUTPUT YOKE ANGLE (A).
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PROPELLER SHAFTS
(4) Subtract smaller figure from larger (C minus A) to obtain transmission OUTPUT OPERATING ANGLE. (5) Rotate propeller shaft 90 degrees and place Inclinometer on pinion yoke bearing parallel to the shaft (Fig. 7). Center bubble in sight glass and record measurement. This measurement will give you the pinion shaft or INPUT YOKE ANGLE (B). (6) Subtract smaller figure from larger (C minus B) to obtain axle INPUT OPERATING ANGLE. Refer to rules given below and the example in (Fig. 8) for additional information. Good cancellation of u-joint operating angles (within 1) Operating angles less than 3 At least 1/2 of one degree continuous operating (propeller shaft) angle
ADJUSTMENT AT AXLE WITH LEAF SPRINGS Adjust the pinion shaft angle at the springs with tapered shims (Fig. 9). Install tapered shims between the springs and axle pad to correct the angle. Refer to Group 3, Rear Suspension and Axle for additional information.
PROPELLER SHAFTS
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rubber insulator around the bearing. Do not use washers. Replace the original bolts with the appropriate increased length bolts.
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PRECAUTIONS
Use exact replacement hardware for attaching the propeller shafts. Exact replacement will ensure safe operation. The specified torque must always be applied when tightening the fasteners. Mark propeller shaft yoke and axle or transmission yoke before removal or component service (Fig. 1). This will assure correct phasing and eliminate possible vibration.
REAR
REMOVAL (1) Shift the transmission and transfer case (if applicable) to their Neutral positions. Raise the vehicle. (2) Scribe alignment marks at the pinion yoke and at each end of the propeller shaft. (3) Remove the U-joint strap bolts at the pinion shaft yoke. (4) Slide the slip yoke off of the transmission/ transfer case output shaft and remove the propeller shaft (Fig. 3). INSTALLATION (1) Slide the slip yoke on the transmission/transfer case output shaft. Align the installation reference marks at the axle yoke and install the propeller shaft (Fig. 3). Replacement U-joint straps and bolts must be installed.
FRONT
REMOVAL (1) Shift the transmission and transfer case (if applicable) to their Neutral positions. Raise the vehicle. Remove skid plates (if equipped) from frame, refer to Group 13, Frames. (2) Scribe alignment marks on the yokes at the transfer case. Place marks at the pinion shaft and at each end of the propeller shaft. These marks will be used for installation reference (Fig. 2). (3) Remove the U-joint strap bolts at the pinion shaft yoke. (4) Remove bolts from transfer case yoke and remove the propeller shaft.
PROPELLER SHAFTS
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(5) Slide the slip yoke off of the transmission/ transfer case output shaft and remove the propeller shaft.
INSTALLATION (1) Slide the slip yoke on the transmission/transfer case output shaft. Align the installation reference marks at the axle yoke and install the propeller shaft. (2) Align and install the center bearing to the support bracket. Install the bolts and tighten to 68 N m (50 ft. lbs.) torque. Replacement U-joint straps and bolts must be installed. (3) Tighten the U-joint strap bolts to 19 N m (14 ft. lbs.) torque. (4) Lower the vehicle.
REARTWO PIECE
REMOVAL (1) Shift the transmission and transfer case (if applicable) to their Neutral positions. Raise the vehicle. (2) Scribe alignment marks at the pinion yoke and at each end of the propeller shaft. (3) Remove the universal joint strap bolts at the pinion shaft yoke. (4) Scribe alignment marks at the frame crossmember for reference. Remove the bolts that attach the center bearing to the support bracket (Fig. 4).
REMOVAL (1) Remove rear two-piece shaft. Refer to two-piece removal. (2) Remove slip joint boot clamp and separate the two shafts. The slip joints are master splined. (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.
Caution: Do not damage shaft spline during removal of center bearing. (5) Set shaft in press and press bearing off the shaft.
INSTALLATION (1) Install new slinger on shaft and drive into position with suitable size pipe. (2) Install new center bearing on shaft with Bearing Installer Tool 6052. Drive on shaft with hammer until bearing is seated. (3) Clean shaft splines and apply a coat of multipurpose grease. (4) Align master splines and slide front and rear shafts together. Reposition slip yoke boot and install new clamp. (5) Install two-piece shaft in vehicle. Refer to installation two-piece shaft.
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PRECAUTIONS
It is important to put reference marks on the yokes before removal or component service. This will assure correct phasing and eliminate possible vibration.
REMOVAL/DISASSEMBLY
Single cardan universal joints are not serviceable. If worn or leaking, they must be replaced as a unit. (1) Remove the propeller shaft. Refer to Propeller Shaft Replacement in this Group. (2) Score alignment marks on the yokes/flanges and propeller shaft for installation reference. (3) Using a soft drift, tap the outside of the bearing assembly to loosen snap ring. (4) Remove snap rings from both sides of yoke (Fig. 1).
ASSEMBLY/INSTALLATION
(1) Apply extreme pressure (EP) N.L.G.I. Grade 1 or 2 grease to aid in installation.
PROPELLER SHAFTS
(2) Position the cross in the yoke with its lube fitting (if equipped) pointing up (Fig. 4).
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(4) Press the bearing assembly into the cross hole enough to install a snap ring. Install a snap ring. (5) Repeat steps 3 and 4 to install the opposite bearing assembly. Strike the yoke with a soft hammer to seat the needle bearings. Install a snap ring. (6) Add grease to lube fitting (if equipped). (7) Install the propeller shaft. Refer to Propeller Shaft Replacement in this Group.
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PROPELLER SHAFTS
(6) Flip assembly and repeat steps 4 and 5 for removing the opposite side bearing. This will then allow removal of the cross centering kit assembly and spring (Fig. 9).
(4) Press the bearing assembly partially from the outboard side of the center yoke, enough to grasp by vise jaws (Fig. 7). Be sure to remove any lube fittings that may interfere with removal.
CLEANING AND INSPECTION (1) Clean all the U-joint yoke bores with cleaning solvent and a wire brush. (2) Inspect the yokes for distortion, cracks and worn bearing assembly bores. ASSEMBLY/INSTALLATION During installation, ensure that the spiders and yokes are aligned to the reference marks. (1) Fit a cross into the tube yoke (Fig. 10).
PROPELLER SHAFTS
(2) Place a bearing assembly in a tube yoke hole and over a trunnion. Keep the needle bearings upright in the bearing assembly (Fig. 11). A needle roller lying at the bottom will prevent proper assembly. Be sure to remove any lube fittings that may interfere with removal.
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(4) Flip the tube yoke and bearing assembly installation on the opposite trunnion. Install a snap ring (Fig. 13).
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PROPELLER SHAFTS
(8) Press the remaining two bearing assemblies into place and install snap rings (Fig. 17).
(6) Install the centering kit assembly inside the center yoke making sure the spring is in place (Fig. 15). Align the lube fitting on the centering kit with the lube fitting on the installed cross.
PROPELLER SHAFTS
(10) Check for proper assembly. Flex the CV joint beyond center, it should snap over-center in both directions when correctly assembled (Fig. 19). (11) Add grease to all three lube fittings. (12) Install the propeller shaft. Refer to Propeller Shaft Replacement in this group.
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STEERING
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STEERING
CONTENTS
page page
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1 POWER STEERING PUMP . . . . . . . . . . . . . . . . . 12 POWER STEERING SYSTEM DIAGNOSIS . . . . . . 3 RACK AND PINION STEERING GEAR . . . . . . . . 33
RECIRCULATING BALL POWER STEERING GEAR . STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . STEERING LINKAGE 4WD VEHICLES . . . . . . TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . .
19 36 17 42
STEERING LINKAGE4WD The steering linkage consists of a pitman arm, idler arm, tie rods, and center link. Adjustment sleeves are used on the tie rods for toe and steering
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STEERING
POWER STEERING PUMP The power steering pump provides pressure for operation of the steering gear. The power steering pump is a constant flow rate and displacement, vanetype pump. The internal parts in the housing operate submerged in fluid. The flow control orifice is part of the high pressure line fitting. The pressure relief valve inside the flow control valve limits the pump pressure. Power steering pumps are not interchangeable with pumps installed in other vehicles. The power steering pump is connected to the steering gear via high pressure and return hose. The pump shaft has a pressed-on drive pulley that is belt driven by the crankshaft pulley. The P-Series pump (Fig. 5) is used in Dakota vehicles.
RACK AND PINION STEERING GEAR2WD The manual and power (assisted) rack and pinion steering gears (Fig. 3, 4) are not serviced or adjusted. If a malfunction or a fluid leak occurs, the complete unit must be replaced. The steering gear must be removed from the vehicle for boot replacement. Refer to Protective Rubber Boot Replacement.
Fig. 5 PumpP-Series
STEERING COLUMNS Two types of steering columns are installed on Dakota vehicles: a fixed, non-tilt column and a tilt column. The ignition key/lock cylinder and the ignition switch are located in the steering column. When the key/lock cylinder is turned to the LOCK position, the ignition switch and the steering shaft cannot be operated. The column to gear intermediate shaft is equipped with universal joints. A Rubber isolator is built into the shafts to absorb noise and vibration from the steering system. Both types of steering columns have anti-theft provisions. They are energy-absorbing (collapse from impact in the event of a front-end collision).
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POWER STEERING PUMP FLOW AND PRESSURE TEST PROCEDURE (1) Check belt tension and adjust as necessary. (2) Disconnect high pressure hose at gear or pump. Use a container for dripping fluid. (3) Connect Pressure Gauge, Special Tool from kit 6815 (Fig. 1) to both hoses using adapter fitting. Connect spare pressure hose to gear or pump. (4) Open the test valve completely. (5) Start engine and let idle long enough to circulate power steering fluid through flow/pressure test gauge and to get air out of the fluid. Then shut off engine. (6) Check fluid level, add fluid as necessary. Start engine again and let idle. (7) Gauge should read below 862 kPa (125 psi), if above, inspect the hoses for restrictions and repair as necessary. The initial pressure reading should be in the range of 345-552 kPa (50-80 psi). The flow meter should read between 1.3 and 1.9 GPM.
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STEERING
POWER STEERING SYSTEM DIAGNOSIS
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POWER STEERING SYSTEM DIAGNOSIS
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POWER STEERING SYSTEM DIAGNOSIS
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POWER STEERING SYSTEM DIAGNOSIS
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POWER STEERING SYSTEM DIAGNOSIS
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POWER STEERING SYSTEM DIAGNOSIS
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PUMP LEAKAGE DIAGNOSIS
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GEAR LEAKAGE DIAGNOSIS
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Drive Pulley Replacement . . . . . . . . . . . Power Steering Pump Initial Operation . . Pressure and Return Hose Replacement Pump Replacement 4 Cylinder Engine
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SERVICE INFORMATION
The power steering pump internal components are not serviced or adjusted. If a malfunction or an internal fluid leak occurs, the complete unit must be replaced. A power steering pump oil cooler is available on some vehicles (Figs 1 and 2).
REMOVAL (1) Place a drain pan under the pump and gear.
INSTALLATION (1) Wipe hose ends, pump and gear unions clean. (2) Connect hose at steering gear and pump. Route hose while avoiding extreme bends or kinks. The hose must be kept away from exhaust system components. Do not distort hose tube ends by bending, kinking or over tightening. (3) When used, the protective foam sleeves must be properly positioned on the hose to prevent chafing. (4) Tighten fittings at pump and gear to 35 N m (25 ft. lbs.) torque. (5) Install clamps on return hose on gear and pump. (6) After installation, inspect and test for fluid leaks.
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INSTALLATION (1) If removed, attach the front mounting bracket to the pump. (2) Position the pump in the rear mounting bracket. Install the retaining bolts/nuts and tighten to 28 N m (21 ft. lbs.) torque. (3) Install front bracket-to-engine bolts and tighten to 28 N m (21 ft. lbs.) torque. (4) Connect fluid hoses to pump. (5) Install and adjust drive belt. Refer to Group 7, Cooling for additional information. (6) Fill reservoir with MOPAR Power Steering Fluid. If necessary, refer to Power Steering Pump Initial Operation.
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STEERING
INSTALLATION (1) Install the bracket to pump attaching bolts (Fig. 9). Tighten the screws to 54 N m (40 ft. lbs.) torque.
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INSTALLATION Service replacement for plastic pulley will be a metal pulley. Install the replacement metal pulley accordingly. (1) Install the pulley with Installer C-4063-B (Fig. 11). Do not use the tool adapters.
RESERVOIR REPLACEMENT
REMOVAL (1) Remove power steering pump. Refer to Pump Replacement in this section. (2) Remove the filler cap and drain the fluid from reservoir before removing parts. (3) Remove mounting studs and pressure fitting (Fig. 12). Rock reservoir by hand or use a soft face mallet to remove. (4) Remove O-ring seals from housing and reservoir (Fig. 12). (5) Remove flow control valve and spring from housing. INSTALLATION (1) Install flow control valve and spring (Fig. 13). (2) Lubricate and install new O-ring seals in housing (Fig. 13). Tighten mounting studs to 48 N m (35 ft. lbs.) torque. (3) Install fitting in flow control valve bore. Tighten the fitting to 75 N m (55 ft. lbs.) torque. (4) Install power steering pump. Refer to Pump Replacement in this section.
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STEERING
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SERVICE INFORMATION
The steering linkage consists of a pitman arm, center link, tie rod, and idler arm. Adjustment sleeves are used on the tie rods for toe and steering wheel alignment. Refer to Group 2, Front Suspension and Axle for additional information. The tie-rod end ball stud seals should be inspected during all oil changes. A damaged ball stud seal requires removal of the seal. Inspect the tie-rod end ball stud at the throat opening. Check for lubricant loss, contamination, ball stud wear or corrosion. If these conditions exist, replace the tie-rod. A replacement seal can be installed if lubricant is in good condition. Otherwise, a complete replacement ball stud end should be installed. Lubricate the tie-rod end with MOPAR Multi-Mileage Lubricant, or equivalent product. Use Puller C-3894-A for tie rod removal. Failure to use this tool could damage the ball stud and seal (Fig. 1).
(3) If necessary, loosen the end clamp bolts and remove the tie rod ends from the tube.
INSTALLATION (1) If necessary, install the tie rod ends in the tube (Fig. 2). Position the tie rod clamp. Tighten to 30 N m (22 ft. lbs.) torque. (2) Install the tie rod on the center link and steering knuckle. Install the retaining nuts. (3) Tighten the ball stud nut on the steering knuckle to 54 N m (40 ft. lbs.) torque. Tighten the ball stud nut to center link to 75 N m (55 ft. lbs.) torque. Install new cotter pins. (4) Set the wheel toe pattern. Refer to Group 2, Front Suspension and Axle for Alignment adjustment.
PITMAN ARM
REMOVAL (1) Remove the cotter pin and nut from the pitman arm at the center link. (2) Remove the pitman arm from the center link with a puller. (3) Remove the nut and washer from the steering gear shaft. Mark the pitman shaft and pitman arm for installation reference. Remove the pitman arm from steering gear with Puller C-4150-A (Fig. 3). INSTALLATION (1) Align and install the pitman arm on steering gear shaft. (2) Install the washer and nut on the shaft. Tighten the nut to 251 N m (185 ft. lbs.) torque. (3) Install center link on the pitman arm ball stud. Install and tighten nut to 54 N m (40 ft. lbs.) torque. Install a new cotter pin.
IDLER ARM
REMOVAL (1) Remove the cotter pin and nut from the idler arm at the center link. (2) Remove the idler arm from the center link with a puller. (3) Remove the bolts from the right frame rail and remove idler arm.
TIE ROD
REMOVAL (1) Remove the cotter pins and nuts at the steering knuckle and center link (Fig. 2). (2) Loosen the ball studs with puller tool to remove the tie rod.
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STEERING
CENTER LINK
REMOVAL (1) Remove the tie rods from the center link (Fig. 2). Refer to Tie Rod Removal in this section. (2) Remove the idler arm from the center link. Refer to Idler Arm Removal in this Section. (3) Remove the pitman arm from the center link. Refer to Pitman ArmRemoval in this Section. (4) Remove the link from the steering knuckle with a puller tool. Remove the same for tie rod and pitman arm. INSTALLATION (1) Install the drag link adjustment sleeve and tie rod end. Position clamp bolts. (2) Position the drag link at the steering linkage (Fig. 2). Install the drag link to the steering knuckle nut. Do the same for the tie rod and pitman arm. (3) Tighten the nut at the steering knuckle to 54 N m (40 ft. lbs.) torque. Tighten the pitman and tie rod ball stud nuts to 75 N m (55 ft. lbs.) torque. Install new cotter pins.
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page . . . . . . . . . . . . . . . . . . . . . . . . 30 28 19 21 32 26
SERVICE INFORMATION
A recirculating-ball steering gear is used with the power (assisted) steering system. The power steering gear can be adjusted and internally serviced.
Stop the engine. (5) Remove backup washer and single lip seal with screwdriver. (6) Inspect the housing for burrs and remove if necessary. Inspect the pitman shaft seal surface for roughness and pitting. If pitted replace shaft.
INSTALLATION (1) Install single lip seal with Installer or a suitable size deep socket (Fig. 2).
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OVER-CENTER ADJUSTMENT (1) Rotate the stub shaft from stop to stop and count the number of turns. (2) Starting at either stop turn the stub shaft back 1/2 the total number of turns. This is the center of the gear travel (Fig. 8).
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STEERING
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STEERING
(3) Install gasket to side cover and bend tabs around edges of side cover. (4) Install pitman shaft assembly and side cover to housing. (5) Install side cover bolts and tighten to 60 N m (44 ft. lbs.). (6) Adjust pitman shaft, refer to Over-Center Adjustment.
INSTALL (1) Install steering gear. Refer to Power Steering Gear Replacement in this section. (2) Install pitman arm onto steering gear. Refer to Steering Linkage in this group.
STEERING
CAUTION: Do not turn stub shaft any further than necessary. The recirculating balls will drop out of the rack piston circuit and fall inside the rack piston chamber. (3) Remove O-ring seal (Fig. 13).
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(2) Install pitman arm onto steering gear. Refer to Steering Linkage in this group.
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STEERING
(1) Install needle bearing into adjuster plug with tool C-4177 and handle C-4171. (2) Apply white petroleum grease on lip seal. Install lip seal into adjuster plug with tool C-4177 and handle C-4171. (3) Apply white petroleum grease to dust seal cavity and install dust seal into adjuster plug with tool C-4177 and handle C-4171. (4) Install retainer snap ring. (5) Install O-ring seal to adjuster plug. (6) Install large bearing race, thrust bearing, small bearing race and bearing spacer to adjuster plug. (7) Install thrust washer bearing retainer to adjuster plug (Fig. 19).
(4) Remove bearing spacer, races and thrust bearing (Fig. 17).
INSTALL (1) Install steering gear. Refer to Power Steering Gear Replacement in this section.
VALVE REPLACEMENT
REMOVE (1) Remove steering gear from vehicle. Refer to Power Steering Gear Replacement in this section.
STEERING
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ASSEMBLE (1) Install valve spool O-ring seal to valve spool. (2) Lubricate valve spool and O-ring seal with power steering fluid. (3) Install valve spool to valve body by pushing and rotating. Hole in valve spool for stub pin must be accessible from opposite end of valve body. (4) Assemble stub shaft to valve spool, if necessary and insert pin (Fig. 25). Notch in stub shaft cap MUST fully engage valve body pin and seat against valve body shoulder. (5) Install O-ring seals and teflon rings to valve body.
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STEERING
INSTALL (1) Install steering gear. Refer to Power Steering Gear Replacement in this section.
STEERING
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the stub shaft COUNTERCLOCKWISE. The rack piston will be forced onto the tool and hold the rack piston balls in place. (7) Install the races and thrust bearing to worm shaft (Fig. 31).
INSTALL (1) Install steering gear. Refer to Power Steering Gear Replacement in this section.
ASSEMBLE (1) Install needle bearing into housing (Fig. 34). (2) Install single lip seal with Installer or a suitable size socket (Fig. 35). (3) Coat the double lip seal and washer with grease. (4) Install the backup washer. (5) Install the double lip seal. (6) Install the backup washer. (7) Install the retainer ring with snap ring pliers.
STEERING
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ASSEMBLE (1) Install the valve into the housing with a 3/8inch diameter piece of tubing 100 mm (4 inches) long. INSTALL (1) Install steering gear. Refer to Power Steering Gear Replacement in this section.
INSTALL (1) Install steering gear. Refer to Power Steering Gear Replacement in this section.
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STEERING
INSTALLATION (1) Align the column coupler shaft to steering gear. Refer to Column Coupler installation in this section. (2) Position the steering gear on the frame rail and install the bolts. Tighten the bolts to 95 N m (70 ft. lbs.) torque. (3) Align and install the pitman arm. Refer to Pitman Arm Installation in the Steering Linkage section. (4) Connect fluid hoses to steering gear. Refer to Pressure and Return Hose Replacement in this group.
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INSTALLATION (1) Position the gear at the front crossmember. Install the attaching bolts (Fig. 1). For manual rack and pinion gears, ensure that the master serration is aligned. (2) Tighten the steering gear-to-crossmember bolts to 203 N m (150 ft. lbs.) torque. (3) Connect the steering shaft coupler to the pinion gear shaft and tighten bolt to 49 N m (36 ft. lbs.).
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STEERING
(4) Loosen the jam nut and un-thread the tie-rod (Fig. 4).
BOOT SEAL
Servicing the rubber boot must be done with the steering gear removed from the vehicle (Fig. 5).
TIE-ROD END
REMOVAL (1) Raise and support the vehicle. (2) Remove the cotter pin and nut from the tie-rod end stud at the steering knuckle arm (Fig. 3). Use Puller C-3894-A for tie rod removal. Failure to use this tool could damage the tie rod and seal (Fig. 3). A damaged ball stud seal requires removal of the seal. Inspect the tie-rod end ball stud at the throat opening. Check for lubricant loss, contamination, ball stud wear or corrosion. If these conditions exist, replace the tie-rod. A replacement seal can be installed if lubricant is in good condition. Otherwise, a complete replacement tie-rod end should be installed. Lubricate the tie-rod end with MOPAR Multi-Mileage Lubricant, or an equivalent product. (3) Install Puller C-3894-A on the tie-rod end stud and steering arm (Fig. 3). Loosen the tie-rod end stud from steering knuckle arm.
REMOVAL (1) Loosen the locknut and remove the tie-rod. (2) Remove the outer clamp from the rubber boot. (3) Remove the boot inner clamp. (4) Mark the vent tube location on steering gear before removing the rubber boot.
STEERING
INSTALLATION (1) Align the vent tube with the reference mark on the steering gear. (2) Position and align the new boot over the housing. (3) Install inner clamp on the rubber boot. (4) Position outer clamp on the inner tie rod. (5) Install the tie-rod end. (6) Lubricate the boot outer groove (tie rod end) with silicone type lubricant. Ensure that the protective rubber boot is not twisted. (7) Install the outer clamp on the boot.
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SERVICE INFORMATION
The Acustar columns (Fig.1) have been designed to be serviced as an assembly; less wiring, switches, shrouds, steering wheel, etc. Also most steering column components can be serviced without removing the column from the vehicle. For additional information refer to Group 8H, Electrical. WARNING: BEFORE BEGINNING ANY AIRBAG SYSTEM REMOVAL OR INSTALLATION PROCEDURES, REMOVE AND ISOLATE THE BATTERY NEGATIVE (-) CABLE FROM THE VEHICLE BATTERY. THIS IS THE ONLY SURE WAY TO DISABLE THE AIRBAG SYSTEM. FAILURE TO DO THIS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
WARNING: WHEN A STEERING COLUMN HAS AN AIRBAG MODULE ATTACHED, NEVER PLACE THE COLUMN ON THE FLOOR OR OTHER SURFACE WITH THE STEERING WHEEL OR MODULE FACE DOWN. CAUTION: Bumping, jolting and hammering on the steering column shaft and gear shift tube must be avoided during all service procedures. CAUTION: Do not attempt to remove pivot pins to dissemble the tilting mechanism. Do not remove ignition locking link, shaft lock plate or shaft lock plate retainer (Fig. 2, 3). Damage will occur.
STEERING
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STEERING WHEEL
REMOVAL When removing a deployed air bag module Refer to Group 8M. (1) Make sure the front wheels are in the straight ahead position. (2) Disconnect battery negative cable and isolate. (3) From underside of steering wheel, remove speed control switch or trim piece mounting screws (Fig. 4). (4) Pull switches from wheel and unplug connector (Fig. 5). (5) Using a small screwdriver remove right rear steering wheel cover (Fig. 6). (6) Remove 4 nuts attaching AirBag Module (Fig. 7). (7) Remove AirBag Module from steering wheel and unplug squib connector from airbag module. (8) Remove the steering wheel retaining nut. Steering wheel and shaft are master splined for installation reference.
INSTALLATION (1) Pull speed control and air bag wires through the lower hole in the steering wheel. Pull the horn wire through the smaller hole at the top (Fig. 8). Ensure the wires are NOT pinched. (2) Install the steering wheel with the scored marks or master splines aligned. (3) Install the retaining nut and tighten to 61 N m (45 ft. lbs.) torque. Force the steering wheel down on the shaft with the retaining nut only. Do not hammer or shock the column with sudden impact to install the wheel. (4) Connect the wires to the horn buttons, speed control switch and air bag module. (5) Connect clockspring wiring connector to the module, by pressing straight in on the connector. The connector should latch securely beneath module locking clip to assure positive connection.
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STEERING
INSTALLATION (1) Snap clockspring assembly onto column. If clockspring is not properly positioned, follow the centering procedures before installing steering wheel. (2) Connect the wire connector to the clockspring.
WARNING: ENSURE CLOCKSPRING WIRE CONNECTION IS COMPLETELY SEATED. THE LATCHING CLIP ARMS MUST BE PROPERLY ENGAGED ON THE MODULE. (3) Install upper and lower steering column shrouds. Be sure wiring is inside of shrouds and not pinched. (4) Install the steering wheel and, refer to Steering Wheel Installation.
CLOCKSPRING
REMOVAL (1) Place the front wheels in the straight ahead position before starting the repair. (2) Disconnect battery negative cable and isolate.
CENTERING PROCEDURE If the rotating tape within the clockspring is not positioned properly, the clockspring may fail during use. The following procedures MUST BE USED to center the clockspring. (1) Place the front wheels in the straight ahead position before starting the procedure. (2) Depress the 2 locking tabs to disengage the locking mechanism (Fig. 9). (3) Keeping the mechanism disengaged, rotate the clockspring rotor in the CLOCKWISE DIRECTION to the end of the travel. Do not apply excessive torque.
STEERING
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Fig. 9 ClockspringAuto-Locking
(4) From the end of travel, rotate the rotor 2 1/2 full turns in the COUNTER CLOCKWISE direction. The horn wire should end up at the top and the squib wire at the bottom (Fig. 9). (5) Install the steering wheel, refer to Steering Wheel Installation.
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STEERING
INSTALLATION
CAUTION: Bumping, jolting and hammering on the steering column shaft and gear shift tube must be avoided during all service procedures.
STEERING
(3) Remove the shipping lock pin (Fig. 1), if necessary. (4) Install column through floor pan. (5) Position the column bracket shear pins on the attaching studs. Install, but loose assemble the two upper bracket washers and nuts. (6) With the front wheels in the straight-ahead position. Align and install the upper and lower coupler. Do not apply force at the top of the steering column shaft. (7) Install the coupler bolt and tighten to 48 N m (36 ft. lbs.) torque. (8) Clip the wiring harness on the steering column. Connect the multi-function switch wiring. (9) Install the upper fixed shroud (Fig. 1). (10) Be sure both spacers are fully seated in the column support bracket by pulling column upwards. Tighten the upper column bracket support nuts to 12 N m (105 in. lbs.) torque (DO NOT OVER TORQUE). (11) Tighten the toe plate attaching bolts/nuts (Fig. 1) to 23 N m (200 in. lbs.) torque. (12) Install the wiring connections to the column. Install the lower fixed shroud. (13) Column shift vehicles, install the gear position indicator cable. (14) Install the lock housing shrouds. Install the tilt lever (if equipped). (15) Install the lower dash panel column cover. (16) Install hood release cable bracket. (17) Install steering wheel on column, refer to Steering Wheel-Installation. (18) Column shift vehicles, connect the shift link rod to the transmission shift lever. Use MOPAR Multipurpose Lubricant, or an equivalent product, to aid the installation. (19) Check operation of the transmission shift linkage and adjust as necessary. Refer to Group 21, Transmission for the shift linkage adjustment. (20) Slowly move the gear shift selector lever from 1 or L (low) to P (PARK). The indicator pointer must align with each indicator position. (21) Connect the battery ground (negative) cable.
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COMPONENT SERVICE
The Acustar columns (Fig.1) have been designed to be serviced as an assembly; less wiring, switches, shrouds, steering wheel, etc. Most steering column components can be serviced without removing the column from the vehicle. For additional information refer to Group 8H, Electrical. (1) The gear shift lever (if equipped) can be serviced. Use a drift and a suitable size socket to drive out the pin (Fig. 18). (2) The gear position indicator driver can be removed by drilling out the rivets (Fig. 19). Use care when installing a new driver. Use the correct replacement rivets. Install with a hand rivet gun (Fig. 20).
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STEERING COLUMN
STEERING LINKAGE
STEERING GEAR
STEERING PUMP
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GENERAL INFORMATION
The AX 15 is a five speed, synchromesh, manual transmission. Fifth gear is an overdrive range with a ratio of 0.789:1. The AX 15 is used with 2.5L and 3.9L engines.
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AX 15 MANUAL TRANSMISSION
Correct lubricant refill or top-off level is to the bottom edge of the fill plug hole. Lubricant dry fill capacity is approximately 3.10 liters (3.27 U.S. quarts) in 4-wheel drive models.
IDENTIFICATION
The AX 15 identification code numbers are on the bottom surface of the transmission gear case (Fig. 2). The first number represents year of manufacture (5 = 1995, 4 = 1994). The second and third numbers indicate month of manufacture (01 = January, 02 = february, etc.). The remaining numbers represent the transmission serial number.
SHIFT PATTERN
The AX 15 shift pattern is shown in Figure 3. First-second and third-fourth gear ranges are in a conventional H pattern. Fifth and reverse gear ranges are in line and positioned at the extreme right of the H pattern (Fig. 3). The AX 15 is equipped with a reverse lockout. The shift lever must be moved through the Neutral detent before a shift to reverse can be completed.
GEAR RATIOS
AX 15 gear ratios are as follows: First gear - 3.83:1 Second gear - 2.33:1 Third gear - 1.44:1 Fourth gear - 1.00:1 Fifth gear - 0.79:1 Reverse - 4.22:1
RECOMMENDED LUBRICANT
Recommended lubricant for the AX 15 transmission is Mopar 75W-90, API Grade GL-5 gear lubricant, or equivalent.
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Worn or damaged synchro rings can cause gear clash when shifting into any forward gear. In some new or rebuilt transmissions, new synchro rings may tend to stick slightly causing hard or noisy shifts. In most cases, this condition will decline as the rings wear-in.
TRANSMISSION DIAGNOSIS
LOW LUBRICANT LEVEL A low transmission lubricant level is generally the result of a leak, inadequate lubricant fill, or an incorrect lubricant level check. Leaks can occur at the mating surfaces of the gear case, intermediate plate and adapter or extension housing, or from the front/rear seals. A suspected leak could also be the result of an overfill condition. Leaks at the rear of the extension or adapter housing will be from the housing oil seals. Leaks at component mating surfaces will probably be the result of inadequate sealer, gaps in the sealer, incorrect bolt tightening, or use of a non-recommended sealer. A leak at the front of the transmission will be from either a loose or damaged, front bearing retainer or retainer seal. Lubricant may also drip from the clutch housing after extended operation. If the leak is severe, it will contaminate the clutch disc causing slip, grab and chatter. Transmissions filled from air or electrically powered lubricant containers can be underfilled. This generally happens when the container delivery mechanism is improperly calibrated. Always check the lubricant level after filling to avoid an under fill condition. A correct lubricant level check can only be made when the vehicle is level; use a drive-on hoist to ensure this. Also allow the lubricant to settle for a minute or so before checking. These recommendations will ensure an accurate check and avoid an under-or-overfill condition. HARD SHIFTING Hard shifting is usually caused by: low lubricant level; improper or contaminated lubricants; transmission component damage; faulty clutch linkage; or damaged clutch cover or disc. Substantial lubricant leaks can result in gear, shift rail, synchro and bearing damage. If a leak goes undetected for an extended period, the first indications of a problem are usually hard shifting and noise. Incorrect or contaminated lubricants can also contribute to hard shifting. The consequence of using non-recommended lubricants is noise, excessive wear, internal bind and hard shifting. Improper clutch release is a frequent cause of hard shifting. A loose, worn, or damaged pressure plate, disc, or clutch linkage can cause incorrect release. If the clutch problem is advanced, gear clash during shifts can result. TRANSMISSION NOISE Most manual transmissions make some noise during normal operation. Rotating gears can generate a mild whine that may only be audible at extreme speeds. Severe, obviously audible transmission noise is generally the result of a lubricant problem. Insufficient, improper, or contaminated lubricant can promote rapid wear of gears, synchros, shift rails, forks and bearings. The overheating caused by a lubricant problem, can also lead to gear breakage.
SPEEDOMETER SERVICE
Rear axle gear ratio and tire size determine pinion gear requirements. If the gear must be replaced, refer to the parts catalogue information for the correct gear.
SPEEDOMETER ASSEMBLY REMOVAL (1) Raise vehicle. (2) Disconnect wires from vehicle speed sensor. (3) Remove adapter clamp and screw (Fig. 11). (4) Remove speed sensor and speedometer adapter as assembly. (5) Remove speed sensor retaining screw and remove sensor from adapter. (6) Remove speedometer pinion from adapter. Replace pinion if worn, cracked, or teeth are chipped. (7) Inspect sensor and adapter O-rings (Fig. 6). Remove and discard O-rings if worn, cut, or torn. (8) Inspect terminal pins in speed sensor. Clean pins with Mopar electrical spray cleaner if dirty or oxidized. Replace sensor if faulty, pins are loose, severely corroded, or damaged. SPEEDOMETER INSTALLATION AND INDEXING (1) Thoroughly clean adapter flange and adapter mounting surface in housing. Surfaces must be clean for proper adapter alignment and speedometer operation. (2) Install new O-rings on speed sensor and speedometer adapter if necessary (Fig. 6). (3) Lubricate sensor and adapter O-rings with transmission fluid. (4) Install vehicle speed sensor in speedometer adapter. Tighten sensor attaching screw to 2-3 N m (15-27 in. lbs.) torque. (5) Install speedometer pinion in adapter.
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AX 15 MANUAL TRANSMISSION
AX 15 MANUAL TRANSMISSION
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AX 15 MANUAL TRANSMISSION
move Y-pipe from vehicle and move remaining pipes aside for working clearance. (16) Lower transmission approximately 7.62 cm (3 in.) for access to shift lever. (17) Reach up and around transmission case and unseat shift lever dust boot from transmission shift tower (Fig. 1). Move boot upward on lever for access to lever retainer. (18) Disengage shift lever from transmission as follows: (a) Reach up and around transmission case and press shift lever retainer downward with your fingers. (b) Turn retainer counterclockwise to release it. (c) Lift lever and retainer out of shift tower (Fig. 9). It is not necessary to remove shift lever from floorpan boot. Simply leave the lever in place for later installation. (19) Remove slave cylinder attaching nuts and remove cylinder from clutch housing. Move cylinder aside for working clearance. (20) Remove clutch housing dust cover. (21) On some models, it may be necessary to remove front axle struts and oil filter for access and removal clearance. Remove these components if necessary. (22) Support transmission with transmission jack. Secure transmission to jack with safety chains. (23) Remove bolts attaching clutch housing to engine block (Fig. 10). (24) Move transmission rearward until clutch housing is clear of engine. Then lower jack and remove transmission from under vehicle. (25) Remove transmission from jack and position transmission on workbench. (26) If transmission will be disassembled for service, remove release bearing and fork. Then remove bolts attaching clutch housing to transmission and remove housing (Fig. 11).
AX 15 MANUAL TRANSMISSION
(6) Install and tighten clutch housing bolts to 68 N m (50 ft. lbs.) torque. Be sure housing is fully seated before tightening bolts. Install housing dust cover after tightening housing bolts. (7) Lower transmission for access to shift tower. (8) Reach up and around transmission and insert shift lever into shift tower. Press lever retainer downward and turn it clockwise to lock it in place. Then install lever dust boot on shift tower. (9) Fill transmission with Mopar 75W-90, or equivalent API grade GL 5 gear lubricant. Correct fill level is to bottom edge of fill plug hole. (10) Connect backup light switch wires. (11) Connect transmission harnesses to clips on case. (12) Install crossmember. Tighten crossmember-toframe bolts to 68 N m (50 ft. lbs.) torque. (13) Tighten crossmember-to-transmission insulator nuts to 68 N m (50 ft. lbs.) torque. (14) Install slave cylinder. Tighten cylinder nuts to 23 N m (200 in. lbs.) torque. (15) Remove jack used to support transmission. (16) Install strut bolts/nuts, if removed. Also install oil filter if removal was necessary. (17) If speedometer was removed, install pinion and adapter. Then index adapter and install speed sensor (Fig. 6). Connect wires to speed sensor. (18) Connect exhaust pipes. (19) Align and install remaining exhaust components that were loosened, or removed. Tighten all clamp and bracket bolts and nuts securely. Be sure exhaust components are clear of all chassis and driveline components. (20) Align and install propeller shaft. Tighten U-joint clamp bolts to 19 N m (170 in. lbs.) torque. (21) Verify that all linkage components, hoses and electrical wires have been connected. (22) Remove any remaining support stands and lower vehicle. (23) Install crankshaft position sensor.
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(5) Align transmission input shaft with release bearing and clutch disc. Then slide clutch housing into place on engine block. (6) Install and tighten clutch housing attaching bolts to 54-61 N m (40-45 ft. lbs.) torque. Be sure housing is fully seated before tightening bolts. If equipped, install dust cover after tightening housing bolts. (7) Lower transmission for access to shift tower. (8) Reach up and around transmission and insert shift lever into shift tower. Press lever retainer downward and turn it clockwise to lock it in place. Then install lever dust boot on shift tower. (9) Fill transmission with Mopar 75W-90, or equivalent API grade GL 5 gear lubricant. Correct fill level is to bottom edge of fill plug hole. (10) Connect backup light switch wires. (11) Connect transmission harnesses and vent line to retainer clips on case. (12) Install center crossmember. Tighten crossmember-to-frame bolts to 67 N m (50 ft. lbs.) torque. (13) Tighten crossmember-to-insulator nuts to 54-61 N m (40-45 ft. lbs.) torque. (14) Install slave cylinder in clutch housing. Tighten cylinder attaching nuts to 23 N m (200 in. lbs.) torque. (15) Remove jack used to support transmission. (16) Install strut bolts/nuts, if removed. (17) Install transfer case. Align and position transfer case with transmission jack or aid of helper. Tilt case upward and work into position on transmission mounting studs. (18) Install and tighten transfer case attaching nuts to 47 N m (35 ft. lbs.) torque. (19) Install and connect transfer case shift linkage and vent hose. (20) If speedometer was removed, install pinion and adapter. Then index adapter and install speed sensor (Fig. 6). Connect wires to sensor after installation. (21) Connect exhaust Y-pipe to engine exhaust manifolds. (22) Align and install remaining exhaust components that were loosened or removed. Tighten all clamp and bracket bolts and nuts securely. Be sure exhaust components are clear of all chassis and driveline components. (23) Align and install front and rear propeller shafts. Tighten U-joint clamp bolts to 19 N m (170 in. lbs.) torque. (24) Verify that all linkage components, hoses and electrical wires have been connected. (25) Check transfer case fluid level. Add Mopar Dexron, or ATF Plus if necessary. Correct level is to bottom edge of fill plug hole. Be sure transfer case is level before checking or adding fluid.
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AX 15 MANUAL TRANSMISSION
(26) Check and adjust transfer case shift linkage if necessary. (27) Install transfer case skid plate, if equipped. (28) Install new oil filter, if original was removed. (29) Remove any remaining support stands and lower vehicle. (30) Install crankshaft position sensor. (31) If new oil filter was installed, add engine oil as needed to bring level to full mark on dipstick.
AX 15 MANUAL TRANSMISSION
(7) Remove shift arm shaft plug (Fig. 6). (8) Remove shift arm shaft with large magnet (Fig. 7). (9) Remove shift arm (Fig. 8).
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(10) Remove plug for reverse shift head lock ball. Plug is at right side of adapter housing near backup light switch (Fig. 9). (11) Remove lock ball spring with pencil magnet (Fig. 10). (12) Remove shift head lock ball with pencil magnet (Fig. 11).
Fig. 6 Removing/Installing Shift Arm Shaft Plug (4WD) Fig. 9 Removing/Installing Lock Ball Plug
Fig. 7 Removing/Installing Shift Arm Shaft (4WD) Fig. 10 Removing/Installing Lock Ball Spring
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AX 15 MANUAL TRANSMISSION
(13) Remove backup light switch from adapter/extension housing. (14) On 2-wheel drive models, remove distance sensor, speedometer adapter and driven gear if not removed previously. (15) Remove adapter/extension housing bolts (Fig. 12). (16) Loosen adapter/extension housing with rubber mallet (Fig. 13). (17) Remove housing after loosening it (Fig. 14)
AX 15 MANUAL TRANSMISSION
(18) Remove adapter housing oil seal with pry tool (Fig. 15).
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Fig. 17 Front Bearing Retainer Seal Location Fig. 15 Removing Adapter Housing Seal
GEAR CASE REMOVAL (1) Remove bearing retainer bolts and remove retainer (Fig. 16).
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AX 15 MANUAL TRANSMISSION
(5) Loosen gear case by tapping it away from intermediate plate with rubber mallet (Fig. 20).
AX 15 MANUAL TRANSMISSION
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AX 15 MANUAL TRANSMISSION
AX 15 MANUAL TRANSMISSION
(14) Remove fifth spline gear (Fig. 33). (15) Remove fifth gear synchro ring (Fig. 34). (16) Remove fifth gear synchro and sleeve assembly (Fig. 35).
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(17) Remove counter fifth gear thrust ring (Fig. 36). (18) Remove thrust ring lock ball with pencil magnet (Fig. 37). (19) Remove bolts attaching output shaft rear bearing retainer to intermediate plate (Fig. 38).
Fig. 33 Removing Fifth Spline Gear Fig. 36 Removing Fifth Gear Thrust Ring
Fig. 34 Removing Fifth Gear Synchro Ring Fig. 37 Removing Thrust Ring Lock Ball
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AX 15 MANUAL TRANSMISSION
SHIFT RAIL AND FORK REMOVAL There are a total of five shift rails in the AX 15 transmission. The 1-2, 3-4, fifth gear and front reverse shift rails are shown in Figure 41. Two shift rails are used for reverse gear range. The front reverse rail is at the forward side of the intermediate plate (Fig. 41). The short rear reverse rail and reverse shift head are at the rear side of the intermediate plate.
AX 15 MANUAL TRANSMISSION
(2) Remove 1-2 and 3-4 shift rail C-rings with two screwdrivers of equal size and length (Fig. 42).
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AX 15 MANUAL TRANSMISSION
(7) Remove 1-2 shift rail interlock pin from shift rail (Fig. 47).
Fig. 49 Removing Fifth Gear Shift Rail Lock Ball Fig. 47 Removing 1-2 Shift Rail Interlock Pin
(8) Remove 1-2 shift rail interlock plug from intermediate plate (Fig. 48).
AX 15 MANUAL TRANSMISSION
(12) Remove reverse shift rail C-ring with two equal length and size screwdrivers (Fig. 51).
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(15) Position shift rails, shift forks, lock balls, interlock plugs and interlock pins on the workbench in order of removal. This will help in identifying components during inspection and assembly.
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AX 15 MANUAL TRANSMISSION
(3) Tap end of output shaft with mallet to unseat and start rear bearing out of intermediate plate (Fig. 55). (4) Remove output shaft by rocking it lightly until rear bearing comes out of intermediate plate (Fig. 56).
AX 15 MANUAL TRANSMISSION
(8) Remove output shaft pilot bearing from input shaft (Fig. 60).
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TRANSMISSION CLEANING AND INSPECTION Clean the transmission components in solvent. Dry the cases, gears, shift mechanism and shafts with compressed air. Dry the bearings with clean, dry shop towels only. Never use compressed air on the bearings. This could damage the bearing rollers. Replace components that are obviously worn, cracked, chipped or damaged in any way. Inspect the transmission case. Replace the case if cracked or porous or if any of the bearing and gear bores are damaged.
Output Shaft Inspection Measure thickness of the output shaft flange with a micrometer (Fig. 64). Minimum allowable flange thickness is 4.70 mm (0.185 in). If shaft flange thickness is OK but previously measured second/third gear thrust clearance was incorrect (Fig. 62), replace the necessary
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AX 15 MANUAL TRANSMISSION
GEAR AND SYNCHRO INSPECTION Install the synchro rings on their respective gears. Rotate each ring on the gear and note synchro action. Replace any synchro ring that exhibits a lack of braking action or binds on the gear. Also replace any ring that is worn or has chipped or broken teeth. Measure end clearance between the synchro ring and the gear with a feeler gauge (Fig. 66). Clearance should be 0.06 mm - 1.6 mm (0.024 - 0.063 in.). Install the needle bearings in the first, second and third gears. Then install the gears on the output shaft and check shaft-to-gear clearance with a dial indicator (Fig. 67). Maximum allowable clearance is 0.16 mm (0.0063 in.). If any gear exhibits excessive clearance, replace the gear and needle bearing.
AX 15 MANUAL TRANSMISSION
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AX 15 MANUAL TRANSMISSION
thread inserts if necessary. However, do not attempt to repair if the cracks are evident around any threaded hole. Inspect the reverse pin in the adapter/extension housing. Replace the pin if worn or damaged. Refer to the replacement procedure in the Transmission Assembly section.
Check clearance between the shift forks and synchro sleeves with a feeler gauge (Fig. 68). Clearance should not exceed 1.0 mm (0.039 in.). Replace the synchro sleeve (and matching hub) if clearance exceeds the stated limit.
FRONT BEARING, SEAL AND PIN INSTALLATION (1) Press front bearing on input shaft. Then secure bearing with thickest snap ring that will fit in shaft groove (Fig. 70).
AX 15 MANUAL TRANSMISSION
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AX 15 MANUAL TRANSMISSION
AX 15 MANUAL TRANSMISSION
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(3) Install cluster gear rear bearing in intermediate plate (Fig. 81). Be sure snap ring groove in bearing is rearward as shown.
OUTPUT SHAFT AND CLUSTER GEAR INSTALLATION (1) Mount intermediate plate in vise (Fig. 24). (2) Lubricate cluster gear journal and rear bearing with petroleum jelly or gear lubricant.
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AX 15 MANUAL TRANSMISSION
AX 15 MANUAL TRANSMISSION
(1) Coat reverse rail interlock pin with petroleum jelly and install pin in rail (Fig. 86).
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AX 15 MANUAL TRANSMISSION
(6) Coat 1-2 shift rail interlock plug with petroleum jelly and install it in intermediate plate bore (Fig. 90).
AX 15 MANUAL TRANSMISSION
(12) Install and tighten shift fork setscrews to 20 N m (14 ft. lbs.) torque (Fig. 95).
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Fig. 97 Installing Thrust Ring Lock Ball Fig. 95 Installing Shift Fork Set Screws
(13) Install 1-2 and 3-4 shift rail C-rings (Fig. 96). (14) Insert fifth gear shift rail through reverse shift fork. Then slide rail into intermediate plate just far enough to secure interlock ball. Do not fully install shift rail at this time.
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AX 15 MANUAL TRANSMISSION
(7) Install fifth spline gear on cluster journal (Fig. 103). Tap spline gear into place with plastic mallet if necessary.
(4) Lubricate two-piece bearing with petroleum jelly and install it in counter fifth gear (Fig. 100).
AX 15 MANUAL TRANSMISSION
(9) Install reverse shift head and rail (Fig. 105). Then install lock ball in shift head.
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through fork, shift head, intermediate plate and reverse shift fork. Be sure interlock ball is not displaced during installation. (12) Align screw holes in shift fork and rail and install set screw (Fig. 108). Tighten screw to 20 N m (15 ft. lbs.) torque.
Fig. 109 Detent Ball And Spring Installation Fig. 107 Installing Fifth Gear Shift Rail
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AX 15 MANUAL TRANSMISSION
(14) Install reverse shift arm bracket (Fig. 110). Tighten bracket bolts to 18 N m (13 ft. lbs.) torque. (15) Install reverse shift arm (Fig. 110). Position arm on reverse fork pin and engage it with pin on shift arm bracket. (16) Verify that shift arm shoe is engaged in reverse idler gear. Then secure shift arm to pin on reverse fork with new E-clip.
AX 15 MANUAL TRANSMISSION
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Fig. 114 Installing Front Bearing Retainer Fig. 117 Access Plug Removal/Installation
(b) Tap roll pin out of housing with pin punch (Fig. 118). Then remove old reverse pin. (c) Install new reverse pin and secure it with roll pin. Then install and tighten access plug to 19 N m (14 ft. lbs.) torque.
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AX 15 MANUAL TRANSMISSION
Fig. 123 Installing Shift Arm Shaft Fig. 120 Installing Detent Ball
Fig. 124 Shift Arm Installation Fig. 121 Installing Detent Spring
(21) Lubricate shift arm shaft and install it in adapter housing (Fig. 123). (22) Position shift arm in adapter housing (Fig. 124). Be sure arm is engaged in shift rails. (23) Align shift arm with shaft and push shaft into arm. (24) Rotate shift arm shaft until set screw holes in shaft and arm are aligned. (25) Install and tighten shift arm set screw to 38 N m (28 ft. lbs.) torque (Fig. 125).
AX 15 MANUAL TRANSMISSION
(26) Install and tighten restrictor pins to 19 N m (14 ft. lbs.) torque (Fig. 125). (27) Install and tighten shift arm shaft access plug to 19 N m (14 ft. lbs.) torque (Fig. 126).
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(28) Position new shift tower gasket on adapter housing (Fig 127). (29) Install shift tower (Fig. 128). Tighten tower attaching bolts to 18 N m (13 ft. lbs.) torque. (30) Install new gasket on backup light switch and install switch. Tighten switch to 37 N m (27 ft. lbs.) torque. (31) Install new washer on drain plug. Then install and tighten plug to 37 N m (27 ft. lbs.) torque. (32) If transmission will be filled with gear lubricant before installation, place transmission in a level position. Then fill with Mopar 75W-90, grade GL-5 gear lubricant. Correct fill level is to bottom edge of fill plug hole. (33) Install new washer on fill plug. Then install and tighten plug to 37 N m (27 ft. lbs.) torque. (34) Install clutch housing and release bearing components. (35) On 2-wheel drive models, install new seal in extension housing with suitable size installer tool (Fig. 129). Lubricate seal lips with petroleum jelly before installation. (36) On 2-wheel drive models, install speedometer driven gear (if removed), and vehicle speed sensor.
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Drain and Fill Plug Locations . . . . . . . . . . . . . . . . General Service Information . . . . . . . . . . . . . . . . Speedometer Service . . . . . . . . . . . . . . . . . . . . . Transmission Assembly . . . . . . . . . . . . . . . . . . . . Transmission Changes . . . . . . . . . . . . . . . . . . . . Transmission Component Cleaning and Inspection Transmission Diagnosis . . . . . . . . . . . . . . . . . . . . Transmission Disassembly and Overhaul . . . . . . .
. . . . . . . .
40 38 41 60 41 56 41 45
Roller bearings are used to support the transmission shafts in the two housings. The transmission gears all rotate on caged type needle bearings. The NV3500 has only one shift shaft; all three shift forks are mounted on the single shaft. The shaft is supported in the front and rear housings by bushings and one bearing. Internal shift components consist of the forks, shaft, shift lever socket, anti-rotation bracket, bias spring and detent components (Fig. 2).
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TRANSMISSION LUBRICANT
Required lubricant for the NV3500 is Mopar Manual Transmission Lubricant P/N 4761526. This is the only lubricant recommended for use in NV3500 transmissions.
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TRANSMISSION CHANGES
The shift lever assembly and shift mechanism are new for 1995. The new design self-biasing shift lever is mounted in a lightweight shift tower. The lever and tower are serviced as an assembly. The shift socket and shift shaft are basically unchanged. However, the bias spring, and anti-rotation bracket and rollers are no longer necessary and have been eliminated. This is made possible by the new self-biasing shift lever assembly.
HARD SHIFTING Hard shifting is usually caused by a low lubricant level, improper or contaminated lubricants, transmission component damage, clutch linkage malfunction, or by a damaged clutch pressure plate or disc. Substantial lubricant leaks can result in gear, shift component, synchro and bearing damage. If a leak goes undetected for an extended period, the first indications of a problem are usually hard shifting and noise. Incorrect or contaminated lubricants can also contribute to hard shifting. The consequence of using non-recommended lubricants is noise, excessive wear, internal bind and hard shifting. Improper clutch release is a frequent cause of hard shifting. Incorrect adjustment or a worn, damaged pressure plate or disc can cause incorrect release. If the clutch problem is advanced, gear clash during shifts can result. Worn or damaged synchro rings can cause gear clash when shifting into any forward gear. In some new or rebuilt transmissions, new synchro rings may tend to stick slightly causing stiff and/or noisy shifts. In most cases, this condition will decline as the rings wear-in. TRANSMISSION NOISE Most manual transmissions make some noise during normal operation. Rotating gears can generate a mild whine that may only be audible at extreme speeds. Severe, obviously audible transmission noise is generally the result of a lubricant problem. Insufficient, improper, or contaminated lubricant can promote rapid wear of gears, synchros, shift rails, forks and bearings. The overheating caused by a lubricant problem, can also lead to gear breakage.
TRANSMISSION DIAGNOSIS
LOW LUBRICANT LEVEL A low transmission lubricant level is generally the result of a leak, inadequate lubricant fill, or an incorrect lubricant level check. Leaks can occur at the mating surfaces of the housings, or from the front/rear seals. A suspected leak could also be the result of an overfill condition. Leaks at component mating surfaces will probably be the result of inadequate sealer, gaps in the sealer, incorrect bolt tightening, or use of a non-recommended sealer. A leak at the front of the transmission will be from either a loose or damaged, front bearing retainer or retainer seal. Lubricant may also drip from the transmission clutch housing after extended operation. If the leak is severe, it will contaminate the clutch disc causing slip, grab and chatter. Transmissions filled from air or electrically powered lubricant containers can be underfilled. This generally happens when the container delivery mechanism is improperly calibrated. Always check the lubricant level after filling to avoid an under fill condition. A correct lubricant level check can only be made when the vehicle is level; use a drive-on hoist to ensure this. Also allow the lubricant to settle for a minute or so before checking. These recommendations will ensure an accurate check and avoid an under-or-overfill condition.
SPEEDOMETER SERVICE
Rear axle gear ratio and tire size determine pinion gear requirements. If the gear must be replaced, refer to the parts catalogue information for the correct gear.
SPEEDOMETER ASSEMBLY REMOVAL (1) Raise vehicle. (2) Disconnect wires from vehicle speed sensor. (3) Remove adapter clamp and screw (Fig. 4). (4) Remove speed sensor and speedometer adapter as assembly. (5) Remove speed sensor retaining screw and remove sensor from adapter. (6) Remove speedometer pinion from adapter. (7) Inspect sensor and adapter O-rings (Fig. 4). Remove and discard O-rings if worn or damaged. (8) Inspect terminal pins in speed sensor. Clean pins with Mopar electrical spray cleaner if dirty or
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SPEEDOMETER INSTALLATION AND INDEXING (1) Thoroughly clean adapter flange and adapter mounting surface in housing. Surfaces must be clean for proper adapter alignment and speedometer operation. (2) Install new O-rings on speed sensor and speedometer adapter if necessary (Fig. 4). (3) Lubricate sensor and adapter O-rings with transmission fluid. (4) Install vehicle speed sensor in speedometer adapter. Tighten sensor attaching screw to 2-3 N m (15-27 in. lbs.) torque. (5) Install speedometer pinion in adapter. (6) Count number of teeth on speedometer pinion. Do this before installing assembly in housing. Then lubricate pinion teeth with transmission fluid. (7) Note index numbers on adapter body (Fig. 5). These numbers will correspond to number of teeth on pinion. (8) Install speedometer assembly in housing. (9) Rotate adapter until required range numbers are at 6 o-clock position. Be sure range index numbers correspond to number of teeth on pinion gear. (10) Install speedometer adapter clamp and retaining screw. Tighten clamp screw to 10-12 N m (90-110 in. lbs.) torque. (11) Connect wires to vehicle speed sensor. (12) Lower vehicle and top off transmission fluid level if necessary.
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isolator and plate assembly can also be removed at this time if plate sealer bead has broken loose. (5) Remove isolator and plate assembly from shift lever opening in rear housing (Fig. 7). Plate assembly is one-way fit. Note position of plate for installation reference before removal. Narrow side of plate goes toward driver side of transmission and rubber coated side faces upward. (6) Cover shift lever opening in rear housing with shop towels to prevent entry of dirt/foreign material. (7) Remove crankshaft position sensor. Retain sensor attaching bolts. (8) Raise vehicle on hoist. (9) Remove skid plate, if equipped. (10) Drain transmission lubricant if transmission will be disassembled for service. (11) Mark propeller shafts and U-joints for installation reference. Then disconnect and remove propeller shafts. (12) Disconnect vehicle speed sensor wires. (13) Disconnect transfer case shift linkage at transfer case range lever. (14) Remove bolts attaching shift linkage bracket to transfer case and move linkage and bracket aside. (15) Remove nuts attaching transfer case to transmission adapter housing. (16) Remove transfer case with aid of helper. Support transfer case with transmission jack. Move transfer case rearward, tilt it away from fixed (welded) rear crossmember and work it out from between transmission and crossmember. (17) Support engine with adjustable jack stand. (18) Remove nuts and bolts attaching support bracket and cushions to fixed crossmember. (19) Remove nuts and bolts attaching removable crossmember to frame rails. Rotate crossmember diagonally to remove it. (20) Disconnect exhaust pipes at manifold and at converter or muffler connections as needed. Then remove Y-pipe, converter and tailpipe. (21) Remove slave cylinder attaching nuts and remove cylinder. Move cylinder aside for working clearance. (22) Remove clutch housing dust cover. (23) On some models, it may be necessary to remove front axle struts and oil filter for access and removal clearance. Remove these components if necessary. (24) Support transmission with transmission jack. Secure transmission to jack with safety chains. (25) Remove bolts attaching transmission clutch housing to engine block. (26) Move transmission rearward until transmission clutch housing is clear of engine. Then lower jack and remove transmission from under vehicle. (27) Remove transmission from jack and position transmission on workbench.
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(22) Check transfer case fluid level. Add Mopar Dexron II if necessary. Correct level is to edge of fill plug hole. Be sure transfer case is level before checking or adding fluid. (23) Check and adjust transfer case shift linkage if necessary. (24) Install transfer case skid plate, if equipped. (25) Install new oil filter, if original was removed. (26) Remove any remaining support stands and lower vehicle. (27) Install crankshaft position sensor. (28) If new oil filter was installed, add engine oil as needed to bring level to full mark on dipstick. (29) Connect battery negative cable. (30) Apply Mopar Gasket Maker, or Loctite 518 to mounting surface of isolator and plate assembly. (31) Remove protective shop towels from shift lever opening in transmission. Then apply Mopar Gasket Maker, or Loctite 518 to isolator and plate assembly mounting surface. (32) Position isolator and plate assembly on transmission. Plate is one-way fit. Narrow side goes toward driver side of transmission. (33) Install shift lever assembly. Tighten shift tower bolts to 7-10 N m (5-7 ft. lbs.) torque. (34) Install shift lever extension and shift boot.
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(12) Remove shift shaft detent plunger and spring (Fig. 10). Use pencil magnet to remove spring then plunger.
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(14) Separate front housing from rear housing (Fig. 12). Use plastic mallet to tap front housing off alignment dowels.
Fig. 15 Removing Shift Shaft Lever Detent Ball And Spring Fig. 13 Input Shaft And Countershaft Front Bearing Location
(16) Note position of input shaft, shift shaft and forks, and geartrain components in housing (Fig. 14). (b) Tap roll pin downward with pin punch (Fig. 16). Roll pin does not have to come completely out of shift shaft. It only has to clear the socket. (c) If roll pin accidentally becomes jammed between gear teeth locking socket and shaft in place, proceed to alternate disassembly method in step (3). (3) If socket roll pin becomes jammed, alternate disassembly method is as follows: (a) Remove rear bearing retainer bolts. (b) Remove reverse idler segment (but leave gear in case). (c) Remove input shaft, bearing, and 3-4 synchro ring.
SHIFT SHAFT, SHIFT FORKS AND REVERSE IDLER SEGMENT REMOVAL (1) Place shop towel over shaft lever and bushing to contain lever detent ball and spring. Then rotate lever and bushing upward out of shift forks and catch ball and spring as they exit shaft lever (Fig. 15). (2) Unseat roll pin that secures shift socket to shift shaft as follows: (a) Tilt socket toward passenger side of case. This places roll pin at slight angle to avoid trapping pin between gear teeth when it is tapped downward.
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Fig. 18 Pulling Shift Shaft Out Of Housing, Shift Socket, And Shift Forks
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Fig. 28 Unseating Rear Housing From Output Shaft Bearing (2-Wheel Drive Transmission)
Fig. 27 Removing/Installing Output Shaft Bearing Retainer Bolts (2-Wheel Drive Transmission)
REAR HOUSING REMOVAL (2-WHEEL DRIVE TRANSMISSION) (1) On 2-wheel drive transmission, remove three bolts that attach output shaft bearing retainer to rear case (Fig. 27). Bolts are to rear of shift tower opening. (2) Unseat output shaft bearing from bearing bore in rear housing. Use plastic or rawhide mallet to tap rear housing upward and off output shaft bearing as shown (Fig. 28).
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(4) Remove countershaft rear bearing from rear housing (Fig. 30). (5) Examine condition of oil tube, bearing bore and idler shaft notch in rear housing (Fig. 30). Replace housing if any of these components are damaged.
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(b) If remover tool has fairly thin jaws, position tool jaws behind third gear. Then remove synchro assembly and gear simultaneously.
Fig. 43 Second Speed Synchro Ring And Synchro Hub Snap Ring Removal
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(11) On 2-wheel drive models, remove output shaft bearing with Remover Tool 1130 and shop press (Fig. 47).
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Component Cleaning Clean the gears, shafts, shift components and transmission housings with a standard parts cleaning solvent. Do not use acid or corrosive base solvents. Dry all parts except bearings with compressed air. Clean the shaft bearings with a mild solvent such as Mopar degreasing solvent, Gunk, or similar solvents. Do not dry the bearings with compressed air. Allow the bearings to either air dry, or wipe them dry with clean shop towels. Shift Lever Assembly The shift lever assembly is not serviceable. Replace the lever and shift tower as an assembly if the tower, lever, lever ball, or internal components are worn, or damaged. Shift Shaft And Forks Inspect the shift fork interlock arms and synchro sleeve contact surfaces (Fig. 54). Replace any fork exhibiting wear or damage in these areas. Do not attempt to salvage shift forks. Inspect the shift shaft bushings and front bearing carefully. The bushings and bearing are
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Check condition of the oil tube in the rear housing. The tube must not be bent or loose. The housing will have to be replaced if the tube is loose or damaged. Pay particular attention to the bushings and bearings in the front and rear housings. The front housing contains the shift shaft front bearing and bushing, the countershaft front bearing race and the detent plunger bushing. The rear housing contains the shift shaft rear bushing and the countershaft rear bearing race. Be advised that these components are NOT serviceable items. The front housing will have to be replaced if the shift shaft bearing and bushing, detent plunger bushing, or countershaft bearing race is loose, worn, or damaged. The rear housing will have to be replaced if the shift shaft rear bushing, or the countershaft rear bearing race is loose, worn, or damaged. Inspect the input shaft bearing retainer. Be sure the release bearing slide surface of the retainer is in good condition. Minor nicks on the surface can be smoothed off with 320/420 grit emery cloth and final polished with oil coated crocus cloth. Replace the retainer seal if necessary. Inspect the output shaft bearing retainer. Be sure the U-shaped retainer is flat and free of distortion. Replace the retainer if the threads are damaged, or if the retainer is bent, or cracked. Countershaft Bearings And Races The countershaft bearings and races are machine lapped during manufacture to form matched sets. The bearings and races should not be interchanged. The bearing races are a permanent press fit in the housings and are NOT serviceable. If a bearing race becomes damaged, it will be necessary to replace the front or rear housing as necessary. In addition, if a countershaft bearing becomes damaged, it will be necessary to replace not only the bearing but the applicable housing as well. A new countershaft bearing will be supplied with each new housing for service use. The countershaft bearings can be installed backwards if care is not exercised. The bearing roller cage is a different diameter on each side. Be sure the bearing is installed so the large diameter side of the cage is facing the countershaft gear (Fig. 55). The small diameter side goes in the bearing race. Reverse Idler Components Inspect the idler gear, bearing, shaft, thrust washer, wave washer and thrust plate (Fig. 53). Replace the bearing if any of the needle bearing rollers are worn, chipped, cracked, flat-spotted, or brinnelled. Also replace the bearing if the plastic bearing cage is damaged or distorted. Replace the thrust washer, wave washer, or thrust plate if cracked, chipped, or worn. Replace the idler
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TRANSMISSION ASSEMBLY
Assembly Information Gaskets are not used in the NV3500 transmission. Sealers are used at all flange joints. Recommended sealers are Mopar Gasket Maker (or Loctite 518) for all flange joints and Loctite Ultra, heavy body silicone (black) sealer (or Mopar equivalent) for the input shaft bearing retainer. Apply these products as indicated in the reassembly procedures. It is very important that the transmission shift components be in Neutral position during assembly. This is necessary to prevent damaging synchro and shift components when the housings are installed. Transmission gears, shafts, and synchro components should all be lubricated with recommended gear lubricant during assembly operations. Petroleum jelly can be used to prelubricate bearings and to hold parts in place during assembly. Only petroleum jelly should be used. Do not use chassis or bearing grease. This type of heavy grease will plug oil channels in the housings and gears resulting in failure. The 3-4, 1-2 and fifth-reverse synchro hub snap rings can be fitted selectively. New snap rings are available in 0.05 mm (0.0019 in.) thickness increments. Use the thickest snap ring that will fit in each snap ring groove. Proper reassembly of the NV3500 requires some special service tools. Geartrain Assembly Fixture 6747 is especially important. The entire geartrain and shift mechanism must be assembled in this fixture before either transmission housing can be properly installed. The tools are needed to avoid damaging the gears, housing, or shift components.
CORRECT ASSEMBLY OF SYNCHRONIZER COMPONENTS The synchronizer sleeves, hubs and struts are different and must be kept in sets. Only the synchro detent balls and springs are interchangeable. The 3-4 and 1-2 synchro rings are all made of cast metal and are interchangeable. However, the reverse gear synchro ring is made of solid brass and must not be interchanged. A total of three detent springs, struts and balls are used in all three synchro assemblies. The balls and springs are interchangeable. The synchro sleeves and hubs must also be correctly positioned on the shaft in order to operate properly. Assemble and install each synchro according to the following instructions.
3-4 Synchro Position Some 3-4 synchro hubs may have a raised shoulder on one side of the spline bore. If so, this side of the hub must face the front of the output shaft after in-
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(5) Lubricate and install reverse gear needle bearing on shaft (Fig. 59). Slide bearing up against shoulder on output shaft as shown.
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(9) Start fifth-reverse synchro assembly on output shaft splines by hand. Then seat synchro onto shaft with shop press and suitable size pipe tool (Fig. 62).
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Fig. 69 First Gear Bearing Installation Fig. 67 Output Shaft Bearing Installation
(15) Install output shaft bearing snap ring (Fig. 68). Use heavy duty snap ring pliers and spread snap ring only enough to install it. Be sure snap ring is completely seated in shaft groove before proceeding.
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(29) Seat thrust washer retaining ring with plastic mallet (Fig. 80).
Fig. 82 Installing Third Gear Fig. 80 Seating Thrust Washer Retaining Ring
(30) Install third gear needle bearing on shaft (Fig. 81).
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side of 1-2 sleeve should be facing first gear. Tapered side of fifth-reverse sleeve should be facing forward.
REVERSE IDLER ASSEMBLY (FIG. 53) (1) Lubricate idler components with gear lube. (2) Slide idler gear bearing on shaft (Fig. 88). Bearing fits either way on shaft. (3) Slide gear onto shaft. Side of gear with recess goes to rear (Fig. 88). (4) Place first lock ball in dimple at rear end of idler shaft (Fig. 88). Petroleum jelly can be used to hold ball in place if desired.
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Fig. 99 Positioning Output Shaft Bearing Retainer For Rear Housing Installation
(13) Assemble 1-2 and fifth reverse-shift forks (Fig. 100). Arm of fifth-reverse fork goes through slot in 1-2 fork.
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Fig. 107 Removing Pilot Stud Tool And Installing Retainer Bolts (2-Wheel Drive Transmission) Fig. 105 Rear Housing Installation (2-Wheel Drive Transmission Shown)
(8) Seat rear housing on output shaft rear bearing and countershaft. Use plastic or rawhide mallet to tap housing into place. (9) Install three bolts that secure rear bearing retainer to rear housing as follows: (a) Apply Mopar Gasket Maker, or Loctite 518 to bolt threads, bolt shanks and under bolt heads (Fig. 106).
REAR ADAPTER HOUSING INSTALLATION (4-WHEEL DRIVE TRANSMISSION) (1) Install rear bearing in adapter housing. Use wood hammer handle or wood dowel to tap bearing into place. (2) Position rear bearing retainer in adapter housing (Fig. 108). (3) Apply Mopar Gasket Maker, or Loctite 518 to threads, bolt shanks and under hex heads of bearing retainer bolts (Fig. 109).
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Fig. 109 Installing Rear Bearing Snap Ring (4-Wheel Drive Transmission)
Fig. 108 Preparing Adapter Housing For Installation (4-Wheel Drive Transmission)
(4) Apply liberal quantity of petroleum jelly to countershaft rear bearing and bearing race. (5) Install countershaft rear bearing in bearing race (Fig. 104). CAUTION: The countershaft bearings can be installed backwards if care is not exercised. Be sure the large diameter side of the roller retainer faces the countershaft and the small diameter side faces the race and housing (Fig. 104). (6) Apply extra petroleum jelly to hold countershaft rear bearing in place when housing is installed. (7) Apply light coat of petroleum jelly to shift shaft bushing/bearing in adapter housing (Fig. 104). (8) Install adapter housing on geartrain. (9) Install rear bearing snap ring on output shaft (Fig. 109). (10) Lubricate lip of new rear seal (Fig. 110) with Mopar Door Ease, or transmission fluid. (11) Install new rear seal in adapter housing bore with suitable size tool. Be sure seal is fully seated in housing bore (Fig. 110).
REVERSE IDLER SEGMENT INSTALLATION (1) Apply Mopar Gasket Maker, or Loctite 518 sealer to underside of idler shaft bolt heads, bolt shanks and bolt threads (Fig. 106). (2) Align idler shaft and rear housing bolt holes with drift, pin punch, or phillips screwdriver. (3) Work segment upward into housing and onto idler shaft (Fig. 111).
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Fig. 114 Shift Shaft Installation Fig. 112 Installing Reverse Idler Shaft Bolts
SHIFT SHAFT, SHAFT LEVER AND BUSHING AND SHIFT SOCKET INSTALLATION (1) Remove geartrain and housing assembly from fixture with aid of helper. (2) Before proceeding, verify that all synchro sleeves are in Neutral position (centered on hub). Move sleeves into neutral if necessary.
CAUTION: The transmission synchros must all be in Neutral position for proper reassembly. Otherwise, the housings, shift forks and gears can be damaged during installation of the two housings. (3) Install 3-4 shift fork in synchro sleeve (Fig. 113). Verify that groove in fork arm is aligned with grooves in 1-2 and fifth-reverse fork arms as shown. (6) Assemble shift shaft shift lever and bushing (Fig. 115). Be sure slot in bushing is facing up and roll pin hole for lever is aligned with hole in shaft. (7) Install assembled lever and bushing on shift shaft (Fig. 116). (8) Slide shift shaft through 1-2 fork and part way into shift lever opening in rear housing (Fig. 117). (9) Align shift socket with shaft and slide shaft through socket and part-way into housing (Fig. 118). (10) Push shift shaft through fifth-reverse fork and into bushing in rear housing. Use plastic mallet to tap shaft into place if necessary. (11) Rotate shift shaft so detent notches in shaft are facing driver side of housing.
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Fig. 119 Roll Pin Identification (Shaft Lever And Shift Socket)
(13) Align roll pin holes in shift shaft, lever and bushing. Then start roll pin into shaft lever by hand (Fig. 120). (14) Seat shaft lever roll pin with pin punch (Fig. 121). CAUTION: The shaft lever roll pin must be flush with the surface of the lever. The lever bushing will bind on the roll pin if the pin is not seated flush. (15) Before proceeding, verify that lock pin slot in lever bushing is positioned as shown (Fig. 121).
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Fig. 124 Shaft Lever Positioned For Detent Ball and Spring Installation
(20) Insert detent spring in lever bore with pencil magnet (Fig. 125). (21) Install detent ball on top of spring in lever bore (Fig. 126). Use pencil magnet to hold ball in place.
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FRONT HOUSING AND INPUT SHAFT BEARING RETAINER INSTALLATION (1) Before proceeding, verify that all synchro are in Neutral position (centered on hub). Move sleeves into neutral if necessary.
CAUTION: The transmission synchros must all be in Neutral position during reassembly. Otherwise, the housings, shift forks and gears can be damaged during installation of the housings. (2) Apply liberal quantity of petroleum jelly to countershaft front bearing. Then insert bearing in front housing race (Fig. 128). Large diameter side of bearing cage goes toward countershaft (Fig. 129). Small diameter side goes toward bearing race in housing. (3) Reach into countershaft front bearing with finger, and push each bearing roller outward against race. Then apply extra petroleum jelly to hold rollers in place. This avoids having rollers becoming displaced during housing installation. This will result in misalignment between bearing and countershaft bearing hub. (4) Install input shaft bearing in front housing bore (Fig. 129). Use plastic mallet to seat bearing. Bearing goes in from front side of housing only. (5) Apply small amount of petroleum jelly to shift
Fig. 127 Correct Seating Of Lever Detent Ball In Shift Fork Arms
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Fig. 129 Input Shaft Bearing And Countershaft Front Bearing Installation
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(14) Lubricate then install shift shaft detent plunger in housing bore (Fig. 136). Lubricate plunger with petroleum jelly or gear lubricant. Be sure plunger is fully seated in detent notch in shift shaft.
Fig. 134 Installing Shift Shaft Bushing Lock Bolt CAUTION: If the lock bolt cannot be fully installed, do not try to force it into place. Either the shift shaft is not in Neutral, or the shaft bushing (or lever) is misaligned (Fig. 135).
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Fig. 142 Applying Sealer To Bearing Retainer And Housing Fig. 139 Installing Backup Light Switch
SHIFT LEVER INSTALLATION On Dakota models, the shift lever assembly cannot be installed until after the transmission is
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Fig. 145 Applying Sealer To Isolator And Plate Assembly Mounting Surface
is a one-way fit. Narrow side of plate goes on driver side of housing mounting surface and rubber coated side faces upward (Fig. 146). (3) Apply 1/8 to 3/16 in. wide bead of Mopar Gasket Maker, or Loctite 518 to metal side of isolator and plate assembly. (4) Install isolator and plate assembly on housing. (5) Apply petroleum jelly to ball end of shift lever and interior of shift socket. (6) Align and install shift lever assembly on isolator plate and in housing (Fig. 147). Be sure ball end of lever is properly seated in shift socket. (7) Install and tighten shift lever attaching bolts to 7-10 N m (5-7 ft. lbs.) torque. Bolts require an 8 mm socket. (8) Raise vehicle and fill transmission to bottom edge of fill plug hole with required lubricant. (9) Install and tighten fill plug to 19-27 N m (14-20 ft. lbs.) torque.
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42RH TRANSMISSION OVERHAUL . . . . . . . . . 147 42RH/46RH IN-VEHICLE SERVICE . . . . . . . . . 125 42RH/46RH OVERDRIVE UNIT OVERHAUL . . 238 46RH TRANSMISSION OVERHAUL . . . . . . . . . 193 AUTOMATIC TRANSMISSION CONTROLS AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 88
AUTOMATIC TRANSMISSION DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 285 TRANSMISSION - CONVERTER - OVERDRIVE REMOVAL/INSTALLATION . . . . . . . . . . . . . . 137
TRANSMISSION DESCRIPTION
Chrysler 42RH and 46RH automatic transmissions are 4-speed, fully automatic units with an overdrive fourth gear range. The 42RH is used with 3.9L V6 engines. The 46RH is used with 5.2L (V8) engines. The 42RH/46RH are dual unit designs. The assembly consists of a three speed automatic transmission with an overdrive unit attached at the rear (Figs. 1 and 2). The overdrive unit provides a fourth gear overdrive ratio of 0.69 to 1. First through third gear ranges are provided by the clutches, bands, overrunning clutch and planetary gear set in the transmission. The overdrive unit contains an overdrive clutch, direct clutch, compound planetary gear set and overrunning clutch. The 42RH/46RH valve body has an additional housing. This housing contains the extra valving and electrical solenoid that provide overdrive fourth gear range. The governor and park lock assemblies are located inside the overdrive unit. The overdrive unit must be removed and disassembled for service access to the park lock and governor components. Fourth gear is selected by a switch in the instrument panel. The switch is a signal device for the powertrain control module (PCM). When the switch is turned ON, it signals the PCM that overdrive range has been selected. The PCM will then energize the overdrive solenoid for a 3-4 upshift.
The transmission must be in D range, third gear before a 3-4 upshift will occur. The overdrive solenoid will not be energized by the PCM when the switch is in the OFF position.
TORQUE CONVERTER
A three element torque converter is used for all applications. The converter consists of an impeller, stator, and turbine. The converter also contains an overrunning clutch and converter clutch mechanism. A new converter is used with 42RH transmissions. It has new design drive flats in the hub instead of the square drive lugs used in previous models. The oil pump inner gear was also changed to accept the new drive flats. This converter is not interchangeable with older style converters and oil pump gears. The converter clutch consists of a piston, damper, and disc. The clutch provides optimum torque transfer and economy when applied. The clutch disc is located in the converter front cover. The piston and damper are attached to the turbine hub. The damper helps to smooth engine firing impulses and loads during converter clutch engagement. Clutch engagement is controlled by the converter clutch valve. The valve is located in the transmission valve body. Clutch engagement occurs in drive range at speeds above approximately 72-80 km/h (45-50 mph).
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RECOMMENDED FLUID
The recommended (and preferred) fluid for 42RH/ 46RH transmissions is Mopar ATF Plus, type 7176. Dexron II is not really recommended and should only be used when ATF Plus is not available.
TRANSMISSION IDENTIFICATION
Transmission identification numbers are stamped on the left side of the case just above the oil pan gasket surface (Fig. 3). The first letter/number group is the transmission part number. The next number group is the build date and the last number group is the serial number. Refer to this information when ordering replacement parts.
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The boost valve tube retainer has been lengthened and an extra tab added to better secure the tube. This change affects 42RH and 46RH transmissions. The thrust plate and front annulus in 42RH transmissions has changed. The thrust plate now has two locating tabs and the annulus support hub has been remachined to accomodate the new plate. Plastic check balls are now being used in some valve bodies. The new check balls entered production as a running change. The plastic and steel check balls are not interchangeable. A converter drainback check valve has been added to the fluid cooler system. The one-way valve is located in the transmission outlet (pressure) line. The valve prevents fluid drainback when the vehicle is parked for lengthy periods. 42RH output shaft for 2WD models has ground outside diameters and must not be interchanged. In addition, 46RH models have a rear servo check ball (in the transfer plate). A new boost valve tube retainer with 2 tabs is also used on 42RH/46RH/
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AUTOMATIC TRANSMISSION CONTROLS AND OPERATION AUTOMATIC TRANSMISSION CONTROLS AND OPERATION INDEX
page page Overdrive Selector Switch . . . . Pressure Regulation . . . . . . . . Quick Fill Valve Operation . . . . Shift Valve Flow Control . . . . . Transmission Hydraulic Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 89 89 89 88
3-4 Shift Sequence . . . . . . Boost Valve Operation . . . . Clutch and Band Application Converter Clutch Control . . Converter Drainback Valve Gearshift Mechanism . . . .
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88 89 90 90 89 88
relieving spring load on the clutch pack. The clutch is disengaged once spring load is relieved. The 3-4 accumulator cushions overdrive clutch engagement to smooth the transition into fourth gear. The accumulator is charged at the same time as apply pressure acts against the overdrive piston.
GEARSHIFT MECHANISM
The gear shift mechanism provides six shift positions which are: park (P) reverse (R) neutral (N) drive (D) manual second (2) manual low (1) Manual low (1) range provides first gear only. Overrun braking is also provided in this range. Manual second (2) range provides first and second gear only. Drive range provides first, second third and overdrive fourth gear ranges. The shift into overdrive fourth gear range occurs only after the transmission has completed the shift into D third gear range. No further movement of the shift mechanism is required to complete the 3-4 shift. The fourth gear upshift occurs automatically when the overdrive selector switch is in the ON position.
