Voyaguer GS 1999-1996-15

NS/GS FUEL SYSTEM—2.5L DIESEL ENGINE/2.
0L GAS ENGINE 14 - 33
DESCRIPTION AND OPERATION

SYSTEM DIAGNOSIS—2.0L ENGINE
Refer to System diagnosis for 2.4/3.0/3.3/3.8L
engines under Description and Operation in the Fuel
Injection System section of group 14 for more infor-
mation.
POWERTRAIN CONTROL MODULE—2.0L ENGINE

Refer to the Powertrain Control Module for 2.4/3.0/
3.3/3.8L engines under Description and Operation in
the Fuel Injection System section of group 14 for
more information.
AIR CONDITIONING PRESSURE TRANSDUCER—

PCM INPUT—2.0L ENGINE
Refer to the Air Conditioning Pressure Transducer Fig. 1 Camshaft Position Sensor—2.0L Engine
for 2.4/3.0/3.3/3.8L engines under Description and
Operation in the Fuel Injection System section of
group 14 for more information.
AIR CONDITIONING SWITCH SENSE—PCM

INPUT—2.0L ENGINE
Refer to the Air Conditioning Switch Sense for 2.4/
3.0/3.3/3.8L engines under Description and Operation
in the Fuel Injection System section of group 14 for
more information.
AUTOMATIC SHUTDOWN (ASD) SENSE—PCM

INPUT—2.0L ENGINE
Refer to the Automatic Shutdown (ASD) Sense for
2.4/3.0/3.3/3.8L engines under Description and Oper-
ation in the Fuel Injection System section of group 14
for more information. Fig. 2 Crankshaft Posistion Sensor—2.0L engine
ENGINE COOLANT TEMPERATURE SENSOR—PCM
BATTERY VOLTAGE—PCM INPUT—2.0L ENGINE
Refer to the Battery Voltage for 2.4/3.0/3.3/3.8L
INPUT—2.0L ENGINE
engines under Description and Operation in the Fuel The coolant temperature sensor threads into the
Injection System section of group 14 for more infor- rear of the cylinder head, next to the camshaft posi-
mation. tion sensor (Fig. 3). New sensors have sealant
applied to the threads.
CAMSHAFT POSITION SENSOR—PCM INPUT— Refer to the Engine Coolant Temperature Sensor
for the 2.4/3.0/3.3/3.8L engines under Description and
2.0L ENGINE Operation in the Fuel Injection System section of
Refer to the Camshaft Position Sensor for 2.4L
group 14 for more information.
engine under Description and Operation in the Fuel
Injection System section of group 14 for more infor- HEATED OXYGEN SENSOR—PCM INPUT—2.0L
mation.
ENGINE
CRANKSHAFT POSITION SENSOR—PCM Refer to the Heated Oxygen Sensor for 2.4/3.0/3.3/
3.8L engines under Description and Operation in the
INPUT—2.0L ENGINE Fuel Injection System section of group 14 for more
Refer to the Crankshaft Position Sensor for 2.4L
information.
engine under Description and Operation in the Fuel
mation.
14 - 34 FUEL SYSTEM—2.5L DIESEL ENGINE/2.0L GAS ENGINE NS/GS
DESCRIPTION AND OPERATION (Continued)
Fig. 3 Engine Coolant Temperature Sensor—2.0L Fig. 6 Knock Sensor—2.0L engine

engine
KNOCK SENSOR—PCM INPUT—2.0L ENGINE
Refer to the Knock Sensor for 2.4/3.0/3.3/3.8L
mation.
MANIFOLD ABSOLUTE PRESSURE (MAP

SENSOR)—PCM INPUT—2.0L ENGINE
Fig. 4 Upstream Heated Oxygen Sensor—2.0L

Engine
Fig. 7 MAP/IAT sensor—2.0L engine

Refer to the Manifold Absolute Pressure and
Intake Air Temperature sensors for 2.4/3.0/3.3/3.8L
mation.
SPEED CONTROL—PCM INPUT—2.0L ENGINE

Refer to the Speed Control for 2.4/3.0/3.3/3.8L
Fig. 5 Downstream Heated Oxygen Sensor—2.0L Injection System section of group 14 for more infor-
Engine mation.
NS/GS FUEL SYSTEM—2.5L DIESEL ENGINE/2.0L GAS ENGINE 14 - 35
THROTTLE POSITION SENSOR/ IDLE AIR STARTER RELAY—PCM OUTPUT—2.0L ENGINE
CONTROL MOTOR—PCM INPUT—2.0L ENGINE Refer to the Starter Relay for 2.4/3.0/3.3/3.8L
mation.
IDLE AIR CONTROL MOTOR—PCM OUTPUT—2.0L

ENGINE
Refer to the Idle Air Control Motor for 2.4/3.0/3.3/
Fuel Injection System section of group 14 for more
information. Refer to (Fig. 8) for component location
ELECTRONIC EGR TRANSDUCER—PCM

OUTPUT—2.0L ENGINE
Fig. 8 Throttle Position Sensor/Idle Air Control

motor—2.0L engine
Refer to the Throttle Control and Idle Air Control
motor for the 2.4/3.0/3.3/3.8L engines under Descrip-
tion and Operation in the Fuel Injection System sec-
tion of group 14 for more information.
AIR CONDITIONING (A/C) RELAY—PCM

OUTPUT—2.0L ENGINE
Refer to the Air Conditioning relay for 2.4/3.0/3.3/
Fuel Injection System section of group 14 for more
information.
Fig. 9 Electronic EGR Transducer—2.0L engine
GENERATOR FIELD—PCM OUTPUT—2.0L ENGINE Refer to the Electronic EGR Transducer for 2.4/3.0/
Refer to Generator Field for 2.4/3.0/3.3/3.8L 3.3/3.8L engines under Description and Operation in
engines under Description and Operation in the Fuel the Fuel Injection System section of group 14 for
Injection System section of group 14 for more infor- more information.
mation.
DATA LINK CONNECTOR—PCM OUTPUT—2.0L
AUTOMATIC SHUTDOWN RELAY—PCM ENGINE
OUTPUT—2.0L ENGINE Refer to the Data Link Connector for 2.4/3.0/3.3/
Refer to Automatic Shutdown Relay for 2.4/3.0/3.3/ 3.8L engines under Description and Operation in the
3.8L engines under Description and Operation in the Fuel Injection System section of group 14 for more
Fuel Injection System section of group 14 for more information.
information.
FUEL INJECTORS—PCM OUTPUT—2.0L ENGINE
FUEL PUMP RELAY—PCM OUTPUT—2.0L ENGINE Refer to the Fuel Injectors for 2.4/3.0/3.3/3.8L
Refer to the Fuel Pump Relay for 2.4/3.0/3.3/3.8L engines under Description and Operation in the Fuel
engines under Description and Operation in the Fuel Injection System section of group 14 for more infor-
Injection System section of group 14 for more information.
mation.
IGNITION COIL—PCM OUTPUT—2.0L ENGINE
Fig. 11 Throttle Body—2.0L engine

Fig. 10 Ignition Coil—2.0L engine DIAGNOSIS AND TESTING
Refer to the Ignition Coil for 2.4/3.0/3.3/3.8L
engines under Description and Operation in the Fuel VISUAL INSPECTION—SOHC
Injection System section of group 14 for more infor- Before diagnosing or servicing the fuel injection
mation. system, perform a visual inspection for loose, discon-
nected, or misrouted wires and hoses. A thorough
MALFUNCTION INDICATOR (CHECK ENGINE) visual inspection that includes the following checks
saves unnecessary test and diagnostic time.
LAMP—PCM OUTPUT—2.0L ENGINE
(1) Inspect the battery connections. Clean corroded
Refer to the Malfunction Indicator Lamp for 2.4/
terminals.
3.0/3.3/3.8L engines under Description and Operation
(2) Check the 2 PCM 40-way connector for
in the Fuel Injection System section of group 14 for
stretched wires on pushed out terminals
more information.
(3) Open the Power Distribution Center (PDC).
Check for blown fuses. Ensure the relays and fuses
RADIATOR FAN CONTROL MODULE—PCM
are fully seated in the PDC. A label on the underside
OUTPUT—2.0L ENGINE of the PDC cover shows the locations of each relay
Refer to the Radiator Fan Control Module for 2.4/ and fuse.
3.0/3.3/3.8L engines under Description and Operation (4) Verify the throttle cable operates freely.
in the Fuel Injection System section of group 14 for (5) Check the electrical connections at the idle air
more information. control motor and throttle position sensor.
(6) Check hose connections between the PCV
SPEED CONTROL SOLENOIDS—PCM OUTPUT— valve, vacuum port - intake manifold and the oil sep-
2.0L ENGINE arator (Fig. 13).
Refer to the Speed Control Solenoids for 2.4/3.0/3.3/ (7) Inspect the electrical connections at the MAP
3.8L engines under Description and Operation in the sensor/intake air temperature sensor and the (Fig.
Fuel Injection System section of group 14 for more 14).
information. (8) Inspect the fuel injector electrical connections
(Fig. 15).
TACHOMETER—PCM OUTPUT—2.0L ENGINE (9) Inspect the ignition coil electrical connector.
Refer to the Tachometer for 2.4/3.0/3.3/3.8L engines Ensure the spark plug insulators are firmly seated
under Description and Operation in the Fuel Injec- over the spark plugs (Fig. 16).
tion System section of group 14 for more information. (10) Check the electrical connection to the radiator
fan.
THROTTLE BODY—2.0L ENGINE (11) Inspect for corrosion on the electrical connec-
Refer to the Throttle Body for 2.4/3.0/3.3/3.8L tions at the starter motor solenoid. Check the ground
engines under Description and Operation in the Fuel cable connection below the starter motor (Fig. 17).
Injection System section of group 14 for more infor- (12) Inspect the air cleaner filter element. Replace
mation. as necessary. Check the air induction system for
restrictions.
DIAGNOSIS AND TESTING (Continued)
Fig. 14 MAP/Intake Air Temperature Sensor
Fig. 12 Idle Air Control Motor and Throttle Position

Sensor—Typical
Fig. 15 Fuel Injectors
Fig. 13 PCV Valve

(13) Check the electrical connection at the knock
sensor (Fig. 18).
(14) Check the electrical connections at the cam-
shaft position sensor and engine coolant temperature
sensor (Fig. 19).
(15) Check the electrical connector at the Elec-
tronic EGR Transducer. Inspect the vacuum and back Fig. 16 Ignition Coil and Spark Plugs—Typical
pressure hoses at the solenoid and transducer for (17) Inspect the electrical connector at the crank-
leaks (Fig. 20). shaft position sensor (Fig. 22).
(16) Inspect the electrical connections at the gen- (18) Check the electrical connection at the vehicle
erator (Fig. 21). Check the generator belt for glazing speed sensor (Fig. 23).
or damage.
Fig. 17 Starter Motor and Ground Strap
Fig. 20 Electronic EGR Transducer
Fig. 18 Knock Sensor
Fig. 21 Generator
Fig. 19 Camshaft Position Sensor and Engine

Coolant Temperature Sensor
(19) Check the electrical connection at the power Fig. 22 Crankshaft Position Sensor
steering pressure switch on the power steering gear
housing (Fig. 24).
Fig. 23 Vehicle Speed Sensor Fig. 26 Downstream Heated Oxygen Sensor

27). Check for pinched, kinked or damaged fuel sup-
ply tube.
Fig. 24 Power Steering Pressure Switch

(20) Inspect the electrical connections at the
upstream and downstream heated oxygen sensors
(Fig. 25) and (Fig. 26). Fig. 27 Fuel Pump Module Electrical Connector
(22) Inspect the connections to the speed control
servo, if equipped. Refer to Group 8H, Vehicle Speed
Control.
(23) Inspect the connection at the battery temper-
ature sensor.
ASD AND FUEL PUMP RELAYS—2.0L ENGINE

Refer to the ASD and Fuel Pump Relays for 2.4/
3.0/3.3/3.8L engines under Diagnosis and Testing in
the Fuel Injection System section of group 14 for
more information.
MANIFOLD ABSOLUTE PRESSURE (MAP)

SENSOR—2.0L ENGINE
To perform a complete test of the MAP sensor and
its circuitry, refer to the DRB scan tool and appropri-
Fig. 25 Upstream Heated Oxygen Sensor ate Powertrain Diagnostics Procedures manual. To
test the MAP sensor only, refer to the following:
(21) Inspect the fuel pump module electrical con-
nection at the fuel tank for corrosion or damage (Fig.
(3) Test the MAP sensor ground circuit at sensor
connector terminal 1 and PCM terminal 43. If OK, go
to next step. If not OK, repair as required.
(4) Test MAP sensor supply voltage between sen-
sor connector terminals 3 and 1 with the key ON.
The voltage should be approximately 5 volts (6.5V).
Five volts (6.5V) should also be at terminal 61 of the
PCM. If OK, replace MAP sensor. If not OK, repair or
replace the wire harness as required.
KNOCK SENSOR—2.0L ENGINE

The knock sensor output voltage to the PCM can
be read with the DRB III scan tool. Sensor output
should be between 80 mV and 4 volts with the engine
running between 576 and 2208 rpm. If the output
falls outside of this range a DTC will be set.
Fig. 28 ASD and Fuel Pump Relay Terminals
CAUTION: When testing the MAP sensor, be sure
CAMSHAFT AND CRANKSHAFT POSITION SENSOR
Refer to Group 8D, Ignition for Diagnosis and Test-
that the harness wires are not damaged by the test
ing of Camshaft and Crankshaft Sensors.
meter probes.
(1) Test the MAP sensor output voltage at the ENGINE COOLANT TEMPERATURE SENSOR
MAP sensor connector between terminals 1 and 4
(Fig. 29). With the ignition switch ON and the engine
not running, output voltage should be 4 to 5 volts.
The voltage should drop to 1.5 to 2.1 volts with a hot,
neutral idle speed condition. If OK, go to next step. If
not OK, go to step 3.
Fig. 30 Engine Coolant Temperature Sensor

Location—SOHC
Refer to the Engine Coolant Temperature sensor
for the 2.4/3.0/3.3/3.8L engines under Diagnosis and
Testing in the Fuel Injection System section of group
14 for more information.
THROTTLE POSITION SENSOR

To perform a complete test of the this sensor and
its circuitry, the DRB III scan tool is the best
method. To test the throttle position sensor only,
refer to the following:
Fig. 29 MAP Sensor Connector The Throttle Position Sensor (TPS) can be tested
(2) Test PCM terminal 36 for the same voltage with a digital voltmeter (DVM). The center terminal
described in the previous step to verify wire harness of the sensor is the output terminal. One of the other
condition. Repair as required. terminals is a 5 volt supply and the remaining ter-
minal is ground.
Connect the DVM between the center and sensor (4) Use a piece of hose to attach Air Metering Ori-
ground terminal. Refer to Group 8W - Wiring Dia- fice 6457 (0.125 in. orifice) to the purge nipple on the
grams for correct pinout. throttle body (Fig. 33).
With the ignition switch in the ON position, check
the output voltage at the center terminal wire of the
connector. Check the output voltage at idle and at
Wide-Open-Throttle (WOT). At idle, TPS output volt-
age should be approximately 0.38 volts to 1.2 volts.
At wide open throttle, TPS output voltage should be
approximately 3.1 volts to 4.4 volts. The output volt-
age should gradually increase as the throttle plate
moves slowly from idle to WOT.
Check for spread terminals at the sensor and PCM
connections before replacing the TPS.
THROTTLE BODY MINIMUM AIR FLOW

(1) Turn ignition key to Off.
(2) Disconnect the PCV valve hose from the intake
manifold nipple (Fig. 31). Cap the PCV vacuum nipple.
Fig. 33 Orifice 6457 Attached to Purge Nipple
(5) Ensure that all accessories are off.
(6) Connect the DRB scan tool to the data link
connector inside the passenger compartment.
(7) Run engine in Park or Neutral until the cooling
fan has cycled on and off at least once (180°F).
(8) Using the DRB scan tool, access Minimum Air-
flow Idle Speed.
(9) The following will then occur:
• Idle air control motor will fully close
• Idle spark advance will become fixed
• PCM will go open loop enriched
• DRB scan tool displays engine RPM
(10) If idle RPM is within the range shown in the
Idle Specification chart, throttle body minimum air-
flow is set correctly.
Fig. 31 PCV Vacuum Nipple
(3) Disconnect purge hose from the nipple on the IDLE SPECIFICATION —2.0L ENGINE
throttle body (Fig. 32).
Odometer Reading Idle RPM
Below 1000 Miles . . . . . . . . . . . . . . . 550–1300 RPM
Above 1000 Miles . . . . . . . . . . . . . . . 600–1300 RPM
(11) If idle RPM is above specifications, use the
DRB scan tool to check idle air control motor opera-
tion. If idle air control motor is OK, replace throttle
body. If idle air flow is below specification, shut off
the engine and clean the throttle body as follows:
WARNING: CLEAN THROTTLE BODY IN A WELL

VENTILATED AREA. WEAR RUBBER OR BUTYL
GLOVES, DO NOT LET MOPAR PARTS CLEANER
COME IN CONTACT WITH EYES OR SKIN. AVOID
INGESTING THE CLEANER. WASH THOROUGHLY
AFTER USING CLEANER.
Fig. 32 Purge Hose

(a) Remove the throttle body from engine. SPECIFICATIONS
(b) While holding the throttle open, spray the
entire throttle body bore and the manifold side of TORQUE
the throttle plate with Mopar Parts Cleaner. Only
use Mopar Parts Cleaner to clean the throttle DESCRIPTION TORQUE
body. Air Cleaner Wingnut . . . . . . . . . 1.5 N·m (15 in. lbs.)
(c) Using a soft scuff pad, clean the top and bot- Air Cleaner Mount. Stud-To-Thrott. Body . . 10 N·m
tom of throttle body bore and the edges and mani- (90 in. lbs.)
fold side of the throttle blade. The edges of the Crankshaft Position Sensor Mounting Bolts . . 8 N·m
throttle blade and portions of the throttle (70 in. lbs.)
bore that are closest to the throttle blade Engine Coolant Temperature Sensor . . . . . . 18 N·m
when closed, must be free of deposits. (165 in. lbs.)
(d) Use compressed air to dry the throttle body. IAC Motor-To-Throttle Body Bolts . . . . . . . . . 7 N·m
(e) Inspect throttle body for foreign material. (60 in. lbs.)
(f) Install throttle body on manifold. MAP/IAT Sensor . . . . . . . . . . . . . 2 N·m (20 in. lbs.)
(g) Repeat steps 1 through 14. If the minimum
MAP/IAT Sensor . . . . . . . . . . . . . 3 N·m (30 in. lbs.)
air flow is still not within specifications, the prob-
Oxygen Sensor . . . . . . . . . . . . . . 28 N·m (20 ft. lbs.)
lem is not caused by the throttle body.
Powertrain Control Module
(12) Shut off engine.
(PCM) Mounting Screws . . . . . 4 N·m (35 in. lbs.)
(13) Remove Air Metering Orifice 6457. Install
Throttle Cable Cover . . . . . . . . 4.5 N·m (40 in. lbs.).
purge hose.
(14) Remove cap from PCV valve. Connect hose to Throttle Body Mounting Bolts . . . . . . . . . . . 23 N·m
PCV valve. (200 in. lbs.)
(15) Remove DRB scan tool. Throttle Position Sensor Mounting Screws . . . 2 N·m
(20 in. lbs.)
Vehicle Speed Sensor Mounting Bolt . . . . . . 2.2 N·m
(20 in. lbs.)
FUEL INJECTION SYSTEM—2.5L DIESEL ENGINE
INDEX
page page
GENERAL INFORMATION SIGNAL GROUND—PCM INPUT . . . . . . . . . . . 45

