2005-2006 Dodge Caravan Manual

GROU P TAB LOCAT OR
Introduction
0 Lubrication & Maintenance
2 Suspension
3 Differential & Driveline
5 Brakes
7 Cooling
8A Audio
8B Chime/Buzzer
8E Electronic Control Modules
8F Engine Systems
8G Heated Systems
8H Horn
8I Ignition Control
8J Instrument Cluster
8L Lamps
8M Message Systems
8N Power Systems
8O Restraints
8P Speed Control
8Q Vehicle Theft Security
8R Wipers/Washers
8T Navigation/Telecommunication
8W Wiring
9 Engine
11 Exhaust System
13 Frame & Bumpers
14 Fuel System
19 Steering
21 Transmission/Transaxle
22 Tires/Wheels
23 Body
24 Heating & Air Conditioning
25 Emissions Control
Component and System Index
Service Manual Comment Forms (Rear of Manual)

RS INTRODUCTION 1
INTRODUCTION
TABLE OF CON T EN T S
page page
BODY CODE PLATE TORQUE REFERENCES

DESCRIPTION . . . . . . . . . . ................1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
FASTENER IDENTIFICATION VEHICLE IDENTIFICATION NUMBER
DESCRIPTION . . . . . . . . . . ................2 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9
FASTENER USAGE VEHICLE CERTIFICATION LABEL
DESCRIPTION DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11
FASTENER USAGE . . . . . ................5 E-MARK LABEL
THREADED HOLE REPAIR ...............5 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11
INTERNATIONAL SYMBOLS VECI LABEL
DESCRIPTION . . . . . . . . . . ................5 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11
METRIC SYSTEM MANUFACTURER PLATE
DESCRIPTION . . . . . . . . . . ................6 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11
BODY CODE PLAT E

DESCRIPTION
Th e Body Code P la t e (F ig. 1) is loca t ed in t h e
en gin e com pa r t m en t on t h e r a dia t or closu r e pa n el
cr ossm em ber. Th er e a r e seven lin es of in for m a t ion on
t h e body code pla t e. Lin es 4, 5, 6, a n d 7 a r e n ot u sed
t o defin e ser vice in for m a t ion . In for m a t ion r ea ds fr om
left t o r igh t , st a r t in g wit h lin e 3 in t h e cen t er of t h e
pla t e t o lin e 1 a t t h e bot t om of t h e pla t e.
BODY CODE PLATE – LINE 3

DIGITS 1 THROUGH 12
Veh icle Or der Nu m ber
DIGITS 13 THROUGH 17
Open Spa ce Fig. 1 BODY CODE PLATE
1 - PRIMARY PAINT
DIGITS 18 AND 19 2 - SECONDARY PAINT
3 - VINYL ROOF
Veh icle Sh ell Lin e 4 - VEHICLE ORDER NUMBER
• RS 5 - CAR LINE SHELL
6 - PAINT PROCEDURE
7 - ENGINE
DIGIT 20 8 - TRIM
Ca r lin e 9 - TRANSMISSION
10 - MARKET
11 - VIN
FWD
• K = Dodge AWD
• Y = Ch r ysler • C = Ch r ysler
• D = Dodge
2 INTRODUCTION RS
BODY CODE PLAT E (Cont inue d)
DIGIT 21 BODY CODE PLATE LINE 1
P r ice Cla ss
• H = H igh lin e DIGITS 1, 2, AND 3
• L = Lowlin e Tr a n sa xle Codes
• P = P r em iu m • DGC = 31TH 3-Speed Au t om a t ic Tr a n sa xle
• S = Lu xu r y • DGL = 41AE /TE 4-Speed E lect r on ic Au t om a t ic
• X = P r em iu m • DDR = T850 5-Speed Ma n u a l Tr a n sa xle
DIGITS 22 AND 23 DIGIT 4

Body Type Open Spa ce
• 52 = Sh or t Wh eel Ba se
• 53 = Lon g Wh eel Ba se DIGIT 5
Ma r ket Code
BODY CODE PLATE LINE 2 • C = Ca n a da
• B = In t er n a t ion a l
DIGITS 1, 2 AND 3 • M = Mexico
P a in t P r ocedu r e • U = Un it ed St a t es
DIGIT 4 DIGIT 6
Open Spa ce Open Spa ce
DIGITS 5 THROUGH 7 DIGITS 7 THROUGH 23

P r im a r y P a in t (Refer t o 23 - BODY/PAINT - SP E C- Veh icle Iden t ifica t ion Nu m ber
IF ICATIONS). • Refer t o Veh icle Iden t ifica t ion Nu m ber (VIN)
pa r a gr a ph for pr oper br ea kdown of VIN code.
DIGIT 8 AND 9
Open Spa ce IF TWO BODY CODE PLATES ARE REQUIRED
Th e la st code sh own on eit h er pla t e will be fol-
DIGITS 10 THROUGH 12 lowed by E ND. Wh en t wo pla t es a r e r equ ir ed, t h e
Secon da r y P a in t la st code spa ce on t h e fir st pla t e will in dica t e (CTD)
Wh en a secon d pla t e is r equ ir ed, t h e fir st fou r
DIGIT 13 AND 14 spa ces of ea ch lin e will n ot be u sed du e t o over la p of
Open Spa ce t h e pla t es.
DIGITS 15 THROUGH 18
In t er ior Tr im Code FAST EN ER I DEN T I FI CAT I ON
DIGIT 19 DESCRIPTION
Open Spa ce Th e SAE bolt st r en gt h gr a des r a n ge fr om gr a de 2
t o gr a de 8. Th e h igh er t h e gr a de n u m ber, t h e gr ea t er
DIGITS 20, 21, AND 22 t h e bolt st r en gt h . Iden t ifica t ion is det er m in ed by t h e
E n gin e Code lin e m a r ks on t h e t op of ea ch bolt h ea d. Th e a ct u a l
• E DZ = 2.4L 4 cyl. 16-Va lve DOH C Ga solin e bolt st r en gt h gr a de cor r espon ds t o t h e n u m ber of lin e
(MP I) m a r ks plu s 2. Th e m ost com m on ly u sed m et r ic bolt
• E GA = 3.3L 6 cyl. Ga solin e (SMP I) st r en gt h cla sses a r e 9.8 a n d 10.9. Th e m et r ic
• E GH = 3.8L 6 cyl. Ga solin e (SMP I) st r en gt h cla ss iden t ifica t ion n u m ber is im pr in t ed on
• E GM = 3.3L 6 cyl. E t h a n ol F lexible F u el t h e h ea d of t h e bolt . Th e h igh er t h e cla ss n u m ber,
• E NJ = 2.5L 4 cyl. 16-Va lve Tu r bo Diesel t h e gr ea t er t h e bolt st r en gt h . Som e m et r ic n u t s a r e
im pr in t ed wit h a sin gle-digit st r en gt h cla ss on t h e
DIGIT 23 n u t fa ce. Refer t o t h e F a st en er Iden t ifica t ion a n d
Open Spa ce F a st en er St r en gt h Ch a r t s.
RS INTRODUCTION 3
FAST EN ER I DEN T I FI CAT I ON (Cont inue d)
FASTENER IDENTIFICATION
4 INTRODUCTION RS
FAST EN ER I DEN T I FI CAT I ON (Cont inue d)
FASTENER STRENGTH
RS INTRODUCTION 5
FAST EN ER U SAGE THREADED HOLE REPAIR

Most st r ipped t h r ea ded h oles ca n be r epa ir ed u sin g
a H elicoil!. F ollow t h e veh icle or H elicoil! r ecom m en -
DESCRI PT I ON da t ion s for a pplica t ion a n d r epa ir pr ocedu r es.
FASTENER USAGE
I N T ERN AT I ON AL SY M BOLS
WARNING: USE OF AN INCORRECT FASTENER
MAY RESULT IN COMPONENT DAMAGE OR PER- DESCRIPTION
SONAL INJURY. Th e gr a ph ic sym bols illu st r a t ed in t h e followin g
In t er n a t ion a l Con t r ol a n d Displa y Sym bols Ch a r t a r e
F a st en er s a n d t or qu e specifica t ion s r efer en ces in u sed t o iden t ify va r iou s in st r u m en t con t r ols. Th e
t h is Ser vice Ma n u a l a r e iden t ified in m et r ic a n d SAE sym bols cor r espon d t o t h e con t r ols a n d displa ys t h a t
for m a t . a r e loca t ed on t h e in st r u m en t pa n el.
Du r in g a n y m a in t en a n ce or r epa ir pr ocedu r es, it is
im por t a n t t o sa lva ge a ll fa st en er s (n u t s, bolt s, et c.)
for r ea ssem bly. If t h e fa st en er is n ot sa lva gea ble, a
fa st en er of equ iva len t specifica t ion m u st be u sed.
INTERNATIONAL CONTROL AND DISPLAY SYMBOLS

1 High Beam 13 Rear Window Washer
2 Fog Lamps 14 Fuel
3 Headlamp, Parking Lamps, Panel Lamps 15 Engine Coolant Temperature
4 Turn Warning 16 Battery Charging Condition
5 Hazard Warning 17 Engine Oil
6 Windshield Washer 18 Seat Belt
7 Windshield Wiper 19 Brake Failure
8 Windshield Wiper and Washer 20 Parking Brake
9 Wind screen Demisting and Defrosting 21 Front Hood
10 Ventilating Fan 22 Rear hood (Decklid)
11 Rear Window Defogger 23 Horn
12 Rear Window Wiper 24 Lighter
6 INTRODUCTION RS
M ET RI C SY ST EM Th e followin g ch a r t will a ssist in con ver t in g m et r ic

u n it s t o equ iva len t E n glish a n d SAE u n it s, or vise
ver sa .
DESCRIPTION
Th e m et r ic syst em is ba sed on qu a n t it ies of on e,
t en , on e h u n dr ed, on e t h ou sa n d a n d on e m illion .
CON V ERSI ON FORM U LAS AN D EQU I VALEN T VALU ES
MULTIPLY BY TO GET MULTIPLY BY TO GET

in-lbs x = Newton Meters N·m x 8.851 = in-lbs
0.11298 (N·m)
ft-lbs x = Newton Meters N·m x = ft-lbs
1.3558 (N·m) 0.7376
Inches Hg (60° F) x 3.377 = Kilopascals (kPa) kPa x = Inches Hg
0.2961
psi x 6.895 = Kilopascals (kPa) kPa x 0.145 = psi
Inches x 25.4 = Millimeters (mm) mm x = Inches
0.03937
Feet x = Meters (M) M x 3.281 = Feet
0.3048
Yards x = Meters M x = Yards
0.9144 1.0936
mph x = Kilometers/Hr. Km/h x = mph
1.6093 (Km/h) 0.6214
Feet/Sec x = Meters/Sec (M/S) M/S x 3.281 = Feet/Sec
0.3048
mph x = Meters/Sec (M/S) M/S x 2.237 = mph
0.4470
Kilometers/Hr. (Km/h) x = Meters/Sec (M/S) M/S x 3.600 Kilometers/Hr.
0.27778 (Km/h)
COM M ON M ET RI C EQU I VALEN T S
1 inch = 25 Millimeters 1 Cubic Inch = 16 Cubic Centimeters

1 Foot = 0.3 Meter 1 Cubic Foot = 0.03 Cubic Meter
1 Yard = 0.9 Meter 1 Cubic Yard = 0.8 Cubic Meter
1 Mile = 1.6 Kilometers
Refer t o t h e Met r ic Con ver sion Ch a r t t o con ver t

t or qu e va lu es list ed in m et r ic Newt on - m et er s (N·m ).
Also, u se t h e ch a r t t o con ver t bet ween m illim et er s
(m m ) a n d in ch es (in .).
RS INTRODUCTION 7
M ET RI C SY ST EM (Cont inue d)
METRIC CONVERSION CHART

8 INTRODUCTION RS
T ORQU E REFEREN CES

DESCRIPTION
TORQUE SPECIFICATIONS
RS INTRODUCTION 9
T ORQU E REFEREN CES (Cont inue d)
In dividu a l Tor qu e Ch a r t s a ppea r wit h in m a n y or t ion . Th e for m u la t o u se t h e ch eck digit is n ot
t h e Gr ou ps. Refer t o t h e St a n da r d Tor qu e Specifica - r elea sed t o t h e gen er a l pu blic.
t ion s Ch a r t for t or qu e r efer en ces n ot list ed in t h e
in dividu a l t or qu e ch a r t s.
V EH I CLE I DEN T I FI CAT I ON

N U M BER
DESCRIPTION
Th e Veh icle Iden t ifica t ion Nu m ber (VIN) ca n be
viewed t h r ou gh t h e win dsh ield a t t h e u pper left cor-
n er of t h e in st r u m en t pa n el, n ea r t h e left win dsh ield
pilla r (F ig. 2). Th e VIN con sist s of 17 ch a r a ct er s in a
com bin a t ion of let t er s a n d n u m ber s t h a t pr ovide spe-
cific in for m a t ion a bou t t h e veh icle. Refer t o VIN
Code Br ea kdown Ch a r t for decodin g in for m a t ion .
To pr ot ect t h e con su m er fr om t h eft a n d possible
fr a u d t h e m a n u fa ct u r er is r equ ir ed t o in clu de a Fig. 2 VEHICLE IDENTIFICATION NUMBER (VIN)
Ch eck Digit a t t h e n in t h posit ion of t h e veh icle iden - 1 - DEFROSTER OUTLET
2 - VEHICLE IDENTIFICATION NUMBER
t ifica t ion n u m ber. Th e ch eck digit is u sed by t h e 3 - HEATED WINDSHIELD GRID
m a n u fa ct u r er a n d gover n m en t a gen cies t o ver ify t h e
a u t h en t icit y of t h e veh icle a n d officia l docu m en t a -
V I N CODE BREAK DOWN CH ART
POSITION INTERPRETATION CODE = DESCRIPTION
Country of Origin 1 = Manufactured By DaimlerChrysler Corporation

1
2 = Manufactured By DaimlerChrysler Canada Inc.
2 Make D = Dodge
C = Chrysler
Vehicle Type 4 = Multipurpose Pass. Vehicle Less Side Air Bags

3
8 = Multipurpose Pass. Vehicle With Side Air Bags
4 Gross Vehicle Weight Rating G = 2268 - 2721 kg. (5001 - 6000 lbs.)
1 = Chrysler Caravan - FWD

P = Chrysler, Town & Country - FWD
P = Dodge, Caravan/Grand Caravan - FWD
P = Dodge, Caravan C/V, Grand Caravan C/V - FWD
T = Chrysler, Town & Country - AWD
5 Car Line T = Dodge, Grand Caravan - AWD
J = Chrysler, Voyager/Grand Voyager - FWD
Y = Voyager/Grand Voyager - FWD Left Hand Drive
C = Voyager/Grand Voyager - AWD Left Hand Drive
H = Voyager/Grand Voyager - FWD Right Hand Drive
K = Voyager/Grand Voyager - AWD Left Hand Drive
10 INTRODUCTION RS
V EH I CLE I DEN T I FI CAT I ON N U M BER (Cont inue d)
POSITION INTERPRETATION CODE = DESCRIPTION
2 = Low Line
3 = Medium
6 Series 4 = High Line

5 = Premium
6 = Sport
7 = Special
6 - Export Series B = 4-Speed Automatic Transaxle
N = 5-Speed Manual Transaxle
1 = Van - Caravan C/V
7 Body Style 3 = Extended Van - Grand Caravan C/V

4 = Extended Wagon - Grand Caravan/Town & Country
5 = Wagon - Caravan, Voyager, Town & Country
1 = EURO Wagon - Long Wheelbase (RG - 53 - S Series)
2 = EURO Wagon - Short Wheelbase (RG - 52 - H Series)

3 = EURO Wagon - Short Wheelbase (RG - 52 - P Series)
4 = EURO Wagon - Long Wheelbase (RG - 53 - P Series)
5 = EURO Wagon - Long Wheelbase (RG - 53 - H Series)
6 = Commercial Van - Short Wheelbase (with- Sales Code -
7 - Export Body Style
CYX Less AS8)
7 = Commercial Van - Short Wheelbase (with Sales Code -
AS8)
8 = Commercial Van-Long Wheelbase (H - Series with Sales
Code - CYX)
9 = Commercial Van - Long Wheelbase (P - Series with
Sales Code - CYX)
B = 2.4L I4 Cyl. 16-Valve Gasoline DOHC (MPI)
E = 3.3L V6 Cyl. OHV Flex Fuel
8 Engine L = 3.8L V6 Cyl. Gasoline (SMPI)

R = 3.3L V6 Cyl. OHV Gasoline
5 = 2.8L I4 Cyl. Turbo Diesel
7 = 2.5L I4 Cyl. 16 Valve Turbo Diesel
9 Check Digit See explanation in this section.
10 Model Year 5 = 2005
11 Assembly Plant B = St. Louis Assembly South
R = Windsor Assembly
U = Eurostar Gesellschaftz Assembly
12 through 17 Sequence Number A six digit number assigned by assembly plant.

RS INTRODUCTION 11
V EH I CLE CERT I FI CAT I ON

LABEL
DESCRIPTION
A veh icle cer t ifica t ion la bel is a t t a ch ed t o t h e r ea r
sh u t fa ce of t h e dr iver ’s door (F ig. 3). Th is la bel in di-
ca t es da t e of m a n u fa ct u r e (m on t h a n d yea r ), Gr oss
Veh icle Weigh t Ra t in g (GVWR), Gr oss Axle Weigh t
Ra t in g (GAWR) fr on t , Gr oss Axle Weigh t Ra t in g
(GAWR) r ea r a n d t h e Veh icle Iden t ifica t ion Nu m ber
(VIN). Th e Mon t h , Da y a n d H ou r of m a n u fa ct u r e is
a lso in clu ded.
All com m u n ica t ion s or in qu ir ies r ega r din g t h e
veh icle sh ou ld in clu de t h e Mon t h -Da y-H ou r a n d
Veh icle Iden t ifica t ion Nu m ber. Fig. 4 E-MARK LABEL
1 - COUNTRY CODE
2 - REGULATION NUMBER
3 - APPROVAL NUMBER
4 - AMENDMENT NUMBER
V ECI LABEL
DESCRIPTION
All m odels h a ve a Veh icle E m ission Con t r ol In for-
m a t ion (VE CI) La bel. Ch r ysler per m a n en t ly a t t a ch es
t h e la bel in t h e en gin e com pa r t m en t . It ca n n ot be
r em oved wit h ou t defa cin g in for m a t ion a n d dest r oyin g
t h e la bel.
Th e la bel con t a in s t h e veh icle’s em ission specifica -
t ion s a n d va cu u m h ose r ou t in gs. All h oses m u st be
con n ect ed a n d r ou t ed a ccor din g t o t h e la bel.
Fig. 3 VEHICLE CERTIFICATION LABEL - TYPICAL
E-M ARK LABEL M AN U FACT U RER PLAT E
DESCRIPTION DESCRIPTION
Th e Ma n u fa ct u r er P la t e (F ig. 5) is loca t ed in t h e
An E -m a r k La bel (F ig. 4) is loca t ed on t h e r ea r
en gin e com pa r t m en t on t h e pa ssen ger side r ea r cor-
sh u t fa ce of t h e dr iver ’s door. Th e la bel con t a in s t h e
n er of t h e h ood. Th e pla t e con t a in s five lin es of in for-
followin g in for m a t ion :
m a t ion :
• Da t e of Ma n u fa ct u r e
1. Veh icle Iden t ifica t ion Nu m ber (VIN)
• Mon t h -Da y-H ou r (MDH )
2. Gr oss Veh icle Ma ss (GVM)
• Veh icle Iden t ifica t ion Nu m ber (VIN)
3. Gr oss Tr a in Ma ss (GTM)
• Cou n t r y Codes
4. Gr oss F r on t Axle Ra t in g (GFAR)
• Regu la t ion Nu m ber
5. Gr oss Rea r Axle Ra t in g (GRAR)
• Regu la t ion Am en dm en t Nu m ber
• Appr ova l Nu m ber
Fig. 5 MANUFACTURER PLATE

RS LUBRICATION & MAINTENANCE 0-1
LUBRICATION & MAINTENANCE

page page
INTERNATIONAL SYMBOLS FLUID CAPACITIES

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . ....1 SPECIFICATIONS - FLUID CAPACITIES . . . . . . . 6
FLUID TYPES FLUID FILL/CHECK LOCATIONS
DESCRIPTION DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DESCRIPTION - ENGINE OIL AND LUBRICATION POINTS
LUBRICANTS . . . . . . . . . . . . . . . . . . . . . ....1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DESCRIPTION - ENGINE COOLANT . . . . ....3 MAINTENANCE SCHEDULES
DESCRIPTION - FLEXIBLE FUEL ENGINE DESCRIPTION
OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....3 DESCRIPTION ........................7
DESCRIPTION - AUTOMATIC/MANUAL DESCRIPTION - EXPORT . . . . . . . . . . . . . . . 13
TRANSAXLE FLUID . . . . . . . . . . . . . . . . . ....4 DESCRIPTION - DIESEL ENGINES -
DESCRIPTION - FUEL REQUIREMENTS . ....4 EXPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
DESCRIPTION - FUEL REQUIREMENTS - HOISTING
DIESEL ENGINE . . . . . . . . . . . . . . . . . . . ....6 STANDARD PROCEDURE - HOISTING . . . . . . . 24
DESCRIPTION - ENGINE OIL - DIESEL JUMP STARTING
ENGINES . . . . . . . . . . . . . . . . . . . . . . . . ....6 STANDARD PROCEDURE - JUMP STARTING . 25
DESCRIPTION - AWD REAR DRIVELINE TOWING
MODULE FLUIDS . . . . . . . . . . . . . . . . . . ....6 STANDARD PROCEDURE - TOWING . . . . . . . . 26
DESCRIPTION - AWD POWER TRANSFER
UNIT FLUID . . . . . . . . . . . . . . . . . . . . . . . ....6
I N T ERN AT I ON AL SY M BOLS FLU I D T Y PES

DESCRIPTION
Da im ler Ch r ysler Cor por a t ion u ses in t er n a t ion a l DESCRI PT I ON
sym bols t o iden t ify en gin e com pa r t m en t lu br ica n t
a n d flu id in spect ion a n d fill loca t ion s (F ig. 1). DESCRIPTION - ENGINE OIL AND LUBRICANTS
WARNING: NEW OR USED ENGINE OIL CAN BE
IRRITATING TO THE SKIN. AVOID PROLONGED OR
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO
YOUR HEALTH. THOROUGHLY WASH EXPOSED
SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL
PROPERLY. CONTACT YOUR DEALER OR GOVERN-
MENT AGENCY FOR LOCATION OF COLLECTION
CENTER IN YOUR AREA.
Fig. 1 INTERNATIONAL SYMBOLS
Wh en ser vice is r equ ir ed, Da im ler Ch r ysler Cor po-
r a t ion r ecom m en ds t h a t on ly Mopa r ! br a n d pa r t s,
lu br ica n t s a n d ch em ica ls be u sed. Mopa r ! pr ovides
the best en gin eer ed pr odu ct s for ser vicin g
Da im ler Ch r ysler Cor por a t ion veh icles.
On ly lu br ica n t s bea r in g design a t ion s defin ed by
t h e followin g or ga n iza t ion sh ou ld be u sed.
0-2 LUBRICATION & MAINTENANCE RS
FLU I D T Y PES (Cont inue d)
• Societ y of Au t om ot ive E n gin eer s (SAE ) t h a t do n ot displa y t h e “Ma r k” on t h e fr on t of t h e
• Am er ica n P et r oleu m In st it u t e (AP I) con t a in er sh ou ld n ot be u sed (F ig. 2).
• Na t ion a l Lu br ica t in g Gr ea se In st it u t e (NLGI) Dia m ler Ch r ysler on ly r ecom m en ds AP I Cer t ified
en gin e oils t h a t m eet t h e r equ ir em en t s of Ma t er ia l
API CERTIFICATION AND LICENSE SYMBOL St a n da r d MS-6395. Use Mopa r or a n equ iva len t oil
Use a n en gin e oil t h a t is AP I Cer t ified (GF -3) a n d m eet in g t h e specifica t ion MS-6395.
Licen sed t o displa y t h e cer t ifica t ion m a r k (F ig. 2).
MOPAR! pr ovides en gin e oils t h a t m eet or exceed, SYNTHETIC ENGINE OILS
Ma t er ia l St a n da r d MS-6395 r equ ir em en t . Th er e a r e a n u m ber of en gin e oils bein g pr om ot ed
a s eit h er syn t h et ic or sem i-syn t h et ic. If you ch ose t o
u se su ch a pr odu ct , u se o n ly t h ose oils t h a t a r e cer-
t ified by t h e Am er ica n P et r oleu m In st it u t e (AP I) t o
displa y t h e “Cer t ifica t ion Ma r k” a n d sh ow SAE vis-
cosit y gr a de r ecom m en ded for ea ch veh icle. F ollow
t h e ser vice sch edu le t h a t descr ibes you r dr ivin g t ype.
ENGINE OIL ADDITIVES/SUPPLEMENTS

Th e m a n u fa ct u r er d o e s n o t re c o m m e n d t h e a ddi-
t ion of a n y en gin e oil a ddit ives/su pplem en t s t o t h e
Fig. 2 API Certification Mark specified en gin e oil. E n gin e oil a ddit ives/su pplem en t s
sh ou ld n ot be u sed t o en h a n ce en gin e oil per for-
SAE VISCOSITY m a n ce. E n gin e oil a ddit ives/su pplem en t s sh ou ld n ot
S AE 5W-20 a n d S AE 5W-30 e n g in e o ils a re re c - be u sed t o ext en d en gin e oil ch a n ge in t er va ls. No
o m m e n d e d fo r a ll o p e ra tin g te m p e ra tu re s . a ddit ive is kn own t o be sa fe for en gin e du r a bilit y a n d
Th e s e e n g in e o ils a re d e s ig n e d to im p ro v e lo w ca n degr a de em ission com pon en t s. Addit ives ca n con -
te m p e ra tu re s ta rtin g a n d v e h ic le fu e l e c o n o m y. t a in u n desir a ble m a t er ia ls t h a t h a r m t h e lon g t er m
Re fe r to th e e n g in e o il fille r c a p fo r th e p re - du r a bilit y of en gin es by:
fe rre d e n g in e o il v is c o s ity g ra d e fo r e a c h v e h i- • In cr ea sin g t h e level of P h osph or u s a n d Su lfu r in
c le (F ig . 3). SAE viscosit y gr a des a r e u sed t o specify t h e en gin e oil. Th e AP I Cer t ified E n gin e Oils con t r ol
t h e cor r ect viscosit y oil for a n en gin e. Use on ly Mu lt i- t h e P h osph or u s a n d Su lfu r con t en t s of t h e oil t o lev-
Viscosit y oils su ch a s SAE 5W-20 or 5W-30. Th ese els t h a t r edu ce t h e con t a m in a t ion effect on t h e veh i-
a r e specified wit h a du a l SAE viscosit y gr a de wh ich cles em ission con t r ol syst em .
in dica t es t h e cold (5W) t o h ot (20, 30) t em per a t u r e • Alt er in g t h e viscosit y ch a r a ct er ist ics of t h e
per for m a n ce r a n ge of t h e oil. en gin e oil so t h a t it n o lon ger m eet s t h e r equ ir e-
m en t s of t h e specified viscosit y gr a de.
• Cr ea t in g pot en t ia l for a n u n desir a ble a ddit ive
com pa t ibilit y in t er a ct ion in t h e en gin e cr a n kca se.
Th e en gin e oils con t a in a per for m a n ce a ddit ive sys-
t em ca r efu lly developed t o opt im ize t h e oils per for-
m a n ce in t h e en gin e. Th e a ddit ion of su pplem en t s
m a y ca u se t h e oil t o t h icken pr em a t u r ely, ca u se
excessive deposit bu ild u p a n d pot en t ia lly sh or t en
en gin e life.
AXLE LUBRICANTS
SAE r a t in gs a lso a pply t o m u lt igr a de gea r lu br i-
ca n t s. In a ddit ion , AP I cla ssifica t ion defin es t h e
Fig. 3 5W-30 Oil Filler Cap lu br ica n t s u sa ge. Su ch a s AP I GL-5 a n d SAE 75W-
90.
CONTAINER IDENTIFICATION
Th e E n gin e Oil Cer t ifica r ion Ma r k wa s developed LUBRICANTS AND GREASES
a n d t r a dem a r ked by t h e AP I t o r efer cu st om er s t o Lu br ica t in g gr ea se is r a t ed for qu a lit y a n d u sa ge
t h ose en gin e oils pr efer r ed by t h e a u t om obile m a n u - by t h e NLGI. All a ppr oved pr odu ct s h a ve t h e NLGI
fa ct u r er s. Th is sym bol m ea n s t h a t t h e oil h a s been sym bol (F ig. 4) on t h e la bel. At t h e bot t om of t h e
cer t ified a n d licen sed by t h e Am er ica n P et r oleu m NLGI sym bol is t h e u sa ge a n d qu a lit y iden t ifica t ion
In st it u t e (AP I). Th is cer t ifica t ion m a r k will on ly be let t er s. Wh eel bea r in g lu br ica n t is iden t ified by t h e
fou n d on t h e fr on t of t h e oil con t a in er s. Th ose oils
let t er “G”. Ch a ssis lu br ica n t is iden t ified by t h e let t er r a dia t or wh er e t h e t u be/fin r a dia t or ca n t r a n sfer t h e
“L”. Th e let t er followin g t h e u sa ge let t er in dica t es h ea t t o t h e a ir.
t h e qu a lit y of t h e lu br ica n t . Th e followin g sym bols Th e u se of a lu m in u m cylin der blocks, cylin der
in dica t e t h e h igh est qu a lit y. h ea ds, a n d wa t er pu m ps r equ ir es specia l cor r osion
pr ot ect ion . Mopa r ! An t ifr eeze/Coola n t , 5
Yea r /100,000 Mile F or m u la (MS-9769), or t h e equ iva -
len t et h ylen e glycol ba se coola n t wit h h ybr id or ga n ic
cor r osion in h ibit or s (ca lled H OAT, for H ybr id Or ga n ic
Addit ive Tech n ology) is r ecom m en ded. Th is coola n t
offer s t h e best en gin e coolin g wit h ou t cor r osion wh en
m ixed wit h 50% E t h ylen e Glycol a n d 50% dist illed
wa t er t o obt a in a fr eeze poin t of -37°C (-35°F ). If it
loses color or becom es con t a m in a t ed, dr a in , flu sh ,
a n d r epla ce wit h fr esh pr oper ly m ixed coola n t solu -
Fig. 4 NLGI SYMBOL t ion .
1 - WHEEL BEARINGS Th e gr een coola n t MU S T N OT B E MIXED wit h
2 - CHASSIS LUBRICATION t h e or a n ge or m a gen t a coola n t s. Wh en r epla cin g cool-
3 - CHASSIS AND WHEEL BEARINGS a n t t h e com plet e syst em flu sh m u st be per for m ed
befor e u sin g t h e r epla cem en t coola n t .
SPECIALIZED LUBRICANTS AND OILS
Som e m a in t en a n ce or r epa ir pr ocedu r es m a y CAUTION: Mopar" Antifreeze/Coolant, 5
r equ ir e t h e u se of specia lized lu br ica n t s or oils. Con - Year/100,000 Mile Formula (MS-9769) may not be
su lt t h e a ppr opr ia t e sect ion s in t h is m a n u a l for t h e mixed with any other type of antifreeze. Doing so
cor r ect a pplica t ion of t h ese lu br ica n t s. will reduce the corrosion protection and may result
in premature water pump seal failure. If non-HOAT
DESCRIPTION - ENGINE COOLANT coolant is introduced into the cooling system in an
emergency, it should be replaced with the specified
WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL coolant as soon as possible.
BASE COOLANT AND IS HARMFUL IF SWAL-
LOWED OR INHALED. IF SWALLOWED, DRINK
TWO GLASSES OF WATER AND INDUCE VOMIT- DESCRIPTION - FLEXIBLE FUEL ENGINE OIL
ING. IF INHALED, MOVE TO FRESH AIR AREA. Th e in for m a t ion in t h is sect ion is for F lexible F u el
SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT Veh icles (F F V) on ly. Th ese veh icles ca n be iden t ified
STORE IN OPEN OR UNMARKED CONTAINERS. by t h e u n iqu e F u el F iller Door La bel t h a t st a t es
WASH SKIN AND CLOTHING THOROUGHLY AFTER E t h a n ol (E -85) or Un lea ded Ga solin e On ly. Th is sec-
COMING IN CONTACT WITH ETHYLENE GLYCOL. t ion on ly cover s t h ose su bject s t h a t a r e u n iqu e t o
KEEP OUT OF REACH OF CHILDREN. DISPOSE OF t h ese veh icles. P lea se r efer t o t h e ot h er sect ion s of
GLYCOL BASE COOLANT PROPERLY, CONTACT t h is m a n u a l for in for m a t ion on fea t u r es t h a t a r e
YOUR DEALER OR GOVERNMENT AGENCY FOR com m on bet ween F lexible F u el a n d ga solin e on ly
LOCATION OF COLLECTION CENTER IN YOUR power ed veh icles.
AREA. DO NOT OPEN A COOLING SYSTEM WHEN
THE ENGINE IS AT OPERATING TEMPERATURE OR ETHANOL FUEL (E-85)
HOT UNDER PRESSURE, PERSONAL INJURY CAN E -85 is a m ixt u r e of a ppr oxim a t ely 85% fu el et h a -
RESULT. AVOID RADIATOR COOLING FAN WHEN n ol a n d 15% u n lea ded ga solin e.
ENGINE COMPARTMENT RELATED SERVICE IS
PERFORMED, PERSONAL INJURY CAN RESULT. WARNING: Ethanol vapors are extremely flammable
and could cause serious personal injury. Never
have any smoking materials lit in or near the vehi-
CAUTION: Use of Propylene Glycol based coolants cle when removing the fuel filler tube cap (gas cap)
is not recommended, as they provide less freeze or filling the tank. Do not use E-85 as a cleaning
protection and less boiling protection. agent and never use it near an open flame.
Th e coolin g syst em is design ed a r ou n d t h e coola n t .
Th e coola n t m u st a ccept h ea t fr om en gin e m et a l, in FUEL REQUIREMENTS
t h e cylin der h ea d a r ea n ea r t h e exh a u st va lves a n d Th e veh icle will oper a t e on bot h u n lea ded ga solin e
en gin e block. Th en coola n t ca r r ies t h e h ea t t o t h e wit h a n oct a n e r a t in g of 87, or E -85 fu el, or a n y m ix-
t u r e of t h ese t wo.
F or best r esu lt s, a r efu elin g pa t t er n t h a t a lt er n a t es TRANSMISSION FLUID
bet ween E -85 a n d u n lea ded ga solin e sh ou ld be Mopa r ! ATF +4 (Au t om a t ic Tr a n sm ission F lu id) is
a voided. Wh en you do swit ch fu els, it is r ecom - r equ ir ed in t h e 4XTE a u t om a t ic a n d T850 m a n u a l
m en ded t h a t t r a n sa xles. Su bst it u t e flu ids ca n in du ce t r a n sm ission
• you do n ot swit ch wh en t h e fu el ga u ge in dica t es pr oblem s a n d/or fa ilu r e.
less t h a n 1/4 fu ll Mopa r ! ATF +4 (Au t om a t ic Tr a n sm ission F lu id)
• you do n ot a dd less t h a n 5 ga llon s wh en r efu el- wh en n ew is r ed in color. Th e ATF is dyed r ed so it
in g ca n be iden t ified fr om ot h er flu ids u sed in t h e veh icle
• you oper a t e t h e veh icle im m edia t ely a ft er r efu el- su ch a s en gin e oil or a n t ifr eeze. Th e r ed color is n ot
in g for a per iod of a t lea st 5 m in u t es per m a n en t a n d is n ot a n in dica t or of flu id con dit ion .
Obser vin g t h ese pr eca u t ion s will a void possible As t h e veh icle is dr iven , t h e ATF will begin t o look
h a r d st a r t in g a n d/or sign ifica n t det er ior a t ion in da r ker in color a n d m a y even t u a lly becom e br own .
dr ivea bilit y du r in g wa r m u p. Th is is n o rm a l. ATF +4 a lso h a s a u n iqu e odor t h a t
m a y ch a n ge wit h a ge. Con sequ en t ly, o d o r a n d c o lo r
FFV STARTING c a n n o t be u s e d to in d ic a te th e flu id c o n d itio n
Th e ch a r a ct er ist ics of E -85 fu el m a ke it u n su it a ble o r th e n e e d fo r a flu id c h a n g e .
for u se wh en a m bien t t em per a t u r es fa ll below 0°F. In
t h e r a n ge of 0°F t o 32°F, you m a y exper ien ce a n FLUID ADDITIVES
in cr ea se in t h e t im e it t a kes for you r en gin e t o st a r t , Da im ler Ch r ysler st r on gly r ecom m en ds a ga in st t h e
a n d a det er ior a t ion in dr ivea bilit y (sa gs a n d/or h esi- a ddit ion of a n y flu ids t o t h e t r a n sm ission , ot h er t h a n
t a t ion s) u n t il t h e en gin e is fu lly wa r m ed u p. t h ose a u t om a t ic t r a n sm ission flu ids list ed a bove.
E xcept ion s t o t h is policy a r e t h e u se of specia l dyes
Engine Operating on E-85 Fuel t o a id in det ect in g flu id lea ks.
If veh icle oper a t es on E -85 fu el eit h er fu ll or pa r t - Va r iou s “specia l” a ddit ives a n d su pplem en t s exist
t im e, u se on ly Mopa r ! F lexible F u el 5W-30 en gin e oil t h a t cla im t o im pr ove sh ift feel a n d/or qu a lit y. Th ese
or a n equ iva len t t h a t m eet s Da im ler Ch r ysler St a n - a ddit ives a n d ot h er s a lso cla im t o im pr ove con ver t er
da r d MS-9214. E qu iva len t com m er cia l F lexible F u el clu t ch oper a t ion a n d in h ibit over h ea t in g, oxida t ion ,
en gin e oils m a y be la beled a s Mu lt i-F u el, Va r ia ble va r n ish , a n d slu dge. Th ese cla im s h a ve n ot been su p-
F u el, F lexible F u el, et c. Th ese en gin e oils m a y be por t ed t o t h e sa t isfa ct ion of Da im ler Ch r ysler a n d
sa t isfa ct or y if t h ey m eet t h e Da im ler Ch r ysler St a n - t h ese a ddit ives m u s t n o t be u s e d . Th e u se of t r a n s-
da r d. m ission “sea ler s” sh ou ld a lso be a voided, sin ce t h ey
SAE 5W-30 en gin e oil is pr efer r ed for u se in F lex- m a y a dver sely a ffect t h e in t egr it y of t r a n sm ission
ible F u el en gin es. sea ls.
CAUTION: If Flexible Fuel engine oil is not used DESCRIPTION - FUEL REQUIREMENTS
when using E-85 fuel, engine wear or damage may You r en gin e is design ed t o m eet a ll em ission s r eg-
result. u la t ion s a n d pr ovide excellen t fu el econ om y a n d per-
for m a n ce wh en u sin g h igh qu a lit y u n lea ded ga solin e
CRUISING RANGE h a vin g a n oct a n e r a t in g of 87. Th e u se of pr em iu m
ga solin e is n ot r ecom m en ded. Th e u se of pr em iu m
Beca u se E -85 fu el con t a in s less en er gy per ga llon
ga solin e will pr ovide n o ben efit over h igh qu a lit y r eg-
t h a n ga solin e, you will exper ien ce a n in cr ea se in fu el
u la r ga solin e, a n d in som e cir cu m st a n ces m a y r esu lt
con su m pt ion . You ca n expect you r MP G a n d you r
in poor er per for m a n ce.
dr ivin g r a n ge t o decr ea se by a bou t 30% com pa r ed t o
Ligh t spa r k kn ock a t low en gin e speeds is n ot
ga solin e oper a t ion .
h a r m fu l t o you r en gin e. H owever, con t in u ed h ea vy
spa r k kn ock a t h igh speeds ca n ca u se da m a ge a n d
DESCRIPTION - AUTOMATIC/MANUAL im m edia t e ser vice is r equ ir ed. E n gin e da m a ge r esu lt -
TRANSAXLE FLUID in g fr om oper a t ion wit h a h ea vy spa r k kn ock m a y
n ot be cover ed by t h e n ew veh icle wa r r a n t y.
NOTE: Refer to the maintenance schedules for the P oor qu a lit y ga solin e ca n ca u se pr oblem s su ch a s
recommended maintenance (fluid/filter change) h a r d st a r t in g, st a llin g a n d h esit a t ion s. If you exper i-
intervals for these transaxles. en ce t h ese sym pt om s, t r y a n ot h er br a n d of ga solin e
befor e con sider in g ser vice for t h e veh icle.
NOTE: All transaxles have a common transmission Over 40 a u t o m a n u fa ct u r er s wor ld-wide h a ve
and differential sump. Filling the transaxle accom- issu ed a n d en dor sed con sist en t ga solin e specifica t ion s
modates the differential as well. (t h e Wor ldwide F u el Ch a r t er, WWF C) t o defin e fu el
pr oper t ies n ecessa r y t o deliver en h a n ced em ission s, a dver sely a ffect ed. Ga solin e sold ou t side of Ca lifor n ia
per for m a n ce a n d du r a bilit y for you r veh icle. We r ec- is per m it t ed t o h a ve h igh er su lfu r levels wh ich m a y
om m en d t h e u se of ga solin es t h a t m eet t h e WWF C a ffect t h e per for m a n ce of t h e veh icle’s ca t a lyt ic con -
specifica t ion s if t h ey a r e a va ila ble. ver t er. Th is m a y ca u se t h e Ma lfu n ct ion In dica t or
La m p (MIL), Ch eck E n gin e or Ser vice E n gin e Soon
REFORMULATED GASOLINE ligh t t o illu m in a t e. We r ecom m en d t h a t you t r y a dif-
Ma n y a r ea s of t h e cou n t r y r equ ir e t h e u se of fer en t br a n d of u n lea ded ga solin e h a vin g lower su lfu r
clea n er bu r n in g ga solin e r efer r ed t o a s “r efor m u - t o det er m in e if t h e pr oblem is fu el r ela t ed pr ior t o
la t ed” ga solin e. Refor m u la t ed ga solin e con t a in oxy- r et u r n in g you r veh icle t o a n a u t h or ized dea ler for
gen a t es, a n d a r e specifica lly blen ded t o r edu ce ser vice.
veh icle em ission s a n d im pr ove a ir qu a lit y.
We st r on gly su ppor t t h e u se of r efor m u la t ed ga so- CAUTION: If the Malfunction Indicator Lamp (MIL),
lin e. P r oper ly blen ded r efor m u la t ed ga solin e will pr o- Check Engine or Service Engine Soon light is flash-
vide excellen t per for m a n ce a n d du r a bilit y for t h e ing, immediate service is required; see on-board
en gin e a n d fu el syst em com pon en t s. diagnostics system section.
GASOLINE/OXYGENATE BLENDS
Som e fu el su pplier s blen d u n lea ded ga solin e wit h MATERIALS ADDED TO FUEL
oxygen a t es su ch a s 10% et h a n ol, MTBE , a n d E TBE . All ga solin e sold in t h e Un it ed St a t es a n d Ca n a da
Oxygen a t es a r e r equ ir ed in som e a r ea s of t h e cou n t r y a r e r equ ir ed t o con t a in effect ive det er gen t a ddit ives.
du r in g t h e win t er m on t h s t o r edu ce ca r bon m on oxide Use of a ddit ion a l det er gen t s or ot h er a ddit ives is n ot
em ission s. F u els blen ded wit h t h ese oxygen a t es m a y n eeded u n der n or m a l con dit ion s.
be u sed in you r veh icle.
FUEL SYSTEM CAUTIONS
CAUTION: DO NOT use gasoline containing METH-
ANOL. Gasoline containing methanol may damage CAUTION: Follow these guidelines to maintain your
critical fuel system components. vehicle’s performance:
• Th e u se of lea ded ga s is pr oh ibit ed by F eder a l

MMT IN GASOLINE la w. Usin g lea ded ga solin e ca n im pa ir en gin e per for-
MMT is a m a n ga n ese-con t a in in g m et a llic a ddit ive m a n ce, da m a ge t h e em ission con t r ol syst em , a n d
t h a t is blen ded in t o som e ga solin e t o in cr ea se oct a n e. cou ld r esu lt in loss of wa r r a n t y cover a ge.
Ga solin e blen ded wit h MMT pr ovide n o per for m a n ce • An ou t -of-t u n e en gin e, or cer t a in fu el or ign it ion
a dva n t a ge beyon d ga solin e of t h e sa m e oct a n e n u m - m a lfu n ct ion s, ca n ca u se t h e ca t a lyt ic con ver t er t o
ber wit h ou t MMT. Ga solin e blen ded wit h MMT over h ea t . If you n ot ice a pu n gen t bu r n in g odor or
r edu ce spa r k plu g life a n d r edu ce em ission syst em som e ligh t sm oke, you r en gin e m a y be ou t of t u n e or
per for m a n ce in som e veh icles. We r ecom m en d t h a t m a lfu n ct ion in g a n d m a y r equ ir e im m edia t e ser vice.
ga solin e fr ee of MMT be u sed in you r veh icle. Th e Con t a ct you r dea ler for ser vice a ssist a n ce.
MMT con t en t of ga solin e m a y n ot be in dica t ed on t h e • Wh en pu llin g a h ea vy loa d or dr ivin g a fu lly
ga solin e pu m p; t h er efor e, you sh ou ld a sk you r ga so- loa ded veh icle wh en t h e h u m idit y is low a n d t h e t em -
lin e r et a iler wh et h er or n ot h is/h er ga solin e con t a in s per a t u r e is h igh , u se a pr em iu m u n lea ded fu el t o
MMT. h elp pr even t spa r k kn ock. If spa r k kn ock per sist s,
It is even m or e im por t a n t t o look for ga solin e wit h - ligh t en t h e loa d, or en gin e pist on da m a ge m a y r esu lt .
ou t MMT in Ca n a da beca u se MMT ca n be u sed a t • Th e u se of fu el a ddit ives wh ich a r e n ow bein g
levels h igh er t h a n a llowed in t h e Un it ed St a t es. sold a s oct a n e en h a n cer s is n ot r ecom m en ded. Most
MMT is pr oh ibit ed in F eder a l a n d Ca lifor n ia r efor- of t h ese pr odu ct s con t a in h igh con cen t r a t ion s of
m u la t ed ga solin e. m et h a n ol. F u el syst em da m a ge or veh icle per for-
m a n ce pr oblem s r esu lt in g fr om t h e u se of su ch fu els
SULFUR IN GASOLINE or a ddit ives is n ot the r espon sibilit y of
If you live in t h e n or t h ea st Un it ed St a t es, you r Da im ler Ch r ysler Cor por a t ion a n d m a y n ot be cover ed
veh icle m a y h a ve been design ed t o m eet Ca lifor n ia u n der t h e n ew veh icle wa r r a n t y.
low em ission st a n da r ds wit h Clea n er-Bu r n in g Ca li-
NOTE: Intentional tampering with emissions control
for n ia r efor m u la t ed ga solin e wit h low su lfu r. If su ch
systems can result in civil penalties being assessed
fu els a r e n ot a va ila ble in st a t es a dopt in g Ca lifor n ia
against you.
em ission st a n da r ds, you r veh icles will oper a t e sa t is-
fa ct or ily on fu els m eet in g feder a l specifica t ion s, bu t
em ission con t r ol syst em per for m a n ce m a y be
DESCRIPTION - FUEL REQUIREMENTS - Th e r ecom m en ded lu br ica n t for t h e Over r u n n in g

Clu t ch H ou sin g is Mopa r ! ATF +4. Th e r ecom m en ded
DIESEL ENGINE
lu br ica n t for t h e Differ en t ia l Ca r r ier is Mopa r !
WARNING: DO NOT USE ALCOHOL OR GASOLINE 80W-90 Gea r a n d Axle Lu br ica n t .
AS A FUEL BLENDING AGENT. THEY CAN BE
UNSTABLE UNDER CERTAIN CONDITIONS AND DESCRIPTION - AWD POWER TRANSFER UNIT
HAZARDOUS OR EXPLOSIVE WHEN MIXED WITH FLUID
DIESEL FUEL. Th e r ecom m en ded lu br ica n t for t h e AWD P ower
Tr a n sfer Un it is Mopa r ! Gea r a n d Axle Lu br ica n t
Use good qu a lit y diesel fu el fr om a r epu t a ble su p- 80W-90.
plier. F or m ost yea r-r ou n d ser vice, n u m ber 2 diesel
fu el m eet in g DIN E N 590 (Cla ss 0 - 4) will pr ovide
good per for m a n ce. If t h e veh icle is exposed t o FLU I D CAPACI T I ES
ext r em e cold (below -18°C/0°F ) or is r equ ir ed t o oper-
a t e a t colder t h a n n or m a l con dit ion s for pr olon ged SPECIFICATIONS - FLUID CAPACITIES
per iods, u se clim a t ize No. 2 diesel fu el or dilu t e t h e
No. 2 diesel fu el wit h 50% No. 1 diesel fu el a s lon g a s
DESCRIPTION SPECIFICATION
it m eet s ASTM D 975: 1D a n d 2D a n d t h e qu a lit y of
lu br ica t ion beh a vior is in a ccor da n ce wit h DIN E N Fuel Tank (Gas) 75 L (20 gal.)
590. Th is will pr ovide bet t er pr ot ect ion fr om fu el gel- Fuel Tank (Diesel) 75 L (20 gal.)
lin g or wa x plu ggin g of t h e fu el filt er s. Engine Oil* - 2.4 L 4.7 L (5.0 qts.)
Diesel fu el is seldom com plet ely fr ee of wa t er. To
pr even t fu el syst em t r ou ble, in clu din g fu el lin e fr eez- Engine Oil* - 3.3/3.8 L 4.7 L (5.0 qts.)
in g in win t er, dr a in t h e a ccu m u la t ed wa t er fr om t h e Engine Oil* - 2.5 L
6.0 L (6.3 qts.)
fu el/wa t er sepa r a t or u sin g t h e fu el/wa t er sepa r a t or (Diesel)
dr a in pr ovided. If you bu y good qu a lit y fu el a n d follow Cooling System** - 2.4 L 10.7 L (11.4 qts.)
t h e cold wea t h er a dvice a bove, fu el con dit ion er s sh ou ld
Cooling System** - 2.5 L
n ot be r equ ir ed in you r veh icle. If a va ila ble in you r
Turbo Diesel with 13.8 L (14.6 qts.)
a r ea , a h igh cet a n e “pr em iu m ” diesel fu el m a y offer
Auxiliary Heater
im pr oved cold st a r t in g a n d wa r m u p per for m a n ce.
Cooling System** -
DESCRIPTION - ENGINE OIL - DIESEL 3.3/3.8 L without Auxiliary 12.6 L (13.4 qts.)
Heater
ENGINES
Use on ly Diesel E n gin e Oil m eet in g st a n da r d MIL- Cooling System** -
2104C or AP I Cla ssifica t ion CD o r h ig h e r or CCML 3.3/3.8 L with Auxiliary 15.4 L (16.3 qts.)
D 4, D 5. Heater
Automatic Transaxle -
SAE VISCOSITY GRADE 3.8 L (4.0 qts.)
Service Fill
CAUTION: Low viscosity oils must have the proper Automatic Transaxle -
9.2 L (9.7 qts.)
API quality or the CCMC G5 designation. 4XTE Overhaul Fill
Manual Transaxle (T850
To a ssu r e of pr oper ly for m u la t ed en gin e oils, it is 2.4-2.7 L (2.5-2.9 qts.)
5-Speed)
r ecom m en ded t h a t SAE Gr a de 10W-40 en gin e oils
t h a t m eet Ch r ysler m a t er ia l st a n da r d MS-6395, be AWD Power Transfer Unit 1.15 L (2.4 pts.)
u sed in a ccor da n ce t o ACE A B3, B4 specifica t ion . Power Steering 1.2 L (2.5 pts.)
E u r opea n Gr a de 10W-40 oils a r e a lso a ccept a ble. AWD Bi-directional
Oils of t h e SAE 5W-40 gr a de n u m ber a r e pr efer r ed 0.575 L (1.22 pts.)
Overrunning Clutch
wh en m in im u m t em per a t u r es con sist en t ly fa ll below
-15°C. AWD Rear Carrier 0.7 L (1.48 pts.)
* (includes oil filter)
DESCRIPTION - AWD REAR DRIVELINE ** (includes heater and recovery/reserve bottle)
MODULE FLUIDS
Th e AWD Rea r Dr ivelin e Modu le Assem bly con sist s
of t wo su ba ssem blies, t h e Over r u n n in g Clu t ch H ou s-
in g (fr on t ) a n d t h e Differ en t ia l Ca r r ier (r ea r ).
FLU I D FI LL/CH ECK At Each Stop for Fuel

• Ch eck t h e en gin e oil level a bou t 5 m in u t es a ft er
LOCAT I ON S a fu lly wa r m ed en gin e is sh u t off. Ch eckin g t h e oil
level wh ile t h e veh icle is on level gr ou n d will
DESCRIPTION im pr ove t h e a ccu r a cy of t h e oil level r ea din g. Add oil
Th e flu id ch eck/fill poin t loca t ion s a r e loca t ed in on ly wh en t h e level is a t or below t h e ADD or MIN
ea ch a pplica ble ser vice m a n u a l sect ion . m a r k.
• Ch eck t h e win dsh ield wa sh er solven t a n d a dd if
r equ ir ed.
LU BRI CAT I ON POI N T S
Once a Month
DESCRIPTION • Ch eck t ir e pr essu r e a n d look for u n u su a l wea r
Lu br ica t ion poin t loca t ion s a r e loca t ed in ea ch or da m a ge.
a pplica ble Sect ion s. • In spect t h e ba t t er y a n d clea n a n d t igh t en t h e
t er m in a ls a s r equ ir ed.
• Ch eck t h e flu id levels of coola n t r eser voir, br a ke
M AI N T EN AN CE SCH EDU LES m a st er cylin der a n d t r a n sm ission , a dd a s n eeded.
• Ch eck a ll ligh t s a n d a ll ot h er elect r ica l it em s for
cor r ect oper a t ion .
DESCRI PT I ON
At Each Oil Change
DESCRIPTION • Ch a n ge t h e en gin e oil filt er.
Th er e a r e t wo m a in t en a n ce sch edu les t h a t sh ow • In spect t h e exh a u st syst em .
t h e re qu ire d ser vice for you r veh icle. • In spect t h e br a ke h oses.
F ir st is Sch edu le “B ”. It is for veh icles t h a t a r e • In spect t h e CV join t s a n d fr on t su spen sion com -
oper a t ed u n der t h e con dit ion s t h a t a r e list ed below pon en t s.
a n d a t t h e begin n in g of t h e sch edu le. • Ch eck t h e a u t om a t ic t r a n sm ission flu id level.
• Da y or n igh t t em per a t u r es a r e below 32° F (0° • Ch eck t h e coola n t level, h oses, a n d cla m ps.
C).
• St op a n d go dr ivin g. SCHEDULE B
• E xt en sive en gin e idlin g. F ollow sch edu le “B” if you u su a lly oper a t e you r
• Dr ivin g in du st y con dit ion s. veh icle u n der on e or m or e of t h e followin g con dit ion s.
• Sh or t t r ips of less t h a n 10 m iles (16 km ). Ch a n ge t h e a u t om a t ic t r a n sm ission flu id a n d filt er
• Mor e t h a n 50% of you r dr ivin g is a t su st a in ed ever y 60,000 m iles (96 000 km ) if t h e veh icle is u su -
h igh speeds du r in g h ot wea t h er, a bove 90° F (32° C). a lly oper a t ed u n der on e or m or e of t h e con dit ion s
• Tr a iler t owin g.# m a r ked wit h a n #.
• Ta xi, police, or deliver y ser vice (com m er cia l ser- • Da y or n igh t t em per a t u r es a r e below 32° F (0°
vice).# C).
• Off-r oa d or deser t oper a t ion . • St op a n d go dr ivin g.
• E xt en sive en gin e idlin g.
NOTE: Most vehicles are operated under the condi-
• Dr ivin g in du st y con dit ion s.
tions listed for Schedule $B$.
• Sh or t t r ips of less t h a n 10 m iles (16 km ).
Secon d is Sch edu le “A”. It is for veh icles t h a t a r e • Mor e t h a n 50% of you r dr ivin g is a t su st a in ed
n ot oper a t ed u n der a n y of t h e con dit ion s list ed u n der h igh speeds du r in g h ot wea t h er, a bove 90° F (32° C).
Sch edu le %B%. • Tr a iler t owin g.#
Use t h e sch edu le t h a t best descr ibes you r dr ivin g • Ta xi, police, or deliver y ser vice (com m er cia l ser-
con dit ion s. Wh er e t im e a n d m ilea ge a r e list ed, follow vice).#
t h e in t er va l t h a t occu r s fir st . • Off-r oa d or deser t oper a t ion .
CAUTION: Failure to perform the required mainte-

nance items may result in damage to the vehicle.
M AI N T EN AN CE SCH EDU LES (Cont inue d)
Miles 3, 000 6, 000 9, 000 12, 000 15, 000 18, 000
(Kilometers) (5 000 ) (10 000 ) (14 000) (19 000) (24 000) (29 000)
Change engine oil and engine X X X X X X
oil filter.
Rotate Tires X X X
Inspect the brake linings. X X
Inspect the engine air cleaner X X X X X
filter, replace if necessary. *
Replace the engine air X
cleaner filter. *
Replace the air conditioning X
filter.
Miles 21, 000 24, 000 27, 000 30, 000 33, 000 36, 000
(Kilometers) (34 000) (38 000) (43 000) (48 000) (53 000) (58 000)
oil filter.
Rotate Tires X X X
cleaner filter.
Inspect the tie rod ends and X
boot seals.
Inspect the PCV valveand X
replace as necessary.*
Replace the air conditioning X X
filter.
Miles 39, 000 42, 000 45, 000 48, 000 51, 000 54, 000
(Kilometers) (62 000) (67 000) (72 000) (77 000) (82 000) (86 000)
oil filter.
Rotate Tires X X X
cleaner filter. *
filter.
Miles 57, 000 60, 000 63, 000 66, 000 69, 000 72, 000
(Kilometers) (91 000) (96 000) (101 000) (106 000) (110 000) (115 000)
oil filter.
Rotate Tires X X X
cleaner filter.
boot seals.
Inspect the PCV valve and X
replace if necessary.*
Inspect the serpentine drive X
belt on 3.3 liter and 3.8 liter
engines, replace if necessary.
‡
Change the automatic X
transmission fluid and filter. #
filter.
Miles 75, 000 78, 000 81, 000 84, 000 87, 000 90, 000
(Kilometers) (120 000) (125 000) (130 000) (134 000) (139 000) (144 000)
oil filter.
Rotate Tires X X X
Inspect the engine air cleaner X X X X
Replace the engine air X X
cleaner filter
Replace the spark plugs on X
3.3 liter and 3.8 liter engines.
Replace the ignition cables X
3.3 liter and 3.8 liter engines.
boot seals.
Check the PCV valve and X
replace if necessary. Not
required if previously
changed.*
Inspect the serpentine drive X X
engines, replace if necessary. ‡
filter.
0 - 10 LUBRICATION & MAINTENANCE RS
Miles 93, 000 96, 000 99, 000 100, 000 102, 000 105, 000
(Kilometers) (149 000) (154 000) (158 000) (160 000) (163 000) (168 000)
Change engine oil and X X X X X
engine oil filter.
Rotate Tires X X
Inspect the brake linings. X
cleaner filter *
‡
Flush and replace the engine X
coolant at 60 months or
100,000 miles.
filter.
Miles 108, 000 111, 000 114, 000 117, 000 120, 000
(Kilometers) (173 000) (178 000) (182 000) (187 000) (192 000)
Change engine oil and engine oil filter. X X X X X
Rotate Tires X X X
Inspect the engine air cleaner filter, replace X X X X
if necessary. *
Replace the engine air cleaner filter. X
Inspect the tie rod ends and boot seals. X
Inspect the PCV valve and replace as X
necessary.*
Inspect the serpentine drive belt on 3.3 liter X
and 3.8 liter engines, replace if necessary. ‡
Change the automatic transmission fluid X
and filter. #
Replace the air conditioning filter. X X
* Th is m a in t en a n ce is r ecom m en ded by t h e m a n u - # Th is m a in t en a n ce is r equ ir ed on ly for police,

fa ct u r e t o t h e own er bu t is n ot r equ ir ed t o m a in t a in t a xi, lim ou sin e t ype oper a t ion , or t r a iler t owin g.
t h e em ission s wa r r a n t y. In spect ion a n d ser vice sh ou ld a lso be per for m ed
‡ Th is m a in t en a n ce is n ot r equ ir ed if pr eviou sly a n yt im e a m a lfu n ct ion is obser ved or su spect ed.
r epla ced. Ret a in a ll r eceipt s.
RS LUBRICATION & MAINTENANCE 0 - 11
SCHEDULE A
Miles 6, 000 12, 000 18, 000 24, 000 30, 000 36, 000
(Kilometers) (10 000) (19 000) (29 000) (38 000 ) (48 000) (58 000)
[Months] [6] [12] [18] [24] [30] [36]
oil filter.
Rotate Tires X X X X X X
cleaner filter.
boot seals.
Replace the air conditioning X X X
filter.
Miles 42, 000 48, 000 54, 000 60, 000 66, 000 72, 000
(Kilometers) (67 000) (77 000) (86 000) (96 000) (106 000) (115 000)
[Months] [42] [48] [54] [60] [66] [72]
oil filter.
cleaner filter.
boot seals.
replace, if necessary.*
Inspect the serpentine drive X X
‡
coolant at 60 months,
regardless of mileage.
filter.
Miles 78, 000 84, 000 90, 000 96, 000 100, 000
(Kilometers) (125 000) (134 000) (144 000) (154 000) (160 000)
[Months] [78] [84] [90] [96]
Change engine oil and engine oil filter. X X X X
Rotate Tires X X X X
if necessary. *
Check and replace the PCV valve, if X
necessary.*
Inspect the serpentine drive belt on 3.3 liter X
and 3.8 liter engines, replace if necessary. ‡
Replace the spark plugs 3.3 liter and 3.8 X
liter engines.
Replace the ignition cables 3.3 liter and X
3.8 liter engines.
Flush and replace the engine coolant at X
100,000 miles, if not done at 60 months.
Miles 102, 000 108, 000 114, 000 120, 000

(Kilometers) (163 000) (173 000) (182 000) (192 000)
[Months] [102] [108] [114] [120]
Inspect the engine air cleaner filter, replace if necessary. * X X X
Check the PCV valve and replace, if necessary.* X
Inspect the serpentine drive belt on 3.3 liter and 3.8 liter X X
Flush and replace the engine coolant at 120 months, if X
not done at 100,000 miles (160 000 km).
* Th is m a in t en a n ce is r ecom m en ded by t h e m a n u - WARNING: You can be badly injured working on or

fa ct u r e t o t h e own er bu t is n ot r equ ir ed t o m a in t a in around a motor vehicle. Do only that service work
t h e em ission s wa r r a n t y. for which you have the knowledge and the right
‡ Th is m a in t en a n ce is n ot r equ ir ed if pr eviou sly equipment. If you have any doubt about your ability
r epla ced. to perform a service job, take your vehicle to a
In spect ion a n d ser vice sh ou ld a lso be per for m ed competent mechanic.
a n yt im e a m a lfu n ct ion is obser ved or su spect ed.
Ret a in a ll r eceipt s.
DESCRIPTION - EXPORT At Each Stop for Fuel

Th er e a r e t wo m a in t en a n ce sch edu les t h a t sh ow • Ch eck t h e en gin e oil level a bou t 5 m in u t es a ft er
t h e re qu ire d ser vice for you r veh icle. a fu lly wa r m ed en gin e is sh u t off. Ch eckin g t h e oil
F ir st is Sch edu le “A”. It is for veh icles t h a t a r e n ot level wh ile t h e veh icle is on level gr ou n d will
oper a t ed u n der a n y of t h e con dit ion s list ed u n der im pr ove t h e a ccu r a cy of t h e oil level r ea din g. Add oil
Sch edu le %B%. on ly wh en t h e level is a t or below t h e ADD or MIN
Secon d is Sch edu le “B ”. It is for veh icles t h a t a r e m a r k.
oper a t ed u n der t h e con dit ion s t h a t a r e list ed below • Ch eck t h e win dsh ield wa sh er solven t a n d a dd if
a n d a t t h e begin n in g of t h e sch edu le. r equ ir ed.
• Da y or n igh t t em per a t u r es a r e below 0° C (32°
F ). Once a Month
• St op a n d go dr ivin g. • Ch eck t ir e pr essu r e a n d look for u n u su a l wea r
• E xt en sive en gin e idlin g. or da m a ge.
• Dr ivin g in du st y con dit ion s. • In spect t h e ba t t er y a n d clea n a n d t igh t en t h e
• Sh or t t r ips of less t h a n 16 km (10 m iles). t er m in a ls a s r equ ir ed.
• Mor e t h a n 50% of you r dr ivin g is a t su st a in ed • Ch eck t h e flu id levels of coola n t r eser voir, br a ke
h igh speeds du r in g h ot wea t h er, a bove 32° C (90° F ). m a st er cylin der a n d t r a n sm ission , a dd a s n eeded.
• Tr a iler t owin g.# • Ch eck a ll ligh t s a n d a ll ot h er elect r ica l it em s for
• Ta xi, police, or deliver y ser vice (com m er cia l ser- cor r ect oper a t ion .
vice).#
• Off-r oa d or deser t oper a t ion . At Each Oil Change
• Ch a n ge t h e en gin e oil filt er.
NOTE: Most vehicles are operated under the condi- • In spect t h e exh a u st syst em .
tions listed for Schedule $B$. • In spect t h e br a ke h oses.
• In spect t h e CV join t s a n d fr on t su spen sion com -
Use t h e sch edu le t h a t best descr ibes you r dr ivin g pon en t s.
con dit ion s. Wh er e t im e a n d m ilea ge a r e list ed, follow • Ch eck t h e a u t om a t ic t r a n sm ission flu id level.
t h e in t er va l t h a t occu r s fir st . • Ch eck t h e m a n u a l t r a n sm ission flu id level.
• Ch eck t h e coola n t level, h oses, a n d cla m ps.
CAUTION: Failure to perform the required mainte-
nance items may result in damage to the vehicle.
SCHEDULE A - EXPORT ONLY
Kilometers 12 000 24 000 36 000 48 000 60 000 72 000

(Miles) (7,500) (15,000) (22,500 (30,000) (37,500) (45,000)
[Months] [6] [12] [18] [24] [30] [36]
oil filter.
cleaner filter.
2.4 liter engines.
boot seals.
filter.
Kilometers 84 000 96 000 108 000 120 000 132 000 144 000
(Miles) (52,500) (60,000) (67,500) (75,000) (82,500) (90,000)
[Months] [42] [48] [54] [60] [66] [72]
oil filter.
cleaner filter.
Replace the spark plugs on X X
2.4 liter engines.
on 2.4 liter engines.
Inspect and adjust the power X X
steering pump belt tension on
2.4 liter engines.
Inspect the tie rod ends and X X
boot seals.
Inspect the generator belt on X X
2.4 liter engines, replace if
necessary.
Check the PCV valve and X X
replace, if necessary.*
Inspect the serpentine drive X X X
belt on 3.3 liter engines,
replace if necessary. ‡
coolant at 60 months,
regardless of mileage.
filter.
Kilometers 156 000 160 000 168 000 180 000 192 000
(Miles) (97,500) (100,000) (105,000) (112,500) (120,000)
[Months] [78] [84] [90] [96]
if necessary. *
Replace the spark plugs on 2.4 liter X
engines.
Replace the ignition cables on 2.4 liter X
engines.
Kilometers 156 000 160 000 168 000 180 000 192 000
(Miles) (97,500) (100,000) (105,000) (112,500) (120,000)
[Months] [78] [84] [90] [96]
Inspect and adjust the power steering pump X X
belt tension on 2.4 liter engines.
Inspect the generator belt on 2.4 liter X X
Check and replace the PCV valve, if X
necessary.*
Inspect the serpentine drive belt on 3.3 liter X X
Replace the spark plugs 3.3 liter engines. X
Replace the ignition cables 3.3 liter X
engines.
Flush and replace the engine coolant at X
100,000 miles, if not done at 60 months.
Replace the engine timing belt on 2.4 liter X
engines only.
Replace the air conditioning filter. X
* Th is m a in t en a n ce is r ecom m en ded by t h e m a n u - In spect ion a n d ser vice sh ou ld a lso be per for m ed

fa ct u r e t o t h e own er bu t is n ot r equ ir ed t o m a in t a in a n yt im e a m a lfu n ct ion is obser ved or su spect ed.
t h e em ission s wa r r a n t y. Ret a in a ll r eceipt s.
‡ Th is m a in t en a n ce is n ot r equ ir ed if pr eviou sly
r epla ced.
SCHEDULE B - EXPORT ONLY • E xt en sive en gin e idlin g.
F ollow sch edu le “B” if you u su a lly oper a t e you r • Dr ivin g in du st y con dit ion s.
veh icle u n der on e or m or e of t h e followin g con dit ion s. • Sh or t t r ips of less t h a n 16 km (10 m iles).
Ch a n ge t h e a u t om a t ic t r a n sm ission flu id a n d filt er • Mor e t h a n 50% of you r dr ivin g is a t su st a in ed
ever y 96 000 km (60,000 m iles) if t h e veh icle is u su - h igh speeds du r in g h ot wea t h er, a bove 32° C (90° F ).
a lly oper a t ed u n der on e or m or e of t h e con dit ion s • Tr a iler t owin g.#
m a r ked wit h a n #. • Ta xi, police, or deliver y ser vice (com m er cia l ser-
• Da y or n igh t t em per a t u r es a r e below 0° C (32° F ). vice).#
• St op a n d go dr ivin g. • Off-r oa d or deser t oper a t ion .
Kilometers 5 000 10 000 14 000 19 000 24 000 29 000

(Miles) (3,000 ) (6,000 ) (9,000) (12,000) (15,000) (18,000)
oil filter.
Rotate Tires X X X
cleaner filter. *
Inspect and adjust the power X
2.4 liter engines.
Inspect the generator belt on X
necessary.
Change the All Wheel Drive X
(AWD) power transfer unit
fluid. (See note at the end of
this chart)
filter.
Kilometers 34 000 38 000 43 000 48 000 53 000 58 000

(Miles) (21,000) (24,000) (27,000) (30,000) (33,000) (36,000)
oil filter.
Rotate Tires X X X
cleaner filter.
Replace the spark plugs 2.4 X
liter engines.
boot seals.
2.4 liter engines.
Kilometers 34 000 38 000 43 000 48 000 53 000 58 000

(Miles) (21,000) (24,000) (27,000) (30,000) (33,000) (36,000)
necessary.
Inspect the PCV valveand X
replace as necessary.*
Change the manual X
transmission fluid.
this chart)
(AWD) overrunning clutch and
rear carrier fluid. (See the
note at the end of this chart)
filter.
Kilometers 62 000 67 000 72 000 77 000 82 000 86 000

(Miles) (39,000) (42,000) (45,000) (48,000) (51,000) (54,000)
oil filter.
Rotate Tires X X X
cleaner filter. *
2.4 liter engines.
necessary.
Change the manual X
transmission fluid.
power transfer unit fluid. (See
the note at the end of this chart.)
rear carrier fluid. (See note at
the end of this chart)
filter.
Kilometers 91 000 96 000 101 000 106 000 110 000 115 000
(Miles) (57,000) (60,000) (63,000) (66,000) (69,000) (72,000)
oil filter.
Rotate Tires X X X
cleaner filter.
2.4 liter engines.
boot seals.
2.4 liter engines.
necessary.
Inspect the PCV valve and X
replace if necessary.*
belt on 3.3 liter engines,
replace if necessary.
Change the automatic X
transmission fluid and filter. #
Change the manual X
transmission fluid.
Change the All Wheel Drive X X
this chart)
filter.
Kilometers 120 000 125 000 130 000 134 000 139 000 144 000
(Miles) (75,000) (78,000) (81,000) (84,000) (87,000) (90,000)
oil filter.
Rotate Tires X X X
cleaner filter
3.3 liter engines.
2.4 liter engines.
Inspect and adjust the power X X
2.4 liter engines.
Inspect the generator belt on X X
necessary.
boot seals.
Inspect engine accessory X X
drive belts on 3.3 liter
‡
Change the manual X
transmission fluid.
replace if necessary. Not
required if previously
changed.*
Change the All Wheel Drive X X
power transfer unit fluid. (See
the note at the end of this
chart.)
Replace the engine timing X
belt on 2.4 liter engines. *
filter.
Kilometers 149 000 154 000 158 000 160 000 163 000 168 000
(Miles) (93,000) (96,000) (99,000) (100,000) (102,000) (105,000)
Change engine oil and engine X X X X X
oil filter.
Rotate Tires X X
cleaner filter *
2.4 liter engines.
necessary.
Inspect engine accessory X
drive belts on 3.3 liter
‡
Change the manual X
transmission fluid.
(AWD) power transfer unit,
overrunning clutch and rear
carrier fluid. (See note at the
end of this chart)
coolant at 60 months or
100,000 miles.
filter.
Kilometers 173 000 178 000 182 000 187 000 192 000
(Miles) (108,000) (111,000) (114,000) (117,000) (120,000)
Rotate Tires X X X
if necessary. *
Replace the spark plugs on 2.4 liter X
engines.
Replace the ignition cables on 2.4 liter X
engines.
Inspect and adjust the power steering pump X
belt tension on 2.4 liter engines.
Kilometers 173 000 178 000 182 000 187 000 192 000
(Miles) (108,000) (111,000) (114,000) (117,000) (120,000)
Inspect the generator belt on 2.4 liter X
Inspect engine accessory drive belts on 3.3 X
liter engines, replace if necessary. ‡
Inspect the PCV valve and replace as X
necessary.*
Change the automatic transmission fluid X
and filter. #
Change the All Wheel Drive (AWD) power X
transfer unit fluid. (See note at the end of
this chart)
Replace the air conditioning filter. X
* Th is m a in t en a n ce is r ecom m en ded by t h e m a n u - • Dr ivin g in du st y con dit ion s.

fa ct u r e t o t h e own er bu t is n ot r equ ir ed t o m a in t a in • Mor e t h a n 50% of you r dr ivin g is a t su st a in ed
t h e em ission s wa r r a n t y. h igh speeds du r in g h ot wea t h er, a bove 32° C (90° F ).
‡ Th is m a in t en a n ce is n ot r equ ir ed if pr eviou sly • Tr a iler t owin g.
r epla ced. • Ta xi, police, or deliver y ser vice (com m er cia l ser-
# Th is m a in t en a n ce is r equ ir ed on ly for police, vice).
t a xi, lim ou sin e t ype oper a t ion , or t r a iler t owin g. Most veh icles a r e oper a t ed u n der t h e con dit ion s
In spect ion a n d ser vice sh ou ld a lso be per for m ed list ed for Sch edu le %B%.
a n yt im e a m a lfu n ct ion is obser ved or su spect ed. Use t h e sch edu le t h a t best descr ibes you r dr ivin g
Ret a in a ll r eceipt s. con dit ion s. Wh er e t im e a n d m ilea ge a r e list ed, follow
t h e in t er va l t h a t occu r s fir st .
NOTE: The AWD power transfer unit fluid and the F a ilu r e t o per for m t h e r equ ir ed m a in t en a n ce it em s
AWD overrunning clutch/ rear carrier fluid must be m a y r esu lt in da m a ge t o t h e veh icle.
changed at the intervals shown in schedule B if the
vehicle is operated under any of the conditions At Each Stop for Fuel
noted by a diamond at the beginning of the sched- • Ch eck t h e en gin e oil level a bou t 5 m in u t es a ft er
ule. a fu lly wa r m ed en gin e is sh u t off. Ch eckin g t h e oil
level wh ile t h e veh icle is on level gr ou n d will
im pr ove t h e a ccu r a cy of t h e oil level r ea din g. Add oil
WARNING: You can be badly injured working on or on ly wh en t h e level is a t or below t h e ADD or MIN
around a motor vehicle. Do only that service work m a r k.
for which you have the knowledge and the right • Ch eck t h e win dsh ield wa sh er solven t a n d a dd if
equipment. If you have any doubt about your ability r equ ir ed.
to perform a service job, take your vehicle to a
competent mechanic. Once a Month
• Ch eck t h e t ir e pr essu r e a n d look for u n u su a l
wea r or da m a ge.
DESCRIPTION - DIESEL ENGINES - EXPORT • In spect t h e ba t t er y a n d clea n a n d t igh t en t h e
Th er e a r e t wo m a in t en a n ce sch edu les t h a t sh ow t er m in a ls a s r equ ir ed.
t h e re qu ire d ser vice for you r veh icle. • Ch eck t h e flu id levels of coola n t dea er a t ion bot -
F ir st is Sch edu le “A”. It is for veh icles t h a t a r e n ot t le, br a ke m a st er cylin der a n d t r a n sm ission , a dd a s
oper a t ed u n der a n y of t h e con dit ion s list ed u n der n eeded.
Sch edu le %B%. • Ch eck a ll ligh t s a n d a ll ot h er elect r ica l it em s for
Secon d is Sch edu le “B ”. It is for veh icles t h a t a r e cor r ect oper a t ion .
oper a t ed u n der t h e con dit ion s t h a t a r e list ed below
a n d a t t h e begin n in g of t h e sch edu le.
• E xt en sive en gin e idlin g.
At Each Oil Change • Ch eck t h e m a n u a l t r a n sm ission flu id level.
• Ch a n ge t h e en gin e oil filt er. • Ch eck t h e coola n t level, h oses, a n d cla m ps.
• In spect t h e exh a u st syst em . • In spect en gin e a ccessor y dr ive belt s. Repla ce a s
• In spect t h e br a ke h oses. n ecessa r y.
• In spect t h e CV join t s a n d fr on t su spen sion com - • In spect for t h e pr esen ce of wa t er in t h e fu el fil-
pon en t s. t er /wa t er sepa r a t or u n it .
SCHEDULE A - DIESEL ENGINES
Kilometers 20 000 km 40 000 km 60 000 km 80 000 km 100 000

km
Rotate Tires X X X X X
Replace engine air filter element X X X X X
Replace fuel filter/water separator unit. X X X X X
Inspect timing belt tensioner. ‡ X
Replace the engine timing belt and idler X
pulleys.
Check front end alignment. X X
Inspect the tie rod ends and boot seals. X X
Inspect the brake linings. X X X X X
Kilometers 120 000 140 000 160 000 180 000 200 000
km km km km km
Rotate Tires X X X X X
Inspect accessory drive belts and replace if X
necessary.
Replace fuel filter/water separator unit. X X X X X
Replace the timing belt, idler pulleys and X
timing belt tensioner.
Flush and replace engine coolant. X
Check front end alignment. X X X
Inspect the tie rod ends and boot seals. X X X
In spect ion a n d ser vice sh ou ld a lso be per for m ed ‡ Repla ce if t h er e is su per ficia l wea r, bea r in g clea r-
a n yt im e a m a lfu n ct ion is obser ved or su spect ed. a n ce, or eviden t gr ea se lea ka ge.
Ret a in a ll r eceipt s.
SCHEDULE B - DIESEL ENGINES • Mor e t h a n 50% of you r dr ivin g is a t su st a in ed
F ollow sch edu le “B” if you u su a lly oper a t e you r h igh speeds du r in g h ot wea t h er, a bove 32° C (90° F ).
veh icle u n der on e or m or e of t h e followin g con dit ion s. • Tr a iler t owin g.
• E xt en sive en gin e idlin g. • Ta xi, police, or deliver y ser vice (com m er cia l ser-
• Dr ivin g in du st y con dit ion s. vice).
Kilometers 10 000 km 20 000 km 30 000 km 40 000 km 50 000 km

Rotate Tires X X
Replace engine accessory drive belt. X
Replace the engine timing belt and idler X
pulleys.
Inspect timing belt tensioner. ‡ X
Replace fuel filter/water separator unit. X X
Change the manual transaxle fluid. X
Kilometers 60 000 km 70 000 km 80 000 km 90 000 km 100 000

km
Rotate Tires X X X
Replace fuel filter/water separator unit. X X X
Replace engine accessory drive belt. X
Replace engine timing belt, idler pulleys X
and timing belt tensioner.
Change the manual transaxle fluid. X X
Kilometers 110 000 120 000 130 000 140 000 150 000 160 000
km km km km km km
oil filter.
Rotate Tires X X X
Replace engine air filter
X X X X X X
element
Replace engine accessory X
drive belt.
Replace the engine timing X
belt and idler pulleys.
Inspect timing belt tensioner. X
‡
Kilometers 110 000 120 000 130 000 140 000 150 000 160 000
km km km km km km
Replace fuel filter/water X X X
separator unit.
Flush and replace engine X
coolant.
Check front end alignment. X X X
Inspect the tie rod ends and X X
boot seals.
Inspect the brake linings. X X X X X X
In spect ion a n d ser vice sh ou ld a lso be per for m ed CAUTION: Do not position hoisting device on any
a n yt im e a m a lfu n ct ion is obser ved or su spect ed. suspension component, including the front suspen-
Ret a in a ll r eceipt s. sion crossmember, the rear leaf springs, and the
‡ Repla ce if t h er e is su per ficia l wea r, bea r in g clea r- rear axle. Do not hoist on the front and rear
a n ce, or eviden t gr ea se lea ka ge. bumpers, the lower liftgate crossmember, the lower
radiator crossmember, the down standing flanges
WARNING: You can be badly injured working on or on the sill or the front engine mount.
around a motor vehicle. Do only that service work
for which you have the knowledge and the right F OR P ROP ER HOIS T P LACEMEN T REF ER
equipment. If you have any doubt about your ability TO (F ig . 5).
to perform a service job, take your vehicle to a Th e h oist in g poin t s a r e iden t ified by S.A.E .
competent mechanic. in ver t ed t r ia n gle h oist in g sym bols (F ig. 5). Th e fr on t
h oist in g poin t s a r e a t t h e bot t om of t h e fon t r a il
below t h e h oist in g sym bol a ppr oxim a t ely 250 m m
beh in d t h e fr on t su spen sion cr ossm em ber. Wh en
H OI ST I N G u sin g ou t boa r d lift h oist s, ver ify t h a t t h e h oist lift
pa ds h a ve been pr oper ly a dju st ed t o elim in a t e con -
STANDARD PROCEDURE - HOISTING t a ct bet ween t h e h oist a r m a n d t h e down st a n din g
Refer t o Own er ’s Ma n u a l pr ovided wit h veh icle for fla n ge on t h e sill. Th e r ea r h oist in g poin t s a r e t h e
pr oper em er gen cy ja ckin g pr ocedu r es. lea f spr in g fr on t m ou n t in g br a cket s. Th e h oist pa d
m u st be posit ion ed t o pick u p t h e fla n ges on t h e
WARNING: THE HOISTING AND JACK LIFTING br a cket , n ot t h e lea f spr in g.
POINTS PROVIDED ARE FOR A COMPLETE VEHI- Wh en ser vicin g t h e lea f spr in gs or t h e lea f spr in g
CLE. WHEN THE ENGINE OR REAR SUSPENSION m ou n t in g br a cket s, specia l pr ovision s a r e r equ ir ed t o
IS REMOVED FROM A VEHICLE, THE CENTER OF su ppor t t h e r ea r of t h e veh icle. P osit ion t h e r ea r
GRAVITY IS ALTERED MAKING SOME HOISTING h oist pa ds u n der t h e h or izon t a l su r fa ce on t h e bot -
CONDITIONS UNSTABLE. PROPERLY SUPPORT OR t om of t h e sill, in boa r d a dja cen t t o t h e fla n ge a n d
SECURE VEHICLE TO HOISTING DEVICE WHEN cen t er ed for e/a ft bet ween t h e ja ckin g in dica t or t a bs
THESE CONDITIONS EXIST. on t h e lower fla n ge. D O N OT HOIS T ON THE
F LAN GE. P la ce a soft pa d bet ween t h e h oist a n d t h e
pa in t ed su r fa ce on t h e sill t o a void scr a t ch in g t h e fin -
ish .
H OI ST I N G (Cont inue d)
WARNING: REMOVE METALLIC JEWELRY WORN
ON HANDS OR WRISTS TO AVOID INJURY BY
ACCIDENTAL ARCING OF BATTERY CURRENT.
WARNING: WHEN USING A HIGH OUTPUT BOOST-

ING DEVICE, DO NOT ALLOW BATTERY VOLTAGE
TO EXCEED 16 VOLTS.
WARNING: REFER TO INSTRUCTIONS PROVIDED

WITH DEVICE BEING USED.
CAUTION: DO NOT ATTEMPT TO PUSH OR TOW

THE VEHICLE TO START IT. THE VEHICLE CANNOT
BE STARTED THIS WAY. PUSHING WITH ANOTHER
VEHICLE MAY DAMAGE THE TRANSAXLE OR THE
REAR OF THE VEHICLE.
(1) Ra ise h ood on disa bled veh icle a n d visu a lly

in spect en gin e com pa r t m en t for :
• Ba t t er y ca ble cla m p con dit ion , clea n if n ecessa r y.
• F r ozen ba t t er y.
• Clea r or br igh t color t est in dica t or, if equ ipped.
• Gen er a t or dr ive belt con dit ion a n d t en sion .
Fig. 5 HOISTING AND JACKING POINTS • F u el fu m es or lea ka ge, cor r ect if n ecessa r y.
1- DRIVE ON LIFT
2 - FRAME CONTACT LIFT (SINGLE POST) CAUTION: If the cause of starting problem on dis-
2 - CHASSIS LIFT (NON-AXLE DUAL POST) abled vehicle is severe, damage to booster vehicle
2 - OUTBOARD LIFT (DUAL POST) charging system can result.
2 - FLOOR JACK
3 - S.A.E. HOISTING SYMBOLS
(2) Wh en u sin g a n ot h er veh icle a s a boost er
sou r ce, pa r k t h e boost er veh icle wit h in ca ble r ea ch .
J U M P START I N G Tu r n off a ll a ccessor ies, set t h e pa r kin g br a ke, pla ce
t h e a u t om a t ic t r a n sm ission in PARK or t h e m a n u a l
STANDARD PROCEDURE - JUMP STARTING t r a n sm ission in NE UTRAL a n d t u r n t h e ign it ion
OF F.
WARNING: REVIEW ALL SAFETY PRECAUTIONS (3) On disa bled veh icle, pla ce gea r select or in pa r k
AND WARNINGS. (Refer to 8 - ELECTRICAL/BAT- or n eu t r a l a n d set pa r k br a ke. Tu r n off a ll a ccesso-
TERY SYSTEM/BATTERY - STANDARD PROCE- r ies.
DURE). (4) Con n ect ju m per ca bles t o boost er ba t t er y. RE D
cla m p t o posit ive t er m in a l (+). BLACK cla m p t o n eg-
WARNING: DO NOT JUMP START A FROZEN BAT- a t ive t er m in a l (-). DO NOT a llow cla m ps a t opposit e
TERY, PERSONAL INJURY CAN RESULT. en d of ca bles t o t ou ch , elect r ica l a r c will r esu lt .
Review a ll wa r n in gs in t h is pr ocedu r e.
(5) On disa bled veh icle, con n ect RE D ju m per ca ble
WARNING: DO NOT JUMP START WHEN MAINTE- cla m p t o posit ive (+) t er m in a l. Con n ect BLACK
NANCE FREE BATTERY INDICATOR DOT IS BRIGHT ju m per ca ble cla m p t o en gin e gr ou n d a s close t o t h e
COLOR. gr ou n d ca ble a t t a ch in g poin t a s possible (F ig. 6).
(Refer t o 8 - E LE CTRICAL/BATTE RY SYSTE M/BAT-
TE RY - STANDARD P ROCE DURE ).
WARNING: DO NOT ALLOW JUMPER CABLE (6) St a r t t h e en gin e in t h e veh icle wh ich h a s t h e
CLAMPS TO TOUCH EACH OTHER WHEN CON- boost er ba t t er y, let t h e en gin e idle a few m in u t es,
NECTED TO A BOOSTER SOURCE. t h en st a r t t h e en gin e in t h e veh icle wit h t h e dis-
ch a r ged ba t t er y.
WARNING: DO NOT USE OPEN FLAME NEAR BAT-
TERY
J U M P START I N G (Cont inue d)
USE A SAFETY CHAIN THAT IS INDEPENDENT
FROM THE TOWING ATTACHMENT DEVICE.
CAUTION: Do not damage brake lines, exhaust sys-

tem, shock absorbers, sway bars, or any other
under vehicle components when attaching towing
device to vehicle.
Do not secure vehicle to towing device by the use
of front or rear suspension or steering components.
Remove or secure loose or protruding objects from
a damaged vehicle before towing.
Refer to state and local rules and regulations before
towing a vehicle.
Do not allow weight of towed vehicle to bear on
lower fascia, air dams, or spoilers.
Fig. 6 JUMPER CABLE CLAMP CONNECTIONS

RECOMMENDED TOWING EQUIPMENT
1 - BATTERY NEGATIVE TERMINAL
2 - POSITIVE JUMPER CABLE
To a void da m a ge t o bu m per fa scia a n d a ir da m s
3 - TEST INDICATOR (IF EQUIPPED) u se:
4 - BATTERY POSITIVE TERMINAL • F WD veh icles, u se of a fla t bed t owin g device or
5 - BATTERY
6 - NEGATIVE JUMPER CABLE
a wh eel lift is r ecom m en ded (F ig. 7).
• AWD veh icles, a fla t bed t owin g device or a
CAUTION: Do not crank starter motor on disabled wh eel lift a n d t owin g dolly is r ecom m en ded (F ig. 7).
vehicle for more than 15 seconds, starter may over- Wh en u sin g a wh eel lift t owin g device, be su r e t h e
heat and could fail. disa bled veh icle h a s a t lea st 100 m m (4 in .) gr ou n d
clea r a n ce. If m in im u m gr ou n d clea r a n ce ca n n ot be
(7) If en gin e does n ot st a r t wit h in 15 secon ds, st op r ea ch ed, u se a t owin g dolly. If a fla t bed device is
cr a n kin g en gin e a n d a llow st a r t er t o cool (15 m in - u sed, t h e a ppr oa ch a n gle sh ou ld n ot exceed 15
u t es), befor e cr a n kin g a ga in . degr ees.
DISCONNECT CABLE CLAMPS AS FOLLOWS:

• Discon n ect BLACK ca ble cla m p fr om en gin e
gr ou n d on disa bled veh icle.
• Wh en u sin g a Boost er veh icle, discon n ect
BLACK ca ble cla m p fr om ba t t er y n ega t ive t er m in a l.
Discon n ect RE D ca ble cla m p fr om ba t t er y posit ive
t er m in a l.
• Discon n ect RE D ca ble cla m p fr om ba t t er y posi-
t ive t er m in a l on disa bled veh icle.
T OWI N G Fig. 7 RECOMMENDED TOWING

1 - WHEEL LIFT
STANDARD PROCEDURE - TOWING 2 - FLAT BED
WARNINGS AND CAUTIONS GROUND CLEARANCE
WARNING: DO NOT ALLOW TOWING ATTACHMENT CAUTION: If vehicle is towed with wheels removed,
DEVICES TO CONTACT THE FUEL TANK OR LINES, install lug nuts to retain brake drums or rotors.
FUEL LEAK CAN RESULT.
A t owed veh icle sh ou ld be r a ised u n t il t h e lift ed
DO NOT LIFT OR TOW VEHICLE BY FRONT OR
wh eels a r e a m in im u m 100 m m (4 in .) fr om t h e
REAR BUMPER.
gr ou n d. Be su r e t h er e is a t lea st 100 m m (4 in .)
DO NOT GO UNDER A LIFTED VEHICLE IF NOT
clea r a n ce bet ween t h e t a il pipe a n d t h e gr ou n d. If
SUPPORTED PROPERLY ON SAFETY STANDS.
n ecessa r y, r em ove t h e wh eels fr om t h e fr on t en d of
DO NOT ALLOW PASSENGERS TO RIDE IN A
t h e veh icle a n d lower t h e fr on t en d closer t o t h e
TOWED VEHICLE.
T OWI N G (Cont inue d)
gr ou n d, t o in cr ea se t h e gr ou n d clea r a n ce a t t h e r ea r bu m per ext en sion bolt s a n d on t h e bot t om of t h e r a il
of t h e veh icle. In st a ll lu g n u t s on wh eel a t t a ch in g ju st r ea r wa r d of t h e jou n ce bu m per. Veh icles
st u ds t o r et a in br a ke dr u m s or r ot or s. equ ipped wit h a r ea r swa y ba r h a ve br a cket s a t t h is
loca t ion .
LOCKED VEHICLE TOWING
Wh en a locked veh icle m u st be t owed wit h t h e TOWING – FRONT WHEEL LIFT
fr on t wh eels on t h e gr ou n d, u se a t owin g dolly or fla t If t h e veh icle is bein g t owed fr om t h e fr on t , wh en -
bed h a u ler. ever possible en su r e a t lea st 10 in ch es r oa d clea r a n ce
t o t h e t ir es.
FLAT TOWING WITH TOW BAR
• Th r ee speed a u t om a t ic t r a n sa xle veh icles ca n be TOWING – REAR WHEEL LIFT
fla t t owed a t speeds n ot t o exceed 40 km /h (25 m ph ) If a veh icle ca n n ot be t owed wit h t h e fr on t wh eels
for n ot m or e t h a n 25 km (15 m iles). Th e st eer in g col- lift ed, t h e r ea r wh eels ca n be lift ed pr ovided t h e fol-
u m n m u st be u n locked a n d gea r select or in n eu t r a l. lowin g gu ide lin es a r e obser ved.
• F ou r speed elect r on ic a u t om a t ic t r a n sa xle veh i-
cles ca n be fla t t owed a t speeds n ot t o exceed 72 CAUTION: Do not use steering column lock to
km /h (44 m ph ) for n ot m or e t h a n 160 km (100 m iles). secure steering wheel during towing operation.
Th e st eer in g colu m n m u st be u n locked a n d gea r
select or in n eu t r a l. • On AWD veh icles, a ll fou r wh eels m u st be fr ee t o
• AWD m odels sh ou ld n ot be fla t t owed. F or a ddi- r ot a t e. Use t owin g dollies a t u n lift ed en d of veh icle.
t ion a l in for m a t ion , r efer t o RECOMMEN D ED TOW- • Un lock st eer in g colu m n a n d secu r e st eer in g
IN G EQU IP MEN T in t h is sect ion . wh eel in st r a igh t a h ea d posit ion wit h a cla m p device
design ed for t owin g.
FLAT BED TOWING TIE DOWNS • Th r ee speed a u t om a t ic t r a n sa xle veh icles ca n be
fla t t owed a t speeds n ot t o exceed 40 km /h (25 m ph )
CAUTION: Do not tie vehicle down by attaching for n ot m or e t h a n 25 km (15 m iles). Th e st eer in g col-
chains or cables to suspension components or u m n m u st be u n locked a n d gea r select or in n eu t r a l.
engine mounts, damage to vehicle can result. • F ou r speed elect r on ic a u t om a t ic t r a n sa xle veh i-
cles ca n be fla t t owed a t speeds n ot t o exceed 72
Th e veh icle ca n be t ied t o a fla t bed device u sin g km /h (44 m ph ) for n ot m or e t h a n 160 km (100 m iles).
t h e t wo pa ir of fr on t slot s on t h e bot t om su r fa ce of Th e st eer in g colu m n m u st be u n locked a n d gea r
t h e r a ils, beh in d t h e fr on t wh eels. Th e t wo pa ir of select or in n eu t r a l.
r ea r slot s on t h e bot t om of t h e r a il bet ween t h e
RS SUSPENSION 2-1
SUSPENSION
page page
FRONT SUSPENSION .....................1 WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . . . 47

REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . 26
FRON T SU SPEN SI ON
TABLE OF CONTENTS
page page
FRONT SUSPENSION INSTALLATION

DESCRIPTION - FRONT SUSPENSION . . . . . . . 2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 11
OPERATION - FRONT SUSPENSION . . . . . . . . . 2 INSTALLATION - EXPORT . . . . . . . . . . . . . . . 11
STANDARD PROCEDURE - LUBRICATION ....2 LOWER CONTROL ARM
SPECIFICATIONS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 12
FRONT SUSPENSION FASTENER TORQUE . . 3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
SPECIAL TOOLS REMOVAL - LOWER CONTROL ARM . . . . . . . . 12
FRONT SUSPENSION . . . . . . . . . . . . . . . . . . . 3 DISASSEMBLY
BUSHINGS DISASSEMBLY - LOWER CONTROL ARM
REMOVAL - STABILIZER BAR CUSHION . . . . . . 4 (REAR BUSHING - STANDARD) . . . . . . . . . . 13
INSTALLATION - STABILIZER BAR CUSHION . . . 4 DISASSEMBLY - LOWER CONTROL ARM
HUB / BEARING (REAR BUSHING - HYDRO) . . . . . . . . . . . . . 13
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 5 INSPECTION - LOWER CONTROL ARM . . . . . . 14
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 ASSEMBLY
DIAGNOSIS AND TESTING - HUB AND ASSEMBLY - LOWER CONTROL ARM
BEARING ............................5 (REAR BUSHING - STANDARD) . . . . . . . . . . 14
REMOVAL .............................5 ASSEMBLY - LOWER CONTROL ARM
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 5 (REAR BUSHING - HYDRO) . . . . . . . . . . . . . 15
KNUCKLE INSTALLATION - LOWER CONTROL ARM . . . . 15
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 6 STABILIZER BAR
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 16
REMOVAL - STEERING KNUCKLE . . . . . . . . . . . 7 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSPECTION - STEERING KNUCKLE . . . . . . . . . 9 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION - STEERING KNUCKLE . . . . . . . 9 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 17
LOWER BALL JOINT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10 STRUT
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 DESCRIPTION - STRUT ASSEMBLY . . . . . . . . . 19
DIAGNOSIS AND TESTING - LOWER BALL OPERATION - STRUT ASSEMBLY . . . . . . . . . . 19
JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 DIAGNOSIS AND TESTING - STRUT
LOWER BALL JOINT SEAL BOOT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . 20
DESCRIPTION - EXPORT . . . . . . . . . . . . . . . . . 10 REMOVAL - STRUT ASSEMBLY . . . . . . . . . . . . 20
REMOVAL DISASSEMBLY - STRUT ASSEMBLY . . . . . . . . 21
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 ASSEMBLY - STRUT ASSEMBLY . . . . . . . . . . . 23
REMOVAL - EXPORT . . . . . . . . . . . . . . . . . . . 11 INSTALLATION - STRUT ASSEMBLY . . . . . . . . 25
2-2 FRONT SUSPENSION RS
FRON T SU SPEN SI ON st r u t m ou n t ) a n d st eer in g kn u ckle (t h r ou gh t h e lower

ba ll join t ) t u r n a s a n a ssem bly.
DESCRIPTION - FRONT SUSPENSION
Th is veh icle h a s a Ma cP h er son St r u t t ype fr on t
STANDARD PROCEDURE - LUBRICATION
Th er e a r e n o ser vicea ble lu br ica t ion poin t s on t h e
su spen sion (F ig. 1).
fr on t su spen sion . Th e ba ll join t s a r e sea led-for-life
a n d r equ ir e n o m a in t en a n ce. Th e lower ba ll join t s
OPERATION - FRONT SUSPENSION
h a ve specia l gr ea se fit t in g ca ps t h a t pr even t n or m a l
Th e fr on t su spen sion a llows ea ch wh eel on a veh i-
gr ea se gu n a t t a ch m en t . Th is h a s been don e t o elim i-
cle t o a da pt t o differ en t r oa d su r fa ces a n d con dit ion s
n a t e t h e possibilit y of over-fillin g, da m a gin g t h e n on -
wit h ou t gr ea t ly a ffect in g t h e opposit e wh eel a n d t h e
ven t ed sea l. Do n ot a t t em pt t o r em ove t h e specia l
a bilit y t o con t r ol t h e veh icle. E a ch side of t h e fr on t
gr ea se fit t in g ca p a n d r epla ce it wit h a n or m a l gr ea se
su spen sion is a llowed t o pivot so t h e veh icle ca n be
zir c fit t in g.
st eer ed in t h e dir ect ion pr efer r ed.
A st r u t a ssem bly is u sed in pla ce of t h e fr on t su s- CAUTION: No attempt should be made to replace
pen sion u pper con t r ol a r m a n d u pper ba ll join t . the ball joint grease fitting cap with a normal zirc
Wh en a veh icle st r ikes a bu m p, t h e for ce is t r a n s- fitting or fill the ball joint with grease. Damage to
fer r ed t h r ou gh t h e h u b, bea r in g, a n d kn u ckle, in t o the grease seal can result.
t h e st r u t a ssem bly t o a bsor b t h e for ce a n d da m pen it .
Th e t op of t h e st r u t is m ou n t ed dir ect ly t o t h e st r u t
t ower of t h e veh icle. Du r in g st eer in g m a n eu ver s, t h e
st r u t a ssem bly (t h r ou gh a pivot bea r in g in t h e u pper
Fig. 1 Front Suspension

1 - TOWER 9 - CRADLE/CROSSMEMBER REINFORCEMENT
2 - CROSSMEMBER TAPPING PLATES 10 - BALL JOINT
3 - LEFT STRUT ASSEMBLY 11 - ISOLATOR BUSHING
4 - LEFT STEERING KNUCKLE (WITH HUB AND BEARING) 12 - STEERING GEAR TIE ROD
5 - STABILIZER BAR LINK 13 - RIGHT STEERING KNUCKLE
6 - STABILIZER BAR 14 - RIGHT HUB AND BEARING
7 - LEFT LOWER CONTROL ARM 15 - RIGHT STRUT ASSEMBLY
8 - CRADLE/CROSSMEMBER
RS FRONT SUSPENSION 2-3
FRON T SU SPEN SI ON (Cont inue d)
SPECI FI CAT I ON S SPECI AL T OOLS

FRONT SUSPENSION FASTENER TORQUE FRONT SUSPENSION
Ft. In.
DESCRIPTION N·m
Lbs. Lbs.
Ball Joint Nut 108 80 —
Cradle Crossmember
163 120 —
Mounting Bolts
Cradle Crossmember
Reinforcement Bolts - Size 153 113 —
M-14 Puller C-3894A
Cradle Crossmember
Reinforcement Bolt - Size 106 78 —
M-12
Cradle Crossmember
Reinforcement Bolts - Size 61 45 —
M-10
Disc Brake Adapter
169 125 —
Mounting Bolts
Hub And Bearing Mounting Press, Ball Joint C-4212F
65 45 —
Bolts
Hub And Bearing Axle Hub
244 180 —
Nut
Lower Control Arm Pivot
183 135 —
Bolt
Stabilizer Bar Bushing
68 50 —
Retainer Bolts
Stabilizer Bar Link Nuts 88 65 —
Installer, Ball Joint 6758
Strut Body/Tower Mounting
28 21 250
Nuts
Strut Clevis-to-Knuckle Nuts 81 + 60 +
90° 90° —
turn turn
Strut Shaft Nut 100 75 —
Tie Rod Adjuster Jam Nut 75 55 —
Tie Rod Steering Arm Nut 75 55 —
Wheel Mounting (Lug) Nuts 135 100 —
Wrench, Strut Rod Nut 6864
FRON T SU SPEN SI ON (Cont inue d)
REMOVER/INSTALLER, BUSHING 8460
Fig. 2 Front Stabilizer Bar Cushion Retainers

1 - STEERING GEAR
2 - STABILIZER BAR
3 - RAISED BEAD
4 - FRONT CRADLE CROSSMEMBER
5 - RETAINERS
REMOVER/INSTALLER, BALL JOINT 8490
BU SH I N GS
REMOVAL - STABILIZER BAR CUSHION
(1) Ra ise Veh icle. Refer t o H oist in g in Lu br ica t ion
a n d Ma in t en a n ce.
(2) Rem ove t h e 2 bolt s fa st en in g t h e em ission lea k
det ect ion pu m p t o t h e cr a dle cr ossm em ber r ein for ce-
m en t .
(3) Move t h e lea k det ect ion pu m p t o t h e side
a llowin g a ccess t o t h e st a bilizer ba r cu sh ion r et a in -
er s.
(4) Rem ove t h e n u t a n d bolt secu r in g ea ch st a bi-
lizer ba r cu sh ion r et a in er t o t h e cr a dle cr ossm em ber
(F ig. 2) a n d r em ove t h e r et a in er s.
(5) Rem ove ea ch st a bilizer ba r cu sh ion fr om t h e Fig. 3 Correctly Installed Stabilizer Bar Cushion
st a bilizer ba r by open in g t h e slit in t h e cu sh ion a n d 1 - SLIT IN SWAY BAR BUSHING.
peelin g it off t h e st a bilizer ba r. 2 - SQUARE CORNER
3 - SWAY BAR
4 - SWAY BAR ISOLATOR BUSHING
INSTALLATION - STABILIZER BAR CUSHION
(1) In st a ll ea ch n ew cu sh ion on st a bilizer ba r by (4) In st a ll ea ch m ou n t in g bolt fr om r ea r of cr a dle
spr ea din g cu sh ion a t slit a n d for cin g it on t o st a bilizer cr ossm em ber t h r ou gh r et a in er. In st a ll t h e t wo n u t s
ba r. a n d t igh t en t o 68 N·m (50 ft . lbs.) t or qu e.
(5) Rea t t a ch em ission lea k det ect ion pu m p t o cr a -
NOTE: Cushions must be installed on stabilizer bar
dle cr ossm em ber r ein for cem en t wit h t wo m ou n t in g
so the square corner of the bushing will be down
bolt s.
and slit in cushion will be facing the rear of the
(6) Lower t h e veh icle.
vehicle when the stabilizer bar is installed (Fig. 3).
(2) P la ce st a bilizer ba r in t o m ou n t ed posit ion wit h

cu sh ion s pr oper ly a lign ed.
(3) H ook ea ch r et a in er in t o cr a dle cr ossm em ber
m ou n t in g h ole a n d over cu sh ion .
H U B / BEARI N G pressed out of the steering knuckle. (Refer to 2 -

SUSPENSION/FRONT/KNUCKLE - REMOVAL)
(1) Ra ise veh icle. (Refer t o LUBRICATION &
DESCRIPTION
MAINTE NANCE /H OISTING - STANDARD P ROCE -
Th e fr on t wh eel bea r in g a n d fr on t wh eel h u b of
DURE )
t h is veh icle a r e a h u b a n d bea r in g u n it t ype a ssem -
(2) Rem ove wh eel lu g n u t s, a n d fr on t t ir e a n d
bly (Un it III). Th is u n it com bin es t h e fr on t wh eel
wh eel a ssem bly.
m ou n t in g h u b (fla n ge) a n d t h e fr on t wh eel bea r in g
(3) Rem ove t h e cot t er pin , n u t lock a n d spr in g
in t o a sea led on e-piece u n it . Th e h u b a n d bea r in g is
wa sh er fr om t h e st u b a xle (F ig. 4).
m ou n t ed t o t h e cen t er of t h e st eer in g kn u ckle (F ig.
1). It is r et a in ed by fou r m ou n t in g bolt s a ccessible
fr om t h e in boa r d side of t h e st eer in g kn u ckle. Th e
h u b fla n ge h a s five wh eel m ou n t in g st u ds.
Th e wh eel m ou n t in g st u ds u sed t o m ou n t t h e t ir e
a n d wh eel t o t h e veh icle a r e t h e on ly r epla cea ble
com pon en t s of t h e h u b a n d bea r in g a ssem bly. Ot h er-
wise, t h e h u b a n d bea r in g is ser viced on ly a s a com -
plet e a ssem bly.
OPERATION
Th e h u b a n d bea r in g h a s in t er n a l bea r in gs t h a t
a llow t h e h u b t o r ot a t e wit h t h e dr ivesh a ft , a lon g
wit h t h e t ir e a n d wh eel. Th e five wh eel m ou n t in g
st u ds m ou n t t h e t ir e a n d wh eel, a n d br a ke r ot or t o
t h e veh icle. Fig. 4 Hub Nut
1 - HUB NUT
DIAGNOSIS AND TESTING - HUB AND 2
3
-
-
NUT LOCK
COTTER PIN
BEARING 4 - SPRING WASHER
Th e con dit ion of t h e fr on t h u b a n d bea r in g a ssem -
bly is dia gn osed u sin g t h e in spect ion a n d t est in g pr o- (4) Wit h a id of a h elper a pplyin g t h e br a kes t o
cedu r e det a iled below. keep t h e fr on t h u b fr om t u r n in g, r em ove t h e h u b n u t
Th e bea r in g con t a in ed in t h e Un it III fr on t h u b/ (F ig. 4).
bea r in g a ssem bly will pr odu ce n oise a n d vibr a t ion (5) Rem ove disc br a ke ca liper a n d a da pt er a s a n
wh en wor n or da m a ged. Th e n oise will gen er a lly a ssem bly fr om kn u ckle a s sh own (F ig. 5). H a n g
ch a n ge wh en t h e bea r in gs a r e loa ded. A r oa d t est of a ssem bly ou t of t h e wa y u sin g a bu n gee cor d or wir e.
t h e veh icle is n or m a lly r equ ir ed t o det er m in e t h e D o n o t a llo w c a lip e r h a n g by bra k e h o s e .
loca t ion of a wor n or da m a ged bea r in g. (6) Rem ove br a ke r ot or fr om h u b a n d bea r in g (F ig.
F in d a sm oot h level r oa d su r fa ce a n d br in g t h e 5).
veh icle u p t o a con st a n t speed. Wh en veh icle is a t a (7) P u sh in on en d of dr ivesh a ft st u b sh a ft , pu sh -
con st a n t speed, swer ve t h e veh icle ba ck a n d for t h in g it s splin es ou t of t h e h u b splin es.
fr om t h e left a n d t o t h e r igh t . Th is will loa d a n d (8) Rem ove t h e fou r h u b a n d bea r in g m ou n t in g
u n loa d t h e bea r in gs a n d ch a n ge t h e n oise level. bolt s fr om t h e r ea r of st eer in g kn u ckle (F ig. 6). U s e
Wh en bea r in g da m a ge is sligh t , t h e n oise is som e- c a re n o t to c o m e in c o n ta c t w ith a n d d a m a g e
t im es n ot icea ble a t lower speeds a n d a t ot h er t im es th e AB S to n e w h e e l o n th e d riv e s h a ft s tu b s h a ft
is m or e n ot icea ble a t speeds a bove 105 km /h (65 u p o n bo lt re m o v a l.
m ph ). (9) Rem ove t h e h u b a n d bea r in g a ssem bly fr om
t h e st eer in g kn u ckle.
REMOVAL
INSTALLATION
NOTE: Replacement of the Unit III front hub/bearing
assembly can be normally done without having to CAUTION: Hub and bearing assembly mounting
remove the steering knuckle from the vehicle. In the surfaces on the steering knuckle and stub axle (Fig.
event that the hub/bearing is frozen in the steering 7) must be smooth and completely free of foreign
knuckle and cannot be removed by hand, it will material or nicks prior to installing hub and bearing
have to be pressed out of the steering knuckle. The assembly.
steering knuckle will require removal from the vehi-
cle to allow the hub/bearing assembly to be
H U B / BEARI N G (Cont inue d)
Fig. 5 Front Brake Mounting Fig. 7 Mounting Surfaces (Typical)

1 - BRAKE ROTOR 1 - BEARING SEAL
2 - HUB AND BEARING 2 - STUB AXLE
3 - STEERING KNUCKLE 3 - THESE SURFACES MUST BE CLEAN AND FREE OF NICKS
4 - ADAPTER MOUNTING BOLTS BEFORE INSTALLING BEARING ASSEMBLY
5 - BRAKE CALIPER 4 - STEERING KNUCKLE
6 - ADAPTER
7 - CLIP st eer in g kn u ckle. Tigh t en m ou n t in g bolt s t o a t or qu e
of 65 N·m (45 ft . lbs.)
(3) In st a ll t h e br a ke r ot or on t h e h u b a n d bea r in g
(F ig. 5).
(4) In st a ll br a ke ca liper a n d a da pt er a ssem bly
ba ck over br a ke r ot or a n d a lign wit h m ou n t in g h oles
on st eer in g kn u ckle (F ig. 5). In st a ll t h e m ou n t in g
bolt s a n d t igh t en t o 169 N·m (125 ft . lbs.) t or qu e.
(5) In st a ll t h e h u b n u t on t h e en d of t h e st u b a xle
(F ig. 4). Wit h a id of a h elper a pplyin g t h e br a kes t o
keep t h e fr on t h u b fr om t u r n in g, t igh t en t h e h u b n u t
t o In st a ll t h e m ou n t in g bolt s a n d t igh t en t o 244 N·m
(180 ft . lbs.) t or qu e.
(6) In st a ll wh eel a n d t ir e a ssem bly on veh icle.
Tigh t en t h e wh eel m ou n t in g st u d n u t s in pr oper
sequ en ce u n t il a ll n u t s a r e t or qu ed t o h a lf specifica -
t ion . Th en r epea t t h e t igh t en in g sequ en ce t o t h e fu ll
specified t or qu e of 135 N·m (100 ft . lbs.).
Fig. 6 Hub And Bearing Mounting Bolts (7) Lower veh icle t o t h e gr ou n d.
1 - HUB (8) Ch eck t h e fr on t wh eel a lign m en t t oe set t in g
2 - STEERING KNUCKLE a n d r eset if n ot wit h in specifica t ion s. (Refer t o 2 -
3 - MOUNTING BOLTS (4)
4 - DRIVESHAFT
SUSP E NSION/WH E E L ALIGNME NT - STANDARD
P ROCE DURE )
CAUTION: When installing hub and bearing into
steering knuckle, be careful not to damage the
bearing seal (Fig. 7) on the outer C/V joint. K N U CK LE
(1) In st a ll h u b a n d bea r in g on t o st u b a xle a n d in t o DESCRIPTION
st eer in g kn u ckle u n t il squ a r ely sea t ed on t h e fa ce of Th e st eer in g kn u ckle is a sin gle a lu m in u m ca st -
t h e st eer in g kn u ckle. in g wit h legs m a ch in ed for a t t a ch m en t of t h e st r u t
(2) In st a ll t h e 4 h u b a n d bea r in g m ou n t in g bolt s a ssem bly, st eer in g lin ka ge, disc br a ke ca liper
fr om t h e r ea r of t h e kn u ckle. E qu a lly t igh t en a ll 4 a da pt er, lower con t r ol a r m ba ll join t a n d st eer in g
m ou n t in g bolt s in a cr iss-cr oss pa t t er n u n t il h u b/ lin ka ge (F ig. 1). Th e h u b a n d bea r in g a ssem bly is
bea r in g a ssem bly is squ a r ely sea t ed a ga in st fr on t of m ou n t ed in t h e cen t er of t h e st eer in g kn u ckle u sin g
K N U CK LE (Cont inue d)
4 bolt s. Th e dr ivesh a ft ’s con st a n t velocit y (C/V) st u b
a xle is splin ed t h r ou gh t h e cen t er of t h e h u b a n d
bea r in g a n d is h eld in pla ce u sin g a n u t , n u t lock a n d
cot t er pin .
Ser vice r epla cem en t of t h e fr on t h u b a n d bea r in g
a ssem bly ca n be don e wit h t h e st eer in g kn u ckle
r em a in in g on t h e veh icle.
OPERATION
Th e st eer in g kn u ckle pivot s wit h t h e st r u t a ssem -
bly bet ween t h e lower ba ll join t a n d t h e pivot bea r in g
in t h e st r u t a ssem bly. Th e st eer in g gea r ou t er t ie r od
en d con n ect s t o t h e t r a ilin g en d of ea ch kn u ckle,
a llowin g t h e veh icle t o be st eer ed.
Th e cen t er of t h e kn u ckle su ppor t s t h e h u b a n d
bea r in g a n d a xle sh a ft .
Fig. 9 Front Brake Mounting
REMOVAL - STEERING KNUCKLE 1 - BRAKE ROTOR
(1) Ra ise veh icle. (Refer t o LUBRICATION & 2 - HUB AND BEARING
MAINTE NANCE /H OISTING - STANDARD P ROCE - 3 - STEERING KNUCKLE
4 - ADAPTER MOUNTING BOLTS
DURE ) 5 - BRAKE CALIPER
(2) Rem ove t h e wh eel a n d t ir e a ssem bly fr om t h e 6 - ADAPTER
veh icle. 7 - CLIP
(3) Rem ove t h e cot t er pin , n u t lock a n d spr in g
wa sh er fr om t h e en d of t h e st u b a xle a n d h u b n u t
(F ig. 8).
Fig. 8 Hub Nut

1 - HUB NUT
2 - NUT LOCK
3 - COTTER PIN
4 - SPRING WASHER
(4) H a ve a h elper a pply t h e veh icle’s br a kes t o

keep h u b fr om t u r n in g, lo o s e n a n d re m o v e t h e h u b
n u t (F ig. 8).
(5) Rem ove disc br a ke ca liper a n d a da pt er a s a n Fig. 10 Caliper And Driveshaft Suspended
a ssem bly fr om kn u ckle a s sh own (F ig. 9). H a n g 1 - HANGER SUSPENDING CALIPER
a ssem bly ou t of t h e wa y u sin g a bu n gee cor d or wir e 2 - HANGER SUSPENDING DRIVESHAFT
(F ig. 10). D o n o t a llo w c a lip e r to h a n g by bra k e 3 - DRIVESHAFT
4 - BRAKE CALIPER
hose.
(6) Rem ove n u t a t t a ch in g ou t er t ie r od en d t o wh ile loosen in g a n d r em ovin g n u t wit h a wr en ch
st eer in g kn u ckle by h oldin g t h e t ie r od en d st u d (F ig. 11).
(8) If equ ipped wit h a n t ilock br a kes, r em ove t h e
fr on t wh eel speed sen sor fr om t h e st eer in g kn u ckle
(F ig. 13).
Fig. 11 Removing Tie Rod End Attaching Nut

1 - TIE ROD END
2 - STEERING KNUCKLE
3 - WRENCH
4 - SOCKET Fig. 13 Front Wheel Speed Sensor
5 - TIE ROD END STUD
1 - MOUNTING BOLT
2 - WHEEL SPEED SENSOR
(7) Rem ove t ie r od en d fr om st eer in g kn u ckle 3 - STEERING KNUCKLE
u sin g Rem over, Specia l Tool C-3894–A (F ig. 12).
(9) Rem ove t h e t wo st eer in g kn u ckle-t o-st r u t clevis
br a cket a t t a ch in g bolt s.
(10) Tip t h e kn u ckle ou t wa r d a n d r em ove t h e
dr ivesh a ft st u b a xle fr om t h e h u b a n d bea r in g. Su s-
pen d dr ivesh a ft st r a igh t ou t wa r d u sin g a bu n gee
cor d or wir e (F ig. 10). D o n o t a llo w d riv e s h a ft to
h a n g by in n e r jo in t.
(11) Rem ove ba ll join t n u t u sin g a power im pa ct
wr en ch . Beca u se t h e t a per ed st u d is h eld su fficien t ly
in t h e kn u ckle a t t h is t im e, it is n ot n ecessa r y t o
h old t h e st u d st a t ion a r y t o r em ove t h e n u t .
(12) Rein st a ll t h e ba ll join t n u t u n t il t h e t op of t h e
n u t is even wit h t h e t op of t h e ba ll join t st u d. Th is
will keep t h e st u d fr om dist or t in g wh ile t h e st u d is
r elea sed fr om t h e kn u ckle in t h e followin g st ep.
CAUTION: Do not remove ball joint stud from steer-

ing knuckle using a hammer. Damage to the Alumi-
num knuckle, ball joint or control arm will result.
(13) Relea se ba ll join t st u d fr om st eer in g kn u ckle

u sin g Rem over, Specia l Tool C-4150A, a s sh own (F ig.
14). To ea se Rem over in st a lla t ion a n d u se, it m a y
h elp t o r ot a t e t h e kn u ckle a r ou n d so t h e in side of t h e
kn u ckle fa ces ou t wa r d.
(14) Rem ove t h e n u t fr om t h e t op of t h e ba ll join t
Fig. 12 Tie Rod Removal With Tool C-3894-A st u d.
1 - OUTER TIE ROD (15) Rem ove t h e st eer in g kn u ckle fr om t h e veh icle.
2 - SPECIAL TOOL C-3894-A (16) If t h e h u b a n d bea r in g n eeds t o be t r a n s-
fer r ed, r em ove t h e fou r bolt s a t t a ch in g t h e h u b a n d
bea r in g t o t h e kn u ckle, t h en r em ove t h e h u b a n d
bea r in g.
damage to the knuckle can occur. Use a clean shop
cloth with Mopar" Brake Parts Cleaner applied to it
for proper cleaning. Do not spray the stud directly.
(2) P la ce t h e kn u ckle on t h e ba ll join t st u d.
(3) In st a ll a NE W st eer in g kn u ckle t o ba ll join t
st u d n u t . Tigh t en t h e n u t by h oldin g ba ll join t st u d
wit h h ex wr en ch wh ile t u r n in g n u t wit h a wr en ch
(F ig. 15). Usin g a cr owsfoot wr en ch on a t or qu e
wr en ch , t igh t en t h e n u t t o a t or qu e of 108 N·m (80 ft .
lbs.).
Fig. 14 Using C-4150A To Release Ball Joint

1 - ALUMINUM KNUCKLE Fig. 15 Ball Joint Nut Installation
2 - SPECIAL TOOL C-4150A
3 - LOWER CONTROL ARM 1 - KNUCKLE
4 - NUT INSTALLED ON BALL JOINT STEM 2 - BALL JOINT STUD
3 - LOWER CONTROL ARM
INSPECTION - STEERING KNUCKLE (4) Slide dr ivesh a ft st u b a xle in t o h u b a n d bea r in g

In spect t h e kn u ckle for t h e followin g: a ssem bly.
• Cr a cks or br ea ks
• Den t s or da m a ge CAUTION: The steering knuckle to strut assembly
• St r ess m a r ks in dica t in g a ben d attaching bolts are serrated and must not be turned
Th e fr on t su spen sion kn u ckle is n ot a r epa ir a ble during installation. Install nuts while holding bolts
com pon en t of t h e veh icles fr on t su spen sion . If ben t , stationary in the steering knuckle.
br oken or da m a ged in a n y wa y, do n ot a t t em pt t o
st r a igh t en or r epa ir t h e st eer in g kn u ckle. It m u st be
r epla ced. CAUTION: If the vehicle being serviced is equipped
If in spect ion lea ds t o t h e h u b a n d bea r in g, (Refer with eccentric strut assembly attaching bolts, the
t o 2 - SUSP E NSION/F RONT/H UB / BE ARING - eccentric bolt must be installed in the bottom (slot-
DIAGNOSIS AND TE STING) ted) hole on the strut clevis bracket (Fig. 16).
INSTALLATION - STEERING KNUCKLE NOTE: The strut clevis-to-steering knuckle bolts are
(1) If t h e h u b a n d bea r in g n eeds t o be in st a lled in
installed differently on each side. Left hand side
t h e kn u ckle, pla ce t h e h u b a n d bea r in g squ a r ely in t o
bolts are to be installed from vehicle rear to front.
t h e cen t er h ole of t h e st eer in g kn u ckle a lign in g t h e
Right side bolts are to be installed from vehicle
t h r ea ded m ou n t in g h oles of t h e h u b a n d bea r in g wit h
front to rear.
t h e m ou n t in g h oles in t h e st eer in g kn u ckle. In st a ll
t h e fou r m ou n t in g bolt s a n d t igh t en t h em t o a t or qu e (5) In st a ll st eer in g kn u ckle in clevis br a cket of
of 65 N·m (45 ft . lbs.). st r u t da m per a ssem bly. In st a ll t h e st r u t clevis-t o-
st eer in g kn u ckle a t t a ch in g bolt s. Tigh t en bot h bolt s
CAUTION: Before installing the knuckle on the ball
t o a t or qu e of 81 N·m (60 ft . lbs.) plu s a n a ddit ion a l
joint stud, wipe the ball joint stud and knuckle con-
1/4 (90°) t u r n .
tact area free of any grease or debris, otherwise
2 - 10 FRONT SUSPENSION RS
LOWER BALL J OI N T
DESCRIPTION
Th e ba ll join t is a n in t egr a l pa r t of t h e lower con -
t r ol a r m (F ig. 1). Th e ba ll join t h a s a t a per ed st u d
t h a t is pr essed in t o t h e a lu m in u m kn u ckle. Th e ba ll
join t st u d is t h r ea ded on t h e en d for a r et a in er n u t .
Th e ba ll join t h a s a n on -ven t ed sea l boot . Th e sea l
boot h a s a n in t egr a t ed h ea t sh ield.
Th e ba ll join t u sed in t h e lower con t r ol a r m of t h is
veh icle is a sea led-for-life ba ll join t a n d r equ ir es n o
m a in t en a n ce lu br ica t ion . Th e ba ll join t h a s been
lu br ica t ed-for-life du r in g t h e m a n u fa ct u r in g pr ocess.
A specia l fit t in g ca p is in st a lled on t h e fill por t . Th is
ca p m u st n ot be r em oved a n d r epla ced wit h a com -
m on zir c fit t in g. Th e specia l ca p is t h er e t o elim in a t e
Fig. 16 Correctly Installed Eccentric Attaching Bolt
t h e possibilit y of lu br ica t ion la t t er du r in g t h e ba ll
1 - STEERING KNUCKLE join t s life, t h u s da m a gin g t h e n on -ven t ed sea l boot .
2 - FLANGED BOLT IN TOP HOLE
3 - CAM BOLT IN BOTTOM HOLE
4 - STRUT CLEVIS BRACKET NOTE: The ball joint does not require any type of
additional lubrication for the life of the vehicle. No
(6) In st a ll t ie r od en d in t o kn u ckle st eer in g a r m . attempt should be made to ever add any lubrication
St a r t n u t on t o st u d of t ie r od en d. Wh ile h oldin g st u d to the lower ball joint.
of t ie r od en d st a t ion a r y u sin g a socket (F ig. 11),
t igh t en t ie r od en d t o st eer in g kn u ckle a t t a ch in g n u t .
Tigh t en t h e t ie r od en d n u t t o a t or qu e of 75 N·m (55 OPERATION
ft . lbs.). Th e ba ll join t is a pivot a l join t on t h e lower con t r ol
(7) If equ ipped wit h a n t ilock br a kes, in st a ll wh eel a r m t h a t a llows t h e kn u ckle t o m ove u p a n d down ,
speed sen sor a n d m ou n t in g bolt on st eer in g kn u ckle a n d t u r n wit h ea se.
(F ig. 13). Tigh t en t h e speed sen sor bolt t o a t or qu e of
7 N·m (60 in . lbs.). DIAGNOSIS AND TESTING - LOWER BALL
(8) In st a ll br a ke r ot or on h u b a n d bea r in g (F ig. 9). JOINT
(9) In st a ll disc br a ke ca liper a n d a da pt er a ssem bly Wit h t h e weigh t of t h e veh icle r est in g on t h e r oa d
on st eer in g kn u ckle. In st a ll a da pt er a m ou n t in g bolt s wh eels, gr a sp t h e specia l fit t in g ca p on t h e bot t om of
a n d t igh t en t o 169 N·m (125 ft . lbs.). t h e ba ll join t a n d wit h n o m ech a n ica l a ssist a n ce or
(10) Clea n a n y debr is fr om t h e t h r ea ds of t h e a dded for ce, a t t em pt t o r ot a t e t h e gr ea se fit t in g.
ou t er C/V join t st u b a xle. If t h e ba ll join t is wor n , t h e gr ea se fit t in g will
(11) In st a ll t h e wa sh er a n d h u b n u t on st u b a xle. r ot a t e ea sily. If m ovem en t is n ot ed, r epla cem en t of
(12) H a ve a h elper a pply t h e veh icle’s br a kes t o t h e con t r ol a r m is r ecom m en ded.
keep h u b fr om t u r n in g, t h en t igh t en h u b n u t t o a
t or qu e of 244 N·m (180 ft . lbs.).
(13) In st a ll t h e spr in g wa ve wa sh er on t h e en d of LOWER BALL J OI N T SEAL
t h e st u b a xle.
(14) In st a ll t h e h u b n u t lock, a n d a n e w cot t er pin
BOOT
(F ig. 8). Wr a p cot t er pin pr on gs t igh t ly a r ou n d t h e
h u b n u t lock. DESCRIPTION - EXPORT
(15) In st a ll wh eel a n d t ir e a ssem bly. In st a ll a n d Th e lower ba ll join t sea l boot is a t wo piece u n it . It
t igh t en t h e wh eel m ou n t in g n u t s in pr oper sequ en ce con sist s of t h e sea l boot , plu s a sepa r a t e sh ield t h a t
u n t il a ll n u t s a r e t or qu ed t o h a lf t h e r equ ir ed speci- is loca t ed in a gr oove a t t h e t op of t h e sea l boot .
fica t ion . Th en r epea t t h e t igh t en in g sequ en ce t o t h e
NOTE: The seal boot should only be replaced if
fu ll specified t or qu e of 135 N·m (100 ft . lbs.).
damaged during vehicle service. The entire lower
(16) Lower veh icle.
control arm should be replaced if the joint has been
(17) Set fr on t wh eel a lign m en t ca m ber a n d t oe a s
contaminated.
n ecessa r y. (Refer t o 2 - SUSP E NSION/WH E E L
ALIGNME NT - STANDARD P ROCE DURE )
RS FRONT SUSPENSION 2 - 11
LOWER BALL J OI N T SEAL BOOT (Cont inue d)
REM OVAL (2) In st a ll a N EW sea l boot by h a n d a s fa r a s pos-

sible on ba ll join t . E n su r e sea l boot sh ield is posi-
REMOVAL t ion ed ou t wa r d fr om con t r ol a r m a s sh own (F ig. 18).
(1) Rem ove st eer in g kn u ckle fr om veh icle. (Refer
to 2 - SUSP E NSION/F RONT/KNUCKLE -
RE MOVAL)
(2) Usin g a scr ewdr iver or ot h er su it a ble t ool, pr y
sea l boot off of ba ll join t (F ig. 17).
Fig. 18 Ball Joint Seal Boot Installed Position

1 - BALL JOINT STUD
3 - SEAL BOOT SHIELD
CAUTION: Do not use an arbor press to install seal

Fig. 17 Ball Joint Seal Boot Removal boot on ball joint. Damage to seal boot will occur if
1 - BALL JOINT STUD excessive pressure is applied while it is being
2 - SCREWDRIVER installed.
3 - SEAL BOOT
(3) P la ce In st a ller, Specia l Tool 6758, over t op of
(3) In spect ba ll join t for eviden ce of dir t or wa t er
sea l boot a n d squ a r ely a lign it wit h bot t om edge of
in t r u sion a n d wipe clea n a s n ecessa r y. If dir t or
sea l boot (F ig. 19). Apply h a n d pr essu r e (or gen t ly
wa t er in t r u sion is ext r em e a n d join t ca n n ot be pr op-
t a p wit h a h a m m er if n ecessa r y) t o t op of In st a ller
er ly clea n ed, lower con t r ol a r m will n eed t o be
u n t il sea l boot is pr essed squ a r ely down a ga in st t op
r epla ced. (Refer t o 2 - SUSP E NSION/F RONT/
su r fa ce of lower con t r ol a r m .
LOWE R CONTROL ARM - RE MOVAL)
(4) Wipe a n y gr ea se off ba ll join t st em u sin g a
clea n sh op t owel wit h Mopa r ! Br a ke P a r t s Clea n er
REMOVAL - EXPORT a pplied t o it .
(1) Rem ove st eer in g kn u ckle fr om veh icle. (Refer
to 2 - SUSP E NSION/F RONT/KNUCKLE - CAUTION: Do not attempt to install a normal grease
RE MOVAL) zirc in ball joint in an effort to lubricate joint
(2) Rem ove sh ield fr om sea l boot by gen t ly pu llin g through zirc fitting.
on it .
(3) Usin g a scr ew dr iver or ot h er su it a ble t ool, pr y (5) In st a ll st eer in g kn u ckle on veh icle. (Refer t o 2 -
sea l boot off lower ba ll join t . SUSP E NSION/F RONT/KNUCKLE - INSTALLA-
TION)
I N STALLAT I ON INSTALLATION - EXPORT
(1) P la ce a liber a l da b of Mopa r ! Wh eel Bea r in g
INSTALLATION Gr ea se a r ou n d t h e ba se of t h e ba ll join t st em a t t h e
(1) P la ce a liber a l da b of Mopa r ! Wh eel Bea r in g socket .
Gr ea se a r ou n d ba se of ba ll join t st u d a t socket . (2) In st a ll a N EW sea l boot by h a n d a s fa r a s pos-
sible on t h e ba ll join t .
LOWER BALL J OI N T SEAL BOOT (Cont inue d)
(5) P la ce t h e sh ield over t h e t op of t h e sea l boot
a n d st r et ch it in t o t h e gr oove a t t h e t op of t h e sea l
boot .
CAUTION: Do not attempt to install a normal grease

zirc in the ball joint and lubricate the joint through
the zirc fitting.
(6) Rein st a ll st eer in g kn u ckle on veh icle. (Refer t o

2 - SUSP E NSION/F RONT/KNUCKLE - INSTALLA-
TION)
LOWER CON T ROL ARM

DESCRIPTION
Th e lower con t r ol a r m is m ou n t ed t o t h e fr on t su s-
pen sion cr ossm em ber u sin g a pivot bolt t h r ou gh t h e
cen t er of t h e fr on t pivot bu sh in g, a n d t h e fr on t su s-
Fig. 19 Installer Positioned On Ball Joint Seal Boot pen sion cr a dle cr ossm em ber r ein for cem en t t r a ps t h e
r ea r bu sh in g in t h e cr ossm em ber (F ig. 1).
1 - INSTALLER 6758
2 - LOWER CONTROL ARM Th e lower con t r ol a r m is a n ir on ca st in g wit h t wo
3 - SEAL BOOT SHIELD r u bber bu sh in gs a n d a ba ll join t . Th e lower con t r ol
a r m fr on t bu sh in g is t h e spool t ype a n d is pr essed
CAUTION: Do not use an arbor press to install the in t o t h e lower con t r ol a r m . Th e st a n da r d (Low-lin e,
sealing boot on the ball joint. Damage to the seal- H igh -lin e) lower con t r ol a r m r ea r bu sh in g is a
ing boot will occur if excessive pressure is applied pu sh -on bu sh in g t h a t is pu sh ed over a st em on t h e
to the sealing boot when it is being installed. r ea r of t h e lower con t r ol a r m . Th e lower con t r ol a r m
r ea r bu sh in g u sed on a ll ot h er m odels is a h ydr o-
(3) P la ce In st a ller, Specia l Tool 6758, over sea l bu sh in g t h a t is pr essed on . It h a s liqu id filled voids
boot a n d squ a r ely a lign it wit h bot t om edge of sea l t h a t pr ovide m or e effect ive da m pen in g t h a n t h e st a n -
boot (F ig. 20). Apply h a n d pr essu r e t o Specia l Tool da r d bu sh in g. Veh icles wit h r ea r h ydr o-bu sh in gs u t i-
6758 u n t il sea l boot is pr essed squ a r ely a ga in st t op lize a differ en t lower con t r ol a r m t h a n veh icles wit h
su r fa ce of lower con t r ol a r m . st a n da r d bu sh in gs. Th ey h a ve a st r a igh t sligh t ly
t a per ed r ou n d st em wh er e t h e h ydr o-bu sh in g is
m ou n t ed wh er ea s t h e st a n da r d a r m h a s a st r a igh t
st em wit h a squ a r ed kn ob on t h e en d t o r et a in t h e
bu sh in g.
Th e lower con t r ol a r m ba ll join t is pr essed in t o t h e
ou t er en d of t h e a r m . Th e ba ll join t h a s a t a per ed
st u d a n d r et a in er n u t for fa st en in g it t o t h e st eer in g
kn u ckle.
OPERATION
Th e lower con t r ol a r m su ppor t s t h e lower en d of
t h e st eer in g kn u ckle a n d a llows for t h e u p a n d down
m ovem en t of t h e su spen sion du r in g t h e jou n ce a n d
r ebou n d t r a vel. Th e lower con t r ol a r m ba ll join t con -
n ect s t h e a r m t o t h e st eer in g kn u ckle.
Fig. 20 Installing Ball Joint Seal Boot (Typical) REMOVAL - LOWER CONTROL ARM
1 - SHIELD (NOT ON RG VEHICLE) (1) Ra ise veh icle. (Refer t o LUBRICATION &
2 - SPECIAL TOOL 6758 MAINTE NANCE /H OISTING - STANDARD P ROCE -
4 - BALL JOINT SEAL BOOT DURE )
(2) Rem ove wh eel a n d t ir e a ssem bly.
(4) Wipe a n y gr ea se off t h e ba ll join t st em . (3) Rem ove t h e st eer in g kn u ckle. (Refer t o 2 -
SUSP E NSION/F RONT/KNUCKLE - RE MOVAL)
LOWER CON T ROL ARM (Cont inue d)
(4) Rem ove t h e bolt s fa st en in g t h e power st eer in g
cooler t o t h e fr on t su spen sion cr a dle cr ossm em ber
r ein for cem en t (F ig. 21).
Fig. 21 Power Steering Cooler

1 - CRADLE CROSSMEMBER REINFORCEMENT
2 - POWER STEERING COOLER
(5) Rem ove t h e lower con t r ol a r m r ea r bu sh in g

r et a in er bolt s loca t ed on ea ch side of ea ch lower con -
t r ol a r m r ea r bu sh in g. Fig. 22 Cradle Crossmember Reinforcement
Attachment
NOTE: The bolts fastening the cradle crossmember 1 - STEERING GEAR
reinforcement are of three different thread sizes. 2 - RIGHT LOWER CONTROL ARM
3 - LEFT LOWER CONTROL ARM
Note the location of the various sizes. 4 - CRADLE CROSSMEMBER REINFORCEMENT
5 - REAR CRADLE CROSSMEMBER ISOLATOR BUSHING
(6) Rem ove t h e bolt s a t t a ch in g t h e cr a dle cr oss- 6 - STABILIZER BAR
m em ber r ein for cem en t t o t h e fr on t su spen sion cr a dle 7 - CRADLE CROSSMEMBER
cr ossm em ber (F ig. 22). Rem ove t h e 2 bolt s fa st en in g
t h e r ein for cem en t a n d r ea r of cr a dle cr ossm em ber t o (3) Usin g a sh a r p kn ife (su ch a s a r a zor ), slit t h e
t h e body of t h e veh icle. Rem ove t h e r ein for cem en t . bu sh in g len gt h wise (F ig. 23) t o a llow it s r em ova l
(7) Rem ove t h e pivot bolt a t t a ch in g t h e fr on t bu sh - fr om t h e lower con t r ol a r m (F ig. 23).
in g of t h e lower con t r ol a r m t o t h e fr on t su spen sion (4) Rem ove t h e bu sh in g fr om t h e lower con t r ol
cr a dle cr ossm em ber. arm.
(8) Rem ove t h e lower con t r ol a r m .
DISASSEMBLY - LOWER CONTROL ARM
(REAR BUSHING - HYDRO)
DI SASSEM BLY (1) Rem ove t h e lower con t r ol a r m fr om t h e fr on t
su spen sion cr a dle. (Refer t o 2 - SUSP E NSION/
DISASSEMBLY - LOWER CONTROL ARM F RONT/LOWE R CONTROL ARM - RE MOVAL)
(REAR BUSHING - STANDARD) (2) Mou n t t h e lower con t r ol a r m in a vise w ith o u t
(1) Rem ove t h e lower con t r ol a r m fr om t h e fr on t u sin g excessive cla m pin g for ce.
su spen sion cr a dle. (Refer t o 2 - SUSP E NSION/ (3) In st a ll Rem over, Specia l Tool 8460, on h ydr o-
F RONT/LOWE R CONTROL ARM - RE MOVAL) bu sh in g a s sh own (F ig. 24). Rem ova l P in , Specia l
(2) Mou n t t h e lower con t r ol a r m in a vise w ith o u t Tool 8460–3, m u st ext en d t h ou gh h ole in cen t er of
u sin g excessive cla m pin g for ce. bu sh in g r ea r.
(4) Tigh t en for cin g scr ew of Br idge (Specia l Tool
8460–1), r em ovin g bu sh in g fr om lower con t r ol a r m .
SION/F RONT/LOWE R BALL J OINT - DIAGNOSIS
AND TE STING)
ASSEM BLY
ASSEMBLY - LOWER CONTROL ARM (REAR
BUSHING - STANDARD)
CAUTION: Do not apply grease or any other type of
lubricant other than the silicone lubricant specified
below to the control arm bushing.
(1) Apply Mopa r Silicon e Spr a y Lu be or a n equ iv-

a len t , t o t h e h ole in lower con t r ol a r m r ea r bu sh in g.
Fig. 23 Slit Lower Control Arm Rear Bushing Th is will a id in t h e in st a lla t ion of t h e bu sh in g on t h e
1 - REAR BUSHING lower con t r ol a r m .
2 - SLIT CUT IN BUSHING (2) Wit h t h e lower con t r ol a r m h eld secu r ely in a
3 - LOWER CONTROL ARM vise, in st a ll bu sh in g on lower con t r ol a r m . In st a ll
bu sh in g by pu sh in g a n d r ockin g t h e bu sh in g u n t il it
is fu lly in st a lled on lower con t r ol a r m . Be su r e t h a t
wh en bu sh in g is in st a lled it is pa st t h e u pset on t h e
en d of t h e lower con t r ol a r m (F ig. 25).
(3) Th e r ea r bu sh in g of t h e lower con t r ol a r m ,
wh en cor r ect ly in st a lled, is t o be posit ion ed on t h e
lower con t r ol a r m a s sh own (F ig. 25).
Fig. 24 HYDRO-BUSHING REMOVAL

1 - REMOVAL PIN (8460-3)
2 - BRIDGE (8460-1)
3 - HYDRO-BUSHING
INSPECTION - LOWER CONTROL ARM Fig. 25 Correctly Installed Lower Control Arm
In spect lower con t r ol a r m for sign s of da m a ge fr om Bushing
con t a ct wit h t h e gr ou n d or r oa d debr is. If lower con - 1 - ROUND SURFACE OF BUSHING
t r ol a r m sh ows a n y sign of da m a ge, in spect lower 2 - LOWER CONTROL ARM
con t r ol a r m for dist or t ion . Do n ot a t t em pt t o r epa ir 3 - LOWER CONTROL ARM REAR BUSHING
4 - UPSET
or st r a igh t en a br oken or ben t lower con t r ol a r m . If 5 - FLAT SURFACE OF BUSHING
da m a ged, t h e lower con t r ol a r m ca st in g is ser viced
on ly a s a com plet e com pon en t . (4) In st a ll lower con t r ol a r m on veh icle. (Refer t o 2
In spect bot h lower con t r ol a r m isola t or bu sh in gs - SUSP E NSION/F RONT/LOWE R CONTROL ARM -
for sever e det er ior a t ion , a n d r epla ce a s r equ ir ed. INSTALLATION)
In spect t h e r ea r h ydr o-bu sh in g for seepa ge. Bot h
t ype r ea r bu sh in gs a r e ser vicea ble. If t h e fr on t bu sh -
in g fa ils, t h e lower con t r ol a r m m u st be r epla ced.
In spect a n d t est t h e ba ll join t per t h e pr ocedu r e
list ed in Lower Ba ll J oin t . (Refer t o 2 - SUSP E N-
ASSEMBLY - LOWER CONTROL ARM (REAR

BUSHING - HYDRO)
CAUTION: Do not apply grease or any other type of
lubricant to the arm stem where the bushing is to
be mounted. Such action will reduce proper bush-
ing adhesion to arm.
(1) Secu r e lower con t r ol a r m in a vise.
NOTE: Hydro bushings and grooves on control arm

stems are unique for right and left sides. Left side
bushing master spline and control arm groove are
on the top (when mounted on vehicle). Right side
bushing master spline and control arm groove are
on the bottom (when mounted on vehicle).
Fig. 27 HYDRO-BUSHING INSTALLATION
(2) Align m a st er splin e on bu sh in g in n er sleeve
1 - LOWER CONTROL ARM FLANGE
wit h gr oove on lower con t r ol a r m r ea r bu sh in g st em 2 - INSTALLER CUP (8460-2)
(F ig. 26). St a r t bu sh in g on st em by h a n d. 3 - BRIDGE (8460-1)
4 - HYDRO-BUSHING
Fig. 26 BUSHING MASTER SPLINE LINED UP WITH

GROOVE (RIGHT SIDE SHOWN) Fig. 28 SPACER PLATE POSITIONED
1 - GROOVE 1 - SPACER PLATE (8460-4)
2 - HYDRO-BUSHING 2 - LOWER CONTROL ARM FLANGE
3 - MASTER SPLINE 3 - BRIDGE (8460-1)
4 - INSTALLER CUP (8460-2)
(3) In st a ll Rem over /In st a ller, Specia l Tool 8460, 5 - HYDRO-BUSHING
over bu sh in g a n d lower con t r ol a r m a s sh own (F ig.
27). E n ga ge fla n ge on lower con t r ol a r m wit h t ips of (6) Ba ck off t h e for cin g scr ew a n d r em ove t ool.
Br idge, Specia l Tool 8460–1 a s sh own (F ig. 27). Th e (7) In st a ll lower con t r ol a r m on veh icle. (Refer t o 2
con t ou r ed side of In st a ller Cu p, Specia l Tool 8460–2, - SUSP E NSION/F RONT/LOWE R CONTROL ARM -
sh ou ld be fit t ed u p a ga in st r ea r of t h e bu sh in g. INSTALLATION)
(4) Begin t o t igh t en for cin g scr ew. As bu sh in g
n ea r s lower con t r ol a r m fla n ge, pla ce Spa cer P la t e, INSTALLATION - LOWER CONTROL ARM
Specia l Tool 8460–4 bet ween fla n ge a n d bu sh in g (1) P osit ion lower con t r ol a r m a ssem bly in t o fr on t
in n er sleeve, st r a ddlin g t h e st em a s sh own (F ig. 28). su spen sion cr a dle cr ossm em ber gu idin g bu sh in gs in t o
(5) In st a ll bu sh in g u p a ga in st Spa cer P la t e, t igh t - m ou n t in g posit ion (F ig. 22).
en in g t h e br idge for cin g scr ew wit h a t or qu e wr en ch (2) In st a ll NE W pivot bolt a t t a ch in g fr on t bu sh in g
u n t il a ppr oxim a t ely 50 N·m (37 ft . lbs.) t or qu e is of lower con t r ol a r m t o fr on t su spen sion cr a dle cr oss-
r ea ch ed. Th is will pr oper ly spa ce bu sh in g on t h e m em ber (F ig. 29). D o n o t tig h te n o r to rqu e p iv o t
st em in r ela t ion t o t h e fla n ge. bo lt a t th is tim e .
Fig. 29 Lower Control Arm Bushing Pivot Bolt Fig. 30 Jack Stands Supporting Vehicle Weight
Correctly Installed 1 - LOWER CONTROL ARMS
2 - BALL JOINT
1 - PIVOT BOLT
3 - JACK STANDS
4 - BALL JOINT
3 - FRONT SUSPENSION CRADLE CROSSMEMBER
(3) In st a ll t h e r ein for cem en t on t h e fr on t su spen - (11) Ra ise veh icle, r em ove ja ck st a n ds a n d lower
sion cr a dle cr ossm em ber a n d in st a ll t h e bolt s a t t a ch - veh icle t o t h e gr ou n d.
in g t h e r ein for cem en t t o t h e cr a dle cr ossm em ber (12) P er for m fr on t wh eel a lign m en t a s n ecessa r y.
(F ig. 22). Tigh t en t h e M-14 size bolt s t o a t or qu e of (Refer t o 2 - SUSP E NSION/WH E E L ALIGNME NT -
153 N·m (113 ft . lbs.). Tigh t en t h e M-12 size bolt s t o STANDARD P ROCE DURE )
a t or qu e of 106 N·m (78 ft . lbs.).
(4) In st a ll t h e lower con t r ol a r m r ea r bu sh in g
r et a in er bolt s t h r ou gh r ein for cem en t on ea ch side of
STABI LI Z ER BAR
ea ch lower con t r ol a r m r ea r bu sh in g. Tigh t en t h ese
M-10 size bolt s t o a t or qu e of 61 N·m (45 ft . lbs.).
DESCRIPTION
(5) In st a ll t h e t wo bolt s a n d bu sh in gs a t t a ch in g Th e st a bilizer ba r in t er con n ect s bot h fr on t st r u t s of
t h e r ein for cem en t a n d r ea r of cr a dle cr ossm em ber t o t h e veh icle a n d is a t t a ch ed t o t h e fr on t cr ossm em ber
body of veh icle (F ig. 22). Tigh t en bolt s t o a t or qu e of (F ig. 1).
163 N·m (120 ft . lbs.). At t a ch m en t of t h e st a bilizer ba r t o t h e fr on t cr oss-
(6) In st a ll t h e power st eer in g cooler (F ig. 21). m em ber is t h r ou gh 2 r u bber-isola t or cu sh ion bu sh -
Tigh t en bolt s t o a t or qu e of 11 N·m (100 in . lbs.). in gs a n d r et a in er s. A dou ble ba ll join t ed st a bilizer
(7) Rein st a ll st eer in g kn u ckle, br a ke r ot or a n d ca l- ba r lin k is u sed t o a t t a ch ea ch en d of t h e st a bilizer
iper. (Refer t o 2 - SUSP E NSION/F RONT/KNUCKLE ba r t o t h e fr on t st r u t a ssem blies. All pa r t s of t h e st a -
- INSTALLATION) bilizer ba r a r e r epla cea ble a s in dividu a l com pon en t s.
Th e st a bilizer ba r t o fr on t cr ossm em ber cu sh ion
CAUTION: When locating jack stands under lower bu sh in gs a r e split for ea sy r em ova l a n d in st a lla t ion .
control arms, do not place the jack stands under Th e split in t h e bu sh in gs sh ou ld be posit ion ed t owa r d
the ball joints (Fig. 30). t h e r ea r of t h e veh icle, wit h t h e squ a r e cor n er fa cin g
down , wh en t h e st a bilizer ba r is in st a lled.
(8) P osit ion ja ck st a n ds u n der t h e lower con t r ol
a r m s a s close t o t h e ba ll join t s a s possible (F ig. 30). OPERATION
Lower t h e veh icle on t o t h e ja ck st a n ds u n t il t h e ja ck J ou n ce a n d r ebou n d m ovem en t s a ffect in g on e
st a n ds a r e su ppor t in g t h e t ot a l weigh t of t h e veh icle. wh eel a r e pa r t ia lly t r a n sm it t ed t o t h e opposit e wh eel
(9) Tigh t en fr on t lower con t r ol a r m pivot bolt t o a of t h e veh icle t h r ou gh t h e st a bilizer ba r. Th is h elps
t or qu e of 183 N·m (135 ft . lbs.). t o m in im ize t h e body r oll of t h e veh icle du r in g su s-
(10) In st a ll t h e wh eel a n d t ir e a ssem bly. In st a ll pen sion m ovem en t .
a n d t igh t en t h e wh eel m ou n t in g st u d n u t s in pr oper Con n ect in g t h e st a bilizer ba r lin ks t o t h e st r u t
sequ en ce u n t il a ll n u t s a r e t or qu ed t o h a lf specifica - a ssem blies h elps r edu ce t h e for e-a n d-a ft r a t e of t h e
t ion . Th en r epea t t h e t igh t en in g sequ en ce t o t h e fu ll st a bilizer ba r fr om t h e r est of t h e fr on t su spen sion .
specified t or qu e of 135 N·m (100 ft . lbs.).
STABI LI Z ER BAR (Cont inue d)
REMOVAL
DURE )
(2) Rem ove t h e bolt s fa st en in g t h e power st eer in g
cooler t o t h e fr on t su spen sion cr a dle cr ossm em ber
r ein for cem en t (F ig. 31).

1 - CRADLE CROSSMEMBER REINFORCEMENT Fig. 32 Cradle Crossmember Reinforcement
Attachment
(3) Rem ove t h e lower con t r ol a r m r ea r bu sh in g 1 - STEERING GEAR
2 - RIGHT LOWER CONTROL ARM
r et a in er bolt s loca t ed on ea ch side of ea ch lower con - 3 - LEFT LOWER CONTROL ARM
t r ol a r m r ea r bu sh in g. 4 - CRADLE CROSSMEMBER REINFORCEMENT
5 - REAR CRADLE CROSSMEMBER ISOLATOR BUSHING
6 - STABILIZER BAR
NOTE: The bolts fastening the cradle crossmember 7 - CRADLE CROSSMEMBER
reinforcement are of two different thread sizes. Note
the location of the various sizes. (6) Rem ove t h e st a bilizer ba r bu sh in g (cu sh ion )
r et a in er s fr om t h e fr on t su spen sion cr a dle cr ossm em -
(4) Rem ove t h e bolt s a t t a ch in g t h e cr a dle cr oss- ber (F ig. 34).
m em ber r ein for cem en t t o t h e fr on t su spen sion cr a dle (7) Rem ove t h e st a bilizer ba r a n d bu sh in gs (cu sh -
cr ossm em ber (F ig. 32). Rem ove t h e 2 bolt s fa st en in g ion s) a s a n a ssem bly fr om t h e fr on t su spen sion cr a -
t h e r ein for cem en t a n d r ea r of cr a dle cr ossm em ber t o dle cr ossm em ber.
t h e body of t h e veh icle. Rem ove t h e r ein for cem en t .
CAUTION: When removing the nut from the stud of

INSPECTION
the stabilizer bar link, do not allow the stud to In spect for br oken or dist or t ed st a bilizer ba r bu sh -
rotate in it’s socket. Hold the stud from rotating by in gs (cu sh ion s), bu sh in g r et a in er s, a n d wor n or da m -
placing an open-end wrench on the flat machined a ged st a bilizer ba r lin ks.
into the stud (Fig. 33).
INSTALLATION
(5) Rem ove t h e st a bilizer ba r lin ks fr om ea ch en d
of t h e st a bilizer ba r (F ig. 33). To do so, pla ce a n open - NOTE: Two different diameter stabilizer bars are
en d wr en ch on t h e fla t m a ch in ed in t o t h e lin k’s available for this vehicle. Therefore, two different
m ou n t in g st u d, t h en r em ove t h e n u t wh ile h oldin g size bushings/cushions are also used. Use the cor-
t h e wr en ch in pla ce. P u sh ea ch st u d ou t of t h e h ole rect bushing/cushion on the correct stabilizer bar.
in t h e st a bilizer ba r.
c le w ith th e s qu a re c o rn e r to w a rd th e g ro u n d ,
w h e n th e s ta bilize r ba r is in s ta lle d o n th e v e h i-
c le (F ig . 35).
Fig. 33 Stabilizer Bar Link To Stabilizer Bar

Attachment Fig. 35 Correctly Installed Stabilizer Bar To Cradle
1 - RATCHET Bushing
2 - WRENCH
3 - STRUT 1 - SWAY BAR ISOLATOR BUSHING
4 - STABILIZER BAR LINK 2 - SLIT IN SWAY BAR BUSHING
5 - NUT 3 - SWAY BAR
6 - STABILIZER BAR
(2) P osit ion st a bilizer ba r in t o fr on t su spen sion
cr a dle so st a bilizer ba r bu sh in gs a r e a lign ed wit h
depr ession s in cr a dle. In st a ll st a bilizer ba r bu sh in g
r et a in er s on t o cr ossm em ber a lign in g r a ised bea d on
r et a in er wit h cu t ou t s in bu sh in gs (F ig. 36). D o n o t
tig h te n S ta bilize r ba r bu s h in g re ta in e rs bo lts a t
th is tim e .
Fig. 34 Front Stabilizer Bar Retainers

1 - STEERING GEAR
2 - STABILIZER BAR
3 - RAISED BEAD
4 - FRONT CRADLE CROSSMEMBER
5 - RETAINERS
(1) If t h e st a bilizer ba r t o fr on t su spen sion cr a dle Fig. 36 Stabilizer Bar Bushing Retainer Installation
bu sh in gs r equ ir e r epla cem en t a t t im e of in spect ion , 1 - SWAY BAR
in st a ll n ew bu sh in gs befor e in st a llin g st a bilizer ba r. 2 - SWAY BAR BUSHING
Bu sh in gs a r e r epla ced by open in g slit on bu sh in gs 3 - BUSHING SPLIT
4 - FRONT SUSPENSION CRADLE
a n d peelin g t h em off st a bilizer ba r. In st a ll n ew bu sh - 5 - BUSHING CUT-OUT
in gs on st a bilizer ba r by spr ea din g bu sh in g a t slit 6 - BUSHING RETAINER
a n d for cin g t h em on t h e st a bilizer ba r. B u s h in g s 7 - RAISED BEAD
m u s t be in s ta lle d o n s ta bilize r ba r s o s lit in
bu s h in g w ill be fa c in g to w a rd th e re a r o f v e h i-
(3) Ch eck posit ion of t h e st a bilizer ba r in t h e fr on t (9) In st a ll t h e t wo bolt s a n d bu sh in gs a t t a ch in g
su spen sion cr a dle. Th e cen t er of t h e cu r ved sect ion of t h e r ein for cem en t a n d r ea r of cr a dle cr ossm em ber t o
t h e st a bilizer ba r m u st be a lign ed wit h t h e r a ised body of veh icle (F ig. 32). Tigh t en bolt s t o a t or qu e of
lin e in t h e cen t er of t h e fr on t su spen sion cr a dle (F ig. 163 N·m (120 ft . lbs.).
37). (10) In st a ll t h e power st eer in g cooler (F ig. 31).
Tigh t en bolt s t o a t or qu e of 11 N·m (100 in . lbs.).
ST RU T
DESCRIPTION - STRUT ASSEMBLY
A Ma cph er son t ype st r u t a ssem bly is u sed in pla ce
of a con ven t ion a l fr on t su spen sion ’s u pper con t r ol
a r m a n d u pper ba ll join t . Th e bot t om of t h e st r u t
m ou n t s dir ect ly t o t h e st eer in g kn u ckle u sin g t wo
bolt s a n d n u t s goin g t h r ou gh t h e st r u t clevis br a cket
a n d st eer in g kn u ckle. Th e t op of t h e st r u t m ou n t s
dir ect ly t o t h e st r u t t ower of t h e veh icle u sin g t h e
t h r ea ded st u ds on t h e st r u t a ssem blies u pper m ou n t .
Th e st r u t a ssem bly in clu des t h e com pon en t s list ed
Fig. 37 Stabilizer Bar Correctly Positioned In Cradle in t h e figu r e (F ig. 38).
1 - RAISED BEAD
E a ch com pon en t is ser viced by r em ovin g t h e st r u t
2 - SWAY BAR a ssem bly fr om t h e veh icle a n d disa ssem blin g it .
3 - WHEN INSTALLING SWAY BAR THE RAISED BEAD ON THE Th e coil spr in gs a r e side-or ien t ed. Spr in gs on t h e
SUSPENSION CRADLE MUST BE IN THE CENTER OF RADIUS
IN SWAY BAR left side of t h e veh icle h a ve a left -h a n d win d t op-t o-
4 - FRONT SUSPENSION CRADLE bot t om wh ile spr in gs on t h e r igh t side h a ve a r igh t -
h a n d win d t op-t o-bot t om . Th is h elps pr ovide bet t er
(4) In st a ll t h e st a bilizer ba r lin k m ou n t in g st u d veh icle st a bilit y du r in g jou n ce a n d r ebou n d m a n eu -
t h r ou gh t h e h ole in ea ch en d of t h e st a bilizer ba r ver s of t h e fr on t su spen sion . Left a n d r igh t spr in gs
(F ig. 33). m u st n ot be in t er ch a n ged. Coil spr in gs a r e r a t ed sep-
a r a t ely for ea ch cor n er or side of t h e veh icle depen d-
CAUTION: When installing the nut on the mounting in g on opt ion a l equ ipm en t a n d t ype of veh icle
stud of the stabilizer bar link, do not allow the stud ser vice. If t h e coil spr in gs r equ ir e r epla cem en t , be
to rotate in it’s socket. Hold the stud from rotating su r e t h a t t h e spr in gs a r e r epla ced wit h spr in gs m eet -
by placing an open-end wrench on the flat in g t h e cor r ect loa d r a t in g a n d spr in g r a t e for t h e
machined into the stud (Fig. 33). veh icle a n d it s specific opt ion s.
(5) H a n d-t h r ea d t h e n u t on t h e en d of ea ch st a bi-
lizer ba r lin k st u d. H old t h e st u ds fr om t u r n in g by
OPERATION - STRUT ASSEMBLY
pla cin g a n open -en d wr en ch on t h e fla t m a ch in ed Th e st r u t a ssem bly cu sh ion s t h e r ide of t h e veh icle,
in t o t h e lin k’s m ou n t in g st u d, t h en t igh t en ea ch n u t con t r ollin g vibr a t ion , a lon g wit h jou n ce a n d r ebou n d
wh ile h oldin g t h e wr en ch in pla ce (F ig. 33). Tigh t en of t h e su spen sion .
ea ch n u t t o a t or qu e of 88 N·m (65 ft . lbs.). Th e coil spr in g con t r ols r ide qu a lit y a n d m a in t a in s
(6) Tigh t en t h e st a bilizer ba r bu sh in g r et a in er t o pr oper r ide h eigh t .
cr a dle a t t a ch in g bolt s (F ig. 34) t o 68 N·m (50 ft . lbs.) Th e spr in g isola t or s isola t e t h e coil spr in g a t t h e
t or qu e. t op a n d bot t om fr om com in g in t o m et a l-t o-m et a l con -
(7) In st a ll t h e r ein for cem en t on t h e fr on t su spen - t a ct wit h t h e u pper sea t a n d st r u t .
sion cr a dle cr ossm em ber a n d in st a ll t h e bolt s a t t a ch - Th e jou n ce bu m per lim it s su spen sion t r a vel a n d
in g t h e r ein for cem en t t o t h e cr a dle cr ossm em ber m et a l-t o-m et a l con t a ct u n der fu ll jou n ce con dit ion .
(F ig. 32). Tigh t en t h e M-14 size bolt s t o a t or qu e of Th e st r u t da m pen s jou n ce a n d r ebou n d m ot ion s of
153 N·m (113 ft . lbs.). Tigh t en t h e M-12 size bolt s t o t h e coil spr in g a n d su spen sion .
a t or qu e of 106 N·m (78 ft . lbs.). Du r in g st eer in g m a n eu ver s, t h e st r u t a ssem bly
(8) In st a ll t h e lower con t r ol a r m r ea r bu sh in g (t h r ou gh a pivot bea r in g in t h e u pper st r u t m ou n t )
r et a in er bolt s t h r ou gh r ein for cem en t on ea ch side of a n d st eer in g kn u ckle (t h r ou gh t h e lower ba ll join t )
ea ch lower con t r ol a r m r ea r bu sh in g. Tigh t en t h ese t u r n a s a n a ssem bly.
M-10 size bolt s t o a t or qu e of 61 N·m (45 ft . lbs.).
ST RU T (Cont inue d)
Fig. 38 STRUT ASSEMBLY

1 - NUT 6 - COIL SPRING
2 - UPPER MOUNT 7 - DUST SHIELD
3 - PIVOT BEARING 8 - JOUNCE BUMPER
4 - UPPER SPRING SEAT 9 - LOWER SPRING ISOLATOR
5 - UPPER SPRING ISOLATOR 10 - STRUT (DAMPER)
DIAGNOSIS AND TESTING - STRUT ASSEMBLY

(1) In spect for da m a ged or br oken coil spr in gs
(F ig. 38).
(2) In spect for t or n or da m a ged st r u t a ssem bly
du st boot s (F ig. 38).
(3) In spect t h e coil spr in g isola t or on t h e lower
spr in g sea t for a n y sign s of da m a ge or det er ior a t ion .
(4) Lift du st boot (F ig. 39) a n d in spect st r u t
a ssem bly for eviden ce of flu id r u n n in g fr om t h e
u pper en d of flu id r eser voir. (Act u a l lea ka ge will be a
st r ea m of flu id r u n n in g down t h e side a n d dr ippin g
off lower en d of u n it ). A sligh t a m ou n t of seepa ge
bet ween t h e st r u t r od a n d st r u t sh a ft sea l is n ot
u n u su a l a n d does n ot a ffect per for m a n ce of t h e st r u t
a ssem bly (F ig. 39). Also in spect jou n ce bu m per s for
sign s of da m a ge or det er ior a t ion .
Fig. 39 Strut Assembly Leakage Inspection (Typical)
REMOVAL - STRUT ASSEMBLY 1 - DUST BOOT
2 - STRUT SHAFT
WARNING: DO NOT REMOVE THE NUT FROM THE 3 - STRUT FLUID RESERVOIR
4 - INSPECT THIS AREA FOR EVIDENCE OF EXCESSIVE FLUID
STRUT ROD WHILE STRUT ASSEMBLY IS LEAKAGE
INSTALLED IN VEHICLE, OR BEFORE STRUT
ASSEMBLY SPRING IS COMPRESSED. (1) Ra ise t h e veh icle. See H oist in g in Lu br ica t ion
a n d Ma in t en a n ce.
(2) Rem ove t h e wh eel a n d t ir e a ssem bly fr om loca -
t ion on fr on t of veh icle r equ ir in g st r u t r em ova l.
(3) If bot h st r u t a ssem blies a r e t o be r em oved,
m a r k t h e st r u t a ssem blies r igh t or left a ccor din g t o
wh ich side of t h e veh icle t h ey wer e r em oved fr om .
(4) Rem ove t h e h ydr a u lic br a ke h ose r ou t in g
br a cket a n d t h e speed sen sor ca ble r ou t in g br a cket
fr om t h e st r u t da m per br a cket s (F ig. 40).
Fig. 41 Stabilizer Bar Link To Strut Attachment

1 - NUT
2 - STRUT
3 - STABILIZER BAR LINK
Fig. 40 Brake Hose And Speed Sensor Cable

Routing
1 - STRUT DAMPER
2 - WHEEL SPEED SENSOR CABLE
3 - ROUTING BRACKET
4 - HYDRAULIC BRAKE HOSE
5 - ATTACHING BOLT
6 - ROUTING BRACKET
CAUTION: When removing the nut from the stud of

the stabilizer bar link, do not allow the stud to
rotate in it’s socket. Hold the stud from rotating by
placing an open-end wrench on the flat machined
into the stud (Fig. 41). Fig. 42 Strut Damper Attachment To Steering
Knuckle
(5) Rem ove t h e st a bilizer ba r lin k fr om t h e br a cket
on t h e st r u t a ssem bly (F ig. 41). To do so, pla ce a n 1 - STRUT CLEVIS BRACKET
2 - ATTACHING BOLTS
open -en d wr en ch on t h e fla t m a ch in ed in t o t h e lin k’s 3 - TIE ROD END
m ou n t in g st u d, t h en r em ove t h e n u t wh ile h oldin g 4 - ROTOR
t h e wr en ch in pla ce. P u sh t h e st u d ou t of t h e 5 - STEERING KNUCKLE
br a cket .
DISASSEMBLY - STRUT ASSEMBLY
CAUTION: The steering knuckle to strut assembly Th e st r u t a ssem bly m u st be r em oved fr om t h e
attaching bolts are serrated and must not be turned veh icle for it t o be disa ssem bled a n d a ssem bled.
during removal. Remove nuts while holding bolts F or t h e disa ssem bly a n d a ssem bly of t h e st r u t
stationary in the steering knuckles. a ssem bly, u se of St r u t Spr in g Com pr essor, P en t a st a r
Ser vice E qu ipm en t (P SE ) t ool W-7200, or t h e equ iva -
(6) Rem ove t h e 2 st r u t a ssem bly clevis br a cket t o len t , is r ecom m en ded t o com pr ess t h e coil spr in g.
st eer in g kn u ckle a t t a ch in g bolt s (F ig. 42). F ollow t h e m a n u fa ct u r er ’s in st r u ct ion s closely.
(7) Rem ove t h e 3 n u t s a t t a ch in g t h e st r u t a ssem -
bly u pper m ou n t t o t h e st r u t t ower (F ig. 43) a n d
r em ove t h e st r u t a ssem bly fr om t h e veh icle.
(8) To disa ssem ble t h e st r u t a ssem bly, (Refer t o 2 -
SUSP E NSION/F RONT/STRUT - DISASSE MBLY).
Fig. 43 Strut Assembly To Strut Tower Attaching

Nuts (Typical)
1 - WINDSHIELD WIPER MODULE
2 - STRUT TOWER
3 - STRUT MOUNT ATTACHING BOLTS
4 - UPPER STRUT MOUNT Fig. 44 Mount Rotated And Hooks Positioned
1 - UPPER MOUNT TURNED TOWARD COMPRESSOR
WARNING: DO NOT REMOVE THE STRUT SHAFT 2 - COMPRESSOR UPPER HOOKS
3 - UPPER SPRING SEAT
NUT BEFORE THE COIL SPRING IS COMPRESSED.
THE COIL SPRING IS HELD UNDER PRESSURE
AND MUST BE COMPRESSED, REMOVING SPRING
TENSION FROM THE UPPER MOUNT AND PIVOT
BEARING, BEFORE THE SHAFT NUT IS REMOVED.
(1) P osit ion t h e st r u t a ssem bly in t h e st r u t coil

spr in g com pr essor followin g t h e m a n u fa ct u r er s
in st r u ct ion s. P osit ion t h e lower h ooks on t h e coil
spr in g fir st . Th e st r u t clevis br a cket sh ou ld be posi-
t ion ed st r a igh t ou t wa r d fr om t h e com pr essor.
(2) Tu r n t h e u pper m ou n t of t h e st r u t a ssem bly
t owa r d t h e in side of t h e com pr essor a s sh own t o
a llow posit ion in g of t h e com pr essor u pper h ooks (F ig.
44). P osit ion t h e u pper h ooks on t op of t h e coil spr in g
u pper sea t a ppr oxim a t ely 1 in ch fr om ou t side dia m e-
t er of sea t (F ig. 47). D o n o t a llo w h o o k s to be
p la c e d c lo s e r to e d g e . P la ce a cla m p on t h e lower
en d of t h e coil spr in g, so t h e st r u t is h eld in pla ce
on ce t h e st r u t sh a ft n u t is r em oved.
(3) Com pr ess t h e coil spr in g u n t il a ll coil spr in g
Fig. 45 Retaining Nut Removal/Installation (Typical)
t en sion is r em oved fr om t h e u pper m ou n t .
(4) In st a ll St r u t Nu t Socket , Specia l Tool 6864, on 1 - UPPER MOUNT
2 - SPECIAL TOOL 6864
t h e st r u t sh a ft r et a in in g n u t (F ig. 45). Next , in st a ll a
10 m m socket on t h e h ex on t h e en d of t h e st r u t NOTE: If the coil spring or upper spring seat needs
sh a ft . Wh ile h oldin g t h e st r u t sh a ft fr om t u r n in g, to be serviced, proceed with the next step, other-
r em ove t h e n u t fr om t h e st r u t sh a ft . wise, proceed with step 10.
(5) Rem ove t h e u pper m ou n t fr om t h e st r u t sh a ft .
(6) If t h e pivot bea r in g n eeds t o be ser viced, (8) Relea se t h e t en sion fr om t h e coil spr in g by
r em ove it fr om t h e t op of t h e coil spr in g u pper sea t ba ckin g off t h e com pr essor dr ive fu lly. P u sh ba ck t h e
by pu llin g it st r a igh t u p. com pr essor u pper h ooks a n d r em ove t h e u pper spr in g
(7) Rem ove t h e cla m p fr om t h e bot t om of t h e coil sea t wit h u pper spr in g isola t or.
spr in g a n d r em ove t h e st r u t ou t t h r ou gh t h e bot t om (9) Rem ove t h e coil spr in g fr om t h e spr in g com -
of t h e coil spr in g. pr essor.
(10) Rem ove t h e du st sh ield a n d jou n ce bu m per a s
a n a ssem bly fr om t h e st r u t sh a ft by pu llin g bot h
st r a igh t u p a n d off t h e st r u t sh a ft . Th e du st sh ield
ca n n ot be sepa r a t ed fr om t h e jou n ce bu m per u n t il
a ft er it is r em oved fr om st r u t sh a ft .
(11) Rem ove t h e jou n ce bu m per fr om t h e du st
sh ield. Th e jou n ce bu m per is r em oved fr om t h e du st
sh ield by colla psin g t h e du st sh ield u n t il t h e jou n ce
bu m per ca n be pu lled fr ee fr om t h e du st boot .
(12) Rem ove t h e spr in g isola t or fr om t h e lower
spr in g sea t on t h e st r u t (F ig. 38).
(13) In spect t h e st r u t a ssem bly com pon en t s (F ig.
38) for t h e followin g a n d r epla ce a s n ecessa r y:
• In spect t h e st r u t for a n y con dit ion of sh a ft bin d-
in g over t h e fu ll st r oke of t h e sh a ft .
• Ch eck t h e u pper m ou n t for cr a cks a n d dist or t ion
a n d it s r et a in in g st u ds for a n y sign of da m a ge. Fig. 46 Spring Positioned In Compressor (Right
• Ch eck t h e u pper sea t for st r ess cr a cks a n d wea r. Spring Shown)
• Ch eck t h e u pper spr in g isola t or for sever e det e- 1 - COMPRESSOR LOWER HOOKS
r ior a t ion . 2 - COIL SPRING END
• Ch eck for bin din g of t h e st r u t a ssem bly pivot
bea r in g. (2) In st a ll t h e u pper sea t a n d u pper isola t or on t op
• In spect t h e du st sh ield for r ips a n d det er ior a - of t h e coil spr in g. P osit ion t h e n ot ch in t h e per im et er
t ion . of t h e u pper sea t t owa r d t h e fr on t of t h e com pr essor
• In spect t h e jou n ce bu m per for cr a cks a n d sign s (sa m e 6 o’clock posit ion a s in st ep 1).
of det er ior a t ion . (3) P osit ion t h e u pper h ooks on t op of t h e coil
spr in g u pper sea t so t h e u pper h ooks spa n a ppr oxi-
ASSEMBLY - STRUT ASSEMBLY m a t ely 1 in ch pa st ou t side dia m et er of u pper sea t
F or t h e disa ssem bly a n d a ssem bly of t h e st r u t (F ig. 47). Th is will a llow pr oper clea r a n ce for u pper
a ssem bly, u se of St r u t Spr in g Com pr essor, P en t a st a r m ou n t in st a lla t ion wit h ou t pin ch in g t h e h ooks in -be-
Ser vice E qu ipm en t (P SE ) t ool W-7200, or t h e equ iva - t ween t h e t wo pieces. D o n o t a llo w h o o k s to be
len t , is r ecom m en ded t o com pr ess t h e coil spr in g. p la c e d c lo s e r to e d g e .
F ollow t h e m a n u fa ct u r er ’s in st r u ct ion s closely.
NOTE: Coil Springs on this vehicle are side-ori-

ented. Springs on the left side of the vehicle have a
left-hand wind top-to-bottom while springs on the
right side have a right-hand wind top-to-bottom.
Left and right springs must not be interchanged.
NOTE: If the coil spring has been removed from the

spring compressor, proceed with the next step, oth-
erwise, proceed with step 5.
(1) P la ce t h e coil spr in g in t h e com pr essor lower

h ooks followin g t h e m a n u fa ct u r er s in st r u ct ion s.
P r oper or ien t a t ion of t h e spr in g t o t h e st r u t (on ce
in st a lled) is n ecessa r y. Con sider t h e followin g wh en
pla cin g t h e coil spr in g in t h e com pr essor : F r om Fig. 47 Hook Placement On Upper Seat
a bove, t h e com pr essor ba ck is a t t h e 12 o’clock posi- 1 - HOOKS POSITIONED 1 INCH FROM EDGE
t ion , a n d you , st a n din g in t h e fr on t of t h e com pr es- 2 - PIVOT BEARING AND UPPER SEAT
sor, a r e a t t h e 6 o’clock posit ion . P la ce t h e lower coil
(4) Com pr ess t h e coil spr in g fa r en ou gh t o a llow
spr in g en d a t t h e 12 o’clock posit ion for left spr in gs
st r u t in st a lla t ion .
a n d a t t h e 6 o’clock posit ion for r igh t spr in gs. (F ig.
(5) If t h e pivot bea r in g h a s been r em oved fr om t h e
46).
u pper sea t , in st a ll t h e pivot bea r in g on t h e t op of t h e
u pper spr in g sea t (F ig. 48). Th e bea r in g m u st be
in st a lled on u pper sea t wit h t h e sm a ller dia m et er
side of t h e pivot bea r in g t owa r d t h e spr in g sea t . Be
su r e t h e pivot bea r in g is sit t in g fla t on t h e spr in g
sea t on ce m ou n t ed.
Fig. 49 Coil Spring Positioning

1 - END OF LEFT COIL SPRING AT STRUT LOWER SEAT
2 - END OF RIGHT COIL SPRING AT STRUT LOWER SEAT
3 - LOWER SEATS OF STRUTS
4 - RIGHT STRUT CLEVIS BRACKET
5 - LEFT STRUT CLEVIS BRACKET
Fig. 48 Pivot Bearing Installation
NOTE: Before releasing the tension the compressor
1 - PIVOT BEARING
2 - UPPER SEAT
has on the spring, using the following figure as ref-
erence (Fig. 50), make sure the upper spring seat,
(6) In st a ll t h e spr in g isola t or on t h e lower spr in g coil spring and strut clevis bracket are all lined up
sea t of t h e st r u t (F ig. 38). properly (within 5° of one another).
(7) In st a ll t h e jou n ce bu m per on t h e st r u t sh a ft
(F ig. 38). Th e jou n ce bu m per is t o be in st a lled wit h
t h e sm a ll en d poin t in g down wa r d.
(8) In st a ll t h e du st sh ield on t h e st r u t . Colla pse
a n d st r et ch t h e du st sh ield down over t h e t op of t h e
jou n ce bu m per u n t il t h e du st sh ield sn a ps in t o t h e
slot on t h e jou n ce bu m per. Th e jou n ce bu m per will be
a t t h e t op of t h e in n er du st boot . Ret u r n t h e du st
sh ield t o it s fu lly ext en ded len gt h .
(9) In st a ll t h e st r u t t h r ou gh t h e bot t om of t h e coil
spr in g u n t il t h e lower spr in g sea t con t a ct s t h e lower
en d of t h e coil spr in g. Th e clevis br a cket on t h e st r u t
sh ou ld poin t st r a igh t ou t wa r d a wa y fr om t h e com -
pr essor (t o t h e 6 o’clock posit ion ). If n ecessa r y, r epo-
sit ion t h e st r u t or coil spr in g in t h e com pr essor so
t h e st r u t clevis br a cket lin es u p wit h t h e lower coil
spr in g en d a s in dica t ed in t h e figu r e (F ig. 49). In st a ll
t h e cla m p t o h old t h e st r u t a n d coil spr in g t oget h er.
(10) In st a ll t h e st r u t m ou n t over t h e st r u t sh a ft
a n d on t o t h e t op of t h e pivot bea r in g a n d u pper sea t
a s sh own (F ig. 44). Loosely in st a ll t h e r et a in in g n u t
on t h e st r u t sh a ft .
(11) In st a ll St r u t Nu t Socket (on t h e en d of a Fig. 50 Components Lined Up
t or qu e wr en ch ), Specia l Tool 6864, on t h e st r u t sh a ft 1 - IMAGINARY VERTICAL LINE
r et a in in g n u t (F ig. 45). Next , in st a ll a 10 m m socket 2 - CLEVIS BRACKET
on t h e h ex on t h e en d of t h e st r u t sh a ft . Wh ile h old- 3 - END OF COIL SPRING (RIGHT SIDE ONLY)
4 - NOTCH IN UPPER SPRING SEAT
in g t h e st r u t sh a ft fr om t u r n in g, t igh t en t h e st r u t
sh a ft r et a in in g n u t t o a t or qu e of 100 N·m (75 ft .
lbs.).
(12) Slowly r elea se t h e t en sion fr om t h e coil spr in g (2) Align st r u t a ssem bly wit h st eer in g kn u ckle.
by ba ckin g off t h e com pr essor dr ive fu lly. As t h e t en - P osit ion a r m of st eer in g kn u ckle in t o st r u t a ssem bly
sion is r elieved, m a ke su r e t h e u pper m ou n t , pivot clevis br a cket . Align t h e st r u t a ssem bly clevis
bea r in g a n d u pper sea t a r e a lign pr oper ly. Rem ove br a cket m ou n t in g h oles wit h t h e st eer in g kn u ckle
t h e cla m p fr om t h e lower en d of t h e coil spr in g a n d m ou n t in g h oles. In st a ll t h e 2 st r u t a ssem bly t o st eer-
st r u t . P u sh ba ck t h e spr in g com pr essor u pper a n d in g kn u ckle a t t a ch in g bolt s (F ig. 42). If s tru t a s s e m -
lower h ooks, t h en r em ove t h e st r u t a ssem bly fr om bly is a tta c h e d to s te e rin g k n u c k le u s in g a c a m
t h e spr in g com pr essor. bo lt, th e c a m bo lt m u s t be in s ta lle d in th e lo w e r
(13) In st a ll st r u t a ssem bly on t h e veh icle. (Refer t o s lo tte d h o le o n s tru t c le v is bra c k e t. Tigh t en t h e
2 - SUSP E NSION/F RONT/STRUT - INSTALLA- st r u t clevis-t o-st eer in g kn u ckle a t t a ch in g bolt s t o a
TION) t or qu e of 81 N·m (60 ft . lbs.) plu s a n a ddit ion a l 1/4
(90°) t u r n a ft er specified t or qu e is m et .
INSTALLATION - STRUT ASSEMBLY (3) In st a ll t h e st a bilizer ba r lin k m ou n t in g st u d
t h r ou gh t h e br a cket on t h e st r u t a ssem bly (F ig. 41).
CAUTION: Front strut coil springs are side-oriented.
When installing a strut assembly, make sure the CAUTION: When installing the nut on the mounting
strut being installed has the correct coil spring for stud of the stabilizer bar link, do not allow the stud
that side of the vehicle. Springs on the left side of to rotate in it’s socket. Hold the stud from rotating
the vehicle have a left-hand wind top-to-bottom by placing an open-end wrench on the flat
while springs on the right side have a right-hand machined into the stud (Fig. 41).
wind top-to-bottom (Fig. 49). Do not interchange the
two sides. (4) H a n d t h r ea d t h e n u t on t h e en d of t h e st a bi-
lizer ba r lin k st u d. H old t h e st u d fr om t u r n in g by
(1) In st a ll st r u t a ssem bly in t o st r u t t ower, a lign in g pla cin g a n open -en d wr en ch on t h e fla t m a ch in ed
a n d in st a llin g t h e 3 st u ds on t h e u pper st r u t m ou n t in t o t h e lin k’s m ou n t in g st u d, t h en t igh t en t h e n u t
in t o t h e h oles in sh ock t ower. In st a ll t h e 3 u pper wh ile h oldin g t h e wr en ch in pla ce (F ig. 41). Tigh t en
st r u t m ou n t a t t a ch in g n u t /wa sh er a ssem blies (F ig. t h e n u t t o a t or qu e of 88 N·m (65 ft . lbs.).
43). Th en u sin g a cr ow foot . t igh t en t h e 3 a t t a ch in g (5) In st a ll t h e h ydr a u lic br a ke h ose a n d speed sen -
n u t s t o a t or qu e of 28 N·m (250 in . lbs.). sor ca ble r ou t in g br a cket s on t h e st r u t a ssem bly
br a cket s (F ig. 40). Tigh t en t h e r ou t in g br a cket
CAUTION: The steering knuckle to strut assembly a t t a ch in g bolt s t o a t or qu e of 13 N·m (10 ft . lbs.).
attaching bolts are serrated and must not be turned (6) In st a ll t h e wh eel/t ir e a ssem bly on t h e veh icle.
during installation. Install nuts while holding bolts (7) In st a ll a n d t igh t en t h e wh eel m ou n t in g st u d
stationary in the steering knuckles. n u t s in pr oper sequ en ce u n t il a ll n u t s a r e t or qu ed t o
h a lf specifica t ion . Th en r epea t t h e t igh t en in g
sequ en ce t o t h e fu ll specified t or qu e of 135 N·m (100
NOTE: The strut clevis-to-steering knuckle bolts are ft . lbs.).
installed differently on each side of the vehicle. Left
hand side bolts are to be installed from vehicle rear
to front. Right side bolts are to be installed from
vehicle front to rear.
2 - 26 REAR SUSPENSION RS
REAR SU SPEN SI ON
TABLE OF CONTENTS
page page
REAR SUSPENSION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 39

DESCRIPTION - REAR SUSPENSION ..... . . 26 SPRING - CARGO
SPECIFICATIONS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
REAR SUSPENSION FASTENER TORQUE . . 28 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 40
SPECIAL TOOLS SPRING - FWD
REAR SUSPENSION . . . . . . . . . . . . . . . . . . . 28 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
BUSHING - LEAF SPRING FRONT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 42
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 SPRING MOUNTS - FRONT
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 30 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
HUB / BEARING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 43
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 30 SPRING MOUNTS - REAR
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
DIAGNOSIS AND TESTING - HUB AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 43
BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 SPRING SHACKLE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 33 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 44
JOUNCE BUMPER STABILIZER BAR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 35 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 44
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
REMOVAL REMOVAL
REMOVAL - AWD, HEAVY DUTY, CARGO . . . 36 REMOVAL - AWD . . . . . . . . . . . . . . . . . . . . . . 44
REMOVAL - FRONT-WHEEL-DRIVE ..... . . 36 REMOVAL - FWD ................. . . . . 45
INSTALLATION REMOVAL - FWD - FOLD-IN-FLOOR
INSTALLATION - AWD, HEAVY DUTY, SEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
CARGO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 INSTALLATION
INSTALLATION - FRONT-WHEEL-DRIVE . . . . 36 INSTALLATION - AWD . . . . . . . . . . . . . . . . . . 45
SHOCK ABSORBER INSTALLATION - FWD . . . . . . . . . . . . . . . . . . 45
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 36 INSTALLATION - FWD - FOLD-IN-FLOOR
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 SEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
REMOVAL - SHOCK ABSORBER . . . . . . . . . . . 36 TRACK BAR
DISASSEMBLY - SHOCK ABSORBER (UPPER DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 45
BUSHING) . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
ASSEMBLY - SHOCK ABSORBER (UPPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
BUSHING) . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 46
INSTALLATION - SHOCK ABSORBER . . . . . . . . 38
SPRING - AWD
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
REAR SU SPEN SI ON • F r on t -Wh eel-Dr ive

• F r on t -Wh eel-Dr ive wit h F old-in -F loor Sea t in g
• All-Wh eel-Dr ive
DESCRIPTION - REAR SUSPENSION
• F r on t -Wh eel-Dr ive Com m er cia l
Th e r ea r su spen sion design on t h is veh icle u ses
Th e F r on t -Wh eel-Dr ive (F WD) r ea r su spen sion
lea f spr in gs, a n d a t u be a n d ca st in g a xle (F ig. 1) (F ig.
u ses a n a xle t h a t is m ou n t ed t o m on o-lea f spr in gs
2). Th e lea f spr in gs u sed on t h e r ea r su spen sion of
u sin g isola t or bu sh in gs a t t h e a xle m ou n t in g br a ck-
t h is veh icle a r e of eit h er a m on o-lea f or m u lt i-lea f
et s. Th e st a bilizer ba r m ou n t s beh in d t h e a xle.
design .
Th er e a r e fou r differ en t r ea r su spen sion design s
a va ila ble:
RS REAR SUSPENSION 2 - 27
REAR SU SPEN SI ON (Cont inue d)
Fig. 1 Front-Wheel-Drive Rear Suspension

1 - SHACKLE 7 - LEAF SPRING (MONO-LEAF)
2 - REAR MOUNT (HANGER) 8 - ISOLATOR
3 - TRACK BAR 9 - FWD REAR AXLE
4 - SPRING PLATE 10 - STABILIZER BAR LINKS
5 - ISOLATOR 11 - STABILIZER BAR
6 - FRONT MOUNT (HANGER)
pen sion except for t h e fa ct t h a t t h e st a bilizer ba r

m ou n t s in fr om of t h e a xle.
Th e All-Wh eel-Dr ive (AWD) r ea r su spen sion u ses a
u n iqu e a xle t h a t is m ou n t ed t o m u lt i-lea f spr in gs,
a n d does n ot u se isola t or bu sh in gs bet ween t h e r ea r
a xle a n d t h e lea f spr in gs.
Th e F r on t -Wh eel-Dr ive Ca r go r ea r su spen sion u ses
m u lt i-lea f spr in gs a n d a differ en t r ea r a xle t h a n
eit h er t h e st a n da r d F WD or AWD. It a lso does n ot
u t ilize a st a bilizer ba r. It is ver y sim ila r ly t o t h e
AWD su spen sion .
Th e r ea r su spen sion con sist s of t h ese m a jor com po-
n en t s:
• Lea f spr in gs (On e ea ch side)
• J ou n ce bu m per s (On e ea ch side)
• Sh ock a bsor ber s (On e ea ch side)
Fig. 2 All-Wheel-Drive Rear Suspension • H u b a n d bea r in gs (On e ea ch side)
1 - SHACKLE • Tr a ck ba r
2 - REAR MOUNT (HANGER) • St a bilizer ba r
3 - LEAF SPRING (MULTI-LEAF)
4 - AWD REAR AXLE
Th e F r on t -Wh eel-Dr ive wit h F old-in -F loor Sea t in g

r ea r su spen sion is ver y m u ch like t h e F WD r ea r su s-
REAR SU SPEN SI ON (Cont inue d)
SPECI FI CAT I ON S SPECI AL T OOLS

REAR SUSPENSION FASTENER TORQUE REAR SUSPENSION
Ft. In.
DESCRIPTION N·m
Lbs. Lbs.
Hub And Bearing Mounting
129 95 —
Bolts
Hub And Bearing Axle Hub
244 180 —
Nut
Jounce Bumper Mounting
33 24 290
Bolt
Leaf Spring Front Mount-To- Remover, Hub/Bearing 8458
61 45 —
Body Bolts
Leaf Spring Front Pivot Bolt 156 115 —
Leaf Spring Plate-To-Axle
95 70 —
Bolts
Leaf Spring Rear Mount-To-
61 45 —
Body Bolts
Leaf Spring Shackle Plate
61 45 —
Nuts
Shock Absorber Mounting
88 65 — Remover/Installer, Bushing 8459
Bolts
Stabilizer Bar Bushing
61 45 —
Retainer Bolts
Stabilizer Bar Link Nuts 61 45 —
Stabilizer Bar Link Frame
61 45 —
Bracket Mounting Bolts
Track Bar Bracket-To-Body
61 45 —
Mount Bolts
Track Bar Pivot Bolts 95 70 —
Wheel Mounting (Lug) Nut 135 100 —
Remover/Installer, Bushing 8526
Press, Ball Joint C-4212F

BU SH I N G - LEAF SPRI N G be n ecessa r y t o pla ce a wooden block bet ween t h e

spr in g a n d veh icle t o h old for wa r d en d of t h e spr in g
FRON T in pla ce.
(6) Rem ove lea f spr in g for wa r d pivot bolt , t h en
REMOVAL r em ove m ou n t in g br a cket .
(1) Ra ise veh icle on fr a m e-con t a ct h oist a s follows: (7) St r a igh t en t h e r et a in er t a bs on t h e bu sh in g
(a ) P osit ion t h e h oist a r m su ppor t in g t h e cor n er (F ig. 4).
of t h e veh icle t o be ser viced a ga in st a block of wood
pla ced on t h e body sill a s sh own (F ig. 3).
(b) P osit ion t h e r em a in in g h oist a r m s a t ea ch
cor n er of t h e veh icle in t h e n or m a l fa sh ion . (Refer
t o LUBRICATION & MAINTE NANCE /H OISTING
- STANDARD P ROCE DURE )
(c) Ra ise t h e veh icle t o a com for t a ble wor kin g
level.
Fig. 4 Straightened Retaining Tabs

1 - SPRING EYE
2 - RETAINING TABS
(8) P la ce Rem over /In st a ller, Specia l Tool 8459 on

lea f spr in g a n d bu sh in g a s sh own (F ig. 5) a n d t igh t en
Set Scr ew secu r in g Rem over P la t e t o t ool t h r ea ded
sh a ft .
Fig. 3 Lifting Point And Spring Mount

1 - BODY SILL AREA
2 - MOUNTING BOLTS
3 - SPRING MOUNTING BRACKET
4 - LEAF SPRING
5 - HOIST LIFT ARM
6 - WOODEN BLOCK
(2) P osit ion a n u n der-h oist u t ilit y ja ck or t r a n sm is-

sion ja ck u n der r ea r a xle t owa r d t h e side n eedin g
bu sh in g r epla cem en t . J a ck pa d sh ou ld ju st con t a ct
a xle.
(3) Rem ove sh ock a bsor ber lower m ou n t in g bolt .
NOTE: If shock absorber bolt deflects upward dur-

ing removal, raise axle by adjusting support jack. If
shock absorber bolt deflects downward during
removal, lower axle by adjusting support jack (or by Fig. 5 Tool 8459 Mounted For Bushing Removal
pulling on axle). 1 - BUSHING
2 - BEARING
3 - WASHER
(4) Rem ove fou r bolt s secu r in g lea f spr in g fr on t 4 - NUT
m ou n t in g br a cket t o t h e body (F ig. 3). 5 - BODY (8459-1)
(5) Usin g ja ck, s lo w ly lower r ea r a xle, per m it t in g 6 - PIN
7 - REMOVER PLATE (8459-2)
t h e for wa r d en d of r ea r spr in g t o h a n g down . Lower 8 - SET SCREW
it en ou gh t o a llow a ccess t o spr in g pivot bolt . It m a y
BU SH I N G - LEAF SPRI N G FRON T (Cont inue d)
(9) Tigh t en n u t (F ig. 5), r em ovin g bu sh in g fr om (7) In st a ll t h e n u t on t h e pivot bolt a n d ligh t ly
spr in g eye. t igh t en . Do n ot fu lly t igh t en bolt a t t h is t im e.
(10) Rem ove t h e t ool fr om spr in g, t h en r em ove (8) Ra ise t h e u n der-h oist u t ilit y ja ck or t r a n sm is-
bu sh in g fr om t ool. sion ja ck, gu idin g t h e for wa r d m ou n t in g br a cket in t o
pla ce a ga in st t h e body. It m a y h elp t o u se a dr ift
INSTALLATION pu n ch pla ced t h r ou gh t h e h ole cen t er ed bet ween t h e
(1) In st a ll by h a n d NE W bu sh in g in left side of m ou n t in g bolt h oles in t h e br a cket a n d t h e pilot h ole
lea f spr in g eye. in t h e body of t h e veh icle a s a gu ide. Wh en t h e fou r
(2) P la ce Rem over /In st a ller, Specia l Tool 8459 on m ou n t in g bolt h oles lin e u p wit h t h eir t h r ea ds in t h e
lea f spr in g a n d bu sh in g a s sh own (F ig. 6) a n d t igh t en body, In st a ll t h e m ou n t in g bolt s (F ig. 3). Tigh t en t h e
Set Scr ew secu r in g In st a ller P la t e (8459–3) t o t ool fou r m ou n t in g bolt s t o 61 N·m (45 ft . lbs.) t or qu e.
t h r ea ded sh a ft . (9) Ra ise or lower t h e ja ck u n t il sh ock a bsor ber
lower eye a lign s wit h t h r ea ds in a xle h ou sin g. In st a ll
sh ock a bsor ber lower m ou n t in g bolt . Do n ot fu lly
t igh t en bolt a t t h is t im e.
(10) Lower t h e veh icle a n d r em ove h oist a r m s a n d
block of wood fr om u n der veh icle.
(11) Tigh t en t h e spr in g fr on t pivot bolt t o 156 N·m
(12) Tigh t en t h e lower sh ock a bsor ber m ou n t in g
bolt t o 88 N·m (65 ft . lbs.) t or qu e.
H U B / BEARI N G
DESCRIPTION
Th e r ea r wh eel bea r in g a n d r ea r wh eel h u b of t h is
veh icle a r e a on e-piece sea led u n it , or h u b a n d bea r-
in g u n it t ype a ssem bly (Un it III). Th e h u b a n d bea r-
in g is m ou n t ed t o t h e cen t er of t h e r ea r a xle u sin g 4
m ou n t in g bolt s. It h a s five wh eel m ou n t in g st u ds on
t h e h u b fla n ge.
Fig. 6 Tool 8459 Mounted For Bushing Installation
All-Wh eel-Dr ive veh icles h a ve a h u b a n d bea r in g
1 - NUT
2 - WASHER
u n it wit h a splin ed h ole in t h e cen t er of t h e h u b for
3 - BEARING r ea r dr ivesh a ft st u b a xle a ccept a n ce.
4 - LEAF SPRING EYE F r on t -Wh eel-Dr ive veh icles wit h a n t ilock br a kes
5 - BUSHING
6 - INSTALLER PLATE (8459-3)
h a ve a n in t er n a lly m ou n t ed wh eel speed sen sor a n d
7 - PIN t on e wh eel. Th is h u b a n d bea r in g ca n be iden t ified
8 - BODY (8459-1) by t h e r ou n ded ca p a n d m olded in con n ect or on t h e
r ea r of t h e a ssem bly (F ig. 7). Th e sen sor a n d t on e
(3) Tigh t en n u t (F ig. 6), in st a llin g bu sh in g in wh eel ca n n ot be ser viced sepa r a t ely fr om t h e h u b
spr in g eye. Tigh t en n u t u n t il t h er e is a ppr oxim a t ely a n d bea r in g.
a 1 m m ga p bet ween t h e bu sh in g fla n ge a n d t h e
spr in g eye. D o n o t bo tto m th e fla n g e a g a in s t th e OPERATION
s p rin g e y e . Th e h u b a n d bea r in g h a s in t er n a l bea r in gs t h a t
(4) Rem ove Rem over /In st a ller fr om t h e bu sh in g a llow t h e h u b t o r ot a t e wit h t h e t ir e a n d wh eel
a n d lea f spr in g. a ssem bly (a n d dr ivesh a ft on All-Wh eel-Dr ive veh i-
(5) Ben d t h e r et a in er t a bs on bu sh in g ou t wa r d cles). Th e five wh eel m ou n t in g st u ds m ou n t t h e t ir e
a ga in st spr in g eye. a n d wh eel a ssem bly, a n d disc br a ke r ot or or br a ke
(6) P osit ion spr in g m ou n t in g br a cket over spr in g dr u m t o t h e veh icle.
eye a n d in st a ll pivot bolt t h r ou gh cen t er of bu sh in g On All-Wh eel-Dr ive veh icles, t h e splin ed m a t in g of
fr om t h e o u tbo a rd side. t h e dr ivesh a ft st u b a xle a n d h u b a llows t h e dr ive-
sh a ft t o r ot a t e wit h t h e h u b a n d wh eel.
NOTE: The pivot bolt must be installed from the
F r on t -Wh eel-Dr ive veh icles equ ipped wit h a n t ilock
outboard side to allow proper bracket to body
br a kes h a ve a wh eel speed sen sor a n d t on e wh eel
mounting.
m ou n t ed t o t h e r ea r of t h e h u b a n d bea r in g. Th e t on e
(b) P u sh u p on m et a l r et a in in g clip (F ig. 8) u n t il
it bot t om s. Th is will r elea se wh eel speed sen sor
h ea d fr om h u b a n d bea r in g.
(c) Wh ile h oldin g m et a l clip u p, pu ll ba ck on
wh eel speed sen sor h ea d r em ovin g it fr om h u b a n d
bea r in g.
Fig. 7 Hub And Bearing - FWD With ABS

wh eel r ot a t es wit h t h e h u b wh ich is sen sed by t h e
wh eel speed sen sor.
DIAGNOSIS AND TESTING - HUB AND

BEARING
Th e bea r in g con t a in ed in t h e h u b a n d bea r in g Fig. 8 Sensor Connector At Hub And Bearing
a ssem bly will pr odu ce n oise a n d vibr a t ion wh en wor n 1 - SECONDARY SENSOR RETAINING CLIP
2 - METAL SENSOR RETAINING CLIP
or da m a ged. Th e n oise will gen er a lly ch a n ge wh en 3 - HUB AND BEARING
t h e bea r in gs a r e loa ded. A r oa d t est of t h e veh icle is
n or m a lly r equ ir ed t o det er m in e t h e loca t ion of a (5) Rem ove t h e 4 bolt s a t t a ch in g t h e h u b a n d bea r-
wor n or da m a ged bea r in g. in g t o t h e r ea r a xle.
F in d a sm oot h level r oa d su r fa ce a n d br in g t h e
veh icle u p t o a con st a n t speed. Wh en veh icle is a t a CAUTION: Corrosion may occur between the hub
con st a n t speed, swer ve t h e veh icle ba ck a n d for t h and bearing, and the axle. If this occurs the hub
fr om t h e left a n d t o t h e r igh t . Th is will loa d a n d and bearing will be difficult to remove from the
u n loa d t h e bea r in gs a n d ch a n ge t h e n oise level. axle. If the hub and bearing will not come out of the
Wh en bea r in g da m a ge is sligh t , t h e n oise is som e- axle by pulling on it by hand, do not pound on the
t im es n ot icea ble a t lower speeds a n d a t ot h er t im es hub and bearing to remove it from the axle. Damage
is m or e n ot icea ble a t speeds a bove 105 km /h (65 will occur. Use the following procedure.
m ph ).
(6) If t h e h u b a n d bea r in g ca n n ot be r em oved fr om
REMOVAL t h e a xle by h a n d, u se Rem over, Specia l Tool 8458
(F ig. 9) a n d t h e followin g pr ocedu r e t o pr ess t h e h u b
FRONT-WHEEL-DRIVE VEHICLES a n d bea r in g ou t of t h e a xle.
(1) Ra ise veh icle. (Refer t o LUBRICATION & (a ) Rem ove t h e t wo ou t boa r d spr in g pla t e bolt s.
MAINTE NANCE /H OISTING - STANDARD P ROCE - (b) Th r ea d Th r ea ded Gu ide P in s in t o h u b a n d
DURE ) bea r in g m ou n t in g bolt h oles.
(2) Rem ove wh eel a n d t ir e. (Refer t o 22 - TIRE S/ (c) Usin g t h e spr in g pla t e bolt s, in st a ll t h e
WH E E LS - RE MOVAL) Scr ew Mou n t , Specia l Tool 8458–2, a s sh own (F ig.
(3) Rem ove br a ke dr u m or disc br a ke ca liper a n d 9). Mou n t t h e Scr ew Mou n t t o t h e spr in g pla t e
r ot or fr om h u b a n d bea r in g. (Refer t o 5 - BRAKE S/ wit h t h e t ool n u m ber fa cin g t h e h u b a n d bea r in g
H YDRAULIC/ME CH ANICAL/DRUM - RE MOVAL- a n d t h e beveled edge on t h e bot t om fa cin g t h e
)(Refer t o 5 - BRAKE S/H YDRAULIC/ME CH ANICAL/ spr in g, ot h er wise t h e F or cin g Scr ew will r u b t h e
ROTOR - RE MOVAL) spr in g pla t e wh en in st a lled.
(4) If equ ipped wit h a n t ilock br a kes, per for m t h e (d) P la ce P u sh P la t e, Specia l Tool 8458–1, on
followin g: en ds of Th r ea ded Gu ide P in s
(a ) Rem ove secon da r y (yellow) r et a in in g clip a t (e) P la ce a da b of gr ea se in dim ple of P u sh
r ea r of wh eel speed sen sor h ea d (F ig. 8). P la t e.
(9) Relea se t h e pa r kin g br a ke.
(10) Rem ove t h e disc br a ke ca liper t o a da pt er
gu ide pin bolt s (F ig. 15).
(11) Rem ove r ea r ca liper fr om a da pt er u sin g t h e
followin g pr ocedu r e. F ir st r ot a t e fr on t of ca liper u p
fr om t h e a da pt er. Th en pu ll t h e r ea r of t h e ca liper
a n d t h e ou t boa r d br a ke sh oe a n t i-r a t t le clip ou t fr om
u n der t h e r ea r a bu t m en t on t h e a da pt er (F ig. 14).
(12) Su ppor t ca liper t o pr even t t h e weigh t of t h e
ca liper fr om da m a gin g t h e flexible br a ke h ose (F ig.
10).
Fig. 9 Removal Using Special Tool 8458

1 - THREADED GUIDE PINS 8458-4
2 - HUB AND BEARING
3 - LEAF SPRING PLATE
4 - FORCING SCREW 8458-3
5 - SCREW MOUNT 8458-2
6 - PUSH PLATE 8458-1
(f) In st a ll F or cin g Scr ew, Specia l Tool 8458–3,

t h r ou gh Scr ew Mou n t fr om r ea r.
Fig. 10 Correctly Supported Caliper
(g) Tigh t en t h e F or cin g Scr ew u p a ga in st dim ple
in P u sh P la t e a n d pr ess h u b a n d bea r in g ou t of 1 - WIRE
2 - CALIPER
a xle by con t in u in g t o t igh t en scr ew. 3 - ADAPTER
(h ) Rem ove t h e t ool. 4 - ROTOR
(i) Rein st a ll t h e t wo ou t boa r d spr in g pla t e bolt s. 5 - INNER FENDER
Tigh t en t h e bolt s t o 102 N·m (75 ft . lbs.) t or qu e.
(13) Rem ove t h e r ot or fr om t h e h u b/bea r in g.
(7) Rem ove t h e h u b/bea r in g fr om t h e r ea r a xle a n d
(14) Rem ove dr ivesh a ft fr om r ea r dr ive lin e m odu le
br a ke su ppor t pla t e.
a n d h u b/bea r in g. Dr ivesh a ft is r em oved by fir st com -
pr essin g t h e in n er join t on t h e dr ivesh a ft a n d r em ov-
ALL-WHEEL-DRIVE VEHICLES
in g it fr om t h e dr ive lin e m odu le. Th en , slide t h e
(1) Set t h e pa r kin g br a ke. Th e p a rk in g bra k e is
ou t er join t of t h e dr ivesh a ft ou t of t h e h u b/bea r in g.
s e t to k e e p th e h u b a n d be a rin g , a n d a x le s h a ft
(15) Rem ove t h e h u b/bea r in g t o a xle m ou n t in g
fro m ro ta tin g w h e n lo o s e n in g th e h u b n u t.
bolt s (F ig. 13).
MAINTE NANCE /H OISTING - STANDARD P ROCE - CAUTION: Corrosion may occur between the hub/
DURE ) bearing and the axle. If this occurs the hub/bearing
(3) Rem ove t h e wh eel/t ir e a ssem bly. (Refer t o 22 - will be difficult to remove from the axle. If the hub/
TIRE S/WH E E LS - RE MOVAL) bearing will not come out of the axle by pulling on
(4) Rem ove t h e cot t er pin a n d n u t r et a in er (F ig. it by hand, do not pound on the hub/bearing to
18) fr om t h e st u b sh a ft of t h e ou t er C/V join t . remove it from the axle. Pounding on the hub/bear-
(5) Rem ove t h e spr in g wa sh er (F ig. 17) fr om t h e ing to remove it from the axle will damage the hub/
st u b sh a ft of t h e ou t er C/V join t . bearing. This damage will result in noise or failure
(6) Rem ove t h e h u b n u t a n d wa sh er (F ig. 16) fr om of the hub/bearing. To remove a hub/bearing which
t h e st u b sh a ft of t h e ou t er C/V join t . is corroded to the axle, lightly tap the disc brake
(7) Rem ove t h e 6 bolt s m ou n t in g t h e dr ivesh a ft caliper adapter using a soft faced hammer. This will
in n er join t t o t h e ou t pu t sh a ft of t h e r ea r dr ive lin e remove both the disc brake caliper adapter and
m odu le. hub/bearing from the axle. The hub/bearing will
(8) Rem ove t h e r ea r wh eel speed sen sor (F ig. 19) then need to be removed from the caliper adapter.
fr om t h e r ea r h u b/bea r in g.
(16) Rem ove t h e h u b/bea r in g fr om t h e a xle. (F ig. (a ) If m et a l sen sor r et a in in g clip is n ot in t h e
12). n eu t r a l in st a lled posit ion on h u b a n d bea r in g ca p,
(17) If t h e disc br a ke ca liper a da pt er a n d h u b/ in st a ll fr om t h e bot t om , if n ecessa r y, a n d pu sh clip
bea r in g wer e r em oved a s a n a ssem bly fr om t h e a xle u pwa r d u n t il it sn a ps in t o posit ion .
a n d t h e h u b/bea r in g ca n n ot be r em oved fr om t h e (b) In st a ll wh eel speed sen sor h ea d in t o r ea r of
a da pt er by h a n d, u se t h e followin g pr ocedu r e t o h u b a n d bea r in g a lign in g in dex t a b wit h t h e n ot ch
r em ove it fr om t h e a da pt er. Wit h a h elper su ppor t in g in t h e t op of t h e m ou n t in g h ole. P u sh t h e sen sor in
t h e ca liper a da pt er in h is h a n ds, posit ion Rem over, u n t il it sn a ps in t o pla ce on t h e m et a l r et a in in g
Specia l Tool 8214-1 on t h e ca st h ou sin g of h u b/bea r- clip.
in g (F ig. 11). D o n o t p o s itio n s p e c ia l to o l o n (c) In st a ll secon da r y (yellow) r et a in in g clip over
in n e r ra c e o f h u b/be a rin g . Ligh t ly st r ike Rem over, wh eel speed sen sor h ea d a n d en ga ge t h e t a bs on
Specia l Tool 8214-1 wit h a h a m m er t o r em ove t h e ea ch side (F ig. 8).
h u b/bea r in g fr om t h e ca liper a da pt er. (5) In st a ll br a ke dr u m or disc br a ke r ot or a n d
br a ke ca liper. (Refer t o 5 - BRAKE S/H YDRAULIC/
ME CH ANICAL/DRUM - INSTALLATION)(Refer t o 5
- BRAKE S/H YDRAULIC/ME CH ANICAL/ROTOR -
INSTALLATION)
(6) In st a ll wh eel a n d t ir e (Refer t o 22 - TIRE S/
WH E E LS - INSTALLATION). Tigh t en t h e wh eel
n u t s in t h e pr oper sequ en ce t o a t or qu e of 135 N·m
(100 ft . lbs.).
(7) Adju st t h e r ea r br a kes a s n ecessa r y. (Refer t o 5
- BRAKE S/H YDRAULIC/ME CH ANICAL/BRAKE
PADS/SH OE S - ADJ USTME NTS)
(8) Lower veh icle.
(9) Roa d t est veh icle t o en su r e pr oper oper a t ion of
br a kes.
ALL-WHEEL-DRIVE VEHICLES
Fig. 11 Hub/Bearing Removal From Caliper Adapter (1) In st a ll h u b/bea r in g on en d of a xle. (F ig. 12).
1 - SPECIAL TOOL 8214-1
2 - PARK BRAKE CABLE
3 - DISC BRAKE CALIPER ADAPTER
4 - HUB/BEARING
INSTALLATION
FRONT-WHEEL-DRIVE VEHICLES
(1) In st a ll t h e 4 h u b a n d bea r in g t o a xle m ou n t in g
bolt s in t o t h e h oles in t h e fla n ge of t h e r ea r a xle.
(2) In st a ll t h e r ea r br a ke su ppor t pla t e on t h e 4
m ou n t in g bolt s in st a lled in t h e fla n ge of t h e r ea r
a xle.
(3) Align t h e r ea r h u b a n d bea r in g wit h t h e 4
m ou n t in g bolt s a n d st a r t m ou n t in g bolt s in t o h u b
a n d bea r in g. Tigh t en t h e 4 bolt s in a cr isscr oss pa t -
t er n u n t il t h e h u b a n d bea r in g a n d br a ke su ppor t
pla t e is fu lly a n d squ a r ely sea t ed on t o fla n ge of r ea r Fig. 12 Hub/Bearing Removal And Installation
a xle. Tigh t en t h e 4 m ou n t in g bolt s t o a t or qu e of 129 1 - PARK BRAKE BRAKE SHOE
N·m (95 ft . lbs.) 2 - HUB/BEARING
3 - PARK BRAKE BRAKE SHOE
NOTE: If equipped with antilock brakes, make sure
wheel speed sensor stays clean and dry as it is (2) In st a ll t h e h u b/bea r in g m ou n t in g bolt s. In a
installed into the hub and bearing cap. pr ogr essive cr isscr oss pa t t er n , t igh t en t h e 4 h u b/
bea r in g m ou n t in g bolt s (F ig. 13) u n t il t h e disc br a ke
(4) If t h e veh icle is equ ipped wit h a n t ilock br a kes, ca liper a da pt er a n d h u b/bea r in g a r e squ a r ely sea t ed
per for m t h e followin g:
a ga in st t h e a xle. Th en t igh t en t h e h u b/bea r in g
m ou n t in g bolt s t o a t or qu e of 129 N·m (95 ft . lbs.).
Fig. 14 Removing/Installing Caliper (Left Side

Shown)
1 - LIFT THIS END OF CALIPER AWAY FROM ADAPTER FIRST
2 - DISC BRAKE CALIPER
Fig. 13 Hub/Bearing Mounting Bolts 3 - ADAPTER ABUTMENT
4 - OUTBOARD BRAKE SHOE HOLD DOWN CLIP
1 - HUB/BEARING
5 - OUTBOARD BRAKE SHOE
2 - AXLE
6 - ROTOR
3 - MOUNTING BOLTS
7 - ADAPTER
4 - CALIPER ADAPTER
(3) In st a ll dr ivesh a ft in h u b/bea r in g a n d on ou t pu t

sh a ft of r ea r dr ive lin e m odu le. Dr ivesh a ft is
in st a lled by fir st slidin g t h e ou t er join t of t h e dr ive-
sh a ft in t o t h e h u b/bea r in g a n d t h en com pr essin g t h e
in n er join t on t h e dr ivesh a ft a n d in st a llin g it on t h e
ou t pu t sh a ft t h e dr ive lin e m odu le.
(4) In st a ll r ot or on h u b/bea r in g.
(5) Ca r efu lly lower disc br a ke ca liper a n d br a ke
sh oes over r ot or a n d on t o ca liper a da pt er by r ever s-
in g t h e r em ova l pr ocedu r e (F ig. 14).
CAUTION: When installing guide pin bolts extreme

caution should be taken not to cross-thread the cal-
iper guide pin bolts.
(6) In st a ll t h e disc br a ke ca liper gu ide pin bolt s

(F ig. 15). Tigh t en t h e gu ide pin bolt s t o a t or qu e of Fig. 15 Caliper Guide Pin Bolts
35 N·m (26 ft . lbs.). 1 - STUD PIN BOLTS
(7) Clea n a ll for eign m a t er ia l off t h e t h r ea ds of t h e 2 - DISC BRAKE CALIPER
3 - DRIVESHAFT
ou t er C/V join t st u b sh a ft . In st a ll t h e wa sh er a n d 4 - AXLE
h u b n u t (F ig. 16) on t h e st u b sh a ft of t h e ou t er C/V 5 - DISC BRAKE CALIPER ADAPTER
join t .
(8) Lower veh icle. (13) In st a ll t h e spr in g wa sh er (F ig. 17) on t h e st u b
(9) Set t h e pa r k br a ke. Th is is re qu ire d to k e e p sh a ft of t h e ou t er C/V join t .
th e d riv e s h a ft fro m ro ta tin g w h e n tig h te n in g (14) In st a ll t h e n u t r et a in er a n d cot t er pin (F ig.
a n d to rqu in g th e h u b n u t a n d d riv e s h a ft in n e r 18) on t h e st u b sh a ft of t h e ou t er C/V join t .
jo in t to d riv e lin e m o d u le m o u n tin g n u ts . (15) In st a ll t h e wh eel speed sen sor on t h e h u b/
(10) Ra ise veh icle. bea r in g a n d a da pt er. In st a ll t h e wh eel speed sen sor
(11) Tigh t en t h e dr ivesh a ft in n er join t t o dr ive lin e a t t a ch in g bolt (F ig. 19). Tigh t en t h e wh eel speed sen -
m odu le ou t pu t sh a ft m ou n t in g bolt s t o a t or qu e of 61 sor a t t a ch in g bolt t o a t or qu e of 12 N·m (105 in . lbs).
N·m (45 ft . lbs.). (16) In st a ll wh eel a n d t ir e. (Refer t o 22 - TIRE S/
(12) Tigh t en t h e ou t er C/V join t h u b n u t (F ig. 16) WH E E LS - INSTALLATION)
t o a t or qu e of 244 N·m (180 ft . lbs.).
Fig. 18 Cotter Pin And Nut Retainer

Fig. 16 Hub Nut And Washer
1 - CALIPER
1 - CALIPER 2 - COTTER PIN
2 - HUB NUT 3 - ROTOR
3 - WASHER 4 - NUT RETAINER
4 - ROTOR 5 - OUTER C/V JOINT
5 - ADAPTER
Fig. 19 Wheel Speed Sensor

Fig. 17 Spring Washer
1 - MOUNTING BOLT
1 - HUB NUT 2 - WHEEL SPEED SENSOR
2 - STUB SHAFT
3 - ROTOR
4 - SPRING WASHER J OU N CE BU M PER
(17) Tigh t en t h e wh eel m ou n t in g st u d n u t s in DESCRIPTION
pr oper sequ en ce u n t il a ll n u t s a r e t or qu ed t o h a lf Th er e a r e t wo jou n ce bu m per s u sed in t h e r ea r
specifica t ion . Th en r epea t t h e t igh t en in g sequ en ce t o su spen sion . On e m ou n t s t o ea ch fr a m e r a il a bove t h e
t h e fu ll specified t or qu e of 135 N·m (100 ft . lbs.). r ea r a xle.
CAUTION: Before moving vehicle, pump the brake

OPERATION
pedal several times to insure the vehicle has a firm Th e jou n ce bu m per lim it s su spen sion t r a vel a n d
brake pedal to adequately stop vehicle. m et a l-t o-m et a l con t a ct of t h e r ea r a xle wit h t h e
fr a m e u n der fu ll jou n ce con dit ion s.
(19) Roa d t est veh icle t o en su r e pr oper oper a t ion
of t h e br a ke syst em .
J OU N CE BU M PER (Cont inue d)
REM OVAL (2) Tigh t en t h e jou n ce bu m per t o 33 N·m (290 in .

lbs.) t or qu e.
REMOVAL - AWD, HEAVY DUTY, CARGO
(1) Usin g slip-join t plier s gr a sp t h e ba se of t h e INSTALLATION - FRONT-WHEEL-DRIVE
jou n ce bu m per. Tu r n t h e ba se cou n t er clockwise (F ig. (1) H ook t h e for wa r d en d of t h e jou n ce bu m per
20). br a cket in t h e m ou n t in g h ole of t h e fr a m e r a il, t h en
(2) Rem ove t h e jou n ce bu m per fr om t h e fr a m e r a il. in st a ll t h e m ou n t in g bolt in t h e opposit e en d, secu r-
in g t h e bu m per t o t h e fr a m e r a il. Tigh t en t h e jou n ce
bu m per m ou n t in g bolt t o 33 N·m (290 in . lbs.) t or qu e.
SH OCK ABSORBER
DESCRIPTION
Th er e is on e sh ock a bsor ber on ea ch side of t h e
r ea r su spen sion . Th e t op of ea ch sh ock a bsor ber is
bolt ed t o t h e fr a m e r a il. Th e bot t om of ea ch sh ock
a bsor ber is bolt ed t o t h e r ea r a xle.
Th is veh icle is a va ila ble wit h eit h er st a n da r d t ype
or loa d-levelin g sh ock a bsor ber s. On t h e ext er ior,
loa d-levelin g sh ock a bsor ber s a r e la r ger in dia m et er
t h a n st a n da r d sh ock a bsor ber s. Th e loa d-levelin g
sh ock a bsor ber s m ou n t t h e sa m e a s t h e st a n da r d
sh ock a bsor ber s.
Fig. 20 Jounce Bumper
1 - JOUNCE BUMPER OPERATION
Th e sh ock a bsor ber da m pen s jou n ce a n d r ebou n d
REMOVAL - FRONT-WHEEL-DRIVE m ot ion s of t h e spr in g a n d su spen sion .
(1) Rem ove t h e bolt a t t a ch in g t h e jou n ce bu m per E a ch loa d-levelin g sh ock a bsor ber is a self-levelin g,
t o fr a m e r a il (F ig. 21). self-con t a in ed veh icle levelin g syst em a n d sh ock
(2) Rem ove t h e jou n ce bu m per fr om t h e fr a m e r a il. a bsor ber com bin ed. It does n ot r equ ir e a n ext er n a l
com pr essor, h oses, or h eigh t levelin g sen sor s. All t h e
h eigh t levelin g sen sor s, h ydr a u lic pu m p, et c., a r e
con t a in ed in side t h e sh ock a bsor ber. It u ses r oa d
in pu t s (bu m ps, st ops, st a r t s, t u r n s, a cceler a t ion ,
deceler a t ion , et c.) t o a ct iva t e pu m pin g, wh ich r esu lt s
in t h e ext en sion a n d com pr ession of t h e sh ock
a bsor ber.
REMOVAL - SHOCK ABSORBER

DURE )
(2) Su ppor t t h e r ea r a xle of t h e veh icle u sin g 2
ja ckst a n ds posit ion ed a t t h e ou t er en ds of t h e a xle.
NOTE: If the shock absorber lower mounting bolt

Fig. 21 Jounce Bumper - FWD deflects upward during removal, raise axle by
adjusting the support jack. If the lower shock
1 - JOUNCE BUMPER
absorber bolt deflects downward during removal,
lower the axle by adjusting the support jack.
I N STALLAT I ON
(3) Rem ove t h e sh ock a bsor ber lower m ou n t in g
INSTALLATION - AWD, HEAVY DUTY, CARGO bolt .
(1) In st a ll jou n ce bu m per t h r ou gh bu m per su ppor t
pla t e a n d t h r ea d in t o welded n u t in fr a m e r a il.
SH OCK ABSORBER (Cont inue d)
(4) Wh ile h oldin g sh ock a bsor ber, r em ove t h e
sh ock a bsor ber u pper m ou n t in g bolt a n d sh ock
a bsor ber.
DISASSEMBLY - SHOCK ABSORBER (UPPER

BUSHING)
NOTE: This procedure applies to load-leveling
shock absorbers only.
(1) Rem ove t h e sh ock a bsor ber fr om t h e veh icle.