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AUTOMATIC TRANSMISSION DIAGNOSIS AND TESTING AUTOMATIC TRANSMISSION DIAGNOSIS AND TESTING INDEX
page Air Testing Transmission Clutch and Band Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Analyzing the Road Test . . . . . . . . . . . . . . . . . . . . 93 Causes of Burned Fluid . . . . . . . . . . . . . . . . . . . . . 92 Checking Fluid Level and Condition . . . . . . . . . . . . 91 Converter Housing Fluid Leak Diagnosis . . . . . . . . 97 Converter Stall Test . . . . . . . . . . . . . . . . . . . . . . . . 96 Diagnosis Charts . . . . . . . . . . . . . . . . . . . . . . . . . 100 Effects of Incorrect Fluid Level . . . . . . . . . . . . . . . 92 Fluid Contamination . . . . . . . . . . . . . . . . . . General Information . . . . . . . . . . . . . . . . . . Hydraulic Pressure Test . . . . . . . . . . . . . . . Overdrive Fourth Gear Electrical Controls . . Preliminary Diagnosis . . . . . . . . . . . . . . . . . Road Testing . . . . . . . . . . . . . . . . . . . . . . . Stall Test Analysis . . . . . . . . . . . . . . . . . . . . Transmission Cable and Linkage Adjustment . . . . . . . .
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GENERAL INFORMATION
Begin diagnosis by checking the easily accessible items such as fluid level, fluid condition and throttle cable/shift linkage adjustments. A road test will determine if further diagnosis is necessary. Procedures outlined in this section should be performed in the following sequence to realize the most accurate results: (1) preliminary diagnosis (2) fluid Level and condition (3) leak checks (if fluid level is low) (4) throttle and shift linkage adjustment (5) overdrive control switch test (6) road test (7) stall test (8) hydraulic pressure test (9) air pressure tests (10) analyze test results (11) refer to diagnosis charts
VEHICLE IS DISABLED (1) Check fluid level and condition. (2) Check for broken, disconnected shift linkage. (3) Check for cracked, leaking cooler lines, or loose, missing pressure port plugs. (4) Raise vehicle, start engine, shift transmission into gear and note following: (a) If propeller shaft turns but wheels do not, problem is with differential or axle shafts. (b) If propeller shaft does not turn and transmission is noisy, stop engine. Remove oil pan, and check for debris. If pan is clear, remove transmission and check for damaged drive plate, converter, oil pump, input shaft, planetary gear, clutches. (c) If propeller shaft does not turn and transmission is not noisy, perform hydraulic pressure test to determine if problem is hydraulic or mechanical.
PRELIMINARY DIAGNOSIS
Two basic procedures are required. One procedure for vehicles that are driveable and an alternate procedure for disabled vehicles (will not back up or move forward).
VEHICLE IS DRIVEABLE (1) Check fluid level and condition. (2) Check throttle cable and gearshift linkage adjustments if complaint was based on delayed, erratic, or harsh shifts. (3) Road test vehicle and note how transmission engages, upshifts, downshifts. (4) Perform stall test if complaint is based on sluggish acceleration or if abnormal throttle opening is needed to maintain normal speeds with a properly tuned engine. (5) Perform hydraulic pressure test if shift problems were noted during road test. (6) Perform air pressure test to check clutch-band operation if hydraulic pressure test is inconclusive.
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(7) Remove dipstick and check fluid level as follows: (a) Dipstick has three fluid level indicator levels (Fig. 1) which are a MIN dot, an OK crosshatch area, and a MAX fill arrow. (b) Correct maximum level is to MAX arrow mark. Correct acceptable level is to OK mark in crosshatch area. (c) Incorrect level is at or below MIN dot. (d) If fluid is low, add only enough Mopar ATF Plus to restore correct level. Do not overfill. CAUTION: Do not overfill the transmission. Overfilling may cause leakage out the pump vent which can be mistaken for a pump seal leak. Overfilling will also cause fluid aeration and foaming as the excess fluid is picked up and churned by the gear train. This will significantly reduce fluid life. (8) If transmission is overfilled, fluid can be removed with 1/8 to 3/16 in. diameter tubing and suction gun. Tubing will have to be adapted to nozzle of gun and be long enough to extend down fill tube and into transmission oil pan.
FLUID CONTAMINATION
Fluid contamination is generally a result of: adding incorrect fluid failure to clean dipstick and fill tube when checking level engine coolant entering fluid internal failure that generates debris overheat that generates sludge (fluid breakdown) failure to reverse flush cooler and lines after repair failure to replace contaminated converter during repair The use of non-recommended fluids can result in transmission failure. The usual results are erratic shifts, slippage, abnormal wear and eventual failure due to fluid breakdown and sludge formation. Avoid this condition by using recommended fluids only. The dipstick cap and fill tube should be wiped clean before checking fluid level. Dirt, grease and other foreign material on the cap and tube could fall into the tube if not removed beforehand. Take the time to wipe the cap and tube clean before withdrawing the dipstick. Engine coolant in the transmission fluid is generally caused by a cooler malfunction. The only remedy is to replace the radiator as the cooler in the radiator is not a serviceable part. If coolant has circulated through the transmission for some time, an overhaul may also be necessary; especially if shift problems had developed. The transmission cooler and lines should be reverse flushed whenever a malfunction generates sludge and/or debris. The torque converter should also be replaced at the same time.
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Slippage indicated by engine flare, usually means clutch, band or overrunning clutch problems. If the condition is advanced, an overhaul may be necessary to restore normal operation. A slipping clutch or band can often be determined by comparing which internal units are applied in the various gear ranges. The Clutch and Band Application chart (Fig. 2) provides a basis for analyzing road test results.
ROAD TESTING
Before road testing, be sure the fluid level and all linkage adjustments have been checked and adjusted if necessary. Observe engine performance during the road test. A poorly tuned engine will not allow an accurate analysis of transmission operation. Operate the transmission in all gear ranges. Check for shift variations and engine flare, which indicates slippage. Note if shifts are harsh, spongy, delayed, early, or if part throttle downshifts are sensitive.
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(3) Move selector lever to D range. This is two detents rearward from full forward position. (4) Read pressures on both gauges as transmission throttle lever is moved from full forward to full rearward position. (5) Line pressure should be 54-60 psi (372-414 kPa) with throttle lever forward and gradually increase as lever is moved rearward. (6) Front servo is pressurized only in D range and should be same as line pressure within 3 psi (21 kPa) up to downshift point. Test FourTransmission In Reverse This test checks pump output, pressure regulation and the front clutch and rear servo circuits. Use 300 psi Test Gauge C-3293-SP for this test. (1) Connect 300 psi gauge to rear servo port (Fig. 3). (2) Start and run engine at 1600 rpm for test. (3) Move valve body selector lever four detents rearward from the full forward position. This is Reverse range. (4) Move throttle lever all way forward then all way rearward and note gauge readings. (5) Pressure should be 145 - 175 psi (1000-1207 kPa) with lever forward and increase to 230 - 280 psi (1586-1931 kPa) as lever is moved rearward. Test FiveGovernor Pressure This test checks governor operation by measuring governor pressure response to changes in engine speed. It is usually not necessary to check governor operation unless shift speeds are incorrect or if the transmission will not downshift. (1) Connect 100 psi Test Gauge C-3292 to governor pressure port (Fig. 3). (2) Move shift lever to D range. (3) Start and run engine at curb idle speed and note pressure. At idle and with vehicle stopped, pressure should be zero to 1-1/2 psi maximum. If pressure exceeds this figure, governor valve or weights are sticking open. (4) Slowly increase engine speed and observe speedometer and pressure test gauge. Governor pressure should increase in proportion to vehicle speed. Or approximately 1 psi for every 1 mph. (5) Pressure rise should be smooth and drop back to 0 to 1-1/2 psi when wheels stop rotating. (6) Compare results of pressure tests with analysis chart (Fig. 4). Test SixTransmission In Overdrive Fourth Gear This test checks line pressure at the overdrive clutch in fourth gear range. Use 300 psi Test Gauge C-3292 for this test. (1) Raise vehicle on hoist.
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(2) Connect test gauge C-3292 to overdrive clutch pressure port (Fig. 3). (3) Lower vehicle to enough to allow entry into drivers seat. Leave vehicle wheels approximately one foot off shop floor. (4) Secure test gauge where it can be viewed from drivers seat. Use extra length of pressure hose to connect gauge if necessary. (5) Start engine and shift into D range. (6) Verify that overdrive switch is in ON position. (7) Record gauge pressure at closed throttle. Then gradually increase engine rpm until 3-4 shift occurs and record gauge pressure again. CAUTION: If the vehicle is being tested on a hoist, do not use more than 1/2 throttle. This necessary to avoid overspeeding and possibly damaging the engine, or axle. (8) Pressure should be 469-496 kPa (68-72 psi) at closed throttle and increase to 620-827 kPa (90-120 psi) at 1/2 throttle. Maximum shift pressure (896 kPa/130 psi) requires 3/4 to full throttle to obtain. This pressure should only be checked when the vehicle is on the road or on a chassis dyno. (9) Refer to test analysis chart (Fig. 4), after completing test.
STALL TEST PROCEDURE (1) Connect tachometer to engine. Position tachometer so it can be viewed from driver seat. (2) Check transmission fluid level. Add fluid if necessary. (3) Drive vehicle to bring transmission fluid up to normal operating temperature. Vehicle can be driven on road, or on chassis dyno if shop is so equipped. (4) Block front wheels. (5) Fully apply service and parking brakes. (6) Open throttle completely and record maximum engine rpm registered on tachometer. It takes 4-10 seconds to reach max rpm. However, once max
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FRONT CLUTCH AIR TEST Place one or two fingers on the clutch housing and apply air pressure through front clutch apply passage (Fig. 8). Piston movement can be felt and a soft thud heard as the clutch applies. REAR CLUTCH AIR TEST Place one or two fingers on the clutch housing and apply air pressure through rear clutch apply passage (Fig. 5). Piston movement can be felt and a soft thud heard as the clutch applies. FRONT SERVO AIR TEST Apply air pressure to the front servo apply passage. The servo rod should extend and cause the band to tighten around the drum. Spring tension should release the servo when air pressure is removed. REAR SERVO AIR TEST Apply air pressure to the rear servo apply passage. The servo rod should extend and cause the band to tighten around the drum. Spring tension should release the servo when air pressure is removed.
LEAK DIAGNOSIS PROCEDURE (1) Raise rear of vehicle and allow accumulated fluid to drain out of converter housing. (2) Check and adjust transmission fluid level. (3) Raise vehicle. Remove converter housing dust cover and wipe as much fluid as possible from converter housing.
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DIAGNOSIS CHARTS
The diagnosis charts provide additional reference when diagnosing a transmission fault. The charts provide general information on a variety of transmission, overdrive and converter fault conditions. The hydraulic flow charts outline fluid flow and hydraulic circuitry. Circuit flow is provided for all gear ranges. Approximate working pressures are also supplied for each gear range.
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(5) Shift transmission momentarily into all gear ranges. Then shift transmission back to Neutral. (6) Clean top of filler tube and dipstick to keep dirt from entering tube. (7) Remove dipstick and check fluid level as follows: (a) Dipstick has three fluid level indicator levels (Fig. 1) which are a MIN dot, an OK crosshatch area, and a MAX fill arrow. (b) Correct maximum level is to MAX arrow mark. Correct acceptable level is to OK mark in crosshatch area. (c) Incorrect level is at or below MIN dot. (d) If fluid is low, add only enough Mopar ATF Plus restore correct level. Do not overfill. CAUTION: Do not overfill the transmission. Overfilling may cause leakage out the pump vent which can be mistaken for a pump seal leak. Overfilling will also cause fluid aeration and foaming as the excess fluid is picked up and churned by the gear train. This will significantly reduce fluid life.
RECOMMENDED FLUID
Recommended (and preferred) fluid for 42RH/46RH transmissions is Mopar ATF Plus, type 7176. Dexron II is not really recommended and should only be used when ATF Plus is not available.
FLUID LEVEL CHECK PROCEDURE (1) Transmission fluid must be at normal operating temperature for accurate fluid level check. Drive vehicle if necessary to bring fluid temperature up to normal hot operating temperature of 82C (180F). (2) Position vehicle on level surface. This is extremely important for accurate fluid level check. (3) Start and run engine at curb idle speed. (4) Apply parking brakes.
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SEVERE USAGE CHANGE INTERVAL Under severe usage, the fluid and filter should be changed and the bands adjusted at 12,000 mile (19 000 Km) intervals. Severe usage is defined as: (a) More than half of vehicle operation occurs in heavy city traffic during hot weather (above 90 F). (b) Vehicle is used for taxi, police, limousine, or similar commercial operation. (c) Vehicle is used for trailer towing or heavy load hauling. FLUID/FILTER REPLACEMENT PROCEDURE (1) Raise vehicle. (2) Remove oil pan and drain fluid. (3) Clean oil pan and pan magnet. Then clean remaining gasket material from gasket surface of transmission case. (4) Remove fluid filter screws and remove filter. (5) Position new filter on valve body and install filter screws. Tighten screws to 4 N m (35 in. lbs.) torque. (6) Adjust rear band at this time if required.
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SHIFT LINKAGE ADJUSTMENT PROCEDURE Check condition of the shift linkage (Fig. 2) before adjustment. Do not attempt adjustment if any parts are worn, loose, or bent. Replace the linkage grommets and bushing if the linkage exhibits excessive play. Replace the torque shaft, brackets, or shift rods if bent, or binding. If either shift rod must be disconnected, replace the grommet securing the rod in the torque shaft arm. Disconnect the rods with a pry tool. Pry only where the grommet and rod attach and not on the rod itself. Then cut away the old grommet. Use pliers to snap the new grommet into the lever and to snap the rod into the grommet. (1) Shift transmission into Park. (2) Raise vehicle. (3) Loosen lock bolt in front shift rod adjusting swivel (Fig. 3). (4) Be sure front shift rod slides freely in swivel. Lube rod and swivel if necessary. (5) Move transmission shift lever fully rearward into Park detent. Then center adjusting swivel in torque shaft grommet and tighten swivel lock bolt to 90 in. lbs. (10 N m) torque. (6) Lower vehicle and check shift linkage adjustment. Engine should only start in Park and Neutral position. If engine starts in any position other than Park or Neutral, adjustment is incorrect or park/neutral position switch is faulty.
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(2) Disconnect indicator cable from steering column (Fig. 5). (3) Reset cable adjuster mechanism by pulling cable downward and quickly releasing it. Repeat the pull/release action 5 or 6 times to be sure mechanism is reset. (4) Reconnect indicator cable to steering column. Be sure cable retainer clip is seated in column bracket (Fig. 5). (5) Shift into Park position. (6) Verify correct pointer alignment.
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(5) Press cable button inward to release cable (Fig. 6). Button only has to move about 2 mm (0.070 in.) to release cable. (6) Center cable end on attachment stud to within 1 mm (0.039 in.) and release cable button (Fig. 8). (7) Check cable adjustment. Be sure transmission throttle lever and lever on throttle body move simultaneously as described in cable adjustment checking procedure.
ADJUSTMENT PROCEDURE (1) Raise vehicle. (2) Loosen band adjusting screw locknut. Then back locknut off 4-5 turns. (3) Be sure adjusting screw turns freely in case. Lubricate screw threads with Mopar spray lube, LPS all purpose spray lube, or equivalent quality product. (4) Tighten band adjusting screw to 8 N m (72 in. lbs.) torque with inch pound Torque Wrench C-3380-A, a 3-in. extension and 5/16 socket (Fig. 9).
CAUTION: If Adapter C-3705 is needed to reach the adjusting screw (Fig. 10), tighten the screw to only 5 N m (47-50 in. lbs.) torque. (5) Back off front band adjusting screw as follows: 2-1/4 turns on 42RH 2-7/8 turns on 46RH (6) Hold adjuster screw in position and tighten locknut to 41 N m (30 ft. lbs.) torque. (7) Lower vehicle.
THROTTLE VALVE CABLE ADJUSTMENT PROCEDURE (1) Turn ignition switch to OFF position. (2) Remove air cleaner. (3) Disconnect cable end from attachment stud. Carefully slide cable off stud. Do not pry or pull cable off. (4) Verify that transmission throttle lever is in fully closed position. Then be sure lever on throttle body is at curb idle position.
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SPEEDOMETER INSTALLATION AND INDEXING (1) Thoroughly clean adapter flange and adapter mounting surface in housing. Surfaces must be clean for proper adapter alignment and speedometer operation. (2) Install new O-rings on speed sensor and speedometer adapter if necessary (Fig. 13). (3) Lubricate sensor and adapter O-rings with transmission fluid. (4) Install vehicle speed sensor in speedometer adapter. Tighten sensor attaching screw to 2-3 N m (15-27 in. lbs.) torque. (5) Install speedometer pinion in adapter. (6) Count number of teeth on speedometer pinion. Do this before installing assembly in housing. Then lubricate pinion teeth with transmission fluid. (7) Note index numbers on adapter body (Fig. 13). These numbers will correspond to number of teeth on pinion. (8) Install speedometer assembly in housing. (9) Rotate adapter until required range numbers are at 6 o-clock position. Be sure range index numbers correspond to number of teeth on pinion gear. (10) Install speedometer adapter clamp and retaining screw. Tighten clamp screw to 10-12 N m (90-110 in. lbs.) torque. (11) Connect wires to vehicle speed sensor. (12) Lower vehicle and top off transmission fluid level if necessary.
SPEEDOMETER SERVICE
Rear axle gear ratio and tire size determine pinion gear requirements. If the gear must be replaced, refer to the parts catalogue information for the correct gear.
SPEEDOMETER ASSEMBLY REMOVAL (1) Raise vehicle. (2) Disconnect wires from vehicle speed sensor.
SWITCH TEST (1) Verify that gearshift linkage is correctly adjusted before testing. Switch will not operate properly if linkage adjustment is incorrect. (2) To test switch, remove wiring connector. Then test continuity between center terminal and trans-
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PARK/NEUTRAL POSITION SWITCH REPLACEMENT (1) Raise vehicle and position drain pan under switch. (2) Disconnect switch wires and remove switch from case.
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(4) Position new seal in housing and orient notch in seal flange to top. Then tap seal into place with Installer Tool C-3995-A or C-3972-A (Fig. 16). (5) Smooth surface of propeller shaft slip yoke with 400 grit paper if necessary. Clean yoke surface with solvent and wipe clean with shop cloth. (6) Lubricate slip yoke and new seal with liberal quantity of Mopar multi mileage grease or petroleum jelly. (7) Carefully guide propeller shaft slip yoke through seal, into housing and onto output shaft splines. (8) Align and connect propeller shaft U-joint to axle yoke. Tighten clamp strap bolts to 19 N m (170 in. lbs.) torque. (9) Lower vehicle.
VALVE BODY REMOVAL (1) Shift transmission into Neutral. (2) Raise vehicle. (3) Remove gearshift and throttle levers from shaft of valve body manual lever. (4) Disconnect and remove neutral switch. (5) Disconnect valve body overdrive and converter clutch solenoid wires at case connector. (6) Position drain pan under transmission oil pan. (7) Remove transmission oil pan and gasket. (8) Remove fluid filter from valve body. (9) Push valve body solenoid wire connector out of case. (10) Remove valve body attaching bolts. (11) Lower valve body slightly and remove accumulator piston and accumulator inner and outer springs. (12) Push manual lever shaft and solenoid case connector out of transmission case. Lower valve body, rotate it away from case, pull park rod out of sprag and remove valve body (Fig. 17).
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(16) Install throttle and gearshift levers on valve body manual lever shaft. (17) Check and adjust front and rear bands if necessary. (18) Connect valve body overdrive and converter clutch solenoid wires to case connector. (19) Install oil pan and new gasket. Tighten pan bolts to 17 N m (13 ft. lbs.) torque. (20) Lower vehicle and fill transmission with Mopar ATF Plus, type 7176 fluid. (21) Check and adjust gearshift linkage and throttle cable if necessary.
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CONNECTING COOLER LINES (BOTH TYPES) (1) If transmission or radiator fittings require replacement, apply Mopar Lock N Seal, or Loctite 242 to fitting threads before installation. (2) Wipe off cooler line and fitting with clean, dry cloth. (3) Insert cooler line into fitting. Then push line inward until retainer secures line. A snap or click sound will be heard and felt when the retainer seats. (4) Pull outward on cooler lines to verify they are properly secured.
CAUTION: It is extremely important to verify cooler line seating as described in step (4). If the fitting clips or lock tabs are not seated, normal fluid pressure could unseat the lines resulting in fluid loss and transmission damage.
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(or hose) into cooler return line. Then force mineral spirits into line and through cooler. (5) Continue reverse flushing until fluid coming out of cooler pressure line is clear. Replace cooler if fluid cannot be pumped through. (6) Clear flushing materials from cooler and lines with short pulses of compressed air. Insert air gun nozzle into cooler return line and continue short air pulses until all fluid is cleared from cooler and lines. (7) Pump one quart of fresh automatic transmission fluid through cooler and lines before reconnecting lines. (8) Install new drainback valve in pressure line. (9) Check and adjust transmission fluid level as described in this section.
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(8) Position cooler on radiator and install cooler attaching U-nuts and screws. (9) Tighten cooler hose clamps securely. (10) Install grille and air conditioning condenser. (11) Check and adjust transmission fluid level. (12) If air conditioning condenser lines were disconnected during service, evacuate and recharge system.
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GENERAL INFORMATION
The entire transmission assembly must be removed in order to service the torque converter, driveplate, and oil pump. The overdrive unit can be removed and serviced separately. It is not necessary to remove the entire transmission assembly to service the overdrive unit. CAUTION: The transmission and torque converter must be removed as an assembly to avoid component damage. The converter drive plate, pump bushing, or oil seal can be damaged if the converter is left attached to the driveplate during removal. Be sure to remove the transmission and converter as an assembly.
(10) Remove converter bolts. Rotate engine in clockwise direction with socket wrench on damper bolt. Rotate engine until each converter bolt becomes accessible then remove bolts. (11) Mark propeller shaft U-joints and axle yokes for assembly alignment. Then disconnect and remove propeller shafts. (12) Disconnect wires at park/neutral position switch, solenoid harness connector, vehicle speed sensor (Fig. 1). Then unclip wire harnesses from clamps and straps attaching harnesses to transmission and transfer case.
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(20) Remove bolts attaching torque converter to drive plate. (21) Disconnect cooler lines at transmission. Refer to In-Vehicle Service section for procedures. (22) Disconnect wire harnesses at solenoid connector, park/neutral position switch, and vehicle speed sensor (Fig. 1). Then remove wire harnesses from clamps and straps securing harnesses to transmission and transfer case. (23) Remove transmission fill tube and dipstick. (24) Lower transmission for access to converter housing upper bolts. (25) Remove bolts attaching transmission converter housing to engine. Note that some bolts are accessible only from front (engine) side of housing. (26) Move transmission rearward until clear of engine block dowels. On some models, part of hem flange joining vehicle cab and dash panel may interfere with transmission removal. Peen this part of flange over with a mallet if necessary. (27) Secure torque converter in housing with small C-clamp. (28) Lower transmission and remove it from under vehicle. (29) Remove C-clamp and remove converter from transmission. Place converter on workbench for inspection or reassembly. Cover converter hub with clean, lint free cloth. (30) Oil pump, converter and driveplate can now be serviced if necessary. Refer to information in this section.
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(25) Connect cooler lines to transmission fittings. Refer to In-Vehicle Service section for procedures. (26) Install transmission fill tube (Fig. 7). Install new seal on tube before installation in transmission case. (27) Install engine-to-transmission struts, if equipped (Fig. 7). Tighten strut-to-transmission bolts first and to 17 N m (150 in. lbs.) torque. Tighten strut-to-engine bolts last and to 41 N m (30 ft. lbs.) torque. (28) Install exhaust components. (29) Align and install propeller shaft. (30) Remove supports and lower vehicle. (31) Adjust gearshift and throttle valve linkages. (32) Refill or top off transmission with Mopar ATF Plus, type 7176 fluid.
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(43) Refill transmission with Mopar ATF Plus, type 7176 fluid. (44) Check and adjust engine oil level as necessary. (45) Connect battery negative cable. (46) Check and adjust transmission and transfer case linkage if necessary.
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CAUTION: The overdrive unit must be supported before moving it rearward. This is necessary to prevent damaging the intermediate shaft. Do not allow the shaft to support the entire weight of the overdrive unit.
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(6) Disconnect vacuum switch hoses at transfer case, if equipped. (7) Disconnect transfer case shift linkage at transfer case range lever. Then remove linkage bracket bolts and remove linkage and bracket from transfer case. Move linkage aside for clearance. (8) Remove nuts attaching transfer case to transmission adapter housing. (9) Remove transfer case with aid of helper. Support transfer case with transmission jack. Move transfer case rearward, tilt it away from fixed (welded) rear crossmember and work it out from between transmission and crossmember. (10) Support transmission with transmission jack. (11) Remove nuts and bolts attaching transmission mount to center crossmember. (12) Remove bolts and nuts attaching center crossmember to frame rails. Rotate crossmember diagonally and remove crossmember. (13) Support overdrive unit with transmission jack. (14) Remove bolts/nuts attaching overdrive unit to transmission. CAUTION: The overdrive unit must be supported during removal. This is necessary to prevent damaging the intermediate shaft. Do not allow the shaft to support the entire weight of the overdrive unit. (15) Carefully slide overdrive unit off intermediate shaft. Do not tilt overdrive unit during removal. Keep it as level as possible. (a) If overdrive unit does not require service, immediately insert Alignment Tool 6227-2 in splines of planetary gear and overrunning clutch (Fig. 11). If misalignment occurs, overdrive unit will have to be disassembled in order to realign splines. (b) If overdrive unit requires service, refer to Overdrive Unit Overhaul procedures. (16) Remove and retain bearing and select fit spacer. These parts may remain on overdrive piston, rear of transmission case, sliding hub, or intermediate shaft during removal. (17) Place several clean shop towels on a bench. Then position unit on towels to absorb spilled fluid. (18) Position overdrive unit over drain pan and tilt unit to drain residual fluid from case. Examine fluid for clutch material or metal fragments. If fluid contains these items, overhaul will be necessary.
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(2) If original case gasket is in good condition, proceed to step (6). If overdrive piston retainer was not removed during service and original case gasket is not reusable, prepare new gasket as described in steps (3) through (5). (3) Cut out old case gasket around piston retainer with razor knife. (4) Use old gasket as template and trim new gasket to fit. (5) Position new gasket over piston retainer and on transmission case. Use petroleum jelly to hold gasket in place if necessary. Do not use any type of sealer to secure gasket. Use petroleum jelly only. (6) Install selective spacer on intermediate shaft, if removed. Spacer goes in groove just rearward of shaft rear splines. (7) Install overdrive piston in retainer, if removed. Lubricate piston seals with Mopar Door Ease, RuGlyde, or petroleum jelly to ease installation. Be sure piston locating lugs are aligned in piston retainer. (8) Install thrust bearing in overdrive clutch hub. Use liberal quantity of petroleum jelly to hold bearing in position. CAUTION: Be sure the shoulder on the inside diameter of the bearing is facing forward. (9) Install thrust plate in overdrive piston hub. Use liberal amount of petroleum jelly to hold thrust plate in position. (10) Verify that splines in overdrive planetary gear and overrunning clutch hub are aligned with Tool 6227-2. Overdrive unit cannot be fully installed if splines have rotated out of alignment. If misaligned has occurred, overdrive will have to be disassembled in order to realign splines. (11) Raise overdrive unit and carefully slide it straight onto intermediate shaft. Insert park rod into
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TRANSMISSION DISASSEMBLY
(1) Remove torque converter if not previously removed. (2) Clean transmission exterior with steam gun or with solvent. Wear eye protection during cleaning operations. (3) Remove shift and throttle levers from valve body manual lever shaft. (4) Remove bolts attaching overdrive unit to transmission (Fig. 1). Note bolt locations as some attaching bolts are different lengths.
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Fig. 4 Overdrive Spline Alignment Tool Installation Fig. 7 Park/Neutral Position Switch Removal/ Installation
(11) Remove oil pan bolts and remove oil pan and gasket. Note location of oil pan magnet for assembly reference (Fig. 8).
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(21) Loosen front band adjusting screw until band is completely loose. (22) Squeeze front band together and remove band strut (Fig. 15).
Fig. 19 Separating Front/Rear Clutch Assemblies Fig. 17 Removing/Installing Front Band Lever
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OVERRUNNING CLUTCH ASSEMBLY (1) Install clutch rollers in spring retainer (Fig. 33). Be sure springs are seated squarely against rollers.
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(3) Loosen bolts that attach pump body to support (Fig. 37).
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OIL PUMP AND REACTION SHAFT SUPPORT CLEANING AND INSPECTION Clean pump and reaction shaft support components with solvent and dry them with compressed air. Inspect the pump housing and support components. Replace the housing or support if the seal ring grooves or machined surfaces are worn, scored, pitted, or damaged. Replace the pump gears if pitted, worn chipped, or damaged. Inspect the thrust washer for wear or damage. Replace the washer if necessary. Note that the inner gear used in 1993 and later 42RH oil pumps has a new design drive lug. The new design incorporates drive flats instead of the square lug used previously. The torque converter hub has also been redesigned to accept the new drive. If pump gear replacement is necessary, be very sure to order and install the new style gears. Inspect the pump and reaction shaft support bushings. Minor bushing wear is acceptable. Replace the bushings only if scored, or severely worn.
REPLACING OIL PUMP BUSHING (1) Remove pump bushing with Tool Handle C-4171 and Bushing Remover SP-3551 (Fig. 44).
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Fig. 42 Measuring Pump Housing-To-Inner Gear Clearances Fig. 45 Staking Oil Pump Bushing
REPLACING REACTION SHAFT SUPPORT BUSHING (1) Assemble Bushing Remover Tools SP-1191, 3633 and 5324 (Fig. 46). Do not clamp any part of reaction shaft or support in vise. (2) Hold Cup Tool SP-3633 firmly against reaction shaft and thread remover SP-5324 into bushing as far as possible by hand. Then thread remover tool 3-4 additional turns into bushing with a wrench. (3) Turn remover tool hex nut down against remover cup to pull bushing from shaft. Clean all chips from shaft after bushing removal. (4) Lightly grip old bushing in vise or with pliers and back remover tool out of bushing. (5) Assemble Bushing Installer Tools C-4171 and SP-5325 (Fig. 46). (6) Slide new bushing onto Installer Tool SP-5325. (7) Position reaction shaft support upright on a clean smooth surface. (8) Align bushing in bore. Then tap bushing into place until Bushing Installer SP-5325 bottoms. (9) Clean reaction shaft support thoroughly after installing bushing.
Fig. 44 Removing Oil Pump Bushing Fig. 46 Replacing Reaction Shaft Support Bushing
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ASSEMBLING OIL PUMP AND REACTION SHAFT SUPPORT (1) Lubricate gear bore in pump housing with transmission fluid. (2) Lubricate pump gears with transmission fluid. (3) Support pump housing on wood blocks (Fig. 47). (4) Install outer gear in pump housing (Fig. 47). Gear can be installed either way (it is not a one-way fit).
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(2) Compress clutch piston spring with Compressor Tool C-3575-A (Fig. 53). Be sure legs of tool are seated squarely on spring retainer before compressing spring. (3) Remove retainer snap ring and remove compressor tool.
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(6) Remove seals from clutch piston and clutch retainer hub. Discard both seals as they are not reusable.
FRONT CLUTCH INSPECTION Clean the front clutch components in solvent and dry them with compressed air only. Do not use rags or shop towels to dry any of the clutch parts. Lint from such materials will adhere to the component surfaces and could restrict or block fluid passages after assembly. Replace the clutch discs if warped, worn, scored, burned or charred, or if the facing is flaking off. Replace the steel plates if heavily scored, warped, or broken. Be sure the driving lugs on the plates are in good condition. The lugs must not be bent, cracked or damaged in any way. Replace the clutch spring and spring retainer if either is distorted, warped or broken. Check the lug grooves in the clutch retainer. The steel plates should slide freely in the slots. Replace the retainer if the grooves are worn or damaged. Check action of the check ball in the retainer (Fig. 54). The ball must move freely and not stick. Inspect the clutch retainer bushings carefully (Fig. 55). The retainer bushings are NOT serviceable. It will be necessary to replace the retainer if either bushing is scored, or worn. Inspect the piston and retainer seal surfaces for nicks or scratches. Minor scratches can be removed with crocus cloth. However, replace the piston and/or retainer if the seal surfaces are seriously scored.
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Fig. 62 Removing Input Shaft From Rear Clutch Retainer Fig. 61 Removing/Installing Input Shaft Snap Ring
if obviously damaged. The input shaft front seal ring is teflon with chamfered ends. The rear ring is metal with interlocking ends. Check the input shaft for wear, or damage. Replace the shaft if worn, scored or damaged in any way. (a) Be sure clutch hub retainer seal ring is fully seated in groove (Fig. 63). Ring must not be twisted, or distorted. (b) Note that input shaft front seal ring is teflon and rear seal ring is metal (Fig. 64). Be sure chamfered ends of teflon ring are properly joined and that ends of rear ring are securely hooked together. (c) Lubricate retainer and shaft seal rings with light coat of petroleum jelly after installation.
REAR CLUTCH ASSEMBLY (1) Soak clutch discs in transmission fluid. (2) Install new seal rings on clutch retainer hub and input shaft (Figs. 63 and 64).
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Fig. 63 Installing Rear Clutch Retainer And Input Shaft Seal Rings
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(10) Install bottom pressure plate (Fig. 60). Ridged side of plate faces downward (toward piston) and flat side toward clutch pack. (11) Install first clutch disc in retainer on top of bottom pressure plate. Then install a clutch plate followed by a clutch disc until entire clutch pack is installed. 4 clutch discs and 3 metal plates are required. (12) Install top pressure plate (Fig. 60). (13) Install selective snap ring (Fig. 60). Be sure snap ring is fully seated in retainer groove. (14) Measure clutch pack clearance (Fig. 67). Clearance should be 0.64 to 1.14 mm (0.025 to 0.045 in.). If clearance is incorrect, steel plates, discs, snap ring and pressure plates may have to be changed (Fig. 53).
PLANETARY GEARTRAIN INSPECTION Clean the planetary components in solvent and dry them with compressed air. Check sun gear and driving shell condition. Replace the gear if damaged or if the bushings are scored or worn. The bushings are not serviceable. Replace the driving shell if worn, cracked or damaged. Replace planetary gear sets if gears, pinion pins, or carrier are damaged in any way. Replace the annulus gears and supports if either component is worn or damaged. Inspect the geartrain spacers, thrust plates, snap rings, and thrust washers. Replace any part that is worn or damaged. Do not attempt to reuse these parts. Inspect the intermediate shaft carefully. Pay particular attention to the machined bushing/bearing surfaces on the shaft. Replace the intermediate shaft if any machined surfaces are scored, pitted, or damaged in any way. Also replace the shaft if the splines are damaged, or exhibits cracks at any location. Be sure the select spacer groove on the shaft is in good condition. Trial fit the spacer if necessary.
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Fig. 71 Installing Assembled Rear Annulus And Planetary Gear On Intermediate Shaft
Fig. 75 Installing Sun Gear And Rear Thrust Plate In Driving Shell
Fig. 73 Installing Sun Gear Spacer Fig. 76 Supporting Sun Gear On Wood Block
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Fig. 79 Installing Rear Thrust Washer On Front Planetary Gear Fig. 77 Installing Sun Gear Lock Ring
(13) Install assembled driving shell and sun gear on intermediate shaft (Fig. 78).
Fig. 78 Installing Assembled Sun Gear And Driving Shell On Intermediate Shaft
(14) Install rear thrust washer on front planetary gear (Fig. 79). Use enough petroleum jelly to hold washer on gear and be sure washer tabs are all properly seated. (15) Assemble front annulus gear and support if necessary. (16) Position thrust plate on front annulus gear support (Fig. 80). Use liberal quantity of petroleum jelly to hold plate in place. (17) Install front planetary gear on intermediate shaft and in driving shell (Fig. 81). (18) Install front thrust washer on front planetary gear (Fig. 81). Use enough petroleum jelly to hold washer in place on gear and be sure washer tabs are seated.
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FRONT BAND AND SERVO INSPECTION Clean the servo components with solvent and dry them with compressed air. Inspect the servo components. Replace the springs if collapsed, distorted or broken. Replace the guide,
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ASSEMBLING REAR SERVO PISTON (1) Assemble piston plug, cushion spring and piston (Fig. 88). (2) Compress cushion spring in vise and install piston plug snap ring (Fig. 87). (3) Install new seal on piston. Be sure seal lip is toward servo bore (Fig. 89). (4) Lubricate piston seal with petroleum jelly. Lubricate other servo parts with transmission fluid.
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Fig. 107 Removing Transfer Plate From Upper Housing Fig. 105 Boost Valve Tube Removal
(19) Turn valve body over so valve lower housing is facing upward (Fig. 106). In this position, check balls in upper housing will remain in place and not fall out when lower housing and transfer plate are removed. (20) Remove screws attaching valve body lower housing to upper housing and transfer plate (Fig. 106). Note position of boost valve tube brace for assembly reference. (21) Remove lower housing and overdrive separator plate from transfer plate (Fig. 106).
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VALVE BODY LOWER HOUSING DISASSEMBLY (FIG. 116) (1) Remove timing valve cover. (2) Remove 3-4 timing valve and spring. (3) Remove 3-4 quick fill valve, spring and plug. (4) Remove 3-4 shift valve and spring. (5) Remove converter clutch valve, spring and plug. (6) Remove converter clutch timing valve, retainer and valve spring. 3-4 ACCUMULATOR HOUSING DISASSEMBLY (FIG. 117) (1) Remove end plate from housing. (2) Remove piston spring.
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Fig. 123 Securing Boost Valve Tube With Tube Brace Tabs
3-4 Accumulator Installation (1) Position converter clutch valve and 3-4 shift valve springs in housing (Fig. 123). (2) Loosely attach accumulator housing with rightside screw (Fig. 124). Install only one screw at this time as accumulator must be free to pivot upward for ease of installation.
Fig. 124 Installing Converter Clutch And 3-4 Shift Valve Springs
(3) Position plug on end of converter clutch valve spring. Then compress and hold springs and plug in place with fingers of one hand. (4) Swing accumulator housing upward over valve springs and plug. (5) Hold accumulator housing firmly in place and install remaining two attaching screws. Be sure springs and clutch valve plug are properly seated (Fig. 125).
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VALVE BODY CONTROL PRESSURE ADJUSTMENTS There are two control pressure adjustments on the valve body which are, line pressure and throttle pressure. Line and throttle pressure work together as each affects shift quality and timing. Both adjustments must be performed properly and in the correct sequence. Line pressure is adjusted first and throttle pressure is adjusted last.
Line Pressure Adjustment Measure distance from the valve body to the inner edge of the adjusting screw with an accurate steel scale (Fig. 128). Distance should be 33.4 mm (1-5/16 inch).
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The kickdown valve spring must be fully compressed and the kickdown valve completely bottomed to obtain correct adjustment.
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with wood blocks, or cut a hole in the bench large enough for the intermediate shaft. Then lower the shaft through the hole and support the transmission case directly on the bench.
TRANSMISSION ASSEMBLY PROCEDURE (1) Install rear servo piston, spring and retainer (Fig. 130). Install spring on top of servo piston and install retainer on top of spring.
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Fig. 137 Rear Band Installation Fig. 135 Overrunning Clutch Installation
(7) Verify that non-threaded hole in clutch cam is properly aligned. Check alignment by threading a bolt into each bolt hole. Adjust clutch cam position if necessary. (8) Install and tighten overrunning clutch cam bolts to 17 N m (13 ft. lbs.) torque. Note that clutch cam bolts are shorter than piston retainer bolts. (9) Lubricate clutch cam rollers with transmission fluid. (10) Install rear band reaction pin (Fig. 136). Be sure pin is fully seated in case. (a) Lubricate overrunning clutch race (on drum hub) with transmission fluid. (b) Guide drum through rear band. (c) Tilt drum slightly and start race (on drum hub) into overrunning clutch rollers. (d) Press drum rearward and turn it in clockwise direction until drum seats in overrunning clutch (Fig. 138). (e) Turn drum back and forth. Drum should rotate freely in clockwise direction and lock in counterclockwise direction (as viewed from front of case).
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overdrive piston retainer. Center hole in gasket is smaller than retainer and cannot be installed over retainer.
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(22) Coat intermediate shaft thrust washer with petroleum jelly. Then install washer in rear clutch hub (Fig. 148). Use enough petroleum jelly to hold washer in place. Be sure grooved side of washer faces rearward as shown. Also note that washer only fits one way in clutch hub.
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Fig. 155 Installing Oil Pump Assembly In Case Fig. 153 Reaction Shaft Support Seal Rings And Front Clutch Thrust Washer Position
(33) Thread two Pilot Stud Tools C-3288-B into bolt holes in oil pump flange (Fig. 154). (34) Align and install oil pump gasket (Fig. 154). (35) Lubricate oil pump body seal with Ru-Glyde, or petroleum jelly. Lubricate pump shaft seal lip with petroleum jelly. (36) Install oil pump (Fig. 155). Align and position pump on pilot studs. Slide pump down studs and (38) Install new seals on overdrive piston. Then lubricate seals with Ru-Glyde, Door-Eze or petroleum jelly. (39) Install overdrive piston in retainer. Align locating lugs on piston in locating bores in retainer (Fig. 156). Use thin plastic strip or feeler gauge to help guide piston outer seal into retainer. (40) Install spacer on intermediate shaft, if not previously installed.
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Fig. 159 Checking Alignment Of Overdrive Planetary Gear And Overrunning Clutch Splines
(45) Carefully withdraw alignment tool from overdrive unit. (46) Lubricate intermediate shaft splines and bushing surfaces with transmission fluid or petroleum jelly. (47) Install overdrive unit. Be sure governor tubes are aligned with feed holes in piston retainer boss. Note that intermediate shaft is snug fit in overdrive planetary gear and overrunning clutch. If overdrive unit will not seat fully, rotate overdrive output shaft slightly to align splines and try again.
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(b) Align and seat valve body on case. Be sure manual lever shaft and overdrive connector are fully seated in case. (c) Install and start all valve body attaching bolts by hand. Then tighten bolts evenly, in a diagonal pattern to 12 N m (105 in. lbs.) torque. Do not overtighten valve body bolts. This could result in distortion and cross leakage after installation.. (53) Install new filter on valve body. Tighten filter screws to 4 N m (35 in. lbs.). (54) Adjust front and rear bands as follows: (a) Loosen band adjusting screw locknuts. (b) Tighten each band adjusting screw to 5 N m (72 in. lbs.) with torque wrench. (c) Back off front band adjusting screw 2-1/4 turns. (d) Back off rear band screw 4 turns. (e) Tighten each adjusting screw locknut. Hold adjusting screws with wrench to prevent turning when tightening locknut. (55) Install seal on park/neutral position switch (Fig. 162). Then install and tighten switch to 34 N m (25 ft. lbs.).
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CAUTION: The transmission cooler and lines must be reverse flushed if overhaul corrected a malfunction that generated sludge, metal particles, or clutch friction material. The torque converter and drain back valve should also be replaced if contaminated by the same malfunction. Debris and residue not flushed from the cooler and lines will flow back into the transmission and converter. The result could be a repeat failure and shop comeback.
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page Planetary Geartrain Overhaul . . . . . . . . . . . . . . . . Rear Clutch Overhaul . . . . . . . . . . . . . . . . . . . . . Rear Servo Overhaul . . . . . . . . . . . . . . . . . . . . . Transmission Assembly . . . . . . . . . . . . . . . . . . . . Transmission Case Cleaning and Inspection . . . . Transmission Disassembly . . . . . . . . . . . . . . . . . Valve Body Cleaning and Inspection . . . . . . . . . . Valve Body Service and Adjustment . . . . . . . . . . . 211 210 204 229 200 193 223 217
TRANSMISSION DISASSEMBLY
(1) Remove torque converter, if not previously removed. (2) Clean transmission exterior with steam gun or solvent. Wear safety goggles while cleaning transmission. (3) Remove shift and throttle levers from shaft of valve body manual lever. (4) Remove bolts attaching overdrive unit to transmission case (Fig. 1).
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Fig. 19 Installing Oil Pump Remover Tools Fig. 16 Accumulator Component Removal
Fig. 17 Removing/Installing Front Band Lever Pin Access Plug (46RH) Fig. 20 Oil Pump Removal
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(26) Remove intermediate shaft thrust washer. Triangular shaped washer will either be on shaft pilot hub or in rear clutch retainer (Fig. 26). (27) Remove thrust plate from intermediate shaft hub (Fig. 27). (28) Remove intermediate shaft-planetary geartrain assembly (Fig. 28). Set assembly aside for disassembly and inspection later in procedure.
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Fig. 34 Removing Rear Band And Link Fig. 32 Removing Overrunning Clutch Assembly
(34) Remove rear band adjusting lever, reaction lever and pin (Fig. 33). (35) Remove strut from rear band. Keep strut with levers and pin for cleaning, inspection and assembly reference. (36) Remove rear band and link (Fig. 34). (37) Compress front servo rod guide with large Cclamp and Tool C-4470, or Compressor Tool C-3422-B (Fig. 35). Compress guide only enough to permit snap ring removal (about 1/8 in.). (38) Remove servo piston snap ring (Fig. 35). Unseat one end of ring. Then carefully work removal tool around back of ring until free of ring groove. Exercise caution when removing snap ring. Servo bore can be scratched or nicked if care is not exercised.
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(39) Remove tools and remove servo piston and spring. (40) Compress rear servo piston with C-clamp and Tool C-4470, or Valve Spring Compressor C-3422-B (Fig. 36). Compress servo spring retainer only enough to permit snap ring removal. (41) Remove servo piston snap ring (Fig. 36). Start one end of ring out of bore. Then carefully work removal tool around back of snap ring until free of ring groove. Exercise caution when removing snap ring. Servo bore can be scratched or nicked if care is not exercised. (42) Remove tools and remove rear servo retainer, spring and piston assembly.
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or length of thin plastic to remove the old seals. Do not use metal tools as they can scratch, or score the seal grooves. Clean the piston and retainer in solvent but do not use any type of caustic materials for cleaning. Such materials may etch the piston surfaces causing damage. Inspect the piston and retainer carefully. Replace either part if cracked, porous or damaged in any way. Check condition of the locating lugs on the piston. Be sure the lugs are in good condition and are not worn, chipped or broken. Inspect the check ball in the piston (Fig. 39). Be sure the ball is secure and is not partially dislodged, or loose. Replace the piston if doubt exists about piston or check ball condition. Check the governor feed tube boss in the retainer. Be sure the boss is in good condition and is not damaged in any way. Carefully work new piston seals into place by hand. Apply a liberal coating of Mopar Door Ease, or RuGlyde to the seals to ease installation. Then cover the piston with paper or clean plastic sheeting to keep it dust free for assembly installation.
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drum hub splines. Replace the drum and race as an assembly if the race is loose on the hub splines. Examine the overrunning clutch assembly carefully. Replace assembly if the rollers, springs, or cage-type retainer are worn, or damaged. If the clutch cam requires replacement, install a new cam as described in the following procedure.
OVERRUNNING CLUTCH CAM REPLACEMENT (1) Tap old cam out of case with pin punch. Insert punch through bolt holes at rear of case (Fig. 40). Alternate position of punch to avoid cocking cam during removal.
OVERRUNNING CLUTCH INSTALLATION (1) Lubricate overdrive piston retainer hub, clutch race, clutch cam, and overrunning clutch rollers with transmission fluid. (2) If any overrunning clutch rollers or springs came out of retainer, reinstall them as follows: Install and seat spring in retainer first. Then insert roller between spring and retainer stop as shown (Fig. 46). Verify that each roller and spring are fully seated before proceeding.
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Fig. 43 Assembling Clutch Cam Puller Bolt And Press Plate (46RH)
ACCUMULATOR OVERHAUL
Inspect the accumulator piston and seal rings (Fig. 48). Replace the seal rings if worn or cut. Replace the piston if chipped or cracked.
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Fig. 49 Front Servo Components (46RH) Fig. 47 Overrunning Clutch Seated In Cam (46RH)
REAR SERVO PISTON OVERHAUL (FIG. 50) (1) Remove small snap ring and remove plug and spring from servo piston. (2) Remove and discard servo piston seal ring. (3) Lubricate piston and guide seals with petroleum jelly. Lubricate other servo parts with Mopar ATF Plus transmission fluid. (4) Install new seal ring on servo piston. (5) Assemble piston, plug, spring and new snap ring. (6) Lubricate piston seal lip with petroleum jelly. (7) Set servo components aside for assembly installation.
FRONT SERVO PISTON OVERHAUL (FIG. 49) (1) Remove seal ring from rod guide. (2) Remove small snap ring from servo piston rod. Then remove piston rod, spring and washer from piston. (3) Remove and discard servo component O-ring and seal rings. (4) Lubricate new O-ring and seal rings with petroleum jelly and install them on piston, guide and rod. (5) Install rod in piston. Install spring and washer on rod. Compress spring and install snap ring. (6) Set servo components aside for installation during transmission reassembly.
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INSPECTING PUMP AND SUPPORT Clean pump and support components with solvent and dry them with compressed air.
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Inspect the pump and support components. Replace the pump or support if the seal ring grooves or machined surfaces are worn, scored, pitted, or damaged. Replace the pump gears if pitted, worn chipped, or damaged. Check the pump vent (Fig. 54). The vent must be secure. Replace the pump body if the vent is cracked, broken, or loose. Inspect the pump bushing (Fig. 54). Then check the reaction shaft support bushing. Replace either bushing only if heavily worn, scored or damaged. It is not necessary to replace the bushings unless they are actually damaged. Install the gears in the pump body and measure end clearance with a feeler gauge and straightedge (Fig. 55). Straightedge should be resting on pump body as shown: End clearance between outer gear and straightedge should be 0.010 to 0.063 mm (0.0004 to 0.0025 in.). End clearance between inner gear and straightedge should be 0.025 to 0.177 mm (0.001 to 0.007 in.). Measure tip clearances with feeler gauge (Fig. 56): Clearance between inner gear tooth and outer gear should be 0.08 to 0.19 mm (0.0035 to 0.0075 in.). Clearance between outer gear and pump housing should also be 0.010 to 0.19 mm (0.0035 to 0.0075 in.).
Fig. 56 Checking Pump Gear Tip Clearance Fig. 54 Pump Vent And Bushing Location
OIL PUMP BUSHING REPLACEMENT (FIG. 57) (1) Position pump housing on clean, smooth surface with gear cavity facing down. (2) Remove bushing with Tool Handle C-4171 and Bushing Remover SP-3550. (3) Assemble Tool Handle C-4171 and Bushing Installer SP-5118. (4) Place bushing on installer tool and start bushing into shaft.
(5) Tap bushing into place until Installer Tool SP5118 bottoms in pump cavity. Keep tool and bushing square with bore. Do not allow bushing to become cocked during installation. (6) Stake pump bushing in two places with blunt punch. Remove burrs from stake points with knife blade (Fig. 58).
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(7) Start bushing in shaft. Tap bushing into shaft until installer tool bottoms against support flange. (8) Clean reaction shaft support thoroughly after bushing replacement (to remove any chips).
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FRONT CLUTCH RETAINER BUSHING REPLACEMENT (FIG. 63) (1) Assemble Tool Handle C-4171 and Bushing Remover SP-3629. (2) Insert remover tool in bushing and drive bushing straight out of clutch retainer. (3) Mount Bushing Installer SP-5511 on tool handle. (4) Slide new bushing onto installer tool and start bushing into retainer. (5) Tap new bushing into place until installer tool bottoms against clutch retainer. (6) Remove installer tools and clean retainer thoroughly. FRONT CLUTCH ASSEMBLY (1) Soak clutch discs in transmission fluid. (2) Install new inner and outer seals on clutch piston. Be sure seal lips face interior of retainer. (3) Lubricate new inner and outer piston seals with Ru-Glyde, or Mopar Door Ease. (4) Install clutch piston in retainer. Use twisting motion to seat piston in bottom of retainer. A thin strip of plastic (about 0.015 - 0.020 in. thick), can be used to guide seals into place if necessary.
CAUTION: Never push the clutch piston straight in. This will fold the seals over causing leakage and clutch slip. In addition, never use any type of metal tool to help ease the piston seals into place. Metal tools will cut, shave, or score the seals. (5) Install and position clutch piston springs (Fig. 64). 46RH has 9 spring front clutch. (6) Install spring retainer on top of piston springs.
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REAR CLUTCH INSPECTION Clean the clutch components with solvent and dry them with compressed air. Check condition of the input shaft seal rings. It is not necessary to remove or replace rings unless they are broken, cracked, or no longer securely hooked together. Inspect the input shaft splines and machined surfaces. Very minor nicks or scratches can be smoothed off with crocus cloth. replace the shaft if the splines are damaged, or any of the machined surfaces are severely scored. Replace the clutch discs if warped, worn, scored, burned/charred, the lugs are damaged, or if the facing is flaking off. Replace the steel plates and the pressure plate if heavily scored, warped, or broken. Be sure the driving lugs on the discs and plates are also in good condition. The lugs must not be bent, cracked or damaged in any way. Replace the piston spring and wave spring if either part is distorted, warped or broken. Check the lug grooves in the clutch retainer. The steel plates should slide freely in the slots. Replace
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INPUT SHAFT REPLACEMENT If the input shaft must be replaced, first remove the retaining ring that secures the shaft in the piston retainer hub. Then press the old shaft out of the retainer with a shop press. Lubricate the splines of the new shaft with petroleum jelly or ATF Plus. Then align the shaft in the piston retainer and carefully press it into place. Do not allow the shaft to become cocked during installation. The retainer can be cracked if misalignment occurs. Install the shaft retaining ring after pressing the shaft into place. Be sure the ring is fully seated before proceeding with clutch assembly. REAR CLUTCH ASSEMBLY (1) Soak clutch discs in transmission fluid before assembly. (2) Install new seals on clutch piston. Lubricate piston seals with Mopar Door Ease, or Ru-Glyde to ease installation. Be sure seal lips face input shaft. (3) Install clutch piston in retainer. Use twisting motion to seat piston in bottom of retainer. A thin strip of plastic (about 0.020 thick), can be used to guide seals into place if necessary.
CAUTION: Never push the clutch piston straight in. This will fold the seals over causing leakage and clutch slip. In addition, never use any type of metal tool to help ease the piston seals into place. Metal tools will cut, shave, or score the seals. (4) Assemble piston retainer and clutch retainer. (5) Support clutch retainer with wood blocks, or insert input shaft through predrilled hole in workbench. Clutch pack components are easier to install if retainers are properly supported. (6) Install piston spring in clutch retainer. Concave side of spring faces upward and away from clutch piston. (7) Install spacer ring on top of piston spring.
(8) Install wave spring on top of spacer ring. Then seat wave spring in retainer groove. If wave spring will not seat properly, spacer ring has probably shifted over and into wave spring groove in retainer. Use small screwdriver to realign spacer ring if necessary. (9) Install inner pressure plate in clutch retainer. (10) Install first clutch disc followed by steel plate until all discs and plates are installed. 4 clutch discs and steel plates are required (Fig. 66). (11) Install reaction plate on top of last clutch disc. (12) Install selective snap ring to secure clutch pack in retainer. (13) Install new seal rings on input shaft if necessary (Fig. 67). Be very sure ring ends are all securely hooked together before proceeding.
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PLANETARY GEARTRAIN CLEANING AND INSPECTION Clean the intermediate shaft and planetary components (Fig. 77) in solvent and dry them with compressed air. Inspect the planetary gear sets and annulus gears. The planetary pinions, shafts, washers, and retaining
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pins are serviceable. However, if a pinion carrier is damaged, the entire planetary gear set must be replaced as an assembly. Replace the annulus gears if the teeth are chipped, broken, or worn, or the gear is cracked. Replace the planetary thrust plates and the tabbed thrust washers if cracked, scored or worn. Inspect the machined surfaces of the intermediate shaft. Be sure the oil passages are open and clear. Replace the shaft if scored, pitted, or damaged. Inspect the sun gear and driving shell (Fig. 77). If either component is worn or damaged, remove the sun gear rear retaining ring and separate the sun gear and thrust plate from the driving shell. Then replace the necessary component. Replace the sun gear as an assembly if the gear teeth are chipped or worn. Also replace the gear as an assembly if the bushings are scored or worn. The sun gear bushings are not serviceable. Replace the thrust plate if worn, or severely scored. Replace the driving shell if distorted, cracked, or damaged in any way. Replace all snap rings during geartrain assembly. Reusing snap rings is not recommended.
PLANETARY GEARTRAIN ASSEMBLY AND ADJUSTMENT (1) Lubricate sun gear and planetary gears with transmission fluid during assembly. Use petroleum jelly to lubricate intermediate shaft bushing surfaces, thrust washers and thrust plates and to hold these parts in place during assembly. (2) Install front snap ring on sun gear and install gear in driving shell. Then install thrust plate over sun gear and against rear side of driving shell (Fig. 78). Install rear snap ring to secure sun gear and thrust plate in driving shell.
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(9) Install tabbed thrust washer in driving shell (Fig. 84). be sure washer tabs are seated in tab slots of driving shell. Use extra petroleum jelly to hold washer in place if desired.
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(11) Install front annulus gear over and onto front planetary gear (Fig. 86). Be sure gears are fully meshed and seated.
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Fig. 94 Detent Ball And Spring Removal Fig. 91 Boost Valve Components
(3) Secure detent ball and spring with Retainer Tool 6583 (Fig. 92). (4) Remove E-clip that secures throttle lever in manual lever (Fig. 93). (5) Lift and rotate manual lever far enough to clear detent housing. (7) Remove washer at top of manual lever shaft. Then lift manual lever and park rod assembly upward and out of valve body (Fig. 95). (8) Remove throttle lever from valve body housing (Fig. 96). (9) Remove park rod E-clip and separate rod from manual lever (Fig. 97).
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(20) Remove screws attaching valve body lower housing to upper housing and transfer plate. Note position of boost valve tube brace for assembly reference. (21) Remove lower housing and overdrive separator plate from transfer plate (Fig. 106).
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VALVE BODY LOWER HOUSING DISASSEMBLY (FIG. 116) (1) Remove timing valve cover. (2) Remove 3-4 timing valve and spring. (3) Remove quick fill valve, spring, and plug. (4) Remove 3-4 shift valve and spring. (5) Remove converter clutch valve, spring and plug. (6) Remove converter clutch timing valve, retainer and valve spring. 3-4 ACCUMULATOR HOUSING DISASSEMBLY (FIG. 117) (1) Remove end plate from housing. (2) Remove piston spring.
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Fig. 122 Securing Boost Valve Tube With Tube Brace Tabs
Fig. 123 Installing Converter Clutch And 3-4 Shift Valve Springs
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(5) Hold accumulator housing firmly in place and install remaining two attaching screws. Be sure springs and clutch valve plug are properly seated (Fig. 124).
VALVE BODY CONTROL PRESSURE ADJUSTMENTS There are two control pressure adjustments on the valve body which are, line pressure and throttle pressure. Line and throttle pressures are interdependent because each affects shift quality and timing. As a result, both adjustments must be performed properly and in the correct sequence. Adjust line pressure first and throttle pressure last.
Line Pressure Adjustment Measure distance from the valve body to the inner
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Maintain pressure against kickdown valve spring. Turn throttle lever stop screw until the screw head touches throttle lever tang and the throttle lever cam touches gauge tool. The kickdown valve spring must be fully compressed and the kickdown valve completely bottomed to obtain correct adjustment.
TRANSMISSION ASSEMBLY
Assembly Tips Do not allow dirt, grease, or foreign material to enter the case or transmission components during assembly. Keep the transmission case and components clean. Also make sure the tools and workbench area used for reassembly operations are equally clean. Shop towels used for wiping off tools and your hands must be made from lint free materials. Lint will stick to transmission parts and could interfere with valve operation or even restrict fluid passages. Lubricate transmission clutch and gear components with Mopar ATF Plus during reassembly. Soak clutch discs in transmission fluid before installation. Use Mopar Door Ease, or Ru-Glyde on piston seals and O-rings to ease installation. Petroleum jelly can also be used to lubricate and hold thrust washers and plates in position during assembly. Do not use chassis grease, bearing grease, white grease, or similar lubricants on any part. These types of lubricants can eventually block or restrict fluid passages and valve operation. Use petroleum jelly only. Do not force parts into place. The transmission components and sub-assemblies are easily installed by hand when properly aligned. If a part seems difficult to install, it is either misaligned or incorrectly assembled. Verify that thrust washers, thrust plates and seal rings are correctly positioned. These parts will prevent proper assembly is mispositioned (or left out by accident). The planetary geartrain, front/rear clutch assem-
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blies and oil pump are all much easier to install when the transmission case is upright or as close to this position as possible. Either tilt the case upward with wood blocks, or cut a hole in the bench large enough for the intermediate shaft and rear support. Then lower the shaft and support into the hole and support the rear of the case directly on the bench.
FRONT/REAR SERVO INSTALLATION (1) Lubricate rear servo piston seal with Mopar Door Ease or ATF Plus. Lubricate servo bore in case with ATF Plus. (2) Install rear servo piston in case. Position piston at slight angle to bore and insert piston with twisting motion (Fig. 129).
Fig. 132 Installing Front Servo Piston Fig. 130 Installing Rear Servo Piston Spring And Retainer
(4) Compress rear servo piston with C-clamp or Valve Spring Compressor C-3422-B and install servo piston snap ring (Fig. 131). (7) Bottom front servo piston in bore and install servo spring. (8) Install front servo piston rod guide as follows: (a) Place Tool SP-5560 (or similar size tool) on guide and position C-clamp on tool and case (Fig. 133).
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(2) Install overdrive piston retainer. Be sure governor tube bores in retainer are aligned with governor feed passages in gasket and case (Fig. 135). Install and tighten retainer bolts to 17 N m (13 ft. lbs.) torque.
Fig. 133 Installing Front Servo Rod Guide And Snap Ring
OVERRUNNING CLUTCH, REAR BAND, LOW-REVERSE DRUM, AND OVERDRIVE PISTON RETAINER INSTALLATION (1) Install new gasket at rear of transmission case. Use petroleum jelly to hold gasket in place. Be sure to align governor feed holes in gasket with feed passages in case (Fig. 134). Install gasket before overdrive piston retainer. Center hole in gasket is smaller than retainer and cannot be installed over retainer.
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(5) Install low-reverse drum (Fig. 137). Slide drum through rear band, onto piston retainer hub and into engagement with overrunning clutch and race.
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Fig. 141 Installing Intermediate Shaft And Planetary Geartrain Fig. 143 Input Shaft Seal Ring And Thrust Washer Installation
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Fig. 147 Front Band And Linkage Installation Fig. 145 Installing Intermediate Shaft Thrust Washer
(2) Install new oil pump gasket on pilot studs and seat it in case. Be sure gasket is properly aligned with fluid passages in case (Fig. 148).
OIL PUMP INSTALLATION (1) Install oil pump Pilot Studs C-3288-B in case (Fig. 148).
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Fig. 150 Reaction Shaft Seal Ring And Thrust Washer Installation
(5) Lubricate oil pump seals with petroleum Mopar ATF Plus. (6) Mount oil pump on pilot studs and slide pump into case opening (Fig. 151). Work pump into case by hand. Do not not use a mallet or similar tools to seat pump. (7) Remove pilot studs and install oil pump bolts. Tighten pump bolts alternately and evenly to fully seat pump in case. Then final-tighten pump bolts to 20 N m (15 ft. lbs.) torque. (8) Verify correct installation. Rotate input and intermediate shafts and check for bind. If bind exists, components are either misassembled, or not seated. Disassemble and correct as necessary before proceeding.
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Fig. 155 Checking Alignment Of Overdrive Planetary Gear And Overrunning Clutch Splines
(11) Apply 1-2 drops of Mopar Lock N Seal (or Loctite 242) to overdrive unit attaching bolts. Then install and tighten bolts to 34 N (25 ft. lbs.) torque.
INPUT SHAFT END PLAY CHECK (1) Check input shaft end play as follows. (2) Attach dial indicator to converter housing (Fig. 156). Position indicator plunger against input shaft and zero indicator. (3) Move input shaft in and out and record reading. (4) End play should be 0.86 - 2.13 mm (0.034 0.084 in.). (5) If end play is incorrect, change intermediate shaft thrust washer. The thrust washer controls end play and is available in three thicknesses for adjustment purposes. BAND ADJUSTMENTS AND INSTALLATION OF ACCUMULATOR, VALVE BODY, OIL PAN, AND TORQUE CONVERTER (1) Install accumulator inner spring, piston and outer spring (Fig. 157).
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Direct Clutch and Geartrain Assembly . . . . . . Governor Overhaul . . . . . . . . . . . . . . . . . . . . Overdrive Clutch Installation and Adjustment . Overdrive Component Cleaning and Inspection
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(11) Remove geartrain assembly from housing (Fig. 11). Set geartrain aside.
Fig. 12 Front Bearing Locating Ring And Governor Support Snap Ring Location
(13) Remove governor support and tube assembly from case (Fig. 13). (14) Remove park pawl retaining bolt and reaction plug snap ring (Fig. 14). Compress snap ring only enough to remove it. Snap ring can be distorted if overcompressed. (15) Remove park pawl shaft, park pawl, pawl spring and reaction plug (Fig. 14). (16) Remove output shaft rear bearing snap ring (Fig. 15). Remove snap ring with long jaw internal type snap ring pliers. Or, rotate snap ring until one end is adjacent to notch in case. Then unseat ring with extra long flat blade screwdriver. (17) Remove rear bearing by tapping overdrive case on wood block to dislodge bearing.
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(16) Remove overrunning clutch assembly with external type snap ring pliers (Fig. 27). Insert pliers into clutch hub. Expand pliers to grip hub splines and remove clutch with counterclockwise, twisting motion.
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(19) Mark position of annulus gear and direct clutch drum for assembly alignment reference (Fig. 29). Use small center punch or scriber to make alignment marks.
Fig. 29 Marking Direct Clutch Drum And Annulus Gear For Assembly Alignment
(20) Remove direct clutch drum rear retaining ring (Fig. 30).
Fig. 32 Marking Annulus Gear And Output Shaft For Assembly Alignment
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Check the bushings in the overdrive case. Replace the bushings if severely scored or worn. Also replace the case seal if loose, distorted, or damaged. Examine the overdrive and direct clutch discs and plates (Fig. 34). Replace the discs if the facing is worn, severely scored, or burned and flaking off. Replace the clutch plates if worn, heavily scored, or cracked. Check the lugs on the clutch plates for wear. The plates should slide freely in the drum. Replace the plates or drum if binding occurs. Check condition of the annulus gear, direct clutch hub, clutch drum and clutch spring (Fig. 34). Replace the gear, hub and drum if worn or damaged. Replace the spring if collapsed, distorted, or cracked. Be sure the splines and lugs on the gear, drum and hub are in good condition. The clutch plates and discs should slide freely in these components. Inspect the thrust bearings and spring plate (Fig. 34). Replace the plate if worn or scored. Replace the bearings if rough, noisy, brinnelled, or worn. Inspect the planetary gear assembly and the sun gear and bushings (Fig. 34). If either the sun gear or the bushings are damaged, replace the gear and bushings as an assembly. The gear and bushings are not serviced separately.
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GOVERNOR OVERHAUL
Governor Changes 1992 and later overdrive units have an aluminum governor valve and different output shaft; the shaft is spotfaced for valve end clearance. The aluminum
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GOVERNOR DISASSEMBLY (1) Remove snap ring and washer that retain governor weight assembly in governor body (Fig. 38). (2) Remove governor weight assembly from governor body. (3) Note position of governor body on drive for installation reference.
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(4) Clamp edge of governor drive in vise equipped with brass protective jaws. Then loosen governor body attaching bolts. (5) Remove bolts attaching governor body to drive. (6) Remove governor body (Fig. 39). (7) Remove filter from governor drive. Note position of filter for assembly reference (Fig. 39).
GOVERNOR ASSEMBLY (1) Lubricate governor components with Mopar ATF Plus transmission fluid during assembly. (2) Install new seal rings on governor drive as follows: (a) Compress (squeeze) each seal over center before installation (Fig. 41); this provides tighter ring fit on drive. (b) Carefully work seal into each groove of drive. Avoid overspreading seals during installation to ensure tight fit.
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(5) Install retainer washer and snap ring that secure governor weight assembly in governor body (Fig. 67).
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(9) Apply 1-2 drops of Loctite Wick N Lock to threads of governor body attaching bolts. Then tighten bolts to 11 N m (8 ft. lbs.) torque. (10) Install output shaft rear bearing in case and install bearing snap ring. Be sure snap ring is fully seated. (11) Position park pawl and spring in case and install park pawl shaft (Fig. 14). Verify that spring end is hooked to pawl and straight end of spring (12) Install pawl shaft retaining bolt. Tighten bolt to 27 N m (20 ft. lbs.) torque. (13) Install park lock reaction plug. Note that plug has locating pin at rear (Fig. 69). Be sure pin is seated in hole in case before installing snap ring. (14) Install reaction plug snap ring (Fig. 70). Compress snap ring only enough for installation; do not distort it.
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(4) Install (5) Install plate. (6) Install same order. (7) Install (8) Install (Fig. 77).
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General Information . . . . NP31 Service Diagnosis Operating Ranges . . . . . Recommended Lubricant Shift Linkage Adjustment Shift Mechanism . . . . . . Speedometer Service . .
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GENERAL INFORMATION
The NP231 is a part-time transfer case with a low range reduction gear system (Fig. 1). The NP231 has
three operating ranges plus a Neutral position. A low range system provides a reduction ratio for increased low speed torque capability.
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SHIFT MECHANISM
Operating ranges are selected with a floor mounted shift lever (Fig 2). The shift lever is connected to the transfer case range lever by an adjustable linkage rod. A straight line shift pattern is used. Range positions are marked on the shifter knob and bezel cover plate. A synchronizer assembly in the transfer case allows the unit to be shifted between two and four high ranges while in motion.
OPERATING RANGES
Transfer case operating ranges are: 2-wheel drive high (2H) 4-wheel drive high (4H) 4-wheel drive low (4H) The 2H range is for use on all road surfaces. The 4H and 4L ranges are for off-road use only. Use these ranges on low traction surfaces such as sand, dirt, or snow covered roads only.
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RECOMMENDED LUBRICANT
Recommended lubricants are Mopar Dexron II, or ATF Plus automatic transmission fluid. Do not use
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SPEEDOMETER SERVICE
Rear axle gear ratio and tire size determine pinion gear requirements. If the gear must be replaced, refer to the parts catalogue for the correct gear.
SPEEDOMETER ASSEMBLY REMOVAL (1) Raise vehicle. (2) Disconnect wires from vehicle speed sensor. (3) Remove adapter clamp and screw (Fig. 5). (4) Remove speed sensor and speedometer adapter as assembly. (5) Remove speed sensor retaining screw and remove sensor from adapter. (6) Remove speedometer pinion from adapter. (7) Inspect sensor and adapter O-rings (Fig. 5). Remove and discard O-rings if worn or damaged.
SPEEDOMETER INSTALLATION AND INDEXING (1) Thoroughly clean adapter flange and adapter mounting surface in housing. Surfaces must be clean for proper adapter alignment and speedometer operation. (2) Install new O-rings on speed sensor and speedometer adapter if necessary (Fig. 5). (3) Lubricate sensor and adapter O-rings with transmission fluid. (4) Install vehicle speed sensor in speedometer adapter. Tighten sensor attaching screw to 2-3 N m (15-27 in. lbs.) torque. (5) Install speedometer pinion in adapter. (6) Count number of teeth on speedometer pinion. Do this before installing assembly in housing. Then lubricate pinion teeth with transmission fluid. (7) Note index numbers on adapter body (Fig. 6). These numbers will correspond to number of teeth on pinion. (8) Install speedometer assembly in housing. (9) Rotate adapter until required range numbers are at 6 o-clock position. Be sure range index numbers correspond to number of teeth on pinion gear. (10) Install speedometer adapter clamp and retaining screw. Tighten clamp screw to 10-12 N m (90-110 in. lbs.) torque. (11) Connect wires to vehicle speed sensor.
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EXTENSION HOUSING/REAR RETAINER/OIL PUMP REMOVAL (1) Raise vehicle and drain transfer case fluid. (2) Mark propeller shaft and axle yokes for assembly reference.
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(7) Remove extension housing bushing and seal if they are to be serviced. (8) Remove rear bearing snap ring (Fig. 8). (9) Remove rear retainer bolts and remove retainer by prying upward at retainer tabs (Fig. 9).
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stop ring. During overhaul, note which version is being serviced and order needed parts accordingly. (1) Remove fill and drain plugs. Also remove speedometer adapter and pinion if not previously removed. (2) Remove front yoke. Discard yoke seal washer and nut. They should not be reused. (3) Move transfer case range lever rearward to 4L position. (4) Remove extension housing attaching bolts. (5) Tap extension housing in clockwise direction to break sealer bead and remove housing (Fig. 1). CAUTION: To avoid damaging the sealing surfaces of the extension housing and rear retainer, do not pry or wedge the housing off the retainer.
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CAUTION: Do not pry against the sealing surfaces of the retainer or rear case. The surfaces could be damaged.
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(19) Remove front output shaft and drive chain (Fig. 10).
Fig. 7 Removing Oil Screen And Pickup Tube Fig. 10 Front Output Shaft And Drive Chain Removal
(20) Remove mainshaft, mode fork and shift rail as assembly d (Fig. 11).
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(21) Remove mode fork and shift rail from synchro sleeve (Fig. 12).
Fig. 13 Hub Snap Ring And Spacer Removal Fig. 16 Drive Sprocket Removal/Installation
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(33) Remove front bearing retainer. Position screwdrivers in retainer slots and lift upward to loosen and remove retainer (Fig. 23).
Fig. 25 Removing Input And Low Range Gear Assembly Fig. 23 Removing Front Bearing Retainer
(34) Remove input gear snap ring (Fig. 24).
CLEANING AND INSPECTION Clean the transfer case components thoroughly with solvent. Remove all traces of sealer from the case and retainer seal surfaces. Clean the oil pickup screen with solvent and dry it with low pressure compressed air. Also use compressed air to remove solvent residue from all oil feed passages and channels in the case halves.
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FRONT CASE ASSEMBLY (1) Lubricate components with automatic transmission fluid (or petroleum jelly where indicated) during assembly. (2) Remove front output shaft seal from front case with crowfoot style pry tool (Fig. 29).
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(4) Tap old front output shaft bearing out of front case with plastic mallet. Install new bearing with Tool Handle C-4171 and Installer Tool 5064 (Fig. 31). (5) Secure front output shaft bearing in front case with new snap ring (Fig. 30). (6) Install new front output shaft seal in front case with suitable size socket or installer tool.
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Fig. 36 Puller Jaws In Retracted Position Fig. 39 Removing Mainshaft Pilot Bearing From Input Gear
(2) Install new needle bearing in input gear with Tool Handle C-4171 and Installer 5065 (Fig. 40). (3) Lubricate and install thrust washers, input gear and retainer in low range gear (Fig. 41). Then install retainer snap ring. Be sure snap ring is fully seated before proceeding. (4) Align and install input/low range gear assembly in case. Use hammer handle to tap low range gear into annulus and input gear into bearing if necessary. (5) Install input gear snap ring (Fig. 42). (6) Install new oil seal in input bearing retainer with suitable size installer tool (Fig. 43).
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Fig. 47 Installing Sector O-Ring And Retainer Bushing Fig. 45 Aligning Retainer Oil Channel With Feed Hole In Case
(9) Install input (front) bearing retainer on front case (Fig. 46). Tighten retainer bolts to 21 N m (16 ft. lbs.) torque.
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OIL PUMP, REAR CASE, REAR RETAINER AND EXTENSION INSTALLATION (1) Install new seal in oil pump feed housing (Fig. 64). (2) Install new pickup tube O-ring in oil pump (Fig. 65). (3) Prime oil pump by pouring transmission fluid into pump through pickup tube opening. (4) Insert pickup tube in oil pump. Then attach oil screen and connecting hose to pickup tube (Fig. 66).
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AX 15 TORQUE SPECIFICATIONS
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TIRES INDEX
page Cleaning of Tires . General Information Pressure Gauges . Repairing Leaks . . Replacement Tires .. . .. .. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1 2 3 2 Rotation . . . . . . . . . . . Tire Inflation Pressures Tire Noise or Vibration Tire Wear Patterns . . . Tread Wear Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . page . . . . . . . . . . 3 2 4 4 3
GENERAL INFORMATION
Tires are designed for each specific vehicle. They provide the best overall performance for normal operation. The ride and handling characteristics match the vehicles requirements. With proper care they will give excellent reliability, traction, skid resistance, and tread life. These tires have specific load carrying capacities. When correctly inflated, they will operate properly. Tires used in cool climates, and with light loads will have a longer life than tires used in hot climates with heavy loads. Abrasive road surfaces will accelerate tire wear. Driving habits have more effect on tire life than any other factor. Careful drivers will obtain much greater mileage than careless drivers. Driving habits that shorten the life of any tire; Rapid acceleration and deceleration Severe application of brakes High-speed driving Taking turns at excessive speeds Striking curbs and other obstacles Longer wearing tires are more susceptible to irregular tread wear. It is very important to follow the tire rotation interval
always printed on the tire sidewall. The letter S indicates that the tire is speed rated up to 112 mph. Q up to 100 mph T up to 118 mph U up to 124 mph H up to 130 mph V up to 149 mph Z more than 149 mph (consult the tire manufacturer for the specific speed rating) An All Season type tire will have either M + S, M & S or MS (indicating mud and snow traction) imprinted on the side wall.
RADIAL-PLY TIRES Radial-ply tires improve handling, tread life, ride quality and decrease rolling resistance. Radial-ply tires must always be used in sets of four. Under no circumstances should they be used on the front only. They may be mixed with temporary spare tires when necessary, but reduced speeds are recommended. Radial-ply tires have the same load-carrying capacity as other types of tires of the same size. They use the same recommended inflation pressures. SPARE TIRE (COMPACT) The compact spare tire is designed for emergency use only. The original tire should be repaired and reinstalled at the first opportunity. Refer to Owners Manual for complete details. TIRE CHAINS Tire snow chains may be used on certain models. Refer to Owners Manual for more information.
IDENTIFICATION Tire type, size, aspect ratio and speed rating are encoded in the letters and numbers imprinted on the side wall of the tire. Refer to the chart to decipher the tire identification code (Fig. 1). Performance tires will have a speed rating letter after the aspect ratio number. The speed rating is not
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CLEANING OF TIRES
Steam cleaning may be used for cleaning. DO NOT use gasoline or wire brush for cleaning. DO NOT use mineral oil or an oil-based solvent.
PRESSURE GAUGES
High-quality, dial-type, air-pressure gauges are recommended. After checking with the gauge, replace valve caps and tighten finger tight.
Inflation pressures specified on the placards are always cold inflation pressure. Cold inflation pressure is obtained after the vehicle has not been operated for at least 3 hours. Tire inflation pressures may increase from 2 to 6 pounds per square inch (psi) during operation. Do not reduce this normal pressure build-up. Vehicles loaded to the maximum capacity should not be driven at continuous speeds above 75 mph (120 km/h). WARNING: OVER OR UNDER INFLATED TIRES CAN AFFECT VEHICLE HANDLING AND CAN FAIL SUDDENLY, RESULTING IN LOSS OF VEHICLE CONTROL.
REPLACEMENT TIRES
OEM tires provide a proper balance of many features such as; Ride Noise Handling
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Tire replacement is necessary when indicators appear in two or more grooves, or if localized balding occurs (Fig. 5).
ROTATION
Tires on the front and rear axles operate at different loads and perform different steering, driving, and braking functions. For these reasons; They wear at unequal rates Tend to develop irregular wear patterns These effects can be reduced by timely rotation of tires. The benefits of rotation are especially worthwhile. Rotation will: Increase tread life Help to maintain mud, snow, and wet traction levels Contribute to a smooth, quiet ride The suggested method of tire rotation is the same side front to rear pattern (Fig. 4). Other rotation methods can be used, but they will not provide all the tire longevity benefits.
REPAIRING LEAKS
For proper repairing, a radial tire must be removed from the wheel. Repairs should only be made if the puncture is in the tread area (Fig. 6). If outside the tread area the tire should be replaced.
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GENERAL INFORMATION
Original equipment wheels are designed for all loads up to the specified Maximum Vehicle Capacity. All models use steel or cast aluminum drop center wheels. The safety rim wheel (Fig. 1) has raised sections between the rim flanges and the rim well.
tightened just snug. Gradually tighten them in sequence to 129 N m (95 ft. lbs.) torque (Fig. 2). Never use oil or grease on studs or nuts.
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. Original equipment wheels are available through your dealer. Replacement wheels from any other source should be equivalent in: Load carrying capacity Diameter Width Offset Mounting configuration Failure to use equivalent replacement wheels may affect the safety and handling of your vehicle. Replacement with used wheels is not recommended. Their service history may have included severe treatment. Refer to the Specifications Chart for information regarding above requirements.