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . 43 SPEED CONTROL—PCM INPUTS . . . . . . . . . . 48
DESCRIPTION AND OPERATION SPEED CONTROL—PCM OUTPUTS . . . . . . . . 48
AIR CONDITIONING (A/C) CONTROLS— START SIGNAL—PCM INPUT . . . . . . . . . . . . . 45
PCM INPUTS . . . . . . . . . . . . . . . . . . . . . . . . 47 TACHOMETER—PCM OUTPUT . . . . . . . . . . . . 49
AIR CONDITIONING RELAY—PCM OUTPUT . . 48 VEHICLE SPEED SENSOR—PCM INPUT . . . . 47
BATTERY VOLTAGE—PCM INPUT . . . . . . . . . . 45 VEHICLE THEFT ALARM . . . . . . . . . . . . . . . . . 45
BOOST PRESSURE SENSOR . . . . . . . . . . . . . 45 DIAGNOSIS AND TESTING
BRAKE SWITCH—PCM INPUT . . . . . . . . . . . . . 47 BOOST PRESSURE SENSOR . . . . . . . . . . . . . 53
DATA LINK CONNECTOR— DIAGNOSTIC TROUBLE CODES . . . . . . . . . . . 53
PCM INPUT AND OUTPUT . . . . . . . . . . . . . . 47 DIESEL DIAGNOSTICS . . . . . . . . . . . . . . . . . . 50
DIESEL PCM RELAY—PCM INPUT . . . . . . . . . 48 DIESEL PCM RELAY TEST . . . . . . . . . . . . . . . 50
ENGINE COOLANT GAUGE—PCM OUTPUT . . 48 ENGINE COOLANT TEMPERATURE
ENGINE COOLANT TEMPERATURE SENSOR— SENSOR TEST . . . . . . . . . . . . . . . . . . . . . . . 50
PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . 46 ENGINE SPEED SENSOR TEST . . . . . . . . . . . 50
ENGINE OIL PRESSURE GAUGE— GLOW PLUG RELAY TEST . . . . . . . . . . . . . . . 51
PCM OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . 48 GLOW PLUG TEST . . . . . . . . . . . . . . . . . . . . . 51
ENGINE SPEED SENSOR—PCM INPUT . . . . . 46 RELAYS—OPERATION/TESTING . . . . . . . . . . . 52
EXHAUST GAS RECIRCULATION (EGR) VEHICLE SPEED SENSOR TEST . . . . . . . . . . . 53
SOLENOID—PCM OUTPUT . . . . . . . . . . . . . 50 REMOVAL AND INSTALLATION
FIVE VOLT POWER—PCM OUTPUT . . . . . . . . 48 A/C CLUTCH RELAY . . . . . . . . . . . . . . . . . . . . 53
FUEL INJECTOR SENSOR—GROUND . . . . . . 46 DIESEL PCM RELAY . . . . . . . . . . . . . . . . . . . . 53
FUEL TIMING SOLENOID—PCM OUTPUT . . . . 48 ENGINE COOLANT TEMPERATURE
GLOW PLUG LAMP—PCM OUTPUT . . . . . . . . 48 SENSOR . . . . . . . . . . . . . . . . . . . . . . . . .. . . 54
GLOW PLUG RELAY—PCM OUTPUT . . . . . . . 49 ENGINE SPEED SENSOR . . . . . . . . . . . . .. . . 53
GLOW PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . 49 GLOW PLUG RELAY . . . . . . . . . . . . . . . . .. . . 55
IGNITION CIRCUIT SENSE—PCM INPUT . . . . 45 GLOW PLUGS . . . . . . . . . . . . . . . . . . . . . .. . . 54
NEEDLE MOVEMENT OR INSTRUMENTED POWERTRAIN CONTROL MODULE (PCM) . . . 55
FIRST INJECTOR—PCM INPUT . . . . . . . . . . 45 VEHICLE SPEED SENSOR . . . . . . . . . . . .. . . 55
POWER GROUND . . . . . . . . . . . . . . . . . . . . . . 45 SPECIFICATIONS
POWERTRAIN CONTROL MODULE (PCM) . . . 44 GLOW PLUG CURRENT DRAW . . . . . . . . . . . . 56
SENSOR RETURN—PCM INPUT (ANALOG TORQUE CHART—2.5L DIESEL . . . . . . . . . . . . 57
GROUND) . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
GENERAL INFORMATION where, if possible, it will ignore the failed sensor, set
a code related to the sensor, and operate the engine
INTRODUCTION in a “Limp Home” mode. When the PCM is operating
This section will cover components either regulated in a “Limp Home” mode, the Diesel Glow Plug lamp
or controlled by the Powertrain Control Module on the instrument panel will be constantly illumi-
(PCM). The fuel heater relay, fuel heater and fuel nated, and the engine will most likely have a notice-
gauge are not operated by the PCM. These compo- able loss of performance. An example of this would be
nents are controlled by the ignition (key) switch. All an Accelerator Pedal Position Sensor failure, and in
other fuel system electrical components necessary to that situation, the engine would run at a constant
operate the engine are controlled or regulated by the 1100 RPM, regardless of the actual position of the
PCM. Refer to the following PCM description for pedal. This is the most extreme of the three “Limp
more information. Home” modes.
Certain fuel system component failures may cause In addition to indicating that the glow plugs are
a no start, or prevent the engine from running. It is hot enough to start combustion, the Glow Plug Lamp
important to know that the PCM has a feature is also used in the diagnosis of the PCM, and when
GENERAL INFORMATION (Continued)
illuminated constantly, it usually indicates a problem through different system components. These compo-
has been detected somewhere within the fuel system. nents are referred to as PCM Outputs. The sensors
The DRBIII scan tool is the best method for commu- and switches that provide inputs to the PCM are con-
nicating with the PCM to diagnose faults within the sidered PCM Inputs.
system. PCM Inputs are:
• Air Conditioning Selection
• Theft Alarm
DESCRIPTION AND OPERATION • Clutch Switch
• Diesel PCM Relay
POWERTRAIN CONTROL MODULE (PCM) • ISO-Protocol
The Powertrain Control Module (PCM) is mounted • Control Sleeve
in the center consule to a bracket located in front of • Fuel Temperature
the Air Bag Module (Fig. 1). • Boost Pressure Sensor
• Accelerator Pedal Sensor
• EGR
• A/C Pressure
• Engine Coolant Temperature Sensor
• Low Idle Position Switch
• 5 Volt Supply
• Vehicle Speed Sensor
• Sensor Return
• Glow Plug
• Engine Speed Sensor (rpm)
• Fuel Injector #1 Sensor
• Starter Signal
• Brake Switch
• Speed Control Switch Position
• Power Ground
• Signal Ground
• Ignition (key) Switch Sense
• Battery Voltage
• SCI Receive (DRB scan tool connection)
PCM Outputs:
After inputs are received by the PCM, certain sen-
sors, switches and components are controlled or reg-
Fig. 1 PCM Location ulated by the PCM. These are considered PCM
Outputs. These outputs are for:
The PCM is a pre–programmed, dual micro–proces-
• A/C Clutch Relay (for A/C clutch operation)
sor digital computer. It will either directly operate or
• Speed Control LED
partially regulate the:
• Data Link Connectors (for DRB scan tool)
• Speed Control
• Speed Control LED lamp
• Diesel PCM Sense
• Fuel Timing Solenoid
• Accelarator Pedal
• Glow Plug Relay
• 5 Volts Supply
• Glow Plugs
• Glow Plug Relay
• EGR Solenoid
• Fan Relay
• Glow Plug Lamp
• Fuel Quantity
• Fuel Timing Solenoid
• Air Conditioning Operation
• Fuel Shut-Off Solenoid
• Tachometer
• Engine Speed Sensor
• Exhaust Gas Recirculation (EGR) Solenoid
• Glow Plug Lamp (malfunction indicator lamp)
The PCM can adapt its programming to meet
• Exhaust Gas Recirculation (EGR) Solenoid
changing operating conditions.
• Glow Plug Relay
The PCM receives input signals from various
• Tachometer
switches and sensors. Based on these inputs, the
• SCI transmit (DRB scan tool connection)
PCM regulates various engine and vehicle operations
BOOST PRESSURE SENSOR If the PCM is put it on a vehicle without VTA the
The Boost Pressure Sensor is mounted to the top of Glow Plug Lamp will start to blink and the vehicle
the intake manifold. (Fig. 2) It is a sensor that mea- will not start.
sures both manifold vacuum and turbo boost, and it The PCM cannot be flashed to remove the VTA.
also contains an integrated intake air temperature
sensor. The Boost Pressure Sensor takes the place of BATTERY VOLTAGE—PCM INPUT
the Mass Air Flow (MAF). In the Intake Air Temper- The battery voltage input provides power to the
ature Sensor component, there is a ceramic element PCM. It also informs the PCM what voltage level is
that changes its resistance based on temperature. being supplied by the generator once the vehicle is
The ceramic element is part of an electronic circuit running.
connected to the PCM, and has a voltage applied to The battery input also provides the voltage that is
it. The ceramic element is exposed to the air inside needed to keep the PCM memory alive. The memory
the intake. This air has a cooling effect on the stores Diagnostic Trouble Code (DTC) messages.
ceramic element, and its resistance changes. This Trouble codes will still be stored even if the battary
causes the voltage flowing through the intake air voltage is lost.
temperature circuit to vary. The voltage signal pro-
duced by the Intake Air Temperature Sensor changes SENSOR RETURN—PCM INPUT (ANALOG
inversely to the temperature, and is measured by the GROUND)
PCM. As a general rule, when the temperature of the Sensor Return provides a low noise Analog ground
air in the intake is high, the voltage signal produced reference for all system sensors.
by the Intake Air Temperature Sensor is low. The
component of the Boost Pressure Sensor that mea- SIGNAL GROUND—PCM INPUT
sures manifold vacuum and turbo boost produces a Signal ground provides a low noise ground to the
voltage signal that is proportional to the pressure in data link connector.
the inake manifold. When the intake manifold pres-
sure is low, the voltage is low, and when the pressure IGNITION CIRCUIT SENSE—PCM INPUT
is high, the voltage is high. The PCM uses the volt- The ignition circuit sense input signals the PCM
age signals from the Boost Pressure Sensor, and the that the ignition (key) switch has been turned to the
Intake Air Temperature Sensor to determine the ON position. This signal initiates the glow plug con-
amount of air flowing through the intake manifold. trol routine to begin the “pre–heat” cycle.
START SIGNAL—PCM INPUT

This input tells the PCM that the engine starter is
being operated. This in turn will start the glow plug
“post–heat” cycle.
POWER GROUND
Provides a common ground for power devices (sole-
noid and relay devices).
NEEDLE MOVEMENT OR INSTRUMENTED FIRST

INJECTOR—PCM INPUT
This input from the PCM supplies a constant 30
mA electrical current source for the first injector sen-
sor. It will vary the voltage to this sensor when it
senses a mechanical movement within the injector
needle (pintle) of the number–1 cylinder fuel injector.
When this voltage has been determined by the PCM,
it will then control an output to the fuel timing sole-
Fig. 2 Boost Pressure Sensor Location noid (the fuel timing solenoid is located on the fuel
injection pump). Also refer to Fuel Injection Pump for
VEHICLE THEFT ALARM additional information.
The PCM can learn if the vehicle has a Vehicle The first injector sensor is a magnetic (inductive)
Theft Alarm (VTA) system. Once it detects the vehi- type.
cle having VTA, the controller can ONLY BE
USED ON VEHICLES WITH VTA.
The first injector sensor is used only on the fuel
injector for the number–1 cylinder (Fig. 3). It is not
used on the injectors for cylinders number 2, 3, or 4.
Fig. 3 Fuel Injector Sensor

FUEL INJECTOR SENSOR—GROUND
Provides a low noise ground for the fuel injector Fig. 4 Engine Coolant Temperature Sensor Location
sensor only.
ENGINE COOLANT TEMPERATURE SENSOR—PCM

INPUT
The 0–5 volt input from this sensor tells the PCM
the temperature of the engine coolant. Based on the
voltage received at the PCM, it will then determine
operation of the fuel timing solenoid, glow plug relay,
electrical vacuum modulator (emission component)
and generator (charging system).
The sensor is located on the side of the #3 cylinder
head near the rear of fuel injection pump (Fig. 4).
ENGINE SPEED SENSOR—PCM INPUT

The engine speed sensor is mounted to the trans-
mission bellhousing at the left/rear side of the engine
block (Fig. 5).
The engine speed sensor produces its own output
signal. If this signal is not received the engine will
not start by the PCM.
The engine speed sensor input is used in conjunc-
tion with the first injector sensor to establish fuel
injection pump timing. Fig. 5 Engine Speed Sensor Location
The flywheel has four notches at its outer edge
(Fig. 6). Each notch is spaced equally every 90°. The The sensor also generates an rpm signal to the
notches cause a pulse to be generated when they PCM. This signal is used as an input for the Diesel
pass under the speed sensor (Fig. 6). These pulses relay for control of the generator field, vehicle speed
are the input to the PCM. The input from this sensor control, and instrument panel mounted tachometer.
determines crankshaft position (in degrees) by moni- If the engine speed sensor should fail, the system
toring the notches. is unable to compensate for the problem and the car
will stop.
(DRB) scan tool with the PCM. The data link connec-
tor is located under the instrument panel near the
bottom of steering column (Fig. 7).
Fig. 6 Speed Sensor Operation

AIR CONDITIONING (A/C) CONTROLS—PCM
INPUTS
The A/C control system information applies to fac- Fig. 7 Data Link Connector Location
tory installed air conditioning units. VEHICLE SPEED SENSOR—PCM INPUT
A/C REQUEST SIGNAL: When either the A/C or The vehicle speed sensor (Fig. 8) is located in the
Defrost mode has been selected and the A/C low and extension housing of the transmission. The sensor
high–pressure switches are closed, an input signal is input is used by the PCM to determine vehicle speed
sent to the powertrain control module (PCM). The and distance traveled.
PCM uses this input to cycle the A/C compressor
through the A/C relay.
If the A/C low or high–pressure switch opens, the
PCM will not receive an A/C request signal. The
PCM will then remove the ground from the A/C relay.
This will deactivate the A/C compressor clutch. Also,
if the engine coolant reaches a temperature outside
normal of its normal range, or it overheats, the PCM
will deactivate the A/C clutch.
BRAKE SWITCH—PCM INPUT

When the brake light switch is activated, the PCM
receives an input indicating that the brakes are
being applied. After receiving this input, the PCM is
used to control the speed control system. There is a
Primary and a Secondary brake switch. The Second-
ary brake switch is closed until the brake pedal is
pressed.
DATA LINK CONNECTOR—PCM INPUT AND

OUTPUT
The 16–way data link connector (diagnostic scan
tool connector) links the Diagnostic Readout Box
Fig. 8 Vehicle Speed Sensor—Typical
The speed sensor generates 8 pulses per sensor If the PCM receives an incorrect signal, or no sig-
revolution. These signals, in conjunction with a nal from certain sensors or components, the lamp
closed throttle signal from the throttle position sen- BLINKS. This is a warning that the PCM has
sor, indicate a closed throttle deceleration to the recorded a system or sensor malfunction. It signals
PCM. When the vehicle is stopped at idle, a closed an immediate need for service. There are only 5
throttle signal is received by the PCM (but a speed HARD faults that can turn on this lamp to make it
sensor signal is not received). blink.
In addition to determining distance and vehicle
speed, the output from the sensor is used to control
speed control operation.
Fig. 9 Glow Plug Lamp Symbol
SPEED CONTROL—PCM INPUTS SPEED CONTROL—PCM OUTPUTS
The speed control system provides five separate These two circuits control the fuel quantity actua-
inputs to the PCM; On/Off, Set, Resume/Accel, Cancel, tor to regulate vehicle speed. Refer to Group 8H for
and Decel.. The On/Off input informs the PCM that Speed Control information.
the speed control system has been activated. The Set
input informs the PCM that a fixed vehicle speed has AIR CONDITIONING RELAY—PCM OUTPUT
been selected. The Resume input indicates to the PCM This circuit controls a ground signal for operation
that the previous fixed speed is requested. of the A/C clutch relay. Also refer to Air Conditioning
Speed control operation will start at 50 km/h–142 (A/C) Controls—PCM Input for additional informa-
km/h (35–85 mph). The upper range of operation is tion.
not restricted by vehicle speed. Inputs that affect The A/C relay is located in the Power Distribution
speed control operation are vehicle speed sensor and Center (PDC). The PDC is located next to the battery
throttle position sensor. in the engine compartment. For the location of the
Refer to Group 8H for further speed control infor- relay within the PDC, refer to label on PDC cover.
mation.
FUEL TIMING SOLENOID—PCM OUTPUT
DIESEL PCM RELAY—PCM INPUT The fuel timing solenoid is located on the bottom of
A 12 volt signal at this input indicates to the PCM the fuel injection pump (Fig. 10).
that the Diesel relay has been activated. The Diesel
relay is located in the PDC. The PDC is located next
to the battery in the engine compartment. For the
location of the relay within the PDC, refer to label on
PDC cover.
This input is used only to sense that the Diesel
relay is energized. If the PCM does not see 12 volts +
at this input when the Diesel relay should be acti-
vated, it will set a Diagnostic Trouble Code (DTC).
FIVE VOLT POWER—PCM OUTPUT

This circuit supplies approximately 5 volts to
power the Accelerator Pedal Postion Sensor, Mass Air
Flow Sensor, and A/C Pressure Sensor.
ENGINE COOLANT GAUGE—PCM OUTPUT

Refer to the Instrument Panel and Gauges group
for additional information.
ENGINE OIL PRESSURE GAUGE—PCM OUTPUT

Refer to the Instrument Panel and Gauges group
for additional information.
GLOW PLUG LAMP—PCM OUTPUT Fig. 10 Fuel Timing Solenoid

The Glow Plug lamp (malfunction indicator lamp) This 12+ volt, pulse width modulated (duty–cycle)
illuminates on the message center each time the igni- output controls the amount of fuel timing (advance)
tion (key) switch is turned on. It will stay on for in the fuel injection pump. The higher the duty-
about two seconds as a bulb test.
–cycle, the lower the advance. The lower the duty- In this chart, Pre–Heat and Post–Heat times are
–cycle, the more advanced the fuel timing. mentioned. Pre–heat is the amount of time the glow
The duty–cycle is determined by the PCM from plug relay circuit is activated when the ignition (key)
inputs it receives from the fuel injector sensor and switch is ON, but the engine has yet to be started.
engine speed sensor. Post–heat is the amount of time the glow plug relay
circuit is activated after the engine is operating. The
TACHOMETER—PCM OUTPUT Glow Plug lamp will not be illuminated during the
The PCM supplies engine rpm values to the Body post–heat cycle.
Controller that then supplies the instrument cluster GLOW PLUG CONTROL
mounted tachometer (if equipped). Refer to Group 8E
for tachometer information.
GLOW PLUG RELAY—PCM OUTPUT

The glow plug relay is located in the engine com-
partment on the left–inner fender (Fig. 11).
GLOW PLUGS
Glow plugs are used to help start a cold or cool
engine. The plug will heat up and glow to heat the
combustion chamber of each cylinder. An individual
plug is used for each cylinder. Each plug is threaded
into the cylinder head above the fuel injector (Fig. 12).
Fig. 11 Glow Plug Relay Location

When the ignition (key) switch is placed in the ON
position, a signal is sent to the PCM relating current
engine coolant temperature. This signal is sent from
the engine coolant temperature sensor.
After receiving this signal, the PCM will determine
if, when and for how long a period the glow plug
relay should be activated. This is done before, during
and after the engine is started. Whenever the glow
plug relay is activated, it will control the 12V+ 100
amp circuit for the operation of the four glow plugs.
The Glow Plug lamp is tied to this circuit. Lamp
operation is also controlled by the PCM.
With a cold engine, the glow plug relay and glow
Fig. 12 Glow Plug
plugs may be activated for a maximum time of 200
seconds. Refer to the following Glow Plug Control Each plug will momentarily draw approximately 25
chart for a temperature/time comparison of glow plug amps of electrical current during the initial key–on
relay operation. cycle. This is on a cold or cool engine. After heating,
the current draw will drop to approximately 9–12
amps per plug.
Total momentary current draw for all four plugs is
approximately 100 amps on a cold engine dropping to
a total of approximately 40 amps after the plugs are
heated.
Electrical operation of the glow plugs are con-
trolled by the glow plug relay. Refer to the previous
Glow Plug Relay—PCM Output for additional infor-
mation.
EXHAUST GAS RECIRCULATION (EGR)

SOLENOID—PCM OUTPUT
This circuit controls operation of the Exhaust Gas
Recirculation (EGR) solenoid. The EGR solenoid (Fig.
11) controls operation of the EGR valve.
Refer to Group 25, Emission Control System for
information. See EGR solenoid.
DIAGNOSIS AND TESTING

DIESEL DIAGONSTICS Fig. 13 Engine Coolant Temperature Sensor
The PCM controller does engine off diagonstics Location
tests, which may be heard for about 60 seconds after
turning the key off. should be less than 1340 ohms with the engine
warm. Refer to the following Sensor Resistance
DIESEL PCM RELAY TEST (OHMS) chart. Replace the sensor if it is not within
To perform a test of the relay and its related cir- the range of resistance specified in the chart.
cuitry, refer to the DRB scan tool. To test the relay SENSOR RESISTANCE (OHMS)
only, refer to Relays—Operation/Testing in this sec-
tion of the group.
Diagnostic Trouble Codes: Refer to On-Board
Diagnostics in Group 25, Emission Control System
for a list of Diagnostic Trouble Codes (DTC’s) for cer-
tain fuel system components.
ENGINE SPEED SENSOR TEST

To perform a test of the engine speed sensor and
its related circuitry, refer to the DRB scan tool.
ENGINE COOLANT TEMPERATURE SENSOR TEST

The sensor is located on the side of cylinder head
near the rear of fuel injection pump (Fig. 13).
For a list of Diagnostic Trouble Codes (DTC’s) for
certain fuel system components, refer to On-Board
Diagnostics in Group 25, Emission Control System.
To test the sensor only, refer to the following:
(1) Disconnect wire harness connector from coolant
(3) Test continuity of the wire harness. Do this
temperature sensor.
between the PCM wire harness connector and the
(2) Test the resistance of the sensor with a high
sensor connector terminal. Also test continuity of
input impedance (digital) volt–ohmmeter. The resis-
wire harness to the sensor connector terminal. Refer
tance (as measured across the sensor terminals)
to Group 8W for wiring connector and circuitry infor- (6) When performing the test, the tester button
mation. Repair the wire harness if an open circuit is (Fig. 14) should be held continuously without release
indicated. for 20 seconds as indicated by the 4 timer lamps.
(4) After tests are completed, connect electrical Each illuminated lamp represents a 5 second time
connector to sensor. lapse.
(a) Press and hold the tester button (Fig. 14)
GLOW PLUG TEST and note the amp gauge reading. The gauge read-
Hard starting or a rough idle after starting may be ing should indicate a momentary, initial current
caused by one or more defective glow plugs. Before draw (surge) of approximately 25 amps. After the
testing the glow plugs, a test of the glow plug relay initial surge, the amp gauge reading should begin
should be performed. This will ensure that 12V+ is to fall off. The glow plug tip should start to glow
available at the plugs when starting the engine. an orange color after 5 seconds. If the tip did not
Refer to the Glow Plug Relay Test for information. glow after 5 seconds, replace the glow plug. Before
For accurate test results, the glow plugs should be discarding the glow plug, check the position of the
removed from the engine. The plugs must be checked circuit breaker on the bottom of the plug tester. It
when cold. Do not check the plugs if the engine may have to be reset. Reset if necessary.
has recently been operated. If plugs are (b) Continue to hold the tester button while
checked when warm, incorrect amp gauge observing the amp gauge and the 4 timer lamps.
readings will result. When all 4 lamps are illuminated, indicating a 20
Use Churchill Glow Plug Tester DX.900 or an second time lapse, the amp gauge reading should
equivalent (Fig. 14) for the following tests. This indicate a 9–12 amp current draw. If not, replace
tester is equipped with 4 timer lamps. the glow plug. Refer to Glow Plug Removal/Instal-
lation.
(7) Check each glow plug in this manner using one
20 second cycle. If the glow plug is to be retested, it
must first be allowed to cool to room temperature.
WARNING: THE GLOW PLUG WILL BECOME

EXTREMELY HOT (GLOWING) DURING THESE
TESTS. BURNS COULD RESULT IF IMPROPERLY
HANDLED. ALLOW THE GLOW PLUG TO COOL
BEFORE REMOVING FROM TESTER.
(8) Remove the glow plug from the tester.
GLOW PLUG RELAY TEST

When the ignition (key) switch is placed in the ON
position, a signal is sent to the PCM relating current
engine coolant temperature. This signal is sent from
the engine coolant temperature sensor.
After receiving this signal, the PCM will deter-
mine if, when and for how long a period the glow
plug relay should be activated. This is done before,
Fig. 14 Typical Glow Plug Tester during and after the engine is started. Whenever the
(1) Remove the glow plugs from the engine. Refer glow plug relay is activated, it will control the 12V+
to Glow Plug Removal/Installation. 100 amp circuit for the operation of the four glow
(2) Attach the red lead of the tester to the 12V+ plugs.
(positive) side of the battery. The Glow Plug lamp is tied to this circuit. Lamp
(3) Attach the black lead of the tester to the 12V– operation is also controlled by the PCM.
(negative) side of the battery. With a cold engine, the glow plug relay and glow
(4) Fit the glow plug into the top of the tester and plugs may be activated for a maximum time of 200
secure it with the spring loaded bar (Fig. 14). seconds. Refer to the Glow Plug Control chart for a
(5) Attach the third lead wire of the tester to the temperature/time comparison of glow plug relay oper-
electrical terminal at the end of the glow plug. ation.
Fig. 16 Wiring Connection at Glow Plug

GLOW PLUG CONTROL
Fig. 15 Glow Plug Relay Location

In this chart, Pre–Heat and Post–Heat times are
mentioned. Pre–heat is the amount of time the glow
plug relay circuit is activated when the ignition (key)
switch is ON, but the engine has yet to be started.
Post–heat is the amount of time the glow plug relay
circuit is activated after the engine is operating. The
Glow Plug lamp will not be illuminated during the
post–heat cycle.
TESTING:
Disconnect and isolate the electrical connectors
(Fig. 16) at all four glow plugs. With the engine cool
or cold, and the key in the ON position, check for
10–12 volts + at each electrical connector. 10–12 volts
+ should be at each connector whenever the PCM is
operating in the pre–heat or post–heat cycles (refer
to the following Glow Plug Control chart). Be very
RELAYS—OPERATION/TESTING
The following description of operation and
careful not to allow any of the four discon-
tests apply only to the Diesel PCM and other
nected glow plug electrical connectors to con-
relays. The terminals on the bottom of each relay
tact a metal surface. When the key is turned to
are numbered (Fig. 17).
the ON position, approximately 100 amps at 12
volts is supplied to these connectors. If 10–12 OPERATION
volts + is not available at each connector, check con- • Terminal number 30 is connected to battery volt-
tinuity of wiring harness directly to the relay. If con- age. For both the Diesel and other relays, terminal
tinuity is good directly to the relay, the fault is either 30 is connected to battery voltage at all times.
with the relay or the relay input from the PCM. To • The PCM grounds the coil side of the relay
test the relay only, refer to Relays—Operation/Test- through terminal number 85.
ing in this section of the group. If the relay test is • Terminal number 86 supplies voltage to the coil
good, refer to the DRB scan tool. side of the relay.
Diagnostic Trouble Codes: Refer to On-Board • When the PCM de-energizes the Diesel PCM
Diagnostics in Group 25, Emission Control System and other relays, terminal number 87A connects to
for a list of Diagnostic Trouble Codes (DTC’s) for cer- terminal 30. This is the Off position. In the off posi-
tain fuel system components. tion, voltage is not supplied to the rest of the circuit.
Terminal 87A is the center terminal on the relay.
meter should now show continuity between relay ter-
minals 87 and 30. The ohmmeter should not show
continuity between relay terminals 87A and 30.
(8) Disconnect jumper wires.
(9) Replace the relay if it did not pass the continu-
ity and resistance tests. If the relay passed the tests,
it operates properly. Check the remainder of the Die-
sel PCM and other relay circuits. Refer to group 8W,
Wiring Diagrams.
BOOST PRESSURE SENSOR

If the boost pressure sensor fails, the PCM records
a DTC into memory and continues to operate the
engine in one of the three “limp-in” modes. When the
PCM is operating in this mode, a loss of power will
be present, as if the turbocharger was not operating.
The best method for diagnosing faults with the boost
pressure sensor is with the DRB III scan tool.
Fig. 17 Diesel PCM and Other Relay Terminals
• When the PCM energizes the Diesel PCM and
VEHICLE SPEED SENSOR TEST
To perform a test of the sensor and its related cir-
other relays, terminal 87 connects to terminal 30.
cuitry, refer to DRB scan tool.
This is the On position. Terminal 87 supplies voltage
to the rest of the circuit.
TESTING for a list of Diagnostic Trouble Codes (DTC’s) for cer-
The following procedure applies to the Diesel PCM tain fuel system components.
and other relays.
(1) Remove relay from connector before testing. DIAGNOSTIC TROUBLE CODES
(2) With the relay removed from the vehicle, use For a list of Diagnostic Trouble Codes (DTC’s),
an ohmmeter to check the resistance between termi- refer to Group 25, Emission Control System for infor-
nals 85 and 86. The resistance should be between 75 mation. See On-Board Diagnostics.
65 ohms.
(3) Connect the ohmmeter between terminals 30 REMOVAL AND INSTALLATION
and 87A. The ohmmeter should show continuity
between terminals 30 and 87A. DIESEL PCM RELAY
(4) Connect the ohmmeter between terminals 87 The Diesel PCM relay is located in the PDC. For
and 30. The ohmmeter should not show continuity at the location of the relay within the PDC, refer to
this time. label on PDC cover.
(5) Connect one end of a jumper wire (16 gauge or
smaller) to relay terminal 85. Connect the other end A/C CLUTCH RELAY
of the jumper wire to the ground side of a 12 volt The A/C clutch relay is located in the PDC. For the
power source. location of the relay within the PDC, refer to label on
(6) Connect one end of another jumper wire (16 PDC cover.
gauge or smaller) to the power side of the 12 volt
power source. Do not attach the other end of the ENGINE SPEED SENSOR
jumper wire to the relay at this time. The engine speed sensor is mounted to the trans-
mission bellhousing at the rear of the engine block
WARNING: DO NOT ALLOW OHMMETER TO CON-
(Fig. 18).
TACT TERMINALS 85 OR 86 DURING THIS TEST.
REMOVAL
(7) Attach the other end of the jumper wire to
(1) Disconnect the harness (on the sensor) from
relay terminal 86. This activates the relay. The ohm-
the main electrical harness.
REMOVAL AND INSTALLATION (Continued)
Fig. 18 Engine Speed Sensor Fig. 19 Engine Coolant Temperature Sensor