(2) In st a ll t h e Receiver, Specia l Tool 8526-1, in t o
t h e cu p of t h e Ba ll J oin t P r ess, Specia l Tool C-4212F,
a n d t igh t en t h e set scr ew. In st a ll t h e Dr iver, Specia l
Tool 8526-2, on t h e t ip of t h e Ba ll J oin t P r ess scr ew
dr ive a s sh own (F ig. 22).
Fig. 23 Removing Bushing From Shock Absorber
1 - SCREW DRIVE
2 - SHOCK ABSORBER
3 - NOTCH
(1) In st a ll t h e Receiver, Specia l Tool 8526-1, in t o

t h e cu p of t h e Ba ll J oin t P r ess, Specia l Tool C-4212F,
a n d t igh t en t h e set scr ew. In st a ll t h e Dr iver, Specia l
Tool 8526-2, on t h e t ip of t h e Ba ll J oin t P r ess scr ew
dr ive a s sh own (F ig. 24). P osit ion t h e Dr iver t h is wa y
t o sea t t h e bu sh in g t o it s cor r ect dept h .
Fig. 22 Special Tools Positioned For Removal

1 - SCREW DRIVE
NOTE: It works well to place the Ball Joint Press,

Special Tool C-4212F, in a bench vise as shown
(Fig. 22) to perform this procedure.
(3) P la ce t h e sh ock a bsor ber u pper m ou n t in g eye

in t h e Receiver so t h e n ot ch in t h e Receiver clea r s
t h e sh ock a bsor ber body (F ig. 23).
(4) Tigh t en t h e scr ew dr ive u n t il t h e Dr iver con -
t a ct s t h e ou t er cir cu m fer en ce of t h e bu sh in g even ly Fig. 24 Special Tools Positioned For Installation
(F ig. 23). Con t in u e t o t igh t en t h e scr ew dr ive u n t il 1 - SCREW DRIVE
t h e bu sh in g is pr essed com plet ely ou t of t h e sh ock
a bsor ber eye a n d in t o t h e Receiver. (2) P la ce t h e sh ock a bsor ber u pper m ou n t in g eye
(5) Ba ck off t h e scr ew dr ive a n d r em ove t h e bu sh - in t h e Receiver so t h e n ot ch in t h e Receiver clea r s
in g fr om t h e Receiver. t h e sh ock a bsor ber body (F ig. 25).
(3) P osit ion t h e bu sh in g bet ween t h e sh ock
ASSEMBLY - SHOCK ABSORBER (UPPER a bsor ber eye a n d t h e Dr iver (F ig. 25). Tigh t en t h e
scr ew dr ive u n t il t h e Dr iver, bu sh in g, a n d sh ock
BUSHING) a bsor ber eye a r e t ou ch in g a n d squ a r ely a lign ed.
NOTE: This procedure applies to load-leveling (4) P r ess t h e bu sh in g in t o t h e sh ock a bsor ber eye
shock absorbers only. u n t il t h e Dr iver bot t om s a ga in st t h e fa ce of t h e eye.
(5) Ba ck off t h e Ba ll J oin t P r ess scr ew dr ive a n d
r em ove t h e sh ock a bsor ber fr om t h e pr ess.
SH OCK ABSORBER (Cont inue d)
Fig. 25 Installing Bushing In Shock Absorber

1 - BUSHING
2 - SCREW DRIVE
3 - SHOCK ABSORBER
4 - NOTCH
Fig. 26 LIFTING POINT AND SPRING MOUNT
1 - BODY SILL AREA
(6) In st a ll t h e sh ock a bsor ber on t h e veh icle. Refer 2 - MOUNTING BOLTS
t o RE MOVAL AND INSTALLATION in t h is sect ion 4 - LEAF SPRING
for t h e pr ocedu r e. 5 - HOIST LIFT ARM
6 - WOODEN BLOCK
INSTALLATION - SHOCK ABSORBER NOTE: If shock absorber bolt deflects upward dur-
(1) Wh ile h oldin g sh ock a bsor ber in posit ion
a ga in st t h e fr a m e r a il, in st a ll t h e sh ock a bsor ber
u pper m ou n t in g bolt .
removal, lower axle by adjusting support jack (or by
(2) In st a ll t h e sh ock a bsor ber lower m ou n t in g bolt
pulling on axle).
secu r in g t h e lower en d of t h e sh ock a bsor ber t o t h e
a xle. (3) Begin r em ova l of t h e sh ock a bsor ber lower
(3) Rem ove t h e su ppor t ja ck. m ou n t in g bolt (F ig. 27).
(4) Lower t h e veh icle t o t h e gr ou n d so t h e fu ll cu r b
weigh t of t h e veh icle is su ppor t ed by t h e su spen sion .
(5) Tigh t en t h e u pper a n d lower sh ock a bsor ber
m ou n t in g bolt t o a t or qu e of 88 N·m (65 ft . lbs.).
SPRI N G - AWD
REMOVAL
(1) Ra ise veh icle on fr a m e-con t a ct h oist a s follows:
(a ) P osit ion t h e h oist a r m su ppor t in g t h e cor n er
pla ced on t h e body sill a s sh own (F ig. 26).
(c) Ra ise t h e veh icle t o a com for t a ble wor kin g Fig. 27 Rear Shock Absorber Mounting Bolt
level. 1 - SHOCK BOLT
sion ja ck u n der r ea r a xle t owa r d t h e side n eedin g (4) Usin g 2 ja ck st a n ds posit ion ed u n der t h e ou t er
spr in g r epla cem en t . J a ck pa d sh ou ld ju st con t a ct en ds of t h e a xle, r a ise t h e a xle en ou gh t o r em ove t h e
a xle. weigh t of t h e a xle fr om t h e r ea r spr in gs.
SPRI N G - AWD (Cont inue d)
(5) Loosen a n d r em ove t h e a xle pla t e bolt s fr om (10) Rem ove t h e lea f spr in g fr om t h e veh icle.
t h e r ea r a xle (F ig. 28). (11) Loosen a n d r em ove t h e pivot bolt fr om t h e
fr on t m ou n t of t h e r ea r lea f spr in g. (F ig. 30).
Fig. 28 Axle Plate Bolts

1 - LEAF SPRING Fig. 30 Leaf Spring Front Mount (Typical)
2 - AXLE PLATE BOLTS (4) 1 - LEAF SPRING
3 - AXLE PLATE 2 - SPRING MOUNT
4 - AXLE
(6) Usin g t h e ja ck st a n ds s lo w ly lower t h e r ea r INSTALLATION

a xle, per m it t in g t h e r ea r spr in gs t o h a n g fr ee.
(7) Loosen a n d r em ove t h e 4 bolt s a t t h e fr on t CAUTION: Pivot bolt must face inboard to prevent
m ou n t of t h e r ea r lea f spr in g (F ig. 26). structural damage during installation of spring.
(8) Loosen a n d r em ove t h e 2 bolt s a n d t h e 2 pin
(1) In st a ll t h e fr on t eyelet of t h e r ea r lea f spr in g
n u t s fr om t h e spr in g sh a ckle for t h e r ea r lea f spr in g
in t o t h e spr in g m ou n t . In st a ll t h e pivot bolt a n d n u t .
(F ig. 29). Th en r em ove t h e in n er h a lf of t h e spr in g
D o n o t tig h te n th e p iv o t bo lt a t th is tim e .
sh a ckle fr om t h e ou t er h a lf h a n ger of t h e spr in g
(2) P osit ion t h e fr on t spr in g m ou n t for t h e r ea r
h a n ger a n d t h e spr in g.
lea f spr in g a ga in st t h e floor pa n of t h e veh icle.
In st a ll t h e 4 m ou n t in g bolt s for t h e fr on t spr in g
m ou n t (F ig. 26). Tigh t en t h e 4 m ou n t in g bolt s t o a
(3) In st a ll t h e r ea r of t h e lea f spr in g on t o t h e ou t er
h a lf of t h e r ea r sh a ckle. In st a ll t h e in n er h a lf of t h e
r ea r h a n ger. In st a ll t h e pin n u t s a n d bolt s on t h e
r ea r sh a ckle, bu t d o n o t tig h te n a t th is tim e .
(4) Ra ise a xle a ssem bly in t o cor r ect posit ion wit h
a xle cen t er ed u n der spr in g loca t or post .
(5) In st a ll a xle pla t e bolt s (F ig. 28). Tigh t en bolt s
t o 95 N·m (70 ft . lbs.) t or qu e.
(6) In st a ll sh ock a bsor ber bolt s. D o n o t tig h te n
a t th is tim e .
Fig. 29 All-Wheel-Drive Rear Suspension

1 - SHACKLE
2 - REAR MOUNT (HANGER)
3 - LEAF SPRING (MULTI-LEAF)
4 - AWD REAR AXLE
(9) Rem ove t h e r ea r lea f spr in g fr om t h e ou t er h a lf

of t h e spr in g sh a ckle.
SPRI N G - AWD (Cont inue d)
CAUTION: The following sequence must be fol- (9) Rem ove t h e h a n ger pla t e fr om t h e h a n ger a n d
lowed when tightening the pin nuts on the rear r em ove t h e spr in g fr om t h e spr in g h a n ger (F ig. 35).
hanger for the rear leaf spring. First the hanger pin (10) Rem ove t h e lea f spr in g fr om t h e veh icle.
nuts must be tightened to the specified torque (11) Loosen a n d r em ove t h e pivot bolt fr om t h e
shown below. Then tighten the retaining bolts for fr on t m ou n t of t h e r ea r lea f spr in g. (F ig. 30).
the inner to outer half of the spring hanger to the
torque specification listed below. This sequence INSTALLATION
must be followed to properly seat the bushings into
the springs and to avoid bending the spring hanger. CAUTION: Pivot bolt must face inboard to prevent
structural damage during installation of spring.
(115 ft . lbs.) t or qu e. (1) In st a ll t h e fr on t eyelet of t h e r ea r lea f spr in g
(9) Tigh t en r ea r spr in g sh a ckle pin n u t s t o 61 N·m in t o t h e spr in g m ou n t . In st a ll t h e pivot bolt a n d n u t .
(45 ft . lbs.) t or qu e. D o n o t tig h te n th e p iv o t bo lt a t th is tim e .
(10) Tigh t en r ea r spr in g sh a ckle in n er t o ou t er (2) P osit ion t h e fr on t spr in g m ou n t for t h e r ea r
h a lf r et a in in g bolt s t o 61 N·m (45 ft . lbs.) t or qu e. lea f spr in g a ga in st t h e floor pa n of t h e veh icle.
(11) Tigh t en t h e lower sh ock a bsor ber m ou n t in g In st a ll t h e 4 m ou n t in g bolt s for t h e fr on t spr in g
bolt t o 102 N·m (75 ft . lbs.) t or qu e. m ou n t (F ig. 26). Tigh t en t h e 4 m ou n t in g bolt s t o a
(3) In st a ll r ea r of spr in g on t o r ea r spr in g sh a ckle.
SPRI N G - CARGO In st a ll sh a ckle pla t e a n d n u t s (F ig. 35). D o n o t
tig h te n a t th is tim e .
REMOVAL (4) Ra ise a xle a ssem bly in t o cor r ect posit ion wit h
(1) Ra ise veh icle on fr a m e-con t a ct h oist a s follows: a xle cen t er ed u n der spr in g loca t or post .
(a ) P osit ion t h e h oist a r m su ppor t in g t h e cor n er (5) In st a ll a xle pla t e bolt s (F ig. 28). Tigh t en bolt s
of t h e veh icle t o be ser viced a ga in st a block of wood t o 95 N·m (70 ft . lbs.) t or qu e.
pla ced on t h e body sill a s sh own (F ig. 26). (6) In st a ll sh ock a bsor ber bolt s. D o n o t tig h te n
(b) P osit ion t h e r em a in in g h oist a r m s a t ea ch a t th is tim e .
cor n er of t h e veh icle in t h e n or m a l fa sh ion . (Refer (7) Lower t h e veh icle a n d r em ove h oist a r m s a n d
t o LUBRICATION & MAINTE NANCE /H OISTING block of wood fr om u n der veh icle.
(c) Ra ise t h e veh icle t o a com for t a ble wor kin g CAUTION: The following sequence must be fol-
level. lowed when tightening the pin nuts on the rear
(2) P osit ion a n u n der-h oist u t ilit y ja ck or t r a n sm is- hanger for the rear leaf spring. First the hanger pin
sion ja ck u n der r ea r a xle t owa r d t h e side n eedin g nuts must be tightened to the specified torque
spr in g r epla cem en t . J a ck pa d sh ou ld ju st con t a ct shown below. Then tighten the retaining bolts for
a xle. the inner to outer half of the spring hanger to the
torque specification listed below. This sequence
NOTE: If shock absorber bolt deflects upward dur- must be followed to properly seat the bushings into
ing removal, raise axle by adjusting support jack. If the springs and to avoid bending the spring hanger.
removal, lower axle by adjusting support jack (or by (8) Tigh t en t h e spr in g fr on t pivot bolt t o 156 N·m
pulling on axle). (115 ft . lbs.) t or qu e.
(9) Tigh t en r ea r spr in g sh a ckle pin n u t s t o 61 N·m
(3) Begin r em ova l of t h e sh ock a bsor ber lower (45 ft . lbs.) t or qu e.
m ou n t in g bolt (F ig. 27). (10) Tigh t en t h e lower sh ock a bsor ber m ou n t in g
(4) Usin g 2 ja ck st a n ds posit ion ed u n der t h e ou t er bolt t o 102 N·m (75 ft . lbs.) t or qu e.
en ds of t h e a xle, r a ise t h e a xle en ou gh t o r em ove t h e
weigh t of t h e a xle fr om t h e r ea r spr in gs.
(5) Loosen a n d r em ove t h e a xle pla t e bolt s fr om SPRI N G - FWD
t h e r ea r a xle (F ig. 28).
(6) Usin g t h e ja ck st a n ds s lo w ly lower t h e r ea r REMOVAL
a xle, per m it t in g t h e r ea r spr in gs t o h a n g fr ee. (1) Ra ise veh icle on fr a m e-con t a ct h oist a s follows:
(7) Loosen a n d r em ove t h e 4 bolt s a t t h e fr on t (a ) P osit ion t h e h oist a r m su ppor t in g t h e cor n er
m ou n t of t h e r ea r lea f spr in g (F ig. 26). of t h e veh icle t o be ser viced a ga in st a block of wood
(8) Loosen a n d r em ove t h e n u t s fr om t h e spr in g pla ced on t h e body sill a s sh own (F ig. 31).
h a n ger for t h e r ea r lea f spr in g (F ig. 35).
SPRI N G - FWD (Cont inue d)
(c) Ra ise t h e veh icle t o a com for t a ble wor kin g
level.
Fig. 32 Rear Shock Mounting Bolt

1 - SHOCK BOLT
Fig. 31 Lifting Point And Spring Mount

1 - BODY SILL AREA
2 - MOUNTING BOLTS
4 - LEAF SPRING
5 - HOIST LIFT ARM
6 - WOODEN BLOCK

sion ja ck u n der r ea r a xle t owa r d t h e side n eedin g
Fig. 33 Spring Plate Bolts
spr in g r epla cem en t . J a ck pa d sh ou ld ju st con t a ct
1 - SPRING PLATE
a xle.
(3) Rem ove t h e sh ock a bsor ber lower m ou n t in g
bolt (F ig. 32).

pulling on axle).
(4) Usin g 2 ja ck st a n ds posit ion ed u n der t h e ou t er

en ds of t h e a xle, r a ise t h e a xle en ou gh t o r em ove t h e
weigh t of t h e a xle fr om t h e r ea r spr in gs.
(5) Loosen a n d r em ove t h e spr in g pla t e bolt s fr om
t h e r ea r a xle (F ig. 33).
(6) Rem ove t h e spr in g pla t e fr om t h e r ea r a xle a n d
t h e lea f spr in g (F ig. 34).
(7) Usin g t h e ja ck st a n ds s lo w ly lower t h e r ea r
a xle, per m it t in g t h e r ea r spr in gs t o h a n g fr ee. Fig. 34 Spring Plate
(8) Loosen a n d r em ove t h e 4 bolt s secu r in g t h e 1 - SPRING PLATE
fr on t m ou n t of t h e lea f spr in g t o t h e veh icle (F ig. 31).
SPRI N G - FWD (Cont inue d)
(9) Loosen a n d r em ove t h e n u t s fr om t h e spr in g
sh a ckle (F ig. 35).
Fig. 36 Leaf Spring Locator Post

1 - LEAF SPRING ISOLATOR
2 - LEAF SPRING
Fig. 35 Rear Spring Hanger/Shackle 3 - LOCATOR POST
1 - SHACKLE PLATE
2 - SPRING HANGER (11) Lower t h e veh icle a n d r em ove h oist a r m s a n d
(10) Rem ove t h e sh a ckle pla t e fr om t h e h a n ger (12) Tigh t en t h e spr in g fr on t pivot bolt t o 156 N·m
a n d r em ove t h e spr in g fr om t h e spr in g h a n ger (F ig. (115 ft . lbs.) t or qu e.
35). (13) Tigh t en r ea r spr in g sh a ckle pin n u t s t o 61
(11) Rem ove t h e lea f spr in g fr om t h e veh icle. N·m (45 ft . lbs.) t or qu e.
(12) Loosen a n d r em ove t h e pivot bolt fr om t h e (14) Tigh t en t h e lower sh ock a bsor ber m ou n t in g
fr on t m ou n t of t h e r ea r lea f spr in g. Rem ove m ou n t . bolt t o 102 N·m (75 ft . lbs.) t or qu e.
INSTALLATION
(1) Assem ble fr on t spr in g m ou n t t o fr on t of spr in g SPRI N G M OU N T S - FRON T
eye a n d in st a ll pivot bolt a n d n u t . D o n o t tig h te n
a t th is tim e . REMOVAL
(1) Ra ise veh icle on fr a m e-con t a ct h oist a s follows:
CAUTION: Pivot bolt must face inboard to prevent
(a ) P osit ion t h e h oist a r m su ppor t in g t h e cor n er
structural damage during installation of spring.
(2) Ra ise fr on t of spr in g a n d in st a ll fou r m ou n t in g pla ced on t h e body sill a s sh own (F ig. 37).
bolt s (F ig. 31). Tigh t en bolt s t o 61 N·m (45 ft . lbs.) (b) P osit ion t h e r em a in in g h oist a r m s a t ea ch
t or qu e. cor n er of t h e veh icle in t h e n or m a l fa sh ion . (Refer
(3) In st a ll r ea r of spr in g on t o r ea r spr in g sh a ckle t o LUBRICATION & MAINTE NANCE /H OISTING
(F ig. 35). In st a ll sh a ckle pla t e a n d n u t s. D o n o t - STANDARD P ROCE DURE )
tig h te n a t th is tim e . (c) Ra ise t h e veh icle t o a com for t a ble wor kin g
(4) Ver ify lower lea f spr in g isola t or is in posit ion . level.
(5) Ra ise a xle in t o cor r ect posit ion on lea f spr in g (2) P osit ion a n u n der-h oist u t ilit y ja ck or t r a n sm is-
wit h a xle cen t er ed u n der spr in g loca t or post (F ig. sion ja ck u n der r ea r a xle t owa r d t h e side n eedin g
36). bu sh in g r epla cem en t . J a ck pa d sh ou ld ju st con t a ct
(6) Ver ify t h a t t h e lea f spr in g isola t or is cor r ect ly a xle.
posit ion ed in t h e spr in g pla t e. (3) Rem ove sh ock a bsor ber lower m ou n t in g bolt .
(7) In st a ll spr in g pla t e in posit ion on t h e spr in g
(F ig. 33).
(8) In st a ll spr in g pla t e bolt s (F ig. 33). Tigh t en
bolt s t o 95 N·m (70 ft . lbs.) t or qu e.
(9) In st a ll lower sh ock a bsor ber bolt . D o n o t
pulling on axle).
tig h te n a t th is tim e .
(10) Rem ove ja ck u n der a xle.
SPRI N G M OU N T S - FRON T (Cont inue d)
(4) Ra ise or lower t h e ja ck u n t il sh ock a bsor ber
lower eye a lign s wit h t h r ea ds in a xle h ou sin g. In st a ll
sh ock a bsor ber lower m ou n t in g bolt . Do n ot fu lly
t igh t en bolt a t t h is t im e.
(7) Tigh t en t h e lower sh ock a bsor ber m ou n t in g
bolt t o 88 N·m (65 ft . lbs.) t or qu e.
SPRI N G M OU N T S - REAR
REMOVAL
(1) Rem ove t h e pin n u t s secu r in g t h e lea f spr in g
r ea r sh a ckle h a lves (F ig. 38) (F ig. 39).
Fig. 37 LIFTING POINT AND SPRING MOUNT

1 - BODY SILL AREA
2 - MOUNTING BOLTS
4 - LEAF SPRING
5 - HOIST LIFT ARM
6 - WOODEN BLOCK
(4) Rem ove fou r bolt s secu r in g lea f spr in g fr on t

m ou n t in g br a cket t o t h e body (F ig. 37).
(5) Usin g ja ck, s lo w ly lower r ea r a xle, per m it t in g
t h e for wa r d en d of r ea r spr in g t o h a n g down . Lower
it en ou gh t o a llow a ccess t o spr in g pivot bolt . It m a y
be n ecessa r y t o pla ce a wooden block bet ween t h e
spr in g a n d veh icle t o h old for wa r d en d of t h e spr in g
in pla ce.
Fig. 38 Leaf Spring Shackle Nuts (FWD)
(6) Rem ove lea f spr in g for wa r d pivot bolt , t h en
r em ove m ou n t in g br a cket . 1 - SHACKLE PLATE
(2) In st a ll a ja ck u n der t h e side of t h e a xle h a vin g

INSTALLATION t h e lea f spr in g m ou n t r em oved. Usin g t h e ja ck, su p-
(1) P osit ion spr in g m ou n t in g br a cket over spr in g
por t t h e weigh t of t h e a xle a n d lea f spr in g.
eye a n d in st a ll pivot bolt t h r ou gh cen t er of bu sh in g
(3) Rem ove t h e lower m ou n t in g bolt fr om t h e
fr om t h e o u tbo a rd side.
sh ock a bsor ber.
NOTE: The pivot bolt must be installed from the (4) Rem ove t h e bolt s a t t a ch in g t h e lea f spr in g r ea r
outboard side to allow proper bracket to body m ou n t t o t h e body of t h e veh icle (F ig. 40).
mounting. (5) Lower t h e ja ck a n d t h e r ea r of t h e lea f spr in g.
(6) AWD on ly – Rem ove t h e r et a in in g bolt s fa st en -
(2) In st a ll t h e n u t on t h e pivot bolt a n d ligh t ly in g in n er t o ou t er h a lves of t h e lea f spr in g sh a ckle
t igh t en . Do n ot fu lly t igh t en bolt a t t h is t im e. (F ig. 39).
(3) Ra ise t h e u n der-h oist u t ilit y ja ck or t r a n sm is- (7) Rem ove t h e sh a ckle fr om t h e lea f spr in g bu sh -
sion ja ck, gu idin g t h e for wa r d m ou n t in g br a cket in t o in g a n d t h e spr in g r ea r m ou n t .
pla ce a ga in st t h e body. It m a y h elp t o u se a dr ift
pu n ch pla ced t h r ou gh t h e h ole cen t er ed bet ween t h e INSTALLATION
m ou n t in g bolt h oles in t h e br a cket a n d t h e pilot h ole (1) Wit h t h e r ea r of t h e spr in g in t h e lower ed posi-
in t h e body of t h e veh icle a s a gu ide. Wh en t h e fou r t ion , in st a ll t h e spr in g sh a ckle h a lves t h r ou gh t h e
m ou n t in g bolt h oles lin e u p wit h t h eir t h r ea ds in t h e lea f spr in g bu sh in gs a n d r ea r m ou n t (F ig. 39).
body, In st a ll t h e m ou n t in g bolt s (F ig. 37). Tigh t en t h e
fou r m ou n t in g bolt s t o 61 N·m (45 ft . lbs.) t or qu e.
SPRI N G M OU N T S - REAR (Cont inue d)
(8) Lower t h e veh icle so t h a t t h e fu ll weigh t of t h e
veh icle is on a ll fou r t ir es (cu r b h eigh t ).
CAUTION: AWD only – In order to avoid bending the

spring shackles, the shackle pin nuts must be tight-
ened to the specified torque before the inboard-to-
outboard shackle half bolts can be tightened.
(9) Tigh t en sh a ckle m ou n t in g n u t s t o 61 N·m (45

ft . lbs.) t or qu e.
(10) If equ ipped wit h AWD, t igh t en sh a ckle-t o-
sh a ckle m ou n t in g bolt s t o 61 N·m (45 ft . lbs.) t or qu e.
(11) Tigh t en sh ock a bsor ber lower m ou n t in g bolt t o
88 N·m (65 ft . lbs.) t or qu e.
Fig. 39 All-Wheel-Drive Rear Suspension

SPRI N G SH ACK LE
1 - SHACKLE
2 - REAR MOUNT (HANGER)
REMOVAL
3 - LEAF SPRING (MULTI-LEAF) (Refer t o 2 - SUSP E NSION/RE AR/SP RING
4 - AWD REAR AXLE MOUNTS - RE MOVAL)
INSTALLATION
(Refer t o 2 - SUSP E NSION/RE AR/SP RING
MOUNTS - INSTALLATION)
STABI LI Z ER BAR
DESCRIPTION
Som e fr on t -wh eel-dr ive m odels u se a st a bilizer ba r.
It is m ou n t ed beh in d t h e r ea r a xle. All-wh eel-dr ive
m odels u se a st a bilizer ba r t h a t is m ou n t ed in fr on t
of t h e r ea r a xle.
Th e st a bilizer ba r in t er con n ect s bot h sides of t h e
r ea r a xle a n d a t t a ch es t o t h e r ea r fr a m e r a ils u sin g 2
r u bber isola t ed lin k a r m s.
Bot h t ype st a bilizer ba r s h a ve t h e sa m e ba sic com -
Fig. 40 Rear Spring Mount (Typical) pon en t s. At t a ch m en t t o t h e r ea r a xle t u be, a n d r ea r
1 - LEAF SPRING MOUNT fr a m e r a ils is t h r ou gh r u bber-isola t ed bu sh in gs.
Th e 2 r u bber isola t ed lin ks a r e con n ect ed t o t h e
(2) In st a ll t h e sh a ckle m ou n t in g n u t s on t h e
r ea r fr a m e r a ils by br a cket s. Th ese br a cket s a r e
h a n ger pin s, bu t DO NOT TIGH TE N AT TH IS
bolt ed t o t h e bot t om of t h e fr a m e r a ils.
TIME .
(3) AWD on ly – In st a ll, BUT DO NOT TIGH TE N,
OPERATION
r et a in in g bolt s fa st en in g in n er t o ou t er h a lves of lea f
J ou n ce a n d r ebou n d m ovem en t s a ffect in g on e
spr in g h a n ger a t t h is t im e (F ig. 39).
wh eel a r e pa r t ia lly t r a n sm it t ed t o t h e opposit e wh eel
(4) Usin g a ja ck, r a ise t h e lea f spr in g in t o
t o r edu ce body r oll.
m ou n t ed posit ion .
(5) In st a ll t h e r ea r spr in g m ou n t -t o-body bolt s
(F ig. 40). Tigh t en r ea r spr in g m ou n t bolt s t o 61 N·m REM OVAL
(6) In st a ll t h e lower m ou n t in g bolt fa st en in g t h e REMOVAL - AWD
sh ock a bsor ber t o t h e a xle. DO NOT TIGH TE N TH E (1) Ra ise veh icle. (Refer t o LUBRICATION &
BOLT AT TH IS TIME . MAINTE NANCE /H OISTING - STANDARD P ROCE -
(7) Rem ove t h e ja ck fr om u n der a xle. DURE )
(2) Rem ove t h e bolt s secu r in g t h e st a bilizer ba r t o I N STALLAT I ON
lin ks on ea ch en d of t h e ba r.
(3) Wh ile h oldin g t h e st a bilizer ba r in pla ce, INSTALLATION - AWD
r em ove t h e bolt s t h a t a t t a ch t h e st a bilizer ba r bu sh - (1) In st a ll t h e st a bilizer ba r on t h e r ea r a xle.
in g r et a in er s t o t h e r ea r a xle. (2) In st a ll bu sh in g r et a in er bolt s. Do n ot t igh t en a t
(4) Rem ove t h e st a bilizer ba r fr om t h e veh icle. t h is t im e.
(5) If t h e lin ks n eed t o be ser viced, r em ove t h e (3) In st a ll bolt s con n ect in g lin ks t o st a bilizer ba r.
u pper lin k a r m t o br a cket bolt . Th en r em ove lin k Do n ot t igh t en a t t h is t im e.
a r m fr om fr a m e r a il a t t a ch in g br a cket . (4) Lower t h e veh icle so t h a t t h e fu ll weigh t of t h e
veh icle is on a ll fou r t ir es. Wit h t h e veh icle a t it s
REMOVAL - FWD cu r b h eigh t , t igh t en t h e followin g bolt s t o t h e t or qu es
(1) Ra ise veh icle. See H oist in g in Lu br ica t ion a n d list ed:
Ma in t en a n ce. • St a bilizer ba r bu sh in g r et a in er-t o-a xle br a cket
(2) Rem ove t h e bolt s secu r in g t h e st a bilizer ba r t o bolt s — 61 N·m (45 ft . lbs.)
lin ks on ea ch side of ba r. • St a bilizer ba r-t o-lin k bolt s — 61 N·m (45 ft . lbs.)
(3) Wh ile h oldin g t h e st a bilizer ba r in pla ce,
r em ove t h e bolt s t h a t a t t a ch t h e st a bilizer ba r bu sh - INSTALLATION - FWD
in g r et a in er s t o t h e r ea r a xle. (1) Lift t h e st a bilizer ba r on t o t h e r ea r a xle a n d
(4) Rem ove t h e st a bilizer ba r fr om t h e veh icle. in st a ll t h e t wo r et a in er m ou n t in g bolt s. DO NOT
TIGH TE N.
REMOVAL - FWD - FOLD-IN-FLOOR SEATING (2) In st a ll t h e bolt s a t t a ch in g t h e st a bilizer ba r
(1) Ra ise a n d su ppor t veh icle. (Refer t o LUBRICA- lin ks t o t h e st a bilizer ba r. DO NOT TIGH TE N.
TION & MAINTE NANCE /H OISTING - STANDARD (3) Lower t h e veh icle so t h a t t h e fu ll weigh t of t h e
P ROCE DURE ) veh icle is on a ll fou r t ir es. Wit h t h e veh icle a t it s
(2) At ea ch en d of t h e st a bilizer ba r, r em ove t h e cu r b h eigh t , t igh t en t h e followin g bolt s t o t h e t or qu es
n u t s a n d bolt s secu r in g t h e ba r t o t h e lin ks (F ig. 41). list ed:
• St a bilizer ba r bu sh in g r et a in er-t o-a xle br a cket
bolt s — 61 N·m (45 ft . lbs.)
• St a bilizer ba r-t o-lin k — 61 N·m (45 ft . lbs.)
INSTALLATION - FWD - FOLD-IN-FLOOR

SEATING
(1) Lift t h e st a bilizer ba r on t o t h e r ea r a xle, h ook-
in g t h e bot t om of t h e bu sh in g r et a in er s on t h e a xle,
t h en in st a ll t h e t wo r et a in er m ou n t in g bolt s (F ig. 41).
DO NOT TIGH TE N AT TH IS TIME .
(2) In st a ll t h e bolt s a n d n u t s a t t a ch in g t h e st a bi-
lizer ba r lin ks t o t h e st a bilizer ba r (F ig. 41). DO NOT
TIGH TE N AT TH IS TIME .
(3) Lower t h e veh icle so t h a t t h e fu ll weigh t of t h e
veh icle is on a ll fou r t ir es. Wit h t h e veh icle a t it s
cu r b h eigh t , t igh t en t h e followin g bolt s t o t h e t or qu es
list ed:
• St a bilizer ba r bu sh in g r et a in er-t o-a xle br a cket
bolt s — 61 N·m (45 ft . lbs.)
Fig. 41 Stabilizer Bar With Fold-In-Floor Seating • St a bilizer ba r-t o-lin k — 61 N·m (45 ft . lbs.)
1 - LINK NUT
2 - LINK BOLT AND NUT
3
4
-
-
STABILIZER LINK
STABILIZER BAR
T RACK BAR
5 - REAR AXLE
6 - BOLTS DESCRIPTION
On fr on t -wh eel-dr ive a pplica t ion s of t h is veh icle
(3) Wh ile h oldin g t h e st a bilizer ba r in pla ce,
t h a t a r e equ ipped wit h sin gle lea f r ea r spr in gs, a
r em ove t h e bolt s t h a t a t t a ch t h e st a bilizer ba r bu sh -
t r a ck ba r is u sed on t h e r ea r a xle (F ig. 1).
in g r et a in er s t o t h e r ea r a xle (F ig. 41).
Th e t r a ck ba r con n ect s t h e r ea r a xle t o t h e fr a m e/
(4) Rem ove t h e st a bilizer ba r fr om t h e veh icle.
body of t h e veh icle. Th e t r a ck ba r is isola t ed fr om t h e
T RACK BAR (Cont inue d)
body of t h e veh icle by a n isola t or bu sh in g loca t ed in (2) Rem ove t h e n u t a n d bolt a t t a ch in g t h e t r a ck
ea ch en d of t h e t r a ck ba r. ba r t o t h e t r a ck br a cket on t h e body of t h e veh icle
(F ig. 42). Rem ove t h e t r a ck ba r.
OPERATION
Th e t r a ck ba r pr even t s excessive side-t o-side m ove- INSTALLATION
m en t of t h e r ea r a xle. Th e t r a ck ba r is u sed t o keep (1) In st a ll t h e t r a ck ba r fir st in t o t h e body br a cket
t h e loca t ion of t h e a xle in t h e cor r ect posit ion for for t h e t r a ck ba r (F ig. 42). In st a ll t h e t r a ck ba r
opt im u m h a n dlin g a n d con t r ol of t h e veh icle. m ou n t in g bolt in t h e dir ect ion sh own , t h en in st a ll
t h e n u t . D o n o t tig h te n a t th is tim e .
REMOVAL (2) In st a ll t h e t r a ck ba r in t o it s m ou n t in g br a cket
(1) Rem ove t h e n u t a n d bolt m ou n t in g t h e t r a ck on t h e r ea r a xle (F ig. 42). In st a ll t h e t r a ck ba r
ba r t o t h e r ea r a xle (F ig. 42). m ou n t in g bolt in t h e dir ect ion sh own , t h en in st a ll
t h e n u t . D o n o t tig h te n a t th is tim e .
(3) Lower t h e veh icle t o t h e gr ou n d u n t il t h e fu ll
weigh t of t h e veh icle is su ppor t ed by t h e wh eels.
Tigh t en bot h t r a ck ba r m ou n t in g bolt s t o 95 N·m (70
ft . lbs.) t or qu e.
Fig. 42 Track Bar Mounting

1 - MOUNTING BOLT
2 - NUT
3 - NUT
4 - MOUNTING BOLT
5 - TRACK BAR
6 - REAR AXLE
7 - FRAME MOUNTED BRACKET
RS WHEEL ALIGNMENT 2 - 47
WH EEL ALI GN M EN T
TABLE OF CONTENTS
page page
WHEEL ALIGNMENT STANDARD PROCEDURE - CURB HEIGHT

DESCRIPTION - WHEEL ALIGNMENT . . . . . . . 47 MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . 55
DIAGNOSIS AND TESTING - SUSPENSION SPECIFICATIONS
AND STEERING . . . . . . . . . . . . . . . . . . . . . . 50 WHEEL ALIGNMENT . . . . . . . . . . . . . . . . . . . 56
STANDARD PROCEDURE
STANDARD PROCEDURE - WHEEL
ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . 52
WH EEL ALI GN M EN T • E xcessive posit ive ca m ber will ca u se t r ea d wea r

on t h e ou t side of t h e t ir e.
DESCRIPTION - WHEEL ALIGNMENT
Veh icle wh eel a lign m en t is t h e posit ion in g of a ll
in t er r ela t ed fr on t a n d r ea r su spen sion a n gles. Th ese
a n gles a ffect t h e h a n dlin g a n d st eer in g of t h e veh icle
wh en it is in m ot ion . P r oper wh eel a lign m en t is
essen t ia l for efficien t st eer in g, good dir ect ion a l st a bil-
it y, a n d pr oper t ir e wea r.
Th e m et h od of ch eckin g a veh icle’s fr on t a n d r ea r
wh eel a lign m en t va r ies depen din g on t h e m a n u fa c-
t u r er a n d t ype of equ ipm en t u sed. Th e m a n u fa ct u r-
er ’s in st r u ct ion s sh ou ld a lwa ys be followed t o en su r e
a ccu r a cy of the a lign m en t , except wh en
Da im ler Ch r ysler Cor por a t ion ’s wh eel a lign m en t spec-
ifica t ion s differ.
On t h is veh icle, t h e su spen sion a n gles t h a t ca n be
a dju st ed a r e a s follows:
• F r on t Ca m ber (wit h ca m ber bolt pa cka ge a n d
st a n da r d pr ocedu r e)
• F r on t Toe
Ch eck t h e wh eel a lign m en t a n d m a ke a ll wh eel
a lign m en t a dju st m en t s wit h t h e veh icle st a n din g a t
it s pr oper cu r b h eigh t specifica t ion . Cu r b h eigh t is
t h e n or m a l r idin g h eigh t of t h e veh icle. It is m ea -
su r ed fr om a cer t a in poin t on t h e veh icle t o t h e
gr ou n d or a design a t ed a r ea wh ile t h e veh icle is sit -
t in g on a fla t , level su r fa ce. Refer t o Cu r b H eigh t
Mea su r em en t in t h is sect ion for a ddit ion a l in for m a -
t ion .
Typica l wh eel a lign m en t a n gles a n d m ea su r em en t s
a r e descr ibed in t h e followin g pa r a gr a ph s.
Fig. 1 Camber
CAMBER
1 - WHEELS TILTED OUT AT TOP
Ca m ber is t h e in wa r d or ou t wa r d t ilt of t h e t op of 2 - WHEELS TILTED IN AT TOP
t h e t ir e a n d wh eel a ssem bly (F ig. 1). Ca m ber is m ea -
su r ed in degr ees of a n gle r ela t ive t o a t r u e ver t ica l
lin e. Ca m ber is a t ir e wea r in g a n gle.
• E xcessive n ega t ive ca m ber will ca u se t r ea d wea r
a t t h e in side of t h e t ir e.
2 - 48 WHEEL ALIGNMENT RS
WH EEL ALI GN M EN T (Cont inue d)
CROSS CAMBER TOE
Cr oss ca m ber is t h e differ en ce bet ween left a n d Toe is t h e in wa r d or ou t wa r d a n gle of t h e wh eels
r igh t ca m ber. To a ch ieve t h e cr oss ca m ber r ea din g, a s viewed fr om a bove t h e veh icle (F ig. 3).
su bt r a ct t h e r igh t side ca m ber r ea din g fr om t h e left . • Toe-in is pr odu ced wh en t h e fr on t edges of t h e
F or exa m ple, if t h e left ca m ber is +0.3° a n d t h e r igh t wh eels on t h e sa m e a xle a r e closer t oget h er t h a n t h e
ca m ber is 0.0°, t h e cr oss ca m ber wou ld be +0.3°. r ea r edges.
• Toe-ou t is pr odu ced wh en t h e fr on t edges of t h e
CASTER wh eels on t h e sa m e a xle a r e fa r t h er a pa r t t h a n t h e
Ca st er is t h e for wa r d or r ea r wa r d t ilt of t h e st eer- r ea r edges.
in g kn u ckle in r efer en ce t o t h e posit ion of t h e u pper Toe-in a n d t oe-ou t ca n occu r a t t h e fr on t wh eels
a n d lower ba ll join t s. Ca st er is m ea su r ed in degr ees a n d t h e r ea r wh eels.
of a n gle r ela t ive t o a t r u e ver t ica l cen t er lin e. Th is Toe is m ea su r ed in degr ees or in ch es. Th e m ea -
lin e is viewed fr om t h e side of t h e t ir e a n d wh eel su r em en t iden t ifies t h e a m ou n t t h a t t h e fr on t of t h e
a ssem bly (F ig. 2). wh eels poin t in wa r d (t oe-in ) or ou t wa r d (t oe-ou t ). Toe
• F or wa r d t ilt (u pper ba ll join t a h ea d of lower ) is m ea su r ed a t t h e spin dle h eigh t . Zer o t oe m ea n s
r esu lt s in a n ega t ive ca st er a n gle. t h e fr on t a n d r ea r edges of t h e wh eels on t h e sa m e
• Rea r wa r d t ilt (u pper ba ll join t t r a ilin g lower ) a xle a r e equ a lly dist a n t .
r esu lt s in a posit ive ca st er a n gle.
Alt h ou gh ca st er does n ot a ffect t ir e wea r, a ca st er
im ba la n ce bet ween t h e t wo fr on t wh eels m a y ca u se
t h e veh icle t o lea d t o t h e side wit h t h e lea st posit ive
ca st er.
Fig. 2 Caster
Fig. 3 Toe
CROSS CASTER 1 - TOE-IN
Cr oss ca st er is t h e differ en ce bet ween left a n d 2 - TOE-OUT
r igh t ca st er.
TOE-OUT ON TURNS STEERING AXIS INCLINATION (S. A. I.)
Toe-ou t on t u r n s is t h e r ela t ive posit ion in g of t h e St eer in g a xis in clin a t ion is t h e a n gle bet ween a
fr on t wh eels wh ile st eer in g t h r ou gh a t u r n (F ig. 4). t r u e ver t ica l lin e st a r t in g a t t h e cen t er of t h e t ir e a t
Th is com pen sa t es for ea ch fr on t wh eel’s t u r n in g t h e r oa d con t a ct poin t a n d a lin e dr a wn t h r ou gh t h e
r a diu s. As t h e veh icle en cou n t er s a t u r n , t h e ou t - cen t er of t h e u pper ba ll join t (or st r u t ) a n d t h e lower
boa r d wh eel m u st t r a vel in a la r ger r a diu s cir cle ba ll join t (F ig. 5). S.A.I. is bu ilt in t o t h e veh icle a n d
t h a n t h e in boa r d wh eel. Th e st eer in g syst em is is n ot a n a dju st a ble a n gle. If S.A.I. is n ot wit h in
design ed t o m a ke ea ch wh eel follow it s pa r t icu la r specifica t ion s, a ben t or da m a ged su spen sion com po-
r a diu s cir cle. To a ccom plish t h is, t h e fr on t wh eels n en t m a y be t h e ca u se.
m u st pr ogr essively t oe ou t wa r d a s t h e st eer in g is
t u r n ed fr om cen t er. Th is elim in a t es t ir e scr u bbin g
a n d u n du e t ir e wea r wh en st eer in g a veh icle t h r ou gh
a turn.
Fig. 5 S.A.I. and I.A.

1 - S.A.I.
2 - CAMBER
Fig. 4 Toe-Out On Turns 3 - I.A.
1 - TOE-OUT ON TURNS
INCLUDED ANGLE (I. A.)
DYNAMIC TOE PATTERN In clu ded a n gle is t h e su m of t h e S.A.I. a n gle plu s
Dyn a m ic t oe pa t t er n is t h e in wa r d a n d ou t wa r d t oe or m in u s t h e ca m ber a n gle, depen din g on wh et h er or
m ovem en t of t h e fr on t a n d r ea r t ir es t h r ou gh t h e n ot t h e wh eel h a s posit ive or n ega t ive ca m ber (F ig.
su spen sion ’s jou n ce a n d r ebou n d t r a vel. As t h e veh i- 5). If ca m ber is posit ive, a dd t h e ca m ber a n gle t o t h e
cle’s su spen sion m oves u p a n d down , t h e t oe pa t t er n S.A.I. a n gle. If ca m ber is n ega t ive, su bt r a ct t h e ca m -
va r ies. Toe pa t t er n is cr it ica l in con t r ollin g t h e dir ec- ber a n gle fr om t h e S.A.I. a n gle. In clu ded a n gle is n ot
t ion a l st a bilit y of t h e veh icle wh ile in m ot ion . F r on t a dju st a ble, bu t ca n be u sed t o dia gn ose a fr a m e m is-
a n d r ea r dyn a m ic t oe pa t t er n is pr eset by t h e fa ct or y a lign m en t or ben t su spen sion com pon en t (spin dle,
a t t h e t im e t h e veh icle is a ssem bled. st r u t ).
It is n ot n ecessa r y t o ch eck or a dju st fr on t or r ea r
dyn a m ic t oe pa t t er n wh en doin g a n or m a l wh eel
a lign m en t . Th e on ly t im e dyn a m ic t oe pa t t er n n eeds
t o be ch ecked or a dju st ed is if t h e fr a m e of t h e veh i-
cle h a s been da m a ged.
THRUST ANGLE
Th r u st a n gle is t h e a ver a ged dir ect ion t h e r ea r
wh eels a r e poin t in g in r ela t ion t o t h e veh icle’s cen t er
lin e (F ig. 6). Th e pr esen ce of n ega t ive or posit ive
t h r u st a n gle ca u ses t h e r ea r t ir es t o t r a ck im pr oper ly
t o t h e left or r igh t of t h e fr on t t ir es (dog t r a ckin g).
• Nega t ive t h r u st a n gle m ea n s t h e r ea r t ir es a r e
t r a ckin g t o t h e left of t h e fr on t t ir es.
• P osit ive t h r u st a n gle m ea n s t h e r ea r t ir es a r e
t r a ckin g t o t h e r igh t of t h e fr on t t ir es.
Im pr oper t r a ckin g ca n ca u se u n du e t ir e wea r, a
lea d or pu ll a n d a cr ooked st eer in g wh eel. E xcessive
t h r u st a n gle ca n u su a lly be cor r ect ed by a dju st in g
t h e r ea r wh eel t oe so t h a t ea ch wh eel h a s on e-h a lf of
t h e t ot a l t oe m ea su r em en t .
Fig. 6 Thrust Angle
DIAGNOSIS AND TESTING - SUSPENSION AND STEERING
CONDITION POSSIBLE CAUSES CORRECTION
Front End Whine On Turns 1. Defective wheel bearing 1. Replace wheel bearing
2. Incorrect wheel alignment 2. Check and reset wheel alignment

3. Worn tires 3. Replace tires
Front End Growl Or 1. Defective wheel bearing 1. Replace wheel bearing

Grinding On Turns 2. Engine mount grounding 2. Check for motor mount hitting frame
rail and reposition engine as required
3. Worn or broken C/V joint 3. Replace C/V joint
4. Loose wheel lug nuts 4. Verify wheel lug nut torque
5. Incorrect wheel alignment 5. Check and reset wheel alignment
7. Front strut pin in upper strut mount 7. Replace the front strut upper mount
and bearing
Front End Clunk Or Snap 1. Loose lug nuts 1. Verify wheel lug nut torque
On Turns
3. Worn or loose tie rod 3. Tighten or replace tie rod end
4. Worn or loose ball joint 4. Tighten or replace ball joint
5. Worn/loose control arm bushing 5. Replace control arm bushing
6. Loose stabilizer bar. 6. Tighten stabilizer bar to specified
torque
7. Loose strut mount to body 7. Tighten strut attachment to specified
attachment torque
8. Loose crossmember bolts 8. Tighten crossmember bolts to
specified torque
Front End Whine With 1. Defective wheel bearing 1. Replace wheel bearing
Vehicle Going Straight At A
Constant Speed 2. Incorrect wheel alignment 2. Check and reset wheel alignment
4. Worn or defective transaxle gears or 4. Replace transaxle gears or bearings
bearings
Front End Growl Or 1. Engine mount grounding 1. Reposition engine as required

Grinding With Vehicle
Going Straight At A 2. Worn or broken C/V joint 2. Replace C/V joint
Constant Speed
Front End Whine When 1. Worn or defective transaxle gears or 1. Replace transaxle gears or bearings
Accelerating Or bearings
Decelerating
Front End Clunk When 1. Worn or broken engine mount 1. Replace engine mount
Accelerating Or
Decelerating 2. Worn or defective transaxle gears or 2. Replace transaxle gears or bearings
bearings
3. Loose lug nuts 3. Verify wheel lug nut torque
5. Worn or loose ball joint 5. Tighten or replace ball joint
6. Worn or loose control arm bushing 6. Replace control arm bushing
7. Loose crossmember bolts 7. Tighten crossmember bolts to
specified torque
8. Worn tie rod end 8. Replace tie rod end
Road Wander 1. Incorrect tire pressure 1. Inflate tires to recommended pressure

2. Incorrect front or rear wheel toe 2. Check and reset wheel toe
3. Worn wheel bearings 3. Replace wheel bearing
4. Worn control arm bushings 4. Replace control arm bushing
5. Excessive friction in steering gear 5. Replace steering gear
6. Excessive friction in steering shaft 6. Replace steering coupler
coupling
7. Excessive friction in strut upper 7. Replace strut bearing
bearing
Lateral Pull 1. Unequal tire pressure 1. Inflate all tires to recommended

pressure
2. Radial tire lead 2. Perform lead correction procedure

3. Incorrect front wheel camber 3. Check and reset front wheel camber
4. Power steering gear imbalance 4. Replace power steering gear
5. Wheel braking 5. Correct braking condition causing
lateral pull
Excessive Steering Free 1. Incorrect Steering Gear Adjustment 1. Adjust Or Replace Steering Gear
Play
2. Worn or loose tie rod ends 2. Replace or tighten tie rod ends
3. Loose steering gear mounting bolts 3. Tighten steering gear bolts to specified
torque
4. Loose or worn steering shaft coupler 4. Replace steering shaft coupler
Excessive Steering Effort 1. Low tire pressure 1. Inflate all tires to recommended
pressure
2. Lack of lubricant in steering gear 2. Replace steering gear
3. Low power steering fluid level 3. Fill power steering fluid reservoir to
correct level
4. Loose power steering pump drive 4. Correctly adjust power steering pump
belt drive belt
5. Lack of lubricant in ball joints 5. Lubricate or replace ball joints
6. Steering gear malfunction 6. Replace steering gear
7. Lack of lubricant in steering coupler 7. Replace steering coupler
STAN DARD PROCEDU RE (5) In spect lower ba ll join t s a n d a ll st eer in g lin k-

a ge for loosen ess, bin din g, wea r or da m a ge. Repa ir a s
STANDARD PROCEDURE - WHEEL ALIGNMENT n ecessa r y.
(6) Ch eck su spen sion fa st en er s for pr oper t or qu e
PRE-WHEEL ALIGNMENT INSPECTION a n d r et igh t en a s n ecessa r y.
Befor e a n y a t t em pt is m a de t o ch a n ge or cor r ect (7) In spect a ll su spen sion com pon en t r u bber bu sh -
t h e wh eel a lign m en t , t h e followin g in spect ion a n d in gs for sign s of wea r or det er ior a t ion . Repla ce a n y
n ecessa r y cor r ect ion s m u st be m a de t o en su r e pr oper fa u lt y bu sh in gs or com pon en t s befor e a lign in g t h e
a lign m en t . veh icle.
(1) Ver ify t h a t t h e fu el t a n k is fu ll of fu el. If t h e (8) Ch eck t h e veh icle’s cu r b h eigh t t o ver ify it is
t a n k is n ot fu ll, t h e r edu ct ion in weigh t will a ffect wit h in specifica t ion s. Refer t o Cu r b H eigh t Mea su r e-
t h e cu r b h eigh t of t h e veh icle a n d t h e a lign m en t m en t .
a n gles.
(2) Th e pa ssen ger a n d lu gga ge com pa r t m en t s of WHEEL ALIGNMENT SETUP
t h e veh icle sh ou ld be fr ee of a n y loa d t h a t is n ot fa c- (1) P osit ion t h e veh icle on a n a lign m en t r a ck.
t or y equ ipm en t . (2) In st a ll a ll r equ ir ed a lign m en t equ ipm en t on
(3) Ch eck t h e t ir es on t h e veh icle. All t ir es m u st be t h e veh icle per t h e a lign m en t equ ipm en t m a n u fa ct u r-
t h e sa m e size a n d in good con dit ion wit h a ppr oxi- er ’s in st r u ct ion s. On t h is veh icle, a fou r-wh eel a lign -
m a t ely t h e sa m e a m ou n t of t r ea d wea r. In fla t e a ll m en t is r ecom m en ded.
t h e t ir es t o t h e r ecom m en ded a ir pr essu r e.
(4) Ch eck t h e fr on t wh eel a n d t ir e a ssem blies for
excessive r a dia l r u n ou t .
NOTE: Prior to reading the vehicle’s alignment h a s been m odified. To in st a ll a n d a dju st t h e ca m ber
readouts, the front and rear of vehicle should be a dju st m en t bolt pa cka ge, follow t h e pr ocedu r e below.
jounced. Induce jounce (rear first, then front) by (1) Ra ise t h e veh icle u n t il it s t ir es a r e n ot su ppor t -
grasping the center of the bumper and jouncing in g t h e weigh t of t h e veh icle.
each end of vehicle an equal number of times. The (2) Rem ove t h e fr on t t ir e a n d wh eel a ssem blies.
bumper should always be released when vehicle is
at the bottom of the jounce cycle. CAUTION: When removing the steering knuckle
from the strut clevis bracket, do not put a strain on
(3) Rea d t h e veh icle’s cu r r en t fr on t a n d r ea r a lign - the brake flex hose. Also, do not let the weight of
m en t set t in gs. Com pa r e t h e veh icle’s cu r r en t a lign - the steering knuckle assembly be supported by the
m en t set t in gs t o t h e veh icle specifica t ion s for ca m ber, brake flex hose when removed from the strut
ca st er a n d t oe-in . (Refer t o 2 - SUSP E NSION/ assembly. If necessary use a wire hanger to sup-
WH E E L ALIGNME NT - SP E CIF ICATIONS) port the steering knuckle assembly or if required
(4) If fr on t ca m ber a n d ca st er a r e n ot wit h in spec- remove the brake flex hose from the caliper assem-
ifica t ion s, pr oceed t o CAMBE R AND CASTE R below. bly.
If ca st er a n d ca m ber a r e wit h in specifica t ion s, pr o-
ceed t o TOE wh ich ca n be fou n d followin g CAMBE R
AND CASTE R. Rea r ca m ber, ca st er a n d t oe a r e n ot CAUTION: The knuckle to strut assembly attaching
a dju st a ble. If fou n d n ot t o be wit h in specifica t ion s, bolt shanks are serrated and must not be turned
r ein spect for da m a ged su spen sion or body com po- during removal. Remove the nuts while holding the
n en t s a n d r epla ce a s n ecessa r y. bolts stationary.
(3) Rem ove t h e t op a n d bot t om , st r u t clevis

CAMBER AND CASTER
br a cket t o st eer in g kn u ckle a t t a ch in g bolt s (F ig.
Ca m ber a n d ca st er set t in gs on t h is veh icle a r e
7)a n d disca r d. Sepa r a t e t h e st eer in g kn u ckle fr om
det er m in ed a t t h e t im e t h e veh icle is design ed, by
t h e st r u t clevis br a cket a n d posit ion st eer in g kn u ckle
t h e loca t ion of t h e veh icle’s su spen sion com pon en t s.
so it is ou t of t h e wa y of t h e st r u t .
Th is is r efer r ed t o a s NE T BUILD. Th e r esu lt is n o
r equ ir ed a dju st m en t of ca m ber a n d ca st er a ft er t h e
veh icle is bu ilt or wh en ser vicin g t h e su spen sion
com pon en t s. Th u s, wh en per for m in g a wh eel a lign -
m en t , ca st er a n d ca m ber a r e n ot n or m a lly con sider ed
a dju st a ble a n gles. Ca m ber a n d ca st er sh ou ld be
ch ecked t o en su r e t h ey m eet veh icle specifica t ion s.
If fr on t ca m ber is fou n d n ot t o m eet a lign m en t
specifica t ion s, it ca n be a dju st ed u sin g a n a va ila ble
ca m ber a dju st m en t bolt pa cka ge. Befor e in st a llin g a
ca m ber a dju st m en t bolt pa cka ge on a veh icle fou n d
t o be ou t side t h e specifica t ion s, in spect t h e su spen -
sion com pon en t s for a n y sign s of da m a ge or ben din g.
CAUTION: Do not attempt to adjust the vehicles

wheel alignment by heating, bending or by perform-
ing any other modification to the vehicle’s front
suspension components or body. Fig. 7 Clevis Bracket To Steering Knuckle Attaching
Bolts
If ca m ber r ea din gs a r e n ot wit h in specifica t ion s, 1 - STRUT CLEVIS BRACKET
u se t h e followin g pr ocedu r e t o in st a ll t h e fr on t ca m - 2 - ATTACHING BOLTS
ber a dju st m en t bolt pa cka ge a n d t h en a dju st fr on t 3 - TIE ROD END
4 - ROTOR
ca m ber. 5 - STEERING KNUCKLE
CAMBER ADJUSTMENT BOLT PACKAGE INSTALLATION CAUTION: When slotting the bottom mounting hole
Th e ca m ber a dju st m en t bolt pa cka ge con t a in s 2 on the strut clevis bracket, do not enlarge the hole
fla n ge bolt s, 2 ca m bolt s, 2 dog bon e wa sh er s, a n d 4 beyond the indentations on the sides of the strut
n u t s. Th is pa cka ge ser vices bot h sides of t h e veh icle. clevis bracket (Fig. 8).
Use t h e pa cka ge t o a t t a ch t h e st r u t clevis br a cket t o
t h e st eer in g kn u ckle a ft er t h e st r u t clevis br a cket
(4) Usin g a n a ppr opr ia t e gr in der a n d gr in din g
wh eel, slot t h e bot t om h ole in bot h sides of t h e st r u t
clevis br a cket (F ig. 8).
Fig. 9 Package Bolts Correctly Installed

Fig. 8 Strut Clevis Bracket Bolt Hole Grinding Area 3 - CAM BOLT IN BOTTOM HOLE
1 - UPPER STRUT TO STEERING KNUCKLE ATTACHING HOLE 4 - STRUT CLEVIS BRACKET
2 - CAMBER ADJUSTMENT SLOT INDENTATION AREA ON
CLEVIS BRACKET
3 - LOWER STRUT TO STEERING KNUCKLE ATTACHING HOLE
4 - STRUT CLEVIS BRACKET
CAUTION: After slotting the strut clevis bracket

hole, do not install the original attaching bolts when
assembling the steering knuckle to the strut assem-
bly. Only the flange bolts, cam bolts, and dog bone
washers from the service package must be used to
attach the steering knuckle to the strut after the
mounting hole is slotted.
NOTE: The strut clevis-to-knuckle bolts are installed

differently on each side of the vehicle. Left-hand-
side bolts are installed from vehicle rear to front
(Fig. 9). Right-hand-side bolts are installed from
vehicle front to rear. Fig. 10 Dog Bone Washer And Nuts Installed
(5) P osit ion t h e kn u ckle ba ck in t o t h e st r u t clevis 2 - DOG BONE WASHER
br a cket . Usin g t h e dir ect ion in dica t ed in t h e a bove 3 - STRUT CLEVIS BRACKET
n ot e, in st a ll a fla n ged bolt fr om t h e ser vice pa cka ge 4 - ATTACHING NUTS
in t o t h e u pper m ou n t in g h ole. Usin g t h e dir ect ion
in dica t ed in t h e a bove n ot e, in st a ll a ca m bolt in t o (9) Lower t h e veh icle. J ou n ce t h e fr on t a n d r ea r of
t h e bot t om m ou n t in g h ole (F ig. 9). veh icle a n equ a l a m ou n t of t im es.
(6) In st a ll a dog bon e wa sh er on t h e st eer in g (10) Adju st t h e fr on t ca m ber t o t h e pr efer r ed set -
kn u ckle t o st r u t clevis br a cket a t t a ch in g bolt s, t h en t in g by r ot a t in g t h e lower eccen t r ic ca m bolt a ga in st
in st a ll t h e n u t s on t o t h e bolt s fr om t h e ser vice pa ck- t h e ca m st op a r ea s on t h e st r u t clevis br a cket (F ig.
a ge (F ig. 10). Tigh t en t h e bolt s ju st en ou gh t o h old 11). Wh en ca m ber is set , t igh t en t h e u pper st r u t cle-
t h e st eer in g kn u ckle in posit ion wh en a dju st in g ca m - vis br a cket bolt a n d lower ca m bolt . Aga in jou n ce
ber, wh ile st ill a llowin g t h e st eer in g kn u ckle t o m ove fr on t a n d r ea r of veh icle a n equ a l a m ou n t of t im es
in clevis br a cket . a n d ver ify fr on t ca m ber set t in g. Tor qu e bot h fr on t
(7) Repea t t h e pr ocedu r e t o t h e ot h er side st r u t st r u t t o st eer in g kn u ckle a t t a ch in g bolt s t o 81 N·m
clevis br a cket . (60 ft . lbs.) plu s a n a ddit ion a l 1/4 (90°) t u r n a ft er t h e
(8) Rein st a ll bot h fr on t t ir e a n d wh eel a ssem blies r equ ir ed t or qu e is m et .
a n d t igh t en t o specifica t ion s.
Fig. 11 Camber Adjustment Cam Bolt Fig. 12 Front Wheel Toe Adjustment
1 - STEERING KNUCKLE 1 - INNER TIE ROD SERRATION
2 - CLEVIS BRACKET CAM STOP AREAS 2 - OUTER TIE ROD JAM NUT
3 - LOWER ECCENTRIC CAMBER ADJUSTMENT BOLT 3 - OUTER TIE ROD END
4 - INNER TIE ROD
(11) If t oe r ea din gs obt a in ed a r e n ot wit h in t h e
r equ ir ed specifica t ion r a n ge, a dju st t oe t o m eet t h e
pr efer r ed specifica t ion set t in g. Toe is a dju st a ble
STANDARD PROCEDURE - CURB HEIGHT
u sin g t h e followin g pr ocedu r e. MEASUREMENT
Th e wh eel a lign m en t is t o be ch ecked a n d a ll a lign -
TOE m en t a dju st m en t s m a de wit h t h e veh icle a t it s
(1) Cen t er t h e st eer in g wh eel a n d lock in pla ce r equ ir ed cu r b h eigh t specifica t ion .
u sin g a st eer in g wh eel cla m p. Veh icle h eigh t is t o be ch ecked wit h t h e veh icle on
a fla t , level su r fa ce, pr efer a bly a veh icle a lign m en t
CAUTION: Do not twist front inner tie rod to steer- r a ck. Th e t ir es a r e t o be in fla t ed t o t h e r ecom m en ded
ing gear rubber boots during front wheel Toe pr essu r e. All t ir es a r e t o be t h e sa m e size a s st a n -
adjustment. da r d equ ipm en t . Veh icle h eigh t is ch ecked wit h t h e
fu el t a n k fu ll of fu el, a n d n o pa ssen ger or lu gga ge
(2) Loosen fr on t in n er t o ou t er t ie r od en d ja m com pa r t m en t loa d.
n u t s (F ig. 12). Gr a sp in n er t ie r ods a t ser r a t ion s a n d Veh icle h eigh t is n ot a dju st a ble. If t h e m ea su r e-
r ot a t e in n er t ie r ods of st eer in g gea r (F ig. 12) t o set m en t is n ot wit h in specifica t ion s, in spect t h e veh icle
fr on t t oe t o t h e pr efer r ed t oe specifica t ion . (Refer t o 2 for ben t or wea k su spen sion com pon en t s. Com pa r e
- SUSP E NSION/WH E E L ALIGNME NT - SP E CIF I- t h e pa r t s t a g on t h e su spect coil spr in g(s) t o t h e
CATIONS) pa r t s book a n d t h e veh icle sa les code, ch eckin g for a
(3) Tigh t en t ie r od ja m n u t s (F ig. 12) t o 75 N·m m a t ch . On ce r em oved fr om t h e veh icle, com pa r e t h e
(55 ft . lbs.) t or qu e. coil spr in g h eigh t t o a cor r ect n ew or kn own good coil
(4) Adju st st eer in g gea r t o t ie r od boot s a t t h e spr in g. Th e h eigh t s sh ou ld va r y if t h e su spect spr in g
in n er t ie r od. is wea k.
(5) Rem ove st eer in g wh eel cla m p. (1) Mea su r e fr om t h e in boa r d edge of t h e wh eel
(6) Rem ove t h e a lign m en t equ ipm en t . open in g fen der lip dir ect ly a bove t h e wh eel cen t er
(7) Roa d t est t h e veh icle t o ver ify t h e st eer in g (spin dle), t o t h e floor or a lign m en t r a ck su r fa ce.
wh eel is st r a igh t a n d t h e veh icle does n ot wa n der or (2) Wh en m ea su r in g, t h e m a xim u m left -t o-r igh t
pu ll. differ en t ia l is n ot t o exceed 12.5 m m (0.5 in .).
(3) Com pa r e t h e m ea su r em en t s t o t h e specifica -
t ion s list ed in t h e followin g Cu r b H eigh t Specifica -
t ion s ch a r t s.
CU RB H EI GH T SPECI FI CAT I ON S
VEHICLE FRONT REAR

755 mm ± 11 mm 795 mm ± 11 mm
CARGO VAN
29.72 in. ± 0.43 in 31.30 in. ± 0.43 in.
755 mm ± 11 mm 770 mm ± 11 mm
ALL OTHERS
29.72 in. ± 0.43 in 30.31 in. ± 0.43 in.
SPECI FI CAT I ON S NOTE: All wheel alignments are to be set at curb

height. (Refer to 2 - SUSPENSION/WHEEL ALIGN-
WHEEL ALIGNMENT MENT - STANDARD PROCEDURE)
NOTE: All specifications are given in degrees.
FRONT WHEEL ALIGNMENT PREFERRED SETTING ACCEPTABLE RANGE

CAMBER +0.10° -0.30° to +0.50°
Cross-Camber (Maximum side-to-side 0.0° 0.50°
difference)
CASTER* +2.31° +1.31° to +3.31°
Cross-Caster (Maximum side-to-side difference) 0.0° 1.00°
TOTAL TOE** +0.10° !0.10° to +0.30°
Maximum side-to-side difference 0.0° 0.06°
REAR WHEEL ALIGNMENT PREFERRED SETTING ACCEPTABLE RANGE
CAMBER* 0.0° -0.25° to +0.25°
TOTAL TOE* ** 0.0° !0.20° to +0.20°
THRUST ANGLE* 0.0° -0.30° to +0.30°
Notes:
* For reference only. These are non-adjustable angles.
** TOTAL TOE is the sum of both left and right wheel toe settings. TOTAL TOE must be equally split between
each front wheel to ensure the steering wheel is centered after setting toe. Positive toe is toe-in and negative toe
is toe-out
RS DIFFERENTIAL & DRIVELINE 3-1
DIFFERENTIAL & DRIVELINE
H ALF SH AFT - FRON T
TABLE OF CONTENTS
page page
HALF SHAFT - FRONT CV BOOT - INNER

DESCRIPTION . . . . . . . . . . . . . . . . . . . . .. . . . .1 REMOVAL .............................6
DIAGNOSIS AND TESTING - HALF SHAFT . . . . .1 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7
REMOVAL ....................... .. . . . .2 CV BOOT - OUTER
INSTALLATION . . . . . . . . . . . . . . . . . . . . .. . . . .4 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SPECIFICATIONS - HALF SHAFT - FRONT . . . .6 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11
H ALF SH AFT - FRON T DIAGNOSIS AND TESTING - HALF SHAFT
DESCRIPTION VEHICLE INSPECTION

All veh icles u se a n u n equ a l len gt h h a lf sh a ft sys- (1) Ch eck for gr ea se in t h e vicin it y of t h e in boa r d
t em (F ig. 1). t r ipod join t a n d ou t boa r d CV join t ; t h is is a sign of
Th e left h a lf sh a ft u ses a t u n ed r u bber da m per in n er or ou t er join t sea l boot or sea l boot cla m p da m -
weigh t . Wh en r epla cin g t h e left h a lf sh a ft , be su r e a ge.
t h e r epla cem en t h a lf sh a ft h a s t h e sa m e da m per
weigh t a s t h e or igin a l. NOISE AND/OR VIBRATION IN TURNS
All h a lf sh a ft a ssem blies u se t h e sa m e t ype of A clickin g n oise a n d/or a vibr a t ion in t u r n s cou ld
in n er a n d ou t er join t s. Th e in n er join t of bot h h a lf be ca u sed by on e of t h e followin g con dit ion s:
sh a ft a ssem blies is a t r ipod join t , a n d t h e ou t er join t • Da m a ged ou t er CV or in n er t r ipod join t sea l
of bot h h a lf sh a ft a ssem blies is a Rzeppa join t . Bot h boot or sea l boot cla m ps. Th is will r esu lt in t h e loss
t r ipod join t s a n d Rzeppa join t s a r e t r u e con st a n t a n d/or con t a m in a t ion of t h e join t gr ea se, r esu lt in g in
velocit y (CV) join t a ssem blies. Th e in n er t r ipod join t in a dequ a t e lu br ica t ion of t h e join t .
a llows for t h e ch a n ges in h a lf sh a ft len gt h t h r ou gh • Noise m a y a lso be ca u sed by a n ot h er com pon en t
t h e jou n ce a n d r ebou n d t r a vel of t h e fr on t su spen - of t h e veh icle com in g in con t a ct wit h t h e h a lf sh a ft s.
sion .
On veh icles equ ipped wit h ABS br a kes, t h e ou t er CLUNKING NOISE DURING ACCELERATION
CV join t is equ ipped wit h a t on e wh eel u sed t o det er- Th is n oise m a y be a r esu lt of on e of t h e followin g
m in e veh icle speed for ABS br a ke oper a t ion . con dit ion s:
Th e in n er t r ipod join t of bot h h a lf sh a ft s is splin ed • A t or n sea l boot on t h e in n er or ou t er join t of t h e
in t o t h e t r a n sa xle side gea r s. Th e in n er t r ipod join t s h a lf sh a ft a ssem bly.
a r e r et a in ed in t h e side gea r s of t h e t r a n sa xle u sin g • A loose or m issin g cla m p on t h e in n er or ou t er
a sn a p r in g loca t ed in t h e st u b sh a ft of t h e t r ipod join t of t h e h a lf sh a ft a ssem bly.
join t . Th e ou t er CV join t h a s a st u b sh a ft t h a t is • A da m a ged or wor n h a lf sh a ft CV join t .
splin ed in t o t h e wh eel h u b a n d r et a in ed by a st eel
hub nut. SHUDDER OR VIBRATION DURING ACCELERATION
Th is pr oblem cou ld be a r esu lt of:
• A wor n or da m a ged h a lf sh a ft in n er t r ipod join t .
3-2 HALF SHAFT - FRONT RS
H ALF SH AFT - FRON T (Cont inue d)
Fig. 1 Unequal Length Half Shaft System

1 - STUB AXLE 8 - OUTER C/V JOINT
2 - OUTER C/V JOINT 9 - RIGHT HALFSHAFT
3 - OUTER C/V JOINT BOOT 10 - INNER TRIPOD JOINT BOOT
4 - TUNED RUBBER DAMPER WEIGHT 11 - INNER TRIPOD JOINT
5 - INTERCONNECTING SHAFT 12 - INNER TRIPOD JOINT
6 - OUTER C/V JOINT BOOT 13 - INNER TRIPOD JOINT BOOT
7 - STUB AXLE 14 - INTERCONNECTING SHAFT LEFT HALFSHAFT
• A st ickin g t r ipod join t spider a ssem bly (in n er t r i-

pod join t on ly).
• Im pr oper wh eel a lign m en t . (Refer t o 2 - SUS-
P E NSION/WH E E L ALIGNME NT - STANDARD
P ROCE DURE )
VIBRATION AT HIGHWAY SPEEDS

Th is pr oblem cou ld be a r esu lt of:
• F or eign m a t er ia l (m u d, et c.) pa cked on t h e ba ck-
side of t h e wh eel(s).
• Ou t of ba la n ce t ir es or wh eels. (Refer t o 22 -
TIRE S/WH E E LS - STANDARD P ROCE DURE )
• Im pr oper t ir e a n d/or wh eel r u n ou t . (Refer t o 22 -
TIRE S/WH E E LS - DIAGNOSIS AND TE STING)
REMOVAL
(1) Ra ise veh icle. Fig. 2 Half Shaft Retaining Nut
(2) Rem ove t h e cot t er pin , n u t lock (F ig. 2) a n d 1 - HUB/BEARING
2 - NUT LOCK
wa ve wa sh er (F ig. 3) fr om t h e en d of t h e h a lf sh a ft . 3 - COTTER PIN
(3) Rem ove t h e wh eel a n d t ir e a ssem bly fr om t h e 4 - STUB AXLE
veh icle. (Refer t o 22 - TIRE S/WH E E LS - RE MOVAL)
sary to install and properly torque a bolt through
CAUTION: The halfshaft outer CV Joint, when the hub. This will ensure that the hub/bearing
installed, acts as a bolt and secures the hub/bear- assembly will not loosen.
ing assembly. If the vehicle is to be supported or
moved while the halfshaft is removed, it is neces-
RS HALF SHAFT - FRONT 3-3
(7) Su ppor t disc br a ke ca liper a ssem bly by u sin g a
wir e h ook a n d su spen din g it fr om t h e st r u t a ssem bly
(F ig. 5). D o n o t a llo w th e bra k e c a lip e r a s s e m bly
to h a n g by th e bra k e fle x h o s e .
Fig. 3 Wave Washer

1 - HUB/BEARING ASSEMBLY
2 - WAVE WASHER
3 - STUB AXLE
(4) Wit h t h e veh icle’s br a kes a pplied t o keep h u b Fig. 5 Properly Supported Disc Brake Caliper -
fr om t u r n in g, lo o s e n a n d re m o v e t h e h a lf sh a ft Typical
nut. 1 - STEERING KNUCKLE
(5) Rem ove t h e t wo fr on t disc br a ke ca liper 2 - BRAKE FLEX HOSE
3 - CALIPER ASSEMBLY
a da pt er t o st eer in g kn u ckle a t t a ch in g bolt s (F ig. 4). 4 - WIRE HANGER
5 - STRUT ASSEMBLY
(8) Rem ove t h e br a ke r ot or fr om t h e h u b a n d bea r-

in g a ssem bly.
(9) Rem ove t h e st eer in g kn u ckle-t o-st r u t a t t a ch -
m en t bolt s (F ig. 6) fr om t h e st eer in g kn u ckle.

1 - BRAKE ROTOR
2 - HUB AND BEARING
4 - ADAPTER MOUNTING BOLTS
5 - BRAKE CALIPER
6 - ADAPTER
7 - CLIP Fig. 6 Strut To Steering Knuckle Attaching Bolts
1 - STRUT CLEVIS BRACKET
(6) Rem ove t h e disc br a ke ca liper a ssem bly fr om 2 - NUTS AND BOLTS
t h e st eer in g kn u ckle. Ca liper a ssem bly is r em oved by 3 - STEERING KNUCKLE
fir st r ot a t in g t op of ca liper a ssem bly a wa y fr om
st eer in g kn u ckle a n d t h en r em ovin g bot t om of a ssem - (10) P u ll t h e st eer in g kn u ckle fr om t h e st r u t clevis
bly ou t fr om u n der m a ch in ed a bu t m en t on st eer in g br a cket .
kn u ckle.
NOTE: Care must be taken not to separate the inner
C/V joint during this operation. Do not allow half shaft
to hang by inner C/V joint after removing outer C/V
Joint from the hub/bearing assembly in steering
knuckle, end of half shaft must be supported.
(11) P u ll st eer in g kn u ckle a ssem bly down a n d

a wa y fr om t h e ou t er C/V join t of t h e h a lf sh a ft
a ssem bly wh ile pu llin g t h e join t ou t of t h e h u b bea r-
in g.
(12) Su ppor t t h e ou t er en d of t h e h a lf sh a ft a ssem -
bly. In ser t a pr y ba r bet ween in n er t r ipod join t a n d
t r a n sa xle ca se (F ig. 7). P r y a ga in st in n er t r ipod join t ,
u n t il t r ipod join t r et a in in g sn a p-r in g is disen ga ged
fr om t r a n sa xle side gea r.
Fig. 8 Tripod Joint Removal from Transaxle

1 - INNER TRIPOD JOINT
2 - TRANSAXLE
3 - SPLINE
4 - OIL SEAL
5 - SNAP-RING
6 - INTERCONNECTING SHAFT
a xle side gea r. Te s t th a t s n a p -rin g is fu lly

e n g a g e d w ith s id e g e a r by a tte m p tin g to
re m o v e trip o d jo in t fro m tra n s a x le by h a n d . If
s n a p -rin g is fu lly e n g a g e d w ith s id e g e a r, trip o d
jo in t w ill n o t be re m o v a ble by h a n d .
(4) Clea n a ll debr is a n d m oist u r e ou t of st eer in g
kn u ckle, in t h e a r ea wer e ou t er CV join t will be
in st a lled in t o st eer in g kn u ckle.
Fig. 7 Disengaging Inner Tripod Joint From (5) E n su r e t h a t fr on t of ou t er CV join t wh ich fit s
Transaxle a ga in st t h e fa ce of t h e h u b a n d bea r in g is fr ee of
1 - INNER TRIPOD JOINT
debr is a n d m oist u r e befor e in st a llin g ou t er CV join t
2 - TRANSAXLE CASE in t o h u b a n d bea r in g a ssem bly (F ig. 9).
3 - PRY BAR
(13) H old in n er t r ipod join t a n d in t er con n ect in g

sh a ft of h a lf sh a ft a ssem bly. Rem ove in n er t r ipod
join t fr om t r a n sa xle, by pu llin g it st r a igh t ou t of
t r a n sa xle side gea r a n d t r a n sa xle oil sea l (F ig. 8).
Wh e n re m o v in g trip o d jo in t, d o n o t le t s p lin e o r
s n a p -rin g d ra g a c ro s s s e a lin g lip o f th e tra n s -
a x le to trip o d jo in t o il s e a l.
INSTALLATION
(1) Th or ou gh ly clea n splin e a n d oil sea l sea lin g
su r fa ce, on t r ipod join t . Ligh t ly lu br ica t e oil sea l
sea lin g su r fa ce on t r ipod join t wit h fr esh clea n t r a n s-
m ission lu br ica n t .
(2) H oldin g h a lf sh a ft a ssem bly by t r ipod join t a n d
in t er con n ect in g sh a ft , in st a ll t r ipod join t in t o t r a n s-
a xle side gea r a s fa r a s possible by h a n d (F ig. 8). Be Fig. 9 Outer CV Joint Inspection
su r e t o en ga ge splin es pr ior t o a pplyin g for ce. 1 - OUTER C/V JOINT
(3) Gr a sp in n er t r ipod join t a n in t er con n ect in g 2 - THIS AREA OF OUTER C/V JOINT MUST BE FREE OF ALL
DEBRIS AND MOISTURE, BEFORE INSTALLATION INTO
sh a ft . F or cefu lly pu sh t h e t r ipod join t in t o side gea r STEERING KNUCKLE.
of t r a n sa xle, u n t il sn a p-r in g is en ga ged wit h t r a n s-
(6) Slide h a lf sh a ft ba ck in t o fr on t h u b a n d bea r- br a ke ca liper a da pt er a t t a ch in g bolt s t o a t or qu e of
in g a ssem bly. 169 N·m (125 ft . lbs.).
(11) Clea n a ll for eign m a t t er fr om t h e t h r ea ds of
CAUTION: The steering knuckle to strut assembly t h e ou t er CV join t . In st a ll t h e wa sh er a n d h a lf sh a ft
attaching bolts are serrated and must not be turned t o h u b/bea r in g a ssem bly n u t on h a lf sh a ft a n d
during installation. Install nuts while holding bolts secu r ely t igh t en n u t .
stationary in the steering knuckle. (12) In st a ll fr on t wh eel a n d t ir e a ssem bly. In st a ll
a n d t igh t en t h e wh eel m ou n t in g st u d n u t s in pr oper
sequ en ce u n t il a ll n u t s a r e t or qu ed t o h a lf t h e
CAUTION: If the vehicle being serviced is equipped
r equ ir ed specifica t ion . Th en r epea t t h e t igh t en in g
with eccentric strut assembly attaching bolts, the
sequ en ce t o t h e fu ll specified t or qu e of 135 N·m (100
eccentric bolt must be installed in the bottom (slot-
ft . lbs.).
ted) hole on the strut clevis bracket (Fig. 10).
(14) Wit h t h e veh icle’s br a kes a pplied t o keep h u b
fr om t u r n in g, t igh t en t h e h u b n u t t o a t or qu e of 244
N·m (180 ft . lbs.) (F ig. 11).
Fig. 10 Correctly Installed Eccentric Attaching Bolt

3 - CAM BOLT IN BOTTOM HOLE
4 - STRUT CLEVIS BRACKET Fig. 11 Torquing Front Half Shaft To Hub Nut
1 - TORQUE WRENCH
(7) In st a ll st eer in g kn u ckle in clevis br a cket of
st r u t da m per a ssem bly. In st a ll t h e st r u t da m per t o (15) In st a ll t h e spr in g wa ve wa sh er on t h e en d of
st eer in g kn u ckle a t t a ch in g bolt s. Tigh t en bot h bolt s t h e h a lf sh a ft .
t o a t or qu e of 88 N·m (65 ft . lbs.) plu s a n a ddit ion a l (16) In st a ll t h e h u b n u t lock, a n d a n e w cot t er pin
1/4 t u r n . (F ig. 2). Wr a p cot t er pin pr on gs t igh t ly a r ou n d t h e
(8) In st a ll br a kin g disc on h u b a n d bea r in g a ssem - h u b n u t lock a s sh own in (F ig. 2).
bly. (17) Ch eck for cor r ect flu id level in t r a n sa xle
(9) In st a ll disc br a ke ca liper a ssem bly on st eer in g a ssem bly. (Refer t o 21 - TRANSMISSION/TRANS-
kn u ckle. Ca liper is in st a lled by fir st slidin g bot t om of AXLE /AUTOMATIC - 41TE /F LUID - STANDARD
ca liper a ssem bly u n der a bu t m en t on st eer in g P ROCE DURE )
kn u ckle, a n d t h en r ot a t in g t op of ca liper a ga in st t op
a bu t m en t .
(10) In st a ll disc br a ke ca liper a da pt er t o st eer in g
kn u ckle a t t a ch in g bolt s (F ig. 4). Tigh t en t h e disc
SPECIFICATIONS - HALF SHAFT - FRONT

TORQUE SPECIFICATIONS
DESCRIPTION N·m Ft. Lbs. In. Lbs.

Bolts, Caliper Adapter to 169 125 -
Knuckle
Nut, Hub 244 180 -
Nuts, Front Wheel Lug 135 100 -
Nut, Tie Rod End to 75 55 -
Knuckle
Nut, Strut Clevis to 81 +90° 60 +90° -
Knuckle
CV BOOT - I N N ER (6) Rem ove sn a p-r in g wh ich r et a in s spider a ssem -

bly t o in t er con n ect in g sh a ft (F ig. 13). D o n o t h it th e
o u te r trip o d be a rin g s in a n a tte m p t to re m o v e
REMOVAL
s p id e r a s s e m bly fro m in te rc o n n e c tin g s h a ft.
(1) Rem ove t h e h a lf sh a ft r equ ir in g boot r epla ce-
(7) Rem ove t h e spider a ssem bly fr om in t er con n ect -
m en t fr om t h e veh icle. (Refer t o 3 - DIF F E RE NTIAL
in g sh a ft . If spider a ssem bly will n ot com e off in t er-
& DRIVE LINE /H ALF SH AF T - RE MOVAL)
con n ect in g sh a ft by h a n d, it ca n be r em oved by
(2) Rem ove la r ge boot cla m p wh ich r et a in s in n er
t a ppin g spider a ssem bly wit h a br a ss dr ift (F ig. 14).
t r ipod join t sea lin g boot t o t r ipod join t h ou sin g a n d
disca r d.
(3) Rem ove sm a ll cla m p wh ich r et a in s in n er t r ipod
join t sea lin g boot t o in t er con n ect in g sh a ft a n d dis-
ca r d.
(4) Rem ove t h e sea lin g boot fr om t h e t r ipod h ou s-
in g a n d slide it down t h e in t er con n ect in g sh a ft .
(5) Slide t h e t r ipod join t h ou sin g off t h e spider
a ssem bly a n d t h e in t er con n ect in g sh a ft (F ig. 12).
Fig. 13 Spider Assembly Retaining Snap-Ring

2 - SPIDER ASSEMBLY
3 - RETAINING SNAP-RING
(8) Slide sea lin g boot off in t er con n ect in g sh a ft .

(9) Th or ou gh ly clea n a n d in spect spider a ssem bly,
t r ipod join t h ou sin g, a n d in t er con n ect in g sh a ft for
a n y sign s of excessive wea r. If a n y p a rts s h o w
Fig. 12 Spider Assembly Removal from Tripod Joint s ig n s o f e x c e s s iv e w e a r, th e h a lf s h a ft a s s e m bly
Housing w ill re qu ire re p la c e m e n t. Co m p o n e n t p a rts o f
1 - TRIPOD JOINT HOUSING th e s e h a lf s h a ft a s s e m blie s a re n o t s e rv ic e a ble .
2 - SPIDER ASSEMBLY
3 - SEALING BOOT
CV BOOT - I N N ER (Cont inue d)
(2) In st a ll spider a ssem bly on t o in t er con n ect in g
sh a ft (F ig. 16). Spider a ssem bly m u st be in st a lled on
in t er con n ect in g sh a ft fa r en ou gh t o fu lly in st a ll spi-
der r et a in in g sn a p-r in g. If t h e spider a ssem bly will
n ot fu lly in st a ll on in t er con n ect in g sh a ft by h a n d, it
ca n be in st a lled by t a ppin g t h e spider body wit h a
br a ss dr ift (F ig. 17). D o n o t h it th e o u te r trip o d
be a rin g s in a n a tte m p t to in s ta ll s p id e r a s s e m -
bly o n in te rc o n n e c tin g s h a ft.
Fig. 14 Spider Assembly Removal from

Interconnecting Shaft
1 - SPIDER ASSEMBLY
2 - DO NOT HIT SPIDER ASSEMBLY BEARINGS WHEN
REMOVING SPIDER ASSEMBLY
3 - BRASS DRIFT
INSTALLATION
(1) Slide in n er CV join t sea l boot r et a in in g cla m p,
on t o t h e in t er con n ect in g sh a ft . Th en , slide t h e
r epla cem en t in n er CV join t sea lin g boot on t o t h e Fig. 16 Spider Assembly Installation on
in t er con n ect in g sh a ft . In n e r CV jo in t s e a l bo o t Interconnecting Shaft
MU S T be p o s itio n e d o n in te rc o n n e c tin g s h a ft 1 - SPIDER ASSEMBLY
s o th e ra is e d be a d o n th e in s id e o f th e s m a ll 2 - INTERCONNECTING SHAFT
d ia m e te r e n d o f th e s e a l bo o t is in m a tin g
g ro o v e o n in te rc o n n e c tin g s h a ft (F ig . 15).
Fig. 17 Installing Spider Assembly on

Fig. 15 Sealing Boot Installation on Interconnecting Interconnecting Shaft
Shaft 1 - DO NOT HIT BEARINGS WHEN INSTALLING THE SPIDER
ASSEMBLY
1 - SEALING BOOT 2 - SPIDER ASSEMBLY
2 - RAISED BEAD IN THIS AREA OF SEALING BOOT 3 - INTERCONNECTING SHAFT
3 - GROOVE 4 - BRASS DRIFT
(3) In st a ll t h e spider a ssem bly t o in t er con n ect in g (7) P la ce cr im pin g t ool C-4975-A over br idge of
sh a ft r et a in in g sn a p-r in g in t o gr oove on en d of in t er- cla m p (F ig. 20).
con n ect in g sh a ft (F ig. 18). Be su r e t h e sn a p-r in g is (8) Tigh t en n u t on cr im pin g t ool C-4975-A u n t il
fu lly sea t ed in t o gr oove on in t er con n ect in g sh a ft . ja ws on t ool a r e closed com plet ely t oget h er, fa ce t o
fa ce (F ig. 21).
Fig. 18 Spider Assembly Retaining Snap-Ring

Installed
Fig. 20 Crimping Tool Installed on Sealing Boot
1 - INTERCONNECTING SHAFT Clamp - Typical
2 - SPIDER ASSEMBLY
3 - RETAINING SNAP-RING 1 - SPECIAL TOOL C-4975-A
3 - CLAMP
(4) Dist r ibu t e 1/2 t h e a m ou n t of gr ea se pr ovided in 4 - SEALING BOOT
t h e sea l boot ser vice pa cka ge (DO NOT USE ANY
OTH E R TYP E OF GRE ASE ) in t o t r ipod h ou sin g. P u t
t h e r em a in in g a m ou n t in t o t h e sea lin g boot .
(5) Align t r ipod h ou sin g wit h spider a ssem bly a n d
t h en slide t r ipod h ou sin g over spider a ssem bly a n d
in t er con n ect in g sh a ft (F ig. 19).
Fig. 21 Sealing Boot Retaining Clamp Installed -

Typical
1 - CLAMP
2 - JAWS OF SPECIAL TOOL C-4975-A MUST BE CLOSED
COMPLETELY TOGETHER HERE
Fig. 19 Installing Tripod Housing on Spider 4 - SEALING BOOT
Assembly
CAUTION: Seal boot must not be dimpled, stretched
1 - TRIPOD JOINT HOUSING
2 - SPIDER ASSEMBLY
or out of shape in any way. If seal boot is NOT
3 - SEALING BOOT shaped correctly, equalize pressure in seal and
shape it by hand.
(6) In st a ll in n er CV join t sea l boot t o in t er con n ect -
in g sh a ft cla m p even ly on sea lin g boot .
(9) P osit ion sea lin g boot in t o t h e t r ipod h ou sin g in th e CV jo in t, p re v e n tin g p re m a tu re s e a lin g
r et a in in g gr oove. In st a ll sea l boot r et a in in g cla m p bo o t fa ilu re .
even ly on sea lin g boot . (13) Cla m p CV join t sea lin g boot t o CV join t , u sin g
(10) P osit ion t r iloba l boot t o in t er fa ce wit h t h e t r i- r equ ir ed pr ocedu r e for t ype of boot cla m p a pplica t ion .
pod h ou sin g. Th e lobes of t h e boot m u st be pr oper ly
a lign ed wit h t h e r ecess’s of t h e t r ipod h ou sin g. CRIMP TYPE BOOT CLAMP
If sea l boot u ses cr im p t ype boot cla m p, u se t h e fol-
CAUTION: The following positioning procedure deter- lowin g pr ocedu r e t o in st a ll t h e r et a in in g cla m p.
mines the correct air pressure inside the inner CV (1) P la ce cr im pin g t ool C-4975-A over br idge of
joint assembly prior to clamping the sealing boot to cla m p (F ig. 23).
inner CV joint housing. If this procedure is not done (2) Tigh t en n u t on cr im pin g t ool C-4975-A u n t il
prior to clamping sealing boot to CV joint housing ja ws on t ool a r e closed com plet ely t oget h er, fa ce t o
sealing boot durability can be adversely affected. fa ce (F ig. 24).
CAUTION: When venting the inner CV joint assembly,

use care so that the inner CV sealing boot does not
get punctured, or in any other way damaged. If sealing
boot is punctured, or damaged in any way while being
vented, the sealing boot can not be used.
(11) In ser t a t r im st ick bet ween t h e CV join t h ou s-

in g a n d t h e sea lin g boot in ser t t o ven t in n er CV join t
a ssem bly (F ig. 22). Wh e n in s e rtin g trim s tic k
be tw e e n trip o d h o u s in g a n d s e a lin g bo o t
e n s u re trim s tic k is h e ld fla t a n d firm ly a g a in s t
th e trip o d h o u s in g . If th is is n o t d o n e d a m a g e
to th e s e a lin g bo o t c a n o c c u r.
Fig. 23 Crimping Tool Installed on Sealing Boot Clamp

1 - CLAMP
2 - TRIPOD JOINT HOUSING
3 - SPECIAL TOOL C-4975-A
4 - SEALING BOOT
Fig. 22 Trim Stick Inserted for Venting CV Joint

1 - INNER CV JOINT SEALING BOOT
2 - SEALING BOOT CLAMP
3 - INNER CV JOINT HOUSING
4 - TRIM STICK
(12) Wit h t r im st ick in ser t ed bet ween sea lin g boot

in ser t a n d t h e CV join t h ou sin g, posit ion t h e in t er con - Fig. 24 Sealing Boot Retaining Clamp Installed
n ect in g sh a ft so it is a t t h e cen t er of it s t r a vel in t h e 1 - CLAMP
2 - TRIPOD HOUSING
t r ipod join t h ou sin g. Rem ove t h e t r im st ick fr om 3 - SPECIAL TOOL C-4975-A
bet ween t h e sea lin g boot in ser t a n d t h e CV join t h ou s- 4 - JAWS OF SPECIAL TOOL C-4975-A MUST BE CLOSED
in g. Th is p ro c e d u re w ill e qu a lize th e a ir p re s s u re COMPLETELY TOGETHER HERE
5 - SEALING BOOT
3 - 10 HALF SHAFT - FRONT RS
LATCHING TYPE BOOT CLAMP CV BOOT - OU T ER
If sea l boot u ses low pr ofile la t ch in g t ype boot
cla m p, u se t h e followin g pr ocedu r e t o in st a ll t h e REMOVAL
r et a in in g cla m p. (1) Rem ove h a lfsh a ft a ssem bly r equ ir in g boot
(1) P la ce pr on gs of cla m p lockin g t ool in t h e h oles r epla cem en t fr om veh icle. (Refer t o 3 - DIF F E RE N-
of t h e cla m p (F ig. 25). TIAL & DRIVE LINE /H ALF SH AF T - RE MOVAL)
(2) Squ eeze t ool t oget h er u n t il t op ba n d of cla m p is (2) Rem ove la r ge boot cla m p r et a in in g C/V join t
la t ch ed beh in d t h e t wo t a bs on lower ba n d of cla m p sea lin g boot t o C/V join t h ou sin g (F ig. 27) a n d dis-
(F ig. 26). ca r d. Rem ove sm a ll cla m p t h a t r et a in s ou t er C/V
join t sea lin g boot t o in t er con n ect in g sh a ft a n d dis-
ca r d. Rem ove sea lin g boot fr om ou t er C/V join t h ou s-
in g a n d slide it down in t er con n ect in g sh a ft .
Fig. 25 Clamping Tool Installed on Sealing Boot

Clamp
1 - CLAMP
2 - TOOL YA3050, OR EQUIVALENT Fig. 27 Outer C/V Joint Seal Boot Clamps
3 - SEALING BOOT
1 - SMALL CLAMP
2 - SEALING BOOT
3 - OUTER C/V JOINT HOUSING
4 - LARGE CLAMP
(3) Wipe a wa y gr ea se t o expose ou t er C/V join t a n d

in t er con n ect in g sh a ft .
(4) Rem ove ou t er C/V join t fr om in t er con n ect in g
sh a ft u sin g t h e followin g pr ocedu r e: Su ppor t in t er-
con n ect in g sh a ft in a vise equ ipped wit h pr ot ect ive
ca ps on ja ws of vise t o pr even t da m a ge t o in t er con -
n ect in g sh a ft . Th en , u sin g a soft –fa ced h a m m er,
sh a r ply h it t h e en d of t h e C/V join t h ou sin g t o dis-
lodge h ou sin g fr om in t er n a l cir clip on in t er con n ect in g
sh a ft (F ig. 28). Th en slide ou t er C/V join t off en d of
in t er con n ect in g sh a ft , join t m a y h a ve t o be t a pped off
sh a ft u sin g a s o ft–fa c e d h a m m er.
Fig. 26 Sealing Boot Clamp Correctly Installed (5) Rem ove la r ge cir clip (F ig. 29) fr om t h e in t er-
1 - INNER TRIPOD JOINT HOUSING con n ect in g sh a ft befor e a t t em pt in g t o r em ove ou t er
2 - TOP BAND OF CLAMP MUST BE RETAINED BY TABS AS C/V join t sea lin g boot .
SHOWN HERE TO CORRECTLY LATCH BOOT CLAMP (6) Slide sea lin g boot off in t er con n ect in g sh a ft .
3 - SEALING BOOT
(7) Th or ou gh ly clea n a n d in spect ou t er C/V join t
(14) In st a ll t h e h a lf sh a ft ba ck in t o t h e veh icle. a ssem bly a n d in t er con n ect in g join t for a n y sign s of
(Refer t o 3 - DIF F E RE NTIAL & DRIVE LINE /H ALF excessive wea r. If a n y p a rts s h o w s ig n s o f e x c e s -
SH AF T - INSTALLATION) s iv e w e a r, th e h a lfs h a ft a s s e m bly w ill re qu ire
re p la c e m e n t. Co m p o n e n t p a rts o f th e s e h a lf-
s h a ft a s s e m blie s a re n o t s e rv ic e a ble .
RS HALF SHAFT - FRONT 3 - 11
CV BOOT - OU T ER (Cont inue d)
Fig. 30 Sealing Boot Installation on Interconnecting

Fig. 28 Outer C/V Joint Removal from Shaft
Interconnecting Shaft 1 - SEALING BOOT
2 - RAISED BEAD IN THIS AREA OF SEALING BOOT
1 - SOFT HAMMER (TAP INNER RACE ONLY) 3 - GROOVE
2 - WEAR SLEEVE 4 - INTERCONNECTING SHAFT
3 - CIRCLIP (OUTER END OF SHAFT)
(3) In st a ll ou t er C/V join t a ssem bly on t o in t er con -
n ect in g sh a ft by u sin g a s o ft–fa c e d h a m m er a n d
t a ppin g en d of st u b a xle (wit h h u b n u t in st a lled)
u n t il ou t er C/V join t is fu lly sea t ed on in t er con n ect -
in g sh a ft (F ig. 31).
Fig. 29 Circlip Removal from Interconnecting Shaft

1 - SNAP RING PLIERS
3 - CIRCLIP
INSTALLATION Fig. 31 Outer C/V Joint Installation on

(1) Slide n ew sea lin g boot t o in t er con n ect in g sh a ft
Interconnecting
r et a in in g cla m p on t o in t er con n ect in g sh a ft . Slide t h e
1 - SOFT FACED HAMMER
ou t er C/V join t a ssem bly sea lin g boot on t o t h e in t er- 2 - STUB AXLE
con n ect in g sh a ft (F ig. 30). S e a l bo o t MU S T be 3 - OUTER C/V JOINT
p o s itio n e d o n in te rc o n n e c tin g s h a ft s o th e 4 - HUB NUT
ra is e d be a d o n th e in s id e o f th e s e a l bo o t is in
g ro o v e o n in te rc o n n e c tin g s h a ft.
(2) Align splin es on in t er con n ect in g sh a ft wit h
splin es on cr oss of ou t er C/V join t a ssem bly a n d st a r t
ou t er C/V join t on t o in t er con n ect in g sh a ft .
3 - 12 HALF SHAFT - FRONT RS
(4) Ou t er C/V join t a ssem bly m u st be in st a lled on
in t er con n ect in g sh a ft u n t il cr oss of ou t er C/V join t
a ssem bly is sea t ed a ga in st cir clip on in t er con n ect in g
sh a ft (F ig. 32).
Fig. 33 Crimping Tool Installed on Sealing Boot

Clamp
Fig. 32 Outer C/V Joint Correctly Installed on 3 - CLAMP
Interconnecting Shaft 4 - SEALING BOOT
2 - CROSS
3 - OUTER C/V JOINT ASSEMBLY
(5) Dist r ibu t e 1/2 t h e a m ou n t of gr ea se pr ovided in

sea l boot ser vice pa cka ge (DO NOT USE ANY
OTH E R TYP E OF GRE ASE ) in t o ou t er C/V join t
a ssem bly h ou sin g. P u t t h e r em a in in g a m ou n t in t o
t h e sea lin g boot .
(6) In st a ll ou t er C/V join t sea lin g boot t o in t er con -
n ect in g sh a ft cla m p even ly on sea lin g boot .
(7) Cla m p sea lin g boot on t o in t er con n ect in g sh a ft
u sin g cr im per, Specia l Tool C-4975-A a n d t h e follow-
in g pr ocedu r e. P la ce cr im pin g t ool C-4975-A over
br idge of cla m p (F ig. 33). Tigh t en n u t on cr im pin g
t ool C-4975-A u n t il ja ws on t ool a r e closed com plet ely
t oget h er, fa ce t o fa ce (F ig. 34).
Fig. 34 Sealing Boot Retaining Clamp Installed
CAUTION: Seal must not be dimpled, stretched, or 1 - CLAMP
out–of–shape in any way. If seal is NOT shaped cor- 2 - JAWS OF SPECIAL TOOL C-4975A MUST BE CLOSED
rectly, equalize pressure in seal and shape it by 3 - INTERCONNECTING SHAFT
hand. 4 - SEALING BOOT
(8) P osit ion ou t er C/V join t sea lin g boot in t o it s

r et a in in g gr oove on ou t er C/V join t h ou sin g. In st a ll
sea lin g boot t o ou t er C/V join t r et a in in g cla m p even ly
on sea lin g boot .
RS HALF SHAFT - FRONT 3 - 13
(9) Cla m p sea lin g boot on t o ou t er C/V join t h ou s-
in g u sin g Cr im per, Specia l Tool C-4975-A a n d t h e fol-
lowin g pr ocedu r e. P la ce cr im pin g t ool C-4975-A over
br idge of cla m p (F ig. 35). Tigh t en n u t on cr im pin g
t ool C-4975-A u n t il ja ws on t ool a r e closed com plet ely
t oget h er, fa ce t o fa ce (F ig. 36).
Fig. 36 Sealing Boot Retaining Clamp Installed

1 - CLAMP
2 - TRIPOD HOUSING
4 - JAWS OF SPECIAL TOOL C-4975A MUST BE CLOSED
5 - SEALING BOOT
Fig. 35 Crimping Tool Installed on Sealing Boot (10) In st a ll t h e h a lfsh a ft r equ ir in g boot r epla ce-
Clamp m en t ba ck on t h e veh icle. (Refer t o 3 - DIF F E RE N-
1 - CLAMP TIAL & DRIVE LINE /H ALF SH AF T -
2 - TRIPOD JOINT HOUSING INSTALLATION)
4 - SEALING BOOT
RS BRAKES 5-1
BRAKES
page page
BRAKES - BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 BRAKES - ABS . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
BRAK ES - BASE
TABLE OF CONTENTS
page page
BRAKES - BASE INSPECTION - BRAKE TUBES AND HOSES . . . 14

DESCRIPTION BRAKE PADS/SHOES - FRONT
DESCRIPTION - BASE BRAKES . . . . . . . . . . . 3 REMOVAL
DESCRIPTION - BASE BRAKES (EXPORT) . . . 3 REMOVAL - FRONT DISC BRAKE SHOES
OPERATION - BASE BRAKES ..............3 (CONTINENTAL TEVES BRAKES) . . . . . . . . . 15
WARNING .............................4 REMOVAL - FRONT DISC BRAKE SHOES
CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 (TRW BRAKES) . . . . . . . . . . . . . . . . . . . . . . . 15
DIAGNOSIS AND TESTING - BASE BRAKE CLEANING - DISC BRAKE SHOES . . . . . . . . . . 16
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 INSPECTION - DISC BRAKE SHOES . . . . . . . . 16
STANDARD PROCEDURE - BASE BRAKE INSTALLATION
BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 INSTALLATION - FRONT DISC BRAKE
SPECIFICATIONS SHOES (CONTINENTAL TEVES BRAKES) . . . 16
BRAKE FASTENER TORQUE . . . . . . . . . . . . . 9 INSTALLATION - FRONT DISC BRAKE
SPECIAL TOOLS SHOES (TRW BRAKES) . . . . . . . . . . . . . . . . 17
BASE BRAKE SYSTEM . . . . . . . . . . . . . . . . . 10 BRAKE PADS/SHOES - REAR DISC
BRAKE FLUID LEVEL SWITCH REMOVAL - REAR DISC BRAKE SHOES . . . . . 17
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10 CLEANING - DISC BRAKE SHOES . . . . . . . . . . 18
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 INSPECTION - DISC BRAKE SHOES . . . . . . . . 18
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 INSTALLATION - REAR DISC BRAKE SHOES . . 19
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11 BRAKE PADS/SHOES - REAR DRUM
ADJUSTABLE PEDALS SWITCH REMOVAL - REAR DRUM BRAKE SHOES . . . . 19
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 INSPECTION - REAR DRUM BRAKE SHOE
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11 LINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
HYDRAULIC/MECHANICAL INSTALLATION - REAR DRUM BRAKE SHOES . . 22
DESCRIPTION ADJUSTMENTS
DESCRIPTION - DISC BRAKES (FRONT) . . . 11 ADJUSTMENT - REAR DRUM BRAKE
DESCRIPTION - DISC BRAKES (REAR) . . . . 13 SHOES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
DESCRIPTION - DISC BRAKES (EXPORT) . . 13 DISC BRAKE CALIPER - FRONT
DESCRIPTION - DRUM BRAKES (REAR) . . . 13 REMOVAL
OPERATION REMOVAL - FRONT DISC BRAKE CALIPER
OPERATION - DISC BRAKES (FRONT) . . . . . 13 (CONTINENTAL TEVES BRAKES) . . . . . . . . . 24
OPERATION - DISC BRAKES (REAR) . . . . . . 14 REMOVAL - FRONT DISC BRAKE CALIPER
DIAGNOSIS AND TESTING - DRUM BRAKE (TRW BRAKES) . . . . . . . . . . . . . . . . . . . . . . . 24
AUTOMATIC ADJUSTER . . . . . . . . . . . . . . . . 14 DISASSEMBLY
BRAKE LINES DISASSEMBLY - CALIPER GUIDE PIN
DESCRIPTION - BRAKE TUBES AND HOSES . . 14 BUSHINGS (CONTINENTAL TEVES
OPERATION - BRAKE TUBES AND HOSES . . . 14 BRAKES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
5-2 BRAKES - BASE RS
DISASSEMBLY - CALIPER PISTON AND DISASSEMBLY - MASTER CYLINDER (FLUID

SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 RESERVOIR) . . . . . . . . . . . . . . . . . . . . . . . . . 38
CLEANING - CALIPER . . . . . . . . . . . . . . . . . . . 25 ASSEMBLY - MASTER CYLINDER (FLUID
INSPECTION - CALIPER . . . . . . . . . . . . . . . . . . 25 RESERVOIR) . . . . . . . . . . . . . . . . . . . . . . . . . 39
ASSEMBLY INSTALLATION
ASSEMBLY - CALIPER GUIDE PIN INSTALLATION - LHD . . . . . . . . . . . . . . . . . . 39
BUSHINGS (CONTINENTAL TEVES INSTALLATION - RHD . . . . . . . . . . . . . . . . . . 39
BRAKES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 PEDALS - ADJUSTABLE
ASSEMBLY - CALIPER PISTON AND SEAL . . 26 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
INSTALLATION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 43
INSTALLATION - FRONT DISC BRAKE PEDAL TORQUE SHAFT - RHD
CALIPER (CONTINENTAL TEVES REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
BRAKES) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 44
INSTALLATION - FRONT DISC BRAKE POWER BRAKE BOOSTER
CALIPER (TRW BRAKES) . . . . . . . . . . . . . . . 27 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 45
DISC BRAKE CALIPER - REAR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
REMOVAL - REAR DISC BRAKE CALIPER . .. . 28 DIAGNOSIS AND TESTING - POWER BRAKE
DISASSEMBLY - CALIPER PISTON AND SEAL . . 28 BOOSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
CLEANING - CALIPER . . . . . . . . . . . . . . . . .. . 29 REMOVAL
INSPECTION - CALIPER . . . . . . . . . . . . . . . .. . 29 REMOVAL - LHD . . . . . . . . . . . . . . . . . . . . . . 46
ASSEMBLY - CALIPER PISTON AND SEAL .. . 30 REMOVAL - RHD . . . . . . . . . . . . . . . . . . . . . . 48
INSTALLATION - REAR DISC BRAKE CALIPER . . 30 INSTALLATION
DISC BRAKE CALIPER ADAPTER INSTALLATION - LHD . . . . . . . . . . . . . . . . . . 50
REMOVAL - FRONT DISC BRAKE CALIPER INSTALLATION - RHD . . . . . . . . . . . . . . . . . . 51
ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 PROPORTIONING VALVE
INSTALLATION - FRONT DISC BRAKE DESCRIPTION - PROPORTIONING VALVE
CALIPER ADAPTER . . . . . . . . . . . . . . . . . . . . 31 (HEIGHT SENSING) . . . . . . . . . . . . . . . . . . . . 53
DISC BRAKE CALIPER GUIDE PINS OPERATION - PROPORTIONING VALVE
REMOVAL - DISC BRAKE CALIPER GUIDE (HEIGHT SENSING) . . . . . . . . . . . . . . . . . . . . 53
PINS (TRW BRAKES) ............... . . . 31 DIAGNOSIS AND TESTING -
INSTALLATION - DISC BRAKE CALIPER PROPORTIONING VALVE (HEIGHT
GUIDE PINS (TRW BRAKES) . . . . . . . . . . . . . 32 SENSING) . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
DRUM REMOVAL - PROPORTIONING VALVE
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 (HEIGHT SENSING) . . . . . . . . . . . . . . . . . . . . 55
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 32 INSTALLATION - PROPORTIONING VALVE
FLUID (HEIGHT SENSING) . . . . . . . . . . . . . . . . . . . . 55
DIAGNOSIS AND TESTING - BRAKE FLUID ROTOR
CONTAMINATION . . . . . . . . . . . . . . . . . . . . . 33 DIAGNOSIS AND TESTING - BRAKE ROTOR . . 55
STANDARD PROCEDURE - BRAKE FLUID STANDARD PROCEDURE - BRAKE ROTOR
LEVEL CHECKING . . . . . . . . . . . . . . . . . . . . . 33 MACHINING . . . . . . . . . . . . . . . . . . . . . . . . . . 58
SPECIFICATIONS REMOVAL - FRONT BRAKE ROTOR ..... . . . 59
BRAKE FLUID . . . . . . . . . . . . . . . . . . . . . . . . 33 INSTALLATION - FRONT BRAKE ROTOR . . . . . 59
JUNCTION BLOCK SPECIFICATIONS
DESCRIPTION - NON-ABS JUNCTION BLOCK . . 33 BRAKE ROTOR . . . . . . . . . . . . . . . . . . . . . . . 60
OPERATION - NON-ABS JUNCTION BLOCK . . 33 BRAKE ROTOR - EXPORT . . . . . . . . . . . . . . 60
REMOVAL - NON-ABS JUNCTION BLOCK . .. . 34 SUPPORT PLATE - DRUM BRAKE
INSTALLATION - NON-ABS JUNCTION BLOCK . . 34 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
MASTER CYLINDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 61
DESCRIPTION WHEEL CYLINDERS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 35 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
DESCRIPTION - RHD . . . . . . . . . . . . . . . . . . 35 INSPECTION ....................... . . . 62
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 62
STANDARD PROCEDURE - MASTER PARKING BRAKE
CYLINDER BLEEDING . . . . . . . . . . . . . . . . . . 36 DESCRIPTION
REMOVAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 62
REMOVAL - LHD . . . . . . . . . . . . . . . . . . . . . . 36 DESCRIPTION - EXPORT . . . . . . . . . . . . . . . 63
REMOVAL - RHD . . . . . . . . . . . . . . . . . . . . . . 37 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
RS BRAKES - BASE 5-3
STANDARD PROCEDURE CABLE - PARKING BRAKE REAR

STANDARD PROCEDURE - PARKING REMOVAL
BRAKE AUTOMATIC ADJUSTER TENSION REMOVAL - RIGHT REAR . . . . . . . . . . . . . . . 70
RELEASE . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 REMOVAL - LEFT REAR . . . . . . . . . . . . . . . . 71
STANDARD PROCEDURE - PARKING REMOVAL - FOLD-IN-FLOOR SEATING . . . . . 72
BRAKE AUTOMATIC ADJUSTER TENSION INSTALLATION
RESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 INSTALLATION - RIGHT REAR . . . . . . . . . . . 74
STANDARD PROCEDURE - CABLE END INSTALLATION - LEFT REAR ......... . . . 75
CLEANING AND LUBRICATION . . . . . . . . . . . 65 INSTALLATION - FOLD-IN-FLOOR
ADJUSTMENTS SEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
ADJUSTMENT - PARKING BRAKE LEVER - PARKING BRAKE
CABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
CABLE - PARKING BRAKE FRONT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 76
REMOVAL LEVER - PARKING BRAKE (EXPORT)
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 REMOVAL - PARKING BRAKE LEVER AND
REMOVAL - FOLD-IN-FLOOR SEATING . . . . . 66 FRONT CABLE . . . . . . . . . . . . . . . . . . . . . . . 77
REMOVAL - EXPORT ................ . . 67 INSTALLATION - PARKING BRAKE LEVER
INSTALLATION AND FRONT CABLE . . . . . . . . . . . . . . . . . . . 77
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 67 SHOES - PARKING BRAKE
INSTALLATION - FOLD-IN-FLOOR SEATING . 68 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
INSTALLATION - EXPORT . . . . . . . . . . . . . . . 68 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 84
CABLE - PARKING BRAKE INTERMEDIATE ADJUSTMENTS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 ADJUSTMENT - PARKING BRAKE SHOES . . 85
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 69
BRAK ES - BASE Veh icles equ ipped wit h t h e opt ion a l a n t ilock br a ke
syst em (ABS) u se a syst em design a t ed Ma r k 20e. It
is a va ila ble wit h or wit h ou t t r a ct ion con t r ol. Th is
DESCRI PT I ON syst em sh a r es m ost ba se br a ke h a r dwa r e u sed on
veh icles wit h ou t ABS. ABS com pon en t s a r e descr ibed
DESCRIPTION - BASE BRAKES in det a il in ANTILOCK BRAKE SYSTE M.
Th e ba se br a ke syst em con sist s of t h e followin g
com pon en t s: DESCRIPTION - BASE BRAKES (EXPORT)
• Br a ke peda l F ou r-Wh eel Disc An t ilock Br a kes a r e st a n da r d on
• P ower br a ke boost er a ll m odels.
• Ma st er cylin der
• Br a ke t u bes a n d h oses OPERATION - BASE BRAKES
• P r opor t ion in g va lve (n on -ABS veh icles on ly) Wh en a veh icle n eeds t o be st opped, t h e dr iver
• Disc br a kes a pplies t h e br a ke peda l. Th e br a ke peda l pu sh es t h e
• Dr u m br a kes in pu t r od of t h e power br a ke boost er in t o t h e boost er.
• Br a ke la m p swit ch Th e boost er u ses va cu u m t o ea se peda l effor t a s for ce
• Br a ke flu id level swit ch is t r a n sfer r ed t h r ou gh t h e boost er t o t h e m a st er cyl-
• P a r kin g br a kes in der. Th e boost er ’s ou t pu t r od pu sh es in t h e m a st er
F r on t disc br a kes con t r ol t h e br a kin g of t h e fr on t cylin der ’s pr im a r y a n d secon da r y pist on s a pplyin g
wh eels; r ea r br a kin g is con t r olled by r ea r dr u m h ydr a u lic pr essu r e t h r ou gh t h e ch a ssis br a ke t u bes
br a kes or r ea r disc br a kes depen din g on opt ion s. t o t h e br a kes a t ea ch t ir e a n d wh eel a ssem bly.
Th e h ydr a u lic br a ke syst em is dia gon a lly split on Th e pa r kin g br a kes a r e foot -oper a t ed. Wh en
bot h t h e n on -a n t ilock br a kin g syst em s a n d a n t ilock a pplied, t h e pa r kin g br a ke lever pu lls on ca bles t h a t
br a kin g syst em s. Th a t m ea n s t h e left fr on t a n d r igh t a ct u a t e br a ke sh oes a t ea ch r ea r wh eel. Th ese sh oes
r ea r br a kes a r e on on e h ydr a u lic cir cu it a n d t h e r igh t com e in con t a ct wit h a h u b m ou n t ed dr u m (dr u m for
fr on t a n d left r ea r a r e on t h e ot h er. disc/dr u m br a kes or dr u m -in -h a t for disc/disc br a kes)
F or in for m a t ion on t h e br a ke la m p swit ch , (Refer a n d h old it in pla ce.
t o 8 - E LE CTRICAL/LAMP S/LIGH TING - E XTE RI-
OR/BRAKE LAMP SWITCH - DE SCRIP TION)
BRAK ES - BASE (Cont inue d)
WARNING CAUTION
WARNING: DUST AND DIRT ACCUMULATING ON CAUTION: During service procedures, grease or
BRAKE PARTS DURING NORMAL USE MAY CON- any other foreign material must be kept off brake
TAIN ASBESTOS FIBERS FROM PRODUCTION OR shoes and braking surfaces of brake rotor or drum,
AFTERMARKET BRAKE LININGS. BREATHING and external surfaces of hub and bearing assembly.
EXCESSIVE CONCENTRATIONS OF ASBESTOS
FIBERS CAN CAUSE SERIOUS BODILY HARM.
EXERCISE CARE WHEN SERVICING BRAKE CAUTION: Brake rotor and caliper handling must be
PARTS. DO NOT SAND OR GRIND BRAKE LINING done in such a way as to avoid damage to the rotor,
UNLESS EQUIPMENT USED IS DESIGNED TO CON- especially the machined surfaces, and scratching or
TAIN THE DUST RESIDUE. DO NOT CLEAN BRAKE nicking of the brake linings.
PARTS WITH COMPRESSED AIR OR BY DRY
BRUSHING. CLEANING SHOULD BE DONE BY CAUTION: Only the recommended jacking or hoist-
DAMPENING THE BRAKE COMPONENTS WITH A ing procedures for this vehicle are to be used
FINE MIST OF WATER, THEN WIPING THE BRAKE whenever it is necessary to lift a vehicle. Failure to
COMPONENTS CLEAN WITH A DAMPENED CLOTH. raise a vehicle utilizing the recommended lift points
DISPOSE OF CLOTH AND ALL RESIDUE CONTAIN- can result in damage to the vehicle. (Refer to
ING ASBESTOS FIBERS IN AN IMPERMEABLE LUBRICATION & MAINTENANCE/HOISTING - STAN-
CONTAINER WITH THE APPROPRIATE LABEL. FOL- DARD PROCEDURE)
LOW PRACTICES PRESCRIBED BY THE OCCUPA-
TIONAL SAFETY AND HEALTH ADMINISTRATION
(OSHA) AND THE ENVIRONMENTAL PROTECTION DIAGNOSIS AND TESTING - BASE BRAKE
AGENCY (EPA) FOR THE HANDLING, PROCESSING,
SYSTEM
AND DISPOSING OF DUST OR DEBRIS THAT MAY
CONTAIN ASBESTOS FIBERS. NOTE: There are three diagnosis charts following
that cover the RED BRAKE WARNING INDICATOR
LAMP, BRAKE NOISE and OTHER BRAKE CONDI-
TIONS.
RED BRAKE WARNING INDICATOR LAMP
RED BRAKE WARNING 1. Parking brake lever not fully 1. Release parking brake lever.
LAMP ON released.
2. Parking brake warning lamp 2. Inspect and replace switch as necessary.
switch on parking brake lever.
3. Brake fluid level low in reservoir. 3. Fill reservoir. Check entire system for
leaks. Repair or replace as required.
4. Brake fluid level switch. 4. Disconnect switch wiring connector. If
lamp goes out, replace switch.
5. Mechanical instrument cluster 5. Refer to appropriate Diagnostic
(MIC) problem. information.
6. Amber ABS Warning Indicator 6. Refer to appropriate Diagnostic
Lamp also illuminated. information.
BRAKE NOISE

CLICK OR SQUAWK ON 1. Brake lamp switch. 1. Replace switch.
PEDAL APPLICATION
2. Brake Transmission Shift Interlock 2. Lubricate BTSI linkage.
Linkage.
3. Pedal pivot bushings 3. Lubricate pivot bushings. Replace if
necessary.
DISC BRAKE CHIRP 1. Excessive brake rotor runout. 1. Follow brake rotor diagnosis and testing.
Correct as necessary.
2. Lack of lubricant on brake caliper 2. Lubricate brake caliper slides.
slides.
3. Caliper/shoes not fully seated. 3. Reseat caliper/shoes.
DISC BRAKE RATTLE OR 1. Broken or missing anti-rattle 1. Replace brake shoes.
CLUNK spring clips on shoes.
2. Caliper guide pins/bolts loose. 2. Tighten guide pins/bolts.
DISC BRAKE SQUEAK AT 1. Brake shoe linings. 1. Replace brake shoes.
LOW SPEED (WHILE
APPLYING LIGHT BRAKE
PEDAL EFFORT)
DRUM BRAKE CHIRP 1. Lack of lubricant on brake shoe 1. Lubricate shoe contact areas on brake
support plate where shoes ride. shoe support plates.
DRUM BRAKE CLUNK 1. Drum(s) have threaded machined 1. Replace brake drums as necessary.
braking surface.
DRUM BRAKE HOWL OR 1. Lack of lubricant on brake shoe 1. Lubricate shoe contact areas on brake
MOAN support plate where shoes ride and shoe support plates and at the anchor.
at the anchor.
2. Rear brake shoes. 2. Replace rear brake shoes.
DRUM BRAKE SCRAPING 1. ABS wheel speed sensor or tone 1. Inspect, correct or replace faulty
OR WHIRRING wheel. component(s).
SCRAPING (METAL-TO- 1. Foreign object interference with 1. Inspect brakes and remove foreign
METAL). brakes. object.
2. Brake shoes worn out. 2. Replace brake shoes. Inspect rotors and
drums. Reface or replace as necessary.
OTHER BRAKE CONDITIONS
BRAKES CHATTER 1. Rear brake drum out of round or 1. Isolate condition as rear or front.
disc brake rotor has excessive Reface or replace brake drums or
thickness variation. rotors as necessary.
BRAKES DRAG (FRONT 1. Contaminated brake fluid. 1. Check for swollen seals. Replace all
OR ALL) system components containing rubber.
2. Binding caliper pins or bushings. 2. Replace pins and bushings.
3. Binding master cylinder. 3. Replace master cylinder.
4. Binding brake pedal. 4. Replace brake pedal.
5. Brake lamp switch not adjusted 5. Straighten mounting bracket and
properly and mounting bracket is replace brake lamp switch.
bent.
BRAKES DRAG (REAR 1. Parking brake cables binding or 1. Check cable routing. Replace cables
ONLY) froze up. as necessary.
2. Parking brake cable return spring 2. Replace cables as necessary.
not returning shoes.
3. Service brakes not adjusted 3. Follow the procedure listed in the
properly (rear drum brakes only). adjustment section.
4. Rear disc brake parking brake not Adjust parking brake shoes.
properly adjusted.
BRAKES GRAB 1. Contaminated brake shoe linings. 1. Inspect and clean, or replace shoes.
Repair source of contamination.
2. Improper power brake booster 2. Refer to power brake booster
assist. diagnosis and testing.
EXCESSIVE PEDAL 1. Obstruction of brake pedal. 1. Inspect, remove or move obstruction.

EFFORT
2. Low power brake booster assist 2. Refer to power brake booster
(vacuum leak). diagnosis and testing.
3. Glazed brake linings. 3. Reface or replace brake rotors as
necessary. Replace brake shoes.
4. Brake shoe lining transfer to brake 4. Reface or replace brake rotors as
rotor. necessary. Replace brake shoes.
EXCESSIVE PEDAL 1. Air in brake lines. 1. Bleed brakes.

TRAVEL (VEHICLE STOPS
OK)
2. Rear drum brake auto-adjuster 2. Inspect and replace drum brake
malfunctioning. components as necessary. Adjust rear
brakes.
EXCESSIVE PEDAL 1. One of the two hydraulic circuits 1. Inspect system for leaks. Check
TRAVEL (ONE FRONT to the front brakes is malfunctioning. master cylinder for internal malfunction.
WHEEL LOCKS UP
DURING HARD BRAKING)
PEDAL PULSATES/ 1. Rear brake drum out of round or 1. Isolate condition as rear or front.
SURGES DURING disc brake rotor has excessive Reface or replace brake drums or
BRAKING thickness variation. rotors as necessary.
PEDAL IS SPONGY 1. Air in brake lines. 1. Bleed brakes.

2. Power brake booster runout 2. Check booster vacuum hose and
(vacuum assist). engine tune for adequate vacuum
supply. Refer to power brake booster
diagnosis and testing.
PREMATURE REAR 1. Contaminated brake shoe linings. 1. Inspect and clean, or replace shoes.
WHEEL LOCKUP Repair source of contamination.
2. Inoperative proportioning valve 2. Refer to proportioning valve
(non-ABS vehicles). diagnosis and testing. Replace valve as
necessary.
3. Improper power brake booster 3. Refer to power brake booster in the
assist. diagnosis and testing section.
STOP/BRAKE LAMPS 1. Brake lamp switch out of 1. Replace brake lamp switch.
STAY ON adjustment.
2. Brake pedal binding. 2. Inspect and replace as necessary.
3. Obstruction in pedal linkage. 3. Remove obstruction.
4. Power Brake Booster not allowing 4. Replace power brake booster.
pedal to return completely.
VEHICLE PULLS TO 1. Frozen brake caliper piston. 1. Replace frozen piston or caliper.
RIGHT OR LEFT ON Bleed brakes.
BRAKING
2. Contaminated brake shoe lining. 2. Inspect and clean, or replace shoes.
Repair source of contamination.
3. Pinched brake lines. 3. Replace pinched line.
4. Leaking piston seal. 4. Replace piston seal or brake caliper.
5. Suspension problem. 5. Refer to the Suspension group.
PARKING BRAKE - 1. Rear drum brakes or rear disc 1. Adjust rear drum brake shoes, or
EXCESSIVE HANDLE brake parking brake shoes out of rear parking brake shoes on vehicles
TRAVEL adjustment. with rear disc brakes.
STANDARD PROCEDURE - BASE BRAKE MANUAL BLEEDING PROCEDURE

BLEEDING
NOTE: Correct manual bleeding of the brakes
NOTE: This bleeding procedure is only for the vehi- hydraulic system will require the aid of a helper.
cle’s base brakes hydraulic system. For bleeding
the antilock brakes hydraulic system, (Refer to 5 - NOTE: To adequately bleed the brakes using the
BRAKES - ABS - STANDARD PROCEDURE) manual bleeding procedure the rear brakes must be
correctly adjusted. Prior to the manual bleeding of
CAUTION: Before removing the master cylinder the brake hydraulic system, correctly adjust the
cover, thoroughly clean the cover and master cylin- rear brakes.
der fluid reservoir to prevent dirt and other foreign
(1) P u m p t h e br a ke peda l t h r ee or fou r t im es a n d
matter from dropping into the master cylinder fluid
h old it down befor e t h e bleeder scr ew is open ed.
reservoir.
(2) P u sh t h e br a ke peda l t owa r d t h e floor a n d h old
it down . Th en open t h e left r ea r bleeder scr ew a t
NOTE: The following wheel sequence should be lea st 1 fu ll t u r n . Wh en t h e bleeder scr ew open s t h e
used when bleeding the brake hydraulic system. br a ke peda l will dr op a ll t h e wa y t o t h e floor.
The use of this wheel sequence will ensure ade-
quate removal of all trapped air from the brake CAUTION: “Just cracking” the bleeder screw often
hydraulic system. restricts fluid flow, allowing only a slow, weak fluid
discharge of fluid. This practice will NOT get all the
• Left Rea r Wh eel air out. Make sure the bleeder is opened at least 1
• Righ t F r on t Wh eel full turn when bleeding.
• Righ t Rea r Wh eel
• Left F r on t Wh eel (3) Relea se t h e br a ke peda l on ly a fte r t h e bleeder
scr ew is closed.
NOTE: When bleeding the brake system, some air (4) Repea t st eps 1 t h r ou gh 3, fou r or five t im es, a t
may be trapped in the brake lines or valves far ea ch bleeder scr ew in t h e pr oper sequ en ce. Th is
upstream, as much as ten feet from the bleeder sh ou ld pa ss a su fficien t a m ou n t of flu id t o expel a ll
screw (Fig. 1). Therefore, it is essential to have a t h e t r a pped a ir fr om t h e br a ke syst em . Be su r e t o
fast flow of a large volume of brake fluid when m on it or t h e flu id level in t h e m a st er cylin der, so it
bleeding the brakes to ensure all the air gets out. st a ys a t a pr oper level so a ir will n ot en t er t h e br a ke
syst em t h r ou gh t h e m a st er cylin der.
(5) Ch eck peda l t r a vel. If peda l t r a vel is excessive
or h a s n ot been im pr oved, en ou gh flu id h a s n ot
pa ssed t h r ou gh t h e syst em t o expel a ll t h e t r a pped
a ir. Con t in u e t o bleed syst em a s n ecessa r y.
(6) P er for m a fin a l a dju st m en t of t h e r ea r br a ke
sh oes (wh en a pplica ble), t h en t est dr ive veh icle t o be
su r e br a kes a r e oper a t in g cor r ect ly a n d t h a t peda l is
solid.
PRESSURE BLEEDING PROCEDURE

CAUTION: Use bleeder tank Special Tool C-3496-B
or equivalent with Adapter, Special Tool 6921, to
pressurize the hydraulic system for bleeding.
Fig. 1 Trapped Air In Brake Fluid Line
1 - TRAPPED AIR
Th e br a kes m a y be m a n u a lly bled or pr essu r e bled.

Refer t o t h e a ppr opr ia t e followin g pr ocedu r e.
F ollow pr essu r e bleeder m a n u fa ct u r er ’s in st r u c- SPECI FI CAT I ON S
t ion s for u se of pr essu r e bleedin g equ ipm en t .
(1) In st a ll t h e Ada pt er Ma st er Cylin der P r essu r e BRAKE FASTENER TORQUE
Bleed Ca p, Specia l Tool 6921 on t h e flu id r eser voir of
t h e m a st er cylin der (F ig. 2). At t a ch t h e flu id h ose
fr om t h e pr essu r e bleeder t o t h e fit t in g on Specia l Ft. In.
DESCRIPTION N·m
Tool 6921. Lbs. Lbs.
ABS ICU Mounting Bolts To
11 — 97
Bracket
ABS ICU Mounting
28 21 250
Bracket-To-Cradle Bolts
ABS CAB-To-HCU Mounting
2 — 17
Screws
ABS Wheel Speed Sensor
13 — 115
Head Mounting Bolt - Front
ABS Wheel Speed Sensor
10 — 90
Head Mounting Bolt - Rear
Adjustable Pedal Position
7.5 66 —
Sensor Mounting Screws
Adjustable Pedal Module
2.0 15 —
Mounting Screws
Brake Tube Nuts 17 — 145
Fig. 2 Tool 6921 Installed On Master Cylinder
1 - SPECIAL TOOL 6921 Brake Hose Intermediate 12 — 105
2 - FLUID RESERVOIR Bracket Bolt
Brake Hose-To-Caliper 47 35 —
(2) At t a ch a clea r pla st ic h ose t o t h e bleeder scr ew Mounting Bolt
a t on e wh eel a n d feed t h e h ose in t o a clea r ja r con -
t a in in g fr esh br a ke flu id. Disc Brake Caliper Guide 35 26 —
(3) Open t h e left r ea r wh eel bleeder scr ew a t lea st Pin Bolts
o n e fu ll tu rn or m or e t o obt a in a n a dequ a t e flow of Disc Brake Caliper Bleeder 15 — 125
br a ke flu id. Screw
Drum Brake Wheel Cylinder 8 — 75
CAUTION: “Just cracking” the bleeder screw often
Mounting Bolts
restricts fluid flow, allowing only a slow, weak fluid
discharge of fluid. This practice will NOT get all the Drum Brake Wheel Cylinder 10 — 80
air out. Make sure the bleeder is opened at least 1 Mounting Bleeder screw
full turn when bleeding. Drum Brake Support Plate 130 95 —
Mounting Bolts
(4) Aft er 4 t o 8 ou n ces of br a ke flu id h a s been bled
Junction Block (Non-ABS 28 21 250
t h r ou gh t h e h ydr a u lic syst em , a n d a n a ir-fr ee flow is
Brakes) Mounting Bolts
m a in t a in ed in t h e h ose a n d ja r, t h is will in dica t e a
good bleed of t h e h ydr a u lic syst em h a s been Master Cylinder Mounting 25 19 225
obt a in ed. Nuts
(5) Repea t t h e pr ocedu r e a t a ll t h e ot h er r em a in - Power Brake Booster 28 21 250
in g bleeder scr ews. Mounting Nuts
(6) Ch eck peda l t r a vel. If peda l t r a vel is excessive Proportioning Valve 54 40 —
or h a s n ot been im pr oved, en ou gh flu id h a s n ot Mounting Bolts
pa ssed t h r ou gh t h e syst em t o expel a ll t h e t r a pped
a ir. Be su r e t o m on it or t h e flu id level in t h e pr essu r e Proportioning Valve Axle 20 — 175
bleeder, so it st a ys a t a pr oper level so a ir will n ot Bracket Mounting Bolt
en t er t h e br a ke syst em t h r ou gh t h e m a st er cylin der. Parking Brake Lever (Pedal) 28 21 250
(7) P er for m a fin a l a dju st m en t of t h e r ea r br a ke Mounting Bolts And Nut
sh oes (wh en a pplica ble), t h en t est dr ive veh icle t o be Wheel Mounting (Lug) Nuts 135 100 —
su r e br a kes a r e oper a t in g cor r ect ly a n d t h a t peda l is
solid.
5 - 10 BRAKES - BASE RS
SPECI AL T OOLS
BASE BRAKE SYSTEM
Handle, Universal C–4171
Tubes, Master Cylinder Bleed 8358
Installer, Dust Boot C-4689 or C-4842

BRAK E FLU I D LEV EL SWI T CH
Adapter, Master Cylinder Pressure Bleed Cap 6921
DESCRIPTION
Th e br a ke flu id level swit ch is loca t ed in t h e br a ke
flu id r eser voir of t h e m a st er cylin der (F ig. 3).
OPERATION
Th e pu r pose of t h e br a ke flu id level swit ch is t o
pr ovide t h e dr iver wit h a n ea r ly wa r n in g t h a t t h e
br a ke flu id level in t h e m a st er cylin der flu id r eser-
Dial Indicator, C-3339 voir h a s dr opped below a n or m a l level. Th is m a y
in dica t e:
• Abn or m a l loss of br a ke flu id in t h e m a st er cyl-
in der flu id r eser voir r esu lt in g fr om a lea k in t h e
h ydr a u lic syst em .
• Br a ke sh oe lin in gs wh ich h a ve wor n t o a poin t
r equ ir in g r epla cem en t .
As t h e br a ke flu id dr ops below t h e m in im u m level,
Gauge, Brake Shoe C-3919 t h e br a ke flu id level swit ch closes t o com plet e t h e r ed
BRAKE wa r n in g in dica t or (la m p) cir cu it . Th is will
t u r n on t h e r ed BRAKE wa r n in g in dica t or. Th e m a s-
t er cylin der flu id r eser voir sh ou ld be ch ecked a n d
r efilled t o t h e F u ll m a r k wit h DOT 3 br a ke flu id. If
th e bra k e flu id le v e l h a s d ro p p e d be lo w th e a d d
lin e in th e m a s te r c y lin d e r flu id re s e rv o ir, th e
e n tire bra k e h y d ra u lic s y s te m s h o u ld be
c h e c k e d fo r e v id e n c e o f a le a k .
RS BRAKES - BASE 5 - 11
BRAK E FLU I D LEV EL SWI T CH (Cont inue d)
REMOVAL H Y DRAU LI C/M ECH AN I CAL

(1) Rem ove wir in g h a r n ess con n ect or fr om br a ke
flu id r eser voir level swit ch (F ig. 3).
DESCRI PT I ON
DESCRIPTION - DISC BRAKES (FRONT)
E a ch fr on t disc br a ke con sist s of t h e followin g com -
pon en t s:
• Br a ke Rot or
• Br a ke Ca liper
• Br a ke Ca liper Ada pt er
• Sh oes (P a ds)
Th er e a r e t wo n on -in t er ch a n gea ble fr on t disc br a ke
syst em s. On e is m a n u fa ct u r ed by TRW a n d t h e ot h er
by Con t in en t a l Teves.
CAUTION: Components used on the TRW brakes

are not interchangeable with the Continental Teves
brakes. The two different systems must not be
Fig. 3 MASTER CYLINDER AND BOOSTER mixed. Improper performance, noise and increased
1 - POWER BRAKE BOOSTER stopping distance can occur.
2 - BOOSTER IDENTIFICATION LABEL
3 - FLUID LEVEL SWITCH CONNECTOR
4 - PRIMARY BRAKE TUBE NUT Th e TRW fr on t br a ke ca liper is a on e piece ca st in g
5 - SECONDARY BRAKE TUBE NUT con t a in in g a sin gle 66 m m dia m et er pist on bor e (F ig.
6 - MASTER CYLINDER
4) wit h a ph en olic pist on . Th e ca liper m ou n t s t o a
ca liper a da pt er u sin g t wo gu ide pin bolt s t h a t t h r ea d
(2) Usin g fin ger s, com pr ess t h e r et a in in g t a bs on
in t o gu ide pin s slid in t o t h e ca liper a da pt er (F ig. 5).
t h e opposit e en d of br a ke flu id level swit ch .
Th e pin s a r e lu br ica t ed a n d h a ve boot s t h a t sea l
(3) Wit h r et a in in g t a bs com pr essed, gr a sp t h e con -
t h em in pla ce in t h e a da pt er.
n ect or en d of br a ke flu id level swit ch a n d pu ll it ou t
of m a st er cylin der br a ke flu id r eser voir.
INSTALLATION
(1) In ser t br a ke flu id level swit ch in t o left side of
br a ke flu id r eser voir. Be su r e swit ch is pu sh ed in
u n t il r et a in in g t a bs lock it t o br a ke flu id r eser voir.
(2) Con n ect veh icle wir in g h a r n ess con n ect or t o
br a ke flu id level swit ch (F ig. 3).
ADJ U STABLE PEDALS

SWI T CH
REMOVAL
Th e a dju st a ble peda ls swit ch is loca t ed in t h e
st eer in g colu m n lower sh r ou d. Rem ove t h e sh r ou d,
Fig. 4 Front Disc Brake Calipers
t h en r em ove t h e swit ch . (Refer t o 19 - STE E RING/
COLUMN/LOWE R SH ROUD - RE MOVAL) 1 - CONTINENTAL TEVES CALIPER (66 mm bore)
2 - TRW CALIPER (66 mm bore)
3 - GUIDE PIN BOLT
INSTALLATION 4 - GUIDE PIN AND BOOT
5 - CALIPER ADAPTER
Th e a dju st a ble peda ls swit ch is loca t ed in t h e st eer- 6 - GUIDE PIN BOLT
in g colu m n lower sh r ou d. In st a ll t h e swit ch in t h e 7 - GUIDE PIN BUSHING
sh r ou d, t h en in st a ll t h e sh r ou d. (Refer t o 19 - STE E R- 8 - CALIPER ADAPTER
ING/COLUMN/LOWE R SH ROUD - INSTALLATION)
On ce in st a lled, t est for pr oper oper a t ion of t h e
a dju st a ble peda ls.
H Y DRAU LI C/M ECH AN I CAL (Cont inue d)
Fig. 5 Guide Pins And Boots

Fig. 6 Anti-Rattle Devices On Calipers
1 - PINS
2 - BOOTS 1 - CONTINENTAL TEVES CALIPER
2 - TRW CALIPER
3 - ANTI-RATTLE CLIP
Th e Con t in en t a l Teves fr on t br a ke ca liper is a on e 4 - ANTI-RATTLE CLIP
piece ca st in g con t a in in g a sin gle pist on 66 m m dia m -
et er bor e (F ig. 4) wit h a ph en olic pist on . Th e ca liper CAUTION: Do not mix rotor types on the same vehi-
m ou n t s t o a ca liper a da pt er u sin g t wo gu ide pin bolt s cle. If brake rotors are mixed, noise and wear prob-
t h a t t h r ea d in t o t h e ca liper a da pt er a n d slide on lems can result.
bu sh in gs m ou n t ed in t h e ca liper.
CAUTION: TRW and Continental Teves calipers are

not interchangeable. Each caliper is specifically
designed for the unique brake system. If calipers
are interchanged, improper performance, noise and
increased stopping distance can occur.
Th e t wo differ en t br a ke ca liper s u se differ en t

devices t o con t r ol r a t t lin g. Wh ile t h e TRW br a kes u se
spr in g clips t h a t m ou n t a t t h e en ds of t h e sh oes in
t h e a da pt er s, Con t in en t a l Teves br a kes u se a clip on
t h e r ea r of t h e in boa r d pa d t o h old it t o t h e pist on
a n d a la r ger clip on t h e ou t side of t h e ca liper, h oldin g
it t o t h e a da pt er (F ig. 6).
All br a ke ca liper a da pt er s m ou n t t o t h e st eer in g
kn u ckle in t h e sa m e wa y u sin g t wo m ou n t in g bolt s.
Th e br a ke r ot or s a r e a lso differ en t depen din g on
br a ke syst em . Th e TRW fr on t br a kes u t ilize a n
in ver t ed-h a t st yle r ot or. Th is r ot or is ext er n a lly
ven t ed m ea n in g t h e in n er m ost dia m et er of t h e br a k- Fig. 7 Externally and Internally Vented Rotors
in g disc ven t s t o t h e ou t boa r d side (or fa ce) of t h e (Cross-Sectional View)
r ot or (F ig. 7). Th e Con t in en t a l Teves fr on t br a kes u t i- 1 - EXTERNAL VENTS (TRW and Continental Teves BR3)
lize t h e fa m ilia r in t er n a lly-ven t ed h a t st yle r ot or. 2 - INTERNAL VENTS (Continental Teves BRE)
In t er n a lly-ven t ed r efer s t o t h e fa ct t h a t t h e in n er
m ost dia m et er of t h e br a kin g disc ven t s t o t h e
in boa r d side of t h e r ot or (F ig. 7).
DESCRIPTION - DISC BRAKES (REAR) DESCRIPTION - DRUM BRAKES (REAR)

Th er e a r e sever a l dist in ct ive fea t u r es t o t h e r ea r Th is veh icle’s r ea r wh eel dr u m br a kes a r e a t wo-
disc br a kes on t h is veh icle (F ig. 8). Th e sin gle pist on , sh oe, in t er n a l-expa n din g t ype wit h a n a u t om a t ic
floa t in g ca liper r ea r disc br a ke syst em in clu des a h u b a dju st er scr ew. Th e a u t om a t ic a dju st er scr ew is
a n d bea r in g a ssem bly, a da pt er, r ot or, ca liper, a n d loca t ed dir ect ly below t h e wh eel cylin der t h a t is
br a ke sh oes. m ou n t ed n ea r t h e t op of t h e br a ke a ssem bly (F ig. 9).
Th ese a n d t wo br a ke sh oes (a n d a t t a ch in g pa r t s) a r e
m ou n t ed t o a su ppor t pla t e a t ea ch r ea r wh eel. A
br a ke dr u m cover s ea ch br a ke a ssem bly.
Fig. 8 Rear Disc Brakes

1 - CALIPER
2 - COTTER PIN
3 - ROTOR Fig. 9 Drum Brake Assembly (Right Shown)
4 - NUT RETAINER
5 - OUTER C/V JOINT 1 - WHEEL CYLINDER
2 - BRAKE SHOE UPPER RETURN SPRING
3 - AUTOMATIC ADJUSTER LEVER
Th is veh icle is equ ipped wit h a ca liper h a vin g a 42 4 - TENSION CLIP
m m (1.65 in .) pist on a n d u ses a 15 in ch solid n on - 5 - AUTOMATIC ADJUSTER ASSEMBLY
ven t ed br a ke r ot or. Th e br a ke r ot or is descr ibed a s a
dr u m -in -h a t st yle beca u se of it s du a l r ole a s a br a k- OPERAT I ON
in g disc a n d pa r kin g br a ke dr u m .
Th e pa r kin g br a ke syst em on veh icles equ ipped OPERATION - DISC BRAKES (FRONT)
wit h r ea r disc br a kes con sist s of a sm a ll du o-ser vo Wh en t h e br a kes a r e a pplied, flu id pr essu r e is sen t
dr u m br a ke m ou n t ed t o t h e ca liper a da pt er a n d u ses t o ea ch br a ke ca liper. Th e pr essu r e a t t h e ca liper is
t h e in t er ior of t h e r ea r disc br a ke r ot or a s a dr u m exer t ed equ a lly a ga in st t h e ca liper pist on . Th e pr es-
(h a t sect ion of dr u m -in -h a t st yle br a ke r ot or ). su r e a pplied t o t h e pist on is t r a n sm it t ed dir ect ly t o
Th e ou t boa r d r ea r disc br a ke sh oes (pa ds) a r e side- t h e in boa r d br a ke sh oe. Th is for ces t h e sh oe lin in g
or ien t ed. Th e sh oes a r e m a r ked in dica t in g wh ich side a ga in st t h e in n er su r fa ce of t h e br a ke r ot or. At t h e
t h ey belon g on . sa m e t im e, flu id pr essu r e wit h in t h e ca liper pist on
bor e for ces t h e ca liper t o slide in wa r d on it s gu ide
DESCRIPTION - DISC BRAKES (EXPORT) pin s. Th is a ct ion br in gs t h e ou t boa r d sh oe lin in g in t o
All veh icles a r e equ ipped wit h F ou r-Wh eel-Disc con t a ct wit h t h e ou t er su r fa ce of t h e br a ke r ot or.
br a kes. Bot h 15” (BRE ) a n d 16” (BR3) disc/disc br a ke Th is pr essu r e on bot h sides of t h e br a ke r ot or ca u ses
syst em s a r e a va ila ble. Th e disc br a kes a r e m a n u fa c- fr ict ion , br in gin g t h e veh icle t o a st op.
t u r ed by Con t in en t a l Teves. Th e BR3 syst em is st a n - Wh en t h e br a ke peda l is r elea sed, so is t h e flu id
da r d equ ipm en t on a ll-wh eel dr ive a n d a ll r igh t -h a n d pr essu r e. Th e pist on sea l in side t h e ca liper is
dr ive m odels. It is opt ion a l on ot h er m odels. design ed t o pu ll t h e pist on ba ck in t o t h e bor e of t h e
Th e BR3 syst em fea t u r es la r ger, ext er n a lly ven t ed ca liper wh en t h e br a ke peda l is r elea sed (F ig. 10).
fr on t br a ke r ot or s. Th is a ct ion h elps m a in t a in t h e pr oper br a ke sh oe-t o-
Alt h ou gh t h er e a r e differ en t disc/disc syst em s, t h ey r ot or clea r a n ce.
a r e ser viced u sin g t h e sa m e ser vice pr ocedu r es. Som e
specifica t ion s differ.
As disc br a ke sh oe lin in gs wea r, m a st er cylin der BRAK E LI N ES
r eser voir br a ke flu id level will dr op. Adju st a s n eces-
sa r y. F lu id level sh ou ld a lwa ys be ch ecked a ft er
DESCRIPTION - BRAKE TUBES AND HOSES
r epla cin g sh oes.
Th e br a ke t u bes a r e st eel wit h a cor r osion -r esis-
t a n t n ylon coa t in g a pplied t o t h e ext er n a l su r fa ces.
Th e flex h oses a r e m a de of r ein for ced r u bber wit h fit -
t in gs a t ea ch en d.
Th e pr im a r y a n d secon da r y br a ke t u bes lea din g
fr om t h e m a st er cylin der t o t h e ABS ICU H ydr a u lic
Con t r ol Un it (H CU) or t h e n on -ABS ju n ct ion block
h a ve a specia l flexible sect ion . Th is flexible sect ion is
r equ ir ed du e t o cr a dle m ovem en t wh ile t h e veh icle is
in m ot ion (Th e ICU a n d n on -ABS ju n ct ion block a r e
m ou n t ed t o t h e cr a dle). If re p la c e m e n t o f th e s e
lin e s is n e c e s s a ry, o n ly th e o rig in a l fa c to ry
bra k e lin e c o n ta in in g th e fle x ible s e c tio n m u s t
Fig. 10 Caliper Piston Seal Function For Automatic be u s e d .
Adjustment
1 - PISTON OPERATION - BRAKE TUBES AND HOSES
2 - CYLINDER BORE Th e pu r pose of t h e ch a ssis br a ke t u bes a n d flex
3 - PISTON SEAL BRAKE PRESSURE OFF h oses is t o t r a n sfer t h e pr essu r ized br a ke flu id devel-
4 - CALIPER HOUSING
5 - DUST BOOT oped by t h e m a st er cylin der t o t h e wh eel br a kes of
6 - PISTON SEAL BRAKE PRESSURE ON t h e veh icle. Th e flex h oses a r e m a de of r u bber t o
a llow for t h e m ovem en t of t h e veh icle’s su spen sion .
OPERATION - DISC BRAKES (REAR)
Th e r ea r disc br a kes oper a t e sim ila r ly t o fr on t disc INSPECTION - BRAKE TUBES AND HOSES
br a kes, h owever, t h er e a r e som e fea t u r es t h a t r equ ir e F lexible r u bber h ose is u sed a t bot h fr on t br a kes
differ en t ser vice pr ocedu r es. a n d a t t h e r ea r a xle. In spect ion of br a ke h oses
sh ou ld be per for m ed wh en ever t h e br a ke syst em is
DIAGNOSIS AND TESTING - DRUM BRAKE ser viced a n d ever y 7,500 m iles or 12 m on t h s, wh ich -
AUTOMATIC ADJUSTER ever com es fir st (ever y en gin e oil ch a n ge). In spect
Th e r ea r dr u m br a kes on t h is veh icle a u t om a t ica lly h ydr a u lic br a ke h oses for su r fa ce cr a ckin g, scu ffin g,
a dju st wh en r equ ir ed du r in g t h e n or m a l oper a t ion of or wor n spot s. If t h e fa br ic ca sin g of t h e r u bber h ose
t h e veh icle ever y t im e t h e br a kes a r e a pplied. Use becom es exposed du e t o cr a cks or a br a sion s in t h e
t h e followin g pr ocedu r e t o t est t h e oper a t ion of t h e r u bber h ose cover, t h e h ose sh ou ld be r epla ced im m e-
a u t om a t ic a dju st er. dia t ely. E ven t u a l det er ior a t ion of t h e h ose ca n t a ke
P la ce t h e veh icle on a h oist wit h a h elper in t h e pla ce wit h possible bu r st fa ilu r e. F a u lt y in st a lla t ion
dr iver ’s sea t t o a pply t h e br a kes. Rem ove t h e a ccess ca n ca u se t wist in g, r esu lt in g in wh eel, t ir e, or ch a ssis
plu g fr om t h e a dju st m en t h ole in ea ch br a ke su ppor t in t er fer en ce.
pla t e t o pr ovide visu a l a ccess of t h e br a ke a dju st er Th e br a ke t u bin g sh ou ld be in spect ed per iodica lly
st a r wh eel. for eviden ce of ph ysica l da m a ge or con t a ct wit h m ov-
To elim in a t e t h e con dit ion wh er e m a xim u m a dju st - in g or h ot com pon en t s.
m en t of t h e r ea r br a ke sh oes does n ot a llow t h e a u t o- Th e flexible br a ke t u be sect ion s u sed on t h is veh i-
m a t ic a dju st er t o oper a t e wh en t est ed, ba ck t h e st a r cle in t h e pr im a r y a n d secon da r y t u bes fr om t h e
wh eel off a ppr oxim a t ely 30 n ot ch es. It will be n eces- m a st er cylin der t o t h e ABS h ydr a u lic con t r ol u n it
sa r y t o h old t h e a dju st er lever a wa y fr om t h e st a r con n ect ion s m u st a lso be in spect ed. Th is flexible t u b-
wh eel t o per m it t h is a dju st m en t . in g m u st be in spect ed for kin ks, fr a yin g a n d con t a ct
H a ve t h e h elper a pply t h e br a kes. Upon a pplica - wit h ot h er com pon en t s or wit h t h e body of t h e veh i-
t ion of t h e br a ke peda l, t h e a dju st er lever sh ou ld cle.
m ove down , t u r n in g t h e a dju st er st a r wh eel. Th u s, a
defin it e r ot a t ion of t h e a dju st er st a r wh eel ca n be
obser ved if t h e a u t om a t ic a dju st er is wor kin g pr op-
er ly. If on e or m or e a dju st er s do n ot fu n ct ion pr op-
er ly, t h e r espect ive dr u m m u st be r em oved for
a dju st er ser vicin g.
BRAK E PADS/SH OES - FRON T
REM OVAL
REMOVAL - FRONT DISC BRAKE SHOES
(CONTINENTAL TEVES BRAKES)
(1) Ra ise t h e veh icle. (Refer t o LUBRICATION &
DURE ).
(2) Rem ove bot h fr on t wh eel a n d t ir e a ssem blies.
(3) Begin on on e side of t h e veh icle.
(4) Rem ove t h e a n t i-r a t t le clip fr om t h e ou t boa r d
side of t h e ca liper a n d a da pt er.
(5) Rem ove t h e t wo ca liper gu ide pin bolt s.
(6) Rem ove ca liper fr om ca liper a da pt er a n d br a ke
r ot or. Fig. 12 Removing Inboard Shoe
1 - INBOARD BRAKE SHOE
CAUTION: Supporting weight of caliper by the flex- 2 - HANGER WIRE
ible brake fluid hose can damage the hose. 4 - RETAINING CLIP
5 - PISTON
(7) Usin g wir e or cor d, h a n g t h e ca liper fr om t h e
fr on t st r u t a ssem bly (F ig. 11). Su ppor t t h e ca liper REMOVAL - FRONT DISC BRAKE SHOES (TRW
fir m ly t o pr even t weigh t of ca liper fr om bein g su p-
por t ed by t h e br a ke flu id h ose.
BRAKES)
(1) Ra ise t h e veh icle. Refer t o H OISTING in
LUBRICATION AND MAINTE NANCE .
NOTE: Perform Step 2 through Step 5 on each side

of the vehicle.
(2) Rem ove t h e fr on t t ir e a n d wh eel a ssem bly.

(3) Rem ove t h e t wo br a ke ca liper gu ide pin bolt s
(F ig. 13).
Fig. 11 Stored Front Disc Brake Caliper

2 - BRAKE FLEX HOSE
4 - WIRE HANGER
5 - STRUT ASSEMBLY
(8) Rem ove t h e ou t boa r d br a ke sh oe fr om t h e ca li-

per a da pt er.
(9) P u ll t h e in boa r d br a ke sh oe a wa y fr om t h e ca l- Fig. 13 Brake Caliper Mounting (Typical)
iper pist on u n t il t h e r et a in in g clip on sh oe is fr ee
1 - BRAKE HOSE
fr om t h e ca vit y in t h e ca liper pist on (F ig. 12). 2 - ADAPTER MOUNTING BOLTS
(10) Repea t t h e a bove pr ocedu r e on ot h er side of 3 - BANJO BOLT
t h e veh icle. 4 - CALIPER GUIDE PIN BOLTS
BRAK E PADS/SH OES - FRON T (Cont inue d)
(4) Rem ove t h e disc br a ke ca liper fr om t h e disc Repla ce bo th disc br a ke sh oes (in boa r d a n d ou t -
br a ke a da pt er a n d h a n g ou t of t h e wa y u sin g wir e or boa r d) on ea ch ca liper. It is n ecessa r y t o r epla ce t h e
a bu n gee cor d. Use ca r e n ot t o over ext en d t h e br a ke sh oes on t h e opposit e side of t h e veh icle a s well a s
h ose wh en doin g t h is. t h e sh oes fa ilin g in spect ion .
(5) Rem ove t h e br a ke sh oes fr om t h e disc br a ke If t h e br a ke sh oe a ssem blies do n ot r equ ir e
ca liper a da pt er. r epla cem en t , be su r e t o r ein st a ll t h e br a ke sh oes in
t h e or igin a l posit ion t h ey wer e r em oved fr om .
CLEANING - DISC BRAKE SHOES
WARNING: DUST AND DIRT ACCUMULATING ON I N STALLAT I ON
BRAKE PARTS DURING NORMAL USE MAY CON-
TAIN ASBESTOS FIBERS FROM PRODUCTION OR INSTALLATION - FRONT DISC BRAKE SHOES
AFTERMARKET BRAKE LININGS. BREATHING (CONTINENTAL TEVES BRAKES)
FIBERS CAN CAUSE SERIOUS BODILY HARM. NOTE: There may be more than 1 lining material
EXERCISE CARE WHEN SERVICING BRAKE released. Make sure proper linings are being
PARTS. DO NOT SAND OR GRIND BRAKE LINING installed.
UNLESS EQUIPMENT USED IS DESIGNED TO CON-
TAIN THE DUST RESIDUE. DO NOT CLEAN BRAKE (1) Begin on on e side of t h e veh icle or t h e ot h er.
PARTS WITH COMPRESSED AIR OR BY DRY (2) Com plet ely r et r a ct t h e ca liper pist on ba ck in t o
BRUSHING. CLEANING SHOULD BE DONE BY it s bor e in t h e br a ke ca liper (Th is is r equ ir ed for ca l-
DAMPENING THE BRAKE COMPONENTS WITH A iper in st a lla t ion on t h e br a ke r ot or wit h n ew br a ke
FINE MIST OF WATER, THEN WIPING THE BRAKE sh oes in st a lled).
COMPONENTS CLEAN WITH A DAMPENED CLOTH. (3) If a pplied, r em ove t h e pr ot ect ive pa per fr om
DISPOSE OF CLOTH AND ALL RESIDUE CONTAIN- t h e n oise su ppr ession ga sket on t h e r ea r of bot h t h e
ING ASBESTOS FIBERS IN AN IMPERMEABLE in n er a n d ou t er br a ke sh oe a ssem blies.
CONTAINER WITH THE APPROPRIATE LABEL. FOL- (4) In st a ll t h e n ew in boa r d br a ke sh oe in t o t h e ca l-
LOW PRACTICES PRESCRIBED BY THE OCCUPA- iper pist on by fir m ly pr essin g it s r et a in in g clip in t o
TIONAL SAFETY AND HEALTH ADMINISTRATION t h e pist on bor e. Be su r e t h e in boa r d br a ke sh oe is
(OSHA) AND THE ENVIRONMENTAL PROTECTION posit ion ed squ a r ely a ga in st t h e fa ce of t h e ca liper
AGENCY (EPA) FOR THE HANDLING, PROCESSING, pist on .
AND DISPOSING OF DUST OR DEBRIS THAT MAY (5) Lu br ica t e bot h a da pt er a bu t m en t s wh er e t h e
CONTAIN ASBESTOS FIBERS. sh oes slide wit h a sm a ll a m ou n t of Mopa r ! Dielect r ic
gr ea se, or equ iva len t .
(6) Slide t h e n ew ou t boa r d br a ke sh oe in t o t h e ca l-
INSPECTION - DISC BRAKE SHOES iper a da pt er wit h t h e lin in g u p a ga in st t h e ou t side of
Visu a lly in spect br a ke sh oes (pa ds) for u n even lin - t h e br a ke r ot or.
in g wea r. Also in spect for excessive lin in g det er ior a -
t ion . Ch eck t h e clea r a n ce bet ween t h e t ips of t h e CAUTION: Use care when installing the caliper
wea r in dica t or s on t h e sh oes (if equ ipped) a n d t h e assembly onto the caliper adapter, so the caliper
br a ke r ot or s. guide pin bushings do not get damaged by the
If a visu a l in spect ion does n ot a dequ a t ely det er- adapter bosses.
m in e t h e con dit ion of t h e lin in g, a ph ysica l ch eck will
be n ecessa r y. To ch eck t h e a m ou n t of lin in g wea r, (7) Ca r efu lly posit ion t h e br a ke ca liper over t h e
r em ove t h e disc br a ke sh oes fr om t h e ca liper s. br a ke r ot or a n d a da pt er.
Mea su r e ea ch br a ke sh oe. Th e com bin ed br a ke (8) In st a ll t h e ca liper gu ide pin bolt s a n d t igh t en
sh oe a n d it s lin in g m a t er ia l t h ickn ess sh ou ld be m ea - t o a t or qu e of 35 N·m (26 ft . lbs.). Ex tre m e c a u tio n
su r ed a t it s t h in n est poin t . s h o u ld be ta k e n n o t to c ro s s th re a d th e c a lip e r
• F or fr on t disc br a ke sh oes, wh en a set of br a ke g u id e p in bo lts .
sh oes a r e wor n t o a t h ickn ess of a ppr oxim a t ely 7.95 (9) In st a ll t h e ca ps over t h e ca liper gu ide pin bolt s.
m m (5/16 in ch ), t h ey sh ou ld be r epla ced. (10) In st a ll t h e n ew ca liper h old down spr in g (a n t i-
• F or r ea r disc br a ke sh oes, wh en a set of br a ke r a t t le clip) on t h e ou t boa r d side of t h e ca liper. St a r t
sh oes a r e wor n t o a t h ickn ess of a ppr oxim a t ely 7.0 t h e spr in g in t o t h e h oles on t h e ca liper, t h en st r et ch
m m (9/32 in ch ), t h ey sh ou ld be r epla ced. t h e clip legs pa st t h e a bu t m en t s on t h e ca liper
• Typica lly, if fr on t sh oes a r e wor n ou t , bot h fr on t s a da pt er.
a n d r ea r s n eed t o be r epla ced. Ma ke su r e t o ch eck (11) Repea t t h e a bove pr ocedu r e on ot h er side of
r ea r s. t h e veh icle.
BRAK E PADS/SH OES - FRON T (Cont inue d)
(12) In st a ll t h e wh eel a n d t ir e a ssem blies. Tigh t en (2) Rem ove r ea r wh eel a n d t ir e a ssem blies fr om
t h e wh eel m ou n t in g n u t s in pr oper sequ en ce u n t il a ll veh icle.
n u t s a r e t or qu ed t o h a lf specifica t ion , t h en r epea t t h e (3) Rem ove t h e ca liper t o a da pt er gu ide pin bolt s
t igh t en in g sequ en ce t o t h e fu ll specified t or qu e of 135 (F ig. 14).
N·m (100 ft . lbs.).
(14) P u m p t h e br a ke peda l sever a l t im es. Th is will
set t h e sh oes t o t h e br a ke r ot or.
(15) Ch eck a n d a dju st br a ke flu id level a s n eces-
sa r y.
(16) Roa d t est t h e veh icle a n d m a ke sever a l st ops
t o wea r off a n y for eign m a t er ia l on t h e br a kes a n d t o
sea t t h e br a ke sh oes.
INSTALLATION - FRONT DISC BRAKE SHOES

(TRW BRAKES)
NOTE: Perform steps Step 1 through Step 5on each
side of the vehicle.
(1) P la ce t h e br a ke sh oes in t h e a da pt er a n t i-r a t t le

Fig. 14 Caliper Guide Pin Bolts
clips.
(2) Com plet ely r et r a ct t h e ca liper pist on ba ck in t o 2 - ADAPTER
t h e bor e of t h e ca liper. 3 - AXLE
4 - GUIDE PIN BOLTS
CAUTION: Use care when installing the caliper onto 5 - DRIVESHAFT (AWD MODELS ONLY)
the disc brake adapter to avoid damaging the boots
(4) Rem ove r ea r ca liper fr om a da pt er u sin g t h e fol-
on the caliper guide pins.
lowin g pr ocedu r e. F ir st r ot a t e fr on t of ca liper u p
(3) In st a ll t h e disc br a ke ca liper over t h e br a ke fr om t h e a da pt er. Th en pu ll t h e r ea r of t h e ca liper
sh oes on t h e br a ke ca liper a da pt er. a n d t h e ou t boa r d br a ke sh oe a n t i-r a t t le clip ou t fr om
(4) Align t h e ca liper gu ide pin bolt h oles wit h t h e u n der t h e r ea r a bu t m en t on t h e a da pt er (F ig. 15).
gu ide pin s. In st a ll t h e ca liper gu ide pin bolt s a n d
t igh t en t h em t o a t or qu e of 35 N·m (26 ft . lbs.) (F ig.
13).
(5) In st a ll t h e t ir e a n d wh eel a ssem bly. Tigh t en
t h e wh eel m ou n t in g n u t s t o a t or qu e of 135 N·m (100
ft . lbs.).
(7) P u m p t h e br a ke peda l sever a l t im es. Th is will
set t h e sh oes t o t h e br a ke r ot or.
(8) Ch eck a n d a dju st t h e br a ke flu id level a s n ec-
essa r y.
(9) Roa d t est t h e veh icle a n d m a ke sever a l st ops t o
wea r off a n y for eign m a t er ia l on t h e br a kes a n d t o
sea t t h e br a ke sh oes.
Fig. 15 Removing/Installing Caliper

BRAK E PADS/SH OES - REAR
DI SC 2 - DISC BRAKE CALIPER
3 - ADAPTER ABUTMENT
REMOVAL - REAR DISC BRAKE SHOES 5 - OUTBOARD BRAKE SHOE
(1) Ra ise veh icle. (Refer t o LUBRICATION & 6 - ROTOR
7 - ADAPTER
DURE ).
BRAK E PADS/SH OES - REAR DI SC (Cont inue d)
(5) Su ppor t ca liper t o pr even t t h e weigh t of t h e
ca liper fr om da m a gin g t h e flexible br a ke h ose (F ig.
16).
Fig. 17 Removing Inboard Brake Shoe

1 - INBOARD BRAKE SHOE
2 - HANGER WIRE
Fig. 16 Correctly Supported Caliper 4 - RETAINING CLIP
1 - WIRE 5 - PISTON
2 - CALIPER
3 - ADAPTER DISPOSE OF CLOTH AND ALL RESIDUE CONTAIN-
4 - ROTOR
5 - INNER FENDER ING ASBESTOS FIBERS IN AN IMPERMEABLE
CONTAINER WITH THE APPROPRIATE LABEL. FOL-
(6) If t h e br a ke r ot or n eeds t o be r em oved it ca n be LOW PRACTICES PRESCRIBED BY THE OCCUPA-
r em oved by r em ovin g t h e r et a in er clips a n d t h en TIONAL SAFETY AND HEALTH ADMINISTRATION
pu llin g t h e r ot or st r a igh t off t h e wh eel m ou n t in g (OSHA) AND THE ENVIRONMENTAL PROTECTION
st u ds. AGENCY (EPA) FOR THE HANDLING, PROCESSING,
(7) Rem ove t h e ou t boa r d br a ke sh oe fr om t h e ca li- AND DISPOSING OF DUST OR DEBRIS THAT MAY
per. Br a ke sh oe is r em oved by pu sh in g t h e sh oe CONTAIN ASBESTOS FIBERS.
t owa r d t h e pist on , disen ga gin g t h e t wo m et a l pr ot r u -
sion s on t h e sh oe ba ck, t h en slidin g t h e br a ke sh oe INSPECTION - DISC BRAKE SHOES
off t h e ca liper. Visu a lly in spect br a ke sh oes (pa ds) for u n even lin -
(8) Rem ove in boa r d br a ke sh oe fr om ca liper. in g wea r. Also in spect for excessive lin in g det er ior a -
In boa r d br a ke sh oe is r em oved by pu llin g it ou t of t ion . Ch eck t h e clea r a n ce bet ween t h e t ips of t h e
t h e ca liper pist on , u n t il t h e r et a in in g clip is fr ee of wea r in dica t or s on t h e sh oes (if equ ipped) a n d t h e
t h e pist on (F ig. 17). br a ke r ot or s.
If a visu a l in spect ion does n ot a dequ a t ely det er-
CLEANING - DISC BRAKE SHOES m in e t h e con dit ion of t h e lin in g, a ph ysica l ch eck will
be n ecessa r y. To ch eck t h e a m ou n t of lin in g wea r,
WARNING: DUST AND DIRT ACCUMULATING ON r em ove t h e disc br a ke sh oes fr om t h e ca liper s.
BRAKE PARTS DURING NORMAL USE MAY CON- Mea su r e ea ch br a ke sh oe. Th e com bin ed br a ke
TAIN ASBESTOS FIBERS FROM PRODUCTION OR sh oe a n d it s lin in g m a t er ia l t h ickn ess sh ou ld be m ea -
AFTERMARKET BRAKE LININGS. BREATHING su r ed a t it s t h in n est poin t .
EXCESSIVE CONCENTRATIONS OF ASBESTOS • F or fr on t disc br a ke sh oes, wh en a set of br a ke
FIBERS CAN CAUSE SERIOUS BODILY HARM. sh oes a r e wor n t o a t h ickn ess of a ppr oxim a t ely 7.95
EXERCISE CARE WHEN SERVICING BRAKE m m (5/16 in ch ), t h ey sh ou ld be r epla ced.
PARTS. DO NOT SAND OR GRIND BRAKE LINING • F or r ea r disc br a ke sh oes, wh en a set of br a ke
UNLESS EQUIPMENT USED IS DESIGNED TO CON- sh oes a r e wor n t o a t h ickn ess of a ppr oxim a t ely 7.0
TAIN THE DUST RESIDUE. DO NOT CLEAN BRAKE m m (9/32 in ch ), t h ey sh ou ld be r epla ced.
PARTS WITH COMPRESSED AIR OR BY DRY • Typica lly, if fr on t sh oes a r e wor n ou t , bot h fr on t s
BRUSHING. CLEANING SHOULD BE DONE BY a n d r ea r s n eed t o be r epla ced. Ma ke su r e t o ch eck
DAMPENING THE BRAKE COMPONENTS WITH A r ea r s.
FINE MIST OF WATER, THEN WIPING THE BRAKE Repla ce bo th disc br a ke sh oes (in boa r d a n d ou t -
COMPONENTS CLEAN WITH A DAMPENED CLOTH. boa r d) on ea ch ca liper. It is n ecessa r y t o r epla ce t h e
BRAK E PADS/SH OES - REAR DI SC (Cont inue d)
sh oes on t h e opposit e side of t h e veh icle a s well a s (12) Roa d t est t h e veh icle a n d m a ke sever a l st ops
t h e sh oes fa ilin g in spect ion . t o wea r off a n y for eign m a t er ia l on t h e br a kes a n d t o
If t h e br a ke sh oe a ssem blies do n ot r equ ir e sea t t h e br a ke sh oe lin in gs.
r epla cem en t , be su r e t o r ein st a ll t h e br a ke sh oes in
t h e or igin a l posit ion t h ey wer e r em oved fr om .
BRAK E PADS/SH OES - REAR
INSTALLATION - REAR DISC BRAKE SHOES DRU M
(1) Com plet ely r et r a ct ca liper pist on ba ck in t o pis-
t on bor e of ca liper a ssem bly. REMOVAL - REAR DRUM BRAKE SHOES
(2) Lu br ica t e bot h a da pt er a bu t m en t s wh er e t h e (1) Ra ise veh icle. (Refer t o LUBRICATION &
sh oes con t a ct wit h a liber a l a m ou n t of Mopa r ! Mu l- MAINTE NANCE /H OISTING - STANDARD P ROCE -
t ipu r pose Lu br ica n t , or equ iva len t . DURE ).
(3) If r em oved, in st a ll t h e br a ke r ot or on t h e h u b, (2) Rem ove t h e r ea r wh eel a n d t ir e a ssem blies
m a kin g su r e it is squ a r ely sea t ed on t h e fa ce of t h e fr om t h e veh icle.
h u b. (3) Rem ove r ea r br a ke dr u m t o h u b r et a in in g clips
(4) In st a ll t h e in boa r d br a ke sh oe in t o t h e ca liper (if equ ipped), t h en r em ove r ea r br a ke dr u m s. (Refer
pist on by fir m ly pr essin g it in t o t h e pist on bor e u sin g t o 5 - BRAKE S/H YDRAULIC/ME CH ANICAL/DRUM
you r t h u m bs. Be su r e in boa r d br a ke sh oe is posi- - RE MOVAL)
t ion ed squ a r ely a ga in st t h e fa ce of t h e ca liper pist on .
NOTE: When creating slack in the park brake cables
NOTE: The outboard shoes are different left to by locking out the automatic adjuster, (Fig. 18) be
right. They can be identified by a L or R stamped on sure that the park brake pedal is in the released
the clip. (most upward) position.
(5) In st a ll t h e ou t boa r d br a ke sh oe on t h e disc (4) Cr ea t e sla ck in t h e r ea r pa r k br a ke ca bles.
br a ke ca liper. Be su r e t h e ou t boa r d sh oe is posit ion ed Sla ck is cr ea t ed by gr a bbin g exposed sect ion of fr on t
squ a r ely a ga in st t h e ou t boa r d fin ger s of t h e ca liper. pa r k br a ke ca ble a n d pu llin g it down a n d r ea r wa r d.
Sla ck is m a in t a in ed in t h e pa r k br a ke ca ble by
CAUTION: Use care when installing the caliper
in st a llin g a pa ir of lockin g plier s on t h e pa r k br a ke
assembly onto the adapter, so the caliper guide pin
ca ble ju st r ea r wa r d of o n ly th e re a r body ou t r igger
bushings do not get damaged by the mounting
br a cket . (F ig. 18)
bosses.
(6) Ca r efu lly lower ca liper a n d br a ke sh oes over

r ot or a n d on t o a da pt er, r ever sin g t h e r em ova l pr oce-
du r e (F ig. 15).
CAUTION: When installing the caliper guide pin

bolts extreme caution should be taken not to
crossthread the guide pin bolts.
(7) In st a ll t h e ca liper gu ide pin bolt s. Tigh t en t h e

gu ide pin bolt s t o a t or qu e of 35 N·m (26 ft . lbs.).
(8) In st a ll t h e wh eel a n d t ir e a ssem bly. Tigh t en
t h e wh eel m ou n t in g n u t s in pr oper sequ en ce u n t il a ll
n u t s a r e t or qu ed t o h a lf specifica t ion . Th en r epea t
t h e t igh t en in g sequ en ce t o t h e fu ll specified t or qu e of
135 N·m (100 ft . lbs.).
(9) Lower veh icle. Fig. 18 Locked Out Park Brake Automatic Adjuster
CAUTION: Before moving vehicle, pump the brake 1 - PARK BRAKE CABLE
2 - REAR BODY OUTRIGGER BRACKET
pedal several times to insure the vehicle has a firm 3 - LOCKING PLIERS
brake pedal to adequately stop the vehicle.
(10) P u m p br a ke peda l sever a l t im es t o set br a ke

sh oes t o r ot or s.
(11) Ch eck flu id level in r eser voir.
BRAK E PADS/SH OES - REAR DRU M (Cont inue d)
(5) Rem ove a dju st m en t lever spr in g (F ig. 19) fr om (7) Rem ove t h e br a ke sh oe t o br a ke sh oe lower
a dju st m en t lever a n d fr on t br a ke sh oe. r et u r n spr in gs (F ig. 21) a n d (F ig. 22).
Fig. 19 Adjustment Lever Actuating Spring (Right

Side Shown) Fig. 21 Remove/Install Brake Shoe Lower Return
1 - TRAILING BRAKE SHOE Spring
2 - LEADING BRAKE SHOE 1 - ANCHOR PLATE
3 - AUTOMATIC ADJUSTER LEVER 2 - LOWER BRAKE SHOE RETURN SPRING
4 - ADJUSTER LEVER ACTUATING SPRING 3 - REAR BRAKE SHOE
4 - FRONT BRAKE SHOE
(6) Rem ove a dju st m en t lever (F ig. 20) fr om lea din g 5 - BRAKE SUPPORT PLATE
br a ke sh oe.
Fig. 20 Adjustment Lever (Right Side Shown) Fig. 22 Brake Shoe Lower Return Spring
1 - AUTOMATIC ADJUSTER 1 - TRAILING BRAKE SHOE
2 - LEADING BRAKE SHOE 2 - LEADING BRAKE SHOE
3 - AUTOMATIC ADJUSTER LEVER 3 - RETURN SPRING
(8) Rem ove t h e t en sion clip (F ig. 23) a t t a ch in g t h e (10) Rem ove t h e t r a ilin g br a ke sh oe a ssem bly t o
u pper r et u r n spr in g t o t h e a u t om a t ic a dju st er a ssem - br a ke su ppor t pla t e h old down spr in g a n d pin (F ig.
bly. 25) fr om t h e br a ke sh oe a ssem bly.
Fig. 23 Tension Clip Attachment To Adjuster Fig. 25 Trailing Brake Shoe Hold Down Spring And
1 - WHEEL CYLINDER Pin
2 - BRAKE SHOE UPPER RETURN SPRING 1 - BRAKE SUPPORT PLATE
3 - AUTOMATIC ADJUSTER LEVER 2 - HOLD DOWN SPRING AND PIN
4 - TENSION CLIP 3 - TRAILING BRAKE SHOE
5 - AUTOMATIC ADJUSTER ASSEMBLY
(11) Rem ove t h e t r a ilin g br a ke sh oe a ssem bly fr om
(9) Rem ove t h e br a ke sh oe t o br a ke sh oe u pper t h e br a ke su ppor t pla t e, pa r k br a ke a ct u a t in g lever
r et u r n spr in g (F ig. 24). a n d pa r k br a ke a ct u a t in g st r u t (F ig. 26). Rem ove t h e
a u t om a t ic a dju st er a ssem bly fr om t h e lea din g br a ke
sh oe.
Fig. 24 Brake Shoe Upper Return Spring

1 - BRAKE SHOE RETURN SPRING
2 - LEADING BRAKE SHOE
3 - TRAILING BRAKE SHOE
Fig. 26 Trailing Brake Shoe Removal/Installation

1 - BRAKE SUPPORT PLATE
3 - PARK BRAKE ACTUATING LEVER
4 - PARK BRAKE ACTUATING STRUT
5 - TRAILING BRAKE SHOE
(12) Rem ove t h e lea din g br a ke sh oe a ssem bly t o INSPECTION - REAR DRUM BRAKE SHOE
br a ke su ppor t pla t e h old down spr in g a n d pin (F ig.
LINING
27) fr om t h e br a ke sh oe. Rem ove t h e lea din g br a ke
(1) Rem ove t h e t ir e a n d wh eel a ssem bly fr om t h e
sh oe fr om t h e br a ke su ppor t pla t e.
veh icle
(2) Rem ove t h e r ea r br a ke a dju st in g h ole plu g
fou n d in t h e br a ke su ppor t .
(3) In ser t a t h in scr ewdr iver in t o br a ke a dju st in g
h ole t o h old t h e a dju st in g lever a wa y fr om t h e
n ot ch es on t h e a dju st in g scr ew st a r wh eel.
(4) In ser t Tool C-3784 in t o br a ke a dju st in g h ole
a n d en ga ge n ot ch es of br a ke a dju st in g scr ew st a r
wh eel. Relea se br a ke by pr yin g down wit h a dju st in g
t ool.
(5) Rem ove t h e r ea r br a ke dr u m fr om t h e r ea r h u b
a n d bea r in g a ssem bly. (Refer t o 5 - BRAKE S/H Y-
DRAULIC/ME CH ANICAL/DRUM - RE MOVAL)
(6) In spect br a ke lin in g for wea r, sh oe a lign m en t ,
a n d or con t a m in a t ion fr om gr ea se or br a ke flu id.
Fig. 27 Leading Brake Shoe Hold Down Spring And INSTALLATION - REAR DRUM BRAKE SHOES
Pin (1) Lu br ica t e t h e eigh t sh oe con t a ct a r ea s on t h e
1 - PARK BRAKE ACTUATING LEVER su ppor t pla t e a n d a n ch or, (F ig. 29) u sin g t h e
2 - BRAKE SUPPORT PLATE r equ ir ed specia l Mopa r ! Br a ke Lu br ica n t or equ iva -
3 - LEADING BRAKE SHOE len t .
4 - HOLD DOWN SPRING AND PIN
(13) Rem ove t h e pa r k br a ke a ct u a t or (F ig. 28)

fr om t h e lea din g br a ke sh oe a n d t r a n sfer t o t h e
r epla cem en t br a ke sh oe.
Fig. 29 Brake Support Plate Contact Areas

1 - REAR BRAKE SUPPORT PLATE
(2) In st a ll lea din g br a ke sh oe on br a ke su ppor t

Fig. 28 Park Brake Actuator Plate pla t e. In st a ll t h e lea din g br a ke sh oe h old down
1 - RETAINING CLIP spr in g a n d pin (F ig. 27) on t h e br a ke sh oe.
2 - BRAKE SHOE ASSEMBLY
3 - ACTUATOR PLATE
(3) In st a ll t h e pa r k br a ke a ct u a t or st r u t (F ig. 30) (13) Adju st br a ke sh oes a ssem blies so a s n ot t o
on t h e lea din g br a ke sh oe. Th en in st a ll t h e pa r k in t er fer e wit h br a ke dr u m in st a lla t ion .
br a ke a ct u a t or lever on t h e st r u t (F ig. 30). (14) In st a ll t h e r ea r br a ke dr u m s on t h e h u bs.
(15) Adju st r ea r br a ke sh oes.
(16) In st a ll t h e wh eel a n d t ir e a ssem bly.
(17) Tigh t en t h e wh eel m ou n t in g st u d n u t s in
pr oper sequ en ce u n t il a ll n u t s a r e t or qu ed t o h a lf
specifica t ion . Th en r epea t t h e t igh t en in g sequ en ce t o
t h e fu ll specified t or qu e of 135 N·m (100 ft . lbs.).
(19) P u sh t h e pa r kin g br a ke lever (peda l) t o t h e
floor on ce a n d r elea se peda l. Th is will a u t om a t ica lly
r em ove t h e sla ck fr om a n d cor r ect ly a dju st t h e pa r k-
in g br a ke ca bles.
(20) Roa d t est veh icle. Th e a u t om a t ic a dju st er will
con t in u e t h e br a ke a dju st m en t du r in g t h e r oa d t est
of t h e veh icle.
Fig. 30 Park Brake Components Assembled On ADJ U ST M EN T S

Leading Brake Shoe
1 - PARK BRAKE CABLE ADJUSTMENT - REAR DRUM BRAKE SHOES
3 - PARK BRAKE ACTUATING STRUT
4 - PARK BRAKE ACTUATING LEVER NOTE: Normally, self-adjusting drum brakes do not
5 - BRAKE SUPPORT PLATE require manual brake shoe adjustment. Although, in
the event of a brake shoe replacement, it is advis-
(4) In st a ll t h e a u t om a t ic a dju st er scr ew on t h e able to make the initial adjustment manually to
lea din g br a ke sh oe. Th en in st a ll t h e t r a ilin g br a ke speed up the adjusting time.
sh oe on t h e pa r k br a ke a ct u a t in g lever a n d pa r k
br a ke a ct u a t in g st r u t (F ig. 26). P osit ion t r a ilin g
br a ke sh oe on br a ke su ppor t pla t e. NOTE: Before raising the vehicle, verify the parking
(5) In st a ll t h e br a ke sh oe h old down pin a n d brake lever is fully released.
spr in g on t h e t r a ilin g br a ke sh oe (F ig. 25).
(6) In st a ll t h e br a ke sh oe t o br a ke sh oe u pper (1) Ra ise t h e veh icle. (Refer t o LUBRICATION &
r et u r n spr in g (F ig. 24). MAINTE NANCE /H OISTING - STANDARD P ROCE -
DURE ).
CAUTION: When installing the tension clip on the (2) Rem ove r u bber plu g fr om r ea r br a ke a dju st in g
automatic adjuster, it must be located on only the h ole in t h e r ea r br a ke su ppor t pla t e.
threaded area of the adjuster assembly (Fig. 23). If it (3) In ser t a t h in scr ewdr iver t h r ou gh t h e a dju st in g
is located on a non-threaded area of the adjuster, the h ole in t h e su ppor t pla t e a n d a ga in st t h e st a r wh eel
function of the automatic adjuster will be affected. of t h e a dju st in g scr ew. Move h a n dle of t h e t ool down -
wa r d, r ot a t in g t h e st a r wh eel u n t il a sligh t dr a g is
(7) In st a ll t h e t en sion clip (F ig. 23) a t t a ch in g t h e felt wh en t ir e a n d wh eel a ssem bly is r ot a t ed.
u pper r et u r n spr in g t o t h e a u t om a t ic a dju st er a ssem bly. (4) In ser t a secon d t h in scr ewdr iver or piece of
(8) In st a ll t h e br a ke sh oe t o br a ke sh oe lower r et u r n weldin g r od in t o br a ke a dju st in g h ole a n d pu sh t h e
spr in gs on t h e br a ke sh oes (F ig. 21) a n d (F ig. 22). a dju st in g lever ou t of en ga gem en t wit h t h e st a r
(9) In st a ll a u t om a t ic a dju st m en t lever on t h e lea d- wh eel. Ca re s h o u ld be ta k e n s o a s n o t to be n d
in g br a ke sh oe of t h e r ea r br a ke a ssem bly (F ig. 20). a d ju s tin g le v e r o r d is to rt le v e r s p rin g .
(10) In st a ll t h e a ct u a t in g spr in g on t h e a u t om a t ic (5) Wh ile h oldin g t h e a dju st in g lever ou t of
a dju st m en t lever a n d lea din g br a ke sh oe a ssem bly en ga gem en t , ba ck off t h e st a r wh eel ju st en ou gh t o
(F ig. 19). en su r e a fr ee wh eel wit h n o br a ke sh oe dr a g.
(11) Ver ify t h a t t h e a u t om a t ic a dju st er lever h a s (6) Repea t t h e a bove a dju st m en t a t t h e ot h er r ea r
posit ive con t a ct wit h t h e st a r wh eel on t h e a u t om a t ic wh eel.
a dju st er a ssem bly. (7) In st a ll t h e a dju st in g h ole r u bber plu gs ba ck in
(12) Wh en a ll com pon en t s of bot h r ea r br a ke t h e r ea r br a ke su ppor t pla t es.
a ssem blies a r e cor r ect ly a n d fu lly in st a lled, r em ove (8) Lower t h e veh icle.
t h e lockin g plier s fr om t h e fr on t pa r k br a ke ca ble.
DI SC BRAK E CALI PER -

FRON T
REM OVAL
REMOVAL - FRONT DISC BRAKE CALIPER
(1) Depr ess t h e br a ke peda l pa st it s fir st in ch of
t r a vel a n d h old it in t h is posit ion u sin g a br a ke peda l
depr essor (h oldin g) t ool. Th is is don e t o isola t e t h e
m a st er cylin der fr om t h e br a ke h ydr a u lic syst em dis-
a llowin g t h e br a ke flu id t o com plet ely dr a in ou t of
t h e br a ke flu id r eser voir.
MAINTE NANCE /H OISTING - STANDARD P ROCE - Fig. 31 Brake Caliper Mounting (Typical)
DURE ). 1 - BRAKE HOSE
(3) Rem ove fr on t wh eel a n d t ir e a ssem bly. 2 - ADAPTER MOUNTING BOLTS
(4) Rem ove t h e ba n jo bolt con n ect in g t h e br a ke 3 - BANJO BOLT
4 - CALIPER GUIDE PIN BOLTS
h ose t o t h e br a ke ca liper. Th er e a r e t wo wa sh er s (on e
on ea ch side of t h e br a ke h ose fit t in g) t h a t will com e (1) Usin g you r fin ger s, colla pse on e side of t h e r u b-
off wit h t h e ba n jo bolt . Disca r d t h ese wa sh er s. ber gu ide pin bu sh in g. P u ll t h e gu ide pin bu sh in g ou t
(5) Rem ove t h e 2 ca liper gu ide pin bolt s. t h e ot h er side of t h e br a ke ca liper m ou n t in g boss.
(6) Rem ove t h e br a ke ca liper fr om t h e a da pt er. (2) Repea t t h is pr ocedu r e on t h e r em a in in g bu sh -
in g.
(TRW BRAKES) DISASSEMBLY - CALIPER PISTON AND SEAL
(1) Usin g a br a ke peda l h oldin g t ool, depr ess t h e
br a ke peda l pa st it s fir st on e in ch of t r a vel a n d h old WARNING: UNDER NO CONDITION SHOULD HIGH
it in t h is posit ion . Th is will isola t e t h e m a st er cylin - PRESSURE AIR EVER BE USED TO REMOVE A PIS-
der fr om t h e br a ke h ydr a u lic syst em a n d will n ot TON FROM A CALIPER BORE. PERSONAL INJURY
a llow t h e br a ke flu id t o dr a in ou t of t h e m a st er cyl- COULD RESULT FROM SUCH A PRACTICE.
in der r eser voir wh en t h e lin es a r e open ed.
(2) Ra ise t h e veh icle. Refer t o H OISTING in
NOTE: Before disassembling the brake caliper,
LUBRICATION AND MAINTE NANCE .
clean and inspect it. Refer to CLEANING AND
(3) Rem ove t h e fr on t t ir e a n d wh eel a ssem bly.
INSPECTION in this section.
(4) Rem ove t h e ba n jo bolt con n ect in g t h e br a ke
h ose t o t h e br a ke ca liper (F ig. 31). Th er e a r e t wo
wa sh er s (on e on ea ch side of t h e flex h ose fit t in g) NOTE: The safest way to remove the piston from
t h a t will com e off wit h t h e ba n jo bolt . Disca r d t h e the caliper bore is to use the hydraulic pressure of
wa sh er s. the vehicle’s brake system.
(5) Rem ove t h e t wo br a ke ca liper gu ide pin bolt s
(F ig. 31). (1) F ollowin g t h e r em ova l pr ocedu r e in DISC
(6) Rem ove t h e disc br a ke ca liper fr om t h e disc BRAKE SH OE S fou n d in t h is sect ion , r em ove t h e
br a ke a da pt er. ca liper fr om t h e br a ke r ot or a n d h a n g t h e a ssem bly
on a wir e h ook a wa y fr om r ot or a n d body of t h e veh i-
cle so br a ke flu id ca n n ot get on t h ese com pon en t s.
DI SASSEM BLY Rem ove t h e br a ke sh oes, a n d pla ce a sm a ll piece of
wood bet ween t h e pist on a n d ca liper fin ger s.
DISASSEMBLY - CALIPER GUIDE PIN (2) Ca r efu lly depr ess t h e br a ke peda l t o h ydr a u li-
BUSHINGS (CONTINENTAL TEVES BRAKES) ca lly pu sh pist on ou t of it s bor e. On ce com plet ed,
Befor e disa ssem blin g t h e br a ke ca liper, clea n a n d a pply a n d h old down t h e br a ke peda l t o a n y posit ion
in spect it . Refer t o CLE ANING or INSP E CTION in beyon d t h e fir st in ch of peda l t r a vel u sin g a br a ke
t h is sect ion . peda l h oldin g t ool. Th is will pr even t t h e flu id in t h e
DI SC BRAK E CALI PER - FRON T (Cont inue d)
m a st er cylin der r eser voir fr om com plet ely dr a in in g CLEANING - CALIPER
ou t .
(3) Discon n ect t h e br a ke flu id flex h ose fr om t h e WARNING: DUST AND DIRT ACCUMULATING ON
ca liper a ssem bly a n d r em ove it fr om t h e veh icle. BRAKE PARTS DURING NORMAL USE MAY CON-
TAIN ASBESTOS FIBERS FROM PRODUCTION OR
CAUTION: Do not use excessive force when clamp- AFTERMARKET BRAKE LININGS. BREATHING
ing caliper in vise. Excessive vise pressure will EXCESSIVE CONCENTRATIONS OF ASBESTOS
cause bore distortion. FIBERS CAN CAUSE SERIOUS BODILY HARM.
EXERCISE CARE WHEN SERVICING BRAKE
(4) Mou n t t h e ca liper in a vise equ ipped wit h pr o-
PARTS. DO NOT SAND OR GRIND BRAKE LINING
t ect ive ja ws.
(5) Rem ove t h e pist on du st boot fr om t h e ca liper
TAIN THE DUST RESIDUE. DO NOT CLEAN BRAKE
a n d disca r d.
PARTS WITH COMPRESSED AIR OR BY DRY
BRUSHING. CLEANING SHOULD BE DONE BY
NOTE: Do not use a screw driver or other metal tool
DAMPENING THE BRAKE COMPONENTS WITH A
for seal removal. Using such tools can scratch the
FINE MIST OF WATER, THEN WIPING THE BRAKE
bore or leave burrs on the seal groove edges.
COMPONENTS CLEAN WITH A DAMPENED CLOTH.
(6) Usin g a soft t ool su ch a s a pla st ic t r im st ick, DISPOSE OF CLOTH AND ALL RESIDUE CONTAIN-
wor k t h e pist on sea l ou t of it s gr oove in ca liper pis- ING ASBESTOS FIBERS IN AN IMPERMEABLE
t on bor e (F ig. 32). Disca r d t h e old sea l. CONTAINER WITH THE APPROPRIATE LABEL. FOL-
(OSHA) AND THE ENVIRONMENTAL PROTECTION
CONTAIN ASBESTOS FIBERS.
To clea n or flu sh t h e in t er n a l pa ssa ges of t h e br a ke

ca liper, u se fr esh br a ke flu id or Mopa r ! Non -Ch lor i-
n a t ed Br a ke P a r t s Clea n er. Never u se ga solin e, ker-
osen e, a lcoh ol, oil, t r a n sm ission flu id or a n y flu id
con t a in in g m in er a l oil t o clea n t h e ca liper. Th ese flu -
ids will da m a ge r u bber cu ps a n d sea ls.
INSPECTION - CALIPER
In spect t h e disc br a ke ca liper for t h e followin g:
• Br a ke flu id lea ks in a n d a r ou n d boot a r ea a n d
in boa r d lin in g
• Ru pt u r es, br it t len ess or da m a ge t o t h e pist on
du st boot
• Da m a ged, dr y or br it t le gu ide pin du st boot s
Fig. 32 Removing Piston Seal If ca liper fa ils in spect ion , disa ssem ble a n d r econ di-
1 - PLASTIC TRIM STICK
t ion ca liper, r epla cin g t h e sea ls a n d du st boot s.
2 - CALIPER
3 - PISTON SEAL GROOVE
4 - PISTON SEAL ASSEM BLY
(7) Clea n t h e pist on bor e a n d dr illed pa ssa ge wa ys ASSEMBLY - CALIPER GUIDE PIN BUSHINGS
u sin g a lcoh ol or a su it a ble solven t . Wipe it dr y u sin g
on ly a lin t -fr ee clot h .
(8) In spect t h e pist on bor e for scor in g or pit t in g. (1) F old t h e gu ide pin bu sh in g in h a lf len gt h wise.
Bor es t h a t sh ow ligh t scr a t ch es or cor r osion ca n u su -
NOTE: To avoid damage to the bushing, do not use
a lly be clea r ed of t h e ligh t scr a t ch es or cor r osion
a sharp object to install the guide pin bushing.
u sin g cr ocu s clot h .
(2) In ser t t h e folded bu sh in g in t o t h e ca liper
m ou n t in g boss u sin g you r fin ger s fr om t h e r ea r of
t h e ca liper.
(3) Un fold t h e bu sh in g u sin g you r fin ger s or a
wooden dowel u n t il t h e bu sh in g is fu lly sea t ed in t o
t h e ca liper h ou sin g. Th e bu sh in g fla n ges sh ou ld be
sea t ed even ly on bot h sides of t h e bu sh in g h ole.
(4) Lu br ica t e in side su r fa ces of bu sh in g u sin g
Mopa r ! Dielect r ic Gr ea se or equ iva len t .
(5) Repea t t h e pr ocedu r e for r em a in in g bu sh in g.
ASSEMBLY - CALIPER PISTON AND SEAL

NOTE: Never use an old piston seal.
(1) Dip t h e n ew pist on sea l in clea n br a ke flu id

a n d in st a ll it in t h e gr oove of t h e ca liper bor e. Th e
sea l sh ou ld be st a r t ed a t on e a r ea of t h e gr oove a n d
gen t ly wor ked a r ou n d a n d in t o t h e gr oove (F ig.
33)u sin g on ly you r clea n fin ger s t o sea t it .
Fig. 34 Installing Piston Into Caliper Bore