WHEEL INSTALLATION
The wheel studs and nuts are designed for specific applications. They must be replaced with equivalent parts. Do not use replacement parts of lesser quality or a substitute design. All aluminum and some steel wheels have wheel stud nuts which feature an enlarged nose. This enlarged nose is necessary to ensure proper retention of the aluminum wheels. CAUTION: Models equipped with chrome plated wheels come with chrome plated lug nuts. Under no circumstances substitute these lug nuts, use only the factory specified lug nuts. Before installing the wheel, be sure to remove any build up of corrosion on the wheel mounting surfaces. Ensure wheels are installed with good metal-to-metal contact. Improper installation could cause loosening of wheel nuts. This could affect the safety and handling of your vehicle. To install the wheel, first position it properly on the mounting surface. All wheel nuts should then be
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WHEEL ORNAMENTATION
WARNING: HANDLE ALL WHEEL ORNAMENTATION WITH EXTREME CARE DURING REMOVAL AND INSTALLATION. SHARP EDGES ON THE COVERS OR CAPS CAN CAUSE PERSONAL INJURY.
to counterbalance the area of imbalance. Place half of this weight on the inner rim flange and the other half on the outer rim flange (Fig. 3, Fig. 4). Off-vehicle balancing is necessary. Wheel balancing can be accomplished with either on or off vehicle equipment. When using on-vehicle balancing equipment, follow these precautions: Limited-slip rear axle differential, remove the opposite wheel/tire Before balancing the wheels/tires on a vehicle equipped with a transfer case, disconnect the drive shafts
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MATCH MOUNTING
Wheels and tires are match mounted at the factory. This means that the high spot of the tire is matched to the low spot on the wheel rim. This technique is used to reduce run-out in the wheel/tire assembly. The high spot on the tire is marked with a paint mark or a bright colored adhesive label on the outboard sidewall. The low spot on the rim is at the valve stem location on the wheel rim. Before dismounting a tire from its wheel, a reference mark should be placed on the tire at the valve stem location. This reference will assure that it is remounted in the original position on the wheel. (1) Measure the total indicator runout on the center of the tire tread rib. Record the indicator reading. Mark the tire to indicate the high spot. Place a mark on the tire at the valve stem location (Fig. 5).
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Check radial runout. If still excessive, mark tire sidewall, wheel, and stud at point of maximum runout and proceed to Method 2.
METHOD 2 (RELOCATE TIRE ON WHEEL) Rotating tire on wheel is particularly effective when there is runout in both tire and wheel. Remove tire from wheel and re-mount wheel on hub in former position. Check wheel radial runout (Fig. 9). STEEL WHEELS: Radial runout 0.040 in., Lateral runout 0.045 in. ALUMINUM WHEELS: Radial runout 0.030 in., Lateral runout 0.035 in. If point of greatest runout is near original chalk mark, remount tire 180 degrees. Recheck runout.
METHOD 1 (RELOCATE WHEEL ON HUB) Check accuracy of the wheel mounting surface; adjust wheel bearings. Drive vehicle a short distance to eliminate tire flat spotting from a parked position. Make sure all wheel nuts are properly torqued. Relocate wheel on the mounting, two studs over from the original position. Re-tighten wheel nuts until all are properly torqued, to eliminate brake distortion.
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Vehicle vibration can be caused by: Tire/wheel unbalance or excessive runout Defective tires with extreme tread wear Nylon overlay flat spots (performance tires only) Incorrect wheel bearing adjustment (if applicable) Loose or worn suspension/steering components Certain tire tread patterns Incorrect drive shaft angles or excessive drive shaft/yoke runout Defective or worn U-joints Excessive brake rotor or drum runout Loose engine or transmission supports/mounts And by engine operated accessories Refer to the appropriate Groups in this manual for additional information.
VIBRATION TYPES
There are two types of vehicle vibration: Mechanical Audible. Mechanical vehicle vibration can be felt through the seats, floor pan and/or steering wheel. Audible vehicle vibration is heard above normal background noise. The sound can be a droning or drumming noise. Vibrations are sensitive to change in engine torque, vehicle speed or engine speed.
ENGINE TORQUE SENSITIVE VIBRATION This vibration can be increased or decreased by: Accelerating Decelerating Coasting Maintaining a constant vehicle speed VEHICLE SPEED SENSITIVE VIBRATION This vibration condition always occurs at the same vehicle speed regardless of the engine torque or engine speed. ENGINE SPEED (RPM) SENSITIVE VIBRATION This vibration occurs at varying engine speeds. It can be isolated by increasing or decreasing the engine speed with the transmission in NEUTRAL position.
VIBRATION DIAGNOSIS
A vibration diagnosis should always begin with a 10 mile (16 km) trip (to warm the vehicle and tires). Then a road test to identify the vibration. Corrective action should not be attempted until the vibration type has been identified via a road test. During the road test, drive the vehicle on a smooth surface. If vibration exists, note and record the following information:
Identify the vehicle speed range when the vibration occurs Identify the type of vibration Identify the vibration sensitivity Determine if the vibration is affected by changes in vehicle speed, engine speed and engine torque. When the vibration has been identified, refer to the Vibration Diagnosis chart for causes. Consider correcting only those causes coded in the chart that are related to the vibration condition. Refer to the following cause codes and descriptions for explanations when referring to the chart. TRRTire and Wheel Radial Runout: Vehicle speed sensitive, mechanical vibration. The runout will not cause vibration below 20 mph (32 km/h). WHWheel Hop: Vehicle speed sensitive, mechanical vibration. The wheel hop generates rapid up-down movement in the steering wheel. The vibration is most noticeable in the 20 - 40 mph (32 - 64 km/h) range. The wheel hop will not cause vibration below 20 mph (32 km/h). Wheel hop is caused by a tire/wheel that has a radial runout of more than 0.045 of-an-inch (1.14 mm). If wheel runout is acceptable and combined runout cannot be reduced by repositioning the tire on wheel, replace tire. TBTire/Wheel Balance: Vehicle speed sensitive, mechanical vibration. Static tire/wheel unbalance will not cause vibration below 30 mph (46 km/h). Dynamic tire/wheel unbalance will not cause vibration below 40 mph (64 km/h). TLRTire/Wheel Lateral runout: Vehicle speed sensitive, mechanical vibration. The runout will not cause vibration below 50 - 55 mph (80 - 88 km/h). Excessive lateral runout will also cause front-end shimmy. TWTire Wear: Vehicle speed sensitive, audible vibration. Abnormal tire wear causes small vibration in the 30 - 55 mph (88 km/h) range. This will produce a whine noise at high speed. The whine will change to a growl noise when the speed is reduced. WTire Waddle: Vehicle speed sensitive, mechanical vibration. Irregular tire uniformity can cause side-to-side motion during speeds up to 15 mph (24 km/h). If the motion is excessive, identify the defective tire and replace it. UAJUniversal Joint (Drive Shaft) Angles: Torque/vehicle speed sensitive, mechanical/audible vibration. Incorrect drive shaft angles cause mechanical vibration below 20 mph (32 km/h) and in the 70 mph (112 km/h) range. The incorrect angles can also produce an audible vibration in the 20 - 50 mph (32 80 km/h) range. Caster adjustment could be required to correct the angles. UJUniversal Joints: Engine torque/vehicle speed sensitive, mechanical/audible vibration. If the
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U-joint is worn it will cause vibration with almost any vehicle speed/engine torque condition. DSYDrive Shaft and Yokes: Vehicle speed sensitive, mechanical/audible vibration. The condition will not cause vibration below 35 mph (56 km/h). Excessive runout, unbalance or dents and bends in the shaft will cause the vibration. Identify the actual cause and repair/replace as necessary. WBWheel Bearings: Vehicle speed sensitive, mechanical/audible vibration. Loose wheel bearings cause shimmy-like vibration at 35 mph (56 km/h) and above. Worn bearings will also produce a growl noise at low vehicle speed and a whine noise at high vehicle speed. The wheel bearings must be adjusted or replaced, as applicable. ANAxle Noise: Engine torque/vehicle speed sensitive, mechanical/audible vibration. The axle will not cause mechanical vibration unless the axle shaft is bent. Worn or damaged axle pinion shaft or differential gears and bearings will cause noise. Replace the defective component(s) as necessary. SSCSuspension and Steering Components: Vehicle speed sensitive, mechanical vibration. Worn suspension/steering components can cause mechanical vibration at speeds above 20 mph (32 km/h). Identify and repair or replace the defective component(s).
EAEngine Driven Accessories: Engine speed sensitive, mechanical/audible vibration. Vibration can be caused by loose or broken A/C compressor, PS pump, water pump, generator or brackets, etc. Usually more noticeable when the transmission is shifted into the NEUTRAL position and the engine speed (rpm) increased. Inspect the engine driven accessories in the engine compartment. Repair/replace as necessary. ADBAccessory Drive Belts: Engine speed sensitive, audible vibration. Worn drive belts can cause a vibration that produces either a droning, fluttering or rumbling noise. Inspect the drive belt(s) and tighten/ replace as necessary. DEMDamaged Engine or Transmission Support Mounts: Engine speed sensitive, mechanical/ audible vibration. If a support mount is worn, noise or vibration will occur. Inspect the support mounts and repair/replace as necessary. ESExhaust System: Engine speed sensitive, mechanical/audible vibration. If loose exhaust components contact the vehicle body they will cause noise and vibration. Inspect the exhaust system for loose, broken and mis-aligned components and repair/replace as necessary.
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BODY COMPONENTS
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BODY COMPONENTS
CONTENTS
page page
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BODY COMPONENTS
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page Fuel Filler Door and Nozzle/Tubes . . . . . . . . . . . . . 15 Grille . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Hood Inside Release Cable . . . . . . . . . . . . . . . . . . . 5 Light Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Spare Tire Winch . . . . . . . . . . . . . . . . . . . . . . . . . 19 Splash Shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Tailgate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
GRILLE
GRILLE REMOVAL (1) Remove screws that attach the headlamp bezels (Fig. 1) to the grille and the closure panel.
GRILLE INSTALLATION (1) Position the grille on the closure panel and loosely install the attaching screws (Fig. 2). (2) Install the headlamps in the bezels. (3) Position the headlamp bezels on the closure panel and loosely install the attaching screws (Fig. 2). (4) Correctly align the grille and the headlamp bezels, and then tighten the screws with 2 N m (17 in. lbs.) torque. CLOSURE PANEL REMOVAL (1) Raise and support the hood. Remove the battery.
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BODY COMPONENTS
CAUTION: Use care to avoid damage to the fender panels and the cowl panel when pivoting the fender panels at the cowl. (16) Move both fender panels outward at the front and remove the closure panel from the frame rails and the vehicle.
CLOSURE PANEL INSTALLATION (1) If necessary, install U-nuts at the closure panel lower flange. (2) Move both fender panels outward at the front and position the closure panel on the frame rails. (3) Move both fender panels inward at the front and install the screws to attach the fender liners to the fender panels (Fig. 3). Tighten the screws with 23 N m (200 in. lbs.) torque. (4) Install the cab front holddown bolts to attach the closure panel to the vehicle frame rails (Fig. 4). Tighten the bolts with 81 N m (60 ft. lbs.) torque. (5) Install the screws to attach the fenders (Fig. 3) to the closure panel. Tighten the screws with 23 N m (200 in. lbs.) torque. (6) Install the screws to attach the fender liners (Fig. 3) to the closure panel. Tighten the screws with 23 N m (200 in. lbs.) torque. (7) Install nuts/retainers to attach the air dam to the front fenders. (8) Install the horns on the closure panel. (9) Connect electrical connector for Ambient Temperature Sensor, if equipped (10) Attach the battery tray to the closure panel. If necessary, refer to the installation procedure. Tighten the screws with 23 N m (200 in. lbs.) torque. (11) Install the radiator in the closure panel. Refill the engine cooling system with coolant. If necessary, refer to Group 7Cooling System for the procedures. (12) Attach the hood release cable to the retaining clip on the closure panel. (13) Adjust the latch-to-retainer clip cable distance to ensure sufficient cable slack length between the clip and the latch. (14) Position the hood latch and the reinforcement plate on the closure panel and install the retaining screws. Tighten the screws with 23 N m (200 in. lbs.) torque. (15) Test the hood latch release cable for proper operation. (16) Install the grille and the headlamp bezels on the closure panel (if necessary, refer to the installation procedure). (17) Install the headlamps in the bezels and in the headlamp receptacles. (18) Install the battery and the holddown bracket. Tighten the holddown rod nuts with 2 N m (20 in. lbs.) torque. (19) Remove the support and close the hood. (20) If necessary, adjust the headlamp beams.
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HOOD
POSITION ADJUSTMENT The hood hinge screw holes are oversize and elongated to ease hood up/down and fore/aft position adjustment. Loosen the hinge-to-fender panel screws for up/down adjustment (in relation to the fenders). Loosen the hinge arm-to-hood bolts for fore/aft adjustment (in relation to the cowl). FORE/AFT AND LATCH/STRIKER ADJUSTMENT The following sequence of hood fore/aft position and latch lock/striker adjustments must be followed as listed to avoid improper adjustment. An improperly adjusted latch lock or striker could cause the front of the hood to be released and be retained only by the safety latch. (1) Loosen the hinge arm-to-hood bolts (Fig. 7) at each side of the vehicle. (2) Loosen the hood latch attaching screws.
INSTALLATION If a replacement hood latch is also being installed, ensure that it is thoroughly lubricated. (1) From inside the vehicle, route the hood release cable through the hole in the dash panel. (2) Position the release cable handle at the bottom of the instrument panel (Fig. 6) and install the attaching screws. Tighten the screws with 1 N m (12 in. lbs.) torque. (3) Install the cable grommet in the dash panel hole (Fig. 5).
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BODY COMPONENTS
REMOVAL (1) Raise and support the hood at the full-open position. (2) If equipped, disconnect the underhood lamp wire harness connector from the lamp connector and remove the wire harness from the hood (Fig. 8). (3) With the aid of an assistant, remove the hinge arm-to-hood bolts (Fig. 7) at each side of the hood. Remove the hood from vehicle. (4) If a replacement hood is being installed, transfer the underhood lamp (Fig. 8) and the insulator panel (Fig. 9). (5) Inspect/test the hood hinges for correct operation and clean them with an appropriate solvent.
INSTALLATION (1) With the aid of an assistant, position the hood on the vehicle and align the hood bolt holes with the hinge arm holes (Fig. 7). Install and finger-tighten the bolts. (2) Align the hood, the latch, and the striker (refer to Fore/Aft And Latch/Striker Adjustment). HINGE REPLACEMENT
REMOVAL If both hinges are being replaced, remove the hood and both hinges as a unit. If only one hinge is being replaced, use the following procedure.
BODY COMPONENTS
(1) Raise and support the hood at the full-open position. (2) Loosen the hinge-to-fender panel screws and the hinge arm-to-hood bolts (Fig. 7). (3) Support the hood at the side to ease hinge removal. Remove the screws, bolts and hinge from the hood and fender panel (Fig. 7). INSTALLATION (1) Position the replacement hinge against the fender panel. Install and finger-tighten the screws. (2) Align the hood bolt holes with the hinge arm holes (Fig. 7). Install and finger-tighten the bolts. (3) Adjust the hood up/down position in relation to the fender. Tighten the hinge-to-fender panel screws with 23 N m (200 in. lbs.) torque. (4) Adjust the hood fore/aft position, the latch, and the striker (refer to Fore/Aft And Latch/Striker Adjustment).
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LATCH STRIKER
REMOVAL (1) Raise and support the hood. (2) Remove the attaching screws and the latch striker from the hood (Fig. 7). INSTALLATION (1) Position the striker on the hood. (2) Install and finger-tighten the attaching screws. ADJUSTMENT Align the latch and the striker (refer to Fore/Aft And Latch/Striker Adjustment).
INSTALLATION (1) Position the screen and grille on the cowl plenum (Fig. 12) and engage the rear of grille with the windshield weatherstrip seal. (2) Attach windshield washer hoses to the nozzles and the retaining clips (Fig. 11). (3) Install the grille attaching screws (Fig. 12). Tighten the screws with 2 N m (17 in. lbs.) torque. (4) Remove the support and close the hood. (5) Install the windshield wiper arms (Fig. 11).
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BODY COMPONENTS
(3) Remove the screws that attach the battery tray to the fender liner, inner fender panel and the closure panel. (4) Remove the battery tray from the vehicle. (5) If necessary, remove the U-nuts and the holddown rods from the battery tray.
INSTALLATION (1) If removed, install the U-nuts and the holddown rods on the battery tray. (2) Position the battery tray against the inner fender panel and on the fender liner. (3) Attach the battery tray to the inner fender panel, the fender liner and the closure panel with the screws. Tighten the screws with 23 N m (200 in. lbs.) torque. (4) Install the battery in the tray. (5) Position the holddown bracket over the holddown rods. (6) Install the retaining nuts on the holddown rods. Tighten the nuts with 2 N m (20 in. lbs.) torque.
FRONT FENDERS
Fig. 12 Cowl Grille, Screen & Seals
The front fenders are attached to the closure panel and the cowl/dash panel with U-nuts, screws, washers, a stud and a nut (Fig. 14). The fender liners are attached to the inner side of the fender panels with screws.
BATTERY TRAY
REMOVAL (1) Remove the nuts and holddown bracket from the holddown rods (Fig 13).
REMOVAL (1) Raise and support the hood. Remove the battery for left fender removal only. (2) Remove the headlamps from the headlamp receptacles in the closure panel and from the bezels.
BODY COMPONENTS
(3) Remove the headlamp bezels closure panel. If necessary, refer to the grille removal procedure. (4) Remove the battery tray for left fender removal only. If necessary, refer to the removal procedure. (5) Remove the screws that attach the fender (Fig. 15) to the closure panel.
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(11) Remove the fender and the liner from the cab (Fig. 15). (12) Remove the screws that attach the fender liner to the fender panel (Fig. 15). Remove the liner from the fender.
INSTALLATION (1) Position the liner on the fender. Install the screws to attach the fender liner to the fender panel (Fig. 15). Tighten the screws with 23 N m (200 in. lbs.) torque. (2) Position the fender and the liner on the cab (Fig. 15). (3) Install the screws to attach the fender and the liner (Fig. 15) to the closure panel. Tighten the screws with 23 N m (200 in. lbs.) torque. (4) Install nut/retainer to attach the air dam to the front fender. (5) Install the screw that attaches the fender liner (Fig. 16) to the dash panel. Tighten the screw with 23 N m (200 in. lbs.) torque. (6) Install the nuts to attach the bottom of the fender (Fig. 14) to the cowl. Tighten the nuts with 23 N m (200 in. lbs.) torque. (7) Install the bolts to attach the top of the fender (Fig. 14) to the cowl. Tighten the bolts with 23 N m (200 in. lbs.) torque. (8) If removed, install the battery tray. If necessary, refer to the installation procedure. Tighten the screws with 23 N m (200 in. lbs.) torque. (9) If removed, install the battery and the holddown bracket. Tighten the holddown rod nuts with 2 N m (20 in. lbs.) torque. (10) Install the headlamp bezels on the closure panel (if necessary, refer to the grille installation procedure). (11) Install the headlamps in the bezels and in the headlamp receptacles. (12) Remove the support and close the hood.
SPLASH SHIELDS
FRONT FENDER WHEELHOUSE2WD VEHICLES
REMOVAL (1) Remove the plastic retainers that attach the splash shield to the wheelhouse liner and to the frame rail (Fig. 17). (2) Remove the screws that attach the splash deflector to the frame rail. (3) Remove the splash shield and the splash deflector from the wheelhouse. INSTALLATION (1) Position the splash shield on the wheelhouse liner.
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BODY COMPONENTS
CARGO BOX WHEELHOUSE
REMOVAL (1) Remove the screws that attach the front splash shield to the wheelhouse liner.
BODY COMPONENTS
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(3) Install 3M 06379 double-sided tape on the moulding. (4) Use masking tape as an alignment reference to indicate the upper position for the moulding. (5) Remove the backing from the double-sided tape, align the moulding with the alignment reference tape or string, and position it on the cab/cargo box panel. (6) Verify that the moulding is properly aligned and remove the alignment reference tape or string. (7) Press the moulding onto the cab/cargo box panel with a roller (or use hand pressure) to ensure complete adhesion. REMOVALWHEEL LIP MOULDINGS ATTACHED WITH SCREWS (1) Remove the retaining screw from the moulding. (Fig. 20 and 21). (2) Carefully remove the wheel lip moulding from the wheelhouse (Fig. 21). INSTALLATIONWHEEL LIP MOULDINGS ATTACHED WITH SCREWS Align the moulding with the screws holes in the fender panel (Fig. 21), and then install the retaining screws into the fender panel. Tighten the screws to 3 N m (24 in. lbs.) torque.
NAMEPLATES/BADGES
REMOVAL (1) Soften the nameplate/badge tape adhesive (Fig. 21) with a heat gun. (2) Lift one edge of the nameplate/badge with a putty knife (or a similar thin-blade tool) and peel the
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BODY COMPONENTS
moulding and tape from the cab panel. Apply additional heat to any location where the tape remains adhered to the panel. (3) Remove the residual tape adhesive from the panel. (4) If the original nameplate/badge is being installed, remove the original tape and all the residual adhesive from it. SURFACE PREPARATION The painted panel area that will be covered by the nameplate/badge must be cleaned with an appropriate cleaning solution. (1) Clean the painted panel surface with a commercial wax and silicone removal solution. Wipe the surface with a clean cloth and allow it to dry. (2) Freshly painted surfaces must be thoroughly dry. If not, the residual solvent in the paint could adversely affect the nameplate/badge tape adhesive. INSTALLATION (1) Install 3M 06379 double-sided tape on the nameplate/badge. (2) For vertical alignment, use masking tape to indicate the upper position for the nameplate/badge on the cab panel. (3) Remove the backing from the double-sided tape, align the nameplate/badge with the alignment reference tape, and position it on the cab panel. (4) Verify that the nameplate/badge is properly aligned and remove the alignment reference tape. (5) Press the nameplate/badge onto the cab panel with a roller (or use hand pressure) to ensure complete adhesion.
TAILGATE DECAL The tailgate is covered with a durable decal (Fig. 22).
REMOVAL The key to successful decal removal is to apply heat only to the immediate area and slowly peel the decal away from the tailgate panel. Slow peeling will ensure that a maximum amount of adhesive remains with the decal as it is removed. (1) Soften the decal adhesive with a heat gun. (2) Lift one edge of the decal with a putty knife (or a similar thin-blade tool). Slowly peel the decal from the tailgate panel. (3) Apply additional heat to any location where the decal remains adhered to the panel. (4) Remove the residual decal adhesive from the panel. SURFACE PREPARATION The painted area that will be covered by the decal must be cleaned with an appropriate cleaning solution.
DOOR EDGE GUARD A door edge guard (Fig. 23) can be removed by grasping it and pulling it outward from the door edge. To install, position the edge guard on the door edge and exert inward force until it is seated on the door edge.
BODY COMPONENTS
ROOF MOULDING
REMOVAL (1) Remove the interior trim panel for access to the moulding retainer stud nuts. If necessary, refer to the removal procedure (Fig. 24).
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(2) Install the retaining nuts on the retainer studs. Tighten the nuts with 2 N m (19 in. lbs.) torque. The nuts have seals that prevent water from entering the interior of the cab. (3) Install the interior trim panel. If necessary, refer to the installation procedure.
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BODY COMPONENTS
BODY COMPONENTS
of wetting solution by thoroughly mixing two or three teaspoons of dish detergent with 1 gallon of water. Do not use soap. Too much detergent will reduce the effectiveness of the mixture.
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Position the replacement tape stripe section at the center of the repair area. Align it with the existing tape stripe. Allow at least 12 mm (1/2 in) of the tape stripe section to extend inward from the existing tape stripe edges. CAUTION: Always remove the carrier from the tape stripe, never remove the tape stripe from the carrier because this could cause the stripe to tear or otherwise damaged. (4) Bend the corner of the carrier outward and, with a flick of the finger, separate the carrier from the tape stripe. (5) Retain the tape stripe firmly against the panel surface while removing the carrier (Fig. 25). (6) Apply the wetting solution to the outer side of the tape stripe to allow the squeegee to freely slide during the application of the stripe to the panel. CAUTION: Avoid unnecessary pulling and stretching at the ends of the tape stripe because this could cause it to tear. (7) Position and slide a squeegee from the center to the ends of the tape stripe. Use firm strokes to remove all of the air bubbles and wetting solution from the underside of the tape stripe. This will ensure complete bonding of the tape stripe to the painted panel surface.Avoid stretching the tape stripe while sliding the squeegee from the center with firm, overlapping strokes. (8) If a wrinkle is trapped in the tape stripe during the squeegee operation, stop immediately. Carefully lift the wrinkled area and re-align the stripe with the panel character line to remove the wrinkle.Do not lift the tape stripe if only a few air bubbles exist. (9) Where applicable, allow 12 mm (1/2 in) extra tape stripe to extend beyond the edges to be folded over onto the panel flange areas. (10) Fold the excess tape stripe back onto the adjacent inside flange area and burnish it until it is completely bonded to the flange area. Where necessary, trim excess tape stripe. (11) Inspect the tape stripe installation. Remove all air and moisture bubbles with a needle or pin. (12) Install any removed components and clean the vehicle as necessary.
REMOVAL The key to successful tape stripe removal is to apply heat only to the immediate area and slowly peel the stripe from the panel. Slow peeling will ensure that a maximum amount of adhesive remains with the stripe as it is removed. (1) Start at one end of the tape stripe and apply heat with a heat gun. Slowly peel the stripe from the panel by pulling it back, in-line with the stripe affixed to the panel.Do not pull the tape stripe outward from the panel.
WARNING: USE THE TAPE STRIPE REMOVAL SOLUTION IN A WELL-VENTILATED AREA ONLY. (2) A commercial tape stripe removal solution can be used for stripe removal at areas where the heat gun is ineffective. (3) After the tape stripe is removed, remove any adhesive remaining on the panel. (4) Wipe the panel with a cloth saturated with a general purpose adhesive cleaning solution.
SURFACE PREPARATION (1) The panel area that will be covered by the tape stripe must be cleaned with an appropriate cleaning solution to remove any paint residue. (2) Freshly painted surfaces must be thoroughly dry. If not, the residual solvent in the paint could cause the tape stripe to blister. (3) Clean the painted surface with a commercial wax and silicone removal solution. Wipe the surface with a clean cloth and allow it to dry. INSTALLATION (1) Use a clean sponge and apply ample wetting solution to the tape stripe adhesive and to the painted panel surface. The wetting solution will permit ease of tape stripe movement when positioning it on the panel. (2) Immediately position the wetted adhesive side of the replacement tape stripe on the panel. The bottom of the carrier should align with the panel character line (Fig. 25). Where applicable: align the end of the replacement tape stripe with the end of the existing tape stripe, and correctly align the index darts and index notches (Fig. 25). (3) If a complete replacement tape stripe is not being installed:
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BODY COMPONENTS
EXTERIOR MIRRORS
Service information for manual exterior rear view mirrors is provided below.
REMOTE/MANUAL MIRROR
REMOVAL (1) Loosen the mirror toggle control setscrew at the bezel (Fig. 31).
NOZZLE/TUBES
REMOVAL (1) Remove the fuel filler door. (2) Remove the cap from the nozzle. (3) Loosen the clamps and separate the hoses from the tubes. (4) Remove the screws that attach the nozzle to the cargo box panel. The fuel cap tether is also attached to the cargo box panel with one of the screws. (5) Remove the nozzle/tubes from the cargo box panel (Fig. 30).
INSTALLATION (1) Position the fuel filler nozzle/tubes and the fuel cap tether at the opening in the cargo box panel. (2) Install the screws to attach the nozzle and tether to the panel. Tighten the screws with 4 N m (35 in-lbs) torque. (3) Attach the hoses to the tubes with the clamps. Tighten the clamp screws with 4 N m (35 in-lbs) torque. (4) Install the cap on the nozzle. (5) Install the fuel filler door.
BODY COMPONENTS
(3) Install the mirror retaining nuts. Tighten the nuts with 7 N m (65 in. lbs.) torque. (4) Install the mirror seal in the door aperture. (5) Position the mirror bezel over the toggle control and tighten the setscrew with 1 N m (9 in. lbs.) torque. (6) Install the mirror bezel retaining screw. Tighten the screw with 2 N m (17 in. lbs.) torque. (7) Install the mirror bezel retaining screw cover plug.
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CAB
The cab is attached to the vehicle front frame structure with bolts (Figs. 33 and 34). If necessary, the cab can be removed for repair or service access.
REMOVAL (1) Disconnect the battery cables from the terminals and remove the battery from the tray. (2) As necessary, disconnect the wire harness connectors from the engine-related components and from the frame. (3) Disconnect the parking brake cable and the brake lines. (4) Disconnect the engine controls. (5) Disconnect the heater and A/C hoses. (6) Disconnect the cable from the starter motor. (7) Disconnect the transmission and transfer case (if equipped) shift linkage. (8) Disconnect the tubing from the clutch master cylinder (if equipped). (9) Disconnect the steering shaft from the steering gear. (10) Disconnect all remaining connections between the cab and the frame-attached components. (11) Remove the restraint cable (Fig. 33) from the cab. (12) Remove the retaining screws and the floor panel-to-holddown bracket plate (Fig. 33) from the cab. (13) Remove the cab holddown bolts (Figs. 33 and 34). The bolts are accessible from the underside of the cab. (14) Separate and remove the cab from the frame (Figs. 33 and 34). INSTALLATION (1) Ensure that the isolators and spacers are correctly positioned on the frame holddown brackets (Figs. 33 and 34). (2) Position the cab on the frame (Figs. 33 and 34). (3) Install the cab holddown bolts (Figs. 33 and 34). Tighten the bolts with 81 N m (60 ft. lbs.) torque. (4) Position the floor panel-to-holddown bracket plate (Fig. 33) on the cab floor panel and install the retaining screws. Tighten the screws with 23 N m (200 in. lbs.) torque. (5) Position the restraint cable ends (Fig. 33) on the cab rear seat belt anchor bolts and install the retaining nuts. Tighten the nuts with 45 N m (33 ft. lbs.) torque. (6) Connect the steering shaft to the steering gear. (7) Connect the tubing to the clutch master cylinder (if equipped). (8) Connect the transmission and transfer case (if equipped) shift linkage. (9) Connect the cable to the starter motor. (10) Connect the heater and A/C hoses. (11) Connect the engine controls.
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BODY COMPONENTS
BODY COMPONENTS
(16) Thoroughly inspect the installation of the cab on the frame and ensure that: All connecting hardware is correctly tightened. All fluids and lubricants are at an acceptable level. All electrical, engine, drivetrain and chassis components are functionally operational.
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(6) Test the handle and latches for correct operation. If necessary, adjust the strikers to eliminate tailgate looseness and noise. (7) Close the tailgate.
TAILGATE
REMOVAL (1) Open the tailgate. (2) Position the tailgate at an angle that will allow the restraint/support cable eyelets to be removed from the tailgate cable pivots (Fig. 35). (3) Separate connector for Center High Mounted Stop Lamp (CHMSL).
DISASSEMBLY (1) Remove the screws that attach the cover plate to the tailgate inside panel. Remove the cover plate from the panel (Fig. 35). (2) Disconnect the plastic clips that attach the handle-to-latch rods to the rod retainer at the handle. (3) Remove the nuts that attach the handle and the rod retainer to the tailgate inner panel. (4) Remove the rod retainer from the opening at the inside of the tailgate. (5) Lower the handle and remove it from the tailgate opening. (6) Support the tailgate. Remove the latches and the restraint/support cables from the ends of the tailgate. ASSEMBLY (1) Lubricate the latches, the handle and the rod retainer before assembly. (2) Install the latches and the restraint/support cables at the ends of the tailgate. Remove the support. (3) Insert the handle in the tailgate opening. (4) Position the rod retainer in the opening at the inside of the tailgate. (5) Install the nuts to attach the handle and the rod retainer to the tailgate inner panel. (6) Connect the handle-to-latch rods to the rod retainer at the handle and retain them with the plastic clips. (7) Position the cover plate over the opening in the tailgate inside panel and install the attaching screws (Fig. 35). (8) Test the handle and latches for correct operation. If necessary, adjust the strikers to eliminate tailgate looseness and noise.
INSTALLATION (1) Position the tailgate at the cargo box. (2) On the left side, insert the tailgate hinge-half into the cargo box hinge-half by moving the tailgate to the left. (3) On the right side, insert the tailgate hinge-half into the slot in cargo box hinge-half. (4) Position the tailgate at an angle that will allow the restraint/support cable eyelets to be installed on the tailgate cable pivots (Fig. 35). (5) Connect CHMSL electrical connector.
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BODY COMPONENTS
(2) Remove the support and lower the vehicle. (3) Attach the spare tire and wheel to the winch. CAUTION: Operate the spare tire winch manually only. Air or electrically powered tools can cause damage to the internal mechanism. (4) Insert a lug wrench into the rear bumper access hole and into the winch actuator. (5) Rotate and force the lug wrench inward to engage it with the winch actuator slot. (6) Rotate the lug wrench clockwise and raise the spare tire and wheel until the tire is flush against the bottom of the cargo box. When this occurs, the winch mechanism will slip. Allow the mechanism to slip 2 or 3 times to ensure that the tire is tightly seated against the cargo box. (7) Remove the lug wrench from the winch actuator and the rear bumper access hole.
CARGO BOX
REMOVAL The cargo box is attached to the vehicle rear frame structure with screws (Fig. 37). If necessary, the box can be removed for repair, service access, or replacement. (1) Disconnect the battery cables from the terminals.
INSTALLATION (1) Position the spare tire winch under the cargo box and install the retaining bolts. Tighten the bolts with 23 N m (200 in. lbs.) torque.
BODY COMPONENTS
(2) Disconnect tail lamp wire harness connectors. (3) Support the exhaust tail pipe and disconnect the support hanger from the cargo box. (4) Loosen the clamps and disconnect the fuel and vent hoses from the nozzle tubes (Fig. 38).
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LIGHT BAR
REMOVAL (1) Disconnect off road lamp wire connectors. (2) Remove nuts and support plates holding light bar to cargo box top rails (Fig. 39). (3) Separate light bar from side support cover. (4) Remove nuts holding side support cover to cargo box top rails.
INSTALLATION (1) Position cargo box on the frame (Fig. 37). (2) If used, insert the shims and install the holddown screws (Fig. 37). Tighten the screws with 41 N m (30 ft. lbs.) torque. (3) Position the spare tire winch tube support bracket at the bottom of the cargo box and install the retaining screws. Tighten the screws securely. (4) Connect the fuel and vent hoses to the nozzle tubes (Fig. 38). Tighten the fuel hose clamp screw with 4 N m (35 in. lbs.) torque. Tighten the vent hose clamp screw with 2 N m (14 in. lbs.) torque. (5) Connect the tail pipe to the support hanger on the cargo box and remove the support. (6) Connect tail lamp wire harness connectors. (7) Connect the battery cables to the terminals. (8) Thoroughly inspect the installation of the cargo box on the frame and ensure that: All connecting hardware is correctly tightened. All electrical system components are functionally operational.
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BODY COMPONENTS
(2) Install light bar on side support cover. (3) Install nuts and support plates holding light bar to cargo box top rails. Torque to 25 N m. (239 in. lbs.). (4) Connect off road lamp wire connectors.
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page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 27 31 27 29 31 23 29
SERVICE INFORMATION
The door (Fig. 1) service procedures include: Complete door. Component removal/installation. Component replacement. Adjustments.
HINGE REPLACEMENT
REMOVAL (1) Support the door with a padded floor jack. (2) Use a wax pencil to mark the outline of the hinge-halves on the door and the cab pillar for installation alignment reference. (3) Remove the hinge-to-cab pillar screws. When removing a door hinge, DO NOT discard the shims (if equipped). (4) Remove the hinge-to-door screws and remove the hinge from the door and the cab (Fig. 1). INSTALLATION (1) Clean the hinge in an appropriate solvent and blow dry with compressed air. (2) Color coat the hinge to match the vehicle color. (3) Lubricate the hinge with engine oil. (4) Position the hinge on the door and install the hinge-to-door screws finger-tight. (5) Install the hinge-to-cab pillar screws fingertight. (6) Align the hinge-halves with the installation reference outlines on the door and the cab. (7) Tighten the hinge screws with 35 N m (26 ft. lbs.) torque. (8) Remove the floor jack from the door.
DOOR ADJUSTMENT
The doors are adjusted at the hinge attaching locations at either the cab pillar or the door, as applicable. Enlarged screw holes are located in the cab pillar for fore, aft and tilt adjustments. Enlarged screw holes are located in the door for up/down and in/out adjustments. Prior to door adjustment, the door latch must be removed to allow the door to close freely and be properly aligned without interference.
FORE AND AFT Fore/aft door adjustment should be made by loosening the screws for one hinge at a time and then moving the door to the correct position.
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BODY COMPONENTS
(1) Support the door with a padded floor jack. (2) Loosen the applicable hinge-to-cab pillar screws and move the door to the required fore/aft position. (3) If necessary, loosen the other hinge-to-cab pillar screws and move the door to the required fore/aft position. (4) Tighten the hinge screws with 35 N m (26 ft. lbs.) torque. (5) Remove the floor jack from the door.
UP AND DOWN (1) Support the door with a padded floor jack. (2) Loosen hinge-to-door screws at both hinges, and move the door to the required up/down position. (3) Tighten the hinge screws with 35 N m (26 ft. lbs.) torque. (4) Remove the floor jack from the door. IN AND OUT In/out door adjustment should be made by loosening the screws for one hinge at a time and then moving the door to the correct position. (1) Support the door with a padded floor jack. (2) Loosen the applicable hinge-to-door screws and move the door to the required in/out position. (3) If necessary, loosen the other hinge-to-door screws and move the door to the required in/out position. (4) Tighten the hinge screws with 35 N m (26 ft. lbs.) torque. (5) Remove the floor jack from the door. DOOR LATCH STRIKER The door latch striker can be adjusted either in or out to position it correctly for the door latch to be completely engaged when the door is closed. When closed, the door should be flush with the adjacent body panels.
INSTALLATION (1) Position the noise insulator on the door inner panel and install the retainers (Fig. 5). (2) Apply an appropriate adhesive/sealant to the waterdam edges before installing it (Fig. 4). (3) Position the waterdam on the door inner panel and press it inward at the areas with the adhesive (Fig. 4) to attach it to the inner panel. (4) Position the trim on the door inner panel and press around the perimeter of the panel to attach the inner panel. (5) Install the armrest (if removed) and the window glass regulator handle (Fig. 3), or (if equipped) the power switch housing (Fig. 2). Tighten the armrest retaining screws with 3 N m (20 in. lbs.) torque. Tighten the housing retaining screw with 2 N m (17 in. lbs.) torque.
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REMOVAL (1) For doors equipped with a power window, power door lock, power mirror and radio speaker, remove the door trim panel/waterdam/noise insulator. If necessary, refer to the removal procedure. (2) Disconnect the component wire harness connectors from the main wire harness (Fig. 6). Remove the main wire harness retainer from the door panel and then remove the main wire harness from the door.
DOOR INSTALLATION (1) If a replacement front door is being installed, coat the door interior with anti-corrosion wax. Also, seal the door hem flange with sealant. (2) Before installing a replacement door, as applicable, transfer: Original window glass and regulator. Electric motors. Key lock cylinder. Latch handles. Trim panel. Any remaining components to the replacement door. Refer to the applicable removal/installation procedures. (3) Lubricate the hinges with engine oil. (4) Position the door in the cab opening.
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BODY COMPONENTS
(4) Use Tool C-4867 to disengage the window glass edge sliders from the glass rear track (Fig. 8).
(5) Support the door with a padded floor jack. (6) Align the door hinge holes with the screw holes and install (but do not tighten) the hinge screws. (7) Install the door restraint (check) pin. (8) Adjust the door as necessary. Tighten the hinge screws with 35 N m (26 ft-lbs) torque. If necessary, refer to the adjustment procedure. (9) Adjust the latch striker and the latch as necessary. (10) Remove the floor jack from the door. (11) If applicable, insert the main wire harness into the door and install the retainer in the door panel. Connect the power window motor, the power door lock motor, the power mirror and the radio speaker wire harness connectors to the main wire harness connectors (Fig. 6). (12) If removed, install the door noise insulator, the waterdam and the trim panel. If necessary, refer to the installation procedure.
DOOR WINDOW GLASS/REGULATOR REMOVAL (1) Remove the door trim panel (or, if applicable, the access panel), the waterdam and the noise insulator. If necessary, refer to the removal procedure. (2) Open the window glass (move the glass down into the door). (3) Remove the retaining screws and the beltline weatherstrip moulding from the door (Fig. 7).
INSTALLATION (1) If removed, position the glass rear channel/ track in the door (Fig. 7) and install the retaining screws. Tighten the screws securely.
BODY COMPONENTS
(2) Install the lift channel and gaskets on the window glass with 1/4-20 x 1/2 bolts and nuts. Tighten the nuts with 10 N m (90 in. lbs.) torque. (3) Install replacement edge sliders on the window glass rear edge (Fig. 8). (4) Position the window glass regulator in the door and install the retaining screws (Fig. 9). Tighten the screws securely. (5) Install the window glass in the door: Insert the window glass into the door. Slide it forward and downward at a 45 angle. Engage the window glass edge sliders with the glass rear track (Fig. 8). Engage the lift channel with the regulator roller. (6) Position the beltline weatherstrip moulding on the door panel and install the retaining screws (Fig. 7). Tighten the screws securely. (7) Install the noise insulator, the waterdam and the door trim panel (or, if applicable, the access panel). If necessary, refer to the installation procedure.
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(2) Connect the lock cylinder-to-latch rod to the door latch. (3) Test the door lock cylinder-to-latch rod operation. (4) Install the door trim panel, the waterdam and the noise insulator. If necessary, refer to the installation procedure.
DETERMINING KEY/LOCK CODE When the door key or the key/lock code is not available, the following procedure can be used to determine the key/lock code. (1) Remove the key lock cylinder from the door. If necessary, refer to the removal procedure. (2) Remove the tumbler cover from the lock cylinder housing and discard it. (3) Individually remove each spring, driver and tumbler set from the lock cylinder housing. (4) Use the code plate to determine the code number for each set and record the results. (5) Continue, as instructed above, to determine the complete key/lock code with the remaining sets of spring, driver and tumbler. (6) Assemble the original tumbler, driver and spring sets (if not damaged) in the lock cylinder housing. (7) Install a replacement tumbler cover on the lock cylinder housing. (8) Install the key lock cylinder in the door. If necessary, refer to the installation procedure. REPAIR (1) Remove the key lock cylinder from the door. If necessary, refer to the removal procedure. (2) Determine the key/lock code. If necessary, refer to the procedure. (3) Discard the original lock cylinder housing tumbler cover, the tumblers, the drivers and the springs.
CAUTION: If the replacement spring coils are tangled, do not separate them by pulling them apart, un-thread them from each other so that they do not become stretched and distorted. (4) Assemble the replacement tumbler, driver and spring sets in the lock cylinder housing and install a replacement tumbler cover. (5) Install the original rod lever and E-clip retainer (if not damaged). (6) Test the repaired key lock cylinder for correct operation and install it in the door. If necessary, refer to the installation procedure.
INSTALLATION (1) Install the lock cylinder in the door hole. Retain the lock cylinder with the clip retainer.
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BODY COMPONENTS
(2) Remove the door trim panel, the waterdam and the noise insulator from the door inner panel. If necessary, refer to the removal procedure. (3) Remove the door handle attaching bracket nuts. (4) Disconnect the handle-to-latch rod from the latch. (5) Remove the handle and gasket from the door outer panel (Fig. 10). INSTALLATION (1) Apply silicone spray lubricant to the handle internal moving parts. (2) Position the gasket and handle on the door outer panel. (3) Position the handle attaching bracket at the inside of the handle. (4) Install and tighten the handle attaching bracket nuts securely. (5) Connect the handle-to-latch rod to the latch. (6) Test and ensure that the handle operates correctly. (7) Install the door noise insulator, the waterdam and the trim panel, the access panel). If necessary, refer to the installation procedure.
DOOR LATCH
REMOVAL (1) Raise the window glass to the completely closed position. (2) Remove the door trim panel, the waterdam and the noise insulator from the door inner panel. If necessary, refer to the removal procedure. (3) Disconnect the: Outside handle-to-latch rod from the latch. Key lock cylinder-to-latch rod from the latch. Inside handle-to-latch rod from the latch (Fig. 11). Lock knob-to-latch rod from the latch (Fig. 11), if equipped. Lock motor-to-latch rod from the latch (Fig. 11). (4) Remove the door latch retaining screws from the door inner panel face (Fig. 12). (5) Remove the door latch from the door via the access hole in the panel (Fig. 12). INSTALLATION (1) Install the latch striker, if removed. (2) Insert the door latch through the access hole in the panel, position it at the door face panel and connect the rods to it (Fig. 11). (3) Install the latch retaining screws in the door panel face (Fig. 12). Tighten the screws with 9 N m (7 ft-lbs) torque. (4) Test and ensure that the latch operates correctly.
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(5) Test and ensure that the latch lock operates correctly. (6) Install the door noise insulator, the waterdam and the trim panel. If necessary, refer to the installation procedure.
INSTALLATION (1) Insert the motor in the access hole in the inner panel and position it at the location of the retaining screw holes (Fig. 13). (2) Connect the lock motor-to-latch rod to the motor (Fig. 13). (3) Install the lock motor retaining screws. Tighten the screws with 11 N m (95 in. lbs.) torque. (4) Connect the lock motor wire harness connector to the door wire harness connector.
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BODY COMPONENTS
WINDOW GLASS SEAL INSTALLATION When installing door window glass weatherstrip seals (including the beltline weatherstrip moulding), open the window glass completely. (1) To install door window glass channel weatherstrip seal, start at the upper, rear corner. (2) A small amount of adhesive can be used to retain the weatherstrip seal in-place, if necessary. (3) Move forward and downward evenly until the weatherstrip seal is fully seated in the channel. (4) Position the beltline weatherstrip moulding on the door panel and install the retaining screws (Fig. 7). Tighten the screws securely. (5) Install the noise insulator, the waterdam and the door trim panel (or, if applicable, the access panel). If necessary, refer to the installation procedure. DOOR SEAL REMOVAL The cab body-to-door seal and the door primary weatherstrip seal are attached to retainer flanges. (Fig. 14).
BODY COMPONENTS
(3) The top of the seal must fit tight against the roof to provide a proper water-tight seal and to have good appearance (Fig. 14). SECONDARY WEATHERSTRIP SEAL (1) Clean the door sill contact surface (Fig. 15) with a 50/50 solution of isopropyl alcohol and clean water. (2) Remove the backing from the tape at the front of the seal. (3) Position the seal on the door sill with the screw holes aligned. The inner edge of the seal must be located under the door primary weatherstrip seal bulb, but must not contact or interfere with the bulb (Fig. 15). (4) Apply pressure to seal at the area of the tape to adhere the tape to the rocker panel/door sill (Fig. 15). (5) Attach the seal to the door sill with the screws (Fig. 15). Tighten the screws securely.
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REARVIEW MIRROR
REMOVAL (1) Loosen the mirror base setscrew and slide the mirror base up and off the support bracket (Fig. 16).
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Quarter Vent WindowClub Cab . . . . . . . . . . . . . . 33 Rear WindowClub Cab . . . . . . . . . . . . . . . . . . . 34 Rear WindowConventional Cab . . . . . . . . . . . . . 35
WINDSHIELD
WINDSHIELD REMOVAL (1) Remove inside rear view mirror (Fig. 1). (2) Remove cowl cover. Refer to Cowl Cover Removal paragraph in this group.
BODY COMPONENTS
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(2) Position the windshield inside up on a suitable work surface with two padded, wood 10 cm by 10 cm by 50 cm (4 in. by 4 in. by 20 in.) blocks, placed parallel 75 cm (2.5 ft.) apart (Fig. 5).
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BODY COMPONENTS
(2) Pull the seal away from the flange around the perimeter of the window opening (Fig. 8).
WEATHERSTRIP SEAL INSTALLATION (1) Position the index mark at the front, top corner and install the seal around the perimeter of the window opening. (2) Mate the seal with the front, vertical flange. (3) Move upward and mate the seal with the top flange. (4) Mate the seal with the rear, vertical flange. (5) Center and butt the seal ends together at the bottom, centerline of the opening. (6) Mate the seal with the bottom flange.
GLASS INSTALLATION (1) If removed, install the latch and frame/hinge on the glass. (2) Position the window glass at the opening, insert the hinge studs in the B-pillar holes, and install the retaining nuts. Tighten the nuts with 11 N m (95 in. lbs.) torque. (3) Attach the latch to the rear side panel with the screws. Tighten the screws with 11 N m (95 in. lbs.) torque. (4) Test the vent window for water leaks. WEATHERSTRIP SEAL REMOVAL (1) Remove the window. If necessary, refer to the removal procedure.
REMOVAL (1) If equipped, remove the window reveal moulding/retainer. (2) Separate the weatherstrip seal lip from the window glass (or frame) at one corner with a thin
BODY COMPONENTS
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window opening flanges in the cab. (2) Install the weatherstrip seal on the window glass or frame (Fig. 12).
REMOVAL (1) Remove quarter trim panels. (2) Remove headliner. (3) Remove rear closure panel trim. (4) Bend rear window retaining tabs inward against glass. (5) Using a suitable pneumatic knife from inside the vehicle, cut urethane holding rear glass frame to opening fence.
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BODY COMPONENTS
(2) Place the frame and glass on a clean, padded area. (3) Loosen the retaining screws located on the bottom of the frame. (4) Carefully spread the frame apart. (5) Remove the sliding vent glass from the frame track.
INSTALLATION (1) Clean urethane adhesive from around rear glass opening fence. (2) Apply black-out primer to outer edge of replacement rear glass frame. (3) Apply black-out primer to rear glass opening frame, (4) Apply a 10 mm (0.4 in.) bead of urethane around perimeter of windshield along the inside of the moldings. (5) Place rear glass into rear glass opening. (6) Firmly push glass against rear window glass opening fence. (7) Bend tabs around edges of rear window opening fence to retain glass. (8) Clean access urethane from exterior with Mopar , Super Clean or equivalent. (9) After urethane has cured, remove tape strips and water test windshield to verify repair. (10) Install interior trim.
INSTALLATION (1) Position the sliding vent glass in the frame track. (2) Tighten all the retaining screws at the bottom of the frame. (3) Test for correct travel and the latch operation for the sliding vent glass. (4) Install rear window in the cab opening. If necessary, refer to the installation procedure. (5) Inspect and ensure that the drain holes are not restricted.
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page . . . . . . . . . . . . . . . . 42 37 39 42
SEATS
BENCH SEAT
REMOVAL Bench seat support brackets are attached to the floor panel with studs, nuts and screws. The trim covers are attached to the brackets with screws (Fig. 1).
are in the same relative position on the lower support before any fasteners are secured. Tighten the front nuts and screws first and then the rear nuts and screws with 28 N m (250 in-lbs) torque. (3) Install the shoulder belt buckles and lap belts. (4) Install the seat track and support bracket covers and retaining screws. Tighten the screws with 2 N m (17 in-lbs) torque.
BUCKET SEAT AND 60/40 SEAT Bucket and 60/40 seat platforms are attached to the floor panel with studs, nuts and screws. The trim covers are attached to the platforms with screws (Fig. 2).
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BODY COMPONENTS
(2) Position the seat in the cab. Verify that stud spacers are seated on the floor. Install the retaining nuts on the studs and screws in the crossmember. Ensure that inboard and outboard adjuster latches are in the same relative position on the lower support before any fasteners are secured. Tighten the front nuts and screws first and then the rear nuts and screws with 28 N m (250 in-lbs) torque. (3) Install the seat platform cover and retaining screws. Tighten the screws with 2 N m (17 in-lbs) torque.
REAR 60/40 SEAT (CLUB CAB) The rear 60/40 seat cushion brackets are attached to the cab back panel with bolts and nuts. The seatback cushion is attached to the cab back panel with screws (Fig. 3).
BODY COMPONENTS
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BODY COMPONENTS
(6) Position the buckles and the lap belt (bench seat only) on the floor panel (Fig. 7 and 8). (7) As applicable, use a Torx bit to install the anchor bolts in the floor panel for: The bench seat left shoulder belt buckle/lap belt and the right shoulder belt/lap belt buckles (Fig. 7). The bucket seat shoulder belt buckles (Fig. 8). (8) Tighten the anchor bolts with 40 N m (350 in. lbs.) torque. (9) As applicable, position the covers over the anchor bolts for: The bench seat left shoulder belt buckle/lap belt and the right shoulder belt/lap belt buckles (Fig. 7). The bucket seat shoulder belt buckles (Fig. 8). (10) Connect the wire harness connectors (Fig. 7 and 8). (11) If applicable, adjust the seat position.
The bench seat left shoulder belt buckle/lap belt and the right shoulder belt/lap belt buckles (Fig. 7). The bucket seat shoulder belt buckles (Fig. 8). (4) As applicable, use a Torx bit to remove the anchor bolts from the floor panel for: The bench seat left shoulder belt buckle/lap belt and the right shoulder belt/lap belt buckles (Fig. 7). The bucket seat shoulder belt buckles (Fig. 8). (5) Remove the buckles and the lap belt (bench seat only) from the floor panel (Fig. 7 and 8). (6) At each side of the cab, remove the cover concealing the shoulder belt upper anchor bolt (Fig. 7 and 8). (7) At each side of the cab, use a Torx bit to remove the upper anchor bolt from the cab side panel (Fig. 7 and 8). (8) At each side of the cab: Slide the cover upward for access (club cab only). Remove the shoulder belt lower anchor bolt from the B-pillar (Fig. 7) or the floor panel (Fig. 8) with a Torx bit. (9) At each side of the cab, remove the belt retractor support retaining bolt from the B-pillar (Fig. 7) or panel (Fig. 8). (10) Remove the shoulder belts and the retractors from the cab (Fig. 7 and 8). INSPECTION Inspect the condition of the shoulder belts, lap belt (bench seat only) and buckles (Fig. 7 and 8). Replace any belt or buckle that is either cut, frayed, torn or damaged in any way. Also, replace the shoulder belt if the retractor is either damaged or inoperative. INSTALLATION (1) At each side of the cab, position the shoulder belt retractor in the receptacle (Fig. 7) or on the floor panel (Fig. 8). Install the support retaining bolt in the B-pillar (Fig. 7) or the floor panel (Fig. 8) with a Torx bit. (2) At each side of the cab, position the other end of the shoulder belt at the B-pillar (Fig. 7) or the floor panel (Fig. 8). Install the washer and the lower anchor bolt in the B-pillar (Fig. 7) or the floor panel (Fig. 8) with a Torx bit. (3) At each side of the cab, position the shoulder belt upper anchor plate on the trim panel (Fig. 7 and 8). Install the upper anchor bolts in the cab side panels with a Torx bit. (4) Tighten the upper and lower anchor bolts with 40 N m (350 in. lbs.) torque. (5) Position the covers over the upper anchor bolts and, for club cabs only, the covers over the lower anchor bolts (Fig. 7 and 8). When installing a replacement shoulder belt in a club cab, the lower anchor bolt cover must be rotated 180 degrees before positioning it over the bolt.
BODY COMPONENTS
(6) At each side of the cab, remove the cover concealing the shoulder belt upper anchor bolt. (7) At each side of the cab, use a Torx bit to remove the upper anchor bolt from the cab side panel. (8) At each side of the cab, remove the shoulder belt lower anchor bolt from the floor panel with a Torx bit. (9) At each side of the cab, remove the belt retractor support retaining bolt from the quarter panel with a Torx bit. (10) Remove the shoulder belts and the retractors from the cab. INSPECTION Inspect the condition of the shoulder belts, lap belt and buckles. Replace any belt or buckle that is either cut, frayed, torn or damaged in any way. Also, replace the shoulder belt if the retractor is either damaged or inoperative. INSTALLATION (1) At each side of the cab, position the shoulder belt retractor in the receptacle. Install the support retaining bolt in the quarter panel with a Torx bit. (2) At each side of the cab, position the other end of the shoulder belt at the floor panel. Install the lower anchor bolt in the floor panel with a Torx bit. (3) At each side of the cab, position the shoulder belt upper anchor plate on the trim panel. Install the upper anchor bolts in the cab side panels with a Torx bit. (4) Tighten the upper and lower anchor bolts with 40 N m (350 in. lbs.) torque. (5) Position the covers over the upper anchor bolts. (6) Position the buckles and the lap belt on the floor panel. (7) Install the anchor bolts in the floor panel for the left shoulder belt/lap belt and the right shoulder belt/lap belt. (8) Tighten the anchor bolts with 40 N m (350 in. lbs.) torque. (9) Install the rear seat. If necessary, refer to the installation procedure. (10) If applicable, adjust the seat position.
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REMOVAL
CAUTION: A cab headliner (Fig. 10) is a one-piece, molded hardboard. It has limited flexibility and must not be bent during removal/installation. (1) Remove the sunvisors and retaining clips. If necessary, refer to the removal procedure. (2) Remove the windshield trim mouldings, B-pillar panels or quarter panels (club cab) and rear window upper trim moulding. If necessary, refer to the removal procedure. (3) As applicable, remove the dome/cargo lamp, the map/reading lamp and/or overhead console. If necessary, refer to the removal procedures. (4) Remove the retaining screws and the assist handle (Fig. 11). (5) Remove the retaining screws and the coat hook (Fig. 10). (6) Remove all other headliner interfering components. (7) Remove the headliner retaining screws. (8) Carefully remove the headliner from the cab (Fig. 10).
HEADLINERS
SERVICE INFORMATION The Dakota standard equipment cab headliner is a molded hardboard. A cloth-cover molded cab headliner is used with SLT model. The cab headliner (Fig. 10), trim mouldings/panels and overhead console are attached to the roof panel with screws. To remove a headliner (Fig. 10), all of the interfering trim mouldings/panels must be removed along with (as applicable): The sunvisors (Fig. 10). The dome/cargo lamp.
INSTALLATION (1) Carefully position the headliner in the cab adjacent to the roof panel (Fig. 10). (2) Install the headliner retaining screws. Tighten the screws with 4 N m (35 in. lbs.) torque.
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BODY COMPONENTS
(2) Remove the retaining screws from the cab rear, inner panel. (3) Disconnect the wire harness connectors. (4) Remove the lamp from the headliner hole and the rear, inner panel. INSTALLATION (1) Position the dome lamp adjacent to the headliner and the rear, inner panel. (2) Connect the lamp wire harness connectors. (3) Position the lamp in the headliner hole and install the retaining screws in the panel. Tighten the screws with 4 N m (35 in. lbs.) torque. (4) Install the lamp lens.
OVERHEAD CONSOLE
Fig. 11 Assist Handle Removal/Installation
(3) Position the assist handle on the headliner and install the retaining screws (Fig. 11). Tighten the screws with 4 N m (35 in. lbs.) torque. (4) Position the coat hook on the headliner and install the retaining screws (Fig. 10). Tighten the screws with 4 N m (35 in. lbs.) torque. (5) Install the trim mouldings/panels, lamps and all other components that were removed for headliner access. As applicable, refer to the installation procedures (if necessary).
REMOVAL (1) Open sunglasses storage bin. (2) Remove console mounting screw (Fig. 13). (3) Slide console forward until it detaches from mounting bracket. (4) Disconnect wire harness from compass. INSTALLATION (1) Connect compass wire harness. (2) Place console forward of mounting bracket and slide console rearward until it attaches to mounting bracket. (3) Install console mounting screw. Tighten the screw with 2 N m (20 in. lbs.) torque.
DOME LAMP
REMOVAL (1) Remove the dome lamp lens by squeezing it and forcing it downward (Fig. 12).
SUNVISORS
REMOVAL (1) Remove the screws that attach the sunvisor arm support bracket to the headliner and the roof panel (Fig. 10). (2) Detach the sunvisor from the retaining clip. (3) Remove the sunvisor from the headliner and roof panel.
BODY COMPONENTS
(4) Remove the attaching screw and the retaining clip from the headliner and the roof panel.
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INSTALLATION (1) Install the sunvisor retaining clip with the attaching screw. (2) Position the sunvisor in the retaining clip and align the arm support bracket holes with the headliner holes. (3) Install the screws that attach the sunvisor arm support bracket to the headliner and the roof panel. Tighten the screws with 4 N m (35 in. lbs.) torque.
INSTALLATION (1) Position the console on the floor panel and bracket. (2) Install the attaching screws in the panel and bracket. Tighten the screws with 4 N m (35 in. lbs.) torque. (3) Install the front bin and close the lid.
STORAGE BOXCLUB CAB The rear seat storage box is attached to the floor pan with screws that are accessible inside the box (Fig. 15).
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BODY COMPONENTS
REMOVAL (1) Remove the protective floor mats (if equipped). (2) Remove all the interfering components. If needed refer to applicable removal procedure. (3) Remove the carpet/mat from the floor panel. INSTALLATION (1) Position the carpet/mat on the floor panel. (2) Install seat(s) and all the components that were removed to ease carpet/mat removal. If needed refer to applicable installation procedures. (3) Install the trim panels, mouldings and scuff plates. (4) Place the protective floor mats (if equipped) on the carpet/mat.
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ble to avoid corrosion. For best results, use Mopar Scratch Filler/Primer, Touch-Up Paints and Clear Top Coat. Refer to Introduction group of this manual for Body Code Plate information.
TOUCH-UP PROCEDURE (1) Scrape loose paint and corrosion from inside scratch or chip. (2) Clean affected area with Mopar Tar/Road Oil Remover and allow to dry. (3) Fill the inside of the scratch or chip with a coat of filler/primer. Do not overlap primer onto good surface finish. The applicator brush should be wet enough to puddle fill the defect without running. Do not stroke brush applicator on body surface. Allow the filler/ primer to dry hard. (4) Cover the filler/primer with color touch-up paint. Do not overlap touch-up color onto the original color coat around the scratch or chip. Butt the new color to the original color if possible. Do not stroke applicator brush on body surface. Allow touch-up paint to dry hard. (5) On vehicles without clear coat, the touch-up color can be lightly (600 grit) wet sanded and polished with rubbing compound. (6) On vehicles with clear coat, Apply clear top coat to touch-up paint with the same technique as described in step 4. Allow clear top coat to dry hard. If desired, step 5 can be performed on clear top coat.
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BODY COMPONENTS
AFTERMARKET PAINT AND TRIM REPAIR PRODUCTSAN-TRUCK
BODY COMPONENTS
TORQUE SPECIFICATIONS
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24 - 1
AIR CONDITIONING AND HEATER PERFORMANCE TEST . . . . . . . . . . . . . . . . . . . 7 COMPONENT SERVICE . . . . . . . . . . . . . . . . . . . 19 COMPRESSOR SERVICE . . . . . . . . . . . . . . . . . . 14 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . 1 HEATING AND AIR CONDITIONING TEST PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . 10
GENERAL INFORMATION
This vehicle is equipped with a common Heater and A/C housing. Vehicles with heater only system have the evaporator and recirculating air door omitted from the housing (Fig. 1). Air flow is directed either through or around the heater core by adjusting the blend-air door with the TEMP lever. Air flow can be directed to the PANEL outlets, BI-LEVEL (panel & floor) outlets, FLOOR outlet, or DEFROST outlets. ant vapor is then pumped into the condenser where it cools by giving off heat to air passing over the condenser fins. As the refrigerant cools in the condenser, it condenses into a liquid. Still under high pressure, the liquid refrigerant passes into the fixed orifice tube. The fixed orifice tube meters the flow of refrigerant into the evaporator coil where a low pressure is maintained by the suction side of the compressor. As it enters the evaporator, the refrigerant immediately begins to boil by absorbing heat from the air passing over the evaporator core. Having given up its heat to boil the refrigerant, the air is cooled and passes into the passenger compartment of the vehicle. From the evaporator the vaporized refrigerant enters the accumulator which separates the liquid from the vapor. The vapor and oil are drawn back into the compressor to repeat the cycle. Ambient air intake can be shut off by closing the recirculating air door. This will cool the air that is already inside the vehicle. This is done by moving the TEMP lever into the RECIRC position. Depressing the A/C button will allow refrigerant to flow through the evaporator. This cools and dries the plenum air before it is directed through or around the heater core (Fig. 1).
HEATER SYSTEM
The heater system is a blend-air type. Outside air enters the cowl opening and passes through the heater core. A temperature control door in the housing directs the air through or around the heater core. The amount of heat is determined by the setting of the temperature lever on the instrument panel. Direction of the air is controlled by the HEAT-DEFROST lever on the instrument panel. A self-adjusting clip, on the control cables simplifies cable adjustment. The clip snaps onto the control cable wire and slides along the wire under a specific load to provide an automatic adjustment.
A/C COMPONENTS
ACCUMULATOR: The Accumulator is mounted in the engine compartment on the right side of the vehicle. The inlet tube of the accumulator attaches directly to the evaporator core outlet tube. Refrigerant enters the accumulator canister through the inlet tube. The liquid oil-laden refrigerant falls to the bottom of the canister which acts as a separator. A desiccant bag is mounted inside the suction accumulator canister to absorb any moisture which may be in the refrigerant system (Fig.2).
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Fig. 2 Accumulator
COMPRESSOR: The SD7H15 Compressor is used on all models. The purpose of the compressor is to compress the low-pressure refrigerant vapor into a high pressure, high temperature vapor. The compressor is serviced as a assembly only. CLUTCH PULLEY AND COIL: They are mounted on the compressor and providing a way to drive the compressor. The compressor clutch and coil are the only serviced parts on the SD7H15 compressor. When the compressor is not in operation, the pulley free wheels on the clutch hub bearing. When the coil is energized the clutch plate is magnetically engaged with the pulley and turns the compressor shaft. AIR CONDITIONING CYCLING SWITCH: The switch is mounted on top of the accumulator on 3.9L and 5.2L engines. On the 2.5L engine the switch is mounted on the side of the accumulator. The switch is wired in series with compressor clutch. The switch contacts open and close turning on an off the compressor clutch. This regulates the system pressure. Lower ambient temperatures, below approximately -1C (30F) during cold weather will also open the switch contacts. This is due to the pressure/temperature relationship of the refrigerant in the system. CONDENSER: The condenser is located in front of the engine radiator. Its function is to cool the hot
REFRIGERANT
This vehicle uses a new type of refrigerant called R-134a. It is a non-toxic, non-flammable, clear colorless liquified gas. R-134a refrigerant is not compatible with R-12 refrigerant in an air conditioning system. Even a small amount of R-12 in a R-134a system will cause compressor failure, refrigerant oil sludge or poor air conditioning system performance.
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REFRIGERANT EQUIPMENT
WARNING: EYE PROTECTION MUST BE USED WHEN SERVICING AN AIR CONDITIONING REFRIGERANT SYSTEM. TURN OFF (ROTATE CLOCKWISE) ALL VALVES ON THE EQUIPMENT BEING USED BEFORE PROCEEDING WITH THIS OPERATION. PERSONNEL INJURY CAN RESULT. Chrysler Corporation recommends a (R-134a) recycling device that meets SAE standard J2210 be used when servicing the refrigerant system. Contact an automotive service equipment supplier for refrigerant recycling equipment that is available in your area. Refer to the operating instructions provided with the recycling equipment for proper operation.
CAUTIONS
CAUTION: Liquid refrigerant is corrosive to metal surfaces. Follow the operating instructions supplied with equipment being used.
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CAUTION: DO NOT use R-12 equipment or parts on the R-134a system. Damage to the system will result. CAUTION: Never add R-12 to a system designed to use R-134a. Damage to the system will result. CAUTION: R-12 compressor oil can not be mixed with the R-134a compressor oil. They ARE NOT compatible.
COOLING SYSTEM
To maintain the performance level of the heating/ air conditioning system, the engine cooling system must be properly maintained. The use of a bug screen is not recommended. Any obstructions in front of the radiator or condenser can reduce the performance of the A/C and/or the engine cooling system.
SERVICE PRECAUTIONS
Never open or loosen a connection before the refrigerant has been recovered from the system. A system which has been opened or one which has discharged through leakage must be evacuated before charging. DO NOT open a refrigerant system or uncap a replacement component unless it is as close as possible to room temperature. This will prevent condensation from forming inside of a component which is cooler than the surrounding air. Before disconnecting a component from the system, clean the outside of the fittings thoroughly. When disconnecting a fitting use a wrench on both halves of the fitting. This will prevent twisting of the refrigerant lines or tubes. Immediately after disconnecting a component from the system, seal the open fittings with a cap or plug. DO NOT remove the sealing caps from a replacement component until ready to install. Before connecting an open fitting always install a new seal. Coat the fitting and seal with clean refrigerant oil before connecting. Tighten fittings only to the specified torque. The aluminum fittings used in the A/C system will not tolerate over tightening. Refrigerant oil absorbs moisture from the atmosphere. DO NOT open an oil container until ready to use and install the cap immediately after using. Store the oil only in a clean moisture-free container. When installing a refrigerant line avoid sharp bends. Position the line away from the exhaust or any sharp edges which may chafe the line.
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operating levels. This will reduce the performance of the air conditioner and damage the compressor. Moisture will boil at near room temperature when exposed to vacuum. To evacuate the refrigerant system use following procedure: (1) Connect a suitable charging station and manifold gauge set to the vehicle. (2) Open the low and high side valves and start vacuum pump. When suction gauge reads 88 kPa (26 in. Hg) vacuum or greater, close all valves and turn off vacuum pump. If system fails to reach specified vacuum, the system has a leak that must be corrected. If system maintains the specified vacuum for 30 minutes, start the vacuum pump. Then open the suction and discharge valves and evacuate an additional 10 minutes. (3) Close all valves. Turn off and disconnect the vacuum pump. The system is now ready to be charged with refrigerant.
REFRIGERANT CHARGE CAPACITY The R-134a system charge capacity is 0.9 kg (2 lbs.).
REFRIGERANT OIL
It is important to have the correct amount of oil in the A/C system. This will ensure proper lubrication of
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the compressor. Too little oil will result in damage to the compressor. Too much oil will reduce the cooling capacity of the system. The oil used in the SD7H15 compressor is a polyalkylene glycol synthetic oil SP-20 PAG, wax-free refrigerant oil. Only refrigerant oil of the same type should be used to service the system. Do not use any other oil. The oil container should be kept tightly capped until it is ready for use and then capped after use to prevent contamination. Refrigerant oil will quickly absorb any moisture it comes in contact with.
OIL LEVEL CHECK It will not be necessary to check oil level in the compressor or to add oil unless there has been an oil loss. This may be due to a rupture or leak from a line, shaft seal, evaporator or condenser. Oil loss at a leak point will be evident by the presence of a wet, shiny surface around the leak. When an A/C system is assembled at the factory, all components (except the compressor) are refrigerant oil free. After the system has been charged and operated, the oil in the compressor is dispersed through the system. The accumulator, evaporator, condenser and compressor will retain a significant amount of oil.
HEATING AND AIR CONDITIONING AIR CONDITIONING AND HEATER PERFORMANCE TEST AIR CONDITIONING PERFORMANCE TEST
REVIEW WARNINGS AND CAUTIONS IN THIS GROUP BEFORE PERFORMING THE FOLLOWING TESTS. Humidity has an important bearing on the temperature of the air delivered to the vehicles interior. It is important to understand the effect humidity has on the performance of the system. When humidity is high, the evaporator has to perform a double duty. It must lower the air temperature and the temperature of the moisture carried in the air. Condensing the moisture in the air transfers a great deal of heat energy into the evaporator fins and tubing. This reduces the amount of heat the evaporator can absorb from the air. High humidity greatly reduces the evaporators ability to lower the temperature of the air. Evaporator capacity used to reduce the amount of moisture in the air is not wasted. Wringing some of the moisture out of the air entering the vehicle adds to the comfort of the passengers. However, an owner may expect too much from their air conditioning system on humid days. A performance test is the best way to determine whether or not the system is performing up to standard. This test also provides valuable clues to the possible cause of trouble. Air temperature in test room and in the vehicle must be 21C (70F) minimum for this test. (1) Connect an engine tachometer and manifold gauge set.
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(2) Set controls to A/C (Compressor ON), RECIRC PANEL, temperature control on full cool and blower on HIGH . (3) Start engine and hold at 1,000 RPM with A/C clutch engaged. (4) Engine should be warmed up with windows and/or doors closed. (5) Insert a thermometer in the left center A/C outlet and operate the engine for 5 minutes. (6) The A/C clutch may cycle depending on ambient conditions. If clutch cycles, remove the clutch cycling pressure switch connector from the switch located on the accumulator (Fig. 1). Place a jumper wire across the terminals of the clutch cycling pressure switch connector. (7) With the A/C clutch engaged, record the discharge air temperature and the compressor discharge pressure. (8) Compare the discharge air temperature to the A/C Performance (Temperature and Pressure) Chart. If the discharge air temperature is high, refer to the Refrigerant Service Procedures (Refrigerant Leak Testing and Pressure Diagnosis Chart). (9) Compare the compressor discharge and suction pressures to the A/C Performance (Temperature and Pressure) Chart. If the compressor discharge pressure or suction (evaporator inlet) pressure is not normal, check the operation of the refrigerant system, referring to Refrigerant System Pressure Diagnosis Chart. The following charts have been developed for quick reference.
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PRESSURE DIAGNOSIS
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TEMPERATURE REFERENCE
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HEATING AND AIR CONDITIONING HEATING AND AIR CONDITIONING TEST PROCEDURES INDEX
page page High Pressure Relief Valve . . . . . . . . . . . . . . . . . . 13 High-Pressure Cut-Off Switch . . . . . . . . . . . . . . . . 13 Vacuum Switch Test . . . . . . . . . . . . . . . . . . . . . . . 10 vacuum test probe. Place vacuum gauge on the cowl so it can be observed from the drivers position as control is operated. Start the test by setting the control selector on FLOOR position. Vacuum gauge needle will drop until the actuator has operated, then return to -25 to -27 kPa (7-1/4 to 8 inches of vacuum). Change selector to DEFROST, BI-LEVEL, PANEL, and (with A/C) RECIRC. The maximum allowable vacuum drop below -27 kPa (8 inches of vacuum) after each operation is -3 kPa (3/4 inch). Bypass the vacuum storage tank, if equipped. If vacuum drop is more than -3 kPa (3/4 inch), insure tester reading is exactly -27 kPa (8 inches). If correct, inspect 7-port hose connector for leaks.
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CAUTION: DO NOT use lubricant on the switch ports or in the holes in the plug, as lubricant will damage the vacuum valve in the switch. If it is difficult to properly position the connector plug on the switch ports, put a drop of clean water in the holes of connector plug. This will allow the plug to slide completely on the switch ports. If vacuum drop is now within limits, proceed with the overall performance test. If vacuum drop is still in excess of -3 kPa (3/4 inch), remove 7-port connector from switch. Seal port No.3 (female connector) with a finger to check source hose. Then remove probe from source line and insert it alternately into each connector port except No.6 (Fig. 1).
BLOWER MOTOR
Power to the blower motor is supplied from fuse #1. The blower speed is controlled by the blower switch and blower resistors. With the switch in LO, the
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ground circuit or the C-2 feed circuit (refer to Group 8W, Wiring Diagrams). (b) If the A/C cutout relay does not click (ignition and A/C button ON), test for battery voltage at single pin connector on A/C cutout relay. Voltage reading OK, proceed to Step 5a. Voltage at 0-1 volt, proceed to Step 5b. (4) With the ignition off, disconnect the 60-way connector from the PCM. Return ignition and A/C to the ON position. Test for battery voltage at cavity 34 of the 60-way connector. Voltage reading OK and female terminal is not damaged, replace the PCM. Voltage reading 0, repair open or short in N13 circuit. (5) With the ignition off, disconnect the 60-way connector from the PCM. Return ignition and A/C to the ON position. Test for battery voltage at the single pin connector of the A/C cutout relay. Voltage reading OK, replace PCM. Voltage reading 0, proceed to Step 6. (6) With ignition and A/C ON, test for battery voltage at the green wire (C25) in the 3-way connector of the A/C cutout relay.
CLUTCH COIL TEST (1) Verify battery state of charge (Test indicator should be green). (2) Connect an ammeter (0-10 ampere scale) in series with the clutch coil terminal. Use a voltmeter (020 volt scale) with clip leads measuring voltage across the battery and A/C clutch. (3) With A/C control in A/C mode and blower at low speed, start the engine and run at normal idle. (4) The A/C clutch should engage immediately and the clutch voltage should be within 2 volts of the battery voltage. If the A/C clutch does not engage, check the fuse (fusible link with front wheel drive vehicles). (5) The A/C clutch coil is acceptable, if the current draw is 2.0 to 3.7 amperes at 11.5 to 12.5 volts at clutch coil. The room ambient temperature should be 21C 3C (70F 5F). Where voltage is more than 12.5 volts, add electrical loads as needed by increasing blower speed and/or switching other electrical accessories on. If coil current reads zero, the coil is open and should be replaced. If the ammeter reading is 4 amperes or more, the coil is shorted and should be replaced. If the coil voltage is not within 2 volts of the battery voltage, check the circuit external to the clutch coil for excessive voltage drop and repair accordingly.
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A/C Compressor Noise . . . . . . . . . . . . . . . . . . . . . 14 Compressor Clutch Coil Assembly . . . . . . . . . . . . . 15 Compressor Drive Belt . . . . . . . . . . . . . . . . . . . . . 14
COMPRESSOR REPLACEMENT
REVIEW WARNINGS AND CAUTIONS IN THIS GROUP BEFORE PERFORMING THE FOLLOWING PROCEDURE.
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(4) Evacuate and charge the A/C system (refer to Refrigerant Service Procedures). (5) Connect the negative cable to the battery.
REMOVAL (1) Disconnect negative cable from battery. (2) Remove drive belt (refer to Group 7, Cooling System). (3) Disconnect compressor clutch wire. (4) Recover refrigerant (refer to Refrigerant Service Procedures). (5) Remove refrigerant lines from compressor and tape openings. (6) Remove compressor attaching bolts and remove compressor. INSTALLATION If a replacement compressor is being installed check the oil level. Add or subtract oil as necessary and install the magnetic clutch on the compressor. (1) Install compressor on the mounting bracket. Tighten compressor mounting bolts to 27 N m (20 ft. lbs.) torque. (2) Remove the tape from opened ports. (3) Install refrigerant lines on compressor with new seals. (4) Install drive belt (refer to Group 7, Cooling System). (5) Connect compressor clutch wire lead and negative battery cable. (6) Evacuate and charge A/C system (refer to Refrigerant Service Procedures). (7) Test system for leaks.
COMPRESSOR MANIFOLD
REVIEW WARNINGS AND CAUTIONS IN THIS GROUP BEFORE PERFORMING THE FOLLOWING PROCEDURE.
REMOVAL (1) Disconnect the negative cable from the battery. (2) Recover refrigerant (refer to Refrigerant Service Procedures). (3) Disconnect refrigerant lines from manifold. (4) Remove manifold bolts and remove manifold. INSTALLATION (1) Install manifold on the compressor with new seal. (2) Install manifold bolts and tighten to 25 N m (19 ft. lbs.) torque. (3) Install refrigerant lines to manifold.
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(7) Tap the end of the driver while guiding the clutch assembly to prevent binding. Tap until the clutch assembly bottoms against the compressor front housing hub. Listen for a distinct change of sound during the tapping process. (8) Install external front housing snap ring. (9) Install front plate assembly. Check that original clutch shims are in place on compressor shaft. (10) Using Shaft Protector Tool 6141-2, tap front plate over compressor shaft until it has bottomed to the clutch shims (Fig. 9). Listen for a distinct change of sound during the tapping process.
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page . . . . . . . . . . . . . . . . . . . . . . . . 21 20 21 20 19 19
REFRIGERANT LINES
REVIEW WARNINGS AND CAUTIONS IN THIS GROUP BEFORE PERFORMING THE FOLLOWING PROCEDURE.
REMOVAL (1) Recover refrigerant (refer to Refrigerant Service Procedures). (2) Fit the appropriate Spring Lock Coupling Tool from A/C Tool Kit 6125 (Fig. 1).
INSTALL (1) Check to ensure that the garter spring is in the cage of the male fitting. If the garter spring is missing, install a new spring by pushing it into the cage opening. If the garter spring is damaged, remove it from the cage with a small wire hook (DO NOT use a screwdriver) and install a new spring. (2) Clean all dirt or foreign material from both pieces of the coupling. (3) Install new O-rings on the male fitting.
CAUTION: Use only the specified O-rings as they are made of a special material for the R-134a system. The use of any O-ring other than the specified O-ring may allow the connection to leak intermittently during vehicle operation. (4) Lubricate the male fitting and O-rings and the inside of the female fitting with clean R-134a (SP20 PAG) refrigerant oil. (5) Install the plastic indicator ring into the cage opening if indicator ring is to be used. (6) Fit female fitting to male fitting and push until garter spring snaps over flared end of female fitting. If plastic indicator ring is used, it will snap out of the cage opening when the coupling is connected to indicate engagement. (7) If indicator ring is not used, ensure coupling engagement. This is done by visually checking to be sure garter spring is over the flared end of female fitting.
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INSTALLATION To install, reverse the preceding operation. To Adjust Temperature Cable, position the TEMP lever on the control to the cool side of its travel. Allowing the self adjusting clip to slide on the cable, rotate the blend-air door crank counterclockwise by hand until it stops.
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HEATER HOSES
REVIEW WARNINGS AND CAUTIONS IN THIS GROUP BEFORE PERFORMING THE FOLLOWING PROCEDURE.
REMOVAL (1) Drain engine cooling system (refer to Group 7, Cooling System). (2) Loosen clamps at each end of hose to be removed (Figs. 8 and 9).
CAUTION: When removing hoses from heater core inlet or outlet nipples, DO NOT use excessive force. Heater core may become damaged and leak engine coolant into heater A/C housing. (3) Carefully rotate hose back and forth while tugging slightly away from connector nipples. (4) On 3.9L and 5.2L engines: (a) Remove the coolant return tube (Fig. 10). (b) Discard the old O-ring.
INSTALLATION (1) On 3.9L/5.2L engines: (a) Install a new O-ring onto the coolant return tube (Fig. 10). Coat the new O-ring with antifreeze before installation. (b) Install the coolant return tube and tighten the coolant return tube bracket bolt. (2) Install the hoses onto the connector nipples. (3) Tighten the clamps at each end of hoses.