(2) Remove the sensor mounting bolts. Location
(3) Remove the sensor. GLOW PLUGS
The glow plugs are located above each fuel injector
INSTALLATION (Fig. 20). Four individual plugs are used.
(1) Install the sensor flush against the opening in
the transmission housing.
(2) Install and tighten the sensor mounting bolt to
19 N·m (14 ft. lbs.) torque.
(3) Connect the electrical connector to the sensor.
ENGINE COOLANT TEMPERATURE SENSOR

The sensor is located on the side of cylinder head
near the rear of fuel injection pump (Fig. 19).
REMOVAL
WARNING: HOT, PRESSURIZED COOLANT CAN

CAUSE INJURY BY SCALDING. COOLING SYSTEM
MUST BE PARTIALLY DRAINED BEFORE REMOV-
ING THE COOLANT TEMPERATURE SENSOR.
REFER TO GROUP 7, COOLING.
Fig. 20 Glow Plug
(1) Partially drain cooling system. Refer to Group
7, Cooling. REMOVAL
(2) Disconnect electrical connector from sensor. (1) Disconnect the negative battery cable at the
(3) Remove sensor from cylinder head. battery.
(2) Clean the area around the glow plug with com-
INSTALLATION pressed air before removal.
(1) Install a new copper gasket to sensor. (3) Disconnect electrical connector (Fig. 21) at glow
(2) Install sensor to cylinder head. plug.
(3) Tighten sensor to 18 N·m (13 ft. lbs.) torque. (4) Remove the glow plug (Fig. 20) from cylinder
(4) Connect electrical connector to sensor. head.
(5) Replace any lost engine coolant. Refer to Group
7, Cooling System.
(3) Disconnect electrical connector at relay and
remove relay.
INSTALLATION
(1) Check condition of electrical connector for dam-
age or corrosion. Repair as necessary.
(2) Install electrical connector to relay.
(3) Install relay to inner fender.
(4) Connect battery cable to battery.
POWERTRAIN CONTROL MODULE (PCM)

The PCM is mounted to a bracket located in the
center consule in front of the air bag module (Fig.
23).
Fig. 21 Glow Plug Electrical Connector

INSTALLATION
(1) Apply high–temperature anti–seize compound
to glow plug threads before installation
(2) Install the glow plug into the cylinder head.
Tighten to 23 N·m (203 in. lbs.) torque.
(3) Connect battery cable to battery.
GLOW PLUG RELAY

Fig. 23 PCM Location

REMOVAL
(1) Disconnect the negative battery cable at the
battery.
(2) Loosen the 68–Way connector (Fig. 23). The
electrical connector has a sliding bar which moves
inward to lock or outward to unlock.
(3) Remove the electrical connector by pulling
straight out.
(4) Remove PCM.
INSTALLATION
(1) After the PCM electrical connector has been
separated from the PCM, inspect the pins for corro-
sion, being spread apart, bent or misaligned. Also
inspect the pin heights in the connector. If the pin
heights are different, this would indicate a pin has
separated from the connector. Repair as necessary.
(2) Engage 68–way connector into PCM. Move
Fig. 22 Glow Plug Relay Location slide bar to lock connector.
(3) Connect negative cable to battery.
REMOVAL
(1) Disconnect the negative battery cable at the VEHICLE SPEED SENSOR
battery. The vehicle speed sensor (Fig. 24) is located on the
(2) Remove relay mounting bolt. extension housing of the transmission.
Fig. 24 Vehicle Speed Sensor Location—Typical Fig. 25 Sensor Removal/Installation—Typical

REMOVAL (2) Tighten sensor mounting bolt. To prevent dam-
(1) Raise and support vehicle. age to sensor or speedometer adapter, be sure the
(2) Clean the area around the sensor before sensor is mounted flush to the adapter before tight-
removal. ening.
(3) Disconnect the electrical connector from the (3) Connect electrical connector to sensor.
sensor (Fig. 25).
(4) Remove the sensor mounting bolt (Fig. 25). SPECIFICATIONS
(5) Pull the sensor from the speedometer pinion
gear adapter for removal. GLOW PLUG CURRENT DRAW
Initial Current Draw: Approximately 22–25
INSTALLATION
amps per plug.
(1) Install new sensor into speedometer gear
After 20 seconds of operation: Approximately
adapter.
9–12 amps per plug.
SPECIFICATIONS (Continued)
TORQUE CHART—2.5L DIESEL
NS STEERING 19 - 1
STEERING
CONTENTS
page page
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . 1 POWER STEERING PUMP . . . . . . . . . . . . . . . . . . 9

POWER STEERING GEAR . . . . . . . . . . . . . . . . . . 26 STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . . 36
GENERAL INFORMATION
INDEX
page page
GENERAL INFORMATION DIAGNOSIS AND TESTING

STEERING SYSTEM AND COMPONENT STEERING SYSTEM DIAGNOSIS CHARTS . . . . . 2
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 1
GENERAL INFORMATION steering effort increases, as in a turn, the torsion bar

twists, causing relative rotary motion between the
STEERING SYSTEM AND COMPONENT rotary valve body and the valve spool. This move-
DESCRIPTION ment directs oil behind the integral rack piston,
The power steering system consists of these four which, in turn, builds up hydraulic pressure and
major components. Power Steering Pump, Power assists in the turning effort.
Steering Gear, Pressure Hose, and Return Line. Drive tangs on the power steering gear pinion
Turning of the steering wheel is converted into linear shaft, mate loosely with the shaft of the steering
travel through the meshing of the helical pinion gear. This is to allow manual steering control to be
teeth with the rack teeth. Power assist steering is maintained, if the drive belt on the power steering
provided by an open center, rotary type control valve. pump should break. However, under these conditions,
It is used to direct oil from the pump to either side of steering effort will significantly increase.
the integral steering rack piston.
Road feel is controlled by the diameter of a torsion
bar which initially steers the vehicle. As required
19 - 2 STEERING NS
DIAGNOSIS AND TESTING

STEERING SYSTEM DIAGNOSIS CHARTS
STEERING NOISE
There is some noise in all power steering systems. One of the most common is a hissing sound evident at
standstill parking. Hiss is a very high frequency noise similar to that experienced while slowly closing a water
tap. The noise is present in every valve and results from high velocity fluid passing over the edges of the valve
orifice. There is no relationship between this noise and the performance of the vehicles steering system. Hiss
may be expected when the steering wheel is at the end of its travel or slowly turning when the vehicle is at
a standstill.
CONDITION POSSIBLE CAUSES CORRECTION

Objectionable Hiss Or Whistle 1. Damaged or mispositioned 1. Check for proper seal between
steering column coupler to dash steering column coupler and dash
panel seal. seal.
2. Noisy valve in power steering 2. Replace steering gear assembly.
gear.
3. Mis-routed power steering hose 3. Check for proper routing of power
steering hoses and ensure they do
contact other components.
Rattle Or Clunk 1. Steering gear loose on front 1. Check steering gear to front
suspension crossmember. suspension crossmember mounting
bolts. Tighten to specified torque if
found to be loose.
2. Front suspension crossmember to 2. Tighten the front suspension
frame bolts or studs loose. crossmember attaching bolts or
studs to the specified torque.
3. Tie rod is loose (outer or inner). 3. Check tie rod pivot points for
wear. Replace worn/loose parts as
required.
4. Loose lower control arm to front 4. Tighten control arm mounting
suspension crossmember bolts. bolts to the specified torques.
5. Loose upper control arm/ shock 5. Check mounting bracket to body
absorber mounting bracket to body attaching bolts for looseness. If
attaching bolts. required tighten to the specified
torques.
6. Power steering fluid pressure 6. Adjust hose to proper position by
hose touching the body of the loosening, repositioning, and
vehicle. tightening fitting to specified torque.
Do not bend tubing.
7. Noise internal to power steering 7. Replace steering gear assembly.
gear.
8. Damaged front suspension 8. Replace front suspension
crossmember. crossmember.
9. Loose stabilizer bar attaching link 9. Tighten the stabilizer bar attaching
mounting nuts. link mounting nuts to the specified
torque.
Chirp or squeal (in the area of the 1. Loose power steering pump drive 1. Adjust power steering pump drive
power steering pump). Particularly belt. belt to specified tension.
noticeable at full wheel travel and
during standstill parking.
NS STEERING 19 - 3

Power steering pump growl results from the development of high pressure fluid flow. Normally this noise
should not be high enough to be objectionable. Abnormal situations, such as a low oil level causing
aeration or hose touching the vehicle body, can create a noise level that could bring complaints.
WHINE OR GROWL (PUMP 1. Low fluid level. 1. Fill power steering fluid
NOISE) reservoir to proper level and
perform leakage diagnosis.
(Recheck fluid level after power
steering fluid is free of air.)
2. Power steering hose touching 2. Reposition power steering
vehicle body or frame. hose. Replace hose if tube ends
are bent.
3. Extreme wear of power 3. Replace power steering pump
steering pump internal parts. and flush system.
SUCKING AIR SOUND 1. Loose clamp on power steering 1. Tighten or replace hose clamp.
fluid low pressure hose.
2. Missing O-Ring on power 2. Inspect connection and replace
steering pressure hose O-Ring as required.
connection.
3. Low power steering fluid level 3. Fill power steering fluid
reservoir to proper level and
perform leakage diagnosis.
4. Air leak between power 4. Inspect and/or replace power
steering fluid reservoir and power steering fluid reservoir or supply
steering pump. hose as required.
SQUEAK OR RUBBING 1. Sound coming from steering 1.Check for squeak in steering
SOUND column. column. Inspect for contact
between shroud, intermediate
shaft, column, and steering wheel.
Realign if necessary. Note: Check
steering column for noise
without clockspriing installed
and with the steering column
shaft removed from the steering
intermediate shaft. This must be
done before removing the
steering column for a noise
complaint.
2. Check for lack or grease on
steering column dash panel to
lower coupler seal.
2.Clockspring 3. Replace Clockspring
3. Sound internal to steering gear. 4. Replace steering gear
assembly.
SCRUBBING OR KNOCKING 1. Incorrect tire size. 1. Verify that tire size on vehicle is
SOUND the same as originally supplied.
2. Check clearance between tires 2. Correct as necessary.
and other vehicle components,
through the full travel of the
suspension.
3. Check for interference between 3.Correct as necessary.
steering gear and other
components.
4.Incorrect steering gear supplied. 4. Replace steering gear with
correct steering gear for specific
vehicle.
19 - 4 STEERING NS
BINDING STICKING SEIZED

CATCHES, STICKS IN CERTAIN 1. Low power steering fluid level. 1. Fill power steering fluid reservoir
POSITIONS OR IS DIFFICULT TO to specified level and perform
TURN. leakage diagnosis.
2. Tires not inflated to specified 2. Inflate tires to the specified
pressure. pressure.
3. Lack of lubrication in front 3. Replace lower ball joint.
suspension lower control arm ball
joints.
4. Worn lower ball joint. 4. Replace the lower ball joint.
5. Lack of lubrication in steering 5. Replace tie rod end.
gear outer tie rod ends.
6. Loose power steering pump drive 6. Tighten the power steering pump
belt. drive belt to the specified tension.
See accessory drive in service
manual.
7. Faulty power steering pump flow 7. Replace power steering pump.
control. (Verify cause using Power
Steering Pump Test Procedure.)
8. Excessive friction in steering 8. Correct condition. (See Steering
column or intermediate shaft. Column Service Procedure)
9. Steering column coupler binding. 9. Realign the steering column to
eliminate the binding condition.
10. Binding lower ball joint. 10. Replace the lower ball joint.
11. Excessive friction in steering 11. Replace steering gear assembly.
gear.
SHAKE SHUDDER VIBRATION

VIBRATION OF THE STEERING 1. Air in the fluid of the power 1. Steering shudder can be expected
WHEEL AND/OR DASH DURING steering system. in new vehicles and vehicles with
DRY PARK OR LOW SPEED recent steering system repairs.
STEERING MANEUVERS. Shudder should improve after the
vehicle has been driven several
weeks.
2. Tires not properly inflated. 2. Inflate tires to the specified
pressure.
3. Excessive engine vibration. 3. Ensure that the engine is running
properly.
4. Loose tie rod end. 4. Check the inner to outer tie rod
jam nut for looseness. If loose
tighten to the specified torque.
Inspect inner tie rod for looseness at
steering gear. Inspect outer tie rod
ball for excessive wear/looseness. If
inner tie rod is loose replace steering
gear, if outer tie has excessive wear
replace tie rod end.
5.Overcharged air conditioning 5.Check air conditioning pump head
system. pressure. (See Air Conditioning
Refrigerant System Diagnosis)
NS STEERING 19 - 5
LOW ASSIST, NO ASSIST, HARD STEERING

STIFF, HARD TO TURN, SURGES, 1. Tires not properly inflated. 1. Inflate tires to specified pressure.
MOMENTARY INCREASE IN
EFFORT WHEN TURNING.
2. Low power steering fluid level. 2. Add power steering fluid as
required to power steering fluid
reservoir to obtain proper level.
Perform leakage diagnosis on power
steering system.
3. Loose power steering pump drive 3. Tighten the power steering pump
belt. drive belt to the specified tension. If
drive belt is defective, replace and
correctly tension.
4. Lack of lubrication in lower control 4. Replace lower ball joint.
arm ball joint.
5. Worn lower ball joint. 5. Replace lower ball joint.
6. Low power steering pump 6. Verify cause using the Power
pressure. (Verify using Power Steering System Test Procedure.
Steering System Test Procedure) Replace the power steering pump if
necessary.
7. High internal leak in steering gear 7. Check steering system using the
assembly. Power Steering System Test
Procedure. If steering gear is
defective replace steering gear.
POOR RETURN TO CENTER

STEERING WHEEL DOES NOT 1. Tires not 1. Inflate tires to specified pressure.
RETURN TO CENTER POSITION. inflated to specified pressure.
2. Improper front wheel alignment. 2. Check and adjust as necessary.
3. Steering column U-joints 3. Realign steering column U-joints.
misaligned.
4. Mispositioned dash cover. 4. Reposition dash cover.
To evaluate items 6 and 7, disconnect
the intermediate shaft. Turn the
steering wheel and feel or listen for
internal rubbing in steering column.
5. Steering wheel rubbing. 5. Adjust steering column shrouds to
eliminate rubbing condition.
6. Damaged, mis-positioned or 6. Determine condition which exists
un-lubricated steering column coupler and correct.
to dash seal.
7. Binding shaft bearing 7. Replace the steering column. Note:
in steering column assembly. Before replacing steering column,
disconnect intermediate steering
coupler from steering column shaft
and remove steering wheel,
clockspring and shrouds from
steering column. This must be done
to verify a binding shaft bearing in
the steering column before
replacing the steering column.
8. Excessive friction in steering 8. Replace steering column coupler.
column coupler.
9. Excessive friction in steering gear. 9. Replace steering gear.
10. Excessive friction in front strut 10. Replace the strut mount or strut
mount bearing mount pivot bearing.
19 - 6 STEERING NS
LOOSE STEERING

EXCESSIVE STEERING WHEEL 1. Air in the fluid of the power 1. Fill power steering fluid reservoir
KICKBACK OR TOO MUCH steering system. to the specified level. Perform
STEERING WHEEL FREE PLAY. procedure to bleed the air out of the
power steering system. Perform
leakage diagnosis.
2. Steering gear loose on front 2. Check steering gear to front
suspension crossmember. suspension crossmember mounting
bolt torque. Tighten to specified
torque if found to be loose.
3. Worn, broken or loose steering 3. Check for worn universal joint,
column to steering gear coupler. broken isolator or loose fasteners.
4. Free play in steering column. 4.Check components of steering
system and repair or replace as
required. Note: Inspect steering
column with steering wheel installed
and steering column shaft
disconnected from intermediate
coupler. Verify that steering wheel
attaching nut is tightened to the
specified torque. Verify that the 4
mounting nuts for the steering
column are tightened to the specified
torque.
5. Loose lower control arm ball joint. 5. Check and or replace the ball joint
or control arm as required.
6. Loose steering knuckle to lower 6. Check attaching nut and tighten if
ball joint stud attaching nut. required to specified torque.
7. Front wheel bearings loose or 7. Tighten hub nut to specified
worn. torque or replace with new parts as
necessary.
8. Loose outer tie rod ends. 8. Check free play of outer tie rod
ends and replace if required.
9. Loose inner tie rod ends. 9. Replace steering gear assembly.
10. Defective steering gear rotary 10. Replace steering gear assembly.
valve.
11. Intermediate steering shaft 11. Replace intermediate steering
coupler flex joint binding. shaft/coupler.
NS STEERING 19 - 7
VEHICLE LEADS TO THE SIDE

STEERING WHEEL DOES NOT 1. Radial tire lead. 1.Rotate tires as recommended in
WANT RETURN TO CENTER the Tire And Wheel Group of this
POSITION. service manual.
2. Front suspension misaligned. 2. Align the front suspension as
required. Refer to the Wheel
Alignment Procedure in the
Suspension Group of this service
manual for the required wheel
alignment procedure.
3. Wheel braking. 3. Check for dragging brakes. Refer
to the procedures in the Brake
Group of this service manual.
4. Unbalanced steering gear valve. 4. Replace steering gear.
(If this is the cause, the steering
efforts will be very light in direction
of lead and heavier in the opposite
direction.
STEERING WHEEL HAS FORE 1. Steering wheel to steering column 1. Tighten the retaining nut to its
AND AFT LOOSENESS. shaft retaining nut not properly specified torque specification.
tightened and torqued.
2. Steering column lower bearing 2. Replace steering column.
spring retainer slipped on steering
column shaft.
3. Loose steering column to 3. Verify that the 4 mounting nuts for
instrument panel mounting nuts. the steering column are tightened to
the specified torque.
4. Binding intermediate steering 4. Disconnect intermediate steering
shaft coupler. coupler and see if looseness no
longer exists. If yes replace
intermendiate steering coupler.
POWER STEERING FLUID LEAK

LOW FLUID LEVEL WITH: NO 1. Overfilled power steering pump 1. Adjust the power steering fluid fill
VISIBLE SIGNS OF A LEAK ON fluid reservoir. to the correct level.
THE STEERING GEAR, POWER
STEERING PUMP, FLOOR OR
ANYWHERE ELSE.
LOW FLUID LEVEL WITH: 2. Power steering hose connections 2. Check for loose fittings and if
VISIBLE LEAK ON STEERING at the power steering pump or found, tighten the fitting to its
GEAR, POWER STEERING steering gear. specified torque. If fittings are tight
PUMP, FLOOR OR ANYWHERE examine the fittings for damaged or
ELSE. missing O-ring seals and replace as
required.
3. Power steering pump or power 3. Identify the location of the leak
steering gear leaking. and repair or replace the component
as required. Refer to Power Steering
Pump and/or Power Steering Gear in
this group of the service manual for
required procedures.
19 - 8 STEERING NS
FOAMY OR MILKY POWER STEERING FLUID

AERATION AND OVERFLOW OF 1. Air leaks. 1. Check for air leaking into the
FLUID. power steering system as described
under Sucking Air Diagnosis and
correct condition.
2. Low fluid level. 2. Extremely cold temperatures may
cause power steering fluid aeration if
the power steering fluid is low. Add
power steering fluid as required to
bring level up to specification.
3. Cracked power steering pump 3. Remove power steering pump
housing. from vehicle and inspect the power
steering pump housing for cracks. If
a defect in the housing is found,
replace the power steering pump.
4. Water contamination. 4. Drain the power steering fluid
from the system if there is evidence
of contamination. Then refill the
system with fresh clean power
steering fluid.
NS STEERING 19 - 9
POWER STEERING PUMP
INDEX
page page
DESCRIPTION AND OPERATION POWER STEERING FLUID RESERVOIR TO

POWER STEERING PUMP OPERATION . . . . . . . 9 PUMP SUPPLY HOSE . . . . . . . . . . . . . . . . . . . 18
DIAGNOSIS AND TESTING POWER STEERING FLUID RETURN HOSE . . . . 21
POWER STEERING PUMP FLOW RATE AND REMOTE POWER STEERING FLUID
PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . 9 RESERVOIR . . . . . . . . . . . . . . . . . . . . . . . . . . 22
SERVICE PROCEDURES DISASSEMBLY AND ASSEMBLY
POWER STEERING PUMP INITIAL POWER STEERING PUMP FLOW CONTROL
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 10 VALVE SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . 23
POWER STEERING SYSTEM FLUID LEVEL POWER STEERING PUMP PULLEY . . . . . . . . . . 23
CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 SPECIFICATIONS
REMOVAL AND INSTALLATION POWER STEERING PUMP FASTENER
2.4 LITER POWER STEERING PUMP . . . . . . . . . 11 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . 24
3.0 LITER POWER STEERING PUMP . . . . . . . . 13 POWER STEERING SYSTEM
3.3/3.8 LITER POWER STEERING PUMP . . . . . . 16 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . 24
POWER STEERING FLUID PRESSURE HOSE . . 19 SPECIAL TOOLS
POWER STEERING PUMP . . . . . . . . . . . . . . . . . 25
DESCRIPTION AND OPERATION DIAGNOSIS AND TESTING

POWER STEERING PUMP OPERATION POWER STEERING PUMP FLOW RATE AND
Hydraulic pressure for the operation of the power PRESSURE TEST
steering gear is provided by a belt driven power The following procedure can be used to test the
steering pump (Fig. 1). The power steering pump is a operation of the power steering system on the vehi-
constant flow rate and displacement vane type pump. cle. This test will provide the flow rate of the power
The power steering pump used on all applications is steering pump along with the maximum relief pres-
the Vane-Submerged remote reservoir style power sure. This test is to be performed any time a power
steering pump. steering system problem is present to determine if
the power steering pump or power steering gear is
not functioning properly. The following pressure and
flow test is performed using Pressure/Flow Tester,
Special Tool 6815 (Fig. 2).
Fig. 1 Vane Submerged Remote Reservoir Power