1 - BOOT
2 - PISTON
3 - CALIPER
Fig. 33 Installing New Piston Seal

1 - CALIPER
2 - PISTON SEAL
3 - SEAL GROOVE
(2) Coa t t h e n ew pist on boot wit h clea n br a ke

flu id.
(3) P osit ion t h e du st boot over t h e pist on a ft er
coa t in g it wit h br a ke flu id.
CAUTION: Force applied to the piston to seat it in

the bore must be applied uniformly to avoid cock-
ing and binding of the piston.
Fig. 35 Installing Dust Boot
(4) In st a ll pist on in t o ca liper bor e pu sh in g it pa st 1 - HAMMER
t h e pist on sea l u n t il it bot t om s in t h e ca liper bor e 2 - SPECIAL TOOL C-4171
(F ig. 34). 3 - SPECIAL TOOL C-4689 or C-4842
4 - CALIPER
(5) P osit ion t h e du st boot in t o t h e cou n t er bor e of
t h e ca liper a ssem bly pist on bor e. (7) Rein st a ll t h e ca liper on t h e veh icle a n d bleed
(6) Usin g a h a m m er a n d In st a ller, Specia l Tool t h e br a kes a s n ecessa r y. Refer t o In st a lla t ion in t h is
C-4689 or C-4842 (depen din g on pist on size), a n d sect ion .
H a n dle, Specia l Tool C-4171, dr ive t h e boot in t o t h e
cou n t er bor e of t h e ca liper a s n ecessa r y (F ig. 35).
I N STALLAT I ON (10) Roa d t est t h e veh icle a n d m a ke sever a l st ops

INSTALLATION - FRONT DISC BRAKE CALIPER sea t t h e br a ke sh oe lin in gs.
(CONTINENTAL TEVES BRAKES) INSTALLATION - FRONT DISC BRAKE CALIPER
CAUTION: TRW and Continental Teves brake cali- (TRW BRAKES)
pers are not interchangeable. Each caliper is specif-
ically designed for the unique brake system. If CAUTION: TRW and Continental Teves brake cali-
calipers are interchanged, improper performance, pers are not interchangeable. Each caliper is specif-
noise and increased stopping distance can occur. ically designed for the unique brake system. If
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL - calipers are interchanged, improper performance,
DESCRIPTION) noise and increased stopping distance can occur.
(Refer to 5 - BRAKES/HYDRAULIC/MECHANICAL -
(1) Com plet ely r et r a ct t h e ca liper pist on ba ck in t o DESCRIPTION)
pist on bor e of t h e ca liper. Use a C-cla m p t o r et r a ct
t h e pist on if n ecessa r y. P la ce a wood block over t h e (1) Com plet ely r et r a ct t h e ca liper pist on ba ck in t o
pist on befor e in st a llin g t h e C-cla m p t o a void da m a g- t h e bor e of t h e ca liper. Use a C-cla m p t o r et r a ct t h e
in g t h e pist on . pist on if n ecessa r y. P la ce a wood block over t h e pis-
t on befor e in st a llin g t h e C-cla m p t o a void da m a gin g
CAUTION: Use care when installing the brake cali- t h e pist on .
per assembly onto the steering knuckle, so that the
seals on the caliper guide pin bushings do not get CAUTION: Use care when installing the caliper onto
damaged by the steering knuckle bosses. the disc brake adapter to avoid damaging the boots
on the caliper guide pins.
(2) Ca r efu lly posit ion t h e br a ke ca liper a n d sh oes
over t h e br a ke r ot or a n d a da pt er. (2) In st a ll t h e disc br a ke ca liper over t h e br a ke
(3) In st a ll t h e ca liper gu ide pin bolt s a n d t igh t en sh oes on t h e br a ke ca liper a da pt er.
t o a t or qu e of 35 N·m (26 ft . lbs.). Ex tre m e c a u tio n (3) Align t h e ca liper gu ide pin bolt h oles wit h t h e
s h o u ld be ta k e n n o t to c ro s s th re a d th e c a lip e r gu ide pin s. In st a ll t h e ca liper gu ide pin bolt s a n d
g u id e p in bo lts . t igh t en t h em t o a t or qu e of 35 N·m (26 ft . lbs.) (F ig.
(4) In st a ll t h e a n t i-r a t t le clip on t h e ou t boa r d side 31).
of t h e ca liper. St a r t t h e clip in t o t h e h oles on t h e ca l- (4) In st a ll t h e ba n jo bolt con n ect in g t h e br a ke h ose
iper, t h en st r et ch t h e clip legs pa st t h e a bu t m en t s on t o t h e br a ke ca liper (F ig. 31). In st a ll NE W copper
t h e ca liper a da pt er. wa sh er s on ea ch side of t h e h ose fit t in g a s t h e ba n jo
bolt is gu ided t h r ou gh t h e fit t in g. Th r ea d t h e ba n jo
CAUTION: When connecting the brake hose to the bolt in t o t h e ca liper a n d t igh t en it t o a t or qu e of 47
caliper, install new brake hose to caliper special N·m (35 ft . lbs.).
copper washers. (5) In st a ll t h e t ir e a n d wh eel a ssem bly. Tigh t en
(5) In st a ll t h e br a ke h ose on t h e ca liper. To do ft . lbs.).
t h is, fir st pla ce on e NE W specia l fit t in g wa sh er on (6) Lower t h e veh icle.
ea ch side of t h e h ose fit t in g, t h en slide t h e ba n jo bolt (7) Rem ove t h e br a ke peda l h oldin g t ool.
t h r ou gh t h e fit t in g. Next , t h r ea d t h e ba n jo bolt in t o (8) Bleed t h e ca liper a s n ecessa r y. (Refer t o 5 -
t h e t h r ea ded por t on t h e r ea r of t h e br a ke ca liper. BRAKE S - BASE - STANDARD P ROCE DURE ).
Tigh t en t h e ba n jo bolt t o a t or qu e of 47 N·m (35 ft . (9) Roa d t est t h e veh icle a n d m a ke sever a l st ops t o
lbs.). wea r off a n y for eign m a t er ia l on t h e br a kes a n d t o
(6) In st a ll t h e wh eel a n d t ir e a ssem bly. Tigh t en sea t t h e br a ke sh oes.
t h e wh eel m ou n t in g st u d n u t s in pr oper sequ en ce
u n t il a ll n u t s a r e t or qu ed t o h a lf specifica t ion , t h en
r epea t t h e t igh t en in g sequ en ce t o t h e fu ll specified
(8) Rem ove t h e br a ke peda l depr essor (h oldin g)
t ool.
(9) Bleed t h e h ydr a u lic br a ke cir cu it t o t h e br a ke
ca liper. (Refer t o 5 - BRAKE S - STANDARD P ROCE -
DURE )
DI SC BRAK E CALI PER - REAR

REMOVAL - REAR DISC BRAKE CALIPER
NOTE: Handling of the rotor and caliper, must be
done in such a way as to avoid damage to the rotor
and scratching or nicking of lining on the brake
shoes.
(1) Depr ess t h e br a ke peda l pa st it s fir st in ch of

t r a vel a n d h old it in t h is posit ion u sin g a br a ke peda l
depr essor (h oldin g) t ool. Th is is don e t o isola t e t h e
m a st er cylin der fr om t h e br a ke h ydr a u lic syst em dis-
a llowin g t h e br a ke flu id t o com plet ely dr a in ou t of
t h e br a ke flu id r eser voir.
(2) Ra ise t h e veh icle. (Refer t o LUBRICATION & Fig. 37 Removing/Installing Caliper
MAINTE NANCE /H OISTING - STANDARD P ROCE - 1 - LIFT THIS END OF CALIPER AWAY FROM ADAPTER FIRST
DURE ) 2 - DISC BRAKE CALIPER
(3) Rem ove r ea r wh eel a n d t ir e a ssem bly fr om 3 - ADAPTER ABUTMENT
veh icle. 5 - OUTBOARD BRAKE SHOE
(4) Rem ove t h e ba n jo bolt con n ect in g t h e br a ke 6 - ROTOR
h ose t o t h e br a ke ca liper. Th er e a r e t wo wa sh er s (on e 7 - ADAPTER
on ea ch side of t h e br a ke h ose fit t in g) t h a t will com e
t h e wh eel m ou n t in g st u ds, t h en pu llin g t h e r ot or
off wit h t h e ba n jo bolt . Disca r d t h ese wa sh er s.
st r a igh t off t h e st u ds.
(5) Rem ove t h e disc br a ke ca liper t o a da pt er gu ide
pin bolt s (F ig. 36).
DISASSEMBLY - CALIPER PISTON AND SEAL
WARNING: UNDER NO CONDITION SHOULD HIGH
PRESSURE AIR EVER BE USED TO REMOVE A PIS-
TON FROM A CALIPER BORE. PERSONAL INJURY
COULD RESULT FROM SUCH A PRACTICE.
NOTE: Before disassembling the brake caliper,

clean and inspect it. Refer to CLEANING AND
INSPECTION in this section.
NOTE: The safest way to remove the piston from

the caliper bore is to use the hydraulic pressure of
the vehicle’s brake system.
(1) F ollowin g t h e r em ova l pr ocedu r e in DISC

Fig. 36 Caliper Guide Pin Bolts BRAKE SH OE S fou n d in t h is sect ion , r em ove t h e
1 - DISC BRAKE CALIPER ca liper fr om t h e br a ke r ot or a n d h a n g t h e a ssem bly
2 - ADAPTER on a wir e h ook a wa y fr om r ot or a n d body of t h e veh i-
3 - AXLE
4 - GUIDE PIN BOLTS cle so br a ke flu id ca n n ot get on t h ese com pon en t s.
5 - DRIVESHAFT (AWD MODELS ONLY) Rem ove t h e br a ke sh oes, a n d pla ce a sm a ll piece of
wood bet ween t h e pist on a n d ca liper fin ger s.
(6) Rem ove r ea r ca liper fr om a da pt er u sin g t h e fol- (2) Ca r efu lly depr ess t h e br a ke peda l t o h ydr a u li-
lowin g pr ocedu r e. F ir st r ot a t e fr on t of ca liper u p ca lly pu sh pist on ou t of it s bor e. On ce com plet ed,
fr om t h e a da pt er. Th en pu ll t h e r ea r of t h e ca liper a pply a n d h old down t h e br a ke peda l t o a n y posit ion
a n d t h e ou t boa r d br a ke sh oe a n t i-r a t t le clip ou t fr om beyon d t h e fir st in ch of peda l t r a vel u sin g a br a ke
u n der t h e r ea r a bu t m en t on t h e a da pt er (F ig. 37). peda l h oldin g t ool. Th is will pr even t t h e flu id in t h e
(7) If t h e br a ke r ot or r equ ir es r em ova l, it ca n n ow m a st er cylin der r eser voir fr om com plet ely dr a in in g
be r em oved by fir st r em ovin g t h e r et a in er clips fr om ou t .
DI SC BRAK E CALI PER - REAR (Cont inue d)
(3) Discon n ect t h e br a ke flu id flex h ose fr om t h e CLEANING - CALIPER
ca liper a ssem bly a n d r em ove it fr om t h e veh icle.
WARNING: DUST AND DIRT ACCUMULATING ON
CAUTION: Do not use excessive force when clamp- BRAKE PARTS DURING NORMAL USE MAY CON-
ing caliper in vise. Excessive vise pressure will TAIN ASBESTOS FIBERS FROM PRODUCTION OR
cause bore distortion. AFTERMARKET BRAKE LININGS. BREATHING
(4) Mou n t t h e ca liper in a vise equ ipped wit h pr o-
FIBERS CAN CAUSE SERIOUS BODILY HARM.
t ect ive ja ws. EXERCISE CARE WHEN SERVICING BRAKE
(5) Rem ove t h e pist on du st boot fr om t h e ca liper
PARTS. DO NOT SAND OR GRIND BRAKE LINING
a n d disca r d.
NOTE: Do not use a screw driver or other metal tool TAIN THE DUST RESIDUE. DO NOT CLEAN BRAKE
for seal removal. Using such tools can scratch the PARTS WITH COMPRESSED AIR OR BY DRY
BRUSHING. CLEANING SHOULD BE DONE BY
bore or leave burrs on the seal groove edges.
DAMPENING THE BRAKE COMPONENTS WITH A
(6) Usin g a soft t ool su ch a s a pla st ic t r im st ick, FINE MIST OF WATER, THEN WIPING THE BRAKE
wor k t h e pist on sea l ou t of it s gr oove in ca liper pis- COMPONENTS CLEAN WITH A DAMPENED CLOTH.
t on bor e (F ig. 38). Disca r d t h e old sea l. DISPOSE OF CLOTH AND ALL RESIDUE CONTAIN-
ING ASBESTOS FIBERS IN AN IMPERMEABLE
CONTAINER WITH THE APPROPRIATE LABEL. FOL-
(OSHA) AND THE ENVIRONMENTAL PROTECTION
CONTAIN ASBESTOS FIBERS.
To clea n or flu sh t h e in t er n a l pa ssa ges of t h e br a ke

ca liper, u se fr esh br a ke flu id or Mopa r ! Non -Ch lor i-
n a t ed Br a ke P a r t s Clea n er. Never u se ga solin e, ker-
osen e, a lcoh ol, oil, t r a n sm ission flu id or a n y flu id
con t a in in g m in er a l oil t o clea n t h e ca liper. Th ese flu -
ids will da m a ge r u bber cu ps a n d sea ls.
INSPECTION - CALIPER
In spect t h e disc br a ke ca liper for t h e followin g:
• Br a ke flu id lea ks in a n d a r ou n d boot a r ea a n d
in boa r d lin in g
• Ru pt u r es, br it t len ess or da m a ge t o t h e pist on
Fig. 38 Removing Piston Seal du st boot
1 - PLASTIC TRIM STICK
• Da m a ged, dr y or br it t le gu ide pin du st boot s
2 - CALIPER If ca liper fa ils in spect ion , disa ssem ble a n d r econ di-
3 - PISTON SEAL GROOVE t ion ca liper, r epla cin g t h e sea ls a n d du st boot s.
4 - PISTON SEAL
(7) Clea n t h e pist on bor e a n d dr illed pa ssa ge wa ys

u sin g a lcoh ol or a su it a ble solven t . Wipe it dr y u sin g
on ly a lin t -fr ee clot h .
(8) In spect t h e pist on bor e for scor in g or pit t in g.
Bor es t h a t sh ow ligh t scr a t ch es or cor r osion ca n u su -
a lly be clea r ed of t h e ligh t scr a t ch es or cor r osion
u sin g cr ocu s clot h .
ASSEMBLY - CALIPER PISTON AND SEAL

NOTE: Never use an old piston seal.
(1) Dip t h e n ew pist on sea l in clea n br a ke flu id

a n d in st a ll it in t h e gr oove of t h e ca liper bor e. Th e
sea l sh ou ld be st a r t ed a t on e a r ea of t h e gr oove a n d
gen t ly wor ked a r ou n d a n d in t o t h e gr oove (F ig.
39)u sin g on ly you r clea n fin ger s t o sea t it .
Fig. 40 Installing Piston Into Caliper Bore

1 - BOOT
2 - PISTON
3 - CALIPER
Fig. 39 Installing New Piston Seal

1 - CALIPER
2 - PISTON SEAL
3 - SEAL GROOVE
(2) Coa t t h e n ew pist on boot wit h clea n br a ke

flu id.
(3) P osit ion t h e du st boot over t h e pist on a ft er
coa t in g it wit h br a ke flu id.
CAUTION: Force applied to the piston to seat it in

the bore must be applied uniformly to avoid cock-
ing and binding of the piston.
(4) In st a ll pist on in t o ca liper bor e pu sh in g it pa st

t h e pist on sea l u n t il it bot t om s in t h e ca liper bor e
(F ig. 40).
(5) P osit ion t h e du st boot in t o t h e cou n t er bor e of
t h e ca liper a ssem bly pist on bor e.
(6) Usin g a h a m m er a n d In st a ller, Specia l Tool
C-4689 or C-4842 (depen din g on pist on size), a n d
H a n dle, Specia l Tool C-4171, dr ive t h e boot in t o t h e Fig. 41 Installing Dust Boot
cou n t er bor e of t h e ca liper a s n ecessa r y (F ig. 41). 1 - HAMMER
(7) Rein st a ll t h e ca liper on t h e veh icle a n d bleed 2 - SPECIAL TOOL C-4171
3 - SPECIAL TOOL C-4689 or C-4842
t h e br a kes a s n ecessa r y. Refer t o In st a lla t ion in t h is 4 - CALIPER
sect ion .
(2) If r em oved, in st a ll t h e br a ke r ot or on t h e h u b,
INSTALLATION - REAR DISC BRAKE CALIPER m a kin g su r e it is squ a r ely sea t ed on t h e fa ce of t h e
(1) Com plet ely r et r a ct ca liper pist on ba ck in t o pis- h u b.
t on bor e of t h e ca liper.
CAUTION: Use care when installing the caliper INSTALLATION - FRONT DISC BRAKE CALIPER
assembly onto the adapter, so the caliper guide pin
ADAPTER
bushings do not get damaged by the mounting
(1) P la ce a da pt er over br a ke r ot or a n d a lign
bosses.
a da pt er m ou n t in g h oles t o kn u ckle.
CAUTION: Adapter mounting bolts have a special
r ot or a n d on t o t h e a da pt er u sin g t h e r ever se pr oce-
Dacromet" coating applied to resist corrosion. If
du r e for r em ova l (F ig. 37).
mounting bolts need to be replaced, use only
CAUTION: When installing guide pin bolts extreme Mopar" replacement parts.
caution should be taken not to cross-thread the cal-
(2) In st a ll a da pt er m ou n t in g bolt s a n d t igh t en t o
169 N·m (125 ft . lbs.) t or qu e.
(4) In st a ll t h e ca liper gu ide pin bolt s. Tigh t en t h e (3) In st a ll br a ke sh oes, disc br a ke ca liper a n d
gu ide pin bolt s t o a t or qu e of 35 N·m (26 ft . lbs.). wh eel a n d t ir e a ssem bly. (Refer t o 5 - BRAKE S/H Y-
DRAULIC/ME CH ANICAL/BRAKE PADS/SH OE S -
CAUTION: When connecting the brake hose to the INSTALLATION)
caliper, install new brake hose to caliper special (4) Lower veh icle.
washers. (5) P u m p t h e br a ke peda l sever a l t im es t o set t h e
pa ds t o t h e br a ke r ot or.
(5) In st a ll t h e br a ke h ose on t h e ca liper. To do (6) Ch eck a n d a dju st br a ke flu id level a s n eces-
t h is, fir st pla ce on e NE W specia l copper wa sh er on sa r y.
ea ch side of t h e h ose fit t in g, t h en slide t h e ba n jo bolt
t h r ou gh t h e fit t in g. Next , t h r ea d t h e ba n jo bolt in t o
t h e t h r ea ded por t on t h e r ea r of t h e br a ke ca liper. DI SC BRAK E CALI PER GU I DE
Tigh t en t h e ba n jo bolt t o a t or qu e of 47 N·m (35 ft . PI N S
lbs.).
(6) In st a ll t h e wh eel a n d t ir e a ssem bly. REMOVAL - DISC BRAKE CALIPER GUIDE PINS
(7) Tigh t en t h e wh eel m ou n t in g st u d n u t s in
pr oper sequ en ce u n t il a ll n u t s a r e t or qu ed t o h a lf (TRW BRAKES)
specifica t ion . Th en r epea t t h e t igh t en in g sequ en ce t o (1) Ra ise t h e veh icle. Refer t o H OISTING in
t h e fu ll specified t or qu e of 135 N·m (100 ft . lbs.). LUBRICATION AND MAINTE NANCE .
(8) Lower t h e veh icle. (2) Rem ove t h e fr on t t ir e a n d wh eel a ssem bly.
(9) Rem ove t h e br a ke peda l depr essor (h oldin g) (3) Rem ove t h e t wo br a ke ca liper gu ide pin bolt s
t ool. (F ig. 42).
(10) Bleed t h e h ydr a u lic br a ke cir cu it t o t h e br a ke
ca liper. (Refer t o 5 - BRAKE S - STANDARD P ROCE -
DURE )
(11) Roa d t est t h e veh icle a n d m a ke sever a l st ops
sea t t h e br a ke sh oe lin in gs.
DI SC BRAK E CALI PER

ADAPT ER
ADAPTER
DURE ) Fig. 42 Brake Caliper Mounting
(2) Rem ove fr on t wh eel a n d t ir e a ssem bly, disc
1 - BRAKE HOSE
br a ke ca liper a n d br a ke sh oes. (Refer t o 5 - BRAKE S/ 2 - ADAPTER MOUNTING BOLTS
H YDRAULIC/ME CH ANICAL/BRAKE PADS/SH OE S 3 - BANJO BOLT
- RE MOVAL) 4 - CALIPER GUIDE PIN BOLTS
(3) Rem ove t wo bolt s fa st en in g a da pt er t o st eer in g
kn u ckle, t h en r em ove disc br a ke ca liper a da pt er.
DI SC BRAK E CALI PER GU I DE PI N S (Cont inue d)
(4) Rem ove t h e disc br a ke ca liper fr om t h e disc DRU M
br a ke ca liper a da pt er a n d h a n g it ou t of t h e wa y
u sin g wir e or a bu n gee cor d. Use ca r e n ot t o over ex-
REMOVAL
t en d t h e br a ke h ose wh en doin g t h is.
(5) Rem ove t h e gu ide pin s a n d boot s fr om t h e
a da pt er a s sh own (F ig. 43).
DURE ).
(2) Rem ove t h e t ir e a n d wh eel a ssem bly fr om t h e
veh icle
(3) Rem ove t h e r ea r br a ke sh oe a dju st in g h ole
cover plu g.
(4) In ser t a t h in scr ewdr iver in t o br a ke a dju st in g
h ole a n d h old a dju st in g lever a wa y fr om n ot ch es of
a dju st in g scr ew st a r wh eel.
(5) In ser t a n ot h er t h in scr ewdr iver in t o br a ke
a dju st in g h ole a n d en ga ge n ot ch es of br a ke a dju st in g
scr ew st a r wh eel. Relea se br a ke a dju st m en t by pr y-
in g u pwa r d wit h a dju st in g t ool.
(6) Rem ove r ea r br a ke dr u m fr om r ea r h u b/bea r-
in g a ssem bly.
NOTE: It may be necessary to insert M8 X 1.25 MM

bolts into the two removal holes on the drum to
Fig. 43 Guide Pins And Boots force the drum off the hub.
1 - PINS
2 - BOOTS
INSTALLATION
INSTALLATION - DISC BRAKE CALIPER GUIDE (1) Adju st br a ke sh oe a ssem blies so a s n ot t o in t er-
PINS (TRW BRAKES) fer e wit h br a ke dr u m in st a lla t ion .
(1) Lu br ica t e t h e gu ide pin s a n d in side t h e boot s (2) In st a ll t h e r ea r br a ke dr u m s on t h e h u bs.
wit h t h e pa cket su pplied wit h t h e ser vice kit , Syt h - (3) Adju st dr u m br a ke sh oes a s n ecessa r y per pr o-
eso GLK-1 lu br ica n t or equ iva len t . cedu r e fou n d in t h e Adju st m en t sect ion of t h is ser-
(2) In st a ll t h e gu ide pin s a n d boot s in t h e a da pt er vice m a n u a l gr ou p (Refer t o 5 - BRAKE S/
a s sh own (F ig. 43). Th e boot s h a ve gr ooves bu ilt in t o H YDRAULIC/ME CH ANICAL/DRUM -
t h eir in n er lips t o fit on t o t h e pin s a n d a da pt er. ADJ USTME NTS).
(4) In st a ll wh eel a n d t ir e a ssem bly.
CAUTION: Use care when installing the caliper onto (5) Tigh t en t h e wh eel m ou n t in g st u d n u t s in
the disc brake adapter to avoid damaging the boots pr oper sequ en ce u n t il a ll n u t s a r e t or qu ed t o h a lf
on the caliper guide pins. specifica t ion . Th en r epea t t h e t igh t en in g sequ en ce t o
t h e fu ll specified t or qu e of 135 N·m (100 ft . lbs.).
(3) In st a ll t h e disc br a ke ca liper over t h e br a ke (6) Lower t h e veh icle.
sh oes on t h e br a ke ca liper a da pt er.
(4) Align t h e ca liper gu ide pin bolt h oles wit h t h e
gu ide pin s. In st a ll t h e ca liper gu ide pin bolt s a n d
t igh t en t h em t o a t or qu e of 35 N·m (26 ft . lbs.) (F ig.
42).
(5) In st a ll t h e t ir e a n d wh eel a ssem bly. Tigh t en
ft . lbs.).
(7) P u m p t h e br a ke peda l sever a l t im es befor e
m ovin g t h e veh icle t o set t h e sh oes t o t h e br a ke
r ot or.
FLU I D CAUTION: Never use reclaimed brake fluid or fluid

from an container which has been left open. An
open container of brake fluid will absorb moisture
DIAGNOSIS AND TESTING - BRAKE FLUID
from the air and contaminate the fluid.
CONTAMINATION
In dica t ion s of flu id con t a m in a t ion a r e swollen or
det er ior a t ed r u bber pa r t s. CAUTION: Never use any type of a petroleum-based
Swollen r u bber pa r t s in dica t e t h e pr esen ce of fluid in the brake hydraulic system. Use of such
pet r oleu m in t h e br a ke flu id. type fluids will result in seal damage of the vehicle
To t est for con t a m in a t ion , pu t a sm a ll a m ou n t of brake hydraulic system causing a failure of the
dr a in ed br a ke flu id in clea r gla ss ja r. If flu id sepa - vehicle brake system. Petroleum based fluids would
r a t es in t o la yer s, t h er e is m in er a l oil or ot h er flu id be items such as engine oil, transmission fluid,
con t a m in a t ion of t h e br a ke flu id. power steering fluid, etc.
If br a ke flu id is con t a m in a t ed, dr a in a n d t h or-
ou gh ly flu sh syst em . Repla ce m a st er cylin der, pr opor-
t ion in g va lve, ca liper sea ls, wh eel cylin der sea ls,
An t ilock Br a ke h ydr a u lic u n it a n d a ll h ydr a u lic flu id
J U N CT I ON BLOCK
h oses.
DESCRIPTION - NON-ABS JUNCTION BLOCK
STANDARD PROCEDURE - BRAKE FLUID A ju n ct ion block is u sed on veh icles t h a t a r e n ot
equ ipped wit h a n t ilock br a kes (ABS). Th e ju n ct ion
LEVEL CHECKING block m ou n t s in t h e sa m e loca t ion a s t h e in t egr a t ed
Ch eck m a st er cylin der r eser voir flu id level a m in i- con t r ol u n it (ICU) does on veh icles equ ipped wit h
m u m of t wice a n n u a lly. ABS. Th is a llows for u se of t h e sa m e br a ke t u be con -
F lu id r eser voir s a r e m a r ked wit h t h e wor ds F ULL figu r a t ion on a ll veh icles. Th e ju n ct ion block is
a n d ADD t o in dica t e pr oper br a ke flu id fill level of loca t ed on t h e dr iver ’s side of t h e fr on t su spen sion
t h e m a st er cylin der. cr a dle/cr ossm em ber below t h e m a st er cylin der (F ig.
If n ecessa r y, a dd br a ke flu id t o br in g t h e level t o 44).
t h e bot t om of t h e F ULL m a r k on t h e side of t h e m a s- It h a s six t h r ea ded por t s t o wh ich t h e br a ke t u bes
t er cylin der flu id r eser voir. con n ect . Two a r e for t h e pr im a r y a n d secon da r y
Use on ly Mopa r ! br a ke flu id or equ iva len t fr om a br a ke t u bes com in g fr om t h e m a st er cylin der. Th e
sea led con t a in er. Br a ke flu id m u st con for m t o DOT 3 r em a in in g fou r a r e for t h e ch a ssis br a ke t u bes goin g
specifica t ion s (DOT 4 or DOT 4+ a r e a ccept a ble). t o ea ch br a ke a ssem bly.
D O N OT u se br a ke flu id wit h a lower boilin g
poin t , a s br a ke fa ilu r e cou ld r esu lt du r in g pr olon ged
OPERATION - NON-ABS JUNCTION BLOCK
h a r d br a kin g.
Th e ju n ct ion block dist r ibu t es t h e br a ke flu id com -
Use on ly br a ke flu id t h a t wa s st or ed in a t igh t ly-
in g fr om t h e m a st er cylin der pr im a r y a n d secon da r y
sea led con t a in er.
por t s t o t h e fou r ch a ssis br a ke t u bes lea din g t o t h e
D O N OT u se pet r oleu m -ba sed flu id beca u se sea l
br a kes a t ea ch wh eel. Sin ce t h e ju n ct ion block
da m a ge will r esu lt . P et r oleu m ba sed flu ids wou ld be
m ou n t s in t h e sa m e loca t ion a s t h e ABS in t egr a t ed
it em s su ch a s en gin e oil, t r a n sm ission flu id, power
con t r ol u n it (ICU), it a llows for t h e com m on u se of
st eer in g flu id et c.
br a ke t u bes goin g t o t h e br a kes wh et h er t h e veh icle
is equ ipped wit h or wit h ou t ABS.
SPECI FI CAT I ON S
NOTE: Although the brake tubes coming from the
master cylinder to the junction block or ABS ICU
BRAKE FLUID
may appear to be the same, they are not. They are
Th e br a ke flu id u sed in t h is veh icle m u st con for m
unique to each brake system application.
t o DOT 3 specifica t ion s (DOT 4 a n d DOT 4+ a r e
a ccept a ble) a n d SAE J 1703 st a n da r ds. No ot h er t ype
of br a ke flu id is r ecom m en ded or a ppr oved for u sa ge
in t h e veh icle br a ke syst em . Use on ly Mopa r ! Br a ke
F lu id or equ iva len t fr om a t igh t ly sea led con t a in er.
J U N CT I ON BLOCK (Cont inue d)
REMOVAL - NON-ABS JUNCTION BLOCK (5) Rem ove t h e pr im a r y a n d secon da r y br a ke

(1) Usin g a br a ke peda l depr essor, m ove a n d lock t u bes fr om t h e t op of t h e ju n ct ion block.
t h e br a ke peda l t o a posit ion pa st it s fir st 1 in ch of (6) Rem ove t h e bolt s a t t a ch in g t h e ju n ct ion block
t r a vel. Th is will pr even t br a ke flu id fr om dr a in in g m ou n t in g br a cket t o t h e fr on t su spen sion cr ossm em -
ou t of t h e m a st er cylin der wh en t h e br a ke t u bes a r e ber (F ig. 44), t h en r em ove t h e ju n ct ion block.
r em oved fr om t h e ju n ct ion block.
(2) Discon n ect t h e ba t t er y n ega t ive ca ble. INSTALLATION - NON-ABS JUNCTION BLOCK
(3) If t h e veh icle is equ ipped wit h speed con t r ol, (1) In st a ll t h e ju n ct ion block a n d m ou n t in g br a cket
per for m t h e followin g: on t h e fr on t su spen sion cr ossm em ber (F ig. 44).
(a ) Discon n ect t h e ba t t er y posit ive ca ble. In st a ll t h e m ou n t in g bolt s a n d t igh t en t o a t or qu e of
(b) Rem ove t h e ba t t er y (Refer t o 8 - E LE CTRI- 28 N·m (250 in . lbs.).
CAL/BATTE RY SYSTE M/BATTE RY - RE MOVAL). (2) In st a ll t h e pr im a r y a n d secon da r y br a ke t u bes
(c) Discon n ect t h e va cu u m h ose con n ect or a t t h e fr om t h e m a st er cylin der in t h eir por t s. Tigh t en t u be
t a n k bu ilt in t o t h e ba t t er y t r a y. n u t s t o a t or qu e of 17 N·m (145 in . lbs.). Ta k e c a re
(d) Rem ove t h e scr ew secu r in g t h e coola n t filler n o t to tw is t tu be s w h e n tig h te n in g tu be n u ts .
n eck t o t h e ba t t er y t r a y. Th e y m u s t be p ro p e rly p o s itio n e d to a llo w fre e
(e) Rem ove t h e ba t t er y t r a y (Refer t o 8 - E LE C- m o v e m e n t w ith ru bbe r is o la te d s u s p e n s io n
TRICAL/BATTE RY SYSTE M/TRAY - RE MOVAL). c ro s s m e m be r.
(f) Rem ove t h e fa st en er s a n d m ove t h e speed (3) In st a ll t h e fou r ch a ssis br a ke t u bes in t o t h e
con t r ol ser vo off t o t h e side, ou t of t h e wa y. ou t let por t s of t h e ju n ct ion block. Tigh t en a ll 6 t u be
n u t s t o a t or qu e of 17 N·m (145 in . lbs.).
CAUTION: Before removing the brake tubes from (4) If t h e veh icle is equ ipped wit h speed con t r ol,
the junction block, the junction block and the brake per for m t h e followin g:
tubes must be thoroughly cleaned. This is required (a ) In st a ll t h e speed con t r ol ser vo wit h it s
to prevent contamination from entering the brake m ou n t in g n u t s.
hydraulic system. (b) Con n ect t h e wir in g h a r n ess t o t h e speed con -
t r ol ser vo.
(4) Rem ove t h e fou r ch a ssis br a ke t u bes fr om t h e (c) In st a ll t h e ba t t er y t r a y (Refer t o 8 - E LE C-
t op of t h e ju n ct ion block (F ig. 44). TRICAL/BATTE RY SYSTE M/TRAY - INSTALLA-
TION).
(d) In st a ll t h e scr ew secu r in g t h e coola n t filler
n eck t o t h e ba t t er y t r a y.
(e) Recon n ect t h e va cu u m h ose con n ect or a t t h e
t a n k bu ilt in t o t h e ba t t er y t r a y.
(f) In st a ll t h e ba t t er y (Refer t o 8 - E LE CTRI-
CAL/BATTE RY SYSTE M/BATTE RY - INSTALLA-
TION).
(g) In st a ll t h e ba t t er y sh ield.
(5) Rem ove t h e br a ke peda l h older.
(6) Con n ect n ega t ive ca ble ba ck on n ega t ive post of
t h e ba t t er y.
(7) Bleed t h e br a ke syst em t h or ou gh ly t o en su r e
t h a t a ll a ir h a s been expelled fr om t h e h ydr a u lic sys-
t em . (Refer t o 5 - BRAKE S - STANDARD P ROCE -
DURE ).
Fig. 44 NON-ABS JUNCTION BLOCK (8) Roa d t est t h e veh icle t o ver ify pr oper oper a t ion
1 - MASTER CYLINDER
2 - JUNCTION BLOCK
3 - SUSPENSION CROSSMEMBER
4 - MOUNTING BOLTS
M AST ER CY LI N DER CAUTION: When replacing a master cylinder, be

sure to use the correct master cylinder for the type
of brake system the vehicle is equipped with.
DESCRI PT I ON
Th e body of t h e m a st er cylin der is a n a n odized a lu -
DESCRIPTION m in u m ca st in g. It h a s a m a ch in ed bor e t o a ccept t h e
Th e m a st er cylin der is loca t ed on t h e power br a ke m a st er cylin der pist on s a n d t h r ea ded por t s wit h
boost er in t h e en gin e com pa r t m en t on t h e dr iver ’s sea t s for t h e h ydr a u lic br a ke lin e con n ect ion s.
side (F ig. 45). Th is veh icle u ses 3 differ en t m a st er Th e br a ke flu id r eser voir is m ou n t ed on t h e t op of
cylin der s. Ma st er cylin der u sa ge depen ds on wh a t t h e m a st er cylin der. It is m a de of a see-t h r ou gh
t ype of br a ke syst em t h e veh icle is equ ipped wit h . polypr opylen e t ype pla st ic for ea sy flu id level view-
in g. A br a ke flu id level swit ch is a t t a ch ed t o t h e
CAUTION: Master cylinders are not interchangeable br a ke flu id r eser voir.
between systems. Performance and stopping dis- Th e m a st er cylin der is n ot a r epa ir a ble com pon en t
tance issues will result if the incorrect master cyl- a n d m u st be r epla ced if dia gn osed t o be fu n ct ion in g
inder is installed on the vehicle. im pr oper ly. Th e br a ke flu id r eser voir a n d br a ke flu id
level swit ch ca n be r epla ced sepa r a t ely.
CAUTION: Do not hone the bore of the cylinder as

this will remove the anodized surface from the bore.
DESCRIPTION - RHD
Th e m a st er cylin der u sed on r igh t h a n d dr ive
(RH D) veh icles fu n ct ion s sim ila r ly t o t h a t u sed on
left h a n d dr ive (LH D) veh icles. Th e RH D m a st er cyl-
in der, a s well a s t h e RH D power br a ke boost er, is
loca t ed in t h e sa m e a r ea , bu t lower in t h e en gin e
com pa r t m en t t h a n LH D m odels (F ig. 46). F or t h a t
r ea son a n ext en sion m a n ifold is pla ced bet ween t h e
flu id r eser voir a n d m a st er cylin der h ou sin g a llowin g
t h e flu id r eser voir t o be posit ion ed in t h e sa m e loca -
t ion a s on LH D m odels.
Fig. 45 Master Cylinder And Booster Location
1 - MASTER CYLINDER
2 - POWER BRAKE BOOSTER
F or in for m a t ion on m a st er cylin der a pplica t ion ,

bor e a n d t ype, view t h e followin g t a ble:
MASTER CYLINDER
BRAKE SYSTEM
BORE/TYPE
23.8 mm (15/16 in.)
Disc/Drum - ABS Conventional
Compensating Port
23.8 mm (15/16 in.)
Disc/Drum - Non-ABS Conventional
Compensating Port
25.4 mm (1.0 in.) Fig. 46 RHD MASTER CYLINDER AND POWER
Disc/Disc - ABS Conventional BRAKE BOOSTER
Compensating Port 1 - POWER BRAKE BOOSTER
Disc/Disc ABS With 25.4 mm (1.0 in.) Dual 2 - BRAKE FLUID LEVEL SWITCH
3 - FLUID RESERVOIR
Traction Control Center Port 4 - MASTER CYLINDER
M AST ER CY LI N DER (Cont inue d)
OPERATION
Wh en t h e br a ke peda l is depr essed, t h e m a st er cyl-
in der pr im a r y a n d secon da r y pist on s a pply br a ke
pr essu r e t h r ou gh t h e ch a ssis t u bes t o t h e br a kes a t
ea ch t ir e a n d wh eel a ssem bly.
Th e m a st er cylin der pr im a r y ou t let por t su pplies
h ydr a u lic pr essu r e t o t h e r igh t fr on t a n d left r ea r
br a kes. Th e secon da r y ou t let por t su pplies h ydr a u lic
pr essu r e t o t h e left fr on t a n d r igh t r ea r br a kes.
STANDARD PROCEDURE - MASTER CYLINDER

BLEEDING
CAUTION: When clamping master cylinder in vise,
only clamp master cylinder by its mounting flange.
Do not clamp master cylinder piston rod, reservoir,
seal or body.
(1) Cla m p m a st er cylin der in a vise.

Fig. 47 Master Cylinder Set Up For Bleeding
NOTE: Use correct bleeder tubes when bleeding 1 - BLEEDER TUBES 8358
master cylinder. Master cylinder outlet ports vary in 2 - WOODEN DOWEL
3 - ADAPTER 8822-2 (USE ONLY ON ABS EQUIPPED MASTER
size and type depending on whether master cylin- CYLINDERS)
der is for a vehicle equipped with ABS or not. ABS 4 - ADAPTER 8822-2 (USE ONLY ON ABS EQUIPPED MASTER
CYLINDERS)
equipped master cylinders require the additional
use of ISO style flare adapters supplied in Special
pr essu r e, a llowin g pist on s t o r et u r n t o r elea sed posi-
Tool Package 8822 to be used in conjunction with
t ion . Repea t sever a l t im es u n t il a ll a ir bu bbles a r e
Bleeder Tubes, Special Tool Package 8358.
expelled. Ma ke su r e flu id level st a ys a bove t ips of
(2) At t a ch specia l t ools for bleedin g m a st er cylin - bleeder t u bes in r eser voir wh ile bleedin g.
der in t h e followin g fa sh ion : (5) Rem ove bleeder t u bes fr om m a st er cylin der
(a ) F o r n o n -AB S c o n tro l e qu ip p e d m a s te r ou t let por t s, t h en plu g ou t let por t s a n d in st a ll fill ca p
c y lin d e rs , t h r ea d a Bleeder Tu be, Specia l Tool on r eser voir.
8358–1, in t o ea ch ou t let por t . Tigh t en ea ch t u be t o (6) Rem ove m a st er cylin der fr om vise.
17 N·m (145 in . lbs.) t or qu e. F lex bleeder t u bes a n d (7) In st a ll m a st er cylin der on veh icle. (Refer t o 5 -
pla ce open en ds in t o m ou t h of flu id r eser voir a s fa r BRAKE S - BASE /H YDRAULIC/ME CH ANICAL/MAS-
down a s possible (F ig. 47). TE R CYLINDE R - INSTALLATION)
(b) F o r AB S e qu ip p e d m a s te r c y lin d e rs ,
t h r ea d on e Ada pt er, Specia l Tool 8822–2, in ea ch REM OVAL
ou t let por t . Tigh t en Ada pt er s t o 17 N·m (145 in .
lbs.) t or qu e. Next , t h r ea d a Bleeder Tu be, Specia l
REMOVAL - LHD
Tool 8358–1, in t o ea ch Ada pt er. Tigh t en ea ch t u be
t o 17 N·m (145 in . lbs.) t or qu e. F lex bleeder t u bes CAUTION: Vacuum in the power brake booster must
a n d pla ce open en ds in t o m ou t h of flu id r eser voir be pumped down (removed) before removing mas-
a s fa r down a s possible (F ig. 47). ter cylinder from power brake booster. This is nec-
essary to prevent the power brake booster from
NOTE: Make sure open ends of bleeder tubes stay
sucking in any contamination as the master cylin-
below surface of brake fluid once reservoir is filled
der is removed. This can be done simply by pump-
to proper level.
ing the brake pedal, with the vehicle’s engine not
(3) F ill br a ke flu id r eser voir wit h Mopa r ! br a ke running, until a firm feeling brake pedal is achieved.
flu id or equ iva len t con for m in g t o DOT 3 (DOT 4 a n d
(1) Wit h en gin e n ot r u n n in g, pu m p br a ke peda l
DOT 4+ a r e a ccept a ble) specifica t ion s. Ma ke su r e
u n t il a fir m peda l is a ch ieved (4-5 st r okes).
flu id level is a bove t ips of bleeder t u bes in r eser voir
(2) Discon n ect n ega t ive ba t t er y t er m in a l.
t o en su r e n o a ir is in gest ed du r in g bleedin g.
(3) Discon n ect posit ive ba t t er y t er m in a l.
(4) Usin g a wooden dowel a s a pu sh r od (F ig. 47),
(4) Rem ove ba t t er y sh ield.
slowly depr ess m a st er cylin der pist on s, t h en r elea se
(5) Rem ove n u t a n d cla m p secu r in g ba t t er y t o t r a y,
r em ove ba t t er y.
(6) Th or ou gh ly clea n a ll su r fa ces of t h e br a ke flu id
r eser voir a n d m a st er cylin der. Use on ly solven t su ch
a s Mopa r ! Br a ke P a r t s Clea n er or equ iva len t .
(7) Rem ove wir in g h a r n ess con n ect or fr om br a ke
flu id level swit ch in m a st er cylin der br a ke flu id r es-
er voir (F ig. 48).
Fig. 49 MASTER CYLINDER MOUNTING

1 - MASTER CYLINDER MOUNTING NUTS
2 - MASTER CYLINDER
3 - SECONDARY TUBE NUT AT ICU
4 - PRIMARY TUBE NUT AT ICU
(12) Rem ove va cu u m sea l loca t ed on t h e m ou n t in g

fla n ge of t h e m a st er cylin der. Th e va cu u m sea l is
r em oved fr om m a st er cylin der by c a re fu lly pu llin g it
Fig. 48 MASTER CYLINDER AND BOOSTER off t h e r ea r of m a st er cylin der. D o n o t a tte m p t to
1 - POWER BRAKE BOOSTER p ry th e s e a l o ff th e m a s te r c y lin d e r by in s e rtin g
2 - BOOSTER IDENTIFICATION LABEL a s h a rp to o l be tw e e n s e a l a n d m a s te r c y lin d e r
3 - FLUID LEVEL SWITCH CONNECTOR c a s tin g .
4 - PRIMARY BRAKE TUBE NUT
5 - SECONDARY BRAKE TUBE NUT
6 - MASTER CYLINDER REMOVAL - RHD
(8) Discon n ect pr im a r y a n d secon da r y br a ke t u bes CAUTION: Vacuum in the power brake booster must
fr om m a st er cylin der h ou sin g (F ig. 48). In st a ll sea l- be pumped down (removed) before removing mas-
in g plu gs in t h e n ow open br a ke t u be ou t let por t s. ter cylinder from power brake booster. This is nec-
essary to prevent the power brake booster from
CAUTION: Before removing the master cylinder sucking in any contamination as the master cylin-
from the power brake vacuum booster, the master der is removed. This can be done simply by pump-
cylinder and vacuum booster must be thoroughly ing the brake pedal, with the vehicle’s engine not
cleaned. This must be done to prevent dirt particles running, until a firm feeling brake pedal is achieved.
from falling into the power brake vacuum booster.
(1) Wit h en gin e n ot r u n n in g, pu m p br a ke peda l
(9) Clea n a r ea wh er e m a st er cylin der a ssem bly u n t il a fir m peda l is a ch ieved (4 or 5 st r okes).
a t t a ch es t o power br a ke boost er. Use on ly a solven t (2) Discon n ect n ega t ive ba t t er y t er m in a l.
su ch a s Mopa r ! Br a ke P a r t s Clea n er or equ iva len t . (3) Discon n ect posit ive ba t t er y t er m in a l.
(10) Rem ove t wo n u t s a t t a ch in g m a st er cylin der t o (4) Rem ove ba t t er y sh ield.
power br a ke boost er (F ig. 49). (5) Rem ove n u t a n d cla m p secu r in g ba t t er y t o t r a y,
(11) Slide m a st er cylin der st r a igh t ou t of power r em ove ba t t er y.
br a ke boost er. (6) Th or ou gh ly clea n a ll su r fa ces of t h e br a ke flu id
r eser voir a n d m a st er cylin der. Use on ly solven t su ch
CAUTION: A seal on the rear of the master cylinder a s Mopa r ! Br a ke P a r t s Clea n er or equ iva len t .
is used to create the seal for holding vacuum in the (7) Rem ove wir in g h a r n ess con n ect or fr om br a ke
power brake vacuum booster. The vacuum seal on flu id level swit ch in m a st er cylin der br a ke flu id r es-
the master cylinder MUST be replaced whenever the er voir (F ig. 46).
master cylinder is removed from the power brake
vacuum booster.
(8) Discon n ect pr im a r y a n d secon da r y br a ke t u bes DISASSEMBLY - MASTER CYLINDER (FLUID
fr om m a st er cylin der h ou sin g (F ig. 50). In st a ll sea l-
RESERVOIR)
in g plu gs in t h e n ow open br a ke t u be ou t let por t s.
(1) Clea n m a st er cylin der h ou sin g a n d br a ke flu id
r eser voir. Use on ly a solven t su ch a s Mopa r Br a ke
P a r t s Clea n er or a n equ iva len t .
(2) Rem ove br a ke flu id r eser voir ca p. Usin g a
syr in ge or equ iva len t t ype t ool em pt y a s m u ch br a ke
flu id a s possible fr om t h e r eser voir.
CAUTION: When removing fluid reservoir from the

master cylinder, do not pry off using any type of
tool. This can damage the fluid reservoir or master
cylinder housing.
(3) Rem ove t h e m a st er cylin der a ssem bly fr om t h e

power br a ke va cu u m boost er. (Refer t o 5 - BRAKE S -
BASE /H YDRAULIC/ME CH ANICAL/MASTE R CYL-
INDE R - RE MOVAL).
(4) Mou n t t h e m a st er cylin der in a vise u sin g t h e
m a st er cylin der m ou n t in g fla n ge.
Fig. 50 RHD MASTER CYLINDER MOUNTING
(5) Usin g cor r ect size pin pu n ch , r em ove t h e t wo
r et a in in g pin s bet ween t h e flu id r eser voir a n d m a st er
3 - MASTER CYLINDER MOUNTING NUTS cylin der h ou sin g (F ig. 51).
CAUTION: Before removing the master cylinder

from the power brake vacuum booster, the master
cylinder and vacuum booster must be thoroughly
cleaned. This must be done to prevent dirt particles
(9) Clea n a r ea wh er e m a st er cylin der a ssem bly

a t t a ch es t o power br a ke boost er. Use on ly a solven t
su ch a s Mopa r ! Br a ke P a r t s Clea n er or equ iva len t .
(10) Rem ove t wo n u t s a t t a ch in g m a st er cylin der t o
power br a ke boost er (F ig. 50).
(11) Slide m a st er cylin der st r a igh t ou t of power
br a ke boost er.
CAUTION: A seal on the rear of the master cylinder

is used to create the seal for holding vacuum in the Fig. 51 Fluid Reservoir Retaining Pins (Typical)
power brake vacuum booster. The vacuum seal on 1 - FLUID RESERVOIR
the master cylinder MUST be replaced whenever the 2 - RETAINING PINS
3 - MASTER CYLINDER
vacuum booster.
(6) Rock t h e br a ke flu id r eser voir fr om side t o side
(12) Rem ove va cu u m sea l loca t ed on t h e m ou n t in g wh ile pu llin g u p t o r em ove it fr om t h e sea l gr om m et s
fla n ge of t h e m a st er cylin der. Th e va cu u m sea l is in m a st er cylin der h ou sin g.
r em oved fr om m a st er cylin der by c a re fu lly pu llin g it (7) Rem ove t h e t wo m a st er cylin der h ou sin g t o
off t h e r ea r of m a st er cylin der. D o n o t a tte m p t to br a ke flu id r eser voir sea l gr om m et s (F ig. 52).
p ry th e s e a l o ff th e m a s te r c y lin d e r by in s e rtin g
a s h a rp to o l be tw e e n s e a l a n d m a s te r c y lin d e r
c a s tin g .
(1) In st a ll a NE W va cu u m sea l on m a st er cylin der
m a kin g su r e sea l fit s squ a r ely in gr oove of m a st er
cylin der ca st in g.
(2) P osit ion m a st er cylin der on st u ds of power
br a ke boost er, a lign in g boost er pu sh r od wit h m a st er
cylin der pist on .
(3) In st a ll t h e t wo m a st er cylin der m ou n t in g n u t s
(F ig. 49). Tigh t en bot h m ou n t in g n u t s t o a t or qu e of
25 N·m (225 in . lbs.).
CAUTION: When tightening the primary and sec-

ondary brake tube nuts at master cylinder, be sure
brake tubes do not contact any other components
within the vehicle and that there is slack in the flex-
ible sections of the tubes. This is required due to
Fig. 52 Master Cylinder To Fluid
the movement between the ABS ICU and the master
Reservoir Seal Grommets
cylinder while the vehicle is in motion.
1 - SEAL GROMMETS
2 - MASTER CYLINDER
(4) Con n ect pr im a r y a n d secon da r y br a ke t u bes t o
m a st er cylin der pr im a r y a n d secon da r y por t s (F ig.
ASSEMBLY - MASTER CYLINDER (FLUID 48). Br a ke t u bes m u st be h eld secu r ely wh en t igh t -
RESERVOIR) en ed t o con t r ol or ien t a t ion of flex sect ion . Tigh t en
(1) In st a ll n ew m a st er cylin der h ou sin g t o br a ke t u be n u t s t o a t or qu e of 17 N·m (145 in . lbs.).
flu id r eser voir sea lin g gr om m et s in m a st er cylin der (5) In st a ll wir in g h a r n ess con n ect or t o br a ke flu id
h ou sin g (F ig. 52). level swit ch m ou n t ed in br a ke flu id r eser voir (F ig.
(2) Lu br ica t e r eser voir m ou n t in g a r ea wit h fr esh 48).
clea n br a ke flu id. P la ce r eser voir in posit ion over (6) In st a ll ba t t er y, cla m p a n d n u t .
sea lin g gr om m et s. Sea t r eser voir in t o sea lin g gr om - (7) In st a ll ba t t er y sh ield.
m et s u sin g a r ockin g m ot ion wh ile fir m ly pr essin g (8) Con n ect posit ive ba t t er y t er m in a l.
down on flu id r eser voir. (9) Con n ect n ega t ive ba t t er y t er m in a l.
(3) Be su r e flu id r eser voir is posit ion ed pr oper ly on (10) F ill m a st er cylin der wit h clea n , fr esh Mopa r !
m a st er cylin der. B o tto m o f flu id re s e rv o ir is to be Br a ke F lu id or equ iva len t .
to u c h in g th e to p o f bo th s e a lin g g ro m m e ts w h e n (11) Roa d t est veh icle t o en su r e pr oper oper a t ion of
p ro p e rly in s ta lle d o n m a s te r c y lin d e r h o u s in g . br a kes.
(4) In st a ll t h e t wo flu id r eser voir t o m a st er cylin -
der r et a in in g pin s (F ig. 51). INSTALLATION - RHD
(5) In st a ll t h e m a st er cylin der a ssem bly on t h e
power br a ke boost er. (Refer t o 5 - BRAKE S/H Y- CAUTION: Different types of master cylinders are
DRAULIC/ME CH ANICAL/MASTE R CYLINDE R - used on this vehicle depending on brake options. If
INSTALLATION) a new master cylinder is being installed, be sure it
(6) F ill flu id r eser voir t o it s pr oper level a s in di- is the correct master cylinder for the type of brake
ca t ed on t h e side of t h e flu id r eser voir. system the vehicle is equipped with.
I N STALLAT I ON CAUTION: When replacing the master cylinder on a

vehicle, a NEW vacuum seal MUST be installed on
INSTALLATION - LHD the master cylinder.
CAUTION: Different types of master cylinders are (1) In st a ll a NE W va cu u m sea l on m a st er cylin der
used on this vehicle depending on brake options. If m a kin g su r e sea l fit s squ a r ely in gr oove of m a st er
a new master cylinder is being installed, be sure it cylin der ca st in g.
is the correct master cylinder for the type of brake (2) P osit ion m a st er cylin der on st u ds of power
system the vehicle is equipped with. br a ke boost er, a lign in g boost er pu sh r od wit h m a st er
cylin der pist on .
(3) In st a ll t h e t wo m a st er cylin der m ou n t in g n u t s
CAUTION: When replacing the master cylinder on a (F ig. 50). Tigh t en bot h m ou n t in g n u t s t o a t or qu e of
vehicle, a NEW vacuum seal MUST be installed on 25 N·m (225 in . lbs.).
the master cylinder.
CAUTION: When tightening the primary and sec-
ondary brake tube nuts at master cylinder, be sure
brake tubes do not contact any other components
within the vehicle and that there is slack in the flex-
ible sections of the tubes. This is required due to
the movement between the ABS ICU and the master
cylinder while the vehicle is in motion.
(4) Con n ect pr im a r y a n d secon da r y br a ke t u bes t o

m a st er cylin der pr im a r y a n d secon da r y por t s (F ig.
50). Br a ke t u bes m u st be h eld secu r ely wh en t igh t -
en ed t o con t r ol or ien t a t ion of flex sect ion . Tigh t en
t u be n u t s t o a t or qu e of 17 N·m (145 in . lbs.).
(5) In st a ll wir in g h a r n ess con n ect or t o br a ke flu id
level swit ch m ou n t ed in br a ke flu id r eser voir (F ig.
46).
(6) In st a ll ba t t er y, cla m p a n d n u t .
(7) In st a ll ba t t er y sh ield.
(8) Con n ect posit ive ba t t er y t er m in a l.
(9) Con n ect n ega t ive ba t t er y t er m in a l. Fig. 53 Lower Steering Column Cover And
(10) F ill m a st er cylin der wit h clea n , fr esh Mopa r ! Reinforcement
Br a ke F lu id or equ iva len t .
1 - INSTRUMENT PANEL
(11) Roa d t est veh icle t o en su r e pr oper oper a t ion of 2 - REINFORCEMENT PLATE
br a kes. 3 - LOWER STEERING COLUMN COVER/KNEE BLOCKER
PEDALS - ADJ U STABLE

REMOVAL
NOTE: Before proceeding, review all Steering Col-
umn and Airbag Warnings and Cautions. (Refer to
19 - STEERING/COLUMN - WARNING)(Refer to 8 -
ELECTRICAL/RESTRAINTS - WARNING)
(1) Move dr iver ’s sea t t o fu ll r ea r wa r d posit ion .

(2) Discon n ect n ega t ive ba t t er y ca ble fr om ba t t er y
post a n d isola t e.
(3) Rem ove t h r ot t le ca ble fr om t h r ot t le body lever.
(Refer t o 14 - F UE L SYSTE M/F UE L INJ E CTION/
TH ROTTLE CONTROL CABLE - RE MOVAL)
(4) Rem ove scr ews secu r in g lower st eer in g colu m n
cover /kn ee blocker, t h en r em ove it (F ig. 53).
(5) Discon n ect pa r kin g br a ke r elea se lin k a t
r elea se h a n dle. Fig. 54 Instrument Panel Lower Left Reinforcement
(6) Com pr ess t a bs on sides of da t a lin k dia gn ost ic
1 - INSTRUMENT PANEL LOWER REINFORCEMENT
con n ect or a n d r em ove it fr om kn ee blocker r ein for ce- 2 - STEERING WHEEL
m en t pla t e. 3 - LOWER LEFT REINFORCEMENT
(7) Rem ove scr ews secu r in g kn ee blocker r ein for ce-
m en t pla t e in pla ce, t h en r em ove r ein for cem en t pla t e (10) Rem ove br a ke la m p swit ch . D is c a rd o rig in a l
(F ig. 53). s w itc h ; it m u s t n o t be re u s e d . (Refer t o 8 - E LE C-
(8) Rem ove h ood r elea se fr om lower left r ein for ce- TRICAL/LAMP S/LIGH TING - E XTE RIOR/BRAKE
m en t . LAMP SWITCH - RE MOVAL)
(9) Rem ove scr ews secu r in g in st r u m en t pa n el (11) Rem ove u pper a n d lower st eer in g colu m n
lower left r ein for cem en t in pla ce, t h en r em ove r ein - sh r ou ds. (Refer t o 19 - STE E RING/COLUMN/
for cem en t (F ig. 54). LOWE R SH ROUD - RE MOVAL)
PEDALS - ADJ U STABLE (Cont inue d)
(12) Discon n ect wir in g h a r n ess con n ect or s (a s (18) Loosen two lower steering column mounting nuts.
equ ipped) fr om clockspr in g, m u lt i-fu n ct ion swit ch , (19) Remove two upper steering column mounting nuts.
SKIM m odu le, ign it ion swit ch a n d BTSI solen oid. (20) Rem ove st eer in g colu m n a ssem bly.
(13) If equ ipped, discon n ect P RNDL ca ble fr om (21) Rem ove da sh sea l silen cer sh ell over st eer in g
sh ift lever a n d colu m n br a cket (F ig. 55). colu m n in t er m edia t e sh a ft (F ig. 57).
(14) Discon n ect sh ift ca ble a t sh ift lever m ech a -
n ism pin (F ig. 55).
Fig. 55 Shift Cable At Steering Column Fig. 57 Intermediate Shaft Dash Seal
1 - SHIFT LEVER MECHANISM And Silencer Shell
2 - SHIFT CABLE 1 - INTERMEDIATE SHAFT
3 - BRACKET 2 - DASH SEAL
4 - PRNDL CABLE (IF EQUIPPED) 3 - SILENCER SHELL
5 - STEERING COLUMN
(22) Rem ove t wo n u t s secu r in g br a ke la m p swit ch

(15) Rem ove pin ch side clip, t h en r em ove sh ift
br a cket t o peda l a ssem bly. Rem ove br a cket .
ca ble fr om br a cket on colu m n .
(23) Discon n ect wir in g con n ect or con n ect in g veh i-
(16) P la ce fr on t wh eels in STRAIGH T-AH E AD
cle wir in g h a r n ess con n ect or t o peda l wir in g h a r n ess
posit ion , t h en secu r e st eer in g wh eel t o colu m n in t h is
(F ig. 58).
posit ion u sin g a ppr opr ia t e r et a in in g m et h od.
(17) Rem ove pin ch bolt secu r in g colu m n cou plin g
t o in t er m edia t e sh a ft (F ig. 56).
Fig. 58 Wiring Harness Connection

Fig. 56 Pinch Bolt
1 - VEHICLE WIRING HARNESS
1 - PINCH BOLT 2 - WIRING CONNECTOR
2 - STEERING COLUMN 3 - ROUTING LOOP
(24) Un fa st en r ou t in g clips r et a in in g veh icle wir-
in g h a r n ess t o peda l wir in g h a r n ess (F ig. 58).
(25) Rem ove power br a ke boost er in pu t r od fr om
br a ke peda l pin by per for m in g followin g:
(a ) P osit ion sm a ll scr ewdr iver bet ween cen t er
t a n g on r et a in in g clip a n d br a ke peda l pin (F ig.
59).
(b) Rot a t e scr ewdr iver, m ovin g r et a in in g clip
cen t er t a n g en ou gh t o a llow it t o pa ss over en d of
br a ke peda l pin , t h en slide r et a in in g clip off br a ke
peda l pin .
(c) Disca r d r et a in in g clip. Re ta in in g c lip m u s t
n o t be re u s e d . In s ta ll N EW re ta in in g c lip
w h e n a s s e m blin g .
(d) Slide boost er in pu t r od off peda l pin .
Fig. 60 Drive Cable Routing

1 - ADJUSTER CABLE
2 - ROUTING LOOP
3 - CABLE ATTACHMENT AT MOTOR
4 - GEAR DRIVE
5 - CABLE ATTACHMENT AT GEAR BOX
6 - STEERING COLUMN BRACKET
Fig. 59 Input Rod Brake Pedal Retaining Clip

Removal
1 - BRAKE PEDAL
2 - INPUT ROD
3 - SCREWDRIVER
4 - RETAINING CLIP
5 - BRAKE PEDAL PIN
(26) Discon n ect peda l a dju st er ca ble a t br a ke

peda l a dju st m en t gea r box (F ig. 60).
(27) Rem ove peda l a dju st er ca ble fr om r ou t in g loop
on st eer in g colu m n br a cket (F ig. 60), t h en pu ll gea r Fig. 61 Booster Mounting (Typical)
box en d of ca ble u pwa r d, ou t of st eer in g colu m n 1 - DASH BRACKET
br a cket , a n d down r igh t side of peda ls a ssem bly. 2 - POWER BRAKE BOOSTER
(28) Rem ove fou r n u t s a t t a ch in g power br a ke 3 - BRAKE PEDAL ASSEMBLY
boost er a n d peda ls a ssem bly t o da sh pa n el (F ig. 61).
(29) Rem ove t wo u pper m ou n t in g bolt s a t t a ch in g
peda ls a ssem bly t o st eer in g colu m n su ppor t br a cket
on da sh .
(30) Discon n ect t h r ot t le ca ble r et a in er a t a cceler a -
t or peda l, t h en r em ove ca ble fr om peda l.
(31) Rem ove a dju st a ble peda ls a ssem bly.
INSTALLATION (19) Con n ect colu m n wir in g h a r n ess con n ect or s (a s

(1) In st a ll a dju st a ble peda ls a ssem bly u n der equ ipped) t o SKIM, BTSI solen oid, ign it ion swit ch ,
in st r u m en t pa n el. m u lt i-fu n ct ion swit ch , a n d clockspr in g.
(2) At t a ch t h r ot t le ca ble t o a cceler a t or peda l u sin g (20) In st a ll lower a n d u pper st eer in g colu m n
ca ble r et a in er. sh r ou ds. (Refer t o 19 - STE E RING/COLUMN/
(3) In st a ll t wo u pper m ou n t in g bolt s a t t a ch in g LOWE R SH ROUD - INSTALLATION)
peda ls a ssem bly t o st eer in g colu m n su ppor t br a cket
CAUTION: Do not reuse the original brake lamp
on da sh pa n el. D o n o t fu lly tig h te n a t th is tim e .
switch. The switch can only be adjusted once. That
(4) In st a ll fou r n u t s a t t a ch in g peda ls a ssem bly a n d
is during initial installation of the switch. If the
power br a ke boost er t o da sh pa n el (F ig. 61).
switch is not adjusted properly or has been
(5) Tigh t en fou r boost er m ou n t in g n u t s a n d t wo
removed for some service, a new switch must be
u pper m ou n t in g bolt s t o 28 N·m (21 ft . lbs.) t or qu e.
(6) Rou t e peda l a dju st er ca ble u p a n d over r igh t installed and adjusted.
side of peda ls a ssem bly a n d st eer in g colu m n br a cket ,
(21) In st a ll a n d a dju st NE W br a ke la m p swit ch .
t h en down t h r ou gh h ole in st eer in g colu m n br a cket
(Refer t o 8 - E LE CTRICAL/LAMP S/LIGH TING -
a s sh own (F ig. 60). At t a ch en d of ca ble t o gea r box. E XTE RIOR/BRAKE LAMP SWITCH - INSTALLA-
(7) P la ce a dju st er ca ble t h r ou gh loop on r igh t side
TION)
of st eer in g colu m n br a cket a s sh own (F ig. 60).
(22) In st a ll in st r u m en t pa n el lower left r ein for ce-
(8) In st a ll boost er in pu t r od on t o br a ke peda l pin m en t (F ig. 54).
a n d in st a ll a NE W r et a in in g clip. (23) At t a ch h ood r elea se t o lower left r ein for ce-
(9) Con n ect wir in g con n ect or con n ect in g veh icle
m en t .
wir in g h a r n ess t o peda l wir in g h a r n ess (F ig. 58). (24) In st a ll kn ee blocker r ein for cem en t pla t e (F ig.
(10) Con n ect r ou t in g clips r et a in in g veh icle wir in g 53).
h a r n ess t o peda l wir in g h a r n ess (F ig. 58). (25) Con n ect pa r kin g br a ke r elea se lin k t o r elea se
(11) In st a ll br a ke la m p swit ch br a cket on peda ls
h a n dle.
a ssem bly. Tigh t en m ou n t in g n u t s t o 6 N·m (50 in . (26) In st a ll da t a lin k dia gn ost ic con n ect or t o
lbs.) t or qu e. m ou n t in g h ole in r ein for cem en t pla t e.
(12) In st a ll da sh sea l silen cer sh ell over st eer in g
(27) In st a ll lower st eer in g colu m n cover /kn ee
colu m n in t er m edia t e sh a ft a n d fa st en in pla ce (F ig. blocker (F ig. 53).
57).
(28) In st a ll t h r ot t le ca ble on t o t h r ot t le body lever.
(13) In st a ll st eer in g colu m n on t o lower m ou n t in g (Refer t o 14 - F UE L SYSTE M/F UE L INJ E CTION/
st u ds wit h n u t s st a r t ed, t h en in st a ll colu m n on t o
TH ROTTLE CONTROL CABLE - INSTALLATION)
u pper m ou n t in g st u ds a n d in st a ll t wo u pper m ou n t -
in g n u t s. Tigh t en u pper, t h en lower m ou n t in g n u t s t o NOTE: When reconnecting the battery on a vehicle
12 N·m (105 in . lbs.) t or qu e. that has had the airbag module removed, the fol-
(14) In st a ll colu m n sh a ft cou plin g on t o in t er m edi- lowing procedure should be used.
a t e sh a ft a n d in st a ll pin ch bolt . Ma ke su r e r ou n ded
side of in t er m edia t e sh a ft is m a t ch ed t o t h e cu r va - (29) Recon n ect gr ou n d ca ble t o n ega t ive post of
t u r e of t h e cou plin g. Tigh t en pin ch bolt t o 28 N·m ba t t er y followin g specia l Dia gn osis An d Test in g pr o-
(250 in . lbs.) t or qu e. cedu r e. (Refer t o 8 - E LE CTRICAL/RE STRAINTS -
(15) Rem ove r et a in er h oldin g st eer in g wh eel in DIAGNOSIS AND TE STING)
pla ce on st eer in g colu m n . (30) Test oper a t ion of a dju st a ble peda ls a n d a ll
(16) At t a ch sh ift ca ble t o br a cket on colu m n . fu n ct ion s t h a t a r e st eer in g colu m n oper a t ed. If a ppli-
(17) Con n ect sh ift ca ble en d t o sh ift lever m ech a - ca ble, r eset r a dio a n d clock.
n ism pin (F ig. 55). (31) Roa d t est t h e veh icle t o en su r e pr oper oper a -
(18) If equ ipped, con n ect P RNDL ca ble t o en d of t ion of st eer in g a n d br a ke syst em s.
sh ift lever m ech a n ism pin a n d colu m n br a cket (F ig.
55).
PEDAL T ORQU E SH AFT - RH D

REMOVAL
(1) Rem ove t h e in st r u m en t pa n el. (Refer t o 23 -
BODY/INSTRUME NT PANE L/INSTRUME NT
PANE L ASSE MBLY - RE MOVAL)
(2) Rem ove t h e H VAC h ou sin g. (Refer t o 24 -
H E ATING & AIR CONDITIONING/DISTRIBUTION/
H VAC H OUSING - RE MOVAL)
(3) Rem ove t h e r et a in in g clip a t t h e t or qu e sh a ft
en d of t h e br a ke peda l-t o-t or qu e sh a ft lin k. Rem ove
t h e lin k fr om t h e t or qu e sh a ft . Disca r d t h e r et a in in g
clip. It is n ot t o be r eu sed. Repla ce wit h a n ew clip
wh en r ea ssem bled.
(4) Loca t e t h e boost er in pu t r od-t o-br a ke peda l
t or qu e sh a ft con n ect ion a n d r em ove t h e r et a in in g clip
(F ig. 62). Disca r d t h e r et a in in g clip. It is n ot t o be
r eu sed. Repla ce wit h a n ew clip wh en r ea ssem bled.
Fig. 63 BOOSTER, TORQUE SHAFT AND PEDAL

MOUNTING
1 - PEDAL MOUNTING NUT
2 - BRAKE PEDAL ASSEMBLY
4 - PEDAL TORQUE SHAFT
5 - BOOSTER MOUNTING NUT
6 - BOOSTER BRACKET
8 - BOOSTER BRACKET MOUNTING NUT
(2) In st a ll t h e br a ke boost er br a cket on t h e left

en d of t h e sh a ft .
(3) In st a ll t h e r et a in in g n u t for t h e br a ke boost er
br a cket in t h e en gin e com pa r t m en t . Tigh t en t h e
Fig. 62 POWER BRAKE BOOSTER BRACKET m ou n t in g n u t t o a t or qu e of 29 N·m (250 in . lbs.).
(4) In st a ll t h e fou r br a ke boost er r et a in in g n u t s
1 - BOOSTER BRACKET
2 - PEDAL TORQUE SHAFT in side t h e pa ssen ger com pa r t m en t . Tigh t en t h e
3 - RETAINING CLIP m ou n t in g n u t s t o a t or qu e of 29 N·m (250 in . lbs.).
4 - BOOSTER MOUNTING NUTS (5) Usin g lu br ipla t e, or equ iva len t , coa t t h e su r-
fa ce of t h e br a ke peda l t or qu e sh a ft pin wh er e it con -
(5) Rem ove t h e fou r (4) br a ke boost er r et a in in g t a ct s t h e boost er in pu t r od. Also coa t t h e su r fa ce of
n u t s fr om in side t h e pa ssen ger com pa r t m en t (F ig. t h e br a ke peda l t or qu e sh a ft pin wh er e it con t a ct s
63). t h e br a ke peda l lin k.
(6) Rem ove t h e r et a in in g n u t fr om t h e br a ke
boost er br a cket loca t ed a bove t h e boost er in t h e CAUTION: When installing the power brake booster
en gin e com pa r t m en t (F ig. 63). input rod on the brake pedal torque shaft pin, do
(7) Rem ove t h e power br a ke boost er br a cket . not reuse the old retaining clip.
(8) Rot a t e t h e peda l t or qu e sh a ft a n d r em ove it ou t
t h e left side of t h e veh icle. (6) In st a ll boost er in pu t r od on br a ke peda l t or qu e
sh a ft pin a n d in st a ll a NE W r et a in in g clip (F ig. 62).
INSTALLATION
(1) Lu br ica t e bot h en ds of t h e t or qu e sh a ft wit h CAUTION: When installing the brake pedal link on
MS-4517 Lu br ica n t or equ iva len t a n d in st a ll t h e the brake pedal torque shaft pin, do not reuse the
t or qu e sh a ft fr om t h e left side r ever sin g t h e r em ova l old retaining clip.
pr ocedu r e.
PEDAL T ORQU E SH AFT - RH D (Cont inue d)
(7) Con n ect t h e br a ke peda l lin k t o t h e t or qu e
sh a ft . In st a ll a NE W r et a in in g clip a t t h e t or qu e
sh a ft en d of t h e br a ke peda l-t o-t or qu e sh a ft lin k.
(8) In st a ll t h e H VAC h ou sin g. (Refer t o 24 - H E AT-
ING & AIR CONDITIONING/DISTRIBUTION/H VAC
H OUSING - INSTALLATION)
(9) In st a ll t h e in st r u m en t pa n el. (Refer t o 23 -
PANE L ASSE MBLY - INSTALLATION)

installed and adjusted.
(10) Rem ove a n d r epla ce t h e br a ke la m p swit ch

wit h a NE W swit ch . (Refer t o 8 - E LE CTRICAL/
LAMP S/LIGH TING - E XTE RIOR/BRAKE LAMP
SWITCH - RE MOVAL), (Refer t o 8 - E LE CTRICAL/
LAMP S/LIGH TING - E XTE RIOR/BRAKE LAMP
Fig. 64 Power Brake Booster (Typical)
SWITCH - INSTALLATION)
1 - VACUUM CHECK VALVE
(11) Roa d t est veh icle t o en su r e pr oper oper a t ion of 2 - POWER BRAKE BOOSTER ASSEMBLY
t h e br a kes. 3 - INPUT ROD
4 - POWER BOOSTER ASSEMBLY TO DASH PANEL MOUNTING
STUDS (4)
5 - MASTER CYLINDER MOUNTING STUDS (2)
POWER BRAK E BOOST ER 6 - OUTPUT ROD
DESCRIPTION
Th e power br a ke boost er m ou n t s on t h e en gin e
com pa r t m en t side of t h e da sh pa n el. It is con n ect ed
t o t h e br a ke peda l by t h e in pu t (pu sh ) r od (F ig. 64).
Th e m a st er cylin der is bolt ed t o t h e fr on t of t h e
boost er. A va cu u m lin e con n ect s t h e power br a ke
boost er t o t h e in t a ke m a n ifold.
All Left -H a n d-Dr ive (LH D) veh icles u se a 270 m m
sin gle dia ph r a gm va cu u m power br a ke boost er. All
Righ t -H a n d-Dr ive (RH D) veh icles u se a 225/200 m m
t a n dem dia ph r a gm va cu u m power br a ke boost er.
Veh icles equ ipped wit h Disc/Disc br a kes u se a dif-
fer en t power br a ke boost er t h a n veh icles equ ipped
wit h Disc/Dr u m br a kes. Differ en ces bet ween t h e t wo
a r e in t er n a l. Ser vice is t h e sa m e for a ll boost er s.
Th e power br a ke boost er ca n be iden t ified by t h e
t a g a t t a ch ed t o t h e body of t h e boost er (F ig. 65). Th is Fig. 65 MASTER CYLINDER AND BOOSTER
t a g con t a in s t h e pr odu ct ion pa r t n u m ber, t h e da t e it 1 - POWER BRAKE BOOSTER
wa s bu ilt , a n d wh o t h e m a n u fa ct u r er of t h e power 2 - BOOSTER IDENTIFICATION LABEL
3 - FLUID LEVEL SWITCH CONNECTOR
br a ke boost er is. 4 - PRIMARY BRAKE TUBE NUT
NOTE: The power brake booster assembly is not a 6 - MASTER CYLINDER
repairable component and must be replaced as a
complete assembly if found to be faulty in any way. Th e differ en t en gin e com bin a t ion s u sed in t h is
The check valve located on the power brake veh icle r equ ir e differ en t va cu u m h ose r ou t in gs t o t h e
booster face is not repairable, but it can be power br a ke boost er. All va cu u m h oses m u st be
replaced separately from the power brake booster. r ou t ed fr om t h e en gin e t o t h e power br a ke boost er
wit h ou t kin ks or excessively t igh t ben ds.
POWER BRAK E BOOST ER (Cont inue d)
OPERATION VACUUM LEAK TEST

Th e power br a ke boost er r edu ces t h e a m ou n t of (1) Discon n ect t h e va cu u m h ose on t h e va cu u m
for ce r equ ir ed by t h e dr iver t o obt a in t h e n ecessa r y ch eck va lve, t h en pla ce a va cu u m ga u ge in lin e
h ydr a u lic pr essu r e t o st op a veh icle. bet ween t h e va cu u m h ose a n d t h e va lve.
Th e power br a ke boost er is va cu u m oper a t ed. Th e (2) St a r t t h e en gin e.
va cu u m is su pplied fr om t h e in t a ke m a n ifold on t h e (3) Allow t h e en gin e t o wa r m u p t o n or m a l oper a t -
en gin e t h r ou gh a va cu u m h ose a n d t h e power br a ke in g t em per a t u r e a n d en gin e idle.
boost er ch eck va lve (F ig. 64). (4) Usin g va cu u m lin e plier s, close off t h e va cu u m
As t h e br a ke peda l is depr essed, t h e power br a ke su pply h ose n ea r t h e boost er, bu t befor e t h e va cu u m
boost er ’s in pu t r od m oves for wa r d (F ig. 64). Th is ga u ge, t h en obser ve t h e va cu u m ga u ge.
open s a n d closes va lves in t h e power boost er a llowin g If t h e va cu u m dr op exceeds 1.0 in ch H g (3.3 kP a )
a t m osph er ic pr essu r e t o en t er on on e side of a dia - in on e m in u t e, r epea t t h e a bove st eps t o con fir m t h e
ph r a gm . E n gin e va cu u m is a lwa ys pr esen t on t h e r ea din g. Th e va cu u m loss sh ou ld be less t h a n 1.0
ot h er side. Th is differ en ce in pr essu r e for ces t h e ou t - in ch H g in on e m in u t e t im e spa n . If t h e loss is m or e
pu t r od of t h e power br a ke boost er ou t a ga in st t h e t h a n 1.0 in ch H g, r epla ce t h e power br a ke boost er. If
pr im a r y pist on of t h e m a st er cylin der. As t h e pist on s it is n ot , con t in u e on wit h t h is t est .
in t h e m a st er cylin der m ove for wa r d t h is cr ea t es t h e (5) Rem ove t h e plier s fr om t h e h ose t em por a r ily.
h ydr a u lic pr essu r e in t h e br a ke syst em . (6) Apply ligh t effor t (a ppr oxim a t ely 15 lbs. of
for ce) t o t h e br a ke peda l a n d h old t h e peda l st ea dy.
DIAGNOSIS AND TESTING - POWER BRAKE Do n ot m ove t h e peda l on ce t h e pr essu r e is a pplied
BOOSTER or t h e t est r esu lt s m a y va r y.
(7) H a ve a n a ssist a n t r ea t t a ch t h e va cu u m lin e
BASIC TEST plier s t o t h e va cu u m su pply h ose.
(1) Wit h en gin e off, depr ess a n d r elea se t h e br a ke (8) Allow 5 secon ds for st a biliza t ion , t h en obser ve
peda l sever a l t im es t o pu r ge a ll va cu u m fr om t h e t h e va cu u m ga u ge.
power br a ke boost er. If t h e va cu u m dr op exceeds 3.0 in ch es H g (10 kP a )
(2) Depr ess a n d h old t h e peda l wit h ligh t effor t (15 in 15 secon ds, r epea t t h e a bove st eps t o con fir m t h e
t o 25 lbs. pr essu r e), t h en st a r t t h e en gin e. r ea din g. Th e va cu u m loss sh ou ld be less t h a n 3.0
Th e peda l sh ou ld fa ll sligh t ly, t h en h old. Less effor t in ch es H g in 15 secon ds t im e spa n . If t h e loss is
sh ou ld be n eeded t o a pply t h e peda l a t t h is t im e. If m or e t h a n 3.0 in ch es H g, r epla ce t h e power br a ke
t h e peda l fell a s in dica t ed, per for m t h e VACUUM boost er. If it is n ot , t h e boost er is n ot defect ive.
LE AK TE ST list ed a ft er t h e BASIC TE ST. If t h e (9) Rem ove t h e plier s a n d va cu u m ga u ge.
peda l did n ot fa ll, con t in u e on wit h t h is BASIC
TE ST. REM OVAL
(3) Discon n ect t h e va cu u m h ose on t h e va cu u m
ch eck va lve, t h en pla ce a va cu u m ga u ge in lin e REMOVAL - LHD
bet ween t h e va cu u m h ose a n d t h e va lve.
(4) St a r t t h e en gin e. CAUTION: Reserve vacuum in power brake booster
(5) Wh en t h e en gin e is a t wa r m oper a t in g t em per- must be pumped down (removed) before removing
a t u r e, a llow it t o idle a n d ch eck t h e va cu u m a t t h e master cylinder from booster. This is necessary to
ga u ge. prevent booster from sucking in any contamination
If t h e va cu u m su pply is 12 in ch es H g (40.5 kP a ) or as master cylinder is removed. This can be done
m or e, t h e power br a ke boost er is defect ive a n d m u st simply by pumping the brake pedal, with the vehi-
be r epla ced. If t h e va cu u m su pply is below 12 in ch es cle’s engine not running, until a firm feeling brake
H g, con t in u e on wit h t h is BASIC TE ST. pedal is achieved.
(6) Sh u t off t h e en gin e.
(7) Con n ect t h e va cu u m ga u ge t o t h e va cu u m r ef- (1) Wit h en gin e n ot r u n n in g, pu m p t h e br a ke
er en ce por t on t h e en gin e in t a ke m a n ifold. peda l u n t il a fir m peda l is a ch ieved (4-5 st r okes).
(8) St a r t t h e en gin e a n d obser ve t h e va cu u m (2) Rem ove n ega t ive ba t t er y ca ble t er m in a l fr om
ga u ge. ba t t er y.
If t h e va cu u m is st ill low, ch eck t h e en gin e t u n e (3) Rem ove posit ive ba t t er y ca ble t er m in a l fr om
a n d r epa ir a s n ecessa r y. If t h e va cu u m is a bove 12 ba t t er y.
in ch es H g, t h e h ose or ch eck va lve t o t h e boost er h a s (4) Rem ove ba t t er y t h er m a l gu a r d sh ield.
a r est r ict ion or lea k. (5) Rem ove ba t t er y cla m p, n u t a n d ba t t er y fr om
On ce a n a dequ a t e va cu u m su pply is obt a in ed, t h e ba t t er y t r a y.
r epea t t h e BASIC TE ST.
(6) Rem ove scr ew secu r in g en gin e coola n t filler (13) Discon n ect pr im a r y a n d secon da r y br a ke
t u be t o ba t t er y t r a y. t u bes fr om ABS in t egr a t ed con t r ol u n it or n on -ABS
(7) If t h e veh icle is equ ipped wit h speed con t r ol, ju n ct ion block (F ig. 67). In st a ll sea lin g plu gs in t h e
discon n ect t h e va cu u m h ose a t t h e va cu u m t a n k bu ilt n ow open br a ke t u be por t s a n d in st a ll ca ps on en ds
in t o t h e ba t t er y t r a y. of t u bes.
(8) Rem ove t h e t wo n u t s a n d on e bolt secu r in g ba t -
t er y t r a y in pla ce. Rem ove ba t t er y t r a y.
(9) If veh icle is equ ipped wit h speed con t r ol:
(a ) Discon n ect wir in g h a r n ess con n ect or fr om
t h e speed con t r ol ser vo.
(b) Rem ove t h e t wo ser vo m ou n t in g n u t s.
(c) La y speed con t r ol ser vo off t o t h e side, ou t of
t h e wa y.
(10) Rem ove t h e wiper m odu le (u n it ). (Refer t o 8 -
E LE CTRICAL/WIP E RS/WASH E RS/WIP E R MOD-
ULE - RE MOVAL)
(11) Discon n ect wir in g h a r n ess con n ect or fr om
br a ke flu id level swit ch in m a st er cylin der flu id r es-
er voir (F ig. 66).
Fig. 67 Master Cylinder Mounting

2 - MASTER CYLINDER
3 - SECONDARY TUBE NUT AT ICU
4 - PRIMARY TUBE NUT AT ICU
NOTE: It is not necessary to remove the brake

tubes from the master cylinder when removing the
master cylinder from the vacuum booster.

(15) Slide m a st er cylin der st r a igh t ou t of power
br a ke boost er. Rem ove m a st er cylin der wit h pr im a r y
a n d secon da r y t u bes fr om veh icle.
Fig. 66 Master Cylinder And Booster
1 - POWER BRAKE BOOSTER CAUTION: A seal on the rear of the master cylinder
2 - BOOSTER IDENTIFICATION LABEL is used to create the seal for holding vacuum in the
3 - FLUID LEVEL SWITCH CONNECTOR power brake vacuum booster. The vacuum seal on
5 - SECONDARY BRAKE TUBE NUT the master cylinder MUST be replaced whenever the
6 - MASTER CYLINDER master cylinder is removed from the power brake
vacuum booster.
from the power brake vacuum booster, the master (16) Discon n ect va cu u m h ose fr om ch eck va lve
cylinder and vacuum booster must be thoroughly loca t ed on va cu u m boost er. D O N OT REMOVE
cleaned. This must be done to prevent dirt particles CHECK VALVE F ROM P OWER B RAKE
from falling into the power brake vacuum booster. B OOS TER.

(17) In side veh icle, r em ove silen cer pa n el u n der
in st r u m en t pa n el below st eer in g colu m n .
(18) Loca t e t h e boost er in pu t r od t o br a ke peda l
con n ect ion u n der t h e in st r u m en t pa n el. P osit ion a
sm a ll scr ewdr iver bet ween t h e cen t er t a n g on t h e
power br a ke boost er in pu t r od t o br a ke peda l pin
r et a in in g clip (F ig. 68).
Fig. 69 Booster Mounting

1 - DASH BRACKET
Fig. 68 Vacuum Booster Input Rod Retaining Pin

1 - BRAKE PEDAL
2 - INPUT ROD
3 - SCREWDRIVER
4 - RETAINING CLIP
5 - BRAKE PEDAL PIN
(19) Rot a t e scr ewdr iver en ou gh t o a llow r et a in in g

clip cen t er t a n g t o pa ss over en d of br a ke peda l pin .
Th en pu ll r et a in in g clip off br a ke peda l pin . D is c a rd
re ta in in g c lip . It is n o t to be re u s e d . Re p la c e
o n ly w ith a n e w re ta in in g c lip w h e n a s s e m -
blin g .
(20) Slide boost er in pu t r od off peda l pin .
(21) Rem ove t h e fou r n u t s a t t a ch in g power br a ke Fig. 70 Booster Removal/Installation
boost er t o da sh pa n el (F ig. 69). (1) Wit h en gin e n ot r u n n in g, pu m p t h e br a ke
(22) Slide power br a ke boost er for wa r d a n d r em ove peda l u n t il a fir m peda l is a ch ieved (4 or 5 st r okes).
t h r ou gh en gin e com pa r t m en t (F ig. 70). (2) Rem ove n ega t ive ba t t er y ca ble t er m in a l fr om
ba t t er y.
CAUTION: Do not attempt to disassemble the power
(3) Rem ove posit ive ba t t er y ca ble t er m in a l fr om
brake vacuum booster. It is serviced ONLY as a
ba t t er y.
complete assembly.
(4) Rem ove ba t t er y t h er m a l gu a r d sh ield.
(5) Rem ove ba t t er y cla m p, n u t a n d ba t t er y fr om
REMOVAL - RHD t h e ba t t er y t r a y.
(6) If t h e veh icle is equ ipped wit h speed con t r ol,
CAUTION: Reserve vacuum in power brake booster discon n ect t h e va cu u m h ose a t t h e va cu u m t a n k bu ilt
must be pumped down (removed) before removing in t o t h e ba t t er y t r a y.
master cylinder from booster. This is necessary to (7) Rem ove t h e t wo n u t s a n d on e bolt secu r in g ba t -
prevent booster from sucking in any contamination t er y t r a y in pla ce. Rem ove ba t t er y t r a y.
as master cylinder is removed. This can be done (8) If veh icle is equ ipped wit h speed con t r ol:
simply by pumping the brake pedal, with the vehi- (a ) Discon n ect wir in g h a r n ess con n ect or fr om
cle’s engine not running, until a firm feeling brake t h e speed con t r ol ser vo.
pedal is achieved. (b) Rem ove t h e t wo ser vo m ou n t in g n u t s.
(c) La y speed con t r ol ser vo off t o t h e side, ou t of
t h e wa y.
(9) If t h e veh icle is equ ipped wit h t h e 2.5L diesel
en gin e, r em ove t h e coola n t r ecover y pr essu r e con -
t a in er a n d br a cket . (Refer t o 7 - COOLING/E NGINE /
COOLANT RE COVE RY P RE SS CONTAINE R -
RE MOVAL)
(10) Discon n ect wir in g h a r n ess con n ect or fr om
br a ke flu id level swit ch in m a st er cylin der flu id r es-
er voir (F ig. 71).
Fig. 72 RHD Master Cylinder Mounting


vacuum booster.
(14) Discon n ect va cu u m h ose fr om ch eck va lve
loca t ed on boost er. D O N OT REMOVE CHECK
VALVE F ROM P OWER B RAKE B OOS TER.
(15) Un der t h e in st r u m en t pa n el, r em ove boost er
Fig. 71 RHD Master Cylinder And Power Brake in pu t r od t r im cover.
Booster (16) Loca t e t h e boost er in pu t r od t o br a ke peda l
1 - POWER BRAKE BOOSTER t or qu e sh a ft con n ect ion u n der t h e in st r u m en t pa n el.
2 - BRAKE FLUID LEVEL SWITCH P osit ion a sm a ll scr ewdr iver bet ween t h e cen t er t a n g
3 - FLUID RESERVOIR
4 - MASTER CYLINDER on t h e r et a in in g clip (F ig. 73).

from the power brake vacuum booster, the master
cylinder and vacuum booster must be thoroughly
cleaned. This must be done to prevent dirt particles

NOTE: It is not necessary to remove the brake

tubes from the master cylinder when removing the
master cylinder from the booster.

(13) Slide m a st er cylin der st r a igh t ou t of power Fig. 73 Booster Input Rod Pin Retaining Clip
br a ke boost er. La y m a st er cylin der wit h pr im a r y a n d (Typical)
secon da r y t u bes t o t h e side, ou t of t h e wa y. 1 - BRAKE PEDAL
2 - INPUT ROD
CAUTION: A seal on the rear of the master cylinder 3 - SCREWDRIVER
4 - RETAINING CLIP
is used to create the seal for holding vacuum in the 5 - BRAKE PEDAL PIN
power brake vacuum booster. The vacuum seal on
the master cylinder MUST be replaced whenever the
(17) Rot a t e scr ewdr iver en ou gh t o a llow r et a in in g
clip cen t er t a n g t o pa ss over en d of br a ke peda l pin .
Th en pu ll r et a in in g clip off br a ke peda l t or qu e sh a ft
pin . D is c a rd re ta in in g c lip . It is n o t to be
re u s e d . Re p la c e o n ly w ith a n e w re ta in in g c lip
w h e n a s s e m blin g .
(18) Rem ove boost er in pu t r od fr om peda l t or qu e
sh a ft pin .
(19) Rem ove t h e t h r ee ea sily a ccessed m ou n t in g
n u t s a t t a ch in g power br a ke boost er t o da sh pa n el
a n d loosen fou r t h (F ig. 74). As fou r t h n u t is loosen ed,
pu sh t h e boost er for wa r d per iodica lly u n t il t h e n u t
ca n be com plet ely r em oved.
Fig. 75 RHD Booster Removal/Installation

2 - MASTER CYLINDER
It m a y be n ecessa r y t o pu sh in on boost er in pu t r od
a s it is gu ided t h r ou gh t h e da sh pa n el.
(2) In st a ll t h e fou r n u t s m ou n t in g t h e boost er t o
t h e da sh pa n el (F ig. 69). Tigh t en t h e m ou n t in g n u t s
t o a t or qu e of 29 N·m (250 in . lbs.).
(3) Usin g lu br ipla t e, or equ iva len t , coa t t h e su r-
fa ce of t h e br a ke peda l pin wh er e it con t a ct s t h e
boost er in pu t r od.
CAUTION: When installing the brake pedal pin on

the power brake booster input rod, do not re-use
the old retaining clip.
(4) In st a ll boost er in pu t r od on br a ke peda l pin

a n d in st a ll a NE W r et a in in g clip (F ig. 76).
Fig. 74 Booster, Torque Shaft And Pedal Mounting
4 - PEDAL TORQUE SHAFT
5 - BOOSTER MOUNTING NUT
6 - BOOSTER BRACKET
8 - BOOSTER BRACKET MOUNTING NUT
(20) Slide power br a ke boost er for wa r d a n d r em ove

t h r ou gh en gin e com pa r t m en t (F ig. 75).
CAUTION: Do not attempt to disassemble the power

brake vacuum booster. It is serviced ONLY as a
complete assembly.
I N STALLAT I ON Fig. 76 Retaining Pin Installed On Brake Pedal Pin

1 - BRAKE PEDAL
2 - RETAINING CLIP
INSTALLATION - LHD 3 - BOOSTER INPUT ROD
(1) P osit ion power br a ke boost er on da sh pa n el
u sin g t h e r ever se pr ocedu r e of it s r em ova l (F ig. 70).
CAUTION: Do not reuse the original brake lamp (11) In st a ll t h e t wo n u t s m ou n t in g t h e m a st er cyl-
switch. The switch can only be adjusted once. That in der t o t h e boost er (F ig. 67). Tigh t en bot h m ou n t in g
is during initial installation of the switch. If the n u t s t o a t or qu e of 25 N·m (225 in . lbs.).
switch is not adjusted properly or has been (12) Con n ect wir in g h a r n ess con n ect or t o br a ke
removed for some service, a new switch must be flu id level swit ch in t h e m a st er cylin der flu id r eser-
installed and adjusted. voir (F ig. 66).
(13) Con n ect pr im a r y a n d secon da r y br a ke t u bes
(5) Rem ove a n d r epla ce t h e br a ke la m p swit ch t o ABS ICU or n on -ABS ju n ct ion block (F ig. 67).
wit h a NE W swit ch . (Refer t o 8 - E LE CTRICAL/ Tigh t en t h e t u be n u t s t o 17 N·m (145 in lbs.).
LAMP S/LIGH TING - E XTE RIOR/BRAKE LAMP (14) In st a ll wiper m odu le (u n it ). (Refer t o 8 -
SWITCH - RE MOVAL), (Refer t o 8 - E LE CTRICAL/ E LE CTRICAL/WIP E RS/WASH E RS/WIP E R MOD-
LAMP S/LIGH TING - E XTE RIOR/BRAKE LAMP ULE - INSTALLATION)
SWITCH - INSTALLATION) (15) If equ ipped wit h speed con t r ol, in st a ll speed
(6) In st a ll t h e silen cer pa n el below t h e st eer in g con t r ol ser vo a n d con n ect wir in g con n ect or. Tigh t en
colu m n . t h e m ou n t in g n u t s t o a t or qu e of 14 N·m (124 in .
(7) Con n ect va cu u m h ose t o ch eck va lve on power lbs.).
br a ke boost er. (16) In st a ll t h e ba t t er y t r a y. In st a ll t h e t wo n u t s
a n d on e bolt a t t a ch in g t h e ba t t er y t r a y t o t h e veh icle.
CAUTION: The master cylinder (and its rear seal) is Tigh t en t h e bolt a n d n u t s t o a t or qu e of 14 N·m (124
used to create the seal for holding vacuum in the in . lbs.).
vacuum booster. The vacuum seal on the master (17) If veh icle is equ ipped wit h speed con t r ol, con -
cylinder MUST be replaced with a NEW seal when- n ect t h e ser vo va cu u m h ose t o t h e va cu u m t a n k on
ever the master cylinder is removed from the vac- t h e ba t t er y t r a y.
uum booster. (18) In st a ll t h e a ir in let r eson a t or a n d h oses a s a n
a ssem bly on t h e t h r ot t le body a n d a ir clea n er h ou s-
CAUTION: When removing the vacuum seal from in g. Secu r ely t igh t en h ose cla m p a t a ir clea n er h ou s-
the master cylinder do not use a sharp tool. in g a n d t h r ot t le body.
(19) Secu r e t h e en gin e coola n t filler n eck t o t h e
(8) Usin g a soft t ool su ch a s a t r im st ick, r em ove ba t t er y t r a y wit h it s m ou n t in g scr ew.
t h e va cu u m sea l fr om t h e m a st er cylin der m ou n t in g (20) In st a ll t h e ba t t er y, cla m p a n d m ou n t in g n u t .
fla n ge. (21) In st a ll t h e posit ive ba t t er y ca ble on t h e ba t -
(9) In st a ll a NE W va cu u m sea l on r ea r m ou n t in g t er y.
fla n ge of t h e m a st er cylin der (F ig. 77). (22) In st a ll t h e n ega t ive ba t t er y ca ble on t h e ba t -
t er y.
(23) In st a ll t h e ba t t er y t h er m a l gu a r d sh ield.
(24) Bleed t h e ba se br a kes a s n ecessa r y. (Refer t o
5 - BRAKE S - STANDARD P ROCE DURE )
(25) Roa d t est veh icle t o en su r e oper a t ion of t h e
br a kes.
INSTALLATION - RHD
(1) P osit ion power br a ke boost er on da sh pa n el
u sin g t h e r ever se pr ocedu r e of it s r em ova l (F ig. 75).
(2) Below in st r u m en t pa n el, fir st in st a ll t h e t wo
u pper n u t s m ou n t in g t h e boost er t o t h e da sh pa n el,
dr a win g it in t o pla ce, t h en in st a ll t h e t wo lower
m ou n t in g n u t s. Tigh t en t h e m ou n t in g n u t s t o a
t or qu e of 29 N·m (250 in . lbs.).
(3) Usin g lu br ipla t e, or equ iva len t , coa t t h e su r-
Fig. 77 Vacuum Seal (Typical) fa ce of t h e br a ke peda l t or qu e sh a ft pin wh er e it con -
1 - MASTER CYLINDER ASSEMBLY
t a ct s t h e boost er in pu t r od.
2 - VACUUM SEAL
CAUTION: When installing the brake pedal torque
(10) P osit ion m a st er cylin der on st u ds of boost er, shaft pin on the power brake booster input rod, do
a lign in g pu sh r od on boost er wit h m a st er cylin der not re-use the old retaining clip.
pist on .
(4) In st a ll boost er in pu t r od on br a ke peda l t or qu e
sh a ft pin a n d in st a ll a NE W r et a in in g clip (F ig. 78).
Fig. 79 Vacuum Seal (Typical)

1 - MASTER CYLINDER ASSEMBLY
2 - VACUUM SEAL
Fig. 78 Retaining Pin Installed On Brake Pedal Pin
(Typical) COOLANT RE COVE RY P RE SS CONTAINE R -
1 - BRAKE PEDAL INSTALLATION)
2 - RETAINING CLIP (13) If equ ipped wit h speed con t r ol, in st a ll speed
3 - BOOSTER INPUT ROD
con t r ol ser vo a n d con n ect wir in g con n ect or. Tigh t en
(5) In st a ll boost er in pu t r od t r im cover. t h e m ou n t in g n u t s t o a t or qu e of 14 N·m (124 in .
(6) Con n ect va cu u m h ose t o ch eck va lve on power lbs.).
br a ke boost er. (14) In st a ll t h e ba t t er y t r a y. In st a ll t h e t wo n u t s
a n d on e bolt a t t a ch in g t h e ba t t er y t r a y t o t h e veh icle.
CAUTION: The master cylinder (and its rear seal) is Tigh t en t h e bolt a n d n u t s t o a t or qu e of 14 N·m (124
used to create the seal for holding vacuum in the in . lbs.).
vacuum booster. The vacuum seal on the master (15) If veh icle is equ ipped wit h speed con t r ol, con -
cylinder MUST be replaced with a NEW seal when- n ect t h e ser vo va cu u m h ose t o t h e va cu u m t a n k on
ever the master cylinder is removed from the vac- t h e ba t t er y t r a y.
uum booster. (16) In st a ll t h e ba t t er y, cla m p a n d m ou n t in g n u t .
(17) In st a ll t h e posit ive ba t t er y ca ble on t h e ba t -
t er y.
CAUTION: When removing the vacuum seal from (18) In st a ll t h e n ega t ive ba t t er y ca ble on t h e ba t -
the master cylinder, do not use a sharp tool. t er y.
(19) In st a ll t h e ba t t er y t h er m a l gu a r d sh ield.
(7) Usin g a soft t ool su ch a s a t r im st ick, r em ove
t h e va cu u m sea l fr om t h e m a st er cylin der m ou n t in g CAUTION: Do not reuse the original brake lamp
fla n ge. switch. The switch can only be adjusted once. That
(8) In st a ll a NE W va cu u m sea l on r ea r m ou n t in g is during initial installation of the switch. If the
fla n ge of t h e m a st er cylin der (F ig. 79). switch is not adjusted properly or has been
(9) P osit ion m a st er cylin der on st u ds of boost er, removed for some service, a new switch must be
a lign in g pu sh r od on boost er wit h m a st er cylin der installed and adjusted.
pist on .
(10) In st a ll t h e t wo n u t s m ou n t in g t h e m a st er cyl- (20) Rem ove a n d r epla ce t h e br a ke la m p swit ch
in der t o t h e boost er (F ig. 72). Tigh t en bot h m ou n t in g wit h a NE W swit ch . (Refer t o 8 - E LE CTRICAL/
n u t s t o a t or qu e of 25 N·m (225 in . lbs.). LAMP S/LIGH TING - E XTE RIOR/BRAKE LAMP
(11) Con n ect wir in g h a r n ess con n ect or t o br a ke SWITCH - RE MOVAL), (Refer t o 8 - E LE CTRICAL/
flu id level swit ch in t h e m a st er cylin der flu id r eser- LAMP S/LIGH TING - E XTE RIOR/BRAKE LAMP
voir (F ig. 71). SWITCH - INSTALLATION)
(12) If t h e veh icle is equ ipped wit h t h e 2.5L diesel (21) Bleed t h e ba se br a kes a s n ecessa r y. (Refer t o
en gin e, in st a ll t h e coola n t r ecover y pr essu r e con - 5 - BRAKE S - STANDARD P ROCE DURE )
t a in er a n d br a cket . (Refer t o 7 - COOLING/E NGINE / (22) Roa d t est veh icle t o en su r e pr oper oper a t ion
of t h e br a kes.
PROPORT I ON I N G VALV E OPERATION - PROPORTIONING VALVE

(HEIGHT SENSING)
DESCRIPTION - PROPORTIONING VALVE Veh icles n ot equ ipped wit h ABS u se a h eigh t sen s-
(HEIGHT SENSING) in g pr opor t ion in g va lve.
Th e h eigh t sen sin g pr opor t ion in g va lve oper a t es
NOTE: Only vehicles without antilock brakes (ABS) sim ila r ly t o a st a n da r d pr opor t ion in g va lve in t h e fol-
have a proportioning valve. Vehicles with ABS uti- lowin g wa y. As h ydr a u lic pr essu r e is a pplied t o t h e
lize electronic brake distribution which is controlled va lve, fu ll in pu t h ydr a u lic pr essu r e is su pplied t o t h e
through the ABS integrated control unit. r ea r br a kes u p t o a cer t a in pr essu r e poin t , ca lled t h e
split poin t . Beyon d t h e split poin t , t h e pr opor t ion in g
Veh icles n ot equ ipped wit h ABS u se a h eigh t sen s- va lve r edu ces t h e a m ou n t of h ydr a u lic pr essu r e t o
in g pr opor t ion in g va lve. It is m ou n t ed t o t h e body of t h e r ea r br a kes a ccor din g t o a given r a t io. Th u s, on
t h e veh icle a bove t h e r ea r a xle (F ig. 80). It h a s a n ligh t br a ke a pplica t ion s, a ppr oxim a t ely equ a l
a ct u a t or lever t h a t a t t a ch es t o t h e r ea r a xle a n d h ydr a u lic pr essu r e will be t r a n sm it t ed t o bot h t h e
m oves wit h t h e a xle t o h elp t h e va lve sen se t h e veh i- fr on t a n d r ea r br a kes. Upon h ea vier br a ke a pplica -
cle h eigh t . t ion s, t h e h ydr a u lic pr essu r e t r a n sm it t ed t o t h e r ea r
br a kes will be lower t h a n t h e fr on t br a kes. Th is will
CAUTION: The height sensing proportioning valve pr even t pr em a t u r e r ea r wh eel locku p a n d skid.
is not adjustable. No attempt should be made to H er e is h ow t h e h eigh t sen sin g pr opor t ion in g va lve
adjust it. It is replaced as a complete assembly. differ s fr om a st a n da r d pr opor t ion in g va lve. As t h e
h eigh t of t h e r ea r su spen sion ch a n ges, t h e h eigh t
sen sin g por t ion of t h e pr opor t ion in g va lve ch a n ges
CAUTION: The use of after-market load leveling or
t h e split poin t of t h e pr opor t ion in g va lve. Wh en t h e
load capacity increasing devices on this vehicle are
h eigh t of t h e r ea r su spen sion is low, t h e pr opor t ion -
prohibited. Using air shock absorbers or helper
in g va lve in t er pr et s t h is a s ext r a loa d a n d t h e split
springs on this vehicle will cause the height sens-
poin t of t h e pr opor t ion in g va lve is r a ised t o a h igh er
ing proportioning valve to inappropriately reduce
pr essu r e t o a llow for m or e r ea r br a kin g. Wh en t h e
the hydraulic pressure to the rear brakes. This inap-
h eigh t of t h e r ea r su spen sion is h igh , t h e pr opor t ion -
propriate reduction in hydraulic pressure potentially
in g va lve in t er pr et s t h is a s a ligh t loa d a n d t h e split
could result in increased stopping distance of the
poin t of t h e pr opor t ion in g va lve is lower ed t o a lower
vehicle.
pr essu r e a n d r ea r br a kin g is r edu ced.
Th e h eigh t sen sin g pr opor t ion in g va lve r egu la t es
t h e pr essu r e by sen sin g t h e loa d con dit ion of t h e
veh icle t h r ou gh t h e m ovem en t of t h e pr opor t ion in g
va lve a ct u a t or lever (F ig. 80). As t h e posit ion of t h e
r ea r a xle ch a n ges, depen din g on t h e loa d t h e veh icle
is ca r r yin g, t h e m ovem en t is t r a n sfer r ed t o t h e pr o-
por t ion in g va lve. Th e pr opor t ion in g va lve a dju st s t h e
h ydr a u lic pr essu r e a ccor din gly.
Th e h eigh t sen sin g pr opor t ion in g va lve a llows t h e
br a ke syst em t o m a in t a in t h e opt im a l fr on t t o r ea r
br a ke ba la n ce r ega r dless of t h e veh icle loa d con di-
t ion . Un der a ligh t loa d con dit ion , h ydr a u lic pr essu r e
t o t h e r ea r br a kes is m in im ized. As t h e r ea r loa d con -
dit ion in cr ea ses, so does t h e h ydr a u lic pr essu r e t o
t h e r ea r br a kes.
Fig. 80 HEIGHT SENSING PROPORTIONING VALVE

1 - PROPORTIONING VALVE
2 - ACTUATOR LEVER
3 - AXLE BRACKET
4 - REAR AXLE
PROPORT I ON I N G VALV E (Cont inue d)
DIAGNOSIS AND TESTING - PROPORTIONING (5) In st a ll t h e pr eviou sly r em oved br a ke lin es in t o

t h e P r essu r e Test F it t in gs. Tigh t en a ll t u be n u t s t o
VALVE (HEIGHT SENSING)
17 N·m (145 in . lbs.).
CAUTION: The use of aftermarket load leveling or (6) In st a ll a pr essu r e ga u ge fr om Ga u ge Set , Spe-
load capacity increasing devices on this vehicle is cia l Tool C-4007-A in t o t h e open por t on ea ch pr es-
prohibited. Using air shock absorbers or helper su r e t est fit t in g. Bleed a ir ou t of h ose fr om pr essu r e
springs on this vehicle will cause the height sens- t est fit t in gs t o pr essu r e ga u ges a t t h e pr essu r e
ing proportioning valve to inappropriately reduce ga u ges. Th en bleed a ir ou t of t h e br a ke lin e bein g
the hydraulic pressure to the rear brakes. This inap- t est ed a t t h a t r ea r wh eel br a ke bleeder.
propriate reduction in hydraulic pressure potentially
NOTE: Actuator rod is a linear spring and is meant
could result in increased stopping distance of the
to flex by design. When rod is raised, it will have
vehicle.
some curvature to it.
Wh en a pr em a t u r e r ea r wh eel skid is obt a in ed on a
(7) Rem ove t h e scr ew fa st en in g t h e pr opor t ion in g
br a ke a pplica t ion , it m a y be a n in dica t ion t h a t t h e
va lve a ct u a t or r od br a cket t o t h e r ea r a xle. Ra ise t h e
h ydr a u lic pr essu r e t o t h e r ea r br a kes is a bove t h e
a ct u a t or lever t o t h e fu ll-u pwa r d posit ion a n d h old it
specified ou t pu t fr om t h e pr opor t ion in g va lve. Th is
t h er e.
con dit ion in dica t es a possible m a lfu n ct ion of t h e
(8) Wit h t h e a id of a h elper, a pply pr essu r e t o t h e
h eigh t sen sin g pr opor t ion in g va lve, wh ich will
br a ke peda l u n t il a pr essu r e of 6895 kP a (1000 psi) is
r equ ir e t est in g t o ver ify t h a t it is pr oper ly con t r ollin g
obt a in ed on t h e pr opor t ion in g va lve in let ga u ge.
t h e h ydr a u lic pr essu r e a llowed t o t h e r ea r br a kes.
Th en , ba sed on t h e t ype of br a ke syst em t h e veh icle
P r em a t u r e r ea r wh eel skid m a y a lso be ca u sed by
is equ ipped wit h a n d t h e pr essu r e specifica t ion
con t a m in a t ed fr on t or r ea r br a ke lin in gs.
sh own on t h e followin g t a ble, com pa r e t h e pr essu r e
P r ior t o t est in g a pr opor t ion in g va lve for fu n ct ion ,
r ea din g on t h e ou t let ga u ge t o t h e specifica t ion . If
ch eck t h a t a ll t ir e pr essu r es a r e cor r ect . Also, en su r e
ou t let pr essu r e a t t h e pr opor t ion in g va lve is n ot
t h e fr on t a n d r ea r br a ke lin in gs a r e in sa t isfa ct or y
wit h in specifica t ion wh en r equ ir ed in let pr essu r e is
con dit ion . It is a ls o n e c e s s a ry to v e rify th a t th e
obt a in ed, r epla ce t h e pr opor t ion in g va lve. (Refer t o 5
bra k e s s h o e a s s e m blie s o n a v e h ic le be in g
- BRAKE S/H YDRAULIC/ME CH ANICAL/P ROP OR-
te s te d a re e ith e r o rig in a l e qu ip m e n t m a n u fa c -
TIONING VALVE - RE MOVAL)
tu re rs (OEM) o r o rig in a l re p la c e m e n t bra k e
s h o e a s s e m blie s m e e tin g th e OEM lin in g m a te - CAUTION: Do not attempt to adjust the height sens-
ria l s p e c ific a tio n . Th is v e h ic le s bra k e s y s te m is ing proportioning valve. If found to be defective,
n o t ba la n c e d fo r a fte rm a rk e t bra k e s h o e a s s e m - replace the valve.
bly lin in g m a te ria l.
If bot h fr on t a n d r ea r br a kes ch eck OK, pr oceed (9) Rem ove t h e pr essu r e t est fit t in gs a n d pr essu r e
wit h t h e followin g t est pr ocedu r e for t h e h eigh t sen s- ga u ges fr om t h e pr opor t ion in g va lve.
in g pr opor t ion in g va lve. (10) In st a ll t h e ch a ssis br a ke lin es in t h e cor r ect
(1) Roa d t est t h e veh icle t o det er m in e wh ich r ea r por t s of t h e pr opor t ion in g va lve. Tigh t en a ll t u be
wh eel br a ke is exh ibit in g pr em a t u r e wh eel skid. n u t s t o 17 N·m (145 in . lbs.).
(2) Ra ise veh icle. (Refer t o LUBRICATION & (11) If n ecessa r y, r epea t t h e a bove st eps on t h e
MAINTE NANCE /H OISTING - STANDARD P ROCE - r em a in in g side of t h e pr opor t ion in g va lve wh ich con -
DURE ) t r ol t h e ot h er r ea r wh eel br a ke.
(3) Rem ove t h e ch a ssis br a ke t u be goin g t o t h e (12) At t a ch t h e a ct u a t or lever a n d br a cket t o t h e
r ea r br a ke in qu est ion a t t h e pr opor t ion in g va lve. r ea r a xle.
Rem ove t h e ch a ssis br a ke t u be com in g fr om t h e ju n c- (13) Bleed r ea r br a kes. (Refer t o 5 - BRAKE S -
t ion block a t t h e pr opor t ion in g va lve (F ig. 81). STANDARD P ROCE DURE )
(4) In st a ll t h e a ppr opr ia t e fit t in gs fr om P r essu r e (14) Roa d t est veh icle.
Test F it t in gs, Specia l Tool 6833, in t o t h e open por t s
of t h e pr opor t ion in g va lve.
PROPORT I ON I N G VALV E (Cont inue d)
PROPORT I ON I N G VALV E SPECI FI CAT I ON S
INLET OUTLET
WHEEL DRIVE SALES BRAKE SPLIT
SLOPE PRESSURE PRESSURE
BASE TRAIN CODE SYSTEM POINT
PSI PSI
15% DISC/
SWB FWD BRB-BGF DRUM W/O VAR. 0.59 1000 PSI 675-875 PSI
ANTILOCK
REMOVAL - PROPORTIONING VALVE (HEIGHT a ct u a t or r od ou t of t h e a xle br a cket a n d r em ove t h e

pr opor t ion in g va lve fr om t h e veh icle.
SENSING)
(1) Usin g a br a ke peda l depr essor, m ove a n d lock
t h e br a ke peda l t o a posit ion pa st it s fir st 1 in ch of
INSTALLATION - PROPORTIONING VALVE
t r a vel. Th is will pr even t br a ke flu id fr om dr a in in g (HEIGHT SENSING)
ou t of t h e m a st er cylin der wh en t h e br a ke t u bes a r e (1) In st a ll t h e en d of t h e a ct u a t or r od t h r ou gh t h e
r em oved fr om t h e pr opor t ion in g va lve. a xle br a cket gr om m et a n d slide t h e pr opor t ion in g
(2) Ra ise veh icle. (Refer t o LUBRICATION & va lve br a cket u n der t h e r ea r t r a ck ba r body br a cket
MAINTE NANCE /H OISTING - STANDARD P ROCE - (F ig. 81).
DURE ). (2) In st a ll t h e pr opor t ion in g va lve a t t a ch in g bolt s
(F ig. 81). Tigh t en t h e a t t a ch in g bolt s t o a t or qu e of
CAUTION: Before removing the brake tubes from 54 N·m (40 ft . lbs.).
the proportioning valve, the proportioning valve and (3) In st a ll t h e fou r ch a ssis br a ke lin es in t o t h e
the brake tubes must be thoroughly cleaned. This is in let a n d ou t let por t s of t h e pr opor t ion in g va lve (F ig.
required to prevent contamination from entering the 81). Tigh t en a ll t u be n u t s t o a t or qu e of 17 N·m (145
proportioning valve or the brake tubes. in . lbs.).
(3) Rem ove t h e fou r br a ke t u bes fr om t h e in let a n d CAUTION: The height sensing proportioning valve
ou t let por t s of t h e pr opor t ion in g va lve (F ig. 81). is not adjustable. No attempt should be made to
adjust it.
(4) Bleed t h e br a ke syst em t h or ou gh ly t o en su r e

t h a t a ll a ir h a s been expelled fr om t h e h ydr a u lic sys-
t em . (Refer t o 5 - BRAKE S - BASE - STANDARD
P ROCE DURE ).
(5) Lower t h e veh icle t o t h e gr ou n d.
(6) Roa d t est t h e veh icle t o ver ify pr oper oper a t ion
ROT OR
DIAGNOSIS AND TESTING - BRAKE ROTOR
An y ser vicin g of t h e r ot or r equ ir es ext r em e ca r e t o
m a in t a in t h e r ot or wit h in ser vice t oler a n ces t o
en su r e pr oper br a ke a ct ion .
Fig. 81 PROPORTIONING VALVE MOUNTING E xcessive r u n ou t or wobble in a r ot or ca n in cr ea se
1 - LEFT REAR OUTLET TUBE peda l t r a vel du e t o pist on kn ock-ba ck. Th is in cr ea ses
2 - RIGHT REAR OUTLET TUBE
3 - RIGHT REAR INLET TUBE gu ide pin sleeve wea r du e t o t h e t en den cy of t h e ca l-
4 - MOUNTING BOLTS iper t o follow t h e r ot or wobble.
5 - LEFT REAR INLET TUBE Wh en dia gn osin g a br a ke n oise or pu lsa t ion , t h e
m a ch in ed disc br a kin g su r fa ce sh ou ld be ch ecked a n d
(4) Rem ove t h e t wo bolt s a t t a ch in g t h e pr opor t ion -
in spect ed.
in g va lve a n d br a cket t o t h e veh icle (F ig. 81).
(5) Slide t h e br a cket ou t fr om u n der r ea r t r a ck ba r
br a cket . Lower t h e va lve down en ou gh t o pu ll it s
ROT OR (Cont inue d)
BRAKING SURFACE INSPECTION ROTOR THICKNESS VARIATION
Ligh t br a kin g su r fa ce scor in g a n d wea r is a ccept - Th ickn ess va r ia t ion in a r ot or ’s br a kin g su r fa ce
a ble. If h ea vy scor in g or wa r pin g is eviden t , t h e r ot or ca n r esu lt in peda l pu lsa t ion , ch a t t er a n d su r ge. Th is
m u st be r efa ced or r epla ced. (Refer t o 5 - BRAKE S/ ca n be ca u sed by excessive r u n ou t in t h e r ot or or t h e
H YDRAULIC/ME CH ANICAL/ROTORS - STAN- h u b.
DARD P ROCE DURE ). Rot or t h ickn ess va r ia t ion m ea su r em en t s sh ou ld be
E xcessive wea r a n d scor in g of t h e r ot or ca n ca u se m a de in con ju n ct ion wit h m ea su r in g r u n ou t . Mea -
im pr oper lin in g con t a ct on t h e r ot or ’s br a kin g su r- su r e t h ickn ess of t h e br a ke r ot or a t 12 equ a l poin t s
fa ce. If t h e r idges on t h e r ot or a r e n ot r em oved befor e a r ou n d t h e r ot or br a kin g su r fa ce wit h a m icr om et er
n ew br a ke sh oes a r e in st a lled, im pr oper wea r of t h e a t a r a diu s a ppr oxim a t ely 25 m m (1 in ch ) fr om edge
sh oes will r esu lt . of r ot or (F ig. 83). If t h ickn ess m ea su r em en t s va r y
If a veh icle h a s n ot been dr iven for a per iod of beyon d t h e specifica t ion list ed in t h e specifa ct ion
t im e, t h e r ot or ’s br a kin g su r fa ce will r u st in t h e t a ble (Refer t o 5 - BRAKE S/H YDRAULIC/ME CH AN-
a r ea s n ot cover ed by t h e br a ke sh oes a t t h a t t im e. ICAL/ROTOR - SP E CIF ICATIONS), t h e r ot or sh ou ld
On ce t h e veh icle is dr iven , n oise a n d ch a t t er fr om be r efa ced or r epla ced. (Refer t o 5 - BRAKE S/H Y-
t h e disc br a kes ca n r esu lt wh en t h e br a kes a r e DRAULIC/ME CH ANICAL/ROTORS - STANDARD
a pplied. P ROCE DURE ).
Som e discolor a t ion or wea r of t h e r ot or su r fa ce is
n or m a l a n d does n ot r equ ir e r esu r fa cin g wh en lin -
in gs a r e r epla ced. If cr a cks or bu r n ed spot s a r e evi-
den t , t h e r ot or m u st be r epla ced.
ROTOR MINIMUM THICKNESS

Mea su r e r ot or t h ickn ess a t t h e cen t er of t h e br a ke
sh oe con t a ct su r fa ce. Repla ce t h e r ot or if it is wor n
below m in im u m t h ickn ess or if m a ch in in g t h e r ot or
will ca u se it s t h ickn ess t o fa ll below specifica t ion s.
CAUTION: Do not machine the rotor if it will cause

the rotor to fall below minimum thickness.
Min im u m t h ickn ess specifica t ion s a r e ca st on t h e

r ot or ’s u n m a ch in ed su r fa ce (F ig. 82). Lim it s ca n a lso
be fou n d in t h is sect ion ’s specifica t ion t a ble. (Refer t o
5 - BRAKE S/H YDRAULIC/ME CH ANICAL/ROTOR -
SP E CIF ICATIONS)
Fig. 83 Checking Rotor For Thickness

1 - CALIPER
Fig. 82 Minimum Brake Rotor Thickness Markings

(Typical)
1 - ROTOR MINIMUM THICKNESS MARKING
2 - ROTOR
ROTOR RUNOUT
On -veh icle r ot or r u n ou t is t h e com bin a t ion of t h e
in dividu a l r u n ou t of t h e h u b fa ce a n d t h e r u n ou t of
t h e r ot or. (Th e h u b a n d r ot or r u n ou t s a r e sepa r a ble).
To m ea su r e r ot or r u n ou t on t h e veh icle, fir st r em ove
t h e t ir e a n d wh eel a ssem bly. Rein st a ll t h e wh eel
m ou n t in g n u t s on t h e st u ds, t igh t en in g t h e r ot or t o
t h e h u b. Mou n t t h e Dia l In dica t or, Specia l Tool
C-3339, wit h Mou n t in g Ada pt or, Specia l Tool SP -
1910 on st eer in g a r m . Th e dia l in dica t or plu n ger
sh ou ld con t a ct br a kin g su r fa ce of r ot or a ppr oxim a t ely
t en m illim et er s fr om edge of r ot or (F ig. 84). Ch eck
la t er a l r u n ou t on bot h sides of t h e r ot or, m a r kin g t h e
low a n d h igh spot s on bot h . Ru n ou t lim it s ca n be
fou n d in t h e specifica t ion t a ble in t h is sect ion . (Refer
t o 5 - BRAKE S/H YDRAULIC/ME CH ANICAL/RO-
TOR - SP E CIF ICATIONS)
Fig. 85 Marking Rotor and Wheel Stud

1 - CHALK MARK
Fig. 84 Checking Rotor Runout

1 - SPECIAL TOOL SP-1910
2 - 10 MILLIMETERS FROM EDGE
3 - DISC SURFACE
4 - SPECIAL TOOL C-3339
If r u n ou t is in excess of t h e specifica t ion , ch eck t h e

la t er a l r u n ou t of t h e h u b fa ce. Befor e r em ovin g t h e
r ot or fr om t h e h u b, pla ce a ch a lk m a r k a cr oss bot h
t h e r ot or a n d t h e on e wh eel st u d closest t o wh er e t h e
h igh r u n ou t m ea su r em en t wa s t a ken . Th is wa y, t h e
or igin a l m ou n t in g spot of t h e r ot or on t h e h u b is
Fig. 86 Checking Hub Runout
in dexed (F ig. 85).
Rem ove t h e r ot or fr om t h e h u b. 1 - HUB SURFACE
3 - SPECIAL TOOL SP-1910
NOTE: Clean the hub face surface before checking
runout. This provides a clean surface to get an H u b r u n ou t sh ou ld n ot exceed 0.03 m m (0.0012
accurate indicator reading. in ch ). If r u n ou t exceeds t h is specifica t ion , t h e h u b
m u st be r epla ced. (Refer t o 2 - SUSP E NSION/
Mou n t Dia l In dica t or, Specia l Tool C-3339, a n d F RONT/H UB / BE ARING - RE MOVAL)(Refer t o 2 -
Mou n t in g Ada pt or, Specia l Tool SP -1910, t o t h e st eer- SUSP E NSION/RE AR/H UB / BE ARING - RE MOVAL)
in g kn u ckle. P osit ion t h e in dica t or st em so it con t a ct s
t h e h u b fa ce n ea r t h e ou t er dia m et er. Ca r e m u st be
t a ken t o posit ion st em ou t side of t h e st u d cir cle, bu t
in side of t h e ch a m fer on t h e h u b r im (F ig. 86).
If t h e h u b r u n ou t does n ot exceed t h is specifica -
t ion , in st a ll t h e r ot or ba ck on t h e h u b, a lign in g t h e
ch a lk m a r ks on t h e r ot or wit h a wh eel m ou n t in g
st u d, t wo st u ds a pa r t fr om t h e or igin a l st u d (F ig. 87).
Tigh t en n u t s in t h e pr oper sequ en ce a n d t or qu e t o
specifica t ion s.
Fig. 88 On-Car Brake Lathe

1 - ON-CAR BRAKE LATHE
NOTE: All rotors have markings for minimum allow-

able thickness cast on an un-machined surface of
the rotor (Fig. 89) (Fig. 90). Minimum thickness
specifications can also be found in the specification
table in this section. (Refer to 5 - BRAKES/HY-
DRAULIC/MECHANICAL/ROTOR - SPECIFICATIONS)
Fig. 87 Index Rotor And Wheel Stud
1 - CHALK MARK
Rech eck br a ke r ot or r u n ou t t o see if t h e r u n ou t is

n ow wit h in specifica t ion s. (Refer t o 5 - BRAKE S/H Y-
DRAULIC/ME CH ANICAL/ROTOR - SP E CIF ICA-
TIONS)
If r u n ou t is n ot wit h in specifica t ion s, r efa ce or
r epla ce t h e br a ke r ot or. (Refer t o 5 - BRAKE S/H Y-
DRAULIC/ME CH ANICAL/ROTORS - STANDARD
P ROCE DURE )
STANDARD PROCEDURE - BRAKE ROTOR

MACHINING
Fig. 89 Front Brake Rotor
NOTE: Refacing the rotor is not required each time
the brake pads are replaced, only when the need is 1 - ROTOR MINIMUM THICKNESS MARKING
2 - ROTOR
foreseen.
An y ser vicin g of t h e r ot or r equ ir es ext r em e ca r e t o

m a in t a in t h e r ot or wit h in ser vice t oler a n ces t o
en su r e pr oper br a ke a ct ion .
If t h e r ot or su r fa ce is deeply scor ed or wa r ped, or
t h er e is a com pla in t of br a ke r ou gh n ess or br a ke
peda l pu lsa t ion , t h e r ot or sh ou ld be r efa ced u sin g a
h u b-m ou n t ed on -ca r br a ke la t h e (F ig. 88), or
r epla ced.
Th e u se of a h u b-m ou n t ed on -ca r br a ke la t h e is Fig. 90 Rear Brake Rotor Minimum Thickness
h igh ly r ecom m en ded t o elim in a t e t h e possibilit y of Markings
excessive r u n ou t . It t r u es t h e br a ke r ot or t o t h e veh i- 1 - ROTOR MINIMUM THICKNESS AND DRUM MAXIMUM
DIAMETER SPECIFICATIONS ARE SHOWN ON THIS SURFACE
cle’s h u b a n d bea r in g. 2 - REAR ROTOR
Min im u m a llowa ble t h ickn ess is t h e m in im u m
t h ickn ess wh ich t h e br a ke r ot or m a ch in ed su r fa ce
m a y be cu t t o.
CAUTION: Do not machine the rotor if it will cause

the rotor to fall below minimum thickness.
Befor e in st a lla t ion , ver ify t h e br a ke r ot or fa ce a n d

t h e h u b a da pt er s a r e fr ee of a n y ch ips, r u st , or con -
t a m in a t ion .
Wh en m ou n t in g a n d u sin g t h e br a ke la t h e, st r ict
a t t en t ion t o t h e br a ke la t h e m a n u fa ct u r er ’s oper a t in g
in st r u ct ion s is r equ ir ed.
Ma ch in e bot h sides of t h e br a ke r ot or a t t h e sa m e
t im e. Cu t t in g bot h sides a t t h e sa m e t im e m in im izes
t h e possibilit y of a t a per ed or u n even cu t .
Wh en r efa cin g a r ot or, t h e r equ ir ed TIR (Tot a l
In dica t or Rea din g) a n d t h ickn ess va r ia t ion lim it s
MUST BE MAINTAINE D. E xt r em e ca r e in t h e oper- 1 - BRAKE ROTOR
2 - HUB AND BEARING
a t ion of r ot or t u r n in g equ ipm en t is r equ ir ed. Specifi- 3 - STEERING KNUCKLE
ca t ion s for br a ke r ot or m a ch in in g ca n be fou n d in 4 - ADAPTER MOUNTING BOLTS
t h is sect ion ’s specifica t ion t a ble. (Refer t o 5 - 5 - BRAKE CALIPER
6 - ADAPTER
BRAKE S/H YDRAULIC/ME CH ANICAL/ROTOR - 7 - CLIP
SP E CIF ICATIONS)
(2) In st a ll br a ke ca liper a n d a da pt er ba ck over
REMOVAL - FRONT BRAKE ROTOR br a ke r ot or a lign in g a da pt er wit h m ou n t in g h oles on
(1) Ra ise veh icle on ja ckst a n ds or cen t er ed on a st eer in g kn u ckle (F ig. 91).
fr a m e con t a ct t ype h oist . See H oist in g in Lu br ica t ion (3) In st a ll t h e t wo a da pt er m ou n t in g bolt s secu r in g
a n d Ma in t en a n ce. t h e a da pt er t o t h e st eer in g kn u ckle. Tigh t en t h e
(2) Rem ove t h e fr on t wh eel a n d t ir e a ssem bly. m ou n t in g bolt s t o 169 N·m (125 ft . lbs.) t or qu e.
(3) Rem ove t h e t wo m ou n t in g bolt s secu r in g t h e (4) In st a ll wh eel a n d t ir e a ssem bly on veh icle.
disc br a ke ca liper a da pt er wit h br a ke ca liper t o t h e Tigh t en t h e wh eel m ou n t in g lu g n u t s in pr oper
st eer in g kn u ckle (F ig. 91). sequ en ce u n t il a ll n u t s a r e t or qu ed t o h a lf specifica -
(4) Rem ove t h e disc br a ke ca liper a n d a da pt er a s t ion , t h en r epea t t h e t igh t en in g sequ en ce t o t h e fu ll
a n a ssem bly fr om t h e st eer in g kn u ckle (F ig. 91). specified t or qu e of 135 N·m (100 ft . lbs.).
H a n g t h e a ssem bly ou t of t h e wa y u sin g wir e or a (5) Lower veh icle t o t h e gr ou n d.
bu n gee cor d. Use ca r e n ot t o over ext en d t h e br a ke
h ose wh en doin g t h is.
(5) Rem ove a n y r et a in er clips fr om t h e wh eel
m ou n t in g st u ds.
(6) Rem ove br a ke r ot or fr om h u b by pu llin g it
st r a igh t off wh eel m ou n t in g st u ds (F ig. 91).
INSTALLATION - FRONT BRAKE ROTOR

(1) In st a ll t h e br a ke r ot or ba ck on t h e h u b a n d
bea r in g (F ig. 91).
SPECI FI CAT I ON S MUST BE MAINTAINE D. E xt r em e ca r e in t h e oper-

a t ion of r ot or t u r n in g equ ipm en t is r equ ir ed.
BRAKE ROTOR
Wh en r efa cin g a r ot or, t h e r equ ir ed TIR (Tot a l
LI M I T S/SPECI FI CAT I ON S
Minimum Rotor Rotor Thickness Rotor Runout*

Braking Rotor Rotor Thickness
Thickness Variation
27.87–28.13 mm 25.3 mm 0.009 mm 0.075 mm
Front - TRW
1.097-1.107 in. 0.996 in. 0.0004 in. 0.0030 in.
Front - Continental 27.90–28.10 mm 25.3 mm 0.008 mm 0.100 mm
Teves 1.098-1.106 in. 0.996 in. 0.0003 in. 0.0039 in.
12.4–12.6 mm 11.25 mm 0.013 mm 0.14 mm
Rear
0.488 -0.496 in. 0.443 in. 0.0005 in. 0.0055 in.
*
TIR Total Indicator Reading (Measured On Vehicle)
BRAKE ROTOR - EXPORT Wh en r efa cin g a r ot or, t h e r equ ir ed TIR (Tot a l

NOTE: Use the following information on all 4 wheel MUST BE MAINTAINE D. E xt r em e ca r e in t h e oper-
disc brake vehicles that are equipped with BR3 a t ion of r ot or t u r n in g equ ipm en t is r equ ir ed.
sales code.
LI M I T S/SPECI FI CAT I ON S
Minimum Rotor Rotor Thickness

Brake Rotor Rotor Thickness Rotor Runout*
Thickness Variation
27.9-28.1 mm 26.5 mm 0.010 mm 0.080 mm
Front
1.098 -1.106 in. 1.043 in 0.0004 in. 0.0031 in.
12.4-12.6 mm 11.25 mm 0.013 mm 0.14 mm
Rear
0.488-0.496 in. 0.443 in. 0.0005 in. 0.0055 in.
* TIR Total Indicator Reading (Measured On Vehicle)
SU PPORT PLAT E - DRU M (12) Rem ove t h e r ea r br a ke su ppor t pla t e fr om t h e

r ea r a xle.
BRAK E
INSTALLATION
REMOVAL (1) In st a ll t h e 4 h u b a n d bea r in g t o a xle m ou n t in g
(1) Usin g a br a ke peda l depr essor, m ove a n d bolt s in t o t h e m ou n t in g h oles in t h e fla n ge of t h e
secu r e br a ke peda l t o a posit ion pa st it s fir st 1 in ch r ea r a xle.
of t r a vel. Th is will pr even t br a ke flu id fr om dr a in in g (2) In st a ll t h e r ea r br a ke su ppor t pla t e on t h e 4
ou t of m a st er cylin der wh en br a ke t u be is r em ove m ou n t in g bolt s in st a lled in t h e fla n ge of t h e r ea r a xle
fr om wh eel cylin der. (F ig. 93).
DURE ).
(3) Rem ove wh eel a n d t ir e a ssem bly.
(4) Discon n ect br a ke t u be fr om r ea r of wh eel cylin -
der. Ca p open en ds
(5) Rem ove br a ke dr u m .
(6) Rem ove br a ke sh oes fr om br a ke su ppor t pla t e.
(Refer t o 5 - BRAKE S/H YDRAULIC/ME CH ANICAL/
BRAKE PADS/SH OE S - RE MOVAL).
(7) Rem ove t h e 2 bolt s a t t a ch in g t h e wh eel cylin -
der t o t h e br a ke su ppor t pla t e.
(8) Rem ove t h e wh eel cylin der fr om t h e br a ke su p-
por t pla t e.
(9) Discon n ect t h e pa r k br a ke ca ble fr om t h e pa r k
br a ke a ct u a t ion lever.
(10) Usin g a su it a ble t ool su ch a s a 14 m m box Fig. 93 Brake Support Plate Mounted On Bearing
wr en ch (F ig. 92) or a n a ir cr a ft t ype h ose cla m p, com - Attaching Bolts
pr ess t h e fla r ed legs on pa r k br a ke ca ble r et a in er. 1 - REAR BRAKE SUPPORT PLATE
Th en pu ll t h e pa r k br a ke ca ble ou t of br a ke su ppor t 2 - HUB/BEARING MOUNTING BOLTS
pla t e.
(3) In st a ll t h e r ea r h u b a n d bea r in g (a n d con n ect
wh eel speed sen sor wh er e a pplica ble) st oppin g sh or t
of in st a llin g t h e br a ke dr u m . (Refer t o 2 - SUSP E N-
SION/RE AR/H UB / BE ARING - INSTALLATION)
(4) In st a ll t h e r ea r pa r k br a ke ca ble in t o it s
m ou n t in g h ole in t h e r ea r br a ke su ppor t pla t e.
(5) In st a ll t h e pa r k br a ke ca ble on t h e pa r k br a ke
a ct u a t ion lever.
(6) Apply sea la n t su ch a s Mopa r Ga sket -In -A-Tu be
or equ iva len t a r ou n d t h e wh eel cylin der open in g in
t h e br a ke su ppor t pla t e.
(7) In st a ll wh eel cylin der on t o br a ke su ppor t .
In st a ll a n d t igh t en t h e wh eel cylin der t o br a ke su p-
por t pla t e a t t a ch in g bolt s t o 8 N·m (75 in . lbs.)
t or qu e.
(8) In st a ll br a ke t u be in t o wh eel cylin der. Tigh t en
Fig. 92 Removing Park Brake Cable From Brake t u be n u t t o a t or qu e of 17 N·m (145 in . lbs.) t or qu e.
Support Plate (9) In st a ll t h e r ea r br a ke sh oes on t h e br a ke su p-
por t pla t e. (Refer t o 5 - BRAKE S/H YDRAULIC/ME -
2 - CABLE RETAINER CH ANICAL/BRAKE PADS/SH OE S -
3 - 14 mm BOX WRENCH INSTALLATION).
4 - BRAKE SUPPORT PLATE (10) In st a ll br a ke dr u m .
(11) In st a ll t h e wh eel a n d t ir e a ssem bly. Tigh t en
(11) Rem ove t h e r ea r h u b a n d bea r in g. (Refer t o 2 t h e wh eel m ou n t in g n u t s in pr oper sequ en ce u n t il a ll
- SUSP E NSION/RE AR/H UB / BE ARING - n u t s a r e t or qu ed t o h a lf specifica t ion , t h en r epea t t h e
RE MOVAL)
SU PPORT PLAT E - DRU M BRAK E (Cont inue d)
t igh t en in g sequ en ce t o t h e fu ll specified t or qu e of 135 (4) In st a ll t h e r ea r br a ke sh oes on t h e br a ke su p-
N·m (100 ft . lbs.). por t pla t e. (Refer t o 5 - BRAKE S/H YDRAULIC/ME -
(12) Adju st dr u m br a ke sh oes. (Refer t o 5 - CH ANICAL/BRAKE PADS/SH OE S -
BRAKE S/H YDRAULIC/ME CH ANICAL/BRAKE INSTALLATION).
PADS/SH OE S - ADJ USTME NTS) (5) In st a ll br a ke dr u m .
(13) Rem ove br a ke peda l depr essor t ool. (6) In st a ll wh eel a n d t ir e. In st a ll a n d t igh t en
(14) Bleed t h e br a ke syst em a s n ecessa r y. (Refer t o wh eel lu g n u t s t o 135 N·m (100 ft . lbs.).
5 - BRAKE S - BASE - STANDARD P ROCE DURE ). (7) Adju st dr u m br a ke sh oes. (Refer t o 5 -
(15) Lower t h e veh icle. BRAKE S/H YDRAULIC/ME CH ANICAL/BRAKE
PADS/SH OE S - ADJ USTME NTS)
(8) Rem ove br a ke peda l depr essor t ool.
WH EEL CY LI N DERS (9) Bleed t h e br a ke syst em a s n ecessa r y. (Refer t o
5 - BRAKE S - BASE - STANDARD P ROCE DURE ).
REMOVAL (10) Lower veh icle.
(1) Usin g a br a ke peda l depr essor, m ove a n d
secu r e br a ke peda l t o a posit ion pa st it s fir st 1 in ch
of t r a vel. Th is will pr even t br a ke flu id fr om dr a in in g PARK I N G BRAK E
ou t of m a st er cylin der wh en br a ke t u be is r em ove
fr om wh eel cylin der.
(2) Ra ise veh icle. (Refer t o LUBRICATION & DESCRI PT I ON
DURE ). DESCRIPTION
(3) Rem ove wh eel a n d t ir e a ssem bly. Th e pa r kin g br a ke syst em is oper a t ed by a foot
(4) Discon n ect br a ke t u be fr om r ea r of wh eel cylin - oper a t ed pa r kin g br a ke lever. Th e pa r kin g br a ke
der. Ca p open en ds lever is m ou n t ed on t h e body of t h e veh icle t o t h e left
(5) Rem ove br a ke dr u m . of t h e br a ke peda l (F ig. 94). It is a a u t om a t ic-a dju st -
(6) Rem ove br a ke sh oes fr om br a ke su ppor t pla t e in g t ype lever.
(Disca r d if con t a m in a t ed).(Refer t o 5 - BRAKE S/H Y-
DRAULIC/ME CH ANICAL/BRAKE PADS/SH OE S -
RE MOVAL)
(7) Rem ove t h e 2 bolt s a t t a ch in g t h e wh eel cylin -
der t o t h e br a ke su ppor t pla t e.
(8) Rem ove t h e wh eel cylin der fr om t h e br a ke su p-
por t pla t e.
INSPECTION
Wit h br a ke dr u m s r em oved, in spect t h e wh eel cyl-
in der boot s for eviden ce of a br a ke flu id lea k. Visu -
a lly ch eck t h e boot s for cu t s, t ea r s, or h ea t cr a cks. If
a n y of t h ese con dit ion s exist , t h e wh eel cylin der s
sh ou ld be com plet ely clea n ed, in spect ed a n d n ew
pa r t s in st a lled.
If a wh eel cylin der is lea kin g a n d t h e br a ke lin in g
m a t er ia l is sa t u r a t ed wit h br a ke flu id, t h e br a ke Fig. 94 Parking Brake Lever (Pedal)
sh oes m u st be r epla ced. 1 - PARK BRAKE PEDAL ASSEMBLY
2 - PARK BRAKE PEDAL
INSTALLATION 3
4
-
-
CARPET
FRONT PARK BRAKE CABLE
(1) Apply sea la n t su ch a s Mopa r Ga sket -In -A-Tu be 5 - SEAL
or equ iva len t a r ou n d t h e wh eel cylin der open in g in 6 - FLOOR PAN
t h e br a ke su ppor t pla t e.
(2) In st a ll wh eel cylin der on t o br a ke su ppor t . Veh icles wit h ou t F old-in -floor sea t in g h a ve fou r
In st a ll a n d t igh t en t h e wh eel cylin der t o br a ke su p- flexible st eel pa r kin g br a ke ca bles. Th ey a r e:
por t pla t e a t t a ch in g bolt s t o 8 N·m (75 in . lbs.) • F r on t
t or qu e. • In t er m edia t e
(3) In st a ll br a ke t u be in t o wh eel cylin der. Tigh t en • Left r ea r
t u be n u t t o a t or qu e of 17 N·m (145 in . lbs.) t or qu e. • Righ t r ea r
PARK I N G BRAK E (Cont inue d)
Veh icles wit h F old-in -floor sea t in g h a ve t h r ee flex- STAN DARD PROCEDU RE
ible st eel pa r kin g br a ke ca bles. Th ey a r e:
• F r on t STANDARD PROCEDURE - PARKING BRAKE
• Left r ea r
• Righ t r ea r
AUTOMATIC ADJUSTER TENSION RELEASE
Th e fr on t pa r kin g br a ke ca ble ext en ds fr om t h e Th e pa r kin g br a ke lever (peda l) m ech a n ism u sed
pa r kin g br a ke lever. A st eel equ a lizer br a cket con - in t h is veh icle is design ed so t h a t t h e a u t om a t ic
a dju st er is n ot r equ ir ed t o be locked ou t wh en ser vic-
n ect s t h e fr on t pa r kin g br a ke ca ble t o t h e left r ea r
in g t h e pa r kin g br a ke lever (peda l) or t h e pa r kin g
a n d in t er m edia t e ca bles on veh icles wit h ou t F old-in -
br a ke ca bles.
floor sea t in g. Th e equ a lizer br a cket con n ect s t h e
Th is pa r kin g br a ke lever (peda l) m ech a n ism is
fr on t pa r kin g br a ke ca ble t o t h e left r ea r a n d r igh t
design ed so t h a t t h e a dju st er m ech a n ism will r ot a t e
r ea r ca bles on veh icles wit h F old-in -floor sea t in g. Th e
on ly h a lf a t u r n wh en t h e t en sion is r elea sed fr om
in t er m edia t e ca ble is con n ect ed t o t h e r igh t r ea r
ca ble on veh icles wit h ou t F old-in -floor sea t in g. A t h e pa r kin g br a ke ca ble. Th is elim in a t es t h e r equ ir e-
m en t t o lock ou t t h e a u t om a t ic a dju st er wh en ser vic-
st a n da r d ca ble con n ect or is u sed t o a ccom plish t h is
in g t h e pa r kin g br a ke lever (peda l) m ech a n ism a n d
con n ect ion .
ca bles.
On veh icles equ ipped wit h r ea r dr u m br a kes, t h e
Use t h e followin g pr ocedu r e t o r elea se t h e t en sion
r ea r ser vice br a kes a lso a ct a s t h e veh icle’s pa r kin g
fr om t h e pa r kin g br a ke ca bles a n d t h e a u t om a t ic
br a kes.
Veh icles equ ipped wit h r ea r disc br a kes u se a a dju st er in t h e pa r kin g br a ke lever (peda l) m ech a -
n ism .
sm a ll du o-ser vo br a ke a ssem bly m ou n t ed t o t h e ea ch
r ea r disc br a ke ca liper a da pt er a s t h e pa r kin g br a ke. (1) Relea se t h e pa r kin g br a ke.
(2) Ra ise a n d su ppor t t h e veh icle. (Refer t o
Th e in side of t h e br a ke r ot or (h a t sect ion of dr u m -in -
h a t st yle br a ke r ot or ) is u sed a s t h e pa r kin g br a ke LUBRICATION & MAINTE NANCE /H OISTING -
STANDARD P ROCE DURE )
dr u m .
(3) If equ ipped wit h F old-in -floor sea t in g, per for m
t h e followin g:
DESCRIPTION - EXPORT
(a ) Cla m p a n a ppr opr ia t e pa ir of lockin g plier s
Th e pa r kin g br a ke syst em on t h is veh icle fea t u r es
on t h e fr on t pa r kin g br a ke ca ble st r a n d a ppr oxi-
a h a n d-oper a t ed pa r kin g br a ke lever. Th e lever is
m a t ely 25 m m (1 in ch ) for wa r d of t h e bu t t on a t t h e
loca t ed bet ween t h e t wo fr on t sea t s a n d r equ ir es a
equ a lizer (F ig. 95).
specia l fr on t ca ble.
OPERATION
Th e a u t om a t ic-a dju st in g fea t u r e in t h e foot oper-
a t ed pa r kin g br a ke lever con t in u ou sly a pplies m in i-
m a l t en sion t o t h e pa r kin g br a ke ca bles wh en t h e
pa r kin g br a ke lever is in t h e r elea sed posit ion t o
keep t h em in a dju st m en t a t a ll t im es. Du e t o t h is
fea t u r e, t h e pa r kin g br a ke ca bles r equ ir e n o per iodic
a dju st m en t .
Wh en t h e pa r kin g br a ke lever is a pplied, t h e
ca bles a r e pu lled, t h u s a pplyin g t h e br a ke sh oes
(r ea r dr u m br a kes) or pa r kin g br a ke sh oes (r ea r disc
br a kes) a t ea ch r ea r wh eel.
Th e br a ke sh oes a r e m ech a n ica lly oper a t ed by a n
in t er n a l lever a n d st r u t con n ect ed t o t h e r ea r pa r k-
in g br a ke ca bles.
An equ a lizer br a cket is u sed a t t h e r ea r en d of t h e
fr on t pa r kin g br a ke ca ble t o dist r ibu t e t en sion
equ a lly t o ea ch pa r kin g br a ke ca ble.
Fig. 95 Location To Grasp Cable At
(b) Gr a sp t h e equ a lizer a n d pu ll r ea r wa r d on it
u n t il en ou gh sla ck is pr esen t t o discon n ect t h e
equ a lizer fr om fr on t or r ea r ca bles. Wh ile h oldin g
t h e fr on t ca ble in t h is posit ion u sin g t h e lockin g
plier s, discon n ect t h e equ a lizer fr om ca bles (F ig.
96).
Fig. 97 Locking Out Automatic Adjuster

3 - LOCKING PLIERS
Fig. 96 Parking Brake Cable Equalizer

1 - INTERMEDIATE BRACKET
2 - EQUALIZER
3 - LEFT REAR CABLE
4 - RIGHT REAR CABLE
5 - FRONT CABLE
(c) E a se u p on t h e fr on t ca ble t en sion a llowin g

t h e lever a u t om a t ic self-a dju st in g m ech a n ism t o
pu ll t h e fr on t ca ble st r a n d for wa r d. Th is a ct ion
a llows t h e a dju st er m ech a n ism t o r ot a t e a r ou n d t o
it s st op, r em ovin g t en sion fr om t h e a dju st er a n d
fr on t pa r kin g br a ke ca ble. Fig. 98 Parking Brake Cable Attachment To
(d) Rem ove t h e lockin g plier s fr om t h e fr on t Equalizer
pa r kin g br a ke ca ble a s n ecessa r y. 1 - EQUALIZER
2 - LEFT REAR PARKING BRAKE CABLE
(4) If n ot equ ipped wit h F old-in -floor sea t in g, per- 3 - LOCKING NUT
for m t h e followin g: 4 - INTERMEDIATE PARKING BRAKE CABLE
(a ) Gr a sp t h e exposed sect ion of t h e fr on t pa r k- 5 - FRONT PARKING BRAKE CABLE
in g br a ke ca ble a n d pu ll r ea r wa r d on it .
(b) Wh ile h oldin g t h e ca ble in t h is posit ion , STANDARD PROCEDURE - PARKING BRAKE
(c) Cla m p a n a ppr opr ia t e pa ir of lockin g plier s AUTOMATIC ADJUSTER TENSION RESET
on t h e fr on t pa r kin g br a ke ca ble st r a n d ju st r ea r-
wa r d of t h e secon d body ou t r igger br a cket (F ig. NOTE: This procedure is designed for vehicles
97). without Fold-in-floor seating.
(d) Discon n ect t h e pa r kin g br a ke ca bles fr om t h e
pa r kin g br a ke ca ble equ a lizer (F ig. 98). Th e pa r kin g br a ke lever (peda l) m ech a n ism u sed
(e) Rem ove t h e lockin g plier s fr om t h e fr on t in t h is veh icle is design ed so t h a t t h e a u t om a t ic
pa r kin g br a ke ca ble a s n ecessa r y. Th is a ct ion a dju st er is n ot r equ ir ed t o be locked ou t wh en ser vic-
a llows t h e a dju st er m ech a n ism t o r ot a t e a r ou n d t o in g t h e pa r kin g br a ke lever (peda l) or t h e pa r kin g
it s st op, r em ovin g t en sion fr om t h e a dju st er a n d br a ke ca bles.
fr on t pa r kin g br a ke ca ble. (1) Gr a sp t h e exposed sect ion of t h e fr on t pa r kin g
br a ke ca ble a n d pu ll r ea r wa r d on it . Wh ile h oldin g
t h e pa r k br a ke in t h is posit ion , in st a ll a pa ir of lock- Th is pr ocedu r e a pplies t o t h e t r a ilin g en d of a ll pa r k-
in g plier s on t h e fr on t pa r kin g br a ke ca ble ju st r ea r- in g br a ke ca bles.
wa r d of t h e secon d body ou t r igger br a cket (F ig. 97).
(2) In st a ll t h e equ a lizer on t h e fr on t pa r kin g br a ke CAUTION: If a liquid cleaner is necessary, use a
ca ble. cleaner such as Mopar" Non-Chlorinated Brake
(3) In st a ll t h e left r ea r a n d in t er m edia t e pa r k Parts Cleaner or equivalent.
br a ke ca ble in t h e cor r ect loca t ion on t h e pa r kin g
br a ke ca ble equ a lizer (F ig. 98). (1) Usin g a n a ppr opr ia t e br ist le br u sh , clea n t h e
(4) Rem ove t h e lockin g plier s fr om t h e fr on t pa r k- ca ble st r a n d in t h e a r ea t h a t r et r a ct s in t o t h e ca ble
in g br a ke ca ble. Th is will a llow t h e a dju st er in t h e h ou sin g wh en t h e pa r kin g br a ke lever is a pplied (F ig.
pa r k br a ke lever (peda l) m ech a n ism t o t en sion t h e 99).
pa r k br a ke ca bles. (2) Clea n t h e ca ble sea l a r ea a t t h e en d of t h e
(5) Apply a n d r elea se t h e pa r kin g br a ke lever ca ble h ou sin g (F ig. 99).
(peda l) on e t im e. Th is will sea t t h e pa r kin g br a ke (3) Lu br ica t e t h e clea n ed a r ea wit h a gen er a l pu r-
ca bles a n d a llow t h e a u t o a dju st er in t h e pa r kin g pose gr ea se lu br ica n t .
br a ke lever (peda l) m ech a n ism t o cor r ect ly t en sion
t h e pa r kin g br a ke ca bles. ADJ U ST M EN T S
STANDARD PROCEDURE - CABLE END ADJUSTMENT - PARKING BRAKE CABLES
CLEANING AND LUBRICATION Th e pa r k br a ke ca bles on t h is veh icle h a ve a n
a u t om a t ic self a dju st er bu ilt in t o t h e pa r k br a ke
peda l m ech a n ism . Wh en t h e foot oper a t ed pa r k br a ke
peda l is in it s r elea sed (u pwa r d m ost ) posit ion , a
clock spr in g a u t om a t ica lly a dju st s t h e pa r k br a ke
ca bles. Th e pa r k br a ke ca bles a r e a dju st ed (t en -
sion ed) ju st en ou gh t o r em ove a ll t h e sla ck fr om t h e
ca bles. Th e a u t om a t ic a dju st er syst em will n ot over
a dju st t h e ca bles ca u sin g r ea r br a ke dr a g.
Du e t o t h e a u t om a t ic a dju st fea t u r e of t h e pa r k
br a ke peda l, a dju st m en t of t h e pa r kin g br a ke ca bles
on t h ese veh icles r elies on pr oper dr u m br a ke a n d
pa r k br a ke sh oe a dju st m en t . (Refer t o 5 - BRAKE S/
H YDRAULIC/ME CH ANICAL/DRUM - ADJ UST-
ME NTS) a n d (Refer t o 5 - BRAKE S/PARKING
BRAKE /SH OE S - ADJ USTME NTS).
Wh en t h e pa r k br a ke peda l is a pplied t h e self
a dju st er is by-pa ssed a n d t h e peda l oper a t es n or-
m a lly t o en ga ge t h e pa r k br a kes.
Wh en a ser vice pr ocedu r e n eeds t o be per for m ed on
Fig. 99 Areas To Be Cleaned And Lubricated t h e pa r k br a ke peda l or t h e pa r k br a ke ca bles, t h e
1 - STRAND AREA a u t om a t ic self a dju st er ca n be m a n u a lly locked ou t
2 - SEAL AREA by t h e ser vice t ech n icia n .
P er iodic clea n in g a n d lu br ica t ion ca n be don e t o

en su r e pr oper oper a t ion of t h e pa r kin g br a ke ca bles.
CABLE - PARK I N G BRAK E

FRON T
REM OVAL
REMOVAL
LUBRICATION & MAINTE NANCE /H OISTING -
STANDARD P ROCE DURE ).
(2) Ma n u a lly r elea se t h e a u t om a t ic self-a dju st in g
m ech a n ism t en sion of t h e pa r kin g br a ke lever (peda l)
a ssem bly. (Refer t o 5 - BRAKE S - STANDARD P RO-
CE DURE ).
(3) Rem ove t h e in t er m edia t e a n d left r ea r pa r k br a ke
ca ble fr om t h e pa r k br a ke ca ble equ a lizer (F ig. 100). Fig. 101 Front Park Brake Cable Attachment To
Body
1 - CABLE HOUSING RETAINER
2 - BODY OUTRIGGER BRACKET
3 - PUSH WRENCH OVER END OF RETAINER HERE
4 - FRONT PARK BRAKE CABLE
Fig. 100 Park Brake Cable Attachment To Equalizer

1 - EQUALIZER
3 - LOCKING NUT
4 - INTERMEDIATE PARKING BRAKE CABLE
5 - FRONT PARKING BRAKE CABLE
Fig. 102 Front Park Brake Cable At Floor Pan
(4) Rem ove t h e fr on t pa r k ca ble h ou sin g r et a in er 1 - PARK BRAKE PEDAL ASSEMBLY
2 - PARK BRAKE PEDAL
fr om body ou t r igger br a cket (F ig. 101). Ca ble is 3 - CARPET
r em ova ble by slidin g a 14 m m box wr en ch over ca ble 4 - FRONT PARK BRAKE CABLE
r et a in er a n d com pr essin g t h e t h r ee r et a in in g fin ger s. 5 - SEAL
6 - FLOOR PAN
Alt er n a t e m et h od is t o u se a n a ir cr a ft t ype h ose
cla m p a n d scr ewdr iver. (11) P u ll fr on t pa r kin g br a ke ca ble a ssem bly ou t of
(5) Lower veh icle. veh icle t h r ou gh h ole in floor pa n .
(6) Rem ove t h e left fr on t door sill m oldin g.
(7) Rem ove t h e left fr on t kick pa n el for a ccess t o REMOVAL - FOLD-IN-FLOOR SEATING
t h e pa r k br a ke ca ble a n d pa r k br a ke peda l a ssem bly.
(8) Lift floor m a t for a ccess t o pa r k br a ke ca ble
a n d floor pa n . P u ll t h e sea l a n d t h e pa r k br a ke ca ble
(F ig. 102) ou t of t h e floor pa n of veh icle.
(9) P u ll pa r kin g br a ke ca ble st r a n d en d for wa r d
(3) Ma n u a lly r elea se t h e a u t om a t ic self-a dju st in g
a n d discon n ect bu t t on fr om clevis. Ta p ca ble h ou sin g
en d fit t in g ou t of peda l a ssem bly br a cket .
(10) Rem ove ca ble r et a in er fr om t h e pa r kin g br a ke
CE DURE ).
lever (peda l) a ssem bly br a cket .
CABLE - PARK I N G BRAK E FRON T (Cont inue d)
(4) Rem ove t h e fr on t ca ble fr om t h e equ a lizer (F ig. (7) P la ce a 13 m m 12-poin t box wr en ch over t h e
103). ca ble r et a in er a t t h e in t er m edia t e br a cket a s sh own
t o colla pse t h e r et a in er fin ger s (F ig. 105).

2 - EQUALIZER Fig. 105 Cable Removal Using Wrench
3 - LEFT REAR CABLE 1 - CABLE RETAINER
4 - RIGHT REAR CABLE 2 - 12-POINT BOX WRENCH
5 - FRONT CABLE
(8) P u ll t h e ca ble ou t of t h e in t er m edia t e br a cket .

(5) Rem ove t h e lockin g plier s fr om t h e ca ble t h a t
wer e in st a lled du r in g St ep 3.
(10) Rem ove t h e left fr on t door sill m oldin g.
(6) Rem ove t h e fr on t ca ble fr om t h e r ou t in g clips
(11) Rem ove t h e left fr on t kick pa n el.
fa st en ed t o t h e u n der body of t h e veh icle (F ig. 104).
(12) P u ll t h e pa r kin g br a ke ca ble st r a n d for wa r d
a n d discon n ect t h e en d bu t t on fr om t h e lever (peda l)
a ssem bly m ech a n ism r eel (F ig. 106).
(13) Slide t h e ca ble ou t of t h e lever br a cket .
(14) Lift ba ck t h e ca r pet a n d pu ll t h e ca ble sea l
loose fr om t h e floor pa n (F ig. 102).
(15) P u ll t h e fr on t pa r kin g br a ke ca ble a ssem bly
ou t of t h e veh icle t h r ou gh t h e h ole in t h e floor pa n .
REMOVAL - EXPORT
(Refer t o 5 - BRAKE S - BASE /PARKING BRAKE /
LE VE R - RE MOVAL)
I N STALLAT I ON
INSTALLATION
(1) P a ss fr on t pa r kin g br a ke ca ble a ssem bly
t h r ou gh h ole in floor pa n fr om t h e in side of t h e veh i-
cle.
Fig. 104 Front Parking Brake Cable Routing (2) P a ss ca ble st r a n d bu t t on t h r ou gh t h e h ole in
1 - SCREW t h e lever (peda l) a ssem bly br a cket .
2 - ROUTING BRACKET (3) In st a ll ca ble r et a in er on t o t h e pa r k br a ke ca ble
3 - SCREW
a n d t h en in st a ll ca ble r et a in er in t o peda l a ssem bly
5 - FRONT CABLE br a cket .
6 - ROUTING BRACKET
CABLE - PARK I N G BRAK E FRON T (Cont inue d)
(4) In st a ll ca ble st r a n d bu t t on in t o t h e r eel on t h e
pa r kin g br a ke lever m ech a n ism (F ig. 106).
(5) In st a ll t h e fr on t pa r kin g br a ke ca ble floor pa n
sea l in t o t h e h ole in t h e floor pa n . Th e sea l fla n ge
sh ou ld be flu sh wit h t h e floor pa n (F ig. 102).
(6) Reposit ion t h e ca r pet in g ba ck down on t h e
floor.
(7) In st a ll t h e left fr on t kick pa n el.
(8) In st a ll t h e left fr on t door sill m oldin g.
(9) Ra ise a n d su ppor t t h e veh icle.
(10) P a ss t h e en d of t h e ca ble t h r ou gh t h e h ole in
t h e en d of t h e in t er m edia t e br a cket (F ig. 104). P r ess
t h e ca ble h ou sin g r et a in er t h r ou gh t h e h ole u n t il t h e
fin ger s on t h e r et a in er lock it in t o pla ce.
(11) At t a ch t h e fr on t ca ble t o t h e r ou t in g clips fa s-
t en ed t o t h e u n der body of t h e veh icle (F ig. 104).
(12) Cla m p a n a ppr opr ia t e pa ir of lockin g plier s on
t h e fr on t ca ble st r a n d a ppr oxim a t ely 25 m m (1 in ch )
for wa r d of t h e bu t t on (F ig. 107).
Fig. 106 Parking Brake Lever Assembly
1 - WIRING CONNECTOR
2 - MECHANISM REEL
3 - FRONT CABLE STRAND
4 - AUTO-ADJUST LOCKOUT PIN
5 - INDICATOR LAMP SWITCH
(4) In st a ll t h e en d of t h e pa r k br a ke ca ble in t o t h e
r et a in er pr eviou sly in st a lled in t o t h e pa r k br a ke
peda l br a cket .
(5) In st a ll ca ble st r a n d bu t t on in t o t h e clevis on
t h e pa r k br a ke peda l m ech a n ism .
(6) In st a ll t h e fr on t pa r k br a ke ca ble floor pa n sea l
in t o h ole in floor pa n . Sea l is t o be in st a lled so t h e
fla n ge on t h e sea l is flu sh wit h t h e floor pa n (F ig.
102). F old ca r pet in g ba ck down on floor.
(7) Ra ise veh icle.
(8) In ser t br a ke ca ble a n d h ou sin g in t o body ou t -
r igger br a cket m a kin g cer t a in t h a t h ou sin g r et a in er
fin ger s lock t h e h ou sin g fir m ly in t o pla ce (F ig. 101).
(9) Ma n u a lly r eset t h e a u t om a t ic self-a dju st in g Fig. 107 Location To Grasp Cable At
a ssem bly. (Refer t o 5 - BRAKE S - STANDARD P RO- (13) P u ll st r a igh t ba ck on t h e fr on t ca ble bu t t on
CE DURE ). (a n d plier s) a n d pr oper ly a t t a ch t h e equ a lizer t o a ll
(10) Assem ble t h e pa r k br a ke ca bles on t o t h e pa r k t h r ee pa r kin g br a ke ca bles (F ig. 103).
br a ke ca ble equ a lizer (F ig. 100). (14) Rem ove t h e lockin g plier s fr om t h e fr on t pa r k-
(11) Lower veh icle a n d a pply t h e pa r k br a ke peda l in g br a ke ca ble a n d a llow t h e a u t om a t ic self-a dju st -
1 t im e. Th is will sea t t h e pa r kin g br a ke ca bles. in g m ech a n ism in t h e lever t o t a ke u p a n y sla ck.
INSTALLATION - FOLD-IN-FLOOR SEATING (16) Apply a n d r elea se pa r k br a ke peda l 1 t im e.
(1) P a ss m ost of t h e fr on t pa r kin g br a ke ca ble Th is will sea t t h e pa r kin g br a ke ca bles.
a ssem bly down t h r ou gh h ole in t h e floor pa n fr om
in side t h e veh icle. INSTALLATION - EXPORT
(2) P a ss t h e lever-en d ca ble st r a n d bu t t on t h r ou gh (Refer t o 5 - BRAKE S - BASE /PARKING BRAKE /
t h e h ole in t h e lever (peda l) a ssem bly br a cket . LE VE R - INSTALLATION)
(3) In st a ll t h e en d of t h e ca ble h ou sin g in t o t h e
r et a in er in st a lled in t o t h e pa r k br a ke peda l br a cket .
CABLE - PARK I N G BRAK E

I N T ERM EDI AT E
REMOVAL
(2) Ma n u a lly lock ou t t h e a u t om a t ic self-a dju st in g
CE DURE ). On ce t h e ca ble is r elea sed fr om t h e equ a l-
izer, do n ot r em ove t h e lockin g plier s u n t il
r ein st a lla t ion of t h e ca ble is com plet e.
(3) Rem ove t h e in t er m edia t e pa r kin g br a ke ca ble
fr om t h e pa r kin g br a ke ca ble equ a lizer (F ig. 108). Fig. 109 Intermediate Cable Attachment To Right
1 - RIGHT REAR PARKING BRAKE CABLE
2 - LOCKING NUT
INSTALLATION
(1) In st a ll t h e en ds of t h e pa r k br a ke ca bles
t h r ou gh t h e fr a m e r a ils a n d in t o t h e side br a cket s.
(2) In st a ll t h e lockin g n u t s a t ea ch en d of t h e ca ble
a n d secu r ely t igh t en (F ig. 108) (F ig. 109).
(3) If t h e veh icle is a sh or t -wh eel-ba se m odel, it
will be n ecessa r y t o r ein st a ll t h e fu el t a n k t o it s n or-
m a l m ou n t in g posit ion . (Refer t o 14 - F UE L SYS-
TE M/F UE L DE LIVE RY/F UE L TANK -
INSTALLATION).
(4) In st a ll t h e in t er m edia t e pa r kin g br a ke ca ble on
t h e ca ble con n ect or a t t h e r igh t r ea r pa r kin g br a ke
Fig. 108 Parking Brake Cable Attachment To ca ble (F ig. 109).
Equalizer (5) In st a ll t h e in t er m edia t e pa r k br a ke ca ble on
1 - EQUALIZER t h e ca ble equ a lizer (F ig. 108).
2 - LEFT REAR PARKING BRAKE CABLE (6) Rem ove t h e lockin g plier s fr om t h e fr on t pa r k
3 - LOCKING NUT br a ke ca ble. Th is will a ct iva t e t h e a u t om a t ic a dju st er
5 - FRONT PARKING BRAKE CABLE a n d cor r ect ly a dju st t h e pa r kin g br a ke ca bles.
(7) In st a ll a n d posit ion t h e foa m colla r on t h e
(4) Rem ove t h e lockin g n u t secu r in g t h e in t er m e- pa r kin g br a ke ca ble t o pr even t it fr om r a t t lin g
dia t e ca ble h ou sin g t o t h e side br a cket on t h e fr a m e a ga in st t h e veh icle’s floor.
r a il (F ig. 108). (8) Lower t h e veh icle a n d a pply t h e pa r k br a ke
(5) Rem ove t h e in t er m edia t e pa r kin g br a ke ca ble peda l 1 t im e, t h is will sea t t h e pa r k br a ke ca bles.
fr om t h e ca ble con n ect or a t t a ch in g it t o t h e r igh t
r ea r pa r kin g br a ke ca ble (F ig. 109). Rem ove t h e lock-
in g n u t secu r in g t h e in t er m edia t e ca ble h ou sin g t o
t h e side br a cket on t h e fr a m e r a il (F ig. 109).
(6) If t h e veh icle is a sh or t -wh eel-ba se m odel, it
will be n ecessa r y t o loosen a n d lower t h e fu el t a n k
fa r en ou gh t o r em ove t h e in t er m edia t e pa r kin g br a ke
ca ble. (Refer t o 14 - F UE L SYSTE M/F UE L DE LIV-
E RY/F UE L TANK - RE MOVAL).
(7) Rem ove t h e in t er m edia t e pa r kin g br a ke ca ble
fr om t h e side br a cket s a n d veh icle.
CABLE - PARK I N G BRAK E (5) Discon n ect t h e r igh t r ea r pa r kin g br a ke ca ble

fr om t h e con n ect or on t h e in t er m edia t e ca ble (F ig.
REAR 111).
REM OVAL
REMOVAL - RIGHT REAR
(2) Rem ove r ea r t ir e a n d wh eel a ssem bly.
(3) Rem ove r ea r br a ke dr u m fr om t h e r ea r wh eel
of t h e veh icle r equ ir in g ser vice t o t h e r ea r pa r k
br a ke ca ble.
(4) Cr ea t e sla ck in t h e r ea r pa r kin g br a ke ca bles
by lockin g ou t t h e a u t om a t ic a dju st er a s descr ibed
h er e. Gr a sp a n exposed sect ion of fr on t pa r kin g
br a ke ca ble n ea r t h e equ a lizer a n d pu ll down on it .
At t h is t im e in st a ll a pa ir of lockin g plier s on t h e Fig. 111 Right Rear Cable Connection To
ca ble ju st r ea r wa r d of t h e secon d body ou t r igger Intermediate Cable
br a cket (F ig. 110). 1 - RIGHT REAR PARKING BRAKE CABLE
2 - LOCKING NUT
(6) To r em ove t h e r igh t pa r kin g br a ke ca ble h ou s-

in g fr om t h e body br a cket , slide a 14 m m box en d
wr en ch over t h e en d of ca ble r et a in er t o com pr ess t h e
r et a in in g fin ger s (F ig. 112). Th e a lt er n a t e m et h od
u sin g a n a ir cr a ft t ype h ose cla m p will n ot wor k on
t h e r igh t side of t h e veh icle.
Fig. 110 Locking Out Automatic Adjuster

3 - LOCKING PLIERS
Fig. 112 Right Park Brake Cable Removal From

Body Bracket
1 - RIGHT REAR BODY BRACKET
3 - 14MM WRENCH
4 - LEAF SPRING AND BRACKET
CABLE - PARK I N G BRAK E REAR (Cont inue d)
(7) Rem ove t h e br a ke sh oes fr om t h e br a ke su p-
CH ANICAL/BRAKE PADS/SH OE S - RE MOVAL).
(8) Discon n ect pa r kin g br a ke ca ble fr om pa r kin g
br a ke a ct u a t or lever.
(9) Rem ove t h e pa r kin g br a ke ca ble h ou sin g
r et a in er fr om t h e br a ke su ppor t pla t e u sin g a 14m m
wr en ch t o com pr ess t h e r et a in in g fin ger s (F ig. 113).
Rem ove t h e ca ble.
Fig. 114 Locked Out Park Brake Automatic Adjuster

3 - LOCKING PLIERS
Fig. 113 Removing Park Brake Cable From Brake

Support Plate
1 - PARK BRAKE CABLE RETAINER
3 - 14MM BOX WRENCH
REMOVAL - LEFT REAR

(2) Rem ove r ea r t ir e a n d wh eel a ssem bly. Fig. 115 Parking Brake Cables At Equalizer
(3) Rem ove r ea r br a ke dr u m fr om t h e r ea r wh eel 1 - EQUALIZER
of t h e veh icle r equ ir in g ser vice t o t h e r ea r pa r k 2 - LEFT REAR PARKING BRAKE CABLE
br a ke ca ble. 3 - LOCKING NUT
(4) Cr ea t e sla ck in r ea r pa r k br a ke ca bles by lock- 5 - FRONT PARKING BRAKE CABLE
in g ou t t h e a u t om a t ic a dju st er a s descr ibed h er e.
Gr a sp a n exposed sect ion of fr on t pa r k br a ke ca ble
n ea r t h e equ a lizer a n d pu ll down on it . Th en in st a ll
a pa ir of lockin g plier s on t h e ca ble ju st r ea r wa r d of
t h e secon d body ou t r igger br a cket (F ig. 114).
(5) Discon n ect t h e left r ea r pa r kin g br a ke ca ble
fr om t h e pa r kin g br a ke ca ble equ a lizer (F ig. 115).
(6) To r em ove pa r kin g br a ke ca ble h ou sin g fr om
t h e body br a cket , slide a 14 m m box en d wr en ch over
r et a in er en d com pr essin g t h e t h r ee fin ger s (F ig. 116).
Alt er n a t e m et h od is t o u se a n a ir cr a ft t ype h ose
cla m p.
Fig. 117 Removing Parking Brake Cable From Brake

Support Plate
1 - PARK BRAKE CABLE RETAINER
3 - 14MM BOX WRENCH
Fig. 116 Parking Brake Cable Removal From Body
Bracket
1 - LEFT REAR PARK BRAKE CABLE
2 - BODY BRACKET
3 - LEAF SPRING MOUNTING BRACKET
4 - CABLE RETAINER
5 - 14MM BOX WRENCH
(7) Rem ove t h e br a ke sh oes fr om t h e br a ke su p-

CH ANICAL/BRAKE PADS/SH OE S - RE MOVAL).
(8) Discon n ect pa r kin g br a ke ca ble fr om pa r kin g
br a ke a ct u a t or lever.
(9) Rem ove t h e pa r kin g br a ke ca ble h ou sin g
r et a in er fr om t h e br a ke su ppor t pla t e u sin g a 14m m
wr en ch t o com pr ess t h e r et a in in g fin ger s (F ig. 117).
REMOVAL - FOLD-IN-FLOOR SEATING

STANDARD P ROCE DURE ) Fig. 118 Parking Brake Cable Equalizer
(3) Ma n u a lly r elea se t h e a u t om a t ic self-a dju st in g 1 - INTERMEDIATE BRACKET
m ech a n ism t en sion of t h e pa r kin g br a ke lever (peda l) 2 - EQUALIZER
3 - LEFT REAR CABLE
a ssem bly. (Refer t o 5 - BRAKE S - STANDARD P RO- 4 - RIGHT REAR CABLE
CE DURE ) 5 - FRONT CABLE
(4) Rem ove t h e equ a lizer (F ig. 118).
(5) Rem ove t h e ca ble fr om t h e r ou t in g br a cket fa s-
t en ed t o t h e u n der body of t h e veh icle (F ig. 119).
(6) If t h e r igh t r ea r ca ble is bein g ser viced, r em ove
t h e scr ews fa st en in g t h e ca ble r ou t in g cla m ps t o t h e
r ea r a xle (F ig. 120).
Fig. 119 Left Rear Cable Routing

1 - ROUTING BRACKET 3 - RIGHT REAR CABLE
2 - LEFT REAR CABLE 4 - SCREW
Fig. 120 Right Rear Cable Routing

1 - SCREWS 3 - REAR AXLE
2 - ROUTING CLAMPS
(7) Rem ove t h e scr ew fa st en in g t h e ca ble t o t h e (11) P u ll t h e ca ble ou t of t h e in t er m edia t e br a cket
r ea r br a ke a da pt er (F ig. 121). a n d r em ove it fr om t h e veh icle (F ig. 123).
Fig. 121 Cable End At Shoe Lever Fig. 123 Cable Intermediate Bracket
1 - SHOE LEVER 1 - FRONT CABLE
2 - SCREW 2 - INTERMEDIATE BRACKET
3 - PARKING BRAKE CABLE 3 - LEFT REAR CABLE
4 - CABLE EYELET 4 - RIGHT REAR CABLE
5 - SCREW
(8) Un h ook t h e ca ble eyelet fr om t h e sh oe lever
(F ig. 121). I N STALLAT I ON
(9) Slide t h e ca ble ou t of t h e br a ke a da pt er.
(10) P la ce a 13 m m 12-poin t box wr en ch over t h e INSTALLATION - RIGHT REAR
ca ble r et a in er a t t h e in t er m edia t e br a cket a s sh own (1) In st a ll t h e r ea r pa r kin g br a ke ca ble in t h e
t o colla pse t h e r et a in er fin ger s (F ig. 122). br a ke su ppor t pla t e. In ser t ca ble h ou sin g r et a in er
in t o br a ke su ppor t pla t e m a kin g cer t a in t h a t ca ble
h ou sin g r et a in er fin ger s lock t h e h ou sin g a n d
r et a in er fir m ly in t o pla ce.
(2) At t a ch t h e pa r kin g br a ke ca ble on t o t h e pa r k-
in g br a ke a ct u a t or lever.
(3) In st a ll t h e br a ke sh oes on t h e r ea r br a ke su p-
CH ANICAL/BRAKE PADS/SH OE S -
INSTALLATION).
(4) In ser t ca ble h ou sin g r et a in er in t o body ou t r ig-
ger br a cket m a kin g cer t a in t h a t ca ble h ou sin g
r et a in er fin ger s lock t h e h ou sin g fir m ly in t o pla ce.
(5) Con n ect t h e r igh t r ea r pa r kin g br a ke ca ble t o
t h e con n ect or on t h e in t er m edia t e pa r kin g br a ke
ca ble (F ig. 111).
(6) In st a ll t h e br a ke dr u m , t h en t h e wh eel a n d t ir e
a ssem bly.
(7) Rem ove t h e lockin g plier s fr om t h e fr on t pa r k
br a ke ca ble. Th is will a u t om a t ica lly a dju st t h e pa r k
Fig. 122 Cable Removal Using Wrench br a ke ca bles.
1 - CABLE RETAINER
2 - 12-POINT BOX WRENCH (9) Apply a n d r elea se pa r k br a ke peda l 1 t im e.
Th is will sea t t h e pa r k br a ke ca bles.
INSTALLATION - LEFT REAR LEV ER - PARK I N G BRAK E

(1) In st a ll t h e r ea r pa r kin g br a ke ca ble in t h e
br a ke su ppor t pla t e. In ser t ca ble h ou sin g r et a in er REMOVAL
in t o br a ke su ppor t pla t e m a kin g cer t a in t h a t ca ble (1) Ma n u a lly r elea se t h e a u t om a t ic self-a dju st in g
h ou sin g r et a in er fin ger s lock t h e h ou sin g a n d m ech a n ism t en sion of t h e pa r kin g br a ke lever (peda l)
r et a in er fir m ly in t o pla ce. a ssem bly. (Refer t o 5 - BRAKE S/PARKING BRAKE -
(2) At t a ch t h e pa r kin g br a ke ca ble on t o t h e pa r k STANDARD P ROCE DURE ).
br a ke a ct u a t or lever. (2) Discon n ect n ega t ive (gr ou n d) ca ble fr om t h e
(3) In st a ll t h e br a ke sh oes on t h e r ea r br a ke su p- ba t t er y a n d isola t e ca ble fr om ba t t er y t er m in a l.
por t pla t e. (Refer t o 5 - BRAKE S/H YDRAULIC/ME - (3) Rem ove sill scu ff pla t e fr om left door sill.
CH ANICAL/BRAKE PADS/SH OE S - (4) Rem ove t h e left side kick pa n el.
INSTALLATION). (5) Rem ove t h e st eer in g colu m n cover fr om t h e
(4) In ser t ca ble h ou sin g r et a in er in t o body ou t r ig- lower in st r u m en t pa n el.
ger br a cket m a kin g cer t a in t h a t ca ble h ou sin g (6) Rem ove t h e r ein for cem en t fr om t h e lower
r et a in er fin ger s lock t h e h ou sin g fir m ly in t o pla ce. in st r u m en t pa n el.
(5) Con n ect r ea r pa r kin g br a ke ca ble t o t h e equ a l- (7) Rem ove t h e t h r ee bolt s m ou n t in g t h e wir in g
izer br a cket (F ig. 115). ju n ct ion block t o t h e in st r u m en t pa n el.
(6) In st a ll br a ke dr u m , a n d wh eel a n d t ir e a ssem -
bly. NOTE: When removing the lower mounting bolt,
(7) Rem ove t h e lockin g plier s fr om t h e fr on t pa r k push the park brake pedal down 5 clicks to access
br a ke ca ble. Th is will a u t om a t ica lly a dju st t h e pa r k the lower mounting bolt.
br a ke ca bles.
(8) Apply a n d r elea se pa r k br a ke peda l 1 t im e. (8) Rem ove t h e lower bolt m ou n t in g t h e pa r kin g
Th is will sea t t h e pa r k br a ke ca bles. br a ke lever (peda l) t o t h e body (F ig. 124).
(9) Rem ove t h e for wa r d n u t m ou n t in g t h e pa r kin g
INSTALLATION - FOLD-IN-FLOOR SEATING br a ke lever t o t h e body (F ig. 124).
(1) P a ss t h e lea din g en d of t h e r ea r pa r kin g br a ke (10) Rem ove t h e u pper bolt m ou n t in g t h e pa r kin g
ca ble t h r ou gh t h e h ole in t h e en d of t h e in t er m edia t e br a ke lever t o t h e body (F ig. 124).
br a cket (F ig. 123). P r ess t h e ca ble h ou sin g r et a in er
t h r ou gh t h e h ole u n t il t h e fin ger s on t h e r et a in er
lock it in t o pla ce.
(2) Rou t e t h e ca ble ba ck t owa r d t h e br a ke a ssem -
bly pla cin g it in t h e r ou t in g clip fa st en ed t o t h e
u n der body of t h e veh icle (F ig. 119). Ma ke su r e t o
st a y t o t h e in side of t h e left st a bilizer ba r lin k wh ile
r ou t in g eit h er ca ble.
(3) If t h e r igh t r ea r ca ble is bein g ser viced, in st a ll
scr ews, a t t a ch in g t h e ca ble r ou t in g cla m ps t o t h e
r ea r a xle (F ig. 120).
(4) P a ss t h e ca ble t h r ou gh t h e h ole in t h e br a ke
a da pt er a n d h ook t h e ca ble eyelet t o t h e sh oe lever
(F ig. 121).
(5) In st a ll t h e scr ew fa st en in g t h e ca ble t o t h e r ea r
br a ke a da pt er (F ig. 121).
(6) P u ll st r a igh t ba ck on t h e fr on t ca ble bu t t on Fig. 124 Parking Brake Lever Mounting
(a n d plier s) a n d pr oper ly a t t a ch t h e equ a lizer t o a ll 1 - WIRE HARNESS CONNECTOR
t h r ee pa r kin g br a ke ca bles (F ig. 118). 2 - LEVER MECHANISM
(7) Rem ove t h e lockin g plier s fr om t h e fr on t pa r k- 3 - FRONT CABLE
in g br a ke ca ble a n d a llow t h e a u t om a t ic self-a dju st -
in g m ech a n ism in t h e lever t o t a ke u p a n y sla ck. (11) P u ll down wa r d on fr on t pa r kin g br a ke ca ble
(8) Lower t h e veh icle. wh ile r ot a t in g lever a ssem bly ou t fr om beh in d ju n c-
(9) Apply a n d r elea se pa r k br a ke peda l 1 t im e. t ion block.
Th is will sea t t h e pa r kin g br a ke ca bles. (12) Rem ove t h e r elea se lin k fr om t h e pa r kin g
br a ke lever a ssem bly.
(13) Discon n ect t h e wir in g con n ect or fr om t h e in di-
ca t or la m p gr ou n d swit ch (F ig. 124) (F ig. 125).
LEV ER - PARK I N G BRAK E (Cont inue d)
(14) Rem ove fr on t pa r kin g br a ke ca ble st r a n d bu t - (7) Loosely in st a ll t h e for wa r d n u t m ou n t in g t h e
t on fr om t h e lever m ech a n ism r eel (F ig. 125). lever t o t h e body (F ig. 124).
(8) Loosely in st a ll t h e lower bolt m ou n t in g t h e
lever t o t h e body (F ig. 124).
(9) Tigh t en lever m ou n t in g bolt s a n d n u t t o 28
N·m (250 in . lbs.).
(10) Ver ify t h a t t h e pa r kin g br a ke lever is in t h e
fu lly r elea sed (fu ll u p) posit ion .
(12) In st a ll t h e fr on t pa r kin g br a ke ca ble on t h e
ca ble equ a lizer. If a n ew lever a ssem bly is NOT bein g
in st a lled, per for m PARKING BRAKE AUTOMATIC
ADJ USTE R TE NSION RE SE T a s n ecessa r y. (Refer
t o 5 - BRAKE S/PARKING BRAKE - STANDARD
P ROCE DURE )
NOTE: If the original lever assembly is being used,

the lever mechanism auto adjuster spring tension
will need to be reset.

(14) If a n ew lever is bein g in st a lled, r em ove t h e
Fig. 125 Parking Brake Lever Assembly lockou t pin fr om t h e a u t om a t ic a dju st er on t h e pa r k-
1 - WIRING CONNECTOR in g br a ke lever m ech a n ism a llowin g t h e a u t om a t ic
2 - MECHANISM REEL
3 - FRONT CABLE STRAND
self-a dju st in g m ech a n ism in t h e lever t o t a ke u p a n y
4 - AUTO-ADJUST LOCKOUT PIN sla ck (F ig. 125).
5 - INDICATOR LAMP SWITCH (15) In st a ll t h e elect r ica l ju n ct ion block on t h e
in st r u m en t pa n el.
(15) Rem ove t h e pa r kin g br a ke lever a ssem bly (16) In st a ll t h e r ein for cem en t on t h e lower in st r u -
fr om t h e ca ble. m en t pa n el.
(17) In st a ll t h e st eer in g colu m n lower cover on t h e
INSTALLATION lower in st r u m en t pa n el.
(1) In st a ll t h e pa r kin g br a ke ca ble en d h ou sin g (18) In st a ll t h e left side kick pa n el.
in t o t h e m ou n t in g h ole in t h e pa r kin g br a ke lever (19) In st a ll t h e sill scu ff pla t e on t h e lower sill of
(peda l) a ssem bly. t h e left door.
(2) In st a ll ca ble st r a n d bu t t on in t o t h e r eel on t h e (20) In st a ll t h e n ega t ive (gr ou n d) ca ble on t h e ba t -
pa r kin g br a ke peda l m ech a n ism (F ig. 125). t er y.
(3) Con n ect t h e wir in g con n ect or t o t h e in dica t or (21) Cycle t h e pa r kin g br a ke peda l on e t im e. Th is
la m p gr ou n d swit ch (F ig. 125). will sea t t h e pa r k br a ke ca bles a n d a llow t h e a u t o-
(4) In st a ll t h e r elea se lin k on t h e r elea se m ech a - m a t ic self-a dju st er t o pr oper ly t en sion t h e pa r kin g
n ism of t h e pa r kin g br a ke lever. br a ke ca bles.
(5) P osit ion t h e lever in t o it s in st a lled posit ion on
t h e body of t h e veh icle.
(6) Loosely in st a ll t h e t op bolt m ou n t in g t h e lever
t o t h e body (F ig. 124).
LEV ER - PARK I N G BRAK E

(EX PORT )
REMOVAL - PARKING BRAKE LEVER AND
FRONT CABLE
DURE )
(2) Gr a sp t h e exposed sect ion of t h e fr on t pa r kin g
t h e pa r k br a ke in t h is posit ion , in st a ll a pa ir of lock-
in g plier s on t h e fr on t pa r kin g br a ke ca ble ju st r ea r-
wa r d of t h e secon d body ou t r igger br a cket (F ig. 126).

1 - EQUALIZER
3 - LOCKING NUT
5 - FRONT PARKING BRAKE CABLE
(10) If equ ipped wit h a m a n u a l t r a n sa xle, r em ove

t h e gea r sh ift m ech a n ism . (Refer t o 21 - TRANSMIS-
SION/TRANSAXLE /MANUAL/SH IF T ME CH ANISM
- RE MOVAL)
(11) Un h ook t h e en d of t h e pa r kin g br a ke ca ble
fr om t h e lever m ech a n ism .
(12) Com pr ess t h e pa r kin g br a ke ca ble r et a in er by
slidin g a 14 m m wr en ch over t h e ca ble r et a in er a n d
com pr ess t h e t h r ee (3) r et a in in g fin ger s.
Fig. 126 Locking Out Automatic Adjuster (13) Rem ove t h e t h r ee scr ews fr om t h e pa r kin g
br a ke gr om m et on t h e floor pa n of t h e pa ssen ger
2 - REAR BODY OUTRIGGER BRACKET com pa r t m en t .
3 - LOCKING PLIERS (14) Lift t h e pa r kin g br a ke lever a n d slide t h e
pa r kin g br a ke ca ble ou t .
(3) Rem ove t h e left r ea r a n d in t er m edia t e pa r kin g (15) P u ll t h e ca ble t h r ou gh t h e floor pa n fr om
br a ke ca bles fr om t h e pa r kin g br a ke ca ble equ a lizer in side t h e veh icle.
(F ig. 127).
(4) Rem ove t h e equ a lizer fr om t h e fr on t pa r kin g INSTALLATION - PARKING BRAKE LEVER AND
br a ke ca ble.
(5) Rem ove t h e lockin g plier s fr om t h e fr on t pa r k- FRONT CABLE
in g br a ke ca ble. Th is will a llow t h e a dju st er in t h e (1) P a ss t h e pa r kin g br a ke ca ble down t h r ou gh t h e
pa r kin g br a ke lever m ech a n ism t o r ot a t e a r ou n d t o h ole in t h e floor pa n fr om in side of veh icle.
it s st op a n d r em ove t h e t en sion fr om t h e a dju st er (2) P a ss ca ble en d bu t t on t h r ou gh t h e h ole in t h e
a n d fr on t pa r k br a ke ca ble. lever br a cket a n d pr ess t h e ca ble h ou sin g in t o t h e
(6) Rem ove t h e fr on t pa r kin g br a ke ca ble h ou sin g h ole u n t il a ll t h r ee r et a in in g fin ger s lock t h e ca ble t o
fr om body ou t r igger br a cket . Ca ble is r em ova ble by t h e lever br a cket .
slidin g a 14 m m box wr en ch over t h e ca ble r et a in er (3) H ook t h e en d of t h e pa r kin g br a ke ca ble on t h e
a n d com pr essin g t h e t h r ee r et a in in g fin ger s. Alte r- pa r kin g br a ke lever m ech a n ism .
n a te m e th o d : Use a n a ir cr a ft t ype h ose cla m p a n d (4) P r ess t h e ca ble gr om m et in t o t h e h ole in t h e
scr ewdr iver. floor pa n a n d in st a ll t h e t h r ee scr ews secu r in g it t o
(7) Rem ove t h e fou r m ou n t in g n u t s fr om t h e bot - t h e floor pa n .
t om of t h e pa r kin g br a ke lever br a cket . (5) If equ ipped wit h a m a n u a l t r a n sa xle, in st a ll
(8) Lower veh icle. t h e gea r sh ift m ech a n ism . (Refer t o 21 - TRANSMIS-
(9) Rem ove t h e floor con sole. (Refer t o 23 - BODY/ SION/TRANSAXLE /MANUAL/SH IF T ME CH ANISM
INTE RIOR/F LOOR CONSOLE - RE MOVAL) - INSTALLATION)
LEV ER - PARK I N G BRAK E (EX PORT ) (Cont inue d)
(6) In st a ll t h e floor con sole. (Refer t o 23 - BODY/
INTE RIOR/F LOOR CONSOLE - INSTALLATION)
(7) Ra ise t h e veh icle.
(8) In st a ll t h e fou r m ou n t in g n u t s secu r in g t h e
pa r kin g br a ke lever br a cket in pla ce.
(9) In st a ll t h e fr on t pa r k ca ble h ou sin g r et a in er t o
t h e body ou t r igger br a cket . P r ess t h e ca ble h ou sin g
in t o t h e ou t r igger h ole u n t il a ll t h r ee r et a in in g fin -
ger s lock t h e ca ble in pla ce.
(10) Gr a sp t h e exposed sect ion of t h e fr on t pa r kin g
t h e pa r k br a ke in t h is posit ion , in st a ll a pa ir of lock-
in g plier s on t h e fr on t pa r kin g br a ke ca ble ju st r ea r-
wa r d of t h e secon d body ou t r igger br a cket .
(11) In st a ll t h e equ a lizer on t h e fr on t pa r kin g
br a ke ca ble a n d in st a ll t h e left r ea r a n d in t er m edia t e
pa r k br a ke ca ble in t h e cor r ect loca t ion on t h e pa r k- Fig. 128 Cotter Pin And Nut Retainer
in g br a ke ca ble equ a lizer (F ig. 127). 1 - CALIPER
(12) Rem ove t h e lockin g plier s fr om t h e fr on t pa r k- 2 - COTTER PIN
3 - ROTOR
in g br a ke ca ble. Th is will a llow t h e a dju st er in t h e 4 - NUT RETAINER
pa r k br a ke lever m ech a n ism t o t en sion t h e pa r kin g 5 - OUTER C/V JOINT
br a ke ca bles.
(14) Apply a n d r elea se t h e pa r kin g br a ke lever on e
t im e. Th is will sea t t h e pa r kin g br a ke ca bles a n d
a llow t h e a u t o a dju st er in t h e pa r kin g br a ke lever
m ech a n ism t o cor r ect ly t en sion t h e pa r kin g br a ke
ca bles.
SH OES - PARK I N G BRAK E

REMOVAL
(1) AWD on ly - Set t h e pa r kin g br a ke. Th e p a rk -
in g bra k e is s e t to k e e p th e h u b/be a rin g a n d
a x le s h a ft fro m ro ta tin g w h e n lo o s e n in g th e
h u b n u t.
MAINTE NANCE /H OISTING - STANDARD P ROCE - Fig. 129 Spring Washer
DURE ). 1 - HUB NUT
(3) Rem ove t h e wh eel a n d t ir e a ssem bly. 2 - STUB SHAFT
3 - ROTOR
(4) AWD on ly - Rem ove t h e cot t er pin a n d n u t 4 - SPRING WASHER
r et a in er (F ig. 128) fr om t h e st u b sh a ft of t h e ou t er
C/V join t .
(5) AWD on ly - Rem ove t h e spr in g wa sh er (F ig.
129) fr om t h e st u b sh a ft of t h e ou t er C/V join t .
SH OES - PARK I N G BRAK E (Cont inue d)
(6) AWD on ly - Rem ove t h e h u b n u t a n d wa sh er (9) Rem ove t h e disc br a ke ca liper t o a da pt er gu ide
(F ig. 130) fr om t h e st u b sh a ft of t h e ou t er C/V join t . pin bolt s (F ig. 132).
Fig. 132 Removing Caliper Guide Pin Bolts

Fig. 130 Hub Nut And Washer
1 - CALIPER 2 - ADAPTER
2 - HUB NUT 3 - AXLE
3 - WASHER 4 - GUIDE PIN BOLTS
4 - ROTOR 5 - DRIVESHAFT (AWD MODELS ONLY)
5 - ADAPTER
(10) Rem ove r ea r ca liper fr om a da pt er u sin g t h e
followin g pr ocedu r e. F ir st r ot a t e fr on t of ca liper u p
(8) Cr ea t e sla ck in t h e r ea r pa r k br a ke ca bles by
fr om t h e a da pt er. Th en pu ll t h e r ea r of t h e ca liper
lockin g t h e ou t t h e a u t om a t ic a dju st er a s descr ibed.
a n d t h e ou t boa r d br a ke sh oe a n t i-r a t t le clip ou t fr om
Gr a sp t h e exposed sect ion of fr on t pa r k br a ke ca ble
u n der t h e r ea r a bu t m en t on t h e a da pt er (F ig. 133).
a n d pu ll down wa r d on it . Th en in st a ll a pa ir of lock-
in g plier s on t h e fr on t pa r k br a ke ca ble ju st r ea r wa r d
of t h e secon d body ou t r igger br a cket (F ig. 131).
Fig. 133 Removing/Installing Caliper

3 - ADAPTER ABUTMENT
Fig. 131 Locking Out Automatic Adjuster 4 - OUTBOARD BRAKE SHOE HOLD DOWN CLIP
1 - PARK BRAKE CABLE 5 - OUTBOARD BRAKE SHOE
2 - REAR BODY OUTRIGGER BRACKET 6 - ROTOR
3 - LOCKING PLIERS 7 - ADAPTER
(11) Su ppor t ca liper t o pr even t t h e weigh t of t h e (15) Rem ove t h e en d of t h e pa r k br a ke ca ble fr om
ca liper fr om da m a gin g t h e flexible br a ke h ose (F ig. t h e a da pt er. P a r k br a ke ca ble is r em oved fr om
134). a da pt er u sin g a 1/2 wr en ch slipped over t h e pa r k
br a ke ca ble r et a in er a s sh ow in (F ig. 136) t o com -
pr ess t h e lockin g t a bs on t h e pa r k br a ke ca ble
r et a in er.
Fig. 134 Correctly Supported Caliper

1 - WIRE
2 - CALIPER
3 - ADAPTER Fig. 136 Park Brake Cable Removal From Adapter
4 - ROTOR
5 - INNER FENDER 1 - DRIVESHAFT
2 - 1/2” WRENCH
(12) Rem ove t h e r ot or fr om t h e h u b/bea r in g. 4 - PARK BRAKE CABLE RETAINER
(13) Rem ove t h e pa r k br a ke ca ble m ou n t in g bolt t o 5 - ADAPTER
a da pt er.
(14) Rem ove t h e en d of t h e pa r k br a ke ca ble fr om (16) AWD on ly - Rem ove ABS wh eel speed sen sor
t h e a ct u a t or lever on t h e a da pt er (F ig. 135). h ea d fr om h u b/bea r in g (F ig. 137).
Fig. 135 Park Brake Cable Attachment To Actuator Fig. 137 Speed Sensor Attaching Bolt (AWD)
1 - ADAPTER 1 - ADAPTER
2 - PARK BRAKE CABLE 2 - TONE WHEEL
3 - ACTUATOR 3 - WHEEL SPEED SENSOR
4 - AXLE 4 - AXLE
5 - DRIVESHAFT 5 - BOLT
6 - PARK BRAKE CABLE RETAINER 6 - DRIVESHAFT
7 - HORSESHOE CLIP
(17) F WD on ly - Rem ove t h e ABS wh eel speed sen - (19) Rem ove t h e h u b/bea r in g (F ig. 140).
sor fr om t h e h u b/bea r in g in t h e followin g fa sh ion :
(a ) Rem ove secon da r y (yellow) r et a in in g clip a t
r ea r of wh eel speed sen sor h ea d (F ig. 138).
(b) P u sh u p on m et a l r et a in in g clip (F ig. 138)
u n t il it bot t om s. Th is will r elea se wh eel speed sen -
sor h ea d fr om h u b a n d bea r in g. Wh ile h oldin g
m et a l clip u p, pu ll ba ck on wh eel speed sen sor
h ea d r em ovin g it fr om h u b a n d bea r in g.
(c) Rem ove wh eel speed sen sor fr om h u b/bea r-
in g.
Fig. 140 Hub/Bearing Removal/Installation (AWD

Shown)
2 - OUTER C/V JOINT
3 - HUB/BEARING
5 - STUB SHAFT
Fig. 138 Sensor Connection At Hub And Bearing

1 - SECONDARY SENSOR RETAINING CLIP
2 - METAL SENSOR RETAINING CLIP
3 - HUB AND BEARING
(18) Rem ove t h e h u b/bea r in g-t o-a xle m ou n t in g

bolt s (F ig. 139).
Fig. 139 Hub/Bearing Mounting Bolts (AWD Shown)

1 - DRIVESHAFT
2 - MOUNTING BOLTS
3 - AXLE
4 - MOUNTING BOLTS
5 - ADAPTER
CAUTION: Corrosion may occur between the hub/
bearing and the axle flange. If this occurs, the hub/
bearing will be difficult to remove from the axle and
disc brake caliper adapter. If the hub/bearing will
not come out by pulling on it by hand, don’t not
pound on it with a hammer. Pounding on the hub/
bearing will damage it. To remove a hub/bearing
that is corroded in place, lightly tap the disc brake
caliper adapter using a soft-face hammer. This will
remove both the caliper adapter and hub/bearing
together from the axle. With a helper supporting the
caliper adapter in his hands, position Remover,
Special Tool 8214-1, on the cast housing of hub/
bearing (Fig. 141). Do not position the special tool
on the inner race of hub/bearing. Lightly strike the
Remover with a hammer to remove the hub/bearing
from the caliper adapter. Fig. 142 Adapter Mounted In Vise
1 - ADAPTER
2 - PARK BRAKE CABLE BOSS
3 - VISE
4 - PARK BRAKE BRAKE SHOES
Fig. 141 Hub/Bearing Removal From Caliper Adapter

3 - DISC BRAKE CALIPER ADAPTER
4 - HUB/BEARING
Fig. 143 Lower Return Spring
(20) Rem ove t h e a da pt er fr om t h e r ea r a xle. 1 - ADAPTER
(21) Mou n t t h e a da pt er in a vise u sin g t h e a n ch or 2 - LEADING PARK BRAKE SHOE
3 - RETURN SPRING
boss for t h e pa r k br a ke ca ble (F ig. 142). 4 - TRAILING PARK BRAKE SHOE
(22) Rem ove t h e lower r et u r n spr in g (F ig. 143)
fr om t h e lea din g a n d t r a ilin g pa r k br a ke sh oes.
(23) Rem ove t h e h old down spr in g a n d pin (F ig. (25) Rem ove t h e lea din g pa r k br a ke sh oe (F ig.
144) fr om t h e lea din g pa r k br a ke sh oe. 146) fr om t h e a da pt er. Lea din g br a ke sh oe is
r em oved by r ot a t in g t h e bot t om of t h e br a ke sh oe
in wa r d (F ig. 146) u n t il t h e t op of t h e br a ke sh oe ca n
be r em oved fr om t h e br a ke sh oe a n ch or. Th en r em ove
t h e u pper r et u r n spr in gs (F ig. 146) fr om t h e lea din g
br a ke sh oe.
Fig. 144 Leading Brake Shoe Hold Down Pin And

Spring
1 - ADAPTER
2 - LEADING PARK BRAKE SHOE
3 - ALLEN WRENCH
4 - HOLD DOWN SPRING/PIN
Fig. 146 Primary Brake Shoe Remove/Install
(24) Rem ove t h e a dju st er (F ig. 145) fr om t h e lea d- 1 - PARK BRAKE ACTUATOR
2 - ANCHOR
in g a n d t r a ilin g pa r k br a ke sh oe. 3 - LEADING PARK BRAKE SHOE
4 - UPPER RETURN SPRINGS
5 - TRAILING PARK BRAKE SHOE
(26) Rem ove t h e u pper r et u r n spr in gs (F ig. 147)

fr om t h e t r a ilin g pa r k br a ke sh oe.
Fig. 145 Brake Shoe Adjuster

1 - LEADING PARK BRAKE SHOE
2 - ADJUSTER
Fig. 147 Upper Return Springs

2 - ADAPTER
3 - PARK BRAKE ACTUATOR
4 - UPPER RETURN SPRINGS
(27) Rem ove t h e h old down spr in g a n d pin (F ig. (7) In st a ll t h e h old down spr in g a n d pin (F ig. 144)
148) fr om t h e t r a ilin g pa r k br a ke sh oe. on t h e lea din g pa r k br a ke sh oe.
(8) In st a ll t h e lower r et u r n spr in g (F ig. 143) on
t h e lea din g a n d t r a ilin g pa r k br a ke sh oes.Wh e n
in s ta llin g th e re tu rn s p rin g , it is to be in s ta lle d
be h in d th e p a rk bra k e s h o e s (F ig . 143).
(9) In st a ll t h e 4 m ou n t in g bolt s for t h e a da pt er
a n d h u b/bea r in g in t o t h e bolt h oles in t h e a xle.
(10) P osit ion t h e a da pt er on t h e 4 m ou n t in g bolt s
in st a lled in t h e r ea r a xle (F ig. 149).
Fig. 148 Trailing Brake Shoe Hold Down Pin And

Spring
1 - HOLD DOWN SPRING PIN
2 - ADAPTER
3 - PARK BRAKE ACTUATOR
5 - ALLEN WRENCH
(28) Rem ove t h e t r a ilin g pa r k br a ke sh oe fr om t h e

a da pt er. Fig. 149 Adapter Installed On Mounting Bolts (AWD
(29) Rem ove t h e pa r k br a ke sh oe a ct u a t or fr om Shown)
t h e a da pt er a n d in spect for sign s of a bn or m a l wea r 1 - DRIVESHAFT OUTER C/V JOINT
a n d bin din g a t t h e pivot poin t . 2 - MOUNTING BOLTS
3 - ADAPTER
4 - PARK BRAKE SHOES
INSTALLATION 5 - MOUNTING BOLTS
(1) In st a ll pa r k br a ke sh oe a ct u a t or in t o a da pt er.
(2) In st a ll t h e t r a ilin g br a ke sh oe on t h e a da pt er. (11) In st a ll t h e h u b/bea r in g on t h e st u b sh a ft of
ou t er C/V join t (AWD on ly) a n d in t o t h e en d of t h e
NOTE: When the hold down pin is installed, the a xle. (F ig. 140).
long part of the hold down pin is to be positioned (12) In a pr ogr essive cr isscr oss pa t t er n , t igh t en
strait up and down. This will ensure that the hold t h e 4 h u b/bea r in g m ou n t in g bolt s u n t il t h e h u b/bea r-
down pin is correctly engaged with the adapter. in g is squ a r ely sea t ed a ga in st t h e a xle. Th en t igh t en
t h e h u b/bea r in g m ou n t in g bolt s t o a t or qu e of 129
(3) In st a ll t h e h old down spr in g a n d pin (F ig. 148) N·m (95 ft . lbs.).
on t h e t r a ilin g pa r k br a ke sh oe. (13) AWD on ly - In st a ll t h e wh eel speed sen sor on
(4) In st a ll t h e u pper r et u r n spr in gs (F ig. 147) on t h e h u b/bea r in g a n d a da pt er. In st a ll t h e wh eel speed
t h e t r a ilin g pa r k br a ke sh oe. sen sor a t t a ch in g bolt (F ig. 137). Tigh t en t h e wh eel
(5) In st a ll t h e u pper r et u r n spr in gs on t h e lea din g speed sen sor a t t a ch in g bolt t o a t or qu e of 12 N·m
pa r k br a ke sh oe (F ig. 146). Th en posit ion t h e t op of (105 in . lbs).
t h e lea din g pa r k br a ke sh oe a t t h e u pper a n ch or a n d (14) F WD on ly - In st a ll t h e wh eel speed sen sor in
r ot a t e t h e bot t om of t h e sh oe ou t wa r d u n t il cor r ect ly t h e followin g fa sh ion :
in st a lled on t h e a da pt er. (a ) If m et a l wh eel speed sen sor r et a in in g clip is
(6) In st a ll t h e a dju st er (F ig. 145) bet ween t h e n ot in t h e n eu t r a l in st a lled posit ion on h u b a n d
lea din g a n d t r a ilin g pa r k br a ke sh oe. bea r in g ca p, in st a ll fr om t h e bot t om , if n ecessa r y,
a n d pu sh clip u pwa r d u n t il it sn a ps in t o posit ion .
NOTE: When the hold down pin is installed, the
(b) In st a ll wh eel speed sen sor h ea d in t o r ea r of
long part of the hold down pin is to be positioned
h u b a n d bea r in g a lign in g in dex t a b wit h t h e n ot ch
strait up and down. This will ensure that the hold
in t h e t op of t h e m ou n t in g h ole. P u sh t h e sen sor in
down pin is correctly engaged with the adapter.
u n t il it sn a ps in t o pla ce on t h e m et a l r et a in in g (31) Roa d t est t h e veh icle a n d m a ke sever a l st ops
clip. t o wea r off a n y for eign m a t er ia l on t h e br a kes a n d t o
(c) In st a ll secon da r y (yellow) r et a in in g clip over sea t t h e br a ke sh oe lin in gs.
wh eel speed sen sor h ea d a n d en ga ge t h e t a bs on
ea ch side.
(15) In st a ll t h e pa r k br a ke ca ble in t o it s m ou n t in g ADJ U ST M EN T S
h ole in t h e a da pt er. B e s u re a ll th e lo c k in g ta bs
o n th e p a rk bra k e c a ble re ta in e r a re e x p a n d e d ADJUSTMENT - PARKING BRAKE SHOES
o u t to e n s u re th e c a ble w ill n o t p u ll o u t o f th e
a d a p te r. CAUTION: Before adjusting the park brake shoes be
(16) In st a ll t h e en d of t h e pa r k br a ke ca ble on t h e sure that the park brake pedal is in the fully
pa r k br a ke a ct u a t or lever (F ig. 135). released position. If park brake pedal is not in the
(17) At t a ch pa r k br a ke ca ble t o a da pt er u sin g fully released position, the park brake shoes can
m ou n t in g bolt . not be accurately adjusted.
(18) Rem ove t h e lockin g plier s (F ig. 131) fr om t h e
fr on t pa r k br a ke ca ble.
(2) Rem ove t ir e a n d wh eel.
(19) Adju st t h e pa r k br a ke dr u m -in -h a t br a ke
(3) Rem ove disc br a ke ca liper fr om ca liper a da pt er
sh oes. (Refer t o 5 - BRAKE S/PARKING BRAKE /
(F ig. 150). (Refer t o 5 - BRAKE S/H YDRAULIC/ME -
SH OE S - ADJ USTME NTS).
CH ANICAL/DISC BRAKE CALIP E RS - RE MOVAL).
(20) In st a ll t h e r ot or on t h e h u b/bea r in g.
r ot or a n d on t o t h e a da pt er u sin g t h e r ever se pr oce-
du r e for r em ova l (F ig. 133).
CAUTION: When installing guide pin bolts extreme

caution should be taken not to crossthread the cal-
(22) In st a ll t h e ca liper gu ide pin bolt s (F ig. 132).