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INSTALLATION BLOWER MOTOR (1) Position the blower motor and wheel assembly to the heater A/C unit housing. Install and tighten the 3 screws. (2) Position the blower housing to the heater A/C unit. Install and tighten the 5 screws. (3) Install and tighten the 2 screws at the top of the blower housing, securing it to the unit cover. (4) Connect blower lead wire connector. On vehicles equipped with A/C, connect the 2 vacuum lines to the recirculating air door actuator. (5) Install the lower instrument panel module (refer to Group 8E, Instrument Panel). (6) Connect the negative cable to the battery.
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REMOVAL (1) Disconnect the negative cable from the battery. (2) Recover refrigerant system (refer to Refrigerant Service Procedures). (3) Remove lower instrument panel module (refer to Group 8E Instrument Panel). (4) Remove the center air distribution duct. (5) Tape wiring harness up and out of the way (Fig. 15).
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ASSEMBLE (1) Install cover into place while guiding the panel air mode door pivot shaft into its socket. (2) Install cover attaching screws into the housing.
INSTALLATION (1) Install the unit with the attaching studs facing downward. Carefully rotate and push the housing forward until attaching studs fit into the dash panel. (2) Install housing support brace and tighten the attaching screw. (3) Install and tighten the 4 housing attaching nuts at the rear engine compartment dash panel. (4) Install the condensate drain tube. (5) Remove plugs from the heater core tubes and connect the heater hoses. (6) Remove tape from the open ends of the refrigerant lines. Install the expansion valve and connect refrigerant lines. (7) Install the self adjusting clip to blend-air-door crank. Connect the temperature control cable flag retainer to the housing. (8) Connect vacuum harness connector from housing to the control connector. Connect the vacuum feed line to check valve. (9) Connect demister hoses to the adapter on top of the housing. (10) Connect heater blower wire. (11) Install the antenna cable to the retaining clip at the right end of the housing. (12) Remove the tape holding the wiring harness up and out of the way. (13) Install the center air distribution duct. (14) Install the lower instrument panel module (refer to Group 8E Instrument Panel). (15) Connect the negative cable to the battery. (16) Fill the engine cooling system (refer to Group 7, Cooling System). (17) Evacuate and charge the refrigerant system (refer to Refrigerant Service Procedures).
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BLEND-AIR DOOR
The heater A/C housing must be removed to service the mode, heater defroster or blend-air door.
REMOVAL (1) Remove heater A/C unit top cover. (2) Remove nut from bottom of the blend-air door pivot shaft and lift from the housing (Fig. 22).
HEATER CORE
REMOVAL (1) Remove housing top cover. (2) Remove the attaching screw from the heater core retaining bracket and lift the heater core from housing. INSTALLATION (1) Position the heater core into housing. Install and tighten the attaching screw to the heater core retaining bracket. (2) Install housing top cover.
EVAPORATOR COIL
REMOVAL (1) Remove housing top cover. (2) Lift the evaporator coil from housing (Fig. 23). INSTALLATION (1) Position the evaporator coil into the housing. (2) Install housing top cover.
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ON-BOARD DIAGNOSTICS
FOR CERTAIN EMISSION SYSTEM COMPONENTS The powertrain control module (PCM) performs an On-Board Diagnostic (OBD) check for certain emission system components on all vehicles. This is done by setting a diagnostic trouble code (DTC). A DTC can be obtained in two different ways. One of the ways is by connecting the DRB scan tool to the data link connector. This connector is located in the engine compartment (Fig. 2). Refer to the appropriate Powertrain Diagnostic Procedures service manual for operation of the DRB scan tool. The other way is to cycle the ignition key and observe the malfunction indicator lamp (MIL). The MIL lamp is displayed on the instrument panel as the CHECK ENGINE lamp (Fig. 3). This lamp will flash a numeric code. If a numeric code number 32 is observed, a problem has
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been found in the EGR system. If a numeric code number 31 is observed, a problem has been found in the EVAP system.
EGR System Check: The OBD check will activate only during selected engine/driving conditions. When the conditions are met, the PCM energizes either the EGR valve control solenoid (3.9L/5.2L engines) or the EGR purge solenoid (2.5L engine) to disable the
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EGR. The PCM checks for a change in the oxygen sensor signal. If the air-fuel mixture goes lean, the PCM will attempt to enrichen the mixture. The PCM registers a diagnostic trouble code (DTC) if the EGR system has failed or degraded. After registering a DTC, the PCM turns the CHECK ENGINE lamp on. Illumination of this lamp indicates the need for immediate service. Note that the CHECK ENGINE lamp will illuminate initially for approximately two seconds each time the ignition key is turned to the ON position. This is done for a bulb test. For a complete operational description of all DTCs, for accessing a DTC and for erasing a
DTC, refer to On-Board Diagnostics. This can be found in the General Diagnosis sections of Group 14, Fuel System. For numeric flash lamp code charts for emission related components, refer to Diagnostic Trouble Code (DTC). This can also be found in the General Diagnosis sections of Group 14, Fuel System.
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EVAP canister purge solenoid allows the EVAP canister to be purged at predetermined times and at certain engine operating conditions.
EVAP CANISTER
A sealed, maintenance free, EVAP canister is used on all vehicles. The canister is mounted in the engine compartment on the right side of the radiator closure panel (Fig. 4). The EVAP canister is filled with granules of an activated carbon mixture. Fuel vapors entering the EVAP canister are absorbed by the charcoal granules. Fuel tank pressure vents into the EVAP canister. Fuel vapors are temporarily held in the canister until they can be drawn into the intake manifold. The
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Fig. 13 Moderate Intake Manifold Vacuum Maximum Vapor Flow Fig. 10 Typical Closed Crankcase Ventilation System
POSITIVE CRANKCASE VENTILATION (PCV) VALVE The PCV valve contains a spring loaded plunger. This plunger meters the amount of crankcase vapors routed into the combustion chamber based on intake manifold vacuum. When the engine is not operating, or during an engine popback, the spring forces the plunger back against the seat. This will prevent vapors from flowing through the valve (Fig. 11). INSPECTION AND SERVICE PROCEDURE (1) With engine idling, remove the PCV valve from cylinder head cover. If the valve is not plugged, a hissing noise will be heard as air passes through the valve. Also, a strong vacuum should be felt at the valve inlet (Fig. 14). (2) Install the PCV valve. Remove the crankcase breather/filter. Hold a piece of stiff paper, such as a parts tag, loosely over the opening of crankcase breather/filter at the cylinder head (valve) cover (Fig. 15).
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EGR (Exhaust Gas Recirculation) Systems . . . . . . 11 Heated Inlet Air System2.5L Engine . . . . . . . . . . 10
amount of air allowed to enter from the ambient and heat stove inlets is determined by the position of the blend door in the air cleaner snorkel. The system is designed to maintain the throttle body inlet air at a calibrated temperature. When ambient air temperature is 9C (15F) or more above system calibration temperature, air flow will be through outside (ambient) air inlet. When ambient air temperature is 12C (10F) or more below system calibration temperature, air flow will be through heat stove inlet of air cleaner. At intermediate temperatures, the air entering the throttle body is a blend of ambient air and heat stove air. The colder the ambient air, the greater the flow of air through the stove. The warmer the air, the greater the flow through the snorkel.
HEATED AIR INLET SYSTEM TESTING2.5L ENGINE An improperly operating heated air inlet system can affect driveability and the vehicles exhaust emission. Perform the following procedure to determine if the air inlet system is functioning properly. (1) Be sure that the heat stove-to-air cleaner flexible connector (Fig. 1) are properly attached. Be sure all vacuum hoses are properly attached and in good condition. (Fig. 2).
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dilute the incoming fuel/air mixture. This dilution reduces peak flame temperature during combustion. A malfunctioning EGR system can cause engine spark knock, sags or hesitation, rough idle, engine stalling and poor driveability.
EGR GAS FLOW TESTALL ENGINES Use the following test procedure to determine if exhaust gas is flowing through the EGR valve. It can also be used to determine if the EGR tube is plugged, or the system passages in the intake or exhaust manifolds are plugged. This is not to be used as a complete test of the EGR system. The engine must be started, running and warmed to operating temperature for this test. (1) All engines are equipped with two fittings located on the EGR valve (Fig. 4). The upper fitting (located on the vacuum motor) supplies engine vacuum to a diaphragm within the EGR valve for valve operation. The lower fitting (located on the base of the EGR valve) is used to supply exhaust back-pressure to the EGR valve control.
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haust gas is flowing through the EGR tube between the intake and exhaust manifolds. (7) If the engine speed did not change, the EGR valve may be defective, the EGR tube may be plugged with carbon, or the passages in the intake and exhaust manifolds may be plugged with carbon. (a) Remove EGR valve from engine. Refer to EGR Valve Removal in this group. (b) Apply vacuum to the vacuum motor fitting and observe the stem on the EGR valve. If the stem is moving, it can be assumed that the EGR valve is functioning correctly. The problem is in either a plugged EGR tube or plugged passages at the intake or exhaust manifolds. Refer to step (c). If the stem will not move, replace the EGR valve. Note: The EGR valve, valve control and attaching hoses are serviced as one unit. Refer to EGR Valve Removal/Installation in this group. (c) Remove the EGR tube between the intake and exhaust manifolds. Check and clean the EGR tube and its related openings on the manifolds. Refer to EGR Tube in this group for procedures. Do not attempt to clean the EGR valve. If the valve shows evidence of heavy carbon build-up near the base, replace it.
EGR SYSTEM OPERATION2.5L 4-CYLINDER ENGINE The system consists of: An EGR valve assembly (Figs. 5 or 7). A engine vacuum operated (non-electrical), transducer-type EGR valve control (Figs. 5 or 7). An electric EGR purge solenoid (Fig. 6). Unlike the 3.9L/5.2L engine, electrical control for engine vacuum operation of the EGR valve is accomplished by this separate and remotely mounted solenoid. The powertrain control module (PCM) to control the electric EGR solenoid. An EGR tube (Fig. 7) connecting a passage in the intake manifold (near the EGR valve) to the exhaust manifold. Hoses to connect the various components. When the PCM removes the ground signal to the EGR purge solenoid, EGR system operation starts to occur. The PCM will monitor and determine when to supply and remove this ground signal depending on certain engine temperatures, throttle positions and other engine operating conditions. If the electrical connector to the EGR purge solenoid is disconnected, or the electrical signal is lost, the EGR valve will operate at all times. This may result in; poor engine performance, rough idle speed and reduced driveability during certain operating conditions. After the ground signal is removed from the EGR solenoid, engine vacuum (full-manifold) will be allowed to pass through the solenoid and on to the EGR valve control with a connecting hose.
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Engine vacuum (full-manifold) is passed through the EGR valve control to the EGR valve. The inlet seat (poppet valve) at the bottom of the EGR valve opens to dilute and recirculate exhaust gas back into the intake manifold. For more information, also refer to Open Loop/ Closed Loop Modes of Operation in the Single-Port Fuel Injection section of Group 14, Fuel Systems for 2.5L engine.
EGR VALVE LEAKAGE TEST2.5L 4CYLINDER ENGINE This is not to be used as a complete test of the EGR system. If the engine will not idle, dies out on idle, or idle is rough or slow, the poppet valve (Fig. 5) at the base of the EGR valve may be leaking in the closed position. The diaphragm (Fig. 5) within the EGR valve may also be ruptured. (1) The engine should be off for the following test. (2) Disconnect the rubber hose from the fitting (Fig. 5) at the top (vacuum motor) side of the EGR valve. (a) Connect a hand-held vacuum pump to this fitting. (b) Apply 15 inches of vacuum to the pump. (c) Observe the gauge reading on the pump. (d) If vacuum falls off, the diaphragm in the EGR valve has ruptured.
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(e) Replace the EGR valve. Note: The EGR valve, valve control and attaching hoses are serviced as one unit. Refer to EGR Valve Removal/Installation in this group. (f) Proceed to the next step. (3) A small metal fitting (back-pressure fitting) is located at the base of the EGR valve (Fig. 5). A rubber back-pressure hose connects it to the back-pressure fitting on the EGR valve control. Disconnect this rubber hose at the EGR valve fitting. (4) Remove the air cleaner housing from the throttle body. (5) Using compressed air, and using an air nozzle with a rubber tip, apply approximately 50 psi of regulated shop air to the metal back-pressure fitting on the EGR valve. (6) By hand, open the throttle to the wide open position. Air should not be heard emitting from the intake manifold while applying air pressure at the back-pressure fitting. (7) If air can be heard emitting from the intake manifold, the poppet valve (Fig. 5) is leaking at the bottom of the EGR valve. Replace the EGR valve. Do not attempt clean the old EGR valve. Note: The EGR valve, valve control and attaching hoses are serviced as one unit. Refer to EGR Valve Removal/Installation in this group.
EGR VALVE CONTROL TEST2.5L 4CYLINDER ENGINE The first part of this test will determine if the transducer diaphragm at the back-pressure side of the valve control has ruptured or is leaking. The second part of the test will determine if engine vacuum (full-manifold) is flowing from the inlet to the outlet side of the valve control. This is not to be used as a complete test of the EGR system. (1) Electrical operation of the electric EGR solenoid should first be checked with the DRB scan tool before proceeding with vacuum test. Refer to the appropriate Powertrain Diagnostic Procedures service manual for operation of the DRB scan tool. (2) Disconnect the rubber back-pressure hose from the fitting at the bottom of EGR valve control (Fig. 5). (3) Connect a hand-held vacuum pump to this fitting. (4) Apply 10 inches of vacuum to this fitting. (5) If vacuum falls off, the valve control diaphragm is leaking. Replace the valve control and EGR valve as an assembly (the valve control and the EGR valve are serviced as one unit). Refer to EGR Valve Control in this group for removal/installation procedures. Proceed to next step for further testing. (6) Remove the rubber hose at the vacuum inlet fitting (Fig. 5) on the EGR valve control. (7) Connect a vacuum gauge into the open end of this hose.
EGR ELECTRIC SOLENOID TEST2.5L 4-CYLINDER ENGINE This is not to be used as a complete test of the EGR system. Electrical operation of the solenoid should be checked with the DRB scan tool. Refer to the appro-
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EGR SYSTEM OPERATION3.9L AND 5.2L ENGINES The system consists of: An EGR valve assembly (Figs. 8 or 9) mounted to the intake manifold. An EGR valve control containing a combination back-pressure transducer and an electric vacuum solenoid (Figs. 8 and 9). The powertrain control module (PCM) to control the electric solenoid portion of the valve control. An EGR tube (Fig. 10) connecting a passage in the intake manifold (near the EGR valve) to the rear of the right exhaust manifold. Hoses to connect the various components.
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gized), and exhaust gas back-pressure entering the EGR valve inlet is high enough, back-pressure is supplied to the valve control. It then holds the bleed valve in the transducer closed. This allows engine vacuum to flow through the EGR valve control to activate and operate the EGR valve for exhaust gas recirculation. If back-pressure is not strong enough to close the bleed valve in the transducer, the valve control will bleed off engine vacuum preventing EGR valve operation. The transducer measures and uses this exhaust back-pressure signal from the EGR valve to regulate and provide the correct amount of exhaust gas recirculation under all conditions. Exhaust gas recirculation will begin in this order when: The powertrain control module (PCM) determines that EGR system operation is necessary. The electrical portion of the EGR valve control is not energized (grounded) by the PCM. Exhaust back-pressure entering the transducer in the EGR valve control is strong enough to close its bleed valve. Engine vacuum is passed through the EGR valve control to the EGR valve. The inlet seat (poppet valve) at the bottom of the EGR valve opens to dilute and recirculate exhaust gas back into the intake manifold. For more information, also refer to Open Loop/ Closed Loop Modes of Operation in the Multi-Port Fuel Injection section of Group 14, Fuel Systems for 3.9L/5.2L engines.
EGR VALVE LEAKAGE TEST3.9L/5.2L ENGINE This is not to be used as a complete test of the EGR system. If the engine will not idle, dies out on idle, or idle is rough or slow, the poppet valve (Fig. 9) at the base of the EGR valve may be leaking in the closed position. The diaphragm (Fig. 9) within the EGR valve may also be ruptured. (1) The engine should be off for the following test. (2) Disconnect the rubber hose from the fitting (Fig. 9) at the top (vacuum motor) side of the EGR valve. (a) Connect a hand-held vacuum pump to this fitting. (b) Apply 15 inches of vacuum to the pump. (c) Observe the gauge reading on the pump. (d) If vacuum falls off, the diaphragm in the EGR valve has ruptured. (e) Replace the EGR valve. Note: The EGR valve, valve control and attaching hoses are serviced as one unit. Refer to EGR Valve Removal/Installation in this group. (f) Proceed to the next step. (3) A small metal fitting (back-pressure fitting) is located at the base of the EGR valve (Fig. 9). A rubber back-pressure hose connects it to the back-pressure fitting on the EGR valve control. Disconnect this rubber hose at the EGR valve fitting. (4) Remove the air cleaner housing from the throttle body. (5) Using compressed air, and using an air nozzle with a rubber tip, apply approximately 50 psi of regulated shop air to the metal back-pressure fitting on the EGR valve. (6) By hand, open the throttle to the wide open position. Air should not be heard emitting from the intake manifold while applying air pressure at the back-pressure fitting. (7) If air can be heard emitting from the intake manifold, the poppet valve (Fig. 9) is leaking at the bottom of the EGR valve. Replace the EGR valve. Note: The EGR valve, valve control and attaching hoses are serviced as one unit. Refer to EGR Valve Removal/Installation in this group. Do not attempt clean the old EGR valve. EGR VALVE CONTROL TEST3.9L/5.2L ENGINES
TESTING ELECTRICAL SOLENOID PORTION OF VALVE CONTROL This is not to be used as a complete test of the EGR system.
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(13) Disconnect the rubber hose at the vacuum outlet fitting (Fig. 9) on the EGR valve control. (14) Connect a vacuum gauge to this fitting. (15) Disconnect the electrical connector (Fig. 8) at the valve control. This will simulate an open circuit (no ground from the PCM) at the valve control. (16) Start the engine and bring to operating temperature. Hold the engine speed to approximately 2000 rpm while checking for engine vacuum (full-manifold) at this fitting. To allow full manifold vacuum to flow through the valve control, exhaust backpressure must be present at valve control. It must be high enough to hold the bleed valve in the transducer portion of the valve control closed. Have a helper momentarily (a second or two) hold a rag over the tailpipe opening to build some exhaust back-pressure while observing the vacuum gauge. Heavy gloves should be worn. Do not cover the tailpipe opening for an extended period of time as damage to components or overheating may result. As temporary back-pressure is built, full manifold vacuum should be observed at the vacuum control outlet fitting. Without back-pressure, and engine at approximately 2000 rpm, the gauge reading will be low. This low reading is normal. At idle speed, the gauge reading will be erratic. This is also normal. (17) If full manifold vacuum is not present at the outlet fitting, but was present at the inlet fitting, replace the valve control. Note: The EGR valve, valve control and attaching hoses are serviced as one unit. Refer to EGR Valve Removal/Installation in this group.
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Air Cleaner Element . . . . . . . . . . . Air Cleaner Housing . . . . . . . . . . . EGR Solenoid2.5L Engine . . . . . EGR Tube2.5L Engine . . . . . . . . EGR Tube3.9L/5.2L Engine . . . . EGR Valve . . . . . . . . . . . . . . . . . . EGR Valve Control . . . . . . . . . . . . Engine Coolant Temperature Sensor
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EGR VALVE
The EGR valve, EGR valve control and attaching hoses are serviced as one unit on the 2.5L engine.
REMOVAL2.5L ENGINE (1) Disconnect vacuum source line to EGR valve control. Inspect for damage. (2) Remove 2 EGR valve mounting bolts from intake manifold (Fig. 1). (3) Remove EGR valve from intake manifold. (4) Clean gasket mating surfaces and discard old gasket. Inspect for any signs of leakage or cracked surfaces. INSTALLATION2.5L ENGINE (1) Assemble EGR valve with new gasket onto the intake manifold.
REMOVAL3.9L/5.2L ENGINES The EGR valve, EGR valve control and attaching hoses are serviced as one unit on the 3.9L/5.2L engine. (1) Disconnect vacuum hoses to EGR valve control and EGR valve. Note position of hoses for easier installation. (2) Remove EGR mounting bolts (Fig. 2). (3) Remove EGR valve and gasket. Discard old gasket. Clean intake manifold mating surface and check for cracks.
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(2) Disconnect 2 vacuum hoses at exhaust gas recirculation (EGR) valve. (3) Remove 2 EGR valve mounting bolts (Fig. 2) and remove EGR valve. Discard old gasket. (4) Disconnect electrical connector at engine oil pressure sending unit. (5) To prevent damage to oil pressure sending unit, a special tool, such as number C-4597 must be used (Fig. 3). Remove sending unit from engine.
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INSTALLATION (1) Clean the EGR tube and exhaust manifold (at EGR tube mounting point) of any old gasket material. (2) Install a new gasket to exhaust manifold end of EGR tube. (3) Install EGR tube to both manifolds. Tighten mounting nut at intake manifold. Tighten 2 mounting bolts at exhaust manifold to 23 N m (204 in. lbs.) torque. (4) Coat the threads of the oil pressure sending unit with thread sealant. Do not allow any of the thread sealant to get into the sending unit opening, or the opening at the engine. Install sending unit to engine and tighten to 14 N m (130 in. lbs.) torque. Install electrical connector to sending unit. (5) Clean the intake manifold and EGR valve of any old gasket material. (6) Install a new EGR valve gasket to intake manifold. (7) Install EGR valve to intake manifold. Tighten 2 mounting bolts to 23 N m (200 in. lbs.) torque. (8) Install vacuum lines to EGR valve. (9) Install spark plug cable loom and plug cables to valve cover mounting stud.
EVAP CANISTER
The EVAP canister is located in the engine compartment on the right inner fender.
REMOVAL (1) Remove fuel tubes/lines at EVAP canister. Note location of tubes/lines before removal for easier installation. (2) Remove canister bracket-to-body bolts (Fig. 6). One of the bracket bolts must be removed from over the top of right front tire. (3) Remove canister and bracket from body.
INSTALLATION (1) Position canister to mounting bracket. (2) Install canister-to-bracket bolt and tighten to 10 N m (95 in. lbs.) torque. (3) Position canister and bracket to body and install bolts. (4) Tighten bolts to 10 N m (95 in. lbs.) torque.
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INSTALLATION (1) Install EVAP canister purge solenoid and its mounting bracket to intake manifold. (2) Connect vacuum harness and wiring connector. (3) Install air cleaner housing.
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door to snorkel side walls for interference or obstructions. Inspect the hinge pin for binding and repair as necessary.
INSTALLATION (1) Insert operating rod into heat control door. Position diaphragm tang into opening and rivet the tab in place. (2) Apply 4 inches of vacuum to diaphragm nipple. The heat control door should operate freely. Do not operate the heat control door by hand. Hand operation could cock the operating rod or diaphragm, restricting proper operation of the system. (3) Assemble air cleaner. (4) Install air cleaner assembly on vehicle and test operation.
INSTALLATION (1) Install TVV into position in air cleaner. (2) Support TVV outer edges and securely install retainer clip. Be sure gasket forms a tight air seal. Do not attempt to adjust TVV. (3) Install venturi tube into air cleaner. (4) Connect vacuum hose to temperature TVV. (5) Install air cleaner.
INDEX
Description Group-Page Description Group-Page Description
Group-Page
3-4 SHIFT SEQUENCE . . . . . . . . . . . . . . . . . 21-88 42RH TRANSMISSION OVERHAUL . . . . . . 21-147 42RH/46RH AUTOMATIC TRANSMISSION . . 21-82 42RH/46RH GENERAL SPECIFICATIONS . . 21-288 42RH/46RH IN-VEHICLE SERVICE . . . . . . . 21-125 42RH/46RH OVERDRIVE UNIT OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . 21-238 42RH/46RH PRESSURE TEST SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . 21-289 42RH/46RH SPACER/THRUST PLATE/SNAP RING SPECIFICATIONS . . . . . 21-288 42RH/46RH TORQUE SPECIFICATIONS . . . 21-289 46RH TRANSMISSION OVERHAUL . . . . . . 21-193 4-CYLINDER ENGINE, COOLING SYSTEM FAN2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33 4-CYLINDER ENGINE, ENGINE FIRING ORDER2.5L . . . . . . . . . . . . . . . . . . . . . . . 8D-29 4-CYLINDER ENGINE, ENGINE VACUUM SCHEMATIC2.5L . . . . . . . . . . . . . . . . . . . . 25-3 4-CYLINDER ENGINE, SERPENTINE DRIVE BELT DIAGNOSIS2.5L . . . . . . . . . . . 7-40 4-CYLINDER ENGINE, V-BELT DIAGNOSIS2.5L . . . . . . . . . . . . . . . . . . . . . 7-39 4-CYLINDER ENGINECONTINUED, SERPENTINE DRIVE BELT DIAGNOSIS2.5L . . . . . . . . . . . . . . . . . . . . . 7-41 4WD VEHICLES, REAR SUSPENSION 2WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 4WD VEHICLES, STEERING LINKAGE . . . 19-17 60-WAY CONNECTOR, POWERTRAIN CONTROL MODULE (PCM) . . . . . . . . . . . . . 14-70 ABS BRAKE BLEEDING RECOMMENDATIONS . . . . . . . . . . . . . . . . . . 5-60 ABS BRAKE OPERATION AND SERVICE . . . . 5-51 ABS COMPONENTS . . . . . . . . . . . . . . . . . . . . 5-51 ABS DATA LINK CONNECTOR . . . . . . . . . 8W-32-2 ABS DIAGNOSTIC CONNECTOR LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 ABS ELECTRONIC CONTROL MODULE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 5-59 ABS ELECTRONIC CONTROL MODULE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59 ABS MANUAL BRAKE BLEEDING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 5-60 ABS OPERATION . . . . . . . . . . . . . . . . . . . . . . 5-54 ABS POWER RELAY . . . . . . . . . . . . . . . . 8W-32-2 ABS SYSTEM NORMAL AND FAULT CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 ABS WARNING LAMP . . . . . . . . . . . . . . . 8W-32-2 ABSOLUTE PRESSURE (MAP) SENSOR, MANIFOLD; FUEL SYSTEM . . . . . . . . 14-47,14-88 ABSOLUTE PRESSURE (MAP) SENSOR, MANIFOLD; IGNITION SYSTEMS . . . . 8D-24,8D-5 ABSOLUTE PRESSURE (MAP) SENSOR TEST, MANIFOLD; FUEL SYSTEM . . . . . . . . 14-71 ABSOLUTE PRESSURE (MAP) SENSOR TEST, MANIFOLD; IGNITION SYSTEMS . . . . 8D-12 ABSOLUTE PRESSURE (MAP) SENSORPCM INPUT, MANIFOLD . . 14-24,14-59 ABSOLUTE PRESSURE SENSOR, MANIFOLD; FUEL/IGNITION . . . . . . . . . . 8W-30-4 ABSOLUTE PRESSURE SENSOR, MANIFOLD; FUEL/IGNITION3.9L AND 5.2L ENGINES . . . . . . . . . . . . . . . . . . . . . 8W-30-9 ABSORBER DIAGNOSIS, SPRING AND SHOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 ABSORBER, SHOCK; FRONT SUSPENSION AND AXLE . . . . . . . . . . . . . 2-14,2-9 ABSORBER, SHOCK; REAR SUSPENSION AND AXLES . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 ABS/RWAL CONTROL MODULE DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 ABS/RWAL FAULT CONDITION CAUSES . . . . 5-10 ABS/RWAL WARNING LIGHT DISPLAY . . . . . . 5-9 A/C CLUTCH RELAY . . . . . . . . . . . . . . . . . . . 14-43 A/C COMPONENTS . . . . . . . . . . . . . . . . . . . . 24-1 A/C COMPRESSOR NOISE . . . . . . . . . . . . . . 24-14 A/C CONDENSER ASSEMBLY . . . . . . . . . . . 24-22 A/C CONTROL SYSTEM VACUUM DIAGNOSIS, HEATER . . . . . . . . . . . . . . . . . . 24-10 A/C CONTROL, VACUUM CIRCUITS HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-11 A/C HOUSING, HEATER . . . . . . . . . . . . . . . . 24-23 A/C PERFORMANCE (TEMPERATURE AND PRESSURE) . . . . . . . . . . . . . . . . . . . . . . 24-7 A/C REFRIGERANT OIL CAPACITIES . . . . . . . 24-6 ACCELERATOR PEDAL . . . . . . . . . . . . . . . . . 14-18
ACCELERATOR PEDAL AND THROTTLE CABLE . . . . . . . . . . . . . . . . . . . 14-18,14-43,14-83 ACCESSORY DRIVE BELT . . . . . . . . . . . . . . . 0-19 ACCESSORY DRIVE BELT TENSION . . . . . . . 7-48 ACCESSORY DRIVE BELTS, ENGINE . . . . . . . 7-39 ACCUMULATOR OVERHAUL . . . . . . . . . . . 21-203 A/C-HEATER CONTROL REMOVE/INSTALL . 8E-20 ACTUATOR, MODE DOOR VACUUM . . . . . . 24-20 ACTUATOR, RECIRCULATING AIR VACUUM . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-20 ADJUSTER PLUG ASSEMBLY REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . 19-25 ADJUSTMENT, COMPASS VARIATION . . . . . . 8C-5 ADJUSTMENT, DOOR . . . . . . . . . . . . . . . . . 23-23 ADJUSTMENT, FRONT BAND . . . . . . . . . . . 21-129 ADJUSTMENT, GEAR SELECTOR INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . 21-127 ADJUSTMENT, OVERDRIVE CLUTCH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 21-257 ADJUSTMENT, PARKING BRAKE CABLE TENSIONER . . . . . . . . . . . . . . . . . . . . . . . . . . 5-67 ADJUSTMENT, REAR BAND . . . . . . . . . . . . 21-129 ADJUSTMENT, REAR DRUM BRAKE . . . . . . . 5-24 ADJUSTMENT, SHIFT LINKAGE . . . 21-127,21-264 ADJUSTMENT, STOPLAMP SWITCH . . . . . . . 5-18 ADJUSTMENT, TRANSMISSION ASSEMBLY; NV3500 MANUAL TRANSMISSION . . . . . . . . . . . . . . . . . . . . . 21-183 ADJUSTMENT, TRANSMISSION ASSEMBLY; TRANSMISSION AND TRANSFER CASE . . . . . . . . . . . . . . . . . . . . . 21-24 ADJUSTMENT, TRANSMISSION CABLE AND LINKAGE . . . . . . . . . . . . . . . . . . . . . . . 21-93 ADJUSTMENT, TRANSMISSION THROTTLE VALVE CABLE . . . . . . . . . . . . . 21-128 ADJUSTMENT USING ALIGNMENT SCREEN, HEADLAMP/FOG LAMP . . . . . . . . . 8L-6 ADJUSTMENT, VALVE BODY SERVICE . . . 21-170, 21-217 ADJUSTMENT WITH GAUGE SET, PINION DEPTH MEASUREMENT . . . . . . . . . . . . . . . . 3-22 ADJUSTMENTS, ALIGNMENT MEASUREMENTS . . . . . . . . . . . . . . . . . . . . . . 2-4 ADJUSTMENTS, STEERING GEAR . . . . . . . . 19-21 AERO HEADLAMP BULB REPLACEMENT . . . 8L-7 AERO HEADLAMP LENS REPLACEMENT . . . 8L-7 AFTER OVERHAUL OR FLUID/FILTER CHANGE, REFILLING . . . . . . . . . . . . . . . . . 21-126 AFTERMARKET PAINT AND TRIM REPAIR PRODUCTS . . . . . . . . . . . . . . . . . . . 23-46 AIR CLEANER ELEMENT; EMISSION CONTROL SYSTEMS . . . . . . . . . . . . . . . . . . 25-18 AIR CLEANER ELEMENT; FUEL SYSTEM . . 14-43, 14-84 AIR CLEANER ELEMENT; LUBRICATION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . 0-17 AIR CLEANER HOUSING; EMISSION CONTROL SYSTEMS . . . . . . . . . . . . . . . . . . 25-18 AIR CLEANER HOUSING; FUEL SYSTEM . . . 14-83 AIR CONDITIONING (A/C) CLUTCH RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-83 AIR CONDITIONING (A/C) CLUTCH RELAYPCM OUTPUT . . . . . . . . . . . 14-25,14-61 AIR CONDITIONING (A/C) CONTROLS PCM INPUT . . . . . . . . . . . . . . . . . . . . 14-23,14-56 AIR CONDITIONING AND HEATER PERFORMANCE TEST . . . . . . . . . . . . . . . . . . 24-7 AIR CONDITIONING CYCLING SWITCH . . . . 24-13 AIR CONDITIONING, HEATING . . . . . . . . . . . 24-26 AIR CONDITIONING OPERATION . . . . . . 8W-42-1, 8W-42-3 AIR CONDITIONING PERFORMANCE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-7 AIR CONDITIONING SYSTEM . . . . . . . . . . . . 24-1 AIR CONDITIONING TEST PROCEDURES, HEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-10 AIR CONDITIONING/HEATER2.5L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-1 AIR CONDITIONING/HEATER3.9 AND 5.2L ENGINES . . . . . . . . . . . . . . . . . . . . . 8W-42-3 AIR CONTROL (IAC) MOTOR, IDLE; FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . 14-46,14-88 AIR CONTROL (IAC) MOTOR, IDLE; FUEL/IGNITION . . . . . . . . . . . . . . . . . . . . 8W-30-3 AIR CONTROL (IAC) MOTOR, IDLE; FUEL/IGNITION3.9L AND 5.2L ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-8 AIR CONTROL (IAC) MOTOR TEST, IDLE . . 14-72
AIR CONTROL (IAC) MOTORPCM OUTPUT, IDLE . . . . . . . . . . . . . . . . . . 14-27,14-61 AIR DISTRIBUTION DUCTS . . . . . . . . . . . . . 24-21 AIR FLOW CHECK, THROTTLE BODY MINIMUM . . . . . . . . . . . . . . . . . . . . . 14-36,14-73 AIR INLET FILTER, PCV/CRANKCASE . . . . . . 0-17 AIR LOUVERS, PANEL . . . . . . . . . . . . . . . . . 24-21 AIR SYSTEM2.5L ENGINE, HEATED INLET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-10 AIR TEMPERATURE SENSOR, INTAKE . 8W-30-10 AIR TEMPERATURE SENSOR, INTAKE MANIFOLD; FUEL SYSTEM . . . . . . . . . . . . . 14-84 AIR TEMPERATURE SENSOR, INTAKE MANIFOLD; IGNITION SYSTEMS . . . . . . . . 8D-23 AIR TEMPERATURE SENSOR, SENSOR RESISTANCE (OHMS)COOLANT TEMPERATURE SENSOR/INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . 14-70 AIR TEMPERATURE SENSOR TEST, INTAKE MANIFOLD; FUEL SYSTEM . . . . . . . 14-70 AIR TEMPERATURE SENSOR TEST, INTAKE MANIFOLD; IGNITION SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-12 AIR TEMPERATURE SENSOR3.9L/5.2L ENGINE, INTAKE MANIFOLD . . . . . . . . . . . . . 8D-5 AIR TEMPERATURE SENSORPCM INPUT, INTAKE MANIFOLD . . . . . . . . . . . . . 14-58 AIR TESTING TRANSMISSION CLUTCH AND BAND OPERATION . . . . . . . . . . . . . . . . 21-97 AIR VACUUM ACTUATOR, RECIRCULATING . . . . . . . . . . . . . . . . . . . . . 24-20 AIRBAG CONTROL MODULE . . . . . . . . . . . . 8M-2 AIRBAG CONTROL MODULE (ACM) . . . . . . 8W-43-1 AIRBAG CONTROL MODULE REMOVE/ INSTALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8M-6 AIRBAG DATA LINK CONNECTOR . . . . . . 8W-43-1 AIRBAG IMPACT SENSORS . . . . . . . . . . 8W-43-1 AIRBAG MODULE . . . . . . . . . . . . . . . . . . . . . 8M-1 AIRBAG MODULE HANDLING . . . . . . . . . . . . 8M-3 AIRBAG MODULE REMOVE/INSTALL . . . . . . 8M-4 AIRBAG SQUIB (AIRBAG IGNITER) . . . . . 8W-43-1 AIRBAG SYSTEM . . . . . . . . . . . . . . . . . . . . . 8M-1 AIRBAG SYSTEM CHECK . . . . . . . . . . . . . . . 8M-2 AIRBAG SYSTEM SERVICE (DEPLOYED) . . . 8M-3 AIRBAG WARNING LAMP . . . . . . . . . . . . 8W-43-1 AIR-CONDITIONER COMPRESSOR . . . . . . . . 0-19 ALIGNMENT, HEADLAMP . . . . . . . . . . . . . . . 8L-6 ALIGNMENT MEASUREMENTS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . 2-4 ALIGNMENT PREPARATION, HEADLAMP . . . 8L-6 ALIGNMENT, REAR AXLE . . . . . . . . . . . . . . . . 3-9 ALIGNMENT SCREEN, HEADLAMP/FOG LAMP ADJUSTMENT USING . . . . . . . . . . . . . 8L-6 ALIGNMENT SPECIFICATIONS, FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 ALIGNMENT, WHEEL . . . . . . . . . . . . . . . . . . . . 2-4 ALUMINUM THREAD REPAIR . . . . . . . . . . 21-136 ANALYSIS, STALL TEST . . . . . . . . . . . . . . . 21-96 ANALYZING THE ROAD TEST . . . . . . . . . . . 21-93 ANGLE, GROUND CLEARANCE AND RAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-11 ANGLE MEASUREMENT, UNIVERSAL JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-4 ANGLING CYLINDER SERVICE, POWER . . . 13-16 ANTENNA . . . . . . . . . . . . . . . . . . . . . . . . 8F-1,8F-5 ANTENNA REMOVE/INSTALL . . . . . . . . . . . . . 8F-9 ANTI-LOCK BRAKE SYSTEM (ABS), ALL WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-32-1 ANTILOCK BRAKE SYSTEM DIAGNOSIS . . . . . 5-8 ANTILOCK BRAKE SYSTEMS . . . . . . . . . . . . . . 5-1 ANTI-LOCK (RWAL) BRAKES, REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-32-3 ANTI-LOCK VALVE, FRONT . . . . . . . . . . . 8W-32-2 ANTILOCK VALVE INSTALLATION, FRONT . . . 5-55 ANTILOCK VALVE INSTALLATION, REAR . . . 5-47, 5-57 ANTI-LOCK VALVE, REAR . . . . . 8W-32-2,8W-32-4 ANTILOCK VALVE REMOVAL, FRONT . . . . . . 5-55 ANTILOCK VALVE REMOVAL, REAR . . . 5-46,5-56 ANTILOCK VALVE SERVICE AND DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 APPLICATION, BULB . . . . . . . . . . . . . . . . . . 8L-13 APPLICATION, CLUTCH AND BAND . . . . . . . 21-90 APPLICATION, CLUTCH DISC . . . . . . . . . . . . . 6-1 ARM, IDLER . . . . . . . . . . . . . . . . . . . . . . . . 19-17 ARM, LOWER SUSPENSION . . . . . . . . . 2-10,2-16 ARM, PITMAN . . . . . . . . . . . . . . . . . . . . . . . 19-17 ARM REMOVE/INSTALL, WIPER . . . . . . . . . . 8K-7
INDEX
Group-Page Description Group-Page Description Group-Page
Description
ARM, UPPER SUSPENSION . . . . . . . . . 2-12,2-16 ARMS AND PUSH RODS, ROCKER . . . . 9-54,9-87 ASH RECEIVER ASSEMBLY REMOVE/ INSTALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-20 ASH RECEIVER LAMP AND CIGAR LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-1 ASSEMBLY, A/C CONDENSER . . . . . . . . . . . 24-22 ASSEMBLY AND ADJUSTMENT, TRANSMISSION; NV3500 MANUAL TRANSMISSION . . . . . . . . . . . . . . . . . . . . . 21-183 ASSEMBLY AND ADJUSTMENT, TRANSMISSION; TRANSMISSION AND TRANSFER CASE . . . . . . . . . . . . . . . . . . . . . 21-24 ASSEMBLY, BLOWER MOTOR AND WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-23 ASSEMBLY, CALIPER . . . . . . . . . . . . . . . 5-32,5-38 ASSEMBLY, COMPRESSOR CLUTCH COIL . 24-15 ASSEMBLY, DIRECT CLUTCH AND GEARTRAIN . . . . . . . . . . . . . . . . . . . . . . . . 21-250 ASSEMBLY, ENGINE . . . . . . . . . . . 9-14,9-53,9-85 ASSEMBLY, OVERDRIVE GEARTRAIN AND CASE . . . . . . . . . . . . . . . . . . . . . . . . . 21-254 ASSEMBLY, PISTON / CONNECTING ROD . 9-103, 9-71 ASSEMBLY REMOVE/INSTALL, ASH RECEIVER . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-20 ASSEMBLY REMOVE/INSTALL, CUP HOLDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-21 ASSEMBLY REMOVE/INSTALL, INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . 8E-23 ASSEMBLY REPLACEMENT, ADJUSTER PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-25 ASSEMBLY REPLACEMENT, COLUMN . . . . . 19-39 ASSEMBLY REPLACEMENT, DRIVE AXLE; FRONT SUSPENSION AND AXLE . . . . . . . . . . 2-31 ASSEMBLY REPLACEMENT, DRIVE AXLE; REAR SUSPENSION AND AXLES . . . . . . . . . . 3-12 ASSEMBLY SERVICE, CYLINDER BLOCK, PISTON AND CONNECTING ROD . . . . . . . . . . 9-34 ASSEMBLY SERVICE, CYLINDER HEAD AND VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19 ASSEMBLY, TRANSFER CASE . . . . . . . . . . 21-273 ASSEMBLY, TRANSMISSION . . . . . . 21-229,21-60 ASSEMBLY/INSTALLATION . . . . . . . . . . . . . 16-10 AUTO SHUTDOWN (ASD) RELAYPCM OUTPUT . . . . . . . . . . . . . . . . . . . . . . . 14-26,14-61 AUTOMATIC BELT TENSIONER3.9L/ 5.2L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 7-45 AUTOMATIC DAY/NIGHT MIRROR . . . . . 8T-1,8T-2 AUTOMATIC DAY/NIGHT MIRROR REMOVE/INSTALL . . . . . . . . . . . . . . . . . . . . . 8T-3 AUTOMATIC SHUT DOWN (ASD) RELAY; FUEL/IGNITION . . . . . . . . . . . . . . . . . . . . 8W-30-2 AUTOMATIC SHUT DOWN (ASD) RELAY; FUEL/IGNITION3.9L AND 5.2L ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-6 AUTOMATIC SHUTDOWN (ASD) RELAY; FUEL SYSTEM . . . . . . . . . . . . . . . . . . 14-43,14-84 AUTOMATIC SHUTDOWN (ASD) RELAY; IGNITION SYSTEMS . . . . . . . . . . . . . . 8D-18,8D-1 AUTOMATIC SHUTDOWN (ASD) RELAY TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-6 AUTOMATIC SHUTDOWN (ASD) SENSEPCM INPUT . . . . . . . . . . . . . . . . . . 14-57 AUTOMATIC TRANSMISSION . . . . . . . . . . . . 0-22 AUTOMATIC TRANSMISSION, 42RH/ 46RH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-82 AUTOMATIC TRANSMISSION CONTROLS AND OPERATION . . . . . . . . . . . . . . . . . . . . . 21-88 AUTOMATIC TRANSMISSION DIAGNOSIS AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 21-91 AUTOMATIC TRANSMISSION OIL COOLERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32 AVAILABLE, TOWING WHEN KEYS ARE NOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-13 AX 15 MANUAL TRANSMISSION . . . . . . . . . 21-1 AX 15 SELECTIVE SNAP RING CHART . . . 21-286 AX 15 TORQUE SPECIFICATIONS . . . . . . . 21-285 AXLE, 7 1/4 AND 8 1/4 INCH . . . . 2-47,3-12,3-36 AXLE, 7 1/4 INCH FRONT . . . . . . . . . . . . . . . 2-31 AXLE, 8 1/4 INCH . . . . . . . . . . . . . . . . . . . . . 3-36 AXLE ALIGNMENT, REAR . . . . . . . . . . . . . . . . 3-9 AXLE ASSEMBLY REPLACEMENT, DRIVE; FRONT SUSPENSION AND AXLE . . . . . . . . . . 2-31 AXLE ASSEMBLY REPLACEMENT, DRIVE; REAR SUSPENSION AND AXLES . . . . . . . . . . 3-12 AXLE, FRONT DRIVE . . . . . . . . . . . . . . . . . . . . 2-2 AXLE MOUNTING, FRONT . . . . . . . . . . . . . . . 2-47
AXLE NOISE/VIBRATION DIAGNOSIS . . . . . . . 3-8 AXLE SHAFT, SEAL AND BEARING . . . . . . . . 2-35 AXLE SHAFT, SEAL AND BEARING SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 AXLE SPECIFICATIONS; FRONT SUSPENSION AND AXLE . . . . . . . . . . . . . . . . 2-47 AXLE SPECIFICATIONS; REAR SUSPENSION AND AXLES . . . . . . . . . . . . . . . 3-36 AXLES, 7 1/4 AND 8 1/4 . . . . . . . . . . . . . 3-1,3-36 AXLES, FRONT AND REAR . . . . . . . . . . . . . . 0-23 BACKUP LAMP SWITCH . . . . . . . . . . . . . . . 8L-11 BACKUP LAMPS . . . . . . . . . . . . . . . . . . . . . 8L-11 BACK-UP LAMPS . . . . . . . . . . . . . . . . . . 8W-51-1 BALANCE, TIRE AND WHEEL . . . . . . . . . . . . 22-7 BALL POWER STEERING GEAR, RECIRCULATING . . . . . . . . . . . . . . . . . . . . . 19-19 BALL STUD, LOWER . . . . . . . . . . . . . . . . . . . 2-11 BALL STUD, UPPER . . . . . . . . . . . . . . . 2-12,2-17 BAND ADJUSTMENT, FRONT . . . . . . . . . . . 21-129 BAND ADJUSTMENT, REAR . . . . . . . . . . . . 21-129 BAND APPLICATION, CLUTCH . . . . . . . . . . . 21-90 BAND OPERATION, AIR TESTING TRANSMISSION CLUTCH . . . . . . . . . . . . . . 21-97 BAND OVERHAUL, FRONT SERVO . . . . . . 21-168, 21-203 BAND OVERHAUL, REAR SERVO . . . . . . . 21-169 BAND SERVICE, LOW-REVERSE DRUM AND REAR . . . . . . . . . . . . . . . . . . . . . . . . . 21-201 BAR, LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . 23-21 BAR, STABILIZER . . . . . . . . . . . . . . . . . . 2-15,2-9 BAR, TORSION . . . . . . . . . . . . . . . . . . . . . . . 2-15 BASE COAT/CLEAR COAT FINISH . . . . . . . . 23-45 BATTERY; BATTERY/STARTER/ GENERATOR SERVICE . . . . . . . . . . . . . . . . . . 8B-1 BATTERY; BATTERY/STARTING/ CHARGING SYSTEMS DIAGNOSTICS . . . . . . 8A-3 BATTERY; LUBRICATION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . 0-18 BATTERY CHARGING . . . . . . . . . . . . . . . . . . . 8A-8 BATTERY CHARGING TIME TABLE . . . . . . . . 8A-8 BATTERY CLASSIFICATIONS AND RATINGS; BATTERY/STARTER/ GENERATOR SERVICE . . . . . . . . . . . . . . . . . . 8B-9 BATTERY CLASSIFICATIONS AND RATINGS; BATTERY/STARTING/ CHARGING SYSTEMS DIAGNOSTICS . . . . . 8A-22 BATTERY DIAGNOSIS . . . . . . . . . . . . . . . . . . 8A-5 BATTERY FEED; FUEL/IGNITION . . . . . . . 8W-30-2 BATTERY FEED; FUEL/IGNITION3.9L AND 5.2L ENGINES . . . . . . . . . . . . . . . . . 8W-30-7 BATTERY REMOVE/INSTALL . . . . . . . . . . . . . 8B-1 BATTERY SPECIFICATIONS; BATTERY/ STARTER/GENERATOR SERVICE . . . . . . . . . . 8B-9 BATTERY SPECIFICATIONS; BATTERY/ STARTING/CHARGING SYSTEMS DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . 8A-22 BATTERY TRAY . . . . . . . . . . . . . . . . . . . . . . . 23-8 BATTERY VOLTAGEPCM INPUT . . . 14-23,14-57 BEAM REPLACEMENT, SEALED . . . . . . . . . . . 8L-6 BEARING, AXLE SHAFT, SEAL . . . . . . . . . . . . 2-35 BEARING LUBRICANTS, CHASSIS COMPONENT AND WHEEL . . . . . . . . . . . . . . 0-25 BEARING NOISE, GEAR; FRONT SUSPENSION AND AXLE . . . . . . . . . . . . . . . . 2-19 BEARING NOISE, GEAR; REAR SUSPENSION AND AXLES . . . . . . . . . . . . . . . . 3-8 BEARING REPLACEMENT, PILOT . . . . . . . . . . 6-12 BEARING REPLACEMENT, PITMAN SHAFT SEALS . . . . . . . . . . . . . . . . . . . . . . . 19-30 BEARING REPLACEMENT, RELEASE . . . . . . . 6-12 BEARING SERVICE, AXLE SHAFT, SEAL . . . . 3-15 BEARING SERVICE, CENTER . . . . . . . . . . . . . 16-9 BEARING SUPPORT CROSSMEMBER, DRIVE SHAFT CENTER . . . . . . . . . . . . . . . . 13-35 BEARINGS, CENTER . . . . . . . . . . . . . . . . . . . 16-2 BEARINGS, CRANKSHAFT MAIN . . . . . 9-105,9-74 BEARINGS, FRONT WHEEL . . . . . . . . . . . . . . 0-26 BEARINGS, WHEEL HUB . . . . . . . . . . . . . 2-14,2-8 BELT, ACCESSORY DRIVE . . . . . . . . . . . . . . . 0-19 BELT, COMPRESSOR DRIVE . . . . . . . . . . . . 24-14 BELT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . 7-39 BELT DIAGNOSIS2.5L 4-CYLINDER ENGINE, SERPENTINE DRIVE . . . . . . . . . . . . 7-40 BELT DIAGNOSIS2.5L 4-CYLINDER ENGINECONTINUED, SERPENTINE DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41 BELT DIAGNOSIS3.9L/5.2L ENGINES, SERPENTINE DRIVE . . . . . . . . . . . . . . . . . . . 7-42
BELT REMOVAL/INSTALLATION . . . . . . . . . . . 7-43 BELT SCHEMATICS . . . . . . . . . . . . . . . . . . . . 7-43 BELT SWITCH, DRIVERS SEAT . . . . . . . . . . 8U-1 BELT SWITCH, DRIVER S SEAT . . . . . . . . . . 8U-3 BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . 7-43 BELT TENSION, ACCESSORY DRIVE . . . . . . . 7-48 BELT TENSIONER3.9L/5.2L ENGINE, AUTOMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . 7-45 BELT/BUCKLES, SHOULDER BELTS/LAP . . . 23-39 BELTS, ENGINE ACCESSORY DRIVE . . . . . . . 7-39 BELTS/LAP BELT/BUCKLES, SHOULDER . . . 23-39 BEZEL REMOVE/INSTALL, CLUSTER . . . . . . 8E-15 BEZEL REMOVE/INSTALL, OVERHEAD CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C-7 BEZEL REMOVE/INSTALL, RIGHT INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . 8E-21 BIN, SUNGLASSES STORAGE . . . . . . . . . . . . 8C-8 BLADES OR ELEMENTS REMOVE/ INSTALL, WIPER . . . . . . . . . . . . . . . . . . . . . . 8K-7 BLEEDING, MASTER CYLINDER . . . . . . . . . . 5-13 BLEEDING PROCEDURE, ABS MANUAL BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60 BLEEDING PROCEDURE, RWAL SYSTEM MANUAL BRAKE . . . . . . . . . . . . . . . . . . . . . . 5-49 BLEEDING RECOMMENDATIONS, ABS BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60 BLEEDING, RWAL SYSTEM BRAKE . . . . . . . . 5-48 BLEND-AIR DOOR . . . . . . . . . . . . . . . . . . . . 24-26 BLIND RIVET REMOVAL . . . . . . . . . . . . . . . . . 23-23 BLOCK, CYLINDER . . . . . . . . . . . . . . . 9-108,9-76 BLOCK HEATERS, ENGINE . . . . . . . . . . . . . . . 7-47 BLOCK, PISTON AND CONNECTING ROD ASSEMBLY SERVICE, CYLINDER . . . . . . . . . . 9-34 BLOCKER REMOVE/INSTALL, KNEE . . . . . . 8E-19 BLOWER MOTOR; AIR CONDITIONING/ HEATER . . . . . . . . . . . . . . . . . . 8W-42-1,8W-42-3 BLOWER MOTOR; HEATING AND AIR CONDITIONING . . . . . . . . . . . . . . . . . . . . . . 24-12 BLOWER MOTOR AND WHEEL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 24-23 BODY CLEANING AND INSPECTION, VALVE . . . . . . . . . . . . . . . . . . . . . . 21-176,21-223 BODY CODE PLATE . . . . . . . . . . . . . . . . . . Intro.-2 BODY CODE PLATE DECODING . . . . . . . . Intro.-3 BODY COMPONENTS . . . . . . . . . . . . . . . . . . . 0-28 BODY COMPONENTS, CHASSIS . . . . . . . . . . 0-25 BODY FITTINGS, THROTTLE . . . . . . . . . . . . 14-49 BODY LUBRICANT SPECIFICATIONS . . . . . . . 0-29 BODY MINIMUM AIR FLOW CHECK, THROTTLE . . . . . . . . . . . . . . . . . . . . . 14-36,14-73 BODY MOULDINGS, NAMEPLATES AND DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-10 BODY SERVICE AND ADJUSTMENT, VALVE . . . . . . . . . . . . . . . . . . . . . . 21-170,21-217 BODY SERVICE INFORMATION, GENERAL . . 23-1 BODY SERVICE, VALVE . . . . . . . . . . . . . . . 21-132 BODY TEMPERATURE SENSOR, THROTTLE; FUEL SYSTEM . . . . . . . . . . . . . 14-49 BODY TEMPERATURE SENSOR, THROTTLE; FUEL/IGNITION . . . . . . . . . . 8W-30-4 BODY TEMPERATURE SENSOR2.5L ENGINE, THROTTLE . . . . . . . . . . . . . . . . . . . 8D-5 BODY TEMPERATURE SENSORPCM INPUT, THROTTLE . . . . . . . . . . . . . . . . . . . . 14-25 BODY, THROTTLE . . . . . 14-30,14-48,14-63,14-89 BOOST VALVE OPERATION . . . . . . . . . . . . . 21-89 BOOSTER CHECK VALVE TEST, POWER . . . . . 5-7 BOOSTER INSTALLATION, POWER BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 BOOSTER REMOVAL, POWER BRAKE . . . . . . 5-17 BOOSTER TEST, MASTER CYLINDER/ POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 BOOSTER VACUUM TEST, POWER . . . . . . . . . 5-7 BOOSTERBRAKE PEDALSTOPLAMP SWITCH, POWER BRAKE . . . . . . . . . . . . . . . 5-17 BOOT SEAL . . . . . . . . . . . . . . . . . . . . . . . . . 19-34 BOOTS, RUBBER . . . . . . . . . . . . . . . . . . . . . . 2-29 BORES, HONING CYLINDER . . . . . . . . . . . . . . 9-2 BOX, CARGO . . . . . . . . . . . . . . . . . . . . . . . . 23-20 BOX LAMP AND SWITCH REMOVE/ INSTALL, GLOVE . . . . . . . . . . . . . . . . . . . . . 8E-21 BOX LAMP, GLOVE . . . . . . . . . . . . . . . . . 8W-44-1 BOX LOCK REMOVE/INSTALL, GLOVE . . . . 8E-21 BOX REMOVE/INSTALL, GLOVE . . . . . . . . . 8E-21 BOX STRIPES, CAB AND CARGO . . . . . . . . 23-13 BOXES, FLOOR CONSOLE AND REAR SEAT STORAGE . . . . . . . . . . . . . . . . . . . . . . 23-43 BRACKET, MIRROR SUPPORT . . . . . . . . . . . 23-31
INDEX
Description Group-Page Description Group-Page Description
Group-Page
BRACKET SERVICE, SOLID MOUNT COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . 9-15 BRACKET, SNOW PLOW PIVOT . . . . . . . . . . 13-16 BRAKE ADJUSTMENT, REAR DRUM . . . . . . . 5-24 BRAKE BLEEDING PROCEDURE, ABS MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60 BRAKE BLEEDING PROCEDURE, RWAL SYSTEM MANUAL . . . . . . . . . . . . . . . . . . . . . 5-49 BRAKE BLEEDING RECOMMENDATIONS, ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60 BRAKE BLEEDING, RWAL SYSTEM . . . . . . . . 5-48 BRAKE BOOSTER INSTALLATION, POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 BRAKE BOOSTER REMOVAL, POWER . . . . . . 5-17 BRAKE BOOSTERBRAKE PEDAL STOPLAMP SWITCH, POWER . . . . . . . . . . . . 5-17 BRAKE CABLE TENSIONER ADJUSTMENT, PARKING . . . . . . . . . . . . . . . . 5-67 BRAKE CHECK, PRELIMINARY . . . . . . . . . . . . 5-3 BRAKE DIAGNOSIS, SERVICE . . . . . . . . . . . . . 5-3 BRAKE DRUM INSTALLATION . . . . . . . . . . . . 5-23 BRAKE DRUM REFINISH LIMITS . . . . . . . . . . 5-22 BRAKE DRUM REFINISHING . . . . . . . . . . . . . 5-22 BRAKE DRUM REMOVAL . . . . . . . . . . . . . . . 5-20 BRAKE DRUM RUNOUT . . . . . . . . . . . . . . . . 5-23 BRAKE FLUID CONTAMINATION . . . . . . . . . . 5-13 BRAKE FLUID, IMPORTANCE OF CLEAN . . . . 5-12 BRAKE FLUID LEVEL, CORRECT . . . . . . . . . . 5-12 BRAKE FLUID, RECOMMENDED . . . . . . . . . . . . 5-12 BRAKE FLUID/LUBRICANTS/CLEANING SOLVENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 BRAKE OPERATION AND SERVICE, ABS . . . . 5-51 BRAKE OPERATION AND SERVICE, RWAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44 BRAKE PEDAL BUSHINGS, CLUTCH . . . . . . . 0-20 BRAKE PEDAL INSTALLATION . . . . . . . . . . . . 5-18 BRAKE PEDAL INSTALLATION, PARKING . . . 5-66 BRAKE PEDAL REMOVAL . . . . . . . . . . . . . . . 5-18 BRAKE PEDAL REMOVAL, PARKING . . . . . . . 5-66 BRAKE PROBLEMS, DIAGNOSING PARKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 BRAKE PROBLEMS, DIAGNOSING SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 BRAKE ROTOR SERVICE, DISC . . . . . . . . . . . 5-41 BRAKE SAFETY PRECAUTIONS . . . . . . . . . . . . 5-2 BRAKE SPEED SENSOR INSTALLATION (2-WHEEL DRIVE MODELS), FRONT . . . . . . . 5-58 BRAKE SPEED SENSOR INSTALLATION (4-WHEEL DRIVE MODELS), FRONT . . . . . . . 5-59 BRAKE SPEED SENSOR INSTALLATION, REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59 BRAKE SPEED SENSOR REMOVAL (2-WHEEL DRIVE MODELS), FRONT . . . . . . . 5-58 BRAKE SPEED SENSOR REMOVAL (4-WHEEL DRIVE MODELS), FRONT . . . . . . . 5-59 BRAKE SPEED SENSOR REMOVAL (ALL), REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59 BRAKE SUPPORT PLATE INSTALLATION . . . 5-23 BRAKE SUPPORT PLATE REMOVAL . . . . . . . 5-23 BRAKE SWITCH . . . . . . . . . . . . . . . . . 14-43,14-84 BRAKE SWITCH INPUT, PARK . . . . . . . . 8W-32-4 BRAKE SWITCHPCM INPUT . . . . . 14-23,14-57 BRAKE SYSTEM (ABS), ALL WHEEL ANTI-LOCK . . . . . . . . . . . . . . . . . . . . . . . 8W-32-1 BRAKE SYSTEM DIAGNOSIS, ANTILOCK . . . . 5-8 BRAKE SYSTEM, POWER . . . . . . . . . . . . . . . 0-27 BRAKE SYSTEMS, ANTILOCK . . . . . . . . . . . . . 5-1 BRAKE UNITS, WHEEL . . . . . . . . . . . . . . . . . . 5-1 BRAKE WARNING LAMP . . . . . . . . . . . . . 8W-32-2 BRAKE WARNING LAMP SWITCH . . . . . 8W-32-4 BRAKE WARNING LIGHT ILLUMINATION, SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 BRAKE WARNING LIGHTS . . . . . . . . . . . . . . . . 5-1 BRAKELINES AND HOSES . . . . . . . . . . . . . . . 5-14 BRAKES, DRUM . . . . . . . . . . . . . . . . . . . . . . 5-20 BRAKES, PARKING . . . . . . . . . . . . . . . . . . . . 5-63 BRAKES, REAR WHEEL ANTI-LOCK (RWAL) . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-32-3 BRAKESHOE AND CALIPER INSPECTION . . . 5-35 BRAKESHOE INSTALLATION . . . . . 5-21,5-29,5-36 BRAKESHOE REMOVAL . . . . . . . . . 5-20,5-28,5-35 BRAKES2-WHEEL DRIVE, DISC . . . . . . . . . 5-27 BRAKES4-WHEEL DRIVE, DISC . . . . . . . . . 5-34 BREAKER, CIRCUIT . . . . . . . . . . . . . . . . . . . . 8S-1 BREAK-IN, ENGINE . . . . . . . . . . . . . . . . . . . . 0-14 BREATHER/FILTER2.5L ENGINE, CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . 25-8
BREATHER/FILTER3.9L/5.2L ENGINES, CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . 25-9 BULB APPLICATION . . . . . . . . . . . . . . . . . . . 8L-13 BULB REPLACEMENT, AERO HEADLAMP . . . 8L-7 BULB REPLACEMENT, UNDERHOOD LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-12 BULBS REMOVE/INSTALL, CLUSTER . . . . . 8E-17 BUMPER, FRONT . . . . . . . . . . . . . . . . . . . . . . 13-1 BUMPER, REAR . . . . . . . . . . . . . . . . . . . . . . . 13-1 BUMPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-1 BURNED FLUID, CAUSES OF . . . . . . . . . . . . 21-92 BUSHING, DISTRIBUTOR . . . . . . . . . . . . . . . 9-64 BUSHING REPLACEMENT, LEAF SPRING EYE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 BUSHINGS, CLUTCH AND BRAKE PEDAL . . . 0-20 BUZZER MODULE . . . . . . . . . . . . . . . . . 8U-1,8U-2 BUZZER MODULE SCHEMATIC . . . . . . . . . . . 8U-3 BYPASS HOSE3.9L/5.2L ENGINE, WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . 7-17 CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-17 CAB AND CARGO BOX STRIPES . . . . . . . . . 23-13 CAB INTERIOR COMPONENTS . . . . . . . . . . 23-37 CAB, QUARTER VENT WINDOWCLUB . . . 23-33 CAB, REAR WINDOWCLUB . . . . . . . . . . . 23-34 CAB, REAR WINDOWCONVENTIONAL . . . 23-35 CABLE, ACCELERATOR PEDAL AND THROTTLE . . . . . . . . . . . . . . . . 14-18,14-43,14-83 CABLE ADJUSTMENT, TRANSMISSION THROTTLE VALVE . . . . . . . . . . . . . . . . . . . 21-128 CABLE AND LINKAGE ADJUSTMENT, TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . 21-93 CABLE, HOOD INSIDE RELEASE . . . . . . . . . . 23-5 CABLE INSTALLATION, FRONT . . . . . . . . . . . 5-63 CABLE INSTALLATION, INTERMEDIATE . . . . . 5-66 CABLE INSTALLATION, REAR . . . . . . . . . . . . 5-66 CABLE REMOVAL, FRONT . . . . . . . . . . . . . . . 5-63 CABLE REMOVAL, INTERMEDIATE . . . . . . . . 5-66 CABLE REMOVAL, REAR . . . . . . . . . . . . . . . . 5-66 CABLE REMOVE/INSTALL, SERVO . . . . . . . . 8H-9 CABLE RESISTANCE, SPARK PLUG . 8D-16,8D-29 CABLE, SERVO . . . . . . . . . . . . . . . . . . . . . . . 8H-1 CABLE, SPEEDOMETER . . . . . . . . . . . . . . . . . 0-29 CABLE, TEMPERATURE CONTROL . . . . . . . 24-19 CABLE TENSIONER ADJUSTMENT, PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . 5-67 CABLE, THROTTLE . . . . . . . . . . . . . . . . . . . 14-19 CABLES, DISTRIBUTOR CAP AND ROTOR, IGNITION . . . . . . . . . . . . . . . . . . . . . 0-18 CABLES, SPARK PLUG SECONDARY . . . . . 8D-15, 8D-25 CALIBRATION, COMPASS . . . . . . . . . . . . . . . 8C-5 CALIPER ASSEMBLY . . . . . . . . . . . . . . . 5-32,5-38 CALIPER CLEANING AND INSPECTION . 5-31,5-37 CALIPER DISASSEMBLY . . . . . . . . . . . . 5-30,5-37 CALIPER INSPECTION, BRAKESHOE . . . . . . . 5-35 CALIPER INSTALLATION . . . . . . . . . . . . 5-32,5-40 CALIPER REMOVAL . . . . . . . . . . . . . . . . 5-30,5-37 CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . 9-63,9-95 CAMSHAFT, CRANKSHAFT AND INTERMEDIATE SHAFTS TIMING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 9-18 CAMSHAFT POSITION SENSOR; FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-84 CAMSHAFT POSITION SENSOR; FUEL/IGNITION3.9L AND 5.2L ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-8 CAMSHAFT POSITION SENSOR; IGNITION SYSTEMS . . . . . . . . . . . . . . . . . . 8D-18 CAMSHAFT POSITION SENSOR TEST . . . . . . 8D-6 CAMSHAFT POSITION SENSOR TESTING . . 14-70 CAMSHAFT POSITION SENSOR3.9L/ 5.2L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 8D-2 CAMSHAFT POSITION SENSORPCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-57 CANISTER, EVAP . . . . . . . . . . . . . . . . . 25-20,25-5 CANISTER PURGE SOLENOID, EVAP; EMISSION CONTROL SYSTEMS . . . . . . . . . . 25-5 CANISTER PURGE SOLENOID, EVAP; FUEL SYSTEM . . . . . . . . . . . . . . . . . . 14-44,14-85 CANISTER PURGE SOLENOID2.5L ENGINE, EVAP . . . . . . . . . . . . . . . . . . . . . . . 25-21 CANISTER PURGE SOLENOIDPCM OUTPUT, EVAP . . . . . . . . . . . . . . . . . 14-27,14-62 CAP AND ROTOR, IGNITION CABLES, DISTRIBUTOR . . . . . . . . . . . . . . . . . . . . . . . . 0-18 CAP, DISTRIBUTOR . . . . . . . . . . . . . . . . . . . . 8D-7 CAP, FUEL TANK FILLER TUBE; EMISSION CONTROL SYSTEMS . . . . . 25-21,25-6
CAP, FUEL TANK FILLER TUBE; FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-15 CAP, RADIATOR PRESSURE . . . . . . . . . . . . . 7-27 CAP REMOVE/INSTALL, LOWER LEFT INSTRUMENT PANEL END . . . . . . . . . . . . . 8E-21 CAPACITIES, A/C REFRIGERANT OIL . . . . . . . 24-6 CAPACITIES, COOLANT . . . . . . . . . . . . . . . . . 7-48 CAPACITIES, FLUID . . . . . . . . . . . . . . . . . . . . . 0-3 CAPACITIES, FUEL TANK . . . . . . . . . . 14-15,14-92 CAPACITY, RWAL FAULT CODE . . . . . . . . . . . 5-10 CAPACITY TEST3.9L/5.2L ENGINE, FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . 14-9 CAPACITY, TRANSMISSION LUBRICANT LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-40 CAPS, PRESSURE TESTING RADIATOR . . . . 7-28 CARDAN (CV), DOUBLE . . . . . . . . . . . . . . . . 16-11 CARGO BOX . . . . . . . . . . . . . . . . . . . . . . . . 23-20 CARGO BOX STRIPES, CAB . . . . . . . . . . . . . 23-13 CARPETS AND FLOOR MATS . . . . . . . . . . . 23-43 CASE (4WD VEHICLES), TRANSFER . . . . . . . 0-22 CASE ASSEMBLY, OVERDRIVE GEARTRAIN . . . . . . . . . . . . . . . . . . . . . . . . 21-254 CASE ASSEMBLY, TRANSFER . . . . . . . . . . 21-273 CASE CLEANING AND INSPECTION, TRANSMISSION . . . . . . . . . . . . . . . 21-154,21-200 CASE DISASSEMBLY AND OVERHAUL, TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . 21-267 CASE IDENTIFICATION, ENGINE AND TRANSMISSION/TRANSFER . . . . . . . . . . . Intro.-3 CASE IDENTIFICATION, TRANSFER . . . . . . 21-261 CASE INSTALLATION, TRANSFER . . . . . . . 21-266 CASE IN-VEHICLE SERVICE, TRANSFER . . 21-265 CASE, LEGEND FOR NP231 TRANSFER . . 21-285 CASE, NP231 TRANSFER . . . . . . . 21-260,21-284 CASE REMOVAL, DIFFERENTIAL . . . . . . . . . . 2-37 CASE REMOVAL, TRANSFER . . . . . . . . . . . 21-266 CASE SPECIFICATIONS, TRANSFER . . . . . 21-262 CATALYTIC CONVERTER . . . . . . . . . . . . 11-1,11-4 CAUSES, ABS/RWAL FAULT CONDITION . . . . 5-10 CAUSES, CLUTCH PROBLEM . . . . . . . . . . . . . 6-3 CAUSES OF BURNED FLUID . . . . . . . . . . . . 21-92 CAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-3 CAUTIONS AND SERVICE PRECAUTIONS, WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . 24-3 CAUTIONS, AND WARNINGS, NOTES . . . 8W-01-1 CENTER BEARING SERVICE . . . . . . . . . . . . . 16-9 CENTER BEARING SUPPORT CROSSMEMBER, DRIVE SHAFT . . . . . . . . . 13-35 CENTER BEARINGS . . . . . . . . . . . . . . . . . . . . 16-2 CENTER HIGH MOUNTED STOP LAMP (CHMSL) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-11 CENTER LINK . . . . . . . . . . . . . . . . . . . . . . . 19-18 CENTERING, CLOCKSPRING . . . . . . . . . . . . . 8M-7 CERTIFICATION LABEL, VEHICLE SAFETY . Intro.-1 CHAIN COVER, TIMING . . . . . . . . . . . . . 9-61,9-93 CHANGE AND FILTER REPLACEMENT, ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . 0-15 CHANGE, LUBRICANT; FRONT SUSPENSION AND AXLE . . . . . . . . . . . . . . . . 2-33 CHANGE, LUBRICANT; REAR SUSPENSION AND AXLES . . . . . . . . . . . . . . . 3-15 CHANGE, REFILLING AFTER OVERHAUL OR FLUID/FILTER . . . . . . . . . . . . . . . . . . . . 21-126 CHANGES AND PARTS INTERCHANGEABILITY, TRANSMISSION . . . 21-87 CHANGES, TRANSMISSION . . . . . . . . . . . . . 21-41 CHARGE RATE . . . . . . . . . . . . . . . . . . . . . . . . 8A-9 CHARGING, BATTERY . . . . . . . . . . . . . . . . . . 8A-8 CHARGING REFRIGERANT SYSTEM . . . . . . . 24-5 CHARGING SYSTEM; BATTERY/ STARTING/CHARGING SYSTEMS DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . 8A-17 CHARGING SYSTEM; CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-1 CHARGING SYSTEM DIAGNOSIS . . . . . . . . 8A-18 CHARGING SYSTEM SPECIFICATIONS; BATTERY/STARTER/GENERATOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-10 CHARGING SYSTEM SPECIFICATIONS; BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS . . . . . . . . . . . . . . . 8A-23 CHARGING TIME TABLE, BATTERY . . . . . . . . 8A-8 CHART 1, DIAGNOSIS; VEHICLE SPEED CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . 8H-4 CHART 2, DIAGNOSIS; VEHICLE SPEED CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . 8H-5 CHART, AX 15 SELECTIVE SNAP RING . . . 21-286 CHART, CLUTCH INSPECTION . . . . . . . . . . . . . 6-5