The remote reservoir type pump (Fig. 1) has the
pump housing and internal components combined
with the fluid housing. But it has a remote reservoir Fig. 2 Power Steering Pump Flow/Pressure Tester
for the power steering fluid supply.
19 - 10 STEERING NS
POWER STEERING PUMP FLOW AND SERVICE PROCEDURES
PRESSURE TEST PROCEDURE
(1) Check power steering pump drive belt tension POWER STEERING SYSTEM FLUID LEVEL CHECK
and adjust as necessary.
(2) Disconnect power steering fluid pressure hose, WARNING: FLUID LEVEL SHOULD BE CHECKED
at power steering pump. Use a container for dripping WITH ENGINE OFF TO PREVENT INJURY FROM
fluid. MOVING PARTS. DO NOT USE AUTOMATIC TRANS-
(3) Connect Pressure Gauge, Special Tool from kit MISSION FLUID IN THE POWER STEERING SYS-
6815 to both hoses using adapter fittings. Connect TEM. DO NOT OVERFILL THE POWER STEERING
spare pressure hose, to power steering pump pres- SYSTEM.
sure hose fitting.
(4) Completely open valve on Special Tool 6815. Wipe reservoir filler cap free of dirt. Then check
(5) Start engine and let idle long enough to circu- fluid level. The dipstick should indicate COLD when
late power steering fluid through flow/pressure test fluid is at normal ambient temperature, approxi-
and get air out of fluid. Then shut off engine. mately 21°C to 27°C (70°F to 80°F). In all pumps add
(6) Check power steering fluid level, and add fluid fluid as necessary, use only Mopar Power Steering
as necessary. Start engine again and let idle. Fluid, or equivalent. DO NOT USE ANY TYPE
(7) Pressure gauge should read below 862 kPa OF AUTOMATIC TRANSMISSION FLUID.
(125 psi), if above, inspect the hoses for restrictions
and repair as necessary. The initial pressure reading POWER STEERING PUMP INITIAL OPERATION
should be in the range of 345-552 kPa (50-80 psi).
The flow meter should read between 1.3 and 1.9 CAUTION: The fluid level should be checked with
GPM engine off to prevent injury from moving compo-
nents. Use only MoparT Power Steering Fluid. Do
CAUTION: The following test procedure involves not use automatic transmission fluid. Do not over-
testing power steering pump maximum pressure fill.
output and flow control valve operation. Do not
leave valve closed for more than 5 seconds as the Wipe filler cap clean, then check the fluid level.
pump could be damaged. The dipstick should indicate FULL COLD when the
fluid is at normal temperature of approximately 21°C
(8) Close valve fully three times and record high- to 27°C (70°F to 80°F).
est pressure indicated each time. All three read- (1) Fill the pump fluid reservoir to the proper level
ings must be within specifications and within and let the fluid settle for at least two (2) minutes.
345 kPa (50 psi) of each other. (2) Start the engine and let run for a few seconds.
Then turn the engine off.
NOTE: Power steering pump maximum relief pres- (3) Add fluid if necessary. Repeat the above proce-
sure is 9653 to 10342 kPa (1400 to 1500 psi.). dure until the fluid level remains constant after run-
ning the engine.
• If power steering pump pressures are within the (4) Raise the front wheels off the ground.
specifications but not within 345 kPa (50 psi) of each (5) Start the engine. Slowly turn the steering
other, then replace power steering pump. wheel right and left, lightly contacting the wheel
• If pressures are within 345 kPa (50 psi) of each stops.
other but below specifications, then replace power (6) Add power steering fluid if necessary.
steering pump. (7) Lower the vehicle and turn the steering wheel
slowly from lock to lock.
CAUTION: Do not force the pump to operate (8) Stop the engine. Check the fluid level and refill
against the stops for more than 5 seconds at a time as required.
because, pump damage will result. (9) If the fluid is extremely foamy, allow the vehi-
cle to stand a few minutes and repeat the above pro-
(9) Open test valve. Turn steering wheel to the
cedure.
extreme left and right positions until against the
stops, recording the highest indicated pressure at
each position. Compare pressure gauge readings to
power steering pump specifications. If highest output
pressures are not the same against either stop, the
steering gear is leaking internally and must be
replaced.
NS STEERING 19 - 11
REMOVAL AND INSTALLATION (8) Remove the catalytic converter from the
exhaust manifold. Then remove all the exhaust sys-
2.4 LITER POWER STEERING PUMP tem hangers/isolators from the brackets on the
exhaust system.
REMOVE (9) Move the exhaust system as far rearward and
to the left side of the vehicle as possible (Fig. 4).
WARNING: POWER STEERING OIL, ENGINE COM-
PONENTS AND THE EXHAUST SYSTEM MAY BE
EXTREMELY HOT IF ENGINE HAS BEEN RUNNING.
DO NOT START ENGINE WITH ANY LOOSE OR DIS-
CONNECTED HOSES. DO NOT ALLOW HOSES TO
TOUCH HOT EXHAUST MANIFOLD OR CATALYST.
(1) Remove cap from power steering fluid reser-

voir.
(2) Using a siphon pump, remove as much power
steering fluid as possible from the power steering
fluid reservoir.
(3) Remove the (-) negative battery cable from the
battery and isolate cable.
(4) Remove the drive belt from the power steering
pump pulley. See Cooling, Group 7 for detailed
removal procedure.
(5) Loosen but do not remove the nut attaching
Fig. 4 Exhaust Positioned For Removing Power
the front bracket for the power steering pump (Fig.
Steering Pump
3) to the aluminum mounting bracket. (10) Raise the heat sleeve on the power steering
return hose to expose the hose to steel tube connec-
tion (Fig. 5). Remove the hose from the power steer-
ing fluid return line on the front suspension cradle
(Fig. 5). Allow the remaining power steering fluid to
drain from the power steering pump and reservoir
through the removed return hose.
Fig. 3 Power Steering Pump Bracket Attaching Nut

(6) Raise vehicle on jack stands or centered on a
frame contact type hoist. See Hoisting, in the Lubri-
cation and Maintenance section of this service man-
ual for the required lifting procedure.
(7) Disconnect the oxygen sensor wiring harness
Fig. 5 Power Steering Return Hose At Return Line
from the vehicle wiring harness. Access to connection
at vehicle wiring harness is through the oxygen sen-
sor wiring harness grommet in the floor pan of the
vehicle.
NOTE: The exhaust system needs to be removed

from the engine to allow for an area to remove the
power steering pump from the vehicle.
19 - 12 STEERING NS
(11) Remove the accessory drive splash shield (Fig.
6).
Fig. 8 Power Steering Fluid Pressure And Return

Hose
Fig. 6 Accessory Drive Splash Shield
(12) Remove the power steering fluid supply hose
coming from the remote fluid reservoir, from the fit-
ting on the power steering pump (Fig. 7). Drain off
excess power steering fluid from hose.
Fig. 9 Power Steering Pump Attaching Nut
Fig. 7 Power Steering Hoses At Power Steering

Pump
(13) Remove the power steering fluid pressure line
(Fig. 8) from the power steering pump. Drain excess
power steering fluid from tube.
(14) Remove the power steering fluid return hose
(Fig. 8) from the power steering pump. Drain excess
(15) Remove the nut attaching rear of power steer-
ing pump to the cast mounting bracket. (Fig. 9)
(16) Loosen the 3 bolts (Fig. 10) attaching the
power steering pump to its front mounting bracket.
Then remove the nut and the bolt (Fig. 10), attaching Fig. 10 Power Steering Pump Mounting To Front
the power steering pump front to the cast bracket. Bracket
(17) Remove the power steering pump and the
front bracket from the cast bracket as an assembly.
NS STEERING 19 - 13
(18) Remove the 3 previously loosened bolts to prevent the overheating of the power steering
attaching the front bracket to the power steering hoses.
pump and separate the power steering pump from
the front bracket prior to removing the pump from (12) When used, properly position the protective
the vehicle. heat sleeves on the power steering hoses (Fig. 5).
(19) The power steering pump is removed from the Then, tie strap the heat sleeves to the power steering
vehicle by pulling it out through the exhaust tunnel hoses to keep them in their proper position.
area in the floor pan of the vehicle. (13) Install the exhaust pipe on the exhaust man-
ifold. Install all exhaust system hangers/isolators on
INSTALL the exhaust system brackets.
(1) Install power steering pump back in vehicle (14) Connect the oxygen sensor wiring harness to
using the reverse order of its removal through the the vehicle wiring harness. Install wiring harness
exhaust tunnel are of the vehicle. grommet in the floor pan of the vehicle.
(2) Install the power steering pump on its cast (15) Lower vehicle.
mounting bracket and loosely install nut to hold (16) Adjust the power steering pump drive belt.
pump in place (Fig. 9). See Cooling, Group 7 for detailed adjustment proce-
(3) Install the front bracket on the power steering dure.
pump and loosely install the 3 mounting bolts (Fig. (17) Tighten the top nut and bottom bolt on the
10). Then install the nut and bolt attaching the front power steering pump front mounting bracket (Fig. 3)
bracket to the cast bracket (Fig. 10). to a torque of 54 N·m (40 ft. lbs.).
(4) Tighten the 3 power steering pump mounting
bolts (Fig. 10) to a torque of 54 N·m (40 ft. lbs.). CAUTION: Do not use automatic transmission fluid
in power steering system. Only use MoparT, Power
NOTE: Before installing power steering fluid pres- Steering Fluid, or equivalent.
sure hose on power steering pump, inspect the
O-ring on the pressure hose for damage and (18) Fill the remote power steering pump fluid res-
replace if necessary. ervoir to correct fluid level.
(19) Install cap on power steering fluid reservoir.
(5) Install the power steering fluid pressure line (20) Connect the negative battery cable on the
onto the output fitting of the power steering pump negative battery post.
(Fig. 8). Tighten the pressure line to pump fitting (21) Start engine and turn steering wheel several
tube nut to a torque of 31 N·m (275 in. lbs.). times from stop to stop to bleed air from fluid in sys-
(6) Install the power steering fluid, low pressure tem. Stop engine, check fluid level, and inspect sys-
return hose on the power steering pump low pressure tem for leaks. See Checking Fluid Level.
fitting (Fig. 8). Be sure hose clamps are properly
reinstalled. 3.0 LITER POWER STEERING PUMP
(7) Install the power steering fluid supply hose
from the power steering fluid reservoir, on the power REMOVE
steering pump fluid fitting (Fig. 7). Be sure hose is
clear of accessory drive belts all hose clamps WARNING: POWER STEERING OIL, ENGINE COM-
are properly reinstalled. PONENTS AND THE EXHAUST SYSTEM MAY BE
(8) Install the power steering pump drive belt on EXTREMELY HOT IF ENGINE HAS BEEN RUNNING.
pulley. See Cooling, Group 7 for detailed installation DO NOT START ENGINE WITH ANY LOOSE OR DIS-
procedure. CONNECTED HOSES. DO NOT ALLOW HOSES TO
(9) Install the accessory drive splash shield (Fig. TOUCH HOT EXHAUST MANIFOLD OR CATALYST.
6).
(10) Install the power steering fluid return hose on
the steel tube at the front suspension cradle (Fig. 5).
(11) Install a screw type hose clamp on the power
voir.
steering hose to steel tube connection. Be sure hose
clamps are properly reinstalled.Tighten the screw
clamp to a torque of 2 N·m (18 in. lbs.).
fluid reservoir.
CAUTION: The protective heat shield sleeves must
cover the entire rubber hose and hose to tube con-
nection portion of both the power steering fluid
pressure and return hoses (Fig. 5). This is required
19 - 14 STEERING NS
(4) Remove the serpentine accessory drive belt
from the engine (Fig. 11). See Cooling, Group 7 for
detailed removal procedure.
Fig. 12 Exhaust Position For Removing Power

Steering Pump
Fig. 11 3.0L Serpentine Drive Belt And Routing

sor wiring harness grommet in the floor pan of the
vehicle.

(7) Remove the catalytic converter from the Fig. 13 Power Steering Return Hose At Return Line
tem hangers/isolators from the brackets on the
exhaust system.
(8) Move the exhaust system as far rearward and
(9) Raise the heat sleeve on the power steering
return hose to expose the return hose to steel tube
connection. Remove the hose from the power steering
fluid return line on the front suspension cradle (Fig.
13). Allow the remaining power steering fluid to
drain from the power steering pump and reservoir
through the removed hose.
(10) Remove the accessory drive splash shield
(Fig. 14).
ting on the power steering pump (Fig. 15). Drain off Fig. 14 Accessory Drive Splash Shield
excess power steering fluid from hose. NOTE: If the return hose is not removed from the
(12) Remove the power steering fluid pressure line power steering pump, it is very difficult to remove
(Fig. 15) from the power steering pump. Drain excess the power steering pump from the vehicle.
NS STEERING 19 - 15
mounting bolts (Fig. 16). Tighten the power steering
pump mounting bolts to a torque of 54 N·m (40 ft.
lbs.).
(3) Install the support bracket attaching rear of
power steering pump to engine (Fig. 16). Tighten the
nut and bolts to a torque of 54 N·m (40 ft. lbs).
NOTE: Before connecting the power steering pres-

sure line to the power steering pump, inspect the
O-ring on the pressure line for damage and replace
if damaged.
(4) Install the power steering fluid pressure line

onto the output fitting of the power steering pump
(Fig. 15). Tighten the pressure line to pump fitting
tube nut to a torque of 31 N·m (275 in. lbs.).
Fig. 15 Power Steering Hoses At Power Steering (5) Install the power steering fluid low pressure
Pump return hose on the power steering pump low pressure
fitting (Fig. 15). Be sure hose clamps are prop-
(13) Remove the power steering fluid return hose erly reinstalled and return hose is clear of all
(Fig. 15) from the power steering pump. accessory drive belts.
(14) Remove the support bracket at the rear of the (6) Install the power steering fluid supply hose
power steering pump attaching the pump to the rear from the power steering fluid reservoir, on the power
of the engine (Fig. 16). steering pump fluid fitting (Fig. 15). Be sure all
hose clamps are properly reinstalled.
(7) Install the serpentine drive belt (Fig. 11). See
Cooling, Group 7 for detailed installation procedure.
the steel tube at the front suspension cradle (Fig.
13).
steering hose to steel tube connection. Tighten the
screw clamp to a torque of 2 N·m (18 in. lbs.).

to prevent overheating of the power steering hoses.
(10) When used, properly position the protective
Fig. 16 Power Steering Pump Mounting heat sleeves on the power steering hoses. Then, tie
strap the heat sleeves to the power steering hoses to
(15) Remove the 2 bolts mounting the power steer- keep them in their proper position.
ing pump to the alternator/power steering pump and (11) Install the exhaust pipe on the exhaust man-
belt tensioner mounting bracket (Fig. 16). ifold. Install all exhaust system hangers/isolators on
(16) Remove the power steering pump from its the exhaust system brackets.
mounting bracket. (12) Connect the oxygen sensor wiring harness to
(17) The power steering pump is removed from the the vehicle wiring harness. Install wiring harness
vehicle by pulling it out through the exhaust tunnel grommet in the floor pan of the vehicle.
area in the floor pan of the vehicle. (13) Install the accessory drive splash shield (Fig.
14).
INSTALL
(14) Lower vehicle.
(1) Install power steering pump back in vehicle
using the reverse order of its removal through the CAUTION: Do not use automatic transmission fluid
exhaust tunnel are of the vehicle. in power steering system. Only use MoparT, Power
(2) Install the power steering pump on its mount- Steering Fluid, or equivalent.
ing bracket. Install the 2 power steering pump
19 - 16 STEERING NS
(15) Fill the remote power steering pump fluid res-
ervoir to correct fluid level.
(16) Install cap on power steering fluid reservoir.
(17) Connect the negative battery cable on the
negative battery post.
(18) Start engine and turn steering wheel several
times from stop to stop to bleed air from fluid in sys-
tem. Stop engine, check fluid level, and inspect sys-
tem for leaks. See Checking Fluid Level.
3.3/3.8 LITER POWER STEERING PUMP

REMOVE
WARNING: POWER STEERING OIL, ENGINE COM-

PONENTS AND THE EXHAUST SYSTEM MAY BE
EXTREMELY HOT IF ENGINE HAS BEEN RUNNING. Fig. 17 Exhaust Position For Removing Power
DO NOT START ENGINE WITH ANY LOOSE OR DIS- Steering Pump

voir.
fluid reservoir.
sor wiring harness grommet in the floor pan of the Fig. 18 Power Steering Return Hose At Return Line
vehicle.

(6) Remove the catalytic converter from the

tem hangers/isolators from the brackets on the
exhaust system.
(7) Move the exhaust system as far rearward and
(8) Raise the heat sleeve on the power steering
hoses to expose the hose to steel tube connection.
Remove the hose from the power steering fluid
return line on the front suspension cradle (Fig. 18).
Allow the remaining power steering fluid to drain
Fig. 19 Accessory Drive Splash Shield
from the pump and fluid reservoir through the
removed return hose.
(9) Remove the accessory drive splash shield (Fig.
19).
NS STEERING 19 - 17
(10) Remove the serpentine accessory drive belt
from the engine (Fig. 20). See Cooling, Group 7 for
detailed removal procedure.
Fig. 22 Power Steering Pump Support Bracket
Fig. 20 Serpentine Drive Belt And Routing

ting on the power steering pump (Fig. 21). Drain off
excess power steering fluid from hose.
Fig. 23 Power Steering Pump Mounting Bolts

(16) Remove the power steering pump from its
mounting bracket.
(17) The power steering pump is removed from the
vehicle by pulling it out through the exhaust tunnel
area in the floor pan of the vehicle.
INSTALL
Fig. 21 Power Steering Hoses At Power Steering
(1) Install power steering pump back in vehicle
Pump
using the reverse order of its removal through the
(12) Remove the power steering fluid pressure line exhaust tunnel are of the vehicle.
(Fig. 21) from the power steering pump. Drain excess (2) Install the power steering pump on its mount-
power steering fluid from tube. ing bracket. Install the 3 power steering pump
(13) Remove the power steering fluid return hose mounting bolts (Fig. 23). Tighten the power steering
(Fig. 21) from the power steering pump. Drain excess pump mounting bolts to a torque of 54 N·m (40 ft.
power steering fluid from tube. lbs.).
(14) Remove the support bracket at the rear of the (3) Install the support bracket attaching rear of
power steering pump attaching the pump to the rear power steering pump to engine (Fig. 22). Tighten the
of the engine (Fig. 22). nut and bolt holding the strut assembly to bracket
(15) Remove the 3 bolts mounting the power steer- and the intake manifold stud to a torque of 54 N·m
ing pump to the alternator/power steering pump and (40 ft. lbs).
belt tensioner mounting bracket (Fig. 23).
19 - 18 STEERING NS
NOTE: Before installing power steering pressure (17) Connect the negative battery cable on the
hose on power steering pump, inspect the O-ring negative battery post.
on the power steering pressure hose for damage (18) Start engine and turn steering wheel several
and replace if required. times from stop to stop to bleed air from fluid in sys-
tem. Stop engine, check fluid level, and inspect sys-
(4) Install the power steering fluid pressure line tem for leaks. See Checking Fluid Level.
onto the output fitting of the power steering pump
(Fig. 21). Tighten the pressure line to pump fitting POWER STEERING FLUID RESERVOIR TO PUMP
tube nut to a torque of 31 N·m (275 in. lbs.). SUPPLY HOSE
(5) Install the power steering fluid, low pressure
return hose on the power steering pump low pressure REMOVE
fitting (Fig. 21). Be sure hose clamps are prop- (1) Remove the filler cap from remote power steer-
erly reinstalled. ing fluid reservoir (Fig. 24).
(6) Install the power steering fluid supply hose
from the power steering fluid reservoir, on the power
steering pump fluid fitting (Fig. 21). Be sure hose is
clear of accessory drive belts and all hose
clamps are properly reinstalled.
(7) Install the serpentine drive belt (Fig. 20). See
Cooling, Group 7 for detailed installation procedure.

18).
clamps are properly reinstalled.Tighten the screw
clamp to a torque of 2 N·m (18 in. lbs.).

cover the entire rubber hose and hose to tube con- Fig. 24 Fluid Supply Hose At Power Steering Fluid
nection portion of both the power steering fluid Reservoir
pressure and return hoses (Fig. 18). This is required (2) Using a siphon pump, remove as much power
to keep the power steering hoses from becoming steering fluid as possible from the power steering
overheated. fluid reservoir.
(3) Remove power steering fluid supply hose rout-
(10) When used, properly position the protective ing clip (Fig. 25) from stud in strut tower.
heat sleeves on the power steering hoses (Fig. 18).
Then, tie strap the heat sleeves to the power steering
hoses to keep them in their proper position.
(11) Install the exhaust pipe on the exhaust man-
ifold. Install all exhaust system hangers/isolators on
the exhaust system brackets.
(12) Connect the oxygen sensor wiring harness to
the vehicle wiring harness. Install wiring harness
grommet in the floor pan of the vehicle.
(13) Install the accessory drive splash shield (Fig.
19).
(14) Lower vehicle.
CAUTION: Do not use automatic transmission fluid

in power steering system. Only use MoparT, Power
Steering Fluid, or equivalent.
(15) Fill the remote power steering pump fluid res- Fig. 25 Power Steering Fluid Hose Routing Clip
ervoir to correct fluid level. (4) Raise vehicle on jack stands or centered on a
(16) Install cap on power steering fluid reservoir. frame contact type hoist. See Hoisting in the Lubri-
NS STEERING 19 - 19
cation and Maintenance section of this service man- (12) Start the engine. Slowly turn the steering
ual, for the required lifting procedure to be used for wheel right and left, lightly contacting the wheel
this vehicle. stops.
(5) Remove at power steering pump, the power (13) Add power steering fluid if necessary.
steering fluid hose coming from the power steering (14) Lower the vehicle and turn the steering wheel
fluid reservoir. Let the power steering fluid drain out slowly from lock to lock.
of the reservoir and hose. (15) Stop the engine. Check the fluid level and
(6) Lower vehicle. refill as required.
(7) Remove hose clamp attaching the power steer- (16) If the fluid is extremely foamy, allow the vehi-
ing fluid supply hose to the power steering fluid res- cle to stand a few minutes and repeat the above pro-
ervoir (Fig. 24). cedure.
from the vehicle. Hose is removed from the top of the POWER STEERING FLUID PRESSURE HOSE
engine compartment. Service all power steering hoses with vehicle raised
on hoist. Cap all open ends of hoses, power steering
INSTALL pump fittings and steering gear ports to prevent
entry of foreign material into the components.
CAUTION: On V-6 engine applications, the power
steering fluid reservoir to power steering hose must WARNING: POWER STEERING OIL, ENGINE
be routed tightly against the strut tower and parallel PARTS AND THE EXHAUST SYSTEM MAY BE
to the dash panel. It must also be routed under the EXTREMELY HOT IF ENGINE HAS BEEN RUNNING.
wiring harness and below the drip tube. This rout- DO NOT START ENGINE WITH ANY LOOSE OR DIS-
ing will prevent the power steering fluid supply CONNECTED HOSES. DO NOT ALLOW HOSES TO
hose from coming in contact with the accessory TOUCH HOT EXHAUST MANIFOLD OR CATALYST.
drive belt.
For part reference and part location for the vehicle
(1) Install and correctly route the power steering that is being serviced, refer to the following figure
fluid supply hose from remote fluid reservoir down to numbers. These show the hose bracket locations,
power steering pump. hose routings and fitting locations by the engine
(2) Install the fluid supply hose onto the power application of the vehicle. Use these figure numbers
steering fluid reservoir (Fig. 24). Install the hose when referring to the removal or installation proce-
clamp on the fluid supply hose. Be sure hose clamp dures for the power steering hoses listed below.
is installed past bead on fluid reservoir fitting.
(3) Raise vehicle on jack stands or centered on a REMOVE
frame contact type hoist. See Hoisting in the Lubri- (1) Remove cap from power steering fluid reser-
cation and Maintenance section of this service man- voir.
ual, for the required lifting procedure to be used for (2) Using a siphon pump, remove as much power
this vehicle. steering fluid as possible from the power steering
(4) Install power steering fluid supply hose on fluid reservoir.
power steering pump. Install the hose clamp on the (3) Raise vehicle See Hoisting, Group 0. Put oil
fluid supply hose. Be sure hose clamp is installed drain pan under vehicle to catch power steering fluid.
past bead on pump fitting. (4) Raise the heat sleeve on the power steering
(5) Lower vehicle. fluid return hose (Fig. 26) to expose the return hose
(6) Install routing clip on power steering fluid sup- to steel tube connection. Remove the hose clamp from
ply hose. Be sure routing clip is installed in a posi- the power steering fluid return hose (Fig. 26).
tion to correctly align with stud in strut tower. Remove power steering fluid return hose from steel
(7) Install routing clip for power steering fluid sup- tube and allow power steering fluid to drain from
ply hose on stud in strut tower (Fig. 25). pump.
(8) Fill the remote fluid reservoir to the proper
level and let the fluid settle for at least two (2) min-
utes.
(9) Start the engine and let run for a few seconds.
Then turn the engine off.
(10) Add fluid if necessary. Repeat the above pro-
cedure until the fluid level remains constant after
running the engine.
(11) Raise the front wheels off the ground.
19 - 20 STEERING NS
Fig. 26 Return Hose Connection To Steel Tube Fig. 28 Power Steering Hose Attachment To
(5) Remove the power steering fluid pressure line Suspension Cradle
from the power steering pump pressure fitting (Fig.
27). Drain excess power steering fluid from hose.
Fig. 29 Power Steering Pressure Hose At Steering