Tigh t en t h e gu ide pin bolt s t o a t or qu e of 35 N·m (26
ft . lbs.).
(23) AWD on ly - Clea n a ll for eign m a t er ia l off t h e
t h r ea ds of t h e ou t er C/V join t st u b sh a ft . In st a ll t h e
wa sh er a n d h u b n u t (F ig. 130) on t h e st u b sh a ft of
t h e ou t er C/V join t .
(24) AWD on ly - Set t h e pa r kin g br a ke.
(25) AWD on ly - Tigh t en t h e h u b n u t t o a t or qu e of Fig. 150 Disc Brake Caliper
244 N·m (180 ft . lbs.). 1 - DISC BRAKE CALIPER
(26) AWD on ly - In st a ll t h e spr in g wa sh er (F ig. 2 - ADAPTER
129) on t h e st u b sh a ft of t h e ou t er C/V join t . 3 - AXLE
4 - GUIDE PIN BOLTS
(27) AWD on ly - In st a ll t h e n u t r et a in er a n d cot t er 5 - DRIVESHAFT (AWD MODELS ONLY)
pin (F ig. 128) on t h e st u b sh a ft of t h e ou t er C/V join t .
(28) In st a ll t h e wh eel a n d t ir e a ssem bly. Tigh t en (4) Rem ove r ot or fr om h u b/bea r in g.
t h e wh eel m ou n t in g st u d n u t s in pr oper sequ en ce
u n t il a ll n u t s a r e t or qu ed t o h a lf specifica t ion . Th en NOTE: When measuring the brake drum diameter,
r epea t t h e t igh t en in g sequ en ce t o t h e fu ll specified the diameter should be measured in the center of
t or qu e of 135 N·m (100 ft . lbs.). the area in which the park brake shoes contact the
(29) Lower veh icle. surface of the brake drum.
(30) F u lly a pply a n d r elea se t h e pa r k br a ke peda l
on e t im e. Th is will sea t a n d cor r ect ly a dju st t h e pa r k
br a ke ca bles.
CAUTION: Before moving vehicle, pump the brake

pedal several times to insure the vehicle has a firm
brake pedal to adequately stop vehicle.
(5) Usin g Br a ke Sh oe Ga u ge, Specia l Tool C-3919,
or equ iva len t , a c c u ra te ly m ea su r e t h e in side dia m -
et er of t h e pa r k br a ke dr u m por t ion of t h e r ot or (F ig.
151).
Fig. 153 Setting Gauge To Park Brake Shoe

Measurement
1 - RULER
Fig. 151 Measuring Park Brake Drum Diameter (9) Usin g t h e st a r wh eel a dju st er, a dju st t h e pa r k
(6) Usin g a r u ler t h a t r ea ds in 64t h of a n in ch , br a ke sh oes u n t il t h e lin in g on t h e pa r k br a ke sh oes
a ccu r a t ely r ea d t h e m ea su r em en t of t h e in side dia m - ju st t ou ch es t h e ja ws on t h e specia l t ool.
et er of t h e pa r k br a ke dr u m fr om t h e specia l t ool (10) Repea t st ep 8 a bove a n d m ea su r e sh oes in
(F ig. 152). bot h dir ect ion s.
(11) In st a ll br a ke r ot or on h u b a n d bea r in g.
(12) Rot a t e r ot or t o ver ify t h a t t h e pa r k br a ke
sh oes a r e n ot dr a ggin g on t h e br a ke dr u m . If pa r k
br a ke sh oes a r e dr a ggin g, r em ove r ot or a n d ba ck off
st a r wh eel a dju st er on e n ot ch a n d r ech eck for br a ke
sh oe dr a g a ga in st dr u m . Con t in u e wit h t h e pr eviou s
st ep u n t il br a ke sh oes a r e n ot dr a ggin g on br a ke
dr u m .
(13) In st a ll disc br a ke ca liper on ca liper a da pt er
(F ig. 150). (Refer t o 5 - BRAKE S/H YDRAULIC/ME -
CH ANICAL/DISC BRAKE CALIP E RS - INSTALLA-
TION).
(14) In st a ll wh eel a n d t ir e.
(15) Tigh t en t h e wh eel m ou n t in g n u t s in t h e
pr oper sequ en ce u n t il a ll n u t s a r e t or qu ed t o h a lf t h e
specified t or qu e. Th en r epea t t h e t igh t en in g sequ en ce
Fig. 152 Reading Park Brake Drum Diameter t o t h e fu ll specified t or qu e of 135 N·m (100 ft . lbs.).
1 - SPECIAL TOOL C-3919 (16) Lower veh icle.
2 - RULER (17) Apply a n d r elea se t h e pa r k br a ke peda l on e
t im e. Th is will sea t a n d cor r ect ly a dju st t h e pa r k
(7) Redu ce t h e in side dia m et er m ea su r em en t of br a ke ca bles.
t h e br a ke dr u m t h a t wa s t a ken u sin g Specia l Tool
C-3919 by 1/64 of a n in ch . Reset Ga u ge, Br a ke Sh oe, CAUTION: Before moving vehicle, pump brake
Specia l Tool C-3919 or t h e equ iva len t u sed, so t h a t pedal several times to ensure the vehicle has a firm
t h e ou t side m ea su r em en t ja ws a r e set t o t h e r edu ced enough pedal to stop the vehicle.
m ea su r em en t (F ig. 153).
(8) P la ce Ga u ge, Br a ke Sh oe, Specia l Tool C-3919, (18) Roa d t est t h e veh icle t o en su r e pr oper fu n c-
or equ iva len t over t h e pa r k br a ke sh oes. Th e specia l t ion of t h e veh icle’s br a ke syst em .
t ool m u st be loca t ed dia gon a lly a cr oss a t t h e t op of
on e sh oe a n d bot t om of opposit e sh oe (widest poin t )
of t h e pa r k br a ke sh oes.
RS BRAKES - ABS 5 - 87
BRAK ES - ABS
TABLE OF CONTENTS
page page
BRAKES - ABS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 92

DESCRIPTION REAR WHEEL SPEED SENSOR - FWD
DESCRIPTION - ANTILOCK BRAKE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 93
DESCRIPTION - ANTILOCK BRAKE TONE WHEEL
SYSTEM (EXPORT) . . . . . . . . . . . . . . . . . . . . 87 INSPECTION - TONE WHEEL . . . . . . . . . . . . . . 94
DESCRIPTION - ELECTRONIC VARIABLE TRACTION CONTROL SWITCH
BRAKE PROPORTIONING . . . . . . . . . . . . . . . 88 DIAGNOSIS AND TESTING - TRACTION
DESCRIPTION - TRACTION CONTROL CONTROL SWITCH . . . . . . . . . . . . . . . . . . . . 94
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
OPERATION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 95
OPERATION - ANTILOCK BRAKE SYSTEM . . 88 HYDRAULIC/MECHANICAL
OPERATION - ELECTRONIC VARIABLE OPERATION - HYDRAULIC CIRCUITS AND
BRAKE PROPORTIONING . . . . . . . . . . . . . . . 89 VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
OPERATION - TRACTION CONTROL HCU (HYDRAULIC CONTROL UNIT)
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 100
CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 101
STANDARD PROCEDURE - ANTILOCK BRAKE ICU (INTEGRATED CONTROL UNIT)
SYSTEM BLEEDING . . . . . . . . . . . . . . . . . . . 90 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 102
SPECIFICATIONS OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 102
ABS FASTENER TORQUE . . . . . . . . . . . . . . . 91 REMOVAL
TONE WHEEL RUNOUT . . . . . . . . . . . . . . . . 91 REMOVAL - LHD . . . . . . . . . . . . . . . . . . . . . 102
WHEEL SPEED SENSOR AIR GAP . . . . . . . . 91 REMOVAL - RHD . . . . . . . . . . . . . . . . . . . . . 104
FRONT WHEEL SPEED SENSOR DISASSEMBLY - ICU . . . . . . . . . . . . . . . . . . . 105
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 ASSEMBLY - ICU . . . . . . . . . . . . . . . . . . . . . . 106
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 92 INSTALLATION
REAR WHEEL SPEED SENSOR - AWD INSTALLATION - LHD . . . . . . . . . . . . . . . . . 106
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 INSTALLATION - RHD . . . . . . . . . . . . . . . . . 107
BRAK ES - ABS DESCRIPTION - ANTILOCK BRAKE SYSTEM

(EXPORT)
F ou r-wh eel disc a n t ilock br a kes a r e st a n da r d on a ll
DESCRI PT I ON m odels. Th e Ma r k 20e a n t ilock br a ke syst em is u sed
on a ll m odels. Depen din g on wh et h er t h e veh icle is a
DESCRIPTION - ANTILOCK BRAKE SYSTEM left -h a n d dr ive (LH D) or r igh t -h a n d dr ive (RH D)
Th is sect ion cover s t h e ph ysica l a n d oper a t ion a l m odel, t h e in t egr a t ed con t r ol u n it (ICU) is loca t ed in
descr ipt ion s a n d t h e on -ca r ser vice pr ocedu r es for t h e on e of t wo loca t ion s. On LH D m odels, t h e ICU is
Ma r k 20e An t ilock Br a ke Syst em a n d t h e Ma r k 20e m ou n t ed a bove t h e fr on t su spen sion cr a dle/cr oss-
An t ilock Br a ke Syst em wit h t r a ct ion con t r ol. m em ber below t h e m a st er cylin der. On RH D m odels,
Th e pu r pose of t h e a n t ilock br a ke syst em (ABS) is t h e ICU is loca t ed beh in d t h e fr on t su spen sion cr a -
t o pr even t wh eel locku p u n der br a kin g con dit ion s on dle/cr ossm em ber on t h e left side of t h e veh icle.
vir t u a lly a n y t ype of r oa d su r fa ce. An t ilock br a kin g is
desir a ble beca u se a veh icle t h a t is st opped wit h ou t
lockin g t h e wh eels r et a in s dir ect ion a l st a bilit y a n d
som e st eer in g ca pa bilit y. Th is a llows t h e dr iver t o
r et a in gr ea t er con t r ol of t h e veh icle du r in g br a kin g.
5 - 88 BRAKES - ABS RS
BRAK ES - ABS (Cont inue d)
DESCRIPTION - ELECTRONIC VARIABLE fou r wh eel cir cu it s is m odu la t ed t o pr even t a n y wh eel

fr om lockin g. E a ch wh eel cir cu it is design ed wit h a set of
BRAKE PROPORTIONING
elect r ic solen oids t o a llow m odu la t ion , a lt h ou gh for veh i-
Veh icles equ ipped wit h ABS u se elect r on ic va r ia ble
cle st a bilit y, bot h r ea r wh eel solen oids r eceive t h e sa m e
br a ke pr opor t ion in g (E VBP ) t o ba la n ce fr on t -t o-r ea r
elect r ica l sign a l. Wh eel locku p m a y be per ceived a t t h e
br a kin g. Th e E VBP is u sed in pla ce of a r ea r pr opor-
ver y en d of a n ABS st op a n d is con sider ed n or m a l.
t ion in g va lve. Th e E VBP syst em u ses t h e ABS syst em
Du r in g a n ABS st op, t h e br a kes h ydr a u lic syst em
t o con t r ol t h e slip of t h e r ea r wh eels in pa r t ia l br a k-
is st ill dia gon a lly split . H owever, t h e br a ke syst em
in g r a n ge. Th e br a kin g for ce of t h e r ea r wh eels is con -
pr essu r e is fu r t h er split in t o t h r ee con t r ol ch a n n els.
t r olled elect r on ica lly by u sin g t h e in let a n d ou t let
Du r in g a n t ilock oper a t ion of t h e veh icle’s br a ke sys-
va lves loca t ed in t h e in t egr a t ed con t r ol u n it (ICU).
t em , t h e fr on t wh eels a r e con t r olled in depen den t ly
E VBP a ct iva t ion is in visible t o t h e cu st om er sin ce
a n d a r e on t wo sepa r a t e con t r ol ch a n n els, a n d t h e
t h er e is n o pu m p m ot or n oise or br a ke peda l feedba ck.
r ea r wh eels of t h e veh icle a r e con t r olled t oget h er.
Th e syst em ca n bu ild a n d r elea se pr essu r e a t ea ch
DESCRIPTION - TRACTION CONTROL SYSTEM wh eel, depen din g on sign a ls gen er a t ed by t h e wh eel
Tr a ct ion con t r ol r edu ces wh eel slip a n d m a in t a in s
speed sen sor s (WSS) a t ea ch wh eel a n d r eceived a t
t r a ct ion a t t h e dr ivin g wh eels a t speeds below 56
t h e con t r oller a n t ilock br a ke (CAB).
km /h (35 m ph ) wh en r oa d su r fa ces a r e slipper y. Th e
t r a ct ion con t r ol syst em r edu ces wh eel slip by br a kin g NOISE AND BRAKE PEDAL FEEL
t h e wh eel t h a t is losin g t r a ct ion . Du r in g ABS br a kin g, som e br a ke peda l m ovem en t
m a y be felt . In a ddit ion , ABS br a kin g will cr ea t e
HYDRAULIC SHUTTLE VALVES t ickin g, poppin g, or gr oa n in g n oises h ea r d by t h e
Two pr essu r e r elief h ydr a u lic sh u t t le va lves a r e dr iver. Th is is n or m a l a n d is du e t o pr essu r ized flu id
in clu ded on veh icles wit h t r a ct ion con t r ol. Th ese bein g t r a n sfer r ed bet ween t h e m a st er cylin der a n d
va lves a r e loca t ed in side t h e H CU a n d ca n n ot be ser- t h e br a kes. If ABS oper a t ion occu r s du r in g h a r d
viced sepa r a t ely fr om t h e H CU. br a kin g, som e pu lsa t ion m a y be felt in t h e veh icle
body du e t o for e a n d a ft m ovem en t of t h e su spen sion
TRACTION CONTROL LAMP a s br a ke pr essu r es a r e m odu la t ed.
Th e t r a ct ion con t r ol fu n ct ion la m p is loca t ed in t h e At t h e en d of a n ABS st op, ABS is t u r n ed off wh en
t r a n sm ission r a n ge in dica t or displa y of t h e in st r u - t h e veh icle is slowed t o a speed of 3–4 m ph . Th er e m a y
m en t clu st er, displa yin g TRAC, TRAC OF F or n ei- be a sligh t br a ke peda l dr op a n yt im e t h a t t h e ABS is
t h er depen din g on syst em m ode. dea ct iva t ed, su ch a s a t t h e en d of t h e st op wh en t h e
Th e TRAC OF F la m p is con t r olled by a Tr a ct ion veh icle speed is less t h a n 3 m ph or du r in g a n ABS st op
Con t r ol Off swit ch t h a t is a m om en t a r y con t a ct t ype wh er e ABS is n o lon ger r equ ir ed. Th ese con dit ion s exist
swit ch . Th e Tr a ct ion Con t r ol Off swit ch is loca t ed on wh en a veh icle is bein g st opped on a r oa d su r fa ce wit h
t h e st eer in g colu m n u pper sh r ou d. pa t ch es of ice, loose gr a vel, or sa n d on it . Also, st oppin g
a veh icle on a bu m py r oa d su r fa ce a ct iva t es ABS
beca u se of t h e wh eel h op ca u sed by t h e bu m ps.
OPERAT I ON
TIRE NOISE AND MARKS
OPERATION - ANTILOCK BRAKE SYSTEM Alt h ou gh t h e ABS syst em pr even t s com plet e wh eel
Th er e a r e a few per for m a n ce ch a r a ct er ist ics of t h e locku p, som e wh eel slip is desir ed in or der t o a ch ieve
Ma r k 20e An t ilock Br a ke Syst em t h a t m a y a t fir st opt im u m br a kin g per for m a n ce. Wh eel slip is defin ed
seem a bn or m a l, bu t in fa ct a r e n or m a l. Th ese ch a r- a s follows: 0 per cen t slip m ea n s t h e wh eel is r ollin g
a ct er ist ics a r e descr ibed below. fr eely a n d 100 per cen t slip m ea n s t h e wh eel is fu lly
locked. Du r in g br a ke pr essu r e m odu la t ion , wh eel slip
NORMAL BRAKING is a llowed t o r ea ch u p t o 25–30 per cen t . Th is m ea n s
Un der n or m a l br a kin g con dit ion s, t h e ABS fu n c- t h a t t h e wh eel r ollin g velocit y is 25–30 per cen t less
t ion s t h e sa m e a s a st a n da r d ba se br a ke syst em wit h t h a n t h a t of a fr ee r ollin g wh eel a t a given veh icle
a dia gon a lly split m a st er cylin der a n d con ven t ion a l speed. Th is slip m a y r esu lt in som e t ir e ch ir pin g,
va cu u m a ssist . depen din g on t h e r oa d su r fa ce. Th is sou n d sh ou ld n ot
be in t er pr et ed a s t ot a l wh eel locku p.
ABS BRAKING Com plet e wh eel locku p n or m a lly lea ves bla ck t ir e
ABS oper a t ion is a va ila ble a t a ll veh icle speeds a bove m a r ks on dr y pa vem en t . Th e ABS will n ot lea ve da r k
3–5 m ph . If a wh eel lockin g t en den cy is det ect ed du r in g bla ck t ir e m a r ks sin ce t h e wh eel n ever r ea ch es a
a br a ke a pplica t ion , t h e br a ke syst em en t er s t h e ABS fu lly locked con dit ion . H owever, t ir e m a r ks m a y be
m ode. Du r in g ABS br a kin g, h ydr a u lic pr essu r e in t h e n ot icea ble a s ligh t pa t ch ed m a r ks.
START-UP CYCLE m a st er cylin der by swit ch in g on t h e ou t let va lve a n d
Wh en t h e ign it ion is t u r n ed on , a poppin g sou n d dr a in in g t h r ou gh t h e in let va lve ch eck va lve. At t h e
a n d a sligh t br a ke peda l m ovem en t m a y be n ot iced. sa m e t im e t h e in let va lve is swit ch ed on in ca se of
Th e ABS wa r n in g la m p will a lso be on for u p t o 5 a n ot h er br a ke a pplica t ion .
secon ds a ft er t h e ign it ion is t u r n ed on . Wh en t h e Th e E VBP will r em a in fu n ct ion a l du r in g m a n y
veh icle is fir st dr iven off, a h u m m in g m a y be h ea r d ABS fa u lt m odes. If bot h t h e r ed BRAKE a n d a m ber
or felt by t h e dr iver a t a ppr oxim a t ely 20–40 kph ABS wa r n in g in dica t or s a r e illu m in a t ed, t h e E VBP
(12–25 m ph ). All of t h ese con dit ion s a r e a n or m a l m a y n ot be fu n ct ion in g.
fu n ct ion of ABS a s t h e syst em is per for m in g a dia g-
n osis ch eck. OPERATION - TRACTION CONTROL SYSTEM
Th e t r a ct ion con t r ol m odu le m on it or s wh eel speed.
PREMATURE ABS CYCLING Du r in g a cceler a t ion , if t h e m odu le det ect s fr on t
Sym pt om s of pr em a t u r e ABS cyclin g in clu de: click- (dr ive) wh eel slip a n d t h e br a kes a r e n ot a pplied, t h e
in g sou n ds fr om t h e solen oid va lves; pu m p/m ot or m odu le en t er s t r a ct ion con t r ol m ode. Tr a ct ion con t r ol
r u n n in g; a n d pu lsa t ion s in t h e br a ke peda l. P r em a - oper a t ion pr oceeds in t h e followin g or der :
t u r e ABS cyclin g ca n occu r a t a n y br a kin g r a t e of t h e (1) Close t h e n or m a lly open isola t ion va lves.
veh icle a n d on a n y t ype of r oa d su r fa ce. Neit h er t h e (2) St a r t t h e pu m p/m ot or a n d su pply volu m e a n d
r ed BRAKE wa r n in g la m p, n or t h e a m ber ABS wa r n - pr essu r e t o t h e fr on t (dr ive) h ydr a u lic cir cu it . (Th e
in g la m p, illu m in a t e a n d n o fa u lt codes a r e st or ed in pu m p/m ot or r u n s con t in u ou sly du r in g t r a ct ion con -
t h e CAB. t r ol oper a t ion .)
P r em a t u r e ABS cyclin g is a con dit ion t h a t n eeds t o (3) Open a n d close t h e bu ild a n d deca y va lves t o
be cor r ect ly a ssessed wh en dia gn osin g pr oblem s wit h m a in t a in m in im u m wh eel slip a n d m a xim u m t r a c-
t h e a n t ilock br a ke syst em . It m a y be n ecessa r y t o u se t ion .
a DRB sca n t ool t o det ect a n d ver ify pr em a t u r e ABS Th e cyclin g of t h e bu ild a n d deca y va lves du r in g
cyclin g. t r a ct ion con t r ol is sim ila r t o t h a t du r in g a n t ilock
Ch eck t h e followin g com m on ca u ses wh en dia gn os- br a kin g, except t h e va lves wor k t o con t r ol wh eel spin
in g pr em a t u r e ABS cyclin g: da m a ged t on e wh eels; by a pplyin g t h e br a kes, wh er ea s t h e ABS fu n ct ion is
in cor r ect t on e wh eels; da m a ged st eer in g kn u ckle t o con t r ol wh eel skid by r elea sin g t h e br a kes.
wh eel speed sen sor m ou n t in g bosses; loose wh eel If t h e br a kes a r e a pplied a t a n yt im e du r in g a t r a c-
speed sen sor m ou n t in g bolt s; excessive t on e wh eel t ion con t r ol cycle, t h e br a ke la m p swit ch t r igger s t h e
r u n ou t ; or a n excessively la r ge t on e wh eel-t o-wh eel con t r oller t o swit ch off t r a ct ion con t r ol.
speed sen sor a ir ga p. Give specia l a t t en t ion t o t h ese
com pon en t s wh en dia gn osin g a veh icle exh ibit in g HYDRAULIC SHUTTLE VALVES
pr em a t u r e ABS cyclin g. Two pr essu r e r elief h ydr a u lic sh u t t le va lves a llow
Aft er dia gn osin g t h e defect ive com pon en t , r epa ir or pr essu r e a n d volu m e t o r et u r n t o t h e m a st er cylin der
r epla ce it a s r equ ir ed. Wh en t h e com pon en t r epa ir or r eser voir wh en n ot con su m ed by t h e bu ild a n d deca y
r epla cem en t is com plet ed, t est dr ive t h e veh icle t o va lves. Th ese va lves a r e n ecessa r y beca u se t h e
ver ify t h a t pr em a t u r e ABS cyclin g h a s been cor- pu m p/m ot or su pplies m or e volu m e t h a n t h e syst em
r ect ed. r equ ir es.
OPERATION - ELECTRONIC VARIABLE BRAKE TRACTION CONTROL LAMP

Th e t r a ct ion con t r ol syst em is en a bled a t ea ch ign i-
PROPORTIONING
t ion cycle. It m a y be t u r n ed off by depr essin g t h e
Upon en t r y in t o E VBP t h e in let va lve for t h e r ea r
Tr a ct ion Con t r ol Off swit ch bu t t on wh en t h e ign it ion
br a ke cir cu it is swit ch ed on so t h a t t h e flu id su pply
is in t h e ON posit ion . Th e t r a ct ion con t r ol fu n ct ion
fr om t h e m a st er cylin der is sh u t off. In or der t o
la m p (TRAC OF F ) illu m in a t es im m edia t ely u pon
decr ea se t h e r ea r br a ke pr essu r e, t h e ou t let va lve for
depr essin g t h e bu t t on .
t h e r ea r br a ke cir cu it is pu lsed. Th is a llows flu id t o
Th e t r a ct ion con t r ol fu n ct ion la m p illu m in a t es du r-
en t er t h e low pr essu r e a ccu m u la t or (LPA) in t h e
in g a t r a ct ion con t r ol cycle, displa yin g TRAC.
h ydr a u lic con t r ol u n it (H CU) r esu lt in g in a dr op in
If t h e CAB ca lcu la t es t h a t t h e br a ke t em per a t u r es
flu id pr essu r e t o t h e r ea r br a kes. In or der t o in cr ea se
a r e h igh , t h e t r a ct ion con t r ol syst em becom es in oper-
t h e r ea r br a ke pr essu r e, t h e ou t let va lve is swit ch ed
a t ive u n t il a t im e-ou t per iod h a s ela psed. Du r in g t h is
off a n d t h e in let va lve is pu lsed. Th is in cr ea ses t h e
“t h er m o-pr ot ect ion m ode,” t h e t r a ct ion con t r ol fu n c-
pr essu r e t o t h e r ea r br a kes. Th is ba ck-a n d-for t h pr o-
t ion la m p illu m in a t es TRAC OF F ; n ot e t h a t n o t r ou -
cess will con t in u e u n t il t h e r equ ir ed slip differ en ce is
ble code is r egist er ed.
obt a in ed. At t h e en d of E VBP br a kin g (br a kes
r elea sed) t h e flu id in t h e LPA dr a in s ba ck t o t h e
CAUTION nector should be disconnected during the welding

Th e ABS u ses a n elect r on ic con t r ol m odu le, t h e operation.
CAB. Th is m odu le is design ed t o wit h st a n d n or m a l
CAUTION: Many components of the ABS System
cu r r en t dr a ws a ssocia t ed wit h veh icle oper a t ion .
are not serviceable and must be replaced as an
Ca r e m u st be t a ken t o a void over loa din g t h e CAB
cir cu it s. assembly. Do not disassemble any component
which is not designed to be serviced.
CAUTION: In testing for open or short circuits, do
not ground or apply voltage to any of the circuits
CAUTION: Only the recommended jacking or hoist-
unless instructed to do so for a diagnostic proce-
ing positions for this vehicle are to be used when-
dure.
ever it is necessary to lift a vehicle. Failure to raise
a vehicle from the recommended locations could
CAUTION: These circuits should only be tested result in lifting a vehicle by the hydraulic control
using a high impedance multi-meter or the DRBIII" unit mounting bracket. Lifting a vehicle by the
scan tool as described in this section. Power hydraulic control unit mounting bracket will result
should never be removed or applied to any control in damage to the mounting bracket and the hydrau-
module with the ignition in the ON position. Before lic control unit.
removing or connecting battery cables, fuses, or
connectors, always turn the ignition to the OFF
CAUTION: Brake fluid will damage painted surfaces.
position. If brake fluid is spilled on any painted surface,
wash off with water immediately.
CAUTION: The CAB 24-way connector should never
be connected or disconnected with the ignition
switch in the ON position. STANDARD PROCEDURE - ANTILOCK BRAKE
SYSTEM BLEEDING
Th e ba se br a ke’s h ydr a u lic syst em m u st be bled
CAUTION: This vehicle utilizes active wheel speed a n yt im e a ir en t er s t h e h ydr a u lic syst em . Th e ABS
sensors. Do not apply voltage to wheel speed sen- t h ou gh , pa r t icu la r ly t h e ICU (H CU), sh ou ld on ly be
sors at any time. bled wh en t h e H CU is r epla ced or r em oved fr om t h e
veh icle. Th e ABS m u st a lwa ys be bled a n yt im e it is
su spect ed t h a t t h e H CU h a s in gest ed a ir. Un der
CAUTION: Use only factory wiring harnesses. Do
m ost cir cu m st a n ces t h a t r equ ir e t h e bleedin g of t h e
not cut or splice wiring to the brake circuits. The
br a kes h ydr a u lic syst em , on ly t h e ba se br a ke
addition of aftermarket electrical equipment (car
h ydr a u lic syst em n eeds t o be bled.
phone, radar detector, citizen band radio, trailer
It is im por t a n t t o n ot e t h a t excessive a ir in t h e
lighting, trailer brakes, etc.) on a vehicle equipped
br a ke syst em will ca u se a soft or spon gy feelin g
with antilock brakes may affect the function of the
br a ke peda l.
antilock brake system.
Du r in g t h e br a ke bleedin g pr ocedu r e, be su r e t h e
br a ke flu id level r em a in s close t o t h e F ULL level in
CAUTION: When performing any service procedure t h e m a st er cylin der flu id r eser voir. Ch eck t h e flu id
on a vehicle equipped with ABS, do not apply a level per iodica lly du r in g t h e bleedin g pr ocedu r e a n d
12-volt power source to the ground circuit of the a dd DOT 3 br a ke flu id a s r equ ir ed.
pump motor in the HCU. Doing this will damage the Th e ABS m u st be bled a s t wo in depen den t br a kin g
pump motor and will require replacement of the syst em s. Th e n on -ABS por t ion of t h e br a ke syst em
entire HCU. wit h ABS is t o be bled t h e sa m e a s a n y n on -ABS sys-
t em .
Th e ABS por t ion of t h e br a ke syst em m u st be bled
CAUTION: An attempt to remove or disconnect cer- sepa r a t ely. Use t h e followin g pr ocedu r e t o pr oper ly
tain system components may result in improper bleed t h e br a ke h ydr a u lic syst em in clu din g t h e ABS.
system operation. Only those components with
approved removal and installation procedures in BLEEDING
this manual should be serviced. Wh en bleedin g t h e ABS syst em , t h e followin g
bleedin g sequ en ce m u st be followed t o in su r e com -
plet e a n d a dequ a t e bleedin g.
CAUTION: If welding work is to be performed on the
vehicle using an electric arc welder, the CAB con-
(1) Ma ke su r e a ll h ydr a u lic flu id lin es a r e in st a lled WHEEL SPEED SENSOR AIR GAP
a n d pr oper ly t or qu ed.
(2) Con n ect t h e DRBIII! sca n t ool t o t h e dia gn os-
t ics con n ect or. Th e dia gn ost ic con n ect or is loca t ed DESCRIPTION SPECIFICATION
u n der t h e lower st eer in g colu m n cover t o t h e left of 0.35 – 1.20 mm
Front Sensor
t h e st eer in g colu m n . 0.014 – 0.047 in.
(3) Usin g t h e DRB, ch eck t o m a ke su r e t h e CAB 0.40 – 1.20 mm
does n ot h a ve a n y fa u lt codes st or ed. If it does, clea r Rear Sensor
0.016 – 0.047 in.
t h em u sin g t h e DRB.
WARNING: WHEN BLEEDING THE BRAKE SYSTEM FRON T WH EEL SPEED

WEAR SAFETY GLASSES. A CLEAR BLEED TUBE
MUST BE ATTACHED TO THE BLEEDER SCREWS SEN SOR
AND SUBMERGED IN A CLEAR CONTAINER FILLED
PART WAY WITH CLEAN BRAKE FLUID. DIRECT REMOVAL
THE FLOW OF BRAKE FLUID AWAY FROM YOUR- (1) Ra ise veh icle. (Refer t o LUBRICATION & MAIN-
SELF AND THE PAINTED SURFACES OF THE VEHI- TE NANCE /H OISTING - STANDARD P ROCE DURE )
CLE. BRAKE FLUID AT HIGH PRESSURE MAY (2) Rem ove t h e t ir e a n d wh eel a ssem bly.
COME OUT OF THE BLEEDER SCREWS WHEN (3) Rem ove t h e sen sor ca ble r ou t in g cla m p scr ews.
OPENED.
CAUTION: When disconnecting the wheel speed
(4) Bleed t h e ba se br a ke syst em u sin g t h e st a n - sensor from vehicle wiring harness, be careful not
da r d pr essu r e or m a n u a l bleedin g pr ocedu r e. (Refer to damage pins on connector
t o 5 - BRAKE S - BASE - STANDARD P ROCE DURE )
(5) Usin g t h e DRB, select ANTILOCK BRAKE S, (4) Rem ove speed sen sor ca ble gr om m et s fr om
followed by MISCE LLANE OUS, t h en BLE E D in t er m edia t e br a cket on st r u t .
BRAKE S. F ollow t h e in st r u ct ion s displa yed. Wh en (5) Discon n ect speed sen sor ca ble fr om veh icle wir-
t h e sca n t ool displa ys TE ST COMP LE TE D, discon - in g h a r n ess beh in d fen der well sh ield.
n ect t h e sca n t ool a n d pr oceed. (6) Rem ove t h e wh eel speed sen sor h ea d m ou n t in g
(6) Bleed t h e ba se br a ke syst em a secon d t im e. bolt (F ig. 1).
Ch eck br a ke flu id level in t h e r eser voir per iodica lly
t o pr even t em pt yin g, ca u sin g a ir t o en t er t h e h ydr a u -
lic syst em .
(7) F ill t h e m a st er cylin der r eser voir t o t h e fu ll
level.
(8) Test dr ive t h e veh icle t o be su r e t h e br a kes a r e
oper a t in g cor r ect ly a n d t h a t t h e br a ke peda l does n ot
feel spon gy.
SPECI FI CAT I ON S
ABS FASTENER TORQUE
Refer t o BRAKE FASTE NE R TORQUE . (Refer t o 5
- BRAKE S - BASE - SP E CIF ICATIONS)
TONE WHEEL RUNOUT Fig. 1 Front Wheel Speed Sensor Attaching Bolt
1 - MOUNTING BOLT
2 - WHEEL SPEED SENSOR
DESCRIPTION SPECIFICATION 3 - DRIVESHAFT
4 - TONE WHEEL
Front Tone Wheel 5 - STEERING KNUCKLE
0.15 mm (0.006 in.)
Maximum Runout
Rear Tone Wheel (7) Rem ove sen sor h ea d fr om st eer in g kn u ckle. If
0.15 mm (0.006 in.) sen sor h a s seized du e t o cor r osion , D O N OT U S E
Maximum Runout
P LIERS ON S EN S OR HEAD . Use a h a m m er a n d a
pu n ch a n d t a p edge of sen sor ea r, r ockin g t h e sen sor
side-t o-side u n t il fr ee.
FRON T WH EEL SPEED SEN SOR (Cont inue d)
(8) Rem ove fr on t wh eel speed sen sor fr om veh icle. (4) Rem ove bolt secu r in g wh eel speed sen sor ca ble
m et a l clip t o r ea r of a xle. Rem ove m et a l clip fr om
INSTALLATION ca ble if n ecessa r y.
CAUTION: Proper installation of wheel speed sen- CAUTION: If speed sensor head has seized due to
sor cables is critical to continued system operation. corrosion, do not use pliers on speed sensor head
Be sure that cables are installed in retainers. Fail- in an attempt to remove it. Use a hammer and a
ure to install cables in retainers as shown in this punch and tap mounting flange edge side-to-side,
section may result in contact with moving parts and rocking the sensor until free.
over extension of cables, resulting in an open cir-
cuit. (5) Rem ove wh eel speed sen sor h ea d a t t a ch in g
bolt .
(1) Con n ect t h e fr on t wh eel speed sen sor ca ble t o (6) Rem ove wh eel speed sen sor h ea d fr om t h e a xle,
t h e veh icle wir in g h a r n ess con n ect or. Be su r e speed a n d r em ove sen sor fr om veh icle.
sen sor ca ble con n ect or is fu lly sea t ed a n d locked in t o
veh icle wir in g h a r n ess con n ect or. INSTALLATION
(2) In st a ll t h e bolt s a t t a ch in g t h e r ou t in g cla m ps
t o t h e body of t h e veh icle. Tigh t en t h e bolt s t o a CAUTION: Proper installation of wheel speed sen-
t or qu e of 14 N·m (125 in . lbs.). sor cables is critical to continued system operation.
(3) In ser t speed sen sor ca ble gr om m et s in t o in t er- Be sure that cables are installed in retainers. Fail-
m edia t e br a cket on st r u t . ure to install cables in retainers as indicated may
(4) In st a ll t h e wh eel speed sen sor h ea d m ou n t in g result in contact with moving parts or over-exten-
bolt (F ig. 1). Tigh t en t h e bolt t o a t or qu e of 13 N·m sion of cables, resulting in an open circuit.
(115 in . lbs.)
(5) In st a ll t h e wh eel a n d t ir e a ssem bly on veh icle. (1) In st a ll wh eel speed sen sor h ea d in a xle fla n ge.
(6) Lower veh icle.
CAUTION: Prior to installing the speed sensor head
(7) Roa d t est veh icle t o en su r e pr oper oper a t ion of
attaching bolt, the plastic anti-rotation pin must be
t h e ba se a n d ABS br a ke syst em s.
fully seated into the bearing flange.
(2) In st a ll wh eel speed sen sor h ea d a t t a ch in g bolt .

REAR WH EEL SPEED SEN SOR Tigh t en bolt t o a t or qu e 10 N·m (90 in . lbs.).
- AWD (3) Ch eck t h e a ir ga p bet ween t h e fa ce of t h e
wh eel speed sen sor a n d t h e t op su r fa ce of t h e t on e
REMOVAL wh eel. (Refer t o 5 - BRAKE S - SP E CIF ICATIONS)
MAINTE NANCE /H OISTING - STANDARD P ROCE - CAUTION: When installing wheel speed sensor
DURE ) cable in the routing clips on rear brake flex hose,
be sure not to damage the routing clips. Routing
CAUTION: When disconnecting speed sensor cable clips are molded onto the hose and will require
from vehicle wiring harness be careful not to dam- replacement of the brake hose if damaged.
age pins on the electrical connectors. Also, inspect
connectors for any signs of previous damage. (4) In st a ll speed sen sor ca ble u n der lea f spr in g
on t o br a ke h ose a n d t u bin g u t ilizin g r ou t in g clips t o
(2) Rem ove gr om m et fr om floor pa n of veh icle a n d secu r e it in pla ce.
discon n ect speed sen sor ca ble con n ect or fr om veh icle (5) In st a ll m et a l r ou t in g clip on speed sen sor ca ble
wir in g h a r n ess. a n d m ou n t it t o r ea r of a xle wit h m ou n t in g bolt .
Tigh t en m ou n t in g bolt t o 16 N·m (140 in . lbs.).
CAUTION: When removing rear wheel speed sensor (6) Con n ect wh eel speed sen sor ca ble t o veh icle
cable from routing clips, be sure not to damage the wir in g h a r n ess.B e s u re s p e e d s e n s o r c a ble c o n -
routing clips. Routing clips that are molded onto n e c to r is fu lly s e a te d a n d lo c k e d in to v e h ic le
the brake hose will require replacement of the brake w irin g h a rn e s s c o n n e c to r.
hose if damaged during removal or installation of (7) In st a ll speed sen sor ca ble gr om m et in t o t h e
the speed sensor cable. floor pa n , bein g su r e t h e gr om m et is fu lly sea t ed in t o
t h e a ccess h ole.
(3) Ca r efu lly r em ove speed sen sor ca ble fr om (8) Lower veh icle.
pr ess-in r ou t in g clips a lon g br a ke h ose a n d t u bin g. (9) Roa d t est veh icle t o en su r e pr oper oper a t ion of
t h e ba se a n d ABS br a kin g syst em s.
REAR WH EEL SPEED SEN SOR

- FWD
REMOVAL
DURE )
CAUTION: When disconnecting speed sensor cable

from vehicle wiring harness be careful not to dam-
age pins on the electrical connectors. Also, inspect
connectors for any signs of previous damage.
(2) Rem ove gr om m et fr om floor pa n of veh icle a n d

discon n ect speed sen sor ca ble con n ect or fr om veh icle
wir in g h a r n ess (F ig. 2). Fig. 3 SPEED SENSOR CABLE ROUTING
1 - METAL CLIP AND MOUNTING BOLT
2 - ROUTING CLIPS
Fig. 2 Wheel Speed Sensor Connector

1 - CONNECTOR
2 - FLOOR PAN Fig. 4 SENSOR CONNECTION AT HUB AND
3 - GROMMET BEARING
1 - SECONDARY SENSOR RETAINING CLIP
CAUTION: When removing rear wheel speed sensor 2 - METAL SENSOR RETAINING CLIP
cable from routing clips, be sure not to damage the 3 - HUB AND BEARING
routing clips. Routing clips that are molded onto
the brake hose will require replacement of the brake (7) Rem ove wh eel speed sen sor a ssem bly fr om
hose if damaged during removal or installation of veh icle.
the speed sensor cable.
INSTALLATION
(3) Ca r efu lly r em ove speed sen sor ca ble fr om
pr ess-in r ou t in g clips (F ig. 3). CAUTION: Proper installation of wheel speed sen-
(4) Rem ove bolt secu r in g m et a l r ou t in g clip t o r ea r sor cable is critical to continued system operation.
of a xle a n d r em ove sen sor ca ble fr om m et a l clip (F ig. Be sure that cable is installed in routing retainers/
3). clips. Failure to install cable in retainers may result
(5) Rem ove secon da r y (yellow) r et a in in g clip a t in contact with moving parts or over extension of
r ea r of wh eel speed sen sor h ea d (F ig. 4). cable, resulting in an open circuit.
(6) P u sh u p on m et a l r et a in in g clip (F ig. 4) u n t il it
bot t om s. Th is will r elea se wh eel speed sen sor h ea d
CAUTION: It is important that only Mopar"Wheel
fr om h u b a n d bea r in g. Wh ile h oldin g m et a l clip u p,
Bearing Grease be used for the following step appli-
pu ll ba ck on wh eel speed sen sor h ea d r em ovin g it
cation. Other lubricants may cause sensor failure.
fr om h u b a n d bea r in g.
REAR WH EEL SPEED SEN SOR - FWD (Cont inue d)
(1) Lu br ica t e t h e sen sor O-r in g wit h Mopa r Wh eel t h e t on e wh eel. (Refer t o 3 - DIF F E RE NTIAL &
Bea r in g Gr ea se befor e in st a lla t ion in t o t h e H u b An d DRIVE LINE /H ALF SH AF T - RE MOVAL)
Bea r in g. If n o t lu bric a te d , a n im p ro p e r s e a l m a y If wh eel speed sen sor t o t on e wh eel con t a ct is evi-
re s u lt d u e to ro llin g o f th e O-rin g . den t , det er m in e t h e ca u se a n d cor r ect it befor e
(2) If m et a l sen sor r et a in in g clip is n ot in t h e n eu - r epla cin g t h e wh eel speed sen sor or t on e wh eel.
t r a l in st a lled posit ion on h u b a n d bea r in g ca p, in st a ll Ch eck t h e ga p bet ween t h e speed sen sor h ea d a n d
fr om t h e bot t om , if n ecessa r y, a n d pu sh clip u pwa r d t h e t on e wh eel t o en su r e it is wit h in specifica t ion s.
u n t il it sn a ps in t o posit ion . (Refer t o 5 - BRAKE S - ABS/E LE CTRICAL - SP E C-
(3) In st a ll wh eel speed sen sor h ea d in t o r ea r of IF ICATIONS)
h u b a n d bea r in g a lign in g in dex t a b wit h t h e n ot ch in E xcessive wh eel speed sen sor r u n ou t ca n ca u se
t h e t op of t h e m ou n t in g h ole. P u sh t h e sen sor in er r a t ic wh eel speed sen sor sign a ls. Refer t o SP E CI-
u n t il it sn a ps in t o pla ce on t h e m et a l r et a in in g clip. F ICATIONS in t h is sect ion of t h e ser vice m a n u a l for
(4) In st a ll secon da r y (yellow) r et a in in g clip over wh eel t h e m a xim u m a llowed t on e wh eel r u n ou t (Refer t o 5 -
speed sen sor h ea d a n d en ga ge t h e t a bs on ea ch side. BRAKE S - ABS/E LE CTRICAL - SP E CIF ICATIONS).
(5) Rou t e sen sor ca ble u n der lea f spr in g a lon g r ea r If t on e wh eel r u n ou t is excessive, det er m in e if it is
of a xle. In st a ll speed sen sor ca ble in t o r ou t in g clips ca u sed by a defect in t h e dr ivesh a ft a ssem bly or h u b
on r ea r br a ke flex h ose (F ig. 3). a n d bea r in g. Repla ce a s n ecessa r y.
(6) In st a ll ca ble in t o m et a l r ou t in g clip a n d a t t a ch Ton e wh eels a r e pr essed on t o t h eir m ou n t in g su r-
it t o t h e r ea r a xle wit h m ou n t in g bolt (F ig. 3). fa ces a n d sh ou ld n ot r ot a t e in depen den t ly fr om t h e
Tigh t en m ou n t in g bolt t o 16 N·m (140 in . lbs.). m ou n t in g su r fa ce. Repla cem en t of t h e fr on t dr ive-
(7) Con n ect wh eel speed sen sor ca ble t o veh icle sh a ft , r ea r dr ivesh a ft (AWD on ly) or r ea r h u b a n d
wir in g h a r n ess (F ig. 2). B e s u re s p e e d s e n s o r bea r in g is n ecessa r y.
c a ble c o n n e c to r is fu lly s e a te d a n d lo c k e d in to
v e h ic le w irin g h a rn e s s c o n n e c to r.
(8) In st a ll speed sen sor ca ble gr om m et in t o h ole in T RACT I ON CON T ROL SWI T CH
floor pa n m a kin g su r e gr om m et is fu lly sea t ed in t o h ole.
(9) Lower veh icle. DIAGNOSIS AND TESTING - TRACTION
(10) Roa d t est veh icle t o en su r e pr oper oper a t ion CONTROL SWITCH
of t h e ba se a n d ABS br a kin g syst em s. (1) Rem ove lower st eer in g colu m n sh r ou d. (Refer
t o 19 - STE E RING/COLUMN/LOWE R SH ROUD -
RE MOVAL)
T ON E WH EEL
INSPECTION - TONE WHEEL
NOTE: Rear tone wheels for front-wheel-drive vehi-
cles are sealed within the hub and bearing assem-
bly and cannot be inspected or replaced.
Replacement of the hub and bearing is necessary.
Ton e wh eels ca n ca u se er r a t ic wh eel speed sen sor

sign a ls. In spect t on e wh eels for t h e followin g possible
ca u ses.
• m issin g, ch ipped, or br oken t eet h
• con t a ct wit h t h e wh eel speed sen sor
• wh eel speed sen sor t o t on e wh eel a lign m en t
• wh eel speed sen sor t o t on e wh eel clea r a n ce
• excessive t on e wh eel r u n ou t
• t on e wh eel loose on it s m ou n t in g su r fa ce
If a fr on t t on e wh eel is fou n d t o n eed r epla cem en t ,
t h e dr ive sh a ft m u st be r epla ced. No a t t em pt sh ou ld
be m a de t o r epla ce ju st t h e t on e wh eel. (Refer t o 3 - Fig. 5 Traction Control And Autostick Wiring
DIF F E RE NTIAL & DRIVE LINE /H ALF SH AF T - Connections
RE MOVAL) 1 - TRACTION CONTROL WIRING CONNECTOR
If a r ea r t on e wh eel is fou n d t o n eed r epla cem en t 2 - ROUTING CLIP
3 - AUTOSTICK WIRING CONNECTOR
on a n a ll-wh eel-dr ive m odel, t h e dr ive sh a ft m u st be 4 - COLUMN WIRING HARNESS
r epla ced. No a t t em pt sh ou ld be m a de t o r epla ce ju st
T RACT I ON CON T ROL SWI T CH (Cont inue d)
(2) Discon n ect t r a ct ion con t r ol swit ch h a r n ess fr om H Y DRAU LI C/M ECH AN I CAL
colu m n h a r n ess (F ig. 5).
(3) Usin g a n oh m m et er, ch eck for con t in u it y
OPERATION - HYDRAULIC CIRCUITS AND
bet ween pin s 1 a n d 2. Wit h t h e swit ch a ct u a t ed,
t h er e sh ou ld be con t in u it y bet ween t h e t wo pin s. VALVES
Wit h t h e swit ch off, t h er e sh ou ld be n o con t in u it y. Th e h ydr a u lic flu id con t r ol va lves con t r ol t h e flow
of pr essu r ized br a ke flu id t o t h e wh eel br a kes du r in g
REMOVAL t h e differ en t m odes of ABS br a kin g. Th e followin g
Th e t r a ct ion con t r ol swit ch is loca t ed in t h e u pper pa r a gr a ph s expla in h ow t h is wor ks. F or pu r poses of
sh r ou d. (Refer t o 19 - STE E RING/COLUMN/UP P E R expla n a t ion on ly, it is a ssu m ed t h a t on ly t h e r igh t
SH ROUD - RE MOVAL) fr on t wh eel is exper ien cin g a n t ilock br a kin g; t h e fol-
lowin g dia gr a m s sh ow on ly t h e r igh t fr on t wh eel in
INSTALLATION a n a n t ilock br a kin g oper a t ion .
Th e t r a ct ion con t r ol swit ch is loca t ed in t h e u pper
sh r ou d. (Refer t o 19 - STE E RING/COLUMN/UP P E R
NORMAL BRAKING HYDRAULIC CIRCUIT AND
SH ROUD - INSTALLATION) SOLENOID VALVE FUNCTION
Th e h ydr a u lic dia gr a m (F ig. 6) sh ows t h e veh icle in
t h e n or m a l br a kin g m ode of t h e ba se br a ke h ydr a u lic
syst em . Th e dia gr a m sh ows n o wh eel spin or slip
occu r r in g r ela t ive t o t h e speed of t h e veh icle. Th e
dr iver is a pplyin g t h e br a ke peda l wh ich bu ilds pr es-
su r e in t h e br a ke h ydr a u lic syst em t o en ga ge t h e
br a kes a n d st op t h e veh icle.
Fig. 6 Normal Braking Hydraulic Circuit

1 - OUTLET VALVE 6 - TO RIGHT FRONT WHEEL
2 - PUMP PISTON 7 - NORMALLY OPEN VALVE (OFF)
3 - PUMP MOTOR (OFF) 8 - MASTER CYLINDER PRESSURE
4 - LOW PRESSURE ACCUMULATOR 9 - FROM MASTER CYLINDER
5 - NORMALLY CLOSED VALVE (OFF) 10 - NOISE DAMPER CHAMBER
ABS PRIMARY HYDRAULIC CIRCUIT AND
SOLENOID VALVE FUNCTION (ABS WITHOUT
TRACTION CONTROL)
t h e ABS br a kin g m ode. Th e dia gr a m sh ows on e
wh eel is slippin g beca u se t h e dr iver is a t t em pt in g t o
st op t h e veh icle a t a fa st er r a t e t h a n is a llowed by
t h e su r fa ce on wh ich t h e t ir es a r e r idin g.
• Th e n or m a lly open a n d n or m a lly closed va lves
m odu la t e (bu ild/deca y) t h e br a ke h ydr a u lic pr essu r e
a s r equ ir ed.
• Th e pu m p/m ot or is swit ch ed on so t h a t t h e
br a ke flu id fr om t h e low pr essu r e a ccu m u la t or s is
r et u r n ed t o t h e m a st er cylin der cir cu it s.
• Th e br a ke flu id is r ou t ed t o eit h er t h e m a st er
cylin der or t h e wh eel br a ke depen din g on t h e posi-
t ion of t h e n or m a lly open va lve.
Fig. 7 ABS Without Traction Control - Primary Hydraulic Circuit

1 - OUTLET VALVE 8 - NORMALLY OPEN VALVE (MODULATING)
2 - PUMP PISTON 9 - FROM MASTER CYLINDER
3 - PUMP MOTOR (ON) 10 - MASTER CYLINDER PRESSURE
4 - LOW PRESSURE ACCUMULATOR PRESSURE 11 - CONTROLLED WHEEL PRESSURE
5 - LOW PRESSURE ACCUMULATOR 12 - PUMP INTERSTAGE PRESSURE
6 - NORMALLY CLOSED VALVE (MODULATING) 13 - NOISE DAMPER CHAMBER
7 - TO RIGHT FRONT WHEEL
ABS SECONDARY HYDRAULIC CIRCUIT AND • Th e pu m p/m ot or is swit ch ed on so t h a t t h e
SOLENOID VALVE FUNCTION (ABS WITHOUT br a ke flu id fr om t h e low pr essu r e a ccu m u la t or s is
TRACTION CONTROL)
• Th e br a ke flu id will t h en be r ou t ed t o eit h er t h e
m a st er cylin der or t h e wh eel br a ke depen din g on t h e
t h e ABS br a kin g m ode. Th e dia gr a m sh ows on e
posit ion of t h e n or m a lly open va lve.
• In t h e secon da r y cir cu it , 1.2 cc br a ke flu id is
t a ken in by t h e lip sea l sa ver t o pr ot ect t h e lip sea ls
on t h e m a st er cylin der pist on .
• Th e n or m a lly open a n d n or m a lly closed va lves
m odu la t e (bu ild/deca y) t h e br a ke h ydr a u lic pr essu r e
a s r equ ir ed.
Fig. 8 ABS Without Traction Control - Secondary Hydraulic Circuit

1 - OUTLET VALVE 6 - MASTER CYLINDER PRESSURE
2 - PUMP PISTON 7 - CONTROLLED WHEEL PRESSURE
3 - LOW PRESSURE ACCUMULATOR PRESSURE 8 - PUMP INTERSTAGE PRESSURE
4 - TO RIGHT FRONT WHEEL 9 - LIP SEAL SAVER (SECONDARY CIRCUIT ONLY)
5 - FROM MASTER CYLINDER
NORMAL BRAKING HYDRAULIC CIRCUIT,
SOLENOID VALVE, AND SHUTTLE VALVE
FUNCTION (ABS WITH TRACTION CONTROL)
Th e h ydr a u lic dia gr a m (F ig. 9) sh ows a veh icle
wit h t r a ct ion con t r ol in t h e n or m a l br a kin g m ode.
Th e dia gr a m sh ows n o wh eel spin or slip occu r r in g
r ela t ive t o t h e speed of t h e veh icle. Th e dr iver is
a pplyin g t h e br a ke peda l wh ich bu ilds pr essu r e in
t h e br a ke h ydr a u lic syst em t o en ga ge t h e br a kes a n d
st op t h e veh icle. t h e h ydr a u lic sh u t t le va lve closes
wit h ever y br a ke peda l a pplica t ion so pr essu r e is n ot
cr ea t ed a t t h e in let t o t h e pu m p/m ot or.
Fig. 9 ABS With Traction Control - Normal Braking Hydraulic Circuit

1 - OUTLET VALVE 8 - NORMALLY OPEN VALVE (OFF)
2 - PUMP PISTON 9 - NORMALLY OPEN ASR VALVE (OFF)
3 - PUMP MOTOR (OFF) 10 - FROM MASTER CYLINDER
4 - SUCTION VALVE 11 - HYDRAULIC SHUTTLE VALVE
5 - LOW PRESSURE ACCUMULATOR 12 - MASTER CYLINDER PRESSURE
6 - NORMALLY CLOSED VALVE (OFF) 13 - NOISE DAMPER CHAMBER
7 - TO RIGHT FRONT WHEEL
ABS BRAKING HYDRAULIC CIRCUIT, SOLENOID • Th e n or m a lly open a n d n or m a lly closed va lves
VALVE, AND SHUTTLE VALVE FUNCTION (ABS m odu la t e (bu ild/deca y) t h e br a ke h ydr a u lic pr essu r e
a s r equ ir ed.
WITH TRACTION CONTROL)
• Th e pu m p/m ot or is swit ch ed on so t h a t t h e
Th e h ydr a u lic dia gr a m (F ig. 10) sh ows t h e veh icle
br a ke flu id fr om t h e low pr essu r e a ccu m u la t or s is
in t h e ABS br a kin g m ode. Th e dia gr a m sh ows on e
• Th e br a ke flu id is r ou t ed t o eit h er t h e m a st er
cylin der or t h e wh eel br a ke depen din g on t h e posi-
t ion of t h e n or m a lly open va lve.
• Th e h ydr a u lic sh u t t le va lve closes u pon br a ke
a pplica t ion so t h a t t h e pu m p/m ot or ca n n ot siph on
br a ke flu id fr om t h e m a st er cylin der.
Fig. 10 ABS With Traction Control - ABS Braking Hydraulic Circuit

1 - OUTLET VALVE 9 - NORMALLY OPEN ASR VALVE (OFF)
2 - PUMP PISTON 10 - FROM MASTER CYLINDER
3 - PUMP MOTOR (ON) 11 - HYDRAULIC SHUTTLE VALVE
4 - SUCTION VALVE 12 - MASTER CYLINDER PRESSURE
5 - LOW PRESSURE ACCUMULATOR 13 - CONTROLLED WHEEL PRESSURE
6 - NORMALLY CLOSED VALVE (MODULATING) 14 - LOW PRESSURE ACCUMULATOR PRESSURE
7 - TO RIGHT FRONT WHEEL 15 - PUMP INTERSTAGE PRESSURE
8 - NORMALLY OPEN VALVE (MODULATING) 16 - NOISE DAMPER CHAMBER
ABS TRACTION CONTROL HYDRAULIC CIRCUIT, H CU (H Y DRAU LI C CON T ROL
SOLENOID VALVE, AND SHUTTLE VALVE UNIT)
FUNCTION (ABS WITH TRACTION CONTROL)
Th e h ydr a u lic dia gr a m (F ig. 11) sh ows t h e veh icle DESCRIPTION
in t h e ABS br a kin g m ode. Th e dia gr a m sh ows a dr ive Th e h ydr a u lic con t r ol u n it (H CU) is m ou n t ed t o
wh eel is spin n in g a n d br a ke pr essu r e is r equ ir ed t o t h e CAB a s pa r t of t h e ICU (F ig. 22). Th e H CU con -
r edu ce it s speed. t r ols t h e flow of br a ke flu id t o t h e br a kes u sin g a
• Th e n or m a lly open ASR va lve is en er gized t o iso- ser ies of va lves a n d a ccu m u la t or s. A pu m p/m ot or is
la t e t h e br a ke flu id bein g pu m ped fr om t h e m a st er m ou n t ed on t h e H CU t o su pply bu ild pr essu r e t o t h e
cylin der a n d t o isola t e t h e dr iven wh eel. br a kes du r in g a n ABS st op.
• Th e n or m a lly open ASR va lve bypa sses t h e Th e H CU on a veh icle equ ipped wit h ABS a n d
pu m p ou t pu t ba ck t o t h e m a st er cylin der a t a fixed t r a ct ion con t r ol h a s a va lve block h ou sin g t h a t is
pr essu r e set t in g. a ppr oxim a t ely 1 in ch lon ger on t h e low pr essu r e flu id
• Th e n or m a lly open a n d n or m a lly closed va lves a ccu m u la t or s side t h a n a H CU on a veh icle t h a t is
m odu la t e (bu ild/deca y) t h e br a ke pr essu r e a s equ ipped wit h on ly ABS.
r equ ir ed t o t h e spin n in g wh eel.
Fig. 11 Traction Control Hydraulic Circuit

1 - OUTLET VALVE 10 - FROM MASTER CYLINDER
2 - PUMP PISTON 11 - HYDRAULIC SHUTTLE VALVE
3 - PUMP MOTOR (ON) 12 - CONTROLLED WHEEL PRESSURE
4 - LOW PRESSURE ACCUMULATOR PRESSURE 13 - SUCTION VALVE
5 - LOW PRESSURE ACCUMULATOR 14 - PUMP INTERSTAGE PRESSURE
6 - NORMALLY CLOSED VALVE (MODULATING) 15 - NOISE DAMPER CHAMBER
7 - TO RIGHT FRONT WHEEL (SPINNING) 16 - MASTER CYLINDER PRESSURE
8 - NORMALLY OPEN VALVE (MODULATING) 17 - PUMP PRESSURE
9 - NORMALLY OPEN ASR VALVE ON (REGULATING)
H CU (H Y DRAU LI C CON T ROL U N I T ) (Cont inue d)
F or m or e in for m a t ion , (Refer t o 5 - BRAKE S/H Y- BRAKE FLUID ACCUMULATORS
DRAULIC/ME CH ANICAL/ICU (INTE GRATE D CON- Th er e a r e t wo flu id a ccu m u la t or s in t h e H CU–on e
TROL UNIT) - DE SCRIP TION) for t h e pr im a r y h ydr a u lic cir cu it a n d on e for t h e sec-
on da r y h ydr a u lic cir cu it . E a ch h ydr a u lic cir cu it u ses
OPERATION a 5 cc a ccu m u la t or.
F or in for m a t ion on t h e oper a t ion of t h e H CU a s a Th e flu id a ccu m u la t or s t em por a r ily st or e br a ke
wh ole, r efer t o H ydr a u lic Cir cu it s An d Va lve Oper a - flu id t h a t is r em oved fr om t h e wh eel br a kes du r in g
t ion wh ich ca n be fou n d elsewh er e in t h is sect ion . a n ABS cycle. Th is st or ed flu id is u sed by t h e pu m p/
F or in for m a t ion on t h e oper a t ion of t h e com pon en t s m ot or t o pr ovide bu ild pr essu r e for t h e br a ke h ydr a u -
wit h in t h e H CU, r efer t o t h e followin g t h r ee t opics. lic syst em . Wh en t h e a n t ilock st op is com plet e, t h e
a ccu m u la t or s a r e dr a in ed by t h e pu m p/m ot or.
VALVES AND SOLENOIDS On ABS-on ly veh icles, t h er e is a m in i-a ccu m u la t or
Th e va lve block con t a in s fou r in let va lves a n d fou r on t h e secon da r y h ydr a u lic cir cu it t h a t pr ot ect s t h e
ou t let va lves. Th e in let va lves a r e spr in g-loa ded in m a st er cylin der sea ls du r in g a n ABS st op, a n d t h er e
t h e open posit ion a n d t h e ou t let va lves a r e spr in g- is a n oise da m pen in g ch a m ber on t h e pr im a r y cir cu it .
loa ded in t h e closed posit ion du r in g n or m a l br a kin g. On ABS wit h t r a ct ion con t r ol veh icles, t h er e a r e
Th e flu id is a llowed t o flow fr om t h e m a st er cylin der t wo n oise da m pen in g ch a m ber s in t h e H CU.
t o t h e wh eel br a kes.
Du r in g a n ABS st op, t h ese va lves cycle t o m a in t a in PUMP/MOTOR
t h e pr oper slip r a t io for ea ch wh eel. Th e in let va lve Th er e a r e t wo pu m p a ssem blies in t h e H CU—on e
closes pr even t in g fu r t h er pr essu r e in cr ea se a n d t h e for t h e pr im a r y h ydr a u lic cir cu it a n d on e for t h e sec-
ou t let va lve open s t o pr ovide a pa t h fr om t h e wh eel on da r y h ydr a u lic cir cu it . Bot h pu m ps a r e dr iven by a
br a ke t o t h e H CU a ccu m u la t or s a n d pu m p/m ot or. com m on elect r ic m ot or. Th is DC-t ype m ot or is in t e-
Th is r elea ses (deca ys) pr essu r e fr om t h e wh eel br a ke, gr a l t o t h e H CU a n d is con t r olled by t h e CAB.
t h u s r elea sin g t h e wh eel fr om excessive slippa ge. Th e pu m p/m ot or pr ovides t h e ext r a a m ou n t of
On ce t h e wh eel is n o lon ger slippin g, t h e ou t let va lve br a ke flu id n eeded du r in g a n t ilock br a kin g. Br a ke
is closed a n d t h e in let va lve is open ed t o r ea pply flu id is r elea sed t o t h e a ccu m u la t or s wh en t h e ou t let
(bu ild) pr essu r e. va lve is open ed du r in g a n a n t ilock st op. Th e pu m p
On veh icles wit h t r a ct ion con t r ol, t h er e is a n ext r a m ech a n ism con sist s of t wo opposin g pist on s oper a t ed
set of va lves a n d solen oids. Th e ASR va lves, m ou n t ed by a n eccen t r ic ca m sh a ft . In oper a t ion , on e pist on
in t h e H CU va lve block, a r e n or m a lly in t h e open dr a ws flu id fr om t h e a ccu m u la t or s, a n d t h e opposin g
posit ion a n d close on ly wh en t h e t r a ct ion con t r ol is pist on pu m ps flu id t o t h e m a st er cylin der cir cu it s.
a pplied. Wh en t h e a n t ilock st op is com plet e, t h e pu m p/m ot or
Th ese isola t or va lves a r e u sed t o isola t e t h e r ea r dr a in s t h e a ccu m u la t or s.
(n on -dr ivin g) wh eels of t h e veh icle fr om t h e h ydr a u lic Th e CAB m a y t u r n on t h e pu m p/m ot or wh en a n
pr essu r e t h a t t h e H CU pu m p/m ot or is sen din g t o t h e a n t ilock st op is det ect ed. Th e pu m p/m ot or con t in u es
fr on t (dr ivin g) wh eels wh en t r a ct ion con t r ol is bein g t o r u n du r in g t h e a n t ilock st op a n d is t u r n ed off a ft er
a pplied. Th e r ea r br a kes n eed t o be isola t ed fr om t h e t h e st op is com plet e. Un der som e con dit ion s, t h e
m a st er cylin der wh en t r a ct ion con t r ol is bein g pu m p/m ot or r u n s t o dr a in t h e a ccu m u la t or s du r in g
a pplied so t h e r ea r wh eels do n ot dr a g. F or m or e t h e n ext dr ive-off.
in for m a t ion , r efer t o Tr a ct ion Con t r ol Syst em in t h is Th e pu m p/m ot or is n ot a ser vicea ble it em ; if it
sect ion . r equ ir es r epla cem en t , t h e H CU m u st be r epla ced.
I CU (I N T EGRAT ED CON T ROL veh icle equ ipped wit h t r a ct ion con t r ol h a s a va lve
block t h a t is a ppr oxim a t ely on e in ch lon ger t h a n a
UNIT) H CU on a veh icle t h a t is equ ipped wit h ABS on ly.
Th e ABS-on ly ICU con sist s of t h e followin g com po-
DESCRIPTION n en t s: t h e CAB, eigh t (bu ild/deca y) solen oid va lves
Th e h ydr a u lic con t r ol u n it (H CU) a n d t h e con t r ol- (fou r in let va lves a n d fou r ou t let va lves), va lve block,
ler a n t ilock br a ke (CAB) u sed wit h t h is a n t ilock flu id a ccu m u la t or s, a pu m p, a n d a n elect r ic m ot or.
br a ke syst em a r e com bin ed (in t egr a t ed) in t o on e Th e ABS-wit h t r a ct ion con t r ol ICU con sist s of t h e
u n it , wh ich is ca lled t h e in t egr a t ed con t r ol u n it (ICU) followin g com pon en t s: t h e CAB, eigh t (bu ild/deca y)
(F ig. 12). Th e ICU is loca t ed below t h e m a st er cylin - solen oid va lves (fou r in let va lves a n d fou r ou t let
der in t h e en gin e com pa r t m en t (F ig. 13). va lves), t wo t r a ct ion con t r ol (ASR) va lves, t wo
h ydr a u lic sh u t t le va lves, va lve block, flu id a ccu m u la -
t or s, a pu m p, a n d a n elect r ic m ot or.
Th e r epla cea ble com pon en t s of t h e ICU a r e t h e
H CU a n d t h e CAB. No a t t em pt sh ou ld be m a de t o
ser vice a n y in dividu a l com pon en t s of t h e H CU or
CAB. F or in for m a t ion on t h e CAB, (Refer t o 8 -
E LE CTRICAL/E LE CTRONIC CONTROL MOD-
ULE S/CONTROLLE R ANTILOCK BRAKE -
DE SCRIP TION).
OPERATION
F or in for m a t ion of t h e ICU, r efer t o t h ese in divid-
u a l com pon en t s of t h e ICU:
• CONTROLLE R ANTILOCK BRAKE (CAB)
(Refer t o 8 - E LE CTRICAL/E LE CTRONIC CON-
TROL MODULE S/CONTROLLE R ANTILOCK
Fig. 12 INTEGRATED CONTROL UNIT (ICU) BRAKE - OP E RATION)
1 - PUMP/MOTOR
• H YDRAULIC CONTROL UNIT (H CU) (Refer t o
2 - HCU 5 - BRAKE S - ABS/H YDRAULIC/ME CH ANICAL/
3 - PUMP/MOTOR CONNECTOR H CU (H YDRAULIC CONTROL UNIT) - OP E RA-
4 - CAB
TION)
F or in for m a t ion on t h e ICU’s h ydr a u lic cir cu it s,
r efer t o H YDRAULIC CIRCUITS AND VALVE
OP E RATION. (Refer t o 5 - BRAKE S - ABS/H Y-
DRAULIC/ME CH ANICAL - OP E RATION)
REM OVAL
REMOVAL - LHD
(1) Discon n ect t h e n ega t ive (gr ou n d) ca ble fr om
t h e ba t t er y a n d isola t e ca ble.
(2) Rem ove t h e ba t t er y sh ield.
(3) Rem ove t h e ba t t er y (Refer t o 8 - E LE CTRI-
CAL/BATTE RY SYSTE M/BATTE RY - RE MOVAL).
(4) Discon n ect t h e va cu u m h ose con n ect or a t t h e
(5) Rem ove t h e scr ew secu r in g t h e en gin e coola n t
Fig. 13 ICU LOCATION IN VEHICLE filler n eck t o t h e ba t t er y t r a y.
1 - POWER BRAKE BOOSTER (6) Rem ove t h e ba t t er y t r a y (Refer t o 8 - E LE C-
2 - MASTER CYLINDER
3 - ICU
TRICAL/BATTE RY SYSTE M/TRAY - RE MOVAL).
Two differ en t ICU’s (H CU a n d CAB) a r e u sed on t h e br a ke peda l t o a posit ion pa st t h e fir st in ch of
t h is veh icle depen din g on wh et h er or n ot t h e veh icle peda l t r a vel. Th is w ill p re v e n t bra k e flu id fro m
is equ ipped wit h t r a ct ion con t r ol. Th e H CU on a
I CU (I N T EGRAT ED CON T ROL U N I T ) (Cont inue d)
d ra in in g o u t o f th e m a s te r c y lin d e r o n c e th e
bra k e tu be s a re re m o v e d fro m th e HCU .
CAUTION: Do not apply a 12–volt power source to

any terminals of the 24-way CAB connector when
disconnected.
(8) Discon n ect t h e wir in g h a r n ess con n ect or fr om

t h e speed con t r ol ser vo.
(9) Rem ove t h e speed con t r ol ser vo m ou n t in g n u t s
a n d m ove t h e ser vo ou t of t h e wa y.
(10) Discon n ect t h e 24–wa y con n ect or fr om t h e
CAB. To discon n ect t h e 24–wa y con n ect or, gr a sp t h e
lock on t h e 24–wa y con n ect or a n d pu ll it a s fa r u p a s
possible. Th is will u n lock t h e 24–wa y con n ect or fr om
t h e socket on t h e CAB.
CAUTION: Before removing the brake tubes from

the HCU, the HCU must be thoroughly cleaned. This
must be done to prevent dirt particles from falling
into the ports of HCU or entering the brake tubes.
(11) Th or ou gh ly clea n a ll su r fa ces of t h e ICU a n d

br a ke t u be n u t s. Use on ly a solven t su ch a s Mopa r ! Fig. 15 Lower Coupling And Dash Seal
Br a ke P a r t s Clea n er or equ iva len t t o clea n t h e ICU. 1 - COUPLING
2 - DASH SEAL
(12) Rem ove t h e br a ke t u bes (4) fr om t h e ou t let 3 - SILENCER
por t s on t h e H CU (F ig. 14). 4 - MOUNTING SCREWS
5 - RETAINING CLIPS
6 - DASH
(18) Rem ove t h e 3 bolt s a t t a ch in g t h e ICU t o it s

m ou n t in g br a cket (F ig. 16).
Fig. 14 Brake Tube Nuts At ICU

1 - PRIMARY BRAKE TUBE
2 - SECONDARY BRAKE TUBE
3 - CHASSIS BRAKE TUBES
(13) Rem ove t h e pr im a r y a n d secon da r y br a ke Fig. 16 ICU Mounting Bolts

t u bes fr om t h e in let por t s on t h e H CU (F ig. 14). 1 - ICU MOUNTING BOLTS
(14) Cen t er a n d pr op t h e st eer in g wh eel. 2 - COUPLER
(15) Rem ove t h e pin ch bolt a n d discon n ect t h e
st eer in g sh a ft cou plin g. (19) Rem ove ICU fr om t h e veh icle t h r ou gh en gin e
(16) If equ ipped, r em ove t h e t wo clips secu r in g com pa r t m en t .
silen cer t o da sh sea l (F ig. 15). Rem ove silen cer. (20) If r equ ir ed, t o sepa r a t in g t h e CAB fr om t h e
(17) Rem ove t h e t h r ee scr ews secu r in g t h e da sh H CU, (Refer t o 5 - BRAKE S - ABS/H YDRAULIC/ME -
sea l (F ig. 15). Rem ove sea l.
CH ANICAL/ICU (INTE GRATE D CONTROL UNIT) -
DISASSE MBLY).
REMOVAL - RHD
NOTE: Before proceeding, (Refer to 5 - BRAKES -
WARNING)(Refer to 5 - BRAKES - CAUTION)
(1) Discon n ect t h e n ega t ive (gr ou n d) ca ble fr om

t h e ba t t er y a n d isola t e ca ble.
t h e br a ke peda l t o a posit ion pa st t h e fir st in ch of
peda l t r a vel. Th is w ill p re v e n t bra k e flu id fro m
d ra in in g o u t o f th e m a s te r c y lin d e r w h e n th e
bra k e tu be s a re re m o v e d fro m th e HCU .
MAINTE NANCE /H OISTING - STANDARD P ROCE - Fig. 18 Unlocked 24-Way CAB Connector
DURE ) 1 - HCU
(4) Rem ove t h e r ou t in g clip a t t a ch in g t h e ICU wir- 2 - CAB
3 - 24–WAY CONNECTOR
in g h a r n ess t o t h e ICU m ou n t in g br a cket (F ig. 17). 4 - CONNECTOR LOCK (UNLOCKED)
CAUTION: Do not apply a 12 volt power source to must be done to prevent dirt particles from falling
any terminals of the HCU connector when discon- into the ports of HCU or entering the brake tubes.
nected. (6) Th or ou gh ly clea n a ll su r fa ces of t h e H CU, a n d
a ll br a ke t u be n u t s loca t ed on t h e H CU. Use on ly a
(5) Rem ove t h e 24-wa y con n ect or (F ig. 17) fr om
solven t su ch a s Mopa r Br a ke P a r t s Clea n er or a n
t h e CAB. Th e 24-wa y con n ect or is r em oved fr om t h e
equ iva len t t o clea n t h e H CU.
CAB u sin g t h e followin g pr ocedu r e. Gr a sp t h e lock
(7) Rem ove t h e br a ke t u bes (6) fr om t h e in let a n d
on t h e 24-wa y con n ect or (F ig. 17) a n d pu ll it a s fa r
ou t let por t s on t h e H CU. (F ig. 19).
ou t a s possible (F ig. 18). Th is will r a ise a n d u n lock
t h e 24-wa y con n ect or fr om t h e socket on t h e CAB.
Fig. 19 Brake Tube Connections To HCU

Fig. 17 CAB 24-Way Connector 1 - LEFT REAR WHEEL BRAKE TUBE
2 - SECONDARY BRAKE TUBE FROM MASTER CYLINDER
1 - CAB WIRING HARNESS 3 - LEFT FRONT WHEEL BRAKE TUBE
2 - 24–WAY CONNECTOR 4 - CAB
3 - FLOOR PAN 5 - RIGHT REAR WHEEL BRAKE TUBE
4 - HCU 6 - HCU MOUNTING BRACKET
5 - CAB 7 - BRAKE TUBE TO HCU CONNECTION LOCATION LEGEND
6 - HCU MOUNTING BRACKET 8 - RIGHT FRONT WHEEL BRAKE TUBE
7 - CONNECTOR LOCK 9 - PRIMARY BRAKE TUBE FROM MASTER CYLINDER
CAUTION: Before removing the brake tubes from

the HCU, the HCU must be thoroughly cleaned. This
(8) Rem ove t h e 3 bolt s (F ig. 20) a t t a ch in g t h e ICU DISASSEMBLY - ICU
m ou n t in g br a cket t o t h e fr on t su spen sion cr ossm em - (1) Rem ove t h e ICU fr om t h e veh icle. (Refer t o 5 -
ber. BRAKE S/H YDRAULIC/ME CH ANICAL/ICU (INTE -
GRATE D CONTROL UNIT) - RE MOVAL)
(2) Discon n ect t h e pu m p/m ot or wir in g h a r n ess
fr om t h e CAB (F ig. 22).
Fig. 20 ICU To Suspension Cradle Mounting Bolts

1 - HCU MOUNTING BRACKET BOLTS
2 - HCU MOUNTING BRACKET BOLT
3 - CAB
4 - HCU MOUNTING BRACKET Fig. 22 INTEGRATED CONTROL UNIT (ICU)
5 - HCU
1 - PUMP/MOTOR
2 - HCU
(9) Rem ove ICU a n d t h e m ou n t in g br a cket a s a 3 - PUMP/MOTOR CONNECTOR
u n it fr om t h e veh icle. 4 - CAB
(10) Rem ove t h e 3 bolt s (F ig. 21) m ou n t in g t h e
ICU t o t h e m ou n t in g br a cket . Sepa r a t e t h e ICU fr om (3) Rem ove t h e 4 bolt s (F ig. 23) a t t a ch in g t h e CAB
t h e m ou n t in g br a cket . t o t h e H CU.
Fig. 21 ICU Mounting Bolts Fig. 23 (TYPICAL) CAB Attaching Bolts

1 - HCU 1 - MOUNTING BOLTS
2 - HCU MOUNTING BOLTS 2 - CAB
3 - HCU MOUNTING BRACKET 3 - HCU VALVE BLOCK
(11) F or t h e pr ocedu r e on sepa r a t in g a n d a t t a ch in g

t h e CAB t o t h e H CU, r efer t o DISASSE MBLY.
(4) Rem ove t h e CAB fr om t h e H CU (F ig. 24). and torqued. These tubes must not contact each
other or other vehicle components when installed.
Also, after the brake tubes are installed on the HCU,
ensure all spacer clips are reinstalled on the brake
tubes.
(7) In st a ll t h e pr im a r y a n d secon da r y br a ke t u bes
in t o t h eir cor r ect por t loca t ion s on t h e H CU va lve
block (F ig. 14). Tigh t en t h e t u be n u t s t o a t or qu e of
17 N·m (145 in . lbs.).
CAUTION: When installing the chassis brake tubes

on the HCU valve block, they must be located cor-
rectly in the valve block to ensure proper ABS oper-
ation.
NOTE: The chassis brake tube attachment locations

to the HCU, are marked on the bottom of the CAB.
Fig. 24 (TYPICAL) Remove/Install CAB
1 - CAB (8) In st a ll t h e (4) ch a ssis br a ke t u bes in t o t h eir
2 - HCU VALVES
3 - HCU VALVE BLOCK
cor r ect por t loca t ion s on t h e H CU va lve block a s
sh own (F ig. 14). Tigh t en t h e t u be n u t s t o a t or qu e of
ASSEMBLY - ICU 17 N·m (145 in . lbs.).
(1) In st a ll t h e CAB (F ig. 24) on t h e H CU. NOTE: Before installing the 24–way connector in
(2) In st a ll t h e 4 bolt s m ou n t in g t h e CAB (F ig. 23) the CAB be sure the seal is properly installed in the
t o t h e H CU. Tigh t en t h e CAB m ou n t in g bolt s t o a connector.
t or qu e of 2 N·m (17 in . lbs.).
(3) P lu g t h e pu m p/m ot or wir in g h a r n ess in t o t h e (9) In st a ll t h e 24–wa y con n ect or on t h e CAB by,
CAB. fir st , posit ion in g t h e 24–wa y con n ect or in t h e socket
(4) In st a ll t h e ICU in t h e veh icle a n d bleed t h e of t h e CAB a n d ca r efu lly pu sh in g it down a s fa r a s
ba se a n d ABS h ydr a u lic syst em s. (Refer t o 5 - possible. On ce con n ect or is fu lly sea t ed by h a n d in t o
BRAKE S/H YDRAULIC/ME CH ANICAL/ICU (INTE - t h e CAB socket , pu sh down on con n ect or lock. Th is
GRATE D CONTROL UNIT) - INSTALLATION) will pu ll t h e con n ect or in t o t h e socket of t h e CAB
a n d lock it in t h e in st a lled posit ion .
(10) In st a ll a n y r ou t in g clips on t h e br a ke t u bes.
I N STALLAT I ON (11) Rem ove t h e br a ke peda l h older.
(12) In st a ll t h e speed con t r ol ser vo wit h it s m ou n t -
INSTALLATION - LHD in g n u t s.
(1) P la ce t h e ICU in it s br a cket below t h e m a st er (13) Con n ect t h e wir in g h a r n ess t o t h e speed con -
cylin der. St a r t t h e u pper m ou n t in g bolt t o h old it in t r ol ser vo.
pla ce. (14) In st a ll t h e ba t t er y t r a y (Refer t o 8 - E LE C-
(2) In side t h e veh icle, in st a ll t h e r em a in in g 2 TRICAL/BATTE RY SYSTE M/TRAY - INSTALLA-
m ou n t in g bolt s a t t a ch in g t h e ICU t o t h e m ou n t in g TION).
br a cket (F ig. 16). Tigh t en a ll 3 m ou n t in g bolt s t o a (15) In st a ll t h e scr ew secu r in g t h e coola n t filler
t or qu e of 11 N·m (97 in . lbs.). n eck t o t h e ba t t er y t r a y.
(3) In st a ll t h e da sh sea l a n d t h r ee m ou n t in g (16) Recon n ect t h e va cu u m h ose con n ect or a t t h e
scr ews (F ig. 15). t a n k bu ilt in t o t h e ba t t er y t r a y.
(4) If equ ipped, in st a ll t h e silen cer on t op of t h e (17) In st a ll t h e ba t t er y (Refer t o 8 - E LE CTRI-
da sh sea l (F ig. 15). CAL/BATTE RY SYSTE M/BATTE RY - INSTALLA-
(5) Con n ect t h e st eer in g sh a ft cou plin g a n d in st a ll TION).
t h e pin ch bolt (F ig. 15). Tigh t en t h e pin ch bolt t o 28 (18) In st a ll t h e ba t t er y sh ield.
N·m (250 in . lbs.). (19) Rem ove t h e br a ke peda l h older.
(6) Rem ove t h e st eer in g wh eel h older. (20) Con n ect n ega t ive ca ble ba ck on n ega t ive post
of t h e ba t t er y.
CAUTION: Because of the flexible section in the pri-
mary and secondary brake tubes, the brake tubes
must be held in proper orientation when tightened
(21) Bleed t h e Ba se a n d ABS br a ke h ydr a u lic sys- (4) In st a ll t h e 24-wa y con n ect or (F ig. 17) on t h e
t em s (Refer t o 5 - BRAKE S - STANDARD P ROCE - CAB u sin g t h e followin g pr ocedu r e. P osit ion t h e
DURE ). 24-wa y con n ect or in t h e socket of t h e CAB a n d ca r e-
(22) Roa d t est veh icle t o en su r e pr oper oper a t ion fu lly pu sh it down a s fa r a s possible. Wh en con n ect or
of t h e ba se a n d a n t ilock br a ke syst em s. is fu lly sea t ed by h a n d in t o t h e CAB socket , pu sh in
t h e con n ect or lock (F ig. 18). Th is will pu ll t h e con n ec-
INSTALLATION - RHD t or in t o t h e socket of t h e CAB a n d lock it in t h e
(1) In st a ll t h e ICU on t h e m ou n t in g br a cket (F ig. in st a lled posit ion .
21). In st a ll t h e 3 bolt s (F ig. 21) a t t a ch in g t h e ICU t o
t h e m ou n t in g br a cket . Tigh t en t h e 3 m ou n t in g bolt s NOTE: The CAB wiring harness must be clipped to
t o a t or qu e of 11 N·m (97 in . lbs.). the ICU mounting bracket. This will ensure the wir-
ing harness is properly routed and does not contact
CAUTION: The ICU mounting bracket to front sus- the brake tubes or the body of the vehicle.
pension cradle mounting bolts have a unique corro-
sion protection coating and a special aluminum (5) Clip t h e ca b wir in g h a r n ess (F ig. 17) t o t h e
washer. For this reason, only the original, or origi- ICU m ou n t in g br a cket .
nal equipment Mopar replacement bolts can be (6) In st a ll t h e r ou t in g clips (F ig. 25) on t h e br a ke
used to mount the ICU bracket to the front suspen- t u bes.
sion crossmember.
(2) In st a ll t h e ICU a n d it s m ou n t in g br a cket a s a n

a ssem bly on t h e fr on t su spen sion cr ossm em ber.
In st a ll t h e 3 bolt s a t t a ch in g t h e ICU br a cket t o t h e
cr ossm em ber (F ig. 20). Tigh t en t h e 3 m ou n t in g bolt s
t o a t or qu e of 28 N·m (250 in . lbs.).
CAUTION: Because of the flexible section in the pri-

mary and secondary brake tubes, and the brake
tubes between the HCU and the proportioning
valve, the brake tubes must be held in proper ori-
entation when tightened and torqued. These tubes
must not contact each other or other vehicle com-
ponents when installed. Also, after the brake tubes
are installed on the HCU, ensure all spacer clips are
reinstalled on the brake tubes. Fig. 25 Brake Tube Routing Clips
1 - ROUTING CLIP
2 - HCU
CAUTION: When installing the chassis brake tubes 3 - BRAKE TUBES
on the HCU valve block, they must be located cor- 4 - ROUTING CLIP
rectly in the valve block to ensure proper ABS oper-
ation. Refer to (Fig. 19) for the correct chassis (7) Lower t h e veh icle.
brake tube locations. (8) Con n ect n ega t ive ca ble ba ck on n ega t ive post of
t h e ba t t er y.
(9) Bleed t h e ba se a n d ABS h ydr a u lic syst em s.
NOTE: The chassis brake tube attachment locations (Refer t o 5 - BRAKE S - STANDARD P ROCE DURE )
to the HCU, are marked on the bottom of the ICU (10) Roa d t est veh icle t o en su r e pr oper oper a t ion
mounting bracket. of t h e ba se a n d a n t ilock br a ke syst em s.
(3) In st a ll t h e 6 ch a ssis br a ke t u bes in t o t h eir cor-
r ect por t loca t ion s on t h e H CU va lve block a s sh own
in (F ig. 19). Tigh t en t h e t u be n u t s t o a t or qu e of 17
N·m (145 in . lbs.).
NOTE: Before installing the 24-way connector in the

CAB be sure the seal is properly installed in the
connector.
RS COOLING 7-1
COOLING
page page
COOLING STANDARD PROCEDURE - COOLING

DESCRIPTION SYSTEM FILLING . . . . . . . . . . . . . . . . . . . . . . 4
DESCRIPTION - COOLING SYSTEM . .......1 STANDARD PROCEDURE - ADDING
DESCRIPTION - HOSE CLAMPS . . . . .......1 ADDITIONAL COOLANT . . . . . . . . . . . . . . . . . 4
OPERATION STANDARD PROCEDURE - COOLANT
OPERATION - COOLING SYSTEM .. .......2 LEVEL CHECK . . . . . . . . . . . . . . . . . . . . . . . . 4
OPERATION - HOSE CLAMPS . . . . . .......2 SPECIFICATIONS
DIAGNOSIS AND TESTING ACCESSORY DRIVE BELT TENSION . . . . . . . 5
DIAGNOSIS AND TESTING - COOLING TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SYSTEM LEAK TEST . . . . . . . . . . . . . .......2 SPECIAL TOOLS
DIAGNOSIS AND TESTING - COOLING COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . 6
SYSTEM FLOW CHECK . . . . . . . . . . .......3 ACCESSORY DRIVE . . . . . . . . . . . . . . . . . . . . . . . 7
DIAGNOSIS AND TESTING - COOLING ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
SYSTEM AERATION . . . . . . . . . . . . . .......4 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . 38
DIAGNOSIS AND TESTING - COOLING
SYSTEM DEAERATION . . . . . . . . . . . .......4
STANDARD PROCEDURE
STANDARD PROCEDURE - COOLING
SYSTEM DRAINING . . . . . . . . . . . . . .......4
COOLI N G
DESCRI PT I ON
DESCRIPTION - COOLING SYSTEM
Th e coolin g syst em com pon en t s con sist of a r a dia -
t or, elect r ic fa n m ot or s, sh r ou d, pr essu r e ca p, t h er m o-
st a t , t r a n sm ission oil cooler, wa t er pu m p, h oses,
cla m ps, coola n t , a n d a coola n t r eser ve syst em t o com -
plet e t h e cir cu it .
DESCRIPTION - HOSE CLAMPS

Th e coolin g syst em u ses spr in g t ype h ose cla m ps.
If a spr in g t ype cla m p r epla cem en t is n ecessa r y,
r epla ce wit h t h e or igin a l Mopa r ! equ ipm en t spr in g
t ype cla m p.
CAUTION: A number or letter is stamped into the Fig. 1 Spring Clamp Size Location
tongue of constant tension clamps. If replacement 1 - SPRING CLAMP SIZE LOCATION
is necessary, use only a original equipment clamp
with matching number or letter (Fig. 1).
7-2 COOLING RS
COOLI N G (Cont inue d)
OPERAT I ON OPERATION - HOSE CLAMPS

Th e spr in g t ype h ose cla m p a pplies con st a n t t en -
OPERATION - COOLING SYSTEM sion on a h ose con n ect ion . To r em ove a spr in g t ype
Th e en gin e coolin g syst em s pr im a r y pu r pose is t o h ose cla m p, u se Specia l Tool 6094 or equ iva len t , con -
m a in t a in en gin e t em per a t u r e in a r a n ge t h a t will st a n t t en sion cla m p plier s (F ig. 3) t o com pr ess t h e
pr ovide sa t isfa ct or y en gin e per for m a n ce a n d em ission h ose cla m p.
levels u n der a ll expect ed dr ivin g con dit ion s. It a lso
pr ovides h ot wa t er (coola n t ) for h ea t er per for m a n ce
a n d coolin g for a u t om a t ic t r a n sm ission oil. It does DI AGN OSI S AN D T EST I N G
t h is by t r a n sfer r in g h ea t fr om en gin e m et a l t o cool-
a n t , m ovin g t h is h ea t ed coola n t t o t h e r a dia t or, a n d DIAGNOSIS AND TESTING - COOLING SYSTEM
t h en t r a n sfer r in g t h is h ea t t o t h e a m bien t a ir. LEAK TEST
• Wh en en gin e is cold: t h er m ost a t is closed, cool-
in g syst em h a s n o flow t h r ou gh t h e r a dia t or. Th e WARNING: THE WARNING WORDS “DO NOT OPEN
coola n t bypa ss flows t h r ou gh t h e en gin e on ly. HOT” ON THE RADIATOR PRESSURE CAP IS A
• Wh en en gin e is wa r m : t h er m ost a t is open , cool- SAFETY PRECAUTION. WHEN HOT, PRESSURE
in g syst em h a s bypa ss flow a n d coola n t flow t h r ou gh BUILDS UP IN COOLING SYSTEM. TO PREVENT
r a dia t or. SCALDING OR INJURY, THE RADIATOR CAP
Coola n t flow cir cu it s for t h e 2.4L a n d 3.3/3.8L SHOULD NOT BE REMOVED WHILE THE SYSTEM
en gin es a r e sh own in (F ig. 2). IS HOT OR UNDER PRESSURE.
Fig. 2 Cooling System Flow

1 - HEATER - REAR (3.3/3.8L OPTIONAL EQUIPMENT) 6 - WATER PUMP
2 - HEATER - FRONT 7 - RADIATOR
3 - ENGINE 8 - COOLANT RECOVERY/RESERVE CONTAINER
4 - THERMOSTAT 9 - COOLANT FLOW - PRESSURE CAP VACUUM
5 - ENGINE OIL COOLER (3.3/3.8L OPTIONAL EQUIPMENT) 10 - COOLANT FLOW - PRESSURE CAP RELIEF
RS COOLING 7-3
If t h er e a r e n o ext er n a l lea ks, a ft er t h e ga u ge dia l
sh ows a dr op in pr essu r e, det a ch t h e t est er. St a r t
en gin e a n d r u n u n t il t h e t h er m ost a t open s, a llowin g
t h e coola n t t o expa n d. Rea t t a ch t h e coolin g syst em
t est er. If t h e n eedle on t h e dia l flu ct u a t es it in dica t es
a com bu st ion lea k, u su a lly a h ea d ga sket lea k.
WARNING: WITH TOOL IN PLACE, PRESSURE WILL

BUILD UP FAST. EXCESSIVE PRESSURE BUILT UP,
BY CONTINUOUS ENGINE OPERATION, MUST BE
RELEASED TO A SAFE PRESSURE POINT. NEVER
PERMIT PRESSURE TO EXCEED 138 kPa (20 psi).
If t h e n eedle on t h e dia l does n ot flu ct u a t e, r a ise

t h e en gin e r pm a few t im es. If a n a bn or m a l a m ou n t
of coola n t or st ea m em it s fr om t h e t a ilpipe, it m a y
Fig. 3 Hose Clamp Tool in dica t e a coola n t lea k ca u sed by a fa u lt y h ea d ga s-
1 - HOSE CLAMP TOOL 6094 ket , cr a cked en gin e block, or cr a cked cylin der h ea d.
2 - HOSE CLAMP Th er e m a y be in t er n a l lea ks t h a t ca n be det er-
m in ed by r em ovin g t h e oil dipst ick. If wa t er globu les
Wit h en gin e n ot r u n n in g, r em ove r a dia t or pr essu r e
a ppea r in t er m ixed wit h t h e oil it will in dica t e a n
ca p a n d wipe t h e r a dia t or filler n eck sea lin g sea t
in t er n a l lea k in t h e en gin e. If t h er e is a n in t er n a l
clea n . Th e r a dia t or sh ou ld be fu ll.
lea k, t h e en gin e m u st be disa ssem bled for r epa ir.
At t a ch t h e Coolin g Syst em Test er 7700 or equ iva -
len t t o t h e r a dia t or, a s sh own in (F ig. 4) a n d a pply
104 kP a (15 psi) pr essu r e. If t h e pr essu r e dr ops m or e
DIAGNOSIS AND TESTING - COOLING SYSTEM
t h a n 13.8 kP a (2 psi) in 2 m in u t es, in spect a ll poin t s FLOW CHECK
for ext er n a l lea ks. To det er m in e wh et h er coola n t is flowin g t h r ou gh
All r a dia t or a n d h ea t er h oses sh ou ld be sh a ken t h e coolin g syst em , u se on e of t h e followin g pr oce-
wh ile a t 104 kP a (15 psi), sin ce som e lea ks occu r on ly du r es:
wh ile dr ivin g du e t o en gin e m ovem en t .
PREFERRED METHOD
WARNING: DO NOT REMOVE THE COOLING SYS-
TEM PRESSURE CAP OR ANY HOSE WITH THE
SYSTEM HOT AND UNDER PRESSURE BECAUSE
SERIOUS BURNS FROM COOLANT CAN OCCUR.
• Rem ove pr essu r e ca p wh en en gin e is cold.

Rem ove sm a ll a m ou n t of coola n t . Idle en gin e u n t il
t h er m ost a t open s. You sh ou ld obser ve coola n t flow
wh ile lookin g down t h e filler n eck. On ce flow is
det ect ed in st a ll t h e pr essu r e ca p. Repla ce r em oved
coola n t in t o coola n t r ecover y con t a in er.
ALTERNATIVE METHOD
• If en gin e is cold, idle en gin e u n t il n or m a l oper-
a t in g t em per a t u r e is r ea ch ed. F eel t h e u pper r a dia t or
h ose. If it is h ot , coola n t is cir cu la t in g.
Fig. 4 Pressure Testing

7-4 COOLING RS
DIAGNOSIS AND TESTING - COOLING SYSTEM STANDARD PROCEDURE - COOLING SYSTEM

AERATION FILLING
Low coola n t level in a cr oss flow r a dia t or will Rem ove r a dia t or pr essu r e ca p (F ig. 5) a n d fill sys-
equ a lize in bot h t a n ks wit h en gin e off. Wit h en gin e t em , u sin g a 50/50 m ix of Mopa r ! An t ifr eeze/Coola n t ,
a t r u n n in g a n d a t oper a t in g t em per a t u r e, t h e h igh 5 Yea r /100,000 Mile F or m u la a n d dist illed wa t er.
pr essu r e in let t a n k r u n s fu ll a n d t h e low pr essu r e Con t in u e fillin g syst em u n t il fu ll. B e c a re fu l n o t
ou t let t a n k dr ops, r esu lt in g in coolin g syst em a er a - to s p ill c o o la n t o n d riv e be lts o r th e g e n e ra to r.
t ion . Aer a t ion will dr a w a ir in t o t h e wa t er pu m p F or coolin g syst em ca pa cit y, (Refer t o LUBRICATION
r esu lt in g in t h e followin g: & MAINTE NANCE /F LUID CAPACITIE S - SP E CIF I-
• H igh r ea din g sh own on t h e t em per a t u r e ga u ge. CATIONS).
• Loss of coola n t flow t h r ou gh t h e h ea t er cor e. F ill coola n t r ecover y/r eser ve con t a in er (F ig. 5) t o a t
• Cor r osion in t h e coolin g syst em . lea st t h e MAX m a r k wit h 50/50 solu t ion . It m a y be
• Wa t er pu m p sea l m a y r u n dr y, in cr ea sin g t h e n ecessa r y t o a dd coola n t t o t h e r ecover y/r eser ve con -
r isk of pr em a t u r e sea l fa ilu r e. t a in er a ft er t h r ee or fou r wa r m u p/cool down cycles
• Com bu st ion ga s lea ks in t o t h e coola n t ca n a lso t o m a in t a in coola n t level bet ween t h e MAX a n d MIN
ca u se t h e a bove pr oblem s. m a r k. Th is will a llow t r a pped a ir t o be r em oved fr om
t h e syst em .
DEAERATION STANDARD PROCEDURE - ADDING
Air ca n on ly be r em oved fr om t h e syst em by ga t h - ADDITIONAL COOLANT
er in g u n der t h e pr essu r e ca p. On t h e n ext h ea t u p it Th e ra d ia to r c a p s h o u ld n o t be re m o v e d .
will be pu sh ed pa st t h e pr essu r e ca p in t o t h e coola n t Wh en a ddit ion a l coola n t is n eeded t o m a in t a in t h is
r ecover y bot t le by t h er m a l expa n sion of t h e coola n t . level, it sh ou ld be a dded t o t h e coola n t r ecover y/r e-
It t h en esca pes t o t h e a t m osph er e in t h e coola n t ser ve con t a in er (F ig. 5). Use on ly 50/50 m ix of et h yl-
r ecover y bot t le a n d is r epla ced wit h coola n t on cool en e glycol t ype a n t ifr eeze a n d dist illed wa t er. F or t h e
down . r ecom m eded a n t ifr eeze/coola n t t ype (Refer t o LUBRI-
To effect ively dea er a t e t h e syst em , m u lt iple t h er- CATION & MAINTE NANCE /F LUID TYP E S -
m a l cycles of t h e syst em m a y be r equ ir ed. DE SCRIP TION).
NOTE: Deaeration does not occur at engine idle— CAUTION: Do not use well water, or suspect water
higher engine speeds are required. Normal driving supply in cooling system. A 50/50 ethylene glycol
will deaerate cooling system. and distilled water mix is recommended. For the
recommeded antifreeze/coolant type (Refer to
LUBRICATION & MAINTENANCE/FLUID TYPES -
DESCRIPTION).
STAN DARD PROCEDU RE
STANDARD PROCEDURE - COOLING SYSTEM STANDARD PROCEDURE - COOLANT LEVEL
DRAINING CHECK
WARNING: DO NOT REMOVE OR LOOSEN THE NOTE: Do not remove radiator cap for routine cool-
COOLANT PRESSURE CAP, CYLINDER BLOCK ant level inspections.
DRAIN PLUGS, OR THE DRAINCOCK WHEN THE
SYSTEM IS HOT AND UNDER PRESSURE Th e coola n t r eser ve syst em pr ovides a qu ick visu a l
BECAUSE SERIOUS BURNS FROM THE COOLANT m et h od for det er m in in g t h e coola n t level wit h ou t
CAN OCCUR. r em ovin g t h e r a dia t or ca p. With th e e n g in e c o ld
a n d n o t ru n n in g , sim ply obser ve t h e level of t h e
(1) With o u t re m o v in g ra d ia to r p re s s u re c a p coola n t in t h e r ecover y/r eser ve con t a in er (F ig. 5). Th e
a n d w ith s y s te m n o t u n d e r p re s s u re , u sin g a coola n t level sh ou ld be bet ween t h e MIN a n d MAX
scr ewdr iver, open t h e dr a in cock. Th e dr a in cock is m a r ks.
loca t ed on t h e lower left side of r a dia t or.
(2) Aft er t h e coola n t r ecover y/r eser ve con t a in er is
em pt y, t h en r em ove coola n t pr essu r e ca p (F ig. 5).
(3) Rem ove t h e cylin der block dr a in plu g(s).
RS COOLING 7-5
Fig. 5 Cooling System Service Locations

1 - COOLANT RECOVERY CONTAINER 3 - ENGINE OIL LEVEL DIPSTICK
2 - ENGINE OIL FILL CAP 4 - RADIATOR PRESSURE CAP
SPECI FI CAT I ON S TORQUE

ACCESSORY DRIVE BELT TENSION DESCRIPTION N·m Ft. In.
Lbs. Lbs.
ACCESSORY TENSION Bolt, Accessory Drive Belt 28 - 250
DRIVE BELT Tensioner Assembly (3.3/3.8L)
2.4L ENGINE Engine Coolant Temperature 7 - 60
Air Conditioning Sensor
Compressor/ Dynamic Tensioner Bolt, Generator & A/C Compressor 54 40 -
Generator Drive Belt Tensioner Assembly
534 - 756 N (2.4L)
New
Power (120 - 170 178 - 212 Hz Bolts, Coolant Outlet Connector/ 28 - 250
Belt
Steering lbs.) Thermostat Housing
Used 356 - 534 N Bolts, Water Pump 12 - 105
145 - 178 Hz
Belt* (80 - 120 lbs) Bolts , Water Pump Inlet Tube 12 - 105
*Belt is considered used after 15 minutes of run-in (2.4L)
time Bolts, Water Pump Inlet Tube 28 - 250
3.3/3.8L ENGINES (3.3/3.8L)
Air Conditioning Dynamic Bolts, Water Pump Pulley (3.3/3.8L) 28 - 250
Compressor Tensioner Screws, Radiator to A/C Condenser 5 - 45
Generator/Water Screws, Radiator Fan 5 - 45
Pump/Power Nuts, Radiator Mounting (Upper 12 - 105
Steering Bracket)
7-6 COOLING RS
SPECI AL T OOLS
COOLING SYSTEM
Fig. 6 TOOL 8875A
Hose Clamp Pliers 6094
DRB III" with PEP Module – OT-CH6010A
Hose Clamp Pliers 8495A
Belt Tension Gauge Adapter 8371
Cooling System Tester 7700
Belt Tension Gauge 7198A
Coolant Refractometer 8286

RS ACCESSORY DRIVE 7-7
ACCESSORY DRI V E
TABLE OF CONTENTS
page page
DRIVE BELTS ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . 10

DIAGNOSIS AND TESTING - ACCESSORY BELT TENSIONER - 2.4L
DRIVE BELT . . . . . . . . . . . . . . . . . . . . ......7 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
CLEANING . . . . . . . . . . . . . . . . . . . . . . . ......8 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11
INSPECTION . . . . . . . . . . . . . . . . . . . . . ......8 DRIVE BELTS - 3.3/3.8L
DRIVE BELTS - 2.4L REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
STANDARD PROCEDURE - CHECKING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
POWER STEERING BELT TENSION . . ......8 BELT TENSIONER - 3.3/3.8L
REMOVAL ....................... ......9 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
INSTALLATION . . . . . . . . . . . . . . . . . . . . ......9 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
DRI V E BELT S
DIAGNOSIS AND TESTING - ACCESSORY DRIVE BELT
CONDITION POSSIBLE CAUSES CORRECTIONS
INSUFFICIENT ACCESSORY 1. Belt too loose 1. (a) Replace belt (auto-tensioned

OUTPUT DUE TO BELT SLIPPAGE belts)
(b) Adjust power steering belt

tension (4 cyl. engine)
2. Belt excessively glazed or worn 2. Replace and tighten as specified
BELT SQUEAL WHEN 1. Belts too loose 1. (a) Replace belt (auto-tensioned
ACCELERATING ENGINE belts)
2. Belt glazed 2. Replace belts
BELT SQUEAK AT IDLE 1. Belts too loose 1. (a) Replace belt (auto-tensioned
belts)

2. Dirt or paint imbedded in belt 2. Replace belt
3. Non-uniform belt 3. Replace belt
4. Misaligned pulleys 4. Align accessories
5. Non-uniform groove or eccentric 5. Replace pulley
pulley
7-8 ACCESSORY DRIVE RS
DRI V E BELT S (Cont inue d)
CONDITION POSSIBLE CAUSES CORRECTIONS
BELT ROLLED OVER IN GROOVE 1. Broken cord in belt 1. Replace belt

OR BELT JUMPS OFF 2. Belt too loose, or too tight 2. (a) Replace belt (auto-tensioned
belts.)
3. Misaligned pulleys 3. Align accessories
4. Non-uniform groove or eccentric 4. Replace pulley
pulley
CLEANING DRI V E BELT S - 2 .4 L

Clea n a ll for eign debr is fr om belt pu lley gr ooves.
Th e belt pu lleys m u st be fr ee of oil, gr ea se, a n d cool- STANDARD PROCEDURE - CHECKING POWER
a n t s befor e in st a llin g t h e dr ive belt .
STEERING BELT TENSION
INSPECTION WARNING: DO NOT CHECK BELT TENSION WITH
Belt r epla cem en t u n der a n y or a ll of t h e followin g ENGINE RUNNING.
con dit ion s is r equ ir ed:
• E xcessive wea r Accessor y dr ive belt t en sion ca n be m ea su r ed wit h
• F r a yed cor ds Specia l Tool 8371 – Belt Ten sion Ga u ge Ada pt er, a n d
• Sever e gla zin g t h e DRBIII! u sin g t h e followin g pr ocedu r es:
P oly-V Belt syst em m a y develop m in or cr a cks (1) Con n ect 8371 t o t h e DRBIII! followin g t h e
a cr oss t h e r ibbed side (du e t o r ever se ben din g). Th ese in st r u ct ion s pr ovided wit h t ool.
m in or cr a cks a r e con sider ed n or m a l a n d a ccept a ble. (2) P la ce en d of m icr oph on e pr obe a ppr oxim a t ely
P a r a llel cr a cks a r e n ot (F ig. 1). 2.54 cm (1 in .) fr om belt a t belt cen t er spa n loca t ion
sh own in (F ig. 2).
NOTE: Do not use any type of belt dressing or (3) P lu ck t h e belt a m in im u m of 3 t im es. (Use you r
restorer on Poly-V Belts. fin ger or ot h er su it a ble t ool) Th e fr equ en cy of t h e
belt in h er t z (H z) will displa y on DRBIII! scr een .
(4) Adju st belt t o obt a in pr oper fr equ en cy (t en -
sion ). Refer t o ACCE SSORY DRIVE BE LT TE NSION
CH ART for belt t en sion specifica t ion s.
ACCESSORY DRI V E BELT T EN SI ON CH ART -

2 .4 L
Accessory Drive Belt Belt Tension

Air Conditioning Dynamic Tensioner
Compressor/Generator
178 - 212
New
Hz
Power Steering Pump
Used* 145 - 178
Hz
*A belt is considered used after 15 minutes of run-in
time.
Fig. 1 Drive Belt Inspection

1 - NORMAL CRACKS - BELT OK
2 - NOT NORMAL CRACKS - REPLACE BELT
RS ACCESSORY DRIVE 7-9
DRI V E BELT S - 2 .4 L (Cont inue d)
Fig. 3 A/C & GENERATOR BELT TENSION RELEASE

1 - BELT TENSIONER
2 - WRENCH
Fig. 2 Power Steering Belt - Center Span Location

1 - POWER STEERING BELT CENTER SPAN LOCATION
REMOVAL
GENERATOR AND AIR CONDITIONING BELT
(1) Ra ise veh icle on h oist .
(2) Rem ove t h e dr ive belt sh ield (F ig. 8).
WARNING: DO NOT ALLOW DRIVE BELT TEN-

SIONER TO SNAP BACK, AS DAMAGE TO TEN-
SIONER AND/OR PERSONAL INJURY COULD
RESULT.
(3) P osit ion a wr en ch on t h e belt t en sion er lu g

(F ig. 3).
(4) Relea se belt t en sion by r ot a t in g t h e t en sion er
clockwise (F ig. 3).
(5) Rem ove belt .
(1) Ca r efu lly r et u r n t en sion er t o it s r ela xed posi-
t ion .
POWER STEERING PUMP

(1) F r om t op of t h e veh icle, loosen lockin g n u t s (1)
a n d (2) (F ig. 4).
(2) F r om u n der t h e veh icle, loosen t h e pivot bolt
(3). Loosen a dju st in g bolt (4) u n t il belt ca n be Fig. 4 Power Steering Pump Belt
r em oved. 1 - REAR LOCKING NUT
2 - FRONT LOCKING NUT
INSTALLATION 3
4
- PIVOT BOLT
- ADJUSTING BOLT
GENERATOR AND AIR CONDITIONING BELT (2) Rot a t e belt t en sion er clockwise u n t il belt ca n
(1) In st a ll belt on t o a ll pu lleys except for t h e be in st a lled on t o t h e cr a n ksh a ft pu lley (F ig. 3).
cr a n ksh a ft (F ig. 5). Slowly r elea se belt t en sion er.
7 - 10 ACCESSORY DRIVE RS
DRI V E BELT S - 2 .4 L (Cont inue d)
(3) Ver ify belt is pr oper ly r ou t ed a n d en ga ged on
a ll pu lleys (F ig. 5).
(4) In st a ll dr ive belt sh ield (F ig. 8) a n d lower veh i-
cle.
Fig. 6 Belt Routing - 2.4L

1 - GENERATOR PULLEY
Fig. 5 Accessory Drive Belts - 2.4L 2 - A/C COMPRESSOR PULLEY
1 - POWER STEERING PUMP PULLEY 3 - CRANKSHAFT PULLEY
2 - BELT TENSIONER 4 - P/S PUMP PULLEY
3 - GENERATOR PULLEY 5 - P/S PUMP BELT
4 - BELT - A/C AND GENERATOR 6 - BELT TENSIONER
5 - A/C COMPRESSOR PULLEY
6 - CRANKSHAFT PULLEY
7 - BELT - POWER STEERING ADJUSTMENTS
Sa t isfa ct or y per for m a n ce of t h e belt dr iven a ccesso-
POWER STEERING PUMP r ies depen ds on pr oper belt t en sion . Belt t en sion in g
(1) In st a ll belt over cr a n ksh a ft a n d power st eer in g sh ou ld be per for m ed wit h t h e a id of Specia l Tool
pu m p pu lleys (F ig. 5) a n d (F ig. 6). 7198. Beca u se of spa ce lim it a t ion s in t h e en gin e com -
(2) Apply a n in it ia l sn u g t or qu e t o pivot bolt (3) pa r t m en t , t h e u se of t h is ga u ge m a y be r est r ict ed.
a n d fr on t lockin g n u t (2) (F ig. 4). Ra ise t h e veh icle on a h oist a n d t h e r em ove t h e
(3) Tigh t en a dju st in g bolt (4) u n t il pr oper belt t en - spla sh sh ield t o ga in a ccess t o t h e dr ive belt s, if n ec-
sion is obt a in ed (F ig. 4). F or belt t en sion ch eck pr o- essa r y. Adju st belt t en sion for eit h er a N e w or U s e d
cedu r e, (Refer t o 7 - COOLING/ACCE SSORY DRIVE / belt . F or specifica t ion s, (Refer t o 7 - COOLING/AC-
DRIVE BE LTS - STANDARD P ROCE DURE - CE SSORY DRIVE - SP E CIF ICATIONS).
CH E CKING P OWE R STE E RING BE LT TE NSION).
(4) Tigh t en pivot bolt (3) a n d fr on t lockin g n u t (2)
t o 54 N·m (40 ft . lbs.) (F ig. 4).
(5) Tigh t en r ea r lockin g n u t (1) t o 54 N·m (40 ft .
lbs.) (F ig. 4).
RS ACCESSORY DRIVE 7 - 11
BELT T EN SI ON ER - 2 .4 L
REMOVAL
(2) Rem ove t h e dr ive belt sh ield.
(3) Rem ove t h e gen er a t or /A/C dr ive belt . (Refer t o
7 - COOLING/ACCE SSORY DRIVE /DRIVE BE LTS -
RE MOVAL)
(4) Rem ove t h e belt t en sion er (F ig. 7).
Fig. 8 Accessory Drive Belt Shield

1 - ATTACHING SCREW
2 - ATTACHING SCREWS
3 - SPLASH SHIELD
(3) P osit ion a wr en ch on t h e belt t en sion er lu g

(F ig. 9).
(4) Relea se belt t en sion by r ot a t in g t h e t en sion er
cou n t er clockwise (F ig. 9).
Fig. 7 Belt Tensioner - 2.4L

1 - BELT TENSIONER
2 - GENERATOR BRACKET
3 - BOLT
INSTALLATION
(1) In st a ll belt t en sion er a n d bolt (F ig. 7). Tigh t en
bolt t o 54 N·m (40 ft . lbs.).
(2) In st a ll gen er a t or /A/C com pr essor dr ive belt .
(Refer t o 7 - COOLING/ACCE SSORY DRIVE /DRIVE
BE LTS - INSTALLATION)
(3) In st a ll spla sh sh ield.
DRI V E BELT S - 3 .3 /3 .8 L Fig. 9 DRIVE BELT TENSION RELEASE

1 - BELT TENSIONER LUG
REMOVAL 2 - WRENCH
(2) Rem ove t h e dr ive belt sh ield (F ig. 8). (5) Rem ove t h e dr ive belt (F ig. 10).
(6) Ca r efu lly r et u r n t en sion er t o it s r ela xed posi-
WARNING: DO NOT ALLOW DRIVE BELT TEN- t ion .
SIONER TO SNAP BACK, AS DAMAGE TO TEN-
SIONER AND/OR PERSONAL INJURY COULD
RESULT.
7 - 12 ACCESSORY DRIVE RS
DRI V E BELT S - 3 .3 /3 .8 L (Cont inue d)
INSTALLATION
(1) Rou t e a n d posit ion t h e dr ive belt on t o a ll pu l-
leys, except for t h e cr a n ksh a ft (F ig. 10).
Fig. 10 ACCESSORY DRIVE BELT

1 - DRIVE BELT
2 - POWER STEERING PUMP PULLEY Fig. 11 3.3/3.8L Belt Routing
3 - BELT TENIONER PULLEY
4 - IDLER PULLEY 1 - GENERATOR PULLEY
5 - GENERATOR PULLEY 2 - A/C COMPRESSOR PULLEY
6 - AIR CONDITIONING COMPRESSOR PULLEY 3 - CRANKSHAFT PULLEY
7 - CRANKSHAFT PULLEY 4 - TENSIONER PULLEY
8 - WATER PUMP PULLEY 5 - WATER PUMP PULLEY
6 - P/S PUMP PULLEY
7 - IDLER PULLEY
(2) Rot a t e belt t en sion er cou n t er clockwise u n t il
belt ca n be in st a lled on t o t h e cr a n ksh a ft pu lley (F ig.
9). Slowly r elea se belt t en sion er.
(3) Ver ify belt is pr oper ly r ou t ed a n d en ga ged on
a ll pu lleys (F ig. 11).
(4) In st a ll dr ive belt sh ield (F ig. 8) a n d lower veh i-
cle.
BELT T EN SI ON ER - 3 .3 /3 .8 L
REMOVAL
(2) Rem ove t h e dr ive belt sh ield.
(3) Rem ove t h e dr ive belt . (Refer t o 7 - COOLING/
ACCE SSORY DRIVE /DRIVE BE LTS - RE MOVAL)
(4) Rem ove t h e belt t en sion er (F ig. 12).
Fig. 12 BELT TENSIONER - 3.3/3.8L
INSTALLATION
1 - BELT TENSIONER
(1) In st a ll t h e belt t en sion er a n d bolt (F ig. 12). 2 - BOLT
Tigh t en bolt t o 28 N·m (250 in . lbs.).
(2) In st a ll t h e dr ive belt . (Refer t o 7 - COOLING/
ACCE SSORY DRIVE /DRIVE BE LTS - INSTALLA-
TION)
(3) In st a ll t h e dr ive belt sh ield.
RS ENGINE 7 - 13
EN GI N E
TABLE OF CONTENTS
page page
ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 27
DIAGNOSIS AND TESTING - ENGINE RADIATOR DRAINCOCK
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . 14 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 27
INSPECTION ........................ . . 18 RADIATOR PRESSURE CAP
COOLANT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 27
DESCRIPTION - ENGINE COOLANT . . . . . . . . . 19 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
DIAGNOSIS AND TESTING - COOLANT DIAGNOSIS AND TESTING
CONCENTRATION TESTING . . . . . . . . . . . . . 19 DIAGNOSIS AND TESTING - COOLING
STANDARD PROCEDURE - COOLANT SYSTEM PRESSURE CAP TESTING . . . . . . . 28
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 DIAGNOSIS AND TESTING - RADIATOR
COOLANT RECOVERY CONTAINER CAP TO FILLER NECK SEAL . . . . . . . . . . . . . 28
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 20 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 INSPECTION ....................... . . . 29
DIAGNOSIS AND TESTING - COOLANT RADIATOR FAN
RECOVERY SYSTEM ................ . . 20 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 29
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 20 DIAGNOSIS AND TESTING - RADIATOR FAN
ENGINE BLOCK HEATER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 20 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
DIAGNOSIS AND TESTING - ENGINE BLOCK RADIATOR FAN RELAY
HEATER TESTING . . . . . . . . . . . . . . . . . . . . . 21 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 31
ENGINE COOLANT TEMPERATURE SENSOR - INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 31
2.4L WATER PUMP - 2.4L
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
ENGINE COOLANT TEMPERATURE SENSOR - INSPECTION ....................... . . . 32
3.3/3.8L INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 32
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 21 WATER PUMP - 3.3/3.8L
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 34
ENGINE COOLANT THERMOSTAT CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 23 INSPECTION ....................... . . . 35
DIAGNOSIS AND TESTING - ENGINE WATER PUMP INLET TUBE - 2.4L
COOLANT THERMOSTAT . . . . . . . . . . . . . . . 23 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 36
ENGINE COOLANT THERMOSTAT - 2.4L REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 36
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 24 WATER PUMP INLET TUBE - 3.3/3.8L
ENGINE COOLANT THERMOSTAT - 3.3/3.8L REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25
RADIATOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7 - 14 ENGINE RS
EN GI N E VISUAL INSPECTION
If t h e coolin g syst em pr oblem is n ot ca u sed by a
DIAGNOSIS AND TESTING - ENGINE COOLING dr ivin g con dit ion , per for m a visu a l in spect ion t o
det er m in e if t h er e wa s a r ecen t ser vice or a cciden t
SYSTEM r epa ir, in clu din g t h e followin g:
E st a blish wh a t dr ivin g con dit ion ca u sed t h e coolin g • Loose/da m a ged wa t er pu m p dr ive belt
syst em com pla in t . Th e pr oblem m a y be ca u sed by a n • In cor r ect coolin g syst em r efillin g (t r a pped a ir or
a bn or m a l loa d on t h e syst em su ch a s t h e followin g: low level)
pr olon ged idle, ver y h igh a m bien t t em per a t u r e, sligh t • Br a kes possibly dr a ggin g
t a il win d a t idle, slow t r a ffic speed, t r a ffic ja m , h igh • Da m a ged h oses
speed, st eep gr a de. • Loose/da m a ged h ose cla m ps
• Da m a ged/in cor r ect en gin e t h er m ost a t
DRIVING TECHNIQUES • Da m a ged coolin g fa n m ot or, fa n bla de a n d fa n
To a void over h ea t in g t h e coolin g syst em :
sh r ou d
(1) Idle wit h A/C off wh en t em per a t u r e ga u ge is a t
• Da m a ged h ea d ga sket
en d of n or m a l r a n ge.
• Da m a ged wa t er pu m p
(2) Do n ot in cr ea se en gin e speed for m or e a ir flow
• Da m a ged r a dia t or
a n d coola n t flow beca u se t h e elect r ic m ot or fa n sys-
• Da m a ged coola n t r ecover y syst em
t em s a r e n ot r espon sive t o en gin e RP M. Th e a dded
• Da m a ged h ea t er cor e
coolin g fr om h igh er coola n t flow r a t e is m or e t h a n
• Open /sh or t ed elect r ica l cir cu it s
offset by in cr ea sed h ea t r eject ion (en gin e h ea t a dded
If t h e visu a l in spect ion r evea ls n on e of t h e a bove
t o coola n t ).
a s ca u se for a coolin g syst em com pla in t , r efer t o t h e
followin g dia gn ost ic ch a r t s.
TRAILER TOWING
Con su lt t h e own er ’s m a n u a l u n der Tr a iler Towin g
a n d do n ot exceed specified lim it s.
COOLI N G SY ST EM DI AGN OSI S CH ART
PRESSURE CAP IS BLOWING 1. Pressure relief valve in radiator 1. Check condition of radiator cap
OFF STEAM AND/OR COOLANT. cap is defective, or was not and cap seal. (Refer to 7 -
TEMPERATURE GAUGE READING properly seated. COOLING/ENGINE/RADIATOR
MAY BE ABOVE NORMAL BUT PRESSURE CAP - DIAGNOSIS
NOT HIGH. COOLANT LEVEL MAY AND TESTING) Replace cap as
BE HIGH IN COOLANT RESERVE/ necessary.
OVERFLOW TANK.
2. Incorrect cap was installed. 2. Replace cap as necessary.
3. Incorrect coolant mixture. 3. Check concentration level of the
coolant. (Refer to 7 - COOLING/
ENGINE/COOLANT - DIAGNOSIS
AND TESTING) Adjust the ethylene
glycol-to-water ratio as required.
COOLANT LOSS TO THE 1. Coolant leaks in radiator, cooling 1. Pressure test and repair as
GROUND WITHOUT PRESSURE system hoses, water pump or necessary. (Refer to 7 - COOLING -
CAP BLOWOFF. GAUGE IS engine. DIAGNOSIS AND TESTING)
READING HIGH OR HOT.
RS ENGINE 7 - 15
EN GI N E (Cont inue d)
DETONATION OR PRE-IGNITION 1. Engine overheating. 1. Check reason for overheating

(NOT CAUSED BY IGNITION and repair as necessary.
SYSTEM). GAUGE MAY NOT BE
READING HIGH. 2. Freeze point of coolant not 2. Check concentration level of the
correct. Mixture too concentrated or coolant. (Refer to 7 - COOLING/
too diluted. ENGINE/COOLANT - DIAGNOSIS
AND TESTING) Adjust the ethylene
glycol-to-water ratio as required.
3. Incorrect cooling system 3. Install correct pressure cap.
pressure cap.
HOSE(S) COLLAPSE AS ENGINE 1. Vacuum created in cooling 1. (a) Pressure cap relief valve
COOLS DOWN. system on engine cool-down is not stuck. (Refer to 7 - COOLING/
being relieved through coolant ENGINE/RADIATOR PRESSURE
recovery system. CAP - DIAGNOSIS AND TESTING)
Replace as necessary.
(b) Hose between the radiator and
overflow container is plugged or
pinched. Clean and repair as
necessary.
(c) Vent at coolant reserve/overflow
container is plugged. Clean vent
and repair as necessary.
(d) Reserve/overflow container is
internally blocked. Clean and repair
as necessary.
INADEQUATE AIR CONDITIONER 1. Radiator and/or A/C condenser is 1. Remove restriction and/or clean
PERFORMANCE (COOLING restricted, obstructed, or dirty as necessary.
SYSTEM SUSPECTED). (insects, leaves, etc.).
2. Electrical radiator fan not 2. For test procedure (Refer to
operating when A/C is operated. appropriate Diagnostic Information).
Repair as necessary.
3. Engine is overheating (heat may 3. Correct overheating condition.
be transferred from radiator to A/C
condenser). High underhood
temperatures due to engine
overheating may also transfer heat
to A/C components.
4. All models are equipped with air 4. Check for missing or damaged air
seals at the radiator and/or A/C seals and repair as necessary.
condenser. If these seals are
missing or damaged, not enough
air flow will be pulled through the
radiator and A/C condenser.
INADEQUATE HEATER 1. Check for a Diagnostic trouble 1. For procedures, (Refer to

PERFORMANCE. code (DTC). appropriate Diagnostic Information).
2. Coolant level low. 2. (Refer to 7 - COOLING -
STANDARD PROCEDURE) Repair
as necessary.
7 - 16 ENGINE RS
3. Obstructions in heater hose 3. Remove heater hoses at both

fitting at engine or at heater core. ends and check for obstructions.
4. Heater hose kinked. 4. Locate kinked area and repair as
necessary.
5. Water pump is not pumping 5. When the engine is fully warmed
coolant to heater core. up, both heater hoses should be hot
to the touch. If only one of the
hoses is hot, the water pump may
not be operating correctly. Replace
components as necessary.
6. Air trapped in heater core. 6. (Refer to 7 - COOLING -
DIAGNOSIS AND TESTING -
COOLING SYSTEM DEAERATION)
HEAT ODOR 1. Various heat shields are used at 1. Locate missing shields and
certain driveline components. One replace or repair as necessary.
or more of these shields may be
missing.
2. Temperature gauge reading 2. Refer to Gauge Is Reading High
above the normal range. in Temperature Gauge Indicatication
Diagnosis Chart.
3. Radiator fan operating 3. (Refer to 7 - COOLING/ENGINE/
incorrectly. RADIATOR FAN - OPERATION)
4. Undercoating been applied to an 4. Clean undercoating as necessary.
unnecessary component.
5. Engine may be running rich, 5. (Refer to Appropriate Diagnostic
causing the catalytic converter to Information) Repair as necessary.
overheat
POOR DRIVEABILITY 1. The engine thermostat must be 1. (Refer to Appropriate Diagnostic

(THERMOSTAT POSSIBLY STUCK operating correctly for proper Information) Replace thermostat, if
OPEN). GAUGE MAY BE READING driveability, clean vehicle emissions, necessary.
LOW. and the prevention of sludge
buildup in the engine oil. Check for
a diagnostic trouble code.
STEAM IS COMING FROM FRONT 1. During wet weather, moisture 1. Occasional steam emitting from
OF VEHICLE NEAR GRILL AREA (snow, ice, rain, or condensation) this area is normal. No repair is
WHEN WEATHER IS WET, on the radiator will evaporate when necessary.
ENGINE WARMED UP AND the thermostat opens. The
RUNNING WITH VEHICLE thermostat opening allows heated
STATIONARY, OR JUST SHUT coolant into the radiator. When the
OFF. TEMPERATURE GAUGE IS moisture contacts the hot radiator,
NORMAL. steam may be emitted. This usually
occurs in cold weather with no fan
or air flow to blow it away.
RS ENGINE 7 - 17
COOLANT COLOR 1. Coolant color is not necessarily 1. Check the freeze point of the
an indication of adequate corrosion coolant. (Refer to 7 - COOLING/
or temperature protection. Do not ENGINE/COOLANT - DIAGNOSIS
rely on coolant color for determining AND TESTING) Adjust the ethylene
condition of coolant. glycol-to-water ratio as necessary.
COOLANT LEVEL CHANGES IN 1. Level changes are to be 1. A normal condition. No repair is

COOLANT BOTTLE. expected as coolant volume necessary.
TEMPERATURE GAUGE IS IN fluctuates with engine temperature.
NORMAL RANGE. The coolant level will also drop as
the system removes air from a
recent filling.
Refer t o (F ig. 1) wh en u sin g t h e TE MP E RATURE

GAUGE INDICATION DIAGNOSIS CH ART.
T EM PERAT U RE GAU GE I N DI CAT I ON DI AGN OSI S CH ART
TEMPERATURE GAUGE READING 1. Normal reaction to fan and/or 1. A normal condition. No correction
IS INCONSISTENT (FLUCTUATES, thermostat cycle (Fig. 1 ), is necessary.
CYCLES OR IS ERRATIC). Examples B and C. During cold
weather operation with the heater
blower in the high position, the
gauge reading may drop slightly
(Fig. 1 ), Example D. Fluctuation is
also influenced by outside
temperature and heavy loads (Fig.
1 ), Example E.
2. Gauge reading rises when 2. A normal condition. No correction
vehicle is brought to a stop after is necessary. Gauge reading should
heavy use (engine still running) return to normal range (Fig. 1 ),
(Fig. 1 ), Example F. Example A, after vehicle is driven.
3. Gauge reading high after 3. A normal condition. No correction
restarting a warmed-up (hot) is necessary. The gauge should
engine. return to normal range (Fig. 1 ),
Example A, after a few minutes of
engine operation.
4. Temperature gauge or engine 4. Check operation of gauge or
coolant temperature sensor engine coolant temperature sensor
defective or shorted. Also, corroded and repair, if necessary.
or loose wiring in the electrical
circuit.
7 - 18 ENGINE RS
Fig. 1 Temperature Gauge Indications
CLEANING INSPECTION
Dr a in coolin g syst em a n d r efill wit h clea n wa t er. Aft er per for m in g a clea n in g/flu sh pr ocedu r e,
Refer t o dr a in a n d fill pr ocedu r es in t h is sect ion . Ru n in spect a ll h oses, cla m ps a n d con n ect ion s for det er io-
en gin e wit h r a dia t or ca p in st a lled u n t il u pper r a dia - r a t ion a n d lea ks. In spect r a dia t or a n d h ea t er cor e for
t or h ose is h ot . St op en gin e a n d dr a in wa t er fr om lea ks.
syst em . If wa t er is dir t y; fill, r u n , a n d dr a in syst em
a ga in , u n t il wa t er r u n s clea r. Refill coolin g syst em
wit h a 50/50 m ixt u r e of t h e r ecom m en ded et h ylen e
glycol a n d dist illed wa t er (Refer t o LUBRICATION &
MAINTE NANCE /F LUID TYP E S - DE SCRIP TION).
RS ENGINE 7 - 19
COOLAN T CAUTION: Mopar" Antifreeze/Coolant, 5

Year/100,000 Mile Formula (MS-9769) may not be
mixed with any other type of antifreeze. Doing so
DESCRIPTION - ENGINE COOLANT
will reduce the corrosion protection and may result
WARNING: ANTIFREEZE IS AN ETHYLENE GLYCOL in premature water pump seal failure. If non-HOAT
BASE COOLANT AND IS HARMFUL IF SWAL- coolant is introduced into the cooling system in an
LOWED OR INHALED. IF SWALLOWED, DRINK emergency, it should be replaced with the specified
TWO GLASSES OF WATER AND INDUCE VOMIT- coolant as soon as possible.
ING. IF INHALED, MOVE TO FRESH AIR AREA.
SEEK MEDICAL ATTENTION IMMEDIATELY. DO NOT
STORE IN OPEN OR UNMARKED CONTAINERS.
DIAGNOSIS AND TESTING - COOLANT
WASH SKIN AND CLOTHING THOROUGHLY AFTER CONCENTRATION TESTING
COMING IN CONTACT WITH ETHYLENE GLYCOL. Coola n t con cen t r a t ion sh ou ld be ch ecked wh en a n y
KEEP OUT OF REACH OF CHILDREN. DISPOSE OF a ddit ion a l coola n t wa s a dded t o syst em or a ft er a
GLYCOL BASE COOLANT PROPERLY, CONTACT coola n t dr a in , flu sh a n d r efill. Th e coola n t m ixt u r e
YOUR DEALER OR GOVERNMENT AGENCY FOR offer s opt im u m en gin e coolin g a n d pr ot ect ion a ga in st
LOCATION OF COLLECTION CENTER IN YOUR cor r osion wh en m ixed t o a fr eeze poin t of -37°C
AREA. DO NOT OPEN A COOLING SYSTEM WHEN (-34°F ) t o -46°C (-50°F ). Th e u se of a h ydr om et er or a
THE ENGINE IS AT OPERATING TEMPERATURE OR r efr a ct om et er ca n be u sed t o t est coola n t con cen t r a -
HOT UNDER PRESSURE, PERSONAL INJURY CAN t ion .
RESULT. AVOID RADIATOR COOLING FAN WHEN A h ydr om et er will t est t h e a m ou n t of glycol in a
ENGINE COMPARTMENT RELATED SERVICE IS m ixt u r e by m ea su r in g t h e specific gr a vit y of t h e m ix-
PERFORMED, PERSONAL INJURY CAN RESULT. t u r e. Th e h igh er t h e con cen t r a t ion of et h ylen e glycol,
t h e la r ger t h e n u m ber of ba lls t h a t will floa t , a n d
h igh er t h e fr eeze pr ot ect ion (u p t o a m a xim u m of
CAUTION: Use of Propylene Glycol based coolants 60% by volu m e glycol).
is not recommended, as they provide less freeze A r efr a ct om et er (Specia l Tool 8286)(Refer t o 7 -
protection and less boiling protection. COOLING - SP E CIAL TOOLS) will t est t h e a m ou n t
of glycol in a coola n t m ixt u r e by m ea su r in g t h e
Th e coolin g syst em is design ed a r ou n d t h e coola n t . a m ou n t a bea m of ligh t ben ds a s it pa sses t h r ou gh
Th e coola n t m u st a ccept h ea t fr om en gin e m et a l, in t h e flu id.
t h e cylin der h ea d a r ea n ea r t h e exh a u st va lves a n d Som e coola n t m a n u fa ct u r es u se ot h er t ypes of gly-
en gin e block. Th en coola n t ca r r ies t h e h ea t t o t h e cols in t o t h eir coola n t for m u la t ion s. P r opylen e glycol
r a dia t or wh er e t h e t u be/fin r a dia t or ca n t r a n sfer t h e is t h e m ost com m on n ew coola n t . H owever, pr opylen e
h ea t t o t h e a ir. glycol ba sed coola n t s do n ot pr ovide t h e sa m e fr eez-
Th e u se of a lu m in u m cylin der blocks, cylin der in g pr ot ect ion a n d cor r osion pr ot ect ion a n d is n ot r ec-
h ea ds, a n d wa t er pu m ps r equ ir es specia l cor r osion om m en ded.
pr ot ect ion . Mopa r ! An t ifr eeze/Coola n t , 5
Yea r /100,000 Mile F or m u la (MS-9769), or t h e equ iva - CAUTION: Do not mix types of coolant—corrosion
len t et h ylen e glycol ba se coola n t wit h h ybr id or ga n ic protection will be severely reduced.
cor r osion in h ibit or s (ca lled H OAT, for H ybr id Or ga n ic
Addit ive Tech n ology) is r ecom m en ded. Th is coola n t
offer s t h e best en gin e coolin g wit h ou t cor r osion wh en STANDARD PROCEDURE - COOLANT SERVICE
m ixed wit h 50% E t h ylen e Glycol a n d 50% dist illed F or en gin e coola n t r ecom m en ded ser vice sch edu le,
wa t er t o obt a in a fr eeze poin t of -37°C (-35°F ). If it (Refer t o LUBRICATION & MAINTE NANCE /MAIN-
loses color or becom es con t a m in a t ed, dr a in , flu sh , TE NANCE SCH E DULE S - DE SCRIP TION).
a n d r epla ce wit h fr esh pr oper ly m ixed coola n t solu -
t ion .
Th e gr een coola n t MU S T N OT B E MIXED wit h
t h e or a n ge or m a gen t a coola n t s. Wh en r epla cin g cool-
a n t t h e com plet e syst em flu sh m u st be per for m ed
befor e u sin g t h e r epla cem en t coola n t .
7 - 20 ENGINE RS
COOLAN T RECOV ERY

CON TAI N ER
DESCRIPTION
Th e coola n t r ecover y/r eser ve syst em con t a in er is
m ou n t ed in t h e en gin e com pa r t m en t (F ig. 2). Th e
con t a in er is m a de of pla st ic.
OPERATION
Th e coola n t r ecover y syst em wor ks wit h t h e r a dia -
t or pr essu r e ca p t o u se t h er m a l expa n sion a n d con -
t r a ct ion of t h e coola n t t o keep t h e coola n t fr ee of
t r a pped a ir. P r ovides a con ven ien t a n d sa fe m et h od
for ch eckin g coola n t level a n d a dju st in g level a t
a t m osph er ic pr essu r e wit h ou t r em ovin g t h e r a dia t or
pr essu r e ca p. It a lso pr ovides r eser ve coola n t t o cover
dea er a t ion , eva por a t ion , or boilin g losses.
DIAGNOSIS AND TESTING - COOLANT

RECOVERY SYSTEM
Th e coolin g syst em is closed a n d design ed t o m a in -
t a in coola n t level t o t h e t op of t h e r a dia t or. Fig. 2 Coolant Recovery Container
(1) Wit h t h e en gin e o ff a n d coolin g syst em n o t 1 - COOLANT RECOVERY CONTAINER
2 - HOSE
u n der pr essu r e, dr a in sever a l ou n ces of coola n t fr om 3 - BOLT
t h e r a dia t or dr a in cock wh ile obser vin g t h e coola n t 4 - SUB FRAME RAIL
r ecover y con t a in er. Coola n t level in t h e con t a in er
sh ou ld dr op. (7) Add coola n t t o con t a in er a s n ecessa r y. (Refer t o
(2) Rem ove t h e r a dia t or pr essu r e ca p. Th e coola n t 7 - COOLING - STANDARD P ROCE DURE )
level sh ou ld be fu ll t o t h e t op r a dia t or n eck. If n ot ,
a n d t h e coola n t level in t h e con t a in er is a t or a bove
t h e MIN m a r k, t h er e is a n a ir lea k in t h e coola n t EN GI N E BLOCK H EAT ER
r ecover y syst em .
(3) Ch eck h ose a n d h ose con n ect ion s t o t h e con - DESCRIPTION
t a in er, r a dia t or filler n eck or t h e pr essu r e ca p sea l t o Th e en gin e block h ea t er is a va ila ble a s a n opt ion a l
t h e r a dia t or filler n eck for lea ks. a ccessor y on a ll m odels. Th e h ea t er is oper a t ed by
or din a r y h ou se cu r r en t (110 Volt A.C.) t h r ou gh a
REMOVAL power cor d loca t ed beh in d t h e r a dia t or gr ille. Th is
(1) Ra ise t h e veh icle on h oist . pr ovides ea sier en gin e st a r t in g a n d fa st er wa r m -u p
(2) Rem ove t h e lower a t t a ch in g scr ews (F ig. 2). wh en veh icle is oper a t ed in a r ea s h a vin g ext r em ely
(3) Lower t h e veh icle. low t em per a t u r es. Th e h ea t er is m ou n t ed in a cor e
(4) Rem ove t h e u pper a t t a ch in g scr ew (F ig. 2). h ole (in pla ce of a cor e h ole plu g) in t h e en gin e block,
(5) Discon n ect r ecover y h ose fr om con t a in er (F ig. wit h t h e h ea t in g elem en t im m er sed in coola n t .
2).
(6) Rem ove t h e r ecover y con t a in er. OPERATION
Th e block h ea t er elem en t is su bm er ged in t h e cool-
INSTALLATION in g syst em ’s coola n t . Wh en elect r ica l power (110 volt
(1) Con n ect t h e r ecover y h ose t o con t a in er (F ig. 2). A.C.) is a pplied t o t h e elem en t , it cr ea t es h ea t . Th is
(2) P osit ion t h e r ecover y con t a in er on t h e fr a m e h ea t is t r a n sfer r ed t o t h e en gin e coola n t . Th is pr o-
r a il (F ig. 2). vides ea sier en gin e st a r t in g a n d fa st er wa r m -u p
(3) In st a ll t h e u pper a t t a ch in g scr ew a n d t igh t en wh en veh icle is oper a t ed in a r ea s h a vin g ext r em ely
t o 7 N·m (60 in . lbs.) (F ig. 2). low t em per a t u r es.
(4) Ra ise t h e veh icle on h oist .
(5) In st a ll t h e lower a t t a ch in g scr ews a n d t igh t en
t o 8.5 N·m (75 in . lbs.) (F ig. 2).
RS ENGINE 7 - 21
EN GI N E BLOCK H EAT ER (Cont inue d)
DIAGNOSIS AND TESTING - ENGINE BLOCK

HEATER TESTING
If u n it does n ot oper a t e, t r ou ble ca n be in eit h er
t h e power cor d or t h e h ea t er elem en t . Test power
cor d for con t in u it y wit h a 110-volt volt m et er or 110-
volt t est ligh t ; t est h ea t er elem en t con t in u it y wit h a n
oh m m et er or 12-volt t est ligh t .
REMOVAL
(1) Dr a in coola n t fr om r a dia t or a n d cylin der block.
(Refer t o 7 - COOLING - STANDARD P ROCE DURE )
(2) Discon n ect t h e power cor d plu g fr om h ea t er.
(3) Loosen scr ew in cen t er of h ea t er. Rem ove t h e
h ea t er a ssem bly.
INSTALLATION
(1) Clea n block cor e h ole a n d h ea t er sea t .
(2) In ser t h ea t er a ssem bly wit h elem en t loop posi-
t ion ed u p w a rd .
(3) Wit h h ea t er sea t ed, t igh t en cen t er scr ew
secu r ely t o a ssu r e a posit ive sea l.
(4) In st a ll power cor d plu g t o h ea t er. Fig. 3 Engine Coolant Temperature Sensor - 2.4L
(5) F ill coolin g syst em wit h coola n t t o t h e pr oper 1 - MAP SENSOR
level. (Refer t o 7 - COOLING - STANDARD P ROCE - 2 - COOLANT TEMPERATURE SENSOR
DURE )
INSTALLATION
(1) In st a ll coola n t t em per a t u r e sen sor (F ig. 3).
EN GI N E COOLAN T Tigh t en sen sor t o 7 N·m (60 in . lbs.).
T EM PERAT U RE SEN SOR - 2 .4 L (2) Con n ect elect r ica l con n ect or t o sen sor.
(3) F ill coolin g syst em . (Refer t o 7 - COOLING -
DESCRIPTION STANDARD P ROCE DURE )
Th e en gin e coola n t t em per a t u r e sen sor t h r ea ds
in t o t h e t op of t h e t h er m ost a t h ou sin g (F ig. 3). New
sen sor s h a ve sea la n t a pplied t o t h e t h r ea ds.
EN GI N E COOLAN T
T EM PERAT U RE SEN SOR -
REMOVAL 3 .3 /3 .8 L
WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING. COOLING SYSTEM
DESCRIPTION
MUST BE PARTIALLY DRAINED BEFORE REMOV- Th e en gin e coola n t t em per a t u r e sen sor t h r ea ds
ING THE COOLANT TEMPERATURE SENSOR. in t o a coola n t pa ssa ge on lower in t a ke m a n ifold n ea r
t h e t h er m ost a t (F ig. 6). New sen sor s h a ve sea la n t
(1) Dr a in t h e coolin g syst em below t h er m ost a t a pplied t o t h e t h r ea ds.
level. (Refer t o 7 - COOLING - STANDARD P ROCE -
DURE ) REMOVAL
(2) Discon n ect coola n t t em per a t u r e sen sor elect r i-
ca l con n ect or. WARNING: HOT, PRESSURIZED COOLANT CAN
(3) Rem ove coola n t t em per a t u r e sen sor (F ig. 3). CAUSE INJURY BY SCALDING. COOLING SYSTEM
MUST BE PARTIALLY DRAINED BEFORE REMOV-
ING THE COOLANT TEMPERATURE SENSOR.
7 - 22 ENGINE RS
EN GI N E COOLAN T T EM PERAT U RE SEN SOR - 3 .3 /3 .8 L (Cont inue d)
(1) Dr a in coolin g syst em below en gin e coola n t t em -
per a t u r e sen sor level. (Refer t o 7 - COOLING -
(2) Rem ove power st eer in g r eser voir a n d r eloca t e
(F ig. 4). Do n ot discon n ect h oses.
Fig. 5 Fuel Rail, Ignition Coil and Bracket

1 - FUEL RAIL
2 - BOLT - FUEL RAIL
Fig. 4 Power Steering Fluid Reservoir 3 - NUT - IGNITION COIL
1 - POWER STEERING RESERVOIR 4 - BOLT - IGNITION COIL
2 - BOLT - RESERVOIR TO MANIFOLD 5 - IGNITION COIL
3 - NUT - RESERVOIR TO COIL BRACKET 6 - BRACKET - IGNITION COIL
7 - STUD - IGNITION COIL
8 - SEPARATOR - SPARK PLUG CABLE
(3) Rem ove ign it ion coil a n d br a cket (F ig. 5). 9 - BRACKET - SPARK PLUG CABLE SEPARATOR
(4) Discon n ect coola n t sen sor elect r ica l con n ect or 10 - BOLT - SEPARATOR BRACKET
11 - BRACKET - SPARK PLUG CABLE SEPARATOR
(F ig. 6).
(5) Rem ove coola n t sen sor (F ig. 6).
RS ENGINE 7 - 23
EN GI N E COOLAN T T EM PERAT U RE SEN SOR - 3 .3 /3 .8 L (Cont inue d)
OPERATION
Th e en gin e coolin g t h er m ost a t is a wa x pellet
dr iven , r ever se poppet ch oke t ype. Th e t h er m ost a t is
design ed t o pr ovide t h e fa st est wa r m u p possible by
pr even t in g lea ka ge t h r ou gh it a n d t o gu a r a n t ee a
m in im u m en gin e oper a t in g t em per a t u r e of 88 t o
93°C (192 t o 199°F ). Th e t h er m ost a t a lso will a u t o-
m a t ica lly r ea ch wide open so it will n ot r est r ict flow
t o t h e r a dia t or a s t em per a t u r e of t h e coola n t r ises in
h ot wea t h er t o a r ou n d 104°C (220°F ). Above t h is
t em per a t u r e t h e coola n t t em per a t u r e is con t r olled by
t h e r a dia t or, fa n , a n d a m bien t t em per a t u r e, n ot t h e
t h er m ost a t .
Th e t h er m ost a t is oper a t ed by a wa x filled con -
t a in er (pellet ) wh ich is sea led. Wh en h ea t ed coola n t
r ea ch es a pr edet er m in ed t em per a t u r e, t h e wa x
expa n ds en ou gh t o over com e t h e closin g spr in g a n d
wa t er pu m p pr essu r e, wh ich for ces t h e va lve t o open .
DIAGNOSIS AND TESTING - ENGINE COOLANT

THERMOSTAT
Th e t h er m ost a t is oper a t ed by a wa x filled ch a m -
Fig. 6 Engine Coolant Temperature Sensor ber (pellet ) wh ich is sea led. Wh en h ea t ed coola n t
1 - ENGINE COOLANT TEMPERATURE SENSOR r ea ch es a pr edet er m in ed t em per a t u r e t h e wa x pellet
2 - CONNECTOR - ENGINE COOLANT SENSOR
3 - FITTING - HEATER SUPPLY expa n ds en ou gh t o over com e t h e closin g spr in g a n d
wa t er pu m p pr essu r e, wh ich for ces t h e va lve t o open .
INSTALLATION Coola n t lea ka ge in t o t h e pellet will ca u se a t h er m o-
(1) In st a ll en gin e coola n t t em per a t u r e sen sor (F ig. st a t t o fa il open . Do n ot a t t em pt t o fr ee u p a t h er m o-
6). Tigh t en sen sor t o 7 N·m (60 in . lbs.). st a t wit h a scr ewdr iver.
(2) Con n ect elect r ica l con n ect or t o sen sor (F ig. 6). Th er m ost a t dia gn ost ics is in clu ded in power t r a in
(3) In st a ll ign it ion coil br a cket (F ig. 5). con t r ol m odu le’s (P CM) pr ogr a m in g for on -boa r d
(4) In st a ll ign it ion coil (F ig. 5). dia gn osis. Th e m a lfu n ct ion in dica t or ligh t (MIL) will
(5) In st a ll power st eer in g r eser voir (F ig. 4). illu m in a t e a n d a dia gn ost ic t r ou ble code (DTC) will
(6) F ill coolin g syst em . (Refer t o 7 - COOLING - be set wh en a n “open t oo soon ” con dit ion occu r s. Do
STANDARD P ROCE DURE ) n ot ch a n ge a t h er m ost a t for la ck of h ea t er per for-
m a n ce or t em per a t u r e ga u ge posit ion , u n less a DTC
is pr esen t . F or ot h er pr oba ble ca u ses, (Refer t o 7 -
EN GI N E COOLAN T COOLING/E NGINE - DIAGNOSIS AND TE STING).
Th er m ost a t fa ilin g sh u t is t h e n or m a l lon g t er m
T H ERM OSTAT m ode of fa ilu r e, a n d n or m a lly, on ly on h igh m ilea ge
veh icles. Th e t em per a t u r e ga u ge will in dica t e t h is
DESCRIPTION (Refer t o 7 - COOLING/E NGINE - DIAGNOSIS AND
Th e en gin e coolin g t h er m ost a t s a r e a wa x pellet TE STING).
dr iven , r ever se poppet ch oke t ype. Th e t h er m ost a t is
m ou n t ed in a h ou sin g on t h e coola n t ou t let of t h e
en gin e (F ig. 8) or (F ig. 10).
7 - 24 ENGINE RS
EN GI N E COOLAN T
T H ERM OSTAT - 2 .4 L
REMOVAL
(1) Dr a in coolin g syst em below t h e t h er m ost a t
level. (Refer t o 7 - COOLING - STANDARD P ROCE -
DURE )
(2) Rem ove r a dia t or u pper h ose fr om t h e coola n t
ou t let h ou sin g (F ig. 7).
Fig. 8 Thermostat and Outlet Connector - 2.4L

Engine
1 - THERMOSTAT
2 - GASKET
3 - COOLANT OUTLET CONNECTOR
4 - BOLT
EN GI N E COOLAN T
T H ERM OSTAT - 3 .3 /3 .8 L
REMOVAL
(1) Dr a in coolin g syst em down below t h e t h er m o-
st a t level. (Refer t o 7 - COOLING - STANDARD
P ROCE DURE )
(2) Rem ove r a dia t or u pper h ose fr om coola n t ou t let
con n ect or (F ig. 9).
Fig. 7 RADIATOR HOSES TO ENGINE - 2.4L

1 - UPPER HOSE
2 - LOWER HOSE
(3) Rem ove coola n t ou t let h ou sin g bolt s a n d h ou s-

in g (F ig. 8).
(4) Rem ove t h er m ost a t . Disca r d ga sket a n d clea n
bot h ga sket sea lin g su r fa ces.
INSTALLATION
(1) P la ce a n ew ga sket (dipped in clea n wa t er ) on
t h e coola n t ou t let con n ect or su r fa ce. P osit ion t h er m o-
st a t wit h a ir bleed a t t h e 12 o’clock posit ion in t h er-
m ost a t h ou sin g (F ig. 8).
(2) P osit ion t h e coola n t ou t let con n ect or a n d ga s-
ket over t h e t h er m ost a t , m a kin g su r e t h er m ost a t is
sea t ed in t h e t h er m ost a t h ou sin g.
(3) P osit ion ou t let con n ect or t o t h er m ost a t h ou sin g
a n d in st a ll bolt s (F ig. 8). Tigh t en bolt s t o 28 N·m
(250 in . lbs.).
(4) In st a ll t h e r a dia t or u pper h ose t o coola n t ou t let
h ou sin g (F ig. 7). Fig. 9 RADIATOR HOSES TO ENGINE - 3.3/3.8L
(5) Refill t h e coolin g syst em . (Refer t o 7 - COOL- 1 - UPPER HOSE
ING - STANDARD P ROCE DURE ) 2 - LOWER HOSE
RS ENGINE 7 - 25
EN GI N E COOLAN T T H ERM OSTAT - 3 .3 /3 .8 L (Cont inue d)
(3) Rem ove coola n t ou t let con n ect or bolt s a n d con -
n ect or (F ig. 10).
(4) Rem ove t h er m ost a t fr om ou t let con n ect or.
(5) Disca r d ga sket a n d clea n bot h ga sket sea lin g
su r fa ces.
Fig. 11 Connector Staking Material Removal

1 - STAKE
2 - OUTLET CONNECTOR
Fig. 10 THERMOSTAT - 3.3/3.8L ENGINE
1 - COOLANT OUTLET CONNECTOR
2 - BOLT
3 - THERMOSTAT
4 - GASKET
INSTALLATION
(1) To en su r e pr oper sea t in g of r epla cem en t t h er-
m ost a t , ca r efu lly r em ove t h e bu lged m et a l fr om t h e
wa ll of t h e ou t let con n ect or r ecess t h a t wa s cr ea t ed
du r in g t h e st a kin g pr ocedu r e t h a t h eld t h e OE M
t h er m ost a t in pla ce (F ig. 11). It is n ot n ecessa r y t o
r est a ke t h e r epla cem en t t h er m ost a t in t o t h e con n ec-
t or.
(2) P osit ion t h er m ost a t t o coola n t ou t let con n ect or.
Align t h e t wo loca t in g n ot ch es on t h er m ost a t t o t h e
con n ect or (F ig. 12). Th is posit ion will en su r e pr oper
loca t ion of t h e t h er m ost a t a ir bleed.
(3) P osit ion a n ew ga sket over t h e t h er m ost a t a n d
con n ect or m a kin g su r e t h er m ost a t is in pr oper posi-
t ion a n d in t h e r ecess pr ovided.
(4) In st a ll t h er m ost a t a n d con n ect or a ssem bly t o Fig. 12 Thermostat Position In Outlet Connector
t h e in t a ke m a n ifold (F ig. 10). Tigh t en bolt s t o 28 1 - LOCATING NOTCH
N·m (250 in . lbs.). 2 - THERMOSTAT
(5) In st a ll t h e r a dia t or u pper h ose t o coola n t ou t let 3 - COOLANT OUTLET CONNECTOR
(6) Refill t h e coolin g syst em t o t h e pr oper level.
(Refer t o 7 - COOLING - STANDARD P ROCE DURE )
7 - 26 ENGINE RS
RADI AT OR
REMOVAL
(1) Discon n ect n ega t ive ca ble fr om ba t t er y.
(2) Rem ove r a dia t or u pper cr ossm em ber su ppor t .
(Refer t o 23 - BODY/E XTE RIOR/GRILLE OP E NING
RE INF ORCE ME NT - RE MOVAL)
WARNING: DO NOT REMOVE THE CYLINDER

BLOCK PLUG OR THE RADIATOR DRAINCOCK
WITH THE SYSTEM HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM COOLANT CAN
OCCUR.
(3) Dr a in t h e coolin g syst em . (Refer t o 7 - COOL-

ING - STANDARD P ROCE DURE )
(4) Rem ove t h e r a dia t or fa n s. (Refer t o 7 - COOL-
ING/E NGINE /RADIATOR FAN - RE MOVAL)
(5) Discon n ect coola n t r eser ve/r ecover y h ose.
(6) Rem ove va por pu r ge solen oid fr om m ou n t in g
br a cket .
(7) Discon n ect u pper a n d lower h oses fr om t h e
r a dia t or (F ig. 13) or (F ig. 14). Fig. 14 Radiator Hoses to Radiator - 3.3/3.8L
1 - UPPER HOSE
2 - LOWER HOSE
(9) Ra dia t or ca n n ow be lift ed fr ee fr om en gin e

com pa r t m en t . Ca re s h o u ld be ta k e n n o t to d a m -
a g e ra d ia to r c o o lin g fin s o r w a te r tu be s d u rin g
re m o v a l.
Fig. 13 Radiator Hoses to Radiator - 2.4L

1 - UPPER HOSE
2 - LOWER HOSE
3 - HOSE SUPPORT CLIP
Fig. 15 A/C Condenser – 2.4L/3.3L/3.8L Engines
(8) Lift t h e A/C con den ser st r a igh t u p t o disen ga ge 1 - A/C CONDENSER
t h e lower A/C con den ser m ou n t in g br a cket s fr om t h e 2 - AUTO TRANS COOLER TAPPING BLOCK
r a dia t or. (F ig. 15). Sepa r a t e t h e con den ser fr om t h e 3 - UPPER CONDENSER MOUNTING BRACKET (2)
4 - RADIATOR
r a dia t or by lift in g u pwa r d t o disen ga ge fr om lower 5 - LOWER CONDENSER MOUNTING BRACKET (2)
m ou n t s (F ig. 15). Allow t h e con den ser t o r est in fr on t
of r a dia t or.
RS ENGINE 7 - 27
RADI AT OR (Cont inue d)
INSTALLATION RADI AT OR PRESSU RE CAP

(1) B e s u re th e a ir s e a l is in p o s itio n be fo re
ra d ia to r is in s ta lle d . Slide r a dia t or down in t o posi- DESCRIPTION
t ion . Sea t t h e r a dia t or wit h t h e r u bber isola t or s in t o Th e coolin g syst em pr essu r e ca p is loca t ed on t h e
t h e m ou n t in g h oles pr ovided, wit h a 10 lbs. for ce. r a dia t or. Th e ca p con st r u ct ion in clu des; st a in less
(2) P osit ion a ir con dit ion in g con den ser on t o t h e st eel swivel t op, r u bber sea ls, a n d r et a in er, m a in
r a dia t or lower m ou n t s a n d in ga ge u pper m ou n t in g spr in g, a n d a spr in g loa ded va lve (F ig. 16).
t a bs. (F ig. 15).
(3) In st a ll t h e r a dia t or u pper a n d lower h oses (F ig.
13) or (F ig. 14).
(4) Con n ect t h e coola n t r eser ve/r ecover y h ose.
(5) Con n ect t h e va por pu r ge solen oid t o t h e m ou n t -
in g br a cket .
(6) In st a ll t h e r a dia t or fa n s. (Refer t o 7 - COOL-
ING/E NGINE /RADIATOR FAN - INSTALLATION)
(7) In st a ll t h e r a dia t or u pper cr ossm em ber su p-
por t . (Refer t o 23 - BODY/E XTE RIOR/GRILLE
OP E NING RE INF ORCE ME NT - INSTALLATION)
(8) F ill t h e coolin g syst em . (Refer t o 7 - COOLING
(9) Con n ect n ega t ive ca ble t o ba t t er y.
Fig. 16 Cooling System Pressure Cap Filler Neck
1 - OVERFLOW NIPPLE
RADI AT OR DRAI N COCK 2
3
-
-
MAIN SPRING
GASKET RETAINER
4 - STAINLESS-STEEL SWIVEL TOP
REMOVAL 5 - RUBBER SEALS
6 - VENT VALVE
7 - RADIATOR
NOTE: It is not necessary to remove draincock dur- 8 - FILLER NECK
ing a routine coolant drain.
OPERATION
Th e coolin g syst em is equ ipped wit h a pr essu r e ca p
t h a t r elea ses excessive pr essu r e; m a in t a in in g a r a n ge
(2) Usin g a scr ewdr iver, open t h e dr a in cock by
of 97-124 kP a (14-18 psi).
t u r n in g it cou n t er clockwise u n t il it st ops.
Th e coolin g syst em will oper a t e a t h igh er t h a n
(3) P u ll t h e dr a in cock fr om t h e r a dia t or t a n k.
a t m osph er ic pr essu r e. Th e h igh er pr essu r e r a ises t h e
coola n t boilin g poin t t h u s, a llowin g in cr ea sed r a dia -
INSTALLATION t or coolin g ca pa cit y.
(1) Align dr a in cock st em t o r a dia t or t a n k open in g. Th er e is a lso a ven t va lve in t h e cen t er of t h e ca p.
(2) P u sh dr a in cock in t o t h e r a dia t or t a n k open in g. Th is va lve a lso open s wh en coola n t is coolin g a n d
con t r a ct in g, a llowin g t h e coola n t t o r et u r n t o coolin g
CAUTION: Do not overtighten. The head of the
syst em fr om coola n t r eser ve syst em t a n k by va cu u m
draincock may break off.
t h r ou gh a con n ect in g h ose. If v a lv e is s tu c k s h u t,
(3) Usin g a scr ewdr iver, t igh t en t h e dr a in cock by o r th e c o o la n t re c o v e ry h o s e is p in c h e d , th e
t u r n in g clockwise u n t il it st ops. ra d ia to r h o s e s w ill be c o lla p s e d o n c o o l d o w n .
(4) F ill t h e coolin g syst em . (Refer t o 7 - COOLING Cle a n th e v e n t v a lv e (F ig . 16) a n d in s p e c t c o o l-
- STANDARD P ROCE DURE ) a n t re c o v e ry h o s e ro u tin g , to e n s u re p ro p e r
s e a lin g w h e n bo ilin g p o in t is re a c h e d .
Th e ga sket in t h e ca p sea ls t h e filler n eck, so t h a t
va cu u m ca n be m a in t a in ed, a llowin g coola n t t o be
dr a wn ba ck in t o t h e r a dia t or fr om t h e r eser ve t a n k.
If th e g a s k e t is d irty o r d a m a g e d , a v a c u u m
m a y n o t be a c h ie v e d , re s u ltin g is lo s s o f c o o la n t
a n d e v e n tu a l o v e rh e a tin g d u e to lo w c o o la n t
le v e l in ra d ia to r a n d e n g in e .
7 - 28 ENGINE RS
RADI AT OR PRESSU RE CAP (Cont inue d)
DI AGN OSI S AN D T EST I N G

PRESSURE CAP TESTING
Dip t h e pr essu r e ca p in wa t er. Clea n a n y deposit s
off t h e ven t va lve or it s sea t a n d a pply ca p t o en d of
t h e P r essu r e Ca p Test Ada pt or t h a t is in clu ded wit h
t h e Coolin g Syst em Test er 7700 (F ig. 17). Wor kin g
t h e plu n ger, br in g t h e pr essu r e t o 104 kP a (15 psi) on
t h e ga u ge. If t h e pr essu r e ca p fa ils t o h old pr essu r e
of a t lea st 97 kP a (14 psi), r epla ce t h e pr essu r e ca p.
CAUTION: The Cooling System Tester Tool is very

sensitive to small air leaks that will not cause cool- Fig. 18 Radiator Pressure Cap Filler Neck
ing system problems. A pressure cap that does not 1 - OVERFLOW NIPPLE
2 - MAIN SPRING
have a history of coolant loss should not be 3 - GASKET RETAINER
replaced just because it leaks slowly when tested 4 - STAINLESS-STEEL SWIVEL TOP
with this tool. Add water to the tool. Turn tool 5 - RUBBER SEALS
6 - VENT VALVE
upside down and recheck pressure cap to confirm 7 - RADIATOR
that cap is bad. 8 - FILLER NECK
If t h e pr essu r e ca p t est s pr oper ly wh ile posit ion ed WARNING: THE WARNING WORDS “DO NOT OPEN
on Coolin g Syst em Test er (F ig. 17), bu t will n ot h old HOT” ON THE RADIATOR PRESSURE CAP IS A
pr essu r e or va cu u m wh en posit ion ed on t h e filler SAFETY PRECAUTION. WHEN HOT, PRESSURE
n eck. In spect t h e filler n eck a n d ca p t op ga sket for BUILDS UP IN COOLING SYSTEM. TO PREVENT
ir r egu la r it ies t h a t m a y pr even t t h e ca p fr om sea lin g SCALDING OR INJURY, THE RADIATOR CAP
pr oper ly. SHOULD NOT BE REMOVED WHILE THE SYSTEM
IS HOT OR UNDER PRESSURE.
Th er e is n o n eed t o r em ove t h e r a dia t or ca p a t a n y

t im e e x c e p t for t h e followin g pu r poses:
(1) Ch eck a n d a dju st coola n t fr eeze poin t .
(2) Refill syst em wit h n ew coola n t .
(3) Con du ct in g ser vice pr ocedu r es.
(4) Ch eckin g for va cu u m lea ks.
WARNING: IF VEHICLE HAS BEEN RUN RECENTLY,

WAIT 15 MINUTES BEFORE REMOVING CAP. THEN
PLACE A SHOP TOWEL OVER THE CAP AND WITH-
OUT PUSHING DOWN ROTATE COUNTERCLOCK-
WISE TO THE FIRST STOP. ALLOW FLUIDS TO
ESCAPE THROUGH THE OVERFLOW TUBE AND
WHEN THE SYSTEM STOPS PUSHING COOLANT
Fig. 17 Testing Cooling System Pressure Cap AND STEAM INTO THE CRS TANK AND PRESSURE
1 - PRESSURE CAP
DROPS PUSH DOWN AND REMOVE THE CAP COM-
2 - PRESSURE TESTER PLETELY. SQUEEZING THE RADIATOR INLET HOSE
WITH A SHOP TOWEL (TO CHECK PRESSURE)
DIAGNOSIS AND TESTING - RADIATOR CAP BEFORE AND AFTER TURNING TO THE FIRST
STOP IS RECOMMENDED.
TO FILLER NECK SEAL
Th e pr essu r e ca p u pper ga sket (sea l) pr essu r e
r elief ca n be ch ecked by r em ovin g t h e over flow h ose CLEANING
a t t h e r a dia t or filler n eck n ipple (F ig. 18). At t a ch t h e
Use on ly a m ild soa p t o clea n t h e pr essu r e ca p.
Ra dia t or P r essu r e Tool t o t h e filler n eck n ipple a n d
pu m p a ir in t o t h e r a dia t or. P r essu r e ca p u pper ga s-
ket sh ou ld r elieve a t 69-124 kP a (10-18 psi) a n d h old
pr essu r e a t 55 kP a (8 psi) m in im u m .
RS ENGINE 7 - 29
RADI AT OR PRESSU RE CAP (Cont inue d)
INSPECTION
H old t h e ca p in you r h a n d, to p s id e u p (F ig. 19).
Th e ven t va lve a t t h e bot t om of t h e ca p sh ou ld open .
If t h e r u bber ga sket h a s swollen , pr even t in g t h e
va lve fr om open in g, r epla ce t h e ca p.
H old t h e clea n ed ca p in you r h a n d, u p s id e d o w n .
If a n y ligh t ca n be seen bet ween ven t va lve a n d t h e
r u bber ga sket , r epla ce t h e ca p. D o n o t u s e a
re p la c e m e n t c a p th a t h a s a s p rin g to h o ld th e
v e n t s h u t.
A r epla cem en t ca p m u st be of t h e t ype design ed for
coola n t r eser ve syst em s. Th is design en su r es coola n t
r et u r n t o t h e r a dia t or. Fig. 19 Cooling System Pressure Cap
1 - OVERFLOW NIPPLE
2 - MAIN SPRING
RADI AT OR FAN 3
4
-
-
GASKET RETAINER
STAINLESS-STEEL SWIVEL TOP
5 - RUBBER SEALS
DESCRIPTION 6 - VENT VALVE
7 - RADIATOR
Th e du a l r a dia t or fa n s a r e m ou n t ed t o t h e ba ck 8 - FILLER NECK
side of t h e r a dia t or (F ig. 20). Th e r a dia t or fa n con sist
of t h e fa n bla de, elect r ic m ot or a n d a su ppor t sh r ou d
wh ich a r e a ll ser viced a s a n a ssem bly.
OPERATION
RADI AT OR FAN OPERAT I ON CH ART
COOLANT TEMPERATURE A/C PRESSURE TRANSAXLE OIL

TEMPERATURE
Fan
Operation Initial Max Initial Max Initial Max
Speeds:
Fan On: 104°C 110°C 1,724 Kpa 2,068 Kpa 96°C (204°F) 111°C (232°F)
(220°F) (230°F) Fan (250 psi) (300 psi) Fan Fan Speed
Speed Speed Duty Cycles
Duty-Cycles Duty-Cycles (Ramps-up)
(Ramps-up) (Ramps-up) from 30% to
from 30% to from 30% to 99%
99% 99%
Fan Off: 101°C Fan Speed 1,710 Kpa Fan Speed 89°C (192°F) Fan Speed
(214°F) Duty-Cycles (248 psi) Duty-Cycles Duty Cycles
(Ramps- (Ramps- (Ramps-down)
down) from down) from from 99% to
99% to 30% 99% to 30% 30%
7 - 30 ENGINE RS
RADI AT OR FAN (Cont inue d)
DIAGNOSIS AND TESTING - RADIATOR FAN MOTOR

RADI AT OR FAN DI AGN OSI S CH ART
NOISY RADIATOR FAN 1. Fan blade loose. 1. Replace fan assembly. (Refer to
7 - COOLING/ENGINE/RADIATOR
FAN - REMOVAL)
2. Fan blade striking a surrounding 2. Locate point of fan blade contact
object. and repair as necessary.
3. Air obstructions at radiator or A/C 3. Remove obstructions and/or
condenser. clean debris.
4. Electric fan motor defective. 4. Replace fan assembly. (Refer to
7 - COOLING/ENGINE/RADIATOR
FAN - REMOVAL)
ELECTRIC FAN MOTOR DOES 1. Fan relay, powertrain control 1. (Refer to Appropriate Diagnostic
NOT OPERATE module (PCM), coolant temperature Information) Repair as necessary.
sensor, or wiring defective.
2. Defective A/C pressure 2. (Refer to Appropriate Diagnostic
transducer. Information) Repair as necessary.
ELECTRIC RADIATOR FAN 1. Fan relay, powertrain control 1. (Refer to Appropriate Diagnostic
OPERATES ALL THE TIME module (PCM), coolant temperature Information) Repair as necessary.
sensor or wiring defective.
2. Check for low coolant level. 2. Add coolant as necessary.
3. Defective A/C pressure 3. (Refer to Appropriate Diagnostic
transducer. Information) Repair as necessary.
REMOVAL
Th er e a r e n o r epa ir s t o be m a de t o t h e fa n or
sh r ou d a ssem bly. If t h e fa n is wa r ped, cr a cked, or
ot h er wise da m a ged, it m u st be r epla ced a s a n a ssem -
bly (F ig. 20).
(1) Rem ove t h e r a dia t or u pper cr ossm em ber. (Refer
t o 23 - BODY/E XTE RIOR/GRILLE OP E NING RE IN-
F ORCE ME NT - RE MOVAL)
(2) Discon n ect t h e r a dia t or fa n elect r ica l con n ec-
t or s.
(3) Rem ove r a dia t or fa n (s) r et a in in g scr ew (F ig.
20).
(4) Rem ove t h e r a dia t or fa n (s) by lift in g u pwa r d t o
r elea se fr om m ou n t s. Fig. 20 Radiator Fans
1 - SCREWS - RADIATOR FAN ATTACHING
INSTALLATION 2 - RADIATOR FAN - RIGHT
3 - MOUNT - RIGHT RADIATOR FAN
(1) In st a ll t h e r a dia t or fa n (s) in t o m ou n t s a n d 4 - CLIPS - RADIATOR FAN LOWER
a t t a ch in g clips on t h e r a dia t or. 5 - MOUNT - LEFT RADIATOR FAN
(2) In st a ll r a dia t or fa n (s) a t t a ch in g scr ews (F ig. 6 - RADIATOR FAN - LEFT
20). Tigh t en t o 5 N·m (45 in . lbs.).
(3) Con n ect t h e r a dia t or fa n (s) elect r ica l con n ec- (4) In st a ll t h e r a dia t or u pper su ppor t cr ossm em -
t or s. ber. (Refer t o 23 - BODY/E XTE RIOR/GRILLE OP E N-
ING RE INF ORCE ME NT - INSTALLATION)
RS ENGINE 7 - 31
RADI AT OR FAN (Cont inue d)
(5) In st a ll t h e u pper r a dia t or m ou n t s t o t h e cr oss-
m em ber bolt s, if r em oved. Tigh t en t o 8 N·m (70 in .
lbs.).
(6) In st a ll t h e r a dia t or u pper h ose t o t h e su ppor t
clip (2.4L en gin e).
RADI AT OR FAN RELAY

DESCRIPTION
Th e r a dia t or fa n r ela y is a solid st a t e t ype a n d is
loca t ed on t h e fr on t bu m per r ein for cm en t (F ig. 21).
Refer t o WIRING DIAGRAMS for a cir cu it sch e-
m a t ic.
OPERATION
Th e solid st a t e r a dia t or fa n r ela y is con t r olled by
t h e P ower t r a in Con t r ol Modu le (P CM) by wa y of a
P u lse Widt h Modu la t ed (P WM) sign a l. Th e r ela y con -
t r ol cir cu it su pplies a 12 volt sign a l t o t h e P CM. Th e
P CM t h en pu lses t h e gr ou n d cir cu it t o a ch ieve fa n on
t im e. Th e r ela y pr ovides a volt a ge t o t h e fa n m ot or s
wh ich is pr opor t ion a l t o t h e pu lse widt h it r eceives
fr om t h e P CM. Th e du t y cycle r a n ges fr om 30% for
low speed oper a t ion , t h en r a m ps-u p t o 100% for h igh
speed oper a t ion . Th is fa n con t r ol syst em pr ovides
in fin it ely va r ia ble fa n speeds, a llowin g for im pr oved
fa n n oise, A/C per for m a n ce, bet t er en gin e coolin g,
a n d a ddit ion a l veh icle power. Fig. 21 Radiator Fan Relay
To con t r ol oper a t ion of t h e r ela y, t h e P CM looks a t 1 - FRONT FASCIA
in pu t s fr om : 2 - FAN RELAY
• E n gin e coola n t t em per a t u r e 3 - RIVET
4 - A/C CONDENSER (FRONT SIDE)
• A/C pr essu r e t r a n sdu cer
• Am bien t t em per a t u r e fr om t h e body con t r oller
• Veh icle speed
INSTALLATION
• Tr a n sm ission oil t em per a t u r e
CAUTION: The relay mounting location is designed
Th e P CM u ses t h ese in pu t s t o det er m in e wh en t h e
to dissipate heat. Ensure the relay is securely
fa n sh ou ld oper a t e a n d a t wh a t speed. F or fu r t h er
attached to prevent relay “thermal” shutdown and
in for m a t ion on fa n oper a t ion , (Refer t o 7 - COOL-
relay damage, resulting in possible engine over-
ING/E NGINE /RADIATOR FAN - OP E RATION).
heating.
REMOVAL (1) P osit ion r ela y a n d in st a ll a n ew r ivet (F ig. 21).
(1) Open h ood. (2) Con n ect elect r ica l con n ect or t o r ela y.
(2) Discon n ect a n d isola t e t h e ba t t er y n ega t ive (3) In st a ll closu r e pa n el a n d a t t a ch in g scr ews.
ca ble. (4) Con n ect n ega t ive ca ble t o ba t t er y.
(3) Rem ove t h e r a dia t or cr ossm em ber t o fr on t fa s-
cia closu r e pa n el.
(4) Discon n ect t h e r ela y elect r ica l con n ect or (F ig.
21).
(5) Rem ove t h e r ivet a t t a ch in g t h e r ela y t o t h e
fr on t bu m per bea m (F ig. 21).
(6) Rem ove t h e r ela y.
7 - 32 ENGINE RS
WAT ER PU M P - 2 .4 L (7) Rem ove r igh t en gin e m ou n t br a cket (F ig. 23).

(8) Rem ove t h e t im in g belt (Refer t o 9 - E NGINE /
VALVE TIMING/TIMING BE LT AND SP ROCKE T(S)
DESCRIPTION
- RE MOVAL).
Th e wa t er pu m p h a s a ca st a lu m in u m body a n d
(9) Rem ove t im in g belt idler pu lley.
h ou sin g wit h a st a m ped st eel im peller. Th e wa t er
(10) H old ca m sh a ft spr ocket wit h Specia l t ool
pu m p bolt s dir ect ly t o t h e block (F ig. 22). Th e cylin -
C-4687 a n d a da pt or C-4687-1 wh ile r em ovin g bolt .
der block t o wa t er pu m p sea l is pr ovided by a r u bber
Rem ove bot h ca m spr ocket s.
O-r in g. Th e wa t er pu m p is dr iven by t h e en gin e t im -
(11) Rem ove t h e t im in g belt r ea r cover (Refer t o 9
in g belt .
- E NGINE /VALVE TIMING/TIMING BE LT COV-
E R(S) - RE MOVAL).
(12) Rem ove t h e gen er a t or a n d br a cket (F ig. 23).
(13) Rem ove wa t er pu m p t o en gin e a t t a ch in g
scr ews (F ig. 24).
CLEANING
Clea n ga sket m a t in g su r fa ces a s n ecessa r y.
INSPECTION
Repla ce wa t er pu m p body a ssem bly if it h a s a n y of
t h ese defect s:
(1) Cr a cks or da m a ge on t h e body.
(2) Coola n t lea ks fr om t h e sh a ft sea l, eviden t by
wet coola n t t r a ces on t h e pu m p body.
(3) Loose or r ou gh t u r n in g bea r in g.
(4) Im peller r u bs eit h er t h e pu m p body or t h e
en gin e block.
(5) Im peller loose or da m a ged.
(6) Spr ocket or spr ocket fla n ge loose or da m a ged.
INSTALLATION
(1) In st a ll n ew O-r in g ga sket in wa t er pu m p body
O-r in g loca t in g gr oove (F ig. 25).
CAUTION: Make sure O-ring is properly seated in

Fig. 22 Water Pump water pump groove before tightening screws. An
1 - CYLINDER BLOCK improperly located O-ring may be damaged and
2 - WATER PUMP cause a coolant leak.
REMOVAL (2) Assem ble pu m p body t o block a n d t igh t en

(1) Discon n ect n ega t ive ca ble fr om ba t t er y. scr ews t o 12 N·m (105 in . lbs.) (F ig. 24). P r essu r ize
(2) Ra ise veh icle on a h oist . coolin g syst em t o 103.4 Kpa (15 psi) wit h pr essu r e
(3) Rem ove t h e r igh t in n er spla sh sh ield. t est er a n d ch eck wa t er pu m p sh a ft sea l a n d O-r in g
(4) Rem ove t h e a ccessor y dr ive belt s (Refer t o 7 - for lea ks.
COOLING/ACCE SSORY DRIVE /DRIVE BE LTS - (3) Rot a t e pu m p by h a n d t o ch eck for fr eedom of
RE MOVAL). m ovem en t .
(5) Dr a in t h e coolin g syst em (Refer t o 7 - COOL- (4) In st a ll t h e t im in g belt r ea r cover (Refer t o 9 -
ING - STANDARD P ROCE DURE ). E NGINE /VALVE TIMING/TIMING BE LT COVE R(S)
(6) Su ppor t en gin e fr om t h e bot t om a n d r em ove - INSTALLATION).
r igh t en gin e m ou n t . (Refer t o 9 - E NGINE /E NGINE (5) In st a ll ca m sh a ft spr ocket s a n d t or qu e bolt s t o
MOUNTING/RIGH T MOUNT - RE MOVAL). 101 N·m (75 ft . lbs.) wh ile h oldin g ca m sh a ft spr ocket
wit h Specia l t ool C-4687 a n d a da pt or C-4687-1.
RS ENGINE 7 - 33
WAT ER PU M P - 2 .4 L (Cont inue d)
Fig. 23 Generator Bracket

1 - BRACKET - ENGINE MOUNT 5 - BOLT
2 - BOLT 6 - TENSIONER - DRIVE BELT
3 - GENERATOR 7 - BOLT
4 - BOLT 8 - BOLT
(6) In st a ll t im in g belt idler pu lley a n d t or qu e (10) In st a ll r igh t en gin e m ou n t br a cket a n d en gin e

m ou n t in g bolt t o 61 N·m (45 ft . lbs.). m ou n t (Refer t o 9 - E NGINE /E NGINE MOUNTING/
(7) In st a ll t h e t im in g belt (Refer t o 9 - E NGINE / RIGH T MOUNT - INSTALLATION).
VALVE TIMING/TIMING BE LT AND SP ROCKE T(S) (11) F ill t h e coolin g syst em (Refer t o 7 - COOLING
- INSTALLATION). - STANDARD P ROCE DURE ).
(8) In st a ll t h e gen er a t or m ou n t br a cket . (F ig. 23) (12) In st a ll t h e a ccessor y dr ive belt s (Refer t o 7 -
(9) In st a ll t h e gen er a t or. COOLING/ACCE SSORY DRIVE /DRIVE BE LTS -
INSTALLATION).
(13) Lower veh icle a n d con n ect ba t t er y ca ble.
7 - 34 ENGINE RS
WAT ER PU M P - 2 .4 L (Cont inue d)
WAT ER PU M P - 3 .3 /3 .8 L
DESCRIPTION
Th e wa t er pu m p h a s a die-ca st a lu m in u m body
a n d a pla st ic im peller. It bolt s dir ect ly t o t h e t im in g
ch a in ca se cover, u sin g a r u bber sea l for sea lin g (F ig.
26). It is dr iven by t h e a ccessor y dr ive belt .
Fig. 24 Water Pump - 2.4L

1 - CYLINDER BLOCK
2 - WATER PUMP Fig. 26 Water Pump - 3.3/3.8L Engine
1 - WATER PUMP
2 - PULLEY - WATER PUMP
3 - BOLT - PULLEY
4 - BOLT - WATER PUMP
5 - SEAL - WATER PUMP
REMOVAL
(2) Rem ove t h e a ccessor y dr ive belt sh ield.
(3) Rem ove t h e a ccessor y dr ive belt . (Refer t o 7 -
COOLING/ACCE SSORY DRIVE /DRIVE BE LTS -
RE MOVAL)
(4) Rem ove wa t er pu m p pu lley bolt s (F ig. 26).
NOTE: To remove the water pump pulley, it MUST

first be positioned between water pump housing
and drive hub. The pulley can then be removed with
the water pump assembly.
(5) Rot a t e pu lley u n t il open in gs in pu lley a lign

Fig. 25 Water Pump Body wit h wa t er pu m p dr ive h u b spokes (F ig. 27). Move
1 - IMPELLER pu lley in wa r d bet ween pu m p h ou sin g a n d h u b (F ig.
2 - WATER PUMP BODY 27).
3 - O-RING LOCATING GROOVE
(6) P osit ion pu lley t o a llow a ccess t o wa t er pu m p
m ou n t in g bolt s. Rem ove wa t er pu m p m ou n t in g bolt s
(F ig. 28).
(7) Rem ove wa t er pu m p wit h t h e pu lley loosely
posit ion ed bet ween h u b a n d t h e pu m p body.
RS ENGINE 7 - 35
WAT ER PU M P - 3 .3 /3 .8 L (Cont inue d)
(3) Im peller r u bs in side of ch a in ca se cover.
(4) E xcessively loose or r ou gh t u r n in g bea r in g.
NOTE: A weepage stain that is black, brown, or grey

is considered normal, if it is dry. If the weep
appears wet; pressure test the cooling system at
15–18 psi and observe the weep area. If weep area
remains unchanged, do not replace the water pump
for this condition. Replace the water pump, if a
steady flow of engine coolant is evident from the
weep hole/reservoir slot (Fig. 29) (shaft seal failure).
Be sure to perform a thorough analysis before
replacing water pump.
Fig. 27 Water Pump Pulley Positioning

1 - HUB - WATER PUMP
2 - PULLEY - WATER PUMP
(8) Rem ove a n d disca r d t h e sea l.

(9) Clea n sea l gr oove a n d sea lin g su r fa ces on
pu m p a n d t im in g ch a in ca se cover. Ta ke ca r e n ot t o
scr a t ch or gou ge sea lin g su r fa ces.
Fig. 29 Water Pump Inspection - 3.3/3.8L Engine

INSTALLATION
(1) In st a ll n ew sea l in t o wa t er pu m p h ou sin g
gr oove (F ig. 30).
NOTE: The water pump pulley MUST be positioned

Fig. 28 Water Pump Bolts - 3.3/3.8L Engine (Shown loosely between the pump housing and drive hub
Without Pulley) BEFORE water pump installation.
1 - WATER PUMP
2 - BOLTS (2) P osit ion t h e wa t er pu m p pu lley loosely bet ween
pu m p h ou sin g a n d dr ive h u b (F ig. 27).
CLEANING (3) In st a ll wa t er pu m p a n d pu lley t o t h e t im in g
Clea n ga sket m a t in g su r fa ces a s n ecessa r y. ch a in ca se cover (F ig. 26). Tigh t en wa t er pu m p bolt s
t o 12 N·m (105 in . lbs.).
INSPECTION (4) P osit ion pu lley on wa t er pu m p h u b. In st a ll
bolt s a n d t igh t en t o 28 N·m (250 in . lbs.) (F ig. 26).
Repla ce t h e wa t er pu m p if it h a s a n y of t h e follow-
(5) Rot a t e pu m p by h a n d t o ch eck for fr eedom of
in g defect s.
m ovem en t .
(1) Da m a ge or cr a cks on t h e pu m p body.
(6) In st a ll t h e a ccessor y dr ive belt . (Refer t o 7 -
(2) Coola n t lea ks; t h is will be eviden t by a wet
st r ea m of coola n t r u n n in g down t h e pu m p body a n d
INSTALLATION)
com pon en t s below. A t h in st a in below t h e weep h ole
r eser voir slot (F ig. 29) is con sider ed n or m a l oper a -
t ion .
7 - 36 ENGINE RS
WAT ER PU M P - 3 .3 /3 .8 L (Cont inue d)
Fig. 31 Water Pump Inlet Tube - 2.4L Engine

1 - O-RING
2 - WATER PUMP INLET TUBE
Fig. 30 Water Pump Seal
1 - WATER PUMP HOUSING
2 - SEAL
3 - IMPELLER
(7) In st a ll dr ive belt sh ield.

WAT ER PU M P I N LET T U BE -
2 .4 L
DESCRIPTION
Th e 2.4L en gin e u ses a m et a l t u be t o con n ect t h e
en gin e block t o t h e lower r a dia t or h ose a n d h ea t er
r et u r n (F ig. 31). Th e t u be h a s a n O-r in g for block t o
t u be sea lin g a n d bolt s a t t a ch t h e t u be t o t h e en gin e Fig. 32 Water Pump Inlet Tube Hose Connections
block. 1 - WATER PUMP INLET TUBE
2 - HOSE - HEATER RETURN
3 - COOLANT INLET
REMOVAL
(1) Dr a in t h e coolin g syst em . (Refer t o 7 - COOL- (3) In st a ll t h e t wo in let t u be fa st en er s a n d t igh t en
ING - STANDARD P ROCE DURE ) t o 12 N·m (105 in . lbs.).
(2) Rem ove r a dia t or u pper h ose t o a ccess t h e h ose (4) Con n ect t h e r a dia t or lower h ose (F ig. 7) a n d
con n ect ion s a t t h e in let t u be. h ea t er h ose t o in let t u be (F ig. 32).
(3) Rem ove r a dia t or lower (F ig. 7) a n d h ea t er (5) In st a ll t h e r a dia t or u pper h ose.
h oses fr om t h e in let t u be (F ig. 32). (6) F ill t h e coolin g syst em . (Refer t o 7 - COOLING
(4) Rem ove t h e t wo fa st en er s t h a t h old t h e in let - STANDARD P ROCE DURE )
t u be t o t h e block.
(5) Rot a t e t u be wh ile r em ovin g t h e t u be fr om t h e
en gin e block.
INSTALLATION
(1) In spect t h e O-r in g for da m a ge befor e in st a llin g
t h e t u be in t o t h e cylin der block (F ig. 31).
(2) Lu be O-r in g wit h coola n t a n d in st a ll in let t u be
in t o t h e cylin der block open in g (F ig. 31).
RS ENGINE 7 - 37
WAT ER PU M P I N LET T U BE -
3 .3 /3 .8 L
REMOVAL
(2) Ra ise veh icle on h oist a n d r em ove t h e belt
spla sh sh ield.
(3) Rem ove t h e r a dia t or lower h ose fr om in let t u be
(F ig. 33).
Fig. 34 Engine Oil Cooler Hoses (Engine Oil Cooler

Equipped)
1 - OIL COOLER INLET TUBE
2 - INLET HOSE
3 - OIL COOLER OUTLET TUBE
4 - OUTLET HOSE
5 - WATER PUMP INLET TUBE
Fig. 33 RAD HOSES TO ENGINE - 3.3/3.8L

1 - UPPER HOSE
2 - LOWER HOSE
(4) Rem ove t h e oil cooler ou t let /h ea t er r et u r n h ose

fr om in let t u be (on ly if equ ipped wit h en gin e oil
cooler ) (F ig. 34).
(5) Rem ove t h e in let t u be bolt s (F ig. 35).
(6) Rem ove t h e in let t u be (F ig. 35). Disca r d t h e
O-r in g sea l. Fig. 35 WATER PUMP INLET TUBE
1 - TIMING CHAIN COVER
INSTALLATION 2 - INLET TUBE
(1) Clea n t h e in let t u be O-r in g sea lin g su r fa ces on 3 - BOLT
4 - BOLT
t h e t im in g cover h ou sin g a n d t u be. 5 - O-RING
(2) Apply Mopa r ! Dielect r ic Gr ea se or equ iva len t
t o t h e O-r in g befor e in st a lla t ion . (6) In st a ll t h e dr ive belt spla sh sh ield a n d lower
(3) P osit ion n ew O-r in g sea l on in let t u be (F ig. 35). veh icle.
(4) In st a ll t h e in let t u be (F ig. 35). Tigh t en bolt s t o (7) F ill t h e coolin g syst em . (Refer t o 7 - COOLING
28 N·m (250 in . lbs.). - STANDARD P ROCE DURE )
(5) Con n ect r a dia t or lower h ose (F ig. 33) a n d
h ea t er r et u r n h ose (if equ ipped wit h en gin e oil
cooler ) (F ig. 34) t o t h e in let t u be.
7 - 38 TRANSMISSION RS
T RAN SM I SSI ON
TABLE OF CONTENTS
page page
TRANSMISSION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 39
STANDARD PROCEDURE - TRANSMISSION TRANSMISSION OIL COOLER LINES
COOLER LINE QUICK CONNECT FITTING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
DISASSEMBLY/ASSEMBLY . . . . . . . . . . . . . . 38 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 40
TRANSMISSION OIL COOLER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 39
T RAN SM I SSI ON
STANDARD PROCEDURE - TRANSMISSION
COOLER LINE QUICK CONNECT FITTING
DISASSEMBLY/ASSEMBLY
DISCONNECT
(1) Rem ove du st ca p by pu llin g it st r a igh t ba ck off
of qu ick con n ect fit t in g. (F ig. 1)
(2) P la ce discon n ect t ool Specia l Tool 8875A on t o
t r a n sm ission cooler lin e wit h t h e fin ger s of t h e t ool
fa cin g t h e qu ick con n ect fit t in g.
(3) Slide discon n ect t ool down t h e t r a n sm ission
lin e a n d en ga ge t h e fin ger s of t h e t ool in t o t h e
r et a in in g clip. Wh en pr oper ly en ga ged in t h e clip, t h e
t ool will fit flu sh a ga in st t h e qu ick con n ect fit t in g.
(4) Rot a t e t h e discon n ect t ool 60° t o expa n d t h e
r et a in in g clip.
(5) Wh ile h oldin g t h e discon n ect t ool a ga in st t h e
qu ick con n ect fit t in g, pu ll ba ck on t h e t r a n sm ission
cooler lin e t o r em ove.
CONNECT
(1) Align t r a n sm ission cooler lin e wit h qu ick con -
n ect fit t in g wh ile pu sh in g st r a igh t in t o t h e fit t in g.
(2) P u sh in on t r a n sm ission cooler lin e u n t il a
“click” is h ea r d or felt (F ig. 2).
(3) Slide du st ca p down t h e t r a n sm ission cooler
lin e a n d sn a p it over t h e qu ick con n ect fit t in g u n t il it
is fu lly sea t ed a n d r ot a t es fr eely (F ig. 2). Du st ca p
will on ly sn a p over qu ick con n ect fit t in g wh en t h e
t r a n sm ission cooler lin e is pr oper ly in st a lled.
NOTE: If dust cap will not snap into place, repeat

assembly step #2.
Fig. 1 Oil Cooler Line Quick Connect Fitting -
Disassembly
1 - QUICK CONNECT FITTING
2 - DUST CAP
3 - OIL COOLER LINE
4 - SPECIAL TOOL 8875A
RS TRANSMISSION 7 - 39
T RAN SM I SSI ON (Cont inue d)
2.5L/2.8L en gin es (Refer t o 24 - H E ATING & AIR
CONDITIONING/P LUMBING/A/C CONDE NSE R -
RE MOVAL). F or in st a lla t ion on veh icles equ ipped
wit h 2.4L/3.3L/3.8L en gin es (Refer t o 24 - H E ATING
& AIR CONDITIONING/P LUMBING/A/C CON-
DE NSE R - INSTALLATION), a n d veh icles equ ipped
wit h 2.5L/2.8L en gin es (Refer t o 24 - H E ATING &
AIR CONDITIONING/P LUMBING/A/C CON-
DE NSE R - INSTALLATION).
INSPECTION
In spect a ll h oses, t u bes, cla m ps a n d con n ect ion s for
lea ks, cr a cks, or da m a ge. Repla ce a s n ecessa r y. Use
on ly a ppr oved t r a n sm ission oil cooler h oses t h a t a r e
m olded t o fit t h e spa ce a va ila ble.
In spect ext er n a l cooler s for lea ks, loose m ou n t s, or
da m a ge. Repla ce a s n ecessa r y.
T RAN SM I SSI ON OI L COOLER

LI N ES
REMOVAL
(1) Rem ove t h e t wo la r ge scr ews t h a t secu r e t h e
fr on t fa scia a n d t h e ou t boa r d en ds of t h e r a dia t or
sigh t sh ield t o t h e r a dia t or closu r e pa n el cr ossm em -
ber (F ig. 3).
(2) Rem ove t h e five sm a ll scr ews t h a t secu r e t h e
fr on t fa scia gr ille in ser t s t o t h e r a dia t or sigh t sh ield.
(3) Rem ove t h e r a dia t or sigh t sh ield fr om t h e r a di-
a t or closu r e pa n el cr ossm em ber.
Fig. 2 Oil Cooler Line Quick Connect Fitting -
Assembly
1 - QUICK CONNECT FITTING
2 - CLIP
3 - OIL COOLER LINE
4 - DUST CAP
T RAN SM I SSI ON OI L COOLER

DESCRIPTION
Th e a u t om a t ic t r a n sm ission cooler is loca t ed in t h e
fr on t of t h e r a dia t or a n d beh in d t h e fr on t fa scia a n d
is con bin ed wit h t h e A/C con den sor. Th e t r a n sm ission
cooler is a h ea t exch a n ger t h a t a llows h ea t in t h e
t r a n sm ission flu d t o be t r a n sfer r ed t o t h e a ir pa ssin g
over t h e cooler fin s.
Th e Tr a n sm ission oil cooler /A/C con den ser a ssem -
blly is equ ipped wit h qu ick con n ect fit t in g for t h e Fig. 3 Radiator Sight Shield - Typical
t r a n sm ission oil cooler lin es, a t a ppin g block, for t h e 1 - LARGE SCREWS (2)
r eceiver /dr ier, a n d m ou n t in g pr ovision s for t h e power 2 - SMALL SCREWS (5)
st eer in g cooler. 3 - RADIATOR SIGHT SHIELD
4 - GRILLE INSERTS
Th e t r a n sm ission oil cooler /AC con den ser is ser- 5 - FRONT FASCIA
viced a s a n a ssem bly. F or r em ova l on veh icles
equ ipped wit h 2.4L/3.3L/3.8L en gin es, (Refer t o 24 -
H E ATING & AIR CONDITIONING/P LUMBING/A/C
CONDE NSE R - RE MOVAL), veh icles equ ipped wit h
7 - 40 TRANSMISSION RS
T RAN SM I SSI ON OI L COOLER LI N ES (Cont inue d)
(4) Rem ove t h e t wo bolt s t h a t secu r e t h e h ood
la t ch t o t h e fr on t of t h e r a dia t or closu r e pa n el cr oss-
m em ber a n d m ove t h e la t ch ou t of t h e wa y over t h e
t op of t h e cr ossm em ber. Ma r k t h e loca t ion of la t ch for
r ein st a lla t ion .
(5) Usin g t ool 8875A, discon n ect t h e t r a n sm ission
oil cooler lin e qu ick-con n ect fit t in gs loca t ed on t h e
dr iver side of t h e A/C con den ser fr om t h e t r a n sm is-
sion oil cooler (Refer t o 7 - COOLING/TRANSMIS-
SION - STANDARD P ROCE DURE -
TRANSMISSION COOLING).
(6) Usin g Tool 8875A, discon n ect t r a n sm ission oil
cooler lin e qu ick-discon n ect fit t in gs a t t h e t r a n sa xle
(Refer t o 7 - COOLING/TRANSMISSION - STAN-
DARD P ROCE DURE ).
INSTALLATION Fig. 4 Radiator Sight Shield – Typical

(1) P osit ion t r a n sm ission cooler lin es in veh icle. 1 - LARGE SCREWS (2)
(2) In st a ll t r a n sm ission cooler lin e a t t r a n sa xle fit - 2 - SMALL SCREWS (5)
3 - RADIATOR SIGHT SHIELD
t in gs (Refer t o 7 - COOLING/TRANSMISSION - 4 - GRILLE INSERTS
STANDARD P ROCE DURE ). 5 - FRONT FASCIA
(3) In st a ll t r a n sm ission cooler lin es a t t r a n sm is-
sion oil cooler /con den sor (Refer t o 7 - COOLING/ (7) In st a ll t h e five sm a ll scr ews t h a t secu r e t h e
TRANSMISSION - STANDARD P ROCE DURE ). fr on t fa scia gr ille in ser t s t o t h e r a dia t or sigh t sh ield.
(4) Reposit ion t h e h ood la t ch t o t h e fr on t of t h e Tigh t en t h e scr ews t o 2 N·m (17 in . lbs.).
r a dia t or closu r e pa n el cr ossm em ber. (8) In st a ll t h e t wo la r ge scr ews t h a t secu r e t h e
(5) In st a ll t h e t wo scr ews t h a t secu r e t h e h ood fr on t fa scia a n d t h e ou t boa r d en ds of t h e r a dia t or
la t ch t o t h e fr on t of t h e r a dia t or closu r e pa n el cr oss- sigh t sh ield t o t h e r a dia t or closu r e pa n el cr ossm em -
m em ber. Ch eck a n d a dju st t h e h ood la t ch a s n eeded. ber. Tigh t en t h e scr ews t o 6 N·m (53 in . lbs.) (F ig. 4)
Tigh t en t h e scr ews t o 14 N·m (123 in . lbs.). (9) St a r t en gin e a n d ch eck t r a n sa xle flu id level.
(6) P osit ion t h e r a dia t or sigh t sh ield on t o t h e r a di- Adju st flu id level a s n ecessa r y.
a t or closu r e pa n el cr ossm em ber.
RS AUDIO/VIDEO 8A - 1
AUDIO/VIDEO
page page
AUDIO/VIDEO INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1 QUARTER GLASS INTEGRAL ANTENNA -
DIAGNOSIS AND TESTING EXPORT
AUDIO/VIDEO . . . . . . . . . . . . . . . . . . . . . . . . . 2 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13
AMPLIFIER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REMOVAL .............................7 DIAGNOSIS AND TESTING
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7 QUARTER GLASS INTEGRAL ANTENNA -
ANTENNA BODY AND CABLE EXPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7 RADIO
DIAGNOSIS AND TESTING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
ANTENNA BODY AND CABLE . . . . . . . . . . . . . 8 DIAGNOSIS AND TESTING
REMOVAL .............................8 RADIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
ANTENNA MODULE - EXPORT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10 RADIO NOISE SUPPRESSION COMPONENTS
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 15
ANTENNA MODULE - EXPORT . . . . . . . . . . . 10 REMOTE SWITCHES
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
ANTENNA - NAVIGATION RADIO DIAGNOSIS AND TESTING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 REMOTE SWITCHES ............... . . . 16
CD CHANGER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11 SPEAKER
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 DIAGNOSIS AND TESTING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 SPEAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
DVD PLAYER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 12 VIDEO SCREEN
INSTRUMENT PANEL ANTENNA CABLE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
AU DI O/V I DEO • Am plifier

• An t en n a
• CD ch a n ger (if equ ipped)
DESCRIPTION
• DVD pla yer (if equ ipped)
An a u dio syst em is st a n da r d on t h is m odel. A r ea r
• Ra dio n oise su ppr ession com pon en t s
sea t video syst em is a n a va ila ble opt ion . Sever a l com -
• Ra dio r eceiver
bin a t ion s of r a dio r eceiver s a r e offer ed on t h is m odel.
• Spea ker s
Th e a u dio/video syst em u ses a n ign it ion swit ch ed
• Video scr een (if equ ipped)
sou r ce of ba t t er y cu r r en t so t h a t t h e syst em will on ly
Cer t a in fu n ct ion s a n d fea t u r es of t h e a u dio/video
oper a t e wh en t h e ign it ion swit ch is in t h e RUN or
syst em r ely u pon r esou r ces sh a r ed wit h ot h er elec-
ACCE SSORY/ACCE SSORY DE LAY posit ion s.
t r on ic m odu les in t h e veh icle over t h e P r ogr a m m a ble
Th e a u dio syst em in clu des t h e followin g com po-
Com m u n ica t ion In t er fa ce (P CI) bu s n et wor k. Th e
n en t s:
da t a bu s n et wor k a llows t h e sh a r in g of sen sor in for-
8A - 2 AUDIO/VIDEO RS
AU DI O/V I DEO (Cont inue d)
m a t ion . F or dia gn osis of t h ese elect r on ic m odu les or III!, re fe r to th e a p p ro p ria te D ia g n o s tic S e rv ic e
of t h e da t a bu s n et wor k, t h e u se of a DRB III! sca n in fo rm a tio n .
t ool a n d t h e pr oper Dia gn ost ic P r ocedu r es in for m a - Re fe r to th e a p p ro p ria te w irin g in fo rm a tio n .
t ion is r ecom m en ded.
WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, REFER TO ELECTRICAL, RESTRAINTS
DI AGN OSI S AN D T EST I N G BEFORE ATTEMPTING ANY STEERING WHEEL,
STEERING COLUMN, OR INSTRUMENT PANEL
AUDIO/VIDEO COMPONENT DIAGNOSIS OR SERVICE. FAILURE
An y d ia g n o s is o f th e Au d io s y s te m s h o u ld TO TAKE THE PROPER PRECAUTIONS COULD
be g in w ith th e u s e o f th e D RB III! d ia g n o s tic RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
to o l. F o r in fo rm a tio n o n th e u s e o f th e D RB AND POSSIBLE PERSONAL INJURY.
AU DI O SY ST EM DI AGN OSI S
CONDITION POSSIBLE CAUSE CORRECTION

NO AUDIO. 1. FUSE INOPERATIVE. 1. CHECK RADIO FUSES IN FUSE BLOCK MODULE.
REPLACE FUSES, IF REQUIRED.
2. RADIO CONNECTOR 2. CHECK FOR LOOSE OR CORRODED RADIO CONNECTOR.
DAMAGED. REPAIR, IF REQUIRED.
3. WIRING DAMAGED. 3. CHECK FOR BATTERY VOLTAGE AT RADIO CONNECTOR.
REPAIR WIRING, IF REQUIRED.
4. GROUND DAMAGED. 4. CHECK FOR CONTINUITY BETWEEN RADIO CHASSIS AND
A KNOWN GOOD GROUND. THERE SHOULD BE
CONTINUITY. REPAIR GROUND, IF REQUIRED.
5. RADIO 5. USING A SCAN TOOL, CHECK FOR TROUBLE CODES IN
INOPERATIVE. THE AUDIO SYSTEM.
6. SPEAKERS 6. REFER TO SPEAKER DIAGNOSIS.
INOPERATIVE
NO DISPLAY. 1. FUSE INOPERATIVE. 1. CHECK RADIO FUSES IN FUSE BLOCK MODULE.
REPLACE FUSES, IF REQUIRED.



NO MEMORY. 1. FUSE INOPERATIVE. 1. CHECK IGNITION-OFF DRAW FUSE. REPLACE FUSE, IF
REQUIRED.




POOR RADIO 1. ANTENNA OR CABLE 1. REFER TO ANTENNA DIAGNOSIS.
RECEPTION. DAMAGED.

4. POOR ANTENNA 4. CHECK ANTENNA CONNECTOR.
CONNECTION AT
RADIO OR IN LINE.
SOUND 1. DOOR TRIM PANEL 1. INSPECT DOOR TRIM PANEL AND CORRECT AS
DISTORTION LOOSE OR MISSING NECESSARY. REPLACE ANY MISSING FASTENERS.
(VIBRATION FASTENERS.
FROM SPEAKER
AREA, BUZZING
- HUMMING)
2. WATER SHIELD 2. INSPECT WATER SHIELD AND ADJUST AS REQUIRED.
LOOSE OR
MISALIGNED.
3. ITEMS PLACED IN 3. REMOVE ITEMS FROM DOOR TRIM PANEL. ENSURE THAT
DOOR TRIM PANEL VIBRATION IS NO LONGER PRESENT.
MAP POCKETS
VIBRATING OR
MOVING FROM SIDE
TO SIDE.
NO/POOR TAPE 1. TAPE DAMAGED. 1. INSERT KNOWN GOOD TAPE AND TEST OPERATION.
OPERATION.
2. FOREIGN OBJECTS 2. REMOVE FOREIGN OBJECTS AND TEST OPERATION.
BEHIND TAPE DOOR.
3. DIRTY CASSETTE 3. CLEAN HEAD WITH MOPAR CASSETTE HEAD CLEANER.

TAPE HEAD.
NO COMPACT 1. CD DAMAGED. 1. INSERT KNOWN GOOD CD AND TEST OPERATION.
DISC
OPERATION
2. FOREIGN MATERIAL 2. CLEAN CD AND TEST OPERATION.
ON CD.
3. CONDENSATION ON 3. ALLOW TEMPERATURE OF VEHICLE INTERIOR TO

CD OR OPTICS. STABILIZE AND TEST OPERATION.

HEADPHONES 1. WEAK BATTERIES IN 1. REPLACE BATTERIES.
WILL NOT HOLD THE HEADPHONES.
A CHANNEL OR
HAVE STATIC
2. CLOSENESS TO 2. MOVE TO AN AREA AWAY FROM THESE CONDITIONS.
RADIO TRANSMITTER
SUCH AS A RADIO
TOWER, AIRPORT
TRANSMITTER OR
SOME MOBILE
RADIOS.
REMOTE 1. WEAK BATTERIES IN 1. REPLACE BATTERIES.
CONTROL THE REMOTE
INOPERATIVE CONTROL.
2. OPERATION 2. MAKE SURE THAT REAR AUDIO IS IN A DIFFERENT MODE
CONSTRAINT OF THAN FRONT SPEAKERS. REMOTE CONTROL WILL NOT
SYSTEM WORK WHEN BOTH ARE IN THE SAME MODE.
V I DEO SY ST EM DI AGN OSI S

NO VIDEO (DVD PLAYER 1. FUSE INOPERATIVE. 1. CHECK FUSES. REPLACE FUSES IF
WILL NOT LOAD OR REQUIRED.
EJECT) 2. LOOSE OR DAMAGED DVD 2. CHECK FOR LOOSE OR CORRODED
PLAYER CONNECTOR DVD PLAYER CONNECTOR (16 PIN).
REPAIR OR REPLACE AS REQUIRED.
3. LOOSE OR DAMAGED 3. CHECK PIN 1 (B+) AND PIN 9
WIRING/DVD PLAYER (GROUND) OF THE 16 PIN CONNECTOR,
INOPERATIVE THEN CHECK PIN 1 (B+) AND PIN 7
(GROUND) OF THE 12 PIN CONNECTOR.
IF THE 16 PIN CONNECTOT DOES NOT
SHOW VOLTAGE, THE 12 PIN
CONNECTOR WILL NOT SHOW VOLTAGE
(THE 12 PIN IS FED FROM THE 16 PIN). IF
VOLTAGE IS OK ON THE 16 PIN, BUT NOT
PRESENT ON THE 12 PIN, UNPLUG THE
12 PIN HARNESS FROM THE PLAYER
AND CHECK THE CONNECTOR PINSON
THE BACK OF THE PLAYER. IF VOLTAGE
IS PRESENT ON THE 12 PIN
CONNECTOR, THE SCREEN OR THE 12
PIN HARNESS SHOULD BE REPLACED. IF
THERE IS STILL NO VOLTAGE ON THE 12
PIN CONNECTOR, THE DVD PLAYER
SHOULD BE REPLACED.
4. GROUND CONNECTION 4. CHECK FOR CONTINUITY BETWEEN
DAMAGED DVD PLAYER AND A KNOWN GOOD
GROUND. THERE SHOULD BE
CONTINUITY. REPAIR GROUND IF
REQUIRED.
5. DVD PLAYER DAMAGED 5. EXCHANGE OR REPLACE DVD PLAYER
IF REQUIRED.
6. DVD DAMAGED. 6. INSERT KNOWN GOOD DVD AND TEST
AVOID USING CD’S OR DVD’S OPERATION.
THAT HAVE ADHESIVE TYPE
LABELS, AS THEY MAY CAUSE
THE DISC TO BECOME
JAMMED.
NO DISPLAY. AUDIO 1. LOOSE OR DAMAGED 1. CHECK FOR LOOSE OR CORRODED
HEARD THROUGH CONNECTORS DVD PLAYER CONNECTOR (12 PIN).
SPEAKERS CHECK FOR LOOSE OR CORRODED
VIDEO SCREEN CONNECTOR. REPAIR IF
REQUIRED. CHECK FOR LOOSE OR
DAMAGED IN-LINE CONNECTOR.