INDEX
Group-Page Description Group-Page Description Group-Page
Description
CHART, LEAD CORRECTION . . . . . . . . . . . . . 22-5 CHART, MIRROR TEST . . . . . . . . . . . . . . . . . 8T-2 CHART, RADIO DIAGNOSIS . . . . . . . . . . . . . . 8F-3 CHARTS, DIAGNOSIS . . . . . . . . . . . . . . . . 21-100 CHARTS, INSPECTION AND DIAGNOSIS . . . . . 6-4 CHASSIS AND BODY COMPONENTS . . . . . . . 0-25 CHASSIS COMPONENT AND WHEEL BEARING LUBRICANTS . . . . . . . . . . . . . . . . . 0-25 CHECK, AIRBAG SYSTEM . . . . . . . . . . . . . . . 8M-2 CHECK, FLUID LEVEL . . . . . . . . . . . . . . . . 21-125 CHECK, PRELIMINARY BRAKE . . . . . . . . . . . . 5-3 CHECK, THROTTLE BODY MINIMUM AIR FLOW . . . . . . . . . . . . . . . . . . . . . . . . . 14-36,14-73 CHECK VALVE REPLACEMENT . . . . . . . . . . 19-31 CHECK VALVE SERVICE, CONVERTER DRAINBACK . . . . . . . . . . . . . . . . . . . . . . . . 21-134 CHECK VALVE TEST, POWER BOOSTER . . . . . 5-7 CHECKING ENGINE OIL PRESSURE . . . . . . . 9-44 CHECKING FLUID LEVEL AND CONDITION . . . . . . . . . . . . . . . . . . . . . . . . . 21-91 CHECKS, PRELIMINARY . . . . . . . . . . . . . . . . . 7-4 CHMSL LAMPS, STOP LAMPS . . . . . . . . 8W-51-1 CHOKE RELAYPREMIUM RADIO ONLY, RADIO . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-1 CHOKE/SPEAKER RELAY, FILTER . . . . . . 8F-1,8F-5 CHOKE/SPEAKER RELAY REMOVE/ INSTALL, FILTER . . . . . . . . . . . . . . . . . . . . . . 8F-8 CIGAR LAMP, ASH RECEIVER LAMP . . . 8W-44-1 CIGAR LIGHTER . . . . . . . . . . . . . . . . . . . 8W-41-1 CIGAR LIGHTER REMOVE/INSTALL . . . . . . . 8E-21 CIRCUIT BREAKER . . . . . . . . . . . . . . . . . . . . 8S-1 CIRCUIT DIAGNOSIS, IGNITION SECONDARY . . . . . . . . . . . . . . . . . . . . . . . . . 8D-9 CIRCUIT IDENTIFICATION . . . . . . . . . . . . 8W-01-2 CIRCUIT REMOVE/INSTALL, PRINTED . . . . 8E-19 CIRCUIT SENSEPCM INPUT, IGNITION . . 14-58 CIRCUIT VOLTAGE, OPEN . . . . . . . . . . . . . . . 8A-7 CIRCUITS HEATER A/C CONTROL, VACUUM . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-11 CLAMPS, FUEL TUBES/LINES/HOSES . . . . 14-10, 14-46,14-87 CLASSIFICATION OF LUBRICANTS . . . . . . . . . 0-1 CLASSIFICATIONS AND RATINGS, BATTERY; BATTERY/STARTER/ GENERATOR SERVICE . . . . . . . . . . . . . . . . . . 8B-9 CLASSIFICATIONS AND RATINGS, BATTERY; BATTERY/STARTING/ CHARGING SYSTEMS DIAGNOSTICS . . . . . 8A-22 CLEAN BRAKE FLUID, IMPORTANCE OF . . . . 5-12 CLEANER ELEMENT, AIR; EMISSION CONTROL SYSTEMS . . . . . . . . . . . . . . . . . . 25-18 CLEANER ELEMENT, AIR; FUEL SYSTEM . . 14-43, 14-84 CLEANER ELEMENT, AIR; LUBRICATION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . 0-17 CLEANER HOUSING, AIR; EMISSION CONTROL SYSTEMS . . . . . . . . . . . . . . . . . . 25-18 CLEANER HOUSING, AIR; FUEL SYSTEM . . 14-83 CLEANING AND INSPECTION; BRAKES . . . . . 5-21 CLEANING AND INSPECTION; PROPELLER SHAFTS . . . . . . . . . . . . . . . . . . 16-10 CLEANING AND INSPECTION, CALIPER . . . . 5-31, 5-37 CLEANING AND INSPECTION, OVERDRIVE COMPONENT . . . . . . . . . . . . . 21-245 CLEANING AND INSPECTION, TRANSMISSION CASE . . . . . . . . . . 21-154,21-200 CLEANING AND INSPECTION, TRANSMISSION COMPONENT . . . . . . . . . . 21-56 CLEANING AND INSPECTION, VALVE BODY . . . . . . . . . . . . . . . . . . . . . . . 21-176,21-223 CLEANING OF TIRES . . . . . . . . . . . . . . . . . . . 22-2 CLEANING/REVERSE FLUSHING, COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . 7-25 CLEANUP PROCEDURE . . . . . . . . . . . . . . . . 8M-3 CLEARANCE AND RAMP ANGLE, GROUND . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-11 CLEARING RWAL FAULT CODES . . . . . . . . . . 5-10 CLIP, FUEL LINE WITH LATCH . . . . . . . . . . 14-13 CLOCKSPRING; RESTRAINT SYSTEMS . . . . 8M-2 CLOCKSPRING; STEERING . . . . . . . . . . . . . 19-38 CLOCKSPRING CENTERING . . . . . . . . . . . . . 8M-7 CLOCKSPRING REMOVE/INSTALL . . . . . . . . 8M-6 CLUSTER BEZEL REMOVE/INSTALL . . . . . . 8E-15 CLUSTER BULBS REMOVE/INSTALL . . . . . . 8E-17 CLUSTER ILLUMINATION LAMPS . . . . 8E-14,8E-4 CLUSTER, INSTRUMENT . . . . . . . . . . . . . 8W-40-1
CLUSTER LENS AND MASK REMOVE/ INSTALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-15 CLUSTER, OPTIONAL . . . . . . . . . . . . . . . . . . 8E-9 CLUSTER REMOVE/INSTALL, INSTRUMENT . . . . . . . . . . . . . . . . . . . . . . . 8E-15 CLUSTER, STANDARD . . . . . . . . . . . . . . . . . . 8E-8 CLUSTERS, INSTRUMENT . . . . . . . . . . . . . . . 8E-1 CLUTCH AND BAND APPLICATION . . . . . . . 21-90 CLUTCH AND BAND OPERATION, AIR TESTING TRANSMISSION . . . . . . . . . . . . . . 21-97 CLUTCH AND BRAKE PEDAL BUSHINGS . . . 0-20 CLUTCH AND GEARTRAIN ASSEMBLY, DIRECT . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-250 CLUTCH COIL ASSEMBLY, COMPRESSOR . 24-15 CLUTCH COMPONENT SERVICE . . . . . . . . . . 6-10 CLUTCH COMPONENTS . . . . . . . . . . . . . . . . . . 6-1 CLUTCH CONTROL, CONVERTER . . . . . . . . 21-90 CLUTCH COVER AND DISC INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 6-10 CLUTCH COVER AND DISC REMOVAL . . . . . 6-10 CLUTCH COVER AND DISC RUNOUT . . . . . . . 6-4 CLUTCH DIAGNOSIS . . . . . . . . . . . . . . . . . . . . 6-3 CLUTCH DIAGNOSIS, COMPRESSOR . . . . . 24-14 CLUTCH DIAGNOSIS, CONVERTER . . . . . . 21-112, 21-113,21-114 CLUTCH DISC APPLICATION . . . . . . . . . . . . . . 6-1 CLUTCH GRAB/CHATTER . . . . . . . . . . . . . . . . . 6-8 CLUTCH HOUSING MISALIGNMENT . . . . . . . . 6-4 CLUTCH HOUSING REPLACEMENT (AX 15) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 CLUTCH HYDRAULIC FLUID . . . . . . . . . . . . . . 6-1 CLUTCH HYDRAULIC LINKAGE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 6-13 CLUTCH HYDRAULIC LINKAGE REMOVAL . . 6-12 CLUTCH INSPECTION CHART . . . . . . . . . . . . . 6-5 CLUTCH INSTALLATION AND ADJUSTMENT, OVERDRIVE . . . . . . . . . . . . 21-257 CLUTCH LINKAGE, HYDRAULIC . . . . . . . . . . . 6-1 CLUTCH LUBRICATION . . . . . . . . . . . . . . . . . . 6-2 CLUTCH MASTER CYLINDER . . . . . . . . . . . . 0-20 CLUTCH MISALIGNMENT . . . . . . . . . . . . . . . . 6-3 CLUTCH NOISE . . . . . . . . . . . . . . . . . . . . . . . . 6-9 CLUTCH OVERHAUL, FRONT . . . . . 21-159,21-208 CLUTCH OVERHAUL, OVERRUNNING . . . . 21-201 CLUTCH OVERHAUL, REAR . . . . . . 21-161,21-210 CLUTCH PEDAL INSTALLATION . . . . . . . . . . 6-13 CLUTCH PEDAL POSITION SWITCH . . . . . . . . 6-2 CLUTCH PEDAL REMOVAL . . . . . . . . . . . . . . 6-13 CLUTCH PROBLEM CAUSES . . . . . . . . . . . . . . 6-3 CLUTCH RELAY, A/C . . . . . . . . . . . . . 14-43,14-83 CLUTCH RELAYPCM OUTPUT, AIR CONDITIONING (A/C) . . . . . . . . . . . . . 14-25,14-61 CLUTCH RELEASE, IMPROPER . . . . . . . . . . . . 6-7 CLUTCH RELEASE OR ENGAGEMENT, IMPROPER . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 CLUTCH SLIPS . . . . . . . . . . . . . . . . . . . . . . . . 6-6 CLUTCH TEST, COMPRESSOR . . . . . . . . . . . 24-13 CLUTCHLOW-REVERSE DRUM OVERDRIVE PISTON RETAINER INSPECTION AND OVERHAUL, OVERRUNNING . . . . . . . . . . . . . . . . . . . . . 21-154 COAT FINISH, BASE COAT/CLEAR . . . . . . . . 23-45 COAT/CLEAR COAT FINISH, BASE . . . . . . . . 23-45 CODE CAPACITY, RWAL FAULT . . . . . . . . . . . 5-10 CODE DESIGNATIONS, VEHICLE . . . . . . . . Intro.-1 CODE (DTC), DIAGNOSTIC TROUBLE . . . . . 14-39, 14-79 CODE, GENERATOR DIAGNOSTIC TROUBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-21 CODE IDENTIFICATION, RWAL FAULT . . . . . . 5-10 CODE IDENTIFICATION, WIRE . . . . . . . . . 8W-01-1 CODE PLATE, BODY . . . . . . . . . . . . . . . . . Intro.-2 CODE PLATE DECODING, BODY . . . . . . . . Intro.-3 CODE, SPEED CONTROL DIAGNOSTIC TROUBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H-6 CODES AND DIMENSIONS/WEIGHTS, DESIGNATIONS, LABELS/PLATES/ DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . Intro.-1 CODES, CLEARING RWAL FAULT . . . . . . . . . 5-10 CODES, GENERATING RWAL FLASH . . . . . . . 5-10 CODES, RWAL DIAGNOSTIC FAULT FLASH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 COIL ASSEMBLY, COMPRESSOR CLUTCH . 24-15 COIL, EVAPORATOR . . . . . . . . . . . . . . . . . . 24-26 COIL, IGNITION; FUEL SYSTEM . . . . 14-47,14-88 COIL, IGNITION; FUEL/IGNITION . . . . . . . 8W-30-2 COIL, IGNITION; FUEL/IGNITION3.9L AND 5.2L ENGINES . . . . . . . . . . . . . . . . . 8W-30-7
. . . . 8D-22, 8D-4,8D-8 COIL RESISTANCE, IGNITION . . . . . . . 8D-29,8D-9 COIL SPRING . . . . . . . . . . . . . . . . . . . . . . . . 2-10 COILPCM OUTPUT, IGNITION . . . . 14-28,14-62 COLUMN ASSEMBLY REPLACEMENT . . . . . 19-39 COLUMN, STEERING . . . . . . . . . . . . . 19-36,19-42 COMBINATION VALVE INSTALLATION . . 5-47,5-57 COMBINATION VALVE OPERATION . . . . 5-46,5-55 COMBINATION VALVE REMOVAL . . . . . 5-47,5-57 COMBINATION VALVE TESTING . . . . . . . 5-10,5-6 COMBUSTION PRESSURE LEAKAGE TEST, CYLINDER . . . . . . . . . . . . . . . . . . . . . . . 9-6 COMPARTMENT DOOR REMOVE/ INSTALL, GARAGE DOOR OPENER STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C-8 COMPASS . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C-1 COMPASS CALIBRATION . . . . . . . . . . . . . . . . 8C-5 COMPASS DEMAGNETIZING . . . . . . . . . . . . . 8C-5 COMPASS VARIATION ADJUSTMENT . . . . . . 8C-5 COMPASS/DISPLAY SELF-DIAGNOSTIC TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C-2 COMPASS/THERMOMETER DIAGNOSIS . . . . 8C-3 COMPASS/THERMOMETER MODULE REMOVE/INSTALL . . . . . . . . . . . . . . . . . . . . . 8C-6 COMPLAINT, HISS NOISE . . . . . . . . . . . . . . . 19-3 COMPLETE DOOR . . . . . . . . . . . . . . . . . . . . 23-25 COMPONENTS2WD, FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . 2-47 . COMPONENTS4WD, FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . 2-47 COMPONENTSIN-VEHICLE SERVICE, CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . 9-21 COMPRESSION PRESSURE TEST, CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 COMPRESSOR, AIR-CONDITIONER . . . . . . . . 0-19 COMPRESSOR AND CLUTCH DIAGNOSIS . . 24-14 COMPRESSOR BRACKET SERVICE, SOLID MOUNT . . . . . . . . . . . . . . . . . . . . . . . . 9-15 COMPRESSOR CLUTCH COIL ASSEMBLY . . 24-15 COMPRESSOR CLUTCH TEST . . . . . . . . . . . 24-13 COMPRESSOR DRIVE BELT . . . . . . . . . . . . 24-14 COMPRESSOR MANIFOLD . . . . . . . . . . . . . 24-15 COMPRESSOR NOISE, A/C . . . . . . . . . . . . . 24-14 COMPRESSOR REPLACEMENT . . . . . . . . . . 24-14 COMPRESSOR SERVICE . . . . . . . . . . . . . . . 24-14 CONDENSER ASSEMBLY, A/C . . . . . . . . . . . 24-22 CONDITION CAUSES, ABS/RWAL FAULT . . . . 5-10 CONDITION, CHECKING FLUID LEVEL . . . . . 21-91 CONDITIONS, ABS SYSTEM NORMAL AND FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 CONNECTING ROD ASSEMBLY, PISTON / . 9-103, 9-71 CONNECTING ROD ASSEMBLY SERVICE, CYLINDER BLOCK, PISTON . . . . . . . . . . . . . . 9-34 CONNECTIONS, INTERMITTENT AND POOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-01-4 CONNECTIONS, STARTER RELAY . . . . . . . . 8A-15 CONNECTOR, ABS DATA LINK . . . . . . . . 8W-32-2 CONNECTOR, AIRBAG DATA LINK . . . . . 8W-43-1 CONNECTOR AND TERMINAL REPLACEMENT . . . . . . . . . . . . . . . . . . . . 8W-01-7 CONNECTOR, DATA LINK; ANTI-LOCK BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . 8W-32-4 CONNECTOR, DATA LINK; FUEL/IGNITION . . . . . . . . . . . . . . . . . . . . 8W-30-5 CONNECTOR, DATA LINK; FUEL/ IGNITION3.9L AND 5.2L ENGINES . . 8W-30-11 CONNECTOR LOCATION, ABS DIAGNOSTIC . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 CONNECTOR LOCATION, RWAL DIAGNOSTIC . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 CONNECTOR LOCATIONS; CONNECTOR LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . 8W-90-1 CONNECTOR LOCATIONS; CONNECTOR PIN OUTS . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-1 CONNECTOR LOCATIONS; WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-1 CONNECTOR, POWERTRAIN CONTROL MODULE (PCM) 60-WAY . . . . . . . . . . . . . . . 14-70 CONNECTOR REPLACEMENT . . . . . . . . . 8W-01-7 CONNECTORPCM INPUT AND OUTPUT, DATA LINK . . . . . . . . . . . . . . . . . . 14-57 CONNECTORS . . . . . . . . . . . . . . . . . . . . . 8W-01-2 CONNECTORS, RADIO AND SPEAKER . . . . . . 8F-4 CONNECTORS, TERMINAL/CONNECTOR REPAIRMOLEX . . . . . . . . . . . . . . . . . . 8W-01-6
INDEX
Description Group-Page Description Group-Page Description
Group-Page
CONSOLE AND REAR SEAT STORAGE BOXES, FLOOR . . . . . . . . . . . . . . . . . . . . . . 23-43 CONSOLE BEZEL REMOVE/INSTALL, OVERHEAD . . . . . . . . . . . . . . . . . . . . . . . . . . 8C-7 CONSOLE, OVERHEAD; BODY COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . 23-42 CONSOLE, OVERHEAD; OVERHEAD CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . 8W-49-1 CONSOLE REMOVE/INSTALL, OVERHEAD . . . 8C-6 CONTAMINATION, BRAKE FLUID . . . . . . . . . . 5-13 CONTAMINATION, FLUID . . . . . . . . . . . . . . . 21-92 CONTROL AND DISPLAY SYMBOLS, INTERNATIONAL . . . . . . . . . . . . . . . . . . . . Intro.-7 CONTROL AND DISPLAY SYMBOLS, INTERNATIONAL VEHICLE . . . . . . . . . . . . . Intro.-3 CONTROL CABLE, TEMPERATURE . . . . . . . 24-19 CONTROL, CONVERTER CLUTCH . . . . . . . . 21-90 CONTROL DIAGNOSTIC TROUBLE CODE, SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H-6 CONTROL, EGR VALVE . . . . . . . . . . . . . . . . 25-20 CONTROL, FUEL PUMP . . . . . . . . . . . . . . . . . 14-4 CONTROL (IAC) MOTOR, IDLE AIR; FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . 14-46,14-88 CONTROL (IAC) MOTOR, IDLE AIR; FUEL/IGNITION . . . . . . . . . . . . . . . . . . . . 8W-30-3 CONTROL (IAC) MOTOR, IDLE AIR; FUEL/IGNITION3.9L AND 5.2L ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-8 CONTROL (IAC) MOTOR TEST, IDLE AIR . . 14-72 CONTROL (IAC) MOTORPCM OUTPUT, IDLE AIR . . . . . . . . . . . . . . . . . . . . . . 14-27,14-61 CONTROL INFORMATION LABEL, TYPICAL VEHICLE EMISSION . . . . . . . . . . . . 25-2 CONTROL INFORMATION (VECI) LABEL, VEHICLE EMISSION . . . . . . . . . . . . . . . . . . . . 25-1 CONTROL MODULE (ACM), AIRBAG . . . . 8W-43-1 CONTROL MODULE, AIRBAG . . . . . . . . . . . . 8M-2 CONTROL MODULE DIAGNOSIS, ABS/RWAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 CONTROL MODULE INSTALLATION, ABS ELECTRONIC . . . . . . . . . . . . . . . . . . . . . . . . . 5-59 CONTROL MODULE INSTALLATION, ELECTRONIC . . . . . . . . . . . . . . . . . . . . . . . . . 5-48 CONTROL MODULE (PCM) 60-WAY CONNECTOR, POWERTRAIN . . . . . . . . . . . . 14-70 CONTROL MODULE (PCM), POWERTRAIN; EMISSION CONTROL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . 25-22 CONTROL MODULE (PCM), POWERTRAIN; FUEL SYSTEM . . . . . 14-21,14-48, 14-56,14-89 CONTROL MODULE (PCM), POWERTRAIN; IGNITION SYSTEMS . . . . . . 8D-12, 8D-24,8D-5 CONTROL MODULE, POWERTRAIN . . . 8H-1,8H-7 CONTROL MODULE REMOVAL, ABS ELECTRONIC . . . . . . . . . . . . . . . . . . . . . . . . . 5-59 CONTROL MODULE REMOVAL, ELECTRONIC . . . . . . . . . . . . . . . . . . . . . . . . . 5-48 CONTROL MODULE REMOVE/INSTALL, AIRBAG . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8M-6 CONTROL MODULE, SNOW PLOW . . . . . . . 13-17 CONTROL MODULE TESTING, POWERTRAIN . . . . . . . . . . . . . . . . . . . . . . . 14-76 CONTROL REMOVE/INSTALL, A/CHEATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-20 CONTROL SERVO REMOVE/INSTALL, SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H-8 CONTROL SERVO, SPEED . . . . . . . . . . 8H-1,8H-7 CONTROL, SHIFT VALVE FLOW . . . . . . . . . . 21-89 CONTROL SOLENOIDPCM OUTPUT, EGR (EXHAUST GAS RECIRCULATION) VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-62 CONTROL SWITCH REMOVE/INSTALL, SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H-8 CONTROL SWITCH, SPEED . . . . . . . . . 8H-1,8H-3 CONTROL SYSTEM, EMISSION . . . . . . . . . . . 0-19 CONTROL SYSTEM, EVAP (EVAPORATION) . . . . . . . . . . . . . . . . . . . . . . 25-5 CONTROL SYSTEM VACUUM DIAGNOSIS, HEATER A/C . . . . . . . . . . . . . . 24-10 CONTROL, VACUUM CIRCUITS HEATER A/C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-11 CONTROL, VEHICLE SPEED . . . . . . . . . . 8W-33-1 CONTROLPCM INPUT, SPEED . . . . . . . . . 14-60 CONTROLPCM OUTPUT, SPEED . . . . . . . 14-63 CONTROLS AND OPERATION, AUTOMATIC TRANSMISSION . . . . . . . . . . . 21-88
CONTROLS, EVAPORATIVE EMISSION . . . . . 25-5 CONTROLS, EXHAUST EMISSION . . . . . . . . 25-10 CONTROLS, OVERDRIVE FOURTH GEAR ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . 21-93 CONTROLS, TRANSMISSION HYDRAULIC . 21-88 CONTROLSPCM INPUT, AIR CONDITIONING (A/C) . . . . . . . . . . . . . 14-23,14-56 CONVERSION FORMULAS AND EQUIVALENT VALUES . . . . . . . . . . . . . . . . Intro.-8 CONVERSION, METRIC . . . . . . . . . . . . . . Intro.-10 CONVERSION, METRIC AND ENGLISH/ SAE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intro.-8 CONVERTER - OVERDRIVE REMOVAL/ INSTALLATION, TRANSMISSION - . . . . . . . 21-137 CONVERTER, CATALYTIC . . . . . . . . . . . . 11-1,11-4 CONVERTER CLUTCH CONTROL . . . . . . . . . 21-90 CONVERTER CLUTCH DIAGNOSIS . 21-112,21-113 ,21-114 CONVERTER DRAINBACK CHECK VALVE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . 21-134 CONVERTER DRAINBACK VALVE . . . . . . . . . 21-89 CONVERTER HOUSING FLUID LEAK DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . 21-97 CONVERTER STALL TEST . . . . . . . . . . . . . . 21-96 CONVERTER, TORQUE . . . . . . . . . . . . . . . . . 21-82 CONVERTER-DRIVE PLATE-RING GEAR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . 21-140 COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23 COOLANT CAPACITIES . . . . . . . . . . . . . . . . . 7-48 COOLANT RESERVE/OVERFLOW SYSTEM . . . . 7-27 COOLANT ROUTING, SYSTEM . . . . . . . . . . . . . 7-2 COOLANT TEMPERATURE SENSOR, ENGINE; EMISSION CONTROL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . 25-18 COOLANT TEMPERATURE SENSOR, ENGINE; FUEL SYSTEM . . . . . . . . . . . 14-44,14-84 COOLANT TEMPERATURE SENSOR, ENGINE; FUEL/IGNITION . . . . . . . . . . . . . 8W-30-4 COOLANT TEMPERATURE SENSOR, ENGINE; FUEL/IGNITION3.9L AND 5.2L ENGINES . . . . . . . . . . . . . . . . . . . . . 8W-30-9 COOLANT TEMPERATURE SENSOR, ENGINE; IGNITION SYSTEMS . . . . . . . 8D-20,8D-4 COOLANT TEMPERATURE SENSOR TEST, ENGINE; FUEL SYSTEM . . . . . . . . . . . . . . . . 14-70 COOLANT TEMPERATURE SENSOR TEST, ENGINE; IGNITION SYSTEMS . . . . . . . . . . . . 8D-8 COOLANT TEMPERATURE SENSOR PCM INPUT, ENGINE . . . . . . . . . . . . . 14-23,14-58 COOLER FLOW TESTING, TRANSMISSION . . . . . . . . . . . . . . . . . . . . . 21-134 COOLER LINE AND FITTING SERVICE, TRANSMISSION . . . . . . . . . . . . . . . . . . . . . 21-133 COOLER REPLACEMENT, TRANSMISSION . 21-136 COOLER REVERSE FLUSHING, TRANSMISSION . . . . . . . . . . . . . . . . . . . . . 21-135 COOLERS, AUTOMATIC TRANSMISSION OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32 COOLING FAN RELAYPCM OUTPUT, RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . 14-28 COOLING SYSTEM; COOLING SYSTEM . . . . . . 7-1 COOLING SYSTEM; HEATING AND AIR CONDITIONING . . . . . . . . . . . . . . . . . . . . . . . 24-4 COOLING SYSTEM CLEANING/REVERSE FLUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25 COOLING SYSTEM COMPONENTS . . . . . . . . . 7-2 COOLING SYSTEM DIAGNOSIS . . . 7-5,7-10,7-11, 7-6,7-7,7-8,7-9 COOLING SYSTEM, DRAINING . . . . . . . . . . . 7-24 COOLING SYSTEM, ENGINE . . . . . . . . . . . . . 0-16 COOLING SYSTEM FAN2.5L 4-CYLINDER ENGINE . . . . . . . . . . . . . . . . . . . 7-33 COOLING SYSTEM FAN3.9L/5.2L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36 COOLING SYSTEM FOR LEAKS, TESTING . . . 7-25 COOLING SYSTEM HOSES . . . . . . . . . . . . . . 7-32 COOLING SYSTEM, REFILLING . . . . . . . . . . . 7-24 CORE, HEATER . . . . . . . . . . . . . . . . . . . . . . 24-26 CORE PLUGS, ENGINE . . . . . . . . . . . . . . . . . 9-38 COUPLER SHAFT, INTERMEDIATE . . . 19-31,19-33 COURTESY LAMP AND IGNITION SWITCH LAMP . . . . . . . . . . . . . . . . . . . . 8W-44-1 COURTESY LAMPS, READING . . . . . . . . . . . 8C-1 COVER AND DISC INSTALLATION, CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 COVER AND DISC REMOVAL, CLUTCH . . . . . 6-10 COVER AND DISC RUNOUT, CLUTCH . . . . . . . 6-4 COVER, CYLINDER HEAD . . . . . . . . . . . 9-54,9-86
COVER REPLACEMENT, PITMAN SHAFT AND SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . 19-24 COVER, TIMING CHAIN . . . . . . . . . . . . . 9-61,9-93 COWL GRILLE AND SCREEN . . . . . . . . . . . . . 23-7 CRANKCASE BREATHER/FILTER2.5L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-8 CRANKCASE BREATHER/FILTER3.9L/ 5.2L ENGINES . . . . . . . . . . . . . . . . . . . . . . . . 25-9 CRANKCASE VENTILATION (PCV) SYSTEM, POSITIVE . . . . . . . . . . . . . . . . . . . . 25-6 CRANKCASE VENTILATION SYSTEMS . . . . . . 0-17 CRANKSHAFT . . . . . . . . . . . . . . . . . . . 9-104,9-72 CRANKSHAFT AND INTERMEDIATE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-28 CRANKSHAFT AND INTERMEDIATE SHAFTS TIMING PROCEDURE, CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18 CRANKSHAFT MAIN BEARINGS . . . . . 9-105,9-74 CRANKSHAFT OIL SEAL REPLACEMENT, FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . 9-63,9-95 CRANKSHAFT OIL SEALS SERVICE . . . . . . . . 9-29 CRANKSHAFT POSITION SENSOR; FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-84 CRANKSHAFT POSITION SENSOR; FUEL/IGNITION3.9L AND 5.2L ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-9 CRANKSHAFT POSITION SENSOR; IGNITION SYSTEMS . . . . . . . . . . . . . . . . . . 8D-19 CRANKSHAFT POSITION SENSOR TEST; FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 14-72 CRANKSHAFT POSITION SENSOR TEST; IGNITION SYSTEMS . . . . . . . . . . . . . . . . . . . 8D-7 CRANKSHAFT POSITION SENSOR3.9L/ 5.2L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 8D-2 CRANKSHAFT POSITION SENSORPCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-58 CRANKSHAFT REAR OIL SEALS . . . . . 9-106,9-74 CRANKSHAFT SERVICE . . . . . . . . . . . . . . . . . 9-30 CROSSMEMBER, DRIVE SHAFT CENTER BEARING SUPPORT . . . . . . . . . . . . . . . . . . . 13-35 CUP HOLDER ASSEMBLY REMOVE/ INSTALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-21 CUT-OFF SWITCH, HIGH-PRESSURE . . . . . . 24-13 CV DRIVE SHAFT . . . . . . . . . . . . . . . . . 2-23,2-47 CV JOINT, INNER . . . . . . . . . . . . . . . . . . . . . . 2-24 CV JOINT, OUTER . . . . . . . . . . . . . . . . . . . . . 2-26 CYCLING SWITCH, AIR CONDITIONING . . . 24-13 CYLINDER BLEEDING, MASTER . . . . . . . . . . 5-13 CYLINDER BLOCK . . . . . . . . . . . . . . . . 9-108,9-76 CYLINDER BLOCK, PISTON AND CONNECTING ROD ASSEMBLY SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-34 CYLINDER BORES, HONING . . . . . . . . . . . . . . 9-2 CYLINDER, CLUTCH MASTER . . . . . . . . . . . . 0-20 CYLINDER COMBUSTION PRESSURE LEAKAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . 9-6 CYLINDER COMPRESSION PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 CYLINDER ENGINE, PUMP REPLACEMENT 4 . . . . . . . . . . . . . . . . . . . 19-13 CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . 9-24 CYLINDER HEAD AND VALVE ASSEMBLY SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19 CYLINDER HEAD COMPONENTSINVEHICLE SERVICE . . . . . . . . . . . . . . . . . . . . . 9-21 CYLINDER HEAD COVER . . . . . . . . . . . . 9-54,9-86 CYLINDER HEAD GASKET FAILURE DIAGNOSIS, ENGINE . . . . . . . . . . . . . . . . . . . . 9-5 CYLINDER HEADS . . . . . . . . . . . . . . . . . 9-55,9-87 CYLINDER INSTALLATION, MASTER . . . . . . . 5-14 CYLINDER INSTALLATION, WHEEL . . . . . . . . 5-24 CYLINDER, KEY LOCK . . . . . . . . . . . . . . . . . 23-27 CYLINDER OVERHAUL, WHEEL . . . . . . . . . . . 5-24 CYLINDER REMOVAL, MASTER . . . . . . . . . . 5-13 CYLINDER REMOVAL, WHEEL . . . . . . . . . . . 5-24 CYLINDER RESERVOIR REPLACEMENT, MASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 CYLINDER SERVICE, IGNITION SWITCH AND KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-27 CYLINDER SERVICE, POWER ANGLING . . . 13-16 CYLINDERBRAKE FLUID BRAKELINES, MASTER . . . . . . . . . . . . . . . . . 5-12 CYLINDER/POWER BOOSTER TEST, MASTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 D FIRST GEAR (BREAKAWAY), HYDRAULIC FLOW IN . . . . . . . . . . . . . . . . 21-118 D FOURTH GEAR (CONVERTER CLUTCH APPLIED), HYDRAULIC FLOW IN . . . . . . . 21-122
INDEX
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Description
D FOURTH GEAR (CONVERTER CLUTCH NOT APPLIED), HYDRAULIC FLOW IN . . . 21-121 D SECOND GEAR, HYDRAULIC FLOW IN . 21-119 D THIRD GEAR, HYDRAULIC FLOW IN . . . 21-120 DAMAGED OR WORN THREADS, REPAIR . . . . 9-4 DAMPER, VIBRATION . . . . . . . . . . . . . . 9-60,9-92 DATA LINK CONNECTOR; ANTI-LOCK BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . 8W-32-4 DATA LINK CONNECTOR; FUEL/IGNITION . . . . . . . . . . . . . . . . . . . . 8W-30-5 DATA LINK CONNECTOR; FUEL/ IGNITION3.9L AND 5.2L ENGINES . . 8W-30-11 DATA LINK CONNECTOR, ABS . . . . . . . . 8W-32-2 DATA LINK CONNECTOR, AIRBAG . . . . . 8W-43-1 DATA LINK CONNECTORPCM INPUT AND OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . 14-57 DAY/NIGHT MIRROR . . . . . . . . . . . . . . . . 8W-44-2 DAY/NIGHT MIRROR, AUTOMATIC . . . . 8T-1,8T-2 DAY/NIGHT MIRROR REMOVE/INSTALL, AUTOMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . 8T-3 DAYTIME RUNNING LAMP (DRL) MODULE . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-2 DAYTIME RUNNING LIGHT MODULE (DRLM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-12 DECALS, BODY MOULDINGS, NAMEPLATES . . . . . . . . . . . . . . . . . . . . . . . 23-10 DECODING, BODY CODE PLATE . . . . . . . . Intro.-3 DECODING, VEHICLE IDENTIFICATION NUMBER (VIN) . . . . . . . . . . . . . . . . . . . . . Intro.-2 DEFLECTOR4WD VEHICLES, ENGINE SPLASH SHIELD/AIR . . . . . . . . . . . . . . . . . . 13-34 . DELAY RELAY, TIME . . . . . . . . . . . . . . . . 8W-44-1 DELIVERY SYSTEM, FUEL . . . . . . . . . . . . . . . 14-3 DEMAGNETIZING, COMPASS . . . . . . . . . . . . 8C-5 DEPTH MEASUREMENT AND ADJUSTMENT WITH GAUGE SET, PINION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 DEPTH VARIANCE, PINION GEAR; FRONT SUSPENSION AND AXLE . . . . . . . . . . . . . . . . 2-42 DEPTH VARIANCE, PINION GEAR; REAR SUSPENSION AND AXLES . . . . . . . . . . . . . . . 3-24 DESCRIPTION AND OPERATION, SYSTEM . . 13-3 DESCRIPTION, TRANSMISSION . . . . . . . . . 21-82 DESCRIPTION/SYSTEM OPERATION 2.5L ENGINE, SINGLE-PORT FUEL INJECTIONCOMPONENT . . . . . . . . . . . . . 14-21 DESCRIPTION/SYSTEM OPERATION 3.9L/5.2L ENGINE, MULTI-PORT FUEL INJECTION (MFI)COMPONENT . . . . . . . . 14-52 DESCRIPTIONTORQUE . . . . . . . . . . . . . . . . 22-12 DESIGNATIONS, LABELS/PLATES/ DECALS, CODES AND DIMENSIONS/ WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . Intro.-1 DESIGNATIONS, VEHICLE . . . . . . . . . . . . . Intro.-1 DESIGNATIONS, VEHICLE CODE . . . . . . . . Intro.-1 DEVICES, ELECTROSTATIC DISCHARGE (ESD) SENSITIVE . . . . . . . . . . . . . . . . . . 8W-01-2 DIAGNOSING PARKING BRAKE PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 DIAGNOSING SERVICE BRAKE PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 DIAGNOSIS; AUDIO SYSTEMS . . . . . . . . . . . 8F-2 DIAGNOSIS; BATTERY/STARTING/ CHARGING SYSTEMS DIAGNOSTICS . . . . . 8A-10, 8A-11,8A-17,8A-3 DIAGNOSIS; CHIME/BUZZER WARNING SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . 8U-2 DIAGNOSIS; COOLING SYSTEM . . . . . . . . . . . 7-3 DIAGNOSIS; HORN . . . . . . . . . . . . . . . . . . . . 8G-2 DIAGNOSIS; INSTRUMENT PANEL AND GAUGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-4 DIAGNOSIS; OVERHEAD CONSOLE . . . . . . . . 8C-2 DIAGNOSIS; POWER LOCKS . . . . . . . . . . . . . 8P-1 DIAGNOSIS; POWER MIRRORS . . . . . . . . . . 8T-2 DIAGNOSIS; POWER WINDOWS . . . . . . . . . . 8S-1 DIAGNOSIS; RESTRAINT SYSTEMS . . . . . . . 8M-2 DIAGNOSIS; TURN SIGNAL AND HAZARD WARNING SYSTEMS . . . . . . . . . . . . . . . . . . . 8J-2 DIAGNOSIS; VEHICLE SPEED CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H-3 DIAGNOSIS; WIPER AND WASHER SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . 8K-3 DIAGNOSIS, ABS/RWAL CONTROL MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 DIAGNOSIS AND TESTING, AUTOMATIC TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . 21-91 DIAGNOSIS AND TESTS, SNOW PLOW MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . 13-4
DIAGNOSIS, ANTILOCK BRAKE SYSTEM . . . . 5-8 DIAGNOSIS, ANTILOCK VALVE SERVICE . . . . . 5-9 DIAGNOSIS, AXLE NOISE/VIBRATION . . . . . . . 3-8 DIAGNOSIS, BATTERY . . . . . . . . . . . . . . . . . . 8A-5 DIAGNOSIS, BELT . . . . . . . . . . . . . . . . . . . . . 7-39 DIAGNOSIS, CHARGING SYSTEM . . . . . . . . 8A-18 DIAGNOSIS CHART 1 . . . . . . . . . . . . . . . . . . 8H-4 DIAGNOSIS CHART 2 . . . . . . . . . . . . . . . . . . 8H-5 DIAGNOSIS CHART, RADIO . . . . . . . . . . . . . . 8F-3 DIAGNOSIS CHARTS . . . . . . . . . . . . . . . . . 21-100 DIAGNOSIS CHARTS, INSPECTION . . . . . . . . . 6-4 DIAGNOSIS, CLUTCH . . . . . . . . . . . . . . . . . . . 6-3 DIAGNOSIS, COMPASS/THERMOMETER . . . . 8C-3 DIAGNOSIS, COMPRESSOR AND CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-14 DIAGNOSIS (CONT.), COOLING SYSTEM . . . 7-10, 7-11,7-6,7-7,7-8,7-9 DIAGNOSIS (CONTD), SERVICE; FRONT SUSPENSION AND AXLE . . . . . . . . . . . . . . . . 2-22 DIAGNOSIS (CONTD), SERVICE; REAR SUSPENSION AND AXLES . . . . . . . . . . . . . . . 3-11 DIAGNOSIS, CONVERTER CLUTCH . . . . . . 21-112, 21-113,21-114 DIAGNOSIS, CONVERTER HOUSING FLUID LEAK . . . . . . . . . . . . . . . . . . . . . . . . . 21-97 DIAGNOSIS, COOLING SYSTEM . . . . . . . . . . . 7-5 DIAGNOSIS, ENGINE . . . . . . . . . . . . . . . . . . . . 9-5 DIAGNOSIS, ENGINE CYLINDER HEAD GASKET FAILURE . . . . . . . . . . . . . . . . . . . . . . . 9-5 . DIAGNOSIS, EXHAUST SYSTEM . . . . . . . . . . 11-2 DIAGNOSIS, FOG/OFF ROAD LAMP . . . . . . . . 8L-3 DIAGNOSIS, GEAR LEAKAGE . . . . . . . . . . . . 19-11 DIAGNOSIS, HEADLAMP . . . . . . . . . . . . . . . . 8L-2 DIAGNOSIS, HEATER A/C CONTROL SYSTEM VACUUM . . . . . . . . . . . . . . . . . . . . 24-10 DIAGNOSIS, IGNITION SECONDARY CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-9 DIAGNOSIS, INTAKE MANIFOLD LEAKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 DIAGNOSIS (MECHANICAL), HEATER . . . . . . 24-9 DIAGNOSIS, NOISE . . . . . . . . . . . . . . . . . . . . 3-30 DIAGNOSIS, NP231 SERVICE . . . . . . . . . . 21-263 DIAGNOSIS, OVERDRIVE . . 21-109,21-110,21-111 DIAGNOSIS, POWER STEERING SYSTEM . . 19-3, 19-4,19-5,19-6,19-7,19-8,19-9 DIAGNOSIS, PRELIMINARY . . . . . . . . . . . . . 21-91 DIAGNOSIS, PRESSURE . . . . . . . . . . . . . . . . 24-8 DIAGNOSIS PROCEDURES . . . . . . . . . . . . 5-3,5-8 DIAGNOSIS, PUMP LEAKAGE . . . . . . . . . . . 19-10 DIAGNOSIS, SERVICE; FRONT SUSPENSION AND AXLE . . . . . . . . . . . . 2-19,2-21 DIAGNOSIS, SERVICE; REAR SUSPENSION AND AXLES . . . . . . . . . . . . . . . 3-10 DIAGNOSIS, SERVICE BRAKE . . . . . . . . . . . . . 5-3 DIAGNOSIS, SNOW PLOW . . . . . . . . . . . . . . 13-9 DIAGNOSIS, SPRING AND SHOCK . . . . . . . . . 3-4 DIAGNOSIS, SPRING AND SHOCK ABSORBER . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 DIAGNOSIS, STARTING SYSTEM . . . . . . . . 8A-14 DIAGNOSIS, SUSPENSION AND STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . 2-5 DIAGNOSIS, THERMOMETER . . . . . . . . . . . . 8C-4 DIAGNOSIS, TRANSMISSION; NV3500 MANUAL TRANSMISSION . . . . . . 21-101,21-102, 21-103,21-104,21-105,21-106,21-107,21-108,21-41 DIAGNOSIS, TRANSMISSION; TRANSMISSION AND TRANSFER CASE . . . . 21-3 DIAGNOSIS, VIBRATION . . . . . . . . . . 22-10,22-11 DIAGNOSIS, WIPER/WASHER . . . . . . . . . . . . 8K-4 DIAGNOSIS2.5L 4-CYLINDER ENGINE, SERPENTINE DRIVE BELT . . . . . . . . . . . . . . . 7-40 DIAGNOSIS2.5L 4-CYLINDER ENGINE, V-BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39 DIAGNOSIS2.5L 4-CYLINDER ENGINECONTINUED, SERPENTINE DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41 DIAGNOSIS2.5L ENGINE, SINGLEPORT FUEL INJECTIONGENERAL . . . . . . 14-32 DIAGNOSIS3.9L/5.2L ENGINE, MULTI-PORT FUEL INJECTION GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-67 DIAGNOSIS3.9L/5.2L ENGINES, SERPENTINE DRIVE BELT . . . . . . . . . . . . . . . 7-42 DIAGNOSISLUBRICATION, SERVICE . . . . . 9-10 DIAGNOSISMECHANICAL, SERVICE . . . . . . 9-9 DIAGNOSISPERFORMANCE, SERVICE . . . . . 9-8 DIAGNOSISVEHICLE RUNS ROUGH AND/OR HAS A MISS, INJECTOR . . . . . . . . 14-77
DIAGNOSIS/PROCEDURES, SERVICE . . . . . . 16-3 DIAGNOSTIC CONNECTOR LOCATION, ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 DIAGNOSTIC CONNECTOR LOCATION, RWAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 DIAGNOSTIC FAULT FLASH CODES, RWAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 DIAGNOSTIC PROCEDURES . . . . . . . . . . . . . 8L-1 DIAGNOSTIC SYSTEM, USING ON-BOARD; BATTERY/STARTING/ CHARGING SYSTEMS DIAGNOSTICS . . . . . 8A-21 DIAGNOSTIC SYSTEM, USING ON-BOARD; VEHICLE SPEED CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H-3 DIAGNOSTIC TROUBLE CODE (DTC) . 14-39,14-79 DIAGNOSTIC TROUBLE CODE, GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . 8A-21 DIAGNOSTIC TROUBLE CODE, SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H-6 DIAGNOSTICS (OBD), ON-BOARD; COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . 7-3 DIAGNOSTICS (OBD), ON-BOARD; FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . 14-36,14-76 DIAGNOSTICS, ON-BOARD; EMISSION CONTROL SYSTEMS . . . . . . . . . . . . . . . . . . . 25-1 DIAGNOSTICS, ON-BOARD; IGNITION SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-16 DIAGNOSTICS/SERVICE PROCEDURES . . . . . 8D-6 DIAGRAM INDEX; AIR CONDITIONING/ HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-3 DIAGRAM INDEX; AIRBAG SYSTEM . . . . 8W-43-1 DIAGRAM INDEX; ANTI-LOCK BRAKES . 8W-32-3, 8W-32-4 DIAGRAM INDEX; FRONT LIGHTING . . . . 8W-50-2 DIAGRAM INDEX; FUEL/IGNITION . . . . . 8W-30-5 DIAGRAM INDEX; FUEL/IGNITION3.9L AND 5.2L ENGINES . . . . . . . . . . . . . . . . 8W-30-11 DIAGRAM INDEX; FUSE BLOCK . . . . . . . 8W-10-1 DIAGRAM INDEX; GROUND DISTRIBUTION . . . . . . . . . . . . . . . . . . . . 8W-15-1 DIAGRAM INDEX; HORN/CIGAR LIGHTER . 8W-41-1 DIAGRAM INDEX; INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-3 DIAGRAM INDEX; INTERIOR LIGHTING . 8W-44-2 DIAGRAM INDEX; OVERHEAD CONSOLE . 8W-49-1 DIAGRAM INDEX; POWER DISTRIBUTION . . . . . . . . . . . . . . . . . . . . 8W-11-1 DIAGRAM INDEX; POWER DOOR LOCKS . . . . . . . . . . . . . . . . . . . . . 8W-61-1 DIAGRAM INDEX; POWER MIRRORS . . . 8W-62-1 DIAGRAM INDEX; POWER WINDOWS . . 8W-60-1 DIAGRAM INDEX; REAR LIGHTING . . . . . 8W-51-2 DIAGRAM INDEX; TRAILER TOW . . . . . . 8W-54-1 DIAGRAM INDEX; TRANSMISSION CONTROLS . . . . . . . . . . . . . . . . . . . . . . . 8W-31-1 DIAGRAM INDEX; TURN SIGNALS . . . . . 8W-52-1 DIAGRAM INDEX; VEHICLE SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-1 DIAGRAM INDEX; WIPERS . . . . . . . . . . . 8W-53-2 DIAGRAM INDEX2.5L; CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-1 DIAGRAM INDEX2.5L; STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-2 DIAGRAM INDEX3.9L/5.2L; CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-1 DIAGRAM INDEX3.9L/5.2L; STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-2 DIAGRAMS, SNOW PLOW WIRING . . . . . . . . 13-4 DIAPHRAGM2.5L ENGINE, VACUUM . . . . 25-21 DIFFERENTIAL AND PINION MEASUREMENT WITH GAUGE SET C-3715-B . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40 DIFFERENTIAL CASE REMOVAL . . . . . . . . . . 2-37 DIFFERENTIAL, LIMITED SLIP . . . . . . . . . . . . . 3-9 DIFFERENTIAL OVERHAUL . . . . . . . . . . . . . . 3-31 DIFFERENTIAL SERVICE . . . . . . . . . . . . . . . . 3-19 DIFFERENTIAL, TRAC-LOC . . . . . . . . . . . . . . 3-30 DIMENSIONS, FRAME . . . . . . . . . . . . . . . . . 13-21 DIMENSIONS, VEHICLE . . . . . . . . . . . . . . . Intro.-3 DIMENSIONS, VEHICLE EXTERIOR . . . . . . Intro.-4 DIMENSIONS/WEIGHTS, DESIGNATIONS, LABELS/PLATES/DECALS, CODES . . . . . . . Intro.-1 DIODE REPLACEMENT . . . . . . . . . . . . . . 8W-01-8 DIRECT CLUTCH AND GEARTRAIN ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 21-250 DISASSEMBLY AND OVERHAUL, TRANSFER CASE . . . . . . . . . . . . . . . . . . . . 21-267
INDEX
Description Group-Page Description Group-Page Description
Group-Page
DISASSEMBLY AND OVERHAUL, TRANSMISSION; NV3500 MANUAL TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . 21-45 DISASSEMBLY AND OVERHAUL, TRANSMISSION; TRANSMISSION AND TRANSFER CASE . . . . . . . . . . . . . . . . . . . . . . 21-8 DISASSEMBLY, CALIPER . . . . . . . . . . . . 5-30,5-37 DISASSEMBLY INFORMATION, GEAR . . . . . 19-22 DISASSEMBLY, OVERDRIVE GEARTRAIN . 21-240 DISASSEMBLY, OVERDRIVE UNIT . . . . . . . 21-238 DISASSEMBLY, TRANSMISSION . . 21-147,21-193 DISC APPLICATION, CLUTCH . . . . . . . . . . . . . 6-1 DISC BRAKE ROTOR SERVICE . . . . . . . . . . . 5-41 DISC BRAKES2-WHEEL DRIVE . . . . . . . . . 5-27 DISC BRAKES4-WHEEL DRIVE . . . . . . . . . 5-34 DISC INSTALLATION, CLUTCH COVER . . . . . 6-10 DISC REMOVAL, CLUTCH COVER . . . . . . . . . 6-10 DISC RUNOUT, CLUTCH COVER . . . . . . . . . . . 6-4 DISCHARGE (ESD) SENSITIVE DEVICES, ELECTROSTATIC . . . . . . . . . . . . . . . . . . . 8W-01-2 DISPLAY, ABS/RWAL WARNING LIGHT . . . . . . 5-9 DISPLAY SYMBOLS, INTERNATIONAL CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . Intro.-7 DISPLAY SYMBOLS, INTERNATIONAL VEHICLE CONTROL . . . . . . . . . . . . . . . . . . Intro.-3 DISTRIBUTION DUCTS, AIR . . . . . . . . . . . . 24-21 DISTRIBUTION, VEHICLE LOADING AND WEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 DISTRIBUTOR . . . . . . . . . . . . . . . . . . . . . . . . 9-97 DISTRIBUTOR BUSHING . . . . . . . . . . . . . . . . 9-64 DISTRIBUTOR CAP . . . . . . . . . . . . . . . . . . . . 8D-7 DISTRIBUTOR CAP AND ROTOR, IGNITION CABLES . . . . . . . . . . . . . . . . . . . . . 0-18 DISTRIBUTOR PICK-UP . . . . . . . . . . . . . 8W-30-3 DISTRIBUTOR ROTOR . . . . . . . . . . . . . . . . . 8D-7 DISTRIBUTOR2.5L ENGINE . . . . . . . . . . . 8D-20 DISTRIBUTOR3.9L/5.2L ENGINE . . . . . . . 8D-21 DISTRIBUTORS . . . . . . . . . . . . . . . . . . . . . . . 8D-3 DOME LAMP . . . . . . . . . . . . . . . . . . . . . . 8W-44-1 DOOR ADJUSTMENT . . . . . . . . . . . . . . . . . . 23-23 DOOR AND NOZZLE/TUBES, FUEL FILLER . 23-15 DOOR, BLEND-AIR . . . . . . . . . . . . . . . . . . . 24-26 DOOR, COMPLETE . . . . . . . . . . . . . . . . . . . . 23-25 DOOR HANDLE, INSIDE . . . . . . . . . . . . . . . . 23-29 DOOR HANDLE, OUTSIDE . . . . . . . . . . . . . . 23-27 DOOR JAMB SWITCH, DRIVERS . . . . . 8U-1,8U-2 DOOR LATCH . . . . . . . . . . . . . . . . . . . . . . . . 23-28 DOOR LATCH LINKAGE . . . . . . . . . . . . . . . . 23-28 DOOR LATCH STRIKER . . . . . . . . . . . . . . . . 23-29 DOOR LOCK MOTOR, POWER . . . . . . . . . . . 23-29 DOOR LOCKS, POWER . . . . . . . . . . . . . . 8W-61-1 DOOR OPENER STORAGE COMPARTMENT DOOR REMOVE/ INSTALL, GARAGE . . . . . . . . . . . . . . . . . . . . . 8C-8 DOOR OPENER STORAGE, REMOTE GARAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C-1 DOOR REMOVE/INSTALL, GARAGE DOOR OPENER STORAGE COMPARTMENT . . . . . . . 8C-8 DOOR TRIM PANEL/WATERDAM/NOISE INSULATOR . . . . . . . . . . . . . . . . . . . . . . . . . 23-24 DOOR VACUUM ACTUATOR, MODE . . . . . . 24-20 DOOR WEATHERSTRIP SEALS, WINDOW GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-29 DOORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-23 DOUBLE CARDAN (CV) . . . . . . . . . . . . . . . . 16-11 DRAIN AND FILL PLUG LOCATIONS . . . . . . 21-40 DRAINBACK CHECK VALVE SERVICE, CONVERTER . . . . . . . . . . . . . . . . . . . . . . . 21-134 DRAINBACK VALVE, CONVERTER . . . . . . . . 21-89 DRAINING COOLING SYSTEM . . . . . . . . . . . . 7-24 DRAW FUSE, IGNITION-OFF . . . . . . . . . . . . . 8F-1 DRAW, IGNITION-OFF . . . . . . . . . . . . . . . . . 8A-10 DRB SCAN TOOL; COOLING SYSTEM . . . . . . . 7-4 DRB SCAN TOOL; EMISSION CONTROL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-3 DRB SCAN TOOL; FUEL SYSTEM . . . 14-39,14-79 DRB SCAN TOOL; IGNITION SYSTEMS . . . . 8D-8 DRIVE AXLE ASSEMBLY REPLACEMENT; FRONT SUSPENSION AND AXLE . . . . . . . . . . 2-31 DRIVE AXLE ASSEMBLY REPLACEMENT; REAR SUSPENSION AND AXLES . . . . . . . . . . 3-12 DRIVE AXLE, FRONT . . . . . . . . . . . . . . . . . . . . 2-2 DRIVE BELT, ACCESSORY . . . . . . . . . . . . . . . 0-19 DRIVE BELT, COMPRESSOR . . . . . . . . . . . . 24-14 DRIVE BELT DIAGNOSIS2.5L 4-CYLINDER ENGINE, SERPENTINE . . . . . . . 7-40
DRIVE BELT DIAGNOSIS2.5L 4-CYLINDER ENGINECONTINUED, SERPENTINE . . . . . . . . . . . . . . . . . . . . . . . . . 7-41 DRIVE BELT DIAGNOSIS3.9L/5.2L ENGINES, SERPENTINE . . . . . . . . . . . . . . . . . 7-42 DRIVE BELT TENSION, ACCESSORY . . . . . . . 7-48 DRIVE BELTS, ENGINE ACCESSORY . . . . . . . 7-39 DRIVE, DISC BRAKES2-WHEEL . . . . . . . . . 5-27 DRIVE, DISC BRAKES4-WHEEL . . . . . . . . . 5-34 DRIVE INDICATOR LAMP SWITCH, FOUR-WHEEL . . . . . . . . . . . . . . . . . . . . . 8W-31-1 DRIVE MODULES REMOVE/INSTALL, LOW FUEL AND TACHOMETER . . . . . . . . . . 8E-16 DRIVE, OVERDRIVE UNIT INSTALLATION2-WHEEL . . . . . . . . . . . . 21-144 DRIVE, OVERDRIVE UNIT INSTALLATION4-WHEEL . . . . . . . . . . . . 21-145 DRIVE, OVERDRIVE UNIT REMOVAL2WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-143 DRIVE, OVERDRIVE UNIT REMOVAL4WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-145 DRIVE PULLEY REPLACEMENT . . . . . . . . . . 19-15 DRIVE SHAFT CENTER BEARING SUPPORT CROSSMEMBER . . . . . . . . . . . . . 13-35 DRIVE SHAFT, CV . . . . . . . . . . . . . . . . . 2-23,2-47 DRIVE SHAFTS . . . . . . . . . . . . . . . . . . . . . . . 0-23 DRIVE SWITCH SENSE, FOUR-WHEEL . 8W-32-2, 8W-32-4 DRIVE, TRANSMISSION INSTALLATION 2-WHEEL; NV3500 MANUAL TRANSMISSION . . . . . . . . . . . . . . . . . . . . . 21-140 DRIVE, TRANSMISSION INSTALLATION 2-WHEEL; TRANSMISSION AND TRANSFER CASE . . . . . . . . . . . . . . . . . . . . . . 21-6 DRIVE, TRANSMISSION INSTALLATION 4-WHEEL; NV3500 MANUAL TRANSMISSION . . . . . . . . . . . . . . . . . . . . . 21-142 DRIVE, TRANSMISSION INSTALLATION 4-WHEEL; TRANSMISSION AND TRANSFER CASE . . . . . . . . . . . . . . . . . . . . . . 21-7 DRIVE, TRANSMISSION REMOVAL2WHEEL; NV3500 MANUAL TRANSMISSION . . . . . . . . . . . . . . . . . . . . . 21-137 DRIVE, TRANSMISSION REMOVAL2WHEEL; TRANSMISSION AND TRANSFER CASE . . . . . . . . . . . . . . . . . . . . . . 21-4 DRIVE, TRANSMISSION REMOVAL4WHEEL; NV3500 MANUAL TRANSMISSION . . . . . . . . . . . . . . . . . . . . . 21-139 DRIVE, TRANSMISSION REMOVAL4WHEEL; TRANSMISSION AND TRANSFER CASE . . . . . . . . . . . . . . . . . . . . . . 21-5 DRIVELINE SNAP; FRONT SUSPENSION AND AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 DRIVELINE SNAP; REAR SUSPENSION AND AXLES . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 DRIVELINE VIBRATION . . . . . . . . . . . . . . . . . 16-3 DRIVE3.9L/5.2L ENGINE, VISCOUS FAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37 DRIVERS DOOR JAMB SWITCH . . . . . 8U-1,8U-2 DRIVERS SEAT BELT SWITCH . . . . . . . . . . . 8U-1 DRIVER S SEAT BELT SWITCH . . . . . . . . . . . 8U-3 DRIVETRAIN . . . . . . . . . . . . . . . . . . . . . . . . . 0-20 DRUM AND REAR BAND SERVICE, LOW-REVERSE . . . . . . . . . . . . . . . . . . . . . 21-201 DRUM BRAKE ADJUSTMENT, REAR . . . . . . . 5-24 DRUM BRAKES . . . . . . . . . . . . . . . . . . . . . . . 5-20 DRUM INSTALLATION, BRAKE . . . . . . . . . . . 5-23 DRUM REFINISH LIMITS, BRAKE . . . . . . . . . 5-22 DRUM REFINISHING, BRAKE . . . . . . . . . . . . 5-22 DRUM REMOVAL, BRAKE . . . . . . . . . . . . . . . 5-20 DRUM RUNOUT, BRAKE . . . . . . . . . . . . . . . . 5-23 DRUMOVERDRIVE PISTON RETAINER INSPECTION AND OVERHAUL, OVERRUNNING CLUTCHLOWREVERSE . . . . . . . . . . . . . . . . . . . . . . . . . . 21-154 DUCTS, AIR DISTRIBUTION . . . . . . . . . . . . 24-21 EFFECT PICK-UP2.5L ENGINE, HALL . . . 8D-23, 8D-4 EFFECTS OF INCORRECT FLUID LEVEL . . . . 21-92 EGR (EXHAUST GAS RECIRCULATION) SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . 25-11 EGR (EXHAUST GAS RECIRCULATION) VALVE CONTROL SOLENOIDPCM OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-62 EGR SOLENOID; FUEL/IGNITION . . . . . . . 8W-30-4 EGR SOLENOID; FUEL/IGNITION3.9L AND 5.2L ENGINES . . . . . . . . . . . . . . . . 8W-30-10
EGR SOLENOID2.5L ENGINE . . . . . . . . . . 25-20 EGR SOLENOIDPCM OUTPUT . . . . . . . . . 14-26 EGR TUBE2.5L ENGINE . . . . . . . . . . . . . . 25-19 EGR TUBE3.9L/5.2L ENGINE . . . . . . . . . . 25-19 EGR VALVE . . . . . . . . . . . . . . . . . . . . . . . . . 25-18 EGR VALVE CONTROL . . . . . . . . . . . . . . . . . 25-20 ELECTRICAL CONTROLS, OVERDRIVE FOURTH GEAR . . . . . . . . . . . . . . . . . . . . . . . 21-93 ELECTRONIC CONTROL MODULE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 5-48 ELECTRONIC CONTROL MODULE INSTALLATION, ABS . . . . . . . . . . . . . . . . . . . 5-59 ELECTRONIC CONTROL MODULE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48 ELECTRONIC CONTROL MODULE REMOVAL, ABS . . . . . . . . . . . . . . . . . . . . . . . 5-59 ELECTROSTATIC DISCHARGE (ESD) SENSITIVE DEVICES . . . . . . . . . . . . . . . . 8W-01-2 ELEMENT, AIR CLEANER; EMISSION CONTROL SYSTEMS . . . . . . . . . . . . . . . . . . 25-18 ELEMENT, AIR CLEANER; FUEL SYSTEM . . 14-43, 14-84 ELEMENT, AIR CLEANER; LUBRICATION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . 0-17 ELEMENT TEST, OXYGEN (O2S) SENSOR HEATING . . . . . . . . . . . . . . . . . . . . . . 14-35,14-72 ELEMENTS REMOVE/INSTALL, WIPER BLADES OR . . . . . . . . . . . . . . . . . . . . . . . . . . 8K-7 EMISSION CONTROL INFORMATION LABEL, TYPICAL VEHICLE . . . . . . . . . . . . . . . 25-2 EMISSION CONTROL INFORMATION (VECI) LABEL, VEHICLE . . . . . . . . . . . . . . . . . 25-1 . EMISSION CONTROL SYSTEM . . . . . . . . . . . 0-19 EMISSION CONTROLS, EVAPORATIVE . . . . . 25-5 EMISSION CONTROLS, EXHAUST . . . . . . . . 25-10 EMR LAMPPCM OUTPUT . . . . . . . . . . . . 14-62 END CAP REMOVE/INSTALL, LOWER LEFT INSTRUMENT PANEL . . . . . . . . . . . . . 8E-21 END PLUG, HOUSING . . . . . . . . . . . . . . . . . 19-24 END, TIE-ROD . . . . . . . . . . . . . . . . . . . . . . . 19-34 ENGAGEMENT, IMPROPER CLUTCH RELEASE OR . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 ENGINE, 2.5L; ENGINE . . . . . . . . . . . . . . . . . 9-11 ENGINE, 2.5L; STARTING SYSTEM . . . . . 8W-21-1 ENGINE ACCESSORY DRIVE BELTS . . . . . . . 7-39 ENGINE, AIR CONDITIONING/HEATER 2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-1 ENGINE AND TRANSMISSION/TRANSFER CASE IDENTIFICATION . . . . . . . . . . . . . . . Intro.-3 ENGINE ASSEMBLY . . . . . . . . . . . . 9-14,9-53,9-85 ENGINE, AUTOMATIC BELT TENSIONER3.9L/5.2L . . . . . . . . . . . . . . . . . 7-45 ENGINE BLOCK HEATERS . . . . . . . . . . . . . . . 7-47 ENGINE BREAK-IN . . . . . . . . . . . . . . . . . . . . . 0-14 ENGINE, CAMSHAFT POSITION SENSOR3.9L/5.2L . . . . . . . . . . . . . . . . . . . 8D-2 ENGINE COMPONENT MARKINGS, OVERSIZE AND UNDERSIZE . . . . . . . . 9-112,9-80 ENGINE COOLANT TEMPERATURE SENSOR; EMISSION CONTROL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . 25-18 ENGINE COOLANT TEMPERATURE SENSOR; FUEL SYSTEM . . . . . . . . . . 14-44,14-84 ENGINE COOLANT TEMPERATURE SENSOR; FUEL/IGNITION . . . . . . . . . . . . 8W-30-4 ENGINE COOLANT TEMPERATURE SENSOR; FUEL/IGNITION3.9L AND 5.2L ENGINES . . . . . . . . . . . . . . . . . . . . . 8W-30-9 ENGINE COOLANT TEMPERATURE SENSOR; IGNITION SYSTEMS . . . . . . 8D-20,8D-4 ENGINE COOLANT TEMPERATURE SENSOR TEST; FUEL SYSTEM . . . . . . . . . . 14-70 ENGINE COOLANT TEMPERATURE SENSOR TEST; IGNITION SYSTEMS . . . . . . . 8D-8 ENGINE COOLANT TEMPERATURE SENSORPCM INPUT . . . . . . . . . . . 14-23,14-58 ENGINE COOLING SYSTEM . . . . . . . . . . . . . . 0-16 ENGINE, COOLING SYSTEM FAN2.5L 4-CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . 7-33 ENGINE, COOLING SYSTEM FAN3.9L/ 5.2L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36 ENGINE CORE PLUGS . . . . . . . . . . . . . . . . . . 9-38 ENGINE, CRANKCASE BREATHER/ FILTER2.5L . . . . . . . . . . . . . . . . . . . . . . . . 25-8 ENGINE, CRANKSHAFT POSITION SENSOR3.9L/5.2L . . . . . . . . . . . . . . . . . . . 8D-2 ENGINE CYLINDER HEAD GASKET FAILURE DIAGNOSIS . . . . . . . . . . . . . . . . . . . . 9-5
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Description
ENGINE DIAGNOSIS . . . . . . . . . . . . . . . . . . . . 9-5 ENGINE, DISTRIBUTOR2.5L . . . . . . . . . . 8D-20 ENGINE, DISTRIBUTOR3.9L/5.2L . . . . . . 8D-21 ENGINE, EGR SOLENOID2.5L . . . . . . . . . 25-20 ENGINE, EGR TUBE2.5L . . . . . . . . . . . . . 25-19 ENGINE, EGR TUBE3.9L/5.2L . . . . . . . . . 25-19 ENGINE, ENGINE FIRING ORDER2.5L 4-CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . 8D-29 ENGINE, ENGINE FIRING ORDER3.9L V-6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-29 ENGINE, ENGINE FIRING ORDER5.2L V-8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-29 ENGINE, ENGINE VACUUM SCHEMATIC2.5L 4-CYLINDER . . . . . . . . . . 25-3 ENGINE, EVAP CANISTER PURGE SOLENOID2.5L . . . . . . . . . . . . . . . . . . . . . 25-21 ENGINE FIRING ORDER2.5L 4-CYLINDER ENGINE . . . . . . . . . . . . . . . . . 8D-29 ENGINE FIRING ORDER3.9L V-6 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-29 ENGINE FIRING ORDER5.2L V-8 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-29 ENGINE FRONT MOUNTS . . . . . . . 9-13,9-49,9-82 ENGINE, FUEL PRESSURE LEAK DOWN TEST3.9L/5.2L . . . . . . . . . . . . . . . . . . . . . . 14-9 ENGINE, FUEL PUMP CAPACITY TEST3.9L/5.2L . . . . . . . . . . . . . . . . . . . . . . 14-9 ENGINE, FUEL PUMP MODULE2.5L . . . . . 14-3 ENGINE, FUEL PUMP MODULE3.9L/ 5.2L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-3 ENGINE, FUEL SYSTEM PRESSURE TEST2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . 14-8 ENGINE, FUEL SYSTEM PRESSURE TEST3.9L/5.2L . . . . . . . . . . . . . . . . . . . . . . 14-8 ENGINE, FUEL/IGNITION2.5L . . . . . . . . 8W-30-1 ENGINE, HALL EFFECT PICK-UP2.5L . . . 8D-23, 8D-4 ENGINE, HEATED INLET AIR SYSTEM 2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-10 ENGINE, INTAKE / EXHAUST MANIFOLDS2.5L . . . . . . . . . . . . . . . . . . . . 11-6 ENGINE, INTAKE MANIFOLD AIR TEMPERATURE SENSOR3.9L/5.2L . . . . . . 8D-5 ENGINE LUBRICATION SYSTEM . . . . . . . . . . 9-39 ENGINE MAINTENANCE . . . . . . . . . . . . . . . . . 0-14 ENGINE MOUNTS . . . . . . . . . . . . . . . . . . . . . 9-13 ENGINE, MULTI-PORT FUEL INJECTION (MFI)COMPONENT DESCRIPTION/ SYSTEM OPERATION3.9L/5.2L . . . . . . . . 14-52 ENGINE, MULTI-PORT FUEL INJECTION (MFI)COMPONENT REMOVAL/ INSTALLATION3.9L/5.2L . . . . . . . . . . . . . 14-83 ENGINE, MULTI-PORT FUEL INJECTIONGENERAL DIAGNOSIS 3.9L/5.2L . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-67 ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . 0-14 ENGINE OIL CHANGE AND FILTER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . 0-15 ENGINE OIL PRESSURE . . . . . . . . . . . . . . . . . 9-7 ENGINE OIL PRESSURE, CHECKING . . . . . . . 9-44 ENGINE PERFORMANCE . . . . . . . . . . . . . . . . . 9-2 ENGINE, PUMP REPLACEMENT 4 CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . 19-13 ENGINE REAR SUPPORT . . . . . . . . 9-13,9-51,9-84 ENGINE, SERPENTINE DRIVE BELT DIAGNOSIS2.5L 4-CYLINDER . . . . . . . . . . 7-40 ENGINE SERVICE PROCEDURES, 3.9L . . . . . 9-49 ENGINE SERVICE PROCEDURES, 5.2L . . . . . 9-82 ENGINE, SINGLE-PORT FUEL INJECTIONCOMPONENT DESCRIPTION/SYSTEM OPERATION 2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-21 ENGINE, SINGLE-PORT FUEL INJECTIONCOMPONENT REMOVAL/ INSTALLATION2.5L . . . . . . . . . . . . . . . . . 14-43 ENGINE, SINGLE-PORT FUEL INJECTIONGENERAL DIAGNOSIS 2.5L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-32 ENGINE SPECIFICATIONS . . . . . . 9-110,9-46,9-78, 9-111,9-112,9-47,9-79,9-80 ENGINE SPEEDPCM INPUT . . . . . . . . . . . 14-23 ENGINE SPLASH SHIELD/AIR DEFLECTOR4WD VEHICLES . . . . . . . . . . 13-34 ENGINE, THERMAL VACUUM VALVE (TVV)2.5L . . . . . . . . . . . . . . . . . . . . . . . . 25-22 ENGINE, THROTTLE BODY TEMPERATURE SENSOR2.5L . . . . . . . . . . 8D-5 ENGINE, VACUUM DIAPHRAGM2.5L . . . . 25-21
ENGINE VACUUM SCHEMATIC2.5L 4-CYLINDER ENGINE . . . . . . . . . . . . . . . . . . . 25-3 ENGINE VACUUM SCHEMATIC3.9L V-6 AND 5.2L V-8 ENGINES . . . . . . . . . . . . . . . . . 25-4 ENGINE, V-BELT DIAGNOSIS2.5L 4-CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . 7-39 ENGINE, VISCOUS FAN DRIVE3.9L/ 5.2L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37 ENGINE, WATER PUMP BYPASS HOSE3.9L/5.2L . . . . . . . . . . . . . . . . . . . . . 7-17 ENGINECONTINUED, SERPENTINE DRIVE BELT DIAGNOSIS2.5L 4-CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . 7-41 ENGINES, 3.9L AND 5.2L; CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-1 ENGINES, 3.9L AND 5.2L; STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-1 ENGINES, AIR CONDITIONING/HEATER 3.9 AND 5.2L . . . . . . . . . . . . . . . . . . . . . 8W-42-3 ENGINES, CRANKCASE BREATHER/ FILTER3.9L/5.2L . . . . . . . . . . . . . . . . . . . . . 25-9 ENGINES, ENGINE VACUUM SCHEMATIC3.9L V-6 AND 5.2L V-8 . . . . . . 25-4 ENGINES, EXHAUST MANIFOLD3.9L / 5.2L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-11 ENGINES, HEAT SHIELD2.5L . . . . . . . . . . . 11-6 ENGINES, HEAT SHIELD3.9L / 5.2L . . . . . . 11-6 ENGINES, INTAKE MANIFOLD3.9L / 5.2L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9 ENGINES, SERPENTINE DRIVE BELT DIAGNOSIS3.9L/5.2L . . . . . . . . . . . . . . . . . 7-42 ENGINE/TRANSMISSION/PAYLOAD . . . . . Intro.-3, Intro.-4 ENGLISH/SAE CONVERSION, METRIC . . . Intro.-8 EQUIPMENT IDENTIFICATION PLATE . . . . Intro.-3 EQUIPMENT, REFRIGERANT . . . . . . . . . . . . . 24-3 EQUIVALENT VALUES, CONVERSION FORMULAS . . . . . . . . . . . . . . . . . . . . . . . . Intro.-8 EVACUATING REFRIGERANT SYSTEM . . . . . . 24-5 EVAP CANISTER . . . . . . . . . . . . . . . . . 25-20,25-5 EVAP CANISTER PURGE SOLENOID; EMISSION CONTROL SYSTEMS . . . . . . . . . . 25-5 EVAP CANISTER PURGE SOLENOID; FUEL SYSTEM . . . . . . . . . . . . . . . . . . 14-44,14-85 EVAP CANISTER PURGE SOLENOID 2.5L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . 25-21 EVAP CANISTER PURGE SOLENOID PCM OUTPUT . . . . . . . . . . . . . . . . . . 14-27,14-62 EVAP (EVAPORATION) CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-5 EVAPORATIVE EMISSION CONTROLS . . . . . . 25-5 EVAPORATOR COIL . . . . . . . . . . . . . . . . . . . 24-26 EVAP/PURGE SOLENOID; FUEL/IGNITION . . . . . . . . . . . . . . . . . . . . 8W-30-5 EVAP/PURGE SOLENOID; FUEL/ IGNITION3.9L AND 5.2L ENGINES . . 8W-30-10 EXHAUST EMISSION CONTROLS . . . . . . . . 25-10 EXHAUST GAS RECIRCULATION (EGR) . . . . . 11-2 EXHAUST MANIFOLD3.9L / 5.2L ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-11 EXHAUST MANIFOLDS2.5L ENGINE, INTAKE / . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6 EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . . . . 11-3 EXHAUST SYSTEM; EXHAUST SYSTEM AND INTAKE MANIFOLD . . . . . . . . . . . . . . . . 11-1 EXHAUST SYSTEM; LUBRICATION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . 0-19 EXHAUST SYSTEM DIAGNOSIS . . . . . . . . . . 11-2 EXTENSION PIPE . . . . . . . . . . . . . . . . . . . . . . 11-4 EXTERIOR COMPONENTS . . . . . . . . . . . . . . . 23-3 EXTERIOR DIMENSIONS, VEHICLE . . . . . . Intro.-4 EXTERIOR LAMPS . . . . . . . . . . . . . . . . . . . . 8L-13 EXTERIOR MIRRORS . . . . . . . . . . . . . . . . . . 23-16 EYE BUSHING REPLACEMENT, LEAF SPRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 FAILURE DIAGNOSIS, ENGINE CYLINDER HEAD GASKET . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 FAN DRIVE3.9L/5.2L ENGINE, VISCOUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37 FAN RELAY AND MOTOR, RADIATOR . . . 8W-42-2 FAN RELAYPCM OUTPUT, RADIATOR COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-28 FAN2.5L 4-CYLINDER ENGINE, COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . 7-33 FAN3.9L/5.2L ENGINE, COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36 FAULT CODE CAPACITY, RWAL . . . . . . . . . . . 5-10 FAULT CODE IDENTIFICATION, RWAL . . . . . . 5-10
FAULT CODES, CLEARING RWAL . . . . . . . . . 5-10 FAULT CONDITION CAUSES, ABS/RWAL . . . . 5-10 FAULT CONDITIONS, ABS SYSTEM NORMAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 FAULT FLASH CODES, RWAL DIAGNOSTIC . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 FEED, BATTERY; FUEL/IGNITION . . . . . . . 8W-30-2 FEED, BATTERY; FUEL/IGNITION3.9L AND 5.2L ENGINES . . . . . . . . . . . . . . . . . 8W-30-7 FENDERS, FRONT . . . . . . . . . . . . . . . . . . . . . 23-8 FIELDPCM OUTPUT, GENERATOR . . . . . . 14-61 FIG. 2 OIL LUBRICATION SYSTEM . . . 9-100,9-68 FIG. 9, LEGEND . . . . . . . . . . . . . . . . . . . . . . 13-15 FILL PLUG LOCATIONS, DRAIN . . . . . . . . . . 21-40 FILL VALVE OPERATION, QUICK . . . . . . . . . 21-89 FILLER DOOR AND NOZZLE/TUBES, FUEL . 23-15 FILLER TUBE CAP, FUEL TANK; EMISSION CONTROL SYSTEMS . . . . . 25-21,25-6 FILLER TUBE CAP, FUEL TANK; FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-15 FILLER TUBE, NO-LEAD FUEL TANK . . . . . . 14-14 FILTER CHOKE/SPEAKER RELAY . . . . . . 8F-1,8F-5 FILTER CHOKE/SPEAKER RELAY REMOVE/INSTALL . . . . . . . . . . . . . . . . . . . . . 8F-8 FILTER, FUEL . . . . . . . . . . . . . . . 14-44,14-85,14-5 FILTER, OIL . . . . . . . . . . . . . . . . . . . . . . . . . . 9-45 FILTER, PCV/CRANKCASE AIR INLET . . . . . . 0-17 FILTER REPLACEMENT, ENGINE OIL CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-15 . FILTER REPLACEMENT, FLUID . . . . . . . . . 21-125 FILTER/FUEL PRESSURE REGULATOR, FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-5 FINISH, BASE COAT/CLEAR COAT . . . . . . . . 23-45 FIRING ORDER2.5L 4-CYLINDER ENGINE, ENGINE . . . . . . . . . . . . . . . . . . . . . 8D-29 FIRING ORDER3.9L V-6 ENGINE, ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-29 FIRING ORDER5.2L V-8 ENGINE, ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-29 FIRST GEAR (1), HYDRAULIC FLOW IN MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . 21-123 FIRST GEAR (BREAKAWAY), HYDRAULIC FLOW IN D . . . . . . . . . . . . . . . . . . . . . . . . 21-118 FITTING SERVICE, TRANSMISSION COOLER LINE . . . . . . . . . . . . . . . . . . . . . . 21-133 FITTINGS, QUICK-CONNECT . . 14-10,14-48,14-89 FITTINGS, THROTTLE BODY . . . . . . . . . . . . 14-49 FLASH CODES, GENERATING RWAL . . . . . . . 5-10 FLASH CODES, RWAL DIAGNOSTIC FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 FLASHERS, HAZARD . . . . . . . . . . . . . . . . 8W-52-1 FLOOR CONSOLE AND REAR SEAT STORAGE BOXES . . . . . . . . . . . . . . . . . . . . 23-43 FLOOR MATS, CARPETS . . . . . . . . . . . . . . . 23-43 FLOW CHECK, THROTTLE BODY MINIMUM AIR . . . . . . . . . . . . . . . . . . 14-36,14-73 FLOW CONTROL, SHIFT VALVE . . . . . . . . . . 21-89 FLOW IN D FIRST GEAR (BREAKAWAY), HYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . 21-118 FLOW IN D FOURTH GEAR (CONVERTER CLUTCH APPLIED), HYDRAULIC . . . . . . . . 21-122 FLOW IN D FOURTH GEAR (CONVERTER CLUTCH NOT APPLIED), HYDRAULIC . . . . 21-121 FLOW IN D SECOND GEAR, HYDRAULIC . 21-119 FLOW IN D THIRD GEAR, HYDRAULIC . . . 21-120 FLOW IN MANUAL FIRST GEAR (1), HYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . 21-123 FLOW IN MANUAL SECOND GEAR (2), HYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . 21-124 FLOW IN NEUTRAL, HYDRAULIC . . . . . . . 21-116 FLOW IN PARK, HYDRAULIC . . . . . . . . . . . 21-115 FLOW IN REVERSE, HYDRAULIC . . . . . . . 21-117 FLOW RATE AND PRESSURE TEST, POWER STEERING PUMP . . . . . . . . . . . . . . . 19-3 FLOW TESTING, TRANSMISSION COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-134 FLUID AND FILTER REPLACEMENT . . . . . . 21-125 FLUID CAPACITIES . . . . . . . . . . . . . . . . . . . . . 0-3 FLUID, CAUSES OF BURNED . . . . . . . . . . . . 21-92 FLUID, CLUTCH HYDRAULIC . . . . . . . . . . . . . . 6-1 FLUID CONTAMINATION . . . . . . . . . . . . . . . 21-92 FLUID CONTAMINATION, BRAKE . . . . . . . . . . 5-13 FLUID, IMPORTANCE OF CLEAN BRAKE . . . . 5-12 FLUID LEAK DIAGNOSIS, CONVERTER HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-97 FLUID LEVEL AND CONDITION, CHECKING . . . . . . . . . . . . . . . . . . . . . . . . . . 21-91 FLUID LEVEL CHECK . . . . . . . . . . . . . . . . . 21-125
INDEX
Description Group-Page Description Group-Page Description
Group-Page