Gear
Fig. 27 Pressure Hose Connection To Power not bend tube ends of the power steering hoses when
Steering Pump installing.
(4) Install the power steering fluid hoses to sus-
(6) Remove bolt, attaching power steering hose
pension cradle routing bracket (Fig. 28). Power steer-
routing bracket to front suspension cradle (Fig. 28).
ing fluid hoses must remain away from the exhaust
(7) Disconnect power steering hose at power steer-
system and must not come in contact with any
ing gear assembly (Fig. 29). Drain the power steering
unfriendly surfaces of the vehicle.
fluid from power steering pump and hose.
(8) Discard the O-rings on the ends of power steer- CAUTION: When tightening and torquing the pres-
ing fluid pressure hose. sure hose at the power steering pump, the pressure
hose is to be rotated against the fluid return hose
INSTALL
fitting on the pump.
(1) Using a lint free towel, wipe clean the open
power steering hose ends, power steering pump pres- (5) Tighten all fasteners shown for specific applica-
sure fitting and steering gear ports. tions to their correct torques listed below:
(2) Install new O-rings on the ends of the power • Pump End Tube Nut 34 N·m (25 ft. lbs.)
steering fluid pressure hose. Lubricate O-rings using • Gear End Tube Nut 34 N·m (25 ft. lbs.)
clean power steering fluid. • Pump Bracket Nut 40 N·m (30 ft. lbs.)
(3) Attach the power steering pressure hose to the
fittings on the power steering pump and steering
gear. Route hose avoiding tight bends or kinking. Do
NS STEERING 19 - 21
26).
CAUTION: The protective heat sleeves must cover

the entire rubber hose and hose to tube connection
portion of both the power steering fluid pressure
and return hoses (Fig. 26).

heat sleeves on the power steering hoses. Then, tie
strap the heat sleeves to the power steering hoses to
keep them in their proper position.
(9) After hoses are installed and power steering Fig. 30 Power Steering Return Hose At Steel Tube
system is filled with fluid and cap is installed on res-
ervoir. Start the engine and check for leaks. (See (5) Remove the power steering fluid return hose
Pump Installation). from the power steering pump return hose fitting.
POWER STEERING FLUID RETURN HOSE INSTALL

(1) Using a lint free towel, wipe clean the open
Service all power steering hoses with vehicle raised
power steering hose ends and power steering pump
on hoist. Cap all open ends of hoses, power steering
fitting.
pump fittings and steering gear ports to prevent
(2) Attach the power steering return hose to the
entry of foreign material into the components.
fitting on the power steering pump. Route hose
WARNING: POWER STEERING OIL, ENGINE smoothly avoiding tight bends or kinking. Hose must
PARTS AND THE EXHAUST SYSTEM MAY BE remain away from the exhaust system and not come
EXTREMELY HOT IF ENGINE HAS BEEN RUNNING. in contact with any unfriendly surfaces of the vehi-
DO NOT START ENGINE WITH ANY LOOSE OR DIS- cle.
CONNECTED HOSES. DO NOT ALLOW HOSES TO (3) Install the power steering fluid return hose on
TOUCH HOT EXHAUST MANIFOLD OR CATALYST. the steel tube at the front suspension cradle (Fig.
30).
For part reference and part location for the vehicle (4) Install a screw type hose clamp on the power
that is being serviced, refer to the following figure steering hose to steel tube connection. Tighten the
numbers. These show the hose bracket locations, screw clamp to a torque of 2 N·m (18 in. lbs.).
hose routings and fitting locations by the engine
application of the vehicle. Use these figure numbers CAUTION: The protective heat shield sleeves must
when referring to the removal or installation proce- cover the entire rubber hose and hose to tube con-
dures for the power steering hoses listed below. nection portion of both the power steering fluid
pressure and return hoses (Fig. 30). This is to pre-
REMOVE vent overheating of the power steering fluid hoses.
voir. (5) When used, position the protective heat sleeves
(2) Using a siphon pump, remove as much power on the power steering hoses so they cover the connec-
steering fluid as possible from the power steering tion to the power steering pump. Then, tie strap the
fluid reservoir. heat sleeves to the power steering hoses to keep
(3) Raise vehicle See Hoisting, Group 0. Put oil them in their proper position.
drain pan under vehicle to catch power steering fluid. (6) After hoses are installed and power steering
(4) Raise the insulating heat sleeve on the power system is filled with fluid and cap is installed on res-
steering hoses to expose the hose to steel tube con- ervoir. Start the engine and check for leaks. (See
nection. Remove hose clamp where rubber portion of Pump Installation).
power steering fluid return hose attaches to steel
tube on suspension cradle (Fig. 30). Remove rubber
hose from steel tube and allow power steering fluid
to drain from pump.
19 - 22 STEERING NS
REMOTE POWER STEERING FLUID RESERVOIR (3) Install the fluid supply hose onto the power
steering fluid reservoir fitting (Fig. 31). Install the
REMOVE hose clamp on the fluid supply hose at the fluid res-
(1) Remove the filler cap from remote power steer- ervoir. Be sure hose clamp in installed past bead
ing fluid reservoir (Fig. 31). on fluid reservoir fitting.
(2) Raise vehicle on jack stands or centered on a (4) Raise vehicle on jack stands or centered on a
frame contact type hoist. See Hoisting in the Lubri- frame contact type hoist. See Hoisting in the Lubri-
cation and Maintenance section of this service man- cation and Maintenance section of this service man-
ual, for the required lifting procedure to be used for ual, for the required lifting procedure to be used for
this vehicle. this vehicle.
(3) Remove at power steering pump, the power (5) Install power steering fluid supply hose on
steering fluid hose coming from the power steering power steering pump. Install the hose clamp on the
fluid reservoir. Let the power steering fluid drain out fluid supply hose at the power steering pump. Be
of the reservoir and hose. sure hose clamp in installed past bead on pump
(4) Lower vehicle. fitting.
(5) Remove the fluid supply hose (Fig. 31) from the (6) Lower vehicle.
remote power steering fluid reservoir. (7) Install routing clip for power steering fluid sup-
(6) Remove the 2 mounting screws (Fig. 31) ply hose on stud in strut tower (Fig. 32).
attaching the remote fluid reservoir to the inner
fender.
(7) Remove remote reservoir from inner fender.
Fig. 32 Power Steering Fluid Hose Routing Clip

(8) Fill the remote fluid reservoir to the proper
level and let the fluid settle for at least two (2) min-
Fig. 31 Remote Power Steering Fluid Reservoir utes.
INSTALL (9) Start the engine and let run for a few seconds.
(1) Install remote power steering fluid reservoir on Then turn the engine off.
inner fender, by first inserting tab on reservoir into (10) Add fluid if necessary. Repeat the above pro-
hole in inner fender. Then rotate reservoir so mount- cedure until the fluid level remains constant after
ing tabs are against inner fender. running the engine.
(2) Install and securely tighten the 2 reservoir (11) Raise the front wheels off the ground.
mounting screws (Fig. 31). (12) Start the engine. Slowly turn the steering
wheel right and left, lightly contacting the wheel
CAUTION: The power steering fluid reservoir to stops.
power steering pump supply hose must be routed (13) Add power steering fluid if necessary.
tightly against the strut tower and parallel to the (14) Lower the vehicle and turn the steering wheel
dash panel. It must also be routed under the wiring slowly from lock to lock.
harness and below the drip tube. This will prevent (15) Stop the engine. Check the fluid level and
the hose from coming in contact with the accessory refill as required.
drive belt. The power steering fluid supply hose (16) If the fluid is extremely foamy, allow the vehi-
must be located in its correct position by clipping it cle to stand a few minutes and repeat the above pro-
to the stud in the strut tower (Fig. 32). cedure.
NS STEERING 19 - 23
DISASSEMBLY AND ASSEMBLY (3) Force pulley flush with the end of the power
steering pump shaft (Fig. 35).
POWER STEERING PUMP PULLEY
DISASSEMBLY
(1) Remove the pulley from the shaft of the power
steering pump using Puller C-4333 or C-4068 (Fig.
33).
Fig. 35 Pulley To Pump Shaft Location

(4) With serpentine belts, run engine until warm
(5 min.) and note any belt chirp. If chirp exists, move
pulley outward approximately 0.5 mm (0.020 in.). If
noise increases, press on 1.0 mm (0.040 in.). Be
careful that pulley does not contact mounting
Fig. 33 Pulley Removal bolts.
CAUTION: Do not hammer on power steering POWER STEERING PUMP FLOW CONTROL VALVE
pump pulley. This will damage the pulley and the SEAL
power steering pump.
DISASSEMBLE
(2) Replace pulley if it is found to be bent, cracked,
or loose. WARNING: POWER STEERING OIL, ENGINE
PARTS AND THE EXHAUST SYSTEM MAY BE
ASSEMBLY
EXTREMELY HOT IF ENGINE HAS BEEN RUNNING.
(1) Install the pulley with Installer C-4063 (Fig.
DO NOT START ENGINE WITH ANY LOOSE OR DIS-
34). Do not use the tool adapters.

voir.
fluid reservoir.
(3) Raise vehicle See Hoisting, Group 0. Put oil
drain pan under vehicle to catch power steering fluid.
(4) Raise the heat sleeve (Fig. 36) on the power
steering return hose to expose the return hose to
steel tube connection. Remove hose clamp from
power steering fluid return hose (Fig. 36). Remove
power steering return hose from steel tube and allow
remaining power steering fluid to drain from power
steering pump and reservoir.
Fig. 34 Pulley Installation (5) Remove the power steering fluid pressure line
from the power steering pump pressure fitting (Fig.
(2) Ensure that the tool and the pulley remain
37). Drain excess power steering fluid from hose.
aligned with the pump shaft. Prevent the pulley from
being cocked on the shaft.
19 - 24 STEERING NS
DISASSEMBLY AND ASSEMBLY (Continued)
(3) Install the power steering fluid pressure hose
in the pressure fitting/flow control valve (Fig. 37).
Tighten the tube nut to a torque of 34 N·m (25 ft.
lbs.)
36).

to keep the power steering hoses from becoming
Fig. 36 Return Hose At Steel Tube overheated.

heat sleeves (Fig. 36) on the power steering hoses.
Then, tie strap the heat sleeves to the power steering
hoses to keep them in their proper position.
(7) Fill the power steering system with fluid, bleed
air from system and check that power steering fluid
is at correct level.
SPECIFICATIONS
POWER STEERING SYSTEM SPECIFICATIONS
Flow At 1500 RPM And Minimum Pressure.5.0 to 7.0

Liters/Min (1.3 to 1.9 GPM)
Control Valve Pressure Relief. 9653 to 10342 kPa (1400
Fig. 37 Pressure Hose Connection To Power to 1500psi)
Steering Pump
POWER STEERING PUMP FASTENER TORQUE
(6) Remove the pressure fitting/flow control valve
from the power steering pump and remove and dis-
SPECIFICATIONS
card the O-Ring seal.
DESCRIPTION TORQUE
ASSEMBLE POWER STEERING PUMP:
(1) Install a new O-Ring seal on the pressure fit- Flow Control Valve Fitting . . . .75 N·m (55 ft. lbs.)
ting/flow control valve, and wet the O-Ring with Mounting Bolts . . . . . . . . . . . . .54 N·m (40 ft. lbs.)
clean fresh power steering fluid. Rear Bracket To Engine
(2) Install the pressure fitting/flow control valve in Mounting Bolts . . . . . . . . . . . . .54 N·m (40 ft. lbs.)
the power steering pump. Tighten the pressure fit- POWER STEERING FLUID HOSES:
ting/flow control valve to a torque of 75 N·m (55 ft. Hose Tube Nuts . . . . . . . . . . . . .34 N·m (25 ft. lbs.)
lbs.). Routing Bracket To
Suspension Cradle . . . . . . . . . .28 N·m (21 ft. lbs.)
CAUTION: When tightening and torquing the pres-
sure hose at the power steering pump, the hose
should be rotated against the fluid return hose fit-
ting on the pump.
NS STEERING 19 - 25
SPECIAL TOOLS
POWER STEERING PUMP
P/S System Analyzer 6815
Installer C-4063B
Puller C-4333
19 - 26 STEERING NS
POWER STEERING GEAR
INDEX
page page
DESCRIPTION AND OPERATION STEERING GEAR INNER TIE ROD BOOT . . . . . 31

STEERING GEAR OPERATION DESCRIPTION . 26 SPECIFICATIONS
DIAGNOSIS AND TESTING STEERING GEAR FASTENER TORQUE
POWER STEERING GEAR . . . . . . . . . . . . . . . . . 27 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . 34
REMOVAL AND INSTALLATION SPECIAL TOOLS
STEERING GEAR . . . . . . . . . . . . . . . . . . . . . . . 27 POWER STEERING GEAR . . . . . . . . . . . . . . . . . 35
DISASSEMBLY AND ASSEMBLY
OUTER TIE ROD END . . . . . . . . . . . . . . . . . . . 33
DESCRIPTION AND OPERATION Turning of the steering wheel is converted into linear
travel through the meshing of the helical pinion
STEERING GEAR OPERATION DESCRIPTION teeth with the rack teeth. Power assist steering is
provided by an open center, rotary type control valve
NOTE: The power steering gear (Fig. 1) should NOT which directs oil from the pump to either side of the
be serviced or adjusted. If a malfunction or oil leak integral rack piston.
occurs, the complete steering gear should be Road feel is controlled by the diameter of a torsion
replaced. bar which initially steers the vehicle. As required
steering effort increases, as in a turn, the torsion bar
If a steering gear boot needs to be replaced due to twists, causing relative rotary motion between the
damage, refer to the power steering gear service sec- rotary valve body and the valve spool. This move-
tion in this manual for proper procedure. ment directs oil behind the integral rack piston,
The power steering system consists of these four which, in turn, builds up hydraulic pressure and
major components. Power Steering Gear, Power assists in the turning effort.
Steering Pump, Pressure Hose, and Return Line.
Fig. 1 Power Steering Gear Assembly

NS STEERING 19 - 27
The drive tangs on the pinion mate loosely with a should be in the range of 345-552 kPa (50-80 psi).
stub shaft to permit manual steering control to be The flow meter should read between 1.3 and 1.9
maintained if the drive belt on the power steering GPM
pump should break. However, under these conditions,
steering effort will be increased. CAUTION: The following test procedure involves
testing power steering pump maximum pressure
output and flow control valve operation. Do not
DIAGNOSIS AND TESTING leave valve closed for more than 5 seconds as the
pump could be damaged.
POWER STEERING GEAR
The following procedure can be used to test the (8) Close valve fully three times and record high-
operation of the power steering system on this vehi- est pressure indicated each time. All three read-
cle. This test will provide the flow rate for the power ings must be within the specifications and
steering system along with the maximum relief pres- within 345 kPa (50 psi) of each other.
sure of the power steering pump. This test is to be
performed any time a power steering system problem NOTE: Power steering pump maximum relief pres-
is present to determine if the power steering pump or sure is 9653 to 10342 kPa (1400 to 1500 psi.).
power steering gear is not functioning properly. The
following pressure and flow test is performed using • If power steering pump pressures are within
Pressure/Flow Tester, Special Tool 6815 (Fig. 2). specifications but not within 345 kPa (50 psi) of each
other, then replace power steering pump.
• If pressures are within 345 kPa (50 psi) of each
other but below specifications, then replace power
steering pump.
CAUTION: Do not force the pump to operate

against the stops for more than 5 seconds at a time
because, pump damage will result.
(9) Open test valve. Turn steering wheel to the

extreme left and right positions until against the
stops, recording the highest indicated pressure at
each position. Compare pressure gauge readings to
power steering pump specifications. If highest output
pressures are not the same against either stop, the
steering gear is leaking internally and must be
Fig. 2 Power Steering Pump Flow/Pressure Tester replaced.
POWER STEERING PUMP FLOW AND
PRESSURE TEST PROCEDURE REMOVAL AND INSTALLATION
(1) Check power steering pump drive belt tension
and adjust as necessary. STEERING GEAR
(2) Disconnect power steering fluid pressure hose,
at power steering pump. Use a container for dripping NOTE: The power steering gear should NOT be ser-
fluid. viced or adjusted. If a malfunction or oil leak
(3) Connect Pressure Gauge, Special Tool from kit occurs, the complete steering gear assembly must
6815 to both hoses using adapter fittings. Connect be replaced.
spare pressure hose, to power steering pump pres-
sure hose fitting.
(4) Completely open valve on Special Tool 6815. REMOVE
(5) Start engine and let idle long enough to circu-
late power steering fluid through flow/pressure test CAUTION: Positioning the steering column in the
and get air out of fluid. Then shut off engine. locked position will prevent the clockspring from
(6) Check power steering fluid level, and add fluid being accidentally over-extended when the steering
as necessary. Start engine again and let idle. column is disconnected from the intermediate
(7) Pressure gauge should read below 862 kPa steering coupler.
(125 psi), if above, inspect the hoses for restrictions
and repair as necessary. The initial pressure reading
19 - 28 STEERING NS
voir.
fluid reservoir.
(3) With the ignition key in the locked position
turn the steering wheel to the left until the steering
wheel is in the locked position.
(4) With the vehicle on the ground, disconnect the
steering column shaft coupler from the steering gear
intermediate coupler (Fig. 3).
Fig. 4 Power Steering Fluid Return Hose

Connection
Fig. 3 Steering Column Shaft To Intermediate Shaft

Attachment
frame contact type hoist. See Hoisting in the Lubri-
ual, for the required lifting procedure to be used for
this vehicle.
(6) Remove the front tires. Fig. 5 Removing/Installing Tie Rod End Attaching
(7) Raise the heat sleeve (Fig. 4) on the power Nut
steering return hose to expose the return hose to
steel tube connection. Remove the return hose from
the metal tube of the power steering fluid return line
(Fig. 4). Then allow the remaining power steering
fluid to drain from the system through the hose and
metal tube.
(8) Remove nut attaching outer tie rod end to
steering knuckle (Fig. 5). Nut is to be removed
from tie rod end using the following procedure,
hold tie rod end stud with a 11/32 socket while
loosening and removing nut with wrench.
(9) Remove both tie rod ends from steering knuck-
les, using Puller Special Tool MB-990635 or
MB-991113 (Fig. 6).
Fig. 6 Tie Rod End Removal From Steering Knuckle

NS STEERING 19 - 29
(10) Remove the 2 bolts and loosen the third (Fig.
7) attaching the antilock brakes hydraulic control
unit (HCU) to the front suspension cradle. Then
rotate the HCU rearward to allow access to the cra-
dle plate attaching nut and bolt just forward of the
HCU.
Fig. 9 Power Steering Tube Bracket
Fig. 7 HCU Bracket Attaching Bolts

(11) Remove the 10 nuts and bolts (Fig. 8) attach-
ing the cradle plate to the bottom of the front sus-
pension cradle. Then remove the cradle plate from
the cradle.
Fig. 10 Power Steering Fluid Pressure And Return

Hoses At Steering Gear
Fig. 8 Front Suspension Cradle Plate And Attaching

Bolts
(12) Remove the bracket (Fig. 9) attaching the
power steering fluid tubes to the front suspension
cradle.
(13) Using a 18mm crowfoot, (Fig. 10) remove the
power steering fluid pressure and return lines (Fig.
10) from the power steering gear. Fig. 11 Steering Gear Mounting To Suspension
(14) Remove the 3 bolts and nuts (Fig. 11) mount- Cradle
ing the steering gear to the front suspension cradle.
19 - 30 STEERING NS
NOTE: The next step must be done to allow the
removal of the steering gear from the front suspen-
sion cradle. The steering gear can not be removed
from the vehicle with the intermediate coupler
attached to the steering gear.
(15) Lower steering gear from suspension cradle

enough to allow access to the intermediate coupler
roll pin (Fig. 12). Install Remover/Installer Special
Tool 6831A through the center of the roll pin, secur-
ing with the knurled nut (Fig. 12). Hold threaded rod
stationary while turning nut, this will pull the roll
pin out of the intermediate coupler.
Fig. 13 Installing Roll Pin In Intermediate Coupler

CAUTION: Proper torque on the steering gear to
suspension cradle mounting bolts is very impor-
tant.
(5) Tighten the 3 steering gear to suspension cra-

dle mounting bolts to a torque of 183 N·m (135 ft.
lbs.).
(6) Attach the power steering fluid pressure and
return lines (Fig. 10) to the proper fittings on the
steering gear. Tighten the power steering fluid line
tube nuts to a torque of 31 N·m (275 in. lbs.).
(7) Install tie rod end into steering knuckle. Start
Fig. 12 Removing Roll Pin From Intermediate tie rod end to steering knuckle attaching nut onto
Coupler stud of tie rod end. While holding stud of tie rod end
stationary using a 11/32 socket, (Fig. 5) tighten tie
(16) Separate the intermediate coupler from the
rod end to steering knuckle attaching nut. Then
shaft of the steering gear.
using a crowfoot and 11/32 socket (Fig. 14), tighten
(17) Remove the steering gear assembly from the
the tie rod end attaching nut to a torque of 54 N·m
front suspension cradle.
(40 ft. lbs.).
INSTALL
(1) Install the steering gear up in the front sus-
pension cradle, leaving room to install intermediate
coupler.
(2) Start the roll pin into the intermediate coupler
before installing coupler on steering gear shaft. Start
roll pin into coupler, using a hammer and tapping it
into the coupler. Then install the intermediate cou-
pler on the shaft of the steering gear.
(3) Install Remover/Installer Special Tool 6831A
through the center of the roll pin, securing it with
the knurled nut (Fig. 13). Hold threaded rod station-
ary while turning nut, this will pull the roll pin into
the intermediate coupler.
(4) Install steering gear assembly on the front sus-
pension cradle. Install the 3 steering gear to front
suspension cradle mounting bolts and nuts (Fig. 11). Fig. 14 Torquing Tie Rod End Attaching Nut
NS STEERING 19 - 31
CAUTION: Proper torque on the cradle plate to (18) Add fluid if necessary. Repeat the above pro-
suspension cradle mounting bolts is very impor- cedure until the fluid level remains constant after
tant. running the engine.
(19) Raise front wheels of vehicle off the ground.
(8) Install cradle plate on front suspension cradle (20) Start the engine. Slowly turn the steering
and install the 10 cradle plate to cradle attaching wheel right and left, lightly contacting the wheel
bolts and nuts (Fig. 8). Tighten all attaching bolts to stops. Then turn the engine off.
a torque of 165 N·m (123 ft. lbs.). (21) Add power steering fluid if necessary.
(9) Install the bracket (Fig. 9) attaching the power (22) Lower the vehicle and turn the steering wheel
steering fluid tubes to the front suspension cradle. slowly from lock to lock.
(23) Stop the engine. Check the fluid level and
CAUTION: refill as required.
(24) If the fluid is extremely foamy, allow the vehi-
cle to stand a few minutes and repeat the above pro-
the steel tube at the front suspension cradle (Fig. 4).
cedure.
(25) Fill power steering reservoir to correct level
with Mopart, Power Steering Fluid, or equivalent.
clamp is installed on return tube past the upset
(26) Adjust toe (Refer to Group 2 Suspension).
bead on the tube. Tighten the screw clamp to a
torque of 2 N·m (18 in. lbs.).
DISASSEMBLY AND ASSEMBLY
cover the entire rubber hose and hose to tube con- STEERING GEAR INNER TIE ROD BOOT
pressure and return hoses (Fig. 4). This is required DISASSEMBLE
to prevent the power steering hoses from being
overheated. NOTE: The removal and installation of the inner tie
rod boot must be performed with the steering gear
(12) When used, properly position the protective assembly removed from the vehicle.
heat sleeves on the power steering hoses. Then, tie
strap the heat sleeves to the power steering hoses to (1) Loosen the inner to outer tie rod jam nut (Fig.
keep them in their proper position. 15). Remove the outer tie rod from the inner tie rod.
(13) Install the front tire and wheel assemblies on
vehicle. Install the wheel lug nuts and torque to 129
N·m (95 ft. lbs.).
(14) Lower the vehicle to a level were the interior
of vehicle is accessible.
(15) Using the intermediate coupler, turn the front
wheels of the vehicle to the left until the intermedi-
ate coupler shaft is properly aligned with the steer-
ing column coupler. Assemble the steering column
shaft coupler (Fig. 3) onto the steering gear interme-
diate coupler. Install steering column coupler to
intermediate shaft retaining pinch bolt (Fig. 3).
Tighten the pinch bolt nut to a torque of 28 N·m (250
in. lbs.).
CAUTION: Do not use automatic transmission fluid

in the power steering system. Only use Mopar,
Power Steering Fluid or an exact equivalent prod-
Fig. 15 Inner To Outer Tie Rod Jam Nut
uct. (2) Remove nut attaching the outer tie rod end to
the steering knuckle (Fig. 16). Nut is to be
(16) Fill power steering pump fluid reservoir to the removed from tie rod end using the following
proper level. procedure, hold tie rod end stud with an 11/32
(17) Start the engine and let run for a few seconds. socket, while loosening and removing nut with
Then turn the engine off. wrench.
19 - 32 STEERING NS
Fig. 16 Removing Tie Rod End Attaching Nut Fig. 18 Tie Rod Boot To Tie Rod Clamp
(3) Remove the tie rod end from the steering
knuckle using Remover, Special Tool MB-991113 (Fig.
17) or MB-990635.
Fig. 19 Tie Rod Boot To Steering Gear Clamp