2. WIRING DAMAGED 2. WITH HARNESS CONNECTED, CHECK
FOR VIDEO SIGNAL VOLTAGE AT DVD
PLAYER AND AT VIDEO SCREEN
HARNESS. PLACE KNOWN GOOD DVD
INTO DVD PLAYER. PLACE POSITIVE
LEAD OF VOLTMETER ON PIN 5 (VIDEO
SIGNAL) OF THE 12 PIN CONNECTOR.
PLACE NEGATIVE LEAD ON PIN 6 (VIDEO
GROUND). READINGS SHOULD BE
BETWEEN 0.1V TO 2V DC.
3. VIDEO SCREEN DAMAGED 3. EXCHANGE OR REPLACE VIDEO
SCREEN IF REQUIRED.
WHITE DISPLAY 1. LOW VOLTAGE 1. CHECK FOR BATTERY VOLTAGE
(9V-16V) AT DVD PLAYER 12 PIN
CONNECTOR (PIN 1-BATTERY, PIN
7-GROUND). DISPLAY WILL BE WHITE IF
VOLTAGE DROPS BELOW 6V.
2. VIDEO SCREEN DAMAGED 2. EXCHANGE OR REPLACE VIDEO

SCREEN IF REQUIRED.
DARK OR BRIGHT SPOTS 1. BRIGHTNESS SETTING 1. ADJUST BRIGHTNESS SETTING OF
ON SCREEN REQUIRES ADJUSTMENT. VIDEO SCREEN BY PRESSING BUTTONS
ON SIDE OF VIDEO SCREEN UNTIL
DESIRED LEVEL IS REACHED. START
WITH A BLACK SCREEN, THEN PRESS
BUTTON UP 16-20 TIMES. THERE ARE 64
TOTAL STEPS OF BRIGHTNESS.
BRIGHT OR DARK DISPLAY 1. VIDEO SCREEN DISPLAY 1. THE ACCEPTABLE LEVEL OF DOTS ON
PIXEL DEFECT. THE SCREEN IS (GREEN-1, RED-2) OR A
TOTAL
(GREEN+RED+BLUE+WHITE+BLACK) = 8.
REPLACE OR EXCHANGE VIDEO
SCREEN IF NECESSARY.
VIDEO SELECTIONS DO 1. ASPECT RATIO IS SET 1. USING MODE BUTTON, ADJUST UNTIL
NOT APPEAR FULL INCORRECTLY. VIDEO APPEARS CORRECTLY.
SCREEN WIDTH
2. SOME DVD’S ARE TWO 2. ENSURE THAT DVD IS INSERTED
SIDED. ONE SIDE IS WIDE CORRECTLY.
SCREEN FORMAT AND THE
OTHER IS FULL SCREEN OR
THERE MAY BE A WIDE
SCREEN OR STANDARD
SCREEN FORMAT ON THE
DISC.

BUTTONS ON VIDEO 1. VIDEO SCREEN DAMAGED. 1. PLACE KNOWN GOOD DVD INTO DVD
SCREEN INOPERATIVE PLAYER. ONCE IMAGE APPEARS ON
VIDEO SCREEN, PRESS TOP BUTTON ON
SIDE OF VIDEO SCREEN TO ADJUST
WIDTH OF DISPLAY. PRESS BOTTOM
BUTTONS TO ADJUST BRIGHTNESS.
ONCE DVD MENU APPEARS ON VIDEO
SCREEN, PRESS MIDDLE BUTTON ON
VIDEO SCREEN. HIGHLIGHTED
SELECTION WILL BEGIN TO PLAY. IF ANY
OF THE BUTTONS DO NOT FUNCTION,
REPLACE OR EXCHANGE VIDEO
SCREEN.
AM PLI FI ER INSTALLATION
(1) In st a ll br a cket t o a m plifier
REMOVAL (2) Con n ect t h e elect r ica l h a r n ess con n ect or s, a n d
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive posit ion a m plifier.
ca ble. (3) In st a ll a n d t igh t en m ou n t in g fa st en er s.
(2) Rem ove t h e r igh t qu a r t er t r im pa n el (Refer t o (4) In st a ll t h e t wo elect r ica l h a r n ess r et a in er s.
23 - BODY/INTE RIOR/QUARTE R TRIM PANE L - (5) In st a ll t h e r igh t r ea r spea ker.
RE MOVAL). (6) In st a ll r igh t qu a r t er t r im pa n el (Refer t o 23 -
(3) Rem ove t h e r igh t r ea r spea ker. BODY/INTE RIOR/QUARTE R TRIM PANE L -
(4) Discon n ect t h e t wo elect r ica l h a r n ess r et a in er s INSTALLATION).
n ea r t h e a m plifier. (7) Con n ect t h e ba t t er y n ega t ive ca ble.
(5) Rem ove t h e m ou n t in g fa st en er s (F ig. 1).
AN T EN N A BODY AN D CABLE
DESCRIPTION
Dom est ic veh icles u se a fixed-len gt h st a in less st eel
r od-t ype a n t en n a m a st , in st a lled a t t h e r igh t fr on t
fen der of t h e veh icle. Th e a n t en n a m a st is con n ect ed
t o t h e cen t er wir e of t h e coa xia l a n t en n a ca ble, a n d is
n ot gr ou n ded t o a n y pa r t of t h e veh icle.
OPERATION
To m in im ize st a t ic, t h e a n t en n a ba se m u st h a ve a
good gr ou n d. Th e coa xia l a n t en n a ca ble sh ield (t h e
ou t er wir e m esh of t h e ca ble) is gr ou n ded t o t h e
a n t en n a ba se a n d t h e r a dio ch a ssis.
Th e a n t en n a coa xia l ca ble h a s a n a ddit ion a l dis-
con n ect , loca t ed n ea r t h e r igh t en d of t h e in st r u m en t
Fig. 1 AMPLIFIER
pa n el. Th is a ddit ion a l discon n ect a llows t h e in st r u -
(6) Discon n ect t h e elect r ica l h a r n ess con n ect or s m en t pa n el a ssem bly t o be r em oved a n d in st a lled
a n d r em ove t h e a m plifier t h r ou gh t h e r igh t r ea r wit h ou t r em ovin g t h e r a dio.
spea ker open in g.
(7) Rem ove t h e br a cket fr om t h e a m plifier.
AN T EN N A BODY AN D CABLE (Cont inue d)
DI AGN OSI S AN D T EST I N G (2) Con n ect a n oh m m et er t est lea d t o t h e in side

cen t er of t h e a n t en n a ba se. Con n ect t h e ot h er t est
ANTENNA BODY AND CABLE lea d t o t h e cen t er pin of t h e a n t en n a coa xia l ca ble
con n ect or.
WARNING: ON VEHICLES EQUIPPED WITH AIR- (3) Con t in u it y sh ou ld exist (t h e oh m m et er sh ou ld
BAGS, REFER TO ELECTRICAL, RESTRAINTS on ly r egist er a fr a ct ion of a n oh m ). H igh or in fin it e
BEFORE ATTEMPTING ANY STEERING WHEEL, r esist a n ce in dica t es da m a ge t o t h e ba se a n d ca ble
STEERING COLUMN, OR INSTRUMENT PANEL a ssem bly. Repla ce t h e fa u lt y ba se a n d ca ble if
COMPONENT DIAGNOSIS OR SERVICE. FAILURE r equ ir ed.
TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT TEST 3
AND POSSIBLE PERSONAL INJURY. Test 3 ch ecks t h e con dit ion of t h e gr ou n d bet ween
t h e a n t en n a ba se a n d t h e veh icle body a s follows:
Th e oh m m et er t est lea d con n ect ion s for ea ch t est (1) Con n ect on e oh m m et er t est lea d t o t h e fen der
a r e sh own in (F ig. 2). on a n exposed m et a l a r ea . Con n ect t h e ot h er t est
lea d t o t h e ou t er cr im p on t h e a n t en n a coa xia l ca ble
con n ect or.
(2) Th e r esist a n ce sh ou ld be less t h a n (1) oh m .
(3) If t h e r esist a n ce is m or e t h a n (1) oh m , clea n
a n d/or t igh t en t h e a n t en n a ba se t o t h e fen der m ou n t -
in g h a r dwa r e.
REMOVAL
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
(2) Rem ove glove box fr om in st r u m en t pa n el,
(Refer t o 23 - BODY/INSTRUME NT PANE L/GLOVE
BOX - RE MOVAL).
(3) Discon n ect a n t en n a ca ble con n ect or fr om ext en -
sion ca ble (F ig. 3).
(4) Rem ove r igh t kick t r im pa n el.
(5) Disen ga ge r u bber gr om m et in su la t or fr om door
h in ge pilla r.
(6) P u ll a n t en n a ca ble t h r ou gh h in ge pilla r in t o
open in g bet ween door h in ges.
(7) H oist a n d su ppor t veh icle on sa fet y st a n ds.
Fig. 2 Antenna Test Points (8) Rem ove fr on t wh eel.
(9) Rem ove fr on t wh eelh ou se spla sh sh ield. (Refer
TEST 1 t o 23 - BODY/E XTE RIOR/LF WH E E LH OUSE
Test 1 det er m in es of t h e a n t en n a m a st is in su la t ed SP LASH SH IE LD - RE MOVAL).
fr om t h e ba se. P r oceed a s follows: (10) Rem ove a n t en n a m a st fr om a n t en n a ba se
(1) Un plu g t h e a n t en n a coa xia l ca ble fr om t h e (F ig. 4).
r a dio ch a ssis a n d isola t e. Rem ove t h e a n t en n a m a st . (11) Usin g ca p n u t t ool, r em ove ca p n u t h oldin g
(2) Con n ect a n oh m m et er t est lea d t o t h e in side a n t en n a ba se t o fr on t fen der (F ig. 5).
cen t er of t h e a n t en n a ba se. Con n ect t h e ot h er t est (12) Rem ove a n t en n a ba se fr om u n der fr on t
lea d t o a m et a llic por t ion on t h e ou t side of t h e fen der.
a n t en n a ba se. Ch eck for con t in u it y.
(3) Th er e sh ou ld be n o con t in u it y. If con t in u it y is INSTALLATION
fou n d, r epla ce t h e fa u lt y or da m a ged a n t en n a ba se (1) In st a ll a n t en n a ba se t o u n der side of fr on t
a n d ca ble a ssem bly. fen der.
(2) In st a ll ca p n u t h oldin g a n t en n a ba se t o fr on t
TEST 2 fen der.
Test 2 ch ecks t h e a n t en n a for a n open cir cu it a s (3) In st a ll a n t en n a m a st t o a n t en n a ba se En s u re
follows: th a t th e a n te n n a m a s t is fu lly s e a te d o n
(1) Un plu g t h e a n t en n a coa xia l ca ble con n ect or a n te n n a ba s e , a n d th a t th e re is n o g a p be tw e e n
fr om t h e r a dio ch a ssis. Rem ove t h e a n t en n a m a st . th e m a s t a n d ba s e ..
AN T EN N A BODY AN D CABLE (Cont inue d)
Fig. 3 Antenna Cable

1 - CAP NUT 5 - A-PILLAR
2 - ADAPTER 6 - RUBBER GROMMET
3 - FENDER 7 - ANTENNA CABLE AND BODY ASSEMBLY
4 - CABLE TO RADIO (EXTENSION CABLE) 8 - RUBBER GROMMET
Fig. 4 Antenna Mast

1 - ANTENNA MAST Fig. 5 Antenna Cap Nut
2 - ADAPTER 1 - CAP NUT
3 - CAP NUT 2 - ANTENNA ADAPTER
3 - TOOL
(4) In st a ll fr on t wh eelh ou se spla sh sh ield.
(5) In st a ll fr on t wh eel. (10) Con n ect a n t en n a ca ble con n ect or t o ext en sion
(6) Lower veh icle. ca ble.
(7) P u sh a n t en n a ca ble t h r ou gh open in g in h in ge (11) In st a ll glove box t o in st r u m en t pa n el.
pilla r. (12) Con n ect t h e ba t t er y n ega t ive ca ble.
(8) In ser t r u bber gr om m et in t o door h in ge pilla r.
(9) In st a ll kick pa n el.
AN T EN N A M ODU LE - EX PORT loca t ed on t h e r igh t r ea r qu a r t er gla ss. Th er e is a lso

a n elect r ica l con n ect or for ba t t er y volt a ge a n d a coa x
ca ble con n ect or.
DESCRIPTION
Th e a n t en n a m odu le is a n elect r om a gn et ic cir cu it
com pon en t design ed t o ca pt u r e a n d en h a n ce RF
OPERATION
Th e a n t en n a m odu le r eceives bot h AM a n d F M
(Ra dio F r equ en cy) sign a ls in bot h t h e AM a n d F M
r a dio sign a ls su pplied by t h e side win dow in t egr a l
br oa dca st ba n ds. Th e a n t en n a m odu le is m ou n t ed t o
r a dio a n t en n a syst em a n d select ively a m plifies t h em .
t h e r igh t r ea r r oof r a il u n der t h e h ea dlin er. Th e m od-
Th e a m plified sign a l is t h en sen t t h r ou gh t h e body
u le is gr ou n ded t h r ou gh t h e m ou n t in g br a cket a n d
len gt h coa x ca ble t o t h e r a dio in pu t .
fa st en er. Th e m odu le h a s a t wo wir e elect r ica l con -
n ect or t h a t con n ect s t o t h e in t egr a l r a dio a n t en n a ,
ANTENNA MODULE - EXPORT

NO AM RECEPTION, 1. Antenna module to antenna 1. Repair open, reconnect
WEAK FM RECEPTION connector open or disconnected. antenna module connector to
glass mounted antenna.
2. Coax open or disconnected. 2. Repair open, reconnect coax.
3. No battery power at antenna 3. Check fuse. if okay, repair
module. open in battery voltage circuit.
NO AM OR FM 1. Coax disconnected at radio. 1. Reconnect coax.
RECEPTION
2. Coax shorted to ground. 2. Repair or Replace coax
WEAK OR NO AM/FM 1. Antenna Module faulty. 1. Replace antenna module
RECEPTION
REMOVAL
ca ble.
(2) Lower h ea dlin er a s n ecessa r y t o a ccess
a n t en n a m odu le (F ig. 6).
(3) Discon n ect a n t en n a coa x ca ble lea d a n d elect r i-
ca l h a r n ess con n ect or fr om a n t en n a m odu le.
(4) Discon n ect t h e a n t en n a m odu le con n ect or fr om
t h e qu a r t er gla ss.
(5) Rem ove t h e m ou n t in g scr ew a n d t h e a n t en n a
m odu le.
INSTALLATION
(1) In st a ll t h e a n t en n a m odu le a n d t h e m ou n t in g
fa st en er.
(2) Con n ect t h e a n t en n a con n ect or t o t h e qu a r t er
gla ss. Fig. 6 ANTENNA MODULE
(3) Con n ect t h e a n t en n a lea d a n d elect r ica l con - 1 - ANTENNA MODULE
n ect or t o t h e a n t en n a m odu le. 2 - ANTENNA MODULE CONNECTOR
(4) Ra ise a n d in st a ll h ea dlin er.
(5) Con n ect t h e ba t t er y n ega t ive ca ble.
AN T EN N A - N AV I GAT I ON CD CH AN GER
RADI O
DESCRIPTION
REMOVAL Th e 6 Disc In -Da sh CD Ch a n ger (if equ ipped) is
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive loca t ed in t h e in st r u m en t pa n el below t h e r a dio. Th e
ca ble. r em ot e ch a n ger does n ot u se a ca r t r idge or m a ga zin e
(2) Rem ove t h e r a dio (Refer t o 8 - E LE CTRICAL/ for t h e CD’s. Up t o 6 CD’s ca n be dir ect ly loa ded in t o
AUDIO/RADIO - RE MOVAL). t h is u n it .
(3) Discon n ect a n t en n a fr om r a dio (F ig. 7). Rem ove
t a pe secu r in g a n t en n a t o a ir du ct , a n d r em ove OPERATION
a n t en n a (F ig. 8). Du e t o it s com pa ct design , t h e CD ch a n ger ca n
ca r r y ou t on ly on e oper a t ion a t a t im e. F or exa m ple,
you ca n n ot loa d a n ew disc wh ile pla yin g a n ot h er a t
t h e sa m e t im e. E a ch oper a t ion h a ppen s sequ en t ia lly.
Th e r a dio u n it pr ovides con t r ol over a ll fea t u r es of
t h e CD ch a n ger wit h t h e except ion of t h e CD loa d
a n d eject fu n ct ion s, wh ich a r e con t r olled by bu t t on s
loca t ed on t h e fr on t of t h e CD ch a n ger. All fea t u r es
you wou ld expect , su ch a s Disc Up/Down , Tr a ck
Up/Down , Ra n dom a n d Sca n a r e con t r olled by t h e
r a dio, wh ich a lso displa ys a ll r eleva n t CD ch a n ger
in for m a t ion on t h e r a dio displa y.
Th e CD ch a n ger con t a in s a E ject bu t t on , six disc
bu t t on s, a n in dica t or LE D for ea ch of t h e six disc
posit ion s a s well a s a n illu m in a t ed disc open in g. Th e
in dividu a l LE D in dica t es wh et h er a CD is cu r r en t ly
loa ded in t h a t pa r t icu la r ch a m ber of t h e CD ch a n ger.
P r essin g t h e in dividu a l bu t t on for a pa r t icu la r ch a m -
Fig. 7 NAVIGATION ANTENNA ber, t h en t h e E ject bu t t on will eject a disc cu r r en t ly
pr esen t in t h a t ch a m ber. If t h e ch a m ber is cu r r en t ly
em pt y, a ct u a t in g t h e in dividu a l bu t t on will posit ion
t h a t ch a m ber t o r eceive a n d loa d a n ew disc in t h a t
ch a m ber.
REMOVAL
ca ble.
(2) Rem ove scr ews h oldin g CD ch a n ger.
(3) Discon n ect t h e wir e con n ect or fr om t h e ba ck of
t h e CD ch a n ger.
(4) Rem ove t h e CD ch a n ger fr om t h e veh icle (F ig.
9).
INSTALLATION
(1) Recon n ect t h e wir e con n ect or t o t h e CD
Fig. 8 NAVIGATION ANTENNA MOUNTING ch a n ger.
(2) In ser t t h e CD ch a n ger in t o t h e in st r u m en t
INSTALLATION pa n el.
(1) Secu r e a n t en n a t o a ir du ct .
(2) Con n ect a n t en n a t o r a dio. NOTE: Use care when inserting CD changer so that
(3) In st a ll r a dio (Refer t o 8 - E LE CTRICAL/AU- cable is not pinched or trapped against instrument
DIO/RADIO - INSTALLATION). panel.
(4) Con n ect ba t t er y n ega t ive ca ble.
CD CH AN GER (Cont inue d)
(3) Discon n ect t h e wir e con n ect or fr om t h e ba ck of
t h e DVD pla yer.
(4) Rem ove t h e DVD pla yer fr om t h e veh icle.
INSTALLATION
(1) Con n ect t h e wir e h a r n ess con n ect or t o t h e DVD
pla yer.
(2) In ser t t h e DVD pla yer in t o t h e in st r u m en t
pa n el.
(3) In st a ll m ou n t in g scr ews.
I N ST RU M EN T PAN EL
AN T EN N A CABLE
Fig. 9 CD - CHANGER REMOVAL
1 - CD-CHANGER
2 - POWER OUTLET
(3) In st a ll scr ews h oldin g CD ch a n ger.
BEFORE ATTEMPTING ANY STEERING WHEEL,
(4) Recon n ect t h e ba t t er y n ega t ive ca ble.
COMPONENT DIAGNOSIS OR SERVICE. FAILURE
DV D PLAY ER TO TAKE THE PROPER PRECAUTIONS COULD
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
DESCRIPTION AND POSSIBLE PERSONAL INJURY.
Th e DVD pla yer (if equ ipped) is loca t ed in t h e (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
in st r u m en t pa n el below t h e r a dio. Th e DVD pla yer ca ble.
ca n h old on e DVD a t a t im e. Th r ee RCA ja cks on t h e (2) Rem ove glove box (Refer t o 23 - BODY/IN-
fr on t of t h e u n it a llow t h e u se of MP 3 pla yer s, video STRUME NT PANE L/GLOVE BOX - RE MOVAL).
ga m e syst em s or ca m cor der s. (3) Discon n ect ext en sion ca ble en d fr om a n t en n a
ca ble en d.
REMOVAL (4) Discon n ect ca ble h a n ger clip fr om H VAC u n it .
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive (5) Rem ove r a dio a s n ecessa r y t o ga in a ccess t o
ca ble. ext en sion ca ble (Refer t o 8 - E LE CTRICAL/AUDIO/
(2) Rem ove scr ews h oldin g DVD pla yer (F ig. 10). RADIO - RE MOVAL).
CAUTION: Pulling the antenna cable straight out of

the radio without pulling on the locking antenna
connector could damage the cable or radio.
(6) Discon n ect t h e a n t en n a ca ble by pu llin g t h e

lockin g a n t en n a con n ect or a wa y fr om t h e r a dio (F ig.
11).
(7) Rem ove ca ble fr om veh icle.
INSTALLATION
(1) In st a ll ext en sion ca ble t o veh icle.
(2) Con n ect ext en sion ca ble t o ba ck of r a dio.
(3) In st a ll r a dio (Refer t o 8 - E LE CTRICAL/AU-
DIO/RADIO - INSTALLATION).
(4) Con n ect ca ble h a n ger clip t o H VAC u n it .
Fig. 10 DVD PLAYER (5) Con n ect ext en sion ca ble en d t o a n t en n a ca ble
en d.
1 - DVD PLAYER
2 - POWER OUTLET
I N ST RU M EN T PAN EL AN T EN N A CABLE (Cont inue d)
OPERATION
Th e in t egr a l a n t en n a r eceives r a dio fr equ en cies
a n d sen ds t h em t o t h e a n t en n a m odu le for a m plifica -
t ion .

QUARTER GLASS INTEGRAL ANTENNA -
EXPORT
Th e a n t en n a gr id pa t t er n is divided in t o t wo sepa -
r a t e pa t t er n s. E a ch t er m in a l con n ect s t o a sepa r a t e
gr id pa t t er n , on e for AM a n d t h e ot h er for F M.
F or cir cu it descr ipt ion s a n d dia gr a m s, r efer t o t h e
a ppr opr ia t e wir in g in for m a t ion .
(1) Discon n ect t h e a n t en n a m odu le con n ect or fr om
Fig. 11 ANTENNA TO RADIO t h e a n t en n a t er m in a ls on t h e gla ss.
1 - RADIO (2) Usin g a n oh m m et er, pla ce a lea d on on e of t h e
2 - LOCKING ANTENNA CONNECTOR
3 - INSTRUMENT PANEL ANTENNA CABLE
t er m in a ls a n d ch eck ea ch en d of t h e gr id pa t t er n con -
n ect ed t o t h is t er m in a l for con t in u it y. If con t in u it y is
(6) In st a ll glove box (Refer t o 23 - BODY/INSTRU- n ot pr esen t , m ove on e lea d t h r ou gh t h e gr id in pr o-
ME NT PANE L/GLOVE BOX - INSTALLATION). gr ession st a r t in g a t t h e t er m in a l wit h t h e ot h er lea d
(7) Con n ect t h e ba t t er y n ega t ive ca ble. on t h e t er m in a l u n t il con t in u it y is lost . Repea t pr o-
cedu r e for t h e ot h er t er m in a l. A br ea k in t h e a n t en n a
gr id ca n be r epa ir ed u sin g a Mopa r Rea r Win dow
QU ART ER GLASS I N T EGRAL Defogger Repa ir Kit (P a r t Nu m ber 4267922) or
equ iva len t . (Refer t o 8 - E LE CTRICAL/H E ATE D
AN T EN N A - EX PORT GLASS/WINDSH IE LD GRID - STANDARD P ROCE -
DURE ).
DESCRIPTION
Th e qu a r t er gla ss in t egr a l a n t en n a elem en t is
bon ded t o t h e r igh t r ea r qu a r t er gla ss a n d is r epla ced RADI O
wit h t h e gla ss a ssem bly on ly (F ig. 12).
DESCRIPTION
Ava ila ble r a dio r eceiver s for t h is veh icle in clu de:
• AM/F M/ca sset t e/CD (RAZ or RBP sa les code)
• AM/F M/ca sset t e/CD wit h r ea r a u dio (RBU sa les
code)
• AM/F M/ca sset t e (RBB sa les code)
• AM/F M/6–disc CD r a dio (RBQ sa les code)
• AM/F M/CD/Na viga t ion (RB3 sa les code)
• AM/F M/CD wit h CD ch a n ger con t r ol (RBK sa les
code) expor t on ly
• AM/F M/ca sset t e/CD (RBY,RAD, or RBT sa les
code) expor t on ly
All r a dio r eceiver s ca n com m u n ica t e on t h e P r o-
gr a m m a ble Com m u n ica t ion s In t er fa ce (P CI) da t a bu s
n et wor k.
Fig. 12 QUARTER GLASS INTEGRAL ANTENNA

1 - REAR QUARTER GLASS
2 - ANTENNA
RADI O (Cont inue d)
OPERATION (2) Ch eck for ba t t er y volt a ge a t t h e fu se in t h e

Th e r a dio r eceiver oper a t es on ign it ion swit ch ed (IP M). If OK, go t o St ep 3. If n ot OK, r epa ir t h e open
ba t t er y cu r r en t t h a t is a va ila ble on ly wh en t h e ign i- cir cu it t o t h e ba t t er y a s r equ ir ed.
t ion swit ch is in t h e On or Accessor y/Accessor y Dela y (3) Tu r n t h e ign it ion swit ch t o t h e ON posit ion .
posit ion s. Th e elect r on ic digit a l clock fu n ct ion of t h e Ch eck for ba t t er y volt a ge a t t h e fu se in t h e ju n ct ion
r a dio oper a t es on fu sed ba t t er y cu r r en t su pplied block. If OK, go t o St ep 4. If n ot OK, r epa ir t h e open
t h r ou gh t h e IOD fu se, r ega r dless of t h e ign it ion cir cu it t o t h e ign it ion swit ch a s r equ ir ed.
swit ch posit ion . (4) Tu r n t h e ign it ion swit ch t o t h e OF F posit ion .
F or com plet e cir cu it dia gr a m s, r efer t o t h e a ppr o- Rem ove t h e r a dio, bu t do n ot u n plu g t h e wir e h a r-
pr ia t e wir in g in for m a t ion . n ess con n ect or s. Ch eck for con t in u it y bet ween t h e
r a dio ch a ssis a n d a good gr ou n d. Th er e sh ou ld be
con t in u it y. If OK, go t o St ep 5. If n ot OK, r epa ir t h e
DI AGN OSI S AN D T EST I N G open r a dio ch a ssis gr ou n d cir cu it a s r equ ir ed.
(5) Con n ect t h e ba t t er y n ega t ive ca ble. Tu r n t h e
RADIO ign it ion swit ch t o t h e ON posit ion . Ch eck for ba t t er y
volt a ge a t t h e fu sed ign it ion swit ch ou t pu t cir cu it
WARNING: ON VEHICLES EQUIPPED WITH AIR- ca vit y of t h e r a dio wir e h a r n ess con n ect or. If OK, go
BAGS, REFER TO ELECTRICAL, RESTRAINTS t o St ep 6. If n ot OK, r epa ir t h e open cir cu it a s
BEFORE ATTEMPTING ANY STEERING WHEEL, r equ ir ed.
STEERING COLUMN, OR INSTRUMENT PANEL (6) Tu r n t h e ign it ion swit ch t o t h e OF F posit ion .
COMPONENT DIAGNOSIS OR SERVICE. FAILURE Ch eck for ba t t er y volt a ge a t t h e fu sed B(+) cir cu it
TO TAKE THE PROPER PRECAUTIONS COULD ca vit y of t h e r a dio wir e h a r n ess con n ect or. If OK,
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT r epla ce t h e fa u lt y r a dio. If n ot OK, r epa ir t h e open
AND POSSIBLE PERSONAL INJURY. cir cu it t o t h e Ign it ion -Off Dr a w (IOD) fu se a s
r equ ir ed.
An y d ia g n o s is o f th e Au d io s y s te m s h o u ld
be g in w ith th e u s e o f th e D RB III! d ia g n o s tic REMOVAL
to o l. F o r in fo rm a tio n o n th e u s e o f th e D RB (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
III!, re fe r to th e a p p ro p ria te D ia g n o s tic S e rv ic e ca ble.
Ma n u a l. (2) Rem ove cu p h older.
Refer t o t h e a ppr opr ia t e wir in g in for m a t ion . (3) Rem ove t r im pa n el a bove cu ph older by pu llin g
If t h e veh icle is equ ipped wit h r em ot e r a dio st r a igh t ou t .
swit ch es loca t ed on t h e ba ck of t h e st eer in g wh eel (4) Rem ove cen t er in st r u m en t pa n el t r im pa n el.
spokes, a n d t h e pr oblem bein g dia gn osed is r ela t ed t o (5) Rem ove scr ews h oldin g r a dio t o in st r u m en t
on e of t h e sym pt om s list ed below, be cer t a in t o ch eck pa n el.
t h e r em ot e r a dio swit ch es a n d cir cu it s a s descr ibed (6) P u ll r a dio r ea r wa r d t o ga in a ccess t o t h e ba ck
in t h is gr ou p, pr ior t o a t t em pt in g r a dio dia gn osis or of r a dio (F ig. 13).
r epa ir.
• St a t ion s ch a n gin g wit h n o r em ot e r a dio swit ch
in pu t
• Ra dio m em or y pr eset s n ot wor kin g pr oper ly
• Volu m e ch a n ges wit h n o r em ot e r a dio swit ch
in pu t
• Rem ot e r a dio swit ch bu t t on s t a kin g on ot h er
fu n ct ion s
• CD pla yer skippin g t r a cks
• Rem ot e r a dio swit ch in oper a t ive.
CAUTION: The speaker output of the radio is a

“floating ground” system. Do not allow any speaker
lead to short to ground, as damage to the radio
may result.
(1) Ch eck t h e fu se(s) in t h e ju n ct ion block a n d t h e

In t egr a t ed P ower Modu le (IP M). If OK, go t o St ep 2. Fig. 13 RADIO
If n ot OK, r epa ir t h e sh or t ed cir cu it or com pon en t a s 1 - RADIO
r equ ir ed a n d r epla ce t h e fa u lt y fu se(s). 2 - CD-PLAYER
RADI O (Cont inue d)
CAUTION: Pulling the antenna cable straight out of Wh en t h e a u dio syst em con ver t s RF I or E MI t o a n
the radio without pulling on the locking antenna a u dible a cou st ic wa ve for m , it is r efer r ed t o a s r a dio
connector could damage the cable or radio. n oise. Th is u n desir a ble r a dio n oise is gen er a lly m a n -
ifest ed in t h e for m of “bu zzin g,” “h issin g,” “poppin g,”
(7) Discon n ect t h e a n t en n a ca ble by pu llin g t h e “clickin g,” “cr a cklin g,” a n d/or “wh ir r in g” sou n ds. In
lockin g a n t en n a con n ect or a wa y fr om t h e r a dio (F ig. m ost ca ses, RF I a n d E MI r a dio n oise ca n be su p-
14). pr essed u sin g a com bin a t ion of veh icle a n d com po-
n en t gr ou n din g, filt er in g a n d sh ieldin g t ech n iqu es.
Th is veh icle is equ ipped wit h fa ct or y-in st a lled r a dio
n oise su ppr ession devices t h a t wer e design ed t o m in -
im ize exposu r e t o t ypica l sou r ces of RF I a n d E MI;
t h er eby, m in im izin g r a dio n oise com pla in t s.
F a ct or y-in st a lled r a dio n oise su ppr ession is a ccom -
plish ed pr im a r ily t h r ou gh cir cu it r y or devices t h a t
a r e in t egr a l t o t h e fa ct or y-in st a lled r a dios, a u dio
power a m plifier s a n d ot h er on -boa r d elect r ica l com -
pon en t s su ch a s gen er a t or s, wiper m ot or s, blower
m ot or s, a n d fu el pu m ps t h a t h a ve been fou n d t o be
pot en t ia l sou r ces of RF I or E MI.
OPERATION
Th er e a r e t wo com m on st r a t egies t h a t ca n be u sed
t o su ppr ess Ra dio F r equ en cy In t er fer en ce (RF I) a n d
Fig. 14 ANTENNA TO RADIO E lect r oMa gn et ic In t er fer en ce (E MI) r a dio n oise. Th e
1 - RADIO fir st su ppr ession st r a t egy in volves pr even t in g t h e
2 - LOCKING ANTENNA CONNECTOR pr odu ct ion of RF I a n d E MI elect r om a gn et ic sign a ls
3 - INSTRUMENT PANEL ANTENNA CABLE a t t h eir sou r ces. Th e secon d su ppr ession st r a t egy
in volves pr even t in g t h e r ecept ion of RF I a n d E MI
(8) Discon n ect t h e wir e con n ect or s fr om t h e ba ck elect r om a gn et ic sign a ls by t h e a u dio syst em com po-
of t h e r a dio. n en t s.
Th e u se of br a ided gr ou n d st r a ps in key loca t ion s
INSTALLATION is pa r t of t h e RF I a n d E MI pr even t ion st r a t egy.
(1) Con n ect wir e h a r n ess t o ba ck of r a dio. Th ese gr ou n d st r a ps en su r e a dequ a t e gr ou n d pa t h s,
(2) Con n ect a n t en n a ca ble t o ba ck of r a dio. pa r t icu la r ly for h igh cu r r en t com pon en t s su ch a s
(3) P osit ion r a dio in t o in st r u m en t pa n el. m a n y of t h ose fou n d in t h e st a r t in g, ch a r gin g, ign i-
(4) In st a ll scr ews h oldin g r a dio t o in st r u m en t t ion , en gin e con t r ol a n d t r a n sm ission con t r ol sys-
pa n el. t em s. An in su fficien t gr ou n d pa t h for a n y of t h ese
(5) In st a ll cen t er in st r u m en t pa n el t r im . h igh cu r r en t com pon en t s m a y r esu lt in r a dio n oise
(6) In st a ll t r im pa n el a bove cu ph older. ca u sed by in du ced volt a ges cr ea t ed a s t h e h igh cu r-
(7) In st a ll cu ph older. r en t seeks a lt er n a t ive gr ou n d pa t h s t h r ou gh com po-
(8) Con n ect ba t t er y n ega t ive ca ble. n en t s or cir cu it s in t en ded for u se by, or in close
pr oxim it y t o t h e a u dio syst em com pon en t s or cir cu it s.
P r even t in g t h e r ecept ion of RF I a n d E MI is a ccom -
RADI O N OI SE SU PPRESSI ON plish ed by en su r in g t h a t t h e a u dio syst em com po-
COM PON EN T S n en t s a r e cor r ect ly in st a lled in t h e veh icle. Loose,
cor r oded or im pr oper ly solder ed wir e h a r n ess con n ec-
DESCRIPTION t ion s, im pr oper ly r ou t ed wir in g a n d in a dequ a t e a u dio
Ra dio n oise su ppr ession devices a r e fa ct or y-in - syst em com pon en t gr ou n din g ca n a ll con t r ibu t e t o
st a lled st a n da r d equ ipm en t on t h is veh icle. Ra dio t h e r ecept ion of RF I a n d E MI. A pr oper ly gr ou n ded
F r equ en cy In t er fer en ce (RF I) a n d E lect r oMa gn et ic a n t en n a body a n d r a dio ch a ssis, a s well a s a sh ielded
In t er fer en ce (E MI) ca n be pr odu ced by a n y on -boa r d a n t en n a coa xia l ca ble wit h clea n a n d t igh t con n ec-
or ext er n a l sou r ce of elect r om a gn et ic en er gy. Th ese t ion s will ea ch h elp r edu ce t h e pot en t ia l for r ecept ion
elect r om a gn et ic en er gy sou r ces ca n r a dia t e elect r o- of RF I a n d E MI.
m a gn et ic sign a ls t h r ou gh t h e a ir, or con du ct t h em
t h r ou gh t h e veh icle elect r ica l syst em .
REM OT E SWI T CH ES DI AGN OSI S AN D T EST I N G
DESCRIPTION REMOTE SWITCHES

AND POSSIBLE PERSONAL INJURY.
An y d ia g n o s is o f th e Au d io s y s te m s h o u ld
be g in w ith th e u s e o f th e D RB III! d ia g n o s tic
to o l. F o r in fo rm a tio n o n th e u s e o f th e D RB
III!, re fe r to th e a p p ro p ria te D ia g n o s tic S e rv ic e
Ma n u a l.
Refer t o t h e a ppr opr ia t e wir in g in for m a t ion .
Fig. 15 Remote Radio Switch Operational View ca ble.
1 - PRESET SEEK (2) Rem ove t h e r em ot e r a dio swit ch (es) fr om t h e
2 - SEEK UP st eer in g wh eel (F ig. 16). (Refer t o 8 - E LE CTRICAL/
3 - VOLUME UP AUDIO/RE MOTE SWITCH E S - RE MOVAL).
4 - MODE
5 - VOLUME DOWN
6 - SEEK DOWN
Two r ocker-t ype swit ch es (if equ ipped) a r e m ou n t ed

on t h e ba ck (in st r u m en t pa n el side) of t h e st eer in g
wh eel spokes (F ig. 15). Th e swit ch on t h e left spoke
is t h e seek swit ch a n d h a s seek u p, seek down , a n d
pr eset st a t ion a dva n ce fu n ct ion s. Th e swit ch on t h e
r igh t spoke is t h e volu m e con t r ol swit ch a n d h a s vol-
u m e u p, a n d volu m e down fu n ct ion s. Th e swit ch on
t h e r igh t spoke a lso in clu des a “m ode” con t r ol t h a t
a llows t h e dr iver t o sequ en t ia lly select AM r a dio, F M
r a dio, ca sset t e pla yer, CD pla yer or CD ch a n ger (if
equ ipped).
OPERATION
Th ese swit ch es a r e r esist or m u lt iplexed u n it s t h a t
a r e h a r d-wir ed t o t h e Body Con t r ol Modu le (BCM)
t h r ou gh t h e clockspr in g. Th e BCM sen ds t h e pr oper Fig. 16 REMOTE RADIO SWITCHES
m essa ges on t h e P r ogr a m m a ble Com m u n ica t ion s 1 - BLACK (LEFT) SWITCH
In t er fa ce (P CI) da t a bu s n et wor k t o t h e r a dio 2 - WHITE (RIGHT) SWITCH
r eceiver. F or dia gn osis of t h e BCM or t h e P CI da t a
(3) Use a n oh m m et er t o ch eck t h e swit ch r esis-
bu s, t h e u se of a DRB III! sca n t ool a n d t h e pr oper
t a n ce a s sh own in t h e Rem ot e Ra dio Swit ch Test
Dia gn ost ic P r ocedu r es m a n u a l a r e r ecom m en ded.
t a ble.
REM OT E SWI T CH ES (Cont inue d)
REM OT E RADI O SWI T CH T EST (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
Switch Switch Position Resistance (2) Rem ove t h e dr iver side a ir ba g (Refer t o 8 -
E LE CTRICAL/RE STRAINTS/DRIVE R AIRBAG -
Right RE MOVAL).
Volume Up 1.210 Kilohms
(White) (3) Rem ove t h e st eer in g wh eel (Refer t o 19 -
Right STE E RING/COLUMN/STE E RING WH E E L -
Volume Down 3.010 Kilohms
(White) RE MOVAL).
Right (4) Un plu g t h e wir e h a r n ess con n ect or fr om t h e
Mode Advance 0.0511 Kilohms r em ot e r a dio swit ch (es).
(White)
(5) Rem ove t h r ee scr ews secu r in g st eer in g wh eel
Left
Seek Up 0.261 Kilohms r ea r cover.
(Black)
(6) Rem ove t h e r em ot e r a dio swit ch fr om t h e st eer-
Left in g wh eel by depr essin g t a bs on ea ch side of ea ch
Seek Down 0.681 Kilohms
(Black) swit ch .
Left Pre-Set Station
0.162 Kilohms NOTE: The right remote radio switch back is white
(Black) Advance
in color. The left switch back is black in color. The
right/left remote radio switch orientation is with the
NOTE: The right remote radio switch back is white
steering wheel installed, and driver in drivers seat.
in color. The left switch back is black in color. The
right/left remote radio switch orientation is with the
steering wheel installed, and driver in drivers seat. INSTALLATION
(4) If t h e swit ch r esist a n ce ch ecks OK, go t o St ep WARNING: ON VEHICLES EQUIPPED WITH AIR-
5. If n ot OK, r epla ce t h e fa u lt y swit ch . BAGS, REFER TO ELECTRICAL, RESTRAINTS
(5) Ch eck for con t in u it y bet ween t h e gr ou n d cir- BEFORE ATTEMPTING ANY STEERING WHEEL,
cu it ca vit y of t h e swit ch wir e h a r n ess con n ect or a n d STEERING COLUMN, OR INSTRUMENT PANEL
a good gr ou n d. Th er e sh ou ld be con t in u it y. If OK, go COMPONENT DIAGNOSIS OR SERVICE. FAILURE
t o St ep 6. If n ot OK, r epa ir t h e open cir cu it a s TO TAKE THE PROPER PRECAUTIONS COULD
r equ ir ed. RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
(6) Un plu g t h e 24-wa y wh it e wir e h a r n ess con n ec- AND POSSIBLE PERSONAL INJURY.
t or fr om t h e Body Con t r ol Modu le (BCM). Ch eck for
con t in u it y bet ween t h e r a dio con t r ol cir cu it ca vit y of (1) In st a ll r em ot e r a dio swit ch t o t h e st eer in g
t h e r em ot e r a dio swit ch wir e h a r n ess con n ect or a n d a wh eel.
good gr ou n d. Th er e sh ou ld be n o con t in u it y. If OK, go (2) In st a ll t h r ee scr ews secu r in g st eer in g wh eel
t o St ep 7. If n ot OK, r epa ir t h e sh or t cir cu it a s r ea r cover.
r equ ir ed. (3) Con n ect t h e wir e h a r n ess t o t h e r em ot e r a dio
(7) Ch eck for con t in u it y bet ween t h e r a dio con t r ol swit ch .
cir cu it ca vit ies of t h e r em ot e r a dio swit ch wir e h a r- (4) In st a ll t h e st eer in g wh eel (Refer t o 19 -
n ess con n ect or a n d t h e BCM wir e h a r n ess con n ect or. STE E RING/COLUMN/STE E RING WH E E L -
Th er e sh ou ld be con t in u it y. If OK, r efer t o t h e pr oper INSTALLATION).
Dia gn ost ic P r ocedu r es m a n u a l t o t est t h e BCM a n d (5) In st a ll t h e dr iver side a ir ba g (Refer t o 8 -
t h e P CI da t a bu s. If n ot OK, r epa ir t h e open cir cu it E LE CTRICAL/RE STRAINTS/DRIVE R AIRBAG -
a s r equ ir ed. INSTALLATION).
REMOVAL
SPEAK ER (6) Discon n ect wir e h a r n ess con n ect or a t t h e in op-

er a t ive spea ker. Ch eck for con t in u it y bet ween t h e
spea ker feed (+) cir cu it ca vit ies of t h e r a dio r eceiver
DI AGN OSI S AN D T EST I N G wir e h a r n ess con n ect or or if equ ipped, t h e a m plifier
wir e h a r n ess con n ect or a n d t h e spea ker wir e h a r n ess
SPEAKER con n ect or. Repea t t h e ch eck bet ween t h e spea ker
r et u r n (-) cir cu it ca vit ies of t h e r a dio r eceiver wir e
WARNING: DISABLE THE AIRBAG SYSTEM h a r n ess con n ect or a n d t h e spea ker wir e h a r n ess con -
BEFORE ATTEMPTING ANY STEERING WHEEL, n ect or. In ea ch ca se, t h er e sh ou ld be con t in u it y. If
STEERING COLUMN, SEAT BELT TENSIONER, SIDE OK, r epla ce t h e fa u lt y spea ker. If n ot OK, r epa ir t h e
AIRBAG, OR INSTRUMENT PANEL COMPONENT open spea ker feed (+) a n d/or r et u r n (-) cir cu it s(s) a s
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO- r equ ir ed.
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS- REMOVAL
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS D-PILLAR SPEAKER
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
SYSTEM. FAILURE TO TAKE THE PROPER PRE- ca ble.
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- (2) Rem ove r ea r h ea der t r im (r igh t side spea ker ).
BAG DEPLOYMENT AND POSSIBLE PERSONAL (3) Rem ove ja ck cover (left side spea ker ).
INJURY. (4) Rem ove lift ga t e scu ff pla t e.
(5) Rem ove u pper sea t belt bolt . (Refer t o 8 -
An y d ia g n o s is o f th e Au d io s y s te m s h o u ld E LE CTRICAL/RE STRAINTS/SE AT BE LT OUT-
be g in w ith th e u s e o f th e D RB III! d ia g n o s tic BOARD F RONT - RE MOVAL).
to o l. F o r in fo rm a tio n o n th e u s e o f th e D RB (6) P a r t ia lly r em ove qu a r t er t r im pa n el t o a ccess
III!, re fe r to th e a p p ro p ria te D ia g n o s tic S e rv ic e t h e D-pilla r spea ker.
Ma n u a l. (7) Slide t h e spea ker fr om t h e r et a in er (F ig. 17).
(1) If a ll spea ker s a r e in oper a t ive, ch eck t h e r a dio
fu ses in t h e J u n ct ion Block (J B). If OK, go t o St ep 2.
If n ot OK, r epa ir t h e sh or t ed cir cu it or com pon en t a s
r equ ir ed a n d r epla ce t h e fa u lt y fu se.
(2) Ch eck t h e a m plifier fu se (if equ ipped) in t h e
ju n ct ion block. If OK, go t o St ep 3. If n ot OK, r epa ir
t h e sh or t ed cir cu it or com pon en t a s r equ ir ed a n d
r epla ce t h e fa u lt y fu se.
(3) Tu r n t h e ign it ion swit ch t o t h e ON posit ion .
Tu r n t h e r a dio r eceiver ON. Adju st t h e ba la n ce a n d
fa der con t r ol con t r ols t o ch eck t h e per for m a n ce of
ea ch in dividu a l spea ker. Not e t h e spea ker loca t ion s
t h a t a r e n ot per for m in g cor r ect ly. Go t o St ep 4.
(4) Tu r n t h e r a dio r eceiver OF F. Tu r n t h e ign it ion
OF F. Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble. If veh icle is n o t equ ipped wit h a a m plifier,
r em ove t h e r a dio r eceiver. If veh icle is equ ipped wit h
a n a m plifier. discon n ect wir e h a r n ess con n ect or a t
Fig. 17 D-PILLAR SPEAKER
ou t pu t side of a m plifier. Go t o St ep 4. 1 - SPEAKER
2 - RETAINER
(5) Ch eck bot h t h e spea ker feed (+) cir cu it a n d 3 - TRIM PANEL
r et u r n (-) cir cu it ca vit ies for t h e in oper a t ive spea ker
a t t h e r a dio r eceiver wir e h a r n ess con n ect or for con - (8) Discon n ect t h e wir e h a r n ess con n ect or fr om t h e
t in u it y t o gr ou n d. Th er e sh ou ld be n o con t in u it y. If spea ker.
OK, go t o St ep 5. If n ot OK, r epa ir t h e sh or t ed
spea ker feed (+) a n d/or r et u r n (-) cir cu it s(s) t o t h e
spea ker a s r equ ir ed.
SPEAK ER (Cont inue d)
FRONT DOOR SPEAKER
ca ble.
(2) Rem ove t h e fr on t door t r im pa n el. (Refer t o 23
- BODY/DOOR - F RONT/TRIM PANE L -
RE MOVAL).
(3) Rem ove t h e spea ker m ou n t in g scr ews (F ig. 18).
Fig. 19 INSTRUMENT PANEL SPEAKER

1 - SPEAKER
2 - WIRE HARNESS CONNECTOR
Fig. 18 DOOR SPEAKER

1 - SPEAKER
(4) Discon n ect wir e h a r n ess con n ect or a n d r em ove

spea ker fr om door.
INSTRUMENT PANEL SPEAKER

ca ble.
(2) Rem ove t h e A-pilla r t r im . (Refer t o 23 - BODY/
INTE RIOR/A-P ILLAR TRIM - RE MOVAL).
(3) Rem ove in st r u m en t pa n el t op pa d (Refer t o 23 -
Fig. 20 QUARTER PANEL SPEAKER
1 - SPEAKER
PANE L TOP PAD - RE MOVAL). 2 - TRIM PANEL
(4) Rem ove spea ker scr ews (F ig. 19).
INSTALLATION
spea ker.
D-PILLAR SPEAKER
QUARTER PANEL SPEAKER
(1) Con n ect t h e wir e h a r n ess con n ect or t o t h e
spea ker.
ca ble.
(2) Slide t h e spea ker in t o t h e r et a in er.
(2) Rem ove t h e qu a r t er t r im bolst er (Refer t o 23 -
(3) In st a ll qu a r t er pa n el t r im .
BODY/INTE RIOR/QUARTE R TRIM BOLSTE R -
(4) In st a ll u pper sea t belt bolt (r igh t side).
RE MOVAL).
(5) In st a ll lift ga t e scu ff pla t e.
(3) Rem ove spea ker r et a in in g scr ews (F ig. 20).
(6) In st a ll r ea r h ea der t r im (r igh t side).
(7) In st a ll ja ck cover (left side).
spea ker.
SPEAK ER (Cont inue d)
FRONT DOOR SPEAKER REMOVAL
(1) Con n ect t h e wir e h a r n ess con n ect or a n d in st a ll (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
spea ker t o door. ba t t er y ca ble.
(2) In st a ll t h e spea ker m ou n t in g scr ews. (2) Rem ove t h e len s bezel.
(3) In st a ll t h e fr on t door t r im pa n el (Refer t o 23 - (3) Rem ove t h e r ea r con sole scr ews (F ig. 21).
BODY/DOOR - F RONT/TRIM PANE L - INSTALLA-
TION).
INSTRUMENT PANEL SPEAKER

(1) Con n ect t h e wir e h a r n ess con n ect or a n d in st a ll
spea ker t o in st r u m en t pa n el.
(2) In st a ll t h e spea ker m ou n t in g scr ews.
(3) In st a ll in st r u m en t pa n el t op pa d (Refer t o 23 -
PANE L TOP PAD - INSTALLATION).
(4) In st a ll A-pilla r t r im (Refer t o 23 - BODY/INTE -
RIOR/A-P ILLAR TRIM - INSTALLATION).
QUARTER PANEL SPEAKER

(1) Con n ect t h e wir e h a r n ess con n ect or a n d in st a ll
Fig. 21 VIDEO SCREEN
spea ker t o t r im pa n el.
(2) In st a ll t h e spea ker m ou n t in g scr ews. (4) Rem ove t h e r ea r A/C t r im bezel.
(3) In st a ll qu a r t er t r im bolst er (Refer t o 23 - (5) Discon n ect A/C wir e h a r n ess con n ect or.
BODY/INTE RIOR/QUARTE R TRIM BOLSTE R - (6) Rem ove r em a in in g m ou n t in g scr ews.
INSTALLATION). (7) Discon n ect wir e h a r n ess con n ect or s.
INSTALLATION
(1) Con n ect wir e h a r n ess con n ect or s.
V I DEO SCREEN (2) In st a ll fr on t m ou n t in g scr ews.
(3) In st a ll t h e r ea r A/C t r im bezel.
DESCRIPTION (4) In st a ll t h e r ea r m ou n t in g scr ews.
Th e video scr een (if equ ipped) is m ou n t ed on t h e (5) In st a ll t h e len s bezel.
h ea dlin er beh in d t h e dr iver a n d fr on t pa ssen ger sea t . (6) Con n ect t h e ba t t er y n ega t ive ca ble.
P r essin g t h e r elea se bu t t on will a llow t h e scr een t o
be open ed.
OPERATION
Oper a t in g in st r u ct ion s for t h e fa ct or y in st a lled
video scr een ca n be fou n d in t h e own er ’s m a n u a l pr o-
vided wit h t h is veh icle.
RS CHIME/BUZZER 8B - 1
CHIME/BUZZER
page page
CHIME/BUZZER PARK ASSIST MODULE

DESCRIPTION . . . . . . . . . .............. ...1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . .4
OPERATION . . . . . . . . . . . .............. ...1 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
WARNING ............ .............. ...2 REMOVAL ........ . . . . . . . . . . . . . . . . . . . . .5
DIAGNOSIS AND TESTING - CHIME SYSTEM ..2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . .6
PARK ASSIST DISPLAY PARK ASSIST SENSOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . .3 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . .6
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
REMOVAL ............ . . . . . . . . . . . . . . . . .4 REMOVAL ........ . . . . . . . . . . . . . . . . . . . . .6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . .4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . .6
CH I M E/BU Z Z ER • P a rk As s is t Mo d u le - su pplies volt a ge t o t h e

object det ect ion sen sor s a n d pa r k a ssist displa y. It
t r igger s t h e sen sor s, a n a lyzes t h e ech o dela y t im es
DESCRIPTION
a n d ca lcu la t es obst a cle dist a n ces. It sen ds displa y
Th e ch im e/bu zzer syst em pr ovides t h e dr iver wit h
in for m a t ion t o t h e pa r k a ssist displa y, per for m s sys-
wa r n in g ch im es for :
t em dia gn ost ics, a n d com m u n ica t es via t h e P r ogr a m -
• Sea t Belt
m a ble Com m u n ica t ion In t er fa ce (P CI) da t e bu s
• E xt er ior La m ps ON
n et wor k.
• Key-In Ign it ion
• P a rk As s is t S e n s o rs - t h er e a r e fou r sen sor s
• E n gin e Tem per a t u r e Cr it ica l
loca t ed in t h e r ea r bu m per t h a t gen er a t e u lt r a son ic
• Tu r n Sign a ls ON
pu lses wh en t r igger ed by t h e pa r k a ssist m odu le. Th e
• Dom e La m p ON
sen sor s sign a l t h e pa r k a ssist m odu le wh en r eflect ed
• Low Oil P r essu r e
u lt r a son ic pu lses a r e r eceived.
• H igh Speed Wa r n in g
• P a rk As s is t D is p la y - t h er e a r e sixt een Ligh t
• Wa r n in g La m p An n ou n cem en t
E m it t in g Diode (LE D) in dica t or s wh ich pr ovide in di-
• Key-In Accessor y
ca t ion of r ela t ive dist a n ce t o obst a cles. Wh en t h e sys-
• Low/H igh Tir e P r essu r e
t em is en ga ged a n d n o obst a cles a r e det ect ed, t h e
• Ser vice Tir e P r essu r e Mon it or (TP M)
t wo ou t er m ost yellow LE D’s a r e lit a t r edu ced br igh t -
n ess t o sh ow t h e syst em is wor kin g. As t h e dist a n ce
HIGH SPEED WARNING - EXPORT
t o a det ect ed obst a cle decr ea ses, m or e yellow LE D’s
Th e ch im e will sou n d, a ct in g a s a wa r n in g t o t h e
t owa r ds t h e cen t er of t h e displa y illu m in a t e.
dr iver t h a t t h e veh icle speed h a s exceeded 120 ± 3
F or dia gn osis a n d t est in g of t h e pa r k a ssist sys-
Kp/h (75 ± 2 m ph ).
t em , u se a sca n t ool a n d t h e a ppr opr ia t e body dia g-
Refer t o t h e pr oper body dia gn ost ic in for m a t ion
n ost ic in for m a t ion .
dia gn osis a n d t est in g wit h a sca n t ool.
PARK ASSIST SYSTEM OPERATION

Refer t o t h e pr oper Body Dia gn ost ic P r ocedu r es
Th e P a r k Assist Syst em is a n elect r on ic pa r kin g
a id t h a t a ler t s t h e dr iver t o obst a cles wh ich a r e m a n u a l for com plet e ch im e/bu zzer oper a t ion a n d con -
dit ion s for oper a t ion .
loca t ed im m edia t ely beh in d t h e veh icle. Object s a r e
sen sed u sin g u lt r a son ic sou n d wa ves. Wh en a n object
is det ect ed, t h e syst em will give t h e dr iver visu a l a n d
HIGH SPEED WARNING - EXPORT
Wh en t h e veh icle speed sen sor sees 120 ± 3 Km /h
a u dible wa r n in gs. Th e syst em is cu st om er pr ogr a m -
(75 ± 2 m ph ), it sen ds a P CI da t a bu s m essa ge t o t h e
m a ble t h r ou gh t h e E lect r on ic Veh icle In for m a t ion
Body Con t r ol Modu le (BCM). Th e BCM t h en t u r n s on
Cen t er (E VIC) bu t will be en a bled fr om t h e fa ct or y
a s a defa u lt . t h e ch im e t o let t h e dr iver kn ow t h a t t h e veh icle h a s
r ea ch ed a speed gr ea t er t h a n 120 ± 3 Km /h (75 ± 2
Th e m a jor com pon en t s of t h e pa r k a ssist syst em
m ph ). Th is a u dible m essa ge will con t in u e u n t il t h e
a r e:
veh icle is slowed below t h e pr edet er m in ed speed.
8B - 2 CHIME/BUZZER RS
CH I M E/BU Z Z ER (Cont inue d)
PARK ASSIST SYSTEM WARNING
Th e P a r k Assist Syst em displa y a ct iva t es a n a u di- On v e h ic le s e qu ip p e d w ith a irba g s , d is a ble
ble t on e t h a t ch a n ges fr om in t er m it t en t t o con t in u - th e a irba g s y s te m be fo re a tte m p tin g a n y s te e r-
ou s a s t h e fin a l t wo Ligh t E m it t in g Diodes (LE D’s) in g w h e e l, s te e rin g c o lu m n , o r in s tru m e n t
a r e illu m in a t ed on on e side or bot h sides of t h e dis- p a n e l c o m p o n e n t d ia g n o s is o r s e rv ic e . D is c o n -
pla y. n e c t a n d is o la te th e ba tte ry n e g a tiv e (g ro u n d )
Th e syst em det ect ion len gt h fr om t h e r ea r of t h e c a ble , th e n w a it tw o m in u te s fo r th e a irba g s y s -
veh icle is 0.3 m et er s t o 1.5 m et er s. Th is a r ea ext en ds te m c a p a c ito r to d is c h a rg e be fo re p e rfo rm in g
a r ou n d t h e r ea r side of t h e veh icle. Th e syst em det ec- fu rth e r d ia g n o s is o r s e rv ic e . Th is is th e o n ly
t ion h eigh t fr om t h e gr ou n d is 0.2 m et er s t o a bou t s u re w a y to d is a ble th e a irba g s y s te m . F a ilu re
1.5 m et er s. Th e r a dio m u t es wh en t h e syst em a ct i- to ta k e th e p ro p e r p re c a u tio n s c o u ld re s u lt in
va t es it s a u dible t on e. a c c id e n ta l a irba g d e p lo y m e n t, p e rs o n a l in ju ry,
Wh en t h e dr iver select s Rever se t h e syst em sca n s o r d e a th .
for object s beh in d t h e veh icle u sin g fou r sen sor s
loca t ed in t h e r ea r bu m per. A wa r n in g displa y a bove DIAGNOSIS AND TESTING - CHIME SYSTEM
t h e r ea r win dow pr ovides bot h visible a n d a u dible Refer t o t h e pr oper Body Dia gn ost ic P r ocedu r es
wa r n in gs in dica t in g t h e r a n ge of t h e object . m a n u a l for com plet e Dia gn osis a n d Test in g of t h e
Th e syst em is a ct ive on ly wh en t h e t r a n sm ission Ch im e Syst em .
gea r select or is in r ever se for veh icle speeds less t h a n
16 Km /h (10 m ph ). If t h e veh icle’s P a r kin g/E m er- NO TONE WHEN IGNITION SWITCH IS TURNED ON
gen cy Br a ke is a pplied, t h e syst em is dea ct iva t ed. AND DRIVER’S SEAT BELT IS NOT BUCKLED.
Th e displa y con t a in s t wo set s of yellow a n d r ed (1) Usin g a DRB lll! sca n t ool, a ct u a t e ch im e
Ligh t E m it t in g Diode’s (LE D’s) t h a t t h e dr iver ca n (BCM a ct u a t es).
see a s t h ey look over t h eir sh ou lder wh ile ba ckin g (2) Usin g a volt m et er, ch eck for volt a ge:
u p. E a ch side of t h e veh icle h a s it s own wa r n in g (a ) BCM h a s t wo ba t t er y feeds a t pin 1 a n d pin
LE D’s. Th e syst em pr ovides a visu a l wa r n in g by illu - 5 of t h e 6–wa y con n ect or.
m in a t in g on e or m or e yellow LE D’s a s t h e veh icle (b) P in 5 of t h e (BX2) 32 wa y con n ect or of t h e
get s closer t o t h e object . As t h e veh icle con t in u es t o BCM for ign it ion feed.
a ppr oa ch t h e object , on e r ed LE D is illu m in a t ed a n d (c) Ch eck volt a ge (P X2) con n ect or, pin 34 for 12v.
t h e syst em em it s a ser ies of sh or t beeps. Th e t on e (d) If volt a ge OK, go t o st ep St ep 3
will r em a in con st a n t a n d bot h r ed LE D’s a r e illu m i- (e) If NO volt a ge r epa ir a s n ecessa r y. Refer t o
n a t ed on ce t h e veh icle is wit h in 12 in ch es (30.5 cm ) t h e a ppr opr ia t e wir in g in for m a t ion . Th e wir in g
of t h e object . in for m a t ion in clu des wir in g dia gr a m s, pr oper wir e
Th e syst em ca n be t u r n ed ON or OF F t h r ou gh t h e a n d con n ect or r epa ir pr ocedu r es, fu r t h er det a ils on
E lect r on ic Veh icle In for m a t ion Cen t er (E VIC) wh en wir e h a r n ess r ou t in g a n d r et en t ion , a s well a s pin -
t h e veh icle is in PARK. If t h e pa r k a ssist syst em is ou t a n d loca t ion views for t h e va r iou s wir e h a r n ess
t u r n ed OF F, a sin gle ch im e will sou n d a n d t h e E VIC con n ect or s, splices a n d gr ou n ds.
will displa y t h e followin g m essa ge “RE AR PARK (3) Ch eck dr iver s sea t belt bu ckle swit ch in pu t
ASSIST OF F ”, wh en t h e veh icle is in r ever se. (fr om Occu pa n t Rest r a in t Con t r oller (ORC) for a
• E n su r e t h a t t h e r ea r bu m per is fr ee of dir t a n d closed cir cu it wh en n ot bu ckled. If in pu t n ot seen ,
debr is t o keep t h e syst em oper a t in g pr oper ly. look for open in wir in g or swit ch . Th e swit ch is
• J a ckh a m m er s, la r ge t r u cks, a n d ot h er vibr a t ion s gr ou n ded wh en belt is n ot bu ckled.
cou ld a ffect t h e per for m a n ce of t h e syst em . (4) Ver ify P r ogr a m m a ble Com m u n ica t ion In t er fa ce
• E n su r e t h a t t h e pa r kin g br a ke is n ot a pplied. (P CI) da t a bu s com m u n ica t ion bet ween ORC a n d
If “Ser vice P a r k Assist Syst em ” a ppea r s in t h e BCM.
E VIC a ft er m a kin g su r e t h e r ea r bu m per is clea n ,
pr oceed t o dia gn ose t h e syst em u sin g a sca n t ool a n d
t h e a ppr opr ia t e dia gn ost ic in for m a t ion .
CH I M E/BU Z Z ER (Cont inue d)
NO FASTEN SEAT BELT LAMP WHEN IGNITION PARK ASSI ST DI SPLAY
SWITCH IS TURNED ON.
(1) Ch eck for bu r n ed ou t la m p. DESCRIPTION
(2) Usin g a volt m et er ch eck for volt a ge a t t h e clu s-
t er con n ect or :
(a ) P in 2 of t h e m ech a n ica l in st r u m en t clu st er
for ba t t er y feed.
(b) P in 11 of t h e m ech a n ica l in st r u m en t clu st er
for ign it ion volt a ge.
(3) Repa ir a s n ecessa r y.
FASTEN SEAT BELT LAMP OR TONE CONTINUES

FOR MORE THAN 10 SECONDS AFTER SEAT
BELTS ARE FASTENED AND DRIVER’S DOOR IS
CLOSED.
Refer t o t h e pr oper Body Dia gn ost ic P r ocedu r es
m a n u a l. Fig. 1 PARK ASSIST DISPLAY
Th e P a r k Assist Displa y is loca t ed in t h e r ea r of
NO TONE WHEN PARK OR HEADLAMPS ARE ON veh icle, over t h e r ea r win dow in t h e h ea dlin er (F ig.
AND DRIVER’S DOOR IS OPEN. 1). It is a m olded pla st ic u n it h ou sin g Ligh t E m it t in g
Ma ke su r e ign it ion is in lock posit ion wit h t h e key Diodes (LE D’s) a n d a ch im e m odu le. Loca t ed in t h e
r em oved. r ea r of t h e veh icle for ea sy visu a l r efer en ce wh en t h e
(1) Ch eck t h e BCM DTC’s a n d BCM sen sor s t o dr iver is ba ckin g u p.
ver ify t h e door is open . Repa ir a s n ecessa r y. Th e displa y is u sed t o a ler t t h e dr iver of a n y obst a -
(2) Act u a t e Ch im e (BCM a ct u a t es). cles det ect ed in t h e r ea r of t h e veh icle. Th e ch im e or
(3) In spect BCM con n ect or s a n d wir es for pr oper a u dible sign a l a lso com es fr om t h e displa y u n it .
con n ect ion .
(4) Mea su r e wit h a volt m et er t h e volt a ge (12v) on OPERATION
BCM con n ect or (P X2) pin 34 wit h h a r n ess con n ect ed. Wh en t h e ign it ion is pu t in t h e RUN posit ion , a ll
(5) Ch eck BCM sen sor s t o ver ify h ea dla m p swit ch t h e Ligh t E m it t in g Diodes (LE D’s) will illu m in a t e for
posit ion . a ppr oxim a t ely on e secon d. Th is will be in t er r u pt ed if
t h e syst em sen ses a n obst a cle.
Th e r ea dy st a t u s will be sen sed by t h e ou t er m ost
t wo yellow LE D’s bein g illu m in a t ed a t 50% in t en sit y.
As t h e obst a cle is sen sed, t h e yellow LE D’s will st a r t
illu m in a t in g in wa r d u n t il t h e object in a ppr oxim a t ely
on e foot a wa y a n d t h en t h e in n er r ed LE D will ligh t .
Th e displa y is sen sit ive t o wh ich side of t h e r ea r of
t h e veh icle t h a t t h e object is det ect ed. If on t h e left
r ea r, t h e left segm en t s will ligh t a n d t h e sa m e for t h e
r igh t side of t h e veh icle.
PARK ASSI ST DI SPLAY (Cont inue d)
CORRELAT I ON OF LED SEGM EN T S T O DI STAN CE
DISTANCE
DISPLAY LED LED COLOR AUDIBLE SIGNAL
REAR CORNERS REAR CENTER
1st LED 150 cm (4.9 ft.) Yellow None
2nd LED 120 cm (3.9 ft.) Yellow None
3rd LED 70 cm (2.2 ft.) Yellow None
4th LED 60 cm (1.9 ft.) 60 cm (1.9 ft.) Yellow None
30 cm (12 in.)
7th LED 30 cm (12 in.) 30 cm (12 in.) Red
Intermittant
20 cm (8 in.)
8th LED 15 cm (6 in.) 20 cm (8 in.) Red
Continuous
Th er e will be a n a u dible t on e wh en t h e object get s INSTALLATION

wit h in 30 cm (1 ft .) fr om t h e r ea r of t h e veh icle. (1) P osit ion t h e P a r k Assist Displa y in h ea dlin er
To dia gn ose a n d t est t h e P a r k Assist Syst em , u se a opein g a n d con n ect t h e displa y elect r ica l con n ect or
sca n t ool a n d t h e a ppr opr ia t e dia gn ost ic in for m a t ion . (F ig. 2).
(2) Ben d t h e r et a in in g t a bs down beh in d t h e h ea d-
REMOVAL lin er (F ig. 2).
(1) Open h ood. (3) Ra ise t h e h ea dlin er in t h e r ea r of t h e veh icle in
(2) Discon n ect a n d isola t e t h e ba t t er y n ega t ive t h e lift ga t e open in g (Refer t o 23 - BODY/INTE RIOR/
ca ble. H E ADLINE R - INSTALLATION).
(3) Open lift ga t e. (4) Close lift ga t e.
(4) Lower t h e h ea dlin er in t h e r ea r of t h e veh icle (5) Con n ect t h e ba t t er y n ega t ive ca ble.
in t h e lift ga t e open in g. F ollow t h e h ea dlin er r em ova l (6) Close h ood.
pr ocedu r e for t h e r ea r of t h e h ea dlin er (Refer t o 23 - (7) Ver ify veh icle a n d syst em oper a t ion .
BODY/INTE RIOR/H E ADLINE R - RE MOVAL).
(5) Ben d t h e r et a in in g t a bs u pwa r ds t o a llow t h e
pa r k a ssist displa y t o dr op ou t of t h e h ea dlin er open - PARK ASSI ST M ODU LE
in g (F ig. 2).
DESCRIPTION
Th e P a r k Assist Modu le is loca t ed on t h e left side
of t h e veh icle, beh in d t h e qu a r t er t r im pa n el, ju st
beh in d t h e C-pilla r (F ig. 3). It is h a s a m olded pla st ic
h ou sin g wh ich h ou sin g in t er n a l cir cu it r y a n d on e
elect r ica l con n ect or. Th er e a r e t wo m ou n t in g t a bs
t h a t a ffix t h e m odu le t o t h e left in n er qu a r t er t r im
pa n el wit h t wo scr ews.
Th e m odu le h a s a n u m ber of fu n ct ion s:
• Su pply volt a ge t o t h e sen sor s a n d displa y.
• Discon n ect ion of t h e displa y wit h bu s idle a n d
Fig. 2 PARK ASSIST DISPLAY - REMOVE/INSTALL
over volt a ge Vm a x.
1 - PARK ASSIST DISPLAY • Tr igger in g t h e sen sor s.
2 - DISPLAY RETAINING TABS
3 - HEADLINER • An a lyze ech o dela y t im es a n d ca lcu la t e obst a cle
4 - DISPLAY ELECTRICAL CONNECTOR dist a n ces.
• Bi-dir ect ion a l da t a com m u n ica t ion t o t h e displa y
(6) Discon n ect t h e displa y elect r ica l con n ect or (F ig. for dia gn osis.
2) a n d r em ove fr om veh icle.
PARK ASSI ST M ODU LE (Cont inue d)
Wh en t h e dr iver select s Rever se, t h e syst em sca n s
for object s beh in d t h e veh icle u sin g fou r sen sor s
loca t ed in t h e r ea r bu m per. Object s ca n be det ect ed
fr om u p t o 1.5 m et er s. A wa r n in g displa y a bove t h e
r ea r win dow pr ovides bot h visible a n d a u dible wa r n -
in gs in dica t in g t h e r a n ge of t h e object .
Th e syst em is a ct ive on ly wh en t h e veh icle is in
r ever se for veh icle speeds less t h a n 16 Km /h (10
m ph ). If t h e veh icles P a r kin g/E m er gen cy Br a ke is
a pplied, t h e syst em is dea ct iva t ed.
Th e displa y con t a in s t wo set s of yellow a n d r ed
Ligh t E m it t in g Diode’s (LE D’s) t h a t t h e dr iver ca n
see a s t h ey look over t h eir sh ou lder wh ile ba ckin g
u p. E a ch side of t h e veh icle h a s it s own wa r n in g
LE D’s. Th e syst em pr ovides a visu a l wa r n in g by illu -
m in a t in g on e or m or e yellow LE D’s a s t h e veh icle
Fig. 3 PARK ASSIST MODULE - LOCATION get s closer t o t h e object . As t h e veh icle con t in u es t o
1 - RETAINING SCREW J-CLIPS a ppr oa ch es t h e object , on e r ed LE D is illu m in a t ed
2 - LEFT QUARTER PANEL/C-PILLAR a n d t h e syst em em it s a ser ies of sh or t beeps. Th e
3 - MODULE RETAINING SCREWS t on e will r em a in con st a n t a n d bot h r ed LE D’s a r e
4 - PARK ASSIST MODULE
illu m in a t ed on ce t h e veh icle is wit h in 12 in ch es (30.5
• Syst em dia gn ost ics - dia gn osis a n d er r or h a n - cm ) of t h e object .
dlin g (sen sor s, displa y, m odu le). Th e syst em ca n be t u r n ed ON or OF F t h r ou gh t h e
• Da t a exch a n ge over t h e P r ogr a m m a ble Com m u - E lect r on ic Veh icle In for m a t ion Cen t er (E VIC) wh en
n ica t ion In t er fa ce (P CI) da t a bu s. t h e veh icle is in PARK. If t h e pa r k a ssist syst em is
t u r n ed OF F, a sin gle ch im e will sou n d a n d t h e E VIC
OPERATION will displa y t h e followin g m essa ge “RE AR PARK
Th e m odu le h a s a n u m ber of fu n ct ion s: ASSIST OF F ”, wh en t h e veh icle is in r ever se.
• Su pply volt a ge t o t h e sen sor s a n d displa y. • E n su r e t h a t t h e r ea r bu m per is fr ee of dir t a n d
• Discon n ect ion of t h e displa y wit h bu s idle a n d debr is t o keep t h e syst em oper a t in g pr oper ly.
over volt a ge Vm a x. • J a ckh a m m er s, la r ge t r u cks, a n d ot h er vibr a t ion s
• Tr igger in g t h e sen sor s. cou ld a ffect t h e per for m a n ce of t h e syst em .
• An a lyze ech o dela y t im es a n d ca lcu la t e obst a cle • E n su r e t h a t t h e pa r kin g br a ke is n ot a pplied.
dist a n ces. If “Ser vice P a r k Assist Syst em ” a ppea r s in t h e
• Bi-dir ect ion a l da t a com m u n ica t ion t o t h e displa y E VIC a ft er m a kin g su r e t h e r ea r bu m per is clea n ,
for dia gn osis. pr oceed t o dia gn ose t h e syst em u sin g a sca n t ool a n d
• Syst em dia gn ost ics - dia gn osis a n d er r or h a n - t h e a ppr opr ia t e dia gn ost ic in for m a t ion .
dlin g (sen sor s, displa y, m odu le). To dia gn ose t h e P a r k Assist Modu le, u se a sca n
• Da t a exch a n ge over t h e P r ogr a m m a ble Com m u - t ool a n d t h e a ppr opr ia t e body dia gn ost ic in for m a t ion .
n ica t ion In t er fa ce (P CI) da t a bu s.
Th e syst em det ect ion len gt h fr om t h e r ea r of t h e REMOVAL
veh icle is 0.3 m et er s t o 1.5 m et er s. Th is a r ea ext en ds (1) Open h ood.
a r ou n d t h e r ea r side of t h e veh icle. Th e syst em det ec- (2) Discon n ect a n d isola t e t h e ba t t er y n ega t ive ca ble.
t ion h eigh t fr om t h e gr ou n d is 0.2 m et er s t o a bou t (3) Rem ove t h e left qu a r t er t r im pa n el (Refer t o 23
1.5 m et er s. Th e r a dio m u t es wh en t h e syst em a ct i- - BODY/INTE RIOR/QUARTE R TRIM PANE L -
va t es it s a u dible t on e. RE MOVAL).
PARK ASSI ST M ODU LE (Cont inue d)
(4) Discon n ect t h e P a r k Assist Modu le elect r ica l
Fig. 5 PARK ASSIST SENSOR LOCATION

OPERATION
Th e P a r k Assist Sen sor s:
• Gen er a t e u lt r a son ic pu lses wh en t r igger ed by
t h e P a r k Assist Modu le.
• Recept ion /filt er in g of u lt r a son ic en er gy r eceived.
• Sign a llin g t h e m odu le of r eceived u lt r a son ic
pu lses t h a t m eet t h r esh old cr it er ia .
Th e sen sor s a r e su pplied power by t h e m odu le. Th e
sen sor su pply is en a bled wh en t h e sen sor fu n ct ion is
n ecessa r y.
Fig. 4 PARK ASSIST MODULE ELECTRICAL Th e sen sor s det ect ion len gt h fr om t h e r ea r of t h e
CONNECTOR veh icle is 0.3 m et er s t o 1.5 m et er s. Th is a r ea ext en ds
1 - MODULE ELECTRICAL CONNECTOR a r ou n d t h e r ea r side of t h e veh icle. Th e sen sor det ec-
2 - PARK ASSIST MODULE t ion h eigh t fr om t h e gr ou n d is 0.2 m et er s t o a bou t
1.5 m et er s.
(5) Rem ove t h e t wo a t t a ch in g scr ews a n d sepa r a t e
• E n su r e t h a t t h e r ea r bu m per (sen sor s) is fr ee of
t h e m odu le fr om veh icle (F ig. 3).
dir t a n d debr is t o keep t h e syst em oper a t in g pr op-
er ly.
INSTALLATION • J a ckh a m m er s, la r ge t r u cks, a n d ot h er vibr a t ion s
(1) P osit ion t h e P a r k Assist Modu le a n d in st a ll t h e cou ld a ffect t h e per for m a n ce of t h e syst em .
t wo a t t a ch in g scr ews (F ig. 3). Tor qu e scr ews t o 3.5 • E n su r e t h a t t h e pa r kin g br a ke is n ot a pplied.
N·m (30 in . lbs.). If “Ser vice P a r k Assist Syst em ” a ppea r s in t h e
(2) Con n ect t h e P a r k Assist Modu le elect r ica l con - E VIC a ft er m a kin g su r e t h e r ea r bu m per is clea n ,
n ect or (F ig. 4). pr oceed t o dia gn ose t h e syst em u sin g a sca n t ool a n d
(3) In st a ll t h e left qu a r t er t r im pa n el (Refer t o 23 - t h e a ppr opr ia t e dia gn ost ic in for m a t ion .
BODY/INTE RIOR/QUARTE R TRIM PANE L -
INSTALLATION).
REMOVAL
(1) Open h ood.
(5) Close h ood.
(6) Ver ify veh icle a n d syst em oper a t ion .
ca ble.
(3) Rem ove r ea r fa scia (Refer t o 13 - F RAME &
PARK ASSI ST SEN SOR BUMP E RS/BUMP E RS/RE AR FASCIA - RE MOVAL).
(4) Un sn a p P a r k Assist Sen sor fr om t h e r et a in in g
h ou sin g a n d r em ove fr om fa scia .
DESCRIPTION
Th e P a r k Assist Sen sor s a r e loca t ed in t h e r ea r
bu m per fa scia m ou n t ed equ a lly a pa r t (F ig. 5). Th e
INSTALLATION
(1) P osit ion t h e P a r k Assist Sen sor over t h e r et a in -
sen sor s gen er a t e u lt r a son ic pu lses wh en t r igger ed by
in g h ou sin g a n d fir m ly sn a p in t o h ou sin g in r ea r fa scia .
t h e pa r k a ssist m odu le wh en a n obst a cle is det ect ed.
(2) In st a ll t h e r ea r fa scia (Refer t o 13 - F RAME &
Th e sen sor s t h en sign a l t h e m odu le wh en r eflect ed
BUMP E RS/BUMP E RS/RE AR FASCIA - INSTALLA-
u lt r a son ic pu lses a r e r eceived.
TION).
Th e sen sor s det ect object s wit h a n u lt r a son ic pu lse
t h a t r eflect s off t h e object a n d t h en is sen t t o t h e
(4) Close h ood.
m odu le t o det er m in e t h e dist a n ce of t h e object .
RS ELECTRONIC CONTROL MODULES 8E - 1
ELECTRONIC CONTROL MODULES

page page
ELECTRONIC CONTROL MODULES OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

STANDARD PROCEDURE - PCM/SKIM DIAGNOSIS AND TESTING
PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . . 1 POWER LIFTGATE CONTROL MODULE . . . . 10
BODY CONTROL MODULE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 POWERTRAIN CONTROL MODULE
REMOVAL .............................4 DESCRIPTION
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 4 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 11
CONTROLLER ANTILOCK BRAKE OPERATION - SENSOR RETURN - PCM
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 4 INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 OPERATION - DATA BUS COMMUNICATION
REMOVAL .............................5 RECEIVE - PCM INPUT . . . . . . . . . . . . . . . . . 14
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6 OPERATION - IGNITION SENSE - PCM
DATA LINK CONNECTOR INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 6 OPERATION - PCM GROUND . . . . . . . . . . . . 14
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 OPERATION - 5 VOLT SUPPLY - PCM
FRONT CONTROL MODULE OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7 STANDARD PROCEDURE
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 STANDARD PROCEDURE - OBTAINING
DIAGNOSIS AND TESTING DIAGNOSTIC TROUBLE CODES . . . . . . . . . . 15
FRONT CONTROL MODULE . . . . . . . . . . . . . . 7 STANDARD PROCEDURE - PINION
REMOVAL .............................7 FACTOR SETTING . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 7 STANDARD PROCEDURE - QUICK LEARN
HEATED SEAT MODULE PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . 15
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8 REMOVAL
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 REMOVAL - SBEC CONTROLLER . . . . . . . . . 16
DIAGNOSIS AND TESTING REMOVAL - NGC CONTROLLER . . . . . . . . . . 16
HEATED SEAT MODULE . . . . . . . . . . . . . . . . . 9 INSTALLATION
REMOVAL .............................9 INSTALLATION - SBEC CONTROLLER . . . . . 17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 17
MEMORY SEAT/MIRROR MODULE SLIDING DOOR CONTROL MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 18
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING
MEMORY SEAT/MIRROR MODULE . . . . . . . . . 9 SLIDING DOOR CONTROL MODULE . . . . . . 18
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
POWER LIFTGATE CONTROL MODULE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10
ELECT RON I C CON T ROL the related component/circuit integrity for failures
not detected due to a double fault in the circuit.
M ODU LES Most PCM driver/control circuit failures are caused
by internal component failures (i.e. relay and sole-
STANDARD PROCEDURE - PCM/SKIM noids) and shorted circuits (i.e. pull-ups, drivers
PROGRAMMING and switched circuits). These failures are difficult to
detect when a double fault has occurred and only
NOTE: Before replacing the PCM for a failed driver, one DTC has set.
control circuit or ground circuit, be sure to check
8E - 2 ELECTRONIC CONTROL MODULES RS
ELECT RON I C CON T ROL M ODU LES (Cont inue d)
Wh en a P CM (SBE C) a n d t h e SKIM a r e r epla ced NOTE: Be sure to enter the correct country code. If
a t t h e sa m e t im e per for m t h e followin g st eps in the incorrect country code is programmed into
or der : SKIM, the SKIM must be replaced.
(1) P r ogr a m t h e n ew P CM (SBE C)
(2) P r ogr a m t h e n ew SKIM (6) Select YE S t o u pda t e VIN (t h e SKIM will lea r n
(3) Repla ce a ll ign it ion keys a n d pr ogr a m t h em t o t h e VIN fr om t h e P CM).
t h e n ew SKIM. (7) P r ess E NTE R t o t r a n sfer t h e secr et key (t h e
P CM will sen d t h e secr et key t o t h e SKIM).
PROGRAMMING THE PCM (SBEC) (8) P r ogr a m ign it ion keys t o SKIM.
Th e SKIS Secr et Key is a n ID code t h a t is u n iqu e
t o ea ch SKIM. Th is code is pr ogr a m m ed a n d st or ed NOTE: If the PCM and the SKIM are replaced at the
in t h e SKIM, P CM a n d t r a n spon der ch ip (ign it ion same time, all vehicle keys will need to be replaced
keys). Wh en r epla cin g t h e P CM it is n ecessa r y t o and programmed to the new SKIM.
pr ogr a m t h e secr et key in t o t h e n ew P CM u sin g t h e
DRB III. P er for m t h e followin g st eps t o pr ogr a m t h e
PROGRAMMING IGNITION KEYS TO THE SKIM
secr et key in t o t h e P CM.
(1) Tu r n t h e ign it ion swit ch on (t r a n sm ission in
pa r k/n eu t r a l).
(2) Use t h e DRB III a n d select TH E F T ALARM,
(2) Use t h e DRB III a n d select TH E F T ALARM,
SKIM t h en MISCE LLANE OUS.
(3) Select P ROGRAM IGNITION KE Y’S.
(3) Select P CM RE P LACE D (GAS E NGINE ).
(4) E n t er secu r ed a ccess m ode by en t er in g t h e
(4) E n t er secu r ed a ccess m ode by en t er in g t h e
veh icle fou r-digit P IN.
veh icle fou r-digit P IN.
(5) Select E NTE R t o u pda t e P CM VIN. NOTE: A maximum of eight keys can be learned to
each SKIM. Once a key is learned to a SKIM it (the
NOTE: If three attempts are made to enter secure
key) cannot be transferred to another vehicle.
access mode using an incorrect PIN, secured
access mode will be locked out for one hour. To If ign it ion key pr ogr a m m in g is u n su ccessfu l, t h e
exit this lockout mode, turn the ignition to the RUN DRB III will displa y on e of t h e followin g m essa ges:
position for one hour then enter the correct PIN. P r ogr a m m in g Not At t em pt ed - Th e DRB III
(Ensure all accessories are turned off. Also monitor a t t em pt s t o r ea d t h e pr ogr a m m ed key st a t u s a n d
the battery state and connect a battery charger if t h er e a r e n o keys pr ogr a m m ed in t o SKIM m em or y.
necessary). P r ogr a m m in g Key F a iled (P ossible Used Key F r om
Wr on g Veh icle) - SKIM is u n a ble t o pr ogr a m key du e
(6) P r ess E NTE R t o t r a n sfer t h e secr et key (t h e
t o on e of t h e followin g:
SKIM will sen d t h e secr et key t o t h e P CM).
• fa u lt y ign it ion key t r a n spon der
(7) P r ess P a ge Ba ck t o get t o t h e Select Syst em
• ign it ion key is pr ogr a m m ed t o a n ot h er veh icle.
m en u a n d select E NGINE , MISCE LLANE OUS, a n d
8 Keys Alr ea dy Lea r n ed, P r ogr a m m in g Not Don e -
SRI ME MORY CH E CK.
SKIM t r a n spon der ID m em or y is fu ll.
(8) Th e DRB III will a sk, Is odom et er r ea din g
(5) Obt a in ign it ion keys t o be pr ogr a m m ed fr om
bet ween XX a n d XX? Select t h e YE S or NO bu t t on on
cu st om er (8 keys m a xim u m ).
t h e DRB III. If NO is select ed, t h e DRB III will r ea d,
(6) Usin g t h e DRB III, er a se a ll ign it ion keys by
E n t er odom et er Rea din g<F r om I.P. odom et er >. E n t er
select in g MISCE LLANE OUS a n d E RASE ALL CUR-
t h e odom et er r ea din g fr om t h e In st r u m en t P a n el a n d
RE NT IGN. KE YS.
pr ess E NTE R.
(7) P r ogr a m a ll ign it ion keys.
Lea r n ed Key In Ign it ion - Ign it ion key t r a n spon der
PROGRAMMING THE SKIM
ID is cu r r en t ly pr ogr a m m ed in SKIM m em or y.
(2) Use t h e DRB III a n d select TH E F T ALARM, BODY CON T ROL M ODU LE
(3) Select P CM RE P LACE D (GAS E NGINE ).
DESCRIPTION
(4) P r ogr a m t h e veh icle fou r-digit P IN in t o SKIM.
Th e Body Con t r ol Modu le (BCM) is loca t ed in t h e
(5) Select COUNTRY CODE a n d en t er t h e cor r ect
pa ssen ger com pa r t m en t , a t t a ch ed t o t h e bu lkh ea d
cou n t r y.
u n der n ea t h t h e left side of t h e in st r u m en t pa n el.
BODY CON T ROL M ODU LE (Cont inue d)
Th e BCM u t ilizes in t egr a t ed cir cu it r y a n d in for m a - • Mem or y Sea t Modu le (MSM)
t ion ca r r ied on t h e P r ogr a m m a ble Com m u n ica t ion s • Sen t r y Key Im m obilizer Modu le (SKIM)
In t er fa ce (P CI) da t a bu s n et wor k a lon g wit h m a n y Th e BCM is oper a t ion a l wh en ba t t er y power is
h a r d wir ed in pu t s t o m on it or m a n y sen sor a n d su pplied t o t h e m odu le.
swit ch in pu t s t h r ou gh ou t t h e veh icle. In r espon se t o Th e BCM pr ovides t h e followin g fea t u r es:
t h ose in pu t s, t h e in t er n a l cir cu it r y a n d pr ogr a m m in g • P ower Door Locks
of t h e BCM a llow it t o con t r ol a n d in t egr a t e m a n y • Au t om a t ic Door Locks
elect r on ic fu n ct ion s a n d fea t u r es of t h e veh icle • Ba t t er y P r ot ect ion - Th e BCM will a u t om a t ica lly
t h r ou gh bot h h a r d wir ed ou t pu t s a n d t h e t r a n sm is- t u r n off a ll ext er ior la m ps a ft er 3 m in u t es, a n d a ll
sion of elect r on ic m essa ge ou t pu t s t o ot h er elect r on ic in t er ior la m ps a ft er 15 m in u t es a ft er t h e ign it ion is
m odu les in t h e veh icle over t h e P CI da t a bu s. t u r n ed off, if t h ey a r e n ot t u r n ed off by t h e dr iver.
• Ch im e Con t r ol
OPERATION • Com pa ss/Min i-Tr ip su ppor t .
Th e Body Con t r ol Modu le (BCM) su pplies veh icle • In t er ior Ligh t in g (Cou r t esy/Rea din g La m ps)
occu pa n t s wit h visu a l a n d a u dible in for m a t ion a n d • BCM Dia gn ost ic Repor t in g
con t r ols va r iou s veh icle fu n ct ion s. To pr ovide a n d • E lect r on ic Lift ga t e Relea se (wit h P ower Door
r eceive in for m a t ion , t h e BCM is in t er fa ced t o t h e Locks)
veh icle’s ser ia l bu s com m u n ica t ion s n et wor k, r efer r ed • E xt er ior Ligh t in g
t o a s t h e P r ogr a m m a ble Com m u n ica t ion s In t er fa ce • H ea dla m p Tim e Dela y (wit h /wit h ou t Au t om a t ic
(P CI) bu s. H ea dla m ps)
Th is n et wor k con sist s of t h e; • Illu m in a t ed E n t r y
• P ower t r a in Con t r ol Modu le (P CM) • F a de t o Off In t er ior La m ps - Th is fea t u r e dim s
• Tr a n sm ission Con t r ol Modu le (TCM) t h e in t er ior ligh t in g (cou r t esy la m ps) gr a du a lly if t h e
• Mech a n ica l In st r u m en t Clu st er (MIC) BCM does n ot r eceive a n y n ew in pu t s t h a t wou ld
• Occu pa n t Rest r a in t Con t r oller (ORC) ca u se t h e in t er ior la m ps t o r em a in on .
• Com pa ss/Min i-Tr ip Com pu t er (CMTC) • P u lse Widt h Modu la t ed In st r u m en t P a n el Dim -
• E lect r on ic Veh icle In for m a t ion Cen t er (E VIC) m in g
• Con t r oller An t ilock Br a ke (CAB) • Door Lock In h ibit - Th is fea t u r e disa bles t h e
• H VAC Con t r ol Modu le door lock fu n ct ion s if t h e key is in t h e ign it ion a n d
• Slidin g Door Con t r ol Modu les (dr iver a n d pa s- eit h er fr on t door is a ja r. P r essin g t h e Rem ot e Keyless
sen ger side door s) E n t r y (RKE ) lock/u n lock bu t t on u n der t h ese con di-
• P ower Lift ga t e Modu le (P LG) t ion s r esu lt in n or m a l lock/u n lock a ct iva t ion .
• Au dio syst em equ ipped wit h RAZ, RBU, RBK, Th e BCM h a s t h e a bilit y t o LE ARN a ddit ion a l fea -
a n d RBB r a dios. t u r es in t h e veh icle, pr ovided t h e a ppr opr ia t e swit ch
• Sen t r y Key Rem ot e E n t r y Modu le (SKRE E M). in pu t a n d P CI da t a bu s m essa ges a r e r eceived. Refer
• Side Im pa ct Air ba g Con t r ol Modu le (SIACM) t o t h e LE ARNE D F E ATURE S t a ble.
LEARN ED FEAT U RES
FEATURE LEARNING KEY

REAR WIPER CONTROL ON HVAC CONTROL ON PCI BUS MESSAGE RECEIVED FROM HVAC
INSTRUMENT PANEL CONTROL
AUTOMATIC HEADLAMPS PCI MESSAGE FROM OVERHEAD OR HEADLAMP
SWITCH POSITION (AUTO)
REMOTE KEYLESS ENTRY SKREEM MESSAGE RECEIVED FROM MODULE
FRONT FOG LAMPS HEADLAMP SWITCH POSITION (PARK W/FRONT
FOG LAMPS)
POWER SLIDING DOOR PCI IFR RECEIVED FROM MODULE
THE BCM HAS FOUR SWITCH INPUTS FOR THE POWER SLIDING DOOR FEATURE; LOCATED IN THE
OVERHEAD CONSOLE ARE THE LEFT AND RIGHT SIDE SLIDING DOOR SWITCHES TO ACTIVATE EITHER
OR BOTH SLIDING DOORS UNDER THE PROPER CONDITIONS. ALSO ARE B-PILLAR SWITCHES LOCATED
ON THE LEFT AND RIGHT B-PILLAR POSTS.
POWER LIFTGATE PCI IFR RECEIVED FROM MODULE
BODY CON T ROL M ODU LE (Cont inue d)
FEATURE LEARNING KEY

THE BCM HAS ONE LIFTGATE INPUT LOCATED IN THE OVERHEAD CONSOLE.
POWER LOCKOUT SWITCH INPUT
THE BCM HAS ONE LOCKOUT SWITCH INPUT THAT WHEN ENABLED WILL DISABLE THE B-PILLAR
SLIDING DOOR SWITCHES FROM ACTIVATING EITHER SLIDING DOOR WHEN DEPRESSED.
PCI AUDIO SYSTEM PCI MESSAGE RECEIVED FROM MODULE
REMOTE RADIO CONTROLS REMOTE RADIO SWITCHES PRESENT
VEHICLE THEFT SECURITY SKREEM MESSAGE RECEIVED, VALID KEY
RECEIVED, & DIAGNOSTIC PID RECEIVED.
MEMORY SEAT AND MIRRORS MEMORY SEAT SWITCH PRESENT AND OR PCI
MESSAGE RECEIVED FROM MEMORY MODULE
ABS W/TRACTION CONTROL PCI MESSAGE RECEIVED FROM CAB
SENTRY KEY IMMOBILIZER SYSTEM PCI MESSAGE RECEIVED FROM SKIM OR VTSS
PRESENT
ADJUSTABLE PEDAL MODULE PCI MESSAGE RECEIVED FROM ADJUSTABLE
PEDAL MODULE (APM)
Wh en r epla cin g a BCM t h er e a r e t h r ee m odu les (3) Rem ove t h e kn ee blocker a n d r ein for cem en t
a va ila ble: (Refer t o 23 - BODY/INSTRUME NT PANE L/KNE E
• Ba se BLOCKE R RE INF ORCE ME NT - RE MOVAL).
• Midlin e (4) Discon n ect t h e five wir e con n ect or s fr om t h e
• RG - E xpor t bot t om of t h e Body Con t r ol Modu le (BCM).
Th e Midlin e con t r oller is u sed on veh icles t h a t (5) Move bu lkh ea d wir in g a side.
h a ve P ower Door Locks. If a veh icle is equ ipped wit h (6) Rem ove t h e scr ews h oldin g t h e BCM t o t h e
t h e Veh icle Th eft Secu r it y Syst em , t h e Midlin e con - bu lkh ea d.
t r oller becom es a P r em iu m wh en t h e t h eft fea t u r e is (7) Rem ove t h e BCM fr om t h e m ou n t in g br a cket .
en a bled.
INSTALLATION
CAUTION: Do not swap Body Control Modules (1) In st a ll t h e BCM t o t h e m ou n t in g br a cket .
between vehicles or body controller’s off the shelf. (2) In st a ll t h e scr ews h oldin g t h e BCM t o t h e
bu lkh ea d.
Th e BCM h a s in t er n a l dia gn ost ic ca pa bilit y t h a t (3) Con n ect t h e five wir e con n ect or s t o t h e bot t om
a ssist s in dia gn osin g t h e syst em er r or. Wh en a n of t h e Body Con t r ol Modu le (BCM).
OP E N or a SH ORT cir cu it exist s, t h e dia gn ost ic t ool (4) In st a ll t h e kn ee blocker a n d r ein for cem en t
ca n be u sed t o r ea d t h e BCM fa u lt s. Th e fa u lt s a r e (Refer t o 23 - BODY/INSTRUME NT PANE L/KNE E
ver y descr ipt ive in iden t ifyin g t h e a ppr opr ia t e fea - BLOCKE R RE INF ORCE ME NT - INSTALLATION).
t u r e t h a t h a s fa u lt ed. (5) In st a ll t h e lower in st r u m en t pa n el silen cer.
Th e on ly t wo fa u lt s t h a t t h e BCM logs t h a t con - (6) Con n ect t h e ba t t er y n ega t ive ca ble.
clu de t h e r epla cem en t of a BCM a r e fa u lt s; (7) Ver ify pr oper oper a t ion of BCM a n d it s fu n c-
• # 01 - In t er n a l BCM fa ilu r e (r epla ce BCM) t ion s.
• # 1F - J 1850 In t er n a l H a r dwa r e F a ilu r e (r epla ce
BCM)
Ot h er wise t h e a ppr opr ia t e dia gn ost ic pr ocedu r es CON T ROLLER AN T I LOCK
for ea ch of t h e fea t u r es sh ou ld be t a ken wh en t h e BRAK E
BCM logs a fa u lt .
DESCRIPTION
REMOVAL Th e con t r oller a n t ilock br a ke (CAB) is a m icr opr o-
cessor-ba sed device wh ich m on it or s t h e a n t ilock
ca ble.
br a ke syst em (ABS) du r in g n or m a l br a kin g a n d con -
(2) Rem ove t h e lower in st r u m en t pa n el silen cer.
t r ols it wh en t h e veh icle is in a n ABS st op. Th e CAB
is m ou n t ed t o t h e H CU a s pa r t of t h e in t egr a t ed con -
t r ol u n it (ICU) (F ig. 1). Th e CAB u ses a 24-wa y elec-
CON T ROLLER AN T I LOCK BRAK E (Cont inue d)
t r ica l con n ect or on t h e veh icle wir in g h a r n ess. Th e Th e CAB con t in u ou sly m on it or s t h e speed of ea ch
power sou r ce for t h e CAB is t h r ou gh t h e ign it ion wh eel t h r ou gh t h e sign a ls gen er a t ed by t h e wh eel
swit ch in t h e RUN or ON posit ion . Th e CAB is on speed sen sor s t o det er m in e if a n y wh eel is begin n in g
t h e P CI bu s. t o lock. Wh en a wh eel lockin g t en den cy is det ect ed,
t h e CAB com m a n ds t h e CAB com m a n d coils t o a ct u -
a t e. Th e coils t h en open a n d close t h e va lves in t h e
H CU t h a t m odu la t e br a ke flu id pr essu r e in som e or
a ll of t h e h ydr a u lic cir cu it s. Th e CAB con t in u es t o
con t r ol pr essu r e in in dividu a l h ydr a u lic cir cu it s u n t il
a lockin g t en den cy is n o lon ger pr esen t .
Th e CAB con t a in s a self-dia gn ost ic pr ogr a m t h a t
m on it or s t h e a n t ilock br a ke syst em for syst em fa u lt s.
Wh en a fa u lt is det ect ed, t h e a m ber ABS wa r n in g
in dica t or la m p is t u r n ed on a n d t h e fa u lt dia gn ost ic
t r ou ble code (DTC) is t h en st or ed in a dia gn ost ic pr o-
gr a m m em or y. A la t ch ed fa u lt will disa ble cer t a in
syst em fu n ct ion a lit y for t h e cu r r en t ign it ion cycle. An
u n la t ch ed fa u lt will disa ble cer t a in syst em fu n ct ion -
a lit y u n t il t h e fa u lt con dit ion disa ppea r s. Th ese
DTC’s will r em a in in t h e CAB m em or y even a ft er t h e
Fig. 1 Integrated Control Unit (ICU) ign it ion h a s been t u r n ed off. Th e DTC’s ca n be r ea d
a n d clea r ed fr om t h e CAB m em or y by a t ech n icia n
1 - PUMP/MOTOR
2 - HCU u sin g t h e DRBIII! sca n t ool. If n ot clea r ed wit h a
3 - PUMP/MOTOR CONNECTOR DRBIII! sca n t ool, t h e fa u lt occu r r en ce a n d DTC will
4 - CAB be a u t om a t ica lly clea r ed fr om t h e CAB m em or y a ft er
t h e iden t ica l fa u lt h a s n ot been seen du r in g t h e n ext
OPERATION 3,500 m iles. Dr ive-off m a y be r equ ir ed for t h e a m ber
Th e pr im a r y fu n ct ion s of t h e con t r oller a n t ilock ABS wa r n in g in dica t or la m p t o go ou t on t h e n ext
br a ke (CAB) a r e t o: ign it ion cycle.
• Mon it or t h e a n t ilock br a ke syst em for pr oper
oper a t ion . CAB INPUTS
• Det ect wh eel lockin g or wh eel slippin g t en den - • Wh eel speed sen sor s (fou r )
cies by m on it or in g t h e speed of a ll fou r wh eels of t h e • Br a ke la m p swit ch
veh icle. • Ign it ion swit ch
• Con t r ol flu id m odu la t ion t o t h e wh eel br a kes • Syst em a n d pu m p volt a ge
wh ile t h e syst em is in a n ABS m ode. • Gr ou n d
• St or e dia gn ost ic in for m a t ion . • Tr a ct ion con t r ol swit ch (if equ ipped)
• P r ovide com m u n ica t ion t o t h e DRBIII! sca n t ool • Dia gn ost ic com m u n ica t ion (P CI)
wh ile in dia gn ost ic m ode.
• Illu m in a t e t h e a m ber ABS wa r n in g in dica t or CAB OUTPUTS
la m p. • Am ber ABS wa r n in g in dica t or la m p a ct u a t ion
• (Wit h t r a ct ion con t r ol on ly) Illu m in a t e t h e TRAC (via BUS)
ON la m p in t h e m essa ge cen t er on t h e in st r u m en t • Red BRAKE wa r n in g in dica t or la m p a ct u a t ion
pa n el wh en a t r a ct ion con t r ol even t occu r s. (via BUS)
• (wit h t r a ct ion con t r ol on ly) Illu m in a t e t h e TRAC • In st r u m en t clu st er (MIC) com m u n ica t ion (P CI)
OF F la m p wh en t h e a m ber ABS wa r n in g in dica t or • Tr a ct ion con t r ol la m ps (if equ ipped)
la m p illu m in a t es. • Dia gn ost ic com m u n ica t ion (P CI, via BUS)
Th e CAB con st a n t ly m on it or s t h e a n t ilock br a ke
syst em for pr oper oper a t ion . If t h e CAB det ect s a REMOVAL
fa u lt , it will t u r n on t h e a m ber ABS wa r n in g in dica - (1) Discon n ect t h e ba t t er y ca bles.
t or la m p a n d disa ble t h e a n t ilock br a kin g syst em . (2) Rem ove t h e ba t t er y (Refer t o 8 - E LE CTRI-
Th e n or m a l ba se br a kin g syst em will r em a in oper a - CAL/BATTE RY SYSTE M/BATTE RY - RE MOVAL).
t ion a l. (3) Discon n ect t h e va cu u m h ose con n ect or a t t h e
NOTE: If the vehicle is equipped with traction con- (4) Rem ove t h e scr ew secu r in g t h e coola n t filler
trol, the TRAC OFF lamp will illuminate anytime the n eck t o t h e ba t t er y t r a y.
amber ABS warning indicator lamp illuminates.
CON T ROLLER AN T I LOCK BRAK E (Cont inue d)
(5) Rem ove t h e ba t t er y t r a y (Refer t o 8 - E LE C- (2) In st a ll scr ews secu r in g t h e CAB t o t h e H CU
TRICAL/BATTE RY SYSTE M/TRAY - RE MOVAL). (F ig. 3) Tigh t en t h e m ou n t in g scr ews t o 2 N·m (17 in
(6) P u ll u p on t h e CAB con n ect or lock a n d discon - lbs).
n ect t h e 24–wa y elect r ica l con n ect or (F ig. 2). (3) Recon n ect t h e 24–wa y wir in g con n ect or a n d
t h e pu m p/m ot or wir in g con n ect or. (F ig. 2)
(4) In st a ll t h e ba t t er y t r a y (Refer t o 8 - E LE CTRI-
CAL/BATTE RY SYSTE M/TRAY - INSTALLATION).
(5) In st a ll t h e scr ew secu r in g t h e coola n t filler
n eck t o t h e ba t t er y t r a y.
(6) Recon n ect t h e va cu u m h ose t o t h e coola n t t a n k
bu ilt in t o t h e ba t t er y t r a y.
(7) In st a ll t h e ba t t er y (Refer t o 8 - E LE CTRICAL/
BATTE RY SYSTE M/BATTE RY - INSTALLATION).
(8) Recon n ect t h e ba t t er y ca bles.
(9) Con n ect a DRBIII! t o t h e veh icle. Ch eck a n d
clea r a n y fa u lt s, a n d in it ia lize t h e syst em .
DATA LI N K CON N ECT OR

DESCRIPTION
Th e da t a lin k con n ect or is loca t ed in side t h e veh i-
cle, below in st r u m en t pa n el n ext t o t h e cen t er col-
Fig. 2 CAB Connector Lock u m n (F ig. 4).
1 - CONNECTOR LOCK
2 - CAB
(7) Discon n ect t h e pu m p/m ot or con n ect or fr om t h e

CAB.
(8) Rem ove t h e scr ews secu r in g t h e CAB t o t h e
H CU (F ig. 3)
Fig. 4 DATA LINK CONNECTOR

OPERATION
Th e da t a lin k con n ect or (dia gn ost ic con n ect or )
lin ks t h e DRB sca n t ool wit h t h e P ower t r a in Con t r ol
Fig. 3 CAB Mounting Screws
Modu le (P CM). Refer t o On -Boa r d Dia gn ost ics in t h e
1 - HCU Gen er a l Dia gn osis sect ion of t h is gr ou p.
2 - MOUNTING SCREWS
3 - CAB
(9) P u ll CAB st r a igh t for wa r d off H CU.
INSTALLATION
(1) Slide t h e CAB on t o t h e H CU (F ig. 3).
FRON T CON T ROL M ODU LE • St op La m p Sen se

• Wa sh er F lu id Level
• Win dsh ield Wiper P a r k
DESCRIPTION
Th e F r on t Con t r ol Modu le (F CM) is a m icr o con -
t r oller ba sed m odu le loca t ed in t h e en gin e com pa r t - DI AGN OSI S AN D T EST I N G
m en t . Th e F CM m a t es t o t h e P ower Dist r ibu t ion
Cen t er (P DC) t o for m t h e In t egr a t ed P ower Modu le FRONT CONTROL MODULE
(IP M). Th e IP M con n ect s dir ect ly t o t h e ba t t er y a n d Th e F r on t Con t r ol Modu le (F CM) is a pr in t ed cir-
pr ovides t h e pr im a r y m ea n s of cir cu it pr ot ect ion a n d cu it boa r d ba sed m odu le wit h a on -boa r d m icr o-pr o-
power dist r ibu t ion for a ll veh icle elect r ica l syst em s. cessor. Th e F CM in t er fa ces wit h ot h er elect r on ic
Th e F CM con t r ols power t o som e of t h ese veh icle sys- m odu les in t h e veh icle via t h e P r ogr a m m a ble Com -
t em s elect r ica l a n d elect r om ech a n ica l loa ds ba sed on m u n ica t ion s In t er fa ce (P CI) da t a bu s. In or der t o
in pu t s r eceived fr om h a r d wir ed swit ch in pu t s a n d obt a in con clu sive t est in g t h e P CI da t a bu s a n d a ll of
da t a r eceived on t h e P r ogr a m m a ble Com m u n ica t ion s t h e elect r on ic m odu les t h a t pr ovide in pu t s t o, or
In t er fa ce (P CI) da t a bu s. r eceive ou t pu t s fr om t h e F CM m u st be ch ecked. All
F or in for m a t ion on t h e IP M, (Refer t o 8 - E LE C- P CI com m u n ica t ion fa u lt s m u st be r esolved pr ior t o
TRICAL/P OWE R DISTRIBUTION/INTE GRATE D fu r t h er dia gn osin g a n y fr on t con t r ol m odu le r ela t ed
P OWE R MODULE - DE SCRIP TION) issu es.
Th e F CM wa s design ed t o be dia gn osed wit h a n
OPERATION a ppr opr ia t e dia gn ost ic sca n t ool, su ch a s t h e DRB
As m essa ges a r e sen t over t h e P r ogr a m m a ble Com - III!. Th e m ost r elia ble, efficien t , a n d a ccu r a t e m ea n s
m u n ica t ion s In t er fa ce (P CI) da t a bu s, t h e F r on t Con - t o dia gn ose t h e fr on t con t r ol m odu le r equ ir es t h e u se
t r ol Modu le (F CM) r ea ds t h ese m essa ges a n d con t r ols of a DRB III! sca n t ool a n d t h e pr oper Body Dia g-
power t o som e of t h e veh icles elect r ica l syst em s by n ost ic P r ocedu r es m a n u a l.
com plet in g t h e cir cu it t o gr ou n d (low side dr iver ) or Befor e a n y t est in g of t h e F CM is a t t em pt ed, t h e
com plet in g t h e cir cu it t o 12 volt power (h igh side ba t t er y sh ou ld be fu lly ch a r ged a n d a ll wir e h a r n ess
dr iver ). a n d gr ou n d con n ect ion s in spect ed a r ou n d t h e a ffect ed
Th e followin g fu n ct ion s a r e c o n tro lle d by t h e a r ea s on t h e veh icle.
F r on t Con t r ol Modu le:
• Accessor y Rela y Act u a t ion REMOVAL
• Br a ke Tr a n sm ission Sh ift In t er lock F u n ct ion s (1) Discon n ect a n d isola t e t h e n ega t ive a n d posi-
(BTSI - ga s en gin e on ly) t ive ba t t er y ca bles fr om t h e ba t t er y.
• Diesel Ca bin H ea t er (Diesel E n gin e Veh icles) (2) Rem ove t h e ba t t er y (Refer t o 8 - E LE CTRI-
• E lect r on ic Ba ck Ligh t (E BL) Rea r Defogger CAL/BATTE RY SYSTE M/BATTE RY - RE MOVAL).
• F r on t a n d Rea r Blower Mot or Rela y Act u a t ion (3) Usin g a lon g fla t -bla ded scr ewdr iver, gen t ly
• F r on t F og La m p Rela y Act u a t ion t wist t h e In t egr a t ed P ower Modu le (IP M) r et a in in g
• Wa sh er Mot or (fr on t a n d r ea r ) clip ou t boa r d t o fr ee t h e IP M fr om it s m ou n t in g
• F r on t Win dsh ield Wiper “H I” & “LO” Rela y br a cket (F ig. 5). Rot a t e IP M u pwa r d t o a ccess t h e
Act u a t ion F r on t Con t r ol Modu le (F CM) r et a in in g scr ews.
• F r on t Win dsh ield Wiper “ON” Rela y Act u a t ion (4) Rem ove t h e fr on t con t r ol m odu le r et a in in g
• H ea dla m p P ower wit h Volt a ge Regu la t ion scr ews.
• H or n Rela y Act u a t ion (5) P u ll t h e F CM st r a igh t fr om t h e IP M a ssem bly
• H ea dla m p Wa sh er Rela y Act u a t ion (IF t o discon n ect t h e elect r ica l con n ect or (F ig. 6) a n d
E QUIP P E D - E XP ORT ONLY) r em ove t h e F CM fr om t h e veh icle.
• Na m e Br a n d Spea ker (NBS) Rela y Act u a t ion
• P a r k La m p Rela y Act u a t ion INSTALLATION
Th e followin g in pu t s a r e Re c e iv e d /Mo n ito re d by
t h e F r on t Con t r ol Modu le: NOTE: Front Control Module must be programmed
• Am bien t Tem per a t u r e Sen sin g to the correct radio EQ curve using the DRB III".
• Ba ck-Up swit ch This will ensure that the audio system is operating
• Br a ke F lu id Level correctly.
• B+ Con n ect ion Det ect ion
• E n gin e Cr a n k Sign a l (Diesel E n gin e Veh icles) (1) In st a ll t h e F r on t Con t r ol Modu le (F CM) in t h e
• H or n In pu t In t egr a t ed P ower Modu le (IP M) a ssem bly by pu sh in g
• Ign it ion Swit ch St a r t On ly t h e 49-wa y elect r ica l con n ect or st r a igh t in .
• Ign it ion Swit ch Ru n a n d St a r t On ly
FRON T CON T ROL M ODU LE (Cont inue d)
(6) Usin g t h e DRB III !, u n der “F RONT CON-
TROL MODULE ” t h en “MISC” pr ogr a m t h e E Q
cu r ve of t h e r a dio in t o t h e F r on t Con t r ol Modu le.
Refer t o t h e a ppr opr ia t e dia gn ost ic m a n u a l.
NOTE: If the vehicle is not equipped with Name

Brand Speakers (Infinity, etc.) or Headlamp Washers
the DRB III" must be used to Disable the appropri-
ate relays in the Integrated Power Module Assem-
bly.
H EAT ED SEAT M ODU LE

DESCRIPTION
Veh icles equ ipped wit h h ea t ed sea t s u t ilize t wo
h ea t ed sea t m odu les. Th e h ea t ed sea t m odu les a r e
loca t ed u n der t h e fr on t sea t s, wh er e t h ey a r e secu r ed
t o t h e sea t cu sh ion pa n s. E a ch h ea t ed sea t m odu le
h a s t h r ee con n ect or r ecept a cles t h a t a llow t h e m od-
Fig. 5 REMOVING INTEGRATED POWER MODULE u les t o be con n ect ed t o a ll of t h e r equ ir ed in pu t s a n d
ou t pu t s t h r ou gh t h e sea t wir e h a r n ess.
Th e h ea t ed sea t m odu les a r e a n elect r on ic m icr o-
pr ocessor con t r olled device design ed a n d pr ogr a m m ed
t o u se in pu t s fr om t h e ign it ion swit ch , h ea t ed sea t
swit ch a n d t h e h ea t ed sea t sen sor t o oper a t e a n d
con t r ol t h e h ea t ed sea t elem en t s in t h e fr on t sea t .
OPERATION
Th e h ea t ed sea t m odu le oper a t es on fu sed ba t t er y
cu r r en t r eceived fr om t h e In t egr a t ed P ower Modu le
(IP M). Th e m odu le is gr ou n ded a t a ll t im es t h r ou gh
t h e sea t wir e h a r n ess. In pu t s t o t h e m odu le in clu de a
r esist or m u lt iplexed h ea t ed sea t swit ch r equ est cir-
cu it for t h e h ea t ed sea t swit ch a n d t h e h ea t ed sea t
sen sor in pu t s fr om t h e sea t cu sh ion s of ea ch fr on t
sea t . In r espon se t o t h ose in pu t s t h e h ea t ed sea t
m odu le con t r ols ba t t er y cu r r en t feeds t o t h e h ea t ed
sea t elem en t s.
Wh en a h ea t ed sea t swit ch r equ est sign a l is
r eceived by t h e h ea t ed sea t m odu le a n d t h e en a ble
in pu t is h igh , t h e h ea t ed sea t m odu le en er gizes t h e
select ed h ea t ed sea t sen sor cir cu it a n d t h e sen sor
Fig. 6 FRONT CONTROL MODULE pr ovides t h e m odu le wit h a n in pu t in dica t in g t h e
1 - FRONT CONTROL MODULE
su r fa ce t em per a t u r e of t h e select ed sea t cu sh ion .
Th e Low h ea t set poin t is a ppr oxim a t ely 35° C (95°
(2) In st a ll t h e F CM r et a in in g scr ews. Tor qu e t h e F ), a n d t h e H igh h ea t set poin t is a ppr oxim a t ely 40°
scr ews t o 1 N·m (7 in . lbs). C (104° F ). If t h e sea t cu sh ion su r fa ce t em per a t u r e
(3) Rot a t e t h e IP M a ssem bly down wa r d t o secu r e in pu t is below t h e t em per a t u r e set poin t for t h e
in m ou n t in g br a cket . select ed t em per a t u r e set t in g, t h e h ea t ed sea t m odu le
(4) In st a ll t h e ba t t er y in t h e veh icle. Refer t o t h e en er gizes a n N-ch a n n el F ield E ffect Tr a n sist or
pr ocedu r e in Ba t t er y Syst em s. (N-F E T) wit h in t h e m odu le wh ich en er gizes t h e
(5) Con n ect t h e posit ive a n d n ega t ive ba t t er y h ea t ed sea t elem en t s in t h e select ed sea t cu sh ion a n d
ca bles. ba ck. Wh en t h e sen sor in pu t t o t h e m odu le in dica t es
t h e cor r ect t em per a t u r e set poin t h a s been a ch ieved,
t h e m odu le de-en er gizes t h e N-F E T wh ich de-en er-
H EAT ED SEAT M ODU LE (Cont inue d)
gizes t h e h ea t ed sea t elem en t s. Th e h ea t ed sea t m od- M EM ORY SEAT /M I RROR
u le will con t in u e t o cycle t h e N-F E T a s n eeded t o
m a in t a in t h e select ed t em per a t u r e set poin t . M ODU LE
DESCRIPTION
DI AGN OSI S AN D T EST I N G Veh icles equ ipped wit h t h e m em or y sea t /m ir r or
opt ion , u t ilize a m em or y m odu le loca t ed u n der t h e
HEATED SEAT MODULE dr iver s fr on t sea t . Th is m odu le is ba sica lly wir ed in -
If a h ea t ed sea t h ea t s bu t on e or bot h in dica t or lin e bet ween t h e power sea t swit ch a n d t h e power
la m ps on t h e h ea t ed sea t swit ch fa il t o oper a t e, t est sea t t r a ck/a dju st er m ot or s, or in -lin e bet ween t h e
t h e h ea t ed sea t swit ch . (Refer t o 8 - E LE CTRICAL/ power m ir r or swit ch a n d t h e power side view m ir-
H E ATE D SE ATS/DRIVE R H E ATE D SE AT SWITCH r or (s) m ot or (s). Th e Mem or y Sea t /Mir r or Modu le
- DIAGNOSIS AND TE STING). If t h e h ea t ed sea t (MSMM) con t a in s a cen t r a l pr ocessin g u n it t h a t com -
swit ch ch ecks OK, pr oceed a s follows. m u n ica t es wit h ot h er m odu les on t h e P r ogr a m m a ble
(1) Ch eck t h e h ea t ed sea t elem en t (Refer t o 8 - Com m u n ica t ion s In t er fa ce (P CI) da t a bu s n et wor k.
E LE CTRICAL/H E ATE D SE ATS/H E ATE D SE AT Th e MSMM r eceives h a r d wir ed in pu t s fr om t h e
E LE ME NT - DIAGNOSIS AND TE STING). dr iver power sea t swit ch a n d t h e pot en t iom et er s on
(2) Ch eck t h e h ea t ed sea t sen sor (Refer t o 8 - ea ch of t h e dr iver side power sea t t r a ck m ot or s, or
E LE CTRICAL/H E ATE D SE ATS/H E ATE D SE AT fr om t h e power m ir r or swit ch a n d t h e pot en t iom et er s
SE NSOR - DIAGNOSIS AND TE STING). on t h e side view m ir r or. Th e MSMM r eceives m es-
(3) Usin g a volt m et er, ba ck pr obe t h e a ppr opr ia t e sa ges over t h e P CI da t a bu s fr om t h e Body Con t r ol
h ea t ed sea t m odu le con n ect or, do n ot discon n ect . Modu le (BCM) (m em or y swit ch st a t u s), t h e P ower-
Ch eck for ba t t er y volt a ge a t t h e a ppr opr ia t e pin ca v- t r a in Con t r ol Modu le (P CM) (veh icle speed st a t u s).
it ies. If OK go t o St ep 4. If n ot OK, r epa ir t h e open Th e MSMM will pr even t t h e sea t m em or y r eca ll
or sh or t ed volt a ge su pply cir cu it a s r equ ir ed. fu n ct ion fr om bein g in it ia t ed if t h e dr iver side sea t
(4) Usin g a oh m m et er, ba ck pr obe t h e a ppr opr ia t e belt is bu ckled, if t h e t r a n sm ission gea r select or lever
h ea t ed sea t m odu le con n ect or, do n ot discon n ect . is n ot in t h e P a r k or Neu t r a l posit ion s, or if t h e veh i-
Ch eck for pr oper con t in u it y t o gr ou n d on t h e gr ou n d cle is m ovin g.
pin ca vit ies. Con t in u it y sh ou ld be pr esen t . If OK F or dia gn osis of t h e MSMM or t h e P CI da t a bu s, a
r epla ce t h e h ea t ed sea t m odu le. If Not OK, r epa ir t h e DRB III! sca n t ool a n d t h e pr oper Dia gn ost ic P r oce-
open or sh or t ed gr ou n d cir cu it a s r equ ir ed. du r es In for m a t ion a r e r ecom m en ded. Th e MSMM
ca n n ot be r epa ir ed a n d, if fa u lt y or da m a ged, it m u st
REMOVAL be r epla ced.
(1) Discon n ect a n d isola t e t h e n ega t ive ba t t er y
ca ble. OPERATION
(2) Rem ove t h e a ppr opr ia t e fr on t sea t fr om t h e Wh en m em or y syst em oper a t ion is r equ est ed
veh icle (Refer t o 23 - BODY/SE ATS/SE AT - (depr essin g of t h e m em or y swit ch ), a r esist or m u lt i-
RE MOVAL). plexed sign a l is sen t fr om t h e m em or y swit ch t o t h e
(3) Un sn a p t h e m odu le fr om t h e sea t cu sh ion pa n . Body Con t r ol Modu le (BCM). Th e BCM will t h en
(4) Discon n ect t h e m odu le wir e h a r n ess con n ec- sen d t h e a ppr opr ia t e sign a ls ou t t o t h e Mem or y Sea t /
t or s. Mir r or Modu le (MSMM), t h e MSMM t h en a pplies t h e
volt a ge su pply t o t h e power sea t t r a ck or side-view
INSTALLATION m ir r or if t h e pr oper r equ ir em en t s a r e m et . Th e veh i-
(1) Con n ect t h e m odu le wir e h a r n ess con n ect or s. cle speed m u st equ a l zer o a n d t h e t r a n sm ission m u st
(2) Sn a p t h e m odu le on t h e sea t cu sh ion pa n . be in pa r k or n eu t r a l in or der for t h e m em or y syst em
(3) In st a ll t h e a ppr opr ia t e fr on t sea t in t h e veh icle t o fu n ct ion .
(Refer t o 23 - BODY/SE ATS/SE AT - INSTALLA-
TION).
(4) Con n ect a n d isola t e t h e n ega t ive ba t t er y ca ble. DI AGN OSI S AN D T EST I N G
MEMORY SEAT/MIRROR MODULE
An y d ia g n o s is o f th e Me m o ry S e a t/Mirro r s y s -
te m s h o u ld be g in w ith th e u s e o f th e D RB III!
d ia g n o s tic to o l. F o r in fo rm a tio n o n th e u s e o f
th e D RB III!, re fe r to th e a p p ro p ria te D ia g n o s -
tic P ro c e d u re s in fo rm a tio n .
M EM ORY SEAT /M I RROR M ODU LE (Cont inue d)
In spect t h e r ela t ed wir in g h a r n ess con n ect or s for
br oken , ben t , pu sh ed ou t , or cor r oded t er m in a ls.
REMOVAL
ca ble.
(2) Rem ove t h e dr iver side fr on t bu cket sea t
r et a in in g n u t s fr om u n der t h e veh icle (Refer t o 23 -
BODY/SE ATS/SE AT - RE MOVAL).
(3) Lift t h e dr iver s sea t u p a n d ou t of t h e m ou n t -
in g h oles in t h e floor pa n a n d la y t h e sea t r ea r wa r d
t o a ccess t h e m odu le loca t ed u n der t h e sea t .
(4) Discon n ect t h e m em or y sea t /m ir r or m odu le
elect r ica l con n ect or s. Depr ess t h e r et a in in g t a b a n d
pu ll st r a igh t a pa r t .
(5) Rem ove t h e m odu le r et a in in g bolt s a n d r em ove
t h e m odu le fr om t h e br a cket .
INSTALLATION
(1) P osit ion a n d in st a ll t h e m odu le r et a in in g bolt s.
(2) Con n ect t h e m em or y sea t /m ir r or m odu le elec-
t r ica l con n ect or s. Fig. 7 POWER LIFTGATE CONTROL MODULE
(3) P osit ion t h e dr iver s sea t in t h e m ou n t in g h oles 1 - POWER LIFTGATE CONTROL MODULE
in t h e floor pa n . 2 - RETAINING SCREWS
3 - D-PILLAR
(4) In st a ll t h e dr iver side fr on t bu cket sea t r et a in - 4 - POWER LIFTGATE MOTOR
in g n u t s fr om u n der t h e veh icle (Refer t o 23 - BODY/ 5 - ELECTRICAL CONNECTORS
SE ATS/SE AT - INSTALLATION).
(5) Con n ect t h e ba t t er y n ega t ive ca ble. (Refer t o 8 - E LE CTRICAL/P OWE R DOORS - OP E R-
ATION) for m or e in for m a t ion .
POWER LI FT GAT E CON T ROL

M ODU LE
POWER LIFTGATE CONTROL MODULE
DESCRIPTION An y d ia g n o s is o f th e P o w e r Liftg a te s y s te m
Veh icles equ ipped wit h a power lift ga t e (P LG) u t i- s h o u ld be g in w ith th e u s e o f th e D RB III! d ia g -
lize a P LG con t r ol m odu le. Th is m odu le is loca t ed on n o s tic to o l. F o r in fo rm a tio n o n th e u s e o f th e
t h e veh icles left side D-pilla r ju st below t h e m ot or D RB III!, re fe r to th e a p p ro p ria te D ia g n o s tic
a ssem bly (F ig. 7) a n d con t a in s a m icr opr ocessor, P ro c e d u re s in fo rm a tio n .
wh ich is u sed t o com m u n ica t e t o t h e veh icles body In spect t h e r ela t ed wir in g h a r n ess con n ect or s for
con t r ol m odu le. Th e P LG con t r ol m odu le r eceives a n d br oken , ben t , pu sh ed ou t , or cor r oded t er m in a ls.
m on it or s logic in pu t s fr om a ll t h e P LG syst em Refer t o t h e a ppr opr ia t e wir in g in for m a t ion .
swit ch es except for t h e ou t side h a n dle swit ch . Th is
m odu le a lso con t a in s t h e soft wa r e t ech n ology t o REMOVAL
det ect lift ga t e obst r u ct ion s a n d st op a n d/or r ever se (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
t h e door a ccor din gly. ca ble.
(2) Rem ove t h e left D-pilla r t r im pa n el fr om t h e
OPERATION veh icle. (Refer t o 23 - BODY/INTE RIOR/LE F T
Th e power lift ga t e con t r ol m odu le con t a in s t h e D-P ILLAR TRIM PANE L - RE MOVAL)
elect r on ic cir cu it r y a n d soft wa r e u sed t o con t r ol t h e (3) Discon n ect t h e wir e h a r n ess con n ect ion s fr om
sequ en ce of even t s for t h e power lift ga t e syst em . Th is t h e power lift ga t e m ot or a ssem bly.
m odu le com m u n ica t es on t h e P r ogr a m m a ble Com m u - (4) Rem ove t h e scr ew h oldin g t h e power lift ga t e
n ica t ion s In t er fa ce (P CI) bu s cir cu it wit h t h e veh icles con t r ol m odu le t o t h e D-pilla r (F ig. 8).
Body Con t r ol Modu le (BCM) t o m on it or m a n y differ- (5) Rem ove t h e power lift ga t e con t r ol m odu le fr om
en t in pu t s a n d ou t pu t s su ch a s door lock st a t u s, t h e veh icle.
t r a n sm ission gea r select or posit ion a n d veh icle speed.
POWER LI FT GAT E CON T ROL M ODU LE (Cont inue d)
P CM r eceives in pu t sign a ls fr om va r iou s swit ch es
a n d sen sor s r efer r ed t o a s P ower t r a in Con t r ol Mod-
u le In pu t s. Ba sed on t h ese in pu t s, t h e P CM a dju st s
va r iou s en gin e a n d veh icle oper a t ion s t h r ou gh
devices r efer r ed t o a s P ower t r a in Con t r ol Modu le
Ou t pu t s.
Fig. 8 POWER LIFTGATE CONTROL MODULE

1 - POWER LIFTGATE CONTROL MODULE
2 - RETAINING SCREWS
3 - D-PILLAR
4 - POWER LIFTGATE MOTOR
5 - ELECTRICAL CONNECTORS
INSTALLATION Fig. 9 Powertrain Control Module (PCM)

(1) In st a ll t h e P ower Lift ga t e (P LG) con t r ol m od- 1 - Battery
u le on t h e D-pilla r a n d in st a ll r et a in in g scr ew. 2 - Power Distribution Center
(2) Con n ect t h e wir e h a r n ess con n ect ion s t o t h e 3 - Powertrain Control Module
P LG con t r ol m odu le. Be cer t a in t o slide con n ect or
locks t o t h e locked posit ion . NOTE: PCM Inputs:
(3) In st a ll t h e D-pilla r t r im pa n el on t h e veh icle.
• Air Con dit ion in g P r essu r e Tr a n sdu cer
(Refer t o 23 - BODY/INTE RIOR/LE F T D-P ILLAR
• Am bien t t em per a t u r e Sen sor
TRIM PANE L - INSTALLATION)
• ASD Rela y
• Ba t t er y Tem per a t u r e Sen sor (NGC)
(5) Usin g a n a ppr opr ia t e sca n t ool, ch eck a n d
• Ba t t er y Volt a ge
er a se a n y P LG con t r ol m odu le dia gn ost ic t r ou ble
• Br a ke Swit ch
codes.
• Ca m sh a ft P osit ion Sen sor
(6) Ver ify P LG syst em oper a t ion . Cycle t h e P LG
• Cr a n ksh a ft P osit ion Sen sor
t h r ou gh on e com plet e open a n d close cycle, t h is will
• Dist a n ce Sen sor (fr om t r a n sm ission con t r ol m od-
a llow t h e P LG con t r ol m odu le t o r elea r n it s cycle
u le)
wit h t h e n ew com pon en t s.
• E GR P osit ion F eedba ck
• E n gin e Coola n t Tem per a t u r e Sen sor
POWERT RAI N CON T ROL • H ea t ed Oxygen Sen sor s
• Ign it ion sen se
M ODU LE • In t a ke Air Tem per a t u r e Sen sor
• Kn ock Sen sor
• Lea k Det ect ion P u m p F eedba ck
DESCRI PT I ON • Ma n ifold Absolu t e P r essu r e (MAP ) Sen sor
• P a r k/Neu t r a l
DESCRIPTION • P CI Bu s
Th e P ower t r a in Con t r ol Modu le (P CM) is a digit a l • P ower St eer in g P r essu r e Swit ch
com pu t er con t a in in g a m icr opr ocessor (F ig. 9). Th e • P r opor t ion a l P u r ge Sen se
POWERT RAI N CON T ROL M ODU LE (Cont inue d)
• SCI Receive • E n gin e Coola n t Tem per a t u r e
• Speed Con t r ol • E n gin e Speed (cr a n ksh a ft posit ion sen sor )
• Th r ot t le P osit ion Sen sor • P a r k/Neu t r a l
• Tr a n sm ission Con t r ol Rela y (Swit ch ed B+) • Tr a n sa xle Gea r E n ga gem en t
• Tr a n sm ission P r essu r e Swit ch es • Th r ot t le P osit ion
• Tr a n sm ission Tem per a t u r e Sen sor • Veh icle Speed
• Tr a n sm ission In pu t Sh a ft Speed Sen sor Th e P CM a dju st s ign it ion t im in g ba sed on t h e fol-
• Tr a n sm ission Ou t pu t Sh a ft Speed Sen sor lowin g in pu t s.
• Tr a n sa xle Gea r E n ga gem en t • In t a ke Air Tem per a t u r e
• Veh icle Speed • E n gin e Coola n t Tem per a t u r e
• E n gin e Speed (cr a n ksh a ft posit ion sen sor )
NOTE: PCM Outputs: • Kn ock Sen sor
• Ma n ifold Absolu t e P r essu r e
• Air Con dit ion in g Clu t ch Rela y • P a r k/Neu t r a l
• Au t om a t ic Sh u t Down (ASD) a n d F u el P u m p • Tr a n sa xle Gea r E n ga gem en t
Rela ys • Th r ot t le P osit ion
• Da t a Lin k Con n ect or (P CI a n d SCI Tr a n sm it ) Th e a u t om a t ic sh u t down (ASD) a n d fu el pu m p
• Dou ble St a r t Over r ide r ela ys a r e m ou n t ed ext er n a lly, bu t t u r n ed on a n d off
• E GR Solen oid by t h e power t r a in con t r ol m odu le t h r ou gh t h e sa m e
• F u el In ject or s cir cu it .
• Gen er a t or F ield Th e ca m sh a ft a n d cr a n ksh a ft sign a ls a r e sen t t o
• H igh Speed F a n Rela y t h e power t r a in con t r ol m odu le. If t h e P CM does n ot
• Idle Air Con t r ol Mot or r eceive bot h sign a ls wit h in a ppr oxim a t ely on e secon d
• Ign it ion Coils of en gin e cr a n kin g, it dea ct iva t es t h e ASD a n d fu el
• Lea k Det ect ion P u m p pu m p r ela ys. Wh en t h ese r ela ys a r e dea ct iva t ed,
• Low Speed F a n Rela y power is sh u t off t o t h e fu el in ject or s, ign it ion coils,
• MTV Act u a t or fu el pu m p a n d t h e h ea t in g elem en t in ea ch oxygen
• P r opor t ion a l P u r ge Solen oid sen sor.
• SRV Va lve Th e P CM con t a in s a volt a ge con ver t er t h a t
• Speed Con t r ol Rela y ch a n ges ba t t er y volt a ge t o a r egu la t ed 8.0 volt s. Th e
• Speed Con t r ol Ven t Rela y 8.0 volt s power t h e ca m sh a ft posit ion sen sor, cr a n k-
• Speed Con t r ol Va cu u m Rela y sh a ft posit ion sen sor a n d veh icle speed sen sor. Th e
• 8 Volt Ou t pu t P CM a lso pr ovides a 5.0 volt s su pply for t h e en gin e
• 5 Volt Ou t pu t coola n t t em per a t u r e sen sor, in t a ke a ir t em per a t u r e
• Tor qu e Redu ct ion Requ est sen sor, m a n ifold a bsolu t e pr essu r e sen sor a n d t h r ot -
• Tr a n sm ission Con t r ol Rela y t le posit ion sen sor.
• Tr a n sm ission Solen oids Th e P CM en gin e con t r ol st r a t egy pr even t s r edu ced
• Veh icle Speed idle speeds u n t il a ft er t h e en gin e oper a t es for 320 km
Ba sed on in pu t s it r eceives, t h e power t r a in con t r ol (200 m iles). If t h e P CM is r epla ced a ft er 320 km (200
m odu le (P CM) a dju st s fu el in ject or pu lse widt h , idle m iles) of u sa ge, u pda t e t h e m ilea ge in n ew P CM. Use
speed, ign it ion t im in g, a n d ca n ist er pu r ge oper a t ion . t h e DRBIII! sca n t ool t o ch a n ge t h e m ilea ge in t h e
Th e P CM r egu la t es t h e coolin g fa n s, a ir con dit ion in g P CM. Refer t o t h e a ppr opr ia t e P ower t r a in Dia gn ost ic
a n d speed con t r ol syst em s. Th e P CM ch a n ges gen er- Ma n u a l a n d t h e DRBIII! sca n t ool.
a t or ch a r ge r a t e by a dju st in g t h e gen er a t or field.
Th e P CM a dju st s in ject or pu lse widt h (a ir-fu el TRANSMISSION CONTROL
r a t io) ba sed on t h e followin g in pu t s.
• Ba t t er y Volt a ge CLUTCH VOLUME INDEX (CVI)
• In t a ke Air Tem per a t u r e Sen sor An im por t a n t fu n ct ion of t h e P CM is t o m on it or
• E n gin e Coola n t Tem per a t u r e Clu t ch Volu m e In dex (CVI). CVIs r epr esen t t h e vol-
• E n gin e Speed (cr a n ksh a ft posit ion sen sor ) u m e of flu id n eeded t o com pr ess a clu t ch pa ck.
• E xh a u st Ga s Oxygen Con t en t (h ea t ed oxygen Th e P CM m on it or s gea r r a t io ch a n ges by m on it or-
sen sor s) in g t h e In pu t a n d Ou t pu t Speed Sen sor s. Th e In pu t ,
• Ma n ifold Absolu t e P r essu r e or Tu r bin e Speed Sen sor sen ds a n elect r ica l sign a l t o
• Th r ot t le P osit ion t h e P CM t h a t r epr esen t s in pu t sh a ft r pm . Th e Ou t -
Th e P CM a dju st s en gin e idle speed t h r ou gh t h e pu t Speed Sen sor pr ovides t h e P CM wit h ou t pu t
idle a ir con t r ol m ot or ba sed on t h e followin g in pu t s. sh a ft speed in for m a t ion .
• Br a ke Swit ch
By com pa r in g t h e t wo in pu t s, t h e P CM ca n det er-
m in e t r a n sa xle gea r r a t io. Th is is im por t a n t t o t h e
CVI ca lcu la t ion beca u se t h e P CM det er m in es CVIs
by m on it or in g h ow lon g it t a kes for a gea r ch a n ge t o
occu r (F ig. 10).
Gea r r a t ios ca n be det er m in ed by u sin g t h e DRB
Sca n Tool a n d r ea din g t h e In pu t /Ou t pu t Speed Sen -
sor va lu es in t h e “Mon it or s” displa y. Gea r r a t io ca n
be obt a in ed by dividin g t h e In pu t Speed Sen sor va lu e
by t h e Ou t pu t Speed Sen sor va lu e.
F or exa m ple, if t h e in pu t sh a ft is r ot a t in g a t 1000
r pm a n d t h e ou t pu t sh a ft is r ot a t in g a t 500 r pm ,
t h en t h e P CM ca n det er m in e t h a t t h e gea r r a t io is
2:1. In dir ect dr ive (3r d gea r ), t h e gea r r a t io ch a n ges
t o 1:1. Th e gea r r a t io ch a n ges a s clu t ch es a r e a pplied
a n d r elea sed. By m on it or in g t h e len gt h of t im e it
t a kes for t h e gea r r a t io t o ch a n ge followin g a sh ift
r equ est , t h e P CM ca n det er m in e t h e volu m e of flu id
u sed t o a pply or r elea se a fr ict ion elem en t .
Th e volu m e of t r a n sm ission flu id n eeded t o a pply Fig. 10 Example of CVI Calculation
t h e fr ict ion elem en t s a r e con t in u ou sly u pda t ed for 1 - OUTPUT SPEED SENSOR
a da pt ive con t r ols. As fr ict ion m a t er ia l wea r s, t h e vol- 2 - OUTPUT SHAFT
u m e of flu id n eed t o a pply t h e elem en t in cr ea ses. 3 - CLUTCH PACK
4 - SEPARATOR PLATE
Cer t a in m ech a n ica l pr oblem s wit h in t h e clu t ch 5 - FRICTION DISCS
a ssem blies (br oken r et u r n spr in gs, ou t of posit ion 6 - INPUT SHAFT
sn a p r in gs, excessive clu t ch pa ck clea r a n ce, im pr oper 7 - INPUT SPEED SENSOR
8 - PISTON AND SEAL
a ssem bly, et c.) ca n ca u se in a dequ a t e or ou t -of-r a n ge
clu t ch volu m es. Also, defect ive In pu t /Ou t pu t Speed
Sen sor s a n d wir in g ca n ca u se t h ese con dit ion s. Th e
followin g ch a r t iden t ifies t h e a ppr opr ia t e clu t ch vol-
u m es a n d wh en t h ey a r e m on it or ed/u pda t ed:
CLUTCH VOLUMES
When Updated Proper Clutch
Clutch
Shift Sequence Oil Temperature Throttle Angle Volume
2-1 or 3-1 coast
L/R > 70° < 5° 35 to 83
downshift
2/4 1-2 shift 20 to 77
5 - 54°
OD 2-3 shift > 110° 48 to 150
UD 4-3 or 4-2 shift > 5° 24 to 70
SHIFT SCHEDULES • E n gin e loa d

• F lu id t em per a t u r e
As m en t ion ed ea r lier, t h e P CM h a s pr ogr a m m in g
• Soft wa r e level
t h a t a llows it t o select a va r iet y of sh ift sch edu les.
As dr ivin g con dit ion s ch a n ge, t h e P CM a ppr opr i-
Sh ift sch edu le select ion is depen den t on t h e follow-
a t ely a dju st s t h e sh ift sch edu le. Refer t o t h e follow-
in g:
in g ch a r t t o det er m in e t h e a ppr opr ia t e oper a t ion
• Sh ift lever posit ion
expect ed, depen din g on dr ivin g con dit ion s.
• Th r ot t le posit ion
Schedule Condition Expected Operation

Extreme Cold Oil temperature at start-up below Park, Reverse, Neutral and 2nd
-16° F gear only (prevents shifting which
may fail a clutch with frequent
shifts)
Cold Oil temperature at start-up above – Delayed 2-3 upshift
-12° F and below 36° F (approximately 22-31 mph)
– Delayed 3-4 upshift (45-53 mph)
– Early 4-3 costdown shift
(approximately 30 mph)
– Early 3-2 coastdown shift
(approximately 17 mph)
– High speed 4-2, 3-2, 2-1 kickdown
shifts are prevented
– No EMCC
Warm Oil temperature at start-up above – Normal operation (upshift,
36° F and below 80 degree F kickdowns, and coastdowns)
– No EMCC
Hot Oil temperature at start-up above – Normal operation (upshift,
80° F kickdowns, and coastdowns)
– Full EMCC, no PEMCC except to
engage FEMCC (except at closed
throttle at speeds above 70-83 mph)
Overheat Oil temperature above 240° F or – Delayed 2-3 upshift (25-32 mph)
engine coolant temperature above – Delayed 3-4 upshift (41-48 mph)
244° F
– 3rd gear FEMCC from 30-48 mph
– 3rd gear PEMCC from 27-31 mph
Super Overheat Oil temperature above 260° F – All %Overheat% shift schedule
features apply
– 2nd gear PEMCC above 22 mph
– Above 22 mph the torque
converter will not unlock unless the
throttle is closed or if a wide open
throttle 2nd PEMCC to 1 kickdown
is made
OPERATION - SENSOR RETURN - PCM INPUT t ics is per for m ed via t h e veh icles J 1850 bu s for t h e
Th e sen sor r et u r n cir cu it pr ovides a low elect r ica l t r a n sm ission side of t h e P CM.
n oise gr ou n d r efer en ce for a ll of t h e syst em s sen sor s.
Th e sen sor r et u r n cir cu it con n ect s t o in t er n a l gr ou n d OPERATION - IGNITION SENSE - PCM INPUT
cir cu it s wit h in t h e P ower t r a in Con t r ol Modu le Th e ign it ion sen se in pu t in for m s t h e P ower t r a in
(P CM). Con t r ol Modu le (P CM) t h a t t h e ign it ion swit ch is in
t h e cr a n k or r u n posit ion .
OPERATION - DATA BUS COMMUNICATION
RECEIVE - PCM INPUT OPERATION - PCM GROUND
Gr ou n d is pr ovided t h r ou gh m u lt iple pin s of t h e
Th e P CM u ses t h e SCI com m u n ica t ion bu s t o pr e-
for m en gin e dia gn ost ics a n d fla sh oper a t ion s. Th e P CM con n ect or. Depen din g on t h e veh icle t h er e m a y
be a s m a n y a s t wo differ en t gr ou n d pin s. Th er e a r e
t r a n sm ission side of t h e P CM u ses t h e SCI com m u -
power gr ou n ds a n d sen sor gr ou n ds.
n ica t ion bu s t o fla sh n ew soft wa r e. H owever, dia gn os-
Th e power gr ou n ds a r e u sed t o con t r ol t h e gr ou n d STANDARD PROCEDURE - PINION FACTOR
side r ela ys, solen oids, ign it ion coil or in ject or s. Th e
SETTING
sign a l gr ou n d is u sed for a n y in pu t t h a t u ses sen sor
r et u r n for gr ou n d, a n d t h e gr ou n d side of a n y in t er- NOTE: This procedure must be performed if the
n a l pr ocessin g com pon en t . PCM has been replaced with a NEW or replacement
Th e P CM ca se is sh ielded t o pr even t RF I a n d E MI. unit. Failure to perform this procedure will result in
Th e P CM ca se is gr ou n ded a n d m u st be fir m ly an inoperative or improperly calibrated speedome-
a t t a ch ed t o a good, clea n body gr ou n d. ter.
In t er n a lly a ll gr ou n ds a r e con n ect ed t oget h er, h ow-
ever t h er e is n oise su ppr ession on t h e sen sor gr ou n d. Th e veh icle speed r ea din gs for t h e speedom et er a r e
F or E MI a n d RF I pr ot ect ion t h e h ou sin g a n d cover t a ken fr om t h e ou t pu t speed sen sor. Th e P CM m u st
a r e a lso gr ou n ded sepa r a t ely fr om t h e gr ou n d pin s. be ca libr a t ed t o t h e differ en t com bin a t ion s of equ ip-
m en t (fin a l dr ive a n d t ir es) a va ila ble. P in ion F a ct or
OPERATION - 5 VOLT SUPPLY - PCM OUTPUT a llows t h e t ech n icia n t o set t h e P ower t r a in Con t r ol
Th e P CM su pplies 5 volt s t o t h e followin g sen sor s: Modu le in it ia l set t in g so t h a t t h e speedom et er r ea d-
• A/C pr essu r e t r a n sdu cer in gs will be cor r ect . To pr oper ly r ea d a n d/or r eset t h e
• Am bien t Tem per a t u r e sen sor P in ion F a ct or, it is n ecessa r y t o u se a DRBIII! sca n
• Ba t t er y t em per a t u r e t ool.
• Ca m sh a ft P osit ion Sen sor (NGC) (1) P lu g t h e DRBIII! sca n t ool in t o t h e dia gn ost ic
• Cr a n ksh a ft P osit ion Sen sor (NGC) con n ect or loca t ed u n der t h e in st r u m en t pa n el.
• E n gin e coola n t t em per a t u r e sen sor (2) Select t h e Tr a n sm ission m en u .
• In let Air Tem per a t u r e Sen sor (3) Select t h e Miscella n eou s m en u .
• Kn ock sen sor (4) Select P in ion F a ct or. Th en follow t h e in st r u c-
• Lin ea r E GR solen oid (if equ ipped) t ion s on t h e DRBIII! sca n t ool scr een .
• Ma n ifold a bsolu t e pr essu r e sen sor
• Oil P r essu r e Swit ch STANDARD PROCEDURE - QUICK LEARN
• Th r ot t le posit ion sen sor PROCEDURE
Th e qu ick lea r n pr ocedu r e r equ ir es t h e u se of t h e
STAN DARD PROCEDU RE DRBIII! sca n t ool. Th is pr ogr a m a llows t h e P CM t o
r eca libr a t e it self. Th is will pr ovide t h e best possible
STANDARD PROCEDURE - OBTAINING t r a n sa xle oper a t ion .
DIAGNOSTIC TROUBLE CODES NOTE: The quick learn procedure should be per-
formed if any of the following procedures are per-
BULB CHECK formed:
Key on : Bu lb illu m in a t ed u n t il veh icle st a r t s, a s
lon g a s a ll on ce per t r ip (r ea din ess) m on it or s com - • Tr a n sa xle Assem bly Repla cem en t
plet ed. If m on it or s h a ve n o t been com plet ed, t h en : • P ower t r a in Con t r ol Modu le Repla cem en t
Key on : bu lb ch eck for a bou t 5 t o 8 secon ds, la m p • Solen oid/P r essu r e Swit ch Assem bly Repla cem en t
t h en fla sh es if on ce per t r ip (r ea din ess) m on it or s • Clu t ch P la t e a n d/or Sea l Repla cem en t
h a ve n o t been com plet ed u n t il veh icle is st a r t ed, • Va lve Body Repla cem en t or Recon dit ion
t h en MIL is ext in gu ish ed. To per for m t h e Qu ick Lea r n P r ocedu r e, t h e follow-
in g con dit ion s m u st be m et :
OBTAINING DTC’S USING DRB SCAN TOOL • Th e br a kes m u st be a pplied
(1) Con n ect t h e DRB sca n t ool t o t h e da t a lin k • Th e en gin e speed m u st be a bove 500 r pm
(dia gn ost ic) con n ect or. Th is con n ect or is loca t ed in • Th e t h r ot t le a n gle (TP S) m u st be less t h a n 3
t h e pa ssen ger com pa r t m en t ; a t t h e lower edge of degr ees
in st r u m en t pa n el; n ea r t h e st eer in g colu m n . • Th e sh ift lever posit ion m u st st a y u n t il
(2) Tu r n t h e ign it ion swit ch on a n d a ccess t h e pr om pt ed t o sh ift t o over dr ive
“Rea d F a u lt ” scr een . • Th e sh ift lever posit ion m u st st a y in over dr ive
(3) Recor d a ll t h e DTC’s a n d “fr eeze fr a m e” in for- a ft er t h e Sh ift t o Over dr ive pr om pt u n t il t h e
m a t ion sh own on t h e DRB sca n t ool. DRBIII! in dica t es t h e pr ocedu r e is com plet e
(4) To er a se DTC’s, u se t h e “E r a se Tr ou ble Code” • Th e ca lcu la t ed oil t em per a t u r e m u st be a bove
da t a scr een on t h e DRB sca n t ool. D o n o t e ra s e a n y 60° a n d below 200°
D TC’s u n til p ro ble m s h a v e be e n in v e s tig a te d
a n d re p a irs h a v e be e n p e rfo rm e d .
(1) P lu g t h e DRBIII! sca n t ool in t o t h e dia gn ost ic
con n ect or. Th e con n ect or is loca t ed u n der t h e in st r u -
m en t pa n el.
(2) Go t o t h e Tr a n sm ission scr een .
(3) Go t o t h e Miscella n eou s scr een .
(4) Select Qu ick Lea r n P r ocedu r e. F ollow t h e
in st r u ct ion s of t h e DRBIII! t o per for m t h e Qu ick
Lea r n P r ocedu r e.
REM OVAL
REMOVAL - SBEC CONTROLLER
(1) Discon n ect t h e n ega t ive ba t t er y ca ble.
(2) Rem ove t h e ba t t er y sh ield, r efer t o t h e Ba t t er y
sect ion for m or e in for m a t ion .
(3) Rem ove t h e 2 u pper P CM br a cket bolt s (F ig.
11).
Fig. 12 PCM LOWER BOLT

REMOVAL - NGC CONTROLLER
Th e P CM en gin e con t r ol st r a t egy pr even t s r edu ced
idle speeds u n t il a ft er t h e en gin e oper a t es for 320 km
(200 m iles). If t h e P CM is r epla ced a ft er 320 km (200
m iles) of u sa ge, u pda t e t h e m ilea ge a n d veh icle iden -
t ifica t ion n u m ber (VIN) in t h e n ew P CM. Use t h e
DRBIII! sca n t ool t o ch a n ge t h e m illa ge a n d VIN in
t h e P CM. If t h is st ep is n ot don e a Dia gn ost ic Tr ou -
ble Code (DTC) m a y be set . Refer t o t h e a ppr opr ia t e
P ower t r a in Dia gn ost ic Ma n u a l a n d t h e DRBIII! sca n
t ool.
Fig. 11 PCM
1 - Attaching Bolts
(4) Rem ove t h e 2 P CM con n ect or s.

(5) Rem ove t h e h ea dla m p, r efer t o t h e La m ps sec-
t ion for m or e in for m a t ion .
(6) Rem ove t h e lower P CM m ou n t in g bolt (F ig. 12).
(7) Rem ove P CM.
NGC CONTROLLER LOCATION

(1) Tu r n wh eels t o t h e left . I N STALLAT I ON
(3) Ra ise veh icle a n d su ppor t . INSTALLATION - SBEC CONTROLLER
(4) Rem ove t h e left fr on t wh eel well spla sh sh ield (1) In st a ll t h e P CM.
(F ig. 13). (2) In st a ll t h e lower P CM m ou n t in g bolt . Tigh t en
bolt .
(3) In st a ll t h e 2 u pper P CM br a cket bolt s. Tigh t en
bolt .
(4) In st a ll t h e h ea dla m p, r efer t o t h e La m ps sec-
(5) In st a ll t h e 2 P CM con n ect or s.
(6) In st a ll t h e ba t t er y sh ield, r efer t o t h e Ba t t er y
(7) Con n ect t h e n ega t ive ba t t er y ca ble.
INSTALLATION
Th e P CM en gin e con t r ol st r a t egy pr even t s r edu ced
idle speeds u n t il a ft er t h e en gin e oper a t es for 320 km
(200 m iles). If t h e P CM is r epla ced a ft er 320 km (200
m iles) of u sa ge, u pda t e t h e m ilea ge a n d veh icle iden -
t ifica t ion n u m ber (VIN) in t h e n ew P CM. Use t h e
DRBIII! sca n t ool t o ch a n ge t h e m illa ge a n d VIN in
t h e P CM. If t h is st ep is n ot don e a dia gn ost ic t r ou ble
code (DTC) m a y be set a n d SKIM m u st be don e or
Fig. 13 SPLASH SHIELD ca r will n ot st a r t if it is a SKIM equ ipped ca r. If a
SKIM ca r you m u st do a secr et key t r a n sfer a lso.
(5) Un lock a n d discon n ect t h e elect r ica l con n ect or s
Refer t o t h e a ppr opr ia t e P ower t r a in Dia gn ost ic Ma n -
(F ig. 14).
u a l a n d t h e DRBIII! sca n t ool.
(1) In st a ll P CM m odu le t o t h e m ou n t in g br a cket .
(2) In st a ll elect r ica l con n ect or s a n d lock.
(3) In st a ll t h e spla sh sh ield.
(4) Lower veh icle.
(6) Usin g DRBIII! sca n t ool, pr ogr a m m ilea ge a n d
veh icle iden t ifica t ion n u m ber (VIN) in t o P CM. Refer
t o t h e DRBIII! sca n t ool a n d t h e a ppr opr ia t e P ower-
t r a in Dia gn ost ic Ma n u a l.
Fig. 14 NGC CONTROLLER

(6) Rem ove 3 scr ews fr om P CM t o m ou n t in g
br a cket .
(7) Rem ove t h e P CM.
SLI DI N G DOOR CON T ROL Th e power door con t r ol m odu le is a r epla cea ble
com pon en t a n d ca n n ot be r epa ir ed, if fou n d t o be
M ODU LE fa u lt y it m u st be r epla ced.
DESCRIPTION OPERATION
Th e power slidin g door con t r ol m odu le ser ves a s
t h e m a in com pu t er for t h e power slidin g door syst em .
All power door fu n ct ion s a r e pr ocessed t h r ou gh t h e
power slidin g door con t r ol m odu le a n d/or t h e veh icles
Body Con t r ol Modu le (BCM). At t h e st a r t of a power
open com m a n d, a sign a l is sen t t o t h e BCM a n d t h en
t o t h e power slidin g door con t r ol m odu le via t h e P r o-
gr a m m a ble Com m u n ica t ion In t er fa ce (P CI) da t a bu s
cir cu it . Th is sign a l, gen er a t ed by a n y of t h e power
door com m a n d swit ch es, t ells t h e power slidin g door
con t r ol m odu le t o a ct iva t e a power la t ch r elea se,
en ga ge t h e clu t ch a ssem bly a n d dr ive t h e door in t o
t h e fu ll open posit ion . If a n obst a cle is felt du r in g
t h is power open cycle, t h e m odu le will r ever se dir ec-
t ion a n d close t h e door. Th is pr ocess is a lso en a bled
du r in g a power close cycle. Th is pr ocess will r epea t
t h r ee t im es, a n d if a fou r t h obst a cle is det ect ed, t h e
door will go in t o fu ll m a n u a l m ode. On ce t h e fu ll
open posit ion is obt a in ed, a h old open la t ch a ssem bly
m ou n t ed fu ll open swit ch t ells t h e power slidin g door
con t r ol m odu le t h a t t h e door h a s r ea ch ed t h e fu ll
open posit ion . If t h e power slidin g door syst em devel-
Fig. 15 Power Side Door Components ops a n y pr oblem s t h e power slidin g door con t r ol m od-
1 - SLIDING DOOR CONTROL MODULE
u le will st or e a n d r eca ll Dia gn ost ic Tr ou ble Codes
2 - MODULE RETAINING SCREW (DTC). Th e u se of a dia gn ost ic sca n t ool, su ch a s t h e
3 - MODULE ELECTRICAL CONNECTORS DRB III! is r equ ir ed t o r ea d a n d t r ou blesh oot t h ese
4 - DOOR MOTOR ASSEMBLY
5 - FLEX DRIVE ASSEMBLY
t r ou ble codes.
6 - DOOR MOTOR RETAINING FASTENERS
7 - DOOR MOTOR ELECTRICAL CONNECTOR
Veh icles equ ipped wit h a power slidin g door syst em
u t ilize a slidin g door con t r ol m odu le. Th e slidin g door SLIDING DOOR CONTROL MODULE
con t r ol m odu le is loca t ed beh in d t h e slidin g door t r im An y d ia g n o s is o f th e p o w e r s lid in g d o o r s y s -
pa n el in t h e cen t er of t h e door, ju st a bove t h e slidin g te m s h o u ld be g in w ith th e u s e o f th e D RB III!
door m ot or (F ig. 15). Th is m odu le con t r ols t h e oper a - d ia g n o s tic to o l. F o r in fo rm a tio n o n th e u s e o f
t ion of t h e door t h r ou gh t h e P r ogr a m m a ble Com m u - th e D RB III!, re fe r to th e a p p ro p ria te D ia g n o s -
n ica t ion In t er fa ce (P CI) da t a bu s cir cu it a n d t h e tic P ro c e d u re s in fo rm a tio n .
Body Con t r ol Modu le (BCM). Th e slidin g door con t r ol In spect t h e r ela t ed wir in g h a r n ess con n ect or s for
m odu le con t a in s soft wa r e t ech n ology wh ich en a bles it br oken , ben t , pu sh ed ou t , or cor r oded t er m in a ls.
t o det ect r esist a n ce t o door t r a vel a n d t o r ever se door Refer t o t h e a ppr opr ia t e wir in g in for m a t ion .
t r a vel in or der t o a void da m a ge t o t h e door or t o
a void possible per son a l in ju r y if t h e obst r u ct ion is a REMOVAL
per son . Th is fea t u r e fu n ct ion s in bot h t h e open in g (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
a n d closin g cycles. If t h e power slidin g door syst em ca ble.
develops a n y pr oblem s t h e con t r ol m odu le will st or e (2) Rem ove t h e a ppr opr ia t e door t r im pa n el fr om
a n d r eca ll Dia gn ost ic Tr ou ble Codes (DTC). Th e u se t h e veh icle. (Refer t o 23 - BODY/DOORS - SLIDING/
of a dia gn ost ic sca n t ool, su ch a s t h e DRB III! is TRIM PANE L - RE MOVAL)
r equ ir ed t o r ea d a n d t r ou blesh oot t h ese t r ou ble (3) Rem ove t h e wea t h er sh ield.
codes. Th e slidin g door con t r ol m odu le ca n be
r efla sh ed if n ecessa r y. Refer t o t h e la t est Tech n ica l
Ser vice Bu llet in (TSB) In for m a t ion for a n y u pda t es.
SLI DI N G DOOR CON T ROL M ODU LE (Cont inue d)
(4) Discon n ect t h e power door con t r ol m odu le elec-
t r ica l con n ect or s. Slide t h e r ed lockin g t a b ou t (a wa y
fr om m odu le) a n d depr ess con n ect or r et a in in g t a b,
wh ile pu llin g st r a igh t a pa r t .
(5) Rem ove t h e con t r ol m odu le r et a in in g scr ew
(F ig. 16).
(6) Rem ove t h e m odu le fr om t h e veh icle.
INSTALLATION
(1) P osit ion t h e slidin g door con t r ol m odu le a n d
in st a ll t h e r et a in in g scr ew.
(2) Con n ect t h e elect r ica l con n ect or s. Slide t h e
lockin g t a b in t o t h e locked posit ion .
(3) In st a ll t h e wea t h er sh ield.
(4) In st a ll t h e a ppr opr ia t e door t r im pa n el on t h e
veh icle. (Refer t o 23 - BODY/DOORS - SLIDING/
TRIM PANE L - INSTALLATION)
er a se a n y power door con t r ol m odu le dia gn ost ic t r ou -
ble codes.
(7) Ver ify power door syst em oper a t ion . Cycle t h e
power door t h r ou gh on e com plet e open a n d close Fig. 16 Power Side Door Components
cycle. 1 - SLIDING DOOR CONTROL MODULE
2 - MODULE RETAINING SCREW
3 - MODULE ELECTRICAL CONNECTORS
RS ENGINE SYSTEMS 8F - 1
ENGINE SYSTEMS
page page
BATTERY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 1 STARTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
BAT T ERY SY ST EM
TABLE OF CONTENTS
page page
BATTERY SYSTEM IGNITION-OFF DRAW TEST . . . . . . . . . . . . . 13

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1 CHECKING BATTERY ELECTROLYTE
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
DIAGNOSIS AND TESTING MICRO 420 BATTERY TESTER . . . . . . . . . . . 15
BATTERY SYSTEM . . . . . . . . . . . . . . . . . . . . . 2 REMOVAL - BATTERY ............ . . . . . . . 16
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 BATTERY HOLDDOWN
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16
SPECIAL TOOLS BATTERY CABLES
BATTERY SYSTEM SPECIAL TOOLS . . . . . . . 7 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 16
BATTERY OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7 DIAGNOSIS AND TESTING
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 BATTERY CABLES . . . . . . . . . . . . . . . . . . . . 17
DIAGNOSIS AND TESTING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19
STANDARD PROCEDURE BATTERY TRAY
SPIRAL PLATE BATTERY CHARGING . . . . . . 10 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 19
CONVENTIONAL BATTERY CHARGING . . . . 11 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
OPEN-CIRCUIT VOLTAGE TEST . . . . . . . . . . 13 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 20
BAT T ERY SY ST EM • B a tte ry Ho ld d o w n - Th e ba t t er y h olddown

h a r dwa r e secu r es t h e ba t t er y in t h e ba t t er y t r a y in
t h e en gin e com pa r t m en t .
DESCRIPTION
• B a tte ry Th e rm o w ra p - Th e ba t t er y t h er m ow-
Th is veh icle is equ ipped wit h a sin gle 12-volt ba t -
r a p in su la t es t h e ba t t er y t o pr ot ect it fr om en gin e
t er y. All of t h e com pon en t s of t h e ba t t er y syst em a r e
com pa r t m en t t em per a t u r e ext r em es.
loca t ed wit h in t h e en gin e com pa r t m en t . Th e ba t t er y
• B a tte ry Tra y - Th e ba t t er y t r a y pr ovides a
syst em for t h is veh icle con t a in s t h e followin g r ela t ed
secu r e m ou n t in g loca t ion in t h e veh icle for t h e ba t -
com pon en t s:
t er y a n d a n a n ch or poin t for t h e ba t t er y h olddown
• B a tte ry - Th e st or a ge ba t t er y pr ovides a r eli-
h a r dwa r e.
a ble m ea n s of st or in g a r en ewa ble sou r ce of elect r ica l
en er gy wit h in t h e veh icle.
• B a tte ry Ca ble - Th e ba t t er y ca bles con n ect t h e
ba t t er y t er m in a l post s t o t h e veh icle elect r ica l sys-
t em .
8F - 2 BATTERY SYSTEM RS
BAT T ERY SY ST EM (Cont inue d)
OPERATION m u st be dia gn osed a n d cor r ect ed befor e a ba t t er y is

Th e ba t t er y syst em is design ed t o pr ovide a sa fe, r epla ced a n d befor e a veh icle is r et u r n ed t o ser vice.
efficien t , r elia ble a n d m obile m ea n s of deliver in g a n d Th e ser vice in for m a t ion for t h ese syst em s h a s been
st or in g elect r ica l en er gy. Th is elect r ica l en er gy is sepa r a t ed wit h in t h is ser vice m a n u a l t o m a ke it ea s-
r equ ir ed t o oper a t e t h e en gin e st a r t in g syst em , a s ier t o loca t e t h e specific in for m a t ion you a r e seekin g.
well a s t o oper a t e m a n y of t h e ot h er veh icle a cces- H owever, wh en a t t em pt in g t o dia gn ose a n y of t h ese
sor y syst em s for lim it ed du r a t ion s wh ile t h e en gin e syst em s, it is im por t a n t t h a t you keep t h eir in t er de-
a n d/or t h e ch a r gin g syst em a r e n ot oper a t in g. Th e pen den cy in m in d.
ba t t er y syst em is a lso design ed t o pr ovide a r eser ve Th e dia gn ost ic pr ocedu r es u sed for t h e ba t t er y,
of elect r ica l en er gy t o su pplem en t t h e ch a r gin g sys- st a r t in g, a n d ch a r gin g syst em s in clu de t h e m ost
t em for sh or t du r a t ion s wh ile t h e en gin e is r u n n in g ba sic con ven t ion a l dia gn ost ic m et h ods, t o t h e m or e
a n d t h e elect r ica l cu r r en t dem a n ds of t h e veh icle soph ist ica t ed On -Boa r d Dia gn ost ics (OBD) bu ilt in t o
exceed t h e ou t pu t of t h e ch a r gin g syst em . In a ddit ion t h e P ower t r a in Con t r ol Modu le (P CM). Use of a n
t o deliver in g, a n d st or in g elect r ica l en er gy for t h e in du ct ion -t ype m illia m per e a m m et er, a volt /oh m m e-
veh icle, t h e ba t t er y syst em ser ves a s a ca pa cit or a n d t er, a ba t t er y ch a r ger, a ca r bon pile r h eost a t (loa d
volt a ge st a bilizer for t h e veh icle elect r ica l syst em . It t est er ) a n d a 12-volt t est la m p m a y be r equ ir ed. All
a bsor bs m ost a bn or m a l or t r a n sien t volt a ges ca u sed OBD-sen sed syst em s a r e m on it or ed by t h e P CM.
by t h e swit ch in g of a n y of t h e elect r ica l com pon en t s E a ch m on it or ed cir cu it is a ssign ed a Dia gn ost ic Tr ou -
or cir cu it s in t h e veh icle. ble Code (DTC). Th e P CM will st or e a DTC in elec-
t r on ic m em or y for a n y fa ilu r e it det ect s. (Refer t o 8 -
E LE CTRICAL/CH ARGING - DIAGNOSIS AND
DI AGN OSI S AN D T EST I N G TE STING) for t h e pr oper ch a r gin g syst em on -boa r d
dia gn ost ic t est pr ocedu r es.
BATTERY SYSTEM
Th e ba t t er y, st a r t in g, a n d ch a r gin g syst em s in t h e MICRO 420 BATTERY TESTER
veh icle oper a t e wit h on e a n ot h er a n d m u st be t est ed Th e Micr o 420 a u t om ot ive ba t t er y t est er is
a s a com plet e syst em . In or der for t h e en gin e t o st a r t design ed t o h elp t h e dea ler sh ip t ech n icia n s dia gn ose
a n d t h e ba t t er y t o m a in t a in it s ch a r ge pr oper ly, a ll of t h e ca u se of a defect ive ba t t er y. F ollow t h e in st r u c-
t h e com pon en t s t h a t a r e u sed in t h ese syst em s m u st t ion m a n u a l su pplied wit h t h e t est er t o pr oper ly
per for m wit h in specifica t ion s. It is im por t a n t t h a t dia gn ose a veh icle. If t h e in st r u ct ion m a n u a l is n ot
t h e ba t t er y, st a r t in g, a n d ch a r gin g syst em s be t h or- a va ila ble r efer t o t h e st a n da r d pr ocedu r e in t h is sec-
ou gh ly t est ed a n d in spect ed a n y t im e a ba t t er y n eeds t ion , wh ich in clu des t h e dir ect ion s for u sin g t h e
t o be ch a r ged or r epla ced. Th e ca u se of a bn or m a l ba t - Micr o 420 ba t t er y t est er.
t er y disch a r ge, over ch a r gin g or ea r ly ba t t er y fa ilu r e
RS BATTERY SYSTEM 8F - 3
BATTERY SYSTEM DIAGNOSIS
THE BATTERY SEEMS 1. The electrical system 1. (Refer to 8 - ELECTRICAL/BATTERY

WEAK OR DEAD WHEN ignition-off draw is excessive. SYSTEM/BATTERY - STANDARD PROCEDURE
ATTEMPTING TO START - IGNITION-OFF DRAW TEST) for the proper test
THE ENGINE. procedures. Repair the excessive ignition-off
draw, as required.
2. The charging system is 2. Determine if the charging system is performing
inoperative. to specifications. (Refer to 8 - ELECTRICAL/
CHARGING - DIAGNOSIS AND TESTING) for
additional charging system diagnosis and testing
procedures. Repair the inoperative charging
system, as required.
3. The battery is discharged. 3. Determine the battery state-of-charge using the
Micro 420 battery tester. Refer to the Standard
Procedures in this section for additional test
procedures. Charge the inoperative battery, as
required.
4. The battery terminal 4. (Refer to 8 - ELECTRICAL/BATTERY
connections are loose or SYSTEM/CABLES - DIAGNOSIS AND TESTING)
corroded. for the proper battery cable diagnosis and testing
procedures. Clean and tighten the battery
terminal connections, as required.
5. The battery has an 5. (Refer to 8 - ELECTRICAL/BATTERY SYSTEM
incorrect size or rating for - SPECIFICATIONS) for the proper size and
this vehicle. rating. Replace an incorrect battery, as required.
6. The battery is inoperative. 6. Test the battery using the Micro 420 battery
tester. Refer to the Standard Procedures in this
section for additional test procedures. Replace
the inoperative battery, as required.
7. The starting system is 7. Determine if the starting system is performing
STARTING - DIAGNOSIS AND TESTING) for the
proper starting system diagnosis and testing
procedures. Repair the inoperative starting
8. The battery is physically 8. Inspect the battery for loose terminal posts or a
damaged. cracked and leaking case. Replace the damaged
battery, as required.
BATTERY SYSTEM DIAGNOSIS
THE BATTERY STATE OF 1. The battery has an 1. (Refer to 8 - ELECTRICAL/BATTERY SYSTEM

CHARGE CANNOT BE incorrect size or rating for - SPECIFICATIONS) for the proper specifications.
MAINTAINED. this vehicle. Replace an incorrect battery, as required.
2. The battery terminal 2. (Refer to 8 - ELECTRICAL/BATTERY

connections are loose or SYSTEM/CABLES - DIAGNOSIS AND TESTING)
corroded. for the proper cable diagnosis and testing
procedures. Clean and tighten the battery
terminal connections, as required.
3. The electrical system 3. (Refer to 8 - ELECTRICAL/BATTERY
ignition-off draw is excessive. SYSTEM/BATTERY - STANDARD PROCEDURE
- IGNITION-OFF DRAW TEST) for the proper test
procedures. Repair the inoperative electrical
4. The battery is inoperative. 4. Test the battery using the Micro 420 battery
tester. Refer to Standard Procedures for
additional test procedures. Replace the
inoperative battery, as required.
5. The starting system is 5. Determine if the starting system is performing
STARTING - DIAGNOSIS AND TESTING) for the
proper starting system diagnosis and testing
procedures. Repair the inoperative starting
6. The charging system is 6. Determine if the charging system is performing
CHARGING - DIAGNOSIS AND TESTING) for
charging system diagnosis and testing
procedures. Repair the inoperative charging
7. Electrical loads exceed the 7. Inspect the vehicle for aftermarket electrical
output of the charging equipment which might cause excessive electrical
system. loads.
8. Slow driving or prolonged 8. Advise the vehicle operator, as required.
idling with high-amperage
draw loads in use.
THE BATTERY WILL NOT 1. The battery is inoperative. 1. Test the battery using the Micro 420 battery
ACCEPT A CHARGE. tester.. Charge or replace the inoperative battery,
as required.
CLEANING
Th e followin g in for m a t ion det a ils t h e r ecom m en ded
clea n in g pr ocedu r es for t h e ba t t er y a n d r ela t ed com -
pon en t s. In a ddit ion t o t h e m a in t en a n ce sch edu les
fou n d in t h is ser vice m a n u a l a n d t h e own er ’s m a n -
u a l, it is r ecom m en ded t h a t t h ese pr ocedu r es be per-
for m ed a n y t im e t h e ba t t er y or r ela t ed com pon en t s
m u st be r em oved for veh icle ser vice.
(1) Clea n t h e ba t t er y ca ble t er m in a l cla m ps of a ll
cor r osion . Rem ove a n y cor r osion u sin g a wir e br u sh
or a post a n d t er m in a l clea n in g t ool, a n d a sodiu m
bica r bon a t e (ba kin g soda ) a n d wa r m wa t er clea n in g
solu t ion (F ig. 1).
Fig. 2 Clean Battery - Typical

1 - CLEANING BRUSH
2 - WARM WATER AND BAKING SODA SOLUTION
3 - BATTERY
(4) Clea n t h e ba t t er y t h er m owr a p wit h a sodiu m

bica r bon a t e (ba kin g soda ) a n d wa r m wa t er clea n in g
solu t ion u sin g a soft br ist le pa r t s clea n in g br u sh t o
r em ove a n y a cid film .
(5) Clea n a n y cor r osion fr om t h e ba t t er y t er m in a l
post s wit h a wir e br u sh or a post a n d t er m in a l
clea n er, a n d a sodiu m bica r bon a t e (ba kin g soda ) a n d
wa r m wa t er clea n in g solu t ion (F ig. 3).
Fig. 1 Clean Battery Cable Terminal Clamp - Typical
INSPECTION
1 - TERMINAL BRUSH
2 - BATTERY CABLE
Th e followin g in for m a t ion det a ils t h e r ecom m en ded
in spect ion pr ocedu r es for t h e ba t t er y a n d r ela t ed
(2) Clea n t h e ba t t er y t r a y a n d ba t t er y h olddown com pon en t s. It is r ecom m en ded t h a t t h ese pr oce-
h a r dwa r e of a ll cor r osion . Rem ove a n y cor r osion du r es be per for m ed a n y t im e t h e ba t t er y or r ela t ed
u sin g a wir e br u sh a n d a sodiu m bica r bon a t e (ba kin g com pon en t s m u st be r em oved for veh icle ser vice.
soda ) a n d wa r m wa t er clea n in g solu t ion . P a in t a n y (1) In spect t h e ba t t er y ca ble t er m in a l cla m ps for
exposed ba r e m et a l. da m a ge. Repla ce a n y ba t t er y ca ble t h a t h a s a da m -
(3) If t h e r em oved ba t t er y is t o be r ein st a lled, a ged or defor m ed t er m in a l cla m p.
clea n t h e ou t side of t h e ba t t er y ca se a n d t h e t op (2) In spect t h e ba t t er y t r a y a n d ba t t er y h olddown
cover wit h a sodiu m bica r bon a t e (ba kin g soda ) a n d h a r dwa r e for da m a ge. Repla ce a n y da m a ged pa r t s.
wa r m wa t er clea n in g solu t ion u sin g a st iff br ist le (3) Slide t h e t h er m owr a p off of t h e ba t t er y ca se.
pa r t s clea n in g br u sh t o r em ove a n y a cid film (F ig. 2). In spect t h e ba t t er y ca se for cr a cks or ot h er da m a ge
Rin se t h e ba t t er y wit h clea n wa t er. E n su r e t h a t t h e t h a t cou ld r esu lt in elect r olyt e lea ks. Also, ch eck t h e
clea n in g solu t ion does n ot en t er t h e ba t t er y cells ba t t er y t er m in a l post s for loosen ess. Ba t t er ies wit h
t h r ou gh t h e ven t h oles. If t h e ba t t er y is bein g da m a ged ca ses or loose t er m in a l post s m u st be
r epla ced, r efer t o Ba t t er y Syst em Specifica t ion s for r epla ced.
t h e fa ct or y-in st a lled ba t t er y specifica t ion s. Con fir m (4) In spect t h e ba t t er y t h er m owr a p for t ea r s,
t h a t t h e r epla cem en t ba t t er y is t h e cor r ect size a n d cr a cks, defor m a t ion or ot h er da m a ge. Repla ce a n y
h a s t h e cor r ect r a t in gs for t h e veh icle. ba t t er y t h er m a l wr a p t h a t h a s been da m a ged.
(RC) r a t in g or Am per e-H ou r s (AH ) r a t in g ca n be
fou n d on t h e or igin a l equ ipm en t ba t t er y la bel. Be
cer t a in t h a t a r epla cem en t ba t t er y h a s t h e cor r ect
Gr ou p Size n u m ber, a s well a s CCA, a n d RC or AH
r a t in gs t h a t equ a l or exceed t h e or igin a l equ ipm en t
specifica t ion for t h e veh icle bein g ser viced. Ba t t er y
sizes a n d r a t in gs a r e discu ssed in m or e det a il below.
• Gro u p S ize - Th e ou t side dim en sion s a n d t er-
m in a l pla cem en t of t h e ba t t er y con for m t o st a n da r ds
est a blish ed by t h e Ba t t er y Cou n cil In t er n a t ion a l
(BCI). E a ch ba t t er y is a ssign ed a BCI Gr ou p Size
n u m ber t o h elp iden t ify a cor r ect ly-sized r epla ce-
m en t .
• Co ld Cra n k in g Am p e ra g e - Th e Cold Cr a n k-
in g Am per a ge (CCA) r a t in g specifies h ow m u ch cu r-
r en t (in a m per es) t h e ba t t er y ca n deliver for t h ir t y
secon ds a t -18° C (0° F ). Ter m in a l volt a ge m u st n ot
fa ll below 7.2 volt s du r in g or a ft er t h e t h ir t y secon d
disch a r ge per iod. Th e CCA r equ ir ed is gen er a lly
h igh er a s en gin e displa cem en t in cr ea ses, depen din g
a lso u pon t h e st a r t er cu r r en t dr a w r equ ir em en t s.
• Re s e rv e Ca p a c ity - Th e Reser ve Ca pa cit y (RC)
Fig. 3 Clean Battery Terminal Post - Typical r a t in g specifies t h e t im e (in m in u t es) it t a kes for ba t -
1 - TERMINAL BRUSH t er y t er m in a l volt a ge t o fa ll below 10.5 volt s, a t a
2 - BATTERY CABLE
3 - BATTERY disch a r ge r a t e of 25 a m per es. RC is det er m in ed wit h
t h e ba t t er y fu lly-ch a r ged a t 26.7° C (80° F ). Th is r a t -
(5) In spect t h e ba t t er y bu ilt -in t est in dica t or sigh t in g est im a t es h ow lon g t h e ba t t er y m igh t la st a ft er a
gla ss (if equ ipped) for a n in dica t ion of t h e ba t t er y ch a r gin g syst em fa ilu r e, u n der m in im u m elect r ica l
con dit ion . If t h e ba t t er y is disch a r ged, ch a r ge a s loa d.
r equ ir ed. (Refer t o 8 - E LE CTRICAL/BATTE RY SYS- • Am p e re -Ho u rs - Th e Am per e-H ou r s (AH ) r a t -
TE M/BATTE RY - STANDARD P ROCE DURE - BAT- in g specifies t h e cu r r en t (in a m per es) t h a t a ba t t er y
TE RY CH ARGING) for t h e pr oper ba t t er y ch a r gin g ca n deliver st ea dily for t wen t y h ou r s, wit h t h e volt -
pr ocedu r es. a ge in t h e ba t t er y n ot fa llin g below 10.5 volt s. Th is
r a t in g is a lso som et im es iden t ified a s t h e t wen t y-
h ou r disch a r ge r a t in g.
SPECI FI CAT I ON S
BATTERY
Th e ba t t er y Gr ou p Size n u m ber, t h e Cold Cr a n kin g
Am per a ge (CCA) r a t in g, a n d t h e Reser ve Ca pa cit y
BATTERY CLASSIFICATIONS & RATINGS

BCI Group Size Cold Cranking Reserve Ampere - Load Test
Part Number
Classification Amperage Capacity Hours Amperage
4686158AD 34 500 110 Minutes 60 250
4727159AD 34 600 120 Minutes 66 300
4727242AD DIN H6 600 120 Minutes 66 300
4868999AA 34 700 90 Minutes 50 350
SPECI AL T OOLS
BATTERY SYSTEM SPECIAL TOOLS
Fig. 4 MAINTENANCE-FREE DIESEL ENGINE

BATTERY
wa t er wit h in t h e elect r olyt e, elim in a t in g t h e n eed t o
Micro 420 Battery Tester a dd dist illed wa t er. Th er efor e, t h ese ba t t er ies h a ve
n on -r em ova ble ba t t er y ven t ca ps (F ig. 4).
BAT T ERY Th e a cid in side a spir a l pla t e ba t t er y is bou n d
wit h in t h e vit r eou s sepa r a t or s, en din g t h e t h r ea t of
DESCRIPTION a cid lea ks. Th is fea t u r e a llows t h e ba t t er y t o be
Th er e a r e t h r ee differ en t ba t t er ies a va ila ble for in st a lled in a n y posit ion a n ywh er e in t h e veh icle.
t h is veh icle. Veh icles equ ipped wit h a diesel en gin e Spir a l pla t e t ech n ology is t h e pr ocess by wh ich t h e
u t ilize a spir a l wou n d pla t e design ed ba t t er y wit h pla t es h oldin g t h e a ct ive m a t er ia l in t h e ba t t er y a r e
r ecom bin a t ion t ech n ology. Th is is a m a in t en a n ce-fr ee wou n d t igh t ly in coils in st ea d of h a n gin g fla t , like
ba t t er y t h a t is ca pa ble of deliver in g m or e power t h a n con ven t ion a l ba t t er ies. Th is design h a s a lower in t er-
a con ven t ion a l ba t t er y. Th is a ddit ion a l power is n a l r esist a n ce a n d a lso in cr ea ses t h e a ct ive m a t er ia l
r equ ir ed by a diesel en gin e du r in g cold cr a n kin g. su r fa ce a r ea .
Veh icles equ ipped wit h a ga solin e en gin e u t ilize a
con ven t ion a l ba t t er y. Refer t o t h e followin g in for m a - WARNING: NEVER EXCEED 14.4 VOLTS WHEN
t ion for det a iled differ en ces a n d descr ipt ion s of t h ese CHARGING A SPIRAL PLATE BATTERY. PERSONAL
ba t t er ies. INJURY AND/OR BATTERY DAMAGE MAY RESULT.
SPIRAL PLATE BATTERY - DIESEL ENGINE Du e t o t h e m a in t a n a n ce-fr ee design , dist illed wa t er

By t igh t ly win din g la yer s of spir a l gr ids a n d a cid- ca n n ot be a dded t o t h is ba t t er y. Th er efor e, if m or e
per m ea t ed vit r eou s sepa r a t or s in t o cells, t h e ba t t er y t h a n 14.4 volt s a r e u sed du r in g t h e spir a l pla t e ba t -
h a s m or e power a n d ser vice life t h a n con ven t ion a l t er y ch a r gin g pr ocess, wa t er va por ca n be exh a u st ed
ba t t er ies of t h e sa m e size. Th e spir a l pla t e ba t t er y is t h r ou gh t h e pr essu r e-sen sit ive ba t t er y ven t s a n d lost
per m a n en t ly sea led. Th r ou gh ga s r ecom bin a t ion , for good. Th is ca n per m a n en t ly da m a ge t h e spir a l
h ydr ogen a n d oxygen wit h in t h e ba t t er y a r e ca pt u r ed pla t e ba t t er y.
du r in g n or m a l ch a r gin g a n d r eu n it ed t o for m t h e
BAT T ERY (Cont inue d)
CONVENTIONAL BATTERY - GASOLINE ENGINE
Fig. 6 Maintenance-Free Battery - Domestic

1 - POSITIVE POST
2 - VENT
3 - CELL CAP
4 - VENT
5 - CELL CAP
6 - VENT
7 - NEGATIVE POST
8 - INDICATOR EYE (if equipped)
9 - ELECTROLYTE LEVEL
Fig. 5 BATTERY CELL CAP REMOVAL/ 10 - PLATE GROUPS
INSTALLATION - LOW-MAINTANANCE GASOLINE 11 - MAINTENANCE-FREE BATTERY
ENGINE BATTERY - EXPORT
ch a r gin g syst em a r e n ot oper a t in g. Th e ba t t er y is
1 - BATTERY CELL CAP
2 - BATTERY CASE m a de u p of six in dividu a l cells t h a t a r e con n ect ed in
ser ies. E a ch cell con t a in s posit ively ch a r ged pla t e
Lo w -m a in te n a n c e ba tte rie s a r e u sed on expor t gr ou ps t h a t a r e con n ect ed wit h lea d st r a ps t o t h e
veh icles equ ipped wit h a ga solin e en gin e, t h ese ba t - posit ive t er m in a l post , a n d n ega t ively ch a r ged pla t e
t er ies h a ve r em ova ble ba t t er y cell ca ps (F ig. 5). gr ou ps t h a t a r e con n ect ed wit h lea d st r a ps t o t h e
Wa t er c a n be a dded t o t h is ba t t er y. Un der n or m a l n ega t ive t er m in a l post . E a ch pla t e con sist s of a st iff
ser vice, t h e com posit ion of t h is ba t t er y r edu ces ga s- m esh fr a m ewor k or gr id coa t ed wit h lea d dioxide
sin g a n d wa t er loss a t n or m a l ch a r ge r a t es. H owever (posit ive pla t e) or spon ge lea d (n ega t ive pla t e). In su -
t h ese ba t t er ies m a y r equ ir e a ddit ion a l dist illed wa t er la t or s or pla t e sepa r a t or s m a de of a n on -con du ct ive
a ft er yea r s of ser vice. m a t er ia l a r e in ser t ed bet ween t h e posit ive a n d n ega -
Ma in te n a n c e -fre e ba tte rie s a r e st a n da r d fa ct o- t ive pla t es t o pr even t t h em fr om con t a ct in g or sh or t -
r y-in st a lled equ ipm en t on a ll dom est ic veh icles. Ma le in g a ga in st on e a n ot h er. Th ese dissim ila r m et a l
post t ype t er m in a ls m a de of a soft lea d m a t er ia l pr o- pla t es a r e su bm er ged in a su lfu r ic a cid a n d wa t er
t r u de fr om t h e t op of t h e m olded pla st ic ba t t er y ca se solu t ion ca lled a n elect r olyt e.
(F ig. 6)t o pr ovide t h e m ea n s for con n ect in g t h e ba t - Som e fa ct or y-in st a lled ba t t er ies h a ve a bu ilt -in t est
t er y t o t h e veh icle elect r ica l syst em . Th e ba t t er y pos- in dica t or (h ydr om et er ). Th e color visible in t h e sigh t
it ive t er m in a l post is visibly la r ger in dia m et er t h a n gla ss of t h e in dica t or will r evea l t h e ba t t er y con di-
t h e n ega t ive t er m in a l post , for ea sy iden t ifica t ion . t ion . F or m or e in for m a t ion on t h e u se of t h e bu ilt -in
Th e let t er s P OS a n d N EG a r e a lso m olded in t o t h e t est in dica t or, r efer t o S ta n d a rd P ro c e d u re s . Th e
t op of t h e ba t t er y ca se a dja cen t t o t h eir r espect ive ch em ica l com posit ion of t h e m et a l coa t ed pla t es
posit ive a n d n ega t ive t er m in a l post s for a ddit ion a l wit h in t h e low-m a in t en a n ce ba t t er y u sed in expor t
iden t ifica t ion con fir m a t ion . m odels r edu ces ba t t er y ga ssin g a n d wa t er loss a t
Th is ba t t er y is design ed t o pr ovide a sa fe, efficien t n or m a l ch a r ge a n d disch a r ge r a t es. Th er efor e, t h e
a n d r elia ble m ea n s of st or in g elect r ica l en er gy in a ba t t er y sh ou ld n ot r equ ir e a ddit ion a l wa t er in n or-
ch em ica l for m . Th is m ea n s of en er gy st or a ge a llows m a l ser vice. If t h e elect r olyt e level in t h is ba t t er y
t h e ba t t er y t o pr odu ce t h e elect r ica l en er gy r equ ir ed does becom e low, dist illed wa t er m u st be a dded. H ow-
t o oper a t e t h e en gin e st a r t in g syst em , a s well a s t o ever, r a pid loss of elect r olyt e ca n be ca u sed by a n
oper a t e m a n y of t h e ot h er veh icle a ccessor y syst em s over ch a r gin g con dit ion . Be cer t a in t o dia gn ose t h e
for lim it ed du r a t ion s wh ile t h e en gin e a n d/or t h e ch a r gin g syst em a ft er r eplen ish in g t h e wa t er in t h e
ba t t er y for a low elect r olyt e con dit ion a n d befor e a r c in t er n a lly a n d explode. If t h e ba t t er y is equ ipped
r et u r n in g t h e veh icle t o ser vice. (Refer t o 8 - E LE C- wit h r em ova ble cell ca ps, a dd dist illed wa t er wh en -
TRICAL/CH ARGING - DIAGNOSIS AND TE STING) ever t h e elect r olyt e level is below t h e t op of t h e
for a ddit ion a l in for m a t ion . pla t es. If t h e ba t t er y cell ca ps ca n n ot be r em oved, t h e
Th e ba t t er y Gr ou p Size n u m ber, t h e Cold Cr a n kin g ba t t er y m u st be r epla ced if t h e elect r olyt e level
Am per a ge (CCA) r a t in g, a n d t h e Reser ve Ca pa cit y becom es low.
(RC) r a t in g or Am per e-H ou r s (AH ) r a t in g ca n be
fou n d on t h e or igin a l equ ipm en t ba t t er y la bel. Be
cer t a in t h a t a r epla cem en t ba t t er y h a s t h e cor r ect DI AGN OSI S AN D T EST I N G
Gr ou p Size n u m ber, a s well a s CCA, a n d RC or AH
r a t in gs t h a t equ a l or exceed t h e or igin a l equ ipm en t BATTERY
specifica t ion for t h e veh icle bein g ser viced. (Refer t o Th e ba t t er y m u st be com plet ely ch a r ged a n d t h e
8 - E LE CTRICAL/BATTE RY SYSTE M - SP E CIF ICA- t er m in a ls sh ou ld be pr oper ly clea n ed a n d in spect ed
TIONS) for t h e pr oper fa ct or y-in st a lled ba t t er y spec- befor e dia gn ost ic pr ocedu r es a r e per for m ed. (Refer t o
ifica t ion s. 8 - E LE CTRICAL/BATTE RY SYSTE M - CLE ANING)
for t h e pr oper clea n in g pr ocedu r es, a n d (Refer t o 8 -
OPERATION E LE CTRICAL/BATTE RY SYSTE M - INSP E CTION)
Th e ba t t er y is design ed t o st or e elect r ica l en er gy in for t h e pr oper ba t t er y in spect ion pr ocedu r es. (Refer
a ch em ica l for m . Wh en a n elect r ica l loa d is a pplied t o t o 8 - E LE CTRICAL/BATTE RY SYSTE M/BATTE RY -
t h e t er m in a ls of t h e ba t t er y, a n elect r och em ica l r ea c- STANDARD P ROCE DURE ) for t h e pr oper ba t t er y
t ion occu r s. Th is r ea ct ion ca u ses t h e ba t t er y t o disch a r gin g pr ocedu r es.
ch a r ge elect r ica l cu r r en t fr om it s t er m in a ls. As t h e
ba t t er y disch a r ges, a gr a du a l ch em ica l ch a n ge t a kes MICRO 420 BATTERY TESTER
pla ce wit h in ea ch cell. Th e su lfu r ic a cid in t h e elec- Th e Micr o 420 a u t om ot ive ba t t er y t est er is
t r olyt e com bin es wit h t h e pla t e m a t er ia ls, ca u sin g design ed t o h elp t h e dea ler sh ip t ech n icia n s dia gn ose
bot h pla t es t o slowly ch a n ge t o lea d su lfa t e. At t h e t h e ca u se of a defect ive ba t t er y. F ollow t h e in st r u c-
sa m e t im e, oxygen fr om t h e posit ive pla t e m a t er ia l t ion m a n u a l su pplied wit h t h e t est er or (Refer t o 8 -
com bin es wit h h ydr ogen fr om t h e su lfu r ic a cid, ca u s- E LE CTRICAL/BATTE RY SYSTE M/BATTE RY -
in g t h e elect r olyt e t o becom e m a in ly wa t er. Th e STANDARD P ROCE DURE - USING TH E MICRO
ch em ica l ch a n ges wit h in t h e ba t t er y a r e ca u sed by 420 BATTE RY TE STE R) t o pr oper ly dia gn ose a veh i-
t h e m ovem en t of excess or fr ee elect r on s bet ween t h e cle
posit ive a n d n ega t ive pla t e gr ou ps. Th is m ovem en t of
WARNING: IF THE BATTERY SHOWS SIGNS OF
elect r on s pr odu ces a flow of elect r ica l cu r r en t
FREEZING, LEAKING OR LOOSE POSTS, DO NOT
t h r ou gh t h e loa d device a t t a ch ed t o t h e ba t t er y t er-
TEST, ASSIST-BOOST, OR CHARGE. THE BATTERY
m in a ls.
MAY ARC INTERNALLY AND EXPLODE. PERSONAL
As t h e pla t e m a t er ia ls becom e m or e sim ila r ch em -
INJURY AND/OR VEHICLE DAMAGE MAY RESULT.
ica lly, a n d t h e elect r olyt e becom es less a cid, t h e volt -
a ge pot en t ia l of ea ch cell is r edu ced. H owever, by
ch a r gin g t h e ba t t er y wit h a volt a ge h igh er t h a n t h a t WARNING: EXPLOSIVE HYDROGEN GAS FORMS IN
of t h e ba t t er y it self, t h e ba t t er y disch a r gin g pr ocess AND AROUND THE BATTERY. DO NOT SMOKE,
is r ever sed. Ch a r gin g t h e ba t t er y gr a du a lly ch a n ges USE FLAME, OR CREATE SPARKS NEAR THE BAT-
t h e su lfa t ed lea d pla t es ba ck in t o spon ge lea d a n d TERY. PERSONAL INJURY AND/OR VEHICLE DAM-
lea d dioxide, a n d t h e wa t er ba ck in t o su lfu r ic a cid. AGE MAY RESULT.
Th is a ct ion r est or es t h e differ en ce in t h e elect r on
ch a r ges deposit ed on t h e pla t es, a n d t h e volt a ge
pot en t ia l of t h e ba t t er y cells. F or a ba t t er y t o r em a in WARNING: THE BATTERY CONTAINS SULFURIC
u sefu l, it m u st be a ble t o pr odu ce h igh -a m per a ge cu r- ACID, WHICH IS POISONOUS AND CAUSTIC. AVOID
r en t over a n ext en ded per iod. A ba t t er y m u st a lso be CONTACT WITH THE SKIN, EYES, OR CLOTHING.
a ble t o a ccept a ch a r ge, so t h a t it s volt a ge pot en t ia l IN THE EVENT OF CONTACT, FLUSH WITH WATER
m a y be r est or ed. AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT
Th e ba t t er y is ven t ed t o r elea se excess h ydr ogen OF THE REACH OF CHILDREN.
ga s t h a t is cr ea t ed wh en t h e ba t t er y is bein g ch a r ged
or disch a r ged. H owever, even wit h t h ese ven t s, A ba t t er y t h a t will n ot a ccept a ch a r ge is in oper a -
h ydr ogen ga s ca n collect in or a r ou n d t h e ba t t er y. If t ive, a n d m u st be r epla ced. F u r t h er t est in g is n ot
h ydr ogen ga s is exposed t o fla m e or spa r ks, it m a y r equ ir ed. A fu lly-ch a r ged ba t t er y m u st be t est ed t o
ign it e. If t h e elect r olyt e level is low, t h e ba t t er y m a y det er m in e it s cr a n kin g ca pa cit y. A ba t t er y t h a t is fu l-
ly-ch a r ged, bu t does n ot pa ss t h e Micr o 420 or loa d Clea n a n d in spect t h e ba t t er y h old down s, t r a y,
t est , is in oper a t ive a n d m u st be r epla ced. t er m in a ls, post s, a n d t op befor e com plet in g ba t t er y
ser vice. (Refer t o 8 - E LE CTRICAL/BATTE RY SYS-
NOTE: Completely discharged batteries may take TE M - CLE ANING) for t h e pr oper ba t t er y syst em
several hours to accept a charge. (Refer to 8 - clea n in g pr ocedu r es, a n d (Refer t o 8 - E LE CTRICAL/
ELECTRICAL/BATTERY SYSTEM/BATTERY - STAN- BATTE RY SYSTE M - INSP E CTION) for t h e pr oper
DARD PROCEDURE) for the proper battery charging ba t t er y syst em in spect ion pr ocedu r es.
procedures.
CHARGING A COMPLETELY DISCHARGED
BATTERY – SPIRAL PLATE BATTERY
STAN DARD PROCEDU RE Th e followin g pr ocedu r e sh ou ld be u sed t o r ech a r ge
a com plet ely disch a r ged ba t t er y. Un less t h is pr oce-
SPIRAL PLATE BATTERY CHARGING du r e is pr oper ly followed, a good ba t t er y m a y be
Veh icles equ ipped wit h a diesel en gin e u t ilize a n eedlessly r epla ced.
u n iqu e spir a l pla t e ba t t er y. Th is ba t t er y h a s a m a xi- (1) Mea su r e t h e volt a ge a t t h e ba t t er y post s wit h a
m u m ch a r gin g volt a ge t h a t m u st n ot be exceeded in volt m et er, a ccu r a t e t o 1/10 (0.10) volt (F ig. 7). (Refer
or der t o r est or e t h e ba t t er y t o it s fu ll pot en t ia l, fa il- t o 8 - E LE CTRICAL/BATTE RY SYSTE M/BATTE RY -
u r e t o u se t h e followin g spir a l pla t e ba t t er y ch a r gin g RE MOVAL) for in st r u ct ion s on h ow t o a ccess t h e ba t -
pr ocedu r e cou ld r esu lt in da m a ge t o t h e ba t t er y or t er y. If t h e r ea din g is below t en volt s, t h e ba t t er y
per son a l in ju r y. ch a r gin g cu r r en t will be low. It cou ld t a ke sever a l
Ba t t er y ch a r gin g is t h e m ea n s by wh ich t h e ba t - h ou r s befor e t h e ba t t er y a ccept s a cu r r en t gr ea t er
t er y ca n be r est or ed t o it s fu ll volt a ge pot en t ia l. A t h a n a few m illia m per es. Su ch low cu r r en t m a y n ot
ba t t er y is fu lly-ch a r ged wh en : be det ect a ble on t h e a m m et er s bu ilt in t o m a n y ba t -
• Micr o 420 ba t t er y t est er in dica t es ba t t er y is OK. t er y ch a r ger s.
• Open -cir cu it volt a ge of t h e ba t t er y is 12.65 volt s
or a bove.
• Ba t t er y pa sses Loa d Test m u lt iple t im es.
WARNING: IF THE BATTERY SHOWS SIGNS OF