FLUID LEVEL, CORRECT BRAKE . . . . . . . . . . 5-12 FLUID LEVEL, EFFECTS OF INCORRECT . . . 21-92 FLUID, RECOMMENDED . . . . . . . . . 21-125,21-86 FLUID, RECOMMENDED BRAKE . . . . . . . . . . 5-12 FLUID WARNING LAMP, LOW WASHER . 8W-53-2 FLUID/FILTER CHANGE, REFILLING AFTER OVERHAUL OR . . . . . . . . . . . . . . . . 21-126 FLUID/LUBRICANTS/CLEANING SOLVENTS, BRAKE . . . . . . . . . . . . . . . . . . . . . 5-1 FLUIDBRAKELINES, MASTER CYLINDERBRAKE . . . . . . . . . . . . . . . . . . . . 5-12 FLUSHING, COOLING SYSTEM CLEANING/REVERSE . . . . . . . . . . . . . . . . . . . 7-25 FLUSHING, TRANSMISSION COOLER REVERSE . . . . . . . . . . . . . . . . . . . . . . . . . . 21-135 FLYWHEEL MISALIGNMENT . . . . . . . . . . . . . . 6-3 FLYWHEEL SERVICE . . . . . . . . . . . . . . . . . . . 6-13 FOG LAMP SWITCH REPLACEMENT . . . . . . 8L-10 FOG LAMPS; FRONT LIGHTING . . . . . . . 8W-50-2 FOG LAMPS; LAMPS . . . . . . . . . . . . . . . . . . . 8L-8 FOG/OFF ROAD LAMP DIAGNOSIS . . . . . . . . 8L-3 FORM-IN-PLACE GASKETS . . . . . . . . . . . . . . . 9-1 FORMULAS AND EQUIVALENT VALUES, CONVERSION . . . . . . . . . . . . . . . . . . . . . . Intro.-8 FOURTH GEAR (CONVERTER CLUTCH APPLIED), HYDRAULIC FLOW IN D . . . . . 21-122 FOURTH GEAR (CONVERTER CLUTCH NOT APPLIED), HYDRAULIC FLOW IN D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-121 FOURTH GEAR ELECTRICAL CONTROLS, OVERDRIVE . . . . . . . . . . . . . . . . . . . . . . . . . 21-93 FOURTH GEAR OVERDRIVE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . 21-86 FOUR-WHEEL DRIVE INDICATOR LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-1 FOUR-WHEEL DRIVE SWITCH SENSE . . 8W-32-2, 8W-32-4 FOUR-WHEEL-DRIVE VEHICLE TOWING . . . . 0-12 FRAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13-20 FRAME COMPONENT SERVICE . . . . . . . . . . 13-34 FRAME DIMENSIONS . . . . . . . . . . . . . . . . . 13-21 FRAME REPAIRS . . . . . . . . . . . . . . . . . . . . . 13-20 FRAME, SNOW PLOW . . . . . . . . . . . . . . . . . 13-16 FRAME STRAIGHTENING . . . . . . . . . . . . . . . 13-20 FREQUENCY INTERFERENCE, RADIO . . . . . . 8F-6 FRONT; PROPELLER SHAFTS . . . . . . . . . . . . 16-8 FRONT AND REAR AXLES . . . . . . . . . . . . . . . 0-23 FRONT ANTI-LOCK VALVE . . . . . . . . . . . . 8W-32-2 FRONT ANTILOCK VALVE INSTALLATION . . . 5-55 FRONT ANTILOCK VALVE REMOVAL . . . . . . . 5-55 FRONT AXLE, 7 1/4 INCH . . . . . . . . . . . . . . . 2-31 FRONT AXLE MOUNTING . . . . . . . . . . . . . . . 2-47 FRONT BAND ADJUSTMENT . . . . . . . . . . . 21-129 FRONT BRAKE SPEED SENSOR INSTALLATION (2-WHEEL DRIVE MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58 FRONT BRAKE SPEED SENSOR INSTALLATION (4-WHEEL DRIVE MODELS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59 FRONT BRAKE SPEED SENSOR REMOVAL (2-WHEEL DRIVE MODELS) . . . . . 5-58 FRONT BRAKE SPEED SENSOR REMOVAL (4-WHEEL DRIVE MODELS) . . . . . 5-59 FRONT BUMPER . . . . . . . . . . . . . . . . . . . . . . 13-1 FRONT CABLE INSTALLATION . . . . . . . . . . . . 5-63 FRONT CABLE REMOVAL . . . . . . . . . . . . . . . 5-63 FRONT CLUTCH OVERHAUL . . . . . 21-159,21-208 FRONT CRANKSHAFT OIL SEAL REPLACEMENT . . . . . . . . . . . . . . . . . . . 9-63,9-95 FRONT DRIVE AXLE . . . . . . . . . . . . . . . . . . . . 2-2 FRONT FENDERS . . . . . . . . . . . . . . . . . . . . . . 23-8 FRONT MOUNTS, ENGINE . . . . . . . 9-13,9-49,9-82 FRONT SERVO AND BAND OVERHAUL . . 21-168, 21-203 FRONT SIDE MARKER LAMP . . . . . . . . . . . . 8L-9 FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . 2-1 FRONT SUSPENSION COMPONENTS 2WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47 FRONT SUSPENSION COMPONENTS 4WD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47 FRONT SUSPENSION2WD VEHICLES . . . . . 2-8 FRONT SUSPENSION4WD VEHICLES . . . . 2-14 FRONT WHEEL ALIGNMENT SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 2-7 FRONT WHEEL BEARINGS . . . . . . . . . . . . . . 0-26 FUEL AND TACHOMETER DRIVE MODULES REMOVE/INSTALL, LOW . . . . . . 8E-16 FUEL DELIVERY SYSTEM . . . . . . . . . . . . . . . 14-3
FUEL FILLER DOOR AND NOZZLE/TUBES . . 23-15 FUEL FILTER . . . . . . . . . . . . . . . 14-44,14-85,14-5 FUEL FILTER/FUEL PRESSURE REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . 14-5 FUEL GAUGE SENDING UNIT . . . . . . . . . . . 14-16 FUEL INJECTION (MFI)COMPONENT DESCRIPTION/SYSTEM OPERATION 3.9L/5.2L ENGINE, MULTI-PORT . . . . . . . . . 14-52 FUEL INJECTION (MFI)COMPONENT REMOVAL/INSTALLATION3.9L/5.2L ENGINE, MULTI-PORT . . . . . . . . . . . . . . . . . 14-83 FUEL INJECTIONCOMPONENT DESCRIPTION/SYSTEM OPERATION 2.5L ENGINE, SINGLE-PORT . . . . . . . . . . . . 14-21 FUEL INJECTIONCOMPONENT REMOVAL/INSTALLATION2.5L ENGINE, SINGLE-PORT . . . . . . . . . . . . . . . . 14-43 FUEL INJECTIONGENERAL DIAGNOSIS2.5L ENGINE, SINGLEPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-32 FUEL INJECTIONGENERAL DIAGNOSIS3.9L/5.2L ENGINE, MULTI-PORT . . . . . . . . . . . . . . . . . . . . . . . . 14-67 FUEL INJECTOR; FUEL SYSTEM . . . . . . . . . 14-44 FUEL INJECTOR; FUEL/IGNITION . . . . . . 8W-30-2 FUEL INJECTOR TEST . . . . . . . . . . . . . . . . . 14-76 FUEL INJECTORPCM OUTPUT . . . . . . . . . 14-27 FUEL INJECTOR(S) . . . . . . . . . . . . . . . . . . . 14-85 FUEL INJECTORS . . . . . . . . . . . . . . . . . . 8W-30-7 FUEL INJECTORSPCM OUTPUT . . . . . . . . 14-62 FUEL LINE WITH LATCH CLIP . . . . . . . . . . . 14-13 FUEL PRESSURE LEAK DOWN TEST3.9L/5.2L ENGINE . . . . . . . . . . . . . . . 14-9 FUEL PRESSURE REGULATOR . . . . . 14-30,14-45, 14-64,14-85 FUEL PUMP CAPACITY TEST3.9L/5.2L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-9 FUEL PUMP CONTROL . . . . . . . . . . . . . . . . . 14-4 FUEL PUMP MODULE; FUEL SYSTEM . . . . 14-46, 14-86 FUEL PUMP MODULE; FUEL/IGNITION . . 8W-30-2 FUEL PUMP MODULE; FUEL/IGNITION 3.9L AND 5.2L ENGINES . . . . . . . . . . . . . 8W-30-7 FUEL PUMP MODULE2.5L ENGINE . . . . . . 14-3 FUEL PUMP MODULE3.9L/5.2L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-3 FUEL PUMP PRESSURE TEST . . . . . . . . . . . 14-76 FUEL PUMP RELAY; FUEL SYSTEM . 14-46,14-86 FUEL PUMP RELAY; FUEL/IGNITION 3.9L AND 5.2L ENGINES . . . . . . . . . . . . . 8W-30-7 FUEL PUMPPCM OUTPUT . . . . . . . . . . . . 14-27 FUEL PUMPREMOVAL/INSTALLATION . . . 14-16 FUEL RAIL . . . . . . . . . . . . . . . . . . . . . 14-63,14-86 FUEL REQUIREMENTS . . . . . . . . . . . . . . . . . . . 0-1 FUEL RESERVOIR . . . . . . . . . . . . . . . . . . . . 14-16 FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 0-17 FUEL SYSTEM PRESSURE RELEASE . . . . . . 14-7 FUEL SYSTEM PRESSURE RELEASE PROCEDURE . . . . . . . . . . . . . . . . . . . 14-46,14-87 FUEL SYSTEM PRESSURE TEST2.5L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-8 FUEL SYSTEM PRESSURE TEST3.9L/ 5.2L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 14-8 FUEL TANK CAPACITIES . . . . . . . . . . 14-15,14-92 FUEL TANK FILLER TUBE CAP; EMISSION CONTROL SYSTEMS . . . . . 25-21,25-6 FUEL TANK FILLER TUBE CAP; FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-15 FUEL TANK FILLER TUBE, NO-LEAD . . . . . . 14-14 FUEL TANK PRESSURE RELIEF/ ROLLOVER VALVE . . . . . . . . . . 14-16,14-46,14-87 FUEL TANKS . . . . . . . . . 14-14,14-15,14-46,14-87 FUEL TUBES/LINES/HOSES AND CLAMPS . 14-10, 14-46,14-87 FUEL USAGE STATEMENT . . . . . . . . . . . . . . . 14-1 FUEL/IGNITION2.5L ENGINE . . . . . . . . 8W-30-1 FUSE, IGNITION-OFF DRAW . . . . . . . . . . . . . 8F-1 GARAGE DOOR OPENER STORAGE COMPARTMENT DOOR REMOVE/ INSTALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C-8 GARAGE DOOR OPENER STORAGE, REMOTE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C-1 GAS RECIRCULATION (EGR), EXHAUST . . . . 11-2 GASKET FAILURE DIAGNOSIS, ENGINE CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . 9-5 GASKETS, FORM-IN-PLACE . . . . . . . . . . . . . . . 9-1 GAUGE SENDING UNIT, FUEL . . . . . . . . . . . 14-16
GAUGE SET C-3715-B, DIFFERENTIAL AND PINION MEASUREMENT WITH . . . . . . . 2-40 GAUGE SET, MANIFOLD . . . . . . . . . . . . . . . . 24-3 GAUGE SET, PINION DEPTH MEASUREMENT AND ADJUSTMENT WITH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 GAUGES . . . . . . . . . . . . . . . . . . . . . . . . 8E-2,8E-4 GAUGES, PRESSURE, TIRES . . . . . . . . . . . . . 22-2 GAUGES REMOVE/INSTALL . . . . . . . . . . . . . 8E-16 GEAR (1), HYDRAULIC FLOW IN MANUAL FIRST . . . . . . . . . . . . . . . . . . . . . 21-123 GEAR (2), HYDRAULIC FLOW IN MANUAL SECOND . . . . . . . . . . . . . . . . . . . 21-124 GEAR ADJUSTMENTS, STEERING . . . . . . . . 19-21 GEAR AND BEARING NOISE; FRONT SUSPENSION AND AXLE . . . . . . . . . . . . . . . . 2-19 GEAR AND BEARING NOISE; REAR SUSPENSION AND AXLES . . . . . . . . . . . . . . . . 3-8 GEAR (BREAKAWAY), HYDRAULIC FLOW IN D FIRST . . . . . . . . . . . . . . . . . . . . . . . . 21-118 GEAR (CONVERTER CLUTCH APPLIED), HYDRAULIC FLOW IN D FOURTH . . . . . . . 21-122 GEAR (CONVERTER CLUTCH NOT APPLIED), HYDRAULIC FLOW IN D FOURTH . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-121 GEAR DEPTH VARIANCE, PINION; FRONT SUSPENSION AND AXLE . . . . . . . . . . . . . . . . 2-42 GEAR DEPTH VARIANCE, PINION; REAR SUSPENSION AND AXLES . . . . . . . . . . . . . . . 3-24 GEAR DISASSEMBLY INFORMATION . . . . . . 19-22 GEAR ELECTRICAL CONTROLS, OVERDRIVE FOURTH . . . . . . . . . . . . . . . . . . 21-93 GEAR, HYDRAULIC FLOW IN D SECOND . 21-119 GEAR, HYDRAULIC FLOW IN D THIRD . . . 21-120 GEAR LEAKAGE DIAGNOSIS . . . . . . . . . . . . 19-11 GEAR, MANUAL STEERING . . . . . . . . . . . . . . 0-27 GEAR OVERDRIVE COMPONENTS, FOURTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-86 GEAR, RACK AND PINION STEERING . . . . . 19-33 GEAR RATIOS; NV3500 MANUAL TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . 21-83 GEAR RATIOS; TRANSMISSION AND TRANSFER CASE . . . . . . . . . . . . . . . . . . . . . . 21-2 GEAR RATIOS, TRANSMISSION . . . . . . . . . 21-40 GEAR, RECIRCULATING BALL POWER STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . 19-19 GEAR REPLACEMENT, STEERING . . . 19-32,19-33 GEAR SELECTOR INDICATOR ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 21-127 GEAR SELECTOR INDICATOR REMOVE/ INSTALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-20 GEAR SERVICE, CONVERTER-DRIVE PLATE-RING . . . . . . . . . . . . . . . . . . . . . . . 21-140 GEAR SHAFT REMOVAL, PINION . . . . . . . . . 2-38 GEAR SPECIFICATIONS, POWER STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . 19-32 GEAR, STEERING . . . . . . . . . . . . . . . . . . . . . 19-42 GEAR TRAIN AND INTERMEDIATE SHAFT OVERHAUL, PLANETARY . . . . . . . . . . . . . . 21-164 GEARSHIFT MECHANISM . . . . . . . . . . . . . . 21-88 GEARTRAIN AND CASE ASSEMBLY, OVERDRIVE . . . . . . . . . . . . . . . . . . . . . . . . 21-254 GEARTRAIN ASSEMBLY, DIRECT CLUTCH . 21-250 GEARTRAIN DISASSEMBLY, OVERDRIVE . 21-240 GEARTRAIN OVERHAUL, PLANETARY . . . . 21-211 GENERAL BODY SERVICE INFORMATION . . . 23-1 GENERAL INFORMATION; AIR CONDITIONING/HEATER . . . . . . 8W-42-1,8W-42-3 GENERAL INFORMATION; ANTI-LOCK BRAKES . . . . . . . . . . . . . . . . . . 8W-32-1,8W-32-3 GENERAL INFORMATION; AUDIO SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-1 GENERAL INFORMATION; AUDIO SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-1 GENERAL INFORMATION; BATTERY/ STARTER/GENERATOR SERVICE . 8B-1,8B-4,8B-7 GENERAL INFORMATION; BATTERY/ STARTING/CHARGING SYSTEMS DIAGNOSTICS . . . 8A-10,8A-11,8A-17,8A-21,8A-1, 8A-3 GENERAL INFORMATION; BRAKES . . . 5-20,5-27, 5-34,5-44,5-63,5-1 GENERAL INFORMATION; CHIME/BUZZER WARNING SYSTEMS . . . . . . . . . . . . . . . . . . . 8U-1 GENERAL INFORMATION; CLUTCH . . . . . . 6-1,6-3 GENERAL INFORMATION; CONNECTOR LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . 8W-90-1
10
INDEX
Group-Page Description Group-Page Description Group-Page
Description
GENERAL INFORMATION; CONNECTOR PIN OUTS . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-1 GENERAL INFORMATION; COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . 7-47,7-48,7-1 GENERAL INFORMATION; EMISSION CONTROL SYSTEMS . . . . . . . . . . . . . . . . . . . 25-1 GENERAL INFORMATION; ENGINE . . . . 9-11,9-49, 9-82,9-5 GENERAL INFORMATION; EXHAUST SYSTEM AND INTAKE MANIFOLD . . . . . . . . . 11-1 GENERAL INFORMATION; FRAME AND BUMPERS . . . . . . . . . . . . . . . . . . . . . . . . . . 13-20 GENERAL INFORMATION; FRONT SUSPENSION AND AXLE . . . . . 2-19,2-31,2-1,2-4 GENERAL INFORMATION; FUEL SYSTEM . . 14-14, 14-18,14-21,14-32,14-52,14-92,14-1 GENERAL INFORMATION; FUEL/IGNITION . . . . . . . . . . . . . . . . . . . . 8W-30-1 GENERAL INFORMATION; GROUND DISTRIBUTION . . . . . . . . . . . . . . . . . . . . 8W-15-1 GENERAL INFORMATION; HEATING AND AIR CONDITIONING . . . . . . . . . . . . . . . . . . . . 24-1 GENERAL INFORMATION; HORN . . . . . . . . . 8G-1 GENERAL INFORMATION; IGNITION SYSTEMS . . . . . . . 8D-18,8D-27,8D-29,8D-1,8D-6 GENERAL INFORMATION; INSTRUMENT PANEL AND GAUGES . . . . . . . . . . . . . . . . . . 8E-1 GENERAL INFORMATION; INTERIOR LIGHTING . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-1 GENERAL INFORMATION; LAMPS . . . . 8L-13,8L-1 GENERAL INFORMATION; LUBRICATION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . 0-1 GENERAL INFORMATION; NV3500 MANUAL TRANSMISSION . 21-137,21-260,21-82, 21-91 GENERAL INFORMATION; OVERHEAD CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C-1 GENERAL INFORMATION; POWER DISTRIBUTION . . . . . . . . . . . . . . . . . . . . 8W-11-1 GENERAL INFORMATION; POWER LOCKS . . 8P-1 GENERAL INFORMATION; POWER MIRRORS . . . . . . . . . . . . . . . . . . . . . . . . . . . 8T-1 GENERAL INFORMATION; POWER WINDOWS . . . . . . . . . . . . . . . . . . . . . . . . . . . 8S-1 GENERAL INFORMATION; PROPELLER SHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-1 GENERAL INFORMATION; REAR SUSPENSION AND AXLES . . . . 3-12,3-30,3-1,3-8 GENERAL INFORMATION; RESTRAINT SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . 8M-1 GENERAL INFORMATION; SPLICE INFORMATION . . . . . . . . . . . . . . . . . . . . . 8W-70-1 GENERAL INFORMATION; SPLICE LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . 8W-95-1 GENERAL INFORMATION; STEERING . . . . . . 19-1 GENERAL INFORMATION; TRANSMISSION AND TRANSFER CASE . . . . 21-1 GENERAL INFORMATION; TURN SIGNAL AND HAZARD WARNING SYSTEMS . . . . . . . 8J-1 GENERAL INFORMATION; VEHICLE SPEED CONTROL . . . . . . . . . . . . . . . . . . 8W-33-1 GENERAL INFORMATION; VEHICLE SPEED CONTROL SYSTEM . . . . . . . . . . . . . . 8H-1 GENERAL INFORMATION; WHEELS AND TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . 22-1,22-6 GENERAL INFORMATION; WIPER AND WASHER SYSTEMS . . . . . . . . . . . . . . . . . . . . 8K-1 GENERAL SERVICE INFORMATION; BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . 5-12,5-17 GENERAL SERVICE INFORMATION; NV3500 MANUAL TRANSMISSION . . . . . . . 21-38 GENERAL SPECIFICATIONS, 42RH/46RH . 21-288 GENERATING RWAL FLASH CODES . . . . . . . 5-10 GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . 8B-7 GENERATOR DIAGNOSTIC TROUBLE CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8A-21 GENERATOR FIELDPCM OUTPUT . . . . . . 14-61 GENERATOR LAMPPCM OUTPUT . . . . . . 14-61 GENERATOR RATINGS; BATTERY/ STARTER/GENERATOR SERVICE . . . . . . . . . 8B-10 GENERATOR RATINGS; BATTERY/ STARTING/CHARGING SYSTEMS DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . 8A-23 GENERATOR REMOVE/INSTALL2.5L . . . . . 8B-7 GENERATOR REMOVE/INSTALL3.9L/ 5.2L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-7 GENERATORPCM OUTPUT . . . . . . . . . . . 14-27
GLASS AND DOOR WEATHERSTRIP SEALS, WINDOW . . . . . . . . . . . . . . . . . . . . . 23-29 GLASS, SLIDING VENT . . . . . . . . . . . . . . . . 23-36 GLASS, URETHANE SET . . . . . . . . . . . . . . . 23-32 GLOVE BOX LAMP . . . . . . . . . . . . . . . . . 8W-44-1 GLOVE BOX LAMP AND SWITCH REMOVE/INSTALL . . . . . . . . . . . . . . . . . . . . 8E-21 GLOVE BOX LOCK REMOVE/INSTALL . . . . . 8E-21 GLOVE BOX REMOVE/INSTALL . . . . . . . . . . 8E-21 GOVERNOR AND PARK LOCK SERVICE . . 21-125 GOVERNOR OVERHAUL . . . . . . . . . . . . . . . 21-246 GRAB/CHATTER, CLUTCH . . . . . . . . . . . . . . . . 6-8 GRILLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-3 GRILLE AND SCREEN, COWL . . . . . . . . . . . . 23-7 GROUND CLEARANCE AND RAMP ANGLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-11 GROUND, POWER . . . . . . . . . . . . . . . . . . . . 14-60 GROUND, POWER (DEVICE); FUEL/ IGNITION . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-5 GROUND, POWER (DEVICE); FUEL/ IGNITION3.9L AND 5.2L ENGINES . . 8W-30-11 GROUP, HOW TO USE THIS . . . . . . . . . . . . . 8W-1 GUIDES, VALVE . . . . . . . . . . . . . . . . . . . . . . . 9-89 HALL EFFECT PICK-UP2.5L ENGINE . . . 8D-23, 8D-4 HANDLE, INSIDE DOOR . . . . . . . . . . . . . . . . 23-29 HANDLE, OUTSIDE DOOR . . . . . . . . . . . . . . 23-27 HANDLING, AIRBAG MODULE . . . . . . . . . . . 8M-3 HAS A MISS, INJECTOR DIAGNOSIS VEHICLE RUNS ROUGH AND/OR . . . . . . . . 14-77 HAZARD FLASHERS . . . . . . . . . . . . . . . . 8W-52-1 HAZARD WARNING . . . . . . . . . . . . . . . . . . . . 8J-3 HAZARD WARNING SYSTEM . . . . . . . . . . . . . 8J-1 HEAD AND VALVE ASSEMBLY SERVICE, CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19 HEAD COMPONENTSIN-VEHICLE SERVICE, CYLINDER . . . . . . . . . . . . . . . . . . . 9-21 HEAD COVER, CYLINDER . . . . . . . . . . . 9-54,9-86 HEAD, CYLINDER . . . . . . . . . . . . . . . . . . . . . 9-24 HEAD GASKET FAILURE DIAGNOSIS, ENGINE CYLINDER . . . . . . . . . . . . . . . . . . . . . 9-5 HEAD NOT REMOVED, VALVE COMPONENTS REPLACECLYINDER . . 9-54,9-87 HEAD REMOVED, VALVE SERVICE CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25 HEADLAMP ALIGNMENT . . . . . . . . . . . . . . . . 8L-6 HEADLAMP ALIGNMENT PREPARATION . . . . 8L-6 HEADLAMP BULB REPLACEMENT, AERO . . . 8L-7 HEADLAMP DIAGNOSIS . . . . . . . . . . . . . . . . 8L-2 HEADLAMP LENS REPLACEMENT, AERO . . . 8L-7 HEADLAMP, POWER MIRROR, OVERDRIVE LOCKOUT SWITCH REMOVE/INSTALL . . . . . . . . . . . . . . . . . . . . 8E-19 HEADLAMP SWITCH; CHIME/BUZZER WARNING SYSTEMS . . . . . . . . . . . . . . 8U-1,8U-3 HEADLAMP SWITCH; LAMPS . . . . . . . . . . . 8L-10 HEADLAMP/FOG LAMP ADJUSTMENT USING ALIGNMENT SCREEN . . . . . . . . . . . . . 8L-6 HEADLAMPS; FRONT LIGHTING . . . . . . . 8W-50-1 HEADLAMPS; LUBRICATION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . 0-29 HEADLINERS . . . . . . . . . . . . . . . . . . . . . . . . 23-41 HEADS, CYLINDER . . . . . . . . . . . . . . . . 9-55,9-87 HEAT SHIELD2.5L ENGINES . . . . . . . . . . . 11-6 HEAT SHIELD3.9L / 5.2L ENGINES . . . . . . 11-6 HEAT SHIELDS; EXHAUST SYSTEM AND INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . 11-2 HEAT SHIELDS; FUEL SYSTEM . . . . . . . . . . 14-15 HEATED INLET AIR SYSTEM2.5L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-10 HEATED OXYGEN SENSOR; FUEL/ IGNITION . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-3 HEATED OXYGEN SENSOR; FUEL/ IGNITION3.9L AND 5.2L ENGINES . . . 8W-30-8 HEATER A/C CONTROL SYSTEM VACUUM DIAGNOSIS . . . . . . . . . . . . . . . . . 24-10 HEATER A/C CONTROL, VACUUM CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-11 HEATER A/C HOUSING . . . . . . . . . . . . . . . . 24-23 HEATER CORE . . . . . . . . . . . . . . . . . . . . . . . 24-26 HEATER DIAGNOSIS (MECHANICAL) . . . . . . 24-9 HEATER HOSES . . . . . . . . . . . . . . . . . . . . . . 24-21 HEATER OUTPUT TEST . . . . . . . . . . . . . . . . . 24-8 HEATER PERFORMANCE TEST, AIR CONDITIONING . . . . . . . . . . . . . . . . . . . . . . . 24-7 HEATER SYSTEM . . . . . . . . . . . . . . . . . . . . . . 24-1 HEATERS, ENGINE BLOCK . . . . . . . . . . . . . . . 7-47 HEATING AND AIR CONDITIONING . . . . . . . 24-26
HEATING AND AIR CONDITIONING TEST PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . 24-10 HEATING ELEMENT TEST, OXYGEN (O2S) SENSOR . . . . . . . . . . . . . . . . . . . . . . 14-35,14-72 HELPFUL INFORMATION . . . . . . . . . . . . . 8W-20-1 HIGH MOUNTED STOP LAMP (CHMSL), CENTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-11 HIGH PRESSURE RELIEF VALVE . . . . . . . . . 24-13 HIGH-PRESSURE CUT-OFF SWITCH . . . . . . 24-13 HINGE REPLACEMENT . . . . . . . . . . . . . . . . 23-23 HISS NOISE COMPLAINT . . . . . . . . . . . . . . . 19-3 HOISTING AND TOWING, JUMP STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-9 HOISTING RECOMMENDATIONS . . . . . . . . . . 0-10 HOLDER ASSEMBLY REMOVE/INSTALL, CUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-21 HONING CYLINDER BORES . . . . . . . . . . . . . . . 9-2 HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-5 HOOD INSIDE RELEASE CABLE . . . . . . . . . . 23-5 HORN . . . . . . . . . . . . . . . . . . . . . . . . . . 8G-1,8G-2 HORN; HORN/CIGAR LIGHTER . . . . . . . . 8W-41-1 HORN RELAY . . . . . . . . . . . . . . . . . . . . 8G-1,8G-2 HORN REMOVE/INSTALL . . . . . . . . . . . . . . . 8G-4 HORN SWITCH . . . . . . . . . . . . . . . . . . . 8G-1,8G-2 HORN SWITCH REMOVE/INSTALL . . . . . . . . 8G-3 HOSE REPLACEMENT, PRESSURE AND RETURN . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-12 HOSE ROUTING SCHEMATICS, VACUUM . . . 25-1 HOSE3.9L/5.2L ENGINE, WATER PUMP BYPASS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17 HOSES, BRAKELINES . . . . . . . . . . . . . . . . . . 5-14 HOSES, COOLING SYSTEM . . . . . . . . . . . . . . 7-32 HOSES, HEATER . . . . . . . . . . . . . . . . . . . . . 24-21 HOSES/TUBING, RUBBER AND PLASTIC . . . . 0-24 HOUSING, AIR CLEANER; EMISSION CONTROL SYSTEMS . . . . . . . . . . . . . . . . . . 25-18 HOUSING, AIR CLEANER; FUEL SYSTEM . . 14-83 HOUSING END PLUG . . . . . . . . . . . . . . . . . . 19-24 HOUSING FLUID LEAK DIAGNOSIS, CONVERTER . . . . . . . . . . . . . . . . . . . . . . . . 21-97 HOUSING, HEATER A/C . . . . . . . . . . . . . . . . 24-23 HOUSING MISALIGNMENT, CLUTCH . . . . . . . . 6-4 HOUSING REPLACEMENT (AX 15), CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 HOW TO USE THIS GROUP . . . . . . . . . . . . . 8W-1 HUB AND BEARINGS, WHEEL . . . . . . . . . 2-14,2-8 HYDRAULIC AND VACUUM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 HYDRAULIC CLUTCH LINKAGE . . . . . . . . . . . . 6-1 HYDRAULIC CONTROLS, TRANSMISSION . 21-88 HYDRAULIC FLOW IN D FIRST GEAR (BREAKAWAY) . . . . . . . . . . . . . . . . . . . . . . 21-118 HYDRAULIC FLOW IN D FOURTH GEAR (CONVERTER CLUTCH APPLIED) . . . . . . . 21-122 HYDRAULIC FLOW IN D FOURTH GEAR (CONVERTER CLUTCH NOT APPLIED) . . . 21-121 HYDRAULIC FLOW IN D SECOND GEAR . . 21-119 HYDRAULIC FLOW IN D THIRD GEAR . . . 21-120 HYDRAULIC FLOW IN MANUAL FIRST GEAR (1) . . . . . . . . . . . . . . . . . . . . . . . . . . 21-123 HYDRAULIC FLOW IN MANUAL SECOND GEAR (2) . . . . . . . . . . . . . . . . . . . . . . . . . . 21-124 HYDRAULIC FLOW IN NEUTRAL . . . . . . . . 21-116 HYDRAULIC FLOW IN PARK . . . . . . . . . . . 21-115 HYDRAULIC FLOW IN REVERSE . . . . . . . . 21-117 HYDRAULIC FLUID, CLUTCH . . . . . . . . . . . . . . 6-1 HYDRAULIC LINKAGE INSTALLATION, CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 HYDRAULIC LINKAGE REMOVAL, CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 HYDRAULIC PRESSURE TEST . . . . . . . . . . . 21-94 HYDRAULIC TAPPETS . . . . . . . . . . . . . . 9-59,9-91 HYDROSTATIC LOCK . . . . . . . . . . . . . . . . . . . . 9-4 IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . 21-2 IDENTIFICATION, CIRCUIT . . . . . . . . . . . 8W-01-2 IDENTIFICATION, ENGINE AND TRANSMISSION/TRANSFER CASE . . . . . . Intro.-3 IDENTIFICATION, MAJOR COMPONENT . . Intro.-3 IDENTIFICATION NUMBER (VIN) DECODING, VEHICLE . . . . . . . . . . . . . . . . Intro.-2 IDENTIFICATION NUMBER (VIN) PLATE, VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . Intro.-1 IDENTIFICATION PLATE, EQUIPMENT . . . . Intro.-3 IDENTIFICATION, RWAL FAULT CODE . . . . . . 5-10 IDENTIFICATION, SECTION . . . . . . . . . . . . . . 8W-1 IDENTIFICATION, TRANSFER CASE . . . . . . 21-261 IDENTIFICATION, TRANSMISSION . . . . . . . . 21-86 IDENTIFICATION, WIRE CODE . . . . . . . . . 8W-01-1
INDEX
Description Group-Page Description Group-Page Description
11
Group-Page
IDENTIFICATION/SYSTEM OPERATION, COMPONENT . . . . . . . . . . . . . . . . . . . . . . . . . 8D-1 IDLE AIR CONTROL (IAC) MOTOR; FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . 14-46,14-88 IDLE AIR CONTROL (IAC) MOTOR; FUEL/IGNITION . . . . . . . . . . . . . . . . . . . . 8W-30-3 IDLE AIR CONTROL (IAC) MOTOR; FUEL/IGNITION3.9L AND 5.2L ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-8 IDLE AIR CONTROL (IAC) MOTOR TEST . . . 14-72 IDLE AIR CONTROL (IAC) MOTORPCM OUTPUT . . . . . . . . . . . . . . . . . . . . . . . 14-27,14-61 IDLER ARM . . . . . . . . . . . . . . . . . . . . . . . . . 19-17 IGNITION CABLES, DISTRIBUTOR CAP AND ROTOR . . . . . . . . . . . . . . . . . . . . . . . . . 0-18 IGNITION CIRCUIT SENSEPCM INPUT . . 14-58 IGNITION COIL; FUEL SYSTEM . . . . . 14-47,14-88 IGNITION COIL; FUEL/IGNITION . . . . . . . 8W-30-2 IGNITION COIL; FUEL/IGNITION3.9L AND 5.2L ENGINES . . . . . . . . . . . . . . . . . 8W-30-7 IGNITION COIL; IGNITION SYSTEMS . . . . . 8D-22, 8D-4,8D-8 IGNITION COIL RESISTANCE . . . . . . . 8D-29,8D-9 IGNITION COILPCM OUTPUT . . . . 14-28,14-62 IGNITION KEY-IN SWITCH . . . . . . . . . . 8U-1,8U-2 IGNITION SECONDARY CIRCUIT DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-9 IGNITION SWITCH; FUEL/IGNITION . . . . 8W-30-1 IGNITION SWITCH; FUEL/IGNITION3.9L AND 5.2L ENGINES . . . . . . . . . . . . . . . . . 8W-30-6 IGNITION SWITCH; IGNITION SYSTEMS . . . . 8D-27 IGNITION SWITCH AND KEY CYLINDER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-27 IGNITION SWITCH LAMP, COURTESY LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-1 IGNITION TIMING . . . . . . . . . . . . . . . . . . . . 8D-11 IGNITION TIMING PROCEDURE . . . . . . . . . . 14-36 IGNITION-OFF DRAW . . . . . . . . . . . . . . . . . . 8A-10 IGNITION-OFF DRAW FUSE . . . . . . . . . . . . . . 8F-1 ILLUMINATION LAMPS, CLUSTER . . . 8E-14,8E-4 ILLUMINATION, RADIO . . . . . . . . . . . . . . 8W-47-1 ILLUMINATION, SERVICE BRAKE WARNING LIGHT . . . . . . . . . . . . . . . . . . . . . . . 5-3 IMPACT SENSOR . . . . . . . . . . . . . . . . . . . . . 8M-2 IMPACT SENSOR REMOVE/INSTALL . . . . . . 8M-4 IMPACT SENSORS, AIRBAG . . . . . . . . . . 8W-43-1 IMPORTANCE OF CLEAN BRAKE FLUID . . . . 5-12 IMPROPER CLUTCH RELEASE . . . . . . . . . . . . 6-7 IMPROPER CLUTCH RELEASE OR ENGAGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 INCORRECT FLUID LEVEL, EFFECTS OF . . . 21-92 INDEX, DIAGRAM; AIR CONDITIONING/ HEATER . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-3 INDEX, DIAGRAM; AIRBAG SYSTEM . . . 8W-43-1 INDEX, DIAGRAM; ANTI-LOCK BRAKES . 8W-32-3, 8W-32-4 INDEX, DIAGRAM; FRONT LIGHTING . . . 8W-50-2 INDEX, DIAGRAM; FUEL/IGNITION . . . . . 8W-30-5 INDEX, DIAGRAM; FUEL/IGNITION3.9L AND 5.2L ENGINES . . . . . . . . . . . . . . . . 8W-30-11 INDEX, DIAGRAM; FUSE BLOCK . . . . . . . 8W-10-1 INDEX, DIAGRAM; GROUND DISTRIBUTION . . . . . . . . . . . . . . . . . . . . 8W-15-1 INDEX, DIAGRAM; HORN/CIGAR LIGHTER . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-1 INDEX, DIAGRAM; INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-3 INDEX, DIAGRAM; INTERIOR LIGHTING . 8W-44-2 INDEX, DIAGRAM; OVERHEAD CONSOLE . 8W-49-1 INDEX, DIAGRAM; POWER DISTRIBUTION . . . . . . . . . . . . . . . . . . . . 8W-11-1 INDEX, DIAGRAM; POWER DOOR LOCKS . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-1 INDEX, DIAGRAM; POWER MIRRORS . . 8W-62-1 INDEX, DIAGRAM; POWER WINDOWS . . 8W-60-1 INDEX, DIAGRAM; REAR LIGHTING . . . . 8W-51-2 INDEX, DIAGRAM; TRAILER TOW . . . . . . 8W-54-1 INDEX, DIAGRAM; TRANSMISSION CONTROLS . . . . . . . . . . . . . . . . . . . . . . . 8W-31-1 INDEX, DIAGRAM; TURN SIGNALS . . . . . 8W-52-1 INDEX, DIAGRAM; VEHICLE SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-1 INDEX, DIAGRAM; WIPERS . . . . . . . . . . 8W-53-2 INDEX, SPLICE . . . . . . . . . . . . . . . . . . . . 8W-70-1 INDEX2.5L, DIAGRAM; CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-1 INDEX2.5L, DIAGRAM; STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-2
INDEX3.9L/5.2L, DIAGRAM; CHARGING SYSTEM . . . . . . . . . . . . . . . . 8W-20-1 INDEX3.9L/5.2L, DIAGRAM; STARTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-2 INDICATOR ADJUSTMENT, GEAR SELECTOR . . . . . . . . . . . . . . . . . . . . . . . . . 21-127 INDICATOR LAMP SWITCH, FOURWHEEL DRIVE . . . . . . . . . . . . . . . . . . . . . 8W-31-1 INDICATOR LAMPPCM OUTPUT, MALFUNCTION . . . . . . . . . . . . . . . . . 14-28,14-62 INDICATOR LAMPS . . . . . . . . . . . . . . . 8E-10,8E-3 INDICATOR REMOVE/INSTALL, GEAR SELECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-20 INDICATORPCM OUTPUT, SHIFT . . . . . . . 14-63 INDICATORS, TREAD WEAR . . . . . . . . . . . . . 22-3 INFLATION PRESSURES, TIRE . . . . . . . . . . . 22-2 INITIAL OPERATION, POWER STEERING PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-16 INJECTION (MFI)COMPONENT DESCRIPTION/SYSTEM OPERATION 3.9L/5.2L ENGINE, MULTI-PORT FUEL . . . . 14-52 INJECTION (MFI)COMPONENT REMOVAL/INSTALLATION3.9L/5.2L ENGINE, MULTI-PORT FUEL . . . . . . . . . . . . 14-83 INJECTIONCOMPONENT DESCRIPTION/SYSTEM OPERATION 2.5L ENGINE, SINGLE-PORT FUEL . . . . . . . 14-21 INJECTIONCOMPONENT REMOVAL/ INSTALLATION2.5L ENGINE, SINGLE-PORT FUEL . . . . . . . . . . . . . . . . . . . 14-43 INJECTIONGENERAL DIAGNOSIS 2.5L ENGINE, SINGLE-PORT FUEL . . . . . . . 14-32 INJECTIONGENERAL DIAGNOSIS 3.9L/5.2L ENGINE, MULTI-PORT FUEL. . . . . 14-67 . INJECTOR DIAGNOSISVEHICLE RUNS ROUGH AND/OR HAS A MISS . . . . . . . . . . . 14-77 INJECTOR, FUEL; FUEL SYSTEM . . . . . . . . . 14-44 INJECTOR, FUEL; FUEL/IGNITION . . . . . . 8W-30-2 INJECTOR TEST, FUEL . . . . . . . . . . . . . . . . . 14-76 INJECTORPCM OUTPUT, FUEL . . . . . . . . 14-27 INJECTOR(S), FUEL . . . . . . . . . . . . . . . . . . . 14-85 INJECTORS, FUEL . . . . . . . . . . . . . . . . . . 8W-30-7 INJECTORSPCM OUTPUT, FUEL . . . . . . . 14-62 INLET AIR SYSTEM2.5L ENGINE, HEATED . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-10 INLET FILTER, PCV/CRANKCASE AIR . . . . . . 0-17 INNER CV JOINT . . . . . . . . . . . . . . . . . . . . . . 2-24 INPUT, AIR CONDITIONING (A/C) CONTROLSPCM . . . . . . . . . . . . . . . 14-23,14-56 INPUT AND OUTPUT, DATA LINK CONNECTORPCM . . . . . . . . . . . . . . . . . . . 14-57 INPUT, AUTOMATIC SHUTDOWN (ASD) SENSEPCM . . . . . . . . . . . . . . . . . . . . . . . 14-57 INPUT, BATTERY VOLTAGEPCM . . . 14-23,14-57 INPUT, BRAKE SWITCHPCM . . . . . 14-23,14-57 INPUT, CAMSHAFT POSITION SENSOR PCM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-57 INPUT, CRANKSHAFT POSITION SENSORPCM . . . . . . . . . . . . . . . . . . . . . . 14-58 INPUT, ENGINE COOLANT TEMPERATURE SENSORPCM . . . . 14-23,14-58 INPUT, ENGINE SPEEDPCM . . . . . . . . . . . 14-23 INPUT, IGNITION CIRCUIT SENSEPCM . . 14-58 INPUT, INTAKE MANIFOLD AIR TEMPERATURE SENSORPCM . . . . . . . . . 14-58 INPUT, MANIFOLD ABSOLUTE PRESSURE (MAP) SENSORPCM . . 14-24,14-59 INPUT, OXYGEN (O2S) SENSORPCM . . . 14-24, 14-59 INPUT, PARK BRAKE SWITCH . . . . . . . . 8W-32-4 INPUT, PARK/NEUTRAL SWITCHPCM . . . 14-60 INPUT, SCI RECEIVEPCM . . . . . . . . . . . . 14-60 INPUT, SENSOR RETURNPCM . . . . . . . . . 14-60 INPUT, SPEED CONTROLPCM . . . . . . . . . 14-60 INPUT, THROTTLE BODY TEMPERATURE SENSORPCM . . . . . . . . . . . . . . . . . . . . . . 14-25 INPUT, THROTTLE POSITION SENSOR (TPS)PCM . . . . . . . . . . . . . . . . . . . 14-25,14-60 INPUT, VEHICLE SPEED SENSORPCM . . 14-25, 14-60 INSIDE DOOR HANDLE . . . . . . . . . . . . . . . . 23-29 INSIDE RELEASE CABLE, HOOD . . . . . . . . . . 23-5 INSPECTION AND DIAGNOSIS CHARTS . . . . . 6-4 INSPECTION AND OVERHAUL, OVERRUNNING CLUTCHLOWREVERSE DRUMOVERDRIVE PISTON RETAINER . . . . . . . . . . . . . . . . . . . . . . . . . 21-154 INSPECTION, BRAKESHOE AND CALIPER . . . 5-35
INSPECTION, CALIPER CLEANING . . . . 5-31,5-37 INSPECTION CHART, CLUTCH . . . . . . . . . . . . . 6-5 INSPECTION, CLEANING; BRAKES . . . . . . . . 5-21 INSPECTION, CLEANING; PROPELLER SHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-10 INSPECTION, COMPONENT . . . . . . . . . . . . . . . 5-4 INSPECTION (ENGINE OIL LEAKS IN GENERAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6 INSPECTION, OVERDRIVE COMPONENT CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . 21-245 INSPECTION, PRE-ALIGNMENT . . . . . . . . . . . . 2-4 INSPECTION, TRANSMISSION CASE CLEANING . . . . . . . . . . . . . . . . . . . 21-154,21-200 INSPECTION, TRANSMISSION COMPONENT CLEANING . . . . . . . . . . . . . . . 21-56 INSPECTION, VALVE BODY CLEANING . . . 21-176, 21-223 INSPECTION, VISUAL . . . . . . . . . . . . 14-32,14-67 INSTALLATION (2-WHEEL DRIVE MODELS), FRONT BRAKE SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58 INSTALLATION (2-WHEEL DRIVE), TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . 21-44 INSTALLATION (4-WHEEL DRIVE MODELS), FRONT BRAKE SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59 INSTALLATION (4-WHEEL DRIVE), TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . 21-45 INSTALLATION, ABS ELECTRONIC CONTROL MODULE . . . . . . . . . . . . . . . . . . . . 5-59 INSTALLATION AND ADJUSTMENT, OVERDRIVE CLUTCH . . . . . . . . . . . . . . . . . 21-257 INSTALLATION, BRAKE DRUM . . . . . . . . . . . 5-23 INSTALLATION, BRAKE PEDAL . . . . . . . . . . . 5-18 INSTALLATION, BRAKE SUPPORT PLATE . . . 5-23 INSTALLATION, BRAKESHOE . . . . 5-21,5-29,5-36 INSTALLATION, CALIPER . . . . . . . . . . . 5-32,5-40 INSTALLATION, CLUTCH COVER AND DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 INSTALLATION, CLUTCH HYDRAULIC LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 INSTALLATION, CLUTCH PEDAL . . . . . . . . . . 6-13 INSTALLATION, COMBINATION VALVE . 5-47,5-57 INSTALLATION, ELECTRONIC CONTROL MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48 INSTALLATION, FRONT ANTILOCK VALVE . . . 5-55 INSTALLATION, FRONT CABLE . . . . . . . . . . . 5-63 INSTALLATION, INTERMEDIATE CABLE . . . . . 5-66 INSTALLATION, MASTER CYLINDER . . . . . . . 5-14 INSTALLATION, PARKING BRAKE PEDAL . . . 5-66 INSTALLATION, POWER BRAKE BOOSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18 INSTALLATION, REAR ANTILOCK VALVE . . . 5-47, 5-57 INSTALLATION, REAR BRAKE SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59 INSTALLATION, REAR CABLE . . . . . . . . . . . . 5-66 INSTALLATION, ROTOR . . . . . . . . . . . . . . . . . 5-41 INSTALLATION, SPEED SENSOR . . . . . . . . . . 5-48 INSTALLATION, TRANSFER CASE . . . . . . . 21-266 INSTALLATION, WHEEL . . . . . . . . . . . . . . . . . 22-6 INSTALLATION, WHEEL CYLINDER . . . . . . . . 5-24 INSTALLATION2-WHEEL DRIVE, OVERDRIVE UNIT . . . . . . . . . . . . . . . . . . . 21-144 INSTALLATION2-WHEEL DRIVE, TRANSMISSION; NV3500 MANUAL TRANSMISSION . . . . . . . . . . . . . . . . . . . . . 21-140 INSTALLATION2-WHEEL DRIVE, TRANSMISSION; TRANSMISSION AND TRANSFER CASE . . . . . . . . . . . . . . . . . . . . . . 21-6 INSTALLATION4-WHEEL DRIVE, OVERDRIVE UNIT . . . . . . . . . . . . . . . . . . . 21-145 INSTALLATION4-WHEEL DRIVE, TRANSMISSION; NV3500 MANUAL TRANSMISSION . . . . . . . . . . . . . . . . . . . . . 21-142 INSTALLATION4-WHEEL DRIVE, TRANSMISSION; TRANSMISSION AND TRANSFER CASE . . . . . . . . . . . . . . . . . . . . . . 21-7 INSTRUMENT CLUSTER . . . . . . . . . . . . . 8W-40-1 INSTRUMENT CLUSTER REMOVE/ INSTALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-15 INSTRUMENT CLUSTERS . . . . . . . . . . . . . . . 8E-1 INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . 8E-1 INSTRUMENT PANEL ASSEMBLY REMOVE/INSTALL . . . . . . . . . . . . . . . . . . . . 8E-23 INSTRUMENT PANEL BEZEL REMOVE/ INSTALL, RIGHT . . . . . . . . . . . . . . . . . . . . . 8E-21
12
INDEX
Group-Page Description Group-Page Description Group-Page
Description
INSTRUMENT PANEL END CAP REMOVE/INSTALL, LOWER LEFT . . . . . . . . 8E-21 INSTRUMENT PANEL MODULE REMOVE/INSTALL, LOWER . . . . . . . . . . . . . 8E-21 INSULATOR, DOOR TRIM PANEL/ WATERDAM/NOISE . . . . . . . . . . . . . . . . . . . 23-24 INTAKE / EXHAUST MANIFOLDS2.5L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6 INTAKE AIR TEMPERATURE SENSOR . . 8W-30-10 INTAKE MANIFOLD . . . . . . . . . . . . . . 14-47,14-88 INTAKE MANIFOLD AIR TEMPERATURE SENSOR; FUEL SYSTEM . . . . . . . . . . . . . . . 14-84 INTAKE MANIFOLD AIR TEMPERATURE SENSOR; IGNITION SYSTEMS . . . . . . . . . . 8D-23 INTAKE MANIFOLD AIR TEMPERATURE SENSOR TEST; FUEL SYSTEM . . . . . . . . . . 14-70 INTAKE MANIFOLD AIR TEMPERATURE SENSOR TEST; IGNITION SYSTEMS . . . . . . 8D-12 INTAKE MANIFOLD AIR TEMPERATURE SENSOR3.9L/5.2L ENGINE . . . . . . . . . . . . 8D-5 INTAKE MANIFOLD AIR TEMPERATURE SENSORPCM INPUT . . . . . . . . . . . . . . . . 14-58 INTAKE MANIFOLD LEAKAGE DIAGNOSIS . . . 9-5 INTAKE MANIFOLD3.9L / 5.2L ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9 INTERCHANGEABILITY, TRANSMISSION CHANGES AND PARTS . . . . . . . . . . . . . . . . 21-87 INTERFERENCE, RADIO FREQUENCY . . . . . . 8F-6 INTERIOR COMPONENTS, CAB . . . . . . . . . . 23-37 INTERIOR LAMPS . . . . . . . . . . . . . . . . . . . . 8L-13 INTERIOR TRIM PANELS . . . . . . . . . . . . . . . 23-38 INTERMEDIATE CABLE INSTALLATION . . . . . 5-66 INTERMEDIATE CABLE REMOVAL . . . . . . . . . 5-66 INTERMEDIATE COUPLER SHAFT . . . 19-31,19-33 INTERMEDIATE SHAFT, CRANKSHAFT . . . . . . 9-28 INTERMEDIATE SHAFT OVERHAUL, PLANETARY GEAR TRAIN . . . . . . . . . . . . . 21-164 INTERMEDIATE SHAFT SERVICE . . . . . . . . . . 9-32 INTERMEDIATE SHAFTS TIMING PROCEDURE, CAMSHAFT, CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . 9-18 INTERMITTENT AND POOR CONNECTIONS . . . . . . . . . . . . . . . . . . . . 8W-01-4 INTERMITTENT WIPE MODULE . . . . . . . . . . 8K-6 INTERNATIONAL CONTROL AND DISPLAY SYMBOLS . . . . . . . . . . . . . . . . . Intro.-7 INTERNATIONAL SYMBOLS . . . . . . . . . . . . . . . 0-1 INTERNATIONAL VEHICLE CONTROL AND DISPLAY SYMBOLS . . . . . . . . . . . . . Intro.-3 INTRODUCTION; BODY COMPONENTS . . . . 23-45 INTRODUCTION; LUBRICATION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . 0-1 IN-VEHICLE SERVICE, 42RH/46RH . . . . . . 21-125 IN-VEHICLE SERVICE, TRANSFER CASE . . 21-265 JAMB SWITCH, DRIVERS DOOR . . . . . 8U-1,8U-2 JOINT ANGLE MEASUREMENT, UNIVERSAL . . . . . . . . . . . . . . . . . . . . . . . . . . 16-4 JOINT, INNER CV . . . . . . . . . . . . . . . . . . . . . . 2-24 JOINT, OUTER CV . . . . . . . . . . . . . . . . . . . . . 2-26 JOINT, PROPELLER SHAFT AND UNIVERSAL . . . . . . . . . . . . . . . . . . . . . . . . . 16-15 JOINT REPLACEMENT, UNIVERSAL . . . . . . . 16-10 JOINTS, UNIVERSAL . . . . . . . . . . . . . . . . . . . 16-2 JUMP STARTING . . . . . . . . . . . . . . . . . . . . . . . 0-9 JUMP STARTING, HOISTING AND TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-9 KEY CYLINDER SERVICE, IGNITION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-27 KEY LOCK CYLINDER . . . . . . . . . . . . . . . . . 23-27 KEY-IN SWITCH, IGNITION . . . . . . . . . . 8U-1,8U-2 KEYS ARE NOT AVAILABLE, TOWING WHEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-13 KNEE BLOCKER REMOVE/INSTALL . . . . . . . 8E-19 KNOCK, LOW SPEED; FRONT SUSPENSION AND AXLE . . . . . . . . . . . . . . . . 2-20 KNOCK, LOW SPEED; REAR SUSPENSION AND AXLES . . . . . . . . . . . . . . . . 3-9 KNUCKLE, STEERING . . . . . . . . . . . . . . 2-13,2-17 LABEL, TYPICAL VEHICLE EMISSION CONTROL INFORMATION . . . . . . . . . . . . . . . 25-2 LABEL, VEHICLE EMISSION CONTROL INFORMATION (VECI) . . . . . . . . . . . . . . . . . . 25-1 LABEL, VEHICLE SAFETY CERTIFICATION . Intro.-1 LABELS/DECALS/PLATES . . . . . . . . . . . . . . . 23-1 LABELS/PLATES/DECALS, CODES AND DIMENSIONS/WEIGHTS, DESIGNATIONS . . . . . . . . . . . . . . . . . . . . . Intro.-1 LAMP, ABS WARNING . . . . . . . . . . . . . . . 8W-32-2
LAMP ADJUSTMENT USING ALIGNMENT SCREEN, HEADLAMP/FOG . . . . . . . . . . . . . . . 8L-6 LAMP, AIRBAG WARNING . . . . . . . . . . . . 8W-43-1 LAMP AND CIGAR LAMP, ASH RECEIVER . 8W-44-1 LAMP AND IGNITION SWITCH LAMP, COURTESY . . . . . . . . . . . . . . . . . . . . . . . 8W-44-1 LAMP AND SWITCH REMOVE/INSTALL, GLOVE BOX . . . . . . . . . . . . . . . . . . . . . . . . . 8E-21 LAMP, ASH RECEIVER LAMP AND CIGAR . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-1 LAMP, BRAKE WARNING . . . . . . . . . . . . 8W-32-2 LAMP BULB REPLACEMENT, UNDERHOOD . . . . . . . . . . . . . . . . . . . . . . . . 8L-12 LAMP (CHMSL), CENTER HIGH MOUNTED STOP . . . . . . . . . . . . . . . . . . . . . 8L-11 LAMP, COURTESY LAMP AND IGNITION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-1 LAMP DIAGNOSIS, FOG/OFF ROAD . . . . . . . . 8L-3 LAMP, DOME . . . . . . . . . . . . . . . . . . . . . . 8W-44-1 LAMP (DRL) MODULE, DAYTIME RUNNING . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-2 LAMP, FRONT SIDE MARKER . . . . . . . . . . . . 8L-9 LAMP, GLOVE BOX . . . . . . . . . . . . . . . . . 8W-44-1 LAMP, LOW WASHER FLUID WARNING . 8W-53-2 LAMP, REAR SIDE MARKER . . . . . . . . . . . . 8L-11 LAMP REPLACEMENT, UNDERHOOD . . . . . 8L-12 LAMP SWITCH, BACKUP . . . . . . . . . . . . . . . 8L-11 LAMP SWITCH, BRAKE WARNING . . . . . 8W-32-4 LAMP SWITCH, FOUR-WHEEL DRIVE INDICATOR. . . . . . . . . . . . . . . . . . . . . . . . 8W-31-1 . LAMP SWITCH REPLACEMENT, FOG . . . . . . 8L-10 LAMP SWITCH REPLACEMENT, OFF ROAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-10 LAMP SWITCH SENSE, STOP . . . . . . . . . 8W-32-2 LAMP SWITCH, STOP . . . . . . . . . . . . . 8H-1,8H-6 LAMP, UNDERHOOD; INTERIOR LIGHTING . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-1 LAMP, UNDERHOOD; LAMPS . . . . . . . . . . . 8L-11 LAMP, UPSHIFT . . . . . . . . . . . . . . . . . . . 8W-30-10 LAMP, WARNING . . . . . . . . . . . . . . . . . . 8W-32-4 LAMPPCM OUTPUT, EMR . . . . . . . . . . . . 14-62 LAMPPCM OUTPUT, GENERATOR . . . . . . 14-61 LAMPPCM OUTPUT, MALFUNCTION INDICATOR . . . . . . . . . . . . . . . . . . . . 14-28,14-62 LAMPS AND CHMSL LAMPS, STOP . . . . 8W-51-1 LAMPS AND REAR LICENSE PLATE LAMPS, TAIL . . . . . . . . . . . . . . . . . . . . . . 8W-51-1 LAMPS, BACKUP . . . . . . . . . . . . . . . . . . . . . 8L-11 LAMPS, BACK-UP . . . . . . . . . . . . . . . . . . 8W-51-1 LAMPS, CLUSTER ILLUMINATION . . . 8E-14,8E-4 LAMPS, EXTERIOR . . . . . . . . . . . . . . . . . . . 8L-13 LAMPS, FOG; FRONT LIGHTING . . . . . . . 8W-50-2 LAMPS, FOG; LAMPS . . . . . . . . . . . . . . . . . . 8L-8 LAMPS, INDICATOR . . . . . . . . . . . . . . 8E-10,8E-3 LAMPS, INTERIOR . . . . . . . . . . . . . . . . . . . . 8L-13 LAMPS, LICENSE PLATE . . . . . . . . . . . . . . . 8L-11 LAMPS, OFF ROAD . . . . . . . . . . . . . . . . . . . . 8L-9 LAMPS, OFF-ROAD . . . . . . . . . . . . . . . . . 8W-50-2 LAMPS, PARK AND TURN SIGNAL . . . . . . . . 8L-9 LAMPS, PARKING . . . . . . . . . . . . . . . . . . 8W-50-1 LAMPS, READING AND COURTESY . . . . . . . 8C-1 LAMPS, READING/COURTESY . . . . . . . . . . . . 8C-8 LAMPS, STOP LAMPS AND CHMSL . . . . 8W-51-1 LAMPS, TAIL LAMPS AND REAR LICENSE PLATE . . . . . . . . . . . . . . . . . . . . 8W-51-1 LAMPS, TAIL, STOP AND TURN SIGNAL . . 8L-11 LATCH CLIP, FUEL LINE WITH . . . . . . . . . . 14-13 LATCH, DOOR . . . . . . . . . . . . . . . . . . . . . . . 23-28 LATCH LINKAGE, DOOR . . . . . . . . . . . . . . . 23-28 LATCH STRIKER, DOOR . . . . . . . . . . . . . . . 23-29 LEAD CORRECTION CHART . . . . . . . . . . . . . . 22-5 LEAF REPLACEMENT, SPRING . . . . . . . . . . . . 3-6 LEAF SPRING EYE BUSHING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . 3-6 LEAF SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . 3-5 LEAK DIAGNOSIS, CONVERTER HOUSING FLUID . . . . . . . . . . . . . . . . . . . . . 21-97 LEAK DOWN TEST3.9L/5.2L ENGINE, FUEL PRESSURE . . . . . . . . . . . . . . . . . . . . . . 14-9 LEAK TESTING REFRIGERANT . . . . . . . . . . . 24-5 LEAKAGE DIAGNOSIS, GEAR . . . . . . . . . . . . 19-11 LEAKAGE DIAGNOSIS, INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 LEAKAGE DIAGNOSIS, PUMP . . . . . . . . . . . 19-10 LEAKAGE TEST, CYLINDER COMBUSTION PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6 LEAKS, REPAIRING . . . . . . . . . . . . . . . . . . . . 22-3 LEAKS, TESTING COOLING SYSTEM . . . . . . . 7-25
LEFT INSTRUMENT PANEL END CAP REMOVE/INSTALL, LOWER . . . . . . . . . . . . . 8E-21 LENS AND MASK REMOVE/INSTALL, CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-15 LENS REPLACEMENT, AERO HEADLAMP . . . 8L-7 LEVEL AND CAPACITY, TRANSMISSION LUBRICANT . . . . . . . . . . . . . . . . . . . . . . . . . 21-40 LEVEL AND CONDITION, CHECKING FLUID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-91 LEVEL CHECK, FLUID . . . . . . . . . . . . . . . . 21-125 LEVEL, CORRECT BRAKE FLUID . . . . . . . . . . 5-12 LEVEL, EFFECTS OF INCORRECT FLUID . . . 21-92 LICENSE PLATE LAMPS . . . . . . . . . . . . . . . 8L-11 LICENSE PLATE LAMPS, TAIL LAMPS AND REAR . . . . . . . . . . . . . . . . . . . . . . . 8W-51-1 LIGHT BAR . . . . . . . . . . . . . . . . . . . . . . . . . 23-21 LIGHT DISPLAY, ABS/RWAL WARNING . . . . . . 5-9 LIGHT ILLUMINATION, SERVICE BRAKE WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3 LIGHT MODULE (DRLM), DAYTIME RUNNING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-12 LIGHTER, CIGAR . . . . . . . . . . . . . . . . . . . 8W-41-1 LIGHTER REMOVE/INSTALL, CIGAR . . . . . . 8E-21 LIGHTS, BRAKE WARNING . . . . . . . . . . . . . . . 5-1 LIMITED SLIP DIFFERENTIAL . . . . . . . . . . . . . 3-9 LIMITS, BRAKE DRUM REFINISH . . . . . . . . . 5-22 LINE AND FITTING SERVICE, TRANSMISSION COOLER . . . . . . . . . . . . . 21-133 LINE WITH LATCH CLIP, FUEL . . . . . . . . . . 14-13 LINES, REFRIGERANT . . . . . . . . . . . . . . . . . 24-19 LINK, CENTER . . . . . . . . . . . . . . . . . . . . . . . 19-18 LINK CONNECTOR, ABS DATA . . . . . . . . 8W-32-2 LINK CONNECTOR, AIRBAG DATA . . . . . 8W-43-1 LINK CONNECTOR, DATA; ANTI-LOCK BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . 8W-32-4 LINK CONNECTOR, DATA; FUEL/IGNITION . . . . . . . . . . . . . . . . . . . . 8W-30-5 LINK CONNECTOR, DATA; FUEL/ IGNITION3.9L AND 5.2L ENGINES . . 8W-30-11 LINK CONNECTORPCM INPUT AND OUTPUT, DATA . . . . . . . . . . . . . . . . . . . . . . . 14-57 LINKAGE ADJUSTMENT, SHIFT . . . 21-127,21-264 LINKAGE ADJUSTMENT, TRANSMISSION CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-93 LINKAGE, DOOR LATCH . . . . . . . . . . . . . . . 23-28 LINKAGE, HYDRAULIC CLUTCH . . . . . . . . . . . 6-1 LINKAGE INSTALLATION, CLUTCH HYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 LINKAGE REMOVAL, CLUTCH HYDRAULIC . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 LINKAGE REMOVE/INSTALL . . . . . . . . . . . . . 8K-8 LINKAGE, STEERING; LUBRICATION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . 0-25 LINKAGE, STEERING; STEERING . . . . . . . . . 19-42 LINKAGE 4WD VEHICLES, STEERING . . . 19-17 LOADING AND WEIGHT DISTRIBUTION, VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 LOCATION, ABS DIAGNOSTIC CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 LOCATION, RWAL DIAGNOSTIC CONNECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 LOCATIONS, CONNECTOR; CONNECTOR LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . 8W-90-1 LOCATIONS, CONNECTOR; CONNECTOR PIN OUTS . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-1 LOCATIONS, CONNECTOR; WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-1 LOCATIONS, DRAIN AND FILL PLUG . . . . . 21-40 LOCATIONS, SPLICE . . . . . . . . . . . . . . . . 8W-95-1 LOCATIONS, SPLICE; WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-1 LOCATIONS, SWITCH AND PLUG . . . . . . . . . 21-2 LOCK CYLINDER, KEY . . . . . . . . . . . . . . . . . 23-27 LOCK, HYDROSTATIC . . . . . . . . . . . . . . . . . . . 9-4 LOCK MOTOR, POWER . . . . . . . . . . . . . . . . . 8P-1 LOCK MOTOR, POWER DOOR . . . . . . . . . . . 23-29 LOCK MOTOR REMOVE/INSTALL, POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8P-2 LOCK REMOVE/INSTALL, GLOVE BOX . . . . 8E-21 LOCK SERVICE, GOVERNOR AND PARK . . 21-125 LOCK SWITCH, POWER . . . . . . . . . . . . . . . . 8P-1 LOCK SWITCH REMOVE/INSTALL, POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8P-2 LOCKOUT SWITCH REMOVE/INSTALL, HEADLAMP, POWER MIRROR, OVERDRIVE . . . . . . . . . . . . . . . . . . . . . . . . . 8E-19 LOCKS, POWER DOOR . . . . . . . . . . . . . . 8W-61-1
INDEX
Description Group-Page Description Group-Page Description
13
Group-Page
LOOP MODES OF OPERATION, OPEN LOOP/CLOSED . . . . . . . . . . . . . . . . . . 14-28,14-64 LOOP/CLOSED LOOP MODES OF OPERATION, OPEN . . . . . . . . . . . . . . 14-28,14-64 LOUVERS, PANEL AIR . . . . . . . . . . . . . . . . . 24-21 LOW FUEL AND TACHOMETER DRIVE MODULES REMOVE/INSTALL . . . . . . . . . . . 8E-16 LOW SPEED KNOCK; FRONT SUSPENSION AND AXLE . . . . . . . . . . . . . . . . 2-20 LOW SPEED KNOCK; REAR SUSPENSION AND AXLES . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 LOW WASHER FLUID WARNING LAMP . 8W-53-2 LOWER BALL STUD . . . . . . . . . . . . . . . . . . . 2-11 LOWER INSTRUMENT PANEL MODULE REMOVE/INSTALL . . . . . . . . . . . . . . . . . . . . 8E-21 LOWER LEFT INSTRUMENT PANEL END CAP REMOVE/INSTALL . . . . . . . . . . . . . . . . 8E-21 LOWER SUSPENSION ARM . . . . . . . . . 2-10,2-16 LOW-REVERSE DRUM AND REAR BAND SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . 21-201 LUBRICANT CHANGE; FRONT SUSPENSION AND AXLE . . . . . . . . . . . . . . . . 2-33 LUBRICANT CHANGE; REAR SUSPENSION AND AXLES . . . . . . . . . . . . . . . 3-15 LUBRICANT LEVEL AND CAPACITY, TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . 21-40 LUBRICANT, RECOMMENDED; NV3500 MANUAL TRANSMISSION . . . . . . . . . . . . . 21-262 LUBRICANT, RECOMMENDED; TRANSMISSION AND TRANSFER CASE . . . . 21-2 LUBRICANT SPECIFICATIONS; FRONT SUSPENSION AND AXLE . . . . . . . . . . . . . . . . 2-31 LUBRICANT SPECIFICATIONS; REAR SUSPENSION AND AXLES . . . . . . . . . . . . . . . 3-12 LUBRICANT SPECIFICATIONS, BODY . . . . . . 0-29 LUBRICANT, TRANSMISSION . . . . . . . . . . . 21-40 LUBRICANTS, CHASSIS COMPONENT AND WHEEL BEARING . . . . . . . . . . . . . . . . . 0-25 LUBRICANTS, CLASSIFICATION OF . . . . . . . . . 0-1 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . 16-2 LUBRICATION AND REPLACEMENT PARTS RECOMMENDATION . . . . . . . . . . . . . . . 0-2 LUBRICATION, CLUTCH . . . . . . . . . . . . . . . . . . 6-2 LUBRICATION, COMPONENTS REQUIRING NO . . . . . . . . . . . . . . . . . . . . . . . . 0-2 LUBRICATION SYSTEM . . . . . . . . . . . . . 9-67,9-99 LUBRICATION SYSTEM, ENGINE . . . . . . . . . . 9-39 LUBRICATION SYSTEM, FIG. 2 OIL . . . 9-100,9-68 LUG NUT, WHEEL . . . . . . . . . . . . . . . . . . . . 22-12 MAIN BEARINGS, CRANKSHAFT . . . . . 9-105,9-74 MAINTENANCE, ENGINE . . . . . . . . . . . . . . . . 0-14 MAINTENANCE SCHEDULES . . . . . . . . . . . . . . 0-4 MAJOR COMPONENT IDENTIFICATION . . . Intro.-3 MALFUNCTION DIAGNOSIS AND TESTS, SNOW PLOW . . . . . . . . . . . . . . . . . . . . . . . . . 13-4 MALFUNCTION INDICATOR LAMPPCM OUTPUT . . . . . . . . . . . . . . . . . . . . . . . 14-28,14-62 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR; FUEL SYSTEM . . . . . . . . . . 14-47,14-88 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR; IGNITION SYSTEMS . . . . . . 8D-24,8D-5 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR TEST; FUEL SYSTEM . . . . . . . . . . 14-71 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR TEST; IGNITION SYSTEMS . . . . . . 8D-12 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSORPCM INPUT . . . . . . . . . . . 14-24,14-59 MANIFOLD ABSOLUTE PRESSURE SENSOR; FUEL/IGNITION . . . . . . . . . . . . 8W-30-4 MANIFOLD ABSOLUTE PRESSURE SENSOR; FUEL/IGNITION3.9L AND 5.2L ENGINES . . . . . . . . . . . . . . . . . . . . . 8W-30-9 MANIFOLD AIR TEMPERATURE SENSOR, INTAKE; FUEL SYSTEM . . . . . . . . . . . . . . . . 14-84 MANIFOLD AIR TEMPERATURE SENSOR, INTAKE; IGNITION SYSTEMS . . . . . . . . . . . 8D-23 MANIFOLD AIR TEMPERATURE SENSOR, SENSOR RESISTANCE (OHMS) COOLANT TEMPERATURE SENSOR/ INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-70 MANIFOLD AIR TEMPERATURE SENSOR TEST, INTAKE; FUEL SYSTEM . . . . . . . . . . . 14-70 MANIFOLD AIR TEMPERATURE SENSOR TEST, INTAKE; IGNITION SYSTEMS . . . . . . 8D-12 MANIFOLD AIR TEMPERATURE SENSOR3.9L/5.2L ENGINE, INTAKE . . . . . 8D-5 MANIFOLD AIR TEMPERATURE SENSORPCM INPUT, INTAKE . . . . . . . . . . 14-58
MANIFOLD, COMPRESSOR . . . . . . . . . . . . . 24-15 MANIFOLD GAUGE SET . . . . . . . . . . . . . . . . . 24-3 MANIFOLD, INTAKE . . . . . . . . . . . . . . 14-47,14-88 MANIFOLD LEAKAGE DIAGNOSIS, INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 MANIFOLD3.9L / 5.2L ENGINES, EXHAUST . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-11 MANIFOLD3.9L / 5.2L ENGINES, INTAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9 MANIFOLDS2.5L ENGINE, INTAKE / EXHAUST . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6 MANUAL BRAKE BLEEDING PROCEDURE, ABS . . . . . . . . . . . . . . . . . . . . . 5-60 MANUAL BRAKE BLEEDING PROCEDURE, RWAL SYSTEM . . . . . . . . . . . . 5-49 MANUAL FIRST GEAR (1), HYDRAULIC FLOW IN . . . . . . . . . . . . . . . . . . . . . . . . . . 21-123 MANUAL SECOND GEAR (2), HYDRAULIC FLOW IN . . . . . . . . . . . . . . . . 21-124 MANUAL STEERING GEAR . . . . . . . . . . . . . . 0-27 MANUAL TRANSMISSION . . . . . . . . . . . . . . . 0-21 MANUAL TRANSMISSION, AX 15 . . . . . . . . . 21-1 MARKER LAMP, FRONT SIDE . . . . . . . . . . . . 8L-9 MARKER LAMP, REAR SIDE . . . . . . . . . . . . 8L-11 MARKINGS, OVERSIZE AND UNDERSIZE ENGINE COMPONENT . . . . . . . . . . . . . 9-112,9-80 MASK REMOVE/INSTALL, CLUSTER LENS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-15 MASTER CYLINDER BLEEDING . . . . . . . . . . . 5-13 MASTER CYLINDER, CLUTCH . . . . . . . . . . . . 0-20 MASTER CYLINDER INSTALLATION . . . . . . . 5-14 MASTER CYLINDER REMOVAL . . . . . . . . . . . 5-13 MASTER CYLINDER RESERVOIR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . 5-13 MASTER CYLINDERBRAKE FLUID BRAKELINES . . . . . . . . . . . . . . . . . . . . . . . . . 5-12 MASTER CYLINDER/POWER BOOSTER TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 MATCH MOUNTING . . . . . . . . . . . . . . . . . . . . 22-8 MATS, CARPETS AND FLOOR . . . . . . . . . . . 23-43 MEASUREMENT AND ADJUSTMENT WITH GAUGE SET, PINION DEPTH . . . . . . . . 3-22 MEASUREMENT AND TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . Intro.-8 MEASUREMENT, UNIVERSAL JOINT ANGLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-4 MEASUREMENT WITH GAUGE SET C-3715-B, DIFFERENTIAL AND PINION . . . . . 2-40 MEASUREMENTS AND ADJUSTMENTS, ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 MEASURING WITH PLASTIGAGE . . . . . . . . . . 9-3 MECHANISM, GEARSHIFT . . . . . . . . . . . . . . 21-88 MECHANISM, SHIFT . . . . . . . . . . . . . . . . . 21-261 MEMORY, RADIO . . . . . . . . . . . . . . . . . . 8W-47-1 METRIC AND ENGLISH/SAE CONVERSION . . . . . . . . . . . . . . . . . . . . . . Intro.-8 METRIC CONVERSION . . . . . . . . . . . . . . Intro.-10 METRIC, THREAD NOTATIONSAE . . . . . Intro.-9 (MFI)COMPONENT DESCRIPTION/ SYSTEM OPERATION3.9L/5.2L ENGINE, MULTI-PORT FUEL INJECTION . . . 14-52 (MFI)COMPONENT REMOVAL/ INSTALLATION3.9L/5.2L ENGINE, MULTI-PORT FUEL INJECTION . . . . . . . . . . 14-83 MINIMUM AIR FLOW CHECK, THROTTLE BODY . . . . . . . . . . . . . . . . . . . . . . . . . 14-36,14-73 MINIMUM THICKNESS, ROTOR . . . . . . . . . . 5-42 MIRROR, AUTOMATIC DAY/NIGHT . . . . 8T-1,8T-2 MIRROR, DAY/NIGHT . . . . . . . . . . . . . . . 8W-44-2 MIRROR, OVERDRIVE LOCKOUT SWITCH REMOVE/INSTALL, HEADLAMP, POWER . . . 8E-19 MIRROR, REARVIEW . . . . . . . . . . . . . . . . . . 23-31 MIRROR REMOVE/INSTALL, AUTOMATIC DAY/NIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . 8T-3 MIRROR REMOVE/INSTALL, POWER . . . . . . 8T-3 MIRROR SUPPORT BRACKET . . . . . . . . . . . 23-31 MIRROR SWITCH, POWER . . . . . . . . . . . . . . 8T-1 MIRROR SWITCH REMOVE/INSTALL, POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8T-3 MIRROR TEST CHART . . . . . . . . . . . . . . . . . . 8T-2 MIRRORS, EXTERIOR . . . . . . . . . . . . . . . . . 23-16 MIRRORS, POWER . . . . . . . . . 8T-1,8T-2,8W-62-1 MISALIGNMENT, CLUTCH . . . . . . . . . . . . . . . . 6-3 MISALIGNMENT, CLUTCH HOUSING . . . . . . . . 6-4 MISALIGNMENT, FLYWHEEL . . . . . . . . . . . . . . 6-3 MISS, INJECTOR DIAGNOSISVEHICLE RUNS ROUGH AND/OR HAS A . . . . . . . . . . 14-77 MODE DOOR VACUUM ACTUATOR . . . . . . . 24-20
MODES OF OPERATION, OPEN LOOP/CLOSED LOOP . . . . . . . . . . . . . 14-28,14-64 MODULE (ACM), AIRBAG CONTROL . . . . 8W-43-1 MODULE, AIRBAG . . . . . . . . . . . . . . . . . . . . 8M-1 MODULE, AIRBAG CONTROL . . . . . . . . . . . . 8M-2 MODULE, BUZZER . . . . . . . . . . . . . . . . 8U-1,8U-2 MODULE, DAYTIME RUNNING LAMP (DRL) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-2 MODULE DIAGNOSIS, ABS/RWAL CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 MODULE (DRLM), DAYTIME RUNNING LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-12 MODULE, FUEL PUMP; FUEL SYSTEM . . . . 14-46, 14-86 MODULE, FUEL PUMP; FUEL/IGNITION . 8W-30-2 MODULE, FUEL PUMP; FUEL/IGNITION 3.9L AND 5.2L ENGINES . . . . . . . . . . . . . 8W-30-7 MODULE HANDLING, AIRBAG . . . . . . . . . . . 8M-3 MODULE INSTALLATION, ABS ELECTRONIC CONTROL . . . . . . . . . . . . . . . . . 5-59 MODULE INSTALLATION, ELECTRONIC CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48 MODULE, INTERMITTENT WIPE . . . . . . . . . . 8K-6 MODULE (PCM) 60-WAY CONNECTOR, POWERTRAIN CONTROL . . . . . . . . . . . . . . . 14-70 MODULE (PCM), POWERTRAIN CONTROL; EMISSION CONTROL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . 25-22 MODULE (PCM), POWERTRAIN CONTROL; FUEL SYSTEM . . . 14-21,14-48,14-56, 14-89 MODULE (PCM), POWERTRAIN CONTROL; IGNITION SYSTEMS . . . . 8D-12,8D-24, 8D-5 MODULE, POWERTRAIN CONTROL . . . 8H-1,8H-7 MODULE REMOVAL, ABS ELECTRONIC CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59 MODULE REMOVAL, ELECTRONIC CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48 MODULE REMOVE/INSTALL, AIRBAG . . . . . 8M-4 MODULE REMOVE/INSTALL, AIRBAG CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . 8M-6 MODULE REMOVE/INSTALL, COMPASS/ THERMOMETER . . . . . . . . . . . . . . . . . . . . . . 8C-6 MODULE REMOVE/INSTALL, LOWER INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . 8E-21 MODULE SCHEMATIC, BUZZER . . . . . . . . . . 8U-3 MODULE, SNOW PLOW CONTROL . . . . . . . 13-17 MODULE TESTING, POWERTRAIN CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . 14-76 MODULE2.5L ENGINE, FUEL PUMP . . . . . 14-3 MODULE3.9L/5.2L ENGINE, FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-3 MODULES REMOVE/INSTALL, LOW FUEL AND TACHOMETER DRIVE . . . . . . . . . . . . . 8E-16 MOTOR AND WHEEL ASSEMBLY, BLOWER . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-23 MOTOR, BLOWER; AIR CONDITIONING/ HEATER . . . . . . . . . . . . . . . . . . 8W-42-1,8W-42-3 MOTOR, BLOWER; HEATING AND AIR CONDITIONING . . . . . . . . . . . . . . . . . . . . . . 24-12 MOTOR, IDLE AIR CONTROL (IAC); FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . 14-46,14-88 MOTOR, IDLE AIR CONTROL (IAC); FUEL/IGNITION . . . . . . . . . . . . . . . . . . . . 8W-30-3 MOTOR, IDLE AIR CONTROL (IAC); FUEL/IGNITION3.9L AND 5.2L ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-8 MOTOR, POWER DOOR LOCK . . . . . . . . . . . 23-29 MOTOR, POWER LOCK . . . . . . . . . . . . . . . . . 8P-1 MOTOR, POWER WINDOW . . . . . . . . . . 8S-1,8S-2 MOTOR, RADIATOR FAN RELAY . . . . . . . 8W-42-2 MOTOR RELAY TEST, STARTER . . . . . . . . . 14-76 MOTOR REMOVE/INSTALL, POWER LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8P-2 MOTOR REMOVE/INSTALL, POWER WINDOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8S-3 MOTOR TEST, IDLE AIR CONTROL (IAC) . . 14-72 MOTOR, WIPER . . . . . . . . . . . . . . . . . . 8K-3,8K-7 MOTORPCM OUTPUT, IDLE AIR CONTROL (IAC) . . . . . . . . . . . . . . . . . 14-27,14-61 MOULDINGS, NAMEPLATES AND DECALS, BODY . . . . . . . . . . . . . . . . . . . . . . 23-10 MOUNT COMPRESSOR BRACKET SERVICE, SOLID . . . . . . . . . . . . . . . . . . . . . . 9-15 MOUNTED STOP LAMP (CHMSL), CENTER HIGH . . . . . . . . . . . . . . . . . . . . . . . 8L-11 MOUNTING, FRONT AXLE . . . . . . . . . . . . . . . 2-47
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INDEX
Group-Page Description Group-Page Description Group-Page
Description
MOUNTING, MATCH . . . . . . . . . . . . . . . . . . . 22-8 MOUNTS, ENGINE . . . . . . . . . . . . . . . . . . . . . 9-13 MOUNTS, ENGINE FRONT . . . . . . . 9-13,9-49,9-82 MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4 MULTI-FUNCTION SWITCH . . . . . . . . . . . . . . 8J-3 MULTI-FUNCTION SWITCH REMOVE/ INSTALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J-4 MULTI-FUNCTION SWITCH SERVICE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . 8L-10 MULTI-FUNCTION SWITCH TESTING PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . 8L-4 MULTI-PORT FUEL INJECTION (MFI)COMPONENT DESCRIPTION/ SYSTEM OPERATION3.9L/5.2L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-52 MULTI-PORT FUEL INJECTION (MFI)COMPONENT REMOVAL/ INSTALLATION3.9L/5.2L ENGINE . . . . . . . 14-83 MULTI-PORT FUEL INJECTION GENERAL DIAGNOSIS3.9L/5.2L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-67 NAMEPLATES AND DECALS, BODY MOULDINGS . . . . . . . . . . . . . . . . . . . . . . . . 23-10 NEUTRAL, HYDRAULIC FLOW IN . . . . . . . 21-116 NO LUBRICATION, COMPONENTS REQUIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-2 NOISE, A/C COMPRESSOR . . . . . . . . . . . . . 24-14 NOISE, CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . 6-9 NOISE COMPLAINT, HISS . . . . . . . . . . . . . . . 19-3 NOISE DIAGNOSIS . . . . . . . . . . . . . . . . . . . . 3-30 NOISE, GEAR AND BEARING; FRONT SUSPENSION AND AXLE . . . . . . . . . . . . . . . . 2-19 . NOISE, GEAR AND BEARING; REAR SUSPENSION AND AXLES . . . . . . . . . . . . . . . . 3-8 NOISE OR VIBRATION, TIRE . . . . . . . . . . . . . 22-4 NOISE SUPPRESSION, RADIO . . . . . . . . . . . . 8F-1 NOISE/VIBRATION DIAGNOSIS, AXLE . . . . . . . 3-8 NO-LEAD FUEL TANK FILLER TUBE . . . . . . 14-14 NORMAL AND FAULT CONDITIONS, ABS SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 NOTATIONSAE AND METRIC, THREAD . Intro.-9 NOTATIONS, SPECIFICATION . . . . . . . . . . Intro.-8 NOTES, CAUTIONS, AND WARNINGS . . . 8W-01-1 NOZZLE/TUBES, FUEL FILLER DOOR . . . . . 23-15 NP231 SERVICE DIAGNOSIS . . . . . . . . . . . 21-263 NP231 TORQUE SPECIFICATIONS . . . . . . . 21-287 NP231 TRANSFER CASE . . . . . . . . 21-260,21-284 NP231 TRANSFER CASE, LEGEND . . . . . . 21-285 NUMBER (VIN) DECODING, VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . Intro.-2 NUMBER (VIN) PLATE, VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . Intro.-1 NUT TIGHTENING, WHEEL . . . . . . . . . . 5-25,5-43 NUT, WHEEL LUG . . . . . . . . . . . . . . . . . . . . 22-12 NV3500 TORQUE SPECIFICATIONS . . . . . . 21-287 OFF ROAD LAMP SWITCH REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . 8L-10 OFF ROAD LAMPS . . . . . . . . . . . . . . . . . . . . . 8L-9 OFF-ROAD LAMPS . . . . . . . . . . . . . . . . . 8W-50-2 OHMSCOOLANT TEMPERATURE SENSOR/INTAKE MANIFOLD AIR TEMPERATURE SENSOR, SENSOR RESISTANCE . . . . . . . . . . . . . . . . . . . . . . . . 14-70 OIL CAPACITIES, A/C REFRIGERANT . . . . . . . 24-6 OIL CHANGE AND FILTER REPLACEMENT, ENGINE . . . . . . . . . . . . . . . . 0-15 OIL COOLERS, AUTOMATIC TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . 7-32 OIL, ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 0-14 OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . 9-45 OIL LUBRICATION SYSTEM . . . . . . . . 9-100,9-68 OIL PAN . . . . . . . . . . . . . . . . . . . . 9-42,9-65,9-97 OIL PRESSURE, CHECKING ENGINE . . . . . . . 9-44 OIL PRESSURE, ENGINE . . . . . . . . . . . . . . . . . 9-7 OIL PRESSURE SENDING UNIT REMOVE/INSTALL . . . . . . . . . . . . . . . . . . . . 8E-16 OIL PUMP . . . . . . . . . . . . . . . . . . . . . . 9-101,9-69 OIL PUMP AND REACTION SHAFT SUPPORT OVERHAUL . . . . . . . . . . 21-154,21-204 OIL PUMP SEAL . . . . . . . . . . . . . . . . . . . . 21-125 OIL PUMP SEAL REPLACEMENT . . . . . . . . 21-139 OIL PUMP SERVICE . . . . . . . . . . . . . . . . . . . 9-42 OIL, REFRIGERANT . . . . . . . . . . . . . . . . . . . . 24-5 OIL SEAL REPLACEMENT, FRONT CRANKSHAFT . . . . . . . . . . . . . . . . . . . . 9-63,9-95 OIL SEALS, CRANKSHAFT REAR . . . . . 9-106,9-74 OIL SEALS SERVICE, CRANKSHAFT . . . . . . . 9-29