ASSEMBLE
(1) Install tie rod boot to steering gear clamp on
Fig. 17 Tie Rod End Removal From Steering tie rod boot.
Knuckle (2) Install tie rod boot and clamp on inner tie rod.
(4) Remove jam nut (Fig. 15) from inner tie rod. (3) Install tie rod boot over steering gear housing
(5) Using pliers expand tie rod boot, to inner tie and onto the end of the breather tube (Fig. 19).
rod clamp (Fig. 18) and remove from steering gear (4) Crimp inner tie rod boot to steering gear clamp
boot. using Crimper, Special Tool C4975A (Fig. 20). When
(6) Remove inner tie rod boot to steering gear installing clamp, Special Tool C4975A must have bot-
clamp (Fig. 19). tom bolt tightened until their is no gap between the
2 bars of the tool (Fig. 20)
NOTE: After removing inner boot clamps. Use a (5) Lubricate inner tie rod boot groove with sili-
very small screwdriver to lift boot from its retaining cone type lubricant, then install outer boot seal to
groove in steering gear. Then the boot can be inner tie rod clamp (Fig. 18). (Clamp will have to be
removed from steering gear. loosened for toe adjustment.)
(6) Install inner to outer tie rod jam nut (Fig. 15)
on inner tie rod.
(7) Install outer tie rod on inner tie rod. Do not
tighten jam nut.
(8) Install tie rod end into the steering knuckle.
Start tie rod end to steering knuckle attaching nut
onto stud of tie rod end. While holding stud of tie rod
NS STEERING 19 - 33
OUTER TIE ROD END
DISASSEMBLE
(1) Loosen inner tie rod to outer tie rod jam nut
(Fig. 22).
Fig. 20 Installing Tie Rod Boot To Steering Gear

Clamp
end stationary, tighten tie rod end to steering
knuckle attaching nut (Fig. 17). Then using a crow-
foot and 11/32 socket (Fig. 21), torque tie rod end
attaching nut to 54 N·m (40 ft. lbs.). Fig. 22 Inner To Outer Tie Rod Jam Nut
(2) Remove nut attaching outer tie rod end to
steering knuckle (Fig. 23). Nut is to be removed
from tie rod end using the following procedure,
hold tie rod end stud with a 11/32 socket while
loosening and removing nut with wrench.
Fig. 21 Torquing Tie Rod End Attaching Nut

CAUTION: During this procedure do not allow the
steering gear boot to become twisted. (See Wheel
Alignment in the suspension section of this service
manual).
Fig. 23 Tie Rod End Attaching Nut
(9) Make toe adjustment by turning inner tie rod.
(3) Remove the tie rod end stud from steering
(10) Tighten the inner to outer tie rod jam nut to
knuckle arm, using Remover, Special Tool,
75 N·m (55 ft. lbs.) torque. Lubricate tie rod boot
MB-991113 (Fig. 24) or MB-990635.
groove with silicone type lubricant, before installing
(4) Remove outer tie rod end from inner tie rod by
outer boot clamp, making sure boot is not twisted.
un-threading it from the inner tie rod.
19 - 34 STEERING NS
Fig. 24 Tie Rod End Removal From Steering Fig. 25 Torquing Tie Rod End Attaching Nut
Knuckle (6) Adjust the steering gear to inner tie rod boots
ASSEMBLE at inner tie rod if they became twisted during Toe
(1) Install outer tie rod onto inner tie rod. Make adjustment.
sure jam nut (Fig. 22) is on inner tie rod.
(2) Do not tighten jam nut.
(3) Install tie rod end into the steering knuckle. SPECIFICATIONS
Start tie rod end to steering knuckle attaching nut
onto stud of tie rod end. While holding stud of tie rod STEERING GEAR FASTENER TORQUE
end stationary, tighten tie rod end to steering SPECIFICATIONS
knuckle attaching nut (Fig. 23). Then using a crow-
foot and 11/32 socket (Fig. 25), torque tie rod end DESCRIPTION TORQUE
attaching nut to 54 N·m (40 ft. lbs.). STEERING GEAR:
To Suspension Cradle Bolts. . . .183 N·m (135 ft. lbs.)
CAUTION: During this procedure do not allow the Tie Rod To Steering
steering gear boot to become twisted. (See Wheel Knuckle Nut . . . . . . . . . . . . . . .54 N·m (40 ft. lbs.)
Alignment in the suspension section of this service Outer To Inner Tie Rod
manual). Jam Nut . . . . . . . . . . . . . . . . . .75 N·m (55 ft. lbs.)
Power Steering Hose
(4) Adjust the front Toe setting on the vehicle. Tube Nuts . . . . . . . . . . . . . . .31 N·m (275 in. lbs.)
Refer to the Toe Setting Procedure in Front Suspen- Coupler Pinch Bolt . . . . . . . . . . .28 N·m (250 in. lbs.)
sion Service Procedures in this group of the service
SUSPENSION CRADLE:
manual. Refer to the Specifications Section at the
Cradle Plate To Cradle
end of this group for the desired front Toe specifica-
Attaching Bolts . . . . . . . . . . .165 N·m (123 ft. lbs.)
tion.
(5) Tighten tie rod jam nut (Fig. 22) to 55 N·m (75
ft. lbs.) torque.
NS STEERING 19 - 35
SPECIAL TOOLS
POWER STEERING GEAR
Installer Boot Clamp C-4975A
Remover Tie Rod End MB–991113
Remover/Installer Steering Shaft Roll Pin 6831A
P/S System Analyzer 6815

19 - 36 STEERING NS
STEERING COLUMN
INDEX
page page
DESCRIPTION AND OPERATION REMOVAL AND INSTALLATION

STEERING COLUMN DESCRIPTION . . . . . . . . . 36 STEERING COLUMN ASSEMBLY . . . . . . . . . . . . 38
DIAGNOSIS AND TESTING SPECIFICATIONS
STEERING COLUMN . . . . . . . . . . . . . . . . . . . . . 38 STEERING COLUMN FASTENER TORQUE
SERVICE PROCEDURES SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . 45
STEERING COLUMN SERVICE PROCEDURE
WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
DESCRIPTION AND OPERATION assembly are the key cylinder, ignition switch, multi-
function switch, clockspring, halo lamp, speed control
STEERING COLUMN DESCRIPTION switches, driver airbag, trim shrouds and steering
The steering column (Fig. 1) has been designed to wheel. These replaceable components of the steering
be serviced only as a complete assembly, if a compo- column can be serviced without requiring removal of
nent of the steering column is defective. The only the steering column from the vehicle.
replaceable components of the steering column
Fig. 1 Steering Column Assembly Components

NS STEERING 19 - 37
Steering Column And Steering System Components

19 - 38 STEERING NS
DIAGNOSIS AND TESTING CAUTION: Do not attempt to remove the pivot pins
to disassemble the tilting mechanism. Damage will
STEERING COLUMN occur.
For diagnosis of conditions relating to the steering
column, refer to the steering system diagnosis charts,
in the diagnosis and testing section at the beginning REMOVAL AND INSTALLATION
of this group.
STEERING COLUMN ASSEMBLY
SERVICE PROCEDURES To service the steering wheel and its components
or the air bag, refer to Group 8M, Restraint Systems.
STEERING COLUMN SERVICE PROCEDURE Follow all WARNINGS.
To service the switches, refer to the appropriate
WARNINGS
section of Group 8, Electrical.
WARNING: BEFORE BEGINNING ANY SERVICE To replace the steering column assembly, refer to
PROCEDURES THAT INVOLVES REMOVING THE the steering column removal procedure.
AIR BAG. REMOVE AND ISOLATE THE NEGATIVE
REMOVE
(-) BATTERY CABLE (GROUND) FROM THE VEHI-
(1) Make sure the front wheels of the vehicle are
CLE BATTERY. THIS IS THE ONLY SURE WAY TO
in the straight ahead position before beginning the
DISABLE THE AIR BAG SYSTEM. FAILURE TO DO
column removal procedure.
THIS COULD RESULT IN ACCIDENTAL AIR BAG
(2) Disconnect negative (ground) cable from the
DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
battery and isolate cable from battery terminal.
(3) Remove the screws attaching the lower steer-
WARNING: THE AIR BAG SYSTEM IS A SENSITIVE, ing column cover to the instrument panel (Fig. 2).
COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE Remove the lower trim panel from the lower instru-
ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL ment panel.
THE AIR BAG SYSTEM COMPONENTS YOU MUST
FIRST DISCONNECT AND ISOLATE THE BATTERY
NEGATIVE (GROUND) CABLE. FAILURE TO DO SO
COULD RESULT IN ACCIDENTAL DEPLOYMENT OF
THE AIR BAG AND POSSIBLE PERSONAL INJURY.
THE FASTENERS, SCREWS, AND BOLTS, ORIGI-
NALLY USED FOR THE AIR BAG COMPONENTS,
HAVE SPECIAL COATINGS AND ARE SPECIFI-
CALLY DESIGNED FOR THE AIR BAG SYSTEM.
THEY MUST NEVER BE REPLACED WITH ANY SUB-
STITUTES. ANYTIME A NEW FASTENER IS
NEEDED, REPLACE WITH THE CORRECT FASTEN-
ERS PROVIDED IN THE SERVICE PACKAGE OR
FASTENERS LISTED IN THE PARTS BOOKS.
BEFORE SERVICING A STEERING COLUMN
EQUIPPED WITH AN AIR BAG, REFER TO GROUP
8M, ELECTRICAL FOR PROPER AND SAFE SER- Fig. 2 Lower Steering Column Cover Attachment
VICE PROCEDURES. Locations
(4) Remove the park brake pedal release cable
NOTE: Safety goggles should be worn at all times from the park brake release lever (Fig. 3).
when working on steering columns. (5) Remove the 10 bolts attaching the steering col-
umn cover liner (Fig. 4) to the instrument panel.
Remove the steering column cover liner from the
CAUTION: Disconnect negative (ground) cable lower instrument panel.
from the battery, before servicing any column com- (6) Rotate key cylinder to the lock position and
ponent. remove key. Rotate the steering wheel a half turn to
the left until the steering column lock engages keep-
ing the steering column in the locked position (Fig.
5).
NS STEERING 19 - 39
steering wheel. Remove air bag module from steering
wheel.
(8) Remove wiring harness connectors from air
bag, horn switch wire, and speed control switches
(Fig. 6). Remove the wiring harness routing clip (Fig.
6) from the air bag module studs.
Fig. 3 Park Brake Release Cable Attachment To

Release Lever
Fig. 6 Air Bag Module Wiring Connections

(9) Remove the steering wheel retaining nut (Fig.
7) from the steering column shaft.
Fig. 4 Lower Steering Column Cover Attachment
Fig. 7 Steering Wheel Retaining Nut

(10) Remove the steering wheel damper (Fig. 7)
from the steering wheel.
CAUTION: Do not bump or hammer on steering

column or steering column shaft when removing
steering wheel from steering column shaft.
Fig. 5 Steering Wheel In Locked Position

(7) Remove the 3 bolts (1 in each spoke of the
steering wheel) attaching the air bag module to the
19 - 40 STEERING NS
CAUTION: When installing steering wheel puller (13) Remove the vehicle wiring harness connectors
bolts in steering wheel, (Fig. 8) do not thread bolt (Fig. 10) from the clock spring assembly.
into steering wheel more than a half inch. If bolts
are threaded into the steering wheel more than a
half inch they will contact and damage the clock-
spring.
(11) Remove the steering wheel from steering col-

umn shaft using Puller, Special Tool, Snap-On
CJ2001JP or an equivalent (Fig. 8).
Fig. 10 Wiring Harness Connections To Clock

Spring
CAUTION: Do not rotate the clock spring after it is
removed from the multifunction switch.
(14) Remove the clock spring from the multi-func-

tion switch.
(15) Remove the vehicle wiring harness connector
Fig. 8 Removing Steering Wheel From Steering
from the top of the multi-function switch (Fig. 11).
Column Shaft
CAUTION: The upper and lower steering column
shrouds are held together using retaining clips.
When separating and removing the shrouds from
the steering column be careful not to break the
retaining clips off the shrouds
(12) Remove the 3 screws (Fig. 9) attaching the

upper and lower shrouds to the steering column.
Then remove the upper and lower shrouds (Fig. 9)
from the steering column.
Fig. 11 Wiring Harness Connection To Multi-

Function Switch
(16) Remove the screw (Fig. 12) attaching the
multi-function switch housing to the tilt head of the
steering column assembly.
(17) Remove the multi-function switch (Fig. 12)
from the tilt head of the steering column assembly.
(18) Remove the vehicle wiring harness connector
from the key cylinder halo light (Fig. 13).
(19) Remove the 3 wiring harness connectors from
the ignition switch (Fig. 14).
Fig. 9 Steering Column Shrouds
NS STEERING 19 - 41
PRNDL actuating cable MUST be removed from
the pin on the gear shifter prior to removing
the gear selector cable from the gear shifter.
Fig. 12 Multi-Function Switch Mounting Housing

Attaching Screw
Fig. 15 PRNDL Actuating Cable At Steering Column

(21) Remove the attaching clip (Fig. 15) for the
PRNDL actuating cable from the steering column/
shift cable bracket.
(22) Remove the gear selector cable from the gear
shifter the steering column (Fig. 16). Gear selector
cable is removed from pin on shift module by care-
fully prying it off with a screw driver (Fig. 16).
Fig. 13 Wiring Harness Connection To Halo Light
Fig. 16 Gear Selector Cable Removal From Shift

Module
(23) Remove the gear selector cable and its mount-
ing bracket as an assembly, from the upper mounting
bracket for the steering column (Fig. 17).
(24) Remove the instrument cluster trim bezel
(Fig. 18) from the instrument panel. The trim bezel
Fig. 14 Ignition Switch Wiring Harness Connections is mounted to the instrument panel using 2 attaching
screws and retaining clips.
(20) If the vehicle is equipped with a 3 speed non- (25) Remove the steering column fixed shroud
electronic transmission, remove the PRNDL actuat- from the steering column assembly (Fig. 19). Shroud
ing cable from the pin on the gear shifter (Fig. 15).
19 - 42 STEERING NS
(26) Disconnect the steering column shaft coupler,
from the steering gear intermediate steering coupler
(Fig. 20).
Fig. 17 Gear Selector Cable Mounting Bracket
Fig. 20 Steering Column Shaft To Intermediate

Coupler Attachment
(27) Loosen but do not fully remove the 2 nut/
washer assemblies attaching the steering column
lower mounting bracket (Fig. 21). Then remove the 2
nut/washer assemblies attaching the steering column
upper mounting bracket (Fig. 21).
Fig. 18 Instrument Cluster Trim Bezel

is mounted to steering column using 2 attaching
screws accessed from top of fixed shroud.
Fig. 19 Steering Column Fixed Shroud

Fig. 21 Steering Column Upper And Lower Mounting
Brackets
NS STEERING 19 - 43
(28) Remove steering column assembly from vehi- ing column/shift cable bracket. Cable guide tube will
cle. Use care to avoid damage to paint or interior bow toward passenger side of vehicle. Verify that
trim. actuating cable is operating correctly, then slip the
loop on the end of the cable over end of pin on shift
INSTALL lever and install in groove (Fig. 15).
(1) Ensure the plastic mounting capsules (Fig. 22) (8) Install the steering column fixed shroud on the
are installed in the upper mounting bracket of the steering column assembly (Fig. 19). Shroud is
steering column. Mounting capsules must be mounted to steering column using 2 attaching screws
installed as shown in (Fig. 22) with the thicker edge accessed from top of fixed shroud.
of the capsule facing the top of the steering column. (9) Install the instrument cluster trim bezel (Fig.
18) on the instrument panel. The trim bezel is
mounted to the instrument panel using 2 attaching
screws (Fig. 18) and retaining clips.
(10) Install the 3 wiring harness connectors on the
ignition switch (Fig. 14).
(11) Install the vehicle wiring harness connector
into the key cylinder halo light (Fig. 13).
(12) Install the multi-function switch (Fig. 12) on
the tilt head of the steering column assembly. Then
install screw (Fig. 12) attaching multi-function
switch to tilt head of steering column.
(13) Install the vehicle wiring harness connector
on the multi-function switch (Fig. 11). Be sure latch
on connector is fully engaged with tab on switch.
(14) Install the clock spring on the multi-function
switch.
Fig. 22 Mounting Capsules Correctly Installed On (15) Install the vehicle wiring harness connector
Steering Column (Fig. 10) on the clock spring assembly.
(16) Install the lower steering column shroud on
(2) Install steering column assembly into its open- the tilt head of the steering column (Fig. 23). Install
ing in instrument panel. Install the steering column and securely tighten the screw attaching the lower
lower bracket so the bracket is squarely installed on shroud to the tilt head.
its mounting studs (Fig. 21). Then align and install
steering column upper bracket on its mounting studs
(Fig. 21). Tighten the 4 steering column assembly
mounting nut/washer assemblies to a torque of 12
N·m (105 in. lbs.).
(3) Assemble the steering column shaft coupler
(Fig. 20) onto the steering gear intermediate coupler.
Install steering column coupler to intermediate shaft
retaining pinch bolt (Fig. 20). Tighten the pinch bolt
nut to a torque of 28 N·m (250 in. lbs.). Install safety
pin (Fig. 20) in steering column shaft coupler pinch
bolt.
(4) Install the gear slector cable and its mounting
bracket on the upper mounting bracket of the steer-
ing column (Fig. 17). Install and securely tighten the
mounting bracket attaching bolt.
(5) Install the gear selector cable on the pin of the
gear shifter (Fig. 16). Fig. 23 Lower Steering Column Shroud Installed
(6) If the vehicle is equipped with a 3 speed non- (17) Install the upper steering column shroud on
electronic transmission, install the PRNDL actuating the tilt head of the steering column (Fig. 24). Install
cable on the gear shifter pin after the gear selector and securely tighten the 2 screws attaching the
cable is installing (Fig. 15). upper shroud to the lower shroud.
(7) If the vehicle is equipped with a 3 speed non-
electronic transmission, install the attaching clip
(Fig. 15) for the PRNDL actuating cable on the steer-
19 - 44 STEERING NS
Fig. 24 Upper And Lower Steering Column Shroud

Installed
CAUTION: Before installing the steering wheel the
clockspring must be centered. If clockspring is not
centered, the wiring in the clockspring may be over-
extended and break when the steering wheel is
rotated. Use the following procedure to center the Fig. 25 Clockspring Assembly
clockspring.
CLOCKSPRING CENTERING PROCEDURE

• Depress the 2 plastic locking pins to disengage
the lock mechanism (Fig. 25).
• With the lock mechanism disengaged, rotate the
clockspring rotor clockwise until the rotor stops. Do
not apply excessive force.
• From the end of the clockwise travel, rotate the
rotor three turns counterclockwise. The clockspring
wires should be at the top. Engage clockspring lock-
ing pins.
• From the center locked position, rotate the clock-
spring one-half additional turn counterclockwise. The
clockspring wiring should now be at the bottom. The
clockspring is now correctly positioned for installa-
tion of the steering wheel. Fig. 26 Steering Wheel And Clock Spring Wire
Routing
CAUTION: Do not force steering wheel onto steer-
ing column shaft by driving it on. Pull steering If the damper is installed with a damaged isolator a
wheel down onto shaft using ONLY the steering buzz, squeak or rattle condition may develop.
wheel retaining nut.
(19) Install the steering wheel damper on the
(18) Align master splines on steering wheel and steering wheel. When damper is installed, it must be
steering shaft, and flats on steering wheel with for- positioned on the steering wheel as shown in (Fig. 7).
mations on clock spring. Install the steering wheel on (20) Install the steering wheel to steering shaft
the steering column shaft (Fig. 26). All wiring leads retaining nut. Tighten the steering wheel retaining
from the clock spring must be routed as shown in nut to a torque of 61 N·m (45 ft. lbs.).
(Fig. 26). (21) Install the wiring leads from the clock spring
on the air bag, horn switch wire, and speed control
NOTE: Before installing the damper on the steering switches (Fig. 6). Attach the wire routing clip (Fig. 6)
wheel, inspect the damper to ensure the rubber iso- to the studs on the air bag module.
lator on the damper is not deteriorated or damaged. (22) Install the air bag module in the steering
wheel.
NS STEERING 19 - 45
(23) Install the 3 bolts (1 in each spoke of the SPECIFICATIONS
steering wheel) attaching the air bag module to the
steering wheel. Tighten the 3 air bag module attach- STEERING COLUMN FASTENER TORQUE
ing nuts to a torque of 11 N·m (100 in. lbs.). SPECIFICATIONS
(24) Install the steering column cover liner (Fig. 4)
on the lower instrument panel. Install and securely DESCRIPTION TORQUE
tighten the 10 bolts (Fig. 4) attaching the steering STEERING WHEEL:
column cover liner to the instrument panel. Retaining Nut . . . . . . . . . . . . . . .61 N·m (45 ft. lbs.)
(25) Install the park brake pedal release cable on
STEERING COLUMN ASSEMBLY:
the park brake release lever in the lower steering col-
Mounting Bracket
umn cover (Fig. 3).
Attaching Nuts. . . . . . . . . . . .12 N·m (105 in. lbs.)
(26) Install the lower steering column trim panel
Flex Coupler Pinch Bolt . . . . . . .27 N·m (240 in. lbs.)
on the lower instrument panel. Install and securely
Airbag Module Attaching Nuts . .11 N·m (100 in. lbs.)
the screws attaching the lower steering column cover
to the instrument panel (Fig. 2).
(27) Connect negative (ground) cable on the bat-
tery terminal.
NS/GS STEERING 19 - 1
STEERING
CONTENTS
page
POWER STEERING—2.5L VM DIESEL . . . . . . . 1
POWER STEERING—2.5L VM DIESEL
INDEX
page page
GENERAL INFORMATION SERVICE PROCEDURES

POWER STEERING GEAR . . . . . . . . . . . . . . . . 1 POWER STEERING PUMP – INITIAL
POWER STEERING PUMP . . . . . . . . . . . . . . . . 1 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
STEERING GEAR OPERATION—RHD & LHD REMOVAL AND INSTALLATION
VEHICLES . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 POWER STEERING PUMP—2.5L DIESEL . . . . . 2
GENERAL INFORMATION
POWER STEERING PUMP
The power steering pump used with the 2.5L VM
Diesel engine operates the same way as the power
steering pump used with the 2.5/4.0L gasoline
engines. Refer to the Description and Operation sec-
tion for the 2.5/4.0L gasoline engine power steering
pump for more information.
STEERING GEAR OPERATION—RHD & LHD

VEHICLES
NOTE: The power steering gear should NOT be ser-
viced or adjusted. If a malfunction or oil leak
occurs, the complete steering gear should be
replaced. Fig. 1 Power Steering Gear—RHD Vehicles
CAUTION: Use MOPAR Power Steering Fluid or
Refer to the Power Steering Gear in group 19 for equivalent. Do not use automatic transmission fluid
more information and do not overfill.
POWER STEERING GEAR Wipe filler cap clean, then check the fluid level.
The dipstick should indicate COLD when the fluid is
SERVICE PROCEDURES at normal temperature.
(1) Fill the pump fluid reservoir to the proper level
POWER STEERING PUMP – INITIAL OPERATION and let the fluid settle for at least two minutes.
(2) Start the engine and let run for a few seconds
WARNING: THE FLUID LEVEL SHOULD BE then turn engine off.
CHECKED WITH ENGINE OFF TO PREVENT INJURY (3) Add fluid if necessary. Repeat the above proce-
FROM MOVING COMPONENTS. dure until the fluid level remains constant after run-
ning the engine.
19 - 2 STEERING NS/GS
SERVICE PROCEDURES (Continued)
(4) Raise the front wheels off the ground.
(5) Slowly turn the steering wheel right and left,
lightly contacting the wheel stops at least 20 times.
(6) Check the fluid level add if necessary.
(7) Lower the vehicle, start the engine and turn
the steering wheel slowly from lock to lock.
(8) Stop the engine and check the fluid level and
refill as required.
(9) If the fluid is extremely foamy or milky look-
ing, allow the vehicle to stand a few minutes and
repeat the procedure.
CAUTION: Do not run a vehicle with foamy fluid for

an extended period. This may cause pump damage.
REMOVAL AND INSTALLATION

POWER STEERING PUMP—2.5L DIESEL
NOTE: The power steering pump is mounted below
the fuel pump on the left side of the engine. The
vehicle should be raised on a hoist to access the
pump from below. Fig. 2 Power Steering Pump Pulley Removal
REMOVAL
(1) Remove serpentine drive belt. Refer to Group 7,
Cooling System, for procedure.
(2) Remove power steering pump pulley. Use a hex
wrench to secure the power steering shaft while
removing the pulley bolt with a box wrench. (Fig. 2)
CAUTION: Do not use an impact wrench to remove

the pump pulley – this can cause rear pump seal
damage. Do not secure power steering shaft with a
wrench on the coupling to the A/C compressor –
this can cause rear pump seal damage.
(3) Remove coupling bolts (2) from A/C compressor

side of coupling.
(4) Loosen A/C compressor bolts and separate com-
pressor from bracket. Do not disconnect A/C hoses.
(5) Remove bolts (2) securing the power steering
pump to the power steering bracket.
(6) Disconnect power steering pump supply hose at
the pump and drain fluid.
(7) Disconnect power steering pressure hose at the Fig. 3 Left SIde Motor Mount—VM DIesel
steering gear assembly. (3) Reverse the above procedures in steps 8
(8) Remove power steering pump. through 1 to complete installation.
(4) Add power steering fluid and perform Power
INSTALLATION Steering Pump Initial Operation.
(1) Install pump on engine.
(2) Tighten pump bracket bolts to 47 N·m (35 ft.
lbs.).
NS TRANSAXLE AND POWER TRANSFER UNIT 21 - 1
TRANSAXLE AND POWER TRANSFER UNIT