FREEZING, LEAKING, LOOSE POSTS OR LOW
ELECTROLYTE LEVEL, DO NOT TEST, ASSIST-
BOOST, OR CHARGE. THE BATTERY MAY ARC
INTERNALLY AND EXPLODE. PERSONAL INJURY
AND/OR VEHICLE DAMAGE MAY RESULT.
CAUTION: Always disconnect and isolate the bat-

tery negative cable before charging a battery.
Charge the battery directly at the battery terminals.
Do not exceed 14.4 volts while charging a battery. Fig. 7 Voltmeter - Typical
CAUTION: The battery should not be hot to the ca ble. Con n ect t h e ba t t er y ch a r ger lea ds. Som e ba t -
touch. If the battery feels hot to the touch, turn off t er y ch a r ger s a r e equ ipped wit h pola r it y-sen sin g cir-
the charger and let the battery cool before continu- cu it r y. Th is cir cu it r y pr ot ect s t h e ba t t er y ch a r ger a n d
ing the charging operation. Damage to the battery t h e ba t t er y fr om bein g da m a ged if t h ey a r e im pr op-
may result. er ly con n ect ed. If t h e ba t t er y st a t e-of-ch a r ge is t oo
low for t h e pola r it y-sen sin g cir cu it r y t o det ect , t h e
Aft er t h e ba t t er y h a s been ch a r ged t o 12.6 volt s or ba t t er y ch a r ger will n ot oper a t e. Th is m a kes it
gr ea t er, per for m a loa d t est t o det er m in e t h e ba t t er y a ppea r t h a t t h e ba t t er y will n ot a ccept ch a r gin g cu r-
cr a n kin g ca pa cit y. (Refer t o 8 - E LE CTRICAL/BAT- r en t . See t h e in st r u ct ion s pr ovided by t h e m a n u fa c-
TE RY SYSTE M/BATTE RY - STANDARD P ROCE - t u r er of t h e ba t t er y ch a r ger for det a ils on h ow t o
DURE - USING TH E MICRO 420 BATTE RY bypa ss t h e pola r it y-sen sin g cir cu it r y.
TE STE R) for t h e pr oper ba t t er y t est pr ocedu r es. If (3) Ba t t er y ch a r ger s va r y in t h e a m ou n t of volt a ge
t h e ba t t er y pa sses a loa d t est , r et u r n t h e ba t t er y t o a n d cu r r en t t h ey pr ovide. Th e a m ou n t of t im e
ser vice. If t h e ba t t er y will n ot pa ss a loa d t est , it is r equ ir ed for a ba t t er y t o a ccept m ea su r a ble ch a r gin g
in oper a t ive a n d m u st be r epla ced. cu r r en t a t va r iou s volt a ges is sh own in t h e Ch a r ge
Ra t e Ta ble. If t h e ch a r gin g cu r r en t is st ill n ot m ea - CONVENTIONAL BATTERY CHARGING
su r a ble a t t h e en d of t h e ch a r gin g t im e, t h e ba t t er y Veh icles equ ipped wit h a diesel en gin e u t ilize a
is in oper a t ive a n d m u st be r epla ced. If t h e ch a r gin g u n iqu e spir a l pla t e ba t t er y. Th is ba t t er y h a s a m a xi-
cu r r en t is m ea su r a ble du r in g t h e ch a r gin g t im e, t h e m u m ch a r gin g volt a ge t h a t m u st be u sed in or der t o
ba t t er y m a y be good a n d t h e ch a r gin g sh ou ld be com - r est or e t h e ba t t er y t o it s fu ll pot en t ia l, fa ilu r e t o u se
plet ed in t h e n or m a l m a n n er. t h e spir a l pla t e ba t t er y ch a r gin g pr ocedu r e cou ld
r esu lt in da m a ge t o t h e ba t t er y or per son a l in ju r y.
SPIRAL-PLATE BATTERY CHARGE RATE TABLE Ba t t er y ch a r gin g is t h e m ea n s by wh ich t h e ba t -
Voltage Minutes t er y ca n be r est or ed t o it s fu ll volt a ge pot en t ia l. A
ba t t er y is fu lly-ch a r ged wh en :
14.4 volts maximum up to 10 minutes • Micr o 420 ba t t er y t est er in dica t es ba t t er y is OK.
13.0 to 14 volts up to 20 minutes • Open -cir cu it volt a ge of t h e ba t t er y is 12.65 volt s
12.9 volts or less up to 30 minutes or a bove.
• Ba t t er y pa sses Loa d Test m u lt iple t im es.
CHARGING TIME REQUIRED WARNING: IF THE BATTERY SHOWS SIGNS OF
Th e t im e r equ ir ed t o ch a r ge a ba t t er y will va r y, FREEZING, LEAKING, LOOSE POSTS, DO NOT
depen din g u pon t h e followin g fa ct or s: TEST, ASSIST-BOOST, OR CHARGE. THE BATTERY
• B a tte ry Ca p a c ity - A com plet ely disch a r ged MAY ARC INTERNALLY AND EXPLODE. PERSONAL
h ea vy-du t y ba t t er y r equ ir es t wice t h e ch a r gin g t im e INJURY AND/OR VEHICLE DAMAGE MAY RESULT.
of a sm a ll ca pa cit y ba t t er y.
• Te m p e ra tu re - A lon ger t im e will be n eeded t o
ch a r ge a ba t t er y a t -18° C (0° F ) t h a n a t 27° C (80° WARNING: EXPLOSIVE HYDROGEN GAS FORMS IN
F ). Wh en a fa st ba t t er y ch a r ger is con n ect ed t o a cold AND AROUND THE BATTERY. DO NOT SMOKE,
ba t t er y, t h e cu r r en t a ccept ed by t h e ba t t er y will be USE FLAME, OR CREATE SPARKS NEAR THE BAT-
ver y low a t fir st . As t h e ba t t er y wa r m s, it will a ccept TERY. PERSONAL INJURY AND/OR VEHICLE DAM-
a h igh er ch a r gin g cu r r en t r a t e (a m per a ge). AGE MAY RESULT.
• Ch a rg e r Ca p a c ity - A ba t t er y ch a r ger t h a t
su pplies on ly five a m per es will r equ ir e a lon ger
WARNING: THE BATTERY CONTAINS SULFURIC
ch a r gin g t im e. A ba t t er y ch a r ger t h a t su pplies eigh t
ACID, WHICH IS POISONOUS AND CAUSTIC. AVOID
a m per es will r equ ir e a sh or t er ch a r gin g t im e.
CONTACT WITH THE SKIN, EYES, OR CLOTHING.
• S ta te -Of-Ch a rg e - A com plet ely disch a r ged ba t -
IN THE EVENT OF CONTACT, FLUSH WITH WATER
t er y r equ ir es m or e ch a r gin g t im e t h a n a pa r t ia lly
AND CALL A PHYSICIAN IMMEDIATELY. KEEP OUT
disch a r ged ba t t er y. E lect r olyt e is n ea r ly pu r e wa t er
OF THE REACH OF CHILDREN.
in a com plet ely disch a r ged ba t t er y. At fir st , t h e
ch a r gin g cu r r en t (a m per a ge) will be low. As t h e ba t -
t er y ch a r ges, t h e specific gr a vit y of t h e elect r olyt e WARNING: IF THE BATTERY IS EQUIPPED WITH
will gr a du a lly r ise. REMOVABLE CELL CAPS, BE CERTAIN THAT EACH
Th e Ba t t er y Ch a r gin g Tim e Ta ble gives a n in dica - OF THE CELL CAPS IS IN PLACE AND TIGHT
t ion of t h e t im e r equ ir ed t o ch a r ge a t ypica l ba t t er y BEFORE THE BATTERY IS RETURNED TO SER-
a t r oom t em per a t u r e ba sed u pon t h e ba t t er y st a t e-of- VICE. PERSONAL INJURY AND/OR VEHICLE DAM-
ch a r ge a n d t h e ch a r ger ca pa cit y. AGE MAY RESULT FROM LOOSE OR MISSING
CELL CAPS.
SPIRAL-PLATE BATTERY CHARGING TIME
TABLE
CAUTION: Always disconnect and isolate the bat-
Charging tery negative cable before charging a battery. Do
5 Amps 8 Amps
Amperage not exceed sixteen volts while charging a battery.
Open Circuit Hours Charging @ 21° Damage to the vehicle electrical system compo-
Voltage C (70° F) nents may result.
12.25 to 12.49 6 hours 3 hours
12.00 to 12.24 10 hours 5 hours
10.00 to 11.99 14 hours 7 hours
Below 10.00 18 hours 9 hours
CAUTION: Battery electrolyte will bubble inside the
battery case during normal battery charging. Elec-
trolyte boiling or being discharged from the battery
vents indicates a battery overcharging condition.
Immediately reduce the charging rate or turn off the
charger to evaluate the battery condition. Damage
to the battery may result from overcharging.
CAUTION: The battery should not be hot to the

touch. If the battery feels hot to the touch, turn off
the charger and let the battery cool before continu-
ing the charging operation. Damage to the battery
may result.
Aft er t h e ba t t er y h a s been ch a r ged t o a n open -cir-

cu it volt a ge r ea din g of 12.4 volt s or gr ea t er, r et est
t h e ba t t er y wit h t h e Micr o 420 t est er or per for m a
loa d t est t o det er m in e t h e ba t t er y cr a n kin g ca pa cit y.
(Refer t o 8 - E LE CTRICAL/BATTE RY SYSTE M/BAT-
Fig. 8 VOLTMETER ACCURATE TO 1/10 VOLT
TE RY - STANDARD P ROCE DURE ) for t h e pr oper
ba t t er y loa d t est pr ocedu r es. If t h e ba t t er y pa sses a t u r er of t h e ba t t er y ch a r ger for det a ils on h ow t o
loa d t est , r et u r n t h e ba t t er y t o ser vice. If t h e ba t t er y bypa ss t h e pola r it y-sen sin g cir cu it r y.
will n ot pa ss a loa d t est , it is in oper a t ive a n d m u st (3) Ba t t er y ch a r ger s va r y in t h e a m ou n t of volt a ge
be r epla ced. a n d cu r r en t t h ey pr ovide. Th e a m ou n t of t im e
Clea n a n d in spect t h e ba t t er y h old down s, t r a y, r equ ir ed for a ba t t er y t o a ccept m ea su r a ble ch a r gin g
t er m in a ls, post s, a n d t op befor e com plet in g ba t t er y cu r r en t a t va r iou s volt a ges is sh own in t h e Ch a r ge
ser vice. (Refer t o 8 - E LE CTRICAL/BATTE RY SYS- Ra t e Ta ble. If t h e ch a r gin g cu r r en t is st ill n ot m ea -
TE M - CLE ANING) for t h e pr oper ba t t er y syst em su r a ble a t t h e en d of t h e ch a r gin g t im e, t h e ba t t er y
clea n in g pr ocedu r es, a n d (Refer t o 8 - E LE CTRICAL/ is in oper a t ive a n d m u st be r epla ced. If t h e ch a r gin g
BATTE RY SYSTE M - INSP E CTION) for t h e pr oper cu r r en t is m ea su r a ble du r in g t h e ch a r gin g t im e, t h e
ba t t er y syst em in spect ion pr ocedu r es. ba t t er y m a y be good a n d t h e ch a r gin g sh ou ld be com -
plet ed in t h e n or m a l m a n n er.
CHARGING A COMPLETELY DISCHARGED
CONVENTIONAL BATTERY CONVENTIONAL BATTERY CHARGE RATE TABLE
Th e followin g pr ocedu r e sh ou ld be u sed t o r ech a r ge Voltage Minutes
a com plet ely disch a r ged ba t t er y. Un less t h is pr oce-
du r e is pr oper ly followed, a good ba t t er y m a y be 16.0 volts maximum up to 10 min.
n eedlessly r epla ced. 14.0 to 15.9 volts up to 20 min.
(1) Mea su r e t h e volt a ge a t t h e ba t t er y post s wit h a 13.9 volts or less up to 30 min.
volt m et er, a ccu r a t e t o 1/10 (0.10) volt (F ig. 8). If t h e
r ea din g is below t en volt s, t h e ba t t er y ch a r gin g cu r-
r en t will be low. It cou ld t a ke som e t im e befor e t h e
CHARGING TIME REQUIRED
ba t t er y a ccept s a cu r r en t gr ea t er t h a n a few m illia m - Th e t im e r equ ir ed t o ch a r ge a ba t t er y will va r y,
per es. Su ch low cu r r en t m a y n ot be det ect a ble on t h e depen din g u pon t h e followin g fa ct or s:
a m m et er s bu ilt in t o m a n y ba t t er y ch a r ger s. • B a tte ry Ca p a c ity - A com plet ely disch a r ged
(2) Discon n ect a n d isola t e t h e ba t t er y n ega t ive h ea vy-du t y ba t t er y r equ ir es t wice t h e ch a r gin g t im e
ca ble. Con n ect t h e ba t t er y ch a r ger lea ds. Som e ba t - of a sm a ll ca pa cit y ba t t er y.
t er y ch a r ger s a r e equ ipped wit h pola r it y-sen sin g cir- • Te m p e ra tu re - A lon ger t im e will be n eeded t o
cu it r y. Th is cir cu it r y pr ot ect s t h e ba t t er y ch a r ger a n d ch a r ge a ba t t er y a t -18° C (0° F ) t h a n a t 27° C (80°
t h e ba t t er y fr om bein g da m a ged if t h ey a r e im pr op- F ). Wh en a fa st ba t t er y ch a r ger is con n ect ed t o a cold
er ly con n ect ed. If t h e ba t t er y st a t e-of-ch a r ge is t oo ba t t er y, t h e cu r r en t a ccept ed by t h e ba t t er y will be
low for t h e pola r it y-sen sin g cir cu it r y t o det ect , t h e ver y low a t fir st . As t h e ba t t er y wa r m s, it will a ccept
ba t t er y ch a r ger will n ot oper a t e. Th is m a kes it a h igh er ch a r gin g cu r r en t r a t e (a m per a ge).
a ppea r t h a t t h e ba t t er y will n ot a ccept ch a r gin g cu r- • Ch a rg e r Ca p a c ity - A ba t t er y ch a r ger t h a t
r en t . See t h e in st r u ct ion s pr ovided by t h e m a n u fa c- su pplies on ly five a m per es will r equ ir e a lon ger
ch a r gin g t im e. A ba t t er y ch a r ger t h a t su pplies
t wen t y a m per es or m or e will r equ ir e a sh or t er ch a r g- ca pa cit y. (Refer t o 8 - E LE CTRICAL/BATTE RY SYS-
in g t im e. TE M/BATTE RY - STANDARD P ROCE DURE -
• S ta te -Of-Ch a rg e - A com plet ely disch a r ged ba t - USING TH E MICRO 420 BATTE RY TE STE R) for
t er y r equ ir es m or e ch a r gin g t im e t h a n a pa r t ia lly t h e pr oper ba t t er y loa d t est pr ocedu r es.
disch a r ged ba t t er y. E lect r olyt e is n ea r ly pu r e wa t er
in a com plet ely disch a r ged ba t t er y. At fir st , t h e OPEN CIRCUIT VOLTAGE TABLE
ch a r gin g cu r r en t (a m per a ge) will be low. As t h e ba t -
t er y ch a r ges, t h e specific gr a vit y of t h e elect r olyt e Open Circuit Voltage Charge Percentage
will gr a du a lly r ise. 11.7 volts or less 0%
Th e Con ven t ion a l Ba t t er y Ch a r gin g Tim e Ta ble 12.0 volts 25%
gives a n in dica t ion of t h e t im e r equ ir ed t o ch a r ge a
12.2 volts 50%
t ypica l ba t t er y a t r oom t em per a t u r e ba sed u pon t h e
ba t t er y st a t e-of-ch a r ge a n d t h e ch a r ger ca pa cit y. 12.45 volts 75%
12.65 volts or more 100%
CONVENTIONAL BATTERY CHARGING TIME TABLE
Charging 10 IGNITION-OFF DRAW TEST
5 Amps 20 Amps Th e t er m Ign it ion -Off Dr a w (IOD) iden t ifies a n or-
Amperage Amps
m a l con dit ion wh er e power is bein g dr a in ed fr om t h e
Open Circuit Hours Charging @ 21° C (70° ba t t er y wit h t h e ign it ion swit ch in t h e Off posit ion . A
Voltage F) n or m a l veh icle elect r ica l syst em will dr a w fr om fif-
12.25 to 12.49 6 hours 3 hours 1.5 t een t o t wen t y-five m illia m per es (0.015 t o 0.025
hours a m per e) wit h t h e ign it ion swit ch in t h e Off posit ion ,
12.00 to 12.24 10 hours 5 hours 2.5 a n d a ll n on -ign it ion con t r olled cir cu it s in pr oper
hours wor kin g or der. Up t o t wen t y-five m illia m per es a r e
n eeded t o en a ble t h e m em or y fu n ct ion s for t h e P ow-
10.00 to 11.99 14 hours 7 hours 3.5
er t r a in Con t r ol Modu le (P CM), digit a l clock, elect r on -
hours
ica lly t u n ed r a dio, a n d ot h er m odu les wh ich m a y
Below 10.00 18 hours 9 hours 4.5 va r y wit h t h e veh icle equ ipm en t .
hours A veh icle t h a t h a s n ot been oper a t ed for a ppr oxi-
m a t ely t wen t y-on e da ys, m a y disch a r ge t h e ba t t er y
OPEN-CIRCUIT VOLTAGE TEST t o a n in a dequ a t e level. Wh en a veh icle will n ot be
A ba t t er y open -cir cu it volt a ge (n o loa d) t est will u sed for t wen t y-on e da ys or m or e (st or ed), r em ove
sh ow t h e a ppr oxim a t e st a t e-of-ch a r ge of a ba t t er y. t h e IOD fu se fr om t h e In t egr a t ed P ower Modu le
Th is t est ca n be u sed if n o ot h er ba t t er y t est er is (IP M). Th is will r edu ce ba t t er y disch a r gin g.
a va ila ble. E xcessive IOD ca n be ca u sed by:
Befor e pr oceedin g wit h t h is t est , com plet ely ch a r ge • E lect r ica l it em s left on .
t h e ba t t er y. (Refer t o 8 - E LE CTRICAL/BATTE RY • F a u lt y or im pr oper ly a dju st ed swit ch es.
SYSTE M/BATTE RY - STANDARD P ROCE DURE ) for • F a u lt y or sh or t ed elect r on ic m odu les a n d com po-
t h e pr oper ba t t er y ch a r gin g pr ocedu r es. n en t s.
(1) Befor e m ea su r in g t h e open -cir cu it volt a ge, t h e • An in t er n a lly sh or t ed gen er a t or.
su r fa ce ch a r ge m u st be r em oved fr om t h e ba t t er y. • In t er m it t en t sh or t s in t h e wir in g.
Tu r n on t h e h ea dla m ps for fift een secon ds, t h en If t h e IOD is over t wen t y-five m illia m per es, t h e
a llow u p t o five m in u t es for t h e ba t t er y volt a ge t o pr oblem m u st be fou n d a n d cor r ect ed befor e r epla c-
st a bilize. in g a ba t t er y. In m ost ca ses, t h e ba t t er y ca n be
(2) Discon n ect a n d isola t e bot h ba t t er y ca bles, n eg- ch a r ged a n d r et u r n ed t o ser vice a ft er t h e excessive
a t ive ca ble fir st . IOD con dit ion h a s been cor r ect ed.
(3) Usin g a volt m et er con n ect ed t o t h e ba t t er y (1) Ver ify t h a t a ll elect r ica l a ccessor ies a r e off.
post s (see t h e in st r u ct ion s pr ovided by t h e m a n u fa c- Tu r n off a ll la m ps, r em ove t h e ign it ion key, a n d close
t u r er of t h e volt m et er ), m ea su r e t h e open -cir cu it volt - a ll door s. If t h e veh icle is equ ipped wit h a n illu m i-
a ge. n a t ed en t r y syst em or a n elect r on ica lly t u n ed r a dio,
See t h e Open -Cir cu it Volt a ge Ta ble. Th is volt a ge a llow t h e elect r on ic t im er fu n ct ion of t h ese syst em s
r ea din g will in dica t e t h e ba t t er y st a t e-of-ch a r ge, bu t t o a u t om a t ica lly sh u t off (t im e ou t ). Th is m a y t a ke
will n ot r evea l it s cr a n kin g ca pa cit y. If a ba t t er y h a s u p t o t wen t y m in u t es.
a n open -cir cu it volt a ge r ea din g of 12.4 volt s or (2) Discon n ect t h e ba t t er y n ega t ive ca ble.
gr ea t er, it m a y be loa d t est ed t o r evea l it s cr a n kin g
(3) Set a n elect r on ic digit a l m u lt i-m et er t o it s a ge IOD sh ou ld n ot exceed t wen t y-five m illia m per es
h igh est a m per a ge sca le. Con n ect t h e m u lt i-m et er (0.025 a m per e). If t h e cu r r en t dr a w exceeds t wen t y-
bet ween t h e discon n ect ed ba t t er y n ega t ive ca ble t er- five m illia m per es, isola t e ea ch cir cu it u sin g t h e fu se
m in a l cla m p a n d t h e ba t t er y n ega t ive t er m in a l post . a n d cir cu it br ea ker r em ove-a n d-r epla ce pr ocess in
Ma ke su r e t h a t t h e door s r em a in closed so t h a t t h e St ep 4. Th e m u lt i-m et er r ea din g will dr op t o wit h in
illu m in a t ed en t r y syst em is n ot a ct iva t ed. Th e m u lt i- t h e a ccept a ble lim it wh en t h e sou r ce of t h e excessive
m et er a m per a ge r ea din g m a y r em a in h igh for u p t o cu r r en t dr a w is discon n ect ed. Repa ir t h is cir cu it a s
t h r ee m in u t es, or m a y n ot give a n y r ea din g a t a ll r equ ir ed; wh et h er a wir in g sh or t , in cor r ect swit ch
wh ile set in t h e h igh est a m per a ge sca le, depen din g a dju st m en t , or a com pon en t fa ilu r e is a t fa u lt .
u pon t h e elect r ica l equ ipm en t in t h e veh icle. Th e
m u lt i-m et er lea ds m u st be secu r ely cla m ped t o t h e CHECKING BATTERY ELECTROLYTE LEVEL
ba t t er y n ega t ive ca ble t er m in a l cla m p a n d t h e ba t - Th e followin g pr ocedu r e ca n be u sed t o ch eck t h e
t er y n ega t ive t er m in a l post . If con t in u it y bet ween t h e elect r olyt e level in a low-m a in t en a n ce lea d-a cid ba t -
ba t t er y n ega t ive t er m in a l post a n d t h e n ega t ive ca ble t er y.
t er m in a l cla m p is lost du r in g a n y pa r t of t h e IOD (1) Un scr ew a n d r em ove t h e ba t t er y cell ca ps wit h
t est , t h e elect r on ic t im er fu n ct ion will be a ct iva t ed a fla t -bla ded scr ew dr iver (F ig. 9).
a n d a ll of t h e t est s will h a ve t o be r epea t ed.
(4) Aft er a bou t t h r ee m in u t es, t h e h igh -a m per a ge
IOD r ea din g on t h e m u lt i-m et er sh ou ld becom e ver y
low or n on exist en t , depen din g u pon t h e elect r ica l
equ ipm en t in t h e veh icle. If t h e a m per a ge r ea din g
r em a in s h igh , r em ove a n d r epla ce ea ch fu se or cir cu it
br ea ker in t h e In t egr a t ed P ower Modu le (IP M), on e
a t a t im e u n t il t h e a m per a ge r ea din g becom es ver y
low, or n on exist en t . Refer t o t h e a ppr opr ia t e wir in g
in for m a t ion for com plet e In t egr a t ed P ower Modu le
fu se, cir cu it br ea ker, a n d cir cu it iden t ifica t ion . Th is
will isola t e ea ch cir cu it a n d iden t ify t h e cir cu it t h a t
is t h e sou r ce of t h e h igh -a m per a ge IOD. If t h e
a m per a ge r ea din g r em a in s h igh a ft er r em ovin g a n d
r epla cin g ea ch fu se a n d cir cu it br ea ker, discon n ect
t h e wir e h a r n ess fr om t h e gen er a t or. If t h e a m per a ge
r ea din g n ow becom es ver y low or n on exist en t , (Refer
t o 8 - E LE CTRICAL/CH ARGING - DIAGNOSIS AND
TE STING) for t h e pr oper ch a r gin g syst em dia gn osis
a n d t est in g pr ocedu r es. Aft er t h e h igh -a m per a ge IOD
h a s been cor r ect ed, swit ch t h e m u lt i-m et er t o pr o-
gr essively lower a m per a ge sca les a n d, if n ecessa r y,
r epea t t h e fu se a n d cir cu it br ea ker r em ove-a n d-r e-
Fig. 9 BATTERY CELL CAP REMOVAL/
pla ce pr ocess t o iden t ify a n d cor r ect a ll sou r ces of
INSTALLATION - LOW-MAINTENANCE BATTERY
excessive IOD. It is n ow sa fe t o select t h e lowest m il-
ONLY
lia m per e sca le of t h e m u lt i-m et er t o ch eck t h e low-
1 - BATTERY CELL CAP
a m per a ge IOD. 2 - BATTERY CASE
CAUTION: Do not open any doors, or turn on any WARNING: NEVER PUT YOUR FACE NEAR A GAS-
electrical accessories with the lowest milliampere SING, HOT OR SWELLED BATTERY. SERIOUS PER-
scale selected, or the multi-meter may be damaged. SONAL INJURY MAY RESULT.
(5) Allow t wen t y m in u t es for t h e IOD t o st a bilize
a n d obser ve t h e m u lt i-m et er r ea din g. Th e low-a m per-
(2) Wea r in g sa fet y gla sses, look t h r ou gh t h e ba t -
t er y cell ca p h oles t o det er m in e t h e level of t h e elec-
t r olyt e in t h e ba t t er y. Th e elect r olyt e sh ou ld be a bove
t h e h ooks in side t h e ba t t er y cells (F ig. 10).
Fig. 11 Micro 420 Battery Tester

is a t th e ba tte ry te rm in a l. If t h e ba t t er y is n ot
a ccessible, you m a y t est u sin g bot h t h e posit ive a n d
n ega t ive ju m per post s. Select TE STING AT J UMP E R
Fig. 10 HOOK INSIDE BATTERY CELLS - LOW-
P OST wh en con n ect in g t o t h a t loca t ion .
MAINTENANCE BATTERY ONLY
(3) Con n ect t h e t est er t o t h e ba t t er y or ju m per
1 - TOP OF BATTERY
2 - HOOK INSIDE BATTERY CELLS
post s, t h e r ed cla m p t o posit ive (+) a n d t h e bla ck
cla m p t o n ega t ive (–).
(3) Ad d o n ly d is tille d w a te r u n t il t h e elect r olyt e
is a bove t h e h ooks in side t h e ba t t er y cells (F ig. 10). NOTE: Multiple batteries connected in parallel must
have the ground cable disconnected to perform a
MICRO 420 BATTERY TESTER battery test. Failure to disconnect may result in
false battery test readings.
Alwa ys u se t h e Micr o 420 In st r u ct ion Ma n u a l t h a t
wa s su pplied wit h t h e t est er a s a r efer en ce. If t h e (4) Usin g t h e ARROW key select in or o u t of veh i-
In st r u ct ion Ma n u a l is n ot a va ila ble t h e followin g pr o- cle t est in g a n d pr ess E NTE R t o m a ke a select ion .
cedu r e ca n be u sed: (5) If n ot select ed, ch oose t h e Cold Cr a n kin g Am p
(CCA) ba t t er y r a t in g. Or select t h e a ppr opr ia t e ba t -
WARNING: ALWAYS WEAR APPROPRIATE EYE
t er y r a t in g for you r a r ea (see m en u ). Th e t est er will
PROTECTION AND USE EXTREME CAUTION WHEN
t h en r u n it s self pr ogr a m m ed t est of t h e ba t t er y a n d
WORKING WITH BATTERIES.
displa y t h e r esu lt s. Refer t o t h e t est r esu lt t a ble
n ot ed below.
BATTERY TESTING
CAUTION: If REPLACE BATTERY is the result of the
(1) If t est in g t h e ba t t er y OUT-OF -VE H ICLE , clea n
test, this may mean a poor connection between the
t h e ba t t er y t er m in a ls wit h a wir e br u sh befor e t est -
vehicle’s cables and battery exists. After discon-
in g. If t h e ba t t er y is equ ipped wit h side post t er m i-
necting the vehicle’s battery cables from the bat-
n a ls, in st a ll a n d t igh t en t h e su pplied lea d t er m in a l
tery, retest the battery using the OUT-OF-VEHICLE
st u d a da pt er s. Do n ot u se st eel bolt s. F a ilu r e t o pr op-
test before replacing.
er ly in st a ll t h e st u d a da pt er s, or u sin g st u d a da pt er s
t h a t a r e dir t y or wor n -ou t m a y r esu lt in fa lse t est (6) Wh ile viewin g t h e ba t t er y t est r esu lt , pr ess t h e
r ea din gs. CODE bu t t on a n d t h e t est er will pr om pt you for t h e
(2) If t est in g t h e ba t t er y IN-TH E -VE H ICLE , m a ke la st 4 digit s of t h e VIN. Use t h e UP /DOWN a r r ow
cer t a in a ll of t h e veh icle a ccessor y loa ds a r e OF F, bu t t on s t o scr oll t o t h e cor r ect ch a r a ct er ; t h en pr ess
in clu din g t h e ign it ion . Th e p re fe rre d te s t p o s itio n E NTE R t o select a n d m ove t o t h e n ext digit . Th en
pr ess t h e E NTE R bu t t on t o view t h e SE RVICE
CODE . P r essin g t h e CODE bu t t on a secon d t im e will
r et u r n you t o t h e t est r esu lt s.
BATTERY TEST RESULTS

GOOD BATTERY Return to service
GOOD - RECHARGE Fully charge battery and
return to service
CHARGE & RETEST Fully charge battery and
retest battery
REPLACE BATTERY Replace the battery and
retest complete system
BAD-CELL REPLACE Replace the battery and
retest complete system
NOTE: The SERVICE CODE is required on every

warranty claim submitted for battery replacement.
REMOVAL - BATTERY
Fig. 12 BATTERY POSITION & ORIENTATION
WARNING: A SUITABLE PAIR OF HEAVY DUTY 1 - BATTERY THERMOWRAP (IF EQUIPPED)
RUBBER GLOVES AND SAFETY GLASSES SHOULD 2 - INTEGRATED POWER MODULE
BE WORN WHEN REMOVING OR SERVICING A 3 - FRONT CONTROL MODULE
BATTERY.
(1) Tu r n t h e ign it ion swit ch t o t h e Off posit ion . Be
cer t a in t h a t a ll elect r ica l a ccessor ies a r e t u r n ed off.
WARNING: REMOVE METALLIC JEWELRY TO (2) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
AVOID INJURY BY ACCIDENTAL ARCING OF BAT- ca ble.
TERY CURRENT. (3) Rem ove t h e n u t wit h wa sh er t h a t secu r es t h e
ba t t er y h old down br a cket t o t h e ba t t er y t r a y a n d
(1) Ver ify t h a t t h e ign it ion swit ch a n d a ll a ccesso- su ppor t u n it .
r ies a r e OF F. (4) Rem ove t h e ba t t er y h old down br a cket fr om
(2) Discon n ect t h e ba t t er y ca bles fr om t h e ba t t er y t h e ba t t er y t r a y a n d su ppor t u n it .
post s, n ega t ive fir st (F ig. 12).
(3) Rem ove t h e ba t t er y h old down r et a in in g n u t . INSTALLATION
(4) Rem ove t h e ba t t er y h old down br a cket . (1) In st a ll t h e ba t t er y h old down br a cket in t h e
(5) Rem ove t h e ba t t er y fr om t h e veh icle. ba t t er y t r a y a n d su ppor t u n it .
(2) In st a ll t h e n u t wit h wa sh er t h a t secu r es t h e
INSTALLATION ba t t er y h old down br a cket t o t h e ba t t er y t r a y a n d
(1) P osit ion t h e ba t t er y in t h e ba t t er y t r a y. su ppor t u n it . Tor qu e t o 20 N·m (180 in . lbs.).
(2) In st a ll t h e ba t t er y h old down br a cket a n d (3) Con n ect t h e ba t t er y n ega t ive ca ble.
r et a in in g n u t . Tor qu e t h e n u t t o 20 N·m (180 in . lbs.).
(3) Con n ect t h e ba t t er y ca bles t o t h e ba t t er y post s,
posit ive ca ble fir st . Tor qu e t er m in a l fa st en er s t o 5 BAT T ERY CABLES
N·m (40 in . lbs.).
DESCRIPTION
Th e ba t t er y ca bles a r e la r ge ga u ge, st r a n ded cop-
BAT T ERY H OLDDOWN per wir es sh ea t h ed wit h in a h ea vy pla st ic or syn -
t h et ic r u bber in su la t in g ja cket . Th e wir e u sed in t h e
REMOVAL ba t t er y ca bles com bin es excellen t flexibilit y a n d r eli-
All of t h e ba t t er y h old down h a r dwa r e ca n be ser- a bilit y wit h h igh elect r ica l cu r r en t ca r r yin g ca pa cit y.
viced wit h ou t r em ova l of t h e ba t t er y or t h e ba t t er y A cla m pin g t ype fem a le ba t t er y t er m in a l m a de of
t r a y a n d su ppor t u n it . st a m ped m et a l is a t t a ch ed t o on e en d of t h e ba t t er y
ca ble wir e. A squ a r e h ea ded pin ch -bolt a n d h ex n u t
BAT T ERY CABLES (Cont inue d)
a r e in st a lled a t t h e open en d of t h e fem a le ba t t er y DI AGN OSI S AN D T EST I N G
t er m in a l cla m p. La r ge eyelet t ype t er m in a ls a r e
cr im ped on t o t h e opposit e en d of t h e ba t t er y ca ble BATTERY CABLES
wir e a n d t h en solder-dipped. Th e ba t t er y posit ive A volt a ge dr op t est will det er m in e if t h er e is exces-
ca ble wir es h a ve a r ed in su la t in g ja cket t o pr ovide sive r esist a n ce in t h e ba t t er y ca ble t er m in a l con n ec-
visu a l iden t ifica t ion a n d fea t u r e a la r ger fem a le ba t - t ion s or t h e ba t t er y ca ble. If excessive r esist a n ce is
t er y t er m in a l cla m p t o a llow con n ect ion t o t h e la r ger fou n d in t h e ba t t er y ca ble con n ect ion s, t h e con n ec-
ba t t er y posit ive t er m in a l post . Th e ba t t er y n ega t ive t ion poin t sh ou ld be disa ssem bled, clea n ed of a ll cor-
ca ble wir es h a ve a bla ck in su la t in g ja cket a n d a r osion or for eign m a t er ia l, t h en r ea ssem bled.
sm a ller fem a le ba t t er y t er m in a l cla m p. F ollowin g r ea ssem bly, ch eck t h e volt a ge dr op for t h e
Th e ba t t er y ca bles ca n n ot be r epa ir ed a n d, if da m - ba t t er y ca ble con n ect ion a n d t h e ba t t er y ca ble a ga in
a ged or fa u lt y t h ey m u st be r epla ced. Bot h t h e ba t - t o con fir m r epa ir.
t er y posit ive a n d n ega t ive ca bles a r e a va ila ble for Wh en per for m in g t h e volt a ge dr op t est , it is im por-
ser vice r epla cem en t on ly a s a u n it wit h t h e ba t t er y t a n t t o r em em ber t h a t t h e volt a ge dr op is givin g a n
wir e h a r n ess, wh ich m a y in clu de por t ion s of t h e wirin dica t ion of t h e r esist a n ce bet ween t h e t wo poin t s a t
in g cir cu it s for t h e gen er a t or a n d ot h er com pon en t s wh ich t h e volt m et er pr obes a r e a t t a ch ed. EXAM-
on som e veh icles. Refer t o t h e a ppr opr ia t e wir in g P LE: Wh en t est in g t h e r esist a n ce of t h e ba t t er y pos-
in for m a t ion for com plet e cir cu it sch em a t ic or con n ec- it ive ca ble, t ou ch t h e volt m et er lea ds t o t h e ba t t er y
t or pin -ou t in for m a t ion . posit ive ca ble t er m in a l cla m p a n d t o t h e ba t t er y pos-
it ive ca ble eyelet t er m in a l a t t h e st a r t er solen oid
OPERATION B(+) t er m in a l st u d. If you pr obe t h e ba t t er y posit ive
Th e ba t t er y ca bles con n ect t h e ba t t er y t er m in a l t er m in a l post a n d t h e ba t t er y posit ive ca ble eyelet
post s t o t h e veh icle elect r ica l syst em . Th ese ca bles t er m in a l a t t h e st a r t er solen oid B(+) t er m in a l st u d,
a lso pr ovide a pa t h ba ck t o t h e ba t t er y for elect r ica l you a r e r ea din g t h e com bin ed volt a ge dr op in t h e
cu r r en t gen er a t ed by t h e ch a r gin g syst em for r est or- ba t t er y posit ive ca ble t er m in a l cla m p-t o-t er m in a l
in g t h e volt a ge pot en t ia l of t h e ba t t er y. Th e fem a le post con n ect ion a n d t h e ba t t er y posit ive ca ble.
ba t t er y t er m in a l cla m ps on t h e en ds of t h e ba t t er y
ca ble wir es pr ovide a st r on g a n d r elia ble con n ect ion VOLTAGE DROP TEST
of t h e ba t t er y ca ble t o t h e ba t t er y t er m in a l post s. Th e followin g oper a t ion will r equ ir e a volt m et er
Th e t er m in a l pin ch bolt s a llow t h e fem a le t er m in a l a ccu r a t e t o 1/10 (0.10) volt . Befor e per for m in g t h is
cla m ps t o be t igh t en ed a r ou n d t h e m a le t er m in a l t est , be cer t a in t h a t t h e followin g pr ocedu r es a r e
post s on t h e t op of t h e ba t t er y. Th e eyelet t er m in a ls a ccom plish ed:
secu r ed t o t h e opposit e en ds of t h e ba t t er y ca ble • Th e ba t t er y is fu lly-ch a r ged a n d loa d t est ed.
wir es fr om t h e fem a le ba t t er y t er m in a l cla m ps pr o- (Refer t o 8 - E LE CTRICAL/BATTE RY SYSTE M/BAT-
vide secu r e a n d r elia ble con n ect ion of t h e ba t t er y TE RY - STANDARD P ROCE DURE - BATTE RY
ca bles t o t h e veh icle elect r ica l syst em . CH ARGING) for t h e pr oper ba t t er y ch a r gin g a n d
Th e ba t t er y posit ive ca ble t er m in a l cla m p is loa d t est pr ocedu r es.
a t t a ch ed t o t h e en ds of t wo wir es. On e wir e h a s a n • F u lly en ga ge t h e pa r kin g br a ke.
eyelet t er m in a l t h a t con n ect s t h e ba t t er y posit ive • If t h e veh icle is equ ipped wit h a n a u t om a t ic
ca ble t o t h e B(+) t er m in a l st u d of t h e In t egr a t ed t r a n sm ission , pla ce t h e gea r sh ift select or lever in t h e
P ower Modu le (IP M), a n d t h e ot h er wir e h a s a n eye- P a r k posit ion . If t h e veh icle is equ ipped wit h a m a n -
let t er m in a l t h a t con n ect s t h e ba t t er y posit ive ca ble u a l t r a n sm ission , pla ce t h e gea r sh ift select or lever in
t o t h e B(+) t er m in a l st u d of t h e en gin e st a r t er m ot or t h e Neu t r a l posit ion a n d block t h e clu t ch peda l in t h e
solen oid. Th e ba t t er y n ega t ive ca ble t er m in a l cla m p fu lly depr essed posit ion .
is a lso a t t a ch ed t o t h e en ds of t wo wir es. On e wir e • Ver ify t h a t a ll la m ps a n d a ccessor ies a r e t u r n ed
h a s a n eyelet t er m in a l t h a t con n ect s t h e ba t t er y n eg- off.
a t ive ca ble t o t h e veh icle power t r a in t h r ou gh a st u d • To pr even t t h e en gin e fr om st a r t in g, r em ove t h e
on t h e left side of t h e en gin e cylin der block. Th e Au t om a t ic Sh u t Down (ASD) r ela y. Th e ASD r ela y is
ot h er wir e h a s a n eyelet t er m in a l t h a t con n ect s t h e loca t ed in t h e In t elligen t P ower Modu le (IP M), in t h e
ba t t er y n ega t ive ca ble t o t h e veh icle body t h r ou gh a en gin e com pa r t m en t . See t h e fu se a n d r ela y la you t
gr ou n d scr ew on t h e left fr on t fen der in n er sh ield, la bel a ffixed t o t h e u n der side of t h e IP M cover for
n ea r t h e ba t t er y. ASD r ela y iden t ifica t ion a n d loca t ion .
(1) Con n ect t h e posit ive lea d of t h e volt m et er t o (3) Con n ect t h e volt m et er t o m ea su r e bet ween t h e
t h e ba t t er y n ega t ive t er m in a l post . Con n ect t h e n eg- ba t t er y posit ive ca ble t er m in a l cla m p a n d t h e st a r t er
a t ive lea d of t h e volt m et er t o t h e ba t t er y n ega t ive solen oid B(+) t er m in a l st u d (F ig. 15). Rot a t e a n d h old
ca ble t er m in a l cla m p (F ig. 13). Rot a t e a n d h old t h e t h e ign it ion swit ch in t h e St a r t posit ion . Obser ve t h e
ign it ion swit ch in t h e St a r t posit ion . Obser ve t h e volt m et er. If t h e r ea din g is a bove 0.2 volt , clea n a n d
volt m et er. If volt a ge is det ect ed, cor r ect t h e poor con - t igh t en t h e ba t t er y posit ive ca ble eyelet t er m in a l con -
n ect ion bet ween t h e ba t t er y n ega t ive ca ble t er m in a l n ect ion a t t h e st a r t er solen oid B(+) t er m in a l st u d.
cla m p a n d t h e ba t t er y n ega t ive t er m in a l post . Repea t t h e t est . If t h e r ea din g is st ill a bove 0.2 volt ,
r epla ce t h e in oper a t ive ba t t er y posit ive ca ble.
Fig. 13 Test Battery Negative Connection Fig. 15 Test Battery Positive Cable Resistance - Typical
Resistance - Typical 1 - BATTERY
2 - VOLTMETER
1 - VOLTMETER 3 - STARTER MOTOR
2 - BATTERY
(4) Con n ect t h e volt m et er t o m ea su r e bet ween t h e

(2) Con n ect t h e posit ive lea d of t h e volt m et er t o
ba t t er y n ega t ive ca ble t er m in a l cla m p a n d a good
t h e ba t t er y posit ive t er m in a l post . Con n ect t h e n ega -
clea n gr ou n d on t h e en gin e block (F ig. 16). Rot a t e
t ive lea d of t h e volt m et er t o t h e ba t t er y posit ive ca ble
a n d h old t h e ign it ion swit ch in t h e St a r t posit ion .
t er m in a l cla m p (F ig. 14). Rot a t e a n d h old t h e ign it ion
Obser ve t h e volt m et er. If t h e r ea din g is a bove 0.2
swit ch in t h e St a r t posit ion . Obser ve t h e volt m et er. If
volt , clea n a n d t igh t en t h e ba t t er y n ega t ive ca ble
volt a ge is det ect ed, cor r ect t h e poor con n ect ion
eyelet t er m in a l con n ect ion t o t h e en gin e block.
bet ween t h e ba t t er y posit ive ca ble t er m in a l cla m p
Repea t t h e t est . If t h e r ea din g is st ill a bove 0.2 volt ,
a n d t h e ba t t er y posit ive t er m in a l post .
r epla ce t h e in oper a t ive ba t t er y n ega t ive ca ble.
Fig. 16 Test Ground Circuit Resistance - Typical

Fig. 14 Test Battery Positive Connection Resistance
1 - VOLTMETER
- Typical 2 - BATTERY
1 - VOLTMETER 3 - ENGINE GROUND
2 - BATTERY
REMOVAL
Th e ba t t er y ca bles on t h is veh icle m a y in clu de por-
t ion s of wir in g cir cu it s for t h e gen er a t or a n d ot h er
com pon en t s on t h e veh icle. If ba t t er y ca ble r epla ce-
m en t is r equ ir ed, it will be n ecessa r y t o ext r a ct t h e
ca bles ou t of t h e en gin e wir e h a r n ess a ssem bly. Use
ca r e n ot t o da m a ge t h e ot h er wir es a n d cir cu it s
wh ich a r e a lso pa cka ged in t o t h e en gin e wir e h a r n ess
a ssem bly.
(1) Tu r n t h e ign it ion swit ch t o t h e Off posit ion . Be
cer t a in t h a t a ll elect r ica l a ccessor ies a r e t u r n ed off.
ca ble.
(3) Rem ove t h e ba t t er y t h er m owr a p (if equ ipped)
fr om t h e ba t t er y t r a y.
(4) Rem ove t h e t a pe fr om t h e en gin e wir e h a r n ess
a ssem bly, t o a ccess t h e desir ed ba t t er y ca ble.
(5) On e a t a t im e, t r a ce a n d discon n ect t h e ba t t er y
ca ble r et a in in g fa st en er s a n d r ou t in g clips u n t il t h e
desir ed ca ble is fr ee fr om t h e veh icle.
(6) F eed t h e ba t t er y ca ble ou t of t h e veh icle.
INSTALLATION Fig. 17 RS BATTERY TRAY

(1) P osit ion t h e ba t t er y ca ble in t h e veh icle. 1 - ENGINE VACUUM RESERVOIR
2 - BATTERY TRAY ASSEMBLY
(2) On e a t a t im e, t r a ce a n d in st a ll t h e ba t t er y 3 - DRAINAGE HOSE
ca ble r et a in in g fa st en er s a n d r ou t in g clips u n t il t h e
desir ed ca ble is pr oper ly in st a lled in t h e en gin e wir e (3) Rem ove t h e ba t t er y fr om t h e veh icle. (Refer t o
h a r n ess a ssem bly. 8 - E LE CTRICAL/BATTE RY SYSTE M/BATTE RY -
(3) In st a ll t h e t a pe on t h e en gin e wir e h a r n ess RE MOVAL).
a ssem bly. (4) Rem ove t h e ba t t er y t r a y r et a in in g fa st en er s
(4) In st a ll t h e ba t t er y t h er m owr a p (if equ ipped) on (F ig. 18).
t h e ba t t er y t r a y.
BAT T ERY T RAY

DESCRIPTION
Th e ba t t er y is m ou n t ed in a m olded pla st ic ba t t er y
t r a y a n d su ppor t u n it loca t ed in t h e left fr on t cor n er
of t h e en gin e com pa r t m en t . Th e ba t t er y t r a y a n d
su ppor t u n it is secu r ed wit h t wo n u t s, on e is loca t ed
dir ect ly u n der t h e ba t t er y a n d t h e ot h er is loca t ed on
t h e r igh t side of t h e t r a y wh ich a lso ser ves a s a cool-
a n t bot t le n eck r et a in in g bolt . An a ddit ion a l bolt is
loca t ed dir ect ly u n der t h e ba t t er y.
Th e ba t t er y t r a y a n d su ppor t u n it a lso in clu des a
en gin e va cu u m r eser voir, loca t ed in t h e r ea r of t h e
u n it (F ig. 17). An d a dr a in a ge h ose, loca t ed in t h e
fr on t of t h e u n it (F ig. 17).
REMOVAL
ca ble.
Fig. 18 BATTERY TRAY POSITION & ORIENTATION
(2) Discon n ect a n d isola t e t h e ba t t er y posit ive
1 - BATTERY TRAY RETAINING FASTENERS
ca ble.
BAT T ERY T RAY (Cont inue d)
(5) P u ll ba t t er y t r a y u p fa r en ou gh t o discon n ect
t h e en gin e va cu u m h a r n ess h ose fr om t h e ba t t er y
t r a y m ou n t ed, va cu u m r eser voir.
(6) Rem ove t h e ba t t er y t r a y fr om t h e veh icle.
INSTALLATION
(1) P osit ion t h e ba t t er y t r a y in t h e veh icle.
(2) Con n ect t h e en gin e va cu u m h a r n ess h ose on
t h e ba t t er y t r a y m ou n t ed va cu u m r eser voir.
(3) P osit ion dr a in a ge h ose a n d in st a ll t h e ba t t er y
t r a y r et a in in g fa st en er s (F ig. 19).
(4) In st a ll t h e ba t t er y in t h e veh icle. (Refer t o 8 -
E LE CTRICAL/BATTE RY SYSTE M/BATTE RY -
INSTALLATION).
(5) Con n ect t h e ba t t er y posit ive ca ble.
Fig. 19 BATTERY TRAY POSITION & ORIENTATION

1 - BATTERY TRAY RETAINING FASTENERS
RS CHARGING 8F - 21
CH ARGI N G
TABLE OF CONTENTS
page page
CHARGING REMOVAL
DESCRIPTION - CHARGING SYSTEM . . . . . . . 21 REMOVAL - 2.4L . . . . . . . . . . . . . . . . . . . . . . 24
OPERATION - CHARGING SYSTEM . . . . . . . . . 21 REMOVAL - 2.5L . . . . . . . . . . . . . . . . . . . . . . 25
DIAGNOSIS AND TESTING REMOVAL - 3.3/3.8L . . . . . . . . . . . . . . . . . . . 27
ON-BOARD DIAGNOSTIC SYSTEM . . . . . . . . 22 INSTALLATION
SPECIFICATIONS INSTALLATION - 2.4L ............. . . . . . 27
GENERATOR ................ . . . . . . . . 23 INSTALLATION - 2.5L ............. . . . . . 27
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 INSTALLATION - 3.3/3.8L . . . . . . . . . . . . . . . . 27
SPECIFICATIONS - BATTERY GENERATOR DECOUPLER PULLEY
TEMPERATURE SENSOR . . . . . . . . . . . . . . . 23 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 28
SPECIAL TOOLS ............... . . . . . . . . 24 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
BATTERY TEMPERATURE SENSOR DIAGNOSIS AND TESTING - GENERATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 24 DECOUPLER PULLEY . . . . . . . . . . . . . . . . . . 28
GENERATOR VOLTAGE REGULATOR
CH ARGI N G P CM or IP M (in t elligen t power m odu le) (if equ ipped)

a n d su pplied t o on e of t h e gen er a t or field t er m in a ls
(Gen . Sou r ce +) a t t h e ba ck of t h e gen er a t or.
DESCRIPTION - CHARGING SYSTEM
Th e gen er a t or is dr iven by t h e en gin e t h r ou gh a
Th e ch a r gin g syst em con sist s of:
ser pen t in e belt a n d pu lley or decou pler pu lley
• Gen er a t or
a r r a n gem en t .
• Decou pler P u lley (If equ ipped)
Th e a m ou n t of DC cu r r en t pr odu ced by t h e gen er-
• E lect r on ic Volt a ge Regu la t or (E VR) cir cu it r y
a t or is con t r olled by t h e E VR (field con t r ol) cir cu it r y
wit h in t h e P ower t r a in Con t r ol Modu le (P CM)
con t a in ed wit h in t h e P CM. Th is cir cu it r y is con -
• Ign it ion swit ch (r efer t o t h e Ign it ion Syst em sec-
n ect ed in ser ies wit h t h e secon d r ot or field t er m in a l
t ion for in for m a t ion )
a n d gr ou n d.
• Ba t t er y (r efer t o t h e Ba t t er y sect ion for in for m a -
An Am bien t a ir t em per a t u r e sen sor is u sed t o ca l-
t ion )
cu la t e t h e t em per a t u r e n ea r t h e ba t t er y. Th is t em -
• Am bien t Air Tem per a t u r e (If equ ipped)
per a t u r e da t a , a lon g wit h da t a fr om m on it or ed lin e
• In let Air Tem per a t u r e (ca lcu la t ed ba t t er y t em -
volt a ge (ba t t er y volt a ge sen se cir cu it ), is u sed by t h e
per a t u r e)(If equ ipped)
P CM t o va r y t h e ba t t er y ch a r gin g r a t e. Th is is don e
• Volt m et er (r efer t o t h e In st r u m en t Clu st er sec-
by cyclin g t h e gr ou n d pa t h t o con t r ol t h e st r en gt h of
t ion for in for m a t ion if equ ipped)
t h e r ot or m a gn et ic field. Th e P CM t h en com pen sa t es
• Wir in g h a r n ess a n d con n ect ion s (r efer t o t h e
a n d r egu la t es gen er a t or cu r r en t ou t pu t a ccor din gly
Wir in g sect ion for in for m a t ion )
t o m a in t a in syst em volt a ge a t t h e t a r get ed syst em
• Accessor y dr ive belt (r efer t o t h e Coolin g sect ion
volt a ge ba sed on ba t t er y t em per a t u r e.
for m or e in for m a t ion )
All veh icles a r e equ ipped wit h On -Boa r d Dia gn os-
• Ba t t er y Tem per a t u r e sen sor (if equ ipped)
t ics (OBD). All OBD-sen sed syst em s, in clu din g E VR
(field con t r ol) cir cu it r y, a r e m on it or ed by t h e P CM.
OPERATION - CHARGING SYSTEM E a ch m on it or ed cir cu it is a ssign ed a Dia gn ost ic Tr ou -
Th e ch a r gin g syst em is t u r n ed on a n d off wit h t h e
ble Code (DTC). Th e P CM will st or e a DTC in elec-
ign it ion swit ch . Th e syst em is on wh en t h e en gin e is
t r on ic m em or y for cer t a in fa ilu r es it det ect s a n d
r u n n in g a n d t h e ASD r ela y is en er gized. Th e ASD illu m in a t e t h e (MIL) la m p. Refer t o On -Boa r d Dia g-
r ela y is en er gized wh en t h e P CM gr ou n ds t h e ASD
n ost ics in t h e E lect r on ic Con t r ol Modu les(Refer t o 8 -
con t r ol cir cu it . Th is volt a ge is con n ect ed t h r ou gh t h e
8F - 22 CHARGING RS
CH ARGI N G (Cont inue d)
ULE S/P OWE RTRAIN CONTROL MODULE - ERASING DIAGNOSTIC TROUBLE CODES
DE SCRIP TION) sect ion for m or e DTC in for m a t ion . Th e DRBIII! Sca n Tool m u st be u sed t o er a se a
Th e Ch a r gin g syst em “Ba t t er y” ligh t in dica t es DTC.
pr oblem s wit h t h e ch a r gin g syst em (volt a ge t oo h igh / Th e followin g pr ocedu r es m a y be u sed t o dia gn ose
low, gen er a t or fa ilu r e, et c.). If a n ext r em e con dit ion is t h e ch a r gin g syst em if:
in dica t ed, t h e la m p will be illu m in a t ed. Th e sign a l t o • t h e ch eck ga u ges la m p or ba t t er y la m p is illu m i-
a ct iva t e t h e la m p is sen t via t h e P CI bu s cir cu it s. n a t ed wit h t h e en gin e r u n n in g
Th e la m p is loca t ed on t h e in st r u m en t pa n el. Refer • t h e volt m et er (if equ ipped) does n ot r egist er
t o t h e In st r u m en t Clu st er sect ion for a ddit ion a l in for- pr oper ly
m a t ion . • a n u n der ch a r ged or over ch a r ged ba t t er y con di-
Th e P CM u ses t h e a m bien t a ir t em per a t u r e sen sor t ion occu r s.
t o con t r ol t h e ch a r ge syst em volt a ge. Th is t em per a - Rem em ber t h a t a n u n der ch a r ged ba t t er y is oft en
t u r e, a lon g wit h da t a fr om m on it or ed lin e volt a ge, is ca u sed by:
u sed by t h e P CM t o va r y t h e ba t t er y ch a r gin g r a t e. • a ccessor ies bein g left on wit h t h e en gin e n ot
Th e syst em volt a ge is h igh er a t cold t em per a t u r es r u n n in g
a n d is gr a du a lly r edu ced a s t h e ca lcu la t ed ba t t er y • a fa u lt y or im pr oper ly a dju st ed swit ch t h a t
t em per a t u r e in cr ea ses. a llows a la m p t o st a y on . Refer t o Ign it ion -Off Dr a w
Th e a m bien t t em per a t u r e sen sor is u sed t o con t r ol Test (Refer t o 8 - E LE CTRICAL/BATTE RY SYSTE M/
t h e ba t t er y volt a ge ba sed u pon a m bien t t em per a t u r e BATTE RY - STANDARD P ROCE DURE )
(a ppr oxim a t ion of ba t t er y t em per a t u r e). Th e P CM • loose gen er a t or belt .
m a in t a in s t h e opt im a l ou t pu t of t h e gen er a t or by
m on it or in g ba t t er y volt a ge a n d con t r ollin g it t o a INSPECTION
r a n ge of 13.5 - 14.7 volt s ba sed on ba t t er y t em per a - Th e P ower t r a in Con t r ol Modu le (P CM) m on it or s
t u r e. cr it ica l in pu t a n d ou t pu t cir cu it s of t h e ch a r gin g sys-
t em , m a kin g su r e t h ey a r e oper a t ion a l. A Dia gn ost ic
Tr ou ble Code (DTC) is a ssign ed t o ea ch in pu t a n d
DI AGN OSI S AN D T EST I N G ou t pu t cir cu it m on it or ed by t h e On -Boa r d Dia gn ost ic
(OBD) syst em . Som e ch a r gin g syst em cir cu it s a r e
ON-BOARD DIAGNOSTIC SYSTEM ch ecked con t in u ou sly, a n d som e a r e ch ecked on ly
Th e P ower t r a in Con t r ol Modu le (P CM) m on it or s u n der cer t a in con dit ion s.
cr it ica l in pu t a n d ou t pu t cir cu it s of t h e ch a r gin g sys- Refer t o Dia gn ost ic Tr ou ble Codes in ; P ower t r a in
t em , m a kin g su r e t h ey a r e oper a t ion a l. A Dia gn ost ic Dia gn ost ic m a n u a l for m or e DTC in for m a t ion . Th is
Tr ou ble Code (DTC) is a ssign ed t o ea ch in pu t a n d will in clu de a com plet e list of DTC’s in clu din g DTC’s
ou t pu t cir cu it m on it or ed by t h e OBD syst em . Som e for t h e ch a r gin g syst em .
cir cu it s a r e ch ecked con t in u ou sly a n d som e a r e To per for m a com plet e t est of t h e ch a r gin g syst em ,
ch ecked on ly u n der cer t a in con dit ion s. r efer t o t h e a ppr opr ia t e P ower t r a in Dia gn ost ic P r oce-
If t h e OBD syst em sen ses t h a t a m on it or ed cir cu it du r es ser vice m a n u a l a n d t h e DRBIII! sca n t ool.
is ba d, it will pu t a DTC in t o elect r on ic m em or y. Th e P er for m t h e followin g in spect ion s befor e a t t a ch in g
DTC will st a y in elect r on ic m em or y a s lon g a s t h e t h e sca n t ool.
cir cu it con t in u es t o be ba d. Th e P CM is pr ogr a m m ed (1) In spect t h e ba t t er y con dit ion . Refer t o t h e Ba t -
t o clea r t h e m em or y a ft er 40 good t r ip if t h e pr oblem t er y sect ion (Refer t o 8 - E LE CTRICAL/BATTE RY
does n ot occu r a ga in . SYSTE M - DIAGNOSIS AND TE STING) for pr oce-
du r es.
DIAGNOSTIC TROUBLE CODES
(2) In spect con dit ion of ba t t er y ca ble t er m in a ls,
A DTC descr ipt ion ca n be r ea d u sin g t h e DRBIII! ba t t er y post s, con n ect ion s a t en gin e block, st a r t er
sca n t ool. Refer t o t h e a ppr opr ia t e P ower t r a in Dia g- solen oid a n d r ela y. Th ey sh ou ld be clea n a n d t igh t .
n ost ic P r ocedu r es m a n u a l for in for m a t ion . Repa ir a s r equ ir ed.
A DTC does n ot iden t ify wh ich com pon en t in a cir- (3) In spect a ll fu ses in bot h t h e fu seblock a n d
cu it is ba d. Th u s, a DTC sh ou ld be t r ea t ed a s a P ower Dist r ibu t ion Cen t er (P DC) or IP M (if
sym pt om , n ot a s t h e ca u se for t h e pr oblem . In som e equ ipped) for t igh t n ess in r ecept a cles. Th ey sh ou ld be
ca ses, beca u se of t h e design of t h e dia gn ost ic t est pr oper ly in st a lled a n d t igh t . Repa ir or r epla ce a s
pr ocedu r e, a DTC ca n be t h e r ea son for a n ot h er DTC r equ ir ed.
t o be set . Th er efor e, it is im por t a n t t h a t t h e t est pr o- (4) In spect gen er a t or m ou n t in g bolt s for t igh t n ess.
cedu r es be followed in sequ en ce, t o u n der st a n d wh a t Repla ce or t igh t en bolt s if r equ ir ed. Refer t o t h e Gen -
ca u sed a DTC t o be set . er a t or Rem ova l/In st a lla t ion sect ion of t h is gr ou p for
RS CHARGING 8F - 23
t or qu e specifica t ion s (Refer t o 8 - E LE CTRICAL/ (7) In spect a u t om a t ic belt t en sion er (if equ ipped).
CH ARGING - SP E CIF ICATIONS). Refer t o t h e Coolin g Syst em for m or e in for m a t ion .
(5) In spect gen er a t or dr ive belt con dit ion a n d t en - (8) In spect gen er a t or elect r ica l con n ect ion s a t gen -
sion . Tigh t en or r epla ce belt a s r equ ir ed. Refer t o er a t or field, ba t t er y ou t pu t , a n d gr ou n d t er m in a l (if
Belt Ten sion Specifica t ion s(Refer t o 7 - COOLING/ equ ipped). Also ch eck gen er a t or gr ou n d wir e con n ec-
ACCE SSORY DRIVE - SP E CIF ICATIONS). t ion a t en gin e (if equ ipped). Th ey sh ou ld a ll be clea n
(6) In spect decou pler pu lley (if equ ipped). E n su r e a n d t igh t . Repa ir a s r equ ir ed.
decou pler pu lley is dr ivin g t h e a lt er n a t or r ot or.
SPECI FI CAT I ON S
GENERATOR Type Engine Minimun Test

Amperage
Type Engine Minimun Test 1. Engine RPM : 2500 RPM ±20 RPM (HOT)
Amperage 2. Voltage Output : 14.0 V ± 0.5 V
Denso 2.4 L 80 Amp (HOT)
3. Field Current : 5 amps ± 0.1 amps
Denso 3.3/3.8L 100 Amp or 115
Amp (HOT) P a r t n u m ber is loca t ed on t h e side of t h e gen er a t or.
Test Specification:
TORQUE

Battery Hold Down Clamp 20 14.7 180
Bolt
Generator B+ Nut 12.4 9.2 110
Battery Terminal Nut 4 35
Generator Mounting Bolt 28.2 20.8 250
2.4L
Generator Mounting Bolts 54.2 40
3.3/3.8L
Starter Solenoid Battery 11.3 8.3 100
Nut 3.3/3.8L
Generator Decoupler 109.8 81
SPECIFICATIONS - BATTERY TEMPERATURE SENSOR
°C °F K-Ohms Min. K-Ohms Max.

(40) (40) 291.4 381.7
(20) (4) 85.8 108.4
20 68 11.4 13.6
25 77 9.1 10.9
120 248 0.37 0.41
130 266 0.28 0.32
8F - 24 CHARGING RS
SPECIAL TOOLS REMOVAL

Th e ba t t er y t em per a t u r e sen sor is n ot ser viced sep-
a r a t ely. If r epla cem en t is n ecessa r y, t h e P CM m u st
be r epla ced.
GEN ERAT OR
DESCRIPTION
Th e gen er a t or is belt -dr iven by t h e en gin e. Th e
gen er a t or pr odu ces DC volt a ge a t t h e B+ t er m in a l. If
t h e gen er a t or is fa iled, t h e gen er a t or a ssem bly su b-
com pon en t s (gen er a t or a n d decou pler pu lley) m u st be
in spect ed for in dividu a l fa ilu r e a n d r epla ced a ccor d-
GENERATOR DECOUPLER 8433 in gly.
BAT T ERY T EM PERAT U RE OPERATION

SEN SOR As t h e en er gized r ot or begin s t o r ot a t e wit h in t h e
gen er a t or, t h e spin n in g m a gn et ic field in du ces a cu r-
r en t in t o t h e win din gs of t h e st a t or coil. On ce t h e
DESCRIPTION gen er a t or begin s pr odu cin g su fficien t cu r r en t , it a lso
(NGC Veh icles) Th e P CM in cor por a t es a Ba t t er y
pr ovides t h e cu r r en t n eeded t o en er gize t h e r ot or.
Tem per a t u r e Sen sor (BTS) on it s cir cu it boa r d.
Th e Y t ype st a t or win din g con n ect ion s deliver t h e
in du ced AC cu r r en t t o 3 posit ive a n d 3 n ega t ive
OPERATION diodes for r ect ifica t ion . F r om t h e diodes, r ect ified DC
Th e P CM u ses t h e t em per a t u r e of t h e ba t t er y a r ea cu r r en t is deliver ed t o t h e veh icles elect r ica l syst em
t o con t r ol t h e ch a r ge syst em volt a ge. Th is t em per a - t h r ou gh t h e gen er a t or, ba t t er y, a n d gr ou n d t er m in a ls.
t u r e, a lon g wit h da t a fr om m on it or ed lin e volt a ge, is E xcessive or a bn or m a l n oise em it t in g fr om t h e gen -
u sed by t h e P CM t o va r y t h e ba t t er y ch a r gin g r a t e. er a t or m a y be ca u sed by:
Th e syst em volt a ge is h igh er a t cold t em per a t u r es • Wor n , loose or defect ive bea r in gs
a n d is gr a du a lly r edu ced a s t em per a t u r e a r ou n d t h e • Loose or defect ive dr ive pu lley (2.4L) or decou -
ba t t er y in cr ea ses. pler (3.3/3.8L)
F or veh icles wit h 1.6L en gin e, t h er e is n o ph ysica l • In cor r ect , wor n , da m a ged or m isa dju st ed dr ive
ba t t er y t em p sen sor in pla ce t o det ect ba t t er y t em p. belt
Ra t h er, a n a lgor it h m bu it in P CM is em ployed t o pr e- • Loose m ou n t in g bolt s
dict ba t t er y t em p u sin g in let a ir t em p, veh icle speed, • Misa lign ed dr ive pu lley
a n d coola n t t em p, a m on g ot h er sign a ls. Th e P CM • Defect ive st a t or or diode
m a in t a in s t h e opt im a l ou t pu t of t h e gen er a t or by • Da m a ged in t er n a l fin s
m on it or in g ba t t er y volt a ge a n d con t r ollin g it t o a
r a n ge of 13.5 - 14.7 volt s ba sed on ba t t er y t em per a -
t u r e. Th e syst em t a r get volt a ge is 13.5 – 14.7 volt s. REM OVAL
H owever t h e a ct u a l volt a ge go below t h is du r in g
h ea vy elect r ica l loa ds a n d gen er a t or speeds. Also t h e REMOVAL - 2.4L
a ct u a l volt a ge ca n be lower t h a n t h e t a r get volt a ge (1) Relea se h ood la t ch a n d open h ood.
bet ween t h e ba t t er y a n d t h e ba t t er y volt a ge sen se (2) Discon n ect ba t t er y n ega t ive ca ble.
cir cu it , a ppr oxim a t ely 0.2 — 0.3 volt s. (3) Discon n ect t h e In let Air Tem per a t u r e sen sor.
Th e ba t t er y t em per a t u r e sen sor is a lso u sed for (4) Rem ove t h e Air Box, r efer t o t h e E n gin e/Air
OBD II dia gn ost ics. Cer t a in fa u lt s a n d OBD II m on - Clea n er for m or e in for m a t ion .
it or s a r e eit h er en a bled or disa bled depen din g u pon (5) Rem ove t h e E VAP P u r ge solen oid fr om it s
t h e ba t t er y t em per a t u r e sen sor in pu t (exa m ple: dis- br a cket a n d r eposit ion .
a ble pu r ge a n d E GR, en a ble LDP ). Most OBD II (6) Discon n ect t h e pu sh -in field wir e con n ect or
m on it or s a r e disa bled below 20°F. fr om ba ck of gen er a t or.
(7) Rem ove n u t h oldin g B+ wir e t er m in a l t o ba ck
of gen er a t or.
(8) Sepa r a t e B+ t er m in a l fr om gen er a t or.
RS CHARGING 8F - 25
GEN ERAT OR (Cont inue d)
(9) Rem ove a ccessor y dr ive belt , r efer t o t h e Cool- (3) Ra ise veh icle a n d su ppor t .
in g Syst em sect ion for pr oper pr ocedu r es. (4) Tu r n wh eels t o t h e r igh t . Rem ove t h e r igh t
(10) Rem ove t h e gen er a t or. fr on t spla sh sh ield (F ig. 3).
REMOVAL - 2.5L
(1) Discon n ect t h e n ega t ive ba t t er y ca ble (F ig. 1).
Fig. 3 SPLASH SHIELD

(5) Rem ove t h e gen er a t or dr ive belt (F ig. 4).
Fig. 1 BATTERY CONNECTION

(2) Rem ove t h e en gin e cover (F ig. 2).
Fig. 4 GENERATOR BELT
Fig. 2 ENGINE COVER

8F - 26 CHARGING RS
(6) Lower veh icle. (10) Rem ove t h e Air Clea n er Box (F ig. 7).
(7) Discon n ect t h e gen er a t or ba t t er y con n ect ion
(F ig. 5).
Fig. 7 AIR BOX REMOVED

(11) Rem ove t h e 2 lower m ou n t in g Bolt s (F ig. 8).
Fig. 5 GENERATOR CONNECTIONS
1 - Battery Connection
2 - Field Connection
(8) Discon n ect t h e field con n ect ion (F ig. 5).

(9) Reloca t e t h e wir in g h a r n ess on u pper gen er a t or
br a cket (F ig. 6).
Fig. 8 GENERATOR LOWER BOLTS

1 - Lower Mounting Bolts
(12) Rem ove gen er a t or.
Fig. 6 UPPER SUPPORT BRACKET

1 - Wiring Harness
2 - Upper Bracket
RS CHARGING 8F - 27
REMOVAL - 3.3/3.8L
(1) Relea se h ood la t ch a n d open h ood.
(2) Discon n ect ba t t er y n ega t ive ca ble.
(3) Discon n ect t h e pu sh -in field wir e con n ect or
fr om ba ck of gen er a t or.
(4) Rem ove n u t h oldin g B+ wir e t er m in a l t o ba ck
of gen er a t or.
(5) Sepa r a t e B+ t er m in a l fr om gen er a t or.
(6) Ra ise veh icle a n d su ppor t .
(7) Rem ove t h e r igh t fr on t lower spla sh sh ield.
(8) Rem ove a ccessor y dr ive belt , r efer t o t h e Cool-
in g Syst em sect ion for pr oper pr ocedu r es.
(9) Rem ove t h e lower oil dip st ick t u be bolt (F ig. 9).
(10) Rem ove wir in g h a r n ess fr om t h e oil dip st ick
t u be
Fig. 10 GENERATOR 3.3/3.8L

(7) In st a ll t h e Air Box, r efer t o t h e E n gin e/Air
Clea n er for m or e in for m a t ion .
(8) Con n ect t h e In let Air Tem per a t u r e sen sor.
INSTALLATION - 2.5L
(1) In st a ll gen er a t or.
(2) In st a ll t h e 2 lower m ou n t in g Bolt s (F ig. 8).
(3) In st a ll t h e Air Clea n er Box (F ig. 7).
(4) In st a ll t h e u pper su ppor t br a cket (F ig. 6).
(5) In st a ll t h e wir in g h a r n ess on u pper gen er a t or
(6) Con n ect t h e field con n ect ion (F ig. 5).
Fig. 9 DIP STICK LOWER BOLT (7) Con n ect t h e gen er a t or ba t t er y con n ect ion (F ig.
(11) Rem ove t h e 3 m ou n t in g bolt s. 5).
(12) Lower veh icle. (8) Ra ise veh icle a n d su ppor t .
(13) Rem ove oil dip st ick t u be fr om veh icle. (9) In st a ll t h e gen er a t or dr ive belt (F ig. 4).
(14) Roll a n d r em ove t h e gen er a t or fr om veh icle (10) In st a ll t h e r igh t fr on t spla sh sh ield (F ig. 3).
(F ig. 10). (11) Lower veh icle.
(12) In st a ll t h e en gin e cover (F ig. 2).
(13) Con n ect t h e n ega t ive ba t t er y ca ble (F ig. 1).
I N STALLAT I ON
INSTALLATION - 3.3/3.8L
INSTALLATION - 2.4L (1) Roll a n d pla ce gen er a t or in posit ion on veh icle
(1) In st a ll t h e gen er a t or. (F ig. 10).
(2) In st a ll t h e a ccessor y dr ive belt , r efer t o t h e (2) In st a ll u pper bolt s t o h old gen er a t or in pla ce.
Coolin g Syst em sect ion for pr oper pr ocedu r es. (3) Lu br ica t e t h e o-r in g. In st a ll oil dip st ick t u be.
(3) Con n ect B+ t er m in a l t o gen er a t or. (4) In st a ll t h e u pper oil dip st ick t u be bolt .
(4) In st a ll n u t h oldin g B+ wir e t er m in a l t o ba ck of (5) P la ce B+ t er m in a l in posit ion on gen er a t or.
gen er a t or. (6) In st a ll n u t t o h old B+ wir e t er m in a l t o ba ck of
(5) Con n ect t h e pu sh -in field wir e con n ect or t o gen er a t or.
ba ck of gen er a t or. (7) Con n ect t h e pu sh -in field wir e con n ect or in t o
(6) In st a ll t h e E VAP P u r ge solen oid t o it s br a cket . ba ck of gen er a t or.
8F - 28 CHARGING RS
(9) In st a ll t h e lower m ou n t in g bolt a n d t igh t en .
(10) In st a ll t h e lower oil dip st ick t u be bolt a n d
t igh t en (F ig. 9).
(11) In st a ll a ccessor y dr ive belt , r efer t o t h e Cool-
in g Syst em sect ion for pr oper pr ocedu r es.
(12) In st a ll t h e r igh t fr on t lower spla sh sh ield.
(14) In st a ll wir in g h a r n ess t o t h e oil dip st ick t u be
(16) Ver ify gen er a t or ou t pu t r a t e.
GEN ERAT OR DECOU PLER

PU LLEY
DESCRIPTION
Th e Gen er a t or Decou pler is a on e wa y clu t ch (F ig. Fig. 11 GENERATOR DECOUPLER 3.3/3.8L
11). It is a t t a ch ed t o t h e gen er a t or a n d r epla ces t h e
st a n da r d pu lley. It is a n on -ser vicea ble it em a n d is t o OPERATION
be r epla ced a s a n a ssem bly. It is a dr y oper a t ion (n o Th e gen er a t or decou pler is a on e wa y clu t ch a n d
gr ea se or lu br ica n t s). Th e oper a t ion of it is n ot t em - sh ou ld be r epla ced a s a n a ssem bly. It is design ed t o
per a t u r e sen sit ive a n d h a s a low sen sit ivit y t o elec- h elp r edu ce belt t en sion flu ct u a t ion , r edu ce fa t igu e
t r ica l loa d. loa ds, im pr ove belt life, r edu ce h u bloa ds on com po-
n en t s, a n d r edu ce n oise.
DIAGNOSIS AND TESTING - GENERATOR DECOUPLER PULLEY
CONDITION VERIFICATION PROCEDURE POSSIBLE CORRECTION

CAUSES
Does not drive generator 1. Start engine and allow engine to idle. Clutch Replace
(Generator not Charging) failure Decoupler
2.Verify generator pulley is rotating.

3. View generator internal fins thru generator housing.
4. Fins either do not rotate or rotate very erratic.
5. Rotate decoupler pulley in clockwise direction then
quickly rotate in counterclockwise direction to see if
clutch engages.
Noise from generator at 1. Start engine and allow engine to idle. Defective Replace
engine shut down. decoupler decoupler
pulley pulley.
bearing.
2. Shutdown engine and listen to generator.
3. Noise heard just as engine stops. Sounds like a
click.
4. Remove accessory drive belt.
5. Verify rotation in counterclock wise direction is
rough.
RS CHARGING 8F - 29
GEN ERAT OR DECOU PLER PU LLEY (Cont inue d)
REMOVAL
(4) Rem ove t h e r igh t fr on t lower spla sh sh ield.
(5) Rem ove a ccessor y dr ive belt , r efer t o t h e Cool-
in g Syst em sect ion for pr oper pr ocedu r es (F ig. 12).
Fig. 13 DECOUPLER REMOVAL (LITENS)
Fig. 12 DRIVE BELT 3.3/3.8L

(6) Lower veh icle.
(7) Rem ove t h e Air Box, r efer t o t h e E n gin e sect ion
for m or e in for m a t ion .
(8) Rem ove t h e decou pler pu lley cover.
(9) Use Specia l Tool #8433 (F ig. 14) t o loosen t h e
Gen er a t or Decou pler (F ig. 13).
(10) Rem ove t h e t ool.
(11) Rem ove t h e Gen er a t or Decou pler.
INSTALLATION
(1) In st a ll t h e Gen er a t or Decou pler t o t h e gen er a -
t or sh a ft .
Fig. 14 SPECIAL TOOL 8433 AND DECOUPLER
(2) Use Specia l Tool #8433 (F ig. 14) t o t igh t en t h e
Gen er a t or Decou pler (F ig. 15). Refer t o t h e t or qu e
ch a r t for t h e pr oper t or qu e.
(3) In st a ll a n ew decou pler pu lley cover.
(4) In st a ll t h e Air Box, r efer t o t h e E n gin e sect ion
(6) In st a ll a ccessor y dr ive belt , r efer t o t h e Coolin g
Syst em sect ion for pr oper pr ocedu r es (F ig. 12).
8F - 30 CHARGING RS
GEN ERAT OR DECOU PLER PU LLEY (Cont inue d)
in g cir cu it loca t ed wit h in t h e P ower t r a in Con t r ol
Modu le (P CM). Th e E VR is n ot ser viced sepa r a t ely. If
r epla cem en t is n ecessa r y, t h e P CM m u st be r epla ced.
OPERATION
Th e a m ou n t of DC cu r r en t pr odu ced by t h e gen er-
a t or is con t r olled by E VR cir cu it r y con t a in ed wit h in
t h e P CM. Th is cir cu it r y is con n ect ed in ser ies wit h
t h e gen er a t or s secon d r ot or field t er m in a l a n d it s
gr ou n d.
Volt a ge is r egu la t ed wit h in t h e P CM on t h e NGC
veh icles, t o con t r ol t h e st r en gt h of t h e r ot or m a gn et ic
field. Th e E VR cir cu it r y m on it or s syst em lin e volt a ge
a t t h e P DC a n d ca lcu la t ed ba t t er y t em per a t u r e or
in let a ir t em per a t u r e sen sor (r efer t o In let Air Tem -
per a t u r e Sen sor, if equ ipped, for m or e in for m a t ion ).
It t h en det er m in es a t a r get ch a r gin g volt a ge. If
sen sed ba t t er y volt a ge is lower t h a n t h e t a r get volt -
a ge, t h e P CM feeds t h e field win din g u n t il sen sed
Fig. 15 DECOUPLER INSTALLATION (Litens) ba t t er y volt a ge is a t t h e t a r get volt a ge. A cir cu it in
t h e P CM cycles t h e feed side of t h e gen er a t or field a t
(7) In st a ll t h e r igh t fr on t lower spla sh sh ield.
250 t im es per secon d (250H z), bu t h a s t h e ca pa bilit y
(8) Lower veh icle.
t o feed t h e field con t r ol wir e 100% of t h e t im e (fu ll
field) t o a ch ieve t h e t a r get volt a ge. If t h e ch a r gin g
r a t e ca n n ot be m on it or ed (lim p-in ), a du t y cycle of
V OLTAGE REGU LAT OR 20% is u sed by t h e P CM in or der t o h a ve som e gen -
er a t or ou t pu t . Also r efer t o Ch a r gin g Syst em Oper a -
DESCRIPTION t ion for a ddit ion a l in for m a t ion .
Th e E lect r on ic Volt a ge Regu la t or (E VR) is n ot a
sepa r a t e com pon en t . It is a ct u a lly a volt a ge r egu la t -
RS STARTING 8F - 31
START I N G
TABLE OF CONTENTS
page page
STARTING SPECIFICATIONS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 31 Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
DIAGNOSIS AND TESTING STARTER MOTOR
DIAGNOSIS AND TESTING - STARTING REMOVAL
SYSTEM TEST . . . . . . . . . . . . . . . . . . . . . . . 31 REMOVAL - 2.4L . . . . . . . . . . . . . . . . . . . . . . 37
DIAGNOSIS AND TESTING - CONTROL REMOVAL - 3.3/3.8L . . . . . . . . . . . . . . . . . . . 38
CIRCUIT TEST . . . . . . . . . . . . . . . . . . . . . . . . 33 REMOVAL - 2.5L . . . . . . . . . . . . . . . . . . . . . . 38
DIAGNOSIS AND TESTING - FEED CIRCUIT INSTALLATION
RESISTANCE TEST . . . . . . . . . . . . . . . . . . . . 35 INSTALLATION - 2.4L . . . . . . . . . . . . . . . . . . 39
DIAGNOSIS AND TESTING - FEED CIRCUIT INSTALLATION - 3.3/3.8L . . . . . . . . . . . . . . . . 39
TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 INSTALLATION - 2.5L . . . . . . . . . . . . . . . . . . 39
START I N G OPERATION
Th ese com pon en t s for m t wo sepa r a t e cir cu it s. A
DESCRIPTION h igh a m per a ge cir cu it t h a t feeds t h e st a r t er m ot or u p
Th e st a r t in g syst em con sist s of: t o 300+ a m ps, a n d a con t r ol cir cu it t h a t oper a t es on
• St a r t er r ela y less t h a n 20 a m ps.
• St a r t er m ot or (in clu din g a n in t egr a l st a r t er sole- Th e P CM con t r ols a dou ble st a r t over-r ide sa fet y
n oid) t h a t does n ot a llow t h e st a r t er t o be en ga ged if t h e
Ot h er com pon en t s t o be con sider ed a s pa r t of st a r t - en gin e is a lr ea dy r u n n in g.
in g syst em a r e:
• Ba t t er y
• Ba t t er y ca bles
• Ign it ion swit ch a n d key lock cylin der
• Clu t ch peda l posit ion swit ch (m a n u a l t r a n sm is-
DIAGNOSIS AND TESTING - STARTING
sion ) SYSTEM TEST
• P a r k/n eu t r a l posit ion swit ch (a u t om a t ic t r a n s- F or cir cu it descr ipt ion s a n d dia gr a m s, r efer t o t h e
m ission ) Wir in g Dia gr a m s.
• Wir e h a r n esses a n d con n ect ion s.
Th e Ba t t er y, St a r t in g, a n d Ch a r gin g syst em s oper- WARNING: ON VEHICLES EQUIPPED WITH AIR-
a t e in con ju n ct ion wit h on e a n ot h er, a n d m u st be BAGS, REFER TO THE PASSIVE RESTRAINT SYS-
t est ed a s a com plet e syst em . F or cor r ect oper a t ion of TEMS BEFORE ATTEMPTING STEERING WHEEL,
st a r t in g/ch a r gin g syst em s, a ll com pon en t s u sed in STEERING COLUMN, OR INSTRUMENT PANEL
t h ese 3 syst em s m u st per for m wit h in specifica t ion s. COMPONENT DIAGNOSIS OR SERVICE. FAILURE
Wh en a t t em pt in g t o dia gn ose a n y of t h ese syst em s, it TO TAKE THE PROPER PRECAUTIONS COULD
is im por t a n t t h a t you keep t h eir in t er depen den cy in RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
m in d. AND POSSIBLE PERSONAL INJURY.
Th e dia gn ost ic pr ocedu r es u sed in ea ch of t h ese
gr ou ps in clu de t h e m ost ba sic con ven t ion a l dia gn ost ic
INSPECTION
m et h ods, t o t h e m or e soph ist ica t ed On -Boa r d Dia g-
Befor e r em ovin g a n y u n it fr om t h e st a r t in g syst em
n ost ics (OBD) bu ilt in t o t h e P ower t r a in Con t r ol Mod-
for r epa ir or dia gn osis, per for m t h e followin g in spec-
u le (P CM). Use of a n in du ct ion -t ype m illia m per e
t ion s:
a m m et er, volt /oh m m et er, ba t t er y ch a r ger, ca r bon pile
• B a tte ry - Visu a lly in spect t h e ba t t er y for in di-
r h eost a t (loa d t est er ), a n d 12-volt t est la m p m a y be
ca t ion s of ph ysica l da m a ge a n d loose or cor r oded
r equ ir ed.
ca ble con n ect ion s. Det er m in e t h e st a t e-of-ch a r ge a n d
cr a n kin g ca pa cit y of t h e ba t t er y. Ch a r ge or r epla ce
8F - 32 STARTING RS
START I N G (Cont inue d)
t h e ba t t er y, if r equ ir ed. Refer t o t h e Ba t t er y sect ion • S ta rte r S o le n o id - Visu a lly in spect t h e st a r t er
for m or e in for m a t ion . solen oid for in dica t ion s of ph ysica l da m a ge a n d loose
• Ig n itio n S w itc h - Visu a lly in spect t h e ign it ion or cor r oded wir e h a r n ess con n ect ion s.
swit ch for in dica t ion s of ph ysica l da m a ge a n d loose • Wirin g - Visu a lly in spect t h e wir e h a r n ess for
or cor r oded wir e h a r n ess con n ect ion s. da m a ge. Repa ir or r epla ce a n y fa u lt y wir in g, a s
• Tra n s m is s io n Ra n g e S e n s o r o r P a rk /N e u - r equ ir ed. Ch eck for loose or cor r oded wir e h a r n ess
tra l S w itc h - Visu a lly in spect t h e t r a n sm ission con n ect ion s a t m a in en gin e gr ou n d a n d r em ot e ju m p
r a n ge sen sor for in dica t ion s of ph ysica l da m a ge a n d post .
loose or cor r oded wir e h a r n ess con n ect ion s. • P o w e r D is tribu tio n Ce n te r (P D C) - Visu a lly
• S ta rte r Re la y - Visu a lly in spect t h e st a r t er in spect t h e B+ con n ect ion s a t t h e P DC for ph ysica l
r ela y for in dica t ion s of ph ysica l da m a ge a n d loose or da m a ge a n d loose or cor r oded h a r n ess con n ect ion s.
cor r oded wir e h a r n ess con n ect ion s.
• S ta rte r Mo to r - Visu a lly in spect t h e st a r t er
m ot or for in dica t ion s of ph ysica l da m a ge a n d loose or
cor r oded wir e h a r n ess con n ect ion s.
START I N G SY ST EM DI AGN OSI S
STARTER FAILS 1. BATTERY 1. REFER TO THE BATTERY SECTION FOR MORE

TO ENGAGE. DISCHARGED OR INFORMATION. CHARGE OR REPLACE BATTERY, IF
FAULTY. REQUIRED.
2. STARTING CIRCUIT 2. REFER TO FEED CIRCUIT RESISTANCE TEST AND FEED
WIRING FAULTY. CIRCUIT TEST IN THIS SECTION.
3. STARTER RELAY 3. REFER TO RELAY TEST, IN THIS SECTION. REPLACE
FAULTY. RELAY, IF NECESSARY.
4. IGNITION SWITCH 4. REFER TO IGNITION SWITCH TEST, IN THE STEERING
FAULTY. SECTION OR 8 WIRING DIAGRAMS. REPLACE SWITCH, IF
NECESSARY.
5. PARK/NEUTRAL 5. REFER PARK/NEUTRAL POSITION SWITCH TEST, IN THE
POSITION SWITCH TRANSAXLE. SECTION FOR MORE INFORMATION. REPLACE
(AUTO TRANS) FAULTY SWITCH, IF NECESSARY.
OR MIS-ADJUSTED.
6. CLUTCH INTERLOCK 6. REFER TO CLUTCH PEDAL POSITION SWITCH TEST, IN
SWITCH (MAN TRANS) THE CLUTCH. SECTION. REPLACE SWITCH, IF NECESSARY.
FAULTY.
7. STARTER SOLENOID 7. REFER TO SOLENOID TEST, IN THIS SECTION. REPLACE
FAULTY. STARTER ASSEMBLY, IF NECESSARY.
8. STARTER ASSEMBLY 8. IF ALL OTHER STARTING SYSTEM COMPONENTS AND
FAULTY. CIRCUITS CHECK OK, REPLACE STARTER ASSEMBLY.
9. FAULTY TEETH ON 9. ROTATE FLYWHEEL 360°, AND INSPECT TEETH AND RING
RING GEAR. GEAR REPLACED IF DAMAGED.
10. PCM DOUBLE 10. REFER TO PCM DIAGNOSTIC. CHECK FOR CONTINUITY
START OVERRIDE BETWEEN PCM AND TERMINAL 85. REPAIR OPEN CIRCUIT
OUTPUT FAILURE. AS REQUIRED. IF OK, PCM MAY BE DEFECTIVE.
STARTER 1. BATTERY 1. REFER TO THE BATTERY SECTION FOR MORE

ENGAGES, DISCHARGED OR INFORMATION. CHARGE OR REPLACE BATTERY AS
FAILS TO TURN FAULTY. NECESSARY.
ENGINE.
RS STARTING 8F - 33
2. STARTING CIRCUIT 2. REFER TO THE FEED CIRCUIT RESISTANCE TEST AND

WIRING FAULTY. THE FEED CIRCUIT TEST IN THIS SECTION. REPAIR AS
NECESSARY.
4. ENGINE SEIZED. 4. REFER TO THE ENGINE SECTION, FOR DIAGNOSTIC AND
SERVICE PROCEDURES.
5. LOOSE 5. INSPECT FOR LOOSE CONNECTIONS.
CONNECTION AT
BATTERY, PDC,
STARTER, OR ENGINE
GROUND.
STARTER 1. BROKEN TEETH ON 1. REMOVE STARTER. INSPECT RING GEAR AND REPLACE
ENGAGES, STARTER RING GEAR. IF NECESSARY.
SPINS OUT
BEFORE
ENGINE
STARTS.
STARTER DOES 1. STARTER 1. INSTALL STARTER. TIGHTEN STARTER MOUNTING

NOT IMPROPERLY HARDWARE TO CORRECT TORQUE SPECIFICATIONS.
DISENGAGE. INSTALLED.
2. STARTER RELAY 2. REFER TO RELAY TEST, IN THIS SECTION. REPLACE
FAULTY. RELAY, IF NECESSARY.
3. IGNITION SWITCH 3. REFER TO IGNITION SWITCH TEST, IN THE STEERING
FAULTY. SECTION. REPLACE SWITCH, IF NECESSARY.
DIAGNOSIS AND TESTING - CONTROL • To disa ble ign it ion a n d fu el syst em s, discon n ect
t h e Au t om a t ic Sh u t down Rela y (ASD). Th e ASD r ela y
CIRCUIT TEST
is loca t ed in t h e P ower Dist r ibu t ion Cen t er (P DC).
Th e st a r t er con t r ol cir cu it h a s:
Refer t o t h e P DC cover for t h e pr oper r ela y loca t ion .
• St a r t er m ot or wit h in t egr a l solen oid
• St a r t er r ela y
STARTER SOLENOID
• Tr a n sm ission r a n ge sen sor, or P a r k/Neu t r a l
P osit ion swit ch wit h a u t om a t ic t r a n sm ission s WARNING: CHECK TO ENSURE THAT THE TRANS-
• Ign it ion swit ch MISSION IS IN THE PARK POSITION WITH THE
• Ba t t er y PARKING BRAKE APPLIED. THIS MAY RESULT IN
• All r ela t ed wir in g a n d con n ect ion s PERSONAL INJURY OR DEATH.
• P ower t r a in Con t r ol Modu le (P CM)
(1) Ver ify ba t t er y con dit ion . Ba t t er y m u st be in
CAUTION: Before performing any starter tests, the good con dit ion wit h a fu ll ch a r ge befor e per for m in g
ignition and fuel systems must be disabled. a n y st a r t er t est s. Refer t o Ba t t er y Test s.
8F - 34 STARTING RS
(2) P er for m St a r t er Solen oid t est BE F ORE per-
for m in g t h e st a r t er r ela y t est .
(3) P er for m a visu a l in spect ion of t h e st a r t er /
st a r t er solen oid for cor r osion , loose con n ect ion s or
fa u lt y wir in g.
(4) Loca t e a n d r em ove t h e st a r t er r ela y fr om t h e
P ower Dist r ibu t ion Cen t er (P DC). Refer t o t h e P DC
la bel for r ela y iden t ifica t ion a n d loca t ion .
(5) Con n ect a r em ot e st a r t er swit ch or a ju m per
wir e bet ween t h e r em ot e ba t t er y posit ive post a n d
t er m in a l 87 of t h e st a r t er r ela y con n ect or.
(a ) If en gin e cr a n ks, st a r t er /st a r t er solen oid is Starter Relay Pinout
good. Go t o t h e St a r t er Rela y Test .
(b) If en gin e does n ot cr a n k or solen oid ch a t t er s,
ch eck wir in g a n d con n ect or s fr om st a r t er r ela y t o
st a r t er solen oid a n d fr om t h e ba t t er y posit ive t er-
m in a l t o st a r t er post for loose or cor r oded con n ec-
t ion s. P a r t icu la r ly a t st a r t er t er m in a ls.
(c) Repea t t est . If en gin e st ill fa ils t o cr a n k pr op-
er ly, t r ou ble is wit h in st a r t er or st a r t er m ou n t ed
solen oid, a n d r epla ce st a r t er. In spect t h e r in g gea r
t eet h .
STARTER RELAY
WARNING: CHECK TO ENSURE THAT THE TRANS-
MISSION IS IN THE PARK/NEUTRAL POSITION
WITH THE PARKING BRAKE APPLIED. THIS MAY
RESULT IN PERSONAL INJURY OR DEATH.
Starter Relay Pinout
RELAY TEST
Th e st a r t er r ela y is loca t ed in t h e P ower Dist r ibu -
t ion Cen t er (P DC) in t h e en gin e com pa r t m en t . Refer
t o t h e P DC la bel for r ela y iden t ifica t ion a n d loca t ion .
Rem ove t h e st a r t er r ela y fr om t h e P DC a s
descr ibed in t h is gr ou p t o per for m t h e followin g t est s:
(1) A r ela y in t h e de-en er gized posit ion sh ou ld
h a ve con t in u it y bet ween t er m in a ls 87A a n d 30, a n d
n o con t in u it y bet ween t er m in a ls 87 a n d 30. If OK, go
t o St ep 2. If n ot OK, r epla ce t h e fa u lt y r ela y.
(2) Resist a n ce bet ween t er m in a ls 85 a n d 86 (elec-
t r om a gn et ) sh ou ld be 75 ±5 oh m s. If OK, go t o St ep Starter Relay Pinout
3. If n ot OK, r epla ce t h e fa u lt y r ela y.
CAV FUNCTION
(3) Con n ect a ba t t er y B+ lea d t o t er m in a ls 85 a n d
a gr ou n d lea d t o t er m in a l 86 t o en er gize t h e r ela y. 30 B (+)
Th e r ela y sh ou ld click. Also t est for con t in u it y 85 IGNITION SWITCH OUTPUT
bet ween t er m in a ls 30 a n d 87, a n d n o con t in u it y 86 PCM-CONTROLLED GROUND
bet ween t er m in a ls 87A a n d 30. If OK, r efer t o Rela y
Cir cu it Test pr ocedu r e. If n ot OK, r epla ce t h e fa u lt y 87 STARTER RELAY OUTPUT
r ela y. 87A NO CONNECT
RS STARTING 8F - 35
RELAY CIRCUIT TEST IGNITION SWITCH
(1) Th e r ela y com m on feed t er m in a l ca vit y (30) is Aft er t est in g st a r t er solen oid a n d r ela y, t est ign i-
con n ect ed t o ba t t er y volt a ge a n d sh ou ld be h ot a t a ll t ion swit ch a n d wir in g. Refer t o t h e Ign it ion Sect ion
t im es. If OK, go t o St ep 2. If n ot OK, r epa ir t h e open or Wir in g Dia gr a m s for m or e in for m a t ion . Ch eck a ll
cir cu it t o t h e P DC fu se a s r equ ir ed. wir in g for open s or sh or t s, a n d a ll con n ect or s for
(2) Th e r ela y n or m a lly closed t er m in a l (87A) is bein g loose or cor r oded.
con n ect ed t o t er m in a l 30 in t h e de-en er gized posit ion ,
bu t is n ot u sed for t h is a pplica t ion . Go t o St ep 3. BATTERY
(3) Th e r ela y n or m a lly open t er m in a l (87) is con - F or ba t t er y dia gn osis a n d t est in g, r efer t o t h e Ba t -
n ect ed t o t h e com m on feed t er m in a l (30) in t h e en er- t er y sect ion for pr ocedu r es.
gized posit ion . Th is t er m in a l su pplies ba t t er y volt a ge
t o t h e st a r t er solen oid field coils. Th er e sh ou ld be ALL RELATED WIRING AND CONNECTORS
con t in u it y bet ween t h e ca vit y for r ela y t er m in a l 87 Refer t o Wir in g Dia gr a m s for m or e in for m a t ion .
a n d t h e st a r t er solen oid t er m in a l a t a ll t im es. If OK,
go t o St ep 4. If n ot OK, r epa ir t h e open cir cu it t o t h e DIAGNOSIS AND TESTING - FEED CIRCUIT
st a r t er solen oid a s r equ ir ed. RESISTANCE TEST
(4) Th e coil ba t t er y t er m in a l (85) is con n ect ed t o Befor e pr oceedin g wit h t h is oper a t ion , r eview Dia g-
t h e elect r om a gn et in t h e r ela y. It is en er gized wh en n ost ic P r epa r a t ion a n d St a r t er F eed Cir cu it Test s.
t h e ign it ion swit ch is h eld in t h e St a r t posit ion a n d Th e followin g oper a t ion will r equ ir e a volt m et er,
t h e clu t ch peda l is depr essed (m a n u a l t r a n s). Ch eck a ccu r a t e t o 1/10 of a volt .
for ba t t er y volt a ge a t t h e ca vit y for r ela y t er m in a l 86
wit h t h e ign it ion swit ch in t h e St a r t posit ion a n d t h e CAUTION: Ignition and Fuel systems must be dis-
clu t ch peda l is depr essed (m a n u a l t r a n s), a n d n o abled to prevent engine start while performing the
volt a ge wh en t h e ign it ion swit ch is r elea sed t o t h e following tests.
On posit ion . If OK, go t o St ep 5. If n ot OK, ch eck for
a n open or sh or t cir cu it t o t h e ign it ion swit ch a n d (1) To disa ble t h e Ign it ion a n d F u el syst em s, dis-
r epa ir, if r equ ir ed. If t h e cir cu it t o t h e ign it ion swit ch con n ect t h e Au t om a t ic Sh u t down Rela y (ASD). Th e
is OK, see t h e Ign it ion Swit ch Test pr ocedu r e in t h is ASD r ela y is loca t ed in t h e P ower Dist r ibu t ion Cen -
gr ou p. t er (P DC). Refer t o t h e P DC cover for pr oper r ela y
(5) Th e coil gr ou n d t er m in a l (86) is con n ect ed t o loca t ion .
t h e elect r om a gn et in t h e r ela y. It is gr ou n ded by t h e (2) Ga in a ccess t o ba t t er y t er m in a ls.
P CM if t h e con dit ion s a r e r igh t t o st a r t t h e ca r. F or (3) Wit h a ll wir in g h a r n esses a n d com pon en t s
a u t om a t ic t r a n s. ca r s t h e P CM m u st see P a r k Neu - pr oper ly con n ect ed, per for m t h e followin g:
t r a l swit ch low a n d n ea r zer o en gin e speed (r pm ). (a ) Con n ect t h e n ega t ive lea d of t h e volt m et er t o
F or m a n u a l t r a n s. ca r s t h e P CM on ly n eeds t o see t h e ba t t er y n ega t ive post , a n d posit ive lea d t o t h e
n ea r zer o en gin e speed (r pm ) a n d low clu t ch in t er- ba t t er y n ega t ive ca ble cla m p. Rot a t e a n d h old t h e
lock in pu t a n d see n ea r zer o en gin e speed (r pm ). To ign it ion swit ch in t h e START posit ion . Obser ve t h e
dia gn ose t h e P a r k Neu t r a l swit ch of t h e t r a n s r a n ge volt m et er. If volt a ge is det ect ed, cor r ect poor con -
sen sor r efer t o t h e t r a n sa xle sect ion . Ch eck for con t i- t a ct bet ween ca ble cla m p a n d post .
n u it y t o gr ou n d wh ile t h e ign it ion swit ch is in t h e (b) Con n ect posit ive lea d of t h e volt m et er t o t h e
st a r t posit ion a n d if equ ipped t h e clu t ch peda l ba t t er y posit ive post , a n d n ega t ive lea d t o t h e ba t -
depr essed. If n ot OK a n d t h e veh icle h a s a n a u t o- t er y posit ive ca ble cla m p. Rot a t e a n d h old t h e ign i-
m a t ic t r a n s. ver ify P a r k Neu t r a l swit ch oper a t ion . If t ion swit ch key in t h e START posit ion . Obser ve t h e
t h a t ch ecks OK ch eck for con t in u it y bet ween P CM volt m et er. If volt a ge is det ect ed, cor r ect poor con -
a n d t h e t er m in a l 86. Repa ir open cir cu it a s r equ ir ed. t a ct bet ween t h e ca ble cla m p a n d post .
Also ch eck t h e clu t ch in t er lock swit ch oper a t ion if (c) Con n ect n ega t ive lea d of volt m et er t o ba t t er y
equ ipped wit h a m a n u a l t r a n sm ission . If OK, t h e n ega t ive t er m in a l, a n d posit ive lea d t o en gin e
P CM m a y be defect ive. block n ea r t h e ba t t er y ca ble a t t a ch in g poin t .
Rot a t e a n d h old t h e ign it ion swit ch in t h e START
SAFETY SWITCHES posit ion . If volt a ge r ea ds a bove 0.2 volt , cor r ect
F or dia gn ost ics of t h e Tr a n sm ission Ra n ge Sen sor, poor con t a ct a t gr ou n d ca ble a t t a ch in g poin t . If
r efer t o t h e Tr a n sa xle sect ion for m or e in for m a t ion . volt a ge r ea din g is st ill a bove 0.2 volt a ft er cor r ect -
If equ ipped wit h Clu t ch In t er lock/Upst op Swit ch , in g poor con t a ct s, r epla ce gr ou n d ca ble.
r efer t o Dia gn osis a n d Test in g in t h e Clu t ch sect ion . (4) Con n ect posit ive volt m et er lea d t o t h e st a r t er
m ot or h ou sin g a n d t h e n ega t ive lea d t o t h e ba t t er y
n ega t ive t er m in a l. H old t h e ign it ion swit ch key in
8F - 36 STARTING RS
t h e START posit ion . If volt a ge r ea ds a bove 0.2 volt , (1) Ch eck ba t t er y befor e per for m in g t h is t est . Ba t -
cor r ect poor st a r t er t o en gin e gr ou n d. t er y m u st be fu lly ch a r ged.
(a ) Con n ect t h e posit ive volt m et er lea d t o t h e (2) Con n ect a volt -a m per e t est er t o t h e ba t t er y t er-
ba t t er y posit ive t er m in a l, a n d n ega t ive lea d t o ba t - m in a ls. Refer t o t h e oper a t in g in st r u ct ion s pr ovided
t er y ca ble t er m in a l on st a r t er solen oid. Rot a t e a n d wit h t h e t est er bein g u sed.
h old t h e ign it ion swit ch in t h e START posit ion . If (3) To disa ble t h e ign it ion a n d fu el syst em s, dis-
volt a ge r ea ds a bove 0.2 volt , cor r ect poor con t a ct a t con n ect t h e Au t om a t ic Sh u t down Rela y (ASD). Th e
ba t t er y ca ble t o solen oid con n ect ion . If r ea din g is ASD r ela y is loca t ed in t h e P ower Dist r ibu t ion Cen -
st ill a bove 0.2 volt a ft er cor r ect in g poor con t a ct s, t er (P DC). Refer t o t h e P DC cover for pr oper r ela y
r epla ce ba t t er y posit ive ca ble. loca t ion .
(b) If r esist a n ce t est s do n ot det ect feed cir cu it (4) Ver ify t h a t a ll ligh t s a n d a ccessor ies a r e OF F,
fa ilu r es, r epla ce t h e st a r t er m ot or. a n d t h e t r a n sm ission sh ift select or is in t h e PARK
a n d SE T pa r kin g br a ke.
DIAGNOSIS AND TESTING - FEED CIRCUIT
CAUTION: Do not overheat the starter motor or
TEST
draw the battery voltage below 9.6 volts during
NOTE: The following results are based upon the cranking operations.
vehicle being at room temperature.
(5) Rot a t e a n d h old t h e ign it ion swit ch in t h e
Th e followin g pr ocedu r e will r equ ir e a su it a ble START posit ion . Obser ve t h e volt -a m per e t est er (F ig.
volt -a m per e t est er (F ig. 1). 1).
• If volt a ge r ea ds a bove 9.6 volt s, a n d a m per a ge
dr a w r ea ds a bove 280 a m ps, ch eck for en gin e seizin g
or fa u lt y st a r t er.
• If volt a ge r ea ds 12.4 volt s or gr ea t er a n d a m per-
a ge r ea ds 0 t o 10 a m ps, ch eck for cor r oded ca bles
a n d/or ba d con n ect ion s.
• Volt a ge below 9.6 volt s a n d a m per a ge dr a w
a bove 300 a m ps, t h e pr oblem is t h e st a r t er. Repla ce
t h e st a r t er r efer t o st a r t er r em ova l.
(6) Aft er t h e st a r t in g syst em pr oblem s h a ve been
cor r ect ed, ver ify t h e ba t t er y st a t e-of-ch a r ge a n d
ch a r ge ba t t er y if n ecessa r y. Discon n ect a ll t est in g
equ ipm en t a n d con n ect ASD r ela y. St a r t t h e veh icle
sever a l t im es t o a ssu r e t h e pr oblem h a s been cor-
r ect ed.
Fig. 1 Volt Ampere Tester
CAUTION: Before performing any starter tests, the
ignition and fuel systems must be disabled.
SPECI FI CAT I ON S
Torques

Starter Mounting Bolts 47.4 35
Starter Solenoid Battery 11.3 8.3 100
Nut
RS STARTING 8F - 37
STARTER (2) Discon n ect a n d isola t e t h e ba t t er y n ega t ive

ca ble.
(3) Discon n ect solen oid wir e con n ect or fr om t er m i-
MANUFACTURER NIPPONDENSO n a l (F ig. 3).
Engine Application 2.4L /3.3/3.8L
Power rating 1.2 Kw
Voltage 12 VOLTS
No. of Fields 4
No. of Poles 4
Brushes 4
Drive Conventional Gear Train
Free running Test
Voltage 11
Amperage Draw 73 Amp
Minimum Speed 3401 RPM
SolenoidClosing Voltage 7.5 Volts
Cranking Amperage Draw 150 - 200 Amps.
test
E n gin e sh ou ld be u p t o oper a t in g t em per a t u r e.
E xt r em ely h ea vy oil or t igh t en gin e will in cr ea se
st a r t er a m per a ge dr a w.
Fig. 3 BATTERY CABLE AND FIELD WIRE 2.4L

START ER M OT OR (4) Rem ove n u t h oldin g B+ wir e t o t er m in a l.
(5) Discon n ect solen oid a n d B+ wir es fr om st a r t er
REM OVAL t er m in a ls.
(6) Rem ove t h e lower bolt .
(7) Rem ove t h e u pper bolt a n d gr ou n d wir e (F ig.
REMOVAL - 2.4L
4).
(1) Relea se h ood la t ch a n d open h ood (F ig. 2).
Fig. 2 STARTER 2.4L

Fig. 4 Upper Bolt and Ground Wire
8F - 38 STARTING RS
START ER M OT OR (Cont inue d)
(8) Rem ove st a r t er. (7) Rem ove st a r t er fr om bellh ou sin g (F ig. 7).
REMOVAL - 3.3/3.8L
ca ble.
(3) H oist a n d su ppor t veh icle on sa fet y st a n ds.
(4) Rem ove n u t h oldin g B+ t er m in a l t o st a r t er
solen oid (F ig. 5).
Fig. 7 STARTER 3.3/3.8L

1 - BELL HOUSING PLATE
2 - FLYWHEEL
3 - ENGINE MOUNT
4 - STARTER
5 - SPACER
(8) Sepa r a t e st a r t er spa cer fr om t r a n sa xle bell-

h ou sin g.
REMOVAL - 2.5L
Fig. 5 Starter
1 - SOLENOID CONNECTOR (3) Rem ove t h e lower en gin e spla sh sh ield.
2 - B+ CONNECTOR
(4) Rem ove t h e elect r ica l con n ect or s fr om the
(5) Discon n ect solen oid con n ect or fr om st a r t er. st a r t er (F ig. 8).
(6) Rem ove bolt s h oldin g st a r t er t o t r a n sa xle bell-
h ou sin g (F ig. 6).
Fig. 6 Starter Bolts

1 - STARTER
2 - STARTER BOLTS
3 - TRANSAXLE
Fig. 8 STARTER LOCATION
4 - ENGINE MOUNT
RS STARTING 8F - 39
START ER M OT OR (Cont inue d)
(5) Rem ove t h e st a r t er m ou n t in g bolt s (F ig. 9). (3) In st a ll t h e u pper bolt a n d gr ou n d wir e (F ig. 4).
(4) P la ce solen oid a n d B+ wir es in posit ion on
st a r t er t er m in a ls (F ig. 3).
(5) In st a ll n u t t o h old B+ wir e t o t er m in a l.
(6) Con n ect solen oid wir e con n ect or on t o t er m in a l.
(8) Ver ify st a r t er oper a t ion .
(1) P la ce st a r t er spa cer in posit ion on t r a n sa xle
bellh ou sin g, fla n ge t owa r d flywh eel.
(2) P la ce st a r t er in posit ion on bellh ou sin g.
(3) In st a ll bolt s a n d gr ou n d wir e (F ig. 4) t o h old
st a r t er t o t r a n sa xle bellh ou sin g.
(4) Con n ect solen oid con n ect or in t o st a r t er.
(5) In st a ll n u t t o h old B+ t er m in a l t o st a r t er sole-
n oid.
(6) Lower veh icle.
(8) Ver ify st a r t er oper a t ion .
Fig. 9 STARTER MOUNTING BOLTS
1 - Starter
INSTALLATION - 2.5L
2 - Mounting Bolts (1) Ra ise veh icle a n d su ppor t .
(2) In st a ll t h e st a r t er.
(6) Rem ove t h e st a r t er. (3) In st a ll t h e st a r t er m ou n t in g bolt s (F ig. 9).
(4) In st a ll t h e elect r ica l con n ect or s t o t h e st a r t er
(F ig. 8).
I N STALLAT I ON (5) In st a ll t h e lower en gin e spla sh sh ield.
INSTALLATION - 2.4L (7) Lower veh icle.
(1) P la ce st a r t er in posit ion on veh icle.
(2) In st a ll t h e lower bolt s t o h old st a r t er t o t r a n s-
a xle bellh ou sin g.
RS HEATED SYSTEMS 8G - 1
HEATED SYSTEMS
page page
HEATED GLASS . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 HEATED SEAT SYSTEM . . . . . . . . . . . . . . . . . . . . . 7

HEATED MIRRORS . . . . . . . . . . . . . . . . . . . . . . . . . 6
H EAT ED GLASS
TABLE OF CONTENTS
page page
HEATED GLASS REMOVAL ................... ..........4

DESCRIPTION . . . . . . . . . . . . . . . . . . . .......1 INSTALLATION . . . . . . . . . . . . . . . . ..........4
OPERATION . . . . . . . . . . . . . . . . . . . . . .......2 REAR WINDOW DEFOGGER SWITCH
DIAGNOSIS AND TESTING DESCRIPTION . . . . . . . . . . . . . . . . ..........4
ELECTRIC BACKLIGHT (EBL) SYSTEM .....2 OPERATION . . . . . . . . . . . . . . . . . . ..........4
REAR WINDOW DEFOGGER RELAY REAR WINDOW DEFOGGER GRID
DESCRIPTION . . . . . . . . . . . . . . . . . . . .......3 STANDARD PROCEDURE
OPERATION . . . . . . . . . . . . . . . . . . . . . .......3 GRID REPAIR PROCEDURE . . . . ..........5
H EAT ED GLASS
DESCRIPTION
CAUTION: Grid lines can be damaged or scraped
off with sharp instruments. Care should be taken in
cleaning glass or removing foreign materials,
decals or stickers. Normal glass cleaning solvents
or hot water used with rags or toweling is recom-
mended.
Th e r ea r win dow defogger syst em , a lso kn own a s

elect r ica l ba ckligh t (E BL), con sist s of t wo ver t ica l bu s
ba r s lin ked by a ser ies of gr id lin es fir ed on t o t h e
in side su r fa ce of t h e r ea r win dow (F ig. 1).
Th e E BL syst em is t u r n ed ON or OF F by a con t r ol
Fig. 1 Rear Window Defogger - Typical
swit ch loca t ed on t h e A/C-h ea t er con t r ol a t t h e cen t er
1 - REAR DEFOGGER GRID
of t h e in st r u m en t pa n el a n d by a r ea r win dow defog- 2 - REAR WINDOW
ger r ela y t im in g cir cu it in t egr a l t o t h e in t egr a t ed
power m odu le (IP M) (Refer t o 8 - E LE CTRICAL/
H E ATE D GLASS/RE AR WINDOW DE F OGGE R
SWITCH - DE SCRIP TION).
Cir cu it pr ot ect ion is pr ovided by a 40 a m p fu se
loca t ed in t h e IP M.
8G - 2 HEATED GLASS RS
H EAT ED GLASS (Cont inue d)
OPERATION (1) Tu r n t h e ign it ion swit ch t o t h e On posit ion . Set

Wh en t h e r ea r win dow defogger bu t t on is t h e defogger swit ch in t h e On posit ion . Th e r ea r win -
depr essed t o t h e On posit ion , cu r r en t is dir ect ed t o dow defogger oper a t ion ca n be ch ecked by feelin g t h e
t h e r ea r defogger gr id lin es a n d t h e h ea t ed power r ea r win dow gla ss. A dist in ct differ en ce in t em per a -
m ir r or s (if equ ipped). Th e h ea t ed gr id lin es h ea t t h e t u r e bet ween t h e gr id lin es a n d t h e a dja cen t clea r
gla ss t o h elp clea r t h e r ea r win dow a n d side m ir r or gla ss ca n be det ect ed wit h in t h r ee t o fou r m in u t es of
su r fa ces of fog or fr ost . oper a t ion .
Th e elect r ic ba ckligh t (E BL) syst em is con t r olled (2) If a t em per a t u r e differ en ce is n ot det ect ed, u se
by a m om en t a r y swit ch loca t ed in t h e A/C-h ea t er a 12-volt DC volt m et er a n d con t a ct t h e r ea r gla ss
con t r ol on t h e in st r u m en t pa n el. A yellow in dica t or in h ea t in g gr id t er m in a l B wit h t h e n ega t ive lea d, a n d
t h e swit ch will illu m in a t e t o in dica t e wh en t h e sys- t er m in a l A wit h t h e posit ive lea d (F ig. 2). Th e volt -
t em is t u r n ed on . Th e in t egr a t ed power m odu le (IP M) m et er sh ou ld r ea d ba t t er y volt a ge. If t h e volt m et er
con t a in s t h e E BL syst em con t r ol cir cu it r y. does n ot r ea d ba t t er y volt a ge, ch eck t h e followin g:
• Con fir m t h a t t h e ign it ion swit ch is in t h e On
NOTE: The rear window defogger turns off automat- posit ion .
ically after approximately 10 minutes of initial oper- • Ma ke su r e t h a t t h e r ea r gla ss h ea t in g gr id feed
ation. Each following activation cycle of the wir e a n d gr ou n d wir e a r e con n ect ed t o t h e t er m in a ls.
defogger system will last approximately five min- Con fir m t h a t t h e gr ou n d wir e h a s con t in u it y t o
utes. gr ou n d.
• Ch eck t h a t fu se 13 (40 a m p) in t h e in t egr a t ed
Th e E BL syst em will be a u t om a t ica lly t u r n ed off power m odu le (IP M) is OK. Th e fu se m u st be t igh t in
a ft er a pr ogr a m m ed t im e in t er va l of a bou t t en m in - it ’s r ecept a cle a n d a ll elect r ica l con n ect ion s m u st be
u t es. Aft er t h e in it ia l t im e in t er va l h a s expir ed, if t h e secu r e.
defogger swit ch is t u r n ed on a ga in du r in g t h e sa m e (3) Wh en t h e a bove st eps h a ve been com plet ed a n d
ign it ion cycle, t h e defogger syst em will a u t om a t ica lly t h e r ea r gla ss h ea t in g gr id is st ill in oper a t ive, on e or
t u r n off a ft er a bou t five m in u t es. m or e of t h e followin g is fa u lt y. It m a y be n ecessa r y t o
Th e E BL syst em will a u t om a t ica lly sh u t off if t h e con n ect a DRBIII! sca n t ool t o per for m fu r t h er dia g-
ign it ion swit ch is t u r n ed t o t h e Off posit ion , or it ca n n ost ics. Refer t o Body Dia gn ost ic P r ocedu r es.
be t u r n ed off m a n u a lly by depr essin g t h e defogger • Rea r win dow defogger swit ch in t h e A/C-h ea t er
swit ch a secon d t im e. con t r ol.
• J 1850 bu s com m u n ica t ion bet ween t h e A/C-
h ea t er con t r ol a n d t h e fr on t con t r ol m odu le (F CM).
DI AGN OSI S AN D T EST I N G • Rea r win dow defogger (E BL) r ela y in t h e IP M.
• Rea r win dow defogger (E BL) r ela y con t r ol cir cu -
ELECTRIC BACKLIGHT (EBL) SYSTEM it y in t h e IP M.
• Ch eck for a loose wir e con n ect or or a wir e
NOTE: Illumination of the defogger switch indicator pu sh ed ou t of a con n ect or.
lamp means that there is electrical current available
• Rea r win dow gr id lin es (a ll gr id lin es wou ld
at the output of the rear window defogger logic cir- h a ve t o be br oken , or t h e power feed or gr ou n d wir e
cuitry, but does not confirm that the electrical cur- n ot con n ect ed, for t h e en t ir e h ea t in g gr id t o be in op-
rent is reaching the rear glass heating grid lines.
er a t ive).
(4) If t h e syst em oper a t ion h a s been ver ified bu t
NOTE: For circuit descriptions and diagrams of the defogger swit ch LE D in dica t or does n ot illu m in a t e,
rear window defogger system, refer to 8W - WIRING r epla ce t h e A/C-h ea t er con t r ol.
DIAGRAM INFORMATION.
Oper a t ion of t h e elect r ica l ba ckligh t (E BL) syst em

ca n be con fir m ed by t h e followin g:
RS HEATED GLASS 8G - 3
H EAT ED GLASS (Cont inue d)
(5) If br oken defogger gr id lin es a r e su spect ed, u se en er gized wh en t h e r ela y coil is pr ovided a gr ou n d
a 12-volt DC volt m et er a n d con t a ct t er m in a l B wit h pa t h by t h e r ea r win dow defogger r ela y con t r ol in t h e
t h e n ega t ive lea d a n d ea ch r ea r gla ss h ea t in g gr id fr on t con t r ol m odu le (F CM).
lin e a t it ’s m id-poin t wit h t h e posit ive lea d. Th e volt - Th e r ea r win dow defogger (E BL) r ela y is loca t ed in
m et er sh ou ld r ea d a ppr oxim a t ely 6 volt s a t ea ch gr id t h e IP M in t h e en gin e com pa r t m en t . See t h e fu se
lin e m id-poin t C. If t h e volt m et er does n ot r ea d a n d r ela y la you t m a p on t h e in n er su r fa ce of t h e
a ppr oxim a t ely 6 volt s, r epa ir t h e open gr id lin e(s) cover of t h e IP M for r ea r win dow defogger r ela y iden -
(Refer t o 8 - E LE CTRICAL/H E ATE D GLASS/RE AR t ifica t ion a n d loca t ion .
WINDOW DE F OGGE R GRID - STANDARD P ROCE - Th e r ea r win dow defogger (E BL) r ela y ca n n ot be
DURE ). a dju st ed or r epa ir ed a n d, if da m a ged or fa u lt y, it
m u st be r epla ced.
Fig. 2 Grid Line Test

1 - VOLTMETER Fig. 3 Rear Window Defogger (EBL) Relay
2 - VOLTAGE FEED (A)
3
4
-
-
FEED WIRE
MID-POINT (C)
OPERATION
5 - HEATED WINDOW GRID Th e ISO-st a n da r d r ea r win dow defogger (E BL)
6 - GROUND WIRE r ela y con sist s of a n elect r om a gn et ic coil, a r esist or or
7 - GROUND (B) diode, a n d t h r ee (t wo fixed a n d on e m ova ble) elect r i-
ca l con t a ct s. Th e m ova ble (com m on feed) r ela y con -
REAR WI N DOW DEFOGGER t a ct is h eld a ga in st on e of t h e fixed con t a ct s
RELAY (n or m a lly closed) by spr in g pr essu r e. Wh en t h e elec-
t r om a gn et ic coil is en er gized, it dr a ws t h e m ova ble
DESCRIPTION con t a ct a wa y fr om t h e n or m a lly closed fixed con t a ct ,
a n d h olds it a ga in st t h e ot h er (n or m a lly open ) fixed
Th e r ea r win dow defogger (E BL) r ela y (F ig. 3) is a
con t a ct .
In t er n a t ion a l St a n da r ds Or ga n iza t ion (ISO)-t ype
Wh en t h e elect r om a gn et ic coil is de-en er gized,
r ela y. Rela ys con for m in g t o t h e ISO specifica t ion s
spr in g pr essu r e r et u r n s t h e m ova ble con t a ct t o t h e
h a ve com m on ph ysica l dim en sion s, cu r r en t ca pa ci-
n or m a lly closed posit ion . Th e r esist or is con n ect ed in
t ies, t er m in a l pa t t er n s, a n d t er m in a l fu n ct ion s. Th e
pa r a llel wit h t h e elect r om a gn et ic coil in t h e r ela y,
r ea r win dow defogger r ela y is a elect r om ech a n ica l
a n d h elps t o dissipa t e volt a ge spikes t h a t a r e pr o-
device t h a t swit ch es ba t t er y cu r r en t t h r ou gh a fu se
du ced wh en t h e coil is de-en er gized.
in t h e in t egr a t ed power m odu le (IP M) t o t h e r ea r
Refer t o t h e a ppr opr ia t e wir in g in for m a t ion for
win dow defogger gr id a n d swit ch es ba t t er y cu r r en t
dia gn osis a n d t est in g of t h e E BL r ela y a n d for com -
t h r ou gh a posit ive t h er m a l coefficien t (P TC) in t h e
plet e E BL syst em wir in g dia gr a m s.
IP M t o t h e ou t side m ir r or h ea t in g gr ids. Th e r ela y is
8G - 4 HEATED GLASS RS
REAR WI N DOW DEFOGGER RELAY (Cont inue d)
REMOVAL REAR WI N DOW DEFOGGER

ca ble.
SWI T CH
(2) Rem ove t h e cover fr om t h e in t egr a t ed power
m odu le (IP M) (F ig. 4). DESCRIPTION
Th e swit ch for t h e E BL syst em is in t egr a t ed in t o
NOTE: Refer to the fuse and relay layout map on t h e A/C-h ea t er con t r ol loca t ed in t h e cen t er of t h e
the inner surface of the cover of the IPM for rear in st r u m en t pa n el (F ig. 5).
window defogger (EBL) relay identification and Wh en t h e r ea r win dow defogger swit ch is t u r n ed t o
location. t h e ON posit ion , cu r r en t is dir ect ed t o t h e r ea r defog-
ger gr id lin es a n d t h e h ea t ed power m ir r or s (if
(3) Rem ove t h e E BL r ela y fr om t h e IP M. equ ipped). Th e h ea t ed gr id lin es h ea t t h e gla ss t o
h elp clea r t h e su r fa ce of fog or fr ost .
Fig. 5 A/C-Heater Control - Typical

1 - TRIM BEZEL
Fig. 4 Rear Window Defogger (EBL) Relay 2 - INFRARED TEMPERATURE SENSOR
1 - INTEGRATED POWER MODULE (IPM) 3 - A/C REQUEST SWITCH
2 - REAR WINDOW DEFOGGER (EBL) RELAY 4 - EBL/HEATED MIRROR SWITCH
3 - FRONT CONTROL MODULE (FCM) 5 - FRONT WINDOW DEFROSTER SELECTOR
INSTALLATION OPERATION
Depr essin g t h e r ea r win dow defogger swit ch en er-
NOTE: Refer to the fuse and relay map on the inner gizes t h e A/C-h ea t er con t r ol m odu le wh ich t h en
surface of the cover of the integrated power module r equ est s t h e fr on t con t r ol m odu le (F CM) t o a ct iva t e
(IPM) for rear window defogger (EBL) relay identifi- t h e r ea r win dow defogger (E BL) r ela y via t h e com -
cation and location. m u n ica t ion bu s. Th e E BL r ela y con t r ols t h e cu r r en t
t o flow t o t h e gr ids of t h e r ea r win dow defogger a n d
(1) P osit ion t h e E BL r ela y in t o t h e pr oper r ecept a - t h e h ea t ed power side view m ir r or s. Th e E BL r ela y
cle in t h e IP M. will be on for a ppr oxim a t ely 10 m in u t es or u n t il t h e
(2) Align t h e E BL r ela y t er m in a ls wit h t h e t er m i- con t r ol swit ch or ign it ion is t u r n ed off. An a m ber
n a l ca vit ies in t h e IP M r ecept a cle. in dica t or la m p in t h e defogger swit ch illu m in a t es t o
(3) P u sh down fir m ly on t h e E BL r ela y u n t il t h e in dica t e wh en t h e E BL syst em is On .
t er m in a ls a r e fu lly sea t ed in t h e t er m in a l ca vit ies. Th e r ea r win dow defogger swit ch a n d in dica t or
(4) In st a ll t h e cover on t o t h e IP M. la m p ca n n ot be r epa ir ed a n d, if fa u lt y or da m a ged,
(5) Recon n ect t h e n ega t ive ba t t er y ca ble. t h e en t ir e A/C-h ea t er con t r ol m u st be r epla ced.
RS HEATED GLASS 8G - 5
REAR WI N DOW DEFOGGER (7) Apply a t h in la yer of con du ct ive epoxy t o t h e

t er m in a l a n d pla ce it in t h e pr oper loca t ion on t h e
GRI D bu s ba r. To pr even t t h e t er m in a l fr om m ovin g wh ile
t h e epoxy is cu r in g, it m u st be wedged or cla m ped.
(8) Ca r efu lly r em ove t h e m a skin g t a pe or t em -
STAN DARD PROCEDU RE pla t e.
GRID REPAIR PROCEDURE CAUTION: Do not allow the glass surface to exceed
204° C (400° F) when using a heat gun, or the glass
WARNING: Materials contained in the Repair Kit may fracture.
(Part Number 04549275) may cause skin or eye irri-
tation. The kit contains epoxy resin and amine type (9) Allow t h e epoxy t o cu r e 24 h ou r s a t r oom t em -
hardener, which are harmful if swallowed. Avoid per a t u r e, or ca r efu lly u se a h ea t gu n for fift een m in -
contact with the skin and eyes. For skin contact, u t es. Wh en u sin g a h ea t gu n , h old it a ppr oxim a t ely
wash the affected areas with soap and water. For 25.4 cen t im et er s (10 in ch es) fr om t h e r epa ir a n d do
contact with the eyes, flush with plenty of water. Do n ot a llow t h e gla ss su r fa ce t o exceed 204° C (400° F ).
not take internally. If taken internally, induce vomit-
ing and call a physician immediately. Use with ade- NOTE: Do not attach the wire harness connectors
quate ventilation. Do not use near fire or flame. to the terminals until the curing process is com-
Contains flammable solvents. Keep out of the reach plete.
of children. Failure to follow the warnings could
result in possible personal injury or death. (10) Aft er t h e con du ct ive epoxy is pr oper ly cu r ed,
r em ove t h e wedge or cla m p fr om t h e t er m in a l.
Repa ir of t h e r ea r gla ss h ea t in g gr id lin es, bu s (11) Con n ect t h e wir e h a r n ess lea ds t o t h e gr id
ba r s or t er m in a ls ca n be a ccom plish ed u sin g t h e t er m in a ls a n d ver ify E BL oper a t ion .
Mopa r ! Rea r Win dow Defogger Repa ir Kit (P a r t
Nu m ber 04549275) or equ iva len t .
(1) Ma sk t h e r epa ir a r ea wit h m a skin g t a pe so
t h a t t h e con du ct ive epoxy ca n be a pplied n ea t ly (F ig.
6). E xt en d t h e epoxy a pplica t ion on t o t h e gr id lin e or
t h e bu s ba r on ea ch side of t h e br ea k.
(2) F ollow t h e in st r u ct ion s in t h e r epa ir kit for
pr epa r in g t h e da m a ged a r ea .
(3) Rem ove t h e pa cka ge sepa r a t or cla m p a n d m ix
t h e t wo con du ct ive epoxy com pon en t s t h or ou gh ly
wit h in t h e pa cka gin g. F old t h e pa cka ge in h a lf a n d
cu t t h e cen t er cor n er t o dispen se t h e epoxy.
(4) F or gr id lin e r epa ir s, m a sk t h e a r ea t o be
r epa ir ed wit h m a skin g t a pe or u se a t em pla t e.
(5) Apply t h e epoxy t h r ou gh t h e slit in t h e m a sk-
Fig. 6 Grid Line Repair
in g t a pe or t em pla t e. Over la p bot h en ds of t h e br ea k
1 - BREAK
by a t lea st 19 m illim et er s (0.75 in ch ). 2 - GRID LINE
(6) F or a t er m in a l r epla cem en t , m a sk t h e a dja cen t 3 - MASKING TAPE
a r ea s so t h e epoxy ca n be ext en ded on t o t h e a dja cen t
gr id lin e a s well a s t h e bu s ba r. Apply a t h in la yer of
epoxy t o t h e a r ea wh er e t h e t er m in a l wa s fa st en ed
a n d on t o t h e a dja cen t gr id lin e.
8G - 6 HEATED MIRRORS RS
H EAT ED M I RRORS
TABLE OF CONTENTS
page page
HEATED MIRRORS OPERATION ............................6

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 6
H EAT ED M I RRORS
DESCRIPTION
Th e opt ion a l h ea t ed m ir r or syst em is con t r olled by
t h e m om en t a r y r ea r win dow defogger swit ch wh ich is
in t egr a l t o t h e A/C-h ea t er con t r ol (F ig. 1). An a m ber
in dica t or la m p in t h e swit ch will illu m in a t e t o in di-
ca t e wh en t h e r ea r win dow defogger (E BL) syst em is
t u r n ed on .
Th e h ea t ed m ir r or syst em on ly oper a t es in con cer t
wit h t h e E BL syst em , a n d will be a u t om a t ica lly sh u t
off a ft er a pr ogr a m m ed t im e in t er va l of a bou t 10
m in u t es. Aft er t h e in it ia l t im e in t er va l h a s expir ed, if
t h e defogger swit ch is t u r n ed on a ga in du r in g t h e
sa m e ign it ion cycle, t h e h ea t ed m ir r or syst em will
a u t om a t ica lly sh u t off a ft er a bou t 5 m in u t es.
Th e h ea t ed m ir r or syst em will a u t om a t ica lly sh u t Fig. 1 A/C-Heater Control Panel
off if t h e ign it ion swit ch is t u r n ed t o t h e Off posit ion , 1 - TRIM BEZEL
2 - INFRARED TEMPERATURE SENSOR
or it ca n be sh u t off m a n u a lly by pr essin g t h e r ea r 3 - A/C REQUEST SWITCH
win dow defogger swit ch a secon d t im e. 4 - EBL/HEATED MIRROR SWITCH
5 - FRONT WINDOW DEFROSTER SELECTOR
OPERATION
If t h e ou t side m ir r or h ea t in g gr ids a r e bot h in oper-
Wh en t h e r ea r win dow defogger swit ch is pr essed,
a t ive, r efer t o DIAGNOSIS AND TE STING - RE AR
t h e r ea r win dow defogger (E BL) syst em becom es a ct i-
WINDOW DE F OGGE R SYSTE M in h is gr ou p. If
va t ed a n d a n elect r ic h ea t er gr id loca t ed beh in d t h e
on ly on e of t h e ou t side m ir r or h ea t in g gr ids is in op-
gla ss of ea ch of t h e ou t side r ea r view m ir r or s is en er-
er a t ive, Refer t o 8 - E LE CTRICAL/P OWE R MIR-
gized. Wh en en er gized, ea ch of t h ese h ea t er gr ids
RORS - DIAGNOSIS AND TE STING.
pr odu ce h ea t t o h elp clea r t h e ou t side r ea r view m ir-
Th e h ea t in g gr id beh in d ea ch ou t side m ir r or gla ss
r or s of ice, sn ow, or fog.
ca n n ot be r epa ir ed a n d, if fa u lt y or da m a ged, t h e
en t ir e power m ir r or a ssem bly m u st be r epla ced.
RS HEATED SEAT SYSTEM 8G - 7
H EAT ED SEAT SY ST EM
TABLE OF CONTENTS
page page
HEATED SEAT SYSTEM HEATED SEAT ELEMENTS

DIAGNOSIS AND TESTING DIAGNOSIS AND TESTING
HEATED SEAT SYSTEM . . . . . . . . . . . . . . . . . 8 HEATED SEAT ELEMENTS . . . . . . . . . . . . . . 11
HEATED SEAT SWITCH REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 HEATED SEAT SENSOR
DIAGNOSIS AND TESTING DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13
DRIVER HEATED SEAT SWITCH ..........9 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 DIAGNOSIS AND TESTING
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10 HEATED SEAT SENSOR . . . . . . . . . . . . . . . . 13
H EAT ED SEAT SY ST EM Veh icles wit h t h e h ea t ed sea t opt ion ca n be visu -

a lly iden t ified by t h e t wo sepa r a t e h ea t ed sea t
swit ch es loca t ed in t h e in st r u m en t pa n el cen t er
DESCRIPTION
st a ck, ju st a bove t h e r a dio (F ig. 1). Th e h ea t ed sea t
syst em a llows t h e fr on t sea t dr iver a n d pa ssen ger t o
select fr om t wo differ en t levels of su pplem en t a l elec-
t r ica l sea t h ea t in g (H I/LO), or n o sea t h ea t in g t o su it
t h eir in dividu a l com for t r equ ir em en t s. Th e h ea t ed
sea t syst em for t h is veh icle in clu des t h e followin g
m a jor com pon en t s:
• He a te d S e a t Ele m e n ts - F ou r h ea t ed sea t ele-
m en t s a r e u sed per veh icle, t wo for ea ch fr on t sea t .
On e h ea t ed sea t elem en t is in t egr a l t o ea ch fr on t
sea t t r im cover, on e in t h e sea t ba ck a n d on e in t h e
sea t bot t om (cu sh ion ). Ser vice r epla cem en t h ea t in g
elem en t s a r e a va ila ble, (Refer t o 8 - E LE CTRICAL/
H E ATE D SE ATS/H E ATE D SE AT E LE ME NT -
DE SCRIP TION) for a ddit ion a l in for m a t ion .
• He a te d S e a t Mo d u le s - Two h ea t ed sea t m od-
u les a r e u sed per veh icle. On e m odu le is m ou n t ed t o
ea ch of t h e sea t cu sh ion pa n s, loca t ed u n der t h e for-
wa r d edge of ea ch fr on t sea t . (Refer t o 8 - E LE CTRI-
CAL/E LE CTRONIC CONTROL MODULE S/
ME MORY H E ATE D SE AT/MIRROR MODULE -
DE SCRIP TION) for a ddit ion a l in for m a t ion .
• He a te d S e a t S e n s o rs - Two h ea t ed sea t sen -
Fig. 1 HEATED SEAT SWITCH LOCATIONS sor s a r e u sed per veh icle, on e for ea ch fr on t sea t . Th e
1 - HEATED SEAT SWITCHES h ea t ed sea t sen sor s a r e in t egr a l t o ea ch of t h e h ea t ed
sea t bot t om s (cu sh ion s).
• He a te d S e a t S w itc h - Two h ea t ed sea t
swit ch es a r e u sed per veh icle, on e for t h e dr iver a n d
on e for t h e pa ssen ger side fr on t sea t s. Th e swit ch es
a r e m ou n t ed in t h e in st r u m en t pa n el cen t er st a ck.
(Refer t o 8 - E LE CTRICAL/H E ATE D SE ATS/
DRIVE R H E ATE D SE AT SWITCH - DE SCRIP TION)
for a ddit ion a l in for m a t ion .
8G - 8 HEATED SEAT SYSTEM RS
H EAT ED SEAT SY ST EM (Cont inue d)
H a r d wir ed cir cu it r y con n ect s t h e h ea t ed sea t sys- H EAT ED SEAT SWI T CH
t em com pon en t s t o ea ch ot h er t h r ou gh t h e elect r ica l
syst em of t h e veh icle. Th ese cir cu it s m a y be con -
DESCRIPTION
n ect ed t o ea ch ot h er, t o t h e veh icle elect r ica l syst em
a n d t o t h e h ea t ed sea t syst em com pon en t s t h r ou gh
t h e u se of a com bin a t ion of solder ed splices a n d
splice block con n ect or s. Refer t o t h e a ppr opr ia t e wir-
in g in for m a t ion for com plet e cir cu it sch em a t ic or con -
n ect or pin -ou t in for m a t ion .
OPERATION
Th e h ea t ed sea t syst em com pon en t s oper a t e on
ba t t er y cu r r en t r eceived t h r ou gh a fu se in t h e In t e-
gr a t ed P ower Modu le (IP M) on a fu sed ign it ion
swit ch ou t pu t (r u n ) cir cu it fr om t h e Body Con t r ol
Modu le (BCM). Th e syst em will on ly oper a t e wh en
t h e ign it ion swit ch is in t h e On posit ion . Th e h ea t ed
sea t syst em will be t u r n ed Off a u t om a t ica lly wh en -
ever t h e ign it ion swit ch is t u r n ed t o a n y posit ion
except On . Also, t h e h ea t ed sea t syst em will n ot oper-
a t e wh en t h e su r fa ce t em per a t u r e of t h e sea t cu sh ion
cover a t eit h er h ea t ed sea t sen sor is a bove t h e
design ed t em per a t u r e set poin t s of t h e syst em .

Fig. 2 HEATED SEAT SWITCH LOCATION
HEATED SEAT SYSTEM 1 - HEATED SEAT SWITCHES
Th e m ost efficien t m ea n s of dia gn osin g t h e h ea t ed
sea t syst em is by in dividu a l com pon en t . F or dia gn o- Th e h ea t ed sea t swit ch es a r e m ou n t ed in t h e
sis of a specific com pon en t r efer t o t h e followin g: in st r u m en t pa n el cen t er bezel (F ig. 2). Th e t wo t h r ee-
• H ea t ed sea t m odu le, (Refer t o 8 - E LE CTRICAL/ posit ion r ocker-t ype swit ch es, on e swit ch for ea ch
E LE CTRONIC CONTROL MODULE S/ME MORY fr on t sea t , a r e in cor por a t ed in t o on e la r ge swit ch
H E ATE D SE AT/MIRROR MODULE - DIAGNOSIS a ssem bly t h a t a lso in clu des t h e h a za r d, r ea r win dow
AND TE STING). wiper a n d wa sh er swit ch es. E a ch h ea t ed sea t swit ch
• H ea t ed sea t elem en t s, (Refer t o 8 - E LE CTRI- pr ovides a r esist or m u lt iplexed sign a l t o it s r espec-
CAL/H E ATE D SE ATS/H E ATE D SE AT E LE ME NT - t ive H ea t ed Sea t Modu le (H SM) t h r ou gh sepa r a t e
DIAGNOSIS AND TE STING). h a r d wir ed cir cu it s. E a ch swit ch h a s a n Off, Low,
• H ea t ed sea t swit ch , (Refer t o 8 - E LE CTRICAL/ a n d H igh posit ion so t h a t bot h t h e dr iver a n d t h e
H E ATE D SE ATS/DRIVE R H E ATE D SE AT SWITCH fr on t sea t pa ssen ger ca n select a pr efer r ed sea t h ea t -
- DIAGNOSIS AND TE STING). in g m ode. E a ch swit ch h a s t wo Ligh t -E m it t in g
• H ea t ed sea t sen sor, (Refer t o 8 - E LE CTRICAL/ Diodes (LE D) wh ich ligh t t o in dica t e t h a t t h e h ea t er
H E ATE D SE ATS/H E ATE D SE AT SE NSOR - DIAG- for t h e sea t is t u r n ed on .
NOSIS AND TE STING). Th e h ea t ed sea t swit ch es a n d t h eir LE Ds ca n n ot
Refer t o t h e a ppr opr ia t e wir in g in for m a t ion for be r epa ir ed. If eit h er swit ch or LE D is fa u lt y or da m -
com plet e cir cu it sch em a t ic or con n ect or pin -ou t in for- a ged, t h e en t ir e swit ch a ssem bly m u st be r epla ced.
m a t ion .
H EAT ED SEAT SWI T CH (Cont inue d)
OPERATION (3) Con n ect t h e ba t t er y n ega t ive ca ble. P la ce t h e

Th er e a r e t h r ee posit ion s t h a t ca n be select ed wit h h ea t ed sea t swit ch in t h e LO posit ion . Usin g a n
ea ch of t h e h ea t ed sea t swit ch es: Off, Low, or H igh . Oh m m et er, ch eck t h e r esist a n ce bet ween ca vit ies 2
Wh en t h e left side of t h e swit ch r ocker is fu lly a n d 3 of t h e gr a y con n ect or n ot ed a bove. Resist a n ce
depr essed, t h e Low posit ion is select ed a n d t h e low sh ou ld be a bou t 3.5 kiloh m s (3500 oh m s). If n ot OK,
posit ion LE D in dica t or illu m in a t es. Wh en t h e r igh t ch eck r esist a n ce dir ect ly a t swit ch , a s n ot ed below. If
side of t h e swit ch r ocker is fu lly depr essed, t h e H igh OK, pr oceed t o t h e n ext st ep. If n ot OK, r epla ce t h e
posit ion is select ed a n d t h e h igh posit ion LE D in di- fa u lt y swit ch .
ca t or illu m in a t es. Wh en t h e swit ch r ocker is m oved (4) P la ce t h e h ea t ed sea t swit ch in t h e H I posit ion .
t o it s n eu t r a l posit ion (m iddle), Off is select ed a n d Usin g a n oh m m et er, ch eck t h e r esist a n ce bet ween
bot h LE D in dica t or s a r e ext in gu ish ed. ca vit ies 2 a n d 3 of t h e gr a y con n ect or n ot ed a bove.
E a ch swit ch pr ovides sepa r a t e r esist or, h a r d wir e Resist a n ce sh ou ld be a bou t 1.4 kiloh m s (1400 oh m s).
in pu t s t o it s r espect ive H ea t ed Sea t Modu le (H SM) t o If n ot OK, ch eck r esist a n ce dir ect ly a t t h e swit ch , a s
in dica t e t h e select ed swit ch posit ion . Th e h ea t ed sea t in dica t ed in t h e H ea t ed Sea t Swit ch Test Ta ble. If
m odu le r espon ds t o t h e h ea t ed sea t swit ch st a t u s OK, pr oceed. If n ot OK r epla ce t h e fa u lt y swit ch .
m essa ges by con t r ollin g t h e ou t pu t t o t h e sea t h ea t er (5) Wit h t h e syst em ON in t h e H I posit ion , ch eck
elem en t s of t h e select ed sea t . Th e Low h ea t posit ion for ba t t er y volt a ge a n d gr ou n d a t ca vit ies 4 a n d 1. If
set poin t is a bou t 36° C (97° F ), a n d t h e H igh h ea t OK, pr oceed wit h t est in g r em a in in g com pon en t s. If
posit ion set poin t is a bou t 41° C (105° F ). n ot OK, r epa ir open or sh or t ed wir in g.
CHECKING SWITCH ONLY

DI AGN OSI S AN D T EST I N G (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble. Rem ove t h e cen t er bezel fr om t h e in st r u m en t
DRIVER HEATED SEAT SWITCH pa n el (Refer t o 23 - BODY/INSTRUME NT PANE L/
Refer t o t h e a ppr opr ia t e wir in g in for m a t ion for INSTRUME NT PANE L CE NTE R BE ZE L -
com plet e cir cu it sch em a t ic or con n ect or pin -ou t in for- RE MOVAL). Ch eck for con t in u it y bet ween t h e
m a t ion . gr ou n d cir cu it ca vit y (#10) of t h e in st r u m en t pa n el
cen t er bezel swit ch elect r ica l con n ect or a n d a good
WARNING: REFER TO THE RESTRAINTS SECTION gr ou n d. Th er e sh ou ld be con t in u it y. If OK, go t o St ep
OF THIS MANUAL BEFORE ATTEMPTING ANY 2. If n ot OK, r epa ir t h e open gr ou n d cir cu it t o gr ou n d
STEERING WHEEL, STEERING COLUMN, SEAT OR a s r equ ir ed.
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR (2) Con n ect t h e ba t t er y n ega t ive ca ble. Tu r n t h e
SERVICE. FAILURE TO TAKE THE PROPER PRE- ign it ion swit ch t o t h e On posit ion . Ch eck for ba t t er y
CAUTIONS COULD RESULT IN ACCIDENTAL AIR- volt a ge a t t h e fu sed ign it ion swit ch ou t pu t (r u n ) cir-
BAG DEPLOYMENT AND POSSIBLE PERSONAL cu it ca vit y of t h e in st r u m en t pa n el cen t er bezel
INJURY. swit ch elect r ica l con n ect or (#4). If OK, t u r n t h e ign i-
t ion swit ch t o t h e Off posit ion , a n d go t o St ep 3. If
n ot OK, r epa ir t h e open fu sed ign it ion swit ch ou t pu t
CHECKING SWITCH SIGNAL AND WIRING AT THE (r u n ) cir cu it a s r equ ir ed.
MODULE (3) Test t h e h ea t ed sea t swit ch a s sh own in t h e
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive H ea t ed Sea t Swit ch Test ch a r t a n d t h e con n ect or pin -
ca ble. ou t below (F ig. 3). If OK, go t o St ep 4. If n ot OK,
(2) Access a n d discon n ect t h e gr a y 4-wa y con n ect or r epla ce t h e in st r u m en t pa n el cen t er bezel swit ch
fr om t h e h ea t ed sea t m odu le. Visu a lly in spect wir in g a ssem bly.
t er m in a ls for da m a ge t h a t wou ld pr even t posit ive
con n ect ion . If n ot OK, r epa ir or r epla ce t h e n ecessa r y
com pon en t s.
REMOVAL
BAGS, REFER TO THE RESTRAINTS SECTION OF
THIS MANUAL BEFORE ATTEMPTING ANY STEER-
ING WHEEL, STEERING COLUMN, SEAT OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR
SERVICE. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.

ca ble.
(2) Rem ove t h e in st r u m en t pa n el cen t er bezel,
(Refer t o 23 - BODY/INSTRUME NT PANE L/IN-
STRUME NT PANE L CE NTE R BE ZE L - RE MOVAL).
(3) Rem ove t h e t h r ee scr ews (F ig. 4) t h a t secu r e
t h e h ea t ed sea t swit ch t o t h e ba ck of t h e in st r u m en t
pa n el cen t er bezel.
Fig. 3 Instrument Panel Center Bezel Switch

Connector
DRIVER HEATED SEAT SWITCH TEST

SWITCH RESISTANCE RESISTANCE
POSITION BETWEEN (OHMS)
Off Pin 4 & 5 OPEN
Low Pin 4 & 5 3570
High Pin 4 & 5 1430
All resistance values are ±1%.
PASSENGER HEATED SEAT SWITCH TEST

SWITCH RESISTANCE RESISTANCE
POSITION BETWEEN (OHMS)
Off Pin 3 & 4 OPEN
Low Pin 3 & 4 3570
High Pin 3 & 4 1430
All resistance values are ±1%. Fig. 4 SWITCH RETAINING SCREWS
(4) Con n ect t h e in st r u m en t pa n el cen t er bezel 1 - HEATED SEAT SWITCH ASSEMBLY
swit ch a n d t est t h e h ea t ed sea t syst em for pr oper 2 - RETAINING SCREWS
oper a t ion . If t h e syst em is st ill in oper a t ive pr oceed
(4) Rem ove t h e h ea t ed sea t swit ch fr om t h e ba ck
wit h ch eckin g r em a in in g com pon en t s.
of t h e in st r u m en t pa n el cen t er bezel.
INSTALLATION
(1) P osit ion t h e h ea t ed sea t swit ch on t o t h e ba ck
of t h e in st r u m en t pa n el cen t er bezel.
(2) In st a ll a n d t igh t en t h e t h r ee scr ews (F ig. 5)
t h a t secu r e t h e h ea t ed sea t swit ch t o t h e ba ck of t h e
in st r u m en t pa n el cen t er bezel. Tigh t en t h e scr ews t o
1.5 N·m (13 in . lbs.).
OPERATION
Th e h ea t ed sea t elem en t s r esist t h e flow of elect r i-
ca l cu r r en t . Wh en ba t t er y cu r r en t is pa ssed t h r ou gh
t h e elem en t s, t h e r esist a n ce of t h e elem en t s t o t h e
cu r r en t flow is r elea sed in t h e for m of h ea t . Th e t em -
per a t u r e sen sor is a Nega t ive Tem per a t u r e Coeffi-
cien t (NTC) t h er m ist or. Wh en t h e t em per a t u r e of t h e
sea t cu sh ion cover r ises, t h e r esist a n ce of t h e sen sor
decr ea ses. Th e h ea t ed sea t m odu le su pplies a five-
volt sign a l t o on e side of ea ch sen sor, a n d m on it or s
t h e volt a ge dr op t h r ou gh t h e sen sor on a r et u r n cir-
cu it . Th e h ea t ed sea t m odu le u ses t h is t em per a t u r e
sen sor in pu t t o m on it or t h e t em per a t u r e of t h e sea t ,
a n d r egu la t es t h e cu r r en t flow t o t h e sea t h ea t in g
elem en t s a ccor din gly.

HEATED SEAT ELEMENTS
Th e wir e h a r n ess con n ect or s for t h e sea t cu sh ion
a n d sea t ba ck h ea t in g elem en t s a r e loca t ed u n der t h e
Fig. 5 SWITCH RETAINING SCREWS sea t , a t t h e h ea t ed sea t m odu le. Refer t o t h e a ppr o-
1 - HEATED SEAT SWITCH ASSEMBLY pr ia t e wir in g in for m a t ion for com plet e cir cu it sch e-
2 - RETAINING SCREWS m a t ic or con n ect or pin -ou t in for m a t ion .
In or der t o a ccess a n d t est t h e h ea t ed sea t ele-
(3) In st a ll t h e cen t er bezel on t o t h e in st r u m en t m en t s it will be n ecessa r y t o r em ove t h e a ppr opr ia t e
pa n el, (Refer t o 23 - BODY/INSTRUME NT PANE L/ fr on t sea t r et a in in g bolt s a n d la y t h e sea t r ea r wa r d,
INSTRUME NT PANE L CE NTE R BE ZE L - INSTAL- u p a ga in st on e of t h e r ea r sea t s. It is n ot n ecessa r y
LATION). t o discon n ect t h e sea t elect r ica l con n ect or s, ju st u se
(4) Con n ect t h e ba t t er y n ega t ive ca ble. ca r e n ot t o da m a ge t h e a t t a ch ed wir e h a r n esses
wh ile t est in g.
H EAT ED SEAT ELEM EN T S NOTE: When checking heated seat elements for
continuity, be certain to move the heating element
DESCRIPTION being checked. Moving the element, such as sitting
Th e h ea t ed sea t syst em in clu des t wo sea t h ea t in g in the seat will eliminate the possibility of an inter-
elem en t s in ea ch fr on t sea t , on e for t h e sea t cu sh ion mittent open in the element which would only be
a n d t h e ot h er for t h e sea t ba ck. Th e t wo elem en t s for evident if the element was in a certain position.
ea ch sea t t h a t a r e con n ect ed in ser ies wit h t h e Failure to check the element in various positions
H ea t ed Sea t Modu le (H SM). Th e t em per a t u r e sen sor could result in an incomplete test.
is a Nega t ive Tem per a t u r e Coefficien t (NTC) t h er-
m ist or. On e t em per a t u r e sen sor is u sed for ea ch sea t ,
a n d it is loca t ed on t h e sea t cu sh ion h ea t in g elem en t SEAT CUSHION ELEMENT
for a ll m odels. (1) F r om u n der t h e veh icle, r em ove t h e a ppr opr i-
Th e sea t h ea t in g elem en t s a r e a t t a ch ed t o t h e sea t a t e sea t s fou r r et a in in g n u t s.
cu sh ion cover t r im a n d sea t ba ck cover t r im u n it s. (2) F r om in side t h e veh icle, pu ll t h e sea t u p, off
Th e h ea t ed sea t elem en t s a n d t h e t em per a t u r e sen - t h e m ou n t in g st u ds a n d la y it ba ck, u p a ga in st on e of
sor ca n n ot be a dju st ed or r epa ir ed a n d, if fa u lt y or t h e r ea r sea t s.
da m a ged, t h e sea t elem en t a ssem bly m u st be (3) Loca t e t h e h ea t ed sea t m odu le, a t t a ch ed t o t h e
r epla ced, (Refer t o 8 - E LE CTRICAL/H E ATE D bot t om of t h e sea t cu sh ion pa n . Rem ove t h e h ea t ed
SE ATS/H E ATE D SE AT E LE ME NT - RE MOVAL). sea t m odu le fr om t h e sea t cu sh ion pa n . Do n ot dis-
con n ect t h e elect r ica l con n ect or s a t t h is t im e.
(4) Loca t e a n d discon n ect t h e gr een 4-wa y elect r i-
ca l con n ect or, con n ect ed t o t h e h ea t ed sea t m odu le.
(5) Ch eck for con t in u it y bet ween t h e t wo ou t boa r d
cir cu it ca vit ies of t h e wir e h a r n ess con n ect or (P in s
H EAT ED SEAT ELEM EN T S (Cont inue d)
1&4). Th er e sh ou ld be con t in u it y. If OK, (Refer t o 8 -
ULE S/ME MORY H E ATE D SE AT/MIRROR MOD-
ULE - DIAGNOSIS AND TE STING) for com plet e
syst em t est in g pr ocedu r es. If n ot OK, in st a ll a
r epla cem en t h ea t ed sea t cu sh ion elem en t , (Refer t o 8
- E LE CTRICAL/H E ATE D SE ATS/H E ATE D SE AT
E LE ME NT - INSTALLATION).
SEAT BACK ELEMENT

(1) F r om u n der t h e veh icle, r em ove t h e a ppr opr i-
a t e sea t s fou r r et a in in g n u t s.
(2) F r om in side t h e veh icle, pu ll t h e sea t u p a n d
off t h e m ou n t in g st u ds a n d la y it ba ck, u p a ga in st
on e of t h e r ea r sea t s.
(3) Loca t e t h e h ea t ed sea t m odu le, a t t a ch ed t o t h e
bot t om of t h e sea t cu sh ion pa n . Rem ove t h e h ea t ed
sea t m odu le fr om t h e sea t cu sh ion pa n . Do n ot dis-
con n ect t h e elect r ica l con n ect or s a t t h is t im e.
(4) Loca t e a n d discon n ect t h e gr a y 2-wa y elect r ica l
con n ect or, con n ect ed t o t h e h ea t ed sea t m odu le.
(5) Ch eck for con t in u it y bet ween t h e t wo cir cu it
ca vit ies of t h e 2-wa y wir e h a r n ess con n ect or. Th er e Fig. 6 HEATING ELEMENT INSTALLED - TYPICAL
sh ou ld be con t in u it y. If OK, (Refer t o 8 - E LE CTRI- 1 - SEAT BACK WIRE HARNESS
CAL/E LE CTRONIC CONTROL MODULE S/ME M- 2 - HEATED SEAT WIRE HARNESS CONNECTOR
ORY H E ATE D SE AT/MIRROR MODULE - 3 - HEATED SEAT CUSHION ELEMENT
DIAGNOSIS AND TE STING) for com plet e syst em
CAUTION: During the installation of the replace-
t est in g pr ocedu r es. If n ot OK, in st a ll a r epla cem en t
ment heating element, be careful not to fold or
h ea t ed sea t ba ck elem en t , (Refer t o 8 - E LE CTRI-
crease the element assembly. Folds or creases will
CAL/H E ATE D SE ATS/H E ATE D SE AT E LE ME NT -
cause premature failure.
INSTALLATION).
REMOVAL
NOTE: Do not remove the factory installed heating
elements from the seat or seat back cushions. The
original element is permanently attached and can-
not be removed without permanent damage. The
replacement heating element is designed to be
applied directly on top of the factory installed heat-
ing element.

ca ble.
(2) Rem ove t h e a ppr opr ia t e sea t cu sh ion or sea t
ba ck t r im cover.
(3) Discon n ect t h e in oper a t ive h ea t ed sea t cu sh ion
or sea t ba ck elem en t elect r ica l con n ect or s (F ig. 6).
(4) Loca t e t h e wir es lea din g fr om t h e in oper a t ive
h ea t in g elem en t a n d cu t t h em off flu sh wit h t h e edge
of t h e or igin a l h ea t in g elem en t .
INSTALLATION
(1) P eel off t h e a dh esive ba ckin g on t h e ba ck of t h e Fig. 7 HEATING ELEMENT INSTALLATION
r epla cem en t h ea t in g elem en t a n d st ick dir ect ly on 1 - ORIGINAL (INOPERATIVE) HEATING ELEMENT
t op of t h e fa ct or y in st a lled h ea t in g elem en t (F ig. 7). 2 - REPLACEMENT HEATING ELEMENT
H EAT ED SEAT ELEM EN T S (Cont inue d)
(2) Con n ect t h e n ew h ea t in g elem en t elect r ica l H EAT ED SEAT SEN SOR
con n ect or s (F ig. 8). P a s s e n g e r s e a t s h o w n , d riv e r
s e a t s im ila r.
DESCRIPTION
Two h ea t ed sea t sen sor s a r e u sed per veh icle, on e
in ea ch fr on t sea t cu sh ion h ea t in g elem en t . Th e
h ea t ed sea t t em per a t u r e sen sor is a Nega t ive Tem -
per a t u r e Coefficien t (NTC) t h er m ist or.
Th e h ea t ed sea t sen sor s ca n n ot be r epa ir ed or
a dju st ed a n d if fou n d t o be fa u lt y, t h e com plet e
h ea t ed sea t cu sh ion elem en t m u st be r epla ced.
OPERATION
Th e t em per a t u r e sen sor is a Nega t ive Tem per a t u r e
Coefficien t (NTC) t h er m ist or. Wh en t h e t em per a t u r e
of t h e sea t cu sh ion cover r ises, t h e r esist a n ce of t h e
sen sor decr ea ses. Th e h ea t ed sea t m odu le su pplies a
five-volt cu r r en t t o on e side of ea ch sen sor, a n d m on -
it or s t h e volt a ge dr op t h r ou gh t h e sen sor on a r et u r n
cir cu it . Th e h ea t ed sea t m odu le u ses t h is t em per a -
t u r e sen sor in pu t t o m on it or t h e t em per a t u r e of t h e
sea t , a n d r egu la t es t h e cu r r en t flow t o t h e sea t h ea t -
in g elem en t s a ccor din gly.

Fig. 8 HEATED SEAT WIRE HARNESS ROUTING
1 - SEAT BACK HEATED SEAT WIRE HARNESS HEATED SEAT SENSOR
2 - PASSENGER SEAT BACK Refer t o t h e a ppr opr ia t e wir in g in for m a t ion for
3 - SEAT BACK ELEMENT CONNECTOR
4 - SEAT CUSHION ELEMENT CONNECTOR
com plet e cir cu it sch em a t ic or con n ect or pin -ou t in for-
m a t ion .
(3) Con n ect t h e ba t t er y n ega t ive ca ble. (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
(4) Ver ify h ea t ed sea t syst em oper a t ion . ca ble. Discon n ect t h e gr een 4-wa y h ea t ed sea t m od-
(5) In st a ll t h e a ppr opr ia t e sea t cu sh ion or sea t u le wir e h a r n ess con n ect or.
ba ck t r im cover. (2) Usin g a n oh m m et er, ch eck t h e r esist a n ce
bet ween ca vit ies 2 a n d 3. Th e sen sor r esist a n ce
NOTE: Make certain the seat wire harness is cor- sh ou ld be bet ween 50 kiloh m s a t 15° C (60° F ) a n d 2
rectly routed through the seat and seat back. The kiloh m s a t 30° C (85° F ). If n ot OK, r epla ce t h e
excess wire between the cushion and back ele- fa u lt y sea t elem en t a n d sen sor a ssem bly.
ments should be securely tucked between the rear
of the cushion foam and the rear carpet flap of the
trim cover.
RS HORN 8H - 1
HORN
page page
HORN SYSTEM REMOVAL .............................4

DESCRIPTION . . . . . . . . ..................1 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 4
OPERATION . . . . . . . . . . ..................1 HORN SWITCH
DIAGNOSIS AND TESTING DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 4
HORN SYSTEM . . . . . . ..................1
HORN
DIAGNOSIS AND TESTING
HORN . . . . . . . . . . . . . ..................3
H ORN SY ST EM DI AGN OSI S AN D T EST I N G
DESCRIPTION HORN SYSTEM

WARNING: ON VEHICLES EQUIPPED WITH AIR- WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAG, REFER TO ELECTRICAL, RESTRAINTS FOR BAGS, REFER TO ELECTRICAL, RESTRAINTS
SAFETY PRECAUTIONS. DISCONNECT THE NEGA- BEFORE ATTEMPTING ANY STEERING WHEEL,
TIVE CABLE FROM THE BATTERY BEFORE SER- STEERING COLUMN, OR INSTRUMENT PANEL
VICING COMPONENTS INVOLVING THE AIRBAG COMPONENT DIAGNOSIS OR SERVICE. FAILURE
SYSTEM. ACCIDENTAL DEPLOYMENT OF AIRBAG TO TAKE THE PROPER PRECAUTIONS COULD
AND PERSONAL INJURY CAN RESULT. RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
Th e h or n cir cu it con sist s of a h or n swit ch , clock-
spr in g, h or n r ela y, h or n s a n d In t egr a t ed P ower Mod- Refer t o H or n Syst em Test below. If t h e h or n does
u le (IP M). Th e h or n swit ch is a m em br a n e swit ch n ot sou n d, ch eck h or n fu se loca t ed in t h e In t egr a t ed
loca t ed in t h e a ir ba g t r im cover. Th e h or n s a r e P ower Modu le (IP M). If t h e fu se is blown , r epla ce
loca t ed for wa r d of t h e left fr on t wh eel beh in d t h e wit h t h e cor r ect fu se. If t h e h or n s fa il t o sou n d a n d
bu m per fa scia . t h e n ew fu se blows wh en depr essin g t h e h or n swit ch ,
a sh or t cir cu it in t h e h or n or t h e h or n wir in g
OPERATION bet ween t h e fu se t er m in a l a n d t h e h or n is r espon si-
Th e h or n r ela y plu gs in t o t h e In t egr a t ed P ower ble, or a defect ive h or n swit ch a llowed t h e h or n t o
Modu le (IP M) wh ich is loca t ed in t h e en gin e com - bu r n ou t is r espon sible.
pa r t m en t . F or cir cu it in for m a t ion a n d com pon en t If t h e fu se is OK, t est h or n r ela y.
loca t ion s, r efer t o t h e a ppr opr ia t e wir in g in for m a t ion . If t h e r ela y is OK, t est h or n .
Th e wir in g in for m a t ion in clu des wir in g dia gr a m s,
pr oper wir e a n d con n ect or r epa ir pr ocedu r es, det a ils CAUTION: Continuous sounding of horn may
of wir e h a r n ess r ou t in g a n d r et en t ion , con n ect or pin - cause horn failure.
ou t in for m a t ion a n d loca t ion views for t h e va r iou s
Sh ou ld t h e h or n sou n d con t in u ou sly, u n plu g t h e
wir e h a r n ess con n ect or s, splices a n d gr ou n ds.
h or n r ela y fr om IP M.
Th e h or n s will n ot fu n ct ion if t h e swit ch is
“CLOSE D” for m or e t h a n 30 secon ds. On ce t h e
swit ch is “OP E N”, a 20–30 secon d dela y will occu r
befor e t h e h or n s a r e fu n ct ion a l a ga in .
8H - 2 HORN RS
H ORN SY ST EM (Cont inue d)
H ORN SY ST EM T EST

HORN SOUNDS CONTINUOUSLY. (1) HORN RELAY (1) REPLACE RELAY.
NOTE: IMMEDIATELY UNPLUG HORN INOPERATIVE.
RELAY IN THE IPM.
(2) HORN CONTROL (2) CHECK TERMINAL 85 IN IPM FOR
CIRCUIT TO RELAY CONTINUITY TO GROUND. IF
SHORTED TO GROUND. CONTINUITY TO GROUND INDICATES:
(A) STEERING WHEEL HORN SWITCH/
LEAD SHORTED TO GROUND.
(B) WIRING HARNESS SHORTED TO
GROUND. FIND THE SHORT AND
REPAIR AS NECESSARY.
(3) PINCHED HORN SWITCH (3) REPLACE DRIVER AIRBAG TRIM
WIRE UNDER DRIVER COVER.
AIRBAG MODULE.
(4) HORN SWITCH (4) REPLACE DRIVER AIRBAG TRIM
INOPERATIVE. COVER.
(5) CLOCKSPRING (5) REPLACE CLOCKSPRING.
INOPERATIVE.
(6) FRONT CONTROL (6) REFER TO ELECTRONIC CONTROL
MODULE INOPERATIVE. MODULES/FRONT CONTROL MODULE.
HORN SOUND INTERMITTENTLY AS (1) HORN RELAY CONTROL (1) REMOVE DRIVER AIRBAG AND/OR
THE STEERING WHEEL IS TURNED. CIRCUIT X3 IS SHORTED TO WHEEL. CHECK FOR RUBBING OR
GROUND INSIDE STEERING LOOSE WIRE/CONNECTOR, REPAIR AS
COLUMN OR WHEEL. NECESSARY.
(2) PINCHED HORN SWITCH (2) REPLACE DRIVER AIRBAG TRIM
WIRE UNDER DRIVER COVER.
AIRBAG MODULE.
INOPERATIVE. COVER.
INOPERATIVE.
HORN DOES NOT SOUND (1) CHECK FUSE 8 IN (1) REPLACE FUSE IF BLOWN REPAIR
INTELLIGENT POWER AS NECESSARY.
MODULE.
(2) NO VOLTAGE AT HORN (2) NO VOLTAGE, REPAIR THE CIRCUIT
RELAY TERMINALS 30 & 86, AS NECESSARY.
AND FUSE IS OK.
(3) OPEN CIRCUIT FROM (3) REPAIR CIRCUIT AS NECESSARY.

TERMINAL 85 OF THE HORN
RELAY TO HORN SWITCH,
X3 CIRCUIT.
(4) HORN INOPERATIVE OR (4) CHECK VOLTAGE AT HORN WHEN
DAMAGED. HORN SWITCH IS PRESSED. IF NO
VOLTAGE, REPLACE HORN.
INOPERATIVE. COVER.
RS HORN 8H - 3
H ORN SY ST EM (Cont inue d)

INOPERATIVE.
(7) FRONT CONTROL (7) REFER TO ELECTRONIC CONTROL
MODULE INOPERATIVE. MODULES/FRONT CONTROL MODULE.
FUSE BLOWS WHEN HORN SOUNDS (1) SHORT CIRCUIT IN (1) REMOVE HORN RELAY, CHECK
HORN OR HORN WIRING. FOR SHORTED HORN OR HORN
WIRING. DISCONNECT HORN WIRE
HARNESS TO ISOLATE SHORT AND
REPAIR AS NECESSARY.
INOPERATIVE.
FUSE BLOWS WITHOUT BLOWING (1) SHORT CIRCUIT. (1) REMOVE RELAY, INSTALL NEW
HORN FUSE, IF FUSE DOES NOT BLOW
REPLACE HORN RELAY. IF FUSE
BLOWS WITH RELAY REMOVED,
CHECK FOR SHORT TO GROUND
WITH OHMMETER ON CIRCUIT
BETWEEN TERMINALS 30 & 86 AND
THE FUSE TERMINAL. REPAIR AS
NECESSARY.
INOPERATIVE.
H ORN (1) Rem ove t h e h or n r ela y fr om t h e in t elligen t

power m odu le.
(2) Usin g a con t in u it y t est er, t est con t in u it y fr om t h e
DI AGN OSI S AN D T EST I N G X3 ca vit y of t h e h or n r ela y t o gr ou n d. Refer t o t h e
a ppr opr ia t e wir in g in for m a t ion . Th e wir in g in for m a t ion
HORN in clu des wir in g dia gr a m s, pr oper wir e a n d con n ect or
r epa ir pr ocedu r es, det a ils of wir e h a r n ess r ou t in g a n d
HORN r et en t ion , con n ect or pin -ou t in for m a t ion a n d loca t ion
(1) Discon n ect wir e con n ect or a t h or n . views for t h e va r iou s wir e h a r n ess con n ect or s, splices
(2) Usin g a volt m et er, con n ect on e lea d t o gr ou n d a n d gr ou n ds.
t er m in a l a n d t h e ot h er lea d t o t h e posit ive wir e t er- (a ) If con t in u it y is det ect ed, pr oceed t o st ep St ep 3.
m in a l (F ig. 1). (b) If NO con t in u it y, r epla ce t h e h or n r ela y.
(3) Depr ess t h e h or n swit ch , ba t t er y volt a ge (3) Rem ove t h e a ir ba g t r im cover fr om t h e st eer in g
sh ou ld be pr esen t . wh eel a n d disen ga ge h or n con n ect or.
(4) If n o volt a ge, r efer t o HORN S WILL N OT (4) In st a ll h or n r ela y in t o In t egr a t ed P ower Mod-
S OU N D . If volt a ge is OK, go t o st ep St ep 5. u le (IP M).
(5) Usin g oh m m et er, t est gr ou n d wir e for con t in u - (a ) If h or n does n ot sou n d, r epla ce a ir ba g t r im
it y t o gr ou n d. cover.
(6) If n o gr ou n d r epa ir a s n ecessa r y. (b) If h or n sou n ds, r epa ir gr ou n ded X3 cir cu it
(7) If wir es t est OK a n d h or n does n ot sou n d, fr om IP M t o clockspr in g in t h e st eer in g colu m n .
r epla ce h or n .
HORNS WILL NOT SOUND
HORNS SOUND CONTINUOUSLY Ch eck h or n fu se # 8 in t h e IP M. If fu se is blown ,
ch eck for a sh or t ed swit ch in t h e a ir ba g m odu le. a n d
CAUTION: Continuous sounding of horns may r efer t o F USE BLOWN sect ion . If fu se is OK, r efer t o
cause relay to fail. F USE OK sect ion .
Th e h or n swit ch (m em br a n e) som et im es ca n be t h e FUSE BLOWN

ca u se wit h ou t t h e swit ch bein g depr essed. (1) Ver ify con dit ion of ba t t er y t er m in a ls a n d volt -
a ge, (Refer t o 8 - E LE CTRICAL/BATTE RY SYSTE M
8H - 4 HORN RS
H ORN (Cont inue d)
- DIAGNOSIS AND TE STING). If ba t t er y con n ec- (8) Usin g a volt m et er, wit h t h e h or n swit ch
t ion s a n d ba t t er y ch a r ge is OK pr oceed t o St ep 2. depr essed t est volt a ge a cr oss h or n con n ect or t er m i-
(2) Usin g a volt m et er, t est for ba t t er y volt a ge a t n a ls of t h e wir e h a r n ess (F ig. 1).
bot h sides of h or n fu se 7. If volt a ge is OK, on bot h (a ) If volt a ge is det ect ed, r epla ce h or n s.
sides of fu se, pr oceed t o F u se OK. If volt a ge is OK, (b) If NO volt a ge, pr oceed t o st ep St ep 9.
on on e side of fu se, t h e fu se is blown , pr oceed t o St ep
3.
(3) Usin g a su it a ble a m m et er in pla ce of t h e fu se,
t est a m per a ge dr a w of t h e h or n cir cu it . If a m per a ge
dr a w is gr ea t er t h a n 20 a m ps wit h ou t t h e h or n
swit ch depr essed, a gr ou n ded cir cu it exist s bet ween
t h e fu se a n d t h e h or n r ela y. P r oceed t o St ep 4. If
a m per a ge dr a w is gr ea t er t h a n 20 a m ps wit h t h e
h or n swit ch depr essed, a gr ou n ded cir cu it exist s
bet ween t h e h or n r ela y a n d t h e h or n . P r oceed t o st ep
St ep 5.
(4) Rem ove t h e h or n r ela y fr om t h e IP M. If t h e
a m per a ge dr a w dr ops t o 0 a m ps, t h e h or n swit ch or
cir cu it is sh or t ed. If t h e a m per a ge dr a w does n ot
Fig. 1 Horn Connector
dr op t o 0 a m ps, r epa ir sh or t a t t h e IP M.
(5) Disen ga ge a wir e con n ect or fr om on e of t h e (9) Wit h t h e h or n swit ch depr essed, t est for volt -
h or n s. If a m per a ge dr ops a n d t h e con n ect ed h or n a ge bet ween t h e X2 cir cu it a n d gr ou n d.
sou n ds, r epla ce t h e fa u lt y h or n . If a m per a ge does n ot (a ) If volt a ge OK, r epa ir syst em gr ou n d a t r igh t
dr op wit h bot h h or n s discon n ect ed a n d t h e h or n cowl a r ea .
swit ch depr essed, pr oceed t o St ep 6. (b) If NO volt a ge, r epa ir open X2 cir cu it bet ween
(6) Usin g a con t in u it y t est er, wit h t h e h or n s dis- t h e r ela y a n d t h e h or n s.
con n ect ed t est con t in u it y of t h e X2 ca vit y of t h e h or n
r ela y t o gr ou n d. If con t in u it y is det ect ed, t h e cir cu it REMOVAL
is gr ou n ded bet ween t h e J u n ct ion Block a n d t h e (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
h or n s. Loca t e a n d r epa ir pin ch ed h a r n ess. ca ble.
(2) H oist a n d su ppor t t h e fr on t of t h e veh icle on
FUSE OK sa fet y st a n ds.
(1) Rem ove t h e h or n r ela y fr om t h e in t elligen t (3) F r om beh in d t h e fr on t fa scia a n d for wa r d of
power m odu le. t h e left fr on t wh eel, discon n ect t h e wir e con n ect or s
(2) Usin g a con t in u it y t est er, Depr ess h or n swit ch fr om h or n .
a n d t est con t in u it y fr om t h e X3 ca vit y of t h e h or n (4) Rem ove t h e m ou n t in g br a cket a t t a ch in g n u t
r ela y t o gr ou n d. fr om t h e bot t om of r a dia t or closu r e pa n el. Do n ot
(a ) If con t in u it y is det ect ed, pr oceed t o St ep 3. r em ove t h e h or n fr om m ou n t in g br a cket .
(b) If NO con t in u it y, pr oceed t o St ep 4. (5) Sepa r a t e t h e h or n (s) fr om veh icle.
(3) Usin g a su it a ble ju m per wir e, ju m p a cr oss t h e
fu se F 62 ca vit y a n d t h e X2 ca vit y of t h e h or n r ela y in INSTALLATION
t h e J u n ct ion Block. (1) In st a ll t h e h or n s t o t h e veh icle.
(a ) If t h e h or n sou n ds, r epla ce t h e h or n r ela y. (2) In st a ll t h e m ou n t in g br a cket fa st en er.
(b) If t h e h or n does n ot sou n d, pr oceed t o St ep 4. (3) Recon n ect t h e wir e con n ect or s t o t h e h or n s.
(4) Rem ove a ir ba g t r im cover fr om st eer in g wh eel. (4) Lower t h e veh icle.
Refer t o E LE CTRICAL, RE STRAINTS. (5) Recon n ect t h e ba t t er y n ega t ive ca ble.
(5) Test con t in u it y a cr oss h or n swit ch con n ect or s
wit h h or n swit ch depr essed.
(a ) If con t in u it y is det ect ed, r epa ir open cir cu it H ORN SWI T CH
bet ween t h e r ela y a n d t h e h or n swit ch .
(b) If NO con t in u it y, r epla ce a ir ba g t r im cover. DESCRIPTION
(6) In st a ll h or n r ela y in t o in t elligen t power m od- Th e h or n swit ch is m olded in t o t h e a ir ba g t r im
u le. cover. Th e h or n swit ch ca n n ot be ser viced sepa r a t ely.
(7) Disen ga ge wir e con n ect or s fr om h or n s. F or ser vice pr ocedu r es (Refer t o 8 - E LE CTRICAL/
RE STRAINTS/AIRBAG COVE R - RE MOVAL).
RS IGNITION CONTROL 8I - 1
IGNITION CONTROL
page page
IGNITION CONTROL REMOVAL - 3.3/3.8L . . . . . . . . . . . . . . . . . . . . 7

DESCRIPTION - IGNITION SYSTEM . .........1 INSTALLATION
OPERATION - IGNITION SYSTEM . . .........1 INSTALLATION - 2.4L . . . . . . . . . . . . . . . . . . . 7
SPECIFICATIONS INSTALLATION - 3.3/3.8L . . . . . . . . . . . . . . . . . 8
TORQUE . . . . . . . . . . . . . . . . . . . . .. . . . . . . .2 KNOCK SENSOR
SPARK PLUG CABLE RESISTANCE . . . . . . . .2 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SPARK PLUG . . . . . . . . . . . . . . . . .. . . . . . . .2 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
FIRING ORDER . . . . . . . . . . . . . . . .. . . . . . . .3 REMOVAL
AUTO SHUT DOWN RELAY REMOVAL - 2.4L . . . . . . . . . . . . . . . . . . . . . . . 8
DESCRIPTION . . . . . . . . . . . . . . . . . .........3 REMOVAL - 3.8L . . . . . . . . . . . . . . . . . . . . . . . 8
OPERATION . . . . . . . . . . . . . . . . . . . .........3 INSTALLATION
CAMSHAFT POSITION SENSOR INSTALLATION - 2.4L . . . . . . . . . . . . . . . . . . . 8
DESCRIPTION . . . . . . . . . . . . . . . . . .........4 INSTALLATION - 3.8L . . . . . . . . . . . . . . . . . . . 8
OPERATION . . . . . . . . . . . . . . . . . . . .........4 SPARK PLUG
REMOVAL DESCRIPTION
REMOVAL - 2.4L . . . . . . . . . . . . . . .........5 DESCRIPTION - STANDARD 4 CYLINDER . . . 9
REMOVAL - 3.3/3.8L . . . . . . . . . . . .........5 DESCRIPTION - PLATINUM PLUGS . . . . . . . . 9
INSTALLATION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION - 2.4L . . . . . . . . . . .........6 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLATION - 3.3/3.8L . . . . . . . . .........6 SPARK PLUG CABLE
IGNITION COIL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10
DESCRIPTION . . . . . . . . . . . . . . . . . .........6 REMOVAL - 2.0/2.4L . . . . . . . . . . . . . . . . . . . . . 10
OPERATION . . . . . . . . . . . . . . . . . . . .........6 INSTALLATION - 2.0/2.4L . . . . . . . . . . . . . . . . . 10
REMOVAL
REMOVAL - 2.4L . . . . . . . . . . . . . . .........7
I GN I T I ON CON T ROL OPERATION - IGNITION SYSTEM

Th e cr a n ksh a ft posit ion sen sor a n d ca m sh a ft posi-
DESCRIPTION - IGNITION SYSTEM t ion sen sor a r e h a ll effect devices. Th e ca m sh a ft posi-
t ion sen sor a n d cr a n ksh a ft posit ion sen sor gen er a t e
NOTE: All engines use a fixed ignition timing sys- pu lses t h a t a r e in pu t s t o t h e P CM. Th e P CM det er-
tem. Basic ignition timing is not adjustable. All m in es en gin e posit ion fr om t h ese sen sor s. Th e P CM
spark advance is determined by the Powertrain ca lcu la t es in ject or sequ en ce a n d ign it ion t im in g fr om
Control Module (PCM). cr a n ksh a ft & ca m sh a ft posit ion . F or a descr ipt ion of
bot h sen sor s, r efer t o Ca m sh a ft P osit ion Sen sor a n d
Th e ign it ion syst em u sed on t h ese en gin es is Cr a n ksh a ft P osit ion Sen sor.
r efer r ed t o a s t h e Dir ect Ign it ion Syst em (DIS). Th e
syst em ’s t h r ee m a in com pon en t s a r e t h e coils, cr a n k-
sh a ft posit ion sen sor, a n d ca m sh a ft posit ion sen sor. If
equ ipped wit h t h e coil on plu g ign it ion syst em it u t i-
lizes a n ign it ion coil for ever y cylin der, it is m ou n t ed
dir ect ly over t h e ea ch spa r k plu g.
8I - 2 IGNITION CONTROL RS
I GN I T I ON CON T ROL (Cont inue d)
SPECI FI CAT I ON S
TORQUE

2.4L Target Magnet Screw 3 30
2.4L Camshaft Sensor 12.9 115
Screw
3.3/3.8L Camshaft Sensor 14.1 125
Screw
2.4L Ignition coil bolts 11.8 105
3.3/3.8LIgnition coil bolts 11.8 105
Spark Plugs 17.5 13
Knock Sensor 10 7
SPARK PLUG CABLE RESISTANCE 3 .3 /3 .8 L
2 .4 L CABLE Maximum Resistance

#1 22.5K ohms
CABLE Maximum Resistance
#2 22.8K ohms
1, 2, 3, & 4 10.8K ohms
#3 19.3K ohms
#4 19.3K ohms
#5 13.6K ohms
#6 16.4K ohms
SPARK PLUG
Engine Spark Plug Gap Thread Size

2.4L RE14MCC5 0.048 TO 0.053 14mm (1 in.) reach
Engine Spark Plug Gap Thread Size

3.3L RE14PLP5 0.048 TO 0.053 14mm (1 in.) reach
3.8L RE14PLP5 0.048 TO 0.053 14mm (1 in. ) reach
I GN I T I ON CON T ROL (Cont inue d)
FIRING ORDER AU T O SH U T DOWN RELAY

DESCRIPTION
Th e r ela y is loca t ed in t h e P ower Dist r ibu t ion Cen -
t er (P DC). F or t h e loca t ion of t h e r ela y wit h in t h e
P DC, r efer t o t h e P DC cover for loca t ion . Ch eck elec-
t r ica l t er m in a ls for cor r osion a n d r epa ir a s n ecessa r y
OPERATION
Th e en gin e swit ch ed ba t t er y (NGC veh icles)
in for m s t h e P CM wh en t h e ASD r ela y en er gizes. A 12
volt sign a l a t t h is in pu t in dica t es t o t h e P CM t h a t
t h e ASD h a s been a ct iva t ed. Th is in pu t is a lso u sed
t o power cer t a in dr iver s on NGC veh icles.
Wh en en er gized, t h e ASD r ela y on NGC veh icles
pr ovides power t o oper a t e t h e in ject or s, ign it ion coil,
gen er a t or field, O2 sen sor h ea t er s (bot h u pst r ea m
a n d down st r ea m ), eva por a t ive pu r ge solen oid, E GR
solen oid (if equ ipped) wa st ega t e solen oid (if
equ ipped), a n d NVLD solen oid (if equ ipped).
Th e ASD r ela y a lso pr ovides a sen se cir cu it t o t h e
P CM for dia gn ost ic pu r poses. If t h e P CM does n ot
r eceive 12 volt s fr om t h is in pu t a ft er gr ou n din g t h e
FIRING ORDER 2.4L con t r ol side of t h e ASD r ela y, it set s a Dia gn ost ic
Tr ou ble Code (DTC). Th e P CM en er gizes t h e ASD
a n y t im e t h er e is a n en gin e speed t h a t exceeds a pr e-
det er m in ed va lu e (t ypica lly a bou t 50 r pm ). Th e ASD
r ela y ca n a lso be en er gized a ft er t h e en gin e h a s been
t u r n ed off t o per for m a n O2 sen sor h ea t er t est , if
veh icle is equ ipped wit h OBD II dia gn ost ics.
As m en t ion ed ea r lier, t h e P CM en er gizes t h e ASD
r ela y du r in g a n O2 sen sor h ea t er t est . On NGC veh i-
cles it ch ecks t h e O2 h ea t er u pon veh icle st a r t . Th e
P CM st ill oper a t es in t er n a lly t o per for m sever a l
ch ecks, in clu din g m on it or in g t h e O2 sen sor h ea t er s.
Firing Order 1-2-3-4-5-6 3.3/3.8L

1 - Electrical Connector
CAM SH AFT POSI T I ON sh a ft pu lse a ft er t h e 3 pu lses in dica t es cylin der 5.

Th e 2 ca m sh a ft pu lses a ft er cylin der 5 sign a ls cylin -
SEN SOR der 6 (F ig. 2). Th e P CM ca n syn ch r on ize on cylin der s
1 or 4.
DESCRIPTION Wh en m et a l a lign s wit h t h e sen sor, volt a ge goes
Th e ca m sh a ft posit ion sen sor for t h e 3.3/3.8L is low (less t h a n 0.3 volt s). Wh en a n ot ch a lign s wit h
m ou n t ed in t h e fr on t of t h e t im in g ca se cover (F ig. 6) t h e sen sor, volt a ge swit ch es h igh (5.0 volt s). As a
a n d t h e ca m sh a ft posit ion sen sor for t h e 2.4L is gr ou p of n ot ch es pa ss u n der t h e sen sor, t h e volt a ge
m ou n t ed on t h e en d of t h e cylin der h ea d (F ig. 3). swit ch es fr om low (m et a l) t o h igh (n ot ch ) t h en ba ck
t o low. Th e n u m ber of n ot ch es det er m in e t h e a m ou n t
OPERATION of pu lses. If a va ila ble, a n oscilloscope ca n displa y t h e
Th e ca m sh a ft posit ion sen sor pr ovides cylin der squ a r e wa ve pa t t er n s of ea ch t im in g even t .
iden t ifica t ion t o t h e P ower t r a in Con t r ol Modu le Top Dea d Cen t er (TDC) does n ot occu r wh en
(P CM) (F ig. 1). Th e sen sor gen er a t es pu lses a s n ot ch es on t h e ca m sh a ft spr ocket pa ss below t h e sen -
gr ou ps of n ot ch es on t h e ca m sh a ft spr ocket pa ss sor. TDC occu r s a ft er t h e ca m sh a ft pu lse (or pu lses)
u n der n ea t h it (F ig. 2). Th e P CM keeps t r a ck of a n d a ft er t h e 4 cr a n ksh a ft pu lses a ssocia t ed wit h t h e
cr a n ksh a ft r ot a t ion a n d iden t ifies ea ch cylin der by pa r t icu la r cylin der. Th e a r r ows a n d cylin der ca ll ou t s
t h e pu lses gen er a t ed by t h e n ot ch es on t h e ca m sh a ft on (F ig. 2) r epr esen t wh ich cylin der t h e fla t spot a n d
spr ocket . F ou r cr a n ksh a ft pu lses follow ea ch gr ou p of n ot ch es iden t ify, t h ey do n ot in dica t e TDC posit ion .
ca m sh a ft pu lses.
Fig. 1 Camshaft Position Sensor

1 - ELECTRICAL CONNECTOR
2 - O-RING
3 - PAPER SPACER
Wh en t h e P CM r eceives 2 ca m pu lses followed by Fig. 2 Camshaft Sprocket

t h e lon g fla t spot on t h e ca m sh a ft spr ocket , it kn ows 1 - CAMSHAFT SPROCKET
t h a t t h e cr a n ksh a ft t im in g m a r ks for cylin der 1 a r e 2 - CYL #6
n ext (on dr ivepla t e). Wh en t h e P CM r eceives on e 3 - CYL #5
4 - CYL #4
ca m sh a ft pu lse a ft er t h e lon g fla t spot on t h e 5 - CYL #3
spr ocket , cylin der n u m ber 2 cr a n ksh a ft t im in g m a r ks 6 - CYL #2
a r e n ext . Aft er 3 ca m sh a ft pu lses, t h e P CM kn ows 7 - CYL #1
cylin der 4 cr a n ksh a ft t im in g m a r ks follow. On e ca m -
CAM SH AFT POSI T I ON SEN SOR (Cont inue d)
REM OVAL REMOVAL - 3.3/3.8L

REMOVAL - 2.4L (2) Rem ove t h e a ir box cover a n d in let t u be (F ig.
Th e ca m sh a ft posit ion sen sor is m ou n t ed t o t h e 5).
r ea r of t h e cylin der h ea d.
(1) Rem ove t h e n ega t ive ba t t er y ca ble.
(2) Discon n ect elect r ica l con n ect or s fr om t h e ca m -
sh a ft posit ion sen sor (F ig. 3).
Fig. 5 AIR BOX COVER

(3) Discon n ect ca m sh a ft posit ion sen sor elect r ica l
con n ect or fr om t h e wir in g h a r n ess con n ect or (F ig. 6).
Fig. 3 EGR/CAM SENSOR 2.4L

(3) Rem ove ca m sh a ft posit ion sen sor m ou n t in g
scr ews. Rem ove sen sor.
(4) Loosen scr ew a t t a ch in g t a r get m a gn et t o r ea r
of ca m sh a ft a n d r em ove m a gn et (F ig. 4).
Fig. 4 Target Magnet Removal/Installation Fig. 6 CAMSHAFT POSITION SENSOR

1 - TARGET MAGNET (4) Rem ove bolt h oldin g sen sor.
2 - MOUNTING BOLT
3 - REAR OF CYLINDER HEAD
(5) Rot a t e sen sor a wa y fr om block.
CAM SH AFT POSI T I ON SEN SOR (Cont inue d)
(6) P u ll sen sor u p ou t of t h e ch a in ca se cover. D o
n o t p u ll o n th e s e n s o r w irin g . Th er e is a n O-r in g
on t h e body of t h e sen sor. Th e O-r in g m a y m a ke
r em ova l difficu lt . A ligh t t a p t o t op of sen sor pr ior t o
r em ova l m a y r edu ce for ce n eeded for r em ova l.
I N STALLAT I ON
INSTALLATION - 2.4L
Th e t a r get m a gn et h a s loca t in g dowels t h a t fit in t o
m a ch in ed loca t in g h oles in t h e en d of t h e ca m sh a ft
(F ig. 7).
Fig. 8 Camshaft Position Sensor and Spacer

2 - O-RING
3 - PAPER SPACER
(3) P u sh sen sor down u n t il con t a ct is m a de wit h

t h e ca m sh a ft gea r. Wh ile h oldin g t h e sen sor in t h is
posit ion , in st a ll a n d t igh t en t h e r et a in in g bolt 14
N·m (125 in . lbs.) t or qu e.
(4) Con n ect ca m sh a ft posit ion sen sor elect r ica l
con n ect or t o h a r n ess con n ect or.
(5) In st a ll t h e a ir box cover a n d in let h ose (F ig. 5).
Fig. 7 Target Magnet Installation

1 - LOCATING DOWELS I GN I T I ON COI L
2 - LOCATING HOLES (2)
(1) In st a ll t a r get m a gn et in en d of ca m sh a ft .
DESCRIPTION
Th e ign it ion coil a ssem bly con sist s of 2 or 3 in de-
Tigh t en m ou n t in g scr ew t o 3 N·m (30 in . lbs.) t or qu e.
pen den t coils m olded t oget h er (F ig. 9) or (F ig. 10).
Over t or qu ein g cou ld ca u se cr a cks in m a gn et . If m a g-
Th e coil a ssem bly for t h e 3.3/3.8L is m ou n t ed on t h e
n et cr a cks r epla ce it .
in t a ke m a n ifold. Th e coil a ssem bly for t h e 2.4L is
(2) In st a ll ca m sh a ft posit ion sen sor. Tigh t en sen sor
m ou n t ed on t h e cylin der h ea d cover. Spa r k plu g
m ou n t in g scr ews t o 12.9 N·m (115 in . lbs.) t or qu e.
ca bles r ou t e t o ea ch cylin der fr om t h e coil.
(3) Ca r efu lly a t t a ch elect r ica l con n ect or t o ca m -
sh a ft posit ion sen sor.
OPERATION
Th e coil fir es t wo spa r k plu gs ever y power st r oke.
INSTALLATION - 3.3/3.8L On e plu g is t h e cylin der u n der com pr ession , t h e
ot h er cylin der fir es on t h e exh a u st st r oke. Th e P ow-
If th e re m o v e d s e n s o r is re in s ta lle d , c le a n o ff
er t r a in Con t r ol Modu le (P CM) det er m in es wh ich of
th e o ld s p a c e r o n th e s e n s o r fa c e . A N EW
t h e coils t o ch a r ge a n d fir e a t t h e cor r ect t im e.
S PACER m u s t be a tta c h e d to th e fa c e be fo re
Th e Au t o Sh u t down (ASD) r ela y pr ovides ba t t er y
in s ta lla tio n . In spect O-r in g for da m a ge, r epla ce if
volt a ge t o t h e ign it ion coil. Th e P CM pr ovides a
n ecessa r y. If t h e sen sor is bein g r epla ced, con fir m
gr ou n d con t a ct (cir cu it ) for en er gizin g t h e coil. Wh en
t h a t t h e pa per spa cer is a t t a ch ed t o t h e fa ce a n d
t h e P CM br ea ks t h e con t a ct , t h e m a gn et ic en er gy in
O-r in g is posit ion ed in gr oove of t h e n ew sen sor (F ig.
t h e coil t r a n sfer s t o t h e secon da r y ca u sin g t h e spa r k.
8).
Th e P CM will de-en er gize t h e ASD r ela y if it does
(1) Apply a cou ple dr ops of clea n en gin e oil t o t h e
n ot r eceive t h e cr a n ksh a ft posit ion sen sor a n d ca m -
O-r in g pr ior t o in st a lla t ion .
sh a ft posit ion sen sor in pu t s. Refer t o Au t o Sh u t down
(2) In st a ll sen sor in t h e ch a in ca se cover a n d
(ASD) Rela y—P CM Ou t pu t , in t h is sect ion for r ela y
r ot a t e in t o posit ion .
oper a t ion .
I GN I T I ON COI L (Cont inue d)
(4) Rem ove coil pa ck a n d h ea t sh ield (F ig. 9).
REMOVAL - 3.3/3.8L
(2) Rem ove t h e t h r ot t le a n d speed con t r ol ca bles
fr om clip.
(3) Rem ove 2 bolt s fr om t h e P ower st eer in g r eser-
voir t o in t a ke m a n ifold.
(4) Loosen t h e lower n u t for t h e power st eer in g
r eser voir fr om st u d on ign it ion coil br a cket .
(5) Reposit ion t h e P ower st eer in g r eser voir (F ig.
11).
Fig. 9 IGNITION COIL - 2.4L
Fig. 11 IGNITION COIL BRACKET 3.3/3.8L

(6) Rem ove t h e ign it ion ca bles fr om t h e ign it ion
coil.
(7) Discon n ect t h e elect r ica l con n ect or fr om t h e
ign it ion coil.
(8) Rem ove 2 n u t s fr om t h e ign it ion coil st u ds.
I N STALLAT I ON
INSTALLATION - 2.4L
Fig. 10 IGNITION COIL - 3.3/3.8L (1) In st a ll ign it ion coil a n d h ea t sh ield t o va lve
1 -Ignition Coil cover a n d t igh t en bolt s.
(2) Con n ect t h e elect r ica l con n ect or t o t h e ign it ion
REM OVAL coil.
(3) Tr a n sfer spa r k plu g ca bles t o n ew coil pa ck.
REMOVAL - 2.4L Th e coil pa ck t ower s a r e n u m ber ed wit h t h e cylin der
Th e elect r on ic ign it ion coil pa ck a t t a ch es dir ect ly iden t ifica t ion . Be su r e t h e ign it ion ca bles a r e fu lly
t o t h e va lve cover. sea t ed on t o t h e t ower s.
(1) Dicon n ect t h e n ega t ive ba t t er y ca ble. (4) Con n ect t h e n ega t ive ba t t er y ca ble.
(2) Discon n ect elect r ica l con n ect or fr om coil pa ck.
(3) Rem ove coil pa ck m ou n t in g bolt s.
I GN I T I ON COI L (Cont inue d)
INSTALLATION - 3.3/3.8L Th e P CM, u sin g sh or t t er m m em or y, ca n r espon d

(1) In st a ll coil over st u ds on br a cket . qu ickly t o r et a r d t im in g wh en en gin e kn ock is
(2) In st a ll 2 n u t s t o t h e ign it ion coil st u ds. Tigh t en det ect ed. Sh or t t er m m em or y is lost a n y t im e t h e
n u t s a n d bolt s. ign it ion key is t u r n ed off.
(3) Con n ect t h e elect r ica l con n ect or t o t h e ign it ion
NOTE: Over or under tightening affects knock sen-
coil.
sor performance, possibly causing improper spark
(4) In st a ll t h e ign it ion ca bles t o t h e ign it ion coil.
control.
(5) Reposit ion t h e P ower st eer in g r eser voir. Slide
br a cket over t h e m ou n t in g st u d (F ig. 11).
(6) In st a ll 2 bolt s t o t h e P ower st eer in g r eser voir
t o in t a ke m a n ifold. REM OVAL
(7) Tigh t en t h e lower n u t t o st u d on ign it ion coil
br a cket . REMOVAL - 2.4L
(8) In st a ll t h e t h r ot t le a n d speed con t r ol ca bles t o Th e kn ock sen sor t h r ea ds in t o t h e side of t h e cyl-
clip. in der block in fr on t of t h e st a r t er (F ig. 12).
(9) Con n ect t h e n ega t ive ba t t er y ca ble. (1) Discon n ect elect r ica l con n ect or fr om kn ock sen -
sor.
(2) Use a cr ow foot socket t o r em ove t h e kn ock
K N OCK SEN SOR sen sor s.
DESCRIPTION REMOVAL - 3.8L

Th e kn ock sen sor t h r ea ds in t o t h e cylin der block. Th e kn ock sen sor t h r ea ds in t o t h e side of t h e cyl-
Th e kn ock sen sor is design ed t o det ect en gin e vibr a - in der block in t h e r ea r.
t ion t h a t is ca u sed by det on a t ion . (1) Discon n ect t h e n ega t ive ba t t er y ca ble.
OPERATION (3) On All Wh eel Dr ive veh icles r em ove t h e P TU
Wh en t h e kn ock sen sor det ect s a kn ock in on e of (P ower Tr a n sfer Un it ), r efer t o t h e Tr a n sm ission sec-
t h e cylin der s, it sen ds a n in pu t sign a l t o t h e P CM. In t ion for m or e in for m a t ion .
r espon se, t h e P CM r et a r ds ign it ion t im in g for a ll cyl- (4) Discon n ect elect r ica l con n ect or fr om kn ock sen -
in der s by a sch edu led a m ou n t . sor.
Kn ock sen sor s con t a in a piezoelect r ic m a t er ia l (5) Use a cr ow foot socket t o r em ove t h e kn ock
wh ich con st a n t ly vibr a t es a n d sen ds a n in pu t volt a ge sen sor.
(sign a l) t o t h e P CM wh ile t h e en gin e oper a t es. As t h e
in t en sit y of t h e cr yst a l’s vibr a t ion in cr ea ses, t h e
kn ock sen sor ou t pu t volt a ge a lso in cr ea ses. I N STALLAT I ON
Th e volt a ge sign a l pr odu ced by t h e kn ock sen sor
in cr ea ses wit h t h e a m plit u de of vibr a t ion . Th e P CM INSTALLATION - 2.4L
r eceives a s a n in pu t t h e kn ock sen sor volt a ge sign a l. Th e kn ock sen sor t h r ea ds in t o t h e side of t h e cyl-
If t h e sign a l r ises a bove a pr edet er m in ed level, t h e in der block in fr on t of t h e st a r t er (F ig. 12).
P CM will st or e t h a t va lu e in m em or y a n d r et a r d (1) In st a ll kn ock sen sor. Tigh t en kn ock sen sor t o
ign it ion t im in g t o r edu ce en gin e kn ock. If t h e kn ock 10 N·m (7 ft . lbs.) t or qu e. Ov e r o r u n d e r tig h te n -
sen sor volt a ge exceeds a pr eset va lu e, t h e P CM in g e ffe c ts k n o c k s e n s o r p e rfo rm a n c e , p o s s ibly
r et a r ds ign it ion t im in g for a ll cylin der s. It is n ot a c a u s in g im p ro p e r s p a rk c o n tro l.
select ive cylin der r et a r d. (2) At t a ch elect r ica l con n ect or t o kn ock sen sor.
Th e P CM ign or es kn ock sen sor in pu t du r in g en gin e
idle con dit ion s. On ce t h e en gin e speed exceeds a INSTALLATION - 3.8L
specified va lu e, kn ock r et a r d is a llowed. Th e kn ock sen sor t h r ea ds in t o t h e side of t h e cyl-
Kn ock r et a r d u ses it s own sh or t t er m a n d lon g in der block in t h e r ea r.
t er m m em or y pr ogr a m . (1) In st a ll kn ock sen sor. Tigh t en kn ock sen sor t o
Lon g t er m m em or y st or es pr eviou s det on a t ion 10 N·m (7 ft . lbs.) t or qu e. Ov e r o r u n d e r tig h te n -
in for m a t ion in it s ba t t er y-ba cked RAM. Th e m a xi- in g e ffe c ts k n o c k s e n s o r p e rfo rm a n c e , p o s s ibly
m u m a u t h or it y t h a t lon g t er m m em or y h a s over t im - c a u s in g im p ro p e r s p a rk c o n tro l.
in g r et a r d ca n be ca libr a t ed. (2) At t a ch elect r ica l con n ect or t o kn ock sen sor.
Sh or t t er m m em or y is a llowed t o r et a r d t im in g u p (3) On All Wh eel Dr ive veh icles in st a ll t h e P TU
t o a pr eset a m ou n t u n der a ll oper a t in g con dit ion s (a s (P ower Tr a n sfer Un it ) for t h e r ea r wh eels, r efer t o
lon g a s r pm is a bove t h e m in im u m r pm ) except WOT. t h e Tr a n sm ission sect ion for m or e in for m a t ion .
K N OCK SEN SOR (Cont inue d)
Wh en t h e spa r k plu gs u se a sin gle or dou ble pla t -
in u m t ips a n d t h ey h a ve a r ecom m en ded ser vice life
of 100,000 m iles for n or m a l dr ivin g con dit ion s per
sch edu le A in t h is m a n u a l. Th e spa r k plu gs h a ve a
r ecom m en ded ser vice life of 75,000 m iles for sever e
dr ivin g con dit ion s per sch edu le B in t h is m a n u a l. A
t h in pla t in u m pa d is welded t o bot h or ju st t h e cen -
t er elect r ode en d(s) a s sh own in (F ig. 13). E xt r em e
ca r e m u st be u sed t o pr even t spa r k plu g cr oss
t h r ea din g, m is-ga ppin g (F ig. 14) a n d cer a m ic in su la -
t or da m a ge du r in g plu g r em ova l a n d in st a lla t ion .
Fig. 12 Knock Sensor

1 - GENERATOR
2 - INTAKE MANIFOLD
3 - KNOCK SENSOR
4 - STARTER
(4) Lower veh icle. Fig. 13 Platinum Pads

(5) Con n ect t h e n ega t ive ca ble. 1 - APPLY ANTI-SEIZE COMPOUND HERE ONLY
2 - PLATINUM SPARK SURFACE
SPARK PLU G CAUTION: Cleaning of the platinum plug may dam-

age the platinum tip.
DESCRI PT I ON
DESCRIPTION - STANDARD 4 CYLINDER
All en gin es u se r esist or spa r k plu gs. Th ey h a ve
r esist a n ce va lu es r a n gin g fr om 6,000 t o 20,000 oh m s
wh en ch ecked wit h a t lea st a 1000 volt spa r k plu g
t est er.
D o n o t u s e a n o h m m e te r to c h e c k th e re s is -
ta n c e o f th e s p a rk p lu g s . Th is w ill g iv e a n in a c -
c u ra te re a d in g .
Refer t o t h e Specifica t ion s sect ion for ga p a n d t ype
of spa r k plu g.
DESCRIPTION - PLATINUM PLUGS

Th e V6 en gin es u se pla t in u m r esist or spa r k plu gs.
Th ey h a ve r esist a n ce va lu es of 6,000 t o 20,000 oh m s
wh en ch ecked wit h a t lea st a 1000 volt t est er. F or
spa r k plu g iden t ifica t ion a n d specifica t ion s, Refer t o
t h e Specifica t ion s sect ion .
D o n o t u s e a n o h m m e te r to c h e c k th e re s is -
Fig. 14 Setting Spark Plug Electrode Gap
ta n c e o f th e s p a rk p lu g s . Th is w ill g iv e a n in a c -
c u ra te re a d in g . 1 - TAPER GAUGE
SPARK PLU G (Cont inue d)
REMOVAL spa r k plu gs a t ea ch cylin der. Th e r esist ive spa r k plu g

Wh en r epla cin g t h e spa r k plu gs a n d spa r k plu g ca bles a r e of n on m et a llic con st r u ct ion . Th e ca bles
ca bles, r ou t e t h e ca bles cor r ect ly a n d secu r e t h em in pr ovide su ppr ession of r a dio fr equ en cy em ission s
t h e a ppr opr ia t e r et a in er s. F a ilu r e t o r ou t e t h e ca bles fr om t h e ign it ion syst em .
pr oper ly ca n ca u se t h e r a dio t o r epr odu ce ign it ion Ch eck t h e spa r k plu g ca ble con n ect ion s for good
n oise, cr oss ign it ion of t h e spa r k plu gs or s h o rt c ir- con t a ct a t t h e coil, a n d spa r k plu gs. Ter m in a ls sh ou ld
c u it th e c a ble s to g ro u n d . be fu lly sea t ed. Th e in su la t or s sh ou ld be in good con -
Alwa ys r em ove ca bles by gr a spin g a t t h e boot , dit ion a n d sh ou ld fit t igh t ly on t h e coil, a n d spa r k
r ot a t in g t h e boot 1/2 t u r n , a n d pu llin g st r a igh t ba ck plu gs. Spa r k plu g ca bles wit h in su la t or s t h a t a r e
in a st ea dy m ot ion . cr a cked or t or n m u st be r epla ced.
(1) P r ior t o r em ovin g t h e spa r k plu g, spr a y com - Clea n Spa r k P lu g ca bles wit h a clot h m oist en ed
pr essed a ir a r ou n d t h e spa r k plu g h ole a n d t h e a r ea wit h a n on -fla m m a ble solven t . Wipe t h e ca bles dr y.
a r ou n d t h e spa r k plu g. Ch eck for br it t le or cr a cked in su la t ion . Th e spa r k
(2) Rem ove t h e spa r k plu g u sin g a qu a lit y socket plu g ca bles a n d spa r k plu g boot s a r e m a de fr om h igh
wit h a foa m in ser t . t em per a t u r e m a t er ia ls.
(3) In spect t h e spa r k plu g con dit ion .
REMOVAL - 2.0/2.4L
INSTALLATION F a ilu r e t o r ou t e t h e ca bles pr oper ly cou ld ca u se t h e
Wh en r epla cin g t h e spa r k plu gs a n d spa r k plu g r a dio t o r epr odu ce ign it ion n oise, cr oss ign it ion of t h e
ca bles, r ou t e t h e ca bles cor r ect ly a n d secu r e t h em in spa r k plu gs or sh or t cir cu it t h e ca bles t o gr ou n d.
t h e a ppr opr ia t e r et a in er s. F a ilu r e t o r ou t e t h e ca bles Rem ove spa r k plu g ca ble fr om coil fir st .
pr oper ly ca n ca u se t h e r a dio t o r epr odu ce ign it ion Alwa ys r em ove t h e spa r k plu g ca ble by gr a spin g
n oise, cr oss ign it ion of t h e spa r k plu gs or s h o rt c ir- t h e t op of t h e spa r k plu g in su la t or, t u r n in g t h e boot
c u it th e c a ble s to g ro u n d . 1/2 t u r n a n d pu llin g st r a igh t u p in a st ea dy m ot ion .
(1) Coa t t h r ea ds of spa r k plu g wit h a n t i-seize. Be
su r e n ot t o get a n t i-seize AN YWHERE B U T ON INSTALLATION - 2.0/2.4L
THE THREAD S OF THE S PARK P LU G a s F a ilu r e t o r ou t e t h e ca bles pr oper ly cou ld ca u se t h e
s h o w n in (F ig . 13). r a dio t o r epr odu ce ign it ion n oise, cr oss ign it ion of t h e
(2) To a void cr oss t h r ea din g, st a r t t h e spa r k plu g spa r k plu gs or sh or t cir cu it t h e ca bles t o gr ou n d.
in t o t h e cylin der h ea d by h a n d. In st a ll spa r k plu g in su la t or s over spa r k plu gs.
(3) Tigh t en spa r k plu gs t o 17.5 N·m (13 ft . lbs.) E n su r e t h e t op of t h e spa r k plu g in su la t or cover s t h e
t or qu e. u pper en d of t h e spa r k plu g t u be, t h en con n ect t h e
(4) In st a ll spa r k plu g ca bles over spa r k plu gs. A ot h er en d t o coil pa ck.
click will be h ea r d a n d felt wh en t h e ca ble pr oper ly
a t t a ch es t o t h e spa r k plu g.
SPARK PLU G CABLE

DESCRIPTION
Spa r k P lu g ca bles a r e som et im es r efer r ed t o a s
secon da r y ign it ion wir es. Th e wir es t r a n sfer elect r i-
ca l cu r r en t fr om t h e ign it ion coil pa ck t o in dividu a l
RS INSTRUMENT CLUSTER 8J - 1
INSTRUMENT CLUSTER
page page
INSTRUMENT CLUSTER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

DESCRIPTION . . . . . . . . . . . . . . . . . . . .......1 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11
OPERATION . . . . . . . . . . . . . . . . . . . . . .......1 CLUSTER LENS
DIAGNOSIS AND TESTING - SELF- INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11
DIAGNOSTICS. . . . . . . . . . . . . . . . . . .......2
DIAGNOSIS AND TESTING - CLUSTER
DIAGNOSIS . . . . . . . . . . . . . . . . . . . . .......3
I N ST RU M EN T CLU ST ER • Glow P lu g (E xpor t On ly)

• Su pplem en t a l Ca bin H ea t er (E xpor t On ly)
DESCRIPTION WATER IN FUEL LAMP - EXPORT
Th e in st r u m en t a t ion ga u ges a r e con t a in ed in a
Th e Wa t er In F u el La m p is loca t ed in t h e m essa ge
su bdia l a ssem bly wit h in t h e in st r u m en t clu st er. Th e
cen t er. Wh en m oist u r e is fou n d wit h in t h e fu el sys-
in dividu a l ga u ges a r e n ot ser vicea ble. If on e of t h e
t em , t h e sen sor sen ds a m essa ge via t h e P CI da t a
clu st er ga u ges becom es fa u lt y, t h e en t ir e clu st er
bu s t o t h e in st r u m en t clu st er. Th e MIC illu m in a t es
wou ld r equ ir e r epla cem en t .
t h e bu lb in t h e m essa ge cen t er, Th e sen sor is loca t ed
Th e Mech a n ica l In st r u m en t Clu st er (MIC) wit h a
u n der n ea t h t h e veh icle, dir ect ly a bove t h e r ea r a xle.
t a ch om et er is equ ipped wit h a elect r on ic va cu u m flu -
Th e sen sor is h ou sed wit h in t h e fu el filt er /wa t er sep-
or escen t t r a n sm ission r a n ge in dica t or (P RND3L),
a r a t or a ssem bly cover. Th e sen sor is n ot ser viced sep-
odom et er, a n d t r ip odom et er displa y.
a r a t ely. If fou n d defect ive, t h e en t ir e a ssem bly cover
Th e MIC wit h ou t a t a ch om et er is equ ipped wit h a
Ligh t E m it t in g Diode (LE D) t r a n sm ission r a n ge in di-
ca t or (P RND3L) a n d a va cu u m flu or escen t odom et er
displa y.
OPERATION
Refer t o t h e veh icle Own er ’s Ma n u a l for oper a t ion
Th e MIC is equ ipped wit h t h e followin g wa r n in g
in st r u ct ion s a n d con dit ion s for t h e In st r u m en t Clu s-
la m ps.
t er Ga u ges.
• Lift Ga t e Aja r
• Low F u el Level
• Low Win dsh ield Wa sh er F lu id Level
WATER IN FUEL LAMP/SENSOR - EXPORT
Th e Wa t er In F u el Sen sor is a r esist ive t ype
• Cr u ise
swit ch . It is ca libr a t ed t o sen se t h e differ en t r esis-
• Ba t t er y Volt a ge
t a n ce bet ween diesel fu el a n d wa t er. Wh en wa t er
• F a st en Sea t Belt
en t er s t h e fu el syst em , it is ca u gh t in t h e bot t om of
• Door Aja r
t h e fu el filt er /wa t er sepa r a t or a ssem bly, wh er e t h e
• Coola n t Tem per a t u r e
sen sor is loca t ed. Wa t er h a s less r esist a n ce t h a n die-
• An t i-Lock Br a ke
sel fu el. Th e sen sor t h en sen ds a P CI da t a bu s m es-
• Br a ke
sa ge t o t h e in st r u m en t clu st er t o illu m in a t e t h e
• Oil P r essu r e
la m p.
• MIL (Ma lfu n ct ion In dica t or La m p)
If t h e la m p is in oper a t ive, per for m t h e self dia g-
• VTSS/SKIS In dica t or
n ost ic t est on t h e in st r u m en t clu st er t o ch eck t h e
• Air ba g
la m p oper a t ion befor e con t in u in g dia gn osis.
• Tr a ct ion Con t r ol
• Au t ost ick
Ex p o rt On ly - u ses a m essa ge cen t er t h a t displa ys
t h e followin g t ellt a les:
• Tu r n s Sign a ls
• H igh Bea m
• Tir e P r essu r e Mon it or in g (TP M)
8J - 2 INSTRUMENT CLUSTER RS
I N ST RU M EN T CLU ST ER (Cont inue d)
DI AGN OSI S AN D T EST I N G CALIBRATION TEST

Th e CLUSTE R CALIBRATION t a ble con t a in s t h e
DIAGNOSIS AND TESTING - SELF- pr oper ca libr a t ion poin t s for ea ch ga u ge. If t h e ga u ge
DIAGNOSTICS poin t er s a r e n ot ca libr a t ed, a pr oblem exist s in t h e
clu st er. If a n y ga u ge is ou t of ca libr a t ion , r epla ce t h e
Th e in st r u m en t clu st er s a r e equ ipped wit h a self
clu st er.
dia gn ost ic t est fea t u r e t o h elp iden t ify elect r on ic
pr oblem s. P r ior t o a n y t est , per for m t h e Self-Dia g-
n ost ic Test . Th e self dia gn ost ic syst em displa ys CLU ST ER CALI BRAT I ON
in st r u m en t clu st er st or ed fa u lt codes in t h e odom et er
displa y, sweeps t h e ga u ges t o t h e ca libr a t ion poin t s, SPEEDOMETER CALIBRATION POINT
a n d bu lb ch ecks t h e wa r n in g in dica t or s. Wh en t h e 1 0 MPH (0 KM/H)
key is in t h e ON posit ion wit h t h e en gin e n ot r u n -
2 20 MPH (40 KM/H)
n in g, t h e MIL will r em a in illu m in a t ed for r egu la t or y
pu r poses. 3 60 MPH (100 KM/H)
To a ct iva t e t h e Self-Dia gn ost ic pr ogr a m : 4 100 MPH (160 KM/H)
(1) Wit h t h e ign it ion swit ch in t h e OF F posit ion , TACHOMETER
depr ess t h e TRIP ODOME TE R RE SE T bu t t on .
(2) Con t in u e t o h old t h e TRIP ODOME TE R 1 0 RPM
RE SE T bu t t on u n t il S o f a n d a n u m ber (soft wa r e ver- 2 1000 RPM
sion n u m ber (i.e. S o f 3.2) a ppea r s in t h e odom et er 3 3000 RPM
win dow t h en r elea se t h e bu t t on . If a fa u lt code is
4 6000 RPM
pr esen t , t h e clu st er will displa y it in t h e odom et er
displa y. Wh en a ll fa u lt codes h a ve been displa yed, FUEL GAUGE
t h e clu st er will displa y “e n d ” in t h e odom et er dis- 1 EMPTY
pla y. Refer t o t h e INSTRUME NT CLUSTE R DTC’S 2 1/4 FILLED
t a ble t o det er m in e wh a t ea ch t r ou ble code m ea n s.
I N ST RU M EN T CLU ST ER DT C’S 3 1/2 FILLED
4 FULL
DTC DESCRIPTION TEMPERATURE
100.0 LOOP-BACK FAILURE GAUGE
100.1 ABS COMMUNICATION FAULT 1 COLD
100.2 BCM COMMUNICATION FAULT 2 1/4
100.3 EATX COMMUNICATION FAULT 3 3/4
100.4 FCM COMMUNICATION FAULT 4 HOT
100.5 ORC COMMUNICATION FAULT

ODOMETER SEGMENT TEST
SBEC/DEC/MCM COMMUNICATION
100.6 If a segm en t in t h e odom et er does n ot illu m in a t e
FAULT
n or m a lly, a pr oblem exist s in t h e displa y.
200.0 AIRBAG LED SHORT
200.1 AIRBAG LED OPEN ELECTRONIC TRANSMISSION RANGE INDICATOR
200.2 ABS LED SHORT SEGMENT TEST
If a segm en t in t h e t r a n sm ission r a n ge in dica t or
200.3 ABS LED OPEN
does n ot illu m in a t e n or m a lly, a pr oblem exist s in t h e
200.6 EL INVERTER TIME-OUT displa y.
200.7 EATX MISMATCH
400.0 EEPROM READ/WRITE FAILURE
IMPROPER POWER DOWN
400.1
DETECTED
DIAGNOSIS AND TESTING - CLUSTER • F UE L GAUGE DIAGNOSIS

• TE MP E RATURE GAUGE DIAGNOSIS
DIAGNOSIS
• ODOME TE R DIAGNOSIS
• E LE CTRONIC GE AR INDICATOR DISP LAY
CONDITIONS
DIAGNOSIS
Refer t o t h e followin g t a bles for possible pr oblem s,
ca u ses, a n d cor r ect ion s. NOTE: Always check the functionality of the cluster
• INSTRUME NT CLUSTE R DIAGNOSIS by running the self test prior to troubleshooting.
• SP E E DOME TE R DIAGNOSIS
• TACH OME TE R DIAGNOSIS
I N ST RU M EN T CLU ST ER DI AGN OSI S

INSTRUMENT CLUSTER NO PCI BUS MESSAGES USE A DRB III" SCAN TOOL TO CHECK THE BCM.
INOPERATIVE. NO FROM THE BCM. IF OK, LOOK FOR ANOTHER POSSIBLE CAUSE
RESPONSE FROM FOR CLUSTER FAILURE. IF NOT OK, REFER TO
INSTRUMENT CLUSTER. THE PROPER BODY DIAGNOSTIC PROCEDURES
MANUAL.
SPREAD TERMINAL(S) REMOVE CLUSTER FROM INSTRUMENT PANEL
ON WIRING HARNESS AND CHECK WIRING HARNESS CONNECTOR FOR
CLUSTER CONNECTOR. SPREAD TERMINAL. IF OK, LOOK FOR ANOTHER
POSSIBLE CAUSE FOR THE CLUSTER FAILURE. IF
NOT OK, REPAIR CONNECTOR.
BCM IS NOT RECEIVING 1. USE A DRB III" SCAN TOOL TO VERIFY IGNITION
PROPER INPUT FROM SWITCH STATUS INTO THE BCM. IF NOT OK, GO
THE IGNITION SWITCH. TO STEP (2). IF OK, LOOK AT ANOTHER POSSIBLE
CAUSE OF FAILURE.
2. CHECK IGNITION SWITCH FUNCTION AND
WIRING.
INTERNAL CLUSTER REPLACE CLUSTER.
FAILURE.
WAKE UP CIRCUIT VERIFY CONTINUITY OF WAKE UP CIRCUIT FROM
FAULTY. BCM TO MIC. CIRCUIT SHALL BE LOW WHENEVER
BCM IS AWAKE.
POWER OR GROUND IF NO RESPONSE FROM THE MIC, CHECK FOR
MISSING. POWER AND GROUND AT THE MIC CONNECTOR.
REFER TO WIRING DIAGRAMS FOR CONNECTOR
CALL OUTS.
SPEEDOM ET ER DI AGN OSI S
NO POINTER 1. INTERNAL CLUSTER 1.A. PERFORM CLUSTER SELF-DIAGNOSTIC TEST

MOVEMENT. FAILURE. AND CHECK FOR FAULT CODES.
• IF SPEEDOMETER POINTER MOVES TO
CALIBRATION POINTS DURING TEST LOOK FOR
ANOTHER POSSIBLE CAUSE OF FAILURE.
• IF THE POINTER DOESN’T MOVE DURING TEST,
CHECK FOR POWER AND GROUND TO THE MIC. IF
POWER AND GROUND ARE PRESENT GO TO STEP
1.B.
1.B. REPLACE CLUSTER. GO TO STEP 1.C.
1.C. CONNECT CLUSTER INTO INSTRUMENT
PANEL WIRING HARNESS. PLACE IT BACK INTO
THE PROPER POSITION IN THE INSTRUMENT
PANEL. PUT IN THE TOP FOUR MOUNTING
SCREWS AND SECURE THE CLUSTER TO THE
INSTRUMENT PANEL.
2. NO SPEED PCI BUS 2.A. CHECK THE PCM (CODE 10) USING A DRB III"
MESSAGE OR ZERO SCAN TOOL. IF OK, GO TO STEP 2.B. IF NOT OK,
MPH PCI SPEED BUS REFER TO THE PROPER POWERTRAIN
MESSAGE. DIAGNOSTIC PROCEDURES MANUAL TO REPAIR
THE PCM.
2.B. CHECK THE SPEED SIGNAL INPUT INTO THE
PCM. THE SPEED SIGNAL ORIGINATES FROM THE
TCM FOR VEHICLES WITH THE 4 SPEED
ELECTRONIC TRANSMISSIONS. CHECK
CONTINUITY FROM TCM TO PCM. IF OK, USE A
DRB III" SCAN TOOL TO CHECK TCM. REFER TO
THE PROPER TRANSMISSION DIAGNOSTIC
PROCEDURES MANUAL TO REPAIR THE TCM. IF
NOT OK, REPAIR WIRING.
ERRATIC POINTER 1. ERRATIC MESSAGE 1.A. CHECK THE BCM USING A DRB III" SCAN
MOVEMENT. FROM ANOTHER TOOL IF OK, GO TO STEP 1.B. IF NOT OK, REFER
MODULE. TO THE PROPER BODY DIAGNOSTIC
PROCEDURES MANUAL TO REPAIR THE BCM.
1.B. CHECK THE PCM USING A DRB III" SCAN
TOOL. IF OK, GO TO STEP 1.C. IF NOT OK, REFER
TO THE PROPER POWERTRAIN DIAGNOSTIC
PROCEDURES MANUAL TO REPAIR THE PCM.
1.C. CHECK THE SPEED SIGNAL INPUT INTO THE
PCM. THE SPEED SIGNAL ORIGINATES FROM THE
TCM FOR VEHICLES WITH THE 4 SPEED
ELECTRONIC TRANSMISSIONS. CHECK
CONTINUITY FROM TCM TO PCM. IF OK, USE A
DRB III" SCAN TOOL TO CHECK TCM. REFER TO
THE PROPER TRANSMISSION DIAGNOSTIC
PROCEDURES MANUAL TO REPAIR THE TCM. IF
NOT OK, REPAIR WIRING.
2. INTERNAL CLUSTER 2.A. PERFORM CLUSTER SELF-DIAGNOSTIC TEST

FAILURE. AND CHECK FOR FAULT CODES.
• IF THE POINTER MOVES DURING TEST BUT
STILL APPEARS ERRATIC, THEN GO TO STEP 2.B.
2.B. REPLACE CLUSTER ASSEMBLY.
SPEEDOMETER 1. SPEEDOMETER OUT 1. PERFORM CLUSTER SELF-DIAGNOSTIC TEST.