ON-BOARD DIAGNOSTIC SYSTEM, USING; BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS . . . . . . . . . . . . . . . 8A-21 ON-BOARD DIAGNOSTIC SYSTEM, USING; VEHICLE SPEED CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H-3 ON-BOARD DIAGNOSTICS; EMISSION CONTROL SYSTEMS . . . . . . . . . . . . . . . . . . . 25-1 ON-BOARD DIAGNOSTICS; IGNITION SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-16 ON-BOARD DIAGNOSTICS (OBD); COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . 7-3 ON-BOARD DIAGNOSTICS (OBD); FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . 14-36,14-76 ONLY, RADIO CHOKE RELAYPREMIUM RADIO . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-1 OPEN CIRCUIT VOLTAGE . . . . . . . . . . . . . . . . 8A-7 OPEN LOOP/CLOSED LOOP MODES OF OPERATION . . . . . . . . . . . . . . . . . . . . 14-28,14-64 OPENER STORAGE COMPARTMENT DOOR REMOVE/INSTALL, GARAGE DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C-8 OPENER STORAGE, REMOTE GARAGE DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C-1 OPERATING RANGES . . . . . . . . . . . . . . . . . 21-261 OPERATING SPECIFICATIONS, PUMP . . . . . . 19-3 OPERATION, ABS . . . . . . . . . . . . . . . . . . . . . 5-54 OPERATION, AIR CONDITIONING . . . . . . 8W-42-1, 8W-42-3 OPERATION, AIR TESTING TRANSMISSION CLUTCH AND BAND . . . . . 21-97 OPERATION AND SERVICE, ABS BRAKE . . . . 5-51 OPERATION AND SERVICE, RWAL BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44 OPERATION, AUTOMATIC TRANSMISSION CONTROLS . . . . . . . . . . . . 21-88 OPERATION, BOOST VALVE . . . . . . . . . . . . . 21-89 OPERATION, COMBINATION VALVE . . . . 5-46,5-55 OPERATION, COMPONENT IDENTIFICATION/SYSTEM . . . . . . . . . . . . . . . 8D-1 OPERATION, OPEN LOOP/CLOSED LOOP MODES OF . . . . . . . . . . . . . . . . . . . . . 14-28,14-64 OPERATION, POWER STEERING PUMP INITIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-16 OPERATION, QUICK FILL VALVE . . . . . . . . . 21-89 OPERATION, RADIO . . . . . . . . . . . . . . . . 8W-47-1 OPERATION, RWAL SYSTEM . . . . . . . . . . . . . 5-45 OPERATION, SYSTEM DESCRIPTION . . . . . . 13-3 OPERATION2.5L ENGINE, SINGLEPORT FUEL INJECTIONCOMPONENT DESCRIPTION/SYSTEM . . . . . . . . . . . . . . . . 14-21 OPERATION3.9L/5.2L ENGINE, MULTI-PORT FUEL INJECTION (MFI)COMPONENT DESCRIPTION/ SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-52 OPTIONAL CLUSTER . . . . . . . . . . . . . . . . . . . 8E-9 ORDER2.5L 4-CYLINDER ENGINE, ENGINE FIRING . . . . . . . . . . . . . . . . . . . . . . 8D-29 ORDER3.9L V-6 ENGINE, ENGINE FIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-29 ORDER5.2L V-8 ENGINE, ENGINE FIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-29 ORNAMENTATION, WHEEL . . . . . . . . . . . . . . 22-7 OUTER CV JOINT . . . . . . . . . . . . . . . . . . . . . 2-26 OUTPUT, AIR CONDITIONING (A/C) CLUTCH RELAYPCM . . . . . . . . . . . 14-25,14-61 OUTPUT, AUTO SHUTDOWN (ASD) RELAYPCM . . . . . . . . . . . . . . . . . . 14-26,14-61 OUTPUT, DATA LINK CONNECTORPCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-57 OUTPUT, EGR (EXHAUST GAS RECIRCULATION) VALVE CONTROL SOLENOIDPCM . . . . . . . . . . . . . . . . . . . . 14-62 OUTPUT, EGR SOLENOIDPCM . . . . . . . . . 14-26 OUTPUT, EMR LAMPPCM . . . . . . . . . . . . 14-62 OUTPUT, EVAP CANISTER PURGE SOLENOIDPCM . . . . . . . . . . . . . . . 14-27,14-62 OUTPUT, FUEL INJECTORPCM . . . . . . . . 14-27 OUTPUT, FUEL INJECTORSPCM . . . . . . . 14-62 OUTPUT, FUEL PUMPPCM . . . . . . . . . . . 14-27 OUTPUT, GENERATOR FIELDPCM . . . . . . 14-61 OUTPUT, GENERATOR LAMPPCM . . . . . . 14-61 OUTPUT, GENERATORPCM . . . . . . . . . . . 14-27 OUTPUT, IDLE AIR CONTROL (IAC) MOTORPCM . . . . . . . . . . . . . . . . . 14-27,14-61 OUTPUT, IGNITION COILPCM . . . . 14-28,14-62 OUTPUT, MALFUNCTION INDICATOR LAMPPCM . . . . . . . . . . . . . . . . . . . 14-28,14-62
OUTPUT, RADIATOR COOLING FAN RELAYPCM . . . . . . . . . . . . . . . . . . . . . . . 14-28 OUTPUT, SCI TRANSMITPCM . . . . . . . . . 14-63 OUTPUT, SHIFT INDICATORPCM . . . . . . . 14-63 OUTPUT, SPEED CONTROLPCM . . . . . . . 14-63 OUTPUT, TACHOMETERPCM . . . . . . . . . . 14-63 OUTPUT TEST, HEATER . . . . . . . . . . . . . . . . . 24-8 OUTS, TAKE . . . . . . . . . . . . . . . . . . . . . . 8W-01-2 OUTSIDE DOOR HANDLE . . . . . . . . . . . . . . 23-27 OVERDRIVE CLUTCH INSTALLATION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . 21-257 OVERDRIVE COMPONENT CLEANING AND INSPECTION . . . . . . . . . . . . . . . . . . . 21-245 OVERDRIVE COMPONENTS, FOURTH GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-86 OVERDRIVE DIAGNOSIS . . 21-109,21-110,21-111 OVERDRIVE FOURTH GEAR ELECTRICAL CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . 21-93 OVERDRIVE GEARTRAIN AND CASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 21-254 OVERDRIVE GEARTRAIN DISASSEMBLY . . 21-240 OVERDRIVE LOCKOUT SWITCH REMOVE/INSTALL, HEADLAMP, POWER MIRROR . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-19 OVERDRIVE PISTON AND RETAINER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . 21-201 OVERDRIVE REMOVAL/INSTALLATION, TRANSMISSION - CONVERTER - . . . . . . . . 21-137 OVERDRIVE SELECTOR SWITCH . . . . . . . . . 21-88 OVERDRIVE SOLENOID . . . . . . . . . . . . . 8W-30-10 OVERDRIVE SWITCH . . . . . . . . . . . . . . . 8W-31-1 OVERDRIVE UNIT DISASSEMBLY . . . . . . . 21-238 OVERDRIVE UNIT INSTALLATION2WHEEL DRIVE . . . . . . . . . . . . . . . . . . . . . . 21-144 OVERDRIVE UNIT INSTALLATION4WHEEL DRIVE . . . . . . . . . . . . . . . . . . . . . . 21-145 OVERDRIVE UNIT OVERHAUL, 42RH/46RH . . . . . . . . . . . . . . . . . . . . . . . . 21-238 OVERDRIVE UNIT REMOVAL2-WHEEL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-143 OVERDRIVE UNIT REMOVAL4-WHEEL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-145 OVERDRIVE/OVERRIDE SWITCH . . . . . . . . . 14-59 OVERHAUL, 42RH TRANSMISSION . . . . . . 21-147 OVERHAUL, 42RH/46RH OVERDRIVE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-238 OVERHAUL, 46RH TRANSMISSION . . . . . . 21-193 OVERHAUL, ACCUMULATOR . . . . . . . . . . . 21-203 OVERHAUL, DIFFERENTIAL . . . . . . . . . . . . . . 3-31 OVERHAUL, FRONT CLUTCH . . . . . 21-159,21-208 OVERHAUL, FRONT SERVO AND BAND . . 21-168, 21-203 OVERHAUL, GOVERNOR . . . . . . . . . . . . . . 21-246 OVERHAUL, OIL PUMP AND REACTION SHAFT SUPPORT . . . . . . . . . . . . . . 21-154,21-204 OVERHAUL OR FLUID/FILTER CHANGE, REFILLING AFTER . . . . . . . . . . . . . . . . . . . 21-126 OVERHAUL, OVERRUNNING CLUTCH . . . . 21-201 OVERHAUL, OVERRUNNING CLUTCH LOW-REVERSE DRUMOVERDRIVE PISTON RETAINER INSPECTION . . . . . . . . 21-154 OVERHAUL, PLANETARY GEAR TRAIN AND INTERMEDIATE SHAFT . . . . . . . . . . . 21-164 OVERHAUL, PLANETARY GEARTRAIN . . . . 21-211 OVERHAUL, REAR CLUTCH . . . . . . 21-161,21-210 OVERHAUL, REAR SERVO . . . . . . . . . . . . . 21-204 OVERHAUL, REAR SERVO AND BAND . . . 21-169 OVERHAUL SERVICE INFORMATION . . . . 21-153, 21-200 OVERHAUL, TRANSFER CASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . 21-267 OVERHAUL, TRANSMISSION DISASSEMBLY; NV3500 MANUAL TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . 21-45 OVERHAUL, TRANSMISSION DISASSEMBLY; TRANSMISSION AND TRANSFER CASE . . . . . . . . . . . . . . . . . . . . . . 21-8 OVERHAUL, WHEEL CYLINDER . . . . . . . . . . . 5-24 OVERHEAD CONSOLE; BODY COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . 23-42 OVERHEAD CONSOLE; OVERHEAD CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . 8W-49-1 OVERHEAD CONSOLE BEZEL REMOVE/ INSTALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C-7 OVERHEAD CONSOLE REMOVE/INSTALL . . . 8C-6 OVERRUNNING CLUTCH OVERHAUL . . . . 21-201
INDEX
Description Group-Page Description Group-Page Description
15
Group-Page
OVERRUNNING CLUTCHLOWREVERSE DRUMOVERDRIVE PISTON RETAINER INSPECTION AND OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . 21-154 OVERSIZE AND UNDERSIZE ENGINE COMPONENT MARKINGS . . . . . . . . . . 9-112,9-80 OXYGEN (O2S) SENSOR; EMISSION CONTROL SYSTEMS . . . . . . . . . . . . . 25-17,25-22 OXYGEN (O2S) SENSOR; FUEL SYSTEM . . 14-47, 14-89 OXYGEN (O2S) SENSOR; IGNITION SYSTEMS . . . . . . . . . . . . . . . . . . . . . . 8D-24,8D-5 OXYGEN (O2S) SENSOR HEATING ELEMENT TEST . . . . . . . . . . . . . . . . . 14-35,14-72 OXYGEN (O2S) SENSORPCM INPUT . . . 14-24, 14-59 OXYGEN SENSOR, HEATED; FUEL/ IGNITION . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-3 OXYGEN SENSOR, HEATED; FUEL/ IGNITION3.9L AND 5.2L ENGINES . . . 8W-30-8 OXYGEN SENSOR (O2S) TESTS . . . . . . . . . 8D-16 PAINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-45 PAINT AND TRIM REPAIR PRODUCTS AFTERMARKET . . . . . . . . . . . . . . . . . . . . . . 23-46 PAINTED SURFACE TOUCH-UP . . . . . . . . . . 23-45 PAN, OIL . . . . . . . . . . . . . . . . . . . . 9-42,9-65,9-97 PANEL AIR LOUVERS . . . . . . . . . . . . . . . . . 24-21 PANEL ASSEMBLY REMOVE/INSTALL, INSTRUMENT . . . . . . . . . . . . . . . . . . . . . . . 8E-23 PANEL BEZEL REMOVE/INSTALL, RIGHT INSTRUMENT . . . . . . . . . . . . . . . . . . . . . . . 8E-21 PANEL END CAP REMOVE/INSTALL, LOWER LEFT INSTRUMENT . . . . . . . . . . . . . 8E-21 . PANEL, INSTRUMENT . . . . . . . . . . . . . . . . . . 8E-1 PANEL MODULE REMOVE/INSTALL, LOWER INSTRUMENT . . . . . . . . . . . . . . . . . 8E-21 PANELS, INTERIOR TRIM . . . . . . . . . . . . . . 23-38 PANEL/WATERDAM/NOISE INSULATOR, DOOR TRIM . . . . . . . . . . . . . . . . . . . . . . . . . 23-24 PARK AND TURN SIGNAL LAMPS . . . . . . . . 8L-9 PARK BRAKE SWITCH INPUT . . . . . . . . . 8W-32-4 PARK, HYDRAULIC FLOW IN . . . . . . . . . . . 21-115 PARK LOCK SERVICE, GOVERNOR . . . . . . 21-125 PARKING BRAKE CABLE TENSIONER ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 5-67 PARKING BRAKE PEDAL INSTALLATION . . . . 5-66 PARKING BRAKE PEDAL REMOVAL . . . . . . . 5-66 PARKING BRAKE PROBLEMS, DIAGNOSING . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 PARKING BRAKES . . . . . . . . . . . . . . . . . . . . . 5-63 PARKING LAMPS . . . . . . . . . . . . . . . . . . 8W-50-1 PARK/NEUTRAL POSITION SWITCH; FUEL/IGNITION3.9L AND 5.2L ENGINES . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-10 PARK/NEUTRAL POSITION SWITCH; NV3500 MANUAL TRANSMISSION . . . . . . 21-130 PARK/NEUTRAL SWITCH . . . . . . . . . . 14-47,14-89 PARK/NEUTRAL SWITCHPCM INPUT . . . 14-60 PARTS INTERCHANGEABILITY, TRANSMISSION CHANGES . . . . . . . . . . . . . 21-87 PARTS RECOMMENDATION, LUBRICATION AND REPLACEMENT . . . . . . . . 0-2 PATTERN, SHIFT . . . . . . . . . . . . . . . . . . . . . . 21-2 PATTERNS, TIRE WEAR . . . . . . . . . . . . . . . . 22-4 PCM SYSTEM SCHEMATICS . . . . . . . 14-36,14-53 PCV/CRANKCASE AIR INLET FILTER . . . . . . . 0-17 PEDAL, ACCELERATOR . . . . . . . . . . . . . . . . 14-18 PEDAL AND THROTTLE CABLE, ACCELERATOR . . . . . . . . . . . . 14-18,14-43,14-83 PEDAL BUSHINGS, CLUTCH AND BRAKE . . . 0-20 PEDAL INSTALLATION, BRAKE . . . . . . . . . . . 5-18 PEDAL INSTALLATION, CLUTCH . . . . . . . . . . 6-13 PEDAL INSTALLATION, PARKING BRAKE . . . 5-66 PEDAL POSITION SWITCH, CLUTCH . . . . . . . . 6-2 PEDAL REMOVAL, BRAKE . . . . . . . . . . . . . . . 5-18 PEDAL REMOVAL, CLUTCH . . . . . . . . . . . . . . 6-13 PEDAL REMOVAL, PARKING BRAKE . . . . . . . 5-66 PEDALSTOPLAMP SWITCH, POWER BRAKE BOOSTERBRAKE . . . . . . . . . . . . . . 5-17 PERFORMANCE, ENGINE . . . . . . . . . . . . . . . . . 9-2 PERFORMANCE (TEMPERATURE AND PRESSURE), A/C . . . . . . . . . . . . . . . . . . . . . . 24-7 PERFORMANCE TEST, AIR CONDITIONING . . . . . . . . . . . . . . . . . . . . . . . 24-7 PERFORMANCE TEST, AIR CONDITIONING AND HEATER . . . . . . . . . . . . 24-7 PICK-UP, DISTRIBUTOR . . . . . . . . . . . . . 8W-30-3
. . . 8D-23, 8D-4 PIECE, REARTWO . . . . . . . . . . . . . . . . . . . 16-9 PILOT BEARING REPLACEMENT . . . . . . . . . . 6-12 PINION DEPTH MEASUREMENT AND ADJUSTMENT WITH GAUGE SET . . . . . . . . . 3-22 PINION GEAR DEPTH VARIANCE; FRONT SUSPENSION AND AXLE . . . . . . . . . . . . . . . . 2-42 PINION GEAR DEPTH VARIANCE; REAR SUSPENSION AND AXLES . . . . . . . . . . . . . . . 3-24 PINION GEAR SHAFT REMOVAL . . . . . . . . . . 2-38 PINION MEASUREMENT WITH GAUGE SET C-3715-B, DIFFERENTIAL . . . . . . . . . . . . 2-40 PINION SEAL REPLACEMENT . . . . . . . . . . . . 3-17 PINION SHAFT SEAL REPLACEMENT . . . . . . 2-34 PINION STEERING GEAR, RACK . . . . . . . . . 19-33 PIPE, EXHAUST . . . . . . . . . . . . . . . . . . . . . . . 11-3 PIPE, EXTENSION . . . . . . . . . . . . . . . . . . . . . 11-4 PISTON / CONNECTING ROD ASSEMBLY . . 9-103, 9-71 PISTON AND CONNECTING ROD ASSEMBLY SERVICE, CYLINDER BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-34 PISTON AND RETAINER SERVICE, OVERDRIVE . . . . . . . . . . . . . . . . . . . . . . . . 21-201 PISTON AND WORM SHAFT REPLACEMENT, RACK . . . . . . . . . . . . . . . . . 19-28 PISTON RETAINER INSPECTION AND OVERHAUL, OVERRUNNING CLUTCHLOW-REVERSE DRUM OVERDRIVE . . . . . . . . . . . . . . . . . . . . . . . . 21-154 PITMAN ARM . . . . . . . . . . . . . . . . . . . . . . . . . 19-17 PITMAN SHAFT AND SIDE COVER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . 19-24 PITMAN SHAFT SEALS AND BEARING REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . 19-30 PITMAN SHAFT SEALS IN CAR REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . 19-19 PIVOT BRACKET, SNOW PLOW . . . . . . . . . . 13-16 PIVOTS REMOVE/INSTALL, WIPER . . . . . . . . 8K-8 PLANETARY GEAR TRAIN AND INTERMEDIATE SHAFT OVERHAUL . . . . . . 21-164 PLANETARY GEARTRAIN OVERHAUL . . . . 21-211 PLASTIC HOSES/TUBING, RUBBER . . . . . . . . 0-24 PLASTIGAGE, MEASURING WITH . . . . . . . . . . 9-3 PLATE, BODY CODE . . . . . . . . . . . . . . . . . Intro.-2 PLATE DECODING, BODY CODE . . . . . . . . Intro.-3 PLATE, EQUIPMENT IDENTIFICATION . . . . Intro.-3 PLATE INSTALLATION, BRAKE SUPPORT . . . 5-23 PLATE LAMPS, LICENSE . . . . . . . . . . . . . . . 8L-11 PLATE LAMPS, TAIL LAMPS AND REAR LICENSE . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-1 PLATE REMOVAL, BRAKE SUPPORT . . . . . . . 5-23 PLATE, VEHICLE IDENTIFICATION NUMBER (VIN) . . . . . . . . . . . . . . . . . . . . . Intro.-1 PLATE-RING GEAR SERVICE, CONVERTER-DRIVE . . . . . . . . . . . . . . . . . . 21-140 PLATES, SKID . . . . . . . . . . . . . . . . . . . . . . . 13-34 PLATE/SNAP RING SPECIFICATIONS, 42RH/46RH SPACER/THRUST . . . . . . . . . . 21-288 PLOW CONTROL MODULE, SNOW . . . . . . . 13-17 PLOW DIAGNOSIS, SNOW . . . . . . . . . . . . . . 13-9 PLOW FRAME, SNOW . . . . . . . . . . . . . . . . . 13-16 PLOW MALFUNCTION DIAGNOSIS AND TESTS, SNOW . . . . . . . . . . . . . . . . . . . . . . . . 13-4 PLOW PIVOT BRACKET, SNOW . . . . . . . . . . 13-16 PLOW, SNOW . . . . . . . . . . . . . . . . . . . . . . . . 13-3 PLOW SPECIFICATIONS, SNOW . . . . . . . . . 13-19 PLOW WIRING DIAGRAMS, SNOW . . . . . . . . 13-4 PLUG ASSEMBLY REPLACEMENT, ADJUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . 19-25 PLUG CABLE RESISTANCE, SPARK . 8D-16,8D-29 PLUG, HOUSING END . . . . . . . . . . . . . . . . . 19-24 PLUG LOCATIONS, DRAIN AND FILL . . . . . 21-40 PLUG LOCATIONS, SWITCH . . . . . . . . . . . . . 21-2 PLUG SECONDARY CABLES, SPARK . . . . . 8D-15, 8D-25 PLUGS, ENGINE CORE . . . . . . . . . . . . . . . . . 9-38 PLUGS, SPARK; IGNITION SYSTEMS . . . . 8D-12, 8D-24,8D-30 PLUGS, SPARK; LUBRICATION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . 0-18 POLISHING, WET SANDING,BUFFING . . . . . 23-45 POOR CONNECTIONS, INTERMITTENT . . 8W-01-4 POSITION SENSOR, CAMSHAFT; FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-84
POSITION SENSOR, CAMSHAFT; FUEL/IGNITION3.9L AND 5.2L ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-8 POSITION SENSOR, CAMSHAFT; IGNITION SYSTEMS . . . . . . . . . . . . . . . . . . 8D-18 POSITION SENSOR, CRANKSHAFT; FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-84 POSITION SENSOR, CRANKSHAFT; FUEL/IGNITION3.9L AND 5.2L ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-9 POSITION SENSOR, CRANKSHAFT; IGNITION SYSTEMS . . . . . . . . . . . . . . . . . . 8D-19 POSITION SENSOR TEST, CAMSHAFT . . . . . 8D-6 POSITION SENSOR TEST, CRANKSHAFT; FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 14-72 POSITION SENSOR TEST, CRANKSHAFT; IGNITION SYSTEMS . . . . . . . . . . . . . . . . . . . 8D-7 POSITION SENSOR TEST, THROTTLE . . . . . 8D-16 POSITION SENSOR TESTING, CAMSHAFT . 14-70 POSITION SENSOR, THROTTLE; FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-50 POSITION SENSOR, THROTTLE; FUEL/IGNITION . . . . . . . . . . . . . . . . . . . . 8W-30-4 POSITION SENSOR, THROTTLE; FUEL/IGNITION3.9L AND 5.2L ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-9 POSITION SENSOR, THROTTLE; IGNITION SYSTEMS . . . . . . . . . . . . . . . . . . . 8D-5 POSITION SENSOR (TPS) TEST, THROTTLE . . . . . . . . . . . . . . . . . . . . . . . . . . 14-72 POSITION SENSOR (TPS), THROTTLE; FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 14-90 POSITION SENSOR (TPS), THROTTLE; IGNITION SYSTEMS. . . . . . . . . . . . . . . . . . . 8D-26 . POSITION SENSOR (TPS)PCM INPUT, THROTTLE . . . . . . . . . . . . . . . . . . . . . 14-25,14-60 POSITION SENSOR3.9L/5.2L ENGINE, CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-2 POSITION SENSOR3.9L/5.2L ENGINE, CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . 8D-2 POSITION SENSORPCM INPUT, CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . 14-57 POSITION SENSORPCM INPUT, CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . 14-58 POSITION SWITCH, CLUTCH PEDAL . . . . . . . . 6-2 POSITION SWITCH, PARK/NEUTRAL; FUEL/IGNITION3.9L AND 5.2L ENGINES . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-10 POSITION SWITCH, PARK/NEUTRAL; NV3500 MANUAL TRANSMISSION . . . . . . 21-130 POSITIVE CRANKCASE VENTILATION (PCV) SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 25-6 POWER ANGLING CYLINDER SERVICE . . . . 13-16 POWER BOOSTER CHECK VALVE TEST . . . . . 5-7 POWER BOOSTER VACUUM TEST . . . . . . . . . 5-7 POWER BRAKE BOOSTER INSTALLATION . . 5-18 POWER BRAKE BOOSTER REMOVAL . . . . . . 5-17 POWER BRAKE BOOSTERBRAKE PEDALSTOPLAMP SWITCH . . . . . . . . . . . . 5-17 POWER BRAKE SYSTEM . . . . . . . . . . . . . . . . 0-27 POWER (DEVICE) GROUND; FUEL/ IGNITION . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-5 POWER (DEVICE) GROUND; FUEL/ IGNITION3.9L AND 5.2L ENGINES . . 8W-30-11 POWER DOOR LOCK MOTOR . . . . . . . . . . . 23-29 POWER DOOR LOCKS . . . . . . . . . . . . . . 8W-61-1 POWER GROUND . . . . . . . . . . . . . . . . . . . . 14-60 POWER LOCK MOTOR . . . . . . . . . . . . . . . . . 8P-1 POWER LOCK MOTOR REMOVE/INSTALL . . 8P-2 POWER LOCK SWITCH . . . . . . . . . . . . . . . . . 8P-1 POWER LOCK SWITCH REMOVE/ INSTALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8P-2 POWER MIRROR, OVERDRIVE LOCKOUT SWITCH REMOVE/INSTALL, HEADLAMP . . . . . . . . . . . . . . . . . . . . . . . . . 8E-19 POWER MIRROR REMOVE/INSTALL . . . . . . . 8T-3 POWER MIRROR SWITCH . . . . . . . . . . . . . . . 8T-1 POWER MIRROR SWITCH REMOVE/ INSTALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8T-3 POWER MIRRORS . . . . . . . . . 8T-1,8T-2,8W-62-1 POWER RELAY, ABS . . . . . . . . . . . . . . . . 8W-32-2 POWER STEERING GEAR, RECIRCULATING BALL . . . . . . . . . . . . . . . . 19-19 POWER STEERING GEAR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . 19-32 POWER STEERING PUMP . . . . . . . . . . . . . . 19-12 POWER STEERING PUMP FLOW RATE AND PRESSURE TEST . . . . . . . . . . . . . . . . . . 19-3
16
INDEX
Group-Page Description Group-Page Description Group-Page
Description
POWER STEERING PUMP INITIAL OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 19-16 POWER STEERING SYSTEM . . . . . . . . . . . . . 0-26 POWER STEERING SYSTEM DIAGNOSIS . . . 19-3, 19-4,19-5,19-6,19-7,19-8,19-9 POWER UNIT . . . . . . . . . . . . . . . . . . . . . . . . 13-13 POWER WINDOW MOTOR . . . . . . . . . . 8S-1,8S-2 POWER WINDOW MOTOR REMOVE/ INSTALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8S-3 POWER WINDOW SWITCH . . . . . . . . . . . . . . 8S-1 POWER WINDOW SWITCH REMOVE/ INSTALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8S-3 POWER WINDOWS . . . . . . . . . . . . . . . . . 8W-60-1 POWERTRAIN CONTROL MODULE . . . . 8H-1,8H-7 POWERTRAIN CONTROL MODULE (PCM); EMISSION CONTROL SYSTEMS . . . 25-22 POWERTRAIN CONTROL MODULE (PCM); FUEL SYSTEM . . 14-21,14-48,14-56,14-89 POWERTRAIN CONTROL MODULE (PCM); IGNITION SYSTEMS . . . 8D-12,8D-24,8D-5 POWERTRAIN CONTROL MODULE (PCM) 60-WAY CONNECTOR . . . . . . . . . . . . . . . . . 14-70 POWERTRAIN CONTROL MODULE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-76 PRE-ALIGNMENT INSPECTION . . . . . . . . . . . . 2-4 PRECAUTIONS . . . . . . . . . . . . . . . 16-10,16-3,16-8 PRECAUTIONS AND WARNINGS, SAFETY; BODY COMPONENTS . . . . . . . . . . 23-32 PRECAUTIONS AND WARNINGS, SAFETY; FRAME AND BUMPERS . . . . . . . . . 13-20 PRECAUTIONS, BRAKE SAFETY . . . . . . . . . . . . . 5-2 PRECAUTIONS, SERVICE . . . . . . . . . . . . . . . . 24-4 PRECAUTIONS, WARNINGS, CAUTIONS AND SERVICE . . . . . . . . . . . . . . . . . . . . . . . . 24-3 PRELIMINARY BRAKE CHECK . . . . . . . . . . . . . 5-3 PRELIMINARY CHECKS . . . . . . . . . . . . . . . . . . 7-4 PRELIMINARY DIAGNOSIS . . . . . . . . . . . . . 21-91 PREPARATION, HEADLAMP ALIGNMENT . . . 8L-6 PRESSURE AND RETURN HOSE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . 19-12 PRESSURE CAP, RADIATOR . . . . . . . . . . . . . 7-27 PRESSURE, CHECKING ENGINE OIL . . . . . . . 9-44 PRESSURE DIAGNOSIS . . . . . . . . . . . . . . . . . 24-8 PRESSURE, ENGINE OIL . . . . . . . . . . . . . . . . . 9-7 PRESSURE GAUGES . . . . . . . . . . . . . . . . . . . 22-2 PRESSURE LEAK DOWN TEST3.9L/ 5.2L ENGINE, FUEL . . . . . . . . . . . . . . . . . . . . 14-9 PRESSURE LEAKAGE TEST, CYLINDER COMBUSTION . . . . . . . . . . . . . . . . . . . . . . . . . 9-6 PRESSURE (MAP) SENSOR, MANIFOLD ABSOLUTE; FUEL SYSTEM . . . . . . . . 14-47,14-88 PRESSURE (MAP) SENSOR, MANIFOLD ABSOLUTE; IGNITION SYSTEMS . . . . 8D-24,8D-5 PRESSURE (MAP) SENSOR TEST, MANIFOLD ABSOLUTE; FUEL SYSTEM . . . . 14-71 PRESSURE (MAP) SENSOR TEST, MANIFOLD ABSOLUTE; IGNITION SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-12 PRESSURE (MAP) SENSORPCM INPUT, MANIFOLD ABSOLUTE . . . . . 14-24,14-59 PRESSURE REGULATION . . . . . . . . . . . . . . 21-89 PRESSURE REGULATOR, FUEL . . . . 14-30,14-45, 14-64,14-85 PRESSURE REGULATOR, FUEL FILTER/FUEL . . . . . . . . . . . . . . . . . . . . . . . . . 14-5 PRESSURE RELEASE, FUEL SYSTEM . . . . . . 14-7 PRESSURE RELEASE PROCEDURE, FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . 14-46,14-87 PRESSURE RELIEF VALVE, HIGH . . . . . . . . 24-13 PRESSURE RELIEF/ROLLOVER VALVE . . . . 25-22, 25-5 PRESSURE RELIEF/ROLLOVER VALVE, FUEL TANK . . . . . . . . . . . . . . . 14-16,14-46,14-87 PRESSURE SENDING UNIT REMOVE/ INSTALL, OIL . . . . . . . . . . . . . . . . . . . . . . . . 8E-16 PRESSURE SENSOR, MANIFOLD ABSOLUTE; FUEL/IGNITION . . . . . . . . . . 8W-30-4 PRESSURE SENSOR, MANIFOLD ABSOLUTE; FUEL/IGNITION3.9L AND 5.2L ENGINES . . . . . . . . . . . . . . . . . . . . . 8W-30-9 PRESSURE TEST, CYLINDER COMPRESSION . . . . . . . . . . . . . . . . . . . . . . . . 9-5 PRESSURE TEST, FUEL PUMP . . . . . . . . . . 14-76 PRESSURE TEST, HYDRAULIC . . . . . . . . . . 21-94 PRESSURE TEST, POWER STEERING PUMP FLOW RATE . . . . . . . . . . . . . . . . . . . . 19-3 PRESSURE TEST SPECIFICATIONS, 42RH/46RH . . . . . . . . . . . . . . . . . . . . . . . . 21-289
PRESSURE TESTING RADIATOR CAPS . . . . . 7-28 PRESSURE TEST2.5L ENGINE, FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-8 PRESSURE TEST3.9L/5.2L ENGINE, FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 14-8 PRESSURES, TIRE INFLATION . . . . . . . . . . . 22-2 PRINTED CIRCUIT REMOVE/INSTALL . . . . . 8E-19 PROBLEM CAUSES, CLUTCH . . . . . . . . . . . . . 6-3 PROBLEMS, DIAGNOSING PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 PROBLEMS, DIAGNOSING SERVICE BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4 PROBLEMS, TROUBLESHOOTING WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-01-5 PROPELLER SHAFT AND UNIVERSAL JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-15 PROPELLER SHAFT REPLACEMENT . . . . . . . 16-8 PROPELLER SHAFTS . . . . . . . . . . . . . . . . . . . 16-1 PULLEY REPLACEMENT, DRIVE . . . . . . . . . 19-15 PUMP AND REACTION SHAFT SUPPORT OVERHAUL, OIL . . . . . . . . . . . . . . . 21-154,21-204 PUMP BYPASS HOSE3.9L/5.2L ENGINE, WATER . . . . . . . . . . . . . . . . . . . . . . 7-17 PUMP CAPACITY TEST3.9L/5.2L ENGINE, FUEL . . . . . . . . . . . . . . . . . . . . . . . . 14-9 PUMP CONTROL, FUEL . . . . . . . . . . . . . . . . . 14-4 PUMP FLOW RATE AND PRESSURE TEST, POWER STEERING . . . . . . . . . . . . . . . 19-3 PUMP INITIAL OPERATION, POWER STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . 19-16 PUMP LEAKAGE DIAGNOSIS . . . . . . . . . . . . . 19-10 PUMP MODULE, FUEL; FUEL SYSTEM . . . . 14-46, 14-86 PUMP MODULE, FUEL; FUEL/IGNITION . 8W-30-2 PUMP MODULE, FUEL; FUEL/IGNITION 3.9L AND 5.2L ENGINES . . . . . . . . . . . . . 8W-30-7 PUMP MODULE2.5L ENGINE, FUEL . . . . . 14-3 PUMP MODULE3.9L/5.2L ENGINE, FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-3 PUMP, OIL . . . . . . . . . . . . . . . . . . . . . . 9-101,9-69 PUMP OPERATING SPECIFICATIONS . . . . . . 19-3 PUMP, POWER STEERING . . . . . . . . . . . . . . 19-12 PUMP PRESSURE TEST, FUEL . . . . . . . . . . 14-76 PUMP RELAY, FUEL; FUEL SYSTEM . 14-46,14-86 PUMP RELAY, FUEL; FUEL/IGNITION 3.9L AND 5.2L ENGINES . . . . . . . . . . . . . 8W-30-7 PUMP REMOVE/INSTALL, WASHER . . . . . . 8K-10 PUMP REPLACEMENT 4 CYLINDER ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-13 PUMP REPLACEMENT V-6 AND V-8 . . . . 19-13 PUMP SEAL, OIL . . . . . . . . . . . . . . . . . . . . 21-125 PUMP SEAL REPLACEMENT, OIL . . . . . . . 21-139 PUMP SERVICE, OIL . . . . . . . . . . . . . . . . . . . 9-42 PUMP, STEERING . . . . . . . . . . . . . . . . . . . . 19-42 PUMP, WASHER . . . . . . . . . . . . . . . . . . . . . . 8K-6 PUMPPCM OUTPUT, FUEL . . . . . . . . . . . 14-27 PUMPREMOVAL/INSTALLATION, FUEL . . 14-16 PUMPSGENERAL INFORMATION, WATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12 PUMPSREMOVAL/INSTALLATION, WATER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12 PURGE SOLENOID, EVAP CANISTER; EMISSION CONTROL SYSTEMS . . . . . . . . . . 25-5 PURGE SOLENOID, EVAP CANISTER; FUEL SYSTEM . . . . . . . . . . . . . . . . . . 14-44,14-85 PURGE SOLENOID2.5L ENGINE, EVAP CANISTER . . . . . . . . . . . . . . . . . . . . . . . . . . 25-21 PURGE SOLENOIDPCM OUTPUT, EVAP CANISTER . . . . . . . . . . . . . . . . . . . . . 14-27,14-62 PUSH RODS, ROCKER ARMS . . . . . . . . 9-54,9-87 QUARTER VENT WINDOWCLUB CAB . . . 23-33 QUICK FILL VALVE OPERATION . . . . . . . . . . 21-89 QUICK-CONNECT FITTINGS . . . 14-10,14-48,14-89 RACK AND PINION STEERING GEAR . . . . . 19-33 RACK PISTON AND WORM SHAFT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . 19-28 RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29 RADIATOR CAPS, PRESSURE TESTING . . . . 7-28 RADIATOR COOLING FAN RELAYPCM OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-28 RADIATOR FAN RELAY AND MOTOR . . . 8W-42-2 RADIATOR PRESSURE CAP . . . . . . . . . . . . . . 7-27 RADIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-2 RADIO AND SPEAKER CONNECTORS . . . . . . 8F-4 RADIO CHOKE RELAYPREMIUM RADIO ONLY . . . . . . . . . . . . . . . . . . . . . . 8W-47-1 RADIO DIAGNOSIS CHART . . . . . . . . . . . . . . 8F-3 RADIO FREQUENCY INTERFERENCE . . . . . . . 8F-6
RADIO ILLUMINATION . . . . . . . . . . . . . . 8W-47-1 RADIO MEMORY . . . . . . . . . . . . . . . . . . . 8W-47-1 RADIO NOISE SUPPRESSION . . . . . . . . . . . . 8F-1 RADIO ONLY, RADIO CHOKE RELAY PREMIUM . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-1 RADIO OPERATION . . . . . . . . . . . . . . . . . 8W-47-1 RADIO REMOVE/INSTALL . . . . . . . . . . . . . . . 8F-7 RADIO, SPEAKERSPREMIUM . . . . . . . 8W-47-1 RADIO, SPEAKERSSTANDARD . . . . . . 8W-47-1 RADIOS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8F-1 RAIL, FUEL . . . . . . . . . . . . . . . . . . . . 14-63,14-86 RAMP ANGLE, GROUND CLEARANCE . . . . . . 0-11 RANGES, OPERATING . . . . . . . . . . . . . . . . 21-261 RATE AND PRESSURE TEST, POWER STEERING PUMP FLOW . . . . . . . . . . . . . . . . 19-3 RATE, CHARGE . . . . . . . . . . . . . . . . . . . . . . . 8A-9 RATINGS, BATTERY CLASSIFICATIONS; BATTERY/STARTER/GENERATOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-9 RATINGS, BATTERY CLASSIFICATIONS; BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS . . . . . . . . . . . . . . . 8A-22 RATINGS, GENERATOR; BATTERY/ STARTER/GENERATOR SERVICE . . . . . . . . . 8B-10 RATINGS, GENERATOR; BATTERY/ STARTING/CHARGING SYSTEMS DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . 8A-23 RATIOS, GEAR; NV3500 MANUAL TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . 21-83 RATIOS, GEAR; TRANSMISSION AND TRANSFER CASE . . . . . . . . . . . . . . . . . . . . . . 21-2 . RATIOS, TRANSMISSION GEAR . . . . . . . . . 21-40 REACTION SHAFT SUPPORT OVERHAUL, OIL PUMP . . . . . . . . . . . . . . . . . . . 21-154,21-204 READING AND COURTESY LAMPS . . . . . . . . 8C-1 READING/COURTESY LAMPS . . . . . . . . . . . . 8C-8 REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-8 REAR ANTI-LOCK VALVE . . . . . 8W-32-2,8W-32-4 REAR ANTILOCK VALVE INSTALLATION . . . . 5-47, 5-57 REAR ANTILOCK VALVE REMOVAL . . . . 5-46,5-56 REAR AXLE ALIGNMENT . . . . . . . . . . . . . . . . . 3-9 REAR AXLES, FRONT . . . . . . . . . . . . . . . . . . 0-23 REAR BAND ADJUSTMENT . . . . . . . . . . . . 21-129 REAR BAND SERVICE, LOW-REVERSE DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-201 REAR BRAKE SPEED SENSOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 5-59 REAR BRAKE SPEED SENSOR REMOVAL (ALL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59 REAR BUMPER . . . . . . . . . . . . . . . . . . . . . . . 13-1 REAR CABLE INSTALLATION . . . . . . . . . . . . . 5-66 REAR CABLE REMOVAL . . . . . . . . . . . . . . . . 5-66 REAR CLUTCH OVERHAUL . . . . . . 21-161,21-210 REAR DRUM BRAKE ADJUSTMENT . . . . . . . 5-24 REAR LICENSE PLATE LAMPS, TAIL LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-1 REAR OIL SEALS, CRANKSHAFT . . . . . 9-106,9-74 REAR SEAT STORAGE BOXES, FLOOR CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-43 REAR SERVO AND BAND OVERHAUL . . . . 21-169 REAR SERVO OVERHAUL . . . . . . . . . . . . . 21-204 REAR SIDE MARKER LAMP . . . . . . . . . . . . 8L-11 REAR SUPPORT, ENGINE . . . . . . . 9-13,9-51,9-84 REAR SUSPENSION2WD AND 4WD VEHICLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 REAR WHEEL ANTI-LOCK (RWAL) BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . 8W-32-3 REAR WHEEL SPEED SENSOR . . . . . . . . 8W-32-3 REAR WINDOWCLUB CAB . . . . . . . . . . . . 23-34 REAR WINDOWCONVENTIONAL CAB . . . 23-35 REARTWO PIECE . . . . . . . . . . . . . . . . . . . . 16-9 REARVIEW MIRROR . . . . . . . . . . . . . . . . . . 23-31 RECEIVEPCM INPUT, SCI . . . . . . . . . . . . 14-60 RECEIVER ASSEMBLY REMOVE/INSTALL, ASH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-20 RECEIVER LAMP AND CIGAR LAMP, ASH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-1 RECIRCULATING AIR VACUUM ACTUATOR . . . . . . . . . . . . . . . . . . . . . . . . . . 24-20 RECIRCULATING BALL POWER STEERING GEAR . . . . . . . . . . . . . . . . . . . . . 19-19 RECIRCULATION (EGR), EXHAUST GAS . . . . 11-2 RECOMMENDATION, LUBRICATION AND REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . 0-2 RECOMMENDATIONS, ABS BRAKE BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-60 RECOMMENDATIONS, HOISTING . . . . . . . . . 0-10
INDEX
Description Group-Page Description Group-Page Description
17
Group-Page
RECOMMENDATIONS, TOWING . . . . . . . . . . . 0-10 RECOMMENDED BRAKE FLUID . . . . . . . . . . . 5-12 RECOMMENDED FLUID . . . . . . . . . . 21-125,21-86 RECOMMENDED LUBRICANT; NV3500 MANUAL TRANSMISSION . . . . . . . . . . . . . 21-262 RECOMMENDED LUBRICANT; TRANSMISSION AND TRANSFER CASE . . . . 21-2 RECOVERING REFRIGERANT SYSTEM . . . . . 24-5 REFERENCE, TEMPERATURE . . . . . . . . . . . . . 24-9 REFILLING AFTER OVERHAUL OR FLUID/FILTER CHANGE . . . . . . . . . . . . . . . 21-126 REFILLING COOLING SYSTEM . . . . . . . . . . . 7-24 REFINISH LIMITS, BRAKE DRUM . . . . . . . . . 5-22 REFINISHING, BRAKE DRUM . . . . . . . . . . . . 5-22 REFINISHING, ROTOR . . . . . . . . . . . . . . . . . . 5-42 REFRIGERANT . . . . . . . . . . . . . . . . . . . . . . . . 24-2 REFRIGERANT EQUIPMENT . . . . . . . . . . . . . . 24-3 REFRIGERANT, LEAK TESTING . . . . . . . . . . . 24-5 REFRIGERANT LINES . . . . . . . . . . . . . . . . . 24-19 REFRIGERANT OIL . . . . . . . . . . . . . . . . . . . . 24-5 REFRIGERANT OIL CAPACITIES, A/C . . . . . . . 24-6 REFRIGERANT SERVICE . . . . . . . . . . . . . . . . 24-5 REFRIGERANT SYSTEM, CHARGING . . . . . . . 24-5 REFRIGERANT SYSTEM, EVACUATING . . . . . 24-5 REFRIGERANT SYSTEM, RECOVERING . . . . . 24-5 REGULATION, PRESSURE . . . . . . . . . . . . . . 21-89 REGULATOR, FUEL FILTER/FUEL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . 14-5 REGULATOR, FUEL PRESSURE . . . . 14-30,14-45, 14-64,14-85 RELAY, ABS POWER . . . . . . . . . . . . . . . . 8W-32-2 RELAY, A/C CLUTCH . . . . . . . . . . . . . . . . . . 14-43 RELAY, AIR CONDITIONING (A/C) CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-83 RELAY AND MOTOR, RADIATOR FAN . . . 8W-42-2 RELAY, AUTOMATIC SHUT DOWN (ASD); FUEL/IGNITION . . . . . . . . . . . . . . . . . . . . 8W-30-2 RELAY, AUTOMATIC SHUT DOWN (ASD); FUEL/IGNITION3.9L AND 5.2L ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-6 RELAY, AUTOMATIC SHUTDOWN (ASD); FUEL SYSTEM . . . . . . . . . . . . . . . . . . 14-43,14-84 RELAY, AUTOMATIC SHUTDOWN (ASD); IGNITION SYSTEMS . . . . . . . . . . . . . . 8D-18,8D-1 RELAY CONNECTIONS, STARTER . . . . . . . . 8A-15 RELAY, FILTER CHOKE/SPEAKER . . . . . . 8F-1,8F-5 RELAY, FUEL PUMP; FUEL SYSTEM . 14-46,14-86 RELAY, FUEL PUMP; FUEL/IGNITION 3.9L AND 5.2L ENGINES . . . . . . . . . . . . . 8W-30-7 RELAY, HORN . . . . . . . . . . . . . . . . . . . . 8G-1,8G-2 RELAY REMOVE/INSTALL, FILTER CHOKE/SPEAKER . . . . . . . . . . . . . . . . . . . . . . 8F-8 RELAY REMOVE/INSTALL, STARTER . . . . . . . 8B-6 RELAY, STARTER AND STARTER . . . . . . . . . . 8B-4 RELAY TEST, AUTOMATIC SHUTDOWN (ASD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-6 RELAY TEST, STARTER MOTOR . . . . . . . . . 14-76 RELAY, TIME DELAY . . . . . . . . . . . . . . . . 8W-44-1 RELAYPCM OUTPUT, AIR CONDITIONING (A/C) CLUTCH . . . . . 14-25,14-61 RELAYPCM OUTPUT, AUTO SHUTDOWN (ASD) . . . . . . . . . . . . . . 14-26,14-61 RELAYPCM OUTPUT, RADIATOR COOLING FAN . . . . . . . . . . . . . . . . . . . . . . . 14-28 RELAYPREMIUM RADIO ONLY, RADIO CHOKE . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-1 RELAYSOPERATION/TESTING . . . . . . . . . 14-74 RELEASE BEARING REPLACEMENT . . . . . . . 6-12 RELEASE CABLE, HOOD INSIDE . . . . . . . . . . 23-5 RELEASE, FUEL SYSTEM PRESSURE . . . . . . 14-7 RELEASE, IMPROPER CLUTCH . . . . . . . . . . . . 6-7 RELEASE OR ENGAGEMENT, IMPROPER CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 RELEASE PROCEDURE, FUEL SYSTEM PRESSURE . . . . . . . . . . . . . . . . . . . . 14-46,14-87 RELIEF VALVE, HIGH PRESSURE . . . . . . . . 24-13 RELIEF/ROLLOVER VALVE, FUEL TANK PRESSURE . . . . . . . . . . . . . . . 14-16,14-46,14-87 RELIEF/ROLLOVER VALVE, PRESSURE . . . 25-22, 25-5 REMOTE GARAGE DOOR OPENER STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C-1 REMOVAL (2-WHEEL DRIVE MODELS), FRONT BRAKE SPEED SENSOR . . . . . . . . . . 5-58 REMOVAL (2-WHEEL DRIVE), TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . 21-42 REMOVAL (4-WHEEL DRIVE MODELS), FRONT BRAKE SPEED SENSOR . . . . . . . . . . 5-59
REMOVAL (4-WHEEL DRIVE), TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . 21-43 REMOVAL, ABS ELECTRONIC CONTROL MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59 REMOVAL (ALL), REAR BRAKE SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59 REMOVAL, BLIND RIVET . . . . . . . . . . . . . . . 23-23 REMOVAL, BRAKE DRUM . . . . . . . . . . . . . . . 5-20 REMOVAL, BRAKE PEDAL . . . . . . . . . . . . . . . 5-18 REMOVAL, BRAKE SUPPORT PLATE . . . . . . . 5-23 REMOVAL, BRAKESHOE . . . . . . . . 5-20,5-28,5-35 REMOVAL, CALIPER . . . . . . . . . . . . . . . 5-30,5-37 REMOVAL, CLUTCH COVER AND DISC . . . . . 6-10 REMOVAL, CLUTCH HYDRAULIC LINKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 REMOVAL, CLUTCH PEDAL . . . . . . . . . . . . . . 6-13 REMOVAL, COMBINATION VALVE . . . . . 5-47,5-57 REMOVAL, DIFFERENTIAL CASE . . . . . . . . . . 2-37 REMOVAL, ELECTRONIC CONTROL MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48 REMOVAL, FRONT ANTILOCK VALVE . . . . . . 5-55 REMOVAL, FRONT CABLE . . . . . . . . . . . . . . . 5-63 REMOVAL, INTERMEDIATE CABLE . . . . . . . . 5-66 REMOVAL, MASTER CYLINDER . . . . . . . . . . 5-13 REMOVAL, PARKING BRAKE PEDAL . . . . . . . 5-66 REMOVAL, PINION GEAR SHAFT . . . . . . . . . 2-38 REMOVAL, POWER BRAKE BOOSTER . . . . . . 5-17 REMOVAL, REAR ANTILOCK VALVE . . . . . 5-46,5-56 REMOVAL, REAR CABLE . . . . . . . . . . . . . . . . 5-66 REMOVAL, ROTOR . . . . . . . . . . . . . . . . . . . . 5-41 REMOVAL, SPEED SENSOR . . . . . . . . . . . . . 5-48 REMOVAL, TRANSFER CASE . . . . . . . . . . . 21-266 REMOVAL, WHEEL CYLINDER . . . . . . . . . . . 5-24 REMOVAL/DISASSEMBLY . . . . . . . . . . . . . . 16-10 REMOVAL/INSTALLATION, BELT . . . . . . . . . . 7-43 REMOVAL/INSTALLATION, COMPONENT; EMISSION CONTROL SYSTEMS . . . . . . . . . 25-18 REMOVAL/INSTALLATION, COMPONENT; IGNITION SYSTEMS . . . . . . . . . . . . . . . . . . 8D-18 REMOVAL/INSTALLATION, SHAFT . . . . . . . . . 2-24 REMOVAL/INSTALLATION, TRANSMISSION - CONVERTER OVERDRIVE . . . . . . . . . . . . . . . . . . . . . . . . 21-137 REMOVAL/INSTALLATION2.5L ENGINE, SINGLE-PORT FUEL INJECTION COMPONENT . . . . . . . . . . . . . . . . . . . . . . . . 14-43 REMOVAL/INSTALLATION3.9L/5.2L ENGINE, MULTI-PORT FUEL INJECTION (MFI)COMPONENT . . . . . . . . . . . . . . . . . . 14-83 REMOVAL2-WHEEL DRIVE, OVERDRIVE UNIT . . . . . . . . . . . . . . . . . . . 21-143 REMOVAL2-WHEEL DRIVE, TRANSMISSION; NV3500 MANUAL TRANSMISSION . . . . . . . . . . . . . . . . . . . . . 21-137 REMOVAL2-WHEEL DRIVE, TRANSMISSION; TRANSMISSION AND TRANSFER CASE . . . . . . . . . . . . . . . . . . . . . . 21-4 REMOVAL4-WHEEL DRIVE, OVERDRIVE UNIT . . . . . . . . . . . . . . . . . . . 21-145 REMOVAL4-WHEEL DRIVE, TRANSMISSION; NV3500 MANUAL TRANSMISSION . . . . . . . . . . . . . . . . . . . . . 21-139 REMOVAL4-WHEEL DRIVE, TRANSMISSION; TRANSMISSION AND TRANSFER CASE . . . . . . . . . . . . . . . . . . . . . . 21-5 REMOVE/INSTALL, A/C-HEATER CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-20 REMOVE/INSTALL, AIRBAG CONTROL MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8M-6 REMOVE/INSTALL, AIRBAG MODULE . . . . . 8M-4 REMOVE/INSTALL, ANTENNA . . . . . . . . . . . . 8F-9 REMOVE/INSTALL, ASH RECEIVER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-20 REMOVE/INSTALL, AUTOMATIC DAY/NIGHT MIRROR . . . . . . . . . . . . . . . . . . . 8T-3 REMOVE/INSTALL, BATTERY . . . . . . . . . . . . . 8B-1 REMOVE/INSTALL, CIGAR LIGHTER . . . . . . 8E-21 REMOVE/INSTALL, CLOCKSPRING . . . . . . . . 8M-6 REMOVE/INSTALL, CLUSTER BEZEL . . . . . . 8E-15 REMOVE/INSTALL, CLUSTER BULBS . . . . . 8E-17 REMOVE/INSTALL, CLUSTER LENS AND MASK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-15 REMOVE/INSTALL, COMPASS/ THERMOMETER MODULE . . . . . . . . . . . . . . . 8C-6 REMOVE/INSTALL, CUP HOLDER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-21 REMOVE/INSTALL, FILTER CHOKE/ SPEAKER RELAY . . . . . . . . . . . . . . . . . . . . . . 8F-8
REMOVE/INSTALL, GARAGE DOOR OPENER STORAGE COMPARTMENT DOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C-8 REMOVE/INSTALL, GAUGES . . . . . . . . . . . . 8E-16 REMOVE/INSTALL, GEAR SELECTOR INDICATOR . . . . . . . . . . . . . . . . . . . . . . . . . 8E-20 REMOVE/INSTALL, GLOVE BOX . . . . . . . . . 8E-21 REMOVE/INSTALL, GLOVE BOX LAMP AND SWITCH . . . . . . . . . . . . . . . . . . . . . . . . 8E-21 REMOVE/INSTALL, GLOVE BOX LOCK . . . . 8E-21 REMOVE/INSTALL, HEADLAMP, POWER MIRROR, OVERDRIVE LOCKOUT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-19 REMOVE/INSTALL, HORN . . . . . . . . . . . . . . . 8G-4 REMOVE/INSTALL, HORN SWITCH . . . . . . . . 8G-3 REMOVE/INSTALL, IMPACT SENSOR . . . . . . 8M-4 REMOVE/INSTALL, INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-15 REMOVE/INSTALL, INSTRUMENT PANEL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-23 REMOVE/INSTALL, KNEE BLOCKER . . . . . . 8E-19 REMOVE/INSTALL, LINKAGE . . . . . . . . . . . . . 8K-8 REMOVE/INSTALL, LOW FUEL AND TACHOMETER DRIVE MODULES . . . . . . . . . 8E-16 REMOVE/INSTALL, LOWER INSTRUMENT PANEL MODULE . . . . . . . . . . . . . . . . . . . . . 8E-21 REMOVE/INSTALL, LOWER LEFT INSTRUMENT PANEL END CAP . . . . . . . . . . 8E-21 REMOVE/INSTALL, MULTI-FUNCTION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J-4 REMOVE/INSTALL, OIL PRESSURE SENDING UNIT. . . . . . . . . . . . . . . . . . . . . . . 8E-16 . REMOVE/INSTALL, OVERHEAD CONSOLE . . . 8C-6 REMOVE/INSTALL, OVERHEAD CONSOLE BEZEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C-7 REMOVE/INSTALL, POWER LOCK MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8P-2 REMOVE/INSTALL, POWER LOCK SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8P-2 REMOVE/INSTALL, POWER MIRROR . . . . . . 8T-3 REMOVE/INSTALL, POWER MIRROR SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8T-3 REMOVE/INSTALL, POWER WINDOW MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8S-3 REMOVE/INSTALL, POWER WINDOW SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8S-3 REMOVE/INSTALL, PRINTED CIRCUIT . . . . 8E-19 REMOVE/INSTALL, RADIO . . . . . . . . . . . . . . . 8F-7 REMOVE/INSTALL, RIGHT INSTRUMENT PANEL BEZEL . . . . . . . . . . . . . . . . . . . . . . . 8E-21 REMOVE/INSTALL, SERVO CABLE . . . . . . . . 8H-9 REMOVE/INSTALL, SPEAKERS . . . . . . . . . . . 8F-7 REMOVE/INSTALL, SPEED CONTROL SERVO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H-8 REMOVE/INSTALL, SPEED CONTROL SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H-8 REMOVE/INSTALL, STARTER RELAY . . . . . . . 8B-6 REMOVE/INSTALL, VACUUM RESERVOIR . . 8H-9 REMOVE/INSTALL, VEHICLE SPEED SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-16 REMOVE/INSTALL, WASHER PUMP . . . . . . 8K-10 REMOVE/INSTALL, WIPER ARM . . . . . . . . . . 8K-7 REMOVE/INSTALL, WIPER BLADES OR ELEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . 8K-7 REMOVE/INSTALL, WIPER PIVOTS . . . . . . . . 8K-8 REMOVE/INSTALL, WIPER/WASHER SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8K-8 REMOVE/INSTALL2.5L, GENERATOR . . . . . 8B-7 REMOVE/INSTALL2.5L, STARTER . . . . . . . 8B-4 REMOVE/INSTALL3.9L/5.2L, GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . 8B-7 REMOVE/INSTALL3.9L/5.2L, STARTER . . . 8B-4 REPAIR, ALUMINUM THREAD . . . . . . . . . . 21-136 REPAIR DAMAGED OR WORN THREADS . . . . 9-4 REPAIR PRODUCTSAN-TRUCK, AFTERMARKET PAINT AND TRIM . . . . . . . . 23-46 REPAIR, WIRING . . . . . . . . . . . . . . . . . . . 8W-01-6 REPAIRING LEAKS . . . . . . . . . . . . . . . . . . . . 22-3 REPAIRMOLEX CONNECTORS, TERMINAL/CONNECTOR . . . . . . . . . . . . . 8W-01-6 REPAIRS, FRAME . . . . . . . . . . . . . . . . . . . . 13-20 REPLACECLYINDER HEAD NOT REMOVED, VALVE COMPONENTS . . . . . 9-54,9-87 REPLACEMENT 4 CYLINDER ENGINE, PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-13 REPLACEMENT V-6 AND V-8, PUMP . . . 19-13 REQUIREMENTS, FUEL . . . . . . . . . . . . . . . . . . 0-1
18
INDEX
Group-Page Description Group-Page Description Group-Page
Description
REQUIRING NO LUBRICATION, COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . 0-2 RESERVE/OVERFLOW SYSTEM, COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27 RESERVOIR, FUEL . . . . . . . . . . . . . . . . . . . . 14-16 RESERVOIR REMOVE/INSTALL, VACUUM . . 8H-9 RESERVOIR REPLACEMENT . . . . . . . . . . . . 19-15 RESERVOIR REPLACEMENT, MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 RESERVOIR, VACUUM . . . . . . . . . . . . . . . . . 8H-1 RESISTANCE, IGNITION COIL . . . . . . . 8D-29,8D-9 RESISTANCE (OHMS)COOLANT TEMPERATURE SENSOR/INTAKE MANIFOLD AIR TEMPERATURE SENSOR, SENSOR . . . . . . . . . . . . . . . . . . . . 14-70 RESISTANCE, SPARK PLUG CABLE . 8D-16,8D-29 RETAINER INSPECTION AND OVERHAUL, OVERRUNNING CLUTCHLOWREVERSE DRUMOVERDRIVE PISTON . . 21-154 RETAINER SERVICE, OVERDRIVE PISTON . 21-201 RETURN HOSE REPLACEMENT, PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 19-12 RETURNPCM INPUT, SENSOR . . . . . . . . . 14-60 REVERSE FLUSHING, TRANSMISSION COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-135 REVERSE, HYDRAULIC FLOW IN . . . . . . . 21-117 RIGHT INSTRUMENT PANEL BEZEL REMOVE/INSTALL . . . . . . . . . . . . . . . . . . . . 8E-21 RING CHART, AX 15 SELECTIVE SNAP . . . 21-286 RING SPECIFICATIONS, 42RH/46RH SPACER/THRUST PLATE/SNAP . . . . . . . . . 21-288 RIVET REMOVAL, BLIND . . . . . . . . . . . . . . . 23-23 ROAD LAMP DIAGNOSIS, FOG/OFF . . . . . . . . 8L-3 ROAD LAMP SWITCH REPLACEMENT, OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-10 ROAD LAMPS, OFF . . . . . . . . . . . . . . . . . . . . 8L-9 ROAD TEST, ANALYZING THE . . . . . . . . . . . 21-93 ROAD TESTING; BRAKES . . . . . . . . . . . . . . . . 5-3 ROAD TESTING; NV3500 MANUAL TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . 21-93 ROCKER ARMS AND PUSH RODS . . . . 9-54,9-87 ROD ASSEMBLY, PISTON / CONNECTING . 9-103, 9-71 ROD ASSEMBLY SERVICE, CYLINDER BLOCK, PISTON AND CONNECTING . . . . . . . 9-34 ROD, TIE . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-17 RODS, ROCKER ARMS AND PUSH . . . . 9-54,9-87 ROTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-3 ROTOR, DISTRIBUTOR . . . . . . . . . . . . . . . . . 8D-7 ROTOR, IGNITION CABLES, DISTRIBUTOR CAP . . . . . . . . . . . . . . . . . . . . 0-18 ROTOR INSTALLATION . . . . . . . . . . . . . . . . . 5-41 ROTOR MINIMUM THICKNESS . . . . . . . . . . . 5-42 ROTOR REFINISHING . . . . . . . . . . . . . . . . . . 5-42 ROTOR REMOVAL . . . . . . . . . . . . . . . . . . . . . 5-41 ROTOR RUNOUT . . . . . . . . . . . . . . . . . . . . . . 5-42 ROTOR SERVICE, DISC BRAKE . . . . . . . . . . . 5-41 ROTOR THICKNESS VARIATION AND TAPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43 ROTOR TYPES . . . . . . . . . . . . . . . . . . . . . . . . 5-41 ROUGH AND/OR HAS A MISS, INJECTOR DIAGNOSISVEHICLE RUNS . . . . . . . . . . . 14-77 ROUTING SCHEMATICS, VACUUM HOSE . . . 25-1 ROUTING, SYSTEM COOLANT . . . . . . . . . . . . . 7-2 RUBBER AND PLASTIC HOSES/TUBING . . . . 0-24 RUBBER BOOTS . . . . . . . . . . . . . . . . . . . . . . 2-29 RUBBER/PLASTIC COMPONENTS . . . . . . . . . 0-19 RUNNING LAMP (DRL) MODULE, DAYTIME . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-2 RUNNING LIGHT MODULE (DRLM), DAYTIME . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-12 RUNOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-4 RUNOUT, BRAKE DRUM . . . . . . . . . . . . . . . . 5-23 RUNOUT, CLUTCH COVER AND DISC . . . . . . . 6-4 RUNOUT, ROTOR . . . . . . . . . . . . . . . . . . . . . . 5-42 RUNOUT SPECIFICATIONS . . . . . . . . . . . . . . 16-4 RUNOUT, TIRE AND WHEEL . . . . . . . . . . . . . 22-8 RUNS ROUGH AND/OR HAS A MISS, INJECTOR DIAGNOSISVEHICLE . . . . . . . . 14-77 RWAL BRAKE OPERATION AND SERVICE . . . 5-44 RWAL DIAGNOSTIC CONNECTOR LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8 RWAL DIAGNOSTIC FAULT FLASH CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 RWAL FAULT CODE CAPACITY . . . . . . . . . . . 5-10 RWAL FAULT CODE IDENTIFICATION . . . . . . 5-10 RWAL FAULT CODES, CLEARING . . . . . . . . . 5-10 RWAL FLASH CODES, GENERATING . . . . . . . 5-10
RWAL SYSTEM BRAKE BLEEDING . . . . . . . . 5-48 RWAL SYSTEM COMPONENTS . . . . . . . . . . . 5-44 RWAL SYSTEM MANUAL BRAKE BLEEDING PROCEDURE . . . . . . . . . . . . . . . . 5-49 RWAL SYSTEM OPERATION . . . . . . . . . . . . . 5-45 SAFETY CERTIFICATION LABEL, VEHICLE . Intro.-1 SAFETY PRECAUTIONS AND WARNINGS; BODY COMPONENTS . . . . . . . . . . . . . . . . . . 23-32 SAFETY PRECAUTIONS AND WARNINGS; FRAME AND BUMPERS . . . . . . . . . . . . . . . . 13-20 SAFETY PRECAUTIONS, BRAKE . . . . . . . . . . . 5-2 SANDING,BUFFING AND POLISHING, WET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-45 SCAN TOOL, DRB; COOLING SYSTEM . . . . . . 7-4 SCAN TOOL, DRB; EMISSION CONTROL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-3 SCAN TOOL, DRB; FUEL SYSTEM . . . 14-39,14-79 SCAN TOOL, DRB; IGNITION SYSTEMS . . . . 8D-8 SCHEDULES, MAINTENANCE . . . . . . . . . . . . . 0-4 SCHEMATIC, BUZZER MODULE . . . . . . . . . . 8U-3 SCHEMATIC2.5L 4-CYLINDER ENGINE, ENGINE VACUUM . . . . . . . . . . . . . . . . . . . . . 25-3 SCHEMATIC3.9L V-6 AND 5.2L V-8 ENGINES, ENGINE VACUUM . . . . . . . . . . . . . 25-4 SCHEMATICS, BELT . . . . . . . . . . . . . . . . . . . . 7-43 SCHEMATICS, PCM SYSTEM . . . . . . 14-36,14-53 SCHEMATICS, SYSTEM . . . . . . . . . . . . . . . . 14-70 SCHEMATICS, VACUUM HOSE ROUTING . . . 25-1 SCI RECEIVEPCM INPUT . . . . . . . . . . . . . . 14-60 SCI TRANSMITPCM OUTPUT . . . . . . . . . 14-63 SCREEN, COWL GRILLE . . . . . . . . . . . . . . . . 23-7 SCREEN, HEADLAMP/FOG LAMP ADJUSTMENT USING ALIGNMENT . . . . . . . . 8L-6 SEAL AND BEARING, AXLE SHAFT . . . . . . . . 2-35 SEAL AND BEARING SERVICE, AXLE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 SEAL AND SPRING REPLACEMENT, VALVE STEM . . . . . . . . . . . . . . . . . . . . . 9-55,9-87 SEAL, BOOT . . . . . . . . . . . . . . . . . . . . . . . . . 19-34 SEAL, OIL PUMP . . . . . . . . . . . . . . . . . . . . 21-125 SEAL REPLACEMENT (2-WHEEL DRIVE MODELS), SLIP YOKE . . . . . . . . . . . . . . . . 21-131 SEAL REPLACEMENT, FRONT CRANKSHAFT OIL . . . . . . . . . . . . . . . . . 9-63,9-95 SEAL REPLACEMENT, OIL PUMP . . . . . . . 21-139 SEAL REPLACEMENT, PINION . . . . . . . . . . . . 3-17 SEAL REPLACEMENT, PINION SHAFT . . . . . . 2-34 SEALED BEAM REPLACEMENT . . . . . . . . . . . 8L-6 SEALS AND BEARING REPLACEMENT, PITMAN SHAFT . . . . . . . . . . . . . . . . . . . . . . 19-30 SEALS, CRANKSHAFT REAR OIL . . . . . 9-106,9-74 SEALS IN CAR REPLACEMENT, PITMAN SHAFT . . . . . . . . . . . . . . . . . . . . . . 19-19 SEALS SERVICE, CRANKSHAFT OIL . . . . . . . 9-29 SEALS SERVICE, TIMING SYSTEM . . . . . . . . 9-16 SEALS, WINDOW GLASS AND DOOR WEATHERSTRIP . . . . . . . . . . . . . . . . . . . . . 23-29 SEAT BELT SWITCH, DRIVERS . . . . . . . . . . 8U-1 SEAT BELT SWITCH, DRIVER S . . . . . . . . . . 8U-3 SEAT STORAGE BOXES, FLOOR CONSOLE AND REAR . . . . . . . . . . . . . . . . . 23-43 SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-37 SECOND GEAR (2), HYDRAULIC FLOW IN MANUAL . . . . . . . . . . . . . . . . . . . . . . . . 21-124 SECOND GEAR, HYDRAULIC FLOW IN D . 21-119 SECONDARY CABLES, SPARK PLUG . . . . . 8D-15, 8D-25 SECONDARY CIRCUIT DIAGNOSIS, IGNITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-9 SECTION IDENTIFICATION . . . . . . . . . . . . . . 8W-1 SELECTIVE SNAP RING CHART, AX 15 . . . 21-286 SELECTOR INDICATOR ADJUSTMENT, GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-127 SELECTOR INDICATOR REMOVE/ INSTALL, GEAR . . . . . . . . . . . . . . . . . . . . . . 8E-20 SELECTOR SWITCH, OVERDRIVE . . . . . . . . 21-88 SELF-DIAGNOSTIC TEST, COMPASS/ DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C-2 SENDING UNIT, FUEL GAUGE . . . . . . . . . . . 14-16 SENDING UNIT REMOVE/INSTALL, OIL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 8E-16 SENSE, FOUR-WHEEL DRIVE SWITCH . 8W-32-2, 8W-32-4 SENSE, STOP LAMP SWITCH . . . . . . . . . 8W-32-2 SENSEPCM INPUT, AUTOMATIC SHUTDOWN (ASD) . . . . . . . . . . . . . . . . . . . 14-57 SENSEPCM INPUT, IGNITION CIRCUIT . . 14-58
SENSITIVE DEVICES, ELECTROSTATIC DISCHARGE (ESD) . . . . . . . . . . . . . . . . . 8W-01-2 SENSOR; FUEL SYSTEM . . . . . . . . . . . . . . . 14-92 SENSOR; IGNITION SYSTEMS . . . . . . . . . . 8D-30 SENSOR, CAMSHAFT POSITION; FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-84 SENSOR, CAMSHAFT POSITION; FUEL/IGNITION3.9L AND 5.2L ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-8 SENSOR, CAMSHAFT POSITION; IGNITION SYSTEMS . . . . . . . . . . . . . . . . . . 8D-18 SENSOR, CRANKSHAFT POSITION; FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-84 SENSOR, CRANKSHAFT POSITION; FUEL/IGNITION3.9L AND 5.2L ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-9 SENSOR, CRANKSHAFT POSITION; IGNITION SYSTEMS . . . . . . . . . . . . . . . . . . 8D-19 SENSOR, ENGINE COOLANT TEMPERATURE; EMISSION CONTROL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . 25-18 SENSOR, ENGINE COOLANT TEMPERATURE; FUEL SYSTEM . . . . . 14-44,14-84 SENSOR, ENGINE COOLANT TEMPERATURE; FUEL/IGNITION . . . . . . . 8W-30-4 SENSOR, ENGINE COOLANT TEMPERATURE; FUEL/IGNITION3.9L AND 5.2L ENGINES . . . . . . . . . . . . . . . . . 8W-30-9 SENSOR, ENGINE COOLANT TEMPERATURE; IGNITION SYSTEMS . 8D-20,8D-4 SENSOR, HEATED OXYGEN; FUEL/ IGNITION . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-3 SENSOR, HEATED OXYGEN; FUEL/ IGNITION3.9L AND 5.2L ENGINES . . . 8W-30-8 SENSOR HEATING ELEMENT TEST, OXYGEN (O2S) . . . . . . . . . . . . . . . . . 14-35,14-72 SENSOR, IMPACT . . . . . . . . . . . . . . . . . . . . . 8M-2 SENSOR INSTALLATION (2-WHEEL DRIVE MODELS), FRONT BRAKE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58 SENSOR INSTALLATION (4-WHEEL DRIVE MODELS), FRONT BRAKE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59 SENSOR INSTALLATION, REAR BRAKE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59 SENSOR INSTALLATION, SPEED . . . . . . . . . . 5-48 SENSOR, INTAKE AIR TEMPERATURE . 8W-30-10 SENSOR, INTAKE MANIFOLD AIR TEMPERATURE; FUEL SYSTEM . . . . . . . . . . 14-84 SENSOR, INTAKE MANIFOLD AIR TEMPERATURE; IGNITION SYSTEMS . . . . . 8D-23 SENSOR, MANIFOLD ABSOLUTE PRESSURE; FUEL/IGNITION . . . . . . . . . . 8W-30-4 SENSOR, MANIFOLD ABSOLUTE PRESSURE; FUEL/IGNITION3.9L AND 5.2L ENGINES . . . . . . . . . . . . . . . . . . . . . 8W-30-9 SENSOR, MANIFOLD ABSOLUTE PRESSURE (MAP); FUEL SYSTEM . . 14-47,14-88 SENSOR, MANIFOLD ABSOLUTE PRESSURE (MAP); IGNITION SYSTEMS . . 8D-24, 8D-5 SENSOR (O2S) TESTS, OXYGEN . . . . . . . . 8D-16 SENSOR, OXYGEN (O2S); EMISSION CONTROL SYSTEMS . . . . . . . . . . . . . 25-17,25-22 SENSOR, OXYGEN (O2S); FUEL SYSTEM . 14-47, 14-89 SENSOR, OXYGEN (O2S); IGNITION SYSTEMS . . . . . . . . . . . . . . . . . . . . . . 8D-24,8D-5 SENSOR, REAR WHEEL SPEED . . . . . . . 8W-32-3 SENSOR REMOVAL (2-WHEEL DRIVE MODELS), FRONT BRAKE SPEED . . . . . . . . . 5-58 SENSOR REMOVAL (4-WHEEL DRIVE MODELS), FRONT BRAKE SPEED . . . . . . . . . 5-59 SENSOR REMOVAL (ALL), REAR BRAKE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59 SENSOR REMOVAL, SPEED . . . . . . . . . . . . . 5-48 SENSOR REMOVE/INSTALL, IMPACT . . . . . . 8M-4 SENSOR REMOVE/INSTALL, VEHICLE SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-16 SENSOR RESISTANCE (OHMS) COOLANT TEMPERATURE SENSOR/ INTAKE MANIFOLD AIR TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-70 SENSOR RETURNPCM INPUT . . . . . . . . . 14-60 SENSOR, SENSOR RESISTANCE (OHMS)COOLANT TEMPERATURE SENSOR/INTAKE MANIFOLD AIR TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . 14-70
INDEX
Description Group-Page Description Group-Page Description
19
Group-Page
SENSOR TEST, CAMSHAFT POSITION . . . . . 8D-6 SENSOR TEST, CRANKSHAFT POSITION; FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 14-72 SENSOR TEST, CRANKSHAFT POSITION; IGNITION SYSTEMS . . . . . . . . . . . . . . . . . . . 8D-7 SENSOR TEST, ENGINE COOLANT TEMPERATURE; FUEL SYSTEM . . . . . . . . . . 14-70 SENSOR TEST, ENGINE COOLANT TEMPERATURE; IGNITION SYSTEMS . . . . . . 8D-8 SENSOR TEST, INTAKE MANIFOLD AIR TEMPERATURE; FUEL SYSTEM . . . . . . . . . . 14-70 SENSOR TEST, INTAKE MANIFOLD AIR TEMPERATURE; IGNITION SYSTEMS . . . . . 8D-12 SENSOR TEST, MANIFOLD ABSOLUTE PRESSURE (MAP); FUEL SYSTEM . . . . . . . 14-71 SENSOR TEST, MANIFOLD ABSOLUTE PRESSURE (MAP); IGNITION SYSTEMS . . . 8D-12 SENSOR TEST, THROTTLE POSITION . . . . . 8D-16 SENSOR TEST, VEHICLE SPEED . . . . 14-35,14-74 SENSOR TESTING, CAMSHAFT POSITION . 14-70 SENSOR, THROTTLE BODY TEMPERATURE; FUEL SYSTEM . . . . . . . . . . 14-49 SENSOR, THROTTLE BODY TEMPERATURE; FUEL/IGNITION . . . . . . . 8W-30-4 SENSOR, THROTTLE POSITION; FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-50 SENSOR, THROTTLE POSITION; FUEL/IGNITION . . . . . . . . . . . . . . . . . . . . 8W-30-4 SENSOR, THROTTLE POSITION; FUEL/IGNITION3.9L AND 5.2L ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-9 SENSOR, THROTTLE POSITION; IGNITION SYSTEMS. . . . . . . . . . . . . . . . . . . . 8D-5 . SENSOR (TPS) TEST, THROTTLE POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . 14-72 SENSOR (TPS), THROTTLE POSITION; FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 14-90 SENSOR (TPS), THROTTLE POSITION; IGNITION SYSTEMS . . . . . . . . . . . . . . . . . . 8D-26 SENSOR (TPS)PCM INPUT, THROTTLE POSITION . . . . . . . . . . . . . . . . . . . . . 14-25,14-60 SENSOR, VEHICLE SPEED; FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . 14-50,14-91 SENSOR, VEHICLE SPEED; FUEL/ IGNITION . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-3 SENSOR, VEHICLE SPEED; FUEL/ IGNITION3.9L AND 5.2L ENGINES . . . 8W-30-8 SENSOR, VEHICLE SPEED; VEHICLE SPEED CONTROL SYSTEM . . . . . . . . . . 8H-1,8H-3 SENSOR/INTAKE MANIFOLD AIR TEMPERATURE SENSOR, SENSOR RESISTANCE (OHMS)COOLANT TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . 14-70 SENSOR2.5L ENGINE, THROTTLE BODY TEMPERATURE . . . . . . . . . . . . . . . . . . 8D-5 SENSOR3.9L/5.2L ENGINE, CAMSHAFT POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-2 SENSOR3.9L/5.2L ENGINE, CRANKSHAFT POSITION . . . . . . . . . . . . . . . . 8D-2 SENSOR3.9L/5.2L ENGINE, INTAKE MANIFOLD AIR TEMPERATURE . . . . . . . . . . 8D-5 SENSORPCM INPUT, CAMSHAFT POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . 14-57 SENSORPCM INPUT, CRANKSHAFT POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . 14-58 SENSORPCM INPUT, ENGINE COOLANT TEMPERATURE . . . . . . . . . 14-23,14-58 SENSORPCM INPUT, INTAKE MANIFOLD AIR TEMPERATURE . . . . . . . . . . 14-58 SENSORPCM INPUT, MANIFOLD ABSOLUTE PRESSURE (MAP) . . . . . . 14-24,14-59 SENSORPCM INPUT, OXYGEN (O2S) . . . 14-24, 14-59 SENSORPCM INPUT, THROTTLE BODY TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . 14-25 SENSORPCM INPUT, VEHICLE SPEED . . 14-25, 14-60 SENSORS, AIRBAG IMPACT . . . . . . . . . . 8W-43-1 SENSORS, WHEEL SPEED . . . . . . . . . . . 8W-32-1 SEQUENCE, 3-4 SHIFT . . . . . . . . . . . . . . . . . 21-88 SERPENTINE DRIVE BELT DIAGNOSIS 2.5L 4-CYLINDER ENGINE . . . . . . . . . . . . . . . 7-40 SERPENTINE DRIVE BELT DIAGNOSIS 2.5L 4-CYLINDER ENGINE CONTINUED . . . . . . . . . . . . . . . . . . . . . . . . . . 7-41 SERPENTINE DRIVE BELT DIAGNOSIS 3.9L/5.2L ENGINES . . . . . . . . . . . . . . . . . . . . 7-42