CONTENTS
page page
31TH AUTOMATIC TRANSAXLE . . . . . . . . . . . . . . 1 POWER TRANSFER UNIT . . . . . . . . . . . . . . . . . 165

41TE AUTOMATIC TRANSAXLE . . . . . . . . . . . . . 71
31TH AUTOMATIC TRANSAXLE
INDEX
page page
GENERAL INFORMATION DISASSEMBLY AND ASSEMBLY

31TH TRANSAXLE . . . . . . . . . . . . . . . . . . . . . . . . 2 ACCUMULATOR-RECONDITION . . . . . . . . . . . . 36
FLUID LEVEL AND CONDITION . . . . . . . . . . . . . . 2 DIFFERENTIAL REPAIR . . . . . . . . . . . . . . . . . . . 46
SELECTION OF LUBRICANT . . . . . . . . . . . . . . . . 3 FRONT CLUTCH-RECONDITION . . . . . . . . . . . . 32
SPECIAL ADDITIVES . . . . . . . . . . . . . . . . . . . . . . 3 FRONT PLANETARY & ANNULUS GEAR-
DESCRIPTION AND OPERATION RECONDITION . . . . . . . . . . . . . . . . . . . . . . . . 35
CLUTCHES, BAND SERVOS, AND KICKDOWN SERVO (CONTROLLED LOAD)-
ACCUMULATOR . . . . . . . . . . . . . . . . . . . . . . 3 RECONDITION . . . . . . . . . . . . . . . . . . . . . . . . 37
FLOW CONTROL VALVES . . . . . . . . . . . . . . . . . . 3 LOW/REVERSE (REAR)
GEARSHIFT AND PARKING LOCK CONTROLS . . 4 SERVO-RECONDITION . . . . . . . . . . . . . . . . . . 36
GOVERNOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 OIL PUMP-RECONDITION . . . . . . . . . . . . . . . . . 31
HYDRAULIC CONTROL SYSTEM . . . . . . . . . . . . . 3 OUTPUT SHAFT REPAIR . . . . . . . . . . . . . . . . . . 43
PRESSURE REGULATING VALVES . . . . . . . . . . . 3 PARKING PAWL . . . . . . . . . . . . . . . . . . . . . . . . . 42
PRESSURE SUPPLY SYSTEM . . . . . . . . . . . . . . . 3 REAR CLUTCH-RECONDITION . . . . . . . . . . . . . 33
TORQUE CONVERTER CLUTCH SOLENOID TRANSAXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
WIRING CONNECTOR . . . . . . . . . . . . . . . . . . . 4 TRANSFER SHAFT REPAIR . . . . . . . . . . . . . . . . 38
TORQUE CONVERTER CLUTCH . . . . . . . . . . . . . 3 VALVE BODY RECONDITION . . . . . . . . . . . . . . . 27
DIAGNOSIS AND TESTING CLEANING AND INSPECTION
CLUTCH AND SERVO AIR PRESSURE TESTS . 15 VALVE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
FLUID LEAKAGE-TRANSAXLE TORQUE ADJUSTMENTS
CONVERTER HOUSING AREA . . . . . . . . . . . . 15 BAND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . 51
HYDRAULIC PRESSURE TESTS . . . . . . . . . . . . 13 BEARING ADJUSTMENT PROCEDURES . . . . . . 52
ROAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 DIFFERENTIAL BEARING . . . . . . . . . . . . . . . . . 53
THREE SPEED TRANSAXLE DIAGNOSIS AND GEARSHIFT CABLE ADJUSTMENT . . . . . . . . . . 51
TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 HYDRAULIC CONTROL PRESSURE
SERVICE PROCEDURES ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . 52
ALUMINUM THREAD REPAIR . . . . . . . . . . . . . . 18 OUTPUT SHAFT BEARING . . . . . . . . . . . . . . . . 52
FLUID AND FILTER CHANGE . . . . . . . . . . . . . . . 16 THROTTLE PRESSURE LINKAGE
FLUID DRAIN AND REFILL . . . . . . . . . . . . . . . . . 18 ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . 51
FLUSHING COOLERS AND TUBES . . . . . . . . . . 18 TRANSFER SHAFT BEARING . . . . . . . . . . . . . . 54
OIL PUMP VOLUME CHECK . . . . . . . . . . . . . . . 19 SCHEMATICS AND DIAGRAMS
REMOVAL AND INSTALLATION 31TH TRANSAXLE HYDRAULIC SCHEMATIC . . 56
FRONT PUMP OIL SEAL . . . . . . . . . . . . . . . . . . 21 SPECIFICATIONS
PARK/NEUTRAL STARTING AND BACK-UP 31TH AUTOMATIC TRANSAXLE . . . . . . . . . . . . . 64
LAMP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . 19 31TH TORQUE SPECIFICATIONS . . . . . . . . . . . 65
TRANSAXLE AND TORQUE CONVERTER SPECIAL TOOLS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 31TH AUTOMATIC TRANSAXLE . . . . . . . . . . . . . 66
VEHICLE SPEED SENSOR PINION GEAR . . . . . 19
21 - 2 TRANSAXLE AND POWER TRANSFER UNIT NS
GENERAL INFORMATION • Two planetary gear sets

This provides three forward ratios and a reverse
31TH TRANSAXLE ratio. The common sun gear of the planetary gear
sets is connected to the front clutch by a driving
NOTE: Safety goggles should be worn at all times shell. The drive shell is splined to the sun gear and
when working on these transaxles. front clutch retainer. The hydraulic system consists
of an oil pump, and a single valve body which con-
This transaxle combines torque converter, three tains all of the valves except the governor valves.
speed transmission, final drive gearing, and differen- The transaxle sump and differential sump are both
tial into a front wheel drive system. The identifica- vented through the dipstick. Output torque from the
tion markings and usage of the transaxle are charted main center line is delivered through helical gears to
in Diagnosis and Tests. the transfer shaft. This gear set is a factor of the
final drive (axle) ratio. The shaft also carries the gov-
NOTE: Transaxle operation requirements are differ- ernor and parking sprag. An integral helical gear on
ent for each vehicle and engine combination. Some the transfer shaft drives the differential ring gear.
internal parts will be different to provide for this. The final drive gearing is completed with one of two
Therefore, when replacing parts, refer to the seven gear ratios of 2.98 or 3.19 depending on model and
digit part number stamped on rear of the transaxle application.
oil pan flange.
FLUID LEVEL AND CONDITION
Within this transaxle, there are three primary
areas: NOTE: The transmission and differential sump have
(1) Main center line plus valve body. a common oil sump with a communicating opening
(2) Transfer shaft center line (includes governor between the two.
and parking sprag).
(3) Differential center line. The torque converter fills in both the P Park and N
(4) Center distances between the main rotating Neutral positions. Place the selector lever in P Park
parts in these three areas are held precise to main- to be sure that the fluid level check is accurate. The
tain a low noise level. engine should be running at idle speed for at
(5) The torque converter, transaxle area, and dif- least one minute, with the vehicle on level
ferential are housed in an integral aluminum die ground. This will assure complete oil level sta-
casting. The differential oil sump is common bilization between differential and transmis-
with the transaxle sump. Separate filling of the sion. The fluid should be at normal operating
differential is NOT necessary. temperature (approximately 82 C. or 180 F.). The
(6) The torque converter is attached to the crank- fluid level is correct if it is in the HOT region (cross-
shaft through a flexible driving plate. Cooling of the hatched area) on the dipstick.
converter is accomplished by circulating the tran- Low fluid level can cause a variety of conditions
saxle fluid through a remote cooler. There are two because it allows the pump to take in air along with
types of coolers used. An oil-to-water type cooler the fluid. As in any hydraulic system, air bubbles
located in the radiator side tank and/or an oil-to air make the fluid spongy, therefore, pressures will be
heat exchanger. The torque converter assembly is a low and build up slowly.
sealed unit that cannot be disassembled. Improper filling can also raise the fluid level too
(7) The transaxle fluid is filtered by an internal fil- high. When the transaxle has too much fluid, the
ter attached to the lower side of the valve body gears churn up foam and cause the same conditions
assembly. which occur with a low fluid level.
(8) Engine torque is transmitted to the torque con- In either case, the air bubbles can cause overheat-
verter then, through the input shaft to multiple-disc ing, fluid oxidation, and varnishing. This can inter-
clutches in the transaxle. The power flow depends on fere with normal valve, clutch, and servo operation.
the application of the clutches and bands. Refer to Foaming can also result in fluid escaping from the
Elements in Use Chart in Diagnosis and Tests sec- transaxle dipstick where it may be mistaken for a
tion. leak.
(9) The transaxle consists of: Along with fluid level, it is important to check the
• Two multiple-disc clutches condition of the fluid. When the fluid smells burned,
• An overrunning clutch and is contaminated with metal or friction material
• Two servos particles, a complete transaxle overhaul is needed.
• A hydraulic accumulator Be sure to examine the fluid on the dipstick closely.
• Two bands
GENERAL INFORMATION (Continued)
If there is any doubt about its condition, drain out a The throttle valve transmits regulated pressure to
sample for a double check. the transaxle (dependent on throttle position) to con-
trol upshift and downshift.
SELECTION OF LUBRICANT
It is important that the proper lubricant be used in FLOW CONTROL VALVES
these transmissions. Mopar ATF PLUS 3 (Automatic The manual valve provides the different transaxle
Transmission Fluid- type 7176) should be used to aid drive ranges as selected by the vehicle operator.
in ensuring optimum transmission performance. It is The 1-2 shift valve automatically shifts the tran-
important that the transmission fluid be maintained saxle from first to second or from second to first,
at the prescribed level using the recommended fluids. depending on the vehicle operation.
The 2-3 shift valve automatically shifts the tran-
SPECIAL ADDITIVES saxle from second to third or from third to second
Chrysler Corporation does not recommend the depending on the vehicle operation.
addition of any fluids to the transmission, other than The kickdown valve makes possible a forced down-
fluid listed above. An exception to this policy is the shift from third to second, second to first, or third to
use of special dyes to aid in detecting fluid leaks. The first (depending on vehicle speed). This can be done
use of transmission sealers should be avoided, since by depressing the accelerator pedal past the detent
they may adversely affect seals. feel near wide open throttle.
The shuttle valve has two separate functions and
performs each independently of the other. The first is
DESCRIPTION AND OPERATION providing fast release of the kickdown band, and
smooth front clutch engagement when a lift-foot
TORQUE CONVERTER CLUTCH upshift from second to third is made. The second
A torque converter clutch is standard on all vehi- function is to regulate the application of the kick-
cles. The torque converter clutch is activated only in down servo and band when making third to second
direct drive and is controlled by the engine electron- kickdown.
ics. A solenoid on the valve body, is powered by the The by-pass valve provides for smooth application
powertrain control module to activate torque con- of the kickdown band on 1-2 upshifts.
verter clutch. The torque converter clutch solenoid allows for the
electronic control of the torque converter clutch. It
HYDRAULIC CONTROL SYSTEM also disengages the torque converter at closed throt-
The hydraulic control system makes the transaxle tle. This is done during engine warm-up, and part-
fully automatic, and has four important functions to throttle acceleration.
perform. The components of any automatic control The switch valve directs oil to apply the torque
system may be grouped into the following basic converter clutch in one position. The switch valve
groups: releases the torque converter clutch in the other posi-
The pressure supply system, the pressure regulat- tion.
ing valves, the flow control valves, the clutches, and
band servos. CLUTCHES, BAND SERVOS, AND ACCUMULATOR
Taking each of these basic groups or systems in The front and rear clutch pistons, and both servo
turn, the control system may be described as follows: pistons are moved hydraulically to engage the
clutches and apply the bands. The pistons are
PRESSURE SUPPLY SYSTEM released by spring tension when hydraulic pressure
The pressure supply system consists of an oil pump is released. On the 2-3 upshift, the kickdown servo
driven by the engine through the torque converter. piston is released by spring tension and hydraulic
The single pump furnishes pressure for all the pressure.
hydraulic and lubrication requirements. Oil pump The accumulator controls the hydraulic pressure
housing assemblies are available with prese- on the apply side of the kickdown servo during the
lected pump gears. 1-2 upshift; thereby, cushioning the kickdown band
application at any throttle position.
PRESSURE REGULATING VALVES
The pressure regulating valve controls line pres-
sure dependent on throttle opening. The governor
valve transmits regulated pressure to the valve body
(in conjunction with vehicle speed) to control upshift
and downshift.
GEARSHIFT AND PARKING LOCK CONTROLS Diagnosis of these problems should always begin
The transaxle is controlled by a lever type gear- by checking the easily accessible variables; fluid level
shift incorporated within the steering column. The and condition, gearshift cable adjustment, and throt-
control has six selector lever positions: P (park), R tle pressure cable adjustment. Then perform a road
(reverse), N (neutral), and D (drive), 2 (second), and test to determine if the problem has been corrected
1 (first). The parking lock is applied by moving the or that more diagnosis is necessary. If the problem
selector lever past a gate to the P position. Do not exists after the preliminary tests and corrections are
apply the parking lock until the vehicle has completed, hydraulic pressure tests should be per-
stopped; otherwise, a severe ratchet noise will formed
occur.
31TH HYDRAULIC TROUBLE CODE CHARTS
TORQUE CONVERTER CLUTCH SOLENOID WIRING The following charts should be used to help diag-
nose hydraulic or mechanical faults in the transaxle .
CONNECTOR
If wiring connector is unplugged, the torque con-
ROAD TEST
verter will not engage (Fig. 1) .
Prior to performing a road test, check the fluid
level, and control cable adjustments.
During the road test, the transaxle should be oper-
ated in each position to check for slipping and any
variation in shifting.
If vehicle operates at high speeds, but has poor
acceleration, the converter’s overrunning clutch may
be slipping. If acceleration is normal, but high throt-
tle opening is needed for high speeds, the stator
clutch may have seized.
Observe closely for slipping or engine speed flare-
up. Slipping or flare-up in any gear usually indicates
clutch, band, or overrunning clutch problems. If the
condition is far advanced, an overhaul will probably
be necessary to restore normal operation.
In most cases, the clutch or band that is slipping
can be determined by noting the transaxle operation
Fig. 1 Torque Converter Clutch Solenoid Wiring in all selector positions. Then comparing which inter-
Connector nal units are applied in those positions. The Ele-
GOVERNOR ments in Use Chart provides a basis for road test
analysis .
The governor may be serviced by removing the
The rear clutch is applied in both the D first gear
transaxle oil pan and valve body assembly. The gov-
and 1 first gear positions. Also the overrunning
ernor may be unbolted from the governor support
clutch is applied in D first gear and the low/reverse
and removed from the transaxle for reconditioning or
band is applied in 1 first gear position. If the tran-
replacement.
saxle slips in D range first gear, but does not slip in
When cleaning or assembling the governor, make
1 first gear, the overrunning clutch is slipping. Simi-
sure the governor valves move freely in the bores of
larly, if the transaxle slips in any two forward gears,
the governor body.
the rear clutch is slipping.
Using the same procedure, the rear clutch and
DIAGNOSIS AND TESTING front clutch are applied in D third gear. If the tran-
saxle slips in third gear, either the front clutch or the
THREE SPEED TRANSAXLE DIAGNOSIS AND rear clutch is slipping. By selecting another gear
TESTS which does not use one of those units, the unit which
Automatic transaxle malfunctions may be caused is slipping can be determined. If the transaxle also
by four general conditions: slips in reverse, the front clutch is slipping. If the
(1) Poor engine performance transaxle does not slip in reverse, the rear clutch is
(2) Improper adjustments slipping.
(3) Hydraulic malfunctions The process of eliminating can be used to detect
(4) Mechanical malfunctions any unit which slips and to confirm proper operation
of good units. Road testing can usually diagnose slip-
ping units. Although the actual cause of the problem
Diagnosis Guide
Diagnosis Guide
Diagnosis Guide
Diagnosis Guide
Diagnosis Guide
Diagnosis Guide
Diagnosis Guide
Diagnosis Guide
ELEMENTS IN USE AT EACH POSITION OF THE SELECTOR LEVER

may not be detected. Practically any condition can be (6) Low-reverse pressure should read the same as
caused by leaking hydraulic circuits or sticking line pressure within 3 psi.
valves. (7) This tests pump output, pressure regulation,
Therefore, unless the condition is obvious, the tran- and condition of rear clutch and rear servo hydraulic
saxle should never be disassembled until hydraulic circuits.
pressure tests have been performed.
TEST TWO (SELECTOR IN 2)
HYDRAULIC PRESSURE TESTS (1) Attach one gauge to line pressure port and tee
Pressure testing is a very important step in the another gauge into lower cooler line fitting. This will
diagnostic procedure. These tests usually reveal the allow lubrication pressure readings to be taken..
cause of most transaxle problems. (2) Operate engine at 1000 rpm for test.
Before performing pressure tests, be certain that (3) Move selector lever on transaxle one detent for-
fluid level and condition, and control cable adjust- ward from full rearward position. This is selector 2
ments have been checked and approved. Fluid must position.
be at operating temperature (150 to 200 degrees F.). (4) Read pressures on both gauges as throttle lever
Install an engine tachometer, raise vehicle on hoist on transaxle is moved from full clockwise position to
which allows front wheels to turn, and position full counterclockwise position.
tachometer so it can be read. (5) Line pressure should read 52 to 58 psi with
Disconnect throttle cable and shift cable from tran- throttle lever clockwise. Pressure should gradually
saxle levers so they can be controlled from outside increase, as lever is moved counterclockwise, to 80 to
the vehicle. 88 psi.
Attach 150 psi gauges to ports required for test (6) Lubrication pressure should be 10 to 25 psi
being conducted. A 300 psi gauge (C-3293) is required with lever clockwise and 10 to 35 psi with lever full
for reverse pressure test at rear servo. counterclockwise.
Test port locations are shown in (Fig. 2) . (7) This tests pump output, pressure regulation,
and condition of rear clutch and lubrication hydraulic
TEST ONE (SELECTOR IN 1) circuits.
(1) Attach gauges to line and low-reverse ports.
(2) Operate engine at 1000 rpm for test. TEST THREE (SELECTOR IN D)
(3) Move selector lever on transaxle all the way (1) Attach gauges to line and kickdown release
rearward (1 position). ports.
(4) Read pressures on both gauges as throttle lever (2) Operate engine at 1600 rpm for test.
on transaxle is moved from full clockwise position to (3) Move selector lever on transaxle two detents
full counterclockwise position. forward from full rearward position. This is selector
(5) Line pressure should read 52 to 58 psi with D position.
throttle lever clockwise. Pressure should gradually (4) Read pressures on both gauges as throttle lever
increase, as lever is moved counterclockwise, to 80 to on transaxle is moved from full clockwise position to
88 psi. full counterclockwise position.
(5) Line pressure should read 52 to 58 psi with
throttle lever clockwise. Pressure should gradually
Fig. 2 Test Port Locations

TEST FOUR (SELECTOR IN REVERSE)
(1) Attach 300 psi gauge to low-reverse port.
(2) Operate engine at 1600 rpm for test.
(3) Move selector lever on transaxle four detents
forward from full rearward position. This is selector
R position.
(4) Low-reverse pressure should read 180 to 220
psi with throttle lever clockwise. Pressure should
gradually increase, as lever is moved counterclock-
wise to 260 to 300 psi.
(5) This tests pump output, pressure regulation,
and condition of front clutch and rear servo hydraulic
circuits.
(6) Move selector lever on transaxle to D position
to check that low-reverse pressure drops to zero.
(7) This tests for leakage into rear servo, due to
Fig. 3 Governor Pressure Tap case porosity, which can cause reverse band burn out.
increase, as lever is moved counterclockwise to 80 to
TEST RESULT INDICATIONS
88 psi.
(1) If proper line pressure, minimum to maximum,
(6) Kickdown release is pressurized only in direct
is found in any one test, the pump and pressure reg-
drive and should be same as line pressure within 3
ulator are working properly.
psi, up to kickdown point.
(2) Low pressure in D, 1, and 2 but correct pres-
(7) This tests pump output, pressure regulation,
sure in R indicates rear clutch circuit leakage.
and condition of rear clutch, front clutch, and
(3) Low pressure in D and R but correct pressure
hydraulic circuits.
in 1 indicates front clutch circuit leakage.
(4) Low pressure in R and 1 but correct pressure REAR CLUTCH
in 2 indicates rear servo circuit leakage. Apply air pressure to rear clutch apply passage
(5) Low line pressure in all positions indicates a and listen for a dull thud which indicates that rear
defective pump, a clogged filter, or a stuck pressure clutch is operating. Also inspect for excessive oil
regulator valve. leaks. If a dull thud cannot be heard in the clutches,
place finger tips on clutch housing and again apply
GOVERNOR PRESSURE air pressure. Movement of piston can be felt as the
Test only if transaxle shifts at wrong vehicle clutch is applied.
speeds when throttle cable is correctly adjusted.
(1) Connect a 0-150 psi pressure gauge to governor KICKDOWN SERVO (FRONT)
pressure take-off point. It is located at lower right Direct air pressure into KICKDOWN SERVO ON
side of case, below differential cover. passage. Operation of servo is indicated by a tighten-
(2) Operate transaxle in third gear to read pres- ing of front band. Spring tension on servo piston
sures. The governor pressure should respond should release the band.
smoothly to changes in mph and should return to 0
to 3 psi when vehicle is stopped. High pressure at LOW AND REVERSE SERVO (REAR)
standstill (above 3 psi) will prevent the transaxle Direct air pressure into LOW-REVERSE SERVO
from downshifting. APPLY passage. Operation of servo is indicated by a
tightening of rear band. Spring tension on servo pis-
THROTTLE PRESSURE ton should release the band.
No gauge port is provided for throttle pressure. If clutches and servos operate properly, no upshift
Incorrect throttle pressure should be suspected if indicates that a malfunction exists in the valve body.
part throttle upshift speeds are either delayed or
occur too early in relation to vehicle speeds. Engine FLUID LEAKAGE-TRANSAXLE TORQUE
runaway on shifts can also be an indicator of low CONVERTER HOUSING AREA
throttle pressure setting, or misadjusted throttle (1) Check for source of leakage.
cable. (2) Since fluid leakage near the torque converter
In no case should throttle pressure be adjusted area may be from an engine oil leak, the area should
until the transaxle throttle cable adjustment has be checked closely. Factory fill fluid is dyed red and,
been verified to be correct. therefore, can be distinguished from engine oil.
(3) Prior to removing the transaxle, perform the
CLUTCH AND SERVO AIR PRESSURE TESTS following checks:
A no drive condition might exist even with correct (4) When leakage is determined to originate from
fluid pressure, because of inoperative clutches or the transaxle, check fluid level prior to removal of
bands. The inoperative units, clutches, bands, and the transaxle and torque converter.
servos can be located through a series of tests. This (5) High oil level can result in oil leakage out the
is done by substituting air pressure for fluid pressure vent in the dipstick. If the fluid level is high, adjust
(Fig. 4) . to proper level.
The front and rear clutches, kickdown servo, and (6) After performing this operation, inspect for
low-reverse servo may be tested by applying air pres- leakage. If a leak persists, perform the following
sure to their respective passages. To make air pres- operation on the vehicle. This will determine if the
sure tests, proceed as follows: torque converter or transaxle is leaking.
NOTE: Compressed air supply must be free of all TORQUE CONVERTER LEAKAGE
dirt or moisture. Use a pressure of 30 psi. Possible sources of torque converter leakage are:
• Torque converter weld leaks at the outside diam-
Remove oil pan and valve body. Refer to Valve eter (peripheral) weld.
Body for removal procedure. • Torque converter hub weld.
• Torque converter impeller shell cracked adjacent
FRONT CLUTCH
to hub.
Apply air pressure to front clutch apply passage
• At drive lug welds.
and listen for a dull thud which indicates that front
clutch is operating. Hold air pressure on for a few NOTE: Hub weld is inside and not visible. Do not
seconds and inspect system for excessive oil leaks. attempt to repair. Replace torque converter.
Fig. 4 Air Pressure Tests