INACCURATE. OF CALIBRATION. • IF SPEEDOMETER IS ACCURATE TO THE
CALIBRATION POINTS THEN LOOK FOR ANOTHER
POSSIBLE CAUSE OF INACCURACY.
• IF SPEEDOMETER IS NOT ACCURATE TO THE
CALIBRATION POINTS, REPLACE CLUSTER
ASSEMBLY.
2. WRONG 2.A. IF VEHICLE HAS A 4 SPEED ELECTRONIC
SPEEDOMETER PINION TRANSMISSION GO TO STEP 2.C. OTHERWISE GO
FOR TIRE SIZE. TO STEP 2.B.
2.B. CHECK IF CORRECT SPEEDOMETER PINION
IS BEING USED WITH TIRES ON VEHICLE. REFER
TO TRANSMISSION FOR DIAGNOSIS AND TESTING.
• IF THE INCORRECT PINION IS IN TRANSMISSION
THEN REPLACE WITH CORRECT PINION.
• IF THE CORRECT PINION IS IN THE
TRANSMISSION, CHECK TIRE SIZE.
2.C. USE A DRB III" SCAN TOOL TO CHECK THE
TCM TO SEE IF THE CORRECT TIRE SIZE HAS
BEEN PROGRAMMED INTO THE TCM.
• IF THE INCORRECT TIRE SIZE WAS SELECTED,
SELECT THE PROPER TIRE SIZE.
• IF THE CORRECT TIRE SIZE WAS SELECTED,
CHECK SPEED SENSOR.
3. BAD SPEED SENSOR. 3. REFER TO TRANSMISSION, SPEED SENSOR,
DIAGNOSIS AND TESTING.
TACH OM ET ER DI AGN OSI S
NO POINTER 1. INTERNAL 1.A. PERFORM CLUSTER SELF-DIAGNOSTIC TEST AND

MOVEMENT. CLUSTER FAILURE. CHECK FOR FAULT CODES.
• IF TACHOMETER POINTER MOVES TO CALIBRATION
POINTS DURING TEST, LOOK FOR ANOTHER POSSIBLE
CAUSE OF FAILURE.
CHECK FOR POWER AND GROUND TO THE MIC. IF
POWER AND GROUND ARE PRESENT GO TO STEP 1.B.
1.B. REPLACE CLUSTER. GO TO STEP 1.C.
2. %NO RPM% PCI BUS 2. CHECK THE PCM USING A DRB III" SCAN TOOL.
MESSAGE OR %ZERO REFER TO THE PROPER POWERTRAIN DIAGNOSTIC
RPM% PCI BUS PROCEDURES MANUAL TO PROPERLY DIAGNOSE AND
MESSAGE FROM REPAIR.
PCM.
ERRATIC POINTER 1. BAD PCI BUS 1. CHECK THE PCM USING A DRB III" SCAN TOOL.
MOVEMENT. MESSAGE FROM REFER TO THE PROPER POWERTRAIN DIAGNOSTIC
PCM. PROCEDURES MANUAL TO PROPERLY DIAGNOSE AND
REPAIR.
2. INTERNAL 2. PERFORM CLUSTER SELF-DIAGNOSTIC TEST AND

CLUSTER FAILURE. CHECK FOR FAULT CODES.
• IF THE POINTER MOVES DURING TEST BUT STILL

APPEARS ERRATIC, REPLACE CLUSTER ASSEMBLY.
TACHOMETER TACHOMETER OUT PERFORM CLUSTER SELF-DIAGNOSTIC TEST.

INACCURATE. OF CALIBRATION. • IF TACHOMETER IS ACCURATE TO THE CALIBRATION
POINTS, LOOK FOR ANOTHER POSSIBLE CAUSE OF
INACCURACY.
• IF TACHOMETER IS NOT ACCURATE TO THE
CALIBRATION POINTS, REPLACE CLUSTER ASSEMBLY.
FU EL GAU GE DI AGN OSI S
NO POINTER 1. INTERNAL CLUSTER 1. PERFORM CLUSTER SELF-DIAGNOSTIC TEST.

MOVEMENT. FAILURE. • IF FUEL GAUGE POINTER MOVES TO
CALIBRATION POINTS, LOOK FOR ANOTHER
POSSIBLE CAUSE OF FAILURE.
VERIFY POWER AND GROUND ARE BEING
PROVIDED TO THE CLUSTER. IF YES, REPLACE
CLUSTER ASSEMBLY. IF NO, DETERMINE CAUSE
OF NO POWER OR GROUND.
2. NO PCI FUEL 2.A. CHECK THE BCM USING A DRB III" SCAN
MESSAGE OR EMPTY TOOL. IF OK, GO TO STEP 2.B. IF NOT OK, REFER
PCI BUS MESSAGE TO THE PROPER BODY DIAGNOSTIC
FROM BODY CONTROL PROCEDURES MANUAL TO PROPERLY DIAGNOSE
MODULE. AND REPAIR.
2.B. REFER TO THE FUEL SECTION OF THE
SERVICE MANUAL FOR THE FUEL LEVEL SENDING
UNIT TEST PROCEDURE. TEST UNIT AND REPAIR
AS INSTRUCTED.
ERRATIC POINTER 1. BAD PCI FUEL 1. USE A DRB III" SCAN TOOL TO CHECK THE BCM.
MOVEMENT. MESSAGE FROM THE IF OK, GO TO STEP 2. IF NOT OK, REFER TO THE
BODY CONTROLLER. PROPER BODY DIAGNOSTIC PROCEDURES
MANUAL TO PROPERLY DIAGNOSE AND REPAIR.
2. REFER TO THE FUEL SECTION OF THE SERVICE

MANUAL FOR THE FUEL LEVEL SENDING UNIT
TEST PROCEDURE. TEST UNIT. IF OK, LOOK FOR
ANOTHER POSSIBLE CAUSE FOR FUEL GAUGE
FAILURE. IF NOT OK, REPAIR SENDING UNIT.
2. INTERNAL CLUSTER 2. PERFORM CLUSTER SELF-DIAGNOSTIC TEST

STILL APPEARS ERRATIC, REPLACE CLUSTER
ASSEMBLY.
FUEL GAUGE 1. FUEL GAUGE OUT OF 1. PERFORM CLUSTER SELF-DIAGNOSTIC TEST. IF

INACCURATE. CALIBRATION. POINTER IS ACCURATE TO THE CALIBRATION
POINTS LOOK FOR ANOTHER POSSIBLE CAUSE
OF FAILURE. IF POINTER IS INACCURATE TO THE
ASSEMBLY.
2. FUEL LEVEL 2. REFER TO THE FUEL SECTION OF THE SERVICE
SENDING UNIT IS OUT MANUAL FOR TESTING AND REPAIR PROCEDURE.
OF CALIBRATION.
T EM PERAT U RE GAU GE DI AGN OSI S
NO POINTER 1. INTERNAL CLUSTER 1. PERFORM CLUSTER SELF-DIAGNOSTIC TEST

MOVEMENT. FAILURE. AND CHECK.
• IF TEMPERATURE GAUGE POINTER MOVES TO
CALIBRATION POINTS, LOOK FOR ANOTHER
POSSIBLE CAUSE OF FAILURE.
VERIFY POWER AND GROUND ARE BEING
PROVIDED TO THE CLUSTER. IF YES, REPLACE
CLUSTER. IF NO, DETERMINE CAUSE OF NO
POWER OR NO GROUND.
2. NO PCI 2.A. CHECK PCM FAULT CODES USING A DRB III"
TEMPERATURE SCAN TOOL. IF THERE ARE NO FAULTS, GO TO
MESSAGE OR COLD PCI STEP 2.B. IF THERE ARE FAULTS, REFER TO THE
BUS MESSAGE FROM PROPER POWERTRAIN DIAGNOSTIC
THE POWERTRAIN PROCEDURES MANUAL TO PROPERLY DIAGNOSE
CONTROL MODULE. AND REPAIR.
2.B. REFER TO FUEL, COOLANT TEMPERATURE
SENSOR, DIAGNOSIS AND TESTING. REPAIR
SENSOR AS NEEDED.
ERRATIC POINTER 1. BAD PCI BUS 1.A. CHECK PCM FAULT CODES USING A DRB III"
MOVEMENT. MESSAGE FROM THE SCAN TOOL. IF THERE ARE NO FAULTS, GO TO
POWERTRAIN CONTROL STEP 1.B. IF THERE ARE FAULTS, REFER TO THE
MODULE. PROPER POWERTRAIN DIAGNOSTIC
PROCEDURES MANUAL TO PROPERLY DIAGNOSE
AND REPAIR.
1.B. REFER TO FUEL, COOLANT TEMPERATURE

SENSOR, DIAGNOSIS AND TESTING. REPAIR
SENSOR AS NEEDED.

STILL APPEARS ERRATIC, REPLACE CLUSTER
ASSEMBLY.
TEMPERATURE GAUGE 1. TEMPERATURE 1. PERFORM CLUSTER SELF-DIAGNOSTIC TEST.

INACCURATE. GAUGE OUT OF • IF POINTER IS ACCURATE TO THE CALIBRATION
CALIBRATION. POINTS LOOK FOR ANOTHER POSSIBLE CAUSE
OF FAILURE.
• IF POINTER IS INACCURATE TO THE
ASSEMBLY.
2. COOLANT SENSOR 2. REFER TO FUEL, COOLANT TEMPERATURE
OUT OF CALIBRATION. SENSOR FOR TEST AND REPAIR PROCEDURE.
ODOM ET ER DI AGN OSI S

NO DISPLAY. 1. NO PCI BUS 1. USE A DRB III" SCAN TOOL TO CHECK THE BCM.
ODOMETER MESSAGE REFER TO THE PROPER BODY DIAGNOSTIC
FROM BCM. PROCEDURES MANUAL TO PROPERLY DIAGNOSE
AND REPAIR.

• IF ODOMETER PASSES THE SEGMENT CHECK,
LOOK FOR ANOTHER POSSIBLE CAUSE OF
FAILURE. IF IT FAILS VERIFY POWER AND
GROUND ARE BEING PROVIDED TO THE
CLUSTER. IF YES, REPLACE CLUSTER. IF NO,
DETERMINE CAUSE OF NO POWER OR GROUND.

ERRATIC DISPLAY 1. INTERNAL CLUSTER 1. PERFORM CLUSTER SELF-DIAGNOSTIC TEST
• IF ODOMETER PASSES THE SEGMENT TEST,

FAILURE MAY NOT BE IN THE CLUSTER. LOOK
FOR ANOTHER POSSIBLE CAUSE OF FAILURE.
2. VERIFY GOOD POWER AND GROUND
CONNECTIONS. IF CONNECTIONS ARE GOOD AND
NO OTHER PROBLEMS ARE FOUND, REPLACE
CLUSTER ASSEMBLY.
2. BAD PCI BUS 2. USE A DRB III" SCAN TOOL TO CHECK THE BCM.
MESSAGE FROM THE REFER TO THE PROPER BODY DIAGNOSTIC
BCM. PROCEDURES MANUAL TO PROPERLY DIAGNOSE
AND REPAIR.
ODOMETER WON’T GO TRIP SWITCH DOESN’T IF CLUSTER WILL NOT GO INTO SELF DIAGNOSTIC
INTO TRIP MODE. WORK. MODE AND CANNOT TOGGLE BETWEEN
ODOMETER AND TRIP ODOMETER, REPLACE
CLUSTER.
TRIP ODOMETER WON’T RESET SWITCH IF CLUSTER WILL NOT GO INTO SELF DIAGNOSTIC
RESET. DOESN’T WORK. MODE AND TRIP ODOMETER WILL NOT RESET,
REPLACE CLUSTER.
ELECT RON I C GEAR I N DI CAT OR DI SPLAY DI AGN OSI S

NO DISPLAY. 1. INTERNAL CLUSTER 1. PERFORM CLUSTER SELF-DIAGNOSTIC TEST
• IF PRND3L (PRND1234 IF AUTOSTICK EQUIPPED)
PASSES THE SEGMENT CHECK, THEN FAILURE
MAY NOT BE IN THE CLUSTER. LOOK FOR
ANOTHER POSSIBLE CAUSE OF FAILURE. IF IT
FAILS, REPLACE CLUSTER ASSEMBLY.
ERRATIC DISPLAY. 1. INTERNAL CLUSTER 1. PERFORM CLUSTER SELF-DIAGNOSTIC TEST
• IF PRND3L (PRND1234 IF AUTOSTICK EQUIPPED)

PASSES THE SEGMENT CHECK, THEN FAILURE
MAY NOT BE IN THE CLUSTER. LOOK FOR
ANOTHER POSSIBLE CAUSE OF FAILURE.
2. BAD PCI BUS 2. USE A DRB III" SCAN TOOL TO CHECK THE TCM.
MESSAGE FROM THE REFER TO THE PROPER TRANSMISSION
TCM. DIAGNOSTIC PROCEDURES MANUAL TO
PROPERLY DIAGNOSE AND REPAIR.

ALL SEGMENTS ARE 1. NO PCI BUS 1.A. PERFORM CLUSTER SELF-DIAGNOSTIC TEST.
ON. MESSAGE FROM THE IF PRND3L (PRND1234 IF AUTOSTICK EQUIPPED)
TCM. PASSES TEST GO TO STEP 1.B. IF PRND3L
(PRND1234 IF AUTOSTICK EQUIPPED) FAILS TEST,
REPLACE CLUSTER ASSEMBLY.
1.B. CHECK THE TCM USING A DRB III" SCAN
TOOL. REFER TO THE PROPER TRANSMISSION
DIAGNOSTIC PROCEDURES MANUAL TO
PROPERLY DIAGNOSE AND REPAIR.
REMOVAL (6) In st a ll t h e Over St eer in g Colu m n Bezel by

(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive fir m ly sn a ppin g in t o pla ce.
ca ble. (7) Con n ect t h e ba t t er y n ega t ive ca ble.
(2) Rem ove Over St eer in g Colu m n Bezel by lift in g
it st r a igh t u p wit h a fir m pu ll.
(3) Rem ove t h e fou r clu st er bezel a t t a ch in g scr ews.
CLU ST ER LEN S
(4) Tilt t h e st eer in g colu m n in t h e fu ll down posi-
t ion . REMOVAL
(5) P u ll r ea r wa r d on t h e clu st er bezel a n d r em ove. (1) Rem ove t h e in st r u m en t clu st er. Refer t o E lec-
(6) Rem ove t h e fou r scr ews h oldin g in st r u m en t t r ica l, In st r u m en t Clu st er, Rem ova l.
clu st er t o in st r u m en t pa n el. (2) Rem ove t h e scr ews h oldin g t h e len s t o t h e
(7) Rot a t e t op of clu st er ou t wa r d. in st r u m en t clu st er.
(8) Discon n ect t h e clu st er h a r n ess con n ect or. (3) P r ess down on t h e sn a p fea t u r es of t h e len s
(9) Rem ove in st r u m en t clu st er fr om in st r u m en t a n d r em ove t h e len s fr om t h e clu st er.
pa n el.
INSTALLATION
INSTALLATION (1) In ser t t h e len s sn a p fea t u r es in t o t h e clu st er.
(1) Con n ect t h e in st r u m en t clu st er wir e con n ect or. (2) In st a ll t h e scr ews h oldin g t h e len s t o t h e
(2) Rot a t e t op of clu st er in wa r d a s pla cin g in t o in st r u m en t clu st er.
in st r u m en t pa n el open in g. (3) In st a ll t h e in st r u m en t clu st er. Refer t o E lect r i-
(3) In st a ll t h e fou r scr ews h oldin g in st r u m en t clu s- ca l, In st r u m en t Clu st er, In st a lla t ion .
t er t o in st r u m en t pa n el.
(4) P osit ion clu st er bezel in t o pla ce.
(5) In st a ll t h e fou r bezel a t t a ch in g scr ews.
RS LAMPS 8L - 1
LAMPS
page page
LAMPS/LIGHTING - EXTERIOR . . . . . . . . . . . . . . . 1 LAMPS/LIGHTING - INTERIOR. . . . . . . . . . . . . . . 20
LAM PS/LI GH T I N G - EX T ERI OR
TABLE OF CONTENTS
page page
LAMPS/LIGHTING - EXTERIOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2 HEADLAMP SWITCH
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 DIAGNOSIS AND TESTING - HEADLAMP
WARNING .............................3 SWITCH .......................... . . 13
EXTERIOR LAMPS . . . . . . . . . . . . . . . . . . . . . 3 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13
BRAKE LAMP SWITCH HEADLAMP UNIT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 4 STANDARD PROCEDURE - HEADLAMP UNIT
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . 14
DIAGNOSIS AND TESTING - BRAKE LAMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
SWITCH .............................4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 15
REMOVAL .............................5 HEADLAMP UNIT - EXPORT
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 5 STANDARD PROCEDURE - HEADLAMP UNIT
CENTER HIGH MOUNTED STOP LAMP ALIGNMENT - EXPORT . . . . . . . . . . . . . . . . . 15
REMOVAL .............................6 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17
CENTER HIGH MOUNTED STOP LAMP UNIT LICENSE LAMP
REMOVAL .............................6 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
FRONT FOG LAMP MULTI-FUNCTION SWITCH
DIAGNOSIS AND TESTING - FRONT FOG DESCRIPTION - TURN SIGNAL SYSTEM . . . . . 17
LAMP ...............................7 OPERATION - TURN SIGNAL SYSTEM . . . . . . . 17
REMOVAL .............................8 DIAGNOSIS AND TESTING - MULTI-
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 8 FUNCTION SWITCH . . . . . . . . . . . . . . . . . . . 18
FRONT FOG LAMP UNIT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
STANDARD PROCEDURE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18
STANDARD PROCEDURE - FRONT FOG PARK/TURN SIGNAL LAMP
LAMP UNIT ALIGNMENT . . . . . . . . . . . . . . . . . 9 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
STANDARD PROCEDURE - FRONT FOG INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18
LAMP UNIT ALIGNMENT - EXPORT . . . . . . . . 9 TAIL LAMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
HEADLAMP TAIL LAMP UNIT
DIAGNOSIS AND TESTING - HEADLAMP . . . . . 11 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8L - 2 LAMPS/LIGHTING - EXTERIOR RS
LAM PS/LI GH T I N G - EX T ERI OR 450 a n d t h e win dsh ield wiper s h a ve been in t h e

in t er m it t en t , low or h igh m ode of oper a t ion for m or e
t h a n t en secon ds. Wh en t h e win dsh ield wiper s a r e
DESCRIPTION
t u r n ed OF F t h e Body Con t r ol Modu le will det er m in e
if t h e in st r u m en t a t ion a n d ext er ior illu m in a t ion
LAMP SYSTEMS
la m ps sh ou ld r em a in ON ba se u pon t h e cu r r en t
Ligh t in g cir cu it s a r e pr ot ect ed by fu ses. Ligh t in g
a m bien t ligh t level.
cir cu it s r equ ir e a n over loa d pr ot ect ed power a n d h igh
side dr iver s sou r ce, ON/OF F device, la m ps a n d body
HEADLAMP SYSTEM
gr ou n ds t o oper a t e pr oper ly. P la st ic la m ps r equ ir e a
Th e con figu r a t ion of t h e h ea dla m p syst em of h ea d-
wir e in t h e h a r n ess t o su pply body gr ou n d t o t h e
la m ps, pa r k la m ps a n d fog la m ps is det er m in ed by
la m p socket . Repla ce socket s a n d bu lbs t h a t a r e cor-
t h e BCM. Th e BCM det er m in es t h e ligh t in g con figu -
r oded.
r a t ion a s a r esu lt of t h e in pu t s fr om t h e ign it ion
Som e of t h e in t er ior a n d ext er ior ligh t in g fu n ct ion s
swit ch , h ea dla m p swit ch a n d m u lt i-fu n ct ion swit ch . A
a r e gover n ed by t h e Body Con t r ol Modu le (BCM).
P CI bu s is t r a n sm it t ed fr om t h e BCM t o t h e F CM t o
Th e h ea dla m p, dom e, a n d t h e door a ja r swit ch es pr o-
en a ble t h e n ecessa r y dr iver s t o set t h e illu m in a t ion
vide sign a ls t o t h e BCM. Th e BCM in t u r n sen ds a
con figu r a t ion . F ou r wir es a r e con n ect ed bet ween t h e
P r ogr a m m a ble Com m u n ica t ion In t er fa ce (P CI) bu s
h ea dla m p swit ch a n d t h e BCM. Th e fir st wir e con -
m essa ge t o t h e F r on t Con t r ol Modu le (F CM) t o
t a in s in for m a t ion r ega r din g t h e posit ion of t h e h ea d-
en a ble t h e n ecessa r y dr iver s t o set t h e r equ ir ed illu -
la m p swit ch (Off, Au t om a t ic H ea dla m ps, Au t om a t ic
m in a t ion con figu r a t ion .
H ea dla m p swit ch fog, P a r k wit h F og, H ea d, or H ea d
Wir e con n ect or s ca n m a ke in t er m it t en t con t a ct or
wit h F og La m ps). Th e secon d wir e con t a in s in for m a -
becom e cor r oded. Befor e cou plin g wir e con n ect or s,
t ion r ega r din g t h e posit ion of t h e dim m er swit ch
in spect t h e t er m in a ls in side t h e con n ect or. Ma le t er-
(Dom e La m p, Da yt im e Br igh t n ess, Dim m in g Level or
m in a ls sh ou ld n ot be ben t or disen ga ged fr om t h e
Off). Th e t h ir d wir e is a dedica t ed sign a l r et u r n
in su la t or. F em a le t er m in a ls sh ou ld n ot be spr u n g
(gr ou n d) wir e. Th e fou r t h wir e pr ovides power t o t h e
open or disen ga ged fr om t h e in su la t or. Ben t a n d
fr on t fog la m p in dica t or.
spr u n g t er m in a ls ca n be r epa ir ed u sin g n eedle n ose
plier s a n d pick t ool. Cor r oded t er m in a ls a ppea r
HEADLAMP TIME DELAY SYSTEM
ch a lky or gr een . Cor r oded t er m in a ls sh ou ld be
Th e h ea dla m p t im e dela y syst em is con t r olled by
r epla ced t o a void r ecu r r en ce of t h e pr oblem sym p-
t h e Body Con t r ol Modu le (BCM) via a P CI bu s m es-
t om s.
sa ge t r a n sm it t ed by t h e BCM t o t h e F CM t o t u r n off
Begin elect r ica l syst em fa ilu r e dia gn osis by t est in g
t h e h ea dla m ps.
r ela t ed fu ses in t h e fu se block a n d in t elligen t power
m odu le. Ver ify t h a t bu lbs a r e in good con dit ion a n d
t est con t in u it y of t h e cir cu it gr ou n d. Refer t o t h e
OPERATION
a ppr opr ia t e wir in g in for m a t ion .
AUTOMATIC HEADLAMP SYSTEM
AUTOMATIC HEADLAMP SYSTEM Au t om a t ic h ea dla m ps a r e con t r olled by t h e Body
Con t r ol Modu le (BCM). Wit h t h e h ea dla m p swit ch in
Th e Au t om a t ic H ea dla m p syst em t u r n s t h e in st r u -
t h e AUTO posit ion , t h e BCM will con t r ol t h e h ea d-
m en t a t ion a n d ext er ior illu m in a t ion la m ps ON wh en
la m p, pa r kin g, side m a r ker, t a il a n d in st r u m en t a t ion
t h e a m bien t ligh t levels a r e Nigh t a n d t h e en gin e
la m ps ba sed on a m bien t ligh t levels. Am bien t ligh t
RP M is 450 or a bove, a n d OF F wh en ligh t levels a r e
levels a r e m on it or ed by t h e BCM u sin g t h e Da y/
Da y.
Nigh t sign a l a n d E lect r och r om a t ic Mir r or (E CM)
DAYTIME RUNNING LAMPS pr esen t fr om t h e Com pa ss Min i Tr ip (CMTC) loca t ed
on t h e fr on t win dsh ield in fr on t of t h e r ea r view m ir-
Oper a t in g t h e h igh -bea m h ea dla m ps a t r edu ced
r or E CM. Am bien t ligh t r ea din gs a r e a ver a ged t o
power pr ovides da yt im e r u n n in g la m ps, wh ich a r e
lim it cyclin g t h e la m ps ON a n d OF F wh en pa ssin g
r equ ir ed on a ll n ew Ca n a dia n veh icles. Da yt im e r u n -
t h r ou gh a r ea s wit h va r yin g ligh t levels. Th e a u t o-
n in g la m ps a r e fu n ct ion a l wh en 450 r pm ’s a r e
m a t ic h ea dla m ps will on ly fu n ct ion wh en t h e en gin e
r ea ch ed.
is r u n n in g wit h RP M > 450. Wh en t h e h ea dla m p
HEADLAMPS ON WITH WINDSHIELD WIPERS swit ch is in t h e AUTO posit ion (Au t om a t ic m ode), t h e
F or veh icles equ ipped wit h t h e Au t om a t ic H ea d- H ea dla m p Tim e Dela y syst em will fu n ct ion wh en t h e
la m p Syst em , t h e in st r u m en t a t ion a n d ext er ior illu - ign it ion swit ch is pla ced in a n y posit ion ot h er t h a n
m in a t ion la m ps will be t u r n ed ON wh en t h e r u n /st a r t .
h ea dla m p swit ch is in t h e AUTO posit ion , RP M >
RS LAMPS/LIGHTING - EXTERIOR 8L - 3
LAM PS/LI GH T I N G - EX T ERI OR (Cont inue d)
DAYTIME RUNNING LAMPS OPTICAL HORN/HIGH BEAMS
P ower is r edu ced u sin g pu lse-widt h m odu la t ion t o Wh en t h e m u lt i-fu n ct ion swit ch is pu lled t o t h e
t h e h igh bea m s, wh er e by t h e power is swit ch ed on fir st det en t (opt ica l h or n ) sign a l, t h e h ea dla m ps a r e
a n d off r a pidly in st ea d of r em a in in g on con t in u ou sly. ON, key-in t h e ign it ion t h e BCM sh a ll sen d a m es-
Th e du r a t ion a n d in t er va l of t h e power pu lses is pr o- sa ge via P CI bu s t o t h e F CM t o t u r n on t h e h ea d-
gr a m m ed in t o t h e F CM. Da yt im e r u n n in g la m ps a r e la m ps dr iver s t o illu m in a t e a ll fou r fila m en t s (Low
fu n ct ion a l wh en 450 r pm ’s a r e r ea ch ed. a n d H igh bea m s). Wh en t h e m u lt i-fu n ct ion swit ch is
pu lled t o t h e secon d det en t (h igh bea m ) sign a l a n d
HEADLAMP SYSTEM t h e h ea dla m ps a r e ON, t h e BCM sh a ll sen d a m es-
Th e h ea dla m p syst em will defa u lt t o h ea dla m ps sa ge via P CI bu s t o t h e F CM t o t u r n on t h e h ea d-
ON posit ion wh en ign it ion swit ch is ON a n d wh en a n la m ps dr iver s. Th e H igh Bea m s a r e illu m in a t ed a n d
open or sh or t cir cu it fa ilu r e occu r s on t h e h ea dla m p t h e Low Bea m s a n d F og La m ps (if ON) a r e ext in -
swit ch in pu t or P CI da t a bu s com m u n ica t ion bet ween gu ish ed. If t h e h ea dla m ps wer e in t h e h igh bea m
t h e BCM a n d t h e F CM fa ils. Th e syst em will r et u r n con figu r a t ion wh en power wa s r em oved fr om t h e
t o n or m a l oper a t ion wh en t h e open or sh or t is h ea dla m ps, t h e h ea dla m ps will be con figu r ed a s low
r epa ir ed. A fa u lt will be r epor t ed by t h e BCM wh en a bea m t h e n ext t im e t h ey a r e a ct iva t ed.
fa ilu r e occu r s on t h e dim m er or h ea dla m p swit ch
in pu t . NOTE: For RG - Export vehicles, the low beams and
If t h e ext er ior la m ps a r e ON a n d t h e h ea dla m p front fog lamps will remain ON when high beams
swit ch is in a n y posit ion ot h er t h a n OF F or AUTO are activated.
a n d wit h t h e ign it ion swit ch OF F (LOCK) a ft er 3
m in u t es t h e BCM sen ds a m essa ge via P CI bu s t o
t h e F CM in for m in g t h e F CM t o t u r n off t h e h ea d- WARNING
la m ps, pa r k la m ps a n d fog la m ps. Th is fea t u r e pr e- Ey e p ro te c tio n s h o u ld be u s e d w h e n s e rv ic in g
ven t s t h e veh icle ba t t er y fr om bein g disch a r ged wh en g la s s c o m p o n e n ts . P e rs o n a l in ju ry o r d e a th c a n
t h e veh icle ligh t s h a ve been left ON. re s u lt.
D o n o t to u c h th e g la s s o f h a lo g e n bu lbs w ith
HEADLAMP TIME DELAY SYSTEM fin g e rs o r o th e r p o s s ibly o ily s u rfa c e , re d u c e d
Th e h ea dla m p t im e dela y syst em is a ct iva t ed by bu lb life w ill re s u lt. D o n o t u s e bu lbs o th e r
t u r n in g t h e h ea dla m ps ON (h igh or low bea m ) wh ile th a n th o s e in d ic a te d in th e B u lb Ap p lic a tio n
t h e en gin e is r u n n in g, t u r n in g t h e ign it ion swit ch ta ble . D a m a g e to la m p a n d /o r D a y tim e Ru n n in g
OF F, a n d t h en t u r n in g t h e h ea dla m p swit ch OF F La m p Mo d u le c a n re s u lt. D o n o t u s e fu s e s , c ir-
wit h in 45 secon ds. Th e syst em will n ot a ct iva t e if c u it bre a k e rs o r re la y s h a v in g g re a te r a m p e r-
m or e t h a n 45 secon ds ela pse bet ween ign it ion swit ch a g e v a lu e th a n in d ic a te d o n th e fu s e p a n e l o r in
OF F a n d h ea dla m p swit ch OF F. Th e BCM will a llow th e Ow n e rs Ma n u a l.
t h e h ea dla m ps t o r em a in ON for 90 secon ds (con fig- D o n o t u s e bu lbs o th e r th a n th o s e lis te d in
u r a ble) befor e t h ey a u t om a t ica lly t u r n off (If t h e key th e B u lb Ap p lic a tio n Ta ble . D a m a g e to la m p
is in t h e ign it ion du r in g t h e h ea dla m p t im e dela y c a n re s u lt. D o n o t to u c h h a lo g e n bu lbs w ith fin -
m ode, t h en bot h t h e h ea dla m ps a n d pa r k la m ps g e rs o r o th e r o ily s u rfa c e s . B u lb life w ill be
(in clu din g pa n el dim m in g) will be ON). Refer t o t h e re d u c e d .
Own er ’s Ma n u a l for m or e in for m a t ion .
If t h e h ea dla m p swit ch is in t h e Au t o H ea dla m p
SPECI FI CAT I ON S
P osit ion , t h e h ea dla m ps a r e ON du e t o t h e n igh t sig-
n a l fr om t h e CMTC a n d t h e ign it ion swit ch is in a n y
posit ion ot h er t h a n r u n /st a r t , t h e BCM sh a ll en t er a
EXTERIOR LAMPS
90 secon d (con figu r a ble) Au t o H ea dla m ps t im e dela y
BU LB APPLI CAT I ON TABLE
m ode. If t h e key is in t h e ign it ion du r in g t h e h ea d-
la m p t im e dela y m ode, t h en bot h t h e h ea dla m ps a n d LAMP BULB
pa r k la m ps (in clu din g pa n el dim m in g) will be ON. If BACK-UP 3057
t h e key is n ot in t h e ign it ion , t h en on ly t h e h ea d-
CHMSL 921
la m ps will be ON. Th e BCM will a llow t h e h ea d-
la m ps t o r em a in ON for 90 secon ds befor e t h ey FRONT SIDE MARKER/PARK/
3157A
a u t om a t ica lly t u r n OF F. Refer t o t h e Own er ’s Ma n - TURN (DODGE)
u a l for m or e in for m a t ion . FRONT SIDE MARKER/PARK/
3157AK
TURN (CHRYSLER)
LAM PS/LI GH T I N G - EX T ERI OR (Cont inue d)
LAMP BULB Wit h t h e br a ke peda l pr essed down (plu n ger

ext en ded), t h e swit ch for t er m in a ls 1 a n d 2 is closed
FRONT FOG 9145 com plet in g t h e cir cu it . Th e swit ch for t er m in a ls 3
HEADLAMP (DODGE) 9007 a n d 4 is open a n d so is t h e swit ch for t er m in a ls 5
HEADLAMP (CHRYSLER H13 a n d 6.
Wh en t h e br a ke peda l is r elea sed (plu n ger pu sh ed
LICENSE 168
in ), t h e t h r ee swit ch es a ssu m e t h e opposit e posit ion s.
TAIL, STOP, TURN SIGNAL 3057 Th e swit ch for t er m in a ls 1 a n d 2 is n ow open wh ile
t h e ot h er t wo swit ch es a r e n ow closed, com plet in g
BU LB APPLI CAT I ON TABLE - EX PORT t h eir cir cu it s.
A lever on t h e ba ck of t h e swit ch is u sed t o set t h e
swit ch in t o t h e “a dju st ed” posit ion . A n on -a dju st ed
LAMP BULB
swit ch will h a ve t h e lever set t o t h e dia gon a l posit ion
HEADLAMP LOW BEAM H7 in r ela t ion t o t h e swit ch h ou sin g. Th e plu n ger ca n be
HEADLAMP HIGH BEAM H9 m oved in a n d ou t , bu t t h e st a t es of t h e in t er n a l
swit ch es will n ot ch a n ge.
FRONT FOG H3
FRONT POSITION W5W CAUTION: Never move the adjustment lever of the
FRONT TURN SIGNAL PY21W new brake lamp switch without it being properly
installed in the vehicle first. Such action will render
SIDE REPEATER T4W
the switch unusable and the switch must be dis-
LICENSE PLATE W5W/168 carded.
REAR TAIL AND STOP P21/5W
On ce in st a lled in t h e veh icle a s descr ibed in t h e
REAR TURN SIGNAL PY21W
br a ke la m p swit ch in st a lla t ion pr ocedu r e (Refer t o 8 -
BACK-UP P21W E LE CTRICAL/LAMP S/LIGH TING - E XTE RIOR/
REAR FOG P21W BRAKE LAMP SWITCH - INSTALLATION), t h e n ew
CHMSL W16W/921 swit ch ’s a dju st m en t lever is r ot a t ed t o t h e a dju st ed
posit ion a s in dica t ed (F ig. 4). Th is a ct ion locks t h e
plu n ger t o t h e in t er n a l swit ch es. On c e in th is p o s i-
BRAK E LAM P SWI T CH tio n th e s w itc h is p e rm a n e n tly a d ju s te d (o r
lo c k e d ) a n d c a n n o t be re a d ju s te d o r re le a s e d
DESCRIPTION e v e n if th e le v e r is m o v e d ba c k .
Th e br a ke la m p swit ch is loca t ed u n der t h e in st r u -
m en t pa n el, a t t h e br a ke peda l a r m (F ig. 3). It h a s
DIAGNOSIS AND TESTING - BRAKE LAMP
t h r ee in t er n a l swit ch es con t r ollin g va r iou s fu n ct ion s SWITCH
of t h e veh icle. It ’s m a in fu n ct ion is t o con t r ol oper a -
t ion of t h e veh icle’s br a ke la m ps via a br a ke swit ch NOTE: Before proceeding with this diagnostic test,
in pu t t o t h e BCM. Th e BCM will t h en a ct iva t e t h e verify the adjustment lever on the back of the
st op la m ps. Ot h er fu n ct ion s in clu de speed con t r ol switch is in the adjusted position. If the lever is in
dea ct iva t ion , br a ke sen se for t h e a n t ilock br a ke sys- the non-adjusted (diagonal) position it may have
t em a n d br a ke sen se for t h e br a ke t r a n sm ission sh ift never been adjusted (Refer to 8 - ELECTRICAL/
in t er lock. LAMPS/LIGHTING - EXTERIOR/BRAKE LAMP
SWITCH - OPERATION). For adjustment, (Refer to 8
CAUTION: The switch can only be adjusted once. - ELECTRICAL/LAMPS/LIGHTING - EXTERIOR/
That is during initial installation of the switch. If the BRAKE LAMP SWITCH - INSTALLATION)
removed for some service, a new switch must be If t h e elect r ica l cir cu it h a s been t est ed a n d t h e
installed and adjusted. br a ke la m p swit ch is su spect ed of bein g fa u lt y, it ca n
be t est ed u sin g t h e followin g m et h od.
(1) Rem ove t h e swit ch fr om t h e veh icle. (Refer t o 8
OPERATION - E LE CTRICAL/LAMP S/LIGH TING - E XTE RIOR/
Wh en t h e br a ke peda l is pr essed, t h e plu n ger on BRAKE LAMP SWITCH - RE MOVAL)
t h e ou t side of t h e br a ke la m p swit ch ext en ds ou t - (2) Wit h t h e swit ch in t h e r elea sed posit ion
wa r d. Th is a ct ion open s or closes t h e con t a ct s of t h e (plu n ger ext en ded), u se a n oh m m et er t o t est ea ch of
t h r ee swit ch es in side t h e br a ke la m p swit ch . t h e t h r ee in t er n a l swit ch es a s sh own (F ig. 1). You
sh ou ld a ch ieve t h e r esu lt s a s list ed in t h e figu r e.
BRAK E LAM P SWI T CH (Cont inue d)
removed for any reason, a new switch must be
REMOVAL
ca ble fr om it s post on t h e ba t t er y.
(2) Rem ove silen cer pa n el below st eer in g colu m n
a n d kn ee blocker.
(3) Rem ove t h e br a ke la m p swit ch by r ot a t in g t h e
swit ch in a cou n t er clockwise dir ect ion a ppr oxim a t ely
30 degr ees a n d pu llin g it ou t of t h e br a cket (F ig. 3).
Fig. 1 SWITCH TEST - RELEASED POSITION

(3) Gen t ly pu sh t h e plu n ger on t h e br a ke la m p
swit ch in u n t il it st ops.
(4) Wit h t h e swit ch in t h is depr essed posit ion
(plu n ger pu sh ed in ), u se a n oh m m et er t o t est ea ch of
t h e t h r ee in t er n a l swit ch es a s sh own (F ig. 2). You
sh ou ld a ch ieve t h e r esu lt s a s list ed in t h e figu r e.
Fig. 3 Brake Lamp Switch And Pedal With Bracket

1 - BRAKE LAMP SWITCH
2 - WIRING CONNECTOR
3 - PEDAL AND BRACKET
(4) Relea se t h e lockin g t a b a n d discon n ect t h e wir-

in g con n ect or fr om t h e swit ch .
(5) Disca r d t h e br a ke la m p swit ch . It m u st n ot be
r eu sed.
Fig. 2 SWITCH TEST - DEPRESSED POSITION
If you do n ot a ch ieve t h e r esu lt s a s list ed in bot h INSTALLATION
figu r es, t h e swit ch is fa u lt y a n d m u st be r epla ced.
Refer t o Rem ova l An d In st a lla t ion in t h is sect ion .
If t h e swit ch is fou n d t o be oper a t in g pr oper ly, it
m a y be m isa dju st ed. Do n ot r ein st a ll t h e swit ch ,
r epla ce it . (Refer t o 8 - E LE CTRICAL/LAMP S/
LIGH TING - E XTE RIOR/BRAKE LAMP SWITCH -
INSTALLATION)
(1) Mou n t a n d a dju st t h e NE W br a ke la m p swit ch
CAUTION: The switch can only be adjusted once.
u sin g t h e followin g pr ocedu r e:
That is during initial installation of the switch. If the
(a ) Con n ect t h e wir in g con n ect or t o t h e swit ch
a n d la t ch t h e lockin g t a b.
BRAK E LAM P SWI T CH (Cont inue d)
(b) In st a ll t h e swit ch in it s br a cket by a lign in g CEN T ER H I GH M OU N T ED
t h e in dex t a b on t h e swit ch wit h t h e slot in t h e
m ou n t in g br a cket . ST OP LAM P U N I T
(c) Wh en t h e swit ch is fu lly sea t ed in it s
br a cket , r ot a t e t h e swit ch clockwise a ppr oxim a t ely REMOVAL
30° t o lock t h e swit ch in t o pla ce. (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
(d) Wit h t h e br a ke peda l in t h e fu lly r elea sed ca ble.
posit ion , m ove t h e lever on t h e ba ck of t h e br a ke (2) Rem ove t h e t wo r et a in in g scr ews (F ig. 5).
la m p swit ch fr om t h e a n gled n on -a dju st ed posit ion
t o t h e fu ll ver t ica l posit ion a s sh own (F ig. 4). Th is
will a dju st t h e br a ke la m p swit ch t o t h e veh icle.
Fig. 5 CHMSL UNIT

1 - CHMSL UNIT
2 - LIFTGATE
(3) Discon n ect t h e r ea r win dow wa sh er n ozzle

a ssem bly (F ig. 6).
Fig. 4 Adjustment Lever Movement
(2) In st a ll silen cer pa n el below st eer in g colu m n
kn ee blocker.
(3) Recon n ect t h e ba t t er y n ega t ive t er m in a l.
(4) Ch eck t h e st op la m ps t o ver ify t h ey a r e oper a t -
in g pr oper ly a n d n ot st a yin g on wh en t h e peda l is in
t h e r elea sed posit ion .
(5) Roa d t est t h e veh icle t o en su r e pr oper oper a -
t ion of t h e br a kes in clu din g ABS a n d speed con t r ol (if
equ ipped).
CEN T ER H I GH M OU N T ED
ST OP LAM P Fig. 6 REAR WASHER NOZZLE ASSEMBLY
1 - BARREL IN CHMSL
2 - NOZZLE ASSEMBLY
REMOVAL 3 - SQUEEZE ARMS TO RELEASE NOZZLE ASSEMBLY
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive 4 - HOSE
ca ble.
(2) Rem ove t wo r et a in in g scr ews (F ig. 5). (4) Discon n ect CH MSL elect r ica l con n ect or fr om
(3) Twist socket cou n t er-clockwise a n d r em ove bu lb socket (F ig. 7).
fr om la m p.
(4) P u ll bu lb fr om socket (F ig. 7). INSTALLATION
(1) Con n ect elect r ica l con n ect or t o CH MSL bu lb
INSTALLATION socket .
(1) P u sh bu lb in t o socket . (2) Recon n ect t h e r ea r win dow wa sh er n ozzle
(2) In st a ll socket in t o t h e la m p u n it . a ssem bly.
(3) In st a ll t h e r et a in in g scr ews.
CEN T ER H I GH M OU N T ED ST OP LAM P U N I T (Cont inue d)
FRON T FOG LAM P

DIAGNOSIS AND TESTING - FRONT FOG LAMP
Wh en a veh icle exper ien ces pr oblem s wit h t h e
fr on t fog la m p syst em , ver ify t h e con dit ion of t h e ba t -
t er y con n ect ion s, fu ses, ch a r gin g syst em , fog la m p
bu lbs, wir e con n ect or s, r ela y, h igh bea m swit ch , a n d
h ea dla m p swit ch . Refer t o t h e a ppr opr ia t e wir in g
in for m a t ion .
E a ch veh icle is equ ipped wit h va r iou s la m p a ssem -
blies. A good gr ou n d is n ecessa r y for pr oper ligh t in g
oper a t ion . Gr ou n din g is pr ovided by t h e la m p socket
wh en it com es in con t a ct wit h t h e m et a l body, or
t h r ou gh a sepa r a t e gr ou n d wir e.
Wh en ch a n gin g la m p bu lbs ch eck t h e socket for
cor r osion . If cor r osion is pr esen t , clea n it wit h a wir e
Fig. 7 CHMSL ELECTRICAL CONNECTOR
br u sh .
1 - CHMSL UNIT Wh en it is n ecessa r y t o r em ove com pon en t s t o ser-
2 - CHMSL ELECTRICAL CONNECTOR
vice a n ot h er, it sh ou ld n ot be n ecessa r y t o a pply
(3) In st a ll t h e r et a in in g scr ews. excessive for ce or ben d a com pon en t t o r em ove it .
(4) Recon n ect t h e ba t t er y n ega t ive ca ble. Befor e da m a gin g a t r im com pon en t , ver ify h idden
fa st en er s or ca pt u r ed edges a r e n ot h oldin g t h e com -
pon en t in pla ce.
FRON T FOG LAM P DI AGN OSI S
FOG LAMPS ARE DIM 1. Loose or corroded battery 1. Clean and secure battery cable clamps and
WITH ENGINE IDLING cables. posts.
OR IGNITION TURNED
OFF. 2. Loose or worn generator drive 2. Adjust or replace generator drive belt.
belt.
3. Charging system output too low. 3. Test and repair charging system. Refer to
Electrical, Charging,
4. Battery has insufficient charge. 4. Test battery state-of-charge. Refer to
Electrical, Battery System.
5. Battery is sulfated or shorted. 5. Load test battery. Refer to Electrical, Battery
System.
6. Poor lighting circuit Z349/Z248 6. Test for voltage drop across Z349/248
ground. ground locations. Refer to Electrical, Wiring
Information.
FOG LAMP BULBS 1. Charging system output too 1. Test and repair charging system. Refer to
BURN OUT high. Electrical, Charging.
FREQUENTLY 2. Loose or corroded terminals or 2. Inspect and repair all connectors and splices.
splices in circuit. Refer to Electrical, Wiring Information.
FRON T FOG LAM P (Cont inue d)
FOG LAMPS ARE DIM 1. Charging system output too low. 1. Test and repair charging system. Refer to
WITH ENGINE Electrical, Charging.
RUNNING ABOVE IDLE
2. Poor lighting circuit Z349/Z248 2. Test for voltage drop across Z349/Z248
ground. ground locations. Refer to Electrical, Wiring
Information.
3. High resistance in fog lamp 3. Test amperage draw of fog lamp circuit.
circuit.
FOG LAMPS FLASH 1. Poor lighting circuit Z349/Z248 1. Test for voltage drop across Z349/Z248
RANDOMLY ground. ground locations. Refer to Electrical, Wiring
Information.
2. Variable resistance in fog lamp 2. Test amperage draw of fog lamp circuit.
circuit.
3. Faulty fog lamp switch (part of 3. Replace headlamp switch.
headlamp switch).
4. Loose or corroded terminals or 4. Inspect and repair all connectors and splices.
5. Is relay engaging properly? 5. Verify function of fog lamp relay in IPM.
6. PCI Bus Communication. 6. Verify PCI bus message (fog lamp info)
transmitted from BCM and received by FCM.
FOG LAMPS DO NOT 1. Blown fuse for fog lamp. 1. Replace fuse. Refer to Electrical, Wiring
ILLUMINATE Information.
2. No Z349/Z248 ground at fog 2. Repair circuit ground. Refer to Electrical,
lamps. Wiring Information.
3. Faulty fog lamp switch (part of 3. Replace headlamp switch.
headlamp switch).
4. Broken connector terminal or 4. Repair connector terminal or wire splice.
wire splice in fog lamp circuit.
5. Faulty or burned out bulb. 5. Replace bulb.
6. Is relay engaging? 6. Verify function of fog lamp relay in IPM.
7. PCI Bus Communication. 7. Verify PCI bus message (fog lamp info)
transmitted from BCM and received by FCM.
REMOVAL INSTALLATION
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive (1) Recon n ect wir e h a r n ess t o bu lb.
ca ble. (2) In st a ll bu lb a n d t wist clockwise.
(2) F r om beh in d t h e bu m per fa scia , t wist bu lb (3) In st a ll ba t t er y n ega t ive ca ble.
cou n t er-clockwise, a n d r em ove bu lb.
(3) Rem ove t h e wir e con n ect or fr om t h e fog la m p
bu lb.
FRON T FOG LAM P U N I T Th e fog la m ps a r e a dju st ed by a a dju st m en t scr ew

a t t h e t op of t h e la m p.
STAN DARD PROCEDU RE STANDARD PROCEDURE - FRONT FOG LAMP

UNIT ALIGNMENT - EXPORT
STANDARD PROCEDURE - FRONT FOG LAMP P r epa r e a n a lign m en t scr een (Refer t o 8 - E LE C-
UNIT ALIGNMENT TRICAL/LAMP S/LIGH TING - E XTE RIOR/H E AD-
LAMP UNIT - STANDARD P ROCE DURE ). A
FOG LAMP UNIT ALIGNMENT pr oper ly a lign ed fog la m p will pr oject a pa t t er n on
P r epa r e a n a lign m en t scr een (Refer t o 8 - E LE C- t h e a lign m en t scr een 200 m m (8 in .) below t h e fog
TRICAL/LAMP S/LIGH TING - E XTE RIOR/H E AD- la m p cen t er lin e a n d st r a igh t a h ea d (F ig. 9). To
LAMP UNIT - STANDARD P ROCE DURE ). A im pr ove visu a l in t er pr et a t ion of t h e fog la m p pa t t er n
pr oper ly a lign ed fog la m p will pr oject a pa t t er n on on t h e a lign m en t scr een , t h e h ea dla m ps sh ou ld be in
t h e a lign m en t scr een 100 m m (4 in .) below t h e fog t h e “off” posit ion .
la m p cen t er lin e a n d st r a igh t a h ea d (F ig. 8). To Th e fog la m ps a r e a dju st ed by a a dju st m en t scr ew
im pr ove visu a l in t er pr et a t ion of t h e fog la m p pa t t er n loca t ed on t h e fr on t side of t h e fog la m p u n it .
on t h e a lign m en t scr een , t h e h ea dla m ps sh ou ld be in
t h e “off” posit ion .
Fig. 8 FRONT FOG LAMP UNIT ALIGNMENT

1 - HIGH INTENSITY AREA 4 - 100MM (4 IN.)
2 - CENTER OF VEHICLE 5 - 7.62 METERS (25 FT.)
3 - HORIZONTAL CENTER OF FOG LAMP 6 - FRONT OF FOG LAMP
FRON T FOG LAM P U N I T (Cont inue d)
Fig. 9 FOG LAMP UNIT ALIGNMENT - EXPORT

1 - HIGH INTENSITY AREA 4 - 200 MM
2 - CENTER OF VEHICLE 5 - 10 METERS
3 - HORIZONTAL CENTER OF FOG LAMP UNIT 6 - FRONT OF FOG LAMP UNIT
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive (1) In st a ll m ou n t in g scr ews.
ca ble. (2) Recon n ect t h e wir e h a r n ess t o t h e fog la m p
(2) F r om beh in d t h e bu m per fa scia , discon n ect t h e bu lb.
wir e h a r n ess fr om t h e fog la m p bu lb. (3) Recon n ect t h e ba t t er y n ega t ive ca ble.
(3) Rem ove m ou n t in g scr ews.
H EADLAM P wh en it com es in con t a ct wit h t h e m et a l body, or

t h r ou gh a sepa r a t e gr ou n d wir e.
Wh en ch a n gin g la m p bu lbs ch eck t h e socket for
DIAGNOSIS AND TESTING - HEADLAMP
cor r osion . If cor r osion is pr esen t , clea n it wit h a wir e
Wh en a veh icle exper ien ces pr oblem s wit h t h e
br u sh .
h ea dla m p syst em , ver ify t h e con dit ion of t h e ba t t er y
Wh en it is n ecessa r y t o r em ove com pon en t s t o ser-
con n ect ion s, fu ses, ch a r gin g syst em , h ea dla m p bu lbs,
vice a n ot h er, it sh ou ld n ot be n ecessa r y t o a pply
wir e con n ect or s, r ela y, h igh bea m swit ch , dim m er
excessive for ce or ben d a com pon en t t o r em ove it .
swit ch , a n d h ea dla m p swit ch . Refer t o t h e a ppr opr i-
Befor e da m a gin g a t r im com pon en t , ver ify h idden
a t e wir in g in for m a t ion .
fa st en er s or ca pt u r ed edges a r e n ot h oldin g t h e com -
E a ch veh icle is equ ipped wit h va r iou s la m p a ssem -
pon en t in pla ce.
blies. A good gr ou n d is n ecessa r y for pr oper ligh t in g
oper a t ion . Gr ou n din g is pr ovided by t h e la m p socket
H EADLAM P DI AGN OSI S
HEADLAMPS ARE DIM 1. Loose or corroded battery 1. Clean and secure battery cable clamps and
WITH ENGINE IDLING cables. posts.
OR IGNITION TURNED
OFF. 2. Loose or worn generator drive 2. Adjust or replace generator drive belt.
belt.
3. Charging system output too low. 3. Test and repair charging system, refer to
Electrical, Charging
4. Battery has insufficient charge. 4. Test battery state-of-charge, refer to
Electrical, Battery System.
5. Battery is sulfated or shorted. 5. Load test battery, refer to Electrical, Battery
System.
6. Poor lighting circuit Z343/Z344- 6. Test for voltage drop across Z343/Z344-
ground. ground locations, refer to Electrical, Wiring
Diagram Information.
HEADLAMP BULBS 1. Integrated Power Module (IPM) 1. Test and repair Integrated Power Module.
BURN OUT not controlling voltage.
FREQUENTLY.
2. Loose or corroded terminals or 2. Inspect and repair all connectors and splices.
HEADLAMPS ARE DIM 1. Charging system output too low. 1. Test and repair charging system, refer to
WITH ENGINE Electrical, Wiring Information.
RUNNING ABOVE IDLE. 2. Poor lighting circuit Z343/Z344- 2. Test for voltage drop across Z343/Z344-
ground. ground locations, refer to Electrical, Wiring
Information.
3. High resistance in headlamp 3. Test amperage draw of headlamp circuit.
circuit.
H EADLAM P (Cont inue d)
HEADLAMPS FLASH 1. Poor lighting circuit Z343/Z344- 1. Test for voltage drop across Z343/Z344-
RANDOMLY ground. ground locations, refer to Electrical, Wiring
Information.
2. Variable resistance in headlamp 2. Test amperage draw of headlamp circuit.

circuit.
3. Loose or corroded terminals or 3. Inspect and repair all connectors and splices,
splices in circuit. refer to Electrical, Wiring Information.
4. Faulty headlamp switch. 4. Replace headlamp switch.
HEADLAMPS DO NOT 1. No voltage to headlamps. 1. Repair open headlamp circuit, refer to

ILLUMINATE. Electrical, Wiring Information.
2. No Z343/Z344-ground at 2. Repair circuit ground, refer to Electrical,

headlamps. Wiring Information.
3. Broken connector terminal or 3. Repair connector terminal or wire splice.
wire splice in headlamp circuit.
4. Faulty or burned out bulb. 4. Replace headlamp bulb(s).
5. Body Control Module 5. Refer to appropriate Body Control Module
malfunction. diagnostics.
6. PCI Bus Communication 6. Verify messages being transmitted by BCM
and received by FCM.
7. IPM/FCM Malfunction. 7. Refer to appropriate IPM/FCM diagnostics.
HEADLAMPS ON WITH 1. Faulty headlamp switch. 1. Replace headlamp switch (review BCM
IGNITION IN RUN, WITH logged faults).
HEADLAMP SWITCH 2. Diagnostic tool indicates (4.7 - 2. Inspect and repair terminals, connectors and
OFF. 5.0V) on headlamp switch input to open circuits.
BCM.
3. PCI Bus Communication. 3. Verify messages being transmitted by BCM
and received by FCM.
REMOVAL
DODGE
ca ble.
(2) Rem ove h ea dla m p u n it r et a in in g scr ews.
(3) Rem ove h ea dla m p u n it t o expose ba ck of u n it .
(4) Rem ove wir in g con n ect or fr om bu lb.
(5) Rot a t e h ea dla m p bu lb r et a in in g r in g cou n t er-
clockwise.
(6) P u ll h ea dla m p bu lb a n d r em ove fr om h ea dla m p
u n it (F ig. 10).
CHRYSLER
ca ble.
(2) Rem ove h ea dla m p u n it r et a in in g scr ews. Fig. 10 HEADLAMP - DODGE
(3) Rem ove h ea dla m p u n it t o expose ba ck of u n it . 1 - HEADLAMP
2 - HEADLAMP UNIT
H EADLAM P (Cont inue d)
(4) Rem ove wir in g con n ect or fr om bu lb by slidin g H EADLAM P SWI T CH CON T I N U I T Y
r ed la t ch lock r ea r wa r d a n d t h en depr essin g r elea se
t a b. HEADLAMP 13 - WAY
(5) Rot a t e h ea dla m p bu lb r et a in in g r in g cou n t er- SWITCH CONNECTOR RESISTANCE
clockwise. POSITION TERMINAL
INSTALLATION OFF 11 TO 6 3651 - 3729 "

PARKING
11 TO 6 1697 - 2517 "
DODGE LAMPS ON
(1) In st a ll h ea dla m p bu lb t o t h e h ea dla m p u n it . PARKING
(2) In st a ll h ea dla m p bu lb r et a in in g r in g. LAMPS WITH
(3) Con n ect wir in g con n ect or t o bu lb. 11 TO 6 5765 - 5886 "
FRONT FOG
(4) In st a ll t h e h ea dla m p u n it . LAMPS ON
(5) In st a ll h ea dla m p u n it r et a in in g scr ews. HEADLAMPS
(6) Con n ect t h e ba t t er y n ega t ive ca ble. 11 TO 6 788 - 809 "
ON
CHRYSLER AUTO ON 11 TO 6 10056 - 10264 "
(1) In st a ll h ea dla m p bu lb t o t h e h ea dla m p u n it . HEADLAMPS
(2) Rot a t e bu lb clockwise t o lock bu lb in h ea dla m p ON WITH
11 TO 6 1171 - 1200 "
u n it . FRONT FOG
(3) Con n ect wir in g con n ect or t o bu lb a n d slide r ed LAMPS
la t ch lock for wa r d. AUTO ON WITH
(4) In st a ll t h e h ea dla m p u n it . FRONT FOG 11 TO 6 24278 - 24773 "
(5) In st a ll h ea dla m p u n it r et a in in g scr ews. LAMPS ON
13 - WAY
DIMMER
CONNECTOR RESISTANCE
POSITION
H EADLAM P SWI T CH TERMINAL
DOME 12 TO 6 15568 - 23357 "
DIAGNOSIS AND TESTING - HEADLAMP PARADE 12 TO 6 5168 - 7757 "
SWITCH DIM HIGH 12 TO 6 2288 - 3437 "
Usin g a Digit a l Mu lt i-m et er, per for m t h e H E AD-
DIM LOW 12 TO 6 688 - 1037 "
LAMP SWITCH CONTINUITY t est a n d r efer t o (F ig.
11). OFF 12 TO 6 240 - 365 "
If t h e H ea dla m p Swit ch is n ot wit h in specifica t ion s
r epla ce t h e swit ch . REMOVAL
ca ble.
(2) Rem ove t h e In st r u m en t P a n el Lower St eer in g
Colu m n Cover. Refer t o Body, In st r u m en t P a n el,
Lower St eer in g Colu m n Cover, Rem ova l.
(3) Rea ch u p beh in d t h e left side of t h e in st r u m en t
pa n el a n d depr ess spr in g clip on t op or bot t om of
h ea dla m p swit ch . F ir m ly pu sh ou t on t h e h ea dla m p
swit ch a ssem bly.
(4) Discon n ect t h e wir in g con n ect or s.
(5) Rem ove swit ch fr om veh icle.
INSTALLATION
(1) Con n ect t h e wir in g con n ect or s.
(2) P la ce h ea dla m p swit ch a ssem bly in t o posit ion
a n d fir m ly sn a p in t o pla ce.
Fig. 11 HEADLAMP SWITCH CONNECTOR (3) In st a ll t h e In st r u m en t P a n el Lower St eer in g
Colu m n Cover. Refer t o Body, In st r u m en t P a n el,
Lower St eer in g Colu m n Cover, In st a lla t ion .
H EADLAM P U N I T (7) F u el t a n k sh ou ld be F ULL. Add 2.94 kg (6.5

lbs.) of weigh t over t h e fu el t a n k for ea ch est im a t ed
ga llon of m issin g fu el.
STANDARD PROCEDURE - HEADLAMP UNIT
ALIGNMENT ALIGNMENT SCREEN PREPARATION
(1) P osit ion veh icle on a level su r fa ce per pen dicu -
HEADLAMP UNIT ALIGNMENT PREPARATION la r t o a fla t wa ll 7.62 m et er s (25 ft .) a wa y fr om fr on t
(1) Ver ify h ea dla m p dim m er swit ch a n d h igh bea m of h ea dla m p len s (F ig. 12).
in dica t or oper a t ion . (2) If n ecessa r y, t a pe a lin e on t h e floor 7.62
(2) In spect a n d cor r ect da m a ged or defect ive com - m et er s (25 ft .) a wa y fr om a n d pa r a llel t o t h e wa ll.
pon en t s t h a t cou ld in t er fer e wit h pr oper h ea dla m p (3) Rock veh icle side-t o-side t h r ee t im es a n d a llow
a lign m en t . su spen sion t o st a bilize.
(3) Ver ify pr oper t ir e in fla t ion . (4) J ou n ce fr on t su spen sion t h r ee t im es by pu sh in g
(4) Clea n h ea dla m p len ses. down wa r d on fr on t bu m per a n d r elea sin g.
(5) Ver ify t h a t lu gga ge a r ea is loa ded a s t h e veh i- (5) Mea su r e t h e dist a n ce fr om t h e cen t er of h ea d-
cle is r ou t in ely u sed. la m p len s t o t h e floor. Tr a n sfer m ea su r em en t t o t h e
(6) Veh icles equ ipped wit h a u t om a t ic loa d levelin g a lign m en t scr een (wit h t a pe). Use t h is lin e for
su spen sion sh ou ld be dr iven n or m a lly for a ppr oxi- u p/down a dju st m en t r efer en ce.
m a t ely 5 km (3 m iles) befor e a t t em pt in g a pr oper
h ea dla m p u n it a lign m en t .
Fig. 12 HEADLAMP ALIGNMENT SCREEN

1 - CENTER OF HEADLAMPS 3 - FRONT OF HEADLAMP
2 - HEADLAMP BEAM 4 - 7.62 METERS (25 FT.)
H EADLAM P U N I T (Cont inue d)
HEADLAMP UNIT ADJUSTMENT
Th e low bea m h ea dla m p will pr oject on t h e scr een
u pper edge of t h e bea m (cu t -off) a t t h e h or izon t a l
la m p cen t er lin e ± 50 m m (2 in .). H or izon t a l a im is
pr eset a n d ca n n ot be a dju st ed. Th e h igh bea m pa t -
t er n sh ou ld be cor r ect wh en t h e low bea m s a r e
a lign ed pr oper ly (F ig. 12). To a dju st h ea dla m p ver t i-
ca l a lign m en t , r ot a t e a dju st m en t scr ew (F ig. 13) t o
a ch ieve t h e specified low bea m cu t -off loca t ion .
Fig. 15 HEADLAMP UNIT

1 - HEADLAMP UNIT
2 - HEADLAMP
3 - PARK/TURN SIGNAL LAMP
4 - WIRE HARNESS RETAINER
(4) Rem ove wir e h a r n ess r et a in er fr om ba ck of

h ea dla m p u n it .
(5) Rem ove t h e h ea dla m p u n it .
Fig. 13 HEADLAMP UNIT ADJUSTMENT INSTALLATION

1 - ADJUSTMENT LOCATION
(1) Recon n ect wir e h a r n ess t o t h e bu lbs.
2 - HEADLAMP UNIT (2) In st a ll wir e h a r n ess r et a in er t o h ea dla m p u n it .
(3) In st a ll t h e t h r ee r et a in in g scr ews.
REMOVAL (4) Recon n ect t h e ba t t er y n ega t ive ca ble.
ca ble.
(2) Rem ove t h e t h r ee r et a in in g scr ews (F ig. 14). H EADLAM P U N I T - EX PORT
STANDARD PROCEDURE - HEADLAMP UNIT
ALIGNMENT - EXPORT
HEADLAMP UNIT ALIGNMENT PREPARATION
(1) Ver ify t h a t t h e h ea dla m p levelin g swit ch is in
t h e “0” posit ion .
(2) In spect a n d cor r ect da m a ged or defect ive com -
pon en t s t h a t cou ld in t er fer e wit h pr oper h ea dla m p
a lign m en t .
(3) Ver ify pr oper t ir e in fla t ion .
(4) Clea n h ea dla m p len ses.
(5) Ver ify t h a t lu gga ge a r ea is loa ded a s t h e veh i-
Fig. 14 HEADLAMP UNIT FASTENERS cle is r ou t in ely u sed.
(6) Veh icles equ ipped wit h a u t om a t ic loa d levelin g
1 - HEADLAMP UNIT RETAINING SCREW
2 - HEADLAMP UNIT su spen sion sh ou ld be dr iven n or m a lly for a ppr oxi-
m a t ely 5 km (3 m iles) befor e a t t em pt in g a pr oper
(3) Discon n ect t h e wir in g h a r n ess fr om t h e bu lbs h ea dla m p u n it a lign m en t .
(F ig. 15). (7) F u el t a n k sh ou ld be F ULL. Add 2.94 kg (6.5
lbs.) of weigh t over t h e fu el t a n k for ea ch est im a t ed
ga llon of m issin g fu el.
H EADLAM P U N I T - EX PORT (Cont inue d)
Fig. 16 HEADLAMP UNIT ALIGNMENT SCREEN - EXPORT

1 - CENTER OF VEHICLE 5 - 10 METERS (32.8 FT.)
2 - CENTER OF HEADLAMPS 6 - HORIZONTAL CUT-OFF LINE
3 - 15° CUT-OFF LINE 7 - 100 mm (3.9 in.)
4 - FRONT OF HEADLAMP
ALIGNMENT SCREEN PREPARATION

(1) P osit ion veh icle on a level su r fa ce per pen dicu -
la r t o a fla t wa ll 10 m et er s (32.8 ft .) a wa y fr om fr on t
of h ea dla m p len s (F ig. 16).
(2) If n ecessa r y, t a pe a lin e on t h e floor 10 m et er s
(32.8 ft .) a wa y fr om a n d pa r a llel t o t h e wa ll.
(3) Rock veh icle side-t o-side t h r ee t im es a n d a llow
su spen sion t o st a bilize.
(4) J ou n ce fr on t su spen sion t h r ee t im es by pu sh in g
down wa r d on fr on t bu m per a n d r elea sin g.
(5) Mea su r e t h e dist a n ce fr om t h e cen t er of h ea d-
la m p len s t o t h e floor. Tr a n sfer m ea su r em en t t o t h e
a lign m en t scr een (wit h t a pe). Use t h is lin e for
u p/down a dju st m en t r efer en ce.
HEADLAMP UNIT ADJUSTMENT

Th e low bea m h ea dla m p will pr oject on t h e scr een Fig. 17 HEADLAMP UNIT ADJUSTMENT - EXPORT
u pper edge of t h e bea m (cu t -off) a t t h e h or izon t a l 1 - HEADLAMP ADJUSTMENT - HORIZONTAL
la m p cu t -off lin e ± 20 m m (0.75 in .). Th e h igh bea m 2 - HEADLAMP ADJUSTMENT - VERTICAL
pa t t er n sh ou ld be cor r ect wh en t h e low bea m s a r e
a lign ed pr oper ly (F ig. 16). To a dju st h ea dla m p a lign -
m en t , r ot a t e a dju st m en t scr ews (F ig. 17) t o a ch ieve
t h e specified low bea m cu t -off loca t ion .
H EADLAM P U N I T - EX PORT (Cont inue d)
REMOVAL
ca ble.
(2) Rem ove t h e t h r ee r et a in in g scr ews.
(3) Discon n ect t h e cen t r a l wir in g h a r n ess con n ec-
t or fr om t h e h ea dla m p u n it .
(4) Rem ove t h e h ea dla m p u n it fr om t h e veh icle by
r ot a t in g t h e t u r n sign a l a r ea ou t a n d t owa r ds t h e
cen t er of t h e veh icle.
INSTALLATION
(1) Con n ect t h e wir in g h a r n ess t o t h e h ea dla m p
u n it ’s cen t r a l con n ect or.
(2) P la ce t h e h ea dla m p u n it in t h e h ea dla m p u n it Fig. 19 LICENSE PLATE LAMP - REMOVE/INSTALL
pocket in fr on t en d fir st by pla cin g t h e in boa r d side 1 - LICENSE PLATE LAMP UNIT
2 - BULB
beh in d t h e fa scia . Com plet e t h e in st a lla t ion by r ot a t -
in g t h e t u r n sign a l a r ea of t h e h ea dla m p in t o pla ce.
(3) P la ce h ea dla m p u n it in t o h ea dla m p u n it pocket INSTALLATION
in fr on t en d. (1) P u sh bu lb in t o socket .
(4) In st a ll t h e t h r ee r et a in in g scr ews. (2) In st a ll socket in t o la m p.
(5) Con n ect t h e ba t t er y n ega t ive ca ble. (3) In st a ll t wo scr ews.
(6) Ver ify veh icle a n d syst em oper a t ion . (4) Recon n ect t h e ba t t er y n ega t ive ca ble.
LI CEN SE LAM P M U LT I -FU N CT I ON SWI T CH

REMOVAL DESCRIPTION - TURN SIGNAL SYSTEM
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive Th e t u r n sign a ls a r e a ct u a t ed wit h a lever on
ca ble. Mu lt i-F u n ct ion Swit ch , loca t ed on t h e left side of t h e
(2) Rem ove t wo scr ews (F ig. 18). st eer in g wh eel. Th e sign a ls a r e a u t om a t ica lly t u r n ed
off by a ca n celin g ca m (t wo lobes m olded t o t h e clock
spr in g m ech a n ism ). Th e ca m com es in con t a ct wit h
t h e ca n cel a ct u a t or on t h e t u r n sign a l (m u lt i-fu n c-
t ion ) swit ch a ssem bly. E it h er ca m lobe, pu sh in g on
t h e ca n cel a ct u a t or, r et u r n s t h e swit ch t o t h e OF F
posit ion . Th e m u lt i-fu n ct ion swit ch is a r esist ive
MUX swit ch t h a t feeds in pu t s t o t h e BCM.
OPERATION - TURN SIGNAL SYSTEM

La n e ch a n ge sign a lin g is a ct u a t ed by a pplyin g pa r-
t ia l t u r n sign a l st a lk m ovem en t t owa r d t h e dir ect ion
desir ed u n t il t h e in dica t or la m ps fla sh es in t h e
in st r u m en t clu st er. Wh en t h e swit ch st a lk is r elea sed
t h e st a lk will spr in g ba ck in t o t h e n eu t r a l posit ion
t u r n in g OF F t h e t u r n sign a l.
Wit h t h e ign it ion swit ch ON a n d t h e t u r n sign a l
swit ch st a lk a ct u a t ed left or r igh t , cu r r en t flows
Fig. 18 LICENSE PLATE LAMP UNITS t h r ou gh t h e:
1 - SCREW • Mu lt i-fu n ct ion swit ch
2 - LICENSE PLATE LAMP
• Body Con t r ol Modu le
(3) Twist bu lb socket a n d r em ove (F ig. 19). • In t egr a t ed P ower Modu le (IP M)
(4) P u ll bu lb fr om socket . • Tu r n in dica t or la m p
• F r on t a n d r ea r t u r n sign a l bu lbs.
A ch im e will sou n d a ft er t h e veh icle h a s t r a veled a
dist a n ce of a ppr oxim a t ely 1.0 m ile a n d a speed of 15
m ph , wit h t h e t u r n sign a l ON.
M U LT I -FU N CT I ON SWI T CH (Cont inue d)
DIAGNOSIS AND TESTING - MULTI-FUNCTION

SWITCH
To t est t u r n sign a l, h ea dla m p bea m select a n d opt i-
ca l h or n por t ion of t h e m u lt i-fu n ct ion swit ch :
(1) Rem ove t h e m u lt i-fu n ct ion swit ch , r efer t o
E lect r ica l, La m ps/Ligh t in g - E xt er ior, Mu lt i-F u n ct ion
Swit ch , Rem ova l, a n d In st a lla t ion .
(2) Usin g a n oh m m et er ch eck t h e r esist a n ce r ea d-
in gs bet ween m u lt i-fu n ct ion swit ch pin s. Refer t o
Wir in g Dia gr a m s for pr oper pin n u m ber s a n d t h e
MULTI-F UNCTION SWITCH RE SISTANCE t a ble.
M U LT I -FU N CT I ON SWI T CH RESI STAN CE
SWITCH PIN NUMBER RESISTANCE

POSITION
Fig. 20 PARK/TURN SIGNAL LAMP
LEFT 2 AND 3 2.7 " ± 5%
1 - PARK/TURN SIGNAL LAMP
RIGHT 2 AND 3 1K " ± 5% 2 - LAMP SOCKET
OPTICAL 2 AND 4 1.7K " ± 5%
HORN INSTALLATION
(1) P u sh bu lb in t o socket .
HI BEAM 2 AND 4 2.32K " ± 5%
(2) Twist socket in t o h ea dla m p.
(3) In st a ll h ea dla m p r et a in in g scr ews.
REMOVAL (4) Recon n ect ba t t er y n ega t ive ca ble.
(1) Discon n ect a n d isola t e ba t t er y n ega t ive ca ble.
(2) Rem ove u pper a n d lower st eer in g colu m n
sh r ou ds. Refer t o St eer in g, Colu m n , Sh r ou d, TAI L LAM P
Rem ova l.
(3) Discon n ect wir e con n ect or fr om ba ck of m u lt i- REMOVAL
fu n ct ion swit ch . (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
(4) Rem ove scr ews h oldin g m u lt i-fu n ct ion swit ch t o ca ble.
st eer in g colu m n a da pt er colla r. (2) Rem ove t h e t a il la m p u n it . (Refer t o 8 - E LE C-
(5) Rem ove t h e m u lt i-fu n ct ion swit ch . TRICAL/LAMP S/LIGH TING - E XTE RIOR/TAIL
LAMP UNIT - RE MOVAL).
INSTALLATION (3) Squ eeze t h e t a bs on t h e bu lb socket a n d
(1) P osit ion t h e swit ch on t o t h e st eer in g colu m n . r em ove fr om t a il la m p u n it (F ig. 21).
(2) In st a ll t h e t wo r et a in in g scr ews.
(3) Con n ect t h e wir e h a r n ess con n ect or.
(4) In st a ll t h e u pper a n d lower st eer in g colu m n
sh r ou ds. Refer t o St eer in g, Colu m n , Sh r ou d, In st a lla -
t ion .
PARK /T U RN SI GN AL LAM P
REMOVAL
(1) Discon n ect a n d isola t e ba t t er y n ega t ive ca ble.
(2) Rem ove h ea dla m p r et a in in g scr ews.
(3) Twist socket cou n t er - clockwise a n d r em ove
(F ig. 20). Fig. 21 TAIL LAMP SOCKET
(4) P u ll bu lb fr om socket . 1 - LAMP SOCKET
2 - TAIL LAMP UNIT
(4) P u ll bu lb fr om la m p socket .
TAI L LAM P (Cont inue d)
INSTALLATION (4) Rot a t e t h e la m p a wa y fr om t h e veh icle body t o

(1) P u sh bu lb in t o t h e la m p socket . disen ga ge h ook fr om t h e r u bber gr om m et in t h e
(2) In st a ll bu lb socket in t o t h e t a il la m p u n it . qu a r t er pa n el open in g.
E n su r e t h a t bot h r et a in in g t a bs en ga ge wit h a n a u di- (5) Discon n ect wir e h a r n ess con n ect or fr om t a il
ble click. la m p u n it by slidin g t h e r ed lock, t h en pr essin g
(3) In st a ll t h e t a il la m p u n it . (Refer t o 8 - E LE C- r elea se t a b.
TRICAL/LAMP S/LIGH TING - E XTE RIOR/TAIL
LAMP UNIT - INSTALLATION). INSTALLATION
(4) Recon n ect t h e ba t t er y n ega t ive ca ble. (1) Recon n ect wir e h a r n ess con n ect or t o t h e t a il
la m p. Slide r ed con n ect or lock in t o posit ion .
(2) E n ga ge h ook in t o r u bber gr om m et in qu a r t er
TAI L LAM P U N I T pa n el open in g.
(3) P la ce la m p in t o posit ion on qu a r t er pa n el.
REMOVAL (4) In ser t t h e t wo r et a in in g fa st en er s by pr essin g
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive in t o posit ion (in ser t in t o t h e h ole fir st , followed by
ca ble. t h e slot ). E n su r e t h a t t h e h ea d of t h e fa st en er is
(2) Ra ise t h e lift ga t e. open befor e in ser t in g.
(3) Rem ove t h e t wo r et a in in g fa st en er s by pr yin g (5) Close t h e lift ga t e.
u n der t h e h ea d of t h e fa st en er wit h a fla t bla ded t ool (6) Recon n ect t h e ba t t er y n ega t ive ca ble.
(F ig. 22).
Fig. 22 TAIL LAMP UNIT FASTENERS

1 - TAIL LAMP UNIT FASTENER
2 - TAIL LAMP UNIT
8L - 20 LAMPS/LIGHTING - INTERIOR RS
LAM PS/LI GH T I N G - I N T ERI OR
TABLE OF CONTENTS
page page
LAMPS/LIGHTING - INTERIOR DOME/CARGO LAMP

INTERIOR LAMPS . . . . . . . . . . . . . . . . . . . . . 20 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 22
CENTER CONSOLE LAMP GLOVE BOX LAMP SWITCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
CENTER CONSOLE LAMP SWITCH LIFTGATE LAMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
CLUSTER ILLUMINATION LAMPS READING LAMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
COURTESY LAMP VANITY LAMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
LAM PS/LI GH T I N G - I N T ERI OR LAMP BULB

LIFTGATE AJAR LED
SPECI FI CAT I ON S LOW FUEL INDICATOR LED
LOW WASHER FLUID
LED
INTERIOR LAMPS INDICATOR
BU LB APPLI CAT I ON TABLE MIL LED
OIL INDICATOR LED
LAMP BULB
OVERHEAD CONSOLE
ABS LED PC579
READING
AIRBAG LED PRNDL INDICATOR
LED
ALARM SET LED (BASE CLUSTER)
BRAKE SYSTEM PRNDL INDICATOR VFD
LED
WARNING READING 578
CONSOLE 194 SEAT BELT INDICATOR LED
CRUISE INDICATOR VFD* TEMPERATURE
LED
DOME/RAIL LAMPS 578 INDICATOR
DOOR AJAR INDICATOR LED TIRE PRESSURE
LED
DOOR COURTESY WARNING
578 TRAC OFF INDICATOR VFD*
LAMP
FRONT DOOR VISOR VANITY 6501966
567
COURTESY VOLTAGE INDICATOR LED
GLOVE BOX 194 * VFD = VACUUM FLUORESCENT DISPLAY
HIGH BEAM INDICATOR LED
CLUSTER
PC74
ILLUMINATION
LIFTGATE 578
RS LAMPS/LIGHTING - INTERIOR 8L - 21
CEN T ER CON SOLE LAM P CLU ST ER I LLU M I N AT I ON

LAM PS
REMOVAL
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive REMOVAL
ca ble. (1) Rem ove t h e In st r u m en t Clu st er. Refer t o E lec-
(2) Open u p con sole lid. t r ica l, In st r u m en t Clu st er, Rem ova l.
(3) Rem ove con sole t r a y. (2) Tu r n over clu st er a n d expose t h e illu m in a t ion
(4) Usin g a t r im st ick (specia l t ool #C-4755) or bu lb socket s.
equ iva len t , gen t ly pr y down on la m p. Ma ke su r e n ot (3) Iden t ify wh ich bu lb is defect ive a n d t wist it ou t
t o let la m p fa ll in t o con sole ba se. of t h e clu st er u sin g a cou n t er clockwise m ot ion .
NOTE: If preferred, a 5/16 piece of hose approxi-
mately 4–6 inches long may be used to pull lamp INSTALLATION
from socket. Push hose over end of lamp and pull (1) In st a ll t h e n ew bu lb socket in t o t h e clu st er
down. u sin g a clockwise m ot ion .
(2) In st a ll t h e In st r u m en t Clu st er. Refer t o E lect r i-
ca l, In st r u m en t Clu st er, In st a lla t ion .
INSTALLATION
NOTE: If preferred, a 5/16 piece of hose approxi- COU RT ESY LAM P
mately 4–6 inches long may be used to install the
new lamp. Push lamp into hose just far enough to REMOVAL
hold bulb. Locate the socket slot and push firmly (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
up. Make sure not to let lamp fall into console base. ca ble.
When bulb is seated, twist hose 1/4 turn to remove (2) Usin g a t r im st ick, pr y la m p fr om door pa n el
from lamp. (F ig. 1).
(1) P la ce la m p in socket slot a n d pu sh fir m ly u p.

Ma ke su r e n ot t o let la m p fa ll in t o con sole ba se.
(2) In st a ll t h e con sole t r a y.
(3) Close con sole lid.
CEN T ER CON SOLE LAM P

SWI T CH
REMOVAL
ca ble. Fig. 1 COURTESY LAMP
(2) Open con sole lid a n d r em ove t r a y. 1 - WIRE HARNESS
(3) Usin g a fla t bla ded t ool, pr y u p on t h e swit ch . 2 - COURTESY LAMP
(4) Rem ove bu lb fr om swit ch .
(3) Discon n ect wir e h a r n ess fr om t h e la m p.
INSTALLATION (4) Rem ove len s fr om t h e la m p a n d r em ove bu lb.
(1) In st a ll bu lb in t o swit ch .
(2) P u sh swit ch in t o con sole open in g. INSTALLATION
(3) In st a ll t r a y a n d close lid. (1) In st a ll bu lb a n d len s t o la m p.
(4) Con n ect ba t t er y n ega t ive ca ble. (2) Recon n ect wir e h a r n ess t o la m p.
(3) P r ess la m p in t o t h e door pa n el.
(4) Recon n ect ba t t er y n ega t ive ca ble.
DOM E/CARGO LAM P LI FT GAT E LAM P

REMOVAL REMOVAL
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble. ca ble.
(2) Usin g a fla t bla ded t ool, pr y off t h e la m p len s. (2) Usin g a fla t bla ded t ool, pr y la m p fr om t r im
(3) Rem ove bu lb fr om la m p. pa n el (F ig. 3).
INSTALLATION
(1) In st a ll bu lb t o la m p.
(2) P r ess len s in t o pla ce.
GLOV E BOX LAM P SWI T CH

REMOVAL
ca ble.
(2) Open glove box door.
(3) P u sh swit ch t h r ou gh fr om beh in d (F ig. 2). Fig. 3 LIFTGATE LAMP
1 - LIFTGATE LAMP
2 - WIRE HARNESS
(3) Discon n ect wir e h a r n ess con n ect or fr om la m p.

(4) P r y off len s a n d r em ove bu lb.
INSTALLATION
(1) In st a ll bu lb a n d sn a p len s in t o pla ce.
(2) Recon n ect wir e h a r n ess con n ect or t o la m p.
(3) P osit ion la m p on t o t r im pa n el a n d sn a p in t o
pla ce.
(4) Recon n ect ba t t er y n ega t ive ca ble.
Fig. 2 GLOVE BOX LAMP/SWITCH

1 - GLOVE BOX BULB
READI N G LAM P
2 - GLOVE BOX LAMP SWITCH
REMOVAL
(4) Discon n ect wir e h a r n ess fr om swit ch . Th e fr on t r ea din g la m ps a r e in cor por a t ed in t o t h e
(5) P u ll bu lb fr om swit ch . over h ea d con sole. If t h e r ea din g la m ps r equ ir e
r epla cem en t , t h e over h ea d con sole m u st be r epla ced.
INSTALLATION (Refer t o 8 - E LE CTRICAL/OVE RH E AD CONSOLE -
(1) P u sh bu lb in t o swit ch . RE MOVAL). Th e r ea r r ea din g la m ps a r e in cor por a t ed
(2) Con n ect wir e h a r n ess t o swit ch . in t o t h e a ssist h a n dle. If t h e r ea r r ea din g la m ps
(3) P u sh swit ch in t o in st r u m en t pa n el. r equ ir e r epla cem en t , t h e a ssist h a n dle m u st be
(4) Close glove box door. r epla ced. (Refer t o 23 - BODY/INTE RIOR/ASSIST
(5) Recon n ect t h e ba t t er y n ega t ive ca ble. H ANDLE - RE MOVAL). Th e bu lbs ca n be ser viced
sepa r a t ely.
RS LAMPS/LIGHTING - INTERIOR 8L - 23
READI N G LAM P (Cont inue d)
ca ble.
(2) Usin g a fla t bla ded t ool, pr y off t h e la m p len s
(F ig. 4), (F ig. 5).
Fig. 6 OVERHEAD CONSOLE LAMP

1 - LAMP
2 - OVERHEAD CONSOLE
Fig. 4 OVERHEAD CONSOLE

1 - LAMP LENS
2 - OVERHEAD CONSOLE
(3) Rem ove bu lb fr om la m p (F ig. 6), (F ig. 7).
Fig. 7 COURTESY/READING LAMP

1 - COURTESY/READING LAMP
Fig. 5 COURTESY/READING LAMP

1 - HVAC LOUVER
2 - ASSIST HANDLE
3 - LAMP LENS
INSTALLATION
(1) In st a ll bu lb t o la m p.
(2) P r ess len s in t o pla ce.
VAN I T Y LAM P
REMOVAL
Th e va n it y la m p is in cor por a t ed in t o t h e visor
a ssem bly. If t h e va n it y la m p n eeds t o be r epla ced,
t h e en t ir e visor m u st be r epla ced. Th e bu lbs a r e ser-
viced sepa r a t ely.
ca ble.
(2) Usin g a pick or ot h er su it a ble t ool, pr y t h e
len s fr om t h e la m p (F ig. 8).
(3) Rem ove bu lb.
INSTALLATION
(1) In st a ll bu lb.
(2) Sn a p la m p len s in t o posit ion .
Fig. 8 VANITY LAMP
1 - VISOR
2 - VISOR/VANITY LAMP
3 - LENS
RS MESSAGE SYSTEMS 8M - 1
MESSAGE SYSTEMS
page page
MESSAGE CENTER. . . . . . . . . . . . . . . . . . . . . . . . . 1 OVERHEAD CONSOLE. . . . . . . . . . . . . . . . . . . . . . . 2
M ESSAGE CEN T ER
TABLE OF CONTENTS
page page
MESSAGE CENTER INSTALLATION ..........................1

REMOVAL .............................1
M ESSAGE CEN T ER NOTE: If the message center lamp needs replacing,

twist out defective bulb socket and replace with a
known good bulb and socket.
REMOVAL
ca ble. INSTALLATION
(2) Usin g a t r im st ick (specia l t ool #C-4755) or (1) Con n ect t h e wir in g con n ect or t o m essa ge cen -
equ iva len t , gen t ly pr y u p on t h e fr on t side of t h e t er.
m essa ge cen t er a n d lift ou t of in st r u m en t pa n el open - (2) P la ce m essa ge cen t er in posit ion on in st r u m en t
in g. pa n el a n d fir m ly sn a p in t o pla ce.
(3) Discon n ect t h e wir e con n ect or fr om t h e ba ck of (3) Con n ect ba t t er y n ega t ive ca ble.
m essa ge cen t er.
(4) Rem ove m essa ge cen t er fr om veh icle.
8M - 2 OVERHEAD CONSOLE RS
OV ERH EAD CON SOLE
TABLE OF CONTENTS
page page
OVERHEAD CONSOLE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2 DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING COMPASS MINI-TRIP COMPUTER . . . . . . . . 10
OVERHEAD CONSOLE . . . . . . . . . . . . . . . . . . 3 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
COMPASS CALIBRATION . . . . . . . . . . . . . . . . 4 UNIVERSAL TRANSMITTER
COMPASS DEMAGNETIZING . . . . . . . . . . . . . 5 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 11
COMPASS VARIATION ADJUSTMENT . . . . . . . 5 DIAGNOSIS AND TESTING
REMOVAL .............................6 UNIVERSAL TRANSMITTER . . . . . . . . . . . . . 11
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 6 STANDARD PROCEDURE
SPECIAL TOOLS SETTING TRANSMITTER CODES . . . . . . . . . 12
OVERHEAD CONSOLE . . . . . . . . . . . . . . . . . . 7 ERASING TRANSMITTER CODES . . . . . . . . . 12
ELECTRONIC VEHICLE INFO CENTER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 7 AMBIENT TEMP SENSOR
ELECTRONIC VEHICLE INFORMATION DIAGNOSIS AND TESTING
CENTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 AMBIENT TEMPERATURE SENSOR . . . . . . . 12
STANDARD PROCEDURE AMBIENT TEMPERATURE SENSOR
ELECTRONIC VEHICLE INFORMATION CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
CENTER PROGRAMMING . . . . . . . . . . . . . . . . 8 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
REMOVAL .............................9 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10
COMPASS/MINI-TRIP COMPUTER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10
OV ERH EAD CON SOLE DESCRIPTION - COMPASS

All over h ea d con soles in clu de com pa ss in for m a t ion .
DESCRIPTION Wh ile in t h e com pa ss/t em per a t u r e m ode, t h e com -
Th r ee over h ea d con soles opt ion s a r e a va ila ble on pa ss will displa y t h e dir ect ion in wh ich t h e veh icle is
t h is veh icle. Th ese opt ion s a r e: poin t ed u sin g t h e eigh t m a jor com pa ss h ea din gs
• Th e E lect r on ic Veh icle In for m a t ion Cen t er (E xa m ples: n or t h is N, n or t h ea st is NE ). Th e self-ca l-
(E VIC) ibr a t in g com pa ss u n it r equ ir es n o a dju st in g in n or-
• Th e Com pa ss Min i-Tr ip Com pu t er (CMTC) m a l u se. Th e on ly ca libr a t ion t h a t m a y be n ecessa r y
All con soles a r e equ ipped wit h t wo r ea din g/cou r- is t o dr ive t h e veh icle in t h r ee com plet e cir cles a t 5
t esy la m ps a n d if t h e veh icle is equ ipped wit h a t o 8 kilom et er s-per-h ou r (3 t o 5 m iles-per-h ou r ), on
power lift ga t e or power slidin g door (s) t h e over h ea d level gr ou n d, for a m in im u m of for t y-eigh t secon ds.
con sole will a lso in clu de swit ch es for t h ese fea t u r es. Th is will r eor ien t t h e com pa ss u n it t o it s veh icle.
Th e over h ea d con sole is m ou n t ed wit h on e scr ew a n d
t wo sn a p clips t o a m olded pla st ic r et a in er br a cket
loca t ed a bove t h e h ea dlin er.
RS OVERHEAD CONSOLE 8M - 3
OV ERH EAD CON SOLE (Cont inue d)
Th e com pa ss u n it will a lso com pen sa t e for m a gn e- If t h e pr oblem wit h t h e over h ea d con sole is a n
t ism t h e veh icle m a y a cqu ir e du r in g n or m a l u se. in a ccu r a t e or da sh ed (- -) displa y, r efer t o SE LF -DI-
H owever, a void pla cin g a n yt h in g m a gn et ic dir ect ly on AGNOSTIC TE ST. If t h e pr oblem wit h t h e over h ea d
t h e r oof of t h e veh icle. Ma gn et ic m ou n t s for a n con sole is in cor r ect Va cu u m F lu or escen t Displa y
a n t en n a , a r epa ir or der h a t , or a fu n er a l pr ocession (VF D) dim m in g levels, u se a DRB III! sca n t ool a n d
fla g ca n exceed t h e com pen sa t in g a bilit y of t h e com - t h e pr oper dia gn ost ic pr ocedu r es in for m a t ion t o t est
pa ss u n it if pla ced on t h e r oof pa n el. Th e u se of m a g- for t h e cor r ect dim m in g m essa ge in pu t s bein g
n et ic t ools on t h e fa st en er s t h a t h old t h e over h ea d r eceived fr om t h e Body Con t r ol Modu le (BCM) or
con sole a ssem bly t o t h e r oof h ea der ca n a lso a ffect F r on t Con t r ol Modu le (F CM) over t h e P r ogr a m m a ble
com pa ss oper a t ion . If t h e com pa ss oper a t ion is Com m u n ica t ion s In t er fa ce (P CI) da t a bu s cir cu it . If
er r a t ic a n d r oof m a gn et iza t ion is su spect ed (Refer t o t h e pr oblem is a n o-displa y con dit ion , u se t h e follow-
8 - E LE CTRICAL/OVE RH E AD CONSOLE - STAN- in g pr ocedu r es.
DARD P ROCE DURE - COMPASS DE MAGNE TIZ- In spect t h e r ela t ed wir in g h a r n ess con n ect or s for
ING). br oken , ben t , pu sh ed ou t , or cor r oded t er m in a ls.
DESCRIPTION - TEMPERATURE (1) Ch eck t h e fu sed B(+) fu se in t h e in t egr a t ed
All over h ea d con soles in clu de t em per a t u r e in for m a - power m odu le. If OK, go t o St ep 2. If n ot OK, r epa ir
t ion . Th e t em per a t u r e displa ys t h e ou t side a m bien t t h e sh or t ed cir cu it or com pon en t a s r equ ir ed a n d
t em per a t u r e in wh ole degr ees. Th e t em per a t u r e dis- r epla ce t h e fa u lt y fu se.
pla y ca n be t oggled fr om F a h r en h eit t o Celsiu s by (2) Ch eck for ba t t er y volt a ge a t t h e fu sed B(+) fu se
select in g t h e desir ed U.S./Met r ic opt ion fr om t h e cu s- in t h e in t egr a t ed power m odu le. If OK, go t o St ep 3.
t om er pr ogr a m m a ble fea t u r es. Th e displa yed t em per- If n ot OK, r epa ir t h e open fu sed B(+) cir cu it t o t h e
a t u r e is n ot a n in st a n t r ea din g of con dit ion s, bu t a n fu sed B(+) fu se in t h e in t egr a t ed power m odu le a s
a ver a ge t em per a t u r e. It m a y t a ke t h e t em per a t u r e r equ ir ed.
displa y sever a l m in u t es t o r espon d t o a m a jor t em - (3) Ch eck t h e fu sed ign it ion swit ch ou t pu t (r u n /
per a t u r e ch a n ge, su ch a s dr ivin g ou t of a h ea t ed st a r t ) fu se in t h e in t egr a t ed power m odu le. If OK, go
ga r a ge in t o win t er t em per a t u r es. t o St ep 4. If n ot OK, r epa ir t h e sh or t ed cir cu it or
Wh en t h e ign it ion swit ch is t u r n ed t o t h e Off posi- com pon en t a s r equ ir ed a n d r epla ce t h e fa u lt y fu se.
t ion , t h e la st displa yed t em per a t u r e r ea din g st a ys in (4) Tu r n t h e ign it ion swit ch t o t h e On posit ion .
t h e elect r on ic con t r ol m odu les (CMTC, E VIC) m em - Ch eck for ba t t er y volt a ge a t t h e fu sed ign it ion swit ch
or y. Wh en t h e ign it ion swit ch is t u r n ed t o t h e On ou t pu t (r u n /st a r t ) fu se in t h e in t egr a t ed power m od-
posit ion a ga in , t h e elect r on ic m odu le will displa y t h e u le. If OK, go t o St ep 5. If n ot OK, r epa ir t h e open
m em or y t em per a t u r e for on e m in u t e; t h en u pda t e t h e fu sed ign it ion swit ch ou t pu t (r u n /st a r t ) cir cu it t o t h e
displa y t o t h e cu r r en t a ver a ge t em per a t u r e r ea din g ign it ion swit ch a s r equ ir ed.
wit h in five m in u t es. (5) Tu r n t h e ign it ion swit ch t o t h e Off posit ion .
Th e t em per a t u r e fu n ct ion is su ppor t ed by a n a m bi- Discon n ect a n d isola t e t h e ba t t er y n ega t ive ca ble.
en t t em per a t u r e sen sor. Th e sen sor is m ou n t ed n ea r Rem ove t h e over h ea d con sole. Ch eck for con t in u it y
t h e fr on t a n d cen t er of t h e veh icle, a n d is h a r d wir ed bet ween t h e gr ou n d cir cu it ca vit y of t h e r oof wir e
t o t h e P ower t r a in Con t r ol Modu le (P CM). Th e P CM h a r n ess con n ect or for t h e elect r on ics m odu le a n d a
sen ds t em per a t u r e st a t u s m essa ges t o t h e m odu le good gr ou n d. Th er e sh ou ld be con t in u it y. If OK, go t o
over t h e P r ogr a m m a ble Com m u n ica t ion In t er fa ce St ep 6. If n ot OK, r epa ir t h e open gr ou n d cir cu it a s
(P CI) da t a bu s cir cu it . r equ ir ed.
(6) Con n ect t h e ba t t er y n ega t ive ca ble. Ch eck for
ba t t er y volt a ge a t t h e fu sed B(+) cir cu it ca vit y of t h e
DI AGN OSI S AN D T EST I N G r oof wir e h a r n ess con n ect or for t h e elect r on ics m od-
u le. If OK, go t o St ep 7. If n ot OK, r epa ir t h e open
OVERHEAD CONSOLE fu sed B(+) cir cu it t o t h e fu sed B(+) fu se in t h e in t e-
An y d ia g n o s is o f th e o v e rh e a d c o n s o le s h o u ld gr a t ed power m odu le a s r equ ir ed.
be g in w ith th e u s e o f th e D RB III! d ia g n o s tic (7) Tu r n t h e ign it ion swit ch t o t h e On posit ion .
to o l. F o r in fo rm a tio n o n th e u s e o f th e D RB Ch eck for ba t t er y volt a ge a t t h e fu sed ign it ion swit ch
III!, re fe r to th e a p p ro p ria te D ia g n o s tic P ro c e - ou t pu t (r u n /st a r t ) cir cu it ca vit y of t h e r oof wir e h a r-
d u re s in fo rm a tio n . n ess con n ect or for t h e elect r on ics m odu le. If OK,
r efer t o SE LF -DIAGNOSTIC TE ST. If n ot OK, r epa ir
t h e open fu sed ign it ion swit ch ou t pu t (r u n /st a r t ) cir-
cu it t o t h e fu se in t h e in t egr a t ed power m odu le a s
r equ ir ed.
SELF-DIAGNOSTIC TEST Th e elect r on ic com pa ss u n it fea t u r es a self-ca li-
A self-dia gn ost ic t est is u sed t o det er m in e t h a t t h e br a t in g design , wh ich sim plifies t h e ca libr a t ion pr o-
elect r on ics m odu le is oper a t in g pr oper ly, a n d t h a t a ll cedu r e. Th is fea t u r e a u t om a t ica lly u pda t es t h e
t h e P CI da t a bu s m essa ges a r e bein g r eceived for in i- com pa ss ca libr a t ion wh ile t h e veh icle is bein g dr iven .
t ia l oper a t ion . In it ia t e t h e self-dia gn ost ic t est a s fol- Th is a llows t h e com pa ss u n it t o com pen sa t e for sm a ll
lows: ch a n ges in t h e r esidu a l m a gn et ism t h e veh icle m a y
(1) Wit h t h e ign it ion swit ch in t h e Off posit ion , on a cqu ir e du r in g n or m a l u se. If t h e com pa ss r ea din gs
E lect r on ic Veh icle In for m a t ion Cen t er (E VIC) a n d a ppea r t o be er r a t ic or ou t of ca libr a t ion , per for m t h e
Com pa ss Min i-Tr ip Com pu t er (CMTC) equ ipped veh i- followin g ca libr a t ion pr ocedu r e. Also, n ew ser vice
cles sim u lt a n eou sly depr ess a n d h old t h e S TEP a n d r epla cem en t E lect r on ic Modu les (E VIC, CMTC, CT)
t h e RES ET bu t t on s. On Com pa ss Tem per a t u r e Mod- m u st h a ve t h eir com pa ss ca libr a t ed u sin g t h is pr oce-
u le (CT) equ ipped veh icles depr ess t h e C/T a n d t h e du r e. Do n ot a t t em pt t o ca libr a t e t h e com pa ss n ea r
U S /M pu sh bu t t on s. la r ge m et a l object s su ch a s ot h er veh icles, la r ge
(2) Tu r n t h e ign it ion swit ch t o t h e On posit ion . bu ildin gs, or br idges; or, n ea r over h ea d or u n der-
(3) F ollowin g com plet ion of t h ese t est s, t h e elec- gr ou n d power lin es.
t r on ics m odu le will displa y on e of t h e followin g m es-
sa ges: NOTE: Whenever the compass is calibrated manu-
a . P a s s S e lf Te s t (EVIC o n ly ), PAS S (CT, ally, the variance number must also be reset. (Refer
CMTC) - Th e elect r on ics m odu le is wor kin g pr oper ly. to 8 - ELECTRICAL/OVERHEAD CONSOLE - STAN-
b. F a ile d S e lf Te s t (EVIC o n ly ), FAIL (CT, DARD PROCEDURE - COMPASS VARIATION
CMTC) - Th e elect r on ics m odu le h a s a n in t er n a l fa il- ADJUSTMENT).
u r e. Th e elect r on ics m odu le is fa u lt y a n d m u st be
Ca libr a t e t h e com pa ss m a n u a lly a s follows:
r epla ced.
(1) Tu r n t h e ign it ion swit ch t o t h e On posit ion . If
NOTE: If the compass functions, but accuracy is t h e com pa ss/t h er m om et er da t a is n ot cu r r en t ly bein g
suspect, it may be necessary to perform a variation displa yed, m om en t a r ily depr ess a n d r elea se t h e C/T
adjustment. This procedure allows the compass pu sh bu t t on t o r ea ch t h e com pa ss/t h er m om et er dis-
unit to accommodate variations in the earth’s mag- pla y.
netic field strength, based on geographic location. (2) On E lect r on ic Veh icle In for m a t ion Cen t er
(Refer to 8 - ELECTRICAL/OVERHEAD CONSOLE - (E VIC) a n d Com pa ss Min i-Tr ip Com pu t er (CMTC)
STANDARD PROCEDURE - COMPASS VARIATION equ ipped veh icles depr ess t h e Reset pu sh bu t t on a n d
ADJUSTMENT). h old t h e bu t t on u n t il “CAL” a ppea r s in t h e displa y.
Th is t a kes a bou t t en secon ds, a n d a ppea r s a bou t five
secon ds a ft er “VAR = XX” is displa yed. On Com pa ss
NOTE: If the compass reading display is blank and Tem per a t u r e Modu le (CT) equ ipped veh icles depr ess
only “CAL” appears in the display, demagnetizing t h e C/T pu sh bu t t on a n d US/M pu sh bu t t on down
may be necessary to remove excessive residual u n t il “CAL” a ppea r s in t h e displa y. Th is t a kes a bou t
magnetic fields from the vehicle. (Refer to 8 - ELEC- t en secon ds, a n d a ppea r s a bou t five secon ds a ft er
TRICAL/OVERHEAD CONSOLE - STANDARD PRO- “VAR = XX” is displa yed.
CEDURE - COMPASS DEMAGNETIZING). (3) Relea se t h e pu sh bu t t on (s).
(4) Dr ive t h e veh icle on a level su r fa ce, a wa y fr om
la r ge m et a l object s a n d power lin es, t h r ou gh t h r ee or
m or e com plet e cir cles a t bet ween five a n d eigh t kilo-
STAN DARD PROCEDU RE m et er s-per-h ou r (t h r ee a n d five m iles-per-h ou r ) for a
m in im u m of 48 secon ds. Th e “CAL” m essa ge will dis-
COMPASS CALIBRATION a ppea r fr om t h e displa y t o in dica t e t h a t t h e com pa ss
is n ow ca libr a t ed.
CAUTION: Do not place any external magnets, such
as magnetic roof mount antennas, in the vicinity of NOTE: If the “CAL” message remains in the display,
the compass. Do not use magnetic tools when ser- either there is excessive magnetism near the com-
vicing the overhead console. pass, or the unit is faulty. Repeat the calibration
procedure one more time.
NOTE: If the wrong direction is still indicated in the
compass display, the area selected for calibration
may be too close to a strong magnetic field. Repeat
the calibration procedure in another location.
COMPASS DEMAGNETIZING
A dega u ssin g t ool (Specia l Tool 6029) is u sed t o
dem a gn et ize, or dega u ss, t h e over h ea d con sole for-
wa r d m ou n t in g scr ew a n d t h e r oof pa n el a bove t h e
over h ea d con sole. E qu iva len t u n it s m u st be r a t ed a s
con t in u ou s du t y for 110/115 volt s a n d 60 H z. Th ey
m u st a lso h a ve a field st r en gt h of over 350 ga u ss a t 7
m illim et er s (0.25 in ch ) beyon d t h e t ip of t h e pr obe.
To dem a gn et ize t h e r oof pa n el a n d t h e over h ea d
con sole for wa r d m ou n t in g scr ew, pr oceed a s follows:
(1) Be cer t a in t h a t t h e ign it ion swit ch is in t h e Off
posit ion , befor e you begin t h e dem a gn et izin g pr oce-
du r e.
(2) Con n ect t h e dega u ssin g t ool (F ig. 1) t o a n elec-
t r ica l ou t let , wh ile keepin g t h e t ool a t lea st 61 cen t i-
m et er s (2 feet ) a wa y fr om t h e com pa ss u n it .
Fig. 2 ROOF DEMAGNETIZING PATTERN

Fig. 1 DEGAUSSING TOOL 6029 (9) Con t a ct t h e r oof pa n el wit h t h e pla st ic coa t ed
(3) Slowly a ppr oa ch t h e h ea d of t h e over h ea d con - t ip of t h e dega u ssin g t ool. Be su r e t h a t t h e t em pla t e
sole for wa r d m ou n t in g scr ew wit h t h e dega u ssin g is in pla ce t o a void scr a t ch in g t h e r oof pa n el. Usin g a
t ool con n ect ed. slow, ba ck-a n d-for t h sweepin g m ot ion , a n d a llowin g
(4) Con t a ct t h e h ea d of t h e scr ew wit h t h e pla st ic 13 m illim et er s (0.50 in ch ) bet ween pa sses, m ove t h e
coa t ed t ip of t h e dega u ssin g t ool for a bou t t wo sec- t ool a t lea st 11 cen t im et er s (4 in ch es) t o ea ch side of
on ds. t h e r oof cen t er lin e, a n d 28 cen t im et er s (11 in ch es)
(5) Wit h t h e dega u ssin g t ool st ill en er gized, slowly ba ck fr om t h e win dsh ield h ea der.
ba ck it a wa y fr om t h e scr ew. Wh en t h e t ip of t h e t ool (10) Wit h t h e dega u ssin g t ool st ill en er gized,
is a t lea st 61 cen t im et er s (2 feet ) fr om t h e scr ew slowly ba ck it a wa y fr om t h e r oof pa n el. Wh en t h e
h ea d, discon n ect t h e t ool. t ip of t h e t ool is a t lea st 61 cen t im et er s (2 feet ) fr om
(6) P la ce a piece of pa per a ppr oxim a t ely 22 by 28 t h e r oof pa n el, discon n ect t h e t ool.
cen t im et er s (8.5 by 11 in ch es), or ien t ed on t h e veh icle (11) Ca libr a t e t h e com pa ss a n d a dju st t h e com pa ss
len gt h wise fr om fr on t t o r ea r, on t h e cen t er lin e of va r ia n ce (Refer t o 8 - E LE CTRICAL/OVE RH E AD
t h e r oof a t t h e win dsh ield h ea der (F ig. 2). Th e pu r- CONSOLE - STANDARD P ROCE DURE ).
pose of t h e pa per is t o pr ot ect t h e r oof pa n el fr om
scr a t ch es, a n d t o defin e t h e a r ea t o be dem a gn et ized. COMPASS VARIATION ADJUSTMENT
(7) Con n ect t h e dega u ssin g t ool t o a n elect r ica l Com pa ss va r ia n ce, a lso kn own a s m a gn et ic decli-
ou t let , wh ile keepin g t h e t ool a t lea st 61 cen t im et er s n a t ion , is t h e differ en ce in a n gle bet ween m a gn et ic
(2 feet ) a wa y fr om t h e com pa ss u n it . n or t h a n d t r u e geogr a ph ic n or t h . In som e geogr a ph ic
(8) Slowly a ppr oa ch t h e cen t er lin e of t h e r oof loca t ion s, t h e differ en ce bet ween m a gn et ic a n d geo-
pa n el a t t h e win dsh ield h ea der, wit h t h e dega u ssin g gr a ph ic n or t h is gr ea t en ou gh t o ca u se t h e com pa ss
t ool con n ect ed. t o give fa lse r ea din gs. If t h is pr oblem occu r s, t h e
com pa ss va r ia n ce set t in g m a y n eed t o be ch a n ged.
To set t h e com pa ss va r ia n ce:
Fig. 3 Variance Settings

(1) Usin g t h e Va r ia n ce Set t in gs m a p, fin d you r (6) On E lect r on ic Veh icle In for m a t ion Cen t er
geogr a ph ic loca t ion a n d n ot e t h e zon e n u m ber (F ig. (E VIC) a n d Com pa ss Min i-Tr ip Com pu t er (CMTC)
3). equ ipped veh icles m om en t a r ily depr ess a n d r elea se
(2) Tu r n t h e ign it ion swit ch t o t h e On posit ion . If t h e RES ET pu sh bu t t on t o en t er t h e displa yed zon e
t h e com pa ss/t h er m om et er da t a is n ot cu r r en t ly bein g n u m ber in t o t h e E VIC/CMTC m odu le m em or y. On
displa yed, m om en t a r ily depr ess a n d r elea se t h e C/T Com pa ss Tem per a t u r e Modu le (CT) equ ipped veh icles
pu sh bu t t on t o r ea ch t h e com pa ss/t h er m om et er dis- depr ess t h e C/T pu sh bu t t on t o en t er t h e displa yed
pla y. zon e n u m ber in t o t h e elect r on ic m odu le m em or y.
(3) On E lect r on ic Veh icle In for m a t ion Cen t er (7) Con fir m t h a t t h e cor r ect dir ect ion s a r e n ow
(E VIC) a n d Com pa ss Min i-Tr ip Com pu t er (CMTC) in dica t ed by t h e com pa ss.
equ ipped veh icles depr ess t h e Reset pu sh bu t t on a n d
h old t h e bu t t on down u n t il “VAR = XX” a ppea r s in REMOVAL
t h e displa y. Th is t a kes a bou t five secon ds. On Com - (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
pa ss Tem per a t u r e Modu le (CT) equ ipped veh icles ca ble.
depr ess t h e C/T pu sh bu t t on a n d US/M pu sh bu t t on (2) Rem ove t h e over h ea d con sole r et a in in g scr ew,
down u n t il “VAR = XX” a ppea r s in t h e displa y. Th is loca t ed in t h e fr on t of con sole.
t a kes a bou t five secon ds. (3) Gr a sp t h e sides of t h e over h ea d con sole a n d
(4) Relea se t h e pu sh bu t t on (s). “VAR =XX ” will pu ll st r a igh t down even ly t o disen ga ge t h e t wo sn a p
r em a in in t h e displa y. “XX” equ a ls t h e cu r r en t va r i- clips a t t h e r ea r of t h e u n it .
a n ce zon e set t in g. (4) Lower t h e over h ea d con sole fa r en ou gh t o
(5) On E lect r on ic Veh icle In for m a t ion Cen t er a ccess t h e wir e h a r n ess con n ect or s.
(E VIC) a n d Com pa ss Min i-Tr ip Com pu t er (CMTC) (5) Discon n ect t h e E VIC, CMTC or CT elect r on ic
equ ipped veh icles m om en t a r ily depr ess a n d r elea se m odu le a n d t h e r ea din g/cou r t esy la m ps elect r ica l
t h e S TEP bu t t on t o st ep t h r ou gh t h e zon e n u m ber s, con n ect or.
u n t il t h e zon e n u m ber for you r geogr a ph ic loca t ion (6) Rem ove t h e over h ea d con sole fr om t h e veh icle.
a ppea r s in t h e displa y. On Com pa ss Tem per a t u r e
Modu le (CT) equ ipped veh icles depr ess t h e U S /M INSTALLATION
pu sh bu t t on t o st ep t h r ou gh t h e zon e n u m ber s, u n t il (1) P osit ion t h e over h ea d con sole in t h e veh icle.
t h e zon e n u m ber for you r geogr a ph ic loca t ion
a ppea r s in t h e displa y.
(2) Con n ect t h e E VIC, CMTC or CT elect r on ic Da t a in pu t for a ll E VIC fu n ct ion s, in clu din g VF D
m odu le a n d t h e r ea din g/cou r t esy la m ps elect r ica l dim m in g level, is r eceived t h r ou gh t h e P CI da t a bu s
con n ect or. cir cu it . Th e E VIC m odu le u ses it s in t er n a l pr ogr a m -
(3) Usin g you r fin ger t ips, gr a sp t h e sides of t h e m in g a n d a ll of it s da t a in pu t s t o ca lcu la t e a n d dis-
over h ea d con sole a n d pu sh st r a igh t u p even ly t o pla y t h e r equ est ed da t a . If t h e da t a displa yed is
en ga ge t h e t wo sn a p clips a t t h e r ea r of t h e u n it . in cor r ect , per for m t h e SE LF - DIAGNOSTIC TE ST
(Refer t o 8 - E LE CTRICAL/OVE RH E AD CONSOLE -
CAUTION: DO NOT PRESS ON THE SUNGLASS DIAGNOSIS AND TE STING). If t h ese t est s pr ove
STORAGE BIN DOOR. DAMAGE TO THE DOOR MAY in con clu sive, t h e u se of a DRBIII! sca n t ool a n d t h e
RESULT. pr oper dia gn ost ic pr ocedu r es in for m a t ion a r e r ecom -
m en ded for fu r t h er t est in g of t h e E VIC m odu le a n d
(4) In st a ll t h e over h ea d con sole r et a in in g scr ew, t h e P CI da t a bu s cir cu it .
loca t ed in t h e fr on t of con sole. Tor qu e t h e scr ew t o Th e E VIC m odu le ca n n ot be r epa ir ed, a n d is a va il-
1.2 N·m (10 in . lbs.). a ble for ser vice on ly a s a u n it . Th is u n it in clu des t h e
(5) Con n ect t h e r em ot e n ega t ive ba t t er y ca ble. pla st ic m odu le a n d displa y len s. If a n y of t h ese com -
pon en t s is fa u lt y or da m a ged, t h e com plet e E VIC
SPECI AL T OOLS m odu le m u st be r epla ced.
OVERHEAD CONSOLE OPERATION

Th e E lect r on ic Veh icle In for m a t ion Cen t er (E VIC)
u ses bot h n on -swit ch ed a n d ign it ion swit ch ed sou r ces
of ba t t er y cu r r en t so t h a t som e of it s fea t u r es r em a in
oper a t ion a l a t a n y t im e, wh ile ot h er s m a y on ly oper-
a t e wit h t h e ign it ion swit ch in t h e On posit ion . Wh en
t h e ign it ion swit ch is t u r n ed t o t h e On posit ion , t h e
E VIC m odu le Va cu u m F lu or escen t Displa y (VF D)
will r et u r n t o t h e la st fu n ct ion bein g displa yed befor e
DEGAUSSING TOOL #6029 t h e ign it ion wa s t u r n ed t o t h e Off posit ion .
Th e com pa ss/t h er m om et er displa y is t h e n or m a l
ELECT RON I C V EH I CLE I N FO E VIC displa y. Wit h t h e ign it ion swit ch in t h e On
posit ion , m om en t a r ily depr essin g a n d r elea sin g t h e
CEN T ER C/T (com pa ss/t h er m om et er ) pu sh bu t t on swit ch will
ca u se t h e E VIC t o r et u r n t o t h e com pa ss/t h er m om e-
DESCRIPTION t er /t r ip com pu t er displa y m ode fr om a n y ot h er m ode.
Th e E lect r on ic Veh icle In for m a t ion Cen t er (E VIC) Wh ile in t h e com pa ss/t h er m om et er /t r ip com pu t er dis-
is loca t ed in t h e over h ea d con sole. Th e E VIC fea t u r es pla y m ode, m om en t a r ily depr essin g a n d r elea sin g t h e
a la r ge Va cu u m F lu or escen t Displa y (VF D) scr een for St ep pu sh bu t t on will st ep t h r ou gh t h e a va ila ble t r ip
displa yin g in for m a t ion , a n d ba ck-lit pu sh bu t t on com pu t er displa y opt ion s.
swit ch es la beled C/T (com pa ss/t h er m om et er ), RE SE T, Th e E VIC t r ip com pu t er fea t u r es sever a l fu n ct ion s
STE P, a n d ME NU. Th e E VIC m odu le con t a in s a cen - t h a t ca n be r eset . Th e fu n ct ion s t h a t ca n be r eset
t r a l pr ocessin g u n it a n d in t er fa ces wit h ot h er elec- a r e:
t r on ic m odu les in t h e veh icle over t h e P r ogr a m m a ble • Aver a ge fu el econ om y
Com m u n ica t ion s In t er fa ce (P CI) da t a bu s cir cu it . • Tr ip odom et er
Th e E VIC “Men u ” pu sh bu t t on pr ovides t h e veh icle • E la psed t im e
oper a t or wit h a u ser in t er fa ce, wh ich a llows t h e Wit h t h e ign it ion swit ch in t h e On posit ion a n d
select ion of sever a l opt ion a l cu st om er pr ogr a m m a ble wit h on e of t h e fu n ct ion s of t h e t r ip com pu t er t h a t
elect r on ic fea t u r es t o su it in dividu a l pr efer en ces. ca n be r eset cu r r en t ly displa yed, depr essin g t h e
(Refer t o 8 - E LE CTRICAL/OVE RH E AD CONSOLE / Reset pu sh bu t t on t wice wit h in fou r secon ds will per-
E LE CTRONIC VE H ICLE INF O CE NTE R - STAN- for m a globa l r eset , a n d a ll of t h e t r ip com pu t er
DARD P ROCE DURE - E LE CTRONIC VE H ICLE in for m a t ion t h a t ca n be r eset will be r eset t o zer o.
INF ORMATION CE NTE R P ROGRAMMING). Wit h t h e ign it ion swit ch in t h e On posit ion a n d t h e
If t h e veh icle is equ ipped wit h t h e opt ion a l u n iver- fu n ct ion t h a t is t o be r eset cu r r en t ly displa yed,
sa l t r a n sm it t er t r a n sceiver, t h e E VIC will a lso dis- m om en t a r ily depr essin g a n d h oldin g t h e Reset pu sh
pla y m essa ges a n d a n icon in dica t in g wh en t h e bu t t on for on e secon d will per for m a loca l r eset , a n d
u n iver sa l t r a n sm it t er t r a n sceiver is bein g t r a in ed, on ly t h e va lu e of t h e displa yed fu n ct ion will be r eset
wh ich of t h e t h r ee t r a n sm it t er bu t t on s is t r a n sm it - t o zer o. A globa l or loca l r eset will on ly occu r if t h e
t in g, a n d wh en t h e t r a n sceiver is clea r ed.
ELECT RON I C V EH I CLE I N FO CEN T ER (Cont inue d)
fu n ct ion cu r r en t ly displa yed is a fu n ct ion t h a t ca n be (3) Mom en t a r ily depr ess a n d r elea se t h e Men u
r eset . Th e dist a n ce t o ser vice fu n ct ion ca n a lso be pu sh bu t t on t o st ep t h r ou gh t h e pr ogr a m m a ble fea -
r eset u sin g t h e loca l r eset m et h od, bu t it will r eset t u r es list . E a ch pr ogr a m m a ble fea t u r e a n d it s cu r-
ba ck t o t h e Ser vice In t er va l dist a n ce t h a t is set in r en t ly select ed opt ion will a ppea r on t h e E VIC
t h e E VIC pr ogr a m m a ble fea t u r es m ode. (Refer t o 8 - displa y in t h e sequ en ce sh own in t h e P r ogr a m m a ble
E LE CTRICAL/OVE RH E AD CONSOLE /E LE C- F ea t u r es list t h a t follows.
TRONIC VE H ICLE INF O CE NTE R - STANDARD (4) Mom en t a r ily depr ess a n d r elea se t h e St ep pu sh
P ROCE DURE ). bu t t on t o st ep t h r ou gh t h e a va ila ble opt ion s for t h e
pr ogr a m m a ble fea t u r e bein g displa yed.
(5) Th e opt ion t h a t la st a ppea r s in t h e displa y
DI AGN OSI S AN D T EST I N G wit h a pr ogr a m m a ble fea t u r e befor e exit in g t h e pr o-
gr a m m in g m ode, becom es t h e n ewly select ed pr o-
ELECTRONIC VEHICLE INFORMATION CENTER gr a m m a ble fea t u r e opt ion .
E lect r on ic Veh icle In for m a t ion Cen t er (E VIC) da t a (6) Th e E VIC exit s t h e pr ogr a m m in g m ode a n d
is obt a in ed fr om t h e Body Con t r ol Modu le (BCM) on r et u r n s t o it s n or m a l oper a t in g m ode wh en t h e C/T
t h e P r ogr a m m a ble Com m u n ica t ion s In t er fa ce (P CI) pu sh bu t t on is depr essed or wh en t h e en d of t h e pr o-
Da t a Bu s cir cu it . Th e E VIC will displa y da sh es (- -) gr a m m a ble fea t u r es m en u list is r ea ch ed, wh ich ever
for a n y of t h e scr een s it did n ot r eceive t h e bu s m es- occu r s fir st .
sa ges. Th e la bel cor r espon din g t o t h e m issin g in for-
m a t ion will be lit . If n o E VIC da t a is displa yed, PROGRAMMABLE FEATURES
ch eck t h e P CI Da t a Bu s cir cu it com m u n ica t ion s a n d
t h e BCM. If t h e dim m in g level is im pr oper ch eck t h e NOTE: Tire pressure monitoring (TPM) system infor-
P CI Da t a Bu s cir cu it . mation is not covered in this section of the service
Th e u se of a DRBIII! sca n t ool a n d t h e pr oper manual. Refer to the tires/wheels section of this
dia gn ost ic pr ocedu r es in for m a t ion a r e r ecom m en ded manual for detailed tire pressure monitoring system
for fu r t h er t est in g of t h e E VIC m odu le a n d t h e P CI information.
da t a bu s cir cu it . P er for m t h e SE LF -DIAGNOSTIC
TE ST befor e r epla cin g t h e E VIC m odu le (Refer t o 8 - • LAN GU AGE? - Th e opt ion s in clu de E n glish ,
E LE CTRICAL/OVE RH E AD CONSOLE - DIAGNO- F r a n ca ise, Deu t sch , It a lia n a , or E spa n ol. Th e defa u lt
SIS AND TE STING). is E n glish . All E VIC displa y n om en cla t u r e, in clu din g
t h e t r ip com pu t er fu n ct ion s, wa r n in g m essa ges a n d
t h e pr ogr a m m a ble fea t u r es a ppea r in t h e select ed
STAN DARD PROCEDU RE la n gu a ge.
• D IS P LAY U .S . OR METRIC? - Th e opt ion s
ELECTRONIC VEHICLE INFORMATION CENTER in clu de U.S. a n d M. Th e defa u lt is U.S. Th is fea t u r e
PROGRAMMING t oggles t h e t r ip com pu t er t em per a t u r e, fu el econ om y
a n d odom et er displa y r ea din gs bet ween U.S. a n d
EVIC PROGRAMMING MODE m et r ic u n it s of m ea su r e. It a lso ch a n ges t h e odom e-
Som e veh icles a r e equ ipped wit h a E lect r on ic Veh i- t er displa y in t h e in st r u m en t clu st er.
cle In for m a t ion Cen t er (E VIC) equ ipped over h ea d • S ERVICE IN TV. = - Th e opt ion s in clu de fr om
con sole. Th e E lect r on ic Veh icle In for m a t ion Cen t er 3200 t o 12000 kilom et er s in 800 kilom et er in cr e-
(E VIC) pr ovides t h e veh icle oper a t or wit h a u ser m en t s (2000 t o 7500 m iles in 500 m ile in cr em en t s).
in t er fa ce, wh ich a llows t h e select ion of sever a l Th e defa u lt is 12000 kilom et er s (7500 m iles). Th e
opt ion a l cu st om er pr ogr a m m a ble elect r on ic fea t u r es select ed dist a n ce becom es t h e in t er va l a t wh ich t h e
t o su it in dividu a l pr efer en ces. Th e E VIC m u st be P er for m Ser vice wa r n in g m essa ge will be displa yed
pla ced in t o it s pr ogr a m m in g m ode in or der t o view or by t h e E VIC. If a n ew dist a n ce is select ed, a secon d
ch a n ge t h e pr ogr a m m a ble fea t u r es. To en t er t h e pr ogr a m m a ble fea t u r e a ppea r s, RES ET S ERVICE
E VIC pr ogr a m m in g m ode a n d t o view or ch a n ge t h e D IS TAN CE? - Th e opt ion s in clu de No a n d Yes. Th e
select ed pr ogr a m m a ble fea t u r es opt ion s, pr oceed a s defa u lt is Yes. Wh en Yes is select ed, t h e a ccu m u la t ed
follows: dist a n ce sin ce t h e la st pr eviou s P er for m Ser vice
(1) Tu r n t h e ign it ion swit ch t o t h e On posit ion . wa r n in g m essa ge will be r eset t o zer o beca u se t h e
(2) Depr ess a n d r elea se t h e Men u pu sh bu t t on . ser vice in t er va l h a s been ch a n ged. Wh en No is
Th e fir st it em in t h e pr ogr a m m a ble fea t u r es m en u select ed, t h e dist a n ce u n t il t h e n ext P er for m Ser vice
list will a ppea r in t h e E VIC displa y. wa r n in g m essa ge is r edu ced by t h e a ccu m u la t ed dis-
t a n ce sin ce t h e la st pr eviou s m essa ge.
• RETRAIN TIRE S EN S ORS ? - Th is pr ogr a m - con fir m a t ion wh en t h e RKE r eceiver r ecogn izes a
m a ble fea t u r e on ly a pplies t o veh icles equ ipped wit h va lid Lock sign a l fr om a n RKE t r a n sm it t er. Wh en No
t h e opt ion a l Tir e P r essu r e Mon it or in g Syst em . Th e is select ed, n o h or n ch ir p will occu r wit h t h e RKE
opt ion s in clu de Yes a n d No. Th e defa u lt is No. Wh en Lock even t . Th is fea t u r e m a y be select ed in depen -
Yes is select ed, a n d t h e m en u bu t t on is depr essed t h e den t of t h e F LAS H LIGHTS WITH LOCKS ? pr o-
E VIC will en t er t h e t r a in in g m ode, st a r t in g wit h t h e gr a m m a ble fea t u r e.
left fr on t t ir e. • F LAS H LIGHTS WITH LOCKS ? - Th e opt ion s
• U S E FACTORY S ETTIN GS ? - Th e opt ion s in clu de Yes a n d No. Th e defa u lt is Yes. Wh en Yes is
in clu de Yes a n d No. Th e defa u lt is Yes. Wh en yes is select ed, a sin gle fla sh of t h e h a za r d wa r n in g la m ps
select ed a ll t h e pr ogr a m m a ble fea t u r es will r et u r n t o will pr ovide a n opt ica l con fir m a t ion wh en t h e RKE
t h er e defa u lt s a n d t h e r est of t h e pr ogr a m m a ble fea - r eceiver r ecogn izes a va lid Lock sign a l fr om a n RKE
t u r es will n ot be displa yed. If No is select ed t h e r est t r a n sm it t er, a n d t wo fla sh es of t h e sa m e la m ps will
of t h e pr ogr a m m a ble fea t u r es will be displa yed a t occu r wh en t h e RKE r eceiver r ecogn izes a va lid
t h er e cu r r en t ch osen va lu es. Th is fea t u r e will a u t o- Un lock sign a l fr om a n RKE t r a n sm it t er. Wh en No is
m a t ica lly r et u r n t o t h e Yes defa u lt u n der t wo con di- select ed, n o la m p fla sh will occu r wit h t h e RKE Lock
t ion s. F ir st , if n o pr ogr a m m a ble fea t u r es a r e ch a n ged or Un lock even t . Th is fea t u r e m a y be select ed in de-
fr om t h er e defa u lt s. Secon d, if a ll t h e pr ogr a m m a ble pen den t of t h e S OU N D HORN ON LOCK? pr o-
fea t u r es equ a l t h er e defa u lt s. gr a m m a ble fea t u r e.
• AU TO D OOR LOCKS ? - Th e opt ion s in clu de • HEAD LAMP D ELAY = - Th e opt ion s in clu de
Yes a n d No. Th e defa u lt is Yes. Wh en Yes is select ed, Off, 30 Sec, 60 Sec, a n d 90 Sec. Th e defa u lt is 90 Sec.
a ll door s a n d t h e lift ga t e lock a u t om a t ica lly wh en Wh en a t im e in t er va l is select ed, t h e h ea dla m ps will
veh icle speed r ea ch es 25 kilom et er s-per-h ou r (15 r em a in on for t h a t len gt h of t im e wh en t h e h ea d-
m iles-per-h ou r ). If YE S is select ed, a secon d pr ogr a m - la m ps a r e t u r n ed off a ft er t h e ign it ion is t u r n ed off,
m a ble fea t u r e a ppea r s, AU TO U N LOCK ON EXIT? or if t h e Au t o m ode is select ed on veh icles wit h t h e
- Th e opt ion s a ga in in clu de Yes a n d No. Th e defa u lt Au t o H ea dla m ps opt ion . Wh en Off is select ed, t h e
is No. Wh en Yes is select ed, followin g ea ch Au t o Door h ea dla m p dela y fea t u r e is disa bled.
Lock even t a ll door s a n d t h e lift ga t e will a u t om a t i- • HEAD LAMP S ON WITH WIP ERS ? - Th is pr o-
ca lly u n lock wh en t h e dr iver door is open ed, if t h e gr a m m a ble fea t u r e on ly a pplies t o veh icles equ ipped
veh icle is st opped a n d t h e t r a n sm ission gea r select or wit h t h e opt ion a l Au t o H ea dla m ps. Th e opt ion s
is in P a r k or Neu t r a l. Th e Au t o Door Un lock even t in clu de Yes a n d No. Th e defa u lt is No. Wh en Yes is
will on ly occu r on ce followin g ea ch Au t o Door Lock select ed, t h e h ea dla m ps will t u r n on a u t om a t ica lly
even t . wh en t h e win dsh ield wiper s a r e t u r n ed on . Th e h ea d-
• REMOTE U N LOCK - Th e opt ion s in clu de la m ps will t u r n off wh en t h e wiper s a r e t u r n ed off,
Dr iver Door 1st a n d All Door s. Th e defa u lt is Dr iver a s lon g a s t h e h ea dla m p swit ch is in t h e Au t o or Off
Door 1st . Wh en Diver Door 1st is select ed, on ly t h e posit ion s. Wh en No is select ed, t h e h ea dla m ps will
dr iver door u n locks wh en t h e Un lock bu t t on of t h e on ly t u r n on if m a n u a lly select ed or if t h e Au t o m ode
Rem ot e Keyless E n t r y (RKE ) t r a n sm it t er is is select ed a n d t h e ou t side a m bien t ligh t levels dic-
depr essed on ce. Th e Un lock bu t t on of t h e RKE t r a n s- t a t e t h a t t h ey sh ou ld be on .
m it t er m u st be depr essed t wice t o u n lock a ll door s. • P OWER ACCES S ORY D ELAY? - Th e opt ion s
Wh en All Door s is select ed, a ll door s u n lock wh en t h e in clu de Yes a n d No. Th e defa u lt is Yes. Wh en No is
Un lock bu t t on of t h e RKE t r a n sm it t er is depr essed select ed, t h e a ccessor y power ed com pon en t s will t u r n
on ce. off a u t om a t ica lly wh en t h e ign it ion key is t u r n ed off.
• REMOTE LIN KED TO MEMORY? - Th is pr o- Wh en Yes is select ed, t h e a ccessor y power ed com po-
gr a m m a ble fea t u r e on ly a pplies t o veh icles equ ipped n en t s will r em a in on for 45 secon ds wh en t h e ign i-
wit h t h e opt ion a l m em or y / h ea t ed syst em . Th e t ion key is t u r n ed off.
opt ion s in clu de Yes a n d No. Th e defa u lt is No. Wh en
Yes is select ed, t h e m em or y syst em will r eca ll t h e REMOVAL
Dr iver 1 or Dr iver 2 m em or y set t in gs a ssign ed t o t h e (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
RKE t r a n sm it t er bein g u sed t o u n lock t h e veh icle. ca ble.
Wh en No is select ed, t h e m em or y syst em will on ly (2) Rem ove over h ea d con sole. (Refer t o 8 - E LE C-
r eca ll m em or y set t in gs wh en t h e Dr iver 1 or Dr iver 2 TRICAL/OVE RH E AD CONSOLE - RE MOVAL).
pu sh bu t t on s of t h e m em or y swit ch on t h e dr iver side (3) Rem ove t h e t en scr ews h oldin g t h e E lect r on ic
fr on t door t r im pa n el a r e depr essed. Veh icle In for m a t ion Cen t er (E VIC) m odu le in t h e
• S OU N D HORN ON LOCK? - Th e opt ion s over h ea d con sole.
in clu de Yes a n d No. Th e defa u lt is No. Wh en Yes is (4) Rem ove E VIC m odu le fr om con sole a ssem bly.
select ed, a sh or t h or n ch ir p will pr ovide a n a u dible
NOTE: If the EVIC module is being replaced, the tire OPERATION
pressure monitoring system (if equipped) must be Th e Com pa ss Min i-Tr ip Com pu t er (CMTC) m odu le
retrained. (Refer to 22 - TIRES/WHEELS/TIRE PRES- in t h e over h ea d con sole h a s bu t t on s u sed t o select
SURE MONITORING/SENSOR - STANDARD PROCE- va r iou s fu n ct ion s. Th e CMTC select or bu t t on s will
DURE) n ot oper a t e u n t il t h e ign it ion is in t h e RUN posit ion .
Wh en t h e ign it ion swit ch is fir st t u r n ed t o t h e
RUN posit ion t h e CMTC displa y;
INSTALLATION • Bla n ks m om en t a r ily
(1) P osit ion t h e E lect r on ic Veh icle In for m a t ion • All segm en t s of t h e VF D will ligh t for on e sec-
Cen t er (E VIC) m odu le in t h e over h ea d con sole. on d
(2) In st a ll t h e t en scr ews h oldin g t h e E VIC m odu le • Bla n ks m om en t a r ily
in t h e over h ea d con sole. • Ret u r n s t o t h e la st m ode set t in g select ed befor e
(3) In st a ll t h e over h ea d con sole (Refer t o 8 - t h e ign it ion wa s la st swit ch ed OF F.
E LE CTRICAL/OVE RH E AD CONSOLE - INSTALLA-
TION).
(4) Con n ect t h e ba t t er y n ega t ive ca ble. DI AGN OSI S AN D T EST I N G
NOTE: If the EVIC module is being replaced, the tire COMPASS MINI-TRIP COMPUTER
pressure monitoring system (if equipped) must be An y d ia g n o s is o f th e c o m p a s s m in i-trip c o m -
retrained. (Refer to 22 - TIRES/WHEELS/TIRE PRES- p u te r s h o u ld be g in w ith th e u s e o f th e D RB III!
SURE MONITORING/SENSOR - STANDARD PROCE- d ia g n o s tic to o l. F o r in fo rm a tio n o n th e u s e o f
DURE). th e D RB III!, re fe r to th e a p p ro p ria te D ia g n o s -
tic P ro c e d u re s in fo rm a tio n .
NOTE: If a new EVIC module has been installed, the Com pa ss Min i-Tr ip Com pu t er (CMTC) da t a is
compass will have to be calibrated and the variance obt a in ed fr om t h e Body Con t r ol Modu le (BCM) on
set. (Refer to 8 - ELECTRICAL/OVERHEAD CON- t h e P r ogr a m m a ble Com m u n ica t ion s In t er fa ce (P CI)
SOLE - STANDARD PROCEDURE - COMPASS CAL- Da t a Bu s cir cu it . Th e CMTC will displa y da sh es (- -)
IBRATION). for a n y of t h e scr een s it did n ot r eceive t h e bu s m es-
sa ges. Th e la bel cor r espon din g t o t h e m issin g in for-
m a t ion will be lit . If n o CMTC da t a is displa yed,
ch eck t h e P CI Da t a Bu s cir cu it com m u n ica t ion s a n d
COM PASS/M I N I -T RI P t h e BCM. If t h e dim m in g level is im pr oper ch eck t h e
COM PU T ER P CI Da t a Bu s cir cu it .
DESCRIPTION REMOVAL
Th e Com pa ss Min i-Tr ip Com pu t er (CMTC) m odu le
ca ble.
is loca t ed in t h e over h ea d con sole. Th e CMTC con -
(2) Rem ove over h ea d con sole(Refer t o 8 - E LE C-
sist s of a elect r on ic con t r ol m odu le wit h a va cu u m
TRICAL/OVE RH E AD CONSOLE - RE MOVAL).
flu or escen t displa y (VF D) a n d fu n ct ion swit ch es. Th e
(3) Rem ove t h e scr ews h oldin g Com pa ss Min i-Tr ip
CMTC con sist s of a elect r on ic m odu le t h a t displa ys
Com pu t er (CMTC) m odu le in t h e over h ea d con sole.
com pa ss, t r ip com pu t er, a n d t em per a t u r e fea t u r es.
(4) Rem ove CMTC m odu le fr om t h e con sole a ssem -
Act u a t in g t h e STE P pu sh bu t t on will ca u se t h e
bly.
CMTC t o ch a n ge m ode of oper a t ion wh en t h e ign it ion
is ON. E xa m ple:
• Aver a ge m iles per ga llon (E CO)
INSTALLATION
(1) P osit ion t h e com pa ss m in i-t r ip com pu t er
• Dist a n ce t o em pt y (DTE )
(CMTC) m odu le in t h e over h ea d con sole.
• In st a n t m iles per ga llon (E CO)
(2) In st a ll t h e t en scr ews h oldin g t h e CMTC m od-
• Tr ip odom et er (ODO)
u le in t h e over h ea d con sole.
• E la psed t im e (E T)
(3) In st a ll t h e over h ea d con sole (Refer t o 8 -
• Bla n k
E LE CTRICAL/OVE RH E AD CONSOLE - INSTALLA-
Act u a t in g t h e C/T pu sh bu t t on will ca u se t h e
TION).
CMTC t o ch a n ge t o t h e Com pa ss/Tem per a t u r e dis-
pla y.
COM PASS/M I N I -T RI P COM PU T ER (Cont inue d)
NOTE: If a new CMTC module has been installed, DI AGN OSI S AN D T EST I N G
the compass will have to be calibrated and the vari-
ance set. (Refer to 8 - ELECTRICAL/OVERHEAD UNIVERSAL TRANSMITTER
CONSOLE - STANDARD PROCEDURE - COMPASS If bot h t h e Un iver sa l Tr a n sm it t er a n d t h e E lec-
CALIBRATION). t r on ic Veh icle In for m a t ion Cen t er (E VIC) a r e in oper-
a t ive, (Refer t o 8 - E LE CTRICAL/OVE RH E AD
CONSOLE /E LE CTRONIC VE H ICLE INF O CE NTE R
U N I V ERSAL T RAN SM I T T ER - DIAGNOSIS AND TE STING). If t h e Un iver sa l
Tr a n sm it t er is in oper a t ive, bu t t h e E VIC is oper a t in g
n or m a lly, r et r a in t h e Tr a n sm it t er wit h a kn own good
DESCRIPTION
t r a n sm it t er (Refer t o 8 - E LE CTRICAL/OVE RH E AD
A Un iver sa l Tr a n sm it t er t r a n sceiver is a va ila ble on
CONSOLE /UNIVE RSAL TRANSMITTE R - STAN-
som e veh icles. Th e u n iver sa l t r a n sm it t er t r a n sceiver
DARD P ROCE DURE - SE TTING TRANSMITTE R
is in t egr a l t o t h e E lect r on ic Veh icle In for m a t ion Cen -
CODE S). If t h e u n it is st ill in oper a t ive, t est t h e u n i-
t er (E VIC) a n d t h e Com pa ss Min i-Tr ip Com pu t er
ver sa l t r a n sm it t er wit h t h e Ra dio F r equ en cy Det ec-
(CMTC) m odu les, wh ich a r e loca t ed in t h e over h ea d
t or specia l t ool a s descr ibed below (F ig. 4):
con sole. Th e on ly visible com pon en t of t h e u n iver sa l
(1) Tu r n t h e Ra dio F r equ en cy (RF ) Det ect or ON. A
t r a n sm it t er a r e t h e t h r ee t r a n sm it t er pu sh bu t t on s
“ch ir p” will sou n d a n d t h e gr een power LE D will
cen t er ed bet ween t h e m odu les pu sh bu t t on s loca t ed
ligh t . If t h e gr een LE D does n ot ligh t , r epla ce t h e
ju st r ea r wa r d of t h e displa y scr een in t h e over h ea d
ba t t er y.
con sole. Th e t h r ee u n iver sa l t r a n sm it t er pu sh bu t -
(2) H old t h e RF det ect or wit h in on e in ch of t h e
t on s a r e iden t ified wit h on e, t wo or t h r ee ligh t in di-
TRAINE D u n iver sa l t r a n sm it t er a n d pr ess a n y of t h e
ca t or s so t h a t t h ey ca n be ea sily iden t ified.
t r a n sm it t er s bu t t on s.
E a ch of t h e t h r ee u n iver sa l t r a n sm it t er pu sh bu t -
(3) Th e r ed sign a l det ect ion LE Ds will ligh t a n d
t on s con t r ols a n in depen den t r a dio t r a n sm it t er ch a n -
t h e t ool will beep if a r a dio sign a l is det ect ed. Repea t
n el. E a ch of t h ese t h r ee ch a n n els ca n be t r a in ed t o
t h is t est t h r ee t im es.
t r a n sm it a differ en t r a dio fr equ en cy sign a l for t h e
r em ot e oper a t ion of ga r a ge door open er s, m ot or ized
ga t e open er s, h om e or office ligh t in g, secu r it y sys-
t em s or ju st a bou t a n y ot h er device t h a t ca n be
equ ipped wit h a r a dio r eceiver in t h e 286 t o 399
Mega H er t z (MH z) fr equ en cy r a n ge for r em ot e oper a -
t ion . Th e u n iver sa l t r a n sm it t er is ca pa ble of oper a t -
in g syst em s u sin g eit h er r ollin g code or n on -r ollin g
code t ech n ology.
Th e elect r on ics m odu le displa ys m essa ges a n d a
sm a ll h ou se-sh a ped icon wit h on e, t wo or t h r ee dot s
cor r espon din g t o t h e t h r ee t r a n sm it t er bu t t on s t o
in dica t e t h e st a t u s of t h e u n iver sa l t r a n sm it t er. Th e
E VIC m essa ges a r e:
• Cle a re d Ch a n n e ls - In dica t es t h a t a ll of t h e
t r a n sm it t er codes st or ed in t h e u n iver sa l t r a n sm it t er
h a ve been su ccessfu lly clea r ed.
• Tra in in g - In dica t es t h a t t h e u n iver sa l t r a n s-
m it t er is in it s t r a n sm it t er lea r n in g m ode.
• Tra in e d - In dica t es t h a t t h e u n iver sa l t r a n sm it -
t er h a s su ccessfu lly a cqu ir ed a n ew t r a n sm it t er code.
• Tra n s m it - In dica t es t h a t a t r a in ed u n iver sa l
t r a n sm it t er bu t t on h a s been depr essed a n d t h a t t h e
u n iver sa l t r a n sm it t er is t r a n sm it t in g. Fig. 4 RADIO FREQUENCY DETECTOR
Th e u n iver sa l t r a n sm it t er ca n n ot be r epa ir ed, a n d 1 - SIGNAL DETECTION LED’S
is a va ila ble for ser vice on ly a s a u n it wit h t h e E VIC 2 - POWER LED
3 - ON/OFF SWITCH
or CMTC m odu les. If a n y of t h ese com pon en t s is 4 - 9V BATTERY
fa u lt y or da m a ged, t h e com plet e E VIC or CMTC
m odu le m u st be r epla ced.
U N I V ERSAL T RAN SM I T T ER (Cont inue d)
STAN DARD PROCEDU RE OPERATION

Th e a m bien t t em per a t u r e sen sor is a va r ia ble
SETTING TRANSMITTER CODES r esist or t h a t oper a t es on a five-volt r efer en ce sign a l
(1) Tu r n off t h e en gin e. sen t by t h e P ower t r a in Con t r ol Modu le (P CM). Th e
(2) E r a se t h e codes by pr essin g t h e t wo ou t side r esist a n ce in t h e sen sor ch a n ges a s t em per a t u r e
bu t t on s. Relea se t h e bu t t on s wh en t h e displa y con - ch a n ges, ch a n gin g t h e t em per a t u r e sen sor sign a l cir-
fir m s t h e oper a t ion (a bou t 20 secon ds). cu it volt a ge t o t h e P CM. Ba sed u pon t h e r esist a n ce
(3) Ch oose on e of t h e t h r ee bu t t on s t o t r a in . P la ce in t h e sen sor, t h e P CM sen ses a specific volt a ge on
t h e h a n d-h eld t r a n sm it t er wit h in on e in ch of t h e u n i- t h e t em per a t u r e sen sor sign a l cir cu it , wh ich it is pr o-
ver sa l t r a n sm it t er a n d pu sh t h e bu t t on s on bot h gr a m m ed t o cor r espon d t o a specific t em per a t u r e.
t r a n sm it t er s. Th e P CM t h en sen ds t h e pr oper a m bien t t em per a -
(4) Relea se bot h bu t t on s. You r u n iver sa l t r a n sm it - t u r e m essa ges t o t h e E lect r on ic Veh icle In for m a t ion
t er is n ow “t r a in ed”. To t r a in t h e ot h er bu t t on s, Cen t er (E VIC)/Com pa ss Min i-Tr ip Com pu t er (CMTC)
r epea t St ep 3 a n d St ep 4. Be su r e t o keep you r h a n d- over t h e P r ogr a m m a ble Com m u n ica t ion In t er fa ce
h eld t r a n sm it t er in ca se you n eed t o r et r a in t h e u n i- (P CI) da t a bu s.
ver sa l t r a n sm it t er. Th e t h er m om et er fu n ct ion is su ppor t ed by t h e
a m bien t t em per a t u r e sen sor, a wir in g cir cu it , t h e
ERASING TRANSMITTER CODES P CM, t h e P CI da t a bu s, a n d t h e E lect r on ics m odu le.
To er a se t h e u n iver sa l t r a n sm it t er codes, sim ply If a n y por t ion of t h e a m bien t t em per a t u r e sen sor cir-
h old down t h e t wo ou t side bu t t on s u n t il t h e displa y cu it fa ils, t h e P CM will self-dia gn ose t h e cir cu it .
con fir m s t h e oper a t ion . Th e a m bien t t em per a t u r e sen sor cir cu it ca n a lso be
dia gn osed m a n u a lly (Refer t o 8 - E LE CTRICAL/
NOTE: Individual channels cannot be erased. Eras- OVE RH E AD CONSOLE /AMBIE NT TE MP SE NSOR
ing the transmitter codes will erase ALL pro- - DIAGNOSIS AND TE STING - AMBIE NT TE M-
grammed codes. P E RATURE SE NSOR CIRCUIT). If t h e t em per a t u r e
sen sor a n d cir cu it a r e con fir m ed t o be OK, bu t t h e
t em per a t u r e displa y is in oper a t ive or in cor r ect ,
REMOVAL (Refer t o 8 - E LE CTRICAL/OVE RH E AD CONSOLE -
(1) F or t h e u n iver sa l t r a n sm it t er r em ova l pr oce- DIAGNOSIS AND TE STING) t o det er m in e t h e ca u se.
du r e, (Refer t o 8 - E LE CTRICAL/OVE RH E AD CON- F or com plet e cir cu it dia gr a m s, r efer t o t h e a ppr opr i-
SOLE /COMPASS/MINI-TRIP COMP UTE R - a t e wir in g in for m a t ion .
RE MOVAL.

AM BI EN T T EM P SEN SOR
AMBIENT TEMPERATURE SENSOR
DESCRIPTION (1) Tu r n t h e ign it ion swit ch t o t h e Off posit ion .
Am bien t a ir t em per a t u r e is m on it or ed by t h e over- Discon n ect a n d isola t e t h e ba t t er y n ega t ive ca ble.
h ea d con sole t h r ou gh a m bien t t em per a t u r e m essa ges Discon n ect t h e a m bien t t em per a t u r e sen sor wir e h a r-
r eceived fr om t h e P ower t r a in Con t r ol Modu le (P CM) n ess con n ect or.
over t h e P r ogr a m m a ble Com m u n ica t ion s In t er fa ce (2) Mea su r e t h e r esist a n ce of t h e a m bien t t em per-
(P CI) da t a bu s cir cu it . Th e P CM r eceives a h a r d a t u r e sen sor. At r oom t em per a t u r e (a ppr ox. 68°F ),
wir ed in pu t fr om t h e a m bien t t em per a t u r e sen sor. t h e sen sor r esist a n ce sh ou ld be bet ween 10-13 Kilo-
Th e a m bien t t em per a t u r e sen sor is a va r ia ble r esis- h m s. Th e sen sor r esist a n ce sh ou ld be bet ween t h ese
t or m ou n t ed t o a br a cket t h a t is secu r ed wit h a scr ew t wo va lu es a t 68°F. If t h e r esist a n ce is ou t of r a n ge
t o t h e r igh t side of t h e h ea dla m p m ou n t in g m odu le r epla ce t h e a m bien t t em per a t u r e sen sor.
gr ille open in g, beh in d t h e r a dia t or gr ille a n d in fr on t
of t h e en gin e com pa r t m en t . AMBIENT TEMPERATURE SENSOR CIRCUIT
F or a ddit ion a l in for m a t ion on t h e P CM, (Refer t o 8 (1) Tu r n t h e ign it ion swit ch t o t h e Off posit ion .
- E LE CTRICAL/E LE CTRONIC CONTROL MOD- Discon n ect a n d isola t e t h e ba t t er y n ega t ive ca ble.
ULE S/P OWE RTRAIN CONTROL MODULE - Discon n ect t h e a m bien t t em per a t u r e sen sor wir e h a r-
DE SCRIP TION). n ess con n ect or a n d t h e P ower t r a in Con t r ol Modu le
(P CM) wir e h a r n ess con n ect or.
AM BI EN T T EM P SEN SOR (Cont inue d)
(2) Con n ect a ju m per wir e bet ween t h e t wo t er m i- ING) t o det er m in e t h e ca u se. If n ot OK, r epa ir t h e
n a ls in t h e body h a lf of t h e a m bien t t em per a t u r e sen - sh or t ed a m bien t t em per a t u r e sen sor sign a l cir cu it a s
sor wir e h a r n ess con n ect or. r equ ir ed.
(3) Ch eck for con t in u it y bet ween t h e sen sor r et u r n
cir cu it a n d t h e a m bien t t em per a t u r e sen sor sign a l REMOVAL
cir cu it ca vit ies of t h e P CM wir e h a r n ess con n ect or. (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
Th er e sh ou ld be con t in u it y. If OK, go t o St ep 4. If n ot ca ble.
OK, r epa ir t h e open sen sor r et u r n cir cu it or a m bien t (2) F r om beh in d t h e fr on t bu m per fa scia , r em ove
t em per a t u r e sen sor sign a l cir cu it t o t h e a m bien t t em - t h e scr ew h oldin g t h e sen sor t o t h e r a dia t or closu r e
per a t u r e sen sor a s r equ ir ed. pa n el.
(4) Rem ove t h e ju m per wir e fr om t h e body h a lf of (3) Discon n ect t h e sen sor elect r ica l con n ect or.
t h e a m bien t t em per a t u r e sen sor wir e h a r n ess con - (4) Rem ove t h e sen sor fr om veh icle.
n ect or. Ch eck for con t in u it y bet ween t h e sen sor
r et u r n cir cu it ca vit y of t h e P CM wir e h a r n ess con n ec- INSTALLATION
t or a n d a good gr ou n d. Th er e sh ou ld be n o con t in u it y. (1) P osit ion t h e sen sor in t h e veh icle a n d con n ect
If OK, go t o St ep 5. If n ot OK, r epa ir t h e sh or t ed t h e sen sor elect r ica l con n ect or.
sen sor r et u r n cir cu it a s r equ ir ed. (2) F r om beh in d t h e fr on t bu m per fa scia , in st a ll
(5) Ch eck for con t in u it y bet ween t h e a m bien t t em - t h e sen sor m ou n t in g scr ew.
per a t u r e sen sor sign a l cir cu it ca vit y of t h e P CM wir e (3) Con n ect t h e ba t t er y n ega t ive ca ble.
h a r n ess con n ect or a n d a good gr ou n d. Th er e sh ou ld
be n o con t in u it y. If OK, (Refer t o 8 - E LE CTRICAL/
OVE RH E AD CONSOLE - DIAGNOSIS AND TE ST-
RS POWER SYSTEMS 8N - 1
POWER SYSTEMS
page page
POWER LIFTGATE SYSTEM . . . . . . . . . . . . . . . . . . 1 POWER SEAT SYSTEM. . . . . . . . . . . . . . . . . . . . . 31

POWER LOCKS. . . . . . . . . . . . . . . . . . . . . . . . . . . 20 POWER SLIDING DOOR SYSTEM . . . . . . . . . . . . 40
POWER MIRRORS . . . . . . . . . . . . . . . . . . . . . . . . 26 POWER WINDOWS. . . . . . . . . . . . . . . . . . . . . . . . 61
POWER LI FT GAT E SY ST EM
TABLE OF CONTENTS
page page
POWER LIFTGATE SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13
DIAGNOSIS AND TESTING LATCH ACTUATOR
POWER LIFTGATE SYSTEM . . . . . . . . . . . . . . 3 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 13
STANDARD PROCEDURE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
LIFTGATE ADJUSTMENT . . . . . . . . . . . . . . . . 8 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
POWER LIFTGATE LEARN CYCLE . . . . . . . . . 8 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14
CHIME/THERMISTOR LIFTGATE MOTOR
REMOVAL .............................8 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
ENGAGE ACTUATOR LIFT GEAR & LINK ROD
REMOVAL .............................9 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
EXTERIOR HANDLE SWITCH PINCH SENSOR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
FULL OPEN SWITCH TRANSVERSE BRACKET
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
LATCH
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 12
8N - 2 POWER LIFTGATE SYSTEM RS
POWER LI FT GAT E SY ST EM Th e lift ga t e h a n dle swit ch is a power r elea se swit ch

a n d is loca t ed in t h e r ea r ligh t ba r a ssem bly, ju st
a bove t h e licen se pla t e. Th e over h ea d con sole swit ch
DESCRIPTION
is a power open a n d close com m a n d swit ch loca t ed in
t h e com pon en t s of t h e power lift ga t e syst em a r e:
t h e veh icles over h ea d con sole.
• Lift ga t e gea r m ot or a ssem bly
Soft wa r e t ech n ology h a s en a bled t h e power lift ga t e
• La t ch a ssem bly
con t r ol m odu le t o det ect r esist a n ce t o lift ga t e t r a vel,
• Lift gea r a n d r od
wh ich a llows t h e power lift ga t e t o st op a n d r ever se
• P ower lift ga t e con t r ol m odu le
dir ect ion a n yt im e a n obst r u ct ion is felt or a n y of t h e
• Ch im e/t h er m ist or
com m a n d swit ch es a r e oper a t ed (on ly in closin g
• F u ll open swit ch
dir ect ion ). Ba t t er y volt a ge is su pplied t o t h e power
• E n ga ge a ct u a t or
lift ga t e syst em t h r ou gh a 40 a m p fu se, loca t ed in t h e
• P in ch sen sor
In t egr a t ed P ower Modu le (IP M) a ssem bly. If t h e
• Lift ga t e h a n dle swit ch
power lift ga t e syst em develops a fa u lt , t h e power lift -
• Over h ea d con sole swit ch
ga t e ca n st ill be oper a t ed m a n u a lly wit h a key, sim -
• Key fob swit ch es (F ig. 1)
ila r t o a m a n u a l lift ga t e.
• P a wl swit ch
Th e power lift ga t e con t r ol m odu le com m u n ica t es
• Ra t ch et swit ch
on t h e P r ogr a m m a ble Com m u n ica t ion In t er fa ce (P CI)
Bu s Cir cu it . Th er efor e, t h e power lift ga t e con t r ol
m odu le ca n gen er a t e a n d st or e it s own Dia gn ost ic
Tr ou ble Codes (DTC). Th e veh icles Body Con t r ol
Modu le (BCM) r eceives a n d su pplies m essa ges t o t h e
power lift ga t e con t r ol m odu le via t h e P CI bu s cir cu it .
A dia gn ost ic sca n t ool, su ch a s t h e DRB III! or equ iv-
a len t , is u sed t o r ea d a n d t r ou blesh oot t h ese DTCs.
Refer t o t h e Body Dia gn ost ic Ma n u a l for a com plet e
list of dia gn ost ic r ou t in es.
F or a ddit ion a l in for m a t ion , (Refer t o 8 - E LE CTRI-
CAL/P OWE R DOORS - OP E RATION). Refer t o t h e
a ppr opr ia t e wir in g in for m a t ion for com plet e cir cu it
sch em a t ic or con n ect or pin -ou t in for m a t ion .
WARNING: BE CERTAIN TO READ ALL WARNINGS

AND CAUTIONS BEFORE ATTEMPTING ANY SER-
VICE OF THE POWER LIFTGATE SYSTEM OR COM-
PONENTS.
OPERATION
Wit h t h e pu sh of a power lift ga t e open /close com -
Fig. 1 KEY FOB m a n d swit ch (key fob or over h ea d con sole m ou n t ed) a
1 - LEFT SLIDING DOOR SWITCH
sign a l is sen t ou t on t h e P r ogr a m m a ble Com m u n ica -
2 - RIGHT SLIDING DOOR SWITCH t ion In t er fa ce (P CI) Da t a Bu s cir cu it . Th is sign a l is
3 - LIFTGATE SWITCH det ect ed a t t h e Body Con t r ol Modu le (BCM). Th e
BCM t h en sen ds a sign a l ou t on t h e P CI Da t a Bu s
Th e power lift ga t e syst em h a s it s own power lift - cir cu it t o t h e power lift ga t e con t r ol m odu le. Th e
ga t e con t r ol m odu le, loca t ed on t h e veh icles left body power lift ga t e con t r ol m odu le t h en sign a ls t h e power
D-pilla r beh in d t h e t r im pa n el. Th e power lift ga t e lift ga t e m ot or t o st a r t a n open or close cycle, depen d-
gea r m ot or a ssem bly is loca t ed ju st a bove t h e con t r ol in g on wh a t posit ion t h e lift ga t e is in .
m odu le. Th e la t ch a ssem bly is loca t ed in t h e bot t om Du r in g a lift ga t e open or close cycle, if t h e power
cen t er of t h e power lift ga t e, below t h e ext er ior lift - lift ga t e m odu le det ect s su fficien t r esist a n ce t o lift ga t e
ga t e h a n dle swit ch . Th e power lift ga t e fu ll open t r a vel, su ch a s a n obst r u ct ion in t h e pa t h of t h e lift -
swit ch , en ga ge a ct u a t or, lift gea r a n d r od a r e pa r t of ga t e, t h e power lift ga t e con t r ol m odu le will im m edi-
t h e lift ga t e gea r m ot or a ssem bly. Th e pa wl a n d a t ely st op t h e lift ga t e m ovem en t a n d r ever se t r a vel
r a t ch et swit ch es a r e pa r t of t h e la t ch a ssem bly. Th e t o t h e fu ll open or closed posit ion . Th e a bilit y for t h e
pin ch sen sor s a r e loca t ed a lon g t h e r igh t a n d left power lift ga t e m odu le t o det ect r esist a n ce t o lift ga t e
sides of t h e power lift ga t e, ju st a bove t h e body lin e.
RS POWER LIFTGATE SYSTEM 8N - 3
POWER LI FT GAT E SY ST EM (Cont inue d)
t r a vel is a ccom plish ed by h a ll effect sen sor s, dr ive LIFTGATE REACHES THE SECONDARY LATCH
m ot or speed a n d pin ch sen sor s (t a pe swit ch es). CONTACT (APPROXIMATELY 1/2 INCH BEFORE
An yt im e t h e lift ga t e is open ed or closed u sin g t h e FULLY CLOSED).
power lift ga t e syst em t h e power lift ga t e con t r ol m od-
u le lea r n s fr om t h e cycle. If a r epla cem en t power lift - WARNING: NEVER ATTEMPT TO ENTER OR EXIT
ga t e com pon en t is in st a lled or a lift ga t e a dju st m en t THE VEHICLE WITH THE LIFTGATE IN MOTION.
is m a de, t h e m odu le will r elea r n t h e effor t a n d/or YOU COULD DAMAGE THE POWER LIFTGATE SYS-
t im e r equ ir ed t o open or close t h e lift ga t e. Th is lea r n TEM AND/OR COMPONENTS AND/OR CAUSE PER-
cycle ca n be per for m ed wit h a DRB III!, or equ iva - SONAL INJURY.
len t sca n t ool, or wit h a com plet e cycle of t h e lift ga t e,
u sin g a n y on e of t h e com m a n d swit ch es. (Refer t o 8 -
WARNING: NEVER STICK OBJECTS IN THE POWER
E LE CTRICAL/P OWE R DOORS - STANDARD P RO-
LIFTGATE WHEN CINCHING CLOSED. YOU COULD
CE DURE ) for det a iled in st r u ct ion s.
DAMAGE THE VEHICLE, POWER LIFTGATE SYS-
Th e power lift ga t e syst em is design ed wit h a n u m -
TEM COMPONENTS AND/OR CAUSE PERSONAL
ber of syst em in h ibit or s. Th ese in h ibit or s a r e n eces-
INJURY.
sa r y for sa fet y a n d / or fea sibilit y of t h e power
lift ga t e syst em . Th e power lift ga t e syst em in h ibit or s
a r e:
• Th e P ower Lift ga t e m a y n ot oper a t e in ext r em e DI AGN OSI S AN D T EST I N G
t em per a t u r es. Th ese ext r em e t em per a t u r es will be
a ppr oxim a t ely less t h a n -12° F (-24.4° C) or gr ea t er POWER LIFTGATE SYSTEM
t h a n 143° F (61.6° C). A ch im e/t h er m ist er a ssem bly Th e power lift ga t e syst em con t a in s m a n y com po-
in t h e r ea r ligh t ba r a ssem bly m on it or s t h e ou t side n en t s a n d m odu les. In or der t o obt a in con clu sive
t em per a t u r e. t est in g t h e P r ogr a m m a ble Com m u n ica t ion s In t er fa ce
• Th e veh icle t r a n sm ission m u st be in P a r k or (P CI) da t a bu s n et wor k a n d a ll of t h e elect r on ic m od-
Neu t r a l for t h e power lift ga t e t o st a r t a cycle. u les t h a t pr ovide in pu t s t o, or r eceive ou t pu t s fr om
• If m u lt iple obst a cles a r e det ect ed du r in g t h e t h e power lift ga t e syst em m u st be ch ecked.
sa m e power open or close cycle, t h e lift ga t e goes in t o Th e power lift ga t e syst em ca n be dia gn osed wit h
m a n u a l oper a t ion . a n a ppr opr ia t e sca n t ool, su ch a s t h e DRB III! or
• If sever e pr oblem s occu r, Dia gn ost ic Tr ou ble equ iva len t . Th e DRB III! ca n be u sed t o obser ve va r-
Codes (DTC) a r e st or ed in t h e power lift ga t e con t r ol iou s swit ch st a t u ses t h r ou gh ou t t h e power lift ga t e
m odu le. syst em t o h elp dia gn ose a n in oper a t ive swit ch or
com pon en t . Th e DRB III! ca n a lso be u sed t o a ct u a t e
POWER LIFTGATE SYSTEM CAUTIONS AND va r iou s com pon en t s t h r ou gh ou t t h e power lift ga t e
WARNINGS syst em t o h elp dia gn ose a n in oper a t ive com pon en t .
Befor e a n y t est in g of t h e power lift ga t e syst em is
WARNING: ALWAYS DISCONNECT THE BATTERY a t t em pt ed, t h e ba t t er y sh ou ld be fu lly ch a r ged, a ll
NEGATIVE CABLE BEFORE ATTEMPTING ANY bu ilt -in power lift ga t e syst em in h ibit or s r ea d a n d
POWER LIFTGATE SYSTEM SERVICE. u n der st ood, a n d a ll wir e h a r n ess a n d gr ou n d con n ec-
t ion s in spect ed a r ou n d t h e a ffect ed a r ea s on t h e veh i-
cle.
WARNING: THERE IS A SMALL AREA ON BOTH
Th e followin g a r e qu ick r efer en ce dia gn ost ic t a bles
SIDES OF THE LOWER POWER LIFTGATE WHICH
t o h elp wh en dia gn osin g a n d t est in g t h e power lift -
IS NOT PROTECTED BY PINCH SENSORS.
ga t e syst em .
EXTREME CARE MUST BE TAKEN TO PREVENT
OBJECTS FROM ENTERING THIS AREA ONCE THE
LI FT GAT E SY ST EM DI AGN OSI S

Liftgate opens unexpectedly Inoperative Power Liftgate Module or Disconnect then reconnect the battery
Body Control Module (BCM) negative cable to reset module. Cycle the
power liftgate, if the power liftgate is still
not operating properly check for loose wire
connections, refer to the appropriate
diagnostic information
Inoperative latch assembly Check for blown fuse and loose wiring
connections
Check for Diagnostic Trouble Codes

(DTCs), replace latch as necessary
Inoperative open/close command Check for shorted or inoperative switch.
switch Replace switch as necessary
Liftgate will not open from Inoperative key cylinder assembly Check for inoperative key cylinder
outside of vehicle manually assembly. Replace key cylinder as
necessary
Check link rod connections at the latch and

key cylinder assembly
Check for binds or kinks in link rod

Check for foreign matter preventing the
operation of key cylinder assembly
Replace the components as necessary
connections

operation of latch assembly
Replace latch assembly as necessary
Binding or sticking of components Check for foreign matter preventing the
operation of door
Establish location of binding
Replace the components as necessary

Liftgate will not open/close Inoperative Power Liftgate Module or Disconnect then reconnect the battery
under power BCM negative cable to reset module. Cycle the
connections

Refer to the appropriate diagnostic
information. Replace latch assembly as
necessary

Inoperative motor assembly Refer to the appropriate diagnostic
information.
Inoperative full open switch Refer to the appropriate diagnostic
information.
Binding or sticking of components Establish location of binding and replace
components as necessary
Power loss during Liftgate Low battery voltage Charge battery
operation
Inoperative Power Liftgate Module or Disconnect then reconnect the battery
BCM negative cable to reset module. Cycle the
Inoperative motor assembly Check for no drive condition
No power latching in Inoperative latch assembly Check for blown fuse and loose wiring
primary and/or secondary connections
positions

necessary
Inoperative Power Liftgate or BCM Disconnect then reconnect the battery
negative cable to reset module. Cycle the
Door seal force too high Inspect seals for damage, mis-assembly,
foreign matter or other possible obstruction
Inoperative motor assembly Check for no drive condition
Latch will not fully release Inoperative latch assembly Check for blown fuse and loose wiring
from primary position connections
Check for foreign matter or damaged

components preventing the operation of
latch assembly
necessary
Inoperative outside handle switch Refer to the appropriate diagnostic
information. Replace switch as necessary

Inoperative Power Liftgate Module or Disconnect then reconnect the battery
BCM negative cable to reset module. Cycle the
Key fob, Outside Handle or Blown Fuse Check fuse and replace
overhead console switches
do not power operate
liftgate
Battery voltage low Charge or replace battery in key fob or
vehicle
Inoperative latch assembly Check for foreign matter preventing the
Check wire connection

Pawl and/or ratchet switch inoperative.
Replace latch as necessary
Inoperative BCM Check electrical connections

information for additional checks
Replace BCM as necessary
Inoperative key fob Verify inoperative key fob by trying other
key fob functions
Replace key fob battery

Reprogram key fob
Replace key fob as necessary
Inoperative Power Liftgate Module Disconnect then reconnect the battery
negative cable to reset module. Cycle the
Inoperative liftgate motor assembly Check for foreign matter preventing the
operation of gear motor assembly
Check wire connections

Motor clutch does not engage. Replace
liftgate motor assembly
Full open switch inoperative, replace switch
as necessary
Liftgate does not stay open Inoperative liftgate prop rods Check for broken attachments. Replace
prop rods as necessary
High inside/outside opening Inoperative liftgate prop rods Check for broken attachments. Replace
effort prop rods as necessary

Gear motor did not disengage Refer to the appropriate diagnostic
information. Replace components as
necessary
Liftgate continues to cinch Inoperative latch assembly Check for blown fuse and loose wiring
closed during power mode connections

information. Replace components as
necessary
Inoperative Power Liftgate Module or Disconnect then reconnect battery to reset
BCM module, function liftgate, if no function
exists check for loose wire connections,
see Body Diagnostic Manual for detailed
procedures
Liftgate continues to open Inoperative Power Liftgate Module or Disconnect then reconnect the battery
during power mode BCM negative cable to reset module. Cycle the
(runaway motor) power liftgate, if the power liftgate is still
Inoperative full open switch Check wire connections
Replace switch, if necessary

Inoperative motor assembly Check for continuous drive condition
Liftgate opens very slowly Inoperative liftgate motor assembly Check wire connections
Replace motor assembly as necessary

Inoperative liftgate prop rods Replace prop rods as necessary
Grade of vehicle too steep for power Operate liftgate manually
operation
Squeaks, Noises and rattles Foreign material in door Remove foreign material
compartment
Loose components Check and tighten loose components as
necessary
STAN DARD PROCEDU RE CH I M E/T H ERM I ST OR

LIFTGATE ADJUSTMENT DESCRIPTION
In or der for t h e power lift ga t e syst em t o fu n ct ion
pr oper ly t h e lift ga t e m u st m ove fr eely a n d sm oot h ly.
Th e power lift ga t e syst em ca n a ccom m oda t e for som e
m in or ch a n ges in t h e effor t r equ ir ed t o m ove t h e lift -
ga t e. H owever, in ext r em e con dit ion s t h e lift ga t e m a y
n eed t o be m ech a n ica lly a dju st ed for pr oper fit a n d
fin ish . (Refer t o 23 - BODY/DE CKLID/H ATCH /LIF T-
GATE /TAILGATE /LIF TGATE - INSTALLATION) for
det a iled in st r u ct ion s.
If a pr oblem exist s wit h t h e power lift ga t e a n d it is
su spect ed t o be ext r em e effor t , ch eck t h e lift ga t e pr op
r ods a n d h in ges for fr ee m ovem en t .
NOTE: Routine application of Mopar MP-50" or

equivalent on the chrome prop rod shafts and lift-
gate latch and hinges will help keep the liftgate in
good working order.
POWER LIFTGATE LEARN CYCLE

An y t im e a power lift ga t e com pon en t is r em oved, Fig. 2 REAR LIGHT BAR
r epla ced or a lift ga t e a dju st m en t is per for m ed a lea r n 1 - CHIME / THERMISTOR
cycle m u st be per for m ed. Th is lea r n cycle en a bles t h e 2 - ELECTRIC RELEASE HANDLE SWITCH
3 - LICENSE PLATE LAMPS
power lift ga t e con t r ol m odu le t o lea r n or r elea r n
in for m a t ion (t r a vel lim it s, r esist a n ce t o door t r a vel, Th e ch im e/t h er m ist or a ssem bly is a sm a ll ca pa cit or
et c.) wh ich a llows it t o per for m pr oper ly a n d sa fely. sh a ped elect r ica l com pon en t m ou n t ed t o t h e r ea r
P er for m t h e followin g t o com plet e a power lift ga t e licen se pla t e la m p h ou sin g a ssem bly (F ig. 2) , loca t ed
lea r n cycle: ju st a bove t h e licen se pla t e. Th e ch im e por t ion of t h e
(1) Obt a in a DRBIII!, or equ iva len t sca n t ool. a ssem bly con t r ols t h e a u dible ch im e sou n d h ea r d a t
(2) Con n ect t h e sca n t ool t o t h e veh icle a n d ch eck t h e r ea r of t h e veh icle wh en t h e power lift ga t e is in
for a n y power lift ga t e syst em st or ed Dia gn ost ic Tr ou - m ot ion . Th e t h er m ist or por t ion of t h e a ssem bly is a
ble Codes (DTCs), cor r ect a n d er a se a n y st or ed t em per a t u r e sen sor, u sed by t h e power lift ga t e con -
DTCs. t r ol m odu le. Th e ch im e/t h er m ist or a ssem bly is a ser-
(3) Usin g t h e sca n t ool, Go in t o Test Rou t in e Men u vicea ble com pon en t .
a n d select t h e power open com m a n d.
(4) Select t h e power close com m a n d. OPERATION
(5) Th e lift ga t e lea r n cycle is com plet e. Th e ch im e/t h er m ist or a ssem bly per for m s t wo dif-
If a DRBIII! or equ iva len t sca n t ool is n ot a va il- fer en t fu n ct ion s for t h e power lift ga t e syst em . F ir st ,
a ble, t h e lea r n cycle ca n be per for m ed by a ct u a t in g t h e ch im e por t ion pr ovides a n a u dible ch im e sou n d
t h e lift ga t e u sin g a n y of t h e n or m a l com m a n d wh ich is con t r olled by t h e power lift ga t e con t r ol m od-
swit ch es. Be cer t a in t o cycle t h e lift ga t e t h r ou gh a u le. Th e ch im e/t h er m ist or a ssem bly is h a r dwir ed t o
com plet e open a n d close cycle befor e r et u r n in g t h e t h e power lift ga t e con t r ol m odu le. Secon d t h e t h er-
veh icle t o ser vice. m ist or pr ovides a ou t side t em per a t u r e r ea din g by
wa y of a r esist a n ce r ea din g su pplied t o t h e power
NOTE: If the power liftgate will not complete a full
lift ga t e con t r ol m odu le. As t em per a t u r e in cr ea ses t h e
cycle a problem exists with the power liftgate sys-
r esist a n ce r ea din g in cr ea ses, a s t em per a t u r e
tem. (Refer to 8 - ELECTRICAL/POWER DOORS -
decr ea ses t h e r esist a n ce r ea din g decr ea ses.
DIAGNOSIS AND TESTING).
REMOVAL
ca ble.
CH I M E/T H ERM I ST OR (Cont inue d)
(2) Rem ove t h e r ea r ligh t ba r a ssem bly fr om t h e OPERATION
veh icle. (Refer t o 8 - E LE CTRICAL/P OWE R DOORS/ Th e en ga ge a ct u a t or s n or m a l posit ion is disen -
SWITCH - RE MOVAL) for t h e pr ocedu r e. ga ged. Wh en a power lift ga t e open or close com m a n d
(3) Gr a sp t h e ligh t ba r a t it s sides n ext t o t h er- is gen er a t ed fr om a n y of t h e com m a n d swit ch es, t h e
m ist or /ch im e a ssem bly a n d gen t ly pu ll t h e t wo sides power lift ga t e con t r ol m odu le sign a ls t h e en ga ge
of t h e ligh t ba r a pa r t u n t il t h e t h er m ist or /ch im e a ct u a t or t o m ove it s lever t o t h e en ga ged posit ion .
a ssem bly ca n be r em oved. Th is en ga ges t h e gea r m ot or t o t h e lift gea r, so wh en
t h e m ot or t u r n s t h e lift ga t e m oves u pwa r d or down -
INSTALLATION wa r ds depen din g on it s cu r r en t posit ion .
(1) Gen t ly pu ll t h e t wo sides of t h e ligh t ba r a pa r t Du r in g a m a n u a l lift ga t e open or close cycle t h e
u n t il t h e t h er m ist or /ch im e a ssem bly ca n be in st a lled. en ga ge a ct u a t or is disen ga ged, a llowin g u n r est r ict ed
(2) In st a ll t h e r ea r ligh t ba r a ssem bly on t h e veh i- lift ga t e m ovem en t .
cle. (Refer t o 8 - E LE CTRICAL/P OWE R DOORS/
SWITCH - INSTALLATION) for t h e pr ocedu r e. REMOVAL
(3) Con n ect t h e ba t t er y n ega t ive ca ble. (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
(2) Rem ove t h e left r ea r D-pilla r t r im fr om t h e
EN GAGE ACT U AT OR veh icle, (Refer t o 23 - BODY/INTE RIOR/LE F T
D-P ILLAR TRIM PANE L - RE MOVAL).
DESCRIPTION (3) Ma n u a lly en ga ge t h e a ct u a t or lin k r od, t h is
m u st be don e t o a ccess on e of t h e en ga ge a ct u a t or
r et a in in g scr ews.
(4) Rem ove t h e t wo en ga ge a ct u a t or r et a in in g
scr ews (F ig. 4).
Fig. 3 LIFTGATE GEAR MOTOR ASSEMBLY

1 - TRANSVERSE BRACKET
2 - ENGAGE ACTUATOR
3 - LIFT GEAR AND ROD ASSEMBLY
4 - LIFTGATE MOTOR
Th e 12 volt en ga ge a ct u a t or (F ig. 3) pr ovides t h e 1 - ENGAGE ACTUATOR RETAINING SCREWS
en ga gem en t a n d disen ga gem en t of t h e lift ga t e gea r 2 - LIFT GEAR RETAINING BOLTS
m ot or t o t h e lift gea r by wa y of a n over cen t er lin k,
a ct iva t ed by a lever. (5) Discon n ect t h e en ga ge a ct u a t or elect r ica l con -
Th e en ga ge a ct u a t or is a ser vicea ble com pon en t n ect or a n d r em ove t h e en ga ge a ct u a t or fr om t h e
a n d ca n n ot be r epa ir ed, if fou n d t o be in oper a t ive it veh icle.
EN GAGE ACT U AT OR (Cont inue d)
INSTALLATION (4) Loca t e t h e t wo wir es goin g t o t h e ext er ior h a n -

(1) P osit ion t h e en ga ge a ct u a t or in t h e veh icle a n d dle swit ch . Cu t t h e t ie st r a p a n d t r a ce t h e wir es t o
con n ect t h e en ga ge a ct u a t or elect r ica l con n ect or. t h e la r ge elect r ica l con n ect or a n d ba ck t h e wir es ou t
(2) In st a ll t h e t wo en ga ge a ct u a t or r et a in in g of t h e la r ge con n ect or a n d t h r ou gh t h e gr om m et .
scr ews. Ta k e c a re to m a rk th e lo c a tio n o f th e w ire te r-
(3) Ma n u a lly disen ga ge t h e a ct u a t or. m in a ls in re la tio n to th e la rg e c o n n e c to r s o
(4) In st a ll t h e left r ea r D-pilla r t r im on t h e veh i- th a t th e y a re p o s itio n e d in th e a p p ro p ria te c a v -
cle, (Refer t o 23 - BODY/INTE RIOR/LE F T D-P ILLAR itie s u p o n s w itc h in s ta lla tio n .
TRIM PANE L - INSTALLATION).
er a se a n y power lift ga t e con t r ol m odu le dia gn ost ic
t r ou ble codes.
(7) Ver ify power lift ga t e syst em a n d en ga ge a ct u a -
t or oper a t ion . Cycle t h e power lift ga t e t h r ou gh on e
com plet e open a n d close cycle.
EX T ERI OR H AN DLE SWI T CH

DESCRIPTION
Th e ext er ior h a n dle swit ch is a n elect r on ic r elea se
swit ch m ou n t ed t o t h e r ea r licen se pla t e la m p h ou s-
in g a ssem bly, loca t ed ju st a bove t h e licen se pla t e.
Th is swit ch con t r ols t h e power lift ga t e r elea se fu n c-
t ion a n d is a lso ca pa ble of r ever sin g t h e power lift -
ga t e wh en it is in m ot ion . A fu ll power open cycle
ca n n ot be per for m ed u sin g t h is swit ch , on ly on e of Fig. 5 REAR LIGHT BAR
t h e power open com m a n d swit ch es (key fob a n d over- 1 - CHIME / THERMISTOR
h ea d con sole m ou n t ed) ca n be u sed t o per for m a fu ll 2 - ELECTRIC RELEASE HANDLE SWITCH
power open cycle. Th e ext er ior h a n dle swit ch is a ser- 3 - LICENSE PLATE LAMPS
vicea ble com pon en t .
(5) Depr ess t h e t wo ext er ior h a n dle swit ch r et a in -
OPERATION in g t a bs a n d r oll t h e swit ch ou t of t h e ligh t ba r
Wh en t h e ext er ior h a n dle swit ch is depr essed, wit h
t h e lift ga t e in t h e closed posit ion , a m essa ge is sen t
t o t h e Body Con t r ol Modu le (BCM). Th e BCM t h en INSTALLATION
sen ds a sign a l t o t h e power lift ga t e con t r ol m odu le (1) In st a ll t h e h a n dle swit ch in t h e ligh t ba r
via t h e P r ogr a m m a ble Com m u n ica t ion In t er fa ce a ssem bly (F ig. 6).
(P CI) da t a bu s cir cu it . Th e power lift ga t e con t r ol (2) Loca t e t h e t wo wir es goin g t o t h e ext er ior h a n -
m odu le t h en sen ds a sign a l t o t h e power la t ch dle swit ch . In st a ll t h e wir es t h r ou gh t h e gr om m et
m ou n t ed a ct u a t or, wh ich m oves t h e lift ga t e fr om t h e a n d in t h e la r ge con n ect or. Secu r e wit h a t ie st r a p.
pr im a r y closed a n d la t ch ed posit ion t o t h e open a n d
NOTE: Be certain wires are reinstalled in the correct
m ova ble posit ion . If t h e lift ga t e is n ot pu lled open
wire cavities. Failure to do so could result in dam-
on ce t h e la t ch r elea ses wit h in a few secon ds, t h e
age to the handle switch. Refer to the appropriate
la t ch will cin ch closed a ga in .
wiring information for complete circuit schematic or
connector pin-out information.
REMOVAL
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive (3) In st a ll t h e r ea r ligh t ba r.
ca ble. (4) In st a ll t h e lift ga t e t r im pa n el, (Refer t o 23 -
(2) Open t h e lift ga t e a n d r em ove t h e lift ga t e t r im BODY/DE CKLID/H ATCH /LIF TGATE /TAILGATE /
pa n el, (Refer t o 23 - BODY/DE CKLID/H ATCH /LIF T- TRIM PANE L - INSTALLATION).
GATE /TAILGATE /TRIM PANE L - RE MOVAL). (5) Con n ect t h e ba t t er y n ega t ive ca ble.
(3) Rem ove t h e r ea r la m p ba r a ssem bly fr om t h e (6) Usin g a n a ppr opr ia t e sca n t ool, ch eck a n y
veh icle. er a se a n y power lift ga t e con t r ol m odu le dia gn ost ic
t r ou ble codes.
EX T ERI OR H AN DLE SWI T CH (Cont inue d)
Fig. 6 REAR LIGHT BAR

1 - CHIME / THERMISTOR
2 - ELECTRIC RELEASE HANDLE SWITCH
3 - LICENSE PLATE LAMPS
Fig. 7 FULL OPEN SWITCH LOCATION
(7) Ver ify power lift ga t e syst em a n d h a n dle swit ch 1 - FULL OPEN SWITCH
2 - GEAR MOTOR ASSEMBLY RETAINING BOLT (1 OF 3)
oper a t ion . Cycle t h e power lift ga t e t h r ou gh on e com -
plet e open a n d close cycle, t h is will a llow t h e power (3) Cu t t h e t wo wir es lea din g t o t h e fu ll open
lift ga t e con t r ol m odu le t o r elea r n it s cycle wit h t h e swit ch or ba ck t h e wir es ou t of t h e elect r ica l con n ec-
n ew com pon en t s. t or.
(4) Rem ove t h e fu ll open swit ch r et a in in g scr ew
a n d r em ove t h e fu ll open swit ch fr om t h e gea r m ot or
FU LL OPEN SWI T CH h ou sin g a ssem bly.
DESCRIPTION INSTALLATION
Th e fu ll open swit ch is loca t ed on t h e gea r m ot or (1) P er for m a wir in g r epa ir on t h e fu ll open swit ch
h ou sin g (F ig. 7) a n d is u sed t o sign a l t h e power lift - wir es followin g t h e a ppr oved pr ocedu r e in t h e Wir in g
ga t e con t r ol m odu le wh en t h e power lift ga t e is in t h e sect ion of t h e ser vice m a n u a l. Or in st a ll n ew t er m i-
fu ll open posit ion . Two wir es a r e u sed fr om t h e fu ll n a ls on t h e wir e en ds a n d r ein st a ll in t h e m a in lift -
open swit ch con t a ct s t o t h e gea r m ot or a ssem blies ga t e m ot or elect r ica l con n ect or.
m a in elect r ica l con n ect or. Th e fu ll open swit ch is a (2) P osit ion a n d in st a ll t h e fu ll open swit ch r et a in -
ser vicea ble com pon en t . in g scr ew.
(3) In st a ll t h e power lift ga t e lift gea r a n d lin k r od
OPERATION a ssem bly. (Refer t o 8 - E LE CTRICAL/P OWE R
Wh en t h e power lift ga t e r ea ch es t h e fu ll open posi- DOORS/CONTROL ROD - INSTALLATION)
t ion , t h e gea r m ot or h ou sin g m ou n t ed fu ll open (4) Con n ect t h e ba t t er y n ega t ive ca ble.
swit ch elect r ica l con t a ct s close. Th is sen ds a gr ou n d (5) Usin g a n a ppr opr ia t e sca n t ool, ch eck a n y
sign a l t o t h e power lift ga t e con t r ol m odu le, t ellin g er a se a n y power lift ga t e con t r ol m odu le dia gn ost ic
t h e m odu le t h a t t h e lift ga t e h a s r ea ch ed t h e fu ll open t r ou ble codes.
posit ion . (6) Ver ify power lift ga t e syst em a n d fu ll open
swit ch oper a t ion . Cycle t h e power lift ga t e t h r ou gh
REMOVAL on e com plet e open a n d close cycle, t h is will a llow t h e
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive power lift ga t e con t r ol m odu le t o r elea r n it s cycle wit h
ca ble. t h e n ew com pon en t s.
(2) Rem ove t h e lift gea r a n d lin k r od a ssem bly
fr om t h e veh icle(Refer t o 8 - E LE CTRICAL/P OWE R
DOORS/CONTROL ROD - RE MOVAL).
LAT CH m a r y closed a n d la t ch ed posit ion . On t h e power

cin ch /r elea se la t ch a n d t h e power r elea se on ly la t ch ,
t h e a ct u a t or r elea ses t h e lift ga t e fr om t h e pr im a r y
DESCRIPTION
closed a n d la t ch ed posit ion t o t h e fu lly u n la t ch ed a n d
m ova ble posit ion .
REMOVAL
ca ble.
(2) Open t h e lift ga t e a n d r em ove t h e lift ga t e t r im
pa n el, (Refer t o 23 - BODY/DE CKLID/H ATCH /LIF T-
GATE /TAILGATE /TRIM PANE L - RE MOVAL).
(3) Discon n ect t h e power la t ch elect r ica l con n ect or
(F ig. 9).
Fig. 8 POWER LATCH ORIENTATION

1 - LATCH & ACTUATOR ASSEMBLY
2 - LATCH ELECTRICAL CONNECTOR
3 - LOCK CYLINDER LINK ROD
4 - LIFTGATE LOCK CYLINDER
Th e power cin ch /r elea se la t ch per for m s t h e sa m e

fea t u r es a s a m a n u a l lift ga t e la t ch a s well a s t h e
power cin ch a n d / or r elea se ca pa bilit y. A secon d t ype
of power la t ch ca n a lso be fou n d on som e veh icles,
t h is la t ch is design ed t o per for m a power r elea se
on ly. Th e power cin ch a n d r elea se ca pa bilit y is Fig. 9 POWER LATCH ORIENTATION
a ccom plish ed by a n a ct u a t or m ou n t ed t o t h e lea din g
edge of t h e la t ch a ssem bly. Th e la t ch is loca t ed in t h e 2 - LATCH ELECTRICAL CONNECTOR
lower cen t er of t h e power lift ga t e a ssem bly (F ig. 8) 3 - LOCK CYLINDER LINK ROD
a n d con t a in s in t egr a l pa wl a n d r a t ch et swit ch es. Th e 4 - LIFTGATE LOCK CYLINDER
r a t ch et swit ch a lso a ct s a s a lift ga t e a ja r swit ch . Th e
power la t ch a ssem bly ca n be ser viced a s a com plet e (4) Rem ove t h e power la t ch r et a in in g bolt s.
a ssem bly, la t ch wit h ou t a ct u a t or or ju st t h e a ct u a t or. (5) Discon n ect t h e lift ga t e lock cylin der lin k r od
(F ig. 9) fr om t h e key cylin der or la t ch a ssem bly. To
OPERATION discon n ect fr om la t ch , r ot a t e t h e pla st ic r et a in in g clip
90 ° t o u n sn a p clip fr om lin kr od. Th en pu ll lin k r od
On t h e power cin ch /r elea se la t ch , t h e la t ch
st r a igh t ou t of la t ch a r m .
m ou n t ed a ct u a t or pr ovides t h e t or qu e r equ ir ed t o
(6) Rem ove t h e power la t ch fr om t h e veh icle.
close t h e power lift ga t e fr om t h e secon da r y t o t h e pr i-
LAT CH (Cont inue d)
INSTALLATION LAT CH ACT U AT OR

(1) P osit ion t h e power la t ch in t h e veh icle.
(2) Con n ect t h e lift ga t e lock cylin der lin k r od (F ig. DESCRIPTION
10) on t h e cin ch la t ch a ssem bly. Rot a t e t h e pla st ic
r et a in in g clip 90 ° t o lock r et a in in g clip on t o t h e lin k
r od.

Fig. 10 POWER LATCH ORIENTATION 3 - LOCK CYLINDER LINK ROD
3 - LOCK CYLINDER LINK ROD Th e power cin ch a n d/or power r elea se la t ch (F ig.
4 - LIFTGATE LOCK CYLINDER 11) is m a de possible by a la t ch a ct u a t or a t t a ch ed t o
t h e lea din g edge of t h e power la t ch a ssem bly. Th is 12
(3) Con n ect t h e lin k r od on t h e lock cylin der. volt la t ch a ct u a t or con t a in s a sm a ll dr ive gea r t h a t
(4) In st a ll t h r ee n ew power la t ch r et a in in g bolt s. m esh es wit h t h e la t ch a ssem blies in t er n a l gea r s t o
Tor qu e t o 10 N·m (90 in . lbs.). per for m t h e power cin ch close / power r elea se oper a -
(5) Con n ect t h e power la t ch elect r ica l con n ect or t ion s. (Refer t o 8 - E LE CTRICAL/P OWE R DOORS/
a n d secu r e pu sh pin r et a in er s. LATCH - DE SCRIP TION) for a ddit ion a l in for m a t ion .
(6) Con n ect t h e ba t t er y n ega t ive ca ble. Th e power cin ch /r elea se a ct u a t or is ser vicea ble com -
(7) Usin g a n a ppr opr ia t e sca n t ool, ch eck a n d pon en t .
t r ou ble codes r ela t ed t o t h e power la t ch . OPERATION
(8) Ver ify power lift ga t e syst em a n d power cin ch / Du r in g a power close cycle, t h e power cin ch a ct u a -
r elea se la t ch oper a t ion . Cycle t h e power lift ga t e t or pr ovides t h e t or qu e r equ ir ed t o close t h e power
t h r ou gh on e com plet e open a n d close cycle, t h is will lift ga t e fr om t h e secon da r y t o t h e pr im a r y closed a n d
a llow t h e power lift ga t e con t r ol m odu le t o r elea r n it s la t ch ed posit ion . Du r in g a power open cycle, t h e
cycle wit h t h e n ew com pon en t s. power r elea se a ct u a t or r elea ses t h e lift ga t e fr om t h e
(9) Ver ify power lift ga t e m a n u a l oper a t ion . Usin g pr im a r y closed a n d la t ch ed posit ion t o t h e fu lly
lift ga t e key r ot a t e t h e lock cylin der t o ver ify door u n la t ch ed a n d m ova ble posit ion .
oper a t ion . P u ll door open u sin g ext er ior lift ga t e h a n -
dle / swit ch . REMOVAL
(10) In st a ll t h e lift ga t e t r im pa n el, (Refer t o 23 - (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
BODY/DE CKLID/H ATCH /LIF TGATE /TAILGATE / ca ble.
LAT CH ACT U AT OR (Cont inue d)
(2) Open t h e lift ga t e a n d r em ove t h e lower lift ga t e NOTE: Be certain wires are reinstalled in the correct
t r im pa n el. (Refer t o 23 - BODY/DE CKLID/H ATCH / wire cavities. Failure to do so could result in dam-
LIF TGATE /TAILGATE /TRIM PANE L - RE MOVAL). age to the latch actuator. Refer to the appropriate
(3) Discon n ect t h e power la t ch elect r ica l con n ect or wiring information for complete circuit schematic or
(F ig. 12). connector pin-out information.
(4) Rem ove t h e t h r ee la t ch r et a in in g bolt s.
(5) Gr a b t h e la t ch a ssem bly a n d u n h ook t h e key (4) Secu r e t h e m a in con n ect or r et a in in g pu sh pin s
cylin der lin k r od fr om t h e key cylin der (F ig. 12). on t h e la t ch a ct u a t or h ou sin g.

Fig. 12 POWER LATCH ORIENTATION 2 - LATCH ELECTRICAL CONNECTOR
1 - LATCH & ACTUATOR ASSEMBLY 4 - LIFTGATE LOCK CYLINDER
(5) Gr a b t h e la t ch a ssem bly a n d h ook t h e key cyl-
in der lin k r od on t h e key cylin der (F ig. 13).
(6) P la ce t h e la t ch a ssem bly on a ben ch a n d loca t e (6) P osit ion t h e la t ch a n d in st a ll t h r ee n ew la t ch
t h e t h r ee wir es lea din g fr om t h e a ct u a t or por t ion of r et a in in g bolt s. Tor qu e t o 10 N·m (90 in . lbs.).
t h e la t ch a ssem bly. (7) Con n ect t h e power la t ch elect r ica l con n ect or
(7) Disen ga ge t h e m a in con n ect or r et a in in g pu sh (F ig. 13).
pin s fr om t h e la t ch a ct u a t or h ou sin g. (8) In st a ll t h e lower lift ga t e t r im pa n el, (Refer t o
(8) Ba ck t h e t h r ee wir es ou t of t h e m a in la t ch elec- 23 - BODY/DE CKLID/H ATCH /LIF TGATE /TAIL-
t r ica l con n ect or. GATE /TRIM PANE L - INSTALLATION).
(9) F lip t h e la t ch a ssem bly over a n d r em ove t h e (9) Con n ect t h e ba t t er y n ega t ive ca ble.
la t ch a ct u a t or r et a in in g scr ew(s). (10) Usin g a n a ppr opr ia t e sca n t ool, ch eck a n d
(10) Rem ove t h e la t ch a ct u a t or fr om t h e la t ch er a se a n y power lift ga t e con t r ol m odu le dia gn ost ic
a ssem bly. t r ou ble codes r ela t ed t o t h e power la t ch .
(11) Ver ify power lift ga t e syst em a n d power cin ch /
INSTALLATION r elea se la t ch oper a t ion . Cycle t h e power lift ga t e
(1) In st a ll t h e la t ch a ct u a t or on t o t h e la t ch a ssem - t h r ou gh on e com plet e open a n d close cycle, t h is will
bly. a llow t h e power lift ga t e con t r ol m odu le t o r elea r n it s
(2) In st a ll t h e t h r ee la t ch a ct u a t or r et a in in g cycle wit h t h e n ew com pon en t s.
scr ews. (12) Ver ify power lift ga t e m a n u a l oper a t ion . Usin g
(3) In st a ll t h e t h r ee wir es in t h e m a in la t ch elec- lift ga t e key r ot a t e t h e lock cylin der t o ver ify door
t r ica l con n ect or. oper a t ion . P u ll door open u sin g ext er ior lift ga t e h a n -
dle / swit ch .
LI FT GAT E M OT OR m ot or a ssem bly, wh ich m oves t h e lift ga t e in t o t h e

open posit ion . Th e lift ga t e m ot or pr ovides t h e t or qu e
a n d power t o m ove t h e door t o it s fu ll open or closed
DESCRIPTION
posit ion (Refer t o 8 - E LE CTRICAL/P OWE R DOORS -
OP E RATION) for a ddit ion a l in for m a t ion .
REMOVAL
Th e power lift ga t e gea r /m ot or a ssem bly is ser viced
in t wo wa ys: t h e com plet e gea r /m ot or a ssem bly, or
t h e m ot or, a lu m in u m h ou sin g, dr ive gea r s a n d wir e
h a r n ess a ssem bly. To per for m t h is ser vice, u se t h e
followin g pr ocedu r e t o r em ove t h e gea r /m ot or a ssem -
bly fr om t h e veh icle. Th en r efer t o t h e ot h er pr oce-
du r es ca lled ou t in t h is sect ion t o t r a n sfer t h e
r em a in in g com pon en t s (en ga ge a ct u a t or, fu ll open
swit ch , t r a n sver se br a cket a n d lift gea r a n d r od) t o
t h e r epla cem en t gea r /m ot or a ssem bly.
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive ca ble.
(2) Rem ove t h e left r ea r D-pilla r t r im pa n el fr om
t h e veh icle, (Refer t o 23 - BODY/INTE RIOR/LE F T
(3) Discon n ect t h e wir e h a r n ess con n ect or fr om t h e
m ot or a ssem bly (F ig. 15).
Fig. 14 POWER LIFTGATE COMPONENTS

1 - POWER LIFTGATE GEAR MOTOR/ASSEMBLY
2 - POWER LIFTGATE CONTROL MODULE
3 - ELECTRICAL GROUND LOCATION
Th e gea r m ot or a ssem bly (F ig. 14) con sist s of a DC

m ot or, h a ll effect sen sor, en ga ge a ct u a t or, fu ll open
swit ch , lift gea r, a lu m in u m h ou sin g, dr ive gea r s a n d
wir e h a r n ess. Th e gea r s a n d m ot or por t ion of t h e
a ssem bly pr ovides t h e power a n d t or qu e r equ ir ed t o
open or close t h e lift ga t e. Th e h a ll effect sen sor is u sed
t o pr ovide t h e lift ga t e con t r ol m odu le wit h a speed r ea d-
in g, wh ich is u sed t o m on it or t h e r esist a n ce of lift ga t e
t r a vel. Th is speed r ea din g a lso a llows t h e power lift ga t e
con t r ol m odu le t o det ect obst r u ct ion s a n d m ove t h e lift -
ga t e a ccor din gly. Th e en ga ge a ct u a t or is u sed t o t oggle
bet ween power open /close m ode a n d fu ll m a n u a l m ode
wh en desir ed. Th e fu ll open swit ch is u sed t o let t h e
power lift ga t e con t r ol m odu le kn ow wh en t h e lift ga t e is
a ppr oa ch in g t h e fu ll open posit ion .
Ser vicea ble com pon en t s of t h e power lift ga t e gea r /m o- Fig. 15 POWER LIFTGATE COMPONENTS
t or a ssem bly a r e t h e com plet e gea r /m ot or a ssem bly, 1 - POWER LIFTGATE GEAR MOTOR/ASSEMBLY
m ot or a n d wir e h a r n ess, lift gea r a n d con t r ol r od, 2 - POWER LIFTGATE CONTROL MODULE
en ga ge a ct u a t or, fu ll open swit ch a n d t h e t r a n sver se 3 - ELECTRICAL GROUND LOCATION
br a cket .
(4) Rem ove t h e t wo bolt s fr om t h e m ot or h ou sin g
OPERATION a n d t h e on e bolt fr om t h e t r a n sver se m ou n t br a cket .
(5) Gr a b t h e lift ga t e m ot or a ssem bly a n d lift
Wit h t h e pu sh of a power lift ga t e com m a n d swit ch
u pwa r d a n d ou t t o u n h ook t h e m ot or a ssem bly fr om
(lift ga t e closed), t h e power lift ga t e con t r ol m odu le
t h e D-pilla r.
will sign a l t h e la t ch a ssem bly t o r elea se t h e lift ga t e
(6) Rem ove t h e lift ga t e m ot or a ssem bly fr om t h e
fr om it s pr im a r y closed a n d la t ch ed posit ion t o t h e
veh icle.
r elea sed a n d m ova ble posit ion . Th e lift ga t e m ot or-
m ou n t ed en ga ge a ct u a t or t h en en ga ges t h e lift ga t e
LI FT GAT E M OT OR (Cont inue d)
INSTALLATION in g t h e D-pilla r t r im (F ig. 16). Th e lift gea r pr ovides

(1) Usin g t h e m ot or h ou sin g t a b, h ook t h e lift ga t e t h e lever a ge t o m ove t h e lift ga t e fr om t h e closed t o
m ot or a ssem bly on t h e D-pilla r. t h e open posit ion . Th e lift gea r a t t a ch es t o a bea r in g
(2) In st a ll t h e t h r ee m ot or a ssem bly r et a in in g on t h e gea r m ot or a ssem bly wit h fou r bolt s. On t h e
bolt s. Tor qu e t h e t wo r ea r m ost bolt s fir st t o 9.5 N·m ou t boa r d side of t h e lift gea r a r e r ivet ed on t eet h ,
(85 in . lbs.). Tor qu e t h e r em a in in g bolt n ext t o t h e wh ich m esh wit h t h e gea r m ot or a ssem bly dr ive
win dow a ct u a t or t o 9.5 N·m (85 in . lbs.). gea r s du r in g a open or close oper a t ion . Th e r od
(3) Con n ect t h e lift ga t e m ot or a ssem bly elect r ica l a ssem bly is a st eel sh a ft , equ ipped wit h t wo sph er i-
con n ect or. ca l r od en ds wh ich a t t a ch es t h e lift gea r t o t h e lift -
(4) In st a ll t h e D-pilla r t r im pa n el on t h e veh icle, ga t e. Th e lift gea r a n d r od a ssem bly a r e ser vicea ble
(Refer t o 23 - BODY/INTE RIOR/LE F T D-P ILLAR com pon en t s.
(5) Con n ect t h e ba t t er y n ega t ive ca ble. OPERATION
(6) Usin g a n a ppr opr ia t e sca n t ool, ch eck a n y On e en d of t h e r od a ssem bly is a t t a ch ed t o t h e lift -
er a se a n y power lift ga t e con t r ol m odu le dia gn ost ic ga t e, t h e ot h er a t t a ch ed t o t h e lift gea r. Wh en t h e lift
t r ou ble codes r ela t ed t o t h e door m ot or a ssem bly. gea r is dr iven by t h e gea r m ot or a ssem bly t h e lift -
(7) Ver ify power lift ga t e syst em oper a t ion . Cycle ga t e is m oved t o t h e open or closed posit ion .
t h e power lift ga t e t h r ou gh on e com plet e open a n d
close cycle, t h is will a llow t h e power lift ga t e con t r ol REMOVAL
m odu le t o r elea r n it s cycle wit h t h e n ew com pon en t s. (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble.
(2) Rem ove t h e left r ea r D-pilla r t r im pa n el fr om
LI FT GEAR & LI N K ROD t h e veh icle, (Refer t o 23 - BODY/INTE RIOR/LE F T
DESCRIPTION (3) Rem ove t h e lift gea r r et a in in g bolt s (F ig. 17).
Fig. 16 LIFTGATE GEAR/MOTOR ASSEMBLY Fig. 17 LIFTGATE GEAR MOTOR ASSEMBLY

1 - TRANSVERSE BRACKET 1 - ENGAGE ACTUATOR RETAINING SCREWS
2 - ENGAGE ACTUATOR 2 - LIFT GEAR RETAINING BOLTS
3 - LIFT GEAR AND ROD ASSEMBLY
4 - LIFTGATE MOTOR (4) Rem ove t h e lift gea r a n d r od fr om t h e veh icle.
Th e lift gea r a n d r od a ssem bly a r e loca t ed in t h e
left r ea r of t h e veh icle a n d a r e visible wit h ou t r em ov-
LI FT GEAR & LI N K ROD (Cont inue d)
INSTALLATION PI N CH SEN SOR

(1) P osit ion t h e lift gea r a n d r od a ssem bly a n d
in st a ll t h e r et a in in g bolt s (F ig. 18). Tor qu e t h e bolt s DESCRIPTION
t o 8 N·m (71 in . lbs.).
Fig. 19 PINCH SENSOR LOCATION

Fig. 18 LIFTGATE GEAR MOTOR ASSEMBLY 1 - LIFTGATE
1 - ENGAGE ACTUATOR RETAINING SCREWS 2 - PINCH SENSOR ASSEMBLY
2 - LIFT GEAR RETAINING BOLTS 3 - LIFTGATE PROP ROD
4 - PINCH SENSOR WIRE HARNESS CONNECTOR
5 - PINCH SENSOR WIRE HARNESS
(2) In st a ll t h e D-pilla r t r im pa n el on t h e veh icle,
P in ch sen sor s a r e loca t ed on ea ch side of t h e lift -
ga t e (F ig. 19). Th ese sen sor s look like wea t h er-st r ips,
h owever t h ey con sist of pieces of elect r ica lly con du c-
(4) Usin g a n a ppr opr ia t e sca n t ool, ch eck a n y
t ive r u bber (t a peswit ch ), wir es, r esist or, dou ble sided
t a pe, a n d a pla st ic ca r r ier. Th ey a r e u sed t o in dica t e
t r ou ble codes r ela t ed t o t h e door m ot or a ssem bly.
a n obst r u ct ion du r in g a power lift ga t e close cycle.
(5) Ver ify power lift ga t e syst em oper a t ion . Cycle
t h e power lift ga t e t h r ou gh on e com plet e open a n d
OPERATION
close cycle, t h is will a llow t h e power lift ga t e con t r ol
Du r in g a power lift ga t e close cycle, if eit h er of t h e
m odu le t o r elea r n it s cycle wit h t h e n ew com pon en t s.
t wo con du ct ive r u bber st r ips (t a peswit ch ) of t h e
CAUTION: Torque link rod to liftgate attachment pin ch sen sor com e in con t a ct wit h a n obst a cle, t h e
bolt to 250 in. lbs. Care must be taken not to over- pin ch sen sor cir cu it is com plet ed. Th is t ells t h e
torque link rod bolt. power lift ga t e con t r ol m odu le t h a t a obst r u ct ion is
felt . Th e con t r ol m odu le will st op t h e lift ga t e im m e-
dia t ely a n d r et u r n it t o t h e fu ll open posit ion .
PI N CH SEN SOR (Cont inue d)
REMOVAL (3) In st a ll t h e r em a in in g t h r ee scr ews h oldin g t h e

(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive sen sor t o t h e lift ga t e. Tor qu e a ll scr ews t o 25 in . lbs.
ca ble. (4) In st a ll wir e h a r n ess gr om m et in lift ga t e fla n ge
(2) Rem ove t r im pa n el fr om lift ga t e, (Refer t o 23 - a n d r ou t e, con n ect t h e pin ch sen sor wir e h a r n ess
BODY/DE CKLID/H ATCH /LIF TGATE /TAILGATE / con n ect or (F ig. 21).
TRIM PANE L - RE MOVAL).
(3) Discon n ect t h e pin ch sen sor wir e h a r n ess con -
n ect or (F ig. 20).
Fig. 21 PINCH SENSOR LOCATION

1 - LIFTGATE
2 - PINCH SENSOR ASSEMBLY
3 - LIFTGATE PROP ROD
Fig. 20 PINCH SENSOR LOCATION 4 - PINCH SENSOR WIRE HARNESS CONNECTOR
1 - LIFTGATE 5 - PINCH SENSOR WIRE HARNESS
2 - PINCH SENSOR ASSEMBLY
3 - LIFTGATE PROP ROD (5) Rem ove pr ot ect ive t a p fr om t h e t op of t h e
4 - PINCH SENSOR WIRE HARNESS CONNECTOR pin ch sen sor. F ir m ly a pply pr essu r e t o t h e sen sor
5 - PINCH SENSOR WIRE HARNESS
a dh esive t o secu r e it t o t h e lift ga t e.
(4) Rem ove scr ews h oldin g t h e pin ch sen sor t o lift - (6) In st a ll t h e t r im pa n el on t h e lift ga t e, (Refer t o
ga t e. 23 - BODY/DE CKLID/H ATCH /LIF TGATE /TAIL-
(5) F eed t h e pin ch sen sor wir e h a r n ess ou t of t h e GATE /TRIM PANE L - INSTALLATION).
lift ga t e a n d r em ove t h e sen sor fr om t h e veh icle. (7) Con n ect t h e ba t t er y n ega t ive ca ble.
INSTALLATION er a se a n y power lift ga t e con t r ol m odu le dia gn ost ic
t r ou ble codes r ela t ed t o t h e pin ch sen sor.
WARNING: USE EXTREME CAUTION WHEN TEST- (9) Ver ify power lift ga t e syst em a n d pin ch sen sor
ING PINCH SENSOR OPERATION. oper a t ion . Cycle t h e power lift ga t e t h r ou gh on e com -
plet e open a n d close cycle, du r in g t h e fin a l close cycle
pr ess t h e pin ch sen sor t o ver ify t h e power lift ga t e
CAUTION: Ensure liftgate surface is clean and dry det ect s a n obst r u ct ion a n d r et u r n s t o t h e fu ll open
prior to pinch sensor installation. Failure to do so posit ion .
will inhibit the adhesive backings ability to adhere
to the liftgate and cause improper system operation
or premature component failure.
(1) P osit ion t h e pin ch sen sor t o t h e lift ga t e.