SERVICECYLINDER HEAD REMOVED, VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25 SERVO AND BAND OVERHAUL, FRONT . . 21-168, 21-203 SERVO AND BAND OVERHAUL, REAR . . . 21-169 SERVO CABLE . . . . . . . . . . . . . . . . . . . . . . . . 8H-1 SERVO CABLE REMOVE/INSTALL . . . . . . . . . 8H-9 SERVO OVERHAUL, REAR . . . . . . . . . . . . . 21-204 SERVO REMOVE/INSTALL, SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H-8 SERVO, SPEED CONTROL . . . . . . . . . . 8H-1,8H-7 SET C-3715-B, DIFFERENTIAL AND PINION MEASUREMENT WITH GAUGE . . . . . 2-40 SET GLASS, URETHANE . . . . . . . . . . . . . . . 23-32 SET, MANIFOLD GAUGE . . . . . . . . . . . . . . . . 24-3 SET, PINION DEPTH MEASUREMENT AND ADJUSTMENT WITH GAUGE . . . . . . . . . 3-22 SHAFT AND SIDE COVER REPLACEMENT, PITMAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-24 SHAFT AND UNIVERSAL JOINT, PROPELLER . . . . . . . . . . . . . . . . . . . . . . . . . 16-15 SHAFT CENTER BEARING SUPPORT CROSSMEMBER, DRIVE . . . . . . . . . . . . . . . 13-35 SHAFT, CRANKSHAFT AND INTERMEDIATE . . . . . . . . . . . . . . . . . . . . . . . 9-28 SHAFT, CV DRIVE . . . . . . . . . . . . . . . . . 2-23,2-47 SHAFT, INTERMEDIATE COUPLER . . . 19-31,19-33 SHAFT OVERHAUL, PLANETARY GEAR TRAIN AND INTERMEDIATE . . . . . . . . . . . 21-164 SHAFT REMOVAL, PINION GEAR . . . . . . . . . 2-38 SHAFT REMOVAL/INSTALLATION . . . . . . . . . 2-24 SHAFT REPLACEMENT, PROPELLER . . . . . . . 16-8 SHAFT REPLACEMENT, RACK PISTON AND WORM . . . . . . . . . . . . . . . . . . . . . . . . . 19-28 SHAFT, SEAL AND BEARING, AXLE . . . . . . . . 2-35 SHAFT, SEAL AND BEARING SERVICE, AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15 SHAFT SEAL REPLACEMENT, PINION . . . . . . 2-34 SHAFT SEALS AND BEARING REPLACEMENT, PITMAN . . . . . . . . . . . . . . . 19-30 SHAFT SEALS IN CAR REPLACEMENT, PITMAN . . . . . . . . . . . . . . . 19-19 SHAFT SERVICE, INTERMEDIATE . . . . . . . . . 9-32 SHAFT SUPPORT OVERHAUL, OIL PUMP AND REACTION . . . . . . . . . . . . . . . 21-154,21-204 SHAFTS, DRIVE . . . . . . . . . . . . . . . . . . . . . . . 0-23 SHAFTS, PROPELLER . . . . . . . . . . . . . . . . . . 16-1 SHAFTS TIMING PROCEDURE, CAMSHAFT, CRANKSHAFT AND INTERMEDIATE . . . . . . . . . . . . . . . . . . . . . . . 9-18 SHIELD/AIR DEFLECTOR4WD VEHICLES, ENGINE SPLASH . . . . . . . . . . . . 13-34 SHIELD2.5L ENGINES, HEAT . . . . . . . . . . . 11-6 SHIELD3.9L / 5.2L ENGINES, HEAT . . . . . . 11-6 SHIELDS, HEAT; EXHAUST SYSTEM AND INTAKE MANIFOLD . . . . . . . . . . . . . . . . . . . . 11-2 SHIELDS, HEAT; FUEL SYSTEM . . . . . . . . . . 14-15 SHIELDS, SPLASH . . . . . . . . . . . . . . . . . . . . . 23-9 SHIFT INDICATORPCM OUTPUT . . . . . . . 14-63 SHIFT LINKAGE ADJUSTMENT . . . 21-127,21-264 SHIFT MECHANISM . . . . . . . . . . . . . . . . . . 21-261 SHIFT PATTERN . . . . . . . . . . . . . . . . . . . . . . . 21-2 SHIFT SEQUENCE, 3-4 . . . . . . . . . . . . . . . . . 21-88 SHIFT VALVE FLOW CONTROL . . . . . . . . . . 21-89 SHOCK ABSORBER; FRONT SUSPENSION AND AXLE . . . . . . . . . . . . . . . . . . . . . . . . 2-14,2-9 SHOCK ABSORBER; REAR SUSPENSION AND AXLES . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 SHOCK ABSORBER DIAGNOSIS, SPRING . . . . 3-4 SHOCK DIAGNOSIS, SPRING . . . . . . . . . . . . . 3-4 SHOULDER BELTS/LAP BELT/BUCKLES . . . 23-39 SHUT DOWN (ASD) RELAY, AUTOMATIC; FUEL/IGNITION . . . . . . . . . . . . . . . . . . . . 8W-30-2 SHUT DOWN (ASD) RELAY, AUTOMATIC; FUEL/IGNITION3.9L AND 5.2L ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-6 SHUTDOWN (ASD) RELAY, AUTOMATIC; FUEL SYSTEM . . . . . . . . . . . . . . . . . . 14-43,14-84 SHUTDOWN (ASD) RELAY, AUTOMATIC; IGNITION SYSTEMS . . . . . . . . . . . . . . 8D-18,8D-1 SHUTDOWN (ASD) RELAY TEST, AUTOMATIC . . . . . . . . . . . . . . . . . . . . . . . . . 8D-6 SHUTDOWN (ASD) RELAYPCM OUTPUT, AUTO . . . . . . . . . . . . . . . . . 14-26,14-61 SHUTDOWN (ASD) SENSEPCM INPUT, AUTOMATIC . . . . . . . . . . . . . . . . . . . . . . . . . 14-57 SIDE COVER REPLACEMENT, PITMAN SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-24
SIDE MARKER LAMP, FRONT . . . . . . . . . . . . 8L-9 SIDE MARKER LAMP, REAR . . . . . . . . . . . . 8L-11 SIGNAL LAMPS, PARK AND TURN . . . . . . . . 8L-9 SIGNAL LAMPS, TAIL, STOP AND TURN . . 8L-11 SIGNAL SYSTEM, TURN . . . . . . . . . . . . . . . . 8J-1 SIGNAL, TURN . . . . . . . . . . . . . . . . . . . . . . . . 8J-2 SIGNALS, TURN . . . . . . . . . . . . . . . . . . . 8W-52-1 SINGLE-PORT FUEL INJECTION COMPONENT DESCRIPTION/SYSTEM OPERATION2.5L ENGINE . . . . . . . . . . . . . 14-21 SINGLE-PORT FUEL INJECTION COMPONENT REMOVAL/ INSTALLATION2.5L ENGINE . . . . . . . . . . . 14-43 SINGLE-PORT FUEL INJECTION GENERAL DIAGNOSIS2.5L ENGINE . . . . . 14-32 SKID PLATES . . . . . . . . . . . . . . . . . . . . . . . . 13-34 SLIDING VENT GLASS . . . . . . . . . . . . . . . . . 23-36 SLIP DIFFERENTIAL, LIMITED . . . . . . . . . . . . . 3-9 SLIP YOKE SEAL REPLACEMENT (2-WHEEL DRIVE MODELS) . . . . . . . . . . . 21-131 SLIPS, CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . 6-6 SNAP, DRIVELINE; FRONT SUSPENSION AND AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 SNAP, DRIVELINE; REAR SUSPENSION AND AXLES . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 SNAP RING CHART, AX 15 SELECTIVE . . . 21-286 SNOW PLOW . . . . . . . . . . . . . . . . . . . . . . . . . 13-3 SNOW PLOW CONTROL MODULE . . . . . . . 13-17 SNOW PLOW DIAGNOSIS . . . . . . . . . . . . . . . 13-9 SNOW PLOW FRAME . . . . . . . . . . . . . . . . . 13-16 SNOW PLOW MALFUNCTION DIAGNOSIS AND TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . 13-4 SNOW PLOW PIVOT BRACKET . . . . . . . . . . 13-16 SNOW PLOW SPECIFICATIONS . . . . . . . . . . 13-19 SNOW PLOW WIRING DIAGRAMS . . . . . . . . 13-4 SOLENOID, EGR; FUEL/IGNITION . . . . . . 8W-30-4 SOLENOID, EGR; FUEL/IGNITION3.9L AND 5.2L ENGINES . . . . . . . . . . . . . . . . 8W-30-10 SOLENOID, EVAP CANISTER PURGE; EMISSION CONTROL SYSTEMS . . . . . . . . . . 25-5 SOLENOID, EVAP CANISTER PURGE; FUEL SYSTEM . . . . . . . . . . . . . . . . . . 14-44,14-85 SOLENOID, EVAP/PURGE; FUEL/IGNITION . . . . . . . . . . . . . . . . . . . . 8W-30-5 SOLENOID, EVAP/PURGE; FUEL/ IGNITION3.9L AND 5.2L ENGINES . . 8W-30-10 SOLENOID, OVERDRIVE . . . . . . . . . . . . 8W-30-10 SOLENOID, TCC . . . . . . . . . . . . . . . . . . 8W-30-10 SOLENOID TESTING SPECIFICATIONS, STARTER; BATTERY/STARTER/ GENERATOR SERVICE . . . . . . . . . . . . . . . . . . 8B-9 SOLENOID TESTING SPECIFICATIONS, STARTER; BATTERY/STARTING/ CHARGING SYSTEMS DIAGNOSTICS . . . . . 8A-22 SOLENOID2.5L ENGINE, EGR . . . . . . . . . 25-20 SOLENOID2.5L ENGINE, EVAP CANISTER PURGE . . . . . . . . . . . . . . . . . . . . 25-21 SOLENOIDPCM OUTPUT, EGR . . . . . . . . . 14-26 SOLENOIDPCM OUTPUT, EGR (EXHAUST GAS RECIRCULATION) VALVE CONTROL . . . . . . . . . . . . . . . . . . . . . 14-62 SOLENOIDPCM OUTPUT, EVAP CANISTER PURGE . . . . . . . . . . . . . . . 14-27,14-62 SOLID MOUNT COMPRESSOR BRACKET SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15 SOLVENTS, BRAKE FLUID/LUBRICANTS/ CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 SPACER/THRUST PLATE/SNAP RING SPECIFICATIONS, 42RH/46RH . . . . . . . . . . 21-288 SPARE TIRE WINCH . . . . . . . . . . . . . . . . . . 23-19 SPARK PLUG CABLE RESISTANCE . . 8D-16,8D-29 SPARK PLUG SECONDARY CABLES . 8D-15,8D-25 SPARK PLUGS; IGNITION SYSTEMS . . . . . 8D-12, 8D-24,8D-30 SPARK PLUGS; LUBRICATION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . 0-18 SPEAKER CONNECTORS, RADIO . . . . . . . . . . 8F-4 SPEAKERS . . . . . . . . . . . . . . . . . . . . . . . 8F-1,8F-5 SPEAKERS REMOVE/INSTALL . . . . . . . . . . . . 8F-7 SPEAKERSPREMIUM RADIO . . . . . . . . 8W-47-1 SPEAKERSSTANDARD RADIO . . . . . . . 8W-47-1 SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . 9-11 SPECIFICATION NOTATIONS . . . . . . . . . . . Intro.-8 SPECIFICATIONS; BATTERY/STARTER/ GENERATOR SERVICE . . . . . . . . . . . . . . . . . . 8B-9 SPECIFICATIONS; BATTERY/STARTING/ CHARGING SYSTEMS DIAGNOSTICS . . . . . 8A-22 SPECIFICATIONS; BRAKES . . . . . . . . . . . . . . 5-68
20
INDEX
Group-Page Description Group-Page Description Group-Page
Description
SPECIFICATIONS; CLUTCH . . . . . . . . . . . . . . 6-15 SPECIFICATIONS; COOLING SYSTEM . . . . . . 7-48 SPECIFICATIONS; FUEL SYSTEM . . . . . . . . 14-92 SPECIFICATIONS; IGNITION SYSTEMS . . . . 8D-29 SPECIFICATIONS; INSTRUMENT PANEL AND GAUGES . . . . . . . . . . . . . . . . . . . . . . . 8E-24 SPECIFICATIONS; NV3500 MANUAL TRANSMISSION . . . . . . . . . . . . . . . . . . . . . 21-285 SPECIFICATIONS; TRANSMISSION AND TRANSFER CASE . . . . . . . . . . . . . . . . . . . . . . 21-3 SPECIFICATIONS, 42RH/46RH GENERAL . 21-288 SPECIFICATIONS, 42RH/46RH PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-289 SPECIFICATIONS, 42RH/46RH SPACER/THRUST PLATE/SNAP RING . . . . 21-288 SPECIFICATIONS, 42RH/46RH TORQUE . . 21-289 SPECIFICATIONS, AX 15 TORQUE . . . . . . . 21-285 SPECIFICATIONS, AXLE; FRONT SUSPENSION AND AXLE . . . . . . . . . . . . . . . . 2-47 SPECIFICATIONS, AXLE; REAR SUSPENSION AND AXLES . . . . . . . . . . . . . . . 3-36 SPECIFICATIONS, BATTERY; BATTERY/ STARTER/GENERATOR SERVICE . . . . . . . . . . 8B-9 SPECIFICATIONS, BATTERY; BATTERY/ STARTING/CHARGING SYSTEMS DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . 8A-22 SPECIFICATIONS, BODY LUBRICANT . . . . . . 0-29 SPECIFICATIONS, CHARGING SYSTEM; BATTERY/STARTER/GENERATOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-10 SPECIFICATIONS, CHARGING SYSTEM; BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS . . . . . . . . . . . . . . . 8A-23 SPECIFICATIONS, ENGINE . . . . . . 9-110,9-46,9-78 SPECIFICATIONS, FRONT WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 SPECIFICATIONS, LUBRICANT; FRONT SUSPENSION AND AXLE . . . . . . . . . . . . . . . . 2-31 SPECIFICATIONS, LUBRICANT; REAR SUSPENSION AND AXLES . . . . . . . . . . . . . . . 3-12 SPECIFICATIONS, MEASUREMENT AND TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . Intro.-8 SPECIFICATIONS, NP231 TORQUE . . . . . . 21-287 SPECIFICATIONS, NV3500 TORQUE . . . . . 21-287 SPECIFICATIONS, POWER STEERING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-32 SPECIFICATIONS, PUMP OPERATING . . . . . . 19-3 SPECIFICATIONS, RUNOUT . . . . . . . . . . . . . . 16-4 SPECIFICATIONS, SNOW PLOW . . . . . . . . . 13-19 SPECIFICATIONS, STANDARD TORQUE . . Intro.-9 SPECIFICATIONS, STARTER AND SOLENOID TESTING; BATTERY/ STARTER/GENERATOR SERVICE . . . . . . . . . . 8B-9 SPECIFICATIONS, STARTER AND SOLENOID TESTING; BATTERY/ STARTING/CHARGING SYSTEMS DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . 8A-22 SPECIFICATIONS, STARTING SYSTEM; BATTERY/STARTER/GENERATOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-9 SPECIFICATIONS, STARTING SYSTEM; BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS . . . . . . . . . . . . . . . 8A-22 SPECIFICATIONS, TORQUE; BODY COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . 23-47 SPECIFICATIONS, TORQUE; BRAKES . . . . . . 5-68 SPECIFICATIONS, TORQUE; CLUTCH . . . . . . 6-15 SPECIFICATIONS, TORQUE; ENGINE . 9-113,9-48, 9-81 SPECIFICATIONS, TORQUE; EXHAUST SYSTEM AND INTAKE MANIFOLD . . . . . . . . 11-12 SPECIFICATIONS, TORQUE; FRAME AND BUMPERS . . . . . . . . . . . . . . . . . . . . . . . . . . 13-36 SPECIFICATIONS, TORQUE; FRONT SUSPENSION AND AXLE . . . . . . . . . . . . . . . . 2-47 SPECIFICATIONS, TORQUE; HEATING AND AIR CONDITIONING . . . . . . . . . . . . . . . 24-26 SPECIFICATIONS, TORQUE; INTRODUCTION . . . . . . . . . . . . . . . . . . . . . Intro.-8 SPECIFICATIONS, TORQUE; PROPELLER SHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-15 SPECIFICATIONS, TORQUE; REAR SUSPENSION AND AXLES . . . . . . . . . . . . . . . 3-36 SPECIFICATIONS, TORQUE; STEERING . . . . 19-42 SPECIFICATIONS, TORQUE; WHEELS AND TIRES . . . . . . . . . . . . . . . . . . . . . . . . . 22-12 SPECIFICATIONS, TRAILER TOWING . . . . Intro.-3, Intro.-6
SPECIFICATIONS, TRANSFER CASE . . . . . 21-262 SPECIFICATIONSCONT., ENGINE . . 9-111,9-112, 9-47,9-79,9-80 SPEED CONTROL DIAGNOSTIC TROUBLE CODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H-6 SPEED CONTROL SERVO . . . . . . . . . . . 8H-1,8H-7 SPEED CONTROL SERVO REMOVE/ INSTALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H-8 SPEED CONTROL SWITCH . . . . . . . . . . 8H-1,8H-3 SPEED CONTROL SWITCH REMOVE/ INSTALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H-8 SPEED CONTROL, VEHICLE . . . . . . . . . . 8W-33-1 SPEED CONTROLPCM INPUT . . . . . . . . . 14-60 SPEED CONTROLPCM OUTPUT . . . . . . . . 14-63 SPEED KNOCK, LOW; FRONT SUSPENSION AND AXLE . . . . . . . . . . . . . . . . 2-20 SPEED KNOCK, LOW; REAR SUSPENSION AND AXLES . . . . . . . . . . . . . . . . 3-9 SPEED SENSOR INSTALLATION . . . . . . . . . . 5-48 SPEED SENSOR INSTALLATION (2-WHEEL DRIVE MODELS), FRONT BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58 SPEED SENSOR INSTALLATION (4-WHEEL DRIVE MODELS), FRONT BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59 SPEED SENSOR INSTALLATION, REAR BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59 SPEED SENSOR, REAR WHEEL . . . . . . . 8W-32-3 SPEED SENSOR REMOVAL . . . . . . . . . . . . . . 5-48 SPEED SENSOR REMOVAL (2-WHEEL DRIVE MODELS), FRONT BRAKE . . . . . . . . . 5-58 SPEED SENSOR REMOVAL (4-WHEEL DRIVE MODELS), FRONT BRAKE . . . . . . . . . 5-59 SPEED SENSOR REMOVAL (ALL), REAR BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-59 SPEED SENSOR REMOVE/INSTALL, VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-16 SPEED SENSOR TEST, VEHICLE . . . . 14-35,14-74 SPEED SENSOR, VEHICLE; FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . 14-50,14-91 SPEED SENSOR, VEHICLE; FUEL/ IGNITION . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-3 SPEED SENSOR, VEHICLE; FUEL/ IGNITION3.9L AND 5.2L ENGINES . . . 8W-30-8 SPEED SENSOR, VEHICLE; VEHICLE SPEED CONTROL SYSTEM . . . . . . . . . . 8H-1,8H-3 SPEED SENSORPCM INPUT, VEHICLE . . 14-25, 14-60 SPEED SENSORS, WHEEL . . . . . . . . . . . 8W-32-1 SPEEDPCM INPUT, ENGINE . . . . . . . . . . . 14-23 SPEEDOMETER CABLE . . . . . . . . . . . . . . . . . 0-29 SPEEDOMETER SERVICE; NV3500 MANUAL TRANSMISSION . . 21-130,21-264,21-41 SPEEDOMETER SERVICE; TRANSMISSION AND TRANSFER CASE . . . . 21-3 SPLASH SHIELD/AIR DEFLECTOR4WD VEHICLES, ENGINE . . . . . . . . . . . . . . . . . . . 13-34 SPLASH SHIELDS . . . . . . . . . . . . . . . . . . . . . 23-9 SPLICE INDEX . . . . . . . . . . . . . . . . . . . . . 8W-70-1 SPLICE LOCATIONS; SPLICE LOCATIONS . 8W-95-1 SPLICE LOCATIONS; WIRING DIAGRAMS . . 8W-1 SPRING AND SHOCK ABSORBER DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 SPRING AND SHOCK DIAGNOSIS . . . . . . . . . . 3-4 SPRING, COIL . . . . . . . . . . . . . . . . . . . . . . . . 2-10 SPRING EYE BUSHING REPLACEMENT, LEAF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6 SPRING LEAF REPLACEMENT . . . . . . . . . . . . . 3-6 SPRING REPLACEMENT, VALVE STEM SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-55,9-87 SPRINGS, LEAF . . . . . . . . . . . . . . . . . . . . . . . . 3-5 SPRINGS, VALVES AND VALVE . . . . . . . 9-56,9-89 SQUIB (AIRBAG IGNITER), AIRBAG . . . . 8W-43-1 STABILIZER BAR . . . . . . . . . . . . . . . . . . . 2-15,2-9 STALL TEST ANALYSIS . . . . . . . . . . . . . . . . 21-96 STALL TEST, CONVERTER . . . . . . . . . . . . . . 21-96 STANDARD CLUSTER . . . . . . . . . . . . . . . . . . 8E-8 STANDARD SERVICE PROCEDURES . . . . . . . . 9-1 STANDARD TORQUE SPECIFICATIONS . . . Intro.-9 STARTER AND SOLENOID TESTING SPECIFICATIONS; BATTERY/STARTER/ GENERATOR SERVICE . . . . . . . . . . . . . . . . . . 8B-9 STARTER AND SOLENOID TESTING SPECIFICATIONS; BATTERY/STARTING/ CHARGING SYSTEMS DIAGNOSTICS . . . . . 8A-22 STARTER AND STARTER RELAY . . . . . . . . . . 8B-4 STARTER MOTOR RELAY TEST . . . . . . . . . . 14-76 STARTER RELAY CONNECTIONS . . . . . . . . . 8A-15
STARTER RELAY REMOVE/INSTALL . . . . . . . 8B-6 STARTER RELAY, STARTER . . . . . . . . . . . . . . 8B-4 STARTER REMOVE/INSTALL2.5L . . . . . . . . 8B-4 STARTER REMOVE/INSTALL3.9L/5.2L . . . . 8B-4 STARTING, HOISTING AND TOWING, JUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-9 STARTING, JUMP . . . . . . . . . . . . . . . . . . . . . . 0-9 STARTING SYSTEM . . . . . . . . . . . . . . . . . . . 8A-11 STARTING SYSTEM DIAGNOSIS . . . . . . . . . 8A-14 STARTING SYSTEM SPECIFICATIONS; BATTERY/STARTER/GENERATOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-9 STARTING SYSTEM SPECIFICATIONS; BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS . . . . . . . . . . . . . . . 8A-22 STEERING COLUMN . . . . . . . . . . . . . 19-36,19-42 STEERING GEAR . . . . . . . . . . . . . . . . . . . . . 19-42 STEERING GEAR ADJUSTMENTS . . . . . . . . 19-21 STEERING GEAR, MANUAL . . . . . . . . . . . . . . 0-27 STEERING GEAR, RACK AND PINION . . . . . 19-33 STEERING GEAR, RECIRCULATING BALL POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-19 STEERING GEAR REPLACEMENT . . . 19-32,19-33 STEERING GEAR SPECIFICATIONS, POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-32 STEERING KNUCKLE . . . . . . . . . . . . . . . 2-13,2-17 STEERING LINKAGE; LUBRICATION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . 0-25 STEERING LINKAGE; STEERING . . . . . . . . . 19-42 STEERING LINKAGE 4WD VEHICLES . . . 19-17 STEERING PUMP . . . . . . . . . . . . . . . . . . . . . 19-42 STEERING PUMP FLOW RATE AND PRESSURE TEST, POWER . . . . . . . . . . . . . . . 19-3 STEERING PUMP INITIAL OPERATION, POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-16 STEERING PUMP, POWER . . . . . . . . . . . . . . 19-12 STEERING SYSTEM COMPONENTS . . . . . . . . 19-1 STEERING SYSTEM DIAGNOSIS, POWER . . 19-3, 19-4,19-5,19-6,19-7,19-8,19-9 STEERING SYSTEM DIAGNOSIS, SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 STEERING SYSTEM, POWER . . . . . . . . . . . . . 0-26 STEERING WHEEL . . . . . . . . . . . . . . . . . . . . 19-37 STEM SEAL AND SPRING REPLACEMENT, VALVE . . . . . . . . . . . . . 9-55,9-87 STOP AND TURN SIGNAL LAMPS, TAIL, . . 8L-11 STOP LAMP (CHMSL), CENTER HIGH MOUNTED . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-11 STOP LAMP SWITCH . . . . . . . . . . . . . . 8H-1,8H-6 STOP LAMP SWITCH SENSE . . . . . . . . . 8W-32-2 STOP LAMPS AND CHMSL LAMPS . . . . 8W-51-1 STOPLAMP SWITCH ADJUSTMENT . . . . . . . 5-18 STORAGE BIN, SUNGLASSES . . . . . . . . . . . . 8C-8 STORAGE BOXES, FLOOR CONSOLE AND REAR SEAT . . . . . . . . . . . . . . . . . . . . . . . . . 23-43 STORAGE COMPARTMENT DOOR REMOVE/INSTALL, GARAGE DOOR OPENER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C-8 STORAGE, REMOTE GARAGE DOOR OPENER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8C-1 STORAGE, SUNGLASSES . . . . . . . . . . . . . . . 8C-2 STRAIGHTENING, FRAME . . . . . . . . . . . . . . 13-20 STRIKER, DOOR LATCH . . . . . . . . . . . . . . . 23-29 STRIPES, CAB AND CARGO BOX . . . . . . . . 23-13 STUD, LOWER BALL . . . . . . . . . . . . . . . . . . . 2-11 STUD, UPPER BALL . . . . . . . . . . . . . . . 2-12,2-17 SUNGLASSES STORAGE . . . . . . . . . . . . . . . . 8C-2 SUNGLASSES STORAGE BIN . . . . . . . . . . . . 8C-8 SUNVISORS . . . . . . . . . . . . . . . . . . . . . . . . . 23-42 SUPPLY TEST, VACUUM . . . . . . . . . . . . . . . . 8H-6 SUPPORT BRACKET, MIRROR . . . . . . . . . . . 23-31 SUPPORT CROSSMEMBER, DRIVE SHAFT CENTER BEARING . . . . . . . . . . . . . . 13-35 SUPPORT, ENGINE REAR . . . . . . . 9-13,9-51,9-84 SUPPORT OVERHAUL, OIL PUMP AND REACTION SHAFT . . . . . . . . . . . . . 21-154,21-204 SUPPORT PLATE INSTALLATION, BRAKE . . . 5-23 SUPPORT PLATE REMOVAL, BRAKE . . . . . . . 5-23 SUPPRESSION, RADIO NOISE . . . . . . . . . . . . 8F-1 SURFACE TOUCH-UP, PAINTED . . . . . . . . . . 23-45 SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 SUSPENSION AND STEERING SYSTEM DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 SUSPENSION ARM, LOWER . . . . . . . . . 2-10,2-16 SUSPENSION ARM, UPPER . . . . . . . . . 2-12,2-16 SUSPENSION COMPONENTS . . . . . . . . . . . . 3-36 SUSPENSION COMPONENTS2WD, FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
INDEX
Description Group-Page Description Group-Page Description
21
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SUSPENSION COMPONENTS4WD, FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47 SUSPENSION, FRONT . . . . . . . . . . . . . . . . . . . 2-1 SUSPENSION2WD AND 4WD VEHICLES, REAR . . . . . . . . . . . . . . . . . . . . . . . 3-4 SUSPENSION2WD VEHICLES, FRONT . . . . . 2-8 SUSPENSION4WD VEHICLES, FRONT . . . . 2-14 SWITCH ADJUSTMENT, STOPLAMP . . . . . . . 5-18 SWITCH, AIR CONDITIONING CYCLING . . . 24-13 SWITCH AND KEY CYLINDER SERVICE, IGNITION . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-27 SWITCH AND PLUG LOCATIONS . . . . . . . . . . 21-2 SWITCH, BACKUP LAMP . . . . . . . . . . . . . . . 8L-11 SWITCH, BRAKE . . . . . . . . . . . . . . . . 14-43,14-84 SWITCH, BRAKE WARNING LAMP . . . . . 8W-32-4 SWITCH, CLUTCH PEDAL POSITION . . . . . . . . 6-2 SWITCH, DRIVERS DOOR JAMB . . . . . 8U-1,8U-2 SWITCH, DRIVERS SEAT BELT . . . . . . . . . . 8U-1 SWITCH, DRIVER S SEAT BELT . . . . . . . . . . 8U-3 SWITCH, FOUR-WHEEL DRIVE INDICATOR LAMP . . . . . . . . . . . . . . . . . . 8W-31-1 SWITCH, HEADLAMP; CHIME/BUZZER WARNING SYSTEMS . . . . . . . . . . . . . . 8U-1,8U-3 SWITCH, HEADLAMP; LAMPS . . . . . . . . . . . 8L-10 SWITCH, HIGH-PRESSURE CUT-OFF . . . . . . 24-13 SWITCH, HORN . . . . . . . . . . . . . . . . . . 8G-1,8G-2 SWITCH, IGNITION; FUEL/IGNITION . . . . 8W-30-1 SWITCH, IGNITION; FUEL/IGNITION 3.9L AND 5.2L ENGINES . . . . . . . . . . . . . 8W-30-6 SWITCH, IGNITION; IGNITION SYSTEMS . . 8D-27 SWITCH, IGNITION KEY-IN . . . . . . . . . . 8U-1,8U-2 SWITCH INPUT, PARK BRAKE . . . . . . . . 8W-32-4 SWITCH LAMP, COURTESY LAMP AND IGNITION . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-1 SWITCH, MULTI-FUNCTION . . . . . . . . . . . . . . 8J-3 SWITCH, OVERDRIVE . . . . . . . . . . . . . . . 8W-31-1 SWITCH, OVERDRIVE SELECTOR . . . . . . . . 21-88 SWITCH, OVERDRIVE/OVERRIDE . . . . . . . . 14-59 SWITCH, PARK/NEUTRAL . . . . . . . . . 14-47,14-89 SWITCH, PARK/NEUTRAL POSITION; FUEL/IGNITION3.9L AND 5.2L ENGINES . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-10 SWITCH, PARK/NEUTRAL POSITION; NV3500 MANUAL TRANSMISSION . . . . . . 21-130 SWITCH, POWER BRAKE BOOSTER BRAKE PEDALSTOPLAMP . . . . . . . . . . . . . 5-17 SWITCH, POWER LOCK . . . . . . . . . . . . . . . . 8P-1 SWITCH, POWER MIRROR . . . . . . . . . . . . . . 8T-1 SWITCH, POWER WINDOW . . . . . . . . . . . . . 8S-1 SWITCH REMOVE/INSTALL, GLOVE BOX LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-21 SWITCH REMOVE/INSTALL, HEADLAMP, POWER MIRROR, OVERDRIVE LOCKOUT . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-19 SWITCH REMOVE/INSTALL, HORN . . . . . . . . 8G-3 SWITCH REMOVE/INSTALL, MULTIFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 8J-4 SWITCH REMOVE/INSTALL, POWER LOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8P-2 SWITCH REMOVE/INSTALL, POWER MIRROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8T-3 SWITCH REMOVE/INSTALL, POWER WINDOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8S-3 SWITCH REMOVE/INSTALL, SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H-8 SWITCH REMOVE/INSTALL, WIPER/ WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8K-8 SWITCH REPLACEMENT, FOG LAMP . . . . . . 8L-10 SWITCH REPLACEMENT, OFF ROAD LAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8L-10 SWITCH SENSE, FOUR-WHEEL DRIVE . 8W-32-2, 8W-32-4 SWITCH SENSE, STOP LAMP . . . . . . . . . 8W-32-2 SWITCH SERVICE PROCEDURES, MULTI-FUNCTION . . . . . . . . . . . . . . . . . . . . 8L-10 SWITCH, SPEED CONTROL . . . . . . . . . 8H-1,8H-3 SWITCH, STOP LAMP . . . . . . . . . . . . . 8H-1,8H-6 SWITCH TEST, VACUUM . . . . . . . . . . . . . . . 24-10 SWITCH TESTING PROCEDURES, MULTI-FUNCTION . . . . . . . . . . . . . . . . . . . . . 8L-4 SWITCH, WIPER/WASHER . . . . . . . . . . . . . . 8K-6 SWITCHPCM INPUT, BRAKE . . . . . 14-23,14-57 SWITCHPCM INPUT, PARK/NEUTRAL . . . 14-60 SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . 8W-01-2 SYMBOLS, INTERNATIONAL . . . . . . . . . . . . . . 0-1 SYMBOLS, INTERNATIONAL CONTROL AND DISPLAY . . . . . . . . . . . . . . . . . . . . . . Intro.-7
SYMBOLS, INTERNATIONAL VEHICLE CONTROL AND DISPLAY . . . . . . . . . . . . . Intro.-3 SYSTEM (ABS), ALL WHEEL ANTI-LOCK BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-32-1 SYSTEM, AIR CONDITIONING . . . . . . . . . . . . 24-1 SYSTEM, AIRBAG . . . . . . . . . . . . . . . . . . . . . 8M-1 SYSTEM AND SEALS SERVICE, TIMING . . . . 9-16 SYSTEM BRAKE BLEEDING, RWAL . . . . . . . . 5-48 SYSTEM, CHARGING; BATTERY/ STARTING/CHARGING SYSTEMS DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . 8A-17 SYSTEM, CHARGING; CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-1 SYSTEM, CHARGING REFRIGERANT . . . . . . . 24-5 SYSTEM CHECK, AIRBAG . . . . . . . . . . . . . . . 8M-2 SYSTEM CLEANING/REVERSE FLUSHING, COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25 SYSTEM COMPONENTS, COOLING . . . . . . . . . 7-2 SYSTEM COMPONENTS, RWAL . . . . . . . . . . 5-44 SYSTEM COMPONENTS, STEERING . . . . . . . 19-1 SYSTEM, COOLANT RESERVE/ OVERFLOW . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27 SYSTEM COOLANT ROUTING . . . . . . . . . . . . . 7-2 SYSTEM, COOLING; COOLING SYSTEM . . . . . 7-1 SYSTEM, COOLING; HEATING AND AIR CONDITIONING . . . . . . . . . . . . . . . . . . . . . . . 24-4 SYSTEM DESCRIPTION AND OPERATION . . . 13-3 SYSTEM DIAGNOSIS, ANTILOCK BRAKE . . . . 5-8 SYSTEM DIAGNOSIS, CHARGING . . . . . . . . 8A-18 SYSTEM DIAGNOSIS (CONT.), COOLING . . . 7-10, 7-11,7-6,7-7,7-8,7-9 SYSTEM DIAGNOSIS, COOLING . . . . . . . . . . . 7-5 SYSTEM DIAGNOSIS, EXHAUST . . . . . . . . . . 11-2 SYSTEM DIAGNOSIS, POWER STEERING . . 19-3, 19-4,19-5,19-6,19-7,19-8,19-9 SYSTEM DIAGNOSIS, STARTING . . . . . . . . 8A-14 SYSTEM DIAGNOSIS, SUSPENSION AND STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 SYSTEM, DRAINING COOLING . . . . . . . . . . . 7-24 SYSTEM, EMISSION CONTROL . . . . . . . . . . . 0-19 SYSTEM, ENGINE COOLING . . . . . . . . . . . . . 0-16 SYSTEM, ENGINE LUBRICATION . . . . . . . . . . 9-39 SYSTEM, EVACUATING REFRIGERANT . . . . . 24-5 SYSTEM, EVAP (EVAPORATION) CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-5 SYSTEM, EXHAUST; EXHAUST SYSTEM AND INTAKE MANIFOLD . . . . . . . . . . . . . . . . 11-1 SYSTEM, EXHAUST; LUBRICATION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . 0-19 SYSTEM FAN2.5L 4-CYLINDER ENGINE, COOLING . . . . . . . . . . . . . . . . . . . . . 7-33 SYSTEM FAN3.9L/5.2L ENGINE, COOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36 SYSTEM, FIG. 2 OIL LUBRICATION . . . 9-100,9-68 SYSTEM FOR LEAKS, TESTING COOLING . . . 7-25 SYSTEM, FUEL . . . . . . . . . . . . . . . . . . . . . . . 0-17 SYSTEM, FUEL DELIVERY . . . . . . . . . . . . . . . 14-3 SYSTEM, HAZARD WARNING . . . . . . . . . . . . 8J-1 SYSTEM, HEATER . . . . . . . . . . . . . . . . . . . . . 24-1 SYSTEM HOSES, COOLING . . . . . . . . . . . . . . 7-32 SYSTEM, LUBRICATION . . . . . . . . . . . . 9-67,9-99 SYSTEM MANUAL BRAKE BLEEDING PROCEDURE, RWAL . . . . . . . . . . . . . . . . . . . 5-49 SYSTEM NORMAL AND FAULT CONDITIONS, ABS . . . . . . . . . . . . . . . . . . . . . . 5-9 SYSTEM OPERATION, RWAL . . . . . . . . . . . . . 5-45 SYSTEM, POSITIVE CRANKCASE VENTILATION (PCV) . . . . . . . . . . . . . . . . . . . 25-6 SYSTEM, POWER BRAKE . . . . . . . . . . . . . . . 0-27 SYSTEM, POWER STEERING . . . . . . . . . . . . . 0-26 SYSTEM PRESSURE RELEASE, FUEL . . . . . . 14-7 SYSTEM PRESSURE RELEASE PROCEDURE, FUEL . . . . . . . . . . . . . . 14-46,14-87 SYSTEM PRESSURE TEST2.5L ENGINE, FUEL . . . . . . . . . . . . . . . . . . . . . . . . 14-8 SYSTEM PRESSURE TEST3.9L/5.2L ENGINE, FUEL . . . . . . . . . . . . . . . . . . . . . . . . 14-8 SYSTEM, RECOVERING REFRIGERANT . . . . . 24-5 SYSTEM, REFILLING COOLING . . . . . . . . . . . 7-24 SYSTEM SCHEMATICS . . . . . . . . . . . . . . . . 14-70 SYSTEM SCHEMATICS, PCM . . . . . . 14-36,14-53 SYSTEM SERVICE (DEPLOYED), AIRBAG . . 8M-3 SYSTEM SPECIFICATIONS, CHARGING; BATTERY/STARTER/GENERATOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-10 SYSTEM SPECIFICATIONS, CHARGING; BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS . . . . . . . . . . . . . . . 8A-23
SYSTEM SPECIFICATIONS, STARTING; BATTERY/STARTER/GENERATOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8B-9 SYSTEM SPECIFICATIONS, STARTING; BATTERY/STARTING/CHARGING SYSTEMS DIAGNOSTICS . . . . . . . . . . . . . . . 8A-22 SYSTEM, STARTING . . . . . . . . . . . . . . . . . . 8A-11 SYSTEM, TURN SIGNAL . . . . . . . . . . . . . . . . 8J-1 SYSTEM, USING ON-BOARD DIAGNOSTIC; BATTERY/STARTING/ CHARGING SYSTEMS DIAGNOSTICS . . . . . 8A-21 SYSTEM, USING ON-BOARD DIAGNOSTIC; VEHICLE SPEED CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . 8H-3 SYSTEM VACUUM DIAGNOSIS, HEATER A/C CONTROL . . . . . . . . . . . . . . . . . . . . . . . 24-10 SYSTEM, WINDSHIELD WASHER . . . . . . . . . 8K-1 SYSTEM, WINDSHIELD WIPER . . . . . . . . . . . 8K-1 SYSTEM2.5L ENGINE, HEATED INLET AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-10 SYSTEMS, ANTILOCK BRAKE . . . . . . . . . . . . . 5-1 SYSTEMS, CRANKCASE VENTILATION . . . . . 0-17 SYSTEMS, EGR (EXHAUST GAS RECIRCULATION) . . . . . . . . . . . . . . . . . . . . 25-11 TABLE, BATTERY CHARGING TIME . . . . . . . . 8A-8 TACHOMETER DRIVE MODULES REMOVE/INSTALL, LOW FUEL . . . . . . . . . . 8E-16 TACHOMETERPCM OUTPUT . . . . . . . . . . 14-63 TAIL LAMPS AND REAR LICENSE PLATE LAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-1 TAIL, STOP AND TURN SIGNAL LAMPS . . . 8L-11 TAILGATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23-19 TAILPIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5 TAKE OUTS . . . . . . . . . . . . . . . . . . . . . . . 8W-01-2 TANK CAPACITIES, FUEL . . . . . . . . . . 14-15,14-92 TANK FILLER TUBE CAP, FUEL; EMISSION CONTROL SYSTEMS . . . . . 25-21,25-6 TANK FILLER TUBE CAP, FUEL; FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-15 TANK FILLER TUBE, NO-LEAD FUEL . . . . . . 14-14 TANK PRESSURE RELIEF/ROLLOVER VALVE, FUEL . . . . . . . . . . . . . . 14-16,14-46,14-87 TANKS, FUEL . . . . . . . . . 14-14,14-15,14-46,14-87 TAPER, ROTOR THICKNESS VARIATION . . . . 5-43 TAPPETS, HYDRAULIC . . . . . . . . . . . . . 9-59,9-91 TCC SOLENOID . . . . . . . . . . . . . . . . . . . 8W-30-10 TEMPERATURE CONTROL CABLE . . . . . . . . 24-19 TEMPERATURE REFERENCE . . . . . . . . . . . . . 24-9 TEMPERATURE SENSOR, ENGINE COOLANT; EMISSION CONTROL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . 25-18 TEMPERATURE SENSOR, ENGINE COOLANT; FUEL SYSTEM . . . . . . . . . 14-44,14-84 TEMPERATURE SENSOR, ENGINE COOLANT; FUEL/IGNITION . . . . . . . . . . . 8W-30-4 TEMPERATURE SENSOR, ENGINE COOLANT; FUEL/IGNITION3.9L AND 5.2L ENGINES . . . . . . . . . . . . . . . . . . . . . 8W-30-9 TEMPERATURE SENSOR, ENGINE COOLANT; IGNITION SYSTEMS . . . . . 8D-20,8D-4 TEMPERATURE SENSOR, INTAKE AIR . 8W-30-10 TEMPERATURE SENSOR, INTAKE MANIFOLD AIR; FUEL SYSTEM . . . . . . . . . . 14-84 TEMPERATURE SENSOR, INTAKE MANIFOLD AIR; IGNITION SYSTEMS . . . . . 8D-23 TEMPERATURE SENSOR, SENSOR RESISTANCE (OHMS)COOLANT TEMPERATURE SENSOR/INTAKE MANIFOLD AIR . . . . . . . . . . . . . . . . . . . . . . 14-70 TEMPERATURE SENSOR TEST, ENGINE COOLANT; FUEL SYSTEM . . . . . . . . . . . . . . 14-70 TEMPERATURE SENSOR TEST, ENGINE COOLANT; IGNITION SYSTEMS . . . . . . . . . . 8D-8 TEMPERATURE SENSOR TEST, INTAKE MANIFOLD AIR; FUEL SYSTEM . . . . . . . . . . 14-70 TEMPERATURE SENSOR TEST, INTAKE MANIFOLD AIR; IGNITION SYSTEMS . . . . . 8D-12 TEMPERATURE SENSOR, THROTTLE BODY; FUEL SYSTEM . . . . . . . . . . . . . . . . . 14-49 TEMPERATURE SENSOR, THROTTLE BODY; FUEL/IGNITION . . . . . . . . . . . . . . 8W-30-4 TEMPERATURE SENSOR/INTAKE MANIFOLD AIR TEMPERATURE SENSOR, SENSOR RESISTANCE (OHMS)COOLANT . . . . . . . . . . . . . . . . . . 14-70 TEMPERATURE SENSOR2.5L ENGINE, THROTTLE BODY . . . . . . . . . . . . . . . . . . . . . 8D-5
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Description
TEMPERATURE SENSOR3.9L/5.2L ENGINE, INTAKE MANIFOLD AIR . . . . . . . . . 8D-5 TEMPERATURE SENSORPCM INPUT, ENGINE COOLANT . . . . . . . . . . . . . . . 14-23,14-58 TEMPERATURE SENSORPCM INPUT, INTAKE MANIFOLD AIR . . . . . . . . . . . . . . . . 14-58 TEMPERATURE SENSORPCM INPUT, THROTTLE BODY . . . . . . . . . . . . . . . . . . . . . 14-25 TENSION, ACCESSORY DRIVE BELT . . . . . . . 7-48 TENSION, BELT . . . . . . . . . . . . . . . . . . . . . . . 7-43 TENSIONER ADJUSTMENT, PARKING BRAKE CABLE . . . . . . . . . . . . . . . . . . . . . . . . 5-67 TENSIONER3.9L/5.2L ENGINE, AUTOMATIC BELT . . . . . . . . . . . . . . . . . . . . . 7-45 TERMINAL REPLACEMENT . . . . . . . . . . . 8W-01-8 TERMINAL REPLACEMENT, CONNECTOR . 8W-01-7 TERMINAL/CONNECTOR REPAIR MOLEX CONNECTORS . . . . . . . . . . . . . . 8W-01-6 TEST, AIR CONDITIONING AND HEATER PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . 24-7 TEST, AIR CONDITIONING PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . 24-7 TEST ANALYSIS, STALL . . . . . . . . . . . . . . . 21-96 TEST, ANALYZING THE ROAD . . . . . . . . . . . 21-93 TEST, AUTOMATIC SHUTDOWN (ASD) RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-6 TEST, CAMSHAFT POSITION SENSOR . . . . . 8D-6 TEST CHART, MIRROR . . . . . . . . . . . . . . . . . 8T-2 TEST, COMPASS/DISPLAY SELFDIAGNOSTIC . . . . . . . . . . . . . . . . . . . . . . . . . 8C-2 TEST, COMPRESSOR CLUTCH . . . . . . . . . . . . 24-13 TEST, CONVERTER STALL . . . . . . . . . . . . . . 21-96 TEST, CRANKSHAFT POSITION SENSOR; FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 14-72 TEST, CRANKSHAFT POSITION SENSOR; IGNITION SYSTEMS . . . . . . . . . . . . . . . . . . . 8D-7 TEST, CYLINDER COMBUSTION PRESSURE LEAKAGE . . . . . . . . . . . . . . . . . . . 9-6 TEST, CYLINDER COMPRESSION PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 TEST, ENGINE COOLANT TEMPERATURE SENSOR; FUEL SYSTEM . . . . . . . . . . . . . . . 14-70 TEST, ENGINE COOLANT TEMPERATURE SENSOR; IGNITION SYSTEMS . . . . . . . . . . . 8D-8 TEST, FUEL INJECTOR . . . . . . . . . . . . . . . . . 14-76 TEST, FUEL PUMP PRESSURE . . . . . . . . . . 14-76 TEST, HEATER OUTPUT . . . . . . . . . . . . . . . . . 24-8 TEST, HYDRAULIC PRESSURE . . . . . . . . . . 21-94 TEST, IDLE AIR CONTROL (IAC) MOTOR . . 14-72 TEST, INTAKE MANIFOLD AIR TEMPERATURE SENSOR; FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-70 TEST, INTAKE MANIFOLD AIR TEMPERATURE SENSOR; IGNITION SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-12 TEST, MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR; FUEL SYSTEM . . . . . . . . . 14-71 TEST, MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR; IGNITION SYSTEMS . . . . . 8D-12 TEST, MASTER CYLINDER/POWER BOOSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6 TEST, OXYGEN (O2S) SENSOR HEATING ELEMENT . . . . . . . . . . . . . . . . . . . . . . 14-35,14-72 TEST, POWER BOOSTER CHECK VALVE . . . . . 5-7 TEST, POWER BOOSTER VACUUM . . . . . . . . . 5-7 TEST, POWER STEERING PUMP FLOW RATE AND PRESSURE . . . . . . . . . . . . . . . . . . 19-3 TEST PROCEDURES, HEATING AND AIR CONDITIONING . . . . . . . . . . . . . . . . . . . . . . 24-10 TEST SPECIFICATIONS, 42RH/46RH PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . 21-289 TEST, STARTER MOTOR RELAY . . . . . . . . . 14-76 TEST, THROTTLE POSITION SENSOR . . . . . 8D-16 TEST, THROTTLE POSITION SENSOR (TPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-72 TEST, VACUUM SUPPLY . . . . . . . . . . . . . . . . 8H-6 TEST, VACUUM SWITCH . . . . . . . . . . . . . . . 24-10 TEST, VEHICLE SPEED SENSOR . . . . 14-35,14-74 TESTING, AUTOMATIC TRANSMISSION DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . 21-91 TESTING, CAMSHAFT POSITION SENSOR . 14-70 TESTING, COMBINATION VALVE . . . . . . . 5-10,5-6 TESTING COOLING SYSTEM FOR LEAKS . . . 7-25 TESTING, POWERTRAIN CONTROL MODULE . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-76 TESTING PROCEDURES, MULTIFUNCTION SWITCH . . . . . . . . . . . . . . . . . . . . 8L-4 TESTING RADIATOR CAPS, PRESSURE . . . . 7-28
TESTING REFRIGERANT, LEAK . . . . . . . . . . . 24-5 TESTING, ROAD; BRAKES . . . . . . . . . . . . . . . . 5-3 TESTING, ROAD; NV3500 MANUAL TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . 21-93 TESTING SPECIFICATIONS, STARTER AND SOLENOID; BATTERY/STARTER/ GENERATOR SERVICE . . . . . . . . . . . . . . . . . . 8B-9 TESTING SPECIFICATIONS, STARTER AND SOLENOID; BATTERY/STARTING/ CHARGING SYSTEMS DIAGNOSTICS . . . . . 8A-22 TESTING TRANSMISSION CLUTCH AND BAND OPERATION, AIR . . . . . . . . . . . . . . . . 21-97 TESTING, TRANSMISSION COOLER FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-134 TEST2.5L ENGINE, FUEL SYSTEM PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . 14-8 TEST3.9L/5.2L ENGINE, FUEL PRESSURE LEAK DOWN . . . . . . . . . . . . . . . . 14-9 TEST3.9L/5.2L ENGINE, FUEL PUMP CAPACITY . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-9 TEST3.9L/5.2L ENGINE, FUEL SYSTEM PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . 14-8 TESTS, OXYGEN SENSOR (O2S) . . . . . . . . 8D-16 TESTS, SNOW PLOW MALFUNCTION DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . . . . . . 13-4 TESTS, TROUBLESHOOTING . . . . . . . . . . 8W-01-4 THERMAL VACUUM VALVE (TVV) . . . . . . . . 14-30 THERMAL VACUUM VALVE (TVV)2.5L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-22 THERMOMETER . . . . . . . . . . . . . . . . . . . . . . 8C-1 THERMOMETER DIAGNOSIS . . . . . . . . . . . . . 8C-4 THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19 THICKNESS, ROTOR MINIMUM . . . . . . . . . . 5-42 THICKNESS VARIATION AND TAPER, ROTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43 THIRD GEAR, HYDRAULIC FLOW IN D . . . 21-120 THIS GROUP, HOW TO USE . . . . . . . . . . . . . 8W-1 THREAD NOTATIONSAE AND METRIC . Intro.-9 THREAD REPAIR, ALUMINUM . . . . . . . . . . 21-136 THREADS, REPAIR DAMAGED OR WORN . . . . 9-4 THROTTLE BODY . . . . . 14-30,14-48,14-63,14-89 THROTTLE BODY FITTINGS . . . . . . . . . . . . . 14-49 THROTTLE BODY MINIMUM AIR FLOW CHECK . . . . . . . . . . . . . . . . . . . . . . . . 14-36,14-73 THROTTLE BODY TEMPERATURE SENSOR; FUEL SYSTEM . . . . . . . . . . . . . . . 14-49 THROTTLE BODY TEMPERATURE SENSOR; FUEL/IGNITION . . . . . . . . . . . . 8W-30-4 THROTTLE BODY TEMPERATURE SENSOR2.5L ENGINE . . . . . . . . . . . . . . . . 8D-5 THROTTLE BODY TEMPERATURE SENSORPCM INPUT . . . . . . . . . . . . . . . . 14-25 THROTTLE CABLE . . . . . . . . . . . . . . . . . . . . 14-19 THROTTLE CABLE, ACCELERATOR PEDAL . . . . . . . . . . . . . . . . . . . 14-18,14-43,14-83 THROTTLE POSITION SENSOR; FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-50 THROTTLE POSITION SENSOR; FUEL/IGNITION . . . . . . . . . . . . . . . . . . . . 8W-30-4 THROTTLE POSITION SENSOR; FUEL/IGNITION3.9L AND 5.2L ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-9 THROTTLE POSITION SENSOR; IGNITION SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-5 THROTTLE POSITION SENSOR TEST . . . . . 8D-16 THROTTLE POSITION SENSOR (TPS); FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 14-90 THROTTLE POSITION SENSOR (TPS); IGNITION SYSTEMS . . . . . . . . . . . . . . . . . . 8D-26 THROTTLE POSITION SENSOR (TPS) TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-72 THROTTLE POSITION SENSOR (TPS)PCM INPUT . . . . . . . . . . . . . 14-25,14-60 THROTTLE VALVE CABLE ADJUSTMENT, TRANSMISSION . . . . . . . . . . . . . . . . . . . . . 21-128 TIE ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-17 TIE-ROD END . . . . . . . . . . . . . . . . . . . . . . . . 19-34 TIGHTENING, WHEEL NUT . . . . . . . . . . 5-25,5-43 TIME DELAY RELAY . . . . . . . . . . . . . . . . 8W-44-1 TIME TABLE, BATTERY CHARGING . . . . . . . . 8A-8 TIMING CHAIN COVER . . . . . . . . . . . . . 9-61,9-93 TIMING, IGNITION . . . . . . . . . . . . . . . . . . . . 8D-11 TIMING PROCEDURE, CAMSHAFT, CRANKSHAFT AND INTERMEDIATE SHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-18 TIMING PROCEDURE, IGNITION . . . . . . . . . 14-36 TIMING SYSTEM AND SEALS SERVICE . . . . 9-16 TIMING, VALVE . . . . . . . . . . . . . . . . . . . 9-60,9-92
TIRE AND WHEEL BALANCE . . . . . . . . . . . . . 22-7 TIRE AND WHEEL RUNOUT . . . . . . . . . . . . . 22-8 TIRE INFLATION PRESSURES . . . . . . . . . . . . 22-2 TIRE NOISE OR VIBRATION . . . . . . . . . . . . . 22-4 TIRE WEAR PATTERNS . . . . . . . . . . . . . . . . . 22-4 TIRE WINCH, SPARE . . . . . . . . . . . . . . . . . . 23-19 TIRES; LUBRICATION AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . 0-28 TIRES; WHEELS AND TIRES . . . . . . . . . . . . . 22-1 TIRES, CLEANING OF . . . . . . . . . . . . . . . . . . 22-2 TIRES, REPLACEMENT . . . . . . . . . . . . . . . . . 22-2 TO USE THIS GROUP, HOW . . . . . . . . . . . . . 8W-1 TONE WHEEL SERVICE . . . . . . . . . . . . . . . . . 5-58 TOOL, DRB SCAN; COOLING SYSTEM . . . . . . 7-4 TOOL, DRB SCAN; EMISSION CONTROL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-3 TOOL, DRB SCAN; FUEL SYSTEM . . . 14-39,14-79 TOOL, DRB SCAN; IGNITION SYSTEMS . . . . 8D-8 TOOLS, TROUBLESHOOTING . . . . . . . . . 8W-01-4 TORQUE; COOLING SYSTEM . . . . . . . . . . . . . 7-48 TORQUE; FUEL SYSTEM . . . . . . . . . . . . . . . 14-93 TORQUE; IGNITION SYSTEMS . . . . . . . . . . 8D-30 TORQUE CONVERTER . . . . . . . . . . . . . . . . . 21-82 TORQUE SPECIFICATIONS; BODY COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . 23-47 TORQUE SPECIFICATIONS; BRAKES . . . . . . . 5-68 TORQUE SPECIFICATIONS; CLUTCH . . . . . . . . 6-15 TORQUE SPECIFICATIONS; ENGINE . . 9-113,9-48, 9-81 TORQUE SPECIFICATIONS; EXHAUST SYSTEM AND INTAKE MANIFOLD . . . . . . . . 11-12 TORQUE SPECIFICATIONS; FRAME AND BUMPERS . . . . . . . . . . . . . . . . . . . . . . . . . . 13-36 TORQUE SPECIFICATIONS; FRONT SUSPENSION AND AXLE . . . . . . . . . . . . . . . . 2-47 TORQUE SPECIFICATIONS; HEATING AND AIR CONDITIONING . . . . . . . . . . . . . . . . . . . 24-26 TORQUE SPECIFICATIONS; INTRODUCTION . . . . . . . . . . . . . . . . . . . . . Intro.-8 TORQUE SPECIFICATIONS; PROPELLER SHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-15 TORQUE SPECIFICATIONS; REAR SUSPENSION AND AXLES . . . . . . . . . . . . . . . 3-36 TORQUE SPECIFICATIONS; STEERING . . . . 19-42 TORQUE SPECIFICATIONS; WHEELS AND TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-12 TORQUE SPECIFICATIONS, 42RH/46RH . . 21-289 TORQUE SPECIFICATIONS, AX 15 . . . . . . . 21-285 TORQUE SPECIFICATIONS, MEASUREMENT . . . . . . . . . . . . . . . . . . . . Intro.-8 TORQUE SPECIFICATIONS, NP231 . . . . . . 21-287 TORQUE SPECIFICATIONS, NV3500 . . . . . 21-287 TORQUE SPECIFICATIONS, STANDARD . . Intro.-9 TORSION BAR . . . . . . . . . . . . . . . . . . . . . . . . 2-15 TOUCH-UP, PAINTED SURFACE . . . . . . . . . . 23-45 TOW, TRAILER . . . . . . . . . . . . . . . . . . . . 8W-54-1 TOWING, FOUR-WHEEL-DRIVE VEHICLE . . . 0-12 TOWING, JUMP STARTING, HOISTING . . . . . . 0-9 TOWING RECOMMENDATIONS . . . . . . . . . . . 0-10 TOWING SPECIFICATIONS, TRAILER . . . . Intro.-3, Intro.-6 TOWING, TWO-WHEEL-DRIVE VEHICLE . . . . 0-11 TOWING WHEN KEYS ARE NOT AVAILABLE . . . . . . . . . . . . . . . . . . . . . . . . . . 0-13 (TPS)PCM INPUT, THROTTLE POSITION SENSOR . . . . . . . . . . . . . . 14-25,14-60 TRAC-LOC DIFFERENTIAL . . . . . . . . . . . . . . . 3-30 TRAILER TOW . . . . . . . . . . . . . . . . . . . . . 8W-54-1 TRAILER TOWING SPECIFICATIONS . . . . Intro.-3, Intro.-6 TRAIN AND INTERMEDIATE SHAFT OVERHAUL, PLANETARY GEAR . . . . . . . . . 21-164 TRANSFER CASE (4WD VEHICLES) . . . . . . . 0-22 TRANSFER CASE ASSEMBLY . . . . . . . . . . 21-273 TRANSFER CASE DISASSEMBLY AND OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . 21-267 TRANSFER CASE IDENTIFICATION . . . . . . 21-261 TRANSFER CASE INSTALLATION . . . . . . . . 21-266 TRANSFER CASE IN-VEHICLE SERVICE . . 21-265 TRANSFER CASE, LEGEND FOR NP231 . . 21-285 TRANSFER CASE, NP231 . . . . . . . 21-260,21-284 TRANSFER CASE REMOVAL . . . . . . . . . . . 21-266 TRANSFER CASE SPECIFICATIONS . . . . . . 21-262 TRANSMISSION - CONVERTER OVERDRIVE REMOVAL/INSTALLATION . . . 21-137 TRANSMISSION, 42RH/46RH AUTOMATIC . . . . . . . . . . . . . . . . . . . . . . . . . 21-82 TRANSMISSION ASSEMBLY . . . . . . 21-229,21-60
INDEX
Description Group-Page Description Group-Page Description
23
Group-Page
TRANSMISSION ASSEMBLY AND ADJUSTMENT; NV3500 MANUAL TRANSMISSION . . . . . . . . . . . . . . . . . . . . . 21-183 TRANSMISSION ASSEMBLY AND ADJUSTMENT; TRANSMISSION AND TRANSFER CASE . . . . . . . . . . . . . . . . . . . . . 21-24 TRANSMISSION, AUTOMATIC . . . . . . . . . . . . 0-22 TRANSMISSION, AX 15 MANUAL . . . . . . . . . 21-1 TRANSMISSION CABLE AND LINKAGE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . 21-93 TRANSMISSION CASE CLEANING AND INSPECTION . . . . . . . . . . . . . . . . . 21-154,21-200 TRANSMISSION CHANGES . . . . . . . . . . . . . 21-41 TRANSMISSION CHANGES AND PARTS INTERCHANGEABILITY . . . . . . . . . . . . . . . . 21-87 TRANSMISSION CLUTCH AND BAND OPERATION, AIR TESTING . . . . . . . . . . . . . 21-97 TRANSMISSION COMPONENT CLEANING AND INSPECTION . . . . . . . . . . . . . . . . . . . . 21-56 TRANSMISSION CONTROLS AND OPERATION, AUTOMATIC . . . . . . . . . . . . . . 21-88 TRANSMISSION COOLER FLOW TESTING . 21-134 TRANSMISSION COOLER LINE AND FITTING SERVICE . . . . . . . . . . . . . . . . . . . 21-133 TRANSMISSION COOLER REPLACEMENT . 21-136 TRANSMISSION COOLER REVERSE FLUSHING . . . . . . . . . . . . . . . . . . . . . . . . . 21-135 TRANSMISSION DESCRIPTION . . . . . . . . . . 21-82 TRANSMISSION DIAGNOSIS; NV3500 MANUAL TRANSMISSION . . . . . . 21-101,21-102, 21-103,21-104,21-105,21-106,21-107,21-108,21-41 TRANSMISSION DIAGNOSIS; TRANSMISSION AND TRANSFER CASE . . . . . 21-3 . TRANSMISSION DIAGNOSIS AND TESTING, AUTOMATIC . . . . . . . . . . . . . . . . . 21-91 TRANSMISSION DISASSEMBLY . . 21-147,21-193 TRANSMISSION DISASSEMBLY AND OVERHAUL; NV3500 MANUAL TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . 21-45 TRANSMISSION DISASSEMBLY AND OVERHAUL; TRANSMISSION AND TRANSFER CASE . . . . . . . . . . . . . . . . . . . . . . 21-8 TRANSMISSION GEAR RATIOS . . . . . . . . . . 21-40 TRANSMISSION HYDRAULIC CONTROLS . . 21-88 TRANSMISSION IDENTIFICATION . . . . . . . . 21-86 TRANSMISSION INSTALLATION (2-WHEEL DRIVE) . . . . . . . . . . . . . . . . . . . . 21-44 TRANSMISSION INSTALLATION (4-WHEEL DRIVE) . . . . . . . . . . . . . . . . . . . . 21-45 TRANSMISSION INSTALLATION2WHEEL DRIVE; NV3500 MANUAL TRANSMISSION . . . . . . . . . . . . . . . . . . . . . 21-140 TRANSMISSION INSTALLATION2WHEEL DRIVE; TRANSMISSION AND TRANSFER CASE . . . . . . . . . . . . . . . . . . . . . . 21-6 TRANSMISSION INSTALLATION4WHEEL DRIVE; NV3500 MANUAL TRANSMISSION . . . . . . . . . . . . . . . . . . . . . 21-142 TRANSMISSION INSTALLATION4WHEEL DRIVE; TRANSMISSION AND TRANSFER CASE . . . . . . . . . . . . . . . . . . . . . . 21-7 TRANSMISSION LUBRICANT . . . . . . . . . . . . 21-40 TRANSMISSION LUBRICANT LEVEL AND CAPACITY . . . . . . . . . . . . . . . . . . . . . . . . . . 21-40 TRANSMISSION, MANUAL . . . . . . . . . . . . . . 0-21 TRANSMISSION OIL COOLERS, AUTOMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32 TRANSMISSION OVERHAUL, 42RH . . . . . . 21-147 TRANSMISSION OVERHAUL, 46RH . . . . . . 21-193 TRANSMISSION REMOVAL (2-WHEEL DRIVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-42 TRANSMISSION REMOVAL (4-WHEEL DRIVE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21-43 TRANSMISSION REMOVAL2-WHEEL DRIVE; NV3500 MANUAL TRANSMISSION . . . . . . . . . . . . . . . . . . . . . 21-137 TRANSMISSION REMOVAL2-WHEEL DRIVE; TRANSMISSION AND TRANSFER CASE . . . . . . . . . . . . . . . . . . . . . . 21-4 TRANSMISSION REMOVAL4-WHEEL DRIVE; NV3500 MANUAL TRANSMISSION . . . . . . . . . . . . . . . . . . . . . 21-139 TRANSMISSION REMOVAL4-WHEEL DRIVE; TRANSMISSION AND TRANSFER CASE . . . . . . . . . . . . . . . . . . . . . . 21-5 TRANSMISSION THROTTLE VALVE CABLE ADJUSTMENT . . . . . . . . . . . . . . . . 21-128
TRANSMISSION/TRANSFER CASE IDENTIFICATION, ENGINE . . . . . . . . . . . . . Intro.-3 TRANSMITPCM OUTPUT, SCI . . . . . . . . . 14-63 TRAY, BATTERY . . . . . . . . . . . . . . . . . . . . . . . 23-8 TREAD WEAR INDICATORS . . . . . . . . . . . . . . 22-3 TRIM PANELS, INTERIOR . . . . . . . . . . . . . . 23-38 TRIM PANEL/WATERDAM/NOISE INSULATOR, DOOR . . . . . . . . . . . . . . . . . . . 23-24 TRIM REPAIR PRODUCTS AFTERMARKET PAINT . . . . . . . . . . . . . . . . . 23-46 TROUBLE CODE (DTC), DIAGNOSTIC . . . . . 14-39, 14-79 TROUBLE CODE, GENERATOR DIAGNOSTIC . . . . . . . . . . . . . . . . . . . . . . . . 8A-21 TROUBLE CODE, SPEED CONTROL DIAGNOSTIC . . . . . . . . . . . . . . . . . . . . . . . . . 8H-6 TROUBLESHOOTING TESTS . . . . . . . . . . 8W-01-4 TROUBLESHOOTING TOOLS . . . . . . . . . . 8W-01-4 TROUBLESHOOTING WIRING PROBLEMS . 8W-01-5 TUBE CAP, FUEL TANK FILLER; EMISSION CONTROL SYSTEMS . . . . . 25-21,25-6 TUBE CAP, FUEL TANK FILLER; FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-15 TUBE, NO-LEAD FUEL TANK FILLER . . . . . . 14-14 TUBE2.5L ENGINE, EGR . . . . . . . . . . . . . 25-19 TUBE3.9L/5.2L ENGINE, EGR . . . . . . . . . 25-19 TUBES/LINES/HOSES AND CLAMPS, FUEL . . . . . . . . . . . . . . . . . . . . 14-10,14-46,14-87 TURN SIGNAL . . . . . . . . . . . . . . . . . . . . . . . . 8J-2 TURN SIGNAL LAMPS, PARK . . . . . . . . . . . . . . 8L-9 TURN SIGNAL LAMPS, TAIL, STOP AND . . 8L-11 TURN SIGNAL SYSTEM . . . . . . . . . . . . . . . . . 8J-1 TURN SIGNALS . . . . . . . . . . . . . . . . . . . . 8W-52-1 (TVV)2.5L ENGINE, THERMAL VACUUM VALVE . . . . . . . . . . . . . . . . . . . . . . 25-22 TWO-WHEEL-DRIVE VEHICLE TOWING . . . . . 0-11 TYPICAL VEHICLE EMISSION CONTROL INFORMATION LABEL . . . . . . . . . . . . . . . . . . 25-2 UNBALANCE . . . . . . . . . . . . . . . . . . . . . . . . . 16-3 UNDERHOOD LAMP; INTERIOR LIGHTING . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-1 UNDERHOOD LAMP; LAMPS . . . . . . . . . . . . 8L-11 UNDERHOOD LAMP BULB REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . 8L-12 UNDERHOOD LAMP REPLACEMENT . . . . . . 8L-12 UNDERSIZE ENGINE COMPONENT MARKINGS, OVERSIZE . . . . . . . . . . . . 9-112,9-80 UNIT DISASSEMBLY, OVERDRIVE . . . . . . . 21-238 UNIT, FUEL GAUGE SENDING . . . . . . . . . . . 14-16 UNIT INSTALLATION2-WHEEL DRIVE, OVERDRIVE . . . . . . . . . . . . . . . . . . . . . . . . 21-144 UNIT INSTALLATION4-WHEEL DRIVE, OVERDRIVE . . . . . . . . . . . . . . . . . . . . . . . . 21-145 UNIT OVERHAUL, 42RH/46RH OVERDRIVE . . . . . . . . . . . . . . . . . . . . . . . . 21-238 UNIT, POWER . . . . . . . . . . . . . . . . . . . . . . . 13-13 UNIT REMOVAL2-WHEEL DRIVE, OVERDRIVE . . . . . . . . . . . . . . . . . . . . . . . . 21-143 UNIT REMOVAL4-WHEEL DRIVE, OVERDRIVE . . . . . . . . . . . . . . . . . . . . . . . . 21-145 UNIT REMOVE/INSTALL, OIL PRESSURE SENDING . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-16 UNITS, WHEEL BRAKE . . . . . . . . . . . . . . . . . . 5-1 UNIVERSAL JOINT ANGLE MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . 16-4 UNIVERSAL JOINT, PROPELLER SHAFT . . . 16-15 UNIVERSAL JOINT REPLACEMENT . . . . . . . 16-10 UNIVERSAL JOINTS . . . . . . . . . . . . . . . . . . . 16-2 UPPER BALL STUD . . . . . . . . . . . . . . . . 2-12,2-17 UPPER SUSPENSION ARM . . . . . . . . . . 2-12,2-16 UPSHIFT LAMP . . . . . . . . . . . . . . . . . . . 8W-30-10 URETHANE SET GLASS . . . . . . . . . . . . . . . . 23-32 USAGE STATEMENT, FUEL . . . . . . . . . . . . . . . 14-1 USE THIS GROUP, HOW TO . . . . . . . . . . . . . 8W-1 USING ALIGNMENT SCREEN, HEADLAMP/FOG LAMP ADJUSTMENT . . . . . 8L-6 USING ON-BOARD DIAGNOSTIC SYSTEM; BATTERY/STARTING/ CHARGING SYSTEMS DIAGNOSTICS . . . . . 8A-21 USING ON-BOARD DIAGNOSTIC SYSTEM; VEHICLE SPEED CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8H-3 V-6 AND 5.2L V-8 ENGINES, ENGINE VACUUM SCHEMATIC3.9L . . . . . . . . . . . . . 25-4 V-6 AND V-8, PUMP REPLACEMENT . . . 19-13 V-6 ENGINE, ENGINE FIRING ORDER 3.9L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-29
V-8 ENGINE, ENGINE FIRING ORDER 5.2L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8D-29 V-8 ENGINES, ENGINE VACUUM SCHEMATIC3.9L V-6 AND 5.2L . . . . . . . . . 25-4 V-8, PUMP REPLACEMENT V-6 . . . . . . . . 19-13 VACUUM ACTUATOR, MODE DOOR . . . . . . 24-20 VACUUM ACTUATOR, RECIRCULATING AIR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-20 VACUUM CIRCUITS HEATER A/C CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . 24-11 VACUUM COMPONENTS, HYDRAULIC . . . . . . 5-1 VACUUM DIAGNOSIS, HEATER A/C CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . 24-10 VACUUM DIAPHRAGM2.5L ENGINE . . . . 25-21 VACUUM HOSE ROUTING SCHEMATICS . . . . 25-1 VACUUM RESERVOIR . . . . . . . . . . . . . . . . . . 8H-1 VACUUM RESERVOIR REMOVE/INSTALL . . . 8H-9 VACUUM SCHEMATIC2.5L 4CYLINDER ENGINE, ENGINE . . . . . . . . . . . . . 25-3 VACUUM SCHEMATIC3.9L V-6 AND 5.2L V-8 ENGINES, ENGINE . . . . . . . . . . . . . 25-4 VACUUM SUPPLY TEST . . . . . . . . . . . . . . . . 8H-6 VACUUM SWITCH TEST . . . . . . . . . . . . . . . 24-10 VACUUM TEST, POWER BOOSTER . . . . . . . . . 5-7 VACUUM VALVE (TVV), THERMAL . . . . . . . 14-30 VACUUM VALVE (TVV)2.5L ENGINE, THERMAL . . . . . . . . . . . . . . . . . . . . . . . . . . 25-22 VALUES, CONVERSION FORMULAS AND EQUIVALENT . . . . . . . . . . . . . . . . . . . . . . . Intro.-8 VALVE ASSEMBLY SERVICE, CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19 VALVE BODY CLEANING AND INSPECTION . . . . . . . . . . . . . . . . . 21-176,21-223 VALVE BODY SERVICE . . . . . . . . . . . . . . . 21-132 VALVE BODY SERVICE AND ADJUSTMENT . . . . . . . . . . . . . . . . 21-170,21-217 VALVE CABLE ADJUSTMENT, TRANSMISSION THROTTLE . . . . . . . . . . . 21-128 VALVE COMPONENTS REPLACE CLYINDER HEAD NOT REMOVED . . . . . 9-54,9-87 VALVE CONTROL, EGR . . . . . . . . . . . . . . . . 25-20 VALVE CONTROL SOLENOIDPCM OUTPUT, EGR (EXHAUST GAS RECIRCULATION) . . . . . . . . . . . . . . . . . . . . 14-62 VALVE, CONVERTER DRAINBACK . . . . . . . . 21-89 VALVE, EGR . . . . . . . . . . . . . . . . . . . . . . . . . 25-18 VALVE FLOW CONTROL, SHIFT . . . . . . . . . . 21-89 VALVE, FRONT ANTI-LOCK . . . . . . . . . . . 8W-32-2 VALVE, FUEL TANK PRESSURE RELIEF/ROLLOVER . . . . . . . . . 14-16,14-46,14-87 VALVE GUIDES . . . . . . . . . . . . . . . . . . . . . . . 9-89 VALVE, HIGH PRESSURE RELIEF . . . . . . . . 24-13 VALVE INSTALLATION, COMBINATION . 5-47,5-57 VALVE INSTALLATION, FRONT ANTILOCK . . . 5-55 VALVE INSTALLATION, REAR ANTILOCK . . . 5-47, 5-57 VALVE OPERATION, BOOST . . . . . . . . . . . . . 21-89 VALVE OPERATION, COMBINATION . . . . 5-46,5-55 VALVE OPERATION, QUICK FILL . . . . . . . . . 21-89 VALVE, PRESSURE RELIEF/ROLLOVER . . . 25-22, 25-5 VALVE, REAR ANTI-LOCK . . . . . 8W-32-2,8W-32-4 VALVE REMOVAL, COMBINATION . . . . . 5-47,5-57 VALVE REMOVAL, FRONT ANTILOCK . . . . . . 5-55 VALVE REMOVAL, REAR ANTILOCK . . . 5-46,5-56 VALVE REPLACEMENT . . . . . . . . . . . . . . . . . 19-26 VALVE REPLACEMENT, CHECK . . . . . . . . . . 19-31 VALVE SERVICE AND DIAGNOSIS, ANTILOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9 VALVE SERVICE, CONVERTER DRAINBACK CHECK . . . . . . . . . . . . . . . . . . 21-134 VALVE SERVICECYLINDER HEAD REMOVED . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-25 VALVE SPRINGS, VALVES . . . . . . . . . . . 9-56,9-89 VALVE STEM SEAL AND SPRING REPLACEMENT . . . . . . . . . . . . . . . . . . . 9-55,9-87 VALVE TEST, POWER BOOSTER CHECK . . . . . 5-7 VALVE TESTING, COMBINATION . . . . . . . 5-10,5-6 VALVE TIMING . . . . . . . . . . . . . . . . . . . . 9-60,9-92 VALVE (TVV), THERMAL VACUUM . . . . . . . 14-30 VALVE (TVV)2.5L ENGINE, THERMAL VACUUM . . . . . . . . . . . . . . . . . . . . . . . . . . . 25-22 VALVES AND VALVE SPRINGS . . . . . . . 9-56,9-89 VARIANCE, PINION GEAR DEPTH; FRONT SUSPENSION AND AXLE . . . . . . . . . . . . . . . . 2-42 VARIANCE, PINION GEAR DEPTH; REAR SUSPENSION AND AXLES . . . . . . . . . . . . . . . 3-24 VARIATION ADJUSTMENT, COMPASS . . . . . . 8C-5
24
INDEX
Group-Page Description Group-Page Description Group-Page
Description
VARIATION AND TAPER, ROTOR THICKNESS . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43 V-BELT DIAGNOSIS2.5L 4-CYLINDER ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39 VEHICLE CODE DESIGNATIONS . . . . . . . . Intro.-1 VEHICLE CONTROL AND DISPLAY SYMBOLS, INTERNATIONAL . . . . . . . . . . . Intro.-3 VEHICLE DESIGNATIONS . . . . . . . . . . . . . Intro.-1 VEHICLE DIMENSIONS . . . . . . . . . . . . . . . Intro.-3 VEHICLE EMISSION CONTROL INFORMATION LABEL, TYPICAL . . . . . . . . . . 25-2 VEHICLE EMISSION CONTROL INFORMATION (VECI) LABEL . . . . . . . . . . . . 25-1 VEHICLE EXTERIOR DIMENSIONS . . . . . . Intro.-4 VEHICLE IDENTIFICATION NUMBER (VIN) DECODING . . . . . . . . . . . . . . . . . . . . . . . . Intro.-2 VEHICLE IDENTIFICATION NUMBER (VIN) PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . Intro.-1 VEHICLE LOADING AND WEIGHT DISTRIBUTION . . . . . . . . . . . . . . . . . . . . . . . . 3-4 VEHICLE SAFETY CERTIFICATION LABEL . Intro.-1 VEHICLE SPEED CONTROL . . . . . . . . . . . 8W-33-1 VEHICLE SPEED SENSOR; FUEL SYSTEM . 14-50, 14-91 VEHICLE SPEED SENSOR; FUEL/ IGNITION . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-3 VEHICLE SPEED SENSOR; FUEL/ IGNITION3.9L AND 5.2L ENGINES . . . 8W-30-8 VEHICLE SPEED SENSOR; VEHICLE SPEED CONTROL SYSTEM . . . . . . . . . . 8H-1,8H-3 VEHICLE SPEED SENSOR REMOVE/ INSTALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8E-16 . VEHICLE SPEED SENSOR TEST . . . . 14-35,14-74 VEHICLE SPEED SENSORPCM INPUT . . 14-25, 14-60 VEHICLE TOWING, FOUR-WHEEL-DRIVE . . . 0-12 VEHICLE TOWING, TWO-WHEEL-DRIVE . . . . 0-11 VEHICLE VIBRATION . . . . . . . . . . . . . . . . . . 22-10 VEHICLE WEIGHTS . . . . . . . . . . . . Intro.-3,Intro.-5 VENT GLASS, SLIDING . . . . . . . . . . . . . . . . 23-36 VENT WINDOWCLUB CAB, QUARTER . . . 23-33 VENTILATION (PCV) SYSTEM, POSITIVE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . 25-6 VENTILATION SYSTEMS, CRANKCASE . . . . . 0-17 VIBRATION; FRONT SUSPENSION AND AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20 VIBRATION; PROPELLER SHAFTS . . . . . . . . . 16-3 VIBRATION; REAR SUSPENSION AND AXLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9 VIBRATION DAMPER . . . . . . . . . . . . . . . 9-60,9-92 VIBRATION DIAGNOSIS . . . . . . . . . . . 22-10,22-11 VIBRATION, DRIVELINE . . . . . . . . . . . . . . . . . 16-3 VIBRATION, TIRE NOISE OR . . . . . . . . . . . . . 22-4 VIBRATION TYPES . . . . . . . . . . . . . . . . . . . . 22-10 VIBRATION, VEHICLE . . . . . . . . . . . . . . . . . 22-10 VISCOUS FAN DRIVE3.9L/5.2L ENGINE . . . 7-37 VISUAL INSPECTION . . . . . . . . . . . . . 14-32,14-67 VOLTAGE, OPEN CIRCUIT . . . . . . . . . . . . . . . 8A-7 VOLTAGEPCM INPUT, BATTERY . . . 14-23,14-57 WARNING, HAZARD . . . . . . . . . . . . . . . . . . . 8J-3 WARNING LAMP . . . . . . . . . . . . . . . . . . . 8W-32-4 WARNING LAMP, ABS . . . . . . . . . . . . . . . 8W-32-2 WARNING LAMP, AIRBAG . . . . . . . . . . . . 8W-43-1 WARNING LAMP, BRAKE . . . . . . . . . . . . 8W-32-2 WARNING LAMP, LOW WASHER FLUID . 8W-53-2 WARNING LAMP SWITCH, BRAKE . . . . . 8W-32-4 WARNING LIGHT DISPLAY, ABS/RWAL . . . . . . 5-9 WARNING LIGHT ILLUMINATION, SERVICE BRAKE . . . . . . . . . . . . . . . . . . . . . . . 5-3 WARNING LIGHTS, BRAKE . . . . . . . . . . . . . . . 5-1 WARNING SYSTEM, HAZARD . . . . . . . . . . . . 8J-1 WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . 24-3 WARNINGS, CAUTIONS AND SERVICE PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . 24-3 WARNINGS, NOTES, CAUTIONS . . . . . . . 8W-01-1 WARNINGS, SAFETY PRECAUTIONS; BODY COMPONENTS . . . . . . . . . . . . . . . . . . 23-32 WARNINGS, SAFETY PRECAUTIONS; FRAME AND BUMPERS . . . . . . . . . . . . . . . . 13-20
WASHER FLUID WARNING LAMP, LOW . 8W-53-2 WASHER PUMP . . . . . . . . . . . . . . . . . . . . . . 8K-6 WASHER PUMP REMOVE/INSTALL . . . . . . . 8K-10 WASHER SYSTEM, WINDSHIELD . . . . . . . . . 8K-1 WATER PUMP BYPASS HOSE3.9L/5.2L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17 WATER PUMPSGENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . 7-12 WATER PUMPSREMOVAL/ INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 7-12 WEAR INDICATORS, TREAD . . . . . . . . . . . . . 22-3 WEAR PATTERNS, TIRE . . . . . . . . . . . . . . . . 22-4 WEATHERSTRIP SEALS, WINDOW GLASS AND DOOR . . . . . . . . . . . . . . . . . . . 23-29 WEIGHT DISTRIBUTION, VEHICLE LOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 WEIGHTS, VEHICLE . . . . . . . . . . . Intro.-3,Intro.-5 WET SANDING,BUFFING AND POLISHING . 23-45 WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . 2-4 WHEEL ALIGNMENT SPECIFICATIONS, FRONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 WHEEL ANTI-LOCK BRAKE SYSTEM (ABS), ALL . . . . . . . . . . . . . . . . . . . . . . . 8W-32-1 WHEEL ANTI-LOCK (RWAL) BRAKES, REAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-32-3 WHEEL ASSEMBLY, BLOWER MOTOR . . . . 24-23 WHEEL BALANCE, TIRE . . . . . . . . . . . . . . . . . 22-7 WHEEL BEARING LUBRICANTS, CHASSIS COMPONENT . . . . . . . . . . . . . . . . . . . . . . . . . 0-25 WHEEL BEARINGS, FRONT . . . . . . . . . . . . . . . 0-26 WHEEL BRAKE UNITS . . . . . . . . . . . . . . . . . . . 5-1 WHEEL CYLINDER INSTALLATION . . . . . . . . 5-24 WHEEL CYLINDER OVERHAUL . . . . . . . . . . . 5-24 WHEEL CYLINDER REMOVAL . . . . . . . . . . . . 5-24 WHEEL HUB AND BEARINGS . . . . . . . . . 2-14,2-8 WHEEL INSTALLATION . . . . . . . . . . . . . . . . . 22-6 WHEEL LUG NUT . . . . . . . . . . . . . . . . . . . . 22-12 WHEEL NUT TIGHTENING . . . . . . . . . . . 5-25,5-43 WHEEL ORNAMENTATION . . . . . . . . . . . . . . . 22-7 WHEEL REPLACEMENT . . . . . . . . . . . . . . . . . 22-6 WHEEL RUNOUT, TIRE . . . . . . . . . . . . . . . . . 22-8 WHEEL SERVICE, TONE . . . . . . . . . . . . . . . . 5-58 WHEEL SPEED SENSOR, REAR . . . . . . . 8W-32-3 WHEEL SPEED SENSORS . . . . . . . . . . . . 8W-32-1 WHEEL, STEERING . . . . . . . . . . . . . . . . . . . 19-37 WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-6 WHEN KEYS ARE NOT AVAILABLE, TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0-13 WINCH, SPARE TIRE . . . . . . . . . . . . . . . . . . 23-19 WINDOW GLASS AND DOOR WEATHERSTRIP SEALS . . . . . . . . . . . . . . . . 23-29 WINDOW MOTOR, POWER . . . . . . . . . . 8S-1,8S-2 WINDOW MOTOR REMOVE/INSTALL, POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8S-3 WINDOW SWITCH, POWER . . . . . . . . . . . . . 8S-1 WINDOW SWITCH REMOVE/INSTALL, POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8S-3 WINDOWCLUB CAB, QUARTER VENT . . . 23-33 WINDOWCLUB CAB, REAR . . . . . . . . . . . 23-34 WINDOWCONVENTIONAL CAB, REAR . . . 23-35 WINDOWS, POWER . . . . . . . . . . . . . . . . 8W-60-1 WINDSHIELD . . . . . . . . . . . . . . . . . . . . . . . . 23-32 WINDSHIELD WASHER SYSTEM . . . . . . . . . 8K-1 WINDSHIELD WIPER SYSTEM . . . . . . . . . . . 8K-1 WIPE MODULE, INTERMITTENT . . . . . . . . . . 8K-6 WIPER ARM REMOVE/INSTALL . . . . . . . . . . 8K-7 WIPER BLADES OR ELEMENTS REMOVE/INSTALL . . . . . . . . . . . . . . . . . . . . . 8K-7 WIPER MOTOR . . . . . . . . . . . . . . . . . . . 8K-3,8K-7 WIPER PIVOTS REMOVE/INSTALL . . . . . . . . 8K-8 WIPER SYSTEM, WINDSHIELD . . . . . . . . . . . 8K-1 WIPERSINTERMITTENT . . . . . . . . . . . . 8W-53-1 WIPERSSTANDARD . . . . . . . . . . . . . . . 8W-53-1 WIPER/WASHER DIAGNOSIS . . . . . . . . . . . . 8K-4 WIPER/WASHER SWITCH . . . . . . . . . . . . . . . 8K-6 WIPER/WASHER SWITCH REMOVE/ INSTALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8K-8 WIRE CODE IDENTIFICATION . . . . . . . . . 8W-01-1
WIRING DIAGRAMS, SNOW PLOW . . . . . . . . 13-4 WIRING PROBLEMS, TROUBLESHOOTING . . . . . . . . . . . . . . . . 8W-01-5 WIRING REPAIR . . . . . . . . . . . . . . . . . . . 8W-01-6 WORM SHAFT REPLACEMENT, RACK PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-28 WORN THREADS, REPAIR DAMAGED OR . . . . 9-4 YOKE SEAL REPLACEMENT (2-WHEEL DRIVE MODELS), SLIP . . . . . . . . . . . . . . . 21-131