SERVICE PROCEDURES TRANSAXLE FLUID EXCHANGER METHOD
(1) To perform the transaxle fluid exchange, the
FLUID AND FILTER CHANGE transaxle must be at operating temperature. Drive
When the factory fill fluid is changed, only fluids the vehicle till it reaches full operating temperature.
labeled MOPARt ATF PLUS 3 (Automatic Transmis- (2) Verify that the fill tank on the transaxle fluid
sion fluid) Type 7176 should be used. exchanger (ATF 2000+ or equivalent) is clean and
If the transaxle is disassembled for any reason, the dry.
fluid and filter should be changed. (3) Fill the tank to the recommended fill capacity
with Mopar ATF Plus 3 Type 7176.
30,000 MILE TRANSAXLE OIL CHANGE (4) Hookup the vehicle to the machine following
When a vehicle attains 30,000 miles on its odome- the manufacturers instructions. Perform the
ter it is recommended that the transaxle oil be exchange procedure following the instructions pro-
changed. To change the oil, use the procedure that vided with the machine.
follows: (5) Once machine has completed the fluid
It is recommended that a transaxle fluid exchanger exchange. Check the fluid level and condition and fill
(ATF 2000+ or equivalent) be used to replace the to proper level with Mopar ATF Plus 3 Type 7176.
used fluid in the transaxle. If a fluid exchanger is not
available use a fluid suction pump (Vaculay or equiv- NOTE: Verify that the transaxle cooler lines are
alent) to draw the fluid out of the dipstick tube. If a tightened to proper specifications. Cooler line
fluid suction pump is not available remove the oil torque specification is 2 N•m (18 in. lbs.).
pan and drain the fluid.
CAUTION: Chrysler Corporation does not recom- DIPSTICK TUBE FLUID SUCTION METHOD
mend using any fluid exchanger that introduces (1) When performing the fluid suction method,
additives into the transaxle. make sure the transaxle is at full operating temper-
ature.
(2) To perform the dipstick tube fluid suction the HOT range. Drive the vehicle a minimum of 10
method, use a suitable fluid suction device (Vaculay miles.
or equivalent). (10) Raise the vehicle on the hoist.
(3) Insert the fluid suction line into the dipstick (11) Check for leaks around the transaxle oil pan
tube. sealing surfaces.
(12) Recheck the fluid level. The level should be in
NOTE: Verify that the suction line is inserted to the the HOT range.
lowest point of the transaxle oil pan. This will
ensure complete evacuation of the fluid in the pan. SEVERE USAGE SERVICE
(4) Follow the manufacturers recommended proce- If the vehicle exhibits any of the following symp-
dure and evacuate the fluid from the transaxle. toms, it is recommended that the transaxle oil and
(5) Remove the suction line from the dipstick tube. filter be replaced.
(6) Add 4 Quarts of Mopar ATF Plus 3 Type 7176 • Transaxle oil discolored
transaxle fluid. • Transaxle oil has high mileage
(7) Start the engine and allow it to idle for a min- • Oil feels grimy when rubbed between fingertips
imum of one minute. With the parking brake applied, • Poor shift quality
press your foot on the service brake and cycle the • Delayed gear engagement
transaxle from park to all gear positions ending in • Vehicle shudder between shifts
neutral or park.
(8) Check the transaxle fluid level and add an TRANSAXLE OIL AND FILTER REPLACEMENT
appropriate amount to bring the transaxle fluid level This procedure involves changing the transaxle
to 3mm (1/8 in.) below the ADD mark on the dip- fluid and filter, driving the vehicle for 10 miles and
stick. changing the transaxle fluid a second time.
(9) Recheck the fluid level after the transaxle is at (1) Bring the vehicle up to normal operating tem-
normal operating temperature. The level should be in perature. Drive the vehicle a minimum of 10 miles.
the HOT range. (2) Raise the vehicle on the hoist.
(3) Loosen the transaxle oil pan and drain the
TRANSAXLE OIL PAN DROP METHOD fluid into a suitable container.
This procedure involves removing the transaxle oil (4) Remove the pan and clean all sealant from the
pan to drain the transaxle fluid. pan and transaxle mating surfaces. Clean the mag-
(1) Bring the vehicle up to normal operating tem- net and the inside of the pan.
perature. Drive the vehicle a minimum of 10 miles. (5) Separate the filter and O-ring from the valve
(2) Raise the vehicle on the hoist. body. Inspect the O-ring for cuts or improper instal-
(3) Loosen the transaxle oil pan and drain the lation. This could lead to delayed garage shifts.
fluid into a suitable container. (6) Install a new filter. Replace the O-ring as nec-
(4) Remove the pan and clean all sealant from the essary.
pan and transaxle mating surfaces. Clean the mag- (7) Apply a 1/8 inch bead of Mopar RTV Sealant to
net and the inside of the pan. the mounting flange of the transaxle oil pan. Apply
(5) Apply a 1/8 inch bead of Mopar RTV Sealant to RTV Sealant to the underside of the attaching bolts.
the mounting flange of the transaxle oil pan. Apply Attach the oil pan to the transaxle. Tighten the bolts
RTV Sealant to the underside of the attaching bolts. to 19 N•m (165 in. lbs.).
Attach the oil pan to the transaxle. Tighten the bolts (8) Lower the vehicle and add 4 Quarts of Mopar
to 19 N•m (165 in. lbs.). ATF Plus 3 Type 7176 transaxle fluid.
(6) Lower the vehicle and add 4 Quarts of Mopar (9) Start the engine and allow it to idle for a min-
ATF Plus 3 Type 7176 transaxle fluid. imum of one minute. With the parking brake applied,
(7) Start the engine and allow it to idle for a min- press your foot on the service brake and cycle the
imum of one minute. With the parking brake applied, transaxle from park to all gear positions ending in
press your foot on the service brake and cycle the neutral or park.
transaxle from park to all gear positions ending in (10) Check the transaxle fluid level and add an
neutral or park. appropriate amount to bring the transaxle fluid level
(8) Check the transaxle fluid level and add an to 3mm (1/8 in.) below the ADD mark on the dip-
appropriate amount to bring the transaxle fluid level stick.
to 3mm (1/8 in.) below the ADD mark on the dip- (11) Recheck the fluid level after the transaxle is
stick. at normal operating temperature. The level should be
(9) Recheck the fluid level after the transaxle is at in the HOT range. Drive the vehicle a minimum of
normal operating temperature. The level should be in 10 miles.
(12) Raise the vehicle on the hoist.
(13) Remove the pan and clean all sealant from ALUMINUM THREAD REPAIR
the pan and transaxle mating surfaces. Clean the Damaged or worn threads in the aluminum transaxle
magnet and the inside of the pan. case and valve body can be repaired by the use of Heli-
(14) Separate the filter from the valve body to Coils, or equivalent. This repair consists of drilling out
allow additional fluid to drain from the transaxle. the worn-out damaged threads. Then tapping the hole
Inspect the filter O-ring for any damage and replace with a Heli-Coil tap, or equivalent, and installing a
as necessary. Heli-Coil insert, or equivalent, into the hole. This
(15) After the transaxle has stopped draining, brings the hole back to its original thread size.
reinstall the filter and O-ring. Heli-Coil, or equivalent, tools and inserts are readily
(16) Apply a 1/8 inch bead of Mopar RTV Sealant available from most automotive parts suppliers.
to the mounting flange of the transaxle oil pan.
Apply RTV Sealant to the underside of the attaching FLUSHING COOLERS AND TUBES
bolts. Attach the oil pan to the transaxle. Tighten the When a transaxle failure has contaminated the
bolts to 19 N•m (165 in. lbs.). fluid, the oil cooler(s) must be flushed. The cooler
(17) Lower the vehicle and add 4 Quarts of Mopar bypass valve in the transaxle must be replaced also.
ATF Plus 3 Type 7176 transaxle fluid. The torque converter must also be replaced with an
(18) Start the engine and allow it to idle for a min- exchange unit. This will ensure that metal particles
imum of one minute. With the parking brake applied, or sludged oil are not later transferred back into the
press your foot on the service brake and cycle the reconditioned (or replaced) transaxle.
transaxle from park to all gear positions ending in The recommended procedure for flushing the cool-
neutral or park. ers and tubes is to use Tool 6906A Cooler Flusher.
(19) Check the transaxle fluid level and add an
appropriate amount to bring the transaxle fluid level WARNING: WEAR PROTECTIVE EYEWEAR THAT
to 3mm (1/8 in.) below the ADD mark on the dip- MEETS THE REQUIREMENTS OF OSHA AND ANSI
stick. Z87.1–1968. WEAR STANDARD INDUSTRIAL RUB-
(20) Recheck the fluid level after the transaxle is BER GLOVES.
at normal operating temperature. The level should be KEEP LIGHTED CIGARETTES, SPARKS, FLAMES,
in the HOT range. AND OTHER IGNITION SOURCES AWAY FROM THE
AREA TO PREVENT THE IGNITION OF COMBUSTI-
FLUID DRAIN AND REFILL BLE LIQUIDS AND GASES. KEEP A CLASS (B) FIRE
(1) Raise vehicle on a hoist (See Group 0, Lubrica- EXTINGUISHER IN THE AREA WHERE THE
tion). Place a drain container with a large opening, FLUSHER WILL BE USED.
under transaxle oil pan. KEEP THE AREA WELL VENTILATED.
(2) Loosen pan bolts and tap the pan at one corner DO NOT LET FLUSHING SOLVENT COME IN CON-
to break it loose allowing fluid to drain, then remove TACT WITH YOUR EYES OR SKIN: IF EYE CONTAM-
the oil pan. INATION OCCURS, FLUSH EYES WITH WATER FOR
(3) Install a new filter and gasket on bottom of the 15 TO 20 SECONDS. REMOVE CONTAMINATED
valve body and tighten retaining screws to 5 N·m (40 CLOTHING AND WASH AFFECTED SKIN WITH
inch-pounds). SOAP AND WATER. SEEK MEDICAL ATTENTION.
(4) Clean the oil pan and magnet. Reinstall pan
using new sealant. Tighten oil pan bolts to 19 N·m
(165 in. lbs.). COOLER FLUSH USING TOOL 6906A
(5) Pour four quarts of Mopar ATF PLUS 3 (Auto- (1) Remove cover plate filler plug on Tool 6906A.
matic Transmission Fluid) Type 7176 through the Fill reservoir 1/2 to 3/4 full of fresh flushing solution.
dipstick opening. Flushing solvents are petroleum based solutions gen-
(6) Start engine and allow to idle for at least one erally used to clean automatic transmission compo-
minute. Then, with parking and service brakes nents. DO NOT use solvents containing acids, water,
applied, move selector lever momentarily to each gasoline, or any other corrosive liquids.
position, ending in the park or neutral position. (2) Reinstall filler plug on Tool 6906A.
(7) Add sufficient fluid to bring level to 1/8 inch (3) Verify pump power switch is turned OFF. Con-
below the ADD mark. nect red alligator clip to positive (+) battery post.
(8) Recheck fluid level after transaxle is at normal Connect black (-) alligator clip to a good ground.
operating temperature. The level should be in the (4) Disconnect the cooler lines at the transmission.
HOT region.
NOTE: When flushing transmission cooler and
lines, ALWAYS reverse flush.
(5) Connect the BLUE pressure line to the OUT- REMOVAL AND INSTALLATION
LET (From) cooler line.
(6) Connect the CLEAR return line to the INLET VEHICLE SPEED SENSOR PINION GEAR
(To) cooler line When the sensor is removed for any reason, a
(7) Turn pump ON for two to three minutes to NEW O-ring must be installed on its outside diame-
flush cooler(s) and lines. Monitor pressure readings ter.
and clear return lines. Pressure readings should sta-
bilize below 20 psi. for vehicles equipped with a sin- REMOVAL
gle cooler and 30 psi. for vehicles equipped with dual (1) Remove harness connector from sensor. Make
coolers. If flow is intermittent or exceeds these pressure weatherseal stays on harness connector.
sures, replace cooler. (2) Remove bolt securing the sensor in the exten-
(8) Turn pump OFF. sion housing.
(9) Disconnect CLEAR suction line from reservoir (3) Carefully pull sensor and pinion gear assembly
at cover plate. Disconnect CLEAR return line at out of extension housing.
cover plate, and place it in a drain pan. (4) Remove pinion gear from sensor.
(10) Turn pump ON for 30 seconds to purge flush-
ing solution from cooler and lines. Turn pump OFF. INSTALLATION
(11) Place CLEAR suction line into a one quart (1) To install, reverse the above procedure. Make
container of Mopar ATF Plus 3 t type 7176 automatic sure extension housing and sensor flange are clean
transmission fluid. prior to installation. Always use a NEW sensor
(12) Turn pump ON until all transmission fluid is O-ring.
removed from the one quart container and lines. This (2) Tighten bolt to 7 N·m (60 in. lbs.). Tighten
purges any residual cleaning solvent from the trans- speedometer cable to 4 N·m (35 in. lbs.).
mission cooler and lines. Turn pump OFF.
(13) Disconnect alligator clips from battery. Recon- PARK/NEUTRAL STARTING AND BACK-UP LAMP
nect flusher lines to cover plate, and remove flushing SWITCH
adapters from cooler lines.
TEST
OIL PUMP VOLUME CHECK The park/neutral starting switch is the center ter-
After the new or repaired transmission has been minal of the 3 terminal switch. It provides ground for
installed, fill to the proper level with Mopart ATF the starter solenoid circuit through the selector lever
PLUS 3 (Type 7176) automatic transmission fluid. in only Park and Neutral positions.
The volume should be checked using the following (1) To test switch, remove wiring connector from
procedure: switch and test for continuity between center pin of
(1) Disconnect the From cooler line at the trans- switch and transaxle case. Continuity should exist
mission and place a collecting container under the only when transaxle is in Park or Neutral.
disconnected line. (2) Check gearshift cable adjustment before replac-
ing a switch which tests bad.
CAUTION: With the fluid set at the proper level,
fluid collection should not exceed (1) quart or inter- REMOVAL
nal damage to the transmission may occur. (1) Unscrew switch from transaxle case allowing
fluid to drain into a container. Move selector lever to
(2) Run the engine at curb idle speed, with the Park, then to Neutral position, and inspect to see the
shift selector in neutral. switch operating lever fingers are centered in switch
(3) If fluid flow is intermittent or it takes more opening.
than 20 seconds to collect one quart of ATF PLUS 3,
disconnect the To Cooler line at the transaxle. INSTALLATION
(4) Refill the transaxle to proper level and recheck (1) Screw the switch with a new seal into tran-
pump volume. saxle case and tighten to 33 N·m (24 ft. lbs.). Retest
(5) If flow is found to be within acceptable limits, switch with the test lamp.
replace the cooler. Then fill transmission to the (2) Add fluid to transaxle to bring up to proper
proper level, using Mopart ATF PLUS 3 (Type 7176) level.
automatic transmission fluid. (3) The back-up lamp switch circuit is through the
(6) If fluid flow is still found to be inadequate, two outside terminals of the 3 terminal switch.
check the line pressure using the Transaxle Hydrau- (4) To test switch, remove wiring connector from
lic Pressure Test procedure. switch and test for continuity between the two out-
side pins.
(5) Continuity should exist only with transaxle in (10) Remove bolts securing exhaust flex joint to
Reverse position. exhaust manifold. Disconnect exhaust pipe from
(6) No continuity should exist from either pin to manifold.
the case. (11) Remove torque converter dust cover. Mark
torque converter and drive plate with chalk, for reas-
TRANSAXLE AND TORQUE CONVERTER REMOVAL sembly. Rotate engine clockwise and remove torque
converter mounting bolts.
NOTE: Transaxle removal does NOT require engine (12) Remove engine mount bracket from front
removal. crossmember.
(13) Remove front mount insulator through-bolt
The transaxle and torque converter must be and bellhousing bolts.
removed as an assembly; otherwise, the torque con- (14) Position transaxle jack (Fig. 6) .
verter drive plate, pump bushing, or oil seal may be
damaged. The drive plate will not support a load;
therefore, none of the weight of the transaxle should
be allowed to rest on the plate during removal.
REMOVAL
(1) Disconnect negative battery cable.
(2) Remove air cleaner and hoses.
(3) Disconnect throttle linkage and shift linkage
from transaxle.
(4) Unplug torque converter clutch connector,
located near the dipstick. Unplug the gear position
switch.
(5) Remove transaxle dipstick tube.
(6) Remove the transaxle cooler lines and plug.
(7) Install engine support fixture (Fig. 5) .
Fig. 6 Transaxle Jack
(15) Remove rear engine mount shield.
(16) Remove rear engine mount bracket bolts and
bracket.
(17) Remove left engine mount thru-bolt.
(18) Remove left engine mount from transaxle.
(19) Remove starter. Remove lower bell housing
bolts.
(20) Carefully work transaxle and torque converter
assembly rearward off engine block dowels and dis-
engage converter hub from end of crankshaft. Attach
a small C clamp to edge of bell housing. This
will hold torque converter in place during tran-
saxle removal. Lower transaxle and remove assem-
bly from under the vehicle.
(21) To remove torque converter assembly, remove
Fig. 5 Engine Support Fixture
C–clamp from edge of bellhousing and slide converter
(8) Remove bell housing upper bolts. out of transaxle.
(9) Raise vehicle. Remove front wheels. Refer to
Group 2, Suspension to remove or install wheel hub INSTALLATION
nut and both drive shafts. (1) When installing transaxle, reverse the above
procedure.
CAUTION: The exhaust flex joint must be discon- (2) If torque converter was removed from transaxle
nected from the exhaust manifold anytime the be sure to align pump inner gear pilot flats with
engine is lowered. If the engine is lowered while the torque converter impeller hub flats.
flex pipe is attached, damage will occur. (3) Adjust gearshift and throttle cables.
(4) Refill transaxle with Mopar ATF PLUS 3
(Automatic Transmission Fluid) Type 7176.
FRONT PUMP OIL SEAL DISASSEMBLY AND ASSEMBLY
The pump oil seal can be replaced without remov-
ing the pump and reaction shaft support assembly TRANSAXLE
from the transaxle case. Prior to removing any transaxle parts, plug all
openings and clean the unit, preferably with steam.
REMOVAL When disassembling, each part should be washed in
(1) Screw seal remover Tool C-3981-B into seal a suitable solvent, then dried with compressed air.
(Fig. 7), then tighten screw portion of tool to with- Do not wipe parts with shop towels. All mating sur-
draw the seal. faces in the transaxles are accurately machined;
therefore, careful handling of all parts must be exer-
cised to avoid nicks or burrs.
DISASSEMBLY
Fig. 7 Remove Pump Oil Seal

INSTALLATION
(1) To install a new seal, place seal in opening of
the pump housing (lip side facing inward). Using Tool
C-4193 and Handle Tool C-4171, drive new seal into Fig. 9 Transaxle Oil Pan Bolts
housing until tool bottoms (Fig. 8). Remove all old sealant before applying new seal-
ant.
Use only Mopart Silicone Rubber Sealant or equiv-
alent when installing oil pan.
Put sealant on the oil pan flange (Fig. 10) and on
all oil pan bolts (underside of bolt head).
Fig. 8 Install Pump Oil Seal
Fig. 10 Transaxle Oil Pan

Fig. 11 Oil Filter Screws Fig. 14 Parking Rod
Fig. 12 Oil Filter Fig. 15 Valve Body Attaching Bolts
Fig. 13 Remove Parking Rod E-Clip Fig. 16 Valve Body and Governor Tubes
Remove neutral starting and back-up lamp switch. required. The thrust washer is located between input
Measuring input shaft end play before disassembly and output shafts.
will usually indicate if a thrust washer change is
Attach a dial indicator to transaxle bell housing
with its plunger seated against end of input shaft
(Fig. 17).
Fig. 19 Pump Attaching Bolts
Fig. 17 Measure Input Shaft End Play

Move input shaft in and out to obtain end play
reading. End play specifications are 0.19 to 1.50 mm
(0.008 to 0.060 inch).
Record indicator reading for reference when reas-
sembling the transaxle.
Fig. 20 Install Tool C-3752 with Adapters L-4437
Fig. 18 Loosen Lock Nut and Tighten Kickdown

Band Adjusting Screw
Remove Number 6 thrust washer from sun
gear driving shell.
Fig. 21 Oil Pump with No. 1 Thrust Washer

Fig. 22 Oil Pump Gasket Fig. 25 Front Clutch Assembly
Fig. 23 Loosen Kickdown Band Adjusting Screw Fig. 26 No. 2 Thrust Washer and Rear Clutch
Fig. 24 Kickdown Band and Strut Fig. 27 No. 3 Thrust Washer

Fig. 31 Sun Gear Driving Shell Components

Fig. 28 Front Planetary Gear Snap Ring
Fig. 32 No. 9 Thrust Washer

Fig. 29 Front Planetary Gear Assembly
Fig. 33 Rear Planetary Gear Assembly

Fig. 30 Sun Gear Driving Shell
Fig. 34 No. 10 Thrust Washer Fig. 37 Loosen or Adjust Low/Reverse Band
Fig. 35 Overrunning Clutch Cam Assembly Fig. 38 Low/Reverse Band and Strut
Fig. 36 Overrunning Clutch Rollers and Spring Fig. 39 No. 11 Thrust Washer

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NS/GS FUEL SYSTEM—2.5L DIESEL ENGINE/2.

DESCRIPTION AND OPERATION

POWERTRAIN CONTROL MODULE—2.0L ENGINE

AIR CONDITIONING PRESSURE TRANSDUCER—

AIR CONDITIONING SWITCH SENSE—PCM

AUTOMATIC SHUTDOWN (ASD) SENSE—PCM

Fig. 3 Engine Coolant Temperature Sensor—2.0L Fig. 6 Knock Sensor—2.0L engine

MANIFOLD ABSOLUTE PRESSURE (MAP

Fig. 4 Upstream Heated Oxygen Sensor—2.0L

Fig. 7 MAP/IAT sensor—2.0L engine

SPEED CONTROL—PCM INPUT—2.0L ENGINE

IDLE AIR CONTROL MOTOR—PCM OUTPUT—2.0L

ELECTRONIC EGR TRANSDUCER—PCM

Fig. 8 Throttle Position Sensor/Idle Air Control

AIR CONDITIONING (A/C) RELAY—PCM

Fig. 11 Throttle Body—2.0L engine

Fig. 14 MAP/Intake Air Temperature Sensor

Fig. 12 Idle Air Control Motor and Throttle Position

Fig. 15 Fuel Injectors

Fig. 13 PCV Valve

Fig. 17 Starter Motor and Ground Strap

Fig. 20 Electronic EGR Transducer

Fig. 18 Knock Sensor

Fig. 19 Camshaft Position Sensor and Engine

Fig. 23 Vehicle Speed Sensor Fig. 26 Downstream Heated Oxygen Sensor

Fig. 24 Power Steering Pressure Switch

ASD AND FUEL PUMP RELAYS—2.0L ENGINE

MANIFOLD ABSOLUTE PRESSURE (MAP)

KNOCK SENSOR—2.0L ENGINE

Fig. 30 Engine Coolant Temperature Sensor

THROTTLE POSITION SENSOR

THROTTLE BODY MINIMUM AIR FLOW

WARNING: CLEAN THROTTLE BODY IN A WELL

Fig. 32 Purge Hose

FUEL INJECTION SYSTEM—2.5L DIESEL ENGINE

GENERAL INFORMATION SIGNAL GROUND—PCM INPUT . . . . . . . . . . . 45

START SIGNAL—PCM INPUT

NEEDLE MOVEMENT OR INSTRUMENTED FIRST

Fig. 3 Fuel Injector Sensor

ENGINE COOLANT TEMPERATURE SENSOR—PCM

ENGINE SPEED SENSOR—PCM INPUT

Fig. 6 Speed Sensor Operation

BRAKE SWITCH—PCM INPUT

DATA LINK CONNECTOR—PCM INPUT AND

FIVE VOLT POWER—PCM OUTPUT

ENGINE COOLANT GAUGE—PCM OUTPUT

ENGINE OIL PRESSURE GAUGE—PCM OUTPUT

GLOW PLUG LAMP—PCM OUTPUT Fig. 10 Fuel Timing Solenoid

GLOW PLUG RELAY—PCM OUTPUT

Fig. 11 Glow Plug Relay Location

EXHAUST GAS RECIRCULATION (EGR)

DIAGNOSIS AND TESTING

ENGINE SPEED SENSOR TEST

ENGINE COOLANT TEMPERATURE SENSOR TEST

WARNING: THE GLOW PLUG WILL BECOME

(8) Remove the glow plug from the tester.

GLOW PLUG RELAY TEST