(2) In st a ll t h e t h ir d scr ew fr om t h e t op of t h e sen -
sor fir st . D o n o t to rqu e s c re w a t th is tim e .
T RAN SV ERSE BRACK ET

DESCRIPTION

2 - ENGAGE ACTUATOR
Fig. 22 LIFTGATE GEAR/MOTOR ASSEMBLY 3 - LIFT GEAR AND ROD ASSEMBLY
4 - LIFTGATE MOTOR
2 - ENGAGE ACTUATOR
3 - LIFT GEAR AND ROD ASSEMBLY INSTALLATION
4 - LIFTGATE MOTOR (1) P osit ion t h e t r a n sver se br a cket in t h e veh icle.
Be cer t a in t h e t r a n sver se br a cket is pr oper ly posi-
Th e t r a n sver se br a cket (F ig. 22) is u sed t o su ppor t
t ion ed. Th e br a cket sh ou ld ju st t ou ch t h e en ga ge
a n d secu r e t h e power lift ga t e gea r /m ot or a ssem bly t o
a ct u a t or a r m a n d be posit ion ed bet ween t h e a ct u a t or
t h e left r ea r body D-pilla r. Th e t r a n sver se br a cket is
a r m a n d t h e m ot or h ou sin g.
a ser vicea ble power lift ga t e com pon en t .
(2) Tor qu e t h e t r a n sver se br a cket r et a in in g bolt s
t o t h e gea r m ot or a ssem bly t o 9.5 N·m (85 in . lbs.).
OPERATION Do n ot t igh t en t h e t r a n sver se br a cket r et a in in g bolt ,
Th e power lift ga t e t r a n sver se br a cket su ppor t s t h e loca t ed u n der t h e win dow a ct u a t or a t t h is t im e.
gea r m ot or a ssem bly by su pplyin g a n a ddit ion a l (3) Tor qu e t h e gea r m ot or a ssem bly r et a in in g bolt s
a t t a ch m en t poin t . Loca t ed on t h e lea din g edge of t h e t o 9.5 N·m (85 in . lbs.).
gea r m ot or a ssem bly, on e en d of t h e t r a n sver se (4) Tor qu e t h e fin a l t r a n sver se br a cket r et a in in g
br a cket a t t a ch es t o t h e m ot or a ssem bly t h e ot h er t o bolt t o 9.5 N·m (85 in . lbs.).
t h e lea din g edge of t h e veh icles D-pilla r. (5) Con n ect t h e gea r m ot or a ssem bly elect r ica l con -
n ect or a n d en ga ge r et a in in g pu sh pin .
REMOVAL (6) In st a ll t h e left D-pilla r t r im , (Refer t o 23 -
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive BODY/INTE RIOR/LE F T D-P ILLAR TRIM PANE L -
ca ble. INSTALLATION).
(2) Rem ove t h e left D-pilla r t r im fr om t h e veh icle, (7) Con n ect t h e ba t t er y n ega t ive ca ble.
(Refer t o 23 - BODY/INTE RIOR/LE F T D-P ILLAR (8) Usin g a n a ppr opr ia t e sca n t ool, ch eck a n y
TRIM PANE L - RE MOVAL). er a se a n y power lift ga t e con t r ol m odu le dia gn ost ic
(3) Discon n ect t h e gea r m ot or a ssem bly elect r ica l t r ou ble codes r ela t ed t o t h e door m ot or a ssem bly.
con n ect or a n d disen ga ge r et a in in g pu sh pin . (9) Ver ify power lift ga t e syst em oper a t ion . Cycle
(4) Loosen t h e gea r m ot or a ssem bly r et a in in g bolt s t h e power lift ga t e t h r ou gh on e com plet e open a n d
t o a llow r oom for t r a n sver se br a cket t o be r em oved. close cycle, t h is will a llow t h e power lift ga t e con t r ol
(5) Rem ove t h e t r a n sver se br a cket r et a in in g bolt s m odu le t o r elea r n it s cycle wit h t h e n ew com pon en t s.
(F ig. 23).
(6) Rem ove t h e t r a n sver se br a cket fr om t h e veh icle.
8N - 20 POWER LOCKS RS
POWER LOCK S
TABLE OF CONTENTS
page page
POWER LOCKS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 23

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 20 KEYLESS ENTRY TRANSMITTER
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 DIAGNOSIS AND TESTING
DOOR CYLINDER LOCK SWITCH - EXPORT KEYLESS ENTRY TRANSMITTER . . . . . . . . . 24
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 22 STANDARD PROCEDURE
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 STANDARD PROCEDURE - HORN CHIRP
DIAGNOSIS AND TESTING PREFERENCE . . . . . . . . . . . . . . . . . . . . . . . . 24
DOOR CYLINDER LOCK SWITCH - STANDARD PROCEDURE - BATTERY
EXPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . 24
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 STANDARD PROCEDURE - REMOTE
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 22 KEYLESS ENTRY TRANSMITTER
DOOR LOCK MOTOR PROGRAMMING . . . . . . . . . . . . . . . . . . . . . . 24
DIAGNOSIS AND TESTING SPECIFICATIONS
DOOR LOCK MOTOR . . . . . . . . . . . . . . . . . . 23 SPECIFICATIONS - TRANSMITTER RANGE . 24
DOOR LOCK SWITCH SPECIFICATIONS - BATTERY . . . . . . . . . . . . 24
DIAGNOSIS AND TESTING SLIDING DOOR LOCK MOTOR
DOOR LOCK SWITCH . . . . . . . . . . . . . . . . . . 23 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
POWER LOCK S AUTOMATIC DOOR LOCKS

Wh en en a bled, t h is fea t u r e will lock a ll of t h e door
DESCRIPTION locks if a ll of t h e door s a r e closed a n d t h e veh icle
speed goes a bove 25.7 km /h (15 m ph ). If a door
POWER LOCKS u n lock h a s occu r r ed, t h en t h e BCM will per for m
Th e power lock syst em a llows a ll of t h e door s t o be a n ot h er a u t o lock, if t h e door s did n ot elect r ica lly
locked or u n locked elect r ica lly by oper a t in g a swit ch u n lock, a n ot h er a u t o lock will n ot occu r.
on eit h er fr on t door t r im pa n el. Th e power lock sys-
t em r eceives n on -swit ch ed ba t t er y cu r r en t t h r ou gh a DOOR LOCK INHIBIT
fu se in t h e In t egr a t ed P ower Modu le (IP M), so t h a t Wh en t h e key is in t h e ign it ion (in a n y swit ch posi-
t h e power locks r em a in oper a t ion a l, r ega r dless of t h e t ion ) a n d eit h er fr on t door is open ed, t h e door lock
ign it ion swit ch posit ion . swit ch es LOCK fu n ct ion s a r e disa bled. Th e
Th e Body Con t r ol Modu le (BCM) locks t h e door s UN-LOCK fu n ct ion s a r e st ill fu n ct ion a l. Th is pr ot ect s
a u t om a t ica lly wh en t h e veh icle is dr iven beyon d t h e a ga in st lockin g t h e veh icle wit h t h e key st ill in t h e
speed of 25.7 Km /h (15 m ph ), a ll door s a r e closed, t h e ign it ion . Th e RKE key fob will st ill lock t h e door s.
a cceler a t or peda l is depr essed a n d t h e door lock a ct u - Aft er t h e key is r em oved fr om t h e ign it ion or t h e
a t ion h a d n ot been pr eviou sly a ct iva t ed. Th e r ollin g door s a r e closed, t h e power door locks will oper a t e
door lock fea t u r e is cu st om er pr ogr a m m a ble. n or m a lly.
Th is veh icle a lso offer s sever a l cu st om er pr ogr a m -
m a ble fea t u r es, wh ich a llows t h e select ion of sever a l REMOTE KEYLESS ENTRY
opt ion a l elect r on ic fea t u r es t o su it in dividu a l pr efer- Th e Rem ot e Keyless E n t r y (RKE ) syst em a llows
en ces. t h e u se of a r em ot e ba t t er y-power ed r a dio t r a n sm it -
Th e power lock syst em for t h is veh icle ca n a lso be t er t o com m u n ica t e wit h t h e BCM t o a ct u a t e t h e
oper a t ed r em ot ely u sin g t h e a va ila ble Rem ot e Key- power lock syst em .
less E n t r y (RKE ) syst em r a dio fr equ en cy t r a n sm it - Th e RKE t r a n sm it t er s a r e a lso equ ipped wit h a
t er s, if equ ipped. P a n ic bu t t on . If t h e P a n ic bu t t on on t h e RKE t r a n s-
m it t er is depr essed, t h e h or n will sou n d a n d t h e
ext er ior ligh t s will fla sh on t h e veh icle for a bou t
t h r ee m in u t es, or u n t il t h e P a n ic bu t t on is depr essed
RS POWER LOCKS 8N - 21
POWER LOCK S (Cont inue d)
a secon d t im e. P r essin g t h e P a n ic bu t t on a lso a ct i- Lock r equ est fr om t h e RKE t r a n sm it t er, or h a vin g n o
va t es t h e cou r t esy la m ps. P r essin g t h e P a n ic bu t t on a u dible ver ifica t ion .
a ga in st ops t h e ext er ior la m ps fr om fla sh in g a n d t h e
h or n fr om sou n din g. H owever, t h e cou r t esy la m ps OPERATION
will r em a in illu m in a t ed u n t il eit h er t h e BCM t im es
ou t la m p oper a t ion or u n t il t h e t u r n in g of t h e ign i- POWER LOCKS
t ion . Th e pa n ic fea t u r e will oper a t e if t h e ign it ion is Th e Body Con t r ol Modu le (BCM) locks or u n locks
ON, bu t on ly if t h e P a n ic bu t t on is pr essed pr ior t o t h e door s wh en a n a ct u a t ion in pu t sign a l fr om a door
st a r t in g t h e veh icle. A veh icle speed of a bou t 25.7 lock swit ch , Cen t r a l Lock key cylin der or Rem ot e
km /h (15 m iles-per-h ou r ) will a lso ca n cel t h e pa n ic Keyless E n t r y (RKE ) is r eceived. Th e BCM t u r n s on
even t . t h e ou t pu t dr iver s a n d pr ovides a volt a ge level t o t h e
Th e RKE syst em ca n a lso per for m ot h er fu n ct ion s door lock m ot or for a specified t im e.
on t h is veh icle. If t h e veh icle is equ ipped wit h t h e
opt ion a l Veh icle Th eft Secu r it y Syst em (VTSS), t h e REMOTE KEYLESS ENTRY
RKE t r a n sm it t er will a r m t h e VTSS wh en t h e Lock Th e RKE t r a n sm it t er u ses r a dio fr equ en cy sign a ls
bu t t on is depr essed, a n d disa r m t h e VTSS wh en t h e t o com m u n ica t e wit h t h e SKRE E M m odu le. Th e
Un lock bu t t on is depr essed. SKRE E M is on t h e P CI bu s. Wh en t h e oper a t or
Th e RKE syst em in clu des t wo t r a n sm it t er s wh en pr esses a bu t t on on t h e t r a n sm it t er, it sen ds a spe-
t h e veh icle is sh ipped fr om t h e fa ct or y, bu t t h e sys- cific r equ est t o t h e SKRE E M. In t u r n , t h e SKRE E M
t em ca n r et a in t h e veh icle a ccess codes of u p t o a sen ds t h e a ppr opr ia t e r equ est over t h e P CI bu s t o
t ot a l of eigh t t r a n sm it t er s. If a n RKE t r a n sm it t er is t h e followin g:
in oper a t ive or lost , n ew t r a n sm it t er veh icle a ccess • In te g ra te d P o w e r Mo d u le (IP M) - t o a ct iva t e
codes ca n be pr ogr a m m ed in t o t h e syst em u sin g a t h e pa r k la m ps, t h e h ea dla m ps a n d t h e h or n for t h e
DRB III! sca n t ool. h or n ch ir p.
Th is veh icle a lso offer s sever a l cu st om er pr ogr a m - • P o w e r Liftg a te Mo d u le (P LGM) - t o con t r ol
m a ble fea t u r es, wh ich a llows t h e select ion of sever a l t h e lift ga t e lock a n d u n lock fu n ct ion s.
opt ion a l elect r on ic fea t u r es t o su it in dividu a l pr efer- Aft er pr essin g t h e lock bu t t on on t h e RKE t r a n s-
en ces. Cu st om er pr ogr a m m a ble fea t u r e opt ion s m it t er, a ll of t h e door locks will lock, t h e illu m in a t ed
a ffect in g t h e RKE syst em in clu de: en t r y will t u r n off (if a ll door s a r e closed) a n d t h e
• Au to m a tic D o o r Lo c k - Cu st om er pr ogr a m m a - veh icle t h eft secu r it y syst em (if equ ipped) will a r m .
ble fea t u r e t h a t a llows t h e BCM t o per for m a n a u t o- P r essin g t h e u n lock bu t t on on e t im e will u n lock
m a t ic door lock if t h e veh icle speed is a bove 25.7 t h e dr iver door, or a ll door s ba sed on t h e cu st om er
km /h (15 m iles-per-h ou r ). pr ogr a m m a ble fea t u r e en a bled, t h e illu m in a t ed en t r y
• Au to m a tic D o o r U n lo c k On Ex it - Cu st om er will t u r n on t h e cou r t esy la m ps a n d t h e veh icle t h eft
pr ogr a m m a ble fea t u r e t h a t a llows t h e BCM t o per- secu r it y syst em (if equ ipped) will disa r m . P r essin g
for m a n a u t om a t ic door u n lock if t h e veh icle speed is t h e u n lock bu t t on a secon d t im e, t h e r em a in in g door
0, veh icle in pa r k a n d dr iver door is open ed. locks will u n lock.
• F la s h Lig h ts w ith Lo c k a n d U n lo c k - Allows If t h e veh icle is equ ipped wit h t h e m em or y syst em ,
t h e opt ion of h a vin g t h e pa r k la m ps fla sh a s a n opt i- t h e m em or y m essa ge will iden t ify wh ich t r a n sm it t er
ca l ver ifica t ion t h a t t h e RKE syst em r eceived a va lid (1 or 2) sen t t h e sign a l.
Lock r equ est or Un lock r equ est fr om t h e RKE t r a n s-
m it t er, or h a vin g n o opt ica l ver ifica t ion . ROLLING CODE
• P ro g ra m m in g Ad d itio n a l Tra n s m itte rs - Th e r ollin g code fea t u r e ch a n ges pa r t of t h e t r a n s-
Allows u p t o a t ot a l of fou r t r a n sm it t er veh icle a ccess m it t er m essa ge ea ch t im e t h a t it is u sed. Th e t r a n s-
codes t o be st or ed. m it t er m essa ge a n d t h e r eceiver m essa ge in cr em en t
• Re m o te U n lo c k S e qu e n c e - Allows t h e opt ion t oget h er. Un der cer t a in con dit ion s wit h a r ollin g code
of h a vin g on ly t h e dr iver side fr on t door u n lock wh en syst em , su ch a s pr essin g a bu t t on on t h e RKE t r a n s-
t h e RKE t r a n sm it t er Un lock bu t t on is depr essed t h e m it t er over 255 t im es ou t side of r eceiver r a n ge or
fir st t im e. Th e r em a in in g door s u n lock wh en t h e bu t - r epla cin g t h e ba t t er y, t h e r eceiver a n d t r a n sm it t er
t on is depr essed a secon d t im e wit h in 5 secon ds of ca n fa ll ou t of syn ch r on iza t ion . To r e-syn ch r on ize,
t h e fir st u n lock pr ess. An ot h er opt ion is h a vin g a ll pr ess a n d r elea se t h e UNLOCK bu t t on on t h e RKE
door s u n lock u pon t h e fir st depr ession of t h e RKE t r a n sm it t er r epea t edly (it m a y t a ke u p t o eigh t
t r a n sm it t er Un lock bu t t on . cycles) wh ile list en in g ca r efu lly for t h e power door
• S o u n d Ho rn o n Lo c k - Allows t h e opt ion of locks in t h e veh icle t o cycle, in dica t in g t h a t r esyn -
h a vin g t h e h or n sou n d a sh or t ch ir p a s a n a u dible ch r on iza t ion h a s occu r r ed.
ver ifica t ion t h a t t h e RKE syst em r eceived a va lid
POWER LOCK S (Cont inue d)
Th e lock fu n ct ion wor ks fr om t h e RKE t r a n sm it t er D RB III!, re fe r to th e a p p ro p ria te D ia g n o s tic
even in a n ou t of syn ch r on iza t ion con dit ion , t h er efor e S e rv ic e Ma n u a l.
it cou ld be ver ified by pr essin g t h e LOCK bu t t on on F or com plet e cir cu it dia gr a m s, r efer t o t h e a ppr o-
t h e RKE key fob. pr ia t e wir in g in for m a t ion .
(1) Visu a lly in spect t h e swit ch for pr oper in st a lla -
t ion . Ma ke su r e it is sea t ed on t h e r ea r of t h e key
DOOR CY LI N DER LOCK cylin der, wit h t h e t a b of t h e door key cylin der pr op-
SWI T CH - EX PORT er ly a lign ed wit h t h e slot on t h e door cylin der lock
swit ch .
DESCRIPTION (2) Discon n ect t h e swit ch a t t h e h a r n ess con n ect or
a n d ch eck t h e r esist a n ce in ea ch swit ch posit ion .
Th e Door Cylin der Lock Swit ch (If equ ipped) is
u sed t o: CAUTION: Do not disconnect the switch from the
• Un lock/Lock a ll t h e door s via t h e Cen t r a l Lock- rear of the door key cylinder. This switch is a one
in g fea t u r e. time use switch. Once it is removed from the rear of
• Ar m /Disa r m t h e Veh icle Th eft Secu r it y Syst em . the switch, it is not reusable and must be replaced.
• Tr igger t h e Illu m in a t ed E n t r y fea t u r e. Test the switch at the harness connector.
Th e door cylin der lock swit ch is m ou n t ed t o t h e
r ea r of t h e dr iver door lock cylin der. Wh en in st a lled DOOR CY LI N DER LOCK SWI T CH RESI STAN CE
on t h e r ea r of t h e cylin der, t h er e is a t a b on t h e lock
cylin der t h a t a lign s wit h t h e swit ch t o pr even t it
SWITCH POSITION RESISTANCE VALUE
fr om t u r n in g. An a n t i-r ot a t in g device. Th e door cylin -
der lock swit ch is a on e t im e u se swit ch . On ce it is COUNTERCLOCKWISE 5.4K OHMS
r em oved fr om t h e r ea r of t h e door lock cylin der, it NEUTRAL 18.4K OHMS
m a y n ot be r ein st a lled a n d a n ew swit ch m u st be
CLOCKWISE 2K OHMS
u sed.
OPERATION REMOVAL
Wh en t h e Door Cylin der Lock Swit ch is t u r n ed
ca ble.
eit h er wa y u sin g t h e door key cylin der, t h e BCM
(2) Rem ove t h e door t r im pa n el of t h e effect ed door
r ea ds a dir ect m essa ge sign a l fr om t h e swit ch .
cylin der lock swit ch (Refer t o 23 - BODY/DOOR -
If t u r n in g t h e key cylin der on ce, t owa r d t h e fr on t
F RONT/TRIM PANE L - RE MOVAL).
of t h e veh icle, t h is will:
(3) Close t h e door win dow.
(1) Mech a n ica lly u n lock t h e door lock.
(4) Discon n ect t h e door cylin der lock swit ch wir e
(2) Disa r m t h e Veh icle Th eft Secu r it y Syst em (if
con n ect or fr om t h e door h a r n ess, a n d wir in g clip
equ ipped).
fr om t h e im pa ct bea m .
(3) Tu r n on t h e Illu m in a t ed E n t r y (if equ ipped) for
(5) Rem ove t h e ou t er door h a n dle fr om t h e door.
a ppr oxim a t ely 30 secon ds.
(6) Rem ove t h e swit ch fr om t h e key cylin der in t h e
If t h e key cylin der is t u r n ed t o t h e u n lock posit ion
door h a n dle a n d r em ove fr om veh icle.
(t owa r d t h e fr on t of veh icle) t wice wit h in t wo sec-
on ds, a ll t h e door s a n d lift ga t e will u n lock (if
equ ipped wit h t h e cen t r a l lockin g fea t u r e). INSTALLATION
To lock t h e veh icle u sin g t h e door cylin der lock (1) In st a ll t h e swit ch on t h e key cylin der in t h e
swit ch , t u r n t h e key cylin der t owa r d t h e r ea r of t h e door h a n dle.
veh icle on ce. Th is will lock t h e door t h a t you a r e (2) In st a ll t h e door h a n dle.
u sin g t h e key on . If equ ipped wit h t h e cen t r a l lockin g (3) Con n ect t h e door cylin der lock swit ch wir e con -
fea t u r e, t h is will lock a ll t h e ot h er door s a n d lift ga t e. n ect or t o t h e door h a r n ess, a n d t h e wir in g clip t o t h e
F u r t h er m or e, t h is will a r m t h e veh icle t h eft secu r it y im pa ct bea m .
syst em a n d t u r n off t h e illu m in a t ed en t r y. (4) In st a ll t h e door t r im pa n el of t h e a ffect ed door
cylin der lock swit ch (Refer t o 23 - BODY/DOOR -
F RONT/TRIM PANE L - INSTALLATION).
DI AGN OSI S AN D T EST I N G (5) Con n ect t h e ba t t er y n ega t ive ca ble.
(6) Ver ify syst em oper a t ion .
DOOR CYLINDER LOCK SWITCH - EXPORT
An y d ia g n o s is o f th e p o w e r lo c k s y s te m
s h o u ld be g in w ith th e u s e o f th e D RB III! d ia g -
n o s tic to o l. F o r in fo rm a tio n o n th e u s e o f th e
DOOR LOCK M OT OR

DOOR LOCK MOTOR
An y d ia g n o s is o f th e p o w e r lo c k s y s te m
s h o u ld be g in w ith th e u s e o f th e D RB III! d ia g -
n o s tic to o l. F o r in fo rm a tio n o n th e u s e o f th e
D RB III!, re fe r to th e a p p ro p ria te D ia g n o s tic Fig. 1 DOOR LOCK SWITCH
S e rv ic e Ma n u a l.
F or com plet e cir cu it dia gr a m s, r efer t o t h e a ppr o- DOOR LOCK SWI T CH CON T I N U I T Y
pr ia t e wir in g in for m a t ion .
Ver ify ba t t er y con dit ion befor e t est in g door lock SWITCH CONTINUITY RESISTANCE
m ot or (s). POSITION BETWEEN VALUE
To det er m in e wh ich m ot or is fa u lt y, ch eck ea ch LOCK 2 and 3 5.3K Ohm ± 5%
in dividu a l door for elect r ica l lock a n d u n lock or dis-
con n ect t h e m ot or con n ect or s on e a t a t im e, wh ile UNLOCK 2 and 3 2.0K Ohm ± 5%
oper a t in g t h e door lock swit ch . In t h e even t t h a t UNACTUATED 2 and 3 18.3K Ohms ±
n on e of t h e m ot or s wor k, t h e pr oblem m a y be ca u sed 5%
by a sh or t ed m ot or or a fa u lt y swit ch . Discon n ect in g
t h e fa u lt y m ot or will a llow t h e ot h er s t o wor k. REMOVAL
To t est a n in dividu a l door lock m ot or, discon n ect (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
t h e elect r ica l con n ect or fr om t h e m ot or. To lock t h e ca ble.
door, con n ect a fu sed 12 volt power sou r ce t o t h e pos- (2) Rem ove door t r im pa n el. Refer t o Body, Door -
it ive pin of t h e lock m ot or a n d a gr ou n d wir e t o t h e F r on t , Tr im P a n el, Rem ova l.
ot h er pin . To u n lock t h e door r ever se t h e wir e con - (3) Discon n ect wir e con n ect or fr om ba ck of door
n ect ion s a t t h e m ot or pin t er m in a ls. If t h ese r esu lt s lock swit ch .
a r e n ot obt a in ed, r epla ce t h e door la t ch . (4) Rem ove t wo scr ews t o door lock swit ch .
(5) Rem ove swit ch fr om veh icle.
DOOR LOCK SWI T CH INSTALLATION

(1) In st a ll t h e swit ch in t o t h e veh icle.
(2) In st a ll t h e t wo scr ews t o door lock swit ch .
(3) Con n ect wir e con n ect or t o ba ck of door lock
swit ch .
DOOR LOCK SWITCH (4) In st a ll door t r im pa n el. Refer t o Body, Door -
(1) Rem ove door t r im pa n el. Refer t o Body, Door -
F r on t , Tr im P a n el, In st a lla t ion .
F r on t , Tr im P a n el, Rem ova l a n d In st a lla t ion .
(2) Discon n ect wir e con n ect or fr om ba ck of door
lock swit ch .
(3) Depr ess swit ch t o LOCK posit ion .
(4) Usin g a n oh m m et er, t est swit ch r esist a n ce
bet ween P in s 2 a n d 3. Refer t o t h e DOOR LOCK
SWITCH CONTINUITY t est a n d (F ig. 1).
(5) Depr ess swit ch t o UNLOCK posit ion .
(6) Test r esist a n ce bet ween P in s 2 a n d 3.
(7) Test r esist a n ce bet ween pin s 2 a n d 3 wh ile
swit ch is in it s n or m a l u n a ct u a t ed m ode.
(8) If r esist a n ce va lu es a r e n ot wit h in t h e pa r a m -
et er s sh own r epla ce t h e door lock swit ch .
K EY LESS EN T RY ENABLING
Th e h or n ch ir p ca n be t oggled u sin g a DRB III! or
T RAN SM I T T ER by u sin g t h e Rem ot e Keyless E n t r y (RKE ) t r a n sm it -
t er.
DI AGN OSI S AN D T EST I N G To E NABLE (r ein st a t e) t h e h or n ch ir p fea t u r e, u se
a n y on e of t h e fou r pr ogr a m m ed in t egr a t ed key/key
fob t r a n sm it t er s a n d r ever se t h e a bove pr ocedu r es. It
KEYLESS ENTRY TRANSMITTER
will E NABLE t h e h or n ch ir p fea t u r e for a ll t r a n sm it -
Usin g specia l t ool 9001, fir st t est t o en su r e t h a t
t er s.
t h e t r a n sm it t er is fu n ct ion in g. Typica l t est in g dis-
t a n ce is 2.5 cen t im et er s (1 in ch ) for Asia n t r a n sm it -
t er s a n d 30.5 cen t im et er s (12 in ch es) for a ll ot h er s.
STANDARD PROCEDURE - BATTERY
To t est , posit ion t h e t r a n sm it t er a s sh own (F ig. 2). REPLACEMENT
P r ess a n y t r a n sm it t er bu t t on , t h en t est ea ch bu t t on (1) Wit h t h e t r a n sm it t er bu t t on s fa cin g down , u se
in dividu a lly. Th e t ool will beep if a r a dio sign a l a coin t o pr y t h e t wo h a lves of t h e t r a n sm it t er a pa r t .
st r en gt h t h a t ligh t s five or m or e LE D’s is det ect ed. Ma ke su r e n ot t o da m a ge t h e r u bber ga sket du r in g
Repea t t h is t est t h r ee t im es. If t r a n sm it t er fa ils a n y sepa r a t ion of t h e h ou sin g h a lves.
of t h e t est , r efer t o t h e Dia gn ost ic P r ocedu r es m a n - (2) Rem ove t h e ba t t er y fr om t h e t r a n sm it t er ba ck
u a l. h ou sin g h older.
(3) Repla ce t h e ba t t er ies. Avoid t ou ch in g t h e n ew
ba t t er ies wit h you r fin ger s, Skin oils m a y ca u se ba t -
t er y det er ior a t ion . If you t ou ch a ba t t er y, clea n it off
wit h r u bbin g a lcoh ol.
(4) To a ssem ble t h e t r a n sm it t er ca se, sn a p t h e t wo
h a lves t oget h er.
STANDARD PROCEDURE - REMOTE KEYLESS

ENTRY TRANSMITTER PROGRAMMING
(Refer t o 8 - E LE CTRICAL/VE H ICLE TH E F T
SE CURITY/TRANSP ONDE R KE Y - STANDARD
P ROCE DURE ) for pr ogr a m m in g pr ocedu r es.
SPECI FI CAT I ON S
Fig. 2 TRANSMITTER DIAGNOSIS - TYPICAL

SPECIFICATIONS - TRANSMITTER RANGE
Nor m a l oper a t ion r a n ge is u p t o a dist a n ce of 7
STAN DARD PROCEDU RE m et er s (23 ft .) of t h e veh icle. Ra n ge m a y be bet t er or
wor se depen din g on t h e en vir on m en t a r ou n d t h e
STANDARD PROCEDURE - HORN CHIRP veh icle.
PREFERENCE
SPECIFICATIONS - BATTERY
DISABLING Th e ba t t er ies ca n be r em oved wit h ou t specia l t ools
Th e h or n ch ir p ca n be t oggled u sin g a DRB III! or a n d a r e r ea dily a va ila ble a t loca l r et a il st or es. Th e
by u sin g a pr ogr a m m ed Rem ot e Keyless E n t r y (RKE ) r ecom m en ded ba t t er y is Du r a cell DL 2016 or equ iva -
t r a n sm it t er. len t , TWO cells a r e r equ ir ed. Ba t t er y life is a bou t
To DISABLE (ca n cellin g) t h e h or n ch ir p fea t u r e, t h r ee yea r s m in im u m .
pr ess a n d h old t h e t r a n sm it t er LOCK bu t t on for a
CAUTION: Do not touch the battery terminals or
m in im u m of five secon ds. Wh ile pr essin g t h e LOCK
handle the batteries any more than necessary.
bu t t on in , pr ess t h e PANIC bu t t on . Th e h or n ch ir p
Hands must be clean and dry.
fea t u r e will n ot fu n ct ion u n t il t h e a bove pr ocedu r e is
r epea t ed.
SLI DI N G DOOR LOCK M OT OR

REMOVAL
ca ble.
(2) Rem ove slidin g door t r im pa n el (Refer t o 23 -
BODY/DOORS - SLIDING/TRIM PANE L -
RE MOVAL).
(3) Rem ove sou n d pa d a s n ecessa r y.
(4) Rem ove la t ch /lock con t r ol cover.
(5) Rem ove la t ch /lock con t r ol.
(6) Rem ove scr ews h oldin g door lock m ot or t o
la t ch /lock con t r ol (F ig. 3).
(7) Rem ove lock m ot or fr om con t r ol.
INSTALLATION
(1) P osit ion t h e lock m ot or on t h e la t ch /lock.
(2) In st a ll t h e scr ews r et a in in g t h e m ot or t o t h e
la t ch /lock.
(3) In st a ll t h e la t ch /lock con t r ol.
(4) In st a ll t h e la t ch /lock con t r ol cover.
(5) In st a ll t h e sou n d pa d a n d t r im pa n el t o t h e Fig. 3 SLIDING DOOR LOCK MOTOR
slidin g door.
1 - SLIDING DOOR POWER LOCK MOTOR
2 - LATCH/LOCK CONTROL
8N - 26 POWER MIRRORS RS
POWER M I RRORS
TABLE OF CONTENTS
page page
POWER MIRRORS OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

DIAGNOSIS AND TESTING REMOTE SWITCH
POWER MIRRORS . . . . . . . . . . . . . . . . . . . . 27 DIAGNOSIS AND TESTING
AUTOMATIC DAY / NIGHT MIRROR REMOTE SWITCH . . . . . . . . . . . . . . . . . . . . . 30
DIAGNOSIS AND TESTING SIDEVIEW MIRROR
AUTOMATIC DAY / NIGHT MIRROR . . . . . . . 28 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
POWER FOLDAWAY MIRROR SWITCH -
EXPORT
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 29
POWER M I RRORS An opt ion a l dr iver side ou t side elect r och r om ic m ir-
r or is a ble t o a u t om a t ica lly ch a n ge it s r eflect a n ce
level. Th is m ir r or is con t r olled by t h e cir cu it r y of t h e
DESCRIPTION
a u t om a t ic da y/n igh t in side r ea r view m ir r or. A t h in
If equ ipped wit h power m ir r or s, t h e con t r ol swit ch
la yer of elect r och r om ic m a t er ia l bet ween t wo pieces
is loca t ed on t h e in st r u m en t pa n el t o t h e left of t h e
of con du ct ive gla ss m a ke u p t h e fa ce of t h e m ir r or.
h ea dla m p swit ch .
Two ph ot ocell sen sor s on t h e in side r ea r view m ir r or
a r e u sed t o m on it or ligh t levels a n d a dju st t h e r eflec-
OPERATION t a n ce of bot h t h e in side a n d dr iver side ou t side m ir-
Th e power m ir r or s a r e con n ect ed t o ba t t er y feed a t r or s. Th is ch a n ge in r eflect a n ce h elps t o r edu ce t h e
a ll t im es. E a ch m ir r or h ea d con t a in s t wo elect r ic gla r e of h ea dla m ps a ppr oa ch in g t h e veh icle fr om t h e
m ot or s, t wo dr ive m ech a n ism s, a n elect r ic h ea t in g
r ea r. (Refer t o 8 - E LE CTRICAL/P OWE R MIRRORS/
elem en t , a n d t h e m ir r or gla ss. If t h e veh icle is AUTOMATIC DAY / NIGH T MIRROR - DE SCRIP -
equ ipped wit h t h e opt ion a l m em or y syst em , t h e TION) for m or e in for m a t ion on t h is syst em .
dr iver side m ir r or h ea d a lso con t a in s bot h a h or izon -
Th e m ot or s wh ich oper a t e t h e m ir r or s a r e pa r t of
t a l a n d a ver t ica l m ot or posit ion sen sor. On e m ot or
t h e m ir r or a ssem bly a n d ca n n ot be ser viced sepa -
a n d dr ive con t r ols m ir r or u p-a n d-down m ovem en t ,
r a t ely.
a n d t h e ot h er con t r ols r igh t -a n d-left m ovem en t .
RS POWER MIRRORS 8N - 27
POWER M I RRORS (Cont inue d)

POWER MIRRORS
(1) Rem ove P ower Mir r or Swit ch . (Refer t o 8 -
E LE CTRICAL/P OWE R MIRRORS/P OWE R MIRROR
SWITCH - RE MOVAL).
(2) Discon n ect wir in g h a r n ess con n ect or t o t h e
power m ir r or swit ch a n d h ea dla m p swit ch .
(3) Usin g t wo ju m per wir es:
• Con n ect on e t o a 12-volt sou r ce
• Con n ect t h e ot h er t o a good body gr ou n d
• Refer t o t h e Mir r or Test Ch a r t for wir e h ooku ps
a t t h e swit ch con n ect or (F ig. 1).
Fig. 1 Power Mirror Connector
POWER M I RROR M OT OR T EST
SWITCH CONNECTOR
12 Volts Ground MIRROR REACTION
Right Left
PIN 12 PIN 6 — UP
PIN 7 PIN 6 — LEFT
PIN 6 PIN 12 — DOWN
PIN 6 PIN 7 — RIGHT
PIN 13 PIN 1 UP —
PIN 8 PIN 1 LEFT —
PIN 1 PIN 13 DOWN —
PIN 1 PIN 8 RIGHT —
(4) If r esu lt s sh own in t a ble a r e n ot obt a in ed,

ch eck for br oken or sh or t ed cir cu it , or r epla ce m ir r or
a ssem bly a s n ecessa r y.
AU T OM AT I C DAY / N I GH T DI AGN OSI S AN D T EST I N G

M I RROR AUTOMATIC DAY / NIGHT MIRROR
F or cir cu it descr ipt ion s a n d dia gr a m s, r efer t o t h e
DESCRIPTION a ppr opr ia t e wir in g in for m a t ion . Th e wir in g in for m a -
An a u t om a t ic dim m in g in side da y/n igh t r ea r view
t ion in clu des wir in g dia gr a m s, pr oper wir e a n d con -
m ir r or a n d a n a u t om a t ic dim m in g dr iver side ou t side
n ect or r epa ir pr ocedu r es, det a ils of wir e h a r n ess
r ea r view m ir r or a r e a va ila ble fa ct or y-in st a lled
r ou t in g a n d r et en t ion , con n ect or pin -ou t in for m a t ion
opt ion s on t h is m odel. F ollowin g is a gen er a l descr ip-
a n d loca t ion views for t h e va r iou s wir e h a r n ess con -
t ion of t h is opt ion a l equ ipm en t .
n ect or s, splices a n d gr ou n ds.
Th e a u t om a t ic da y/n igh t m ir r or is a ble t o a u t om a t -
(1) Ch eck t h e fu se in t h e in t elligen t power m odu le.
ica lly ch a n ge it s r eflect a n ce. A t h in la yer of elect r o-
If OK, go t o St ep 2. If n ot OK, r epa ir t h e sh or t ed cir-
ch r om ic m a t er ia l bet ween t wo pieces of con du ct ive
cu it or com pon en t a s r equ ir ed a n d r epla ce t h e fa u lt y
gla ss m a ke u p t h e fa ce of t h e m ir r or. Two ph ot ocell
fu se.
sen sor s a r e u sed t o m on it or ligh t levels a n d a dju st
(2) Tu r n t h e ign it ion swit ch t o t h e On posit ion .
t h e r eflect a n ce of t h e m ir r or t o r edu ce t h e gla r e of
Ch eck for ba t t er y volt a ge a t t h e fu se in t h e in t elli-
h ea dla m ps a ppr oa ch in g t h e veh icle fr om t h e r ea r.
gen t power m odu le. If OK, go t o St ep 3. If n ot OK,
F or r em ova l pr ocedu r es, (Refer t o 23 - BODY/IN-
r epa ir t h e open cir cu it t o t h e ign it ion swit ch a s
TE RIOR/RE AR VIE W MIRROR - RE MOVAL).
r equ ir ed.
(3) Un plu g t h e wir e h a r n ess con n ect or fr om t h e
OPERATION a u t om a t ic da y/n igh t m ir r or. Ch eck for ba t t er y volt a ge
Th e a m bien t ph ot ocell sen sor fa ces for wa r d, t o a t t h e fu sed ign it ion swit ch ou t pu t cir cu it ca vit y of
det ect t h e ou t side ligh t levels. A secon d sen sor fa ces t h e a u t om a t ic da y/n igh t m ir r or wir e h a r n ess con n ec-
r ea r wa r d t o det ect t h e ligh t level r eceived t h r ou gh t or. If OK, go t o St ep 4. If n ot OK, r epa ir t h e open
t h e veh icles ba ck win dow. Wh en t h e differ en ce cir cu it t o t h e ju n ct ion block a s r equ ir ed.
bet ween t h e t wo ligh t levels becom es t oo gr ea t (t h e (4) Tu r n t h e ign it ion swit ch t o t h e Off posit ion .
ligh t level r eceived a t t h e r ea r of t h e m ir r or is m u ch Ch eck for con t in u it y bet ween t h e gr ou n d cir cu it ca v-
h igh er t h a n t h a t a t t h e fr on t of t h e m ir r or ), t h e m ir- it y of t h e a u t om a t ic da y/n igh t m ir r or wir e h a r n ess
r or begin s t o da r ken . con n ect or a n d a good gr ou n d. Th er e sh ou ld be con t i-
Th e m ir r or swit ch a llows t h e dr iver a m a n u a l con - n u it y. If OK, go t o St ep 5. If n ot OK, r epa ir t h e cir-
t r ol of wh et h er t h e a u t om a t ic dim m in g fea t u r e is cu it t o gr ou n d a s r equ ir ed.
oper a t ion a l. Wh en AUTO is select ed a sm a ll Ligh t - (5) Tu r n t h e ign it ion swit ch t o t h e On posit ion . Set
E m it t in g Diode (LE D), t o t h e r igh t of t h e m ir r or t h e pa r kin g br a ke. P la ce t h e t r a n sm ission gea r selec-
swit ch , is illu m in a t ed. Th e a u t om a t ic dim m in g fea - t or lever in t h e Rever se posit ion . Ch eck for ba t t er y
t u r e will on ly oper a t e wh en t h e ign it ion swit ch is in volt a ge a t t h e ba cku p la m p swit ch ou t pu t cir cu it ca v-
t h e On posit ion . Th e m ir r or a lso sen ses t h e ba cku p it y of t h e a u t om a t ic da y/n igh t m ir r or wir e h a r n ess
la m p cir cu it , a n d will a u t om a t ica lly disa ble it s self- con n ect or. If volt a ge is pr esen t , r ein st a ll t h e a u t o-
dim m in g fea t u r e wh en ever t h e t r a n sm ission gea r m a t ic da y/n igh t m ir r or wir e h a r n ess con n ect or a n d
select or is in t h e Rever se posit ion . go t o St ep 6. If n ot OK, r epa ir t h e open cir cu it a s
r equ ir ed.
NOTE: The mirror always defaults to an ON state
(6) P la ce t h e t r a n sm ission gea r select or lever in
upon ignition.
t h e Neu t r a l posit ion . P la ce t h e a u t om a t ic da y/n igh t
Th e dr iver side a u t om a t ic dim m in g m ir r or is st a n - m ir r or swit ch in t h e On (LE D in t h e swit ch is
da r d wit h t h e a u t om a t ic dim m in g in side m ir r or. Th e ligh t ed) posit ion . Cover t h e for wa r d fa cin g a m bien t
sign a l t o con t r ol t h e dim m in g of t h a t m ir r or is gen - ph ot ocell sen sor t o keep ou t a n y a m bien t ligh t .
er a t ed by t h e a u t om a t ic da y/n igh t in side r ea r view
NOTE: The ambient photocell sensor must be cov-
m ir r or cir cu it r y. Th a t sign a l is t h en deliver ed t o t h e
ered completely, so that no light reaches the sen-
dr iver side ou t side r ea r view m ir r or on a h a r d wir ed
sor. Use a finger pressed tightly against the sensor,
cir cu it .
or cover the sensor completely with electrical tape.
Th e a u t om a t ic da y/n igh t m ir r or ca n n ot be
r epa ir ed. If fa u lt y or da m a ged, t h e en t ir e in side r ea r (7) Sh in e a ligh t in t o t h e r ea r wa r d fa cin g h ea d-
view m ir r or a ssem bly m u st be r epla ced. la m p ph ot ocell sen sor. Th e a u t om a t ic da y/n igh t m ir-
r or sh ou ld da r ken . Th e a u t om a t ic da y/n igh t m ir r or
sh ou ld da r ken wit h in 2 m in u t es if t est in g for t h e
fir st t im e. F or im m edia t e r espon se, t u r n t h e veh icle
RS POWER MIRRORS 8N - 29
AU T OM AT I C DAY / N I GH T M I RROR (Cont inue d)
OF F a n d ba ck ON wit h t h e for wa r d-fa cin g ligh t sen -
sor st ill cover ed. Th is defea t s t h e da y-det ect logic. If
OK, go t o St ep 8. If n ot OK, r epla ce t h e fa u lt y m ir r or
u n it .
(8) Wit h t h e m ir r or da r ken ed, pla ce t h e t r a n sm is-
sion gea r select or lever in t h e Rever se posit ion . Th e
a u t om a t ic da y/n igh t m ir r or sh ou ld r et u r n t o it s n or-
m a l r eflect a n ce. If n ot OK, r epla ce t h e fa u lt y m ir r or
u n it .
Ben ch t est in g bot h m ir r or s ca n be don e, of ca r e is
exer cised. F or a n in side m ir r or, t h e pin closest t o h e
m ou n t is 12V (+), t h e n ext is 12V (-). Th e t h ir d is
r ever se over r ide. Th e fou r t h is ou t side m ir r or (+), a n d
t h e fift h is ou t side m ir r or (-). D o n o t a p p ly 12 v o lts to
th e fo u rth a n d fifth p in s . Wit h 12 volt s on pin s 1 a n d
2, t h e m ir r or ca n be t est ed by blockin g t h e r ea r sen sor
a n d sh in in g a ligh t in t o t h e for wa r d sen sor. F or a n ou t - Fig. 2 POWER FOLDAWAY MIRROR SWITCH
side m ir r or, t h er e is a 2–pin con n ect or. Applyin g 1.2 1 - POWER FOLDAWAY MIRROR SWITCH
volt s will ca u se t h e m ir r or t o dim . If t h e m ir r or does n ot 2 - STEERING COLUMN
dim , t h e en t ir e gla ss a ssem bly ca n be r epla ced ju st a s it
is wh en t h e gla ss is br oken . r ela y, wir es a n d fu se. Refer t o t h e a ppr opr ia t e wir in g
in for m a t ion . Th e wir in g in for m a t ion in clu des wir in g
WARNING: Do not apply 12 volts to the outside mir- dia gr a m s, pr oper wir e a n d con n ect or r epa ir pr ocedu r es,
ror. Damage to the mirror will result. det a ils of wir e h a r n ess r ou t in g a n d r et en t ion , con n ect or
pin -ou t in for m a t ion a n d loca t ion views for t h e va r iou s
wir e h a r n ess con n ect or s, splices a n d gr ou n ds.
POWER FOLDAWAY M I RROR REMOVAL

SWI T CH - EX PORT (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive ca ble.
(2) Rem ove t h e u pper a n d lower st eer in g colu m n
DESCRIPTION sh r ou d (Refer t o 19 - STE E RING/COLUMN/LOWE R
Th ese veh icles m a y be equ ipped wit h P ower F old- SH ROUD - RE MOVAL).
a wa y Mir r or s. Th is fea t u r e a llows bot h t h e dr iver (3) Discon n ect elect r ica l h a r n ess con n ect or.
a n d pa ssen ger side view m ir r or s t o fold in wa r d
(r et r a ct ) on dem a n d. Th e veh icle h a s a n a ddit ion a l
swit ch loca t ed on t h e st eer in g colu m n t h a t con t r ols
t h e foldin g fu n ct ion of t h e m ir r or a ssem bly (F ig. 2).
Th e fold-a wa y side view m ir r or is a t t a ch ed t o t h e
veh icle’s door in t h e sa m e m a n n er a s m ir r or s wit h ou t
t h e fold-a wa y opt ion . Th e fold-a wa y m ir r or s u n iqu e
opt ion is t h e in t er n a l m ot or wh ich a llows t h e m ir r or s t o
fold in wa r d on dem a n d. Th e fold-a wa y m ir r or m ot or is
n ot ser vicea ble sepa r a t ely a n d if a m ot or is fou n d t o be
fa u lt y t h e en t ir e side view m ir r or m u st be r epla ced.
OPERATION
Wh en t h e m ir r or r et r a ct swit ch is depr essed, bot h
of t h e side view m ir r or s will fold in wa r d, Th u s m a k-
in g t h e over a ll widt h of t h e veh icle t h e sm a llest pos-
sible. Th is ca n be h elpfu l wer e pa r kin g spa ce is a Fig. 3 POWER FOLDING MIRROR SWITCH
a bsolu t e m in im u m . 1 - STEERING COLUMN SHROUD
Wh en t h e dr iver ’s door is open ed, on ly t h e dr iver ’s 2 - POWER FOLDAWAY SWITCH
door m ir r or will u n fold. If t h e pa ssen ger door is
open ed, bot h m ir r or s will u n fold. (4) Rem ove swit ch fr om st eer in g colu m n sh r ou d
Th e power fold a wa y m ir r or syst em con sist s of t h e fol- (F ig. 3).
lowin g com pon en t s: m ir r or swit ch , side view m ir r or,
POWER FOLDAWAY M I RROR SWI T CH - EX PORT (Cont inue d)
INSTALLATION MIRROR SELECT SWITCH IN “LEFT”

(1) In st a ll swit ch t o st eer in g colu m n sh r ou d. POSITION
(2) Con n ect wir e h a r n ess con n ect or. UP PIN 9 - PIN 13,
(3) In st a ll t h e u pper a n d lower st eer in g colu m n PIN 1 - PIN 11,
sh r ou d (Refer t o 19 - STE E RING/COLUMN/LOWE R PIN 9 - PIN 12
SH ROUD - INSTALLATION).
(4) Con n ect t h e ba t t er y n ega t ive ca ble. LEFT PIN 9 - PIN 8,
PIN 1 - PIN 11,
PIN 9 - PIN 7
REM OT E SWI T CH DOWN PIN 9 - PIN 1,
PIN 13 - PIN 11,
PIN 12 - PIN 11
RIGHT PIN 9 - PIN 1,
PIN 8 - PIN 11,
REMOTE SWITCH
PIN 7 - PIN 11
(1) Rem ove power m ir r or swit ch . (Refer t o 8 -
E LE CTRICAL/P OWE R MIRRORS/P OWE R MIRROR
SWITCH - RE MOVAL). (4) If r esu lt s sh own in t h e t a ble a r e n ot obt a in ed,
(2) Discon n ect wir in g h a r n ess a t swit ch con n ect or. r epla ce t h e swit ch .
(3) Usin g a oh m m et er, t est for con t in u it y bet ween
t h e t er m in a ls of t h e swit ch (F ig. 4). REMOVAL
ca ble.
(2) Rem ove in st r u m en t pa n el lower cover.
(3) F r om beh in d h ea dla m p swit ch a ssem bly,
depr ess r et a in in g t a bs a n d pu sh swit ch fr om in st r u -
m en t pa n el.
(4) Discon n ect wir e con n ect or fr om power m ir r or
Fig. 4 Mirror Switch swit ch .
(5) Disen ga ge lock t a bs a bove a n d below t h e m ir-
M I RROR SWI T CH T EST
r or swit ch .
(6) Rem ove power m ir r or swit ch fr om h ea dla m p
MIRROR SELECT SWITCH IN “LEFT” swit ch bezel.
POSITION
Move Continuity Between INSTALLATION
Button (1) In st a ll power m ir r or swit ch t o t h e h ea dla m p
UP PIN 9 - PIN 12, swit ch bezel.
PIN 6 - PIN 11, (2) Con n ect wir e con n ect or t o t h e power m ir r or
PIN 9 - PIN 13 swit ch .
(3) In ser t h ea dla m p swit ch a ssem bly in t o in st r u -
LEFT PIN 9 - PIN 7, m en t pa n el.
PIN 6 - PIN 11, (4) In st a ll in st r u m en t pa n el lower cover.
PIN 9 - PIN 8 (5) Con n ect ba t t er y n ega t ive ca ble.
DOWN PIN 9 - PIN 6,
PIN 12 - PIN 11,
PIN 13 - PIN 11 SI DEV I EW M I RROR
RIGHT PIN 9 - PIN 6,
PIN 7 - PIN 11, REMOVAL
PIN 8 - PIN 11 F or ser vice pr ocedu r es, (Refer t o 23 - BODY/E XTE -
RIOR/SIDE VIE W MIRROR - RE MOVAL).
MIRROR SELECT SWITCH IN “RIGHT”
POSITION
Move Continuity Between
Button
RS POWER SEAT SYSTEM 8N - 31
POWER SEAT SY ST EM
TABLE OF CONTENTS
page page
POWER SEAT SYSTEM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 36

DESCRIPTION MEMORY SWITCH
POWER SEAT SYSTEM . . . . . . . . . . . . . . . . 31 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 36
MEMORY SYSTEM . . . . . . . . . . . . . . . . . . . . 32 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
OPERATION DIAGNOSIS AND TESTING
POWER SEAT SYSTEM . . . . . . . . . . . . . . . . 32 MEMORY SWITCH . . . . . . . . . . . . . . . . . . . . 37
MEMORY SYSTEM . . . . . . . . . . . . . . . . . . . . 33 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
DIAGNOSIS AND TESTING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 37
POWER SEAT SYSTEM . . . . . . . . . . . . . . . . 33 POWER SEAT TRACK
MEMORY SYSTEM . . . . . . . . . . . . . . . . . . . . 33 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 37
SEAT SWITCH OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 34 DIAGNOSIS AND TESTING
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 POWER SEAT TRACK . . . . . . . . . . . . . . . . . . 38
DRIVER SEAT SWITCH . . . . . . . . . . . . . . . . . 34 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 39
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
POWER SEAT SY ST EM
DESCRI PT I ON
POWER SEAT SYSTEM
Th e power sea t syst em opt ion a llows t h e dr iver
a n d fr on t sea t pa ssen ger t o elect r ica lly a dju st t h eir
sea t in g posit ion s for opt im u m con t r ol a n d com for t .
Th e dr iver side power fr on t sea t ca n be a dju st ed in
eigh t differ en t dir ect ion s: u p, down , fr on t u p, fr on t
down , r ea r u p, r ea r down , for wa r d, r ea r wa r d a n d
r eclin er for wa r d a n d r ea r wa r d. Th e pa ssen ger side
power fr on t sea t ca n be a dju st ed in fou r differ en t
dir ect ion s: for wa r d, r ea r wa r d a n d r eclin er for wa r d
a n d r ea r wa r d.
Th e power sea t syst em r eceives ba t t er y cu r r en t
t h r ou gh a 40 a m p fu se in t h e In t egr a t ed P ower Mod-
u le (IP M) a n d a 30 a m p cir cu it br ea ker u n der t h e
sea t so t h a t t h e power sea t s r em a in oper a t ion a l,
r ega r dless of t h e ign it ion swit ch posit ion .
WARNING: SOME VEHICLES ARE EQUIPPED WITH Fig. 1 IDENTIFYING A SIDE AIRBAG EQUIPPED
SEATBACK MOUNTED AIRBAGS (Fig. 1). BEFORE SEAT
ATTEMPTING TO DIAGNOSE OR SERVICE ANY 1 - AIRBAG LABEL
SEAT OR POWER SEAT SYSTEM COMPONENT
YOU MUST FIRST DISCONNECT AND ISOLATE THE RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
BATTERY NEGATIVE CABLE. THEN WAIT TWO MIN- AND POSSIBLE PERSONAL INJURY.
UTES FOR THE SYSTEM CAPACITOR TO DIS- Th e eigh t -wa y dr iver side power sea t is a lso a va il-
CHARGE BEFORE FURTHER SYSTEM SERVICE. a ble wit h t h e h ea t ed sea t a n d/or m em or y sea t sys-
THIS IS THE ONLY SURE WAY TO DISABLE THE t em . Th e m em or y sea t syst em a u t om a t ica lly
AIRBAG SYSTEM. FAILURE TO DO SO COULD posit ion s t h e power sea t for t wo differ en t dr iver s.
8N - 32 POWER SEAT SYSTEM RS
POWER SEAT SY ST EM (Cont inue d)
(Refer t o 8 - E LE CTRICAL/H E ATE D SE ATS - • P osit ion pot en t iom et er s on t h e dr iver side power
DE SCRIP TION) for m or e in for m a t ion on t h e h ea t ed sea t t r a ck a n d power sea t r eclin er m ot or s
sea t opt ion . (Refer t o 8 - E LE CTRICAL/P OWE R • E lect r on ic Veh icle In for m a t ion Cen t er (E VIC)
SE ATS - DE SCRIP TION - ME MORY SE AT SYS- • Ra dio r eceiver (if P CI da t a bu s ca pa ble)
TE M) for m or e in for m a t ion on t h e m em or y sea t sys- Cer t a in fu n ct ion s of t h e m em or y syst em r ely u pon
t em . r esou r ces sh a r ed wit h ot h er elect r on ic m odu les in t h e
Th e power sea t syst em in clu des t h e followin g com - veh icle over t h e P r ogr a m m a ble Com m u n ica t ion s
pon en t s: In t er fa ce (P CI) da t a bu s n et wor k. In it ia l dia gn osis of
• P ower sea t r eclin er s t h ese elect r on ic m odu les or t h e P CI da t a bu s n et wor k
• P ower sea t swit ch es r equ ir es t h e u se of a DRBIII! or equ iva len t sca n t ool
• P ower sea t t r a cks a n d t h e pr oper Dia gn ost ic P r ocedu r es in for m a t ion . If
• Cir cu it br ea ker t h is m et h od does n ot pr ove con clu sive, t h e pr oper
Th e power sea t syst em wit h m em or y a n d h ea t ed wir in g sch em a t ics a n d t h e ser vice m a n u a l dia gn ost ic
sea t opt ion s in clu des t h e followin g com pon en t s: in for m a t ion a r e r equ ir ed.
• P ower sea t r eclin er Th e ot h er elect r on ic m odu les t h a t m a y a ffect m em -
• P ower sea t swit ch or y syst em oper a t ion a r e:
• P ower sea t t r a ck. • B o d y Co n tro l Mo d u le (B CM) - (Refer t o 8 -
• Mem or y Sea t Mir r or Modu le (MSMM) E LE CTRICAL/E LE CTRONIC CONTROL MOD-
• Mem or y set swit ch ULE S/BODY CONTROL/CE NTRAL TIME R MODUL
• H ea t ed Sea t Modu le (H SM) - DE SCRIP TION) for a ddit ion a l in for m a t ion .
• H ea t ed sea t swit ch • P o w e rtra in Co n tro l Mo d u le (P CM) - (Refer
• E lect r on ic Veh icle In for m a t ion Cen t er (E VIC) t o 8 - E LE CTRICAL/E LE CTRONIC CONTROL
MODULE S/P OWE RTRAIN CONTROL MODULE -
MEMORY SYSTEM DE SCRIP TION) for a ddit ion a l in for m a t ion .
Th e m em or y syst em is a ble t o st or e a n d r eca ll t h e • Tra n s m is s io n Co n tro l Mo d u le (TCM) - (Refer
dr iver side power sea t posit ion s (in clu din g t h e power t o 8 - E LE CTRICAL/E LE CTRONIC CONTROL
r eclin er posit ion ), power a dju st a ble peda l posit ion s MODULE S/TRANSMISSION CONTROL MODULE -
a n d t h e dr iver ou t side m ir r or posit ion for t wo dr iv- DE SCRIP TION) for a ddit ion a l in for m a t ion .
er s. On veh icles equ ipped wit h a fa ct or y r a dio, t h e (Refer t o 8 - E LE CTRICAL/H E ATE D SE ATS -
m em or y syst em is a lso a ble t o st or e a n d r eca ll r a dio DE SCRIP TION) for a ddit ion a l in for m a t ion on t h e
st a t ion pr eset s for t wo dr iver s. Th e m em or y syst em h ea t ed sea t syst em . (Refer t o 8 - E LE CTRICAL/
a lso will st or e a n d r eca ll t h e la st st a t ion list en ed t o P OWE R LOCKS - DE SCRIP TION) for a ddit ion a l
for ea ch dr iver, even if it is n ot on e of t h e pr eset st a - in for m a t ion on t h e RKE syst em .
t ion s.
Th e m em or y syst em will a u t om a t ica lly r et u r n t o
it s pr eset set t in gs wh en t h e cor r espon din g n u m ber ed OPERAT I ON
bu t t on of t h e m em or y swit ch is depr essed, or wh en
t h e door s a r e u n locked u sin g t h e cor r espon din g POWER SEAT SYSTEM
Rem ot e Keyless E n t r y (RKE ) t r a n sm it t er. A cu st om er Th e power sea t syst em r eceives ba t t er y cu r r en t
pr ogr a m m a ble fea t u r e of t h e m em or y syst em a llows t h r ou gh fu se #22 in t h e In t egr a t ed P ower Modu le
t h e RKE r eca ll of m em or y fea t u r es t o be disa bled, if (IP M) a n d a cir cu it br ea ker u n der t h e fr on t sea t s,
desir ed. Th is pr ogr a m m a ble fea t u r e is in t er n a l in t h e r ega r dless of t h e ign it ion swit ch posit ion .
E lect r on ic Veh icle In for m a t ion Cen t er (E VIC) m od- Wh en a power sea t swit ch con t r ol kn ob or kn obs
u le, wh ich is loca t ed in t h e over h ea d con sole. a r e a ct u a t ed, a ba t t er y feed a n d a gr ou n d pa t h a r e
A Mem or y Sea t Mir r or Modu le (MSMM) is u sed t o a pplied t h r ou gh t h e swit ch con t a ct s t o t h e a ppr opr i-
con t r ol a n d in t egr a t e t h e m a n y elect r on ic fu n ct ion s a t e power sea t t r a ck a dju st er m ot or. Th e select ed
a n d fea t u r es in clu ded in t h e m em or y sea t a n d m ir r or a dju st er m ot or oper a t es t o m ove t h e sea t t r a ck
syst em s. t h r ou gh it s dr ive u n it in t h e select ed dir ect ion u n t il
Th e m em or y syst em in clu des t h e followin g com po- t h e swit ch is r elea sed, or u n t il t h e t r a vel lim it of t h e
n en t s: sea t t r a ck is r ea ch ed. Wh en t h e swit ch is m oved in
• Mem or y Sea t Mir r or Modu le (MSMM) t h e opposit e dir ect ion , t h e ba t t er y feed a n d gr ou n d
• Mem or y set swit ch pa t h t o t h e m ot or a r e r ever sed t h r ou gh t h e swit ch
• P osit ion pot en t iom et er s on t h e dr iver ou t side con t a ct s. Th is ca u ses t h e a dju st er m ot or t o r u n in t h e
side view m ir r or opposit e dir ect ion .
• P osit ion pot en t iom et er s on t h e power a dju st a ble No power sea t swit ch sh ou ld be h eld a pplied in a n y
peda l m ot or dir ect ion a ft er t h e sea t t r a ck h a s r ea ch ed it s t r a vel
lim it . Th e power sea t a dju st er m ot or ea ch con t a in a
self-r eset t in g cir cu it br ea ker t o pr ot ect t h em fr om t h e dr iver side power sea t wit h t h e m em or y syst em
over loa d. H owever, con secu t ive or fr equ en t r eset t in g opt ion , t h e P r ogr a m m a ble Com m u n ica t ion s In t er fa ce
of t h e cir cu it br ea ker m u st n ot be a llowed t o con - (P CI) da t a bu s n et wor k a n d a ll of t h e elect r on ic m od-
t in u e, or t h e m ot or m a y be da m a ged. u les t h a t pr ovide in pu t s t o, or r eceive ou t pu t s fr om
t h e m em or y syst em com pon en t s m u st be ch ecked,
MEMORY SYSTEM (Refer t o 8 - E LE CTRICAL/P OWE R SE ATS - DIAG-
Th e Mem or y Sea t Mir r or Modu le (MSMM) r eceives NOSIS AND TE STING).
ba t t er y cu r r en t t h r ou gh fu se #22 in t h e In t egr a t ed
P ower Modu le (IP M) a n d t h e power sea t syst em cir- WARNING: SOME VEHICLES ARE EQUIPPED WITH
cu it br ea ker, loca t ed u n der t h e dr iver side fr on t sea t SEATBACK MOUNTED AIRBAGS. BEFORE
n ea r t h e r ea r edge of t h e sea t cu sh ion pa n . Th e m em - ATTEMPTING TO DIAGNOSE OR SERVICE ANY
or y syst em does n ot oper a t e wit h t h e Ign it ion -Off SEAT OR POWER SEAT SYSTEM COMPONENT
Dr a w (IOD) fu se r em oved. Th e MSMM will dr ive a YOU MUST FIRST DISCONNECT AND ISOLATE THE
m a xim u m of 2 m ot or s a t a t im e in a given dir ect ion . BATTERY NEGATIVE CABLE. THEN WAIT TWO MIN-
If con flict in g dir ect ion s a r e r equ est ed, t h e pr ior it y for UTES FOR THE SYSTEM CAPACITOR TO DIS-
r espon se will be a ppr oxim a t ely a s follows: CHARGE BEFORE FURTHER SYSTEM SERVICE.
• Sea t Tr a ck Rea r wa r d or F or wa r d THIS IS THE ONLY SURE WAY TO DISABLE THE
• Sea t F r on t Down or Up AIRBAG SYSTEM. FAILURE TO DO SO COULD
• Sea t Rea r Down or Up RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
• Reclin er Rea r wa r d or F or wa r d AND POSSIBLE PERSONAL INJURY.
Th e in pu t s fr om t h ese swit ch es t o t h e MSMM is a
(1) If eit h er power sea t is com plet ely in oper a ble,
cu r r en t lim it ed ba t t er y sou r ce fed by t h e MSMM.
ch eck t h e power sea t cir cu it br ea ker, loca t ed u n der
Th is pr ot ect s t h e MSMM pr in t ed cir cu it boa r d t r a ces
t h e t r a ilin g edge of t h e dr iver side power sea t . If t h e
fr om a ct in g a s fu ses. All of t h ese swit ch con t a ct
power sea t cir cu it br ea ker is OK, con t in u e t o t h e
in pu t s t o t h e MSMM a r e n or m a lly closed t o gr ou n d,
n ext st ep.
except wh en a ct u a t ed.
(2) Ch eck for pr oper ba t t er y a n d gr ou n d con n ec-
F or dia gn osis of t h e MSMM, t h e P r ogr a m m a ble
t ion s a t t h e power sea t swit ch a n d/or m em or y sea t
Com m u n ica t ion In t er fa ce (P CI) da t a bu s, or t h e ot h er
m odu le. Repa ir a n y wir in g a s n ecessa r y.
elect r on ic m odu les on t h e P CI da t a bu s t h a t pr ovide
(3) Ch eck t h e power sea t syst em wir e h a r n ess con -
in pu t s a n d ou t pu t s for t h e m em or y syst em , t h e u se of
n ect ion s a n d pin s t o en su r e pr oper cir cu it con t in u it y
a DRBIII! or equ iva len t sca n t ool a n d t h e pr oper
a n d gr ou n d pa t h s.
Dia gn ost ic P r ocedu r es in for m a t ion is r ecom m en ded.
ELECTRONIC VEHICLE INFORMATION CENTER MEMORY SYSTEM

Th e E lect r on ic Veh icle In for m a t ion Cen t er (E VIC) In or der t o obt a in con clu sive t est in g of t h e m em or y
ser ves a s t h e u ser in t er fa ce for t h e m em or y syst em . syst em , t h e P r ogr a m m a ble Com m u n ica t ion s In t er fa ce
It displa ys m em or y syst em st a t u s m essa ges a n d pr o- (P CI) da t a bu s n et wor k a n d a ll of t h e elect r on ic m od-
vides t h e u ser wit h t h e m ea n s for en a blin g a n d dis- u les t h a t pr ovide in pu t s t o, or r eceive ou t pu t s fr om
a blin g t h e m a n y cu st om er pr ogr a m m a ble fea t u r es t h e m em or y syst em com pon en t s m u st be ch ecked.
a va ila ble on t h e veh icle, in clu din g t h ose for t h e m em - Th e m ost r elia ble, efficien t , a n d a ccu r a t e m ea n s t o
or y syst em . dia gn ose t h e dr iver side power sea t wit h t h e m em or y
(Refer t o 8 - E LE CTRICAL/OVE RH E AD CON- syst em opt ion r equ ir es t h e u se of a DRBIII! or
SOLE /E LE CTRONIC VE H ICLE INF O CE NTE R - equ iva len t sca n t ool a n d t h e pr oper Dia gn ost ic P r oce-
DE SCRIP TION) for a ddit ion a l in for m a t ion on t h e du r es in for m a t ion . Th e DRBIII! sca n t ool ca n pr o-
E VIC. vide con fir m a t ion t h a t t h e P CI da t a bu s is fu n ct ion a l,
t h a t a ll of t h e elect r on ic m odu les a r e sen din g a n d
r eceivin g t h e pr oper m essa ges on t h e P CI da t a bu s,
DI AGN OSI S AN D T EST I N G a n d t h a t t h e m em or y syst em is r eceivin g t h e pr oper
h a r d wir ed in pu t s a n d r ela yin g t h e pr oper h a r d
POWER SEAT SYSTEM wir ed ou t pu t s t o per for m it s dr iver side power sea t
F ollowin g a r e t est s t h a t will h elp t o dia gn ose t h e fu n ct ion s.
h a r d wir ed com pon en t s a n d cir cu it s of t h e power sea t (1) If t h e dr iver power sea t exh ibit s a n in t er r u pt ed
syst em . H owever, if t h e veh icle is a lso equ ipped wit h or jer ky m ot ion , en su r e t h e wir e h a r n ess is con n ect ed
t h e opt ion a l m em or y syst em , t h ese t est s m a y n ot cor r ect ly. To ver ify t h e con cer n , obt a in a DRB III! or
pr ove con clu sive in t h e dia gn osis of t h e dr iver side equ iva len t sca n t ool a n d en er gize ea ch a xis on e a t a
power sea t . In or der t o obt a in con clu sive t est in g of t im e. If a n y a xis st ops in a ppr oxim a t ely 2 secon ds
(wit h ou t h it t in g t h e en d of t r a vel), t h e feedba ck for
t h a t a xis m a y h a ve a n open , sh or t or be in cor r ect ly Th e power sea t swit ch ca n n ot be r epa ir ed. If on e
con n ect ed. Ch eck t h e wir in g t o t h a t a xis (m odu le t o swit ch is da m a ged or fa u lt y, t h e en t ir e power sea t
m ot or ). Repa ir a n y wir in g pr oblem s a n d r et r y t h a t swit ch u n it m u st be r epla ced.
a xis. Refer t o t h e a ppr opr ia t e wir in g in for m a t ion for
com plet e cir cu it sch em a t ic or con n ect or pin -ou t in for- OPERATION
m a t ion . Wh en a power sea t swit ch con t r ol kn ob or kn obs
a r e a ct u a t ed, a ba t t er y feed a n d a gr ou n d pa t h a r e
a pplied t h r ou gh t h e swit ch con t a ct s t o t h e power sea t
SEAT SWI T CH t r a ck or r eclin er a dju st er m ot or. Th e select ed
a dju st er m ot or oper a t es t o m ove t h e sea t t r a ck or
DESCRIPTION r eclin er t h r ou gh it s dr ive u n it in t h e select ed dir ec-
t ion u n t il t h e swit ch is r elea sed, or u n t il t h e t r a vel
lim it of t h e a dju st er is r ea ch ed. Wh en t h e swit ch is
m oved in t h e opposit e dir ect ion , t h e ba t t er y feed a n d
gr ou n d pa t h t o t h e m ot or a r e r ever sed t h r ou gh t h e
swit ch con t a ct s. Th is ca u ses t h e a dju st er m ot or t o
r u n in t h e opposit e dir ect ion .
No power sea t swit ch sh ou ld be h eld a pplied in a n y
dir ect ion a ft er t h e a dju st er h a s r ea ch ed it s t r a vel
lim it . Th e power sea t a dju st er m ot or s ea ch con t a in a
self-r eset t in g cir cu it br ea ker t o pr ot ect t h em fr om
over loa d. H owever, con secu t ive or fr equ en t r eset t in g
of t h e cir cu it br ea ker m u st n ot be a llowed t o con -
t in u e, or t h e m ot or m a y be da m a ged.

DRIVER SEAT SWITCH
(1) Rem ove t h e power sea t swit ch , (Refer t o 8 -
E LE CTRICAL/P OWE R SE ATS/DRIVE R SE AT
SWITCH - RE MOVAL).
(2) Usin g a n oh m m et er, ch eck pin #1 of t h e power
sea t swit ch wir e h a r n ess con n ect or for con t in u it y t o
Fig. 2 POWER SEAT SWITCH LOCATION gr ou n d. It sh ou ld be pr esen t . If OK, go t o St ep 3. If
1 - POWER SEAT SWITCH n ot OK, r epa ir t h e open gr ou n d cir cu it a s r equ ir ed.
2 - SEAT CUSHION SIDE SHIELD
(3) Usin g a volt m et er, ch eck pin #5 of t h e power
Veh icles equ ipped wit h a dr iver side power sea t sea t swit ch wir e h a r n ess con n ect or for ba t t er y cu r-
u t ilize a n eigh t -wa y power sea t swit ch . Veh icles r en t . It sh ou ld be pr esen t . If OK, go t o St ep 4. If n ot
equ ipped wit h a pa ssen ger side power sea t u t ilize a OK, r epa ir t h e open volt a ge su pply cir cu it a s
fou r-wa y power sea t swit ch . Th ese power sea t r equ ir ed.
swit ch es fea t u r es t wo kn obs ga n ged t oget h er on t h e (4) Usin g a n oh m m et er, t est t h e power sea t swit ch
ou t boa r d sea t cu sh ion side sh ield (F ig. 2). for con t in u it y, r efer t o SE AT SWITCH CONTINUITY
Th e swit ch is secu r ed t o t h e ba ck of t h e sea t cu sh - TE ST TABLE (F ig. 3). If con t in u it y is n ot pr esen t a s
ion side sh ield wit h t wo scr ews. H owever, t h e con t r ol in dica t ed, r epla ce t h e power sea t swit ch .
kn obs for t h e sea t swit ch u n it m u st be r em oved
befor e t h e sea t swit ch ca n be r em oved fr om t h e side
sh ield.
SEAT SWI T CH (Cont inue d)
SEAT SWI T CH CON T I N U I T Y T EST TABLE
SWITCH CONTINUITY BETWEEN PINS CONTINUITY BETWEEN PINS

POSITION DRIVER PASSENGER
OFF PIN 1 & 4 PIN 1 & 4
PIN 1 & 3 PIN 1 & 3
PIN 1 & 2 PIN 1 & 2
PIN 1 & 10 PIN 1 & 10
PIN 1 & 9 PIN 1 & 9
PIN 1 & 8 PIN 1 & 8
PIN 1 & 7 PIN 1 & 7
PIN 1 & 6 PIN 1 & 6
FRONT RISER
PIN 5 & 7 PIN 5 & 10
UP
FRONT RISER
PIN 5 & 10 PIN 5 & 7
DOWN
CENTER
SWITCH PIN 5 & 6 PIN 5 & 6
FORWARD
CENTER
SWITCH PIN 5 & 3 PIN 5 & 3
REARWARD
REAR RISER UP PIN 5 & 8 PIN 5 & 9
REAR RISER
PIN 5 & 9 PIN 5 & 8
DOWN
RECLINER UP PIN 5 & 2 PIN 5 & 2
RECLINER
PIN 5 & 4 PIN 5 & 4
DOWN
Fig. 3 SEAT SWITCH PIN-OUT

SEAT SWI T CH (Cont inue d)
REMOVAL (4) In st a ll t h e ou t boa r d sea t cu sh ion side cover,

(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive (Refer t o 23 - BODY/SE ATS/SE AT CUSH ION SIDE
ca ble. COVE RS - INSTALLATION).
(2) Usin g a pu sh pin r em over or ot h er su it a ble (5) In st a ll t h e power sea t a n d power r eclin er
wide fla t -bla ded t ool, gen t ly pr y t h e power sea t a n d swit ch kn obs on t o t h e swit ch con t r ol lever s.
power r eclin er swit ch kn obs off of t h e swit ch lever s (6) Recon n ect t h e ba t t er y n ega t ive ca ble.
(F ig. 4).
M EM ORY SWI T CH
DESCRIPTION
Fig. 4 REMOVING SWITCH CONTROL KNOBS -

TYPICAL
(3) Rem ove t h e scr ews t h a t secu r e t h e ou t boa r d
sea t cu sh ion side cover t o t h e sea t cu sh ion fr a m e,
Fig. 5 MEMORY SWITCH LOCATION
(Refer t o 23 - BODY/SE ATS/SE AT CUSH ION SIDE
1 - MEMORY SWITCH
COVE RS - RE MOVAL). 2 - SWITCH BEZEL
(4) P u ll t h e ou t boa r d sea t cu sh ion side cover a wa y
fr om t h e sea t cu sh ion fr a m e fa r en ou gh t o a ccess t h e Veh icles equ ipped wit h t h e m em or y syst em h a ve a
power sea t swit ch wir e h a r n ess con n ect or. m em or y swit ch m ou n t ed t o t h e dr iver side fr on t door
(5) Discon n ect t h e power sea t wir e h a r n ess con n ec- t r im pa n el (F ig. 5). Th is swit ch is u sed t o set a n d r eca ll
t or fr om t h e power sea t swit ch con n ect or r ecept a cle. a ll of t h e m em or y syst em set t in gs for u p t o t wo dr iver s.
(6) Rem ove t h e scr ews t h a t secu r e t h e power sea t Th e m em or y swit ch is a r esist or m u lt iplexed u n it t h a t
swit ch t o t h e in side of t h e ou t boa r d sea t cu sh ion side is h a r d wir ed t o t h e Body Con t r ol Modu le (BCM). Th e
cover. BCM sen ds ou t t h e m em or y syst em set a n d r eca ll
(7) Rem ove t h e power sea t swit ch fr om t h e ou t - r equ est s t o t h e ot h er elect r on ic m odu les over t h e P r o-
boa r d sea t cu sh ion side cover. gr a m m a ble Com m u n ica t ion s In t er fa ce (P CI) da t a bu s.
Th e m em or y swit ch ca n n ot be a dju st ed or r epa ir ed
INSTALLATION a n d, if fa u lt y or da m a ged, it m u st be r epla ced.
(1) P osit ion t h e power sea t swit ch on t o t h e ou t -
boa r d sea t cu sh ion side cover. OPERATION
(2) In st a ll a n d t igh t en t h e scr ews t h a t secu r e t h e Th e m em or y swit ch h a s t h r ee m om en t a r y swit ch
power sea t swit ch t o t h e in side of t h e ou t boa r d sea t bu t t on s la beled Set , 1 a n d 2. Wh en t h e m em or y set
cu sh ion side cover. Tigh t en t h e scr ews t o 1.5 N·m (14 swit ch is depr essed, a r esist a n ce va lu e is sen t t o t h e
in . lbs.). Body Con t r ol Modu le (BCM) via h a r d wir ed con n ec-
(3) Recon n ect t h e power sea t wir e h a r n ess con n ec- t ion s. Wh en t h e m em or y syst em is in “set ” m ode a
t or t o t h e power sea t swit ch con n ect or r ecept a cle. ch im e will be gen er a t ed by t h e BCM.
M EM ORY SWI T CH (Cont inue d)
DI AGN OSI S AN D T EST I N G INSTALLATION

(1) P osit ion t h e m em or y swit ch a n d in st a ll a n d
MEMORY SWITCH t igh t en t h e t wo scr ews t h a t secu r e t h e m em or y
(1) Rem ove t h e m em or y swit ch fr om t h e dr iver s swit ch t o t h e ba ck of t h e dr iver side fr on t door t r im
door pa n el (Refer t o 8 - E LE CTRICAL/P OWE R pa n el swit ch bezel. Tigh t en t h e scr ews t o 2.2 N·m (20
SE ATS/ME MORY SE T SWITCH - RE MOVAL). in . lbs.).
(2) Usin g a n oh m m et er, ch eck t h e con t in u it y of t h e (2) Recon n ect t h e m em or y swit ch wir e h a r n ess
m em or y select swit ch MUX cir cu it bet ween t h e C2 con n ect or t o t h e m em or y swit ch .
wir e h a r n ess con n ect or for t h e Body Con t r ol Modu le (3) In st a ll t h e t r im pa n el swit ch bezel on t o t h e
(BCM) a n d t h e wir e h a r n ess con n ect or for t h e m em - dr iver side fr on t door.
or y swit ch . Th er e sh ou ld be con t in u it y. If OK, go t o (4) Recon n ect t h e ba t t er y n ega t ive ca ble.
St ep 3. If n ot OK, r epa ir t h e open or sh or t ed MUX
cir cu it a s r equ ir ed.
(3) Usin g a n oh m m et er, ch eck t h e con t in u it y of t h e POWER SEAT T RACK
m em or y select swit ch r et u r n cir cu it bet ween t h e C2
wir e h a r n ess con n ect or for t h e BCM a n d t h e wir e DESCRIPTION
h a r n ess con n ect or for t h e m em or y swit ch . Th er e Th e power sea t opt ion in clu des a n elect r ica lly oper-
sh ou ld be con t in u it y. If OK, go t o St ep 4. If n ot OK, a t ed power sea t t r a ck loca t ed u n der t h e fr on t sea t . If
r epa ir t h e open or sh or t ed r et u r n cir cu it a s r equ ir ed. equ ipped wit h Mem or y Syst em , t h e fr on t power sea t
(4) Usin g a n oh m m et er, t est t h e r esist a n ces of t h e t r a ck on t h e dr iver side of t h e veh icle a lso pr ovides
m em or y swit ch , r efer t o t h e ME MORY SWITCH t h e m ou n t in g loca t ion for t h e Mem or y Sea t /Mir r or
TE ST TABLE . If OK, (Refer t o 8 - E LE CTRICAL/ Modu le (MSMM). Th e power sea t cir cu it br ea ker s a r e
P OWE R SE ATS - DIAGNOSIS AND TE STING - m ou n t ed on t h e r ea r of t h e power sea t t r a ck, ju st
ME MORY SYSTE M). If n ot OK, r epla ce t h e m em or y beh in d t h e sea t r ea r t r im pa n el. Th e lower h a lf of t h e
swit ch , (Refer t o 8 - E LE CTRICAL/P OWE R SE ATS/ power sea t t r a ck is secu r ed t o t h e floor pa n el via fou r
ME MORY SE T SWITCH - RE MOVAL). st u ds a n d n u t s t h a t m u st be a ccessed fr om t h e
M EM ORY SWI T CH T EST TABLE u n der side of t h e veh icle. F ou r bolt s secu r e t h e bot -
t om of t h e sea t cu sh ion pa n t o t h e u pper h a lf of t h e
MEMORY RESISTANCE RESISTANCE power sea t t r a ck u n it . F ou r a ddit ion a l bolt s secu r e
SWITCH BETWEEN RANGE t h e sea t ba ck fr a m e t o t h e power sea t t r a ck u n it .
POSITION PINS (OHMS) Th e eigh t -wa y power sea t t r a ck u n it in clu des fou r
r ever sible elect r ic m ot or s t h a t a r e secu r ed t o t h e
NEUTRAL 1&2 24650 ± 5% u pper h a lf of t h e t r a ck u n it . E a ch m ot or m oves t h e
(24.65 k) sea t a dju st er t h r ou gh a com bin a t ion of wor m -dr ive
MEMORY 1 1&2 6850 ± 5% gea r boxes a n d scr ew-t ype dr ive u n it s. E a ch of t h e
(6.85 k) fou r power sea t t r a ck m ot or s u sed on m odels
MEMORY 2 1&2 2100 ± 5% equ ipped wit h t h e opt ion a l m em or y syst em in cor po-
(2.10 k) r a t e a posit ion pot en t iom et er in t egr a l t o t h e m ot or
a ssem bly, wh ich elect r on ica lly m on it or s t h e m ot or
SET 1&2 4490 ± 5%
posit ion . Th is en a bles t h e m em or y syst em t o fu n ct ion
(4.49 k)
by r efer en cin g t h e m ot or posit ion s pr ogr a m m ed in t o
t h e m em or y sea t /m ir r or m odu le.
REMOVAL Th e fr on t a n d r ea r of t h e sea t a r e oper a t ed by t wo
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive sepa r a t e ver t ica l a dju st m en t m ot or s. Th ese m ot or s
ca ble. ca n be oper a t ed in depen den t ly of ea ch ot h er, t ilt in g
(2) Rem ove t h e fr on t door t r im pa n el swit ch bezel t h e en t ir e sea t a ssem bly for wa r d or r ea r wa r d. Th ey
fr om t h e dr iver side fr on t door. Usin g a t h in fla t - ca n a lso be oper a t ed in u n ison by select in g t h e
bla ded pr y t ool, gen t ly pr y t h e swit ch bezel a wa y pr oper power sea t swit ch fu n ct ion s, wh ich will r a ise
fr om t h e dr iver s door t r im pa n el. or lower t h e en t ir e sea t a ssem bly. A t h ir d m ot or is
(3) Discon n ect t h e m em or y swit ch wir e h a r n ess t h e h or izon t a l a dju st m en t m ot or, wh ich m oves t h e
con n ect or fr om t h e m em or y swit ch . sea t t r a ck in t h e for wa r d a n d a ft dir ect ion s. Th e
(4) Rem ove t h e t wo scr ews t h a t secu r e t h e m em or y for t h m ot or is t h e r eclin er a dju st m en t m ot or, wh ich
swit ch t o t h e ba ck of t h e dr iver side fr on t door t r im m oves t h e sea t ba ck in t h e for wa r d a n d r ea r wa r d
pa n el swit ch bezel. dir ect ion s.
(5) Rem ove t h e m em or y swit ch . Th e fou r-wa y power sea t t r a ck u n it in clu des t wo
r ever sible elect r ic m ot or s t h a t a r e secu r ed t o t h e
POWER SEAT T RACK (Cont inue d)
u pper h a lf of t h e t r a ck u n it . E a ch m ot or m oves t h e t h a t t h e a dju st er is n ot a t it s t r a vel lim it . If t h e
sea t a dju st er t h r ou gh a com bin a t ion of wor m -dr ive power sea t t r a ck a dju st er st ill oper a t es in on e dir ec-
gea r boxes a n d scr ew-t ype dr ive u n it s. Th e h or izon t a l t ion on ly, (Refer t o 8 - E LE CTRICAL/P OWE R
a dju st m en t m ot or m oves t h e sea t t r a ck in t h e for- SE ATS/DRIVE R SE AT SWITCH - DIAGNOSIS AND
wa r d a n d a ft dir ect ion s. Th e r eclin er a dju st m en t TE STING). If t h e power sea t t r a ck a dju st er does n ot
m ot or m oves t h e sea t ba ck in t h e for wa r d a n d r ea r- oper a t e in m or e t h a n on e dir ect ion , per for m t h e fol-
wa r d dir ect ion s. lowin g t est s.
Th e power sea t t r a ck u n it ca n n ot be r epa ir ed, a n d
is ser viced on ly a s a com plet e u n it . If a n y com pon en t TESTING POWER SEAT TRACK MOTORS
in t h is u n it is fa u lt y or da m a ged, t h e en t ir e power (1) Ch eck t h e power sea t cir cu it br ea ker u n der t h e
sea t t r a ck u n it m u st be r epla ced. sea t . If OK, go t o St ep 2. If n ot OK, r epla ce t h e
fa u lt y power sea t cir cu it br ea ker.
OPERATION (2) Ch eck for ba t t er y volt a ge a t t h e power sea t cir-
Wh en t h e power sea t swit ch con t r ol kn ob or kn obs cu it br ea ker u n der t h e sea t . If OK, go t o St ep 3. If
a r e a ct u a t ed, a ba t t er y feed a n d a gr ou n d pa t h a r e n ot OK, r epa ir t h e open fu sed B(+) cir cu it t o t h e fu se
a pplied t h r ou gh t h e swit ch con t a ct s t o t h e power sea t in t h e In t egr a t ed P ower Modu le (IP M) a s r equ ir ed.
t r a ck or r eclin er a dju st er m ot or. Th e select ed (3) Rem ove t h e ou t boa r d sea t cu sh ion side cover,
a dju st er m ot or oper a t es t o m ove t h e sea t t r a ck or (Refer t o 23 - BODY/SE ATS/SE AT CUSH ION SIDE
r eclin er t h r ou gh it s dr ive u n it in t h e select ed dir ec- COVE RS - RE MOVAL). Discon n ect t h e wir e h a r n ess
t ion u n t il t h e swit ch is r elea sed, or u n t il t h e t r a vel con n ect or fr om t h e power sea t swit ch . Ch eck for ba t -
lim it of t h e a dju st er is r ea ch ed. Wh en t h e swit ch is t er y volt a ge a t t h e fu sed B(+) cir cu it ca vit y of t h e
m oved in t h e opposit e dir ect ion , t h e ba t t er y feed a n d power sea t swit ch wir e h a r n ess con n ect or. If OK, go
gr ou n d pa t h t o t h e m ot or a r e r ever sed t h r ou gh t h e t o St ep 4. If n ot OK, r epa ir t h e open fu sed B(+) cir-
swit ch con t a ct s. Th is ca u ses t h e a dju st er m ot or t o cu it t o t h e power sea t cir cu it br ea ker u n der t h e sea t
r u n in t h e opposit e dir ect ion . a s r equ ir ed.
No power sea t swit ch sh ou ld be h eld a pplied in a n y (4) Ch eck for con t in u it y bet ween t h e gr ou n d cir-
dir ect ion a ft er t h e a dju st er h a s r ea ch ed it s t r a vel cu it ca vit y of t h e power sea t swit ch wir e h a r n ess con -
lim it . Th e power sea t a dju st er m ot or s ea ch con t a in a n ect or a n d a kn own good gr ou n d. Th er e sh ou ld be
self-r eset t in g cir cu it br ea ker t o pr ot ect t h em fr om con t in u it y. If OK, go t o St ep 5. If n ot OK, r epa ir t h e
over loa d. H owever, con secu t ive or fr equ en t r eset t in g open gr ou n d cir cu it a s r equ ir ed.
of t h e cir cu it br ea ker m u st n ot be a llowed t o con - (5) Test t h e power sea t swit ch , (Refer t o 8 - E LE C-
t in u e, or t h e m ot or m a y be da m a ged. TRICAL/P OWE R SE ATS/DRIVE R SE AT SWITCH -
DIAGNOSIS AND TE STING). If t h e swit ch t est s OK,
t est t h e cir cu it s of t h e power sea t wir e h a r n ess
DI AGN OSI S AN D T EST I N G bet ween t h e in oper a t ive power sea t t r a ck a dju st er
m ot or a n d t h e power sea t swit ch for sh or t s or open s.
POWER SEAT TRACK If t h e cir cu it s ch eck OK, r epla ce t h e fa u lt y power
sea t t r a ck u n it . If t h e cir cu it s a r e n ot OK, r epa ir t h e
WARNING: SOME VEHICLES ARE EQUIPPED WITH power sea t wir e h a r n ess a s r equ ir ed.
SEATBACK MOUNTED AIRBAGS. BEFORE
ATTEMPTING TO DIAGNOSE OR SERVICE ANY REMOVAL
SEAT OR POWER SEAT SYSTEM COMPONENT
YOU MUST FIRST DISCONNECT AND ISOLATE THE WARNING: SOME VEHICLES ARE EQUIPPED WITH
BATTERY NEGATIVE CABLE. THEN WAIT TWO MIN- SEATBACK MOUNTED AIRBAGS. BEFORE
UTES FOR THE SYSTEM CAPACITOR TO DIS- ATTEMPTING TO DIAGNOSE OR SERVICE ANY
CHARGE BEFORE FURTHER SYSTEM SERVICE. SEAT OR POWER SEAT SYSTEM COMPONENT
THIS IS THE ONLY SURE WAY TO DISABLE THE YOU MUST FIRST DISCONNECT AND ISOLATE THE
AIRBAG SYSTEM. FAILURE TO DO SO COULD BATTERY NEGATIVE CABLE. THEN WAIT TWO MIN-
RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT UTES FOR THE SYSTEM CAPACITOR TO DIS-
AND POSSIBLE PERSONAL INJURY. CHARGE BEFORE FURTHER SYSTEM SERVICE.
THIS IS THE ONLY SURE WAY TO DISABLE THE
Act u a t e t h e power sea t swit ch t o m ove t h e power AIRBAG SYSTEM. FAILURE TO DO SO COULD
sea t t r a ck a dju st er s in ea ch dir ect ion . Th e power sea t RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
t r a ck a dju st er s sh ou ld m ove in ea ch of t h e select ed AND POSSIBLE PERSONAL INJURY.
dir ect ion s. If a power sea t t r a ck a dju st er oper a t es in
on e dir ect ion on ly, m ove t h e a dju st er a sh or t dist a n ce (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
in t h e opposit e dir ect ion a n d t est a ga in t o be cer t a in ca ble.
POWER SEAT T RACK (Cont inue d)
(2) Rem ove t h e a ppr opr ia t e sea t fr om t h e veh icle INSTALLATION
a n d pla ce it on a clea n wor k su r fa ce, (Refer t o 23 - (1) P osit ion t h e sea t cu sh ion on t h e sea t t r a ck.
BODY/SE ATS/SE AT - RE MOVAL). (2) In st a ll t h e fou r sea t t r a ck r et a in in g bolt s in t h e
(3) Rem ove t h e Mem or y Sea t /Mir r or Modu le sea t cu sh ion pa n . Tor qu e t h e bolt s t o 28.5 N·m (21 ft -
(MSMM) m ou n t in g fa st en er s (if equ ipped). lbs.).
(4) Discon n ect t h e MSMM elect r ica l h a r n ess con - (3) P osit ion t h e sea t ba ck a n d in st a ll t h e t wo sea t
n ect or s a n d r em ove t h e MSMM fr om t h e power sea t ba ck fr a m e m ou n t in g bolt s a n d t h e t wo sea t ba ck
t r a ck (if equ ipped). r eclin er bolt s. Tor qu e t h e bolt s t o 55 N·m (40.5
(5) Rem ove t h e fr on t sea t t r a ck r ea r cover, (Refer ft -lbs.).
t o 23 - BODY/SE ATS/SE AT TRACK RE AR COVE R - (4) Rou t e a n d con n ect t h e elect r ica l con n ect or s
RE MOVAL). bet ween t h e power sea t t r a ck a n d t h e sea t a ssem bly.
(6) Rem ove t h e sea t side cover a n d power sea t (5) In st a ll t h e sea t side cover a n d power sea t
swit ch a s a n a ssem bly (Refer t o 23 - BODY/SE ATS/ swit ch a s a n a ssem bly (Refer t o 23 - BODY/SE ATS/
SE AT CUSH ION SIDE COVE RS - RE MOVAL). SE AT CUSH ION SIDE COVE RS - INSTALLATION).
(7) Discon n ect a ll elect r ica l con n ect or s con n ect in g (6) In st a ll t h e fr on t sea t t r a ck r ea r cover, (Refer t o
t h e power sea t t r a ck t o t h e sea t a ssem bly. 23 - BODY/SE ATS/SE AT TRACK RE AR COVE R -
(8) P u ll t h e sea t ba ck t r im cover u p sligh t ly t o INSTALLATION).
a ccess a n d r em ove t h e t wo sea t ba ck fr a m e m ou n t in g (7) P osit ion t h e Mem or y Sea t /Mir r or Modu le
bolt s a n d a lso r em ove t wo sea t ba ck r eclin er bolt s. (MSMM) a n d con n ect t h e MSMM elect r ica l con n ec-
(9) Rem ove fou r sea t t r a ck m ou n t in g bolt s fr om t or s (if equ ipped).
t h e sea t cu sh ion pa n . (8) In st a ll t h e MSMM m ou n t in g fa st en er s (if
(10) Rem ove t h e power sea t t r a ck fr om t h e sea t . equ ipped).
(9) In st a ll t h e sea t a ssem bly in t h e veh icle (Refer
t o 23 - BODY/SE ATS/SE AT - INSTALLATION).
8N - 40 POWER SLIDING DOOR SYSTEM RS
POWER SLI DI N G DOOR SY ST EM
TABLE OF CONTENTS
page page
POWER SLIDING DOOR SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

DIAGNOSIS AND TESTING LOWER DRIVE UNIT
POWER SLIDING DOOR SYSTEM ... . . . . . 42 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 53
STANDARD PROCEDURE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
POWER SLIDING DOOR LEARN CYCLE . . . . 48 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
PUSH-PIN GROMMET REPLACEMENT . . . . . 48 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 54
POWER SLIDING DOOR ADJUSTMENT . . . . 49 FLEX DRIVE
LATCH DESCRIPTION . . . . . . . . ........ . . . . . . . . . 55
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 49 OPERATION . . . . . . . . . . ........ . . . . . . . . . 55
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 REMOVAL . . . . . . . . . . . . ........ . . . . . . . . . 55
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 INSTALLATION . . . . . . . . ........ . . . . . . . . . 56
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 50 LOWER DRIVE UNIT TRACK & RACK
SLIDING DOOR MOTOR DESCRIPTION . . . . . . . . ........ . . . . . . . . . 57
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 51 OPERATION . . . . . . . . . . ........ . . . . . . . . . 57
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 REMOVAL . . . . . . . . . . . . ........ . . . . . . . . . 57
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 INSTALLATION . . . . . . . . ........ . . . . . . . . . 58
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 51 WIRING HARNESS
FULL OPEN SWITCH DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 59
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 52 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
B-PILLAR SWITCH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 59
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 52
POWER SLI DI N G DOOR E a ch power slidin g door h a s it s own door con t r ol

m odu le, loca t ed in t h e cen t er of t h e door beh in d t h e
SY ST EM door t r im pa n el. (Refer t o 8 - E LE CTRICAL/E LE C-
TRONIC CONTROL MODULE S/DOOR CONTROL
DESCRIPTION MODULE - DE SCRIP TION) Th e power slidin g door
Som e veh icles a r e equ ipped wit h a power slidin g m ot or is loca t ed in t h e fr on t por t ion of t h e door, on
door syst em . Veh icles m a y be equ ipped wit h on ly a t h e in n er door pa n el sh eet m et a l. Th e la t ch a ssem bly
r igh t side power slidin g door or a r igh t a n d left side is loca t ed in t h e r ea r of t h e power slidin g door, n ea r
power slidin g door s. Th e com pon en t s of t h e power t h e body lin e. Th e lower dr ive u n it is a t t a ch ed t o t h e
slidin g door syst em a r e: lower door h in ge. Th e flex dr ive a ssem bly con n ect s
• Door m ot or a ssem bly t h e door m ot or t o t h e lower dr ive u n it . Th e wir e h a r-
• La t ch a ssem bly n ess a n d t r a ck a n d t h e lower dr ive u n it t r a ck a r e vis-
• Slidin g door con t r ol m odu le ible wit h t h e door open in t h e lower door sill a r ea .
• Lower dr ive u n it a ssem bly Th e power slidin g door fu ll open swit ch is loca t ed
• F lex dr ive a ssem bly u n der t h e lower dr ive u n it a n d is pa r t of t h e h old
• Wir e h a r n ess a n d t r a ck open la t ch a ssem bly. Th e pa wl, r a t ch et , h a n dle a n d
• Lower dr ive u n it t r a ck a n d r a ck a ssem bly ch ild lockou t swit ch es a r e a ll loca t ed on t h e power
• F u ll open swit ch slidin g door la t ch a ssem bly. Th e B-pilla r swit ch is a n
• B-pilla r swit ch open a n d close com m a n d swit ch loca t ed on t h e in t e-
• Over h ea d con sole swit ch r ior B-pilla r t r im . Th e over h ea d con sole swit ch , is a n
• Key fob swit ch es (F ig. 1) open a n d close com m a n d swit ch loca t ed in t h e veh i-
• P a wl swit ch cle’s over h ea d con sole.
• Ra t ch et swit ch Soft wa r e t ech n ology h a s en a bled t h e power slidin g
• Ch ild lockou t a n d h a n dle swit ch es door con t r ol m odu le t o det ect r esist a n ce t o door
RS POWER SLIDING DOOR SYSTEM 8N - 41
POWER SLI DI N G DOOR SY ST EM (Cont inue d)
WARNING: BE CERTAIN TO READ ALL WARNINGS
AND CAUTIONS IN POWER SLIDING DOOR OPER-
ATION BEFORE ATTEMPTING ANY SERVICE OF
THE POWER SLIDING DOOR SYSTEM OR COMPO-
NENTS.
OPERATION
Wit h t h e pu sh of a power slidin g door open /close
com m a n d swit ch (key fob, over h ea d con sole or B-pil-
la r m ou n t ed) a sign a l is sen t ou t t o t h e Body Con t r ol
Modu le (BCM). Th e BCM t h en sen ds a sign a l ou t on
t h e P r ogr a m m a ble Com m u n ica t ion In t er fa ce (P CI)
Da t a Bu s cir cu it t o t h e power slidin g door m odu le.
Th e power slidin g door m odu le t h en sign a ls t h e
power slidin g door la t ch t o r elea se t h e door t o t h e
u n la t ch ed a n d m ova ble posit ion . Th e m ot or t h en
st a r t s a n open cycle.
Du r in g t h e door cycle, if t h e power slidin g door
m odu le det ect s su fficien t r esist a n ce t o door t r a vel,
su ch a s a n obst r u ct ion in t h e door ’s pa t h , t h e power
slidin g door m odu le will im m edia t ely st op door m ove-
Fig. 1 KEY FOB m en t a n d r ever se door t r a vel t o t h e fu ll open or
1 - LEFT SLIDING DOOR SWITCH closed posit ion . Th e a bilit y for t h e power slidin g door
2 - RIGHT SLIDING DOOR SWITCH m odu le t o det ect r esist a n ce t o door t r a vel is a ccom -
3 - LIFTGATE SWITCH plish ed by h a ll effect sen sor s det ect in g t h e door
m ot or speed.
t r a vel. Th is a llows t h e power slidin g door t o st op a n d Th e power slidin g door con t r ol m odu le h a s t h e a bil-
r ever se dir ect ion a n y t im e a n obst r u ct ion is felt or it y t o lea r n . An yt im e a door is open ed or closed u sin g
a n y of t h e com m a n d swit ch es a r e oper a t ed (wh ile t h e power slidin g door syst em t h e m odu le lea r n s
closin g on ly). Ba t t er y volt a ge is su pplied t o t h e power fr om it s cycle. If a r epla cem en t power slidin g door
slidin g door syst em t h r ou gh a 40 a m p fu se, loca t ed in com pon en t is in st a lled or a door a dju st m en t is m a de,
t h e In t egr a t ed P ower Modu le (IP M) a ssem bly. Th e t h e m odu le m u st r e-lea r n t h e effor t r equ ir ed t o open
ch ild lockou t swit ch pr even t s ch ildr en fr om open in g or close t h e door. A lea r n cycle ca n be per for m ed wit h
or a ct u a t in g t h e power slidin g door syst em wh en a com plet e cycle of t h e door, u sin g a n y on e of t h e
desir ed. In t h e u n likely even t t h a t t h e power slidin g com m a n d swit ch es or wit h t h e DRB III!, or equ iva -
door syst em develops a fa u lt , t h e power slidin g door len t sca n t ool. (Refer t o 8 - E LE CTRICAL/P OWE R
ca n st ill be oper a t ed m a n u a lly fr om t h e in t er ior or DOORS - STANDARD P ROCE DURE - LE ARN
ext er ior door h a n dle, ju st like a st a n da r d m a n u a l CYCLE ) for det a iled in st r u ct ion s.
slidin g door. Th e power slidin g door syst em is design ed wit h a
Th e power slidin g door con t r ol m odu le com m u n i- n u m ber of syst em in h ibit or s. Th ese in h ibit or s a r e
ca t es on t h e P r ogr a m m a ble Com m u n ica t ion In t er fa ce n ecessa r y for sa fet y a n d/or fea sibilit y of t h e power
(P CI) Da t a Bu s Cir cu it . Th er efor e, t h e power slidin g slidin g door syst em . Th e power slidin g door syst em
door con t r ol m odu le ca n gen er a t e a n d st or e it s own in h ibit or s a r e:
Dia gn ost ic Tr ou ble Codes (DTC). A dia gn ost ic sca n • Th e power slidin g door m u st be in t h e fu ll open
t ool, su ch a s t h e DRB III! is u sed t o r ea d a n d dia g- or closed posit ion in or der for t h e power slidin g door
n ose t h ese t r ou ble codes. syst em t o st a r t a cycle. If t h e door is n ot in t h is posi-
t ion (ba sed on t h e in pu t fr om t h e fu ll open , pa wl or
NOTE: It may be possible to generate Sliding Door
r a t ch et swit ch es) t h e door con t r ol m odu le will n ot
Diagnostic Trouble Codes during normal power
r espon d t o com m a n d swit ch in pu t s.
sliding door operation. Refer to the Body Diagnos-
• Th e t r a n sm ission m u st be in p a rk o r n e u tra l
tic Manual for a complete list of diagnostic routines.
in or der for t h e power slidin g door syst em t o st a r t a
F or a ddit ion a l in for m a t ion , (Refer t o 8 - E LE CTRI- cycle.
CAL/P OWE R DOORS - OP E RATION). Refer t o t h e • Th e ch ild lockou t swit ch m u st be in t h e
a ppr opr ia t e wir in g in for m a t ion for com plet e cir cu it “UNLOCKE D” posit ion in or der for t h e power slidin g
sch em a t ic or con n ect or pin -ou t in for m a t ion . door syst em s B-pilla r swit ch es t o fu n ct ion .
• If m u lt iple obst a cles a r e det ect ed du r in g t h e WARNING: NEVER ATTEMPT TO DRIVE AWAY WITH
sa m e power open or close cycle t h e power slidin g THE POWER SLIDING DOOR IN MOTION. YOU
door m a y go in t o fu ll m a n u a l m ode. COULD DAMAGE THE POWER SLIDING DOOR SYS-
• If sever e Dia gn ost ic Tr ou ble Codes (DTC) a r e TEM OR COMPONENTS AND/OR CAUSE PER-
st or ed in t h e power slidin g door con t r ol m odu le t h e SONAL INJURY.
power slidin g door m a y go in t o fu ll m a n u a l m ode.
• Du e t o t h e h igh pr essu r e cr ea t ed in t h e pa ssen -
ger com pa r t m en t wit h t h e blower m ot or on h igh , t h e
power slidin g door m a y n ot com plet e a power close
cycle u n less a win dow is cr a cked, a llowin g t h e pr es-
su r e t o esca pe. Th is sit u a t ion will on ly be exper i- POWER SLIDING DOOR SYSTEM
en ced on som e veh icles, or veh icles wit h br a n d n ew Th e power slidin g door syst em con t a in s m a n y com -
side door wea t h er sea ls in st a lled. pon en t s a n d m odu les. In or der t o obt a in con clu sive
• Th e fu el t a n k filler door m u st be in t h e closed t est in g, t h e P r ogr a m m a ble Com m u n ica t ion s In t er fa ce
posit ion . Du e t o t h e slidin g door in t er fer en ce wit h (P CI) da t a bu s n et wor k a n d a ll of t h e elect r on ic m od-
t h e open fu el t a n k filler door, a m ech a n ica l lin ka ge u les t h a t pr ovide in pu t s t o, or r eceive ou t pu t s fr om
pr even t s t h e side door fr om open in g a n d st r ikin g t h e t h e power slidin g door syst em m u st be ch ecked.
fu el door. Refer t o t h e Body sect ion of t h is m a n u a l for Th e power slidin g door syst em wa s design ed t o be
det a iled in for m a t ion on t h e fu el door lockou t fea t u r e. dia gn osed wit h a n a ppr opr ia t e dia gn ost ic sca n t ool,
su ch a s t h e DRB III!. Th e m ost r elia ble, efficien t ,
POWER SLIDING DOOR SYSTEM WARNINGS a n d a ccu r a t e m ea n s t o dia gn ose t h e power slidin g
door syst em r equ ir es t h e u se of a DRB III! sca n t ool
WARNING: ALWAYS DISCONNECT THE NEGATIVE a n d t h e pr oper Body Dia gn ost ic P r ocedu r es m a n u a l.
BATTERY CABLE BEFORE ATTEMPTING ANY Th e DRB III! ca n be u sed t o obser ve va r iou s swit ch
POWER SLIDING DOOR SYSTEM SERVICE. st a t u ses t h r ou gh ou t t h e power slidin g door syst em t o
h elp t h e t ech n icia n dia gn ose a defect ive swit ch or
com pon en t . Th e DRB III! ca n a lso be u sed t o a ct u a t e
WARNING: EXTREME CARE MUST BE TAKEN TO va r iou s com pon en t s t h r ou gh ou t t h e power slidin g
PREVENT OBJECTS FROM ENTERING THE DOORS door syst em t o h elp t h e t ech n icia n dia gn ose a defec-
PATH ONCE THE DOOR REACHES THE CINCH t ive com pon en t .
MOTOR CONTACT (APPROXIMATELY 1 INCH Befor e a n y t est in g of t h e power slidin g door syst em
BEFORE FULLY CLOSED). NEVER PLACE is a t t em pt ed, t h e ba t t er y sh ou ld be fu lly ch a r ged, a ll
OBJECTS IN THE POWER SLIDING DOOR WHEN bu ilt -in power slidin g door syst em in h ibit or s r ea d
CINCHING CLOSED. THE OBSTACLE DETECTION a n d u n der st ood (Refer t o 8 - E LE CTRICAL/P OWE R
FUNCTION IS INOPERATIVE DURING THE CINCH DOORS - OP E RATION) a n d a ll wir e h a r n ess a n d
PHASE AND DAMAGE TO THE VEHICLE, POWER gr ou n d con n ect ion s in spect ed a r ou n d t h e a ffect ed
SLIDING DOOR SYSTEM OR COMPONENTS a r ea s on t h e veh icle.
AND/OR PERSONAL INJURY MAY OCCUR. Th e followin g a r e qu ick r efer en ce dia gn ost ic t a bles
t o h elp wh en dia gn osin g a n d t est in g t h e power slid-
in g door syst em .
WARNING: NEVER ATTEMPT TO ENTER OR EXIT
THE VEHICLE WHILE THE POWER SLIDING DOOR
IS IN MOTION. YOU COULD DAMAGE THE POWER
SLIDING DOOR SYSTEM OR COMPONENTS
AND/OR CAUSE PERSONAL INJURY.
POWER SLI DI N G DOOR SY ST EM DI AGN OSI S

Door opens unexpectedly Inoperative sliding door control module Disconnect then reconnect battery negative
or Body Control Module (BCM) cable to reset module. Cycle door, if no
function exists check for loose wire
connections, Refer to the Body Diagnostic
Manual for detailed procedures
Inoperative latch assembly Check wiring/cable connections
Check for trouble codes, replace latch if
necessary
Inoperative open/close command Check for shorted or defective switch
switch
Inoperative striker Striker misaligned or loose
Striker damaged
Replace striker if necessary
Door will not open manually The child lock out switch is in the Ensure the child lock out switch is in the
using inside handle %LOCKED% position %UNLOCKED% position
Inoperative inside handle assembly
Check for broken inside handle
assembly
Check cable connections at latch and
handle assembly.
Check for binds or kinks in cable.

operation of handle assembly
Replace the handle if necessary
Inoperative latch assembly Check cable connections

Replace latch if necessary
Inoperative inside handle cable Check cable for binding
assembly
Check cable for broken condition

Replace the cable, if necessary
operation of door

Replace necessary components
Door will not open manually Inoperative outside handle assembly Check for broken outside handle assembly
using outside handle
Check cable connections at latch and handle

assembly.
Check for binds or kinks in cable.


operation of handle assembly
Replace the handle if necessary

Replace latch assembly, if necessary
Inoperative outside handle cable Check cable for binding
assembly
Check cable for broken condition
Replace the cable, if necessary

operation of door
Replace necessary components

Sliding door will not Binding or sticking of components Establish location of binding. Disconnect flex
open/close manually drive and recheck. Replace necessary
components

Sliding door will not Binding or sticking of components Open and close door manually to assess
open/close under power binding or high effort to move door. Establish
location of binding and replace necessary
components
Inoperative sliding door control module Disconnect then reconnect battery negative
or BCM cable to reset module. Cycle door, if no
connections, see Body Diagnostic Manual for
detailed procedures
Inoperative latch assembly Check for blown fuse and wire connections
Check cable connections

Troubleshoot using body diagnostic manual
Inoperative motor assembly Troubleshoot using body diagnostic manual
Inoperative full open switch assembly Troubleshoot using body diagnostic manual
Inoperative flex drive assembly Disconnect flex drive and check for broken
condition
Inoperative lower drive unit assembly Remove lower drive unit and check for
broken condition

Wiring problems (system or vehicle) Troubleshoot using the appropriate wiring
information
Power loss during power Wiring problems (system or vehicle) Troubleshoot using the appropriate wiring
door operation information
Low battery voltage Charge battery
detailed procedures
Inoperative drive assembly Remove lower drive unit and check for no
drive condition
No latching in primary and/or Inoperative inside/outside handle Go to that %POSSIBLE CAUSE% and review
secondary positions assembly %CORRECTIONS%
Inoperative latch assembly Check wire connections and for blown fuse

necessary components
detailed procedures
Door seal force too high Inspect seals for damage, mis-assembly,
foreign matter. (Refer to 8 - ELECTRICAL/
POWER DOORS - STANDARD
PROCEDURE) for door adjustment
procedure and specifications in the Body
section of the service manual for
specifications
drive condition
Striker damaged
Latch will not fully release Inoperative latch assembly Check wire connections and for blown fuse
from primary position


Inoperative fuel filler door lockout Check operation of fuel filler door lockout
mechanism mechanism.
detailed procedures
Striker damaged
Cables worn and stretched Replace cables as necessary
Key fob, B-pillar or overhead Blown Fuse Check fuse and replace
console switch does not
operate power sliding door
Battery voltage low Charge or replace battery
Inoperative latch assembly Check for foreign matter preventing the
Check wire connection

Pawl and/or ratchet switch inoperative
Replace latch if necessary
information
Inoperative BCM Check electrical connections
Refer to the body diagnostic manual for

additional checks
Replace BCM if necessary
Inoperative key fob Verify inoperative key fob by trying other key
fob functions
Replace key fob battery

Reprogram key fob
Replace key fob if necessary
cable to reset module. Cycle door, if no
detailed procedures
Inoperative door motor assembly Check for foreign matter preventing the
operation of gear motor assembly
Check wire connections

Gear motor clutch does not engage, replace
assembly

Full open switch inoperative, replace hold
open latch assembly
Replace motor assembly. if necessary
Door does not stay open Inoperative hold open latch assembly Check wire/cable connections
Replace hold open latch, if necessary

Inoperative hold open latch striker Replace hold open latch striker, if necessary
High inside/outside opening Inoperative latch assembly Check wire connections and for blown fuse
effort

Inoperative inside/outside handle Go to that %POSSIBLE CAUSE% and review
assembly %CORRECTIONS%
Door continues to cinch Inoperative latch assembly Check wire connections and for blown fuse
closed during power mode

detailed procedures
information
Door continues to open Inoperative sliding door control module Disconnect then reconnect battery negative
during power mode (runaway or BCM cable to reset module. Cycle door, if no
motor) function exists check for loose wire
detailed procedures
Inoperative hold open latch assembly Check wire/cable connections
Replace hold open latch, if necessary

drive condition
Wiring problems (system or vehicle) Troubleshoot using electrical schematics.
Refer to wiring diagrams
Door opens very slowly Inoperative door motor assembly Check wire/cable connections
Replace motor assembly, if necessary


Squeaks, Noises and rattles Foreign material in door compartment Remove foreign material
Loose components Check and tighten loose components
Missing stabilizers, bumpers or Check to ensure components are present.
anti-rattle components Replace as necessary
Misadjusted stabilizers, bumpers or Adjust components as necessary
anti-rattle components
Poor door track lubrication Lubricate the front portions of the side door
tracks with %Door Ease"% or equivalent
STAN DARD PROCEDU RE sign s of wea r, it m u st be r epla ced. F ollow t h e pr oce-

du r e below if r epla cem en t is n ecessa r y.
POWER SLIDING DOOR LEARN CYCLE (1) Rem ove t h e door m ot or fr om t h e door in n er
An y t im e a power slidin g door com pon en t is r em oved, pa n el. (Refer t o 8 - E LE CTRICAL/P OWE R DOORS/
r epla ced, door a dju st m en t is per for m ed or dia gn ost ic MOTOR - RE MOVAL).
t r ou ble codes a r e a ddr essed a n d er a sed, a lea r n cycle (2) Usin g a t r im pa n el t ool (specia l t ool #C-4755)
m u s t be per for m ed. Th is lea r n cycle en a bles t h e power or equ iva len t , r em ove t h e pu sh -pin gr om m et s fr om
slidin g door con t r ol m odu le t o lea r n or r elea r n it s cr it ica l t h e in n er pa n el by pu llin g t h em st r a igh t ou t (F ig. 2).
in for m a t ion (t r a vel lim it s, r esist a n ce t o door t r a vel, et c.)
wh ich a llows it t o per for m pr oper ly a n d sa fely. To per-
for m a power slidin g door lea r n cycle do t h e followin g:
(1) Obt a in a DRB III!, or equ iva len t sca n t ool.
Con n ect t h e sca n t ool t o t h e veh icle a n d ch eck for
a n y power slidin g door syst em st or ed dia gn ost ic t r ou -
ble codes, er a se a n y st or ed codes. Oper a t e t h e syst em
a n d ch eck t o see if a n y t r ou ble codes r et u r n . If a n y
dia gn ost ic t r ou ble codes r et u r n , dia gn ose, cor r ect a n d
er a se t h e codes befor e per for m in g t h e lea r n cycle. If a
DRB III!, or equ iva len t sca n t ool is n ot a va ila ble, t h e
lea r n cycle ca n be per for m ed by open in g a n d closin g
t h e power slidin g door u sin g a n y of t h e n or m a l open /
close com m a n d swit ch es. Be cer t a in t o cycle t h e
power slidin g door t h r ou gh a com plet e open a n d
close cycle or t h e pr ocedu r e will n ot be com plet e.
(2) Usin g t h e sca n t ool, Go in t o Test Rou t in e Men u
a n d select a power open com m a n d.
(3) Select a power close com m a n d.
(4) Th e power side door lea r n cycle is com plet e.
NOTE: If the power sliding door will not complete a

full cycle, a problem exists with the power sliding door Fig. 2 SIDE DOOR MOTOR PUSH-PIN GROMMETS
system. (Refer to 8 - ELECTRICAL/POWER DOORS -
1 - PUSH-PIN GROMMETS
DIAGNOSIS AND TESTING) for additional information. 2 - SIDE DOOR INNER PANEL
(3) In st a ll t h e r epla cem en t pu sh -pin gr om m et s in

PUSH-PIN GROMMET REPLACEMENT t h e in n er pa n el a n d in st a ll t h e door m ot or (Refer t o 8
P u sh -pin gr om m et s a r e u sed t o h old a n d isola t e - E LE CTRICAL/P OWE R DOORS/MOTOR - INSTAL-
t h e power slidin g door m ot or t o a n d fr om t h e door LATION).
in n er pa n el. Th is secu r es t h e door m ot or a ssem bly t o
t h e in n er pa n el a n d keeps t h e a u dible m ot or vibr a -
t ion s t o a m in im u m . If a pu sh -pin gr om m et sh ows
POWER SLIDING DOOR ADJUSTMENT ext er ior h a n dle a n d h old open la t ch ca bles. If a n y of t h e
In or der for t h e power slidin g door syst em t o fu n c- com pon en t s of t h e la t ch a ssem bly a r e in oper a t ive t h e
t ion pr oper ly t h e door m u st m ove fr eely a n d com plet e power la t ch a ssem bly m u st be r epla ced.
sm oot h ly. Th e power slidin g door syst em ca n a ccom -
m oda t e for som e m in or ch a n ges in t h e effor t r equ ir ed OPERATION
t o m ove t h e door. H owever, in ext r em e con dit ion s t h e Th e power la t ch per for m s t h e sa m e oper a t ion a s a fu ll
door m a y n eed t o be m ech a n ica lly a dju st ed for pr oper m a n u a l door la t ch a s well a s power cin ch , r elea se, lock
fit . (Refer t o 23 - BODY/DOORS - SLIDING/SLID- a n d u n lock oper a t ion s. Th e power la t ch m ou n t ed a ct u a -
ING DOOR - ADJ USTME NTS). t or cin ch es t h e door closed a n d la t ch es it in it s pr im a r y
If a pr oblem exist s wit h t h e power slidin g door a n d la t ch ed posit ion . Du r in g a power close cycle, t h e power
it is su spect ed t o be ext r em e effor t , ch eck for pr oper cin ch a ct u a t or will n ot oper a t e u n t il t h e power slidin g
door a lign m en t a n d a dju st m en t fir st , t h en ch eck t h e door h a s r ea ch ed it s secon da r y la t ch posit ion (det er-
door t r a cks a n d dr ive u n it for fr ee m a n u a l oper a t ion . m in ed by pa wl a n d r a t ch et swit ch es). Du r in g a power
(Refer t o 23 - BODY/DOORS - SLIDING/SLIDING open cycle, t h e power r elea se a ct u a t or will st op on ce t h e
DOOR - ADJ USTME NTS) for det a iled in st r u ct ion s. slidin g door h a s m oved fr om t h e pr im a r y la t ch posit ion .
Th e power la t ch u ses in pu t s fr om t h e lock/u n lock
a ct u a t or, power slidin g door con t r ol m odu le a n d ch ild
LAT CH lockou t , pa wl, r a t ch et a n d h a n dle swit ch es t o pr ovide
sa fe power cin ch a n d r elea se oper a t ion s. (Refer t o 8 -
DESCRIPTION E LE CTRICAL/P OWE R DOORS - OP E RATION) for
a ddit ion a l in for m a t ion .
REMOVAL
(2) Rem ove t h e a ppr opr ia t e side door t r im pa n el,
(Refer t o 23 - BODY/DOORS - SLIDING/TRIM
PANE L - RE MOVAL).
(3) Rem ove t h e wea t h er sh ield if n ecessa r y.
(4) Open t h e side door a ll t h e wa y a n d r em ove t h e
door la t ch r et a in in g bolt s (F ig. 4).
Fig. 3 REMOVING/INSTALLING POWER LATCH IN

SLIDING DOOR
1 - POWER LATCH ASSEMBLY
On e power la t ch is u sed for ea ch power slidin g door.

Th e la t ch is loca t ed on t h e t r a ilin g edge of t h e slidin g
door a ssem bly (F ig. 3). Th is power la t ch a ssem bly is com -
pr ised of m a n y differ en t com pon en t s wh ich h a ve t h e a bil-
it y t o per for m t h e power cin ch , r elea se, lock, u n lock a n d
sa fet y r ela t ed oper a t ion s. Th ese com pon en t s a r e t h e door
la t ch , lock/u n lock a ct u a t or, cin ch /r elea se a ct u a t or a n d
ch ild lockou t , pa wl, r a t ch et a n d h a n dle swit ch es. Th e Fig. 4 REMOVING LATCH RETAINING BOLTS
pa wl a n d r a t ch et swit ch es a r e u sed t o in dica t e t h e pr i- 1 - LATCH RETAINING BOLTS
m a r y a n d secon da r y la t ch ed posit ion s. Th e cin ch la t ch 2 - SIDE DOOR
a lso pr ovides a con n ect ion poin t for t h e in t er ior h a n dle,
(5) P a r t ia lly close t h e door a n d pu ll t h e la t ch
a ssem bly ou t of t h e side door in n er pa n el, (F ig. 5).
Fig. 6 POWER LATCH POSITION & ORIENTATION

Fig. 5 POWER LATCH POSITION & ORIENTATION
(6) Discon n ect a ll elect r ica l con n ect or s lea din g t o

t h e la t ch a ssem bly.
(7) Discon n ect t h e in side a n d ou t side h a n dle ca bles
fr om t h e la t ch a ssem bly.
(8) Discon n ect t h e h old open la t ch ca ble fr om t h e
la t ch a ssem bly.
(9) Discon n ect lock a ct u a t or lin k r od fr om t h e
la t ch a ssem bly.
(10) Rem ove t h e la t ch a ssem bly fr om t h e veh icle.
INSTALLATION
(1) P osit ion t h e la t ch a ssem bly in t h e veh icle. Be
cer t a in a ll la t ch m ou n t ed com pon en t s a r e in st a lled
on t h e r epla cem en t la t ch a ssem bly. If n ot , t r a n sfer
com pon en t s fr om t h e old la t ch t o t h e n ew la t ch
a ssem bly, (F ig. 6).
(2) Con n ect t h e lock a ct u a t or lin k r od on t h e la t ch
a ssem bly.
(3) Con n ect t h e h old open la t ch ca ble on t h e la t ch
a ssem bly.
(4) Con n ect t h e in side a n d ou t side h a n dle ca bles Fig. 7 REMOVING LATCH RETAINING BOLTS
on t h e la t ch a ssem bly. 1 - LATCH RETAINING BOLTS
2 - SIDE DOOR
(5) Con n ect a ll elect r ica l con n ect or s lea din g t o t h e
la t ch a ssem bly. (8) In st a ll t h e a ppr opr ia t e side door t r im pa n el,
(6) Wit h a ssist a n ce fr om a n ot h er per son , posit ion (Refer t o 23 - BODY/DOORS - SLIDING/TRIM
t h e side door a n d in st a ll t h e door la t ch r et a in in g PANE L - INSTALLATION) for det a iled in st r u ct ion s.
bolt s, (F ig. 7). Tor qu e t o 10 - 12 N·m (100 in . lbs.). (9) Con n ect t h e n ega t ive ba t t er y ca ble.
(7) In st a ll t h e wea t h er sh ield if n ecessa r y.
SLI DI N G DOOR M OT OR door u n der power a n d disen ga ges it so t h e door ca n

be m oved ea sily u n der m a n u a l oper a t ion .
DESCRIPTION
REMOVAL
ca ble.
(2) Rem ove t h e door t r im pa n el fr om t h e a ppr opr i-
a t e door, (Refer t o 23 - BODY/DOORS - SLIDING/
(3) Rem ove t h e wa t er sh ield a s n ecessa r y t o ga in
a ccess t o m ot or a ssem bly.
(4) Rem ove r et a in in g clip h oldin g flex dr ive a ssem -
bly t o t h e m ot or (F ig. 9). P u ll flex dr ive ca ble st r a igh t
ou t of t h e m ot or a ssem bly.
Fig. 8 POWER SLIDING DOOR COMPONENTS

1 - POWER SLIDING DOOR CONTROL MODULE
Th e door m ot or is loca t ed in t h e cen t er of t h e

power slidin g door (F ig. 8) a n d is com pr ised of t h r ee
pa r t s. Th e t h r ee pa r t s of t h e door m ot or a ssem bly a r e
t h e m ot or, gea r r edu ct ion a n d clu t ch a ssem bly. Th e Fig. 9 FLEX DRIVE RETAINING CLIP
door m ot or a ssem bly pr ovides t h e power a n d t or qu e 1 - FLEX DRIVE CABLE RETAINING CLIP
t o m ove t h e slidin g door fr om t h e open /closed posi- 2 - FLEX DRIVE CABLE
t ion t o fu ll closed/open posit ion , a ft er t h e power 3 - DOOR MOTOR ASSEMBLY
la t ch in g m ech a n ism h a s r elea sed.
Th e door m ot or is r epla ced a s a com plet e a ssem bly, (5) Discon n ect door m ot or elect r ica l con n ect or.
wh ich in clu des t h e DC m ot or, gea r r edu ct ion a n d (6) Usin g a t r im st ick (specia l t ool #C-4755) or
clu t ch a ssem blies. equ iva len t , gen t ly pr y ou t pu sh -pin fa st en er s r et a in -
in g t h e door m ot or.
OPERATION (7) Rem ove t h e door m ot or a ssem bly fr om t h e
veh icle.
Wit h t h e pu sh of a power slidin g door com m a n d
swit ch , t h e power slidin g door con t r ol m odu le will
sign a l t h e la t ch a ssem bly t o r elea se t h e door fr om it s INSTALLATION
pr im a r y locked posit ion . Th e door m ot or will t h en (1) P osit ion t h e door m ot or a ssem bly on t h e door
t a ke over t o pr ovide t h e power t o open t h e door t o it s in n er pa n el.
fu ll open or closed posit ion . Th e gea r r edu ct ion por- (2) In st a ll t h e pu sh -pin fa st en er s r et a in in g t h e
t ion of t h e m ot or a ssem bly r edu ces t h e speed of t h e m ot or a ssem bly t o t h e power slidin g door.
m ot or fr om 5800 t o 260 r pm a n d a lso in cr ea ses t h e
t or qu e t o t h e lower dr ive u n it . Th e clu t ch por t ion of
t h e m ot or a ssem bly en ga ges t h e m ot or t o dr ive t h e
SLI DI N G DOOR M OT OR (Cont inue d)
NOTE: Push in on the push-pins at the clutch hous- Th e fu ll open swit ch is in cor por a t ed in t o t h e h old
ing (plastic side) until you hear one click. Push in open la t ch . If t h e fu ll open swit ch is in oper a t ive, t h e
on the push-pin fasteners at the motor mount en t ir e h old open la t ch a ssem bly m u st be r epla ced.
(sheet metal side) until you hear two clicks. This
assures proper installation/attachment of the motor OPERATION
to the sliding door. Th e fu ll open swit ch is t r igger ed by a pa wl lever in
t h e h old open la t ch . Wh en t h e fu ll open swit ch is
(3) In st a ll t h e flex sh a ft by lin in g u p t h e squ a r e closed (cir cu it t o gr ou n d) t h e r a t ch et h a s en ga ged on
sh a ped dr ive sh a ft wit h t h e cor r espon din g h ole in t h e t h e h old open st r iker a n d t h e pa wl lever h a s en ga ged
door m ot or dr ive u n it a n d pu sh st r a igh t in . on t h e r a t ch et , lockin g t h e la t ch fr om open in g a n d
(4) In st a ll t h e E -clip t o secu r e flex-sh a ft . h oldin g t h e door in t h e fu ll open posit ion .
(5) In st a ll t h e wea t h er sh ield a s n ecessa r y.
(6) In st a ll t h e door t r im pa n el on t h e slidin g door,
(Refer t o 23 - BODY/DOORS - SLIDING/TRIM B-PI LLAR SWI T CH
PANE L - INSTALLATION) for t h e pr ocedu r e.
(7) Con n ect t h e ba t t er y n ega t ive ca ble. DESCRIPTION
Th e B-pilla r swit ch es a r e loca t ed on t h e in t er ior of
t h e veh icle, on t h e B-pilla r t r im pa n els. Th ese
FU LL OPEN SWI T CH swit ch es ser ve a s a n open a n d close com m a n d swit ch
for t h e a ppr opr ia t e power slidin g door.
DESCRIPTION
OPERATION
Wh en t h e B-pilla r swit ch is depr essed a sign a l is
sen t t o t h e Body Con t r ol Modu le (BCM), t h is sign a l
is t h en sen t t o t h e power slidin g door con t r ol m odu le,
t ellin g it t o st a r t a power open or close cycle. Th e
ch ild lockou t fea t u r e m u st be disa bled a n d t h e slid-
in g door m u st be u n locked in or der for t h e B-pilla r
swit ch t o fu n ct ion .
REMOVAL
ca ble.
(2) Usin g a t r im st ick (specia l t ool # C-4755) or
equ iva len t , gen t ly pr y t h e lea din g u pper edge of t h e
B-pilla r swit ch a wa y fr om t h e B-pilla r t r im .
(3) On ce t h e u pper edge is fr ee fr om B-pilla r t r im ,
r ock t h e swit ch ou t of t h e swit ch open in g.
(4) Discon n ect t h e B-pilla r swit ch elect r ica l con -
n ect or. F ir st , slide t h e con n ect or lock a wa y fr om t h e
swit ch t h en , depr ess con n ect or r et a in in g t a b wh ile
pu llin g st r a igh t a pa r t .
(5) Rem ove t h e B-pilla r swit ch fr om t h e veh icle.
Fig. 10 FULL OPEN SWITCH POSITION &
ORIENTATION INSTALLATION
1 - HOLD OPEN LATCH ASSEMBLY (1) Con n ect t h e B-pilla r swit ch elect r ica l con n ect or.
2 - HOLD OPEN LATCH CABLE Slide con n ect or lock t owa r d t h e swit ch t o lock in
3 - FULL OPEN SWITCH
pla ce.
Th e fu ll open swit ch is loca t ed in t h e h old open (2) H ook t h e lower edge of t h e B-pilla r swit ch on
la t ch (F ig. 10) u n der t h e slidin g door lower h in ge. t h e B-pilla r t r im a n d t h en pu sh t h e swit ch fir m ly
Wh en t h e power slidin g door con t r ol m odu le r eceives in t o posit ion .
a gr ou n d sign a l in pu t fr om t h e fu ll open swit ch , a n d (3) Con n ect t h e ba t t er y n ega t ive ca ble.
a s lon g a s t h e cin ch in g la t ch a ct u a t or is n ot in power
m ode or t h e h a n dle swit ch is open , t h e sign a l in di-
ca t es t h a t t h e door is a t t h e fu ll open posit ion .
LOWER DRI V E U N I T
DESCRIPTION
Fig. 12 SLIDING DOOR LOWER HINGE ASSEMBLY

1 - LOWER DRIVE UNIT COVER
2 - LOWER DRIVE UNIT COVER RETAINING SCREWS
3 - SLIDING DOOR
4 - LOWER HINGE ARM BRACKET
Fig. 11 LOWER DRIVE UNIT
1 - LOWER DRIVE UNIT
Th e lower dr ive u n it is loca t ed on t h e power slidin g

door lower h in ge a ssem bly (F ig. 11). Th is dr ive u n it
is u sed t o t r a n sfer t h e r ot a t ion of t h e flex dr ive
a ssem bly in t o lon git u din a l m ovem en t via t h e dr ive
u n it gea r a n d door t r a ck r a ck t eet h (F ig. 11).
OPERATION
Du r in g a power open or close cycle, t h e power dr ive
u n it is dr iven by t h e flex dr ive a ssem bly. Th e lower
dr ive u n it s m a in gea r en ga ges t h e lower door t r a cks
r a ck t eet h , t h is m oves t h e power slidin g door a ssem -
bly a ccor din gly.
REMOVAL
ca ble.
(2) Open t h e a ppr opr ia t e slidin g door a n d r em ove
t h e lower dr ive u n it cover r et a in in g scr ews (F ig. 12).
(3) Rem ove t h e lower dr ive u n it r et a in in g fa st en -
er s (F ig. 13).
Fig. 13 LOWER DRIVE UNIT RETAINING
(4) Discon n ect t h e flex dr ive a ssem bly fr om t h e
FASTENERS
lower dr ive u n it . E xpa n d t h e flex dr ive colla r u n t il
t h e lower dr ive u n it ca n be pu lled st r a igh t off. 1 - LOWER DRIVE UNIT RETAINING SCREW
2 - DO NOT REMOVE
(5) Rem ove t h e lower dr ive u n it fr om t h e veh icle. 3 - LOWER DRIVE UNIT RETAINING BOLT
LOWER DRI V E U N I T (Cont inue d)
INSTALLATION
(1) P osit ion t h e lower dr ive u n it n ea r t h e lower
h in ge.
(2) Con n ect t h e flex dr ive a ssem bly on t h e lower
dr ive u n it . P u sh t h e flex dr ive colla r st r a igh t on u n t il
t h e it sn a ps in pla ce (F ig. 14). It m a y be n e c e s s a ry
to ro ta te th e d riv e u n it s lig h tly u n til th e fle x
d riv e s e a ts in p la c e .
Fig. 15 LOWER DRIVE UNIT RETAINING

FASTENERS
1 - LOWER DRIVE UNIT RETAINING SCREW
2 - DO NOT REMOVE
3 - LOWER DRIVE UNIT RETAINING BOLT
Fig. 14 LOWER DRIVE UNIT

1 - LOWER DRIVE UNIT
(3) In st a ll t h e lower dr ive u n it r et a in in g fa st en er s

(F ig. 15). Tor qu e t h e la r ger a llen h ea ded cen t er st u d
t o 9 N·m (80 in . lbs.). Tor qu e t h e sm a ller scr ew t o 3
N·m (28 in . lbs.).
(4) In st a ll t h e lower dr ive u n it cover a n d r et a in in g
scr ews (F ig. 16).
Fig. 16 SLIDING DOOR LOWER HINGE ASSEMBLY

3 - SLIDING DOOR
FLEX DRI V E t h e flex dr ive t r a n sfer s t h e power a n d t or qu e fr om

t h e m ot or t o t h e dr ive u n it . A squ a r e sh a ped dr ive
ca ble, in side t h e flex dr ive a ssem bly en ga ges t h e
DESCRIPTION
m ot or dr ive a n d r ot a t es t o m ove t h e door a ccor din gly.
REMOVAL
ca ble.
(2) Rem ove t h e a ppr opr ia t e slidin g door t r im
pa n el, (Refer t o 23 - BODY/DOORS - SLIDING/TRIM
PANE L - RE MOVAL).
(3) P osit ion t h e wea t h er sh ield a side t o ga in a ccess
t o t h e flex dr ive a ssem bly.
(4) Rem ove t h e E -clip fr om t h e flex dr ive a ssem bly
(F ig. 18).
Fig. 17 POWER SLIDING DOOR COMPONENTS

1 - POWER SLIDING DOOR CONTROL MODULE
Th e flex dr ive a ssem bly is loca t ed in t h e lower por-

t ion of t h e power slidin g door (F ig. 17) a n d is u sed t o
con n ect t h e door m ot or t o t h e lower dr ive u n it . An
E -clip is u sed t o secu r e t h e flex dr ive t o t h e m ot or
a ssem bly, wh ile t h e flex dr ive colla r is u sed t o secu r e Fig. 18 FLEX DRIVE E-CLIP
t h e dr ive t o t h e lower dr ive u n it . Th e flex dr ive 1 - FLEX DRIVE CABLE RETAINING CLIP
a ssem bly is ba sica lly a flexible dr ive sh a ft for t h e 2 - FLEX DRIVE CABLE
power slidin g door syst em . Th e flex dr ive a ssem bly is 3 - DOOR MOTOR ASSEMBLY
a r epla cea ble com pon en t .
(5) P u ll t h e flex dr ive st r a igh t ou t of t h e m ot or
OPERATION a ssem bly.
Wit h on e en d of t h e flex dr ive a t t a ch ed t o t h e door
m ot or a n d t h e ot h er a t t a ch ed t o t h e lower dr ive u n it ,
FLEX DRI V E (Cont inue d)
(6) Rem ove t h e lower dr ive u n it cover r et a in in g
scr ews a n d r em ove t h e cover (F ig. 19).
Fig. 20 LOWER HINGE/DRIVE ASSEMBLY

Fig. 19 LOWER HINGE/DRIVE ASSEMBLY 3 - SLIDING DOOR
1 - LOWER DRIVE UNIT COVER 4 - LOWER HINGE ARM BRACKET
3 - SLIDING DOOR
(7) E xpa n d t h e flex dr ive colla r, n ext t o t h e lower

dr ive u n it u n t il t h e flex dr ive ca n be pu lled st r a igh t
off t h e lower dr ive u n it .
(8) Rem ove t h e flex dr ive a ssem bly fr om t h e veh i-
cle.
INSTALLATION
(1) P osit ion t h e flex dr ive a ssem bly in t h e veh icle.
(2) In st a ll t h e flex dr ive on t h e lower dr ive u n it .
P u sh st r a igh t on u n t il it sn a ps in pla ce. It m a y be
n ecessa r y t o r ot a t e dr ive u n it gea r sligh t ly u n t il t h e
flex dr ive sea t s in pla ce.
scr ews (F ig. 20).
(4) In st a ll t h e flex dr ive in t h e m ot or a ssem bly.
Lin e u p t h e squ a r e sh a ped in n er sh a ft a n d pu sh
st r a igh t on (F ig. 21).
(5) In st a ll t h e E -clip on t h e flex dr ive a ssem bly.
(6) In st a ll t h e wea t h er sh ield.
(7) In st a ll t h e slidin g door t r im pa n el, (Refer t o 23
- BODY/DOORS - SLIDING/TRIM PANE L - INSTAL- Fig. 21 FLEX DRIVE CABLE
LATION). 1 - DOOR MOTOR
2 - FLEX DRIVE COLLAR
(8) Con n ect t h e ba t t er y n ega t ive ca ble. 3 - FLEX DRIVE INNER SHAFT
LOWER DRI V E U N I T T RACK & REMOVAL

RACK ca ble.
(2) Rem ove t h e side door sill pla t e, (Refer t o 23 -
DESCRIPTION BODY/INTE RIOR/SLIDING DOOR SILL P LATE -
RE MOVAL).
(3) Rem ove t h e h old-open st r iker, (Refer t o 23 -
BODY/DOORS - SLIDING/H OLD OP E N LATCH
STRIKE R - RE MOVAL).
(4) P osit ion a floor ja ck, wit h a block of wood
u n der t h e lea din g edge of t h e side door t o su ppor t it
(F ig. 23).
Fig. 22 RACK ACCESS HOLE LOCATIONS

1 - LOWER DOOR TRACK AND RACK ASSEMBLY
2 - WIRE HARNESS
3 - RACK ACCESS HOLE SEALING PATCHES
Th e door t r a ck a n d r a ck a ssem bly pr ovides a m a t -

in g r a ck gea r (F ig. 22) for t h e lower dr ive u n it t o
en ga ge. Th e t r a ck a lso a ccept s t h e lower h in ge r oll- Fig. 23 Supporting Sliding Door
er s, wh ich h elps su ppor t t h e weigh t of t h e slidin g
(5) Rem ove t h e lower h in ge a ssem bly fr om t h e
door a s well a s pr ovidin g a sm oot h su r fa ce for t h e
door, (Refer t o 23 - BODY/DOORS - SLIDING/
h in ge r oller s t o m ove u pon . Th e lower door t r a ck is a
LOWE R ROLLE R ARM - RE MOVAL).
r epla cea ble com pon en t .
(6) P osit ion t h e wir e h a r n ess a ssem bly ou t of door
open in g, t h is will a llow su fficien t r oom t o r em ove t h e
OPERATION door t r a ck.
Wit h t h e st a r t of a power slidin g door open cycle,
t h e door m ot or dr ives t h e flex dr ive a ssem bly. Th e
flex dr ive a ssem bly dr ives t h e lower dr ive u n it . A
m et a l dr ive gea r wh ich is pa r t of t h e lower dr ive
u n it , m esh es wit h t h e door t r a ck r a ck t eet h a n d
m oves t h e slidin g door in t o t h e fu ll open posit ion .
Th e sa m e oper a t ion r epea t s it self, du r in g a power
close cycle on ly t h e syst em r ot a t es in t h e opposit e
dir ect ion .
LOWER DRI V E U N I T T RACK & RACK (Cont inue d)
(7) P u ll ba ck t h e sea lin g pa t ch es a n d r em ove t h e
lower t r a ck r et a in in g n u t s (F ig. 24).
Fig. 25 Lower Track Retaining Nuts

1 - Lower Track Retaining Nuts
2 - Lower Door Track
NOTE: Take care to locate the lower hinge assem-

Fig. 24 Lower Track Retaining Nuts bly on the door in its original position (ie. match
1 - Lower Track Retaining Nuts screw washer with rings left on hinge). Adjust door
2 - Lower Door Track
fit if required, (Refer to 23 - BODY/DOORS - SLID-
(8) Ca r efu lly r em ove t h e lower slidin g door t r a ck ING/SLIDING DOOR - ADJUSTMENTS).
fr om t h e veh icle.
(4) Rem ove t h e floor ja ck.
(5) In st a ll t h e h old-open st r iker, (Refer t o 23 -
INSTALLATION BODY/DOORS - SLIDING/H OLD OP E N LATCH
(1) Ca r efu lly posit ion t h e lower slidin g door t r a ck STRIKE R - INSTALLATION).
in t h e veh icle. (6) In st a ll t h e side door sill pla t e, (Refer t o 23 -
(2) In st a ll t h e lower t r a ck r et a in in g n u t s a n d BODY/INTE RIOR/SLIDING DOOR SILL P LATE -
in st a ll t h e sea lin g pa t ch es, (F ig. 25). Tor qu e t h e n u t s INSTALLATION).
t o 8 N·m (70 in . lbs). (7) Con n ect t h e ba t t er y n ega t ive ca ble.
(3) In st a ll t h e lower h in ge a ssem bly on t h e door,
(Refer t o 23 - BODY/DOORS - SLIDING/LOWE R
ROLLE R ARM - INSTALLATION).
WI RI N G H ARN ESS
DESCRIPTION

3 - SLIDING DOOR
Fig. 26 WIRE HARNESS POSITION AND
ORIENTATION (4) Discon n ect t h e power slidin g door elect r ica l
1 - LOWER DOOR TRACK AND RACK ASSEMBLY con n ect or, loca t ed ju st beh in d t h e lower dr ive u n it
2 - WIRE HARNESS
3 - RACK ACCESS HOLE SEALING PATCHES a ssem bly.
4 - LOWER DRIVE UNIT COVER (5) Disen ga ge r et a in in g pu sh pin a n d pu ll wir e h a r-
n ess a wa y fr om it s power slidin g door m ou n t in g loca -
Th e wir e h a r n ess su pplies power (12v), gr ou n d a n d t ion .
va r iou s elect r ica l sign a ls t o t h e power slidin g door for (6) Usin g a su it a ble fla t bla ded t ool, u n sn a p t h e
va r iou s power door fu n ct ion s. A pla st ic ch a in or wir- wir e h a r n ess r et a in in g clip fr om t h e lower dr ive u n it .
in g t r a ck cover s t h e wir e h a r n ess a ssem bly (F ig. 26) (7) Slide t h e wir e h a r n ess off t h e for wa r d lower
a n d is u sed t o pr ot ect t h e wir e h a r n ess fr om a br a sion dr ive u n it st u d.
a n d/or t a n glin g. Th is wir in g t r a ck is r epla ced wit h (8) Usin g a pu sh pin r em ova l t ool (specia l t ool #
t h e wir e h a r n ess a ssem bly. Th e wir e h a r n ess a ssem - C-4755), u n sn a p wir e h a r n ess r et a in in g pu sh pin s
bly is a r epla cea ble com pon en t . fr om t h e r ocker pa n el.
(9) Rem ove slidin g door lower sill pla t e, (Refer t o
OPERATION 23 - BODY/INTE RIOR/SLIDING DOOR SILL P LATE
Th e wir e h a r n ess a n d pla st ic wir in g t r a ck pr ovide - RE MOVAL).
a sa fe a n d r elia ble m ea n s of su pplyin g power, gr ou n d (10) P u ll ba ck t h e r ea r wa r d edge of t h e B-pilla r
a n d ot h er va r iou s elect r ica l con n ect ion s t o t h e power t r im t o a ccess t h e wir e h a r n ess con n ect or a n d discon -
slidin g door. Du r in g slidin g door m ovem en t t h e wir- n ect con n ect or.
in g t r a ck folds a n d u n folds like t h e lin ks in a ch a in . (11) Rem ove t h e wir e h a r n ess a ssem bly fr om t h e
veh icle.
REMOVAL
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive INSTALLATION
ca ble. (1) P osit ion t h e wir e h a r n ess a ssem bly in t h e veh i-
(2) Rem ove t h e a ppr opr ia t e door t r im pa n el fr om cle.
t h e power slidin g door, (Refer t o 23 - BODY/DOORS - (2) Con n ect t h e wir e h a r n ess con n ect or loca t ed a t
SLIDING/TRIM PANE L - RE MOVAL). t h e r ea r wa r d edge of t h e B-pilla r.
(3) Rem ove t h e lower dr ive u n it cover r et a in in g
scr ews a n d r em ove t h e cover (F ig. 27).
WI RI N G H ARN ESS (Cont inue d)
(3) In st a ll t h e slidin g door lower sill pla t e, (Refer
t o 23 - BODY/INTE RIOR/SLIDING DOOR SILL
P LATE - INSTALLATION).
(4) Sn a p t h e wir e h a r n ess r et a in in g pu sh pin s in
t h e r ocker pa n el.
(5) Slide t h e wir e h a r n ess on t h e lower dr ive u n it
st u d.
(6) In st a ll t h e wir e h a r n ess r et a in in g clip on t h e
lower dr ive u n it st u d.
(7) Con n ect t h e power slidin g door elect r ica l con -
n ect or, loca t ed ju st beh in d t h e lower dr ive u n it .
scr ews (F ig. 28).
(9) In st a ll t h e a ppr opr ia t e slidin g door t r im pa n el,
(Refer t o 23 - BODY/DOORS - SLIDING/TRIM
PANE L - INSTALLATION).

3 - SLIDING DOOR
RS POWER WINDOWS 8N - 61
POWER WI N DOWS
TABLE OF CONTENTS
page page
POWER WINDOWS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 62

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 61 WINDOW MOTOR
DIAGNOSIS AND TESTING WINDOW SWITCH
POWER WINDOWS . . . . . . . . . . . . . . . . . . . . 61 DIAGNOSIS AND TESTING
VENT WINDOW MOTOR WINDOW SWITCH ... . . . . . . . . . . . . . . . . . 63
VENT WINDOW MOTOR . . . . . . . . . . . . . . . . 62 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 64
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
POWER WI N DOWS m ot or t est . Refer t o t h e a ppr opr ia t e wir in g in for m a -

t ion .
(1) Rem ove fr on t door t r im pa n el a n d sou n d pa d a s
DESCRIPTION
n ecessa r y t o ga in a ccess t o power win dow m ot or wir e
Th e P ower Win dow Syst em is a ct iva t ed t h r ou gh
con n ect or, (Refer t o 23 - BODY/DOOR - F RONT/
swit ch es m ou n t ed on t h e dr iver a n d pa ssen ger door
pa n els.
(2) Discon n ect power win dow m ot or wir e con n ect or
fr om door h a r n ess.
OPERATION (3) Usin g t wo ju m per wir es, con n ect on e t o a ba t -
F r on t door win dow lift m ot or s u se per m a n en t t ype t er y (+) sou r ce a n d t h e ot h er t o a good gr ou n d (-).
m a gn et s. Th e B+ a n d gr ou n d a pplied a t t h e m ot or (4) Con n ect t h e Nega t ive (-) ju m per pr obe t o on e of
t er m in a l pin s will ca u se t h e m ot or t o r ot a t e in on e t h e m ot or con n ect or t er m in a ls.
dir ect ion . Rever sin g cu r r en t t h r ou gh t h e m ot or t er- (5) Mom en t a r ily t ou ch t h e P osit ive (+) ju m per
m in a ls will ca u se t h e m ot or t o r ot a t e in t h e opposit e pr obe t o t h e ot h er m ot or con n ect or t er m in a l.
dir ect ion . Wh en posit ive pr obe is con n ect ed t h e m ot or sh ou ld
Th e power win dow m ot or s gr ou n d t h r ou gh t h e r ot a t e in on e dir ect ion t o eit h er m ove win dow u p or
m a st er swit ch in t h e dr iver door by a bla ck wir e down . If win dow is a ll t h e wa y u p or down t h e m ot or
a t t a ch ed t o t h e left cowl pa n el. Refer t o t h e a ppr opr i- will gr u n t a n d t h e in n er door pa n el will flex wh en
a t e wir in g in for m a t ion . a ct u a t ed in t h a t on e dir ect ion .
Th e power r ea r ven t win dows, if equ ipped, a r e (6) Rever se ju m per pr obes a t t h e m ot or con n ect or
oper a t ed by swit ch es m ou n t ed in t h e dr iver door t er m in a ls a n d win dow sh ou ld n ow m ove in opposit e
swit ch bezel. A sepa r a t e swit ch is u sed for ea ch win - dir ect ion . If win dow does n ot m ove or gr u n t , r epla ce
dow. P er m a n en t m a gn et t ype m ot or s con n ect ed t o a t h e m ot or.
cr a n k syst em a r e u sed t o open a n d close t h e r ea r If win dow m oved com plet ely u p or down , r ever se
ven t win dows. A ba t t er y posit ive a n d n ega t ive con - t h e ju m per pr obes a n d cycle win dow t o t h e opposit e
n ect ion t o eit h er of t h e t wo m ot or t er m in a ls will posit ion t o ver ify fu ll oper a t ion .
ca u se t h e m ot or t o r ot a t e in on e dir ect ion . Rever sin g If m ot or gr u n t s a n d does n ot m ove, ver ify t h a t r eg-
cu r r en t t h r ou gh t h ese sa m e t wo con n ect ion s will u la t or is n ot bin din g.
ca u se t h e m ot or t o r ot a t e in t h e opposit e dir ect ion .
WIRING VOLTAGE TEST
DI AGN OSI S AN D T EST I N G Th e followin g wir in g t est det er m in es wh et h er or
n ot volt a ge is con t in u ou s t h r ou gh t h e body h a r n ess
POWER WINDOWS t o swit ch .
(1) Rem ove t h e power win dow swit ch a n d bezel
POWER WINDOW MOTOR TEST a ssem bly fr om t h e dr iver door. (Refer t o 8 - E LE C-
TRICAL/P OWE R WINDOWS/P OWE R WINDOW
If t h e power win dow m ot or is r eceivin g pr oper cu r-
SWITCH - RE MOVAL).
r en t a n d gr ou n d a n d does n ot oper a t e, pr oceed wit h
(2) Discon n ect wir e con n ect or fr om ba ck of power
win dow swit ch .
8N - 62 POWER WINDOWS RS
POWER WI N DOWS (Cont inue d)
(3) Swit ch ign it ion ON posit ion . (2) Rem ove D-pilla r t r im pa n el. (Refer t o 23 -
(4) Con n ect t h e clip en d of a 12 volt t est ligh t t o BODY/INTE RIOR/LE F T D-P ILLAR TRIM PANE L -
P in 13 in door h a r n ess con n ect or a t t h e win dow RE MOVAL) or (Refer t o 23 - BODY/INTE RIOR/
swit ch . Tou ch t h e t est ligh t pr obe t o P in 9 a n d t h en RIGH T D-P ILLAR TRIM PANE L - RE MOVAL).
t o P in 11. (3) Discon n ect wir e con n ect or fr om power ven t
• If t h e t est ligh t illu m in a t es, t h e wir in g cir cu it m ot or.
bet ween t h e ba t t er y a n d swit ch is OK. (4) Usin g a fla t bla ded t ool, ca r efu lly lift t h e cir cu -
• If t h e la m p does n ot illu m in a t e, fir st ch eck t h e la r a ct u a t or lin k t a b. Rem ove lin k fr om win dow ba ll
25 a m p cir cu it br ea ker a t t a ch ed t o t h e elect r ica l dis- socket .
t r ibu t ion wir in g br a cket . If t h e cir cu it br ea ker is OK, (5) Rem ove bolt s h oldin g power ven t m ot or t o
t h en ch eck t h e 40 a m p fu se (#28) in t h e In t egr a t ed D-pilla r (F ig. 1).
P ower Modu le (IP M). If bot h com pon en t s a r e OK,
t h en ch eck for a br oken wir e.
V EN T WI N DOW M OT OR

VENT WINDOW MOTOR
If t h e power ven t win dow m ot or is r eceivin g pr oper
cu r r en t a n d gr ou n d a n d does n ot oper a t e pr oceed
wit h m ot or t est . Refer t o t h e a ppr opr ia t e wir in g
in for m a t ion .
(1) Rem ove D-pilla r t r im pa n el n ecessa r y t o ga in
a ccess t o power ven t win dow m ot or wir e con n ect or,
TRIM PANE L - RE MOVAL) or (Refer t o 23 - BODY/ Fig. 1 VENT WINDOW MOTOR
INTE RIOR/RIGH T D-P ILLAR TRIM PANE L - 1 - VENT WINDOW MOTOR
RE MOVAL). 3 - BOLT
(2) Discon n ect power ven t win dow m ot or wir e con - 4 - VENT WINDOW
n ect or fr om body h a r n ess.
(3) Usin g t wo ju m per wir es, con n ect on e t o a ba t - (6) Rem ove power ven t m ot or.
t er y (+) sou r ce a n d t h e ot h er t o a good gr ou n d (-).
(4) Con n ect t h e Nega t ive (-) ju m per pr obe t o on e of INSTALLATION
t h e m ot or con n ect or t er m in a ls. (1) Obt a in n ew ven t win dow m ot or.
(5) Mom en t a r ily t ou ch t h e P osit ive (+) ju m per (2) Sn a p t h e a ct u a t or lin k socket on t o t h e qu a r t er
pr obe t o t h e ot h er m ot or con n ect or t er m in a l. win dow ba ll socket . Usin g a soft r u bber m a llet , pu sh
Wh en posit ive pr obe is con n ect ed t h e m ot or sh ou ld t h e cir cu la r lin k t a b flu sh wit h lin k su r fa ce.
r ot a t e in on e dir ect ion t o eit h er m ove win dow open or (3) In st a ll bolt s h oldin g power ven t m ot or t o D-pil-
closed. If win dow is a ll t h e wa y open or closed t h e la r.
m ot or will gr u n t a n d t h e cr a n k syst em will flex wh en (4) Recon n ect wir e con n ect or t o power ven t m ot or.
a ct u a t ed in t h a t on e dir ect ion . (5) Recon n ect t h e ba t t er y n ega t ive ca ble.
Rever se ju m per pr obes a t t h e m ot or con n ect or t er- (6) Cycle qu a r t er win dow open /close t o ver ify fu n c-
m in a ls a n d win dow sh ou ld n ow m ove in opposit e t ion .
dir ect ion . If win dow does n ot m ove or gr u n t , r epla ce (7) In st a ll D-pilla r t r im pa n el.
t h e m ot or.
If win dow m oved com plet ely open or closed, r ever se
t h e ju m per pr obes a n d cycle win dow t o t h e opposit e WI N DOW M OT OR
posit ion t o ver ify fu ll oper a t ion .
If m ot or gr u n t s a n d does n ot m ove, ver ify t h a t REMOVAL
cr a n k syst em is n ot bin din g. Th e win dow m ot or is in cor por a t ed in t o t h e win dow
r egu la t or a ssem bly. If t h e win dow m ot or r equ ir es
REMOVAL r epla cem en t , t h e win dow r egu la t or m u st be r epla ced.
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive (Refer t o 23 - BODY/DOOR - F RONT/WINDOW
ca ble. RE GULATOR - RE MOVAL).
RS POWER WINDOWS 8N - 63
WI N DOW SWI T CH

WINDOW SWITCH
(1) Rem ove t h e desir ed swit ch t o be t est ed fr om
t h e door t r im pa n el. Dr iver ’s side (m a st er ) or pa ssen -
ger side. (Refer t o 8 - E LE CTRICAL/P OWE R WIN-
DOWS/P OWE R WINDOW SWITCH - RE MOVAL).
(2) Usin g a n oh m m et er, Test dr iver door swit ch for
con t in u it y a s descr ibed in (F ig. 2).
Fig. 3 Passenger Door Power Window Switch

PASSEN GER WI N DOW SWI T CH T EST
Fig. 2 Power Window Master Switch Connector
SWITCH POSITION CONTINUITY BETWEEN
POWER WI N DOW M AST ER SWI T CH T EST
OFF 3 AND 8
SWITCH POSITION CONTINUITY BETWEEN OFF 2 AND 5
OFF 13 and 1 UP 1 AND 8
13 and 2 DOWN 1 AND 5
13 and 3
(5) If t h e r esu lt s a r e n ot OK, r epla ce t h e swit ch .
13 and 4 Th e power win dow m a st er swit ch h a s a Au t o-Down
13 and 5 fea t u r e. Th e swit ch is equ ipped wit h t wo det en t posi-
13 and 6 t ion s wh en a ct u a t in g t h e power win dow OP E N. Th e
fir st det en t posit ion a llows t h e win dow t o r oll down
13 and 7
a n d st op wh en t h e swit ch is r elea sed. Th e secon d
13 and 8 det en t posit ion a ct u a t es a n in t egr a l expr ess r oll
UP DRIVER 11 and 8 down r ela y t h a t r olls t h e win dow down a ft er t h e
*DOWN DRIVER 11 and 6 swit ch is r elea sed. Wh en t h e expr ess down cir cu it
sen ses st a ll cu r r en t (win dow h a s r ea ch ed en d of
*X DOWN DRIVER 11and 6 down t r a vel), t h e swit ch will t u r n cu r r en t off t o t h e
UP PASSENGER 9 and 4 m ot or. Th e AUTO fea t u r e ca n be ca n celled by a ct u a t -
DOWN PASSENGER 9 and 2 in g t h e swit ch UP or DOWN wh ile win dow is in
m ot ion . If t h e elect r on ic cir cu it in t h e swit ch fa ils t o
LEFT VENT OPEN 11 and 7
det ect a st a ll cu r r en t , t h e a u t o down cir cu it will t im e
LEFT VENT CLOSE 9 and 3 ou t wit h in 9 t o 13 secon ds.
RIGHT VENT OPEN 9 and 1
RIGHT VENT CLOSE 11 and 5
* MUST TE ST WITH B+ ON P IN 9 AND

GROUND ON P IN 13 F OR CONTINUITY
BE TWE E N P INS 11 AND 6
(3) If t h e r esu lt a r e n ot OK, r epla ce t h e dr iver side
win dow lift swit ch .
(4) Test pa ssen ger door swit ch for con t in u it y a s
descr ibed in (F ig. 3).
8N - 64 POWER WINDOWS RS
WI N DOW SWI T CH (Cont inue d)
REMOVAL
ca ble.
(2) Usin g a t r im st ick, st a r t a t t h e bot t om of t h e
swit ch a n d bezel a ssem bly a n d pr y u p t o r em ove t h e
swit ch a n d bezel a ssem bly fr om t h e door t r im pa n el
(F ig. 4).
(3) Un la t ch t h e lockin g t a b on t h e h a r n ess side
con n ect or of t h e swit ch .
(4) Discon n ect wir e h a r n ess con n ect or s fr om
swit ch .
INSTALLATION
(1) Recon n ect wir e h a r n ess con n ect or t o swit ch .
(2) In ser t swit ch in t o door t r im pa n el a n d pr ess
in t o pla ce.
(3) Recon n ect ba t t er y n ega t ive ca ble. Fig. 4 POWER WINDOW SWITCH
1 - DOOR TRIM PANEL
2 - POWER WINDOW SWITCH AND BEZEL ASSEMBLY
RS RESTRAINTS 8O - 1
RESTRAINTS
page page
RESTRAINTS OCCUPANT RESTRAINT CONTROLLER

WARNING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 29
DIAGNOSIS AND TESTING - AIRBAG SYSTEM . 6 PASSENGER AIRBAG
STANDARD PROCEDURE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 30
STANDARD PROCEDURE - HANDLING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
AIRBAGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
STANDARD PROCEDURE - SERVICE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 32
AFTER AN AIRBAG DEPLOYMENT . . . . . . . . . 7 PASSENGER AIRBAG DISABLED INDICATOR
BELT TENSION SENSOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 33
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
CHILD RESTRAINT ANCHOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 34
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9 SEAT BELT BUCKLE - FRONT INBOARD
CLOCKSPRING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 35
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10 SEAT BELT BUCKLE - FIRST ROW INBOARD -
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 QUAD BUCKET
STANDARD PROCEDURE - CLOCKSPRING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
CENTERING . . . . . . . . . . . . . . . . . . . . . . . . . 11 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 36
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 SEAT BELT BUCKLE - FIRST ROW - BENCH
CURTAIN AIRBAG INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 37
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 12 SEAT BELT BUCKLE - SECOND ROW
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 INBOARD - 50/50 BENCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
DRIVER AIRBAG SEAT BELT HEIGHT ADJUSTER - B OR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 16 C-PILLAR
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 18 SEAT BELT HEIGHT ADJUSTER KNOB
IMPACT SENSOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 18 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 38
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 SEAT BELT & RETRACTOR - OUTBOARD -
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21 FRONT
KNEE BLOCKER AIRBAG REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 22 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 39
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 SEAT BELT & RETRACTOR - FIRST ROW -
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 OUTBOARD
OCCUPANT CLASSIFICATION MODULE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 40
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 25 SEAT BELT BUCKLE - SECOND ROW - THREE
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 PASSENGER BENCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
8O - 2 RESTRAINTS RS
SEAT BELT & RETRACTOR - SECOND ROW - INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 42

RIGHT OUTBOARD SEAT BELT TENSIONER
SEAT BELT & RETRACTOR - SECOND ROW - SEAT WEIGHT BLADDER & PRESSURE
RIGHT OUTBOARD WITH REAR HVAC - LWB SENSOR
SEAT BELT & RETRACTOR - SECOND ROW -
LEFT OUTBOARD
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
REST RAI N T S • Re a r S e a t B e lts - Bot h ou t boa r d r ea r secon d

a n d t h ir d sea t in g posit ion s a r e equ ipped wit h t h r ee-
poin t sea t belt syst em s. Th e ou t boa r d sea t in g posi-
DESCRIPTION
t ion belt s em ploy a lower C or D-pilla r m ou n t ed
Th is veh icle is equ ipped wit h a F r on t a l Im pa ct Air-
in er t ia la t ch -t ype r et r a ct or, a fixed posit ion u pper C
ba g Syst em , wh ich u t ilizes t h e dr iver /pa ssen ger a ir-
or D-pilla r m ou n t ed t u r n in g loop, a n d a fixed lower
ba gs, t wo fr on t im pa ct sen sor s, a n d sea t belt
sea t belt a n ch or secu r ed t o t h e in boa r d side of t h e
t en sion er s loca t ed in t h e fr on t sea t belt bu ckles. Th is
sea t cu sh ion fr a m e.
syst em is design ed t o pr ot ect occu pa n t s in t h e even t
• Ch ild Re s tra in t An c h o rs - Also equ ipped in
of a fr on t im pa ct collision . Th ese a ir ba gs a r e a ll ser-
t h is veh icle a r e t wo, fixed-posit ion , ch ild sea t u pper
vicea ble pa r t s. Th e t en sion er s a r e in t egr a l t o t h e
t et h er a n ch or s loca t ed on t h e lower sea t cu sh ion , in
fr on t sea t belt bu ckles. If t h ese pyr ot ech n ics a r e
t h e r ea r of t h e lower sea t cu sh ion . Th er e is on e
deployed or defect ive, t h ey m u st be r epla ced.
a n ch or in t egr a l t o t h e ba ck of t h e t h ir d r ow sea t ba ck
Veh icles equ ipped wit h t h e Side Im pa ct Air ba g
pa n el, on e on ea ch sea t ba ck pa n el. Two lower secon d
Syst em u t ilize a cu r t a in a ir ba g, t h r ee side im pa ct
r ow a n ch or s a r e a lso pr ovided for ea ch r ea r ou t boa r d
sen sor s, a n d t h e Occu pa n t Rest r a in t Con t r oller
sea t in g posit ion . Th e lower a n ch or s a r e in t egr a l t o
(ORC) t o det er m in e if t h e a ir ba g sh ou ld be deployed.
t h e sea t cu sh ion fr a m e a n d a r e a ccessed fr om t h e
F ollowin g a side im pa ct even t wh er e t h e side a ir ba g
fr on t of t h e secon d r ow sea t wh er e t h e sea t ba ck
wa s deployed, t h e h ea dlin er a s well a s t h e cu r t a in
m eet s t h e sea t cu sh ion .
a ir ba g m u st be r epla ced.
Th e occu pa n t r est r a in t s in clu de bot h a ct ive a n d
PASSIVE RESTRAINTS
pa ssive t ypes. Act ive r est r a in t s a r e t h ose wh ich
Th e pa ssive r est r a in t s a va ila ble for t h is m odel
r equ ir e t h e veh icle occu pa n t s t o t a ke som e a ct ion t o
in clu de t h e followin g:
em ploy, su ch a s fa st en in g a sea t belt ; wh ile pa ssive
• D u a l F ro n t Airba g s - Mu lt ist a ge dr iver. fr on t
r est r a in t s r equ ir e n o a ct ion by t h e veh icle occu pa n t s
pa ssen ger, a n d dr iver kn ee blocker a ir ba gs a r e a va il-
t o be em ployed.
a ble for t h is m odel. Th is a ir ba g syst em is a pa ssive,
in fla t a ble, Su pplem en t a l Rest r a in t Syst em (SRS) a n d
ACTIVE RESTRAINTS
veh icles wit h t h is equ ipm en t ca n be r ea dily iden t ified
Th e a ct ive r est r a in t s in clu de:
by t h e “SRS - AIRBAG” logo m olded in t o t h e dr iver
• F ro n t S e a t B e lts - Bot h fr on t sea t in g posit ion s
a ir ba g t r im cover in t h e cen t er of t h e st eer in g wh eel
a r e equ ipped wit h t h r ee-poin t sea t belt syst em s
a n d a lso in t o t h e pa ssen ger a ir ba g door on t h e
em ployin g a lower B-pilla r m ou n t ed in er t ia la t ch -
in st r u m en t pa n el a bove t h e glove box. Veh icles wit h
t ype r et r a ct or, h eigh t -a dju st a ble u pper B-pilla r
t h e a ir ba g syst em ca n a lso be iden t ified by t h e a ir ba g
m ou n t ed t u r n in g loops, a fixed lower sea t belt a n ch or
in dica t or, wh ich will illu m in a t e in t h e in st r u m en t
secu r ed t o t h e lower B-pilla r, a n d a t r a velin g en d-r e-
clu st er for a bou t seven secon ds a s a bu lb t est ea ch
lea se bu ckle secu r ed t o t h e in boa r d side of t h e sea t
t im e t h e ign it ion swit ch is t u r n ed t o t h e ON posit ion .
cu sh ion fr a m e. Th e dr iver side fr on t sea t belt bu ckle
A pyr ot ech n ic-t ype sea t belt t en sion er is in t egr a l t o
in clu des a n in t egr a l H a ll-effect sea t belt swit ch t h a t
t h e dr iver a n d pa ssen ger fr on t sea t belt bu ckle of a ll
det ect s wh et h er t h e dr iver side fr on t sea t belt h a s
m odels equ ipped wit h du a l fr on t a ir ba gs.
been fa st en ed.
REST RAI N T S (Cont inue d)
• Oc c u p a n t Cla s s ific a tio n S y s te m - Th ese Rest r a in t Con t r oller (ORC) m u st be dia gn osed follow-
veh icles a lso in clu de a n Occu pa n t Cla ssifica t ion Sys- in g pr ocedu r es ou t lin ed in t h e dia gn ost ic in for m a t ion .
t em (OCS) wit h com pon en t s t h a t a r e loca t ed on or in
t h e pa ssen ger fr on t sea t cu sh ion . Th ese com pon en t s
in clu de a n Occu pa n t Cla ssifica t ion Modu le (OCM)
a n d a sea t weigh t bla dder a n d pr essu r e sen sor
a ssem bly. In a ddit ion , t h is syst em in clu des a belt
t en sion sen sor in t egr a l t o t h e lower a n ch or of t h e
pa ssen ger side fr on t sea t belt . Veh icles equ ipped wit h
t h e OCS ca n be r ea dily iden t ified by a P a ssen ger Air-
ba g Disa bled (PAD) in dica t or (F ig. 1) loca t ed in t h e
cen t er st a ck on t h e in st r u m en t pa n el a bove H VAC
con t r ol h ea d a n d r a dio.
• Cu rta in Airba g s - Cu r t a in a ir ba gs a r e a va il-
a ble for t h is m odel wh en it is a lso equ ipped wit h
du a l fr on t a ir ba gs. Th is a ir ba g syst em is a pa ssive, Fig. 3 AIRBAG COMPONENT LOCATION -
in fla t a ble, Su pplem en t a l Rest r a in t Syst em (SRS) a n d INSTRUMENT PANEL
veh icles wit h t h is equ ipm en t ca n be r ea dily iden t ified
1 - DRIVER AIRBAG
by a m olded iden t ifica t ion t r im bu t t on wit h t h e “SRS 2 - PASSENGER AIRBAG DISABLED (PAD) INDICATOR
- AIRBAG” logo (F ig. 2) loca t ed on t h e h ea dlin er 3 - PASSENGER AIRBAG
a bove ea ch B-pilla r. 4 - OCCUPANT RESTRAINT CONTROLLER (ORC)
5 - KNEE BLOCKER AIRBAG
Th e Dr iver a n d P a ssen ger Air ba g Syst em wa s

design ed t o r edu ce t h e likelih ood of in ju r y or dea t h
in fr on t a l collision s. E a ch sepa r a t e syst em is su pple-
m en t a l (F ig. 2) or P a s s iv e t o t h e pr im a r y r est r a in t
device, wh ich a r e t h e sea t belt s.
• Airba g In d ic a to r - Th e a ir ba g in dica t or is in t e-
Fig. 1 PAD INDICATOR gr a l t o t h e In st r u m en t Clu st er, wh ich is loca t ed on
t h e in st r u m en t pa n el in fr on t of t h e dr iver.
• B e lt Te n s io n S e n s o r - Veh icles equ ipped wit h
t h e Occu pa n t Cla ssifica t ion Syst em (OCS) in clu de a
belt t en sion sen sor. Th is sen sor is in t egr a l t o t h e pa s-
sen ger side fr on t sea t belt lower a n ch or wh ich is
secu r ed t o t h e floor, ou t boa r d a n d r ea r of t h e fr on t
pa ssen ger sea t . -.....con cea led ben ea t h a n a ccess cover
on t h e sea t belt a ssem bly.
• Clo c k s p rin g - Th e clockspr in g is loca t ed n ea r
t h e t op of t h e st eer in g colu m n , dir ect ly ben ea t h t h e
st eer in g wh eel (F ig. 3).
• Cu rta in Airba g - A side cu r t a in a ir ba g is
loca t ed on ea ch in side r oof side r a il a bove t h e h ea d-
lin er, a n d ext en ds fr om t h e A-pilla r t o ju st beyon d
t h e D-pilla r.
• D riv e r Airba g - Th e dr iver a ir ba g is loca t ed in
t h e cen t er of t h e st eer in g wh eel, ben ea t h t h e dr iver
Fig. 2 SRS LOGO
a ir ba g t r im cover (F ig. 3).
Th is veh icle is equ ipped wit h a F r on t a l Im pa ct Air- • F ro n t Im p a c t S e n s o r - Two fr on t im pa ct sen -
ba g Syst em , wh ich u t ilizes t h e dr iver /pa ssen ger a ir- sor s a r e u sed on veh icles equ ipped wit h du a l fr on t
ba gs, dr iver kn ee blocker a ir ba g, a n d sea t belt a ir ba gs, on e left side a n d on e r igh t side. Th e sen sor s
t en sion er s. Th is syst em is design ed t o pr ot ect occu - a r e loca t ed on t h e r a il t ips, r ea r wa r d of t h e bu m per
pa n t s in t h e even t of a fr on t im pa ct collision . Th ese a t t a ch m en t s.
a ir ba gs a n d sea t belt t en sion er s a r e a ll ser vicea ble • Kn e e B lo c k e r Airba g - Th e dr iver kn ee blocker
pa r t s. If t h ese pyr ot ech n ics a r e deployed or defect ive, a ir ba g is secu r ed t o t h e in st r u m en t pa n el beh in d t h e
t h ey m u st be r epla ced, a s well a s t h e Occu pa n t st eer in g colu m n open in g cover (F ig. 3).
• Oc c u p a n t Cla s s ific a tio n Mo d u le - Veh icles OPERATION
equ ipped wit h t h e Occu pa n t Cla ssifica t ion Syst em
(OCS) in clu de a n Occu pa n t Cla ssifica t ion Modu le ACTIVE RESTRAINTS
(OCM) wh ich is secu r ed t o a st a m ped st eel m ou n t in g Th e pr im a r y pa ssen ger r est r a in t s in t h is or a n y
br a cket on t h e u n der side of t h e pa ssen ger side fr on t ot h er veh icle a r e t h e sea t belt s a n d ch ild r est r a in t
sea t cu sh ion fr a m e. a n ch or s. Sea t belt s a n d ch ild r est r a in t a n ch or s a r e
• Oc c u p a n t Re s tra in t Co n tro lle r - Th e Occu - r efer r ed t o a s a n a ct ive r est r a in t beca u se t h e veh icle
pa n t Rest r a in t Con t r oller (ORC) is a lso som et im es occu pa n t s a r e r equ ir ed t o ph ysica lly fa st en a n d pr op-
r efer r ed t o a s t h e Air ba g Con t r ol Modu le (ACM). Th e er ly a dju st t h ese r est r a in t s in or der t o ben efit fr om
ORC is loca t ed on a m ou n t on t h e floor t r a n sm ission t h em . See t h e own er ’s m a n u a l in t h e veh icle glove
t u n n el ju st u n der n ea t h t h e in st r u m en t pa n el cen t er box for m or e in for m a t ion on t h e fea t u r es, u se a n d
st a ck (F ig. 3). oper a t ion of a ll of t h e a ct ive r est r a in t s.
• P a s s e n g e r Airba g - Th e pa ssen ger a ir ba g is
loca t ed on t h e in st r u m en t pa n el, ben ea t h t h e in st r u - PASSIVE RESTRAINTS
m en t pa n el t op pa d a n d a bove t h e glove box on t h e Th e pa ssive r est r a in t s a r e r efer r ed t o a s a su pple-
pa ssen ger side of t h e veh icle (F ig. 3). m en t a l r est r a in t syst em beca u se t h ey wer e design ed
• P a s s e n g e r Airba g D is a ble d (PAD ) In d ic a to r a n d a r e in t en ded t o en h a n ce t h e pr ot ect ion for t h e
- Veh icles equ ipped wit h t h e Occu pa n t Cla ssifica t ion occu pa n t s of t h e veh icle ON LY wh en u sed in con -
Syst em (OCS) in clu de a pa ssen ger a ir ba g disa bled ju n ct ion wit h t h e sea t belt s. Th ey a r e r efer r ed t o a s
(PAD) in dica t or wh ich is loca t ed in t h e in st r u m en t pa ssive r est r a in t s beca u se t h e veh icle occu pa n t s a r e
pa n el cen t er st a ck (F ig. 3). n ot r equ ir ed t o do a n yt h in g t o m a ke t h em oper a t e;
• P a s s e n g e r Kn e e B lo c k e r - Th e pa ssen ger kn ee h owever, t h e veh icle occu pa n t s m u st be wea r in g t h eir
blocker is a st r u ct u r a l r ein for cem en t t h a t is in t egr a l sea t belt s in or der t o obt a in t h e m a xim u m sa fet y
t o a n d con cea led wit h in t h e glove box door (F ig. 3). ben efit fr om t h e su pplem en t a l r est r a in t syst em .
• S e a t B e lt Te n s io n e r - A sea t belt t en sion er is Th e su pplem en t a l r est r a in t syst em elect r ica l cir-
in t egr a l t o bot h fr on t sea t belt bu ckles. Th e sea t belt cu it s a r e con t in u ou sly m on it or ed a n d con t r olled by a
bu ckles a r e secu r ed t o t h e in n er sea t fr a m e sides, m icr opr ocessor a n d soft wa r e con t a in ed wit h in t h e
ben ea t h a cu sh ion t r im pa n el. Occu pa n t Rest r a in t Con t r oller (ORC). An a ir ba g in di-
• S e a t We ig h t B la d d e r a n d P re s s u re S e n s o r ca t or in t h e E lect r oMech a n ica l In st r u m en t Clu st er
As s e m bly - Veh icles equ ipped wit h t h e Occu pa n t (E MIC) illu m in a t es for a bou t seven secon ds a s a bu lb
Cla ssifica t ion Syst em (OCS) in clu de a sea t weigh t t est ea ch t im e t h e ign it ion swit ch is t u r n ed t o t h e
bla dder t h a t is sa n dwich ed bet ween a n in su la t or pa d ON or START posit ion s. F ollowin g t h e bu lb t est , t h e
on t h e t op of t h e pa ssen ger side fr on t sea t pa n a n d a ir ba g in dica t or is t u r n ed ON or OF F by t h e ORC t o
t h e sea t cu sh ion foa m pa ddin g. A sh or t h ose con n ect s in dica t e t h e st a t u s of t h e su pplem en t a l r est r a in t sys-
t h e bla dder t o a pr essu r e sen sor wh ich is secu r ed t o t em . If t h e a ir ba g in dica t or com es ON a t a n y t im e
t h e Occu pa n t Cla ssifica t ion Modu le (OCM) m ou n t in g ot h er t h a n du r in g t h e bu lb t est , it in dica t es t h a t
br a cket on t h e u n der side of t h e pa ssen ger side fr on t t h er e is a pr oblem in t h e su pplem en t a l r est r a in t sys-
sea t cu sh ion fr a m e. t em elect r ica l cir cu it s. Su ch a pr oblem m a y ca u se a ir-
• S id e Im p a c t S e n s o rs - Six side im pa ct sen sor s ba gs n ot t o deploy wh en r equ ir ed, or t o deploy wh en
a r e u sed on veh icles equ ipped wit h t h e cu r t a in a ir- n ot r equ ir ed.
ba gs, t h r ee left side a n d t h r ee r igh t side. Th e fir st Deploym en t of t h e su pplem en t a l r est r a in t s
r ow side im pa ct sen sor is loca t ed in t h e B-pilla r, ju st depen ds u pon t h e a n gle a n d sever it y of a n im pa ct .
a bove t h e fr on t sea t belt r et r a ct or. Th e secon d r ow Deploym en t is n ot ba sed u pon veh icle speed; r a t h er,
side im pa ct sen sor is loca t ed in t h e slidin g side door deploym en t is ba sed u pon t h e r a t e of deceler a t ion a s
t r a ck open in g, ju st in fr on t of t h e C-pilla r. Th e t h ir d m ea su r ed by t h e for ces of gr a vit y (G for ce) u pon t h e
r ow side im pa ct sen sor is loca t ed beh in d t h e qu a r t er im pa ct sen sor s. Wh en a n im pa ct is sever e en ou gh ,
t r im pa n el, a bove t h e r ea r t ir e wh eel well, bet ween t h e m icr opr ocessor in t h e ORC sign a ls t h e in fla t or of
t h e C a n d D-pilla r s. t h e a ppr opr ia t e a ir ba g u n it s t o deploy t h eir a ir ba g
Th e ORC, t h e OCM, a n d t h e clu st er ea ch con t a in a cu sh ion s. Th e fr on t sea t belt t en sion er s a r e pr ovided
m icr opr ocessor a n d pr ogr a m m in g t h a t a llow t h em t o wit h a deploym en t sign a l by t h e ORC in con ju n ct ion
com m u n ica t e wit h ea ch ot h er u sin g t h e P r ogr a m m a - wit h t h e fr on t a ir ba gs. Du r in g a fr on t a l veh icle
ble Com m u n ica t ion s In t er fa ce (P CI) da t a bu s n et - im pa ct , t h e kn ee blocker s wor k in con cer t wit h pr op-
wor k. Th is m et h od of com m u n ica t ion is u sed by t h e er ly fa st en ed a n d a dju st ed sea t belt s t o r est r a in bot h
ORC for con t r ol of t h e a ir ba g in dica t or s. t h e dr iver a n d t h e fr on t sea t pa ssen ger in t h e pr oper
posit ion for a n a ir ba g deploym en t . Th e kn ee blocker s
a lso a bsor b a n d dist r ibu t e t h e cr a sh en er gy fr om t h e
dr iver a n d t h e fr on t sea t pa ssen ger t o t h e st r u ct u r e r eceived fr om t h e OCM. Th is in dica t or is illu m in a t ed
of t h e in st r u m en t pa n el (Refer t o 8 - E LE CTRICAL/ wh en ever t h e pa ssen ger a ir ba g a n d sea t belt t en -
RE STRAINTS/KNE E BLOCKE R AIRBAG - sion er oper a t ion h a s been su ppr essed, a n d is t u r n ed
DE SCRIP TION). Th e sea t belt t en sion er s r em ove t h e OF F wh en ever t h ey a r e en a bled or wh en t h e pa ssen -
sla ck fr om t h e fr on t sea t belt s t o pr ovide fu r t h er ger sea t is cla ssified a s em pt y.
a ssu r a n ce t h a t t h e dr iver a n d fr on t sea t pa ssen ger Wh en t h e OCM m on it or s a pr oblem in a n y of t h e
a r e pr oper ly posit ion ed a n d r est r a in ed for a n a ir ba g OCS cir cu it s or com pon en t s, it st or es a fa u lt code or
deploym en t . DTC in it s m em or y cir cu it a n d sen ds a n elect r on ic
Wh en t h e ORC m on it or s a pr oblem in a n y of t h e m essa ge t o t h e ORC. Th e ORC t h en sen ds a n elec-
du a l fr on t a ir ba g syst em cir cu it s or com pon en t s, t r on ic m essa ge t o t h e E MIC t o t u r n ON t h e a ir ba g
in clu din g t h e sea t belt t en sion er s, it st or es a Dia g- in dica t or. If for a n y r ea son t h e OCM is u n a ble t o
n ost ic Tr ou ble Code (DTC) in it s m em or y a n d sen ds cla ssify t h e occu pa n t it sen ds a n elect r on ic m essa ge
a n elect r on ic m essa ge t o t h e E MIC t o t u r n on t h e t o t h e ORC, a n d t h e ORC su ppr esses pa ssen ger a ir-
a ir ba g in dica t or. P r oper t est in g of t h e su pplem en t a l ba g a n d sea t belt t en sion er oper a t ion . P r oper t est in g
r est r a in t syst em com pon en t s, t h e P r ogr a m m a ble of t h e OCS com pon en t s, t h e P r ogr a m m a ble Com m u -
Com m u n ica t ion s In t er fa ce (P CI) da t a bu s, t h e elec- n ica t ion s In t er fa ce (P CI) da t a bu s, t h e elect r on ic
t r on ic m essa ge in pu t s t o a n d ou t pu t s fr om t h e E MIC m essa ge in pu t s t o a n d ou t pu t s fr om t h e OCM, t h e
or t h e ORC, a s well a s t h e r et r ieva l or er a su r e of a E MIC or t h e ORC, a s well a s t h e r et r ieva l or er a su r e
DTC fr om t h e ORC or t h e E MIC r equ ir es t h e u se of of a DTC’s, r equ ir es t h e u se of a sca n t ool. Refer t o
a sca n t ool. Refer t o t h e a ppr opr ia t e dia gn ost ic in for- t h e a ppr opr ia t e dia gn ost ic in for m a t ion .
m a t ion .
OCCUPANT CLASSIFICATION SYSTEM WARN I N G

Th e Occu pa n t Cla ssifica t ion Syst em (OCS) a u t o-
m a t ica lly su ppr esses or en a bles pa ssen ger a ir ba g a n d WARNINGS
sea t belt t en sion er oper a t ion ba sed u pon wh et h er or D is c o n n e c t a n d is o la te th e ba tte ry n e g a tiv e
n ot t h e pa ssen ger side fr on t sea t is occu pied a n d, if c a ble be fo re be g in n in g a n y a irba g s y s te m c o m -
t h e sea t is occu pied, cla ssifies t h e size of t h e occu - p o n e n t d ia g n o s is , te s tin g , re m o v a l, o r in s ta lla -
pa n t a n d wh et h er t h e sea t is occu pied by a ch ild tio n p ro c e d u re s . Allo w s y s te m c a p a c ito r to
sea t . d is c h a rg e fo r tw o m in u te s be fo re be g in n in g a n y
Th e OCS h a s a n Occu pa n t Cla ssifica t ion Modu le c o m p o n e n t te s tin g o r s e rv ic e . Th is w ill d is a ble
(OCM) t h a t m on it or s in pu t s fr om t h e sea t weigh t th e a irba g s y s te m . F a ilu re to d is c o n n e c t th e
bla dder pr essu r e sen sor u n der t h e pa ssen ger side ba tte ry n e g a tiv e c a ble m a y re s u lt in a c c id e n ta l
fr on t sea t cu sh ion a n d fr om t h e belt t en sion sen sor a irba g d e p lo y m e n t, p e rs o n a l in ju ry, o r d e a th .
on t h e pa ssen ger side fr on t sea t belt lower a n ch or. D o n o t p la c e a n in ta c t u n d e p lo y e d a irba g
Ba sed u pon t h ose in pu t s t h e m icr opr ocessor wit h in fa c e d o w n o n a s o lid s u rfa c e . Th e a irba g w ill
t h e OCM cla ssifies t h e occu pa n t of t h e pa ssen ger p ro p e l in to th e a ir if a c c id e n ta lly d e p lo y e d a n d
side fr on t sea t . Th e OCM t h en sen ds elect r on ic occu - m a y re s u lt in p e rs o n a l in ju ry o r d e a th .
pa n t cla ssifica t ion m essa ges t o t h e ORC. Th e m icr o- Wh e n c a rry in g o r h a n d lin g a n u n d e p lo y e d
pr ocessor a n d pr ogr a m m in g of t h e ORC u ses t h ese a irba g , th e trim s id e (fa c e ) o f th e a irba g s h o u ld
occu pa n t cla ssifica t ion m essa ges t o det er m in e be p o in tin g to w a rd s th e bo d y to m in im ize p o s -
wh et h er t o en a ble or disa ble t h e deploym en t cir cu it s s ibility o f in ju ry if a c c id e n ta l d e p lo y m e n t
for t h e pa ssen ger a ir ba g a n d sea t belt t en sion er. o c c u rs . F a ilu re to d o th is m a y re s u lt in p e r-
Th e OCS elect r ica l cir cu it s a n d com pon en t s a r e s o n a l in ju ry o r d e a th .
con t in u ou sly m on it or ed by t h e OCM, a n d t h e OCM is Re p la c e a irba g s y s te m c o m p o n e n ts w ith
con t in u ou sly m on it or ed by t h e ORC. A pa ssen ger a ir- Mo p a r! re p la c e m e n t p a rts . S u bs titu te p a rts
ba g ON/OF F in dica t or is loca t ed in t h e in st r u m en t m a y a p p e a r in te rc h a n g e a ble , bu t in te rn a l d if-
pa n el cen t er st a ck a r ea . Th is in dica t or r eceives ba t - fe re n c e s m a y re s u lt in in fe rio r o c c u p a n t p ro te c -
t er y cu r r en t wh en ever t h e ign it ion swit ch is in t h e tio n . F a ilu re to d o s o m a y re s u lt in o c c u p a n t
ON or START posit ion s, a n d illu m in a t es on ly wh en p e rs o n a l in ju ry o r d e a th .
t h e ORC pu lls t h e in dica t or con t r ol cir cu it t o gr ou n d. We a r s a fe ty g la s s e s , ru bbe r g lo v e s , a n d lo n g
Th e in dica t or illu m in a t es for a bou t seven secon ds a s s le e v e d c lo th in g w h e n c le a n in g p o w d e r re s id u e
a bu lb t est ea ch t im e t h e ign it ion swit ch is t u r n ed t o fro m v e h ic le a fte r a irba g d e p lo y m e n t. S o d iu m
t h e ON or START posit ion s. F ollowin g t h e bu lb t est , h y d ro x id e p o w d e r re s id u e e m itte d fro m a
t h e in dica t or is t u r n ed ON or OF F by t h e ORC ba sed d e p lo y e d a irba g c a n c a u s e s k in irrita tio n .
u pon t h e elect r on ic occu pa n t cla ssifica t ion m essa ges F lu s h a ffe c te d a re a w ith c o o l w a te r if irrita tio n
is e x p e rie n c e d . If n a s a l o r th ro a t irrita tio n is
e x p e rie n c e d , e x it th e v e h ic le fo r fre s h a ir u n til s a m e tim e , a n irre v e rs ible fa u lt w ill be s e t in
th e irrita tio n c e a s e s . If irrita tio n c o n tin u e s , s e e bo th m o d u le s a n d th e OCS m a y m a lfu n c tio n
a p h y s ic ia n . a n d c a u s e p e rs o n a l in ju ry o r d e a th .
D o n o t u s e a re p la c e m e n t a irba g th a t is n o t in
th e o rig in a l p a c k a g in g . Th is m a y re s u lt in DIAGNOSIS AND TESTING - AIRBAG SYSTEM
im p ro p e r d e p lo y m e n t, p e rs o n a l in ju ry, o r (1) Wit h t h e ba t t er y n ega t ive r em ot e ca ble discon -
d e a th . n ect ed, con n ect t h e sca n t ool t o t h e Da t a Lin k Con -
Th e fa c to ry in s ta lle d fa s te n e rs , s c re w s a n d n ect or (DLC).
bo lts u s e d to fa s te n a irba g c o m p o n e n ts h a v e a (2) Tu r n t h e ign it ion key t o t h e ON posit ion , t h en
s p e c ia l c o a tin g a n d a re s p e c ific a lly d e s ig n e d exit veh icle wit h t h e sca n t ool.
fo r th e a irba g s y s te m . D o n o t u s e s u bs titu te fa s - (3) Aft er ch eckin g t h a t n o on e is in side t h e veh icle,
te n e rs . U s e o n ly o rig in a l e qu ip m e n t fa s te n e rs con n ect t h e ba t t er y n ega t ive r em ot e t er m in a l.
lis te d in th e p a rts c a ta lo g w h e n fa s te n e r (4) Rea d a n d r ecor d t h e ACTIVE Dia gn ost ic Tr ou -
re p la c e m e n t is re qu ire d . ble Code (DTC) da t a .
D u rin g , a n d fo llo w in g , a n y c h ild re s tra in t (5) Rea d a n d r ecor d a n y S TORED DTC’s.
a n c h o r s e rv ic e , d u e to im p a c t e v e n t o r v e h ic le (6) Refer t o t h e pr oper dia gn ost ic in for m a t ion if
re p a ir, c a re fu lly in s p e c t a ll m o u n tin g h a rd - a n y DTC’s a r e fou n d in St ep 4 a n d St ep 5.
w a re , te th e r s tra p s , a n d a n c h o rs fo r p ro p e r (7) If t h e a ir ba g wa r n in g la m p eit h er fa ils t o ligh t ,
in s ta lla tio n , o p e ra tio n , o r d a m a g e . If a c h ild or goes ON a n d st a ys ON, t h er e is a syst em m a lfu n c-
re s tra in t a n c h o r is fo u n d d a m a g e d in a n y w a y, t ion . To t est t h e a ir ba g wa r n in g la m p (bu lb) oper a -
th e a n c h o r m u s t be re p la c e d . F a ilu re to d o th is t ion in t h e clu st er (Refer t o 8 - E LE CTRICAL/
m a y re s u lt in p e rs o n a l in ju ry o r d e a th . INSTRUME NT CLUSTE R - DIAGNOSIS AND
D e p lo y e d a n d n o n d e p lo y e d a irba g s m a y o r TE STING). Refer t o t h e pr oper dia gn ost ic in for m a -
m a y n o t h a v e liv e p y ro te c h n ic m a te ria l w ith in t ion for a n y ot h er syst em pr oblem s.
th e a irba g in fla to r. D o n o t d is p o s e o f d riv e r/
p a s s e n g e r/s e a t/c u rta in /k n e e blo c k e r a irba g s o r
s e a t be lt te n s io n e rs u n le s s y o u a re s u re o f c o m - STAN DARD PROCEDU RE
p le te d e p lo y m e n t. Re fe r to th e Ha za rd o u s S u b-
s ta n c e Co n tro l S y s te m fo r p ro p e r d is p o s a l. STANDARD PROCEDURE - HANDLING
D is p o s e o f d e p lo y e d a irba g s a n d te n s io n e rs AIRBAGS
c o n s is te n t w ith s ta te , p ro v in c ia l, lo c a l, a n d fe d -
e ra l re g u la tio n s . DEPLOYED AIRBAG
Afte r a n y a irba g c o m p o n e n t te s tin g o r s e r-
v ic e , d o n o t c o n n e c t th e ba tte ry n e g a tiv e c a ble WARNING: The vehicle interior may contain a very
(Re fe r to 8 - ELECTRICAL/RES TRAIN TS - small amount of powder, a by-product of airbag
D IAGN OS IS AN D TES TIN G - AIRB AG S YS TEM). deployment. This powder can irritate the skin, eyes,
P e rs o n a l in ju ry o r d e a th m a y re s u lt if th e s y s - nose and throat. Wear safety glasses, rubber
te m te s t is n o t p e rfo rm e d firs t. gloves, and long sleeved clothing when cleaning
If th e v e h ic le is e qu ip p e d w ith th e Oc c u p a n t any of the powder residue from the vehicle. If you
Cla s s ific a tio n S y s te m (OCS ), d o n o t c o n n e c t th e find that the cleanup is irritating your skin, run cool
ba tte ry n e g a tiv e c a ble be fo re p e rfo rm in g th e water over the affected area. Also, if you experience
OCS Ve rific a tio n Te s t u s in g th e s c a n to o l a n d nasal or throat irritation, exit the vehicle for fresh
th e a p p ro p ria te d ia g n o s tic in fo rm a tio n . P e r- air until the irritation ceases. If irritation continues,
s o n a l in ju ry o r d e a th m a y re s u lt if th e s y s te m see a physician.
te s t is n o t p e rfo rm e d p ro p e rly.
N e v e r re p la c e bo th th e Oc c u p a n t Re s tra in t
Co n tro lle r (ORC) a n d th e Oc c u p a n t Cla s s ific a -
tio n Mo d u le (OCM) a t th e s a m e tim e . If bo th
re qu ire re p la c e m e n t, re p la c e o n e , th e n p e rfo rm
th e Airba g S y s te m te s t (Re fe r to 8 - ELECTRI-
CAL/RES TRAIN TS - D IAGN OS IS AN D TES TIN G
- AIRB AG S YS TEM) be fo re re p la c in g th e o th e r.
B o th th e ORC a n d th e OCM s to re Oc c u p a n t
Cla s s ific a tio n S y s te m (OCS ) c a libra tio n d a ta ,
w h ic h th e y tra n s fe r to o n e a n o th e r w h e n o n e o f
th e m is re p la c e d . If bo th a re re p la c e d a t th e
UNDEPLOYED AIRBAG KNEE BLOCKER AIRBAG
Aft er a Kn ee Blocker Air ba g h a s been deployed du e
WARNING: The airbags must be stored in its origi- t o a collision . t h e followin g MU S T be r epla ced:
nal special container until used for service. At no • Kn ee Blocker Air ba g
time should a source of electricity be permitted • In st r u m en t P a n el a n d P a d Assem bly
near the inflator on the back of an airbag. When All ot h er a ir ba g a n d veh icle com pon en t s sh ou ld be
carrying or handling an undeployed airbag, the trim closely in spect ed followin g a n y a ir ba g deploym en t ,
side of the airbag should be pointing toward the a n d sh ou ld be r epla ced wh en visible da m a ge is
body to minimize the possibility of personal injury in cu r r ed.
or death if accidental deployment occurs. Do not
place undeployed airbag face down on a solid sur- WARNING: Do not connect the battery negative
face, the airbag will propel into the air if accidental cable (Refer to 8 - ELECTRICAL/RESTRAINTS -
deployment occurs. DIAGNOSIS AND TESTING - AIRBAG SYSTEM). Per-
sonal injury or death may result if the system test
is not performed first.
STANDARD PROCEDURE - SERVICE AFTER AN
AIRBAG DEPLOYMENT
CURTAIN AIRBAG
DRIVER AIRBAG Aft er a Cu r t a in Air ba g h a s been deployed du e t o a
Aft er a Dr iver Air ba g h a s been deployed du e t o a collision . t h e followin g MU S T be r epla ced:
collision , t h e followin g MU S T be r epla ced: • Cu r t a in Air ba g Assem bly
• Dr iver Air ba g • H ea dlin er
• Clockspr in g Assem bly • A, B, a n d C-P illa r Tr im on deployed side.
• St eer in g Wh eel All ot h er a ir ba g a n d veh icle com pon en t s sh ou ld be
• Com plet e St eer in g Colu m n Assem bly w/Lower closely in spect ed followin g a n y a ir ba g deploym en t ,
St eer in g Colu m n Cou pler a n d sh ou ld be r epla ced wh en visible da m a ge is
All ot h er a ir ba g a n d veh icle com pon en t s sh ou ld be in cu r r ed.
closely in spect ed followin g a n y a ir ba g deploym en t ,
WARNING: Do not connect the battery negative
a n d sh ou ld be r epla ced wh en visible da m a ge is
cable (Refer to 8 - ELECTRICAL/RESTRAINTS -
in cu r r ed.
DIAGNOSIS AND TESTING - AIRBAG SYSTEM). Per-
WARNING: Do not connect the battery negative sonal injury or death may result if the system test
cable (Refer to 8 - ELECTRICAL/RESTRAINTS - is not performed first.
OCCUPANT CLASSIFICATION SYSTEM (OCS)
Aft er a n im pa ct even t , eit h er fr on t , r ea r, or side,
t h e OCS syst em com pon en t s n eed t o be in spect ed
PASSENGER AIRBAG a n d r epla ced if fou n d t o be da m a ged.
Aft er a P a ssen ger Air ba g h a s been deployed du e t o Th is in clu des:
a collision . t h e followin g MU S T be r epla ced: • Belt Ten sion Sen sor
• P a ssen ger Air ba g • Occu pa n t Cla ssifica t ion Modu le (OCM)
• In st r u m en t P a n el a n d P a d Assem bly • P a ssen ger Air ba g ON/Off In dica t or
All ot h er a ir ba g a n d veh icle com pon en t s sh ou ld be • Sea t Weigh t Bla dder a n d Sen sor
closely in spect ed followin g a n y a ir ba g deploym en t ,
a n d sh ou ld be r epla ced wh en visible da m a ge is
in cu r r ed.

WARNING: Never replace both the Occupant Restraint cu r t a in , or sea t ba ck). Th en t a pe t h e r ipped cover
Controller (ORC) and the Occupant Classification Mod- over t h e deployed a ir ba g if a pplica ble.
ule (OCM) at the same time. If both require replace- Use a va cu u m clea n er t o r em ove a n y r esidu a l pow-
ment, replace one, then perform the Airbag System der fr om t h e veh icle in t er ior. Wor k fr om t h e ou t side
test (Refer to 8 - ELECTRICAL/RESTRAINTS - DIAGNO- in t o a void kn eelin g or sit t in g in a con t a m in a t ed
SIS AND TESTING - AIRBAG SYSTEM) before replac- a r ea . Va cu u m t h e h ea t er a n d A/C ou t let s a s well (F ig.
ing the other. Both the ORC and the OCM store 4). If t h e h ea t er or a ir con dit ion er wa s in RE CIRC
Occupant Classification System (OCS) calibration m ode a t t im e of a ir ba g deploym en t , oper a t e blower
data, which they transfer to one another when one of m ot or on low speed a n d va cu u m powder r esidu e
them is replaced. If both are replaced at the same expelled fr om t h e h ea t er a n d A/C ou t let s. Mu lt iple
time, an irreversible fault will be set in both modules va cu u m clea n in g m a y be n ecessa r y t o decon t a m in a t e
and the OCS may malfunction and result in personal t h e in t er ior of t h e veh icle.
injury or death.
Wh et h er r epla ced or n ot , t h e OCS m u st be r e-ze-

r oed t o m a ke su r e t h a t t h e syst em in wit h in pr oper
pa r a m et er s t o sen se t h e occu pa n t s weigh t cor r ect ly.

WARNING: Following successful completion of the

Airbag System test procedure, the Occupant Classi- Fig. 4 VACUUM HEATER AND A/C OUTLETS - TYPICAL
fication System Verification Test must be done
using a scan tool and the appropriate diagnostic BELT T EN SI ON SEN SOR
information. Personal injury or death may result if
the system test is not performed. DESCRIPTION
SEAT BELTS AND TENSIONERS

Aft er a fr on t a l im pa ct wh er e a n a ir ba g h a s been
deployed du e t o a collision . t h e followin g MU S T be
r epla ced:
• F r on t Sea t Belt Bu ckle (dr iver a n d pa ssen ger )
wit h in t egr a l Ten sion er s.

All ot h er sea t belt s sh ou ld be closely in spect ed for

cu t s, t ea r s, fr a yin g, or da m a ge in a n y wa y followin g
a n y fr on t a l im pa ct or a ir ba g deploym en t . Th e ot h er
sea t belt s a r e t o be r epla ced wh en visible da m a ge is
in cu r r ed. In spect t h e Lower An ch or s a n d Tet h er for
CH ildr en (LATCH ) ch ild r est r a in t a n ch or s for da m -
Fig. 5 BELT TENSION SENSOR
a ge a ft er a n im pa ct even t a n d r epla ce a s n eeded. 1 - SEAT BELT WEBBING
2 - B-PILLAR
3 - SEAT BELT LOWER ANCHOR BOLT
CLEAN UP PROCEDURE 4 - BELT TENSION SENSOR
Roll or fold t h e a ir ba g t owa r ds it s m ou n t in g poin t
(i.e. in st r u m en t pa n el, st eer in g wh eel, kn ee blocker, Veh icles equ ipped wit h t h e Occu pa n t Cla ssifica t ion
Syst em (OCS) in clu de a belt t en sion sen sor (F ig. 5).
BELT T EN SI ON SEN SOR (Cont inue d)
Th is sen sor is in t egr a l t o t h e pa ssen ger side fr on t tool and the appropriate diagnostic information.
sea t belt lower a n ch or wh ich is secu r ed t o t h e lower Personal injury or death may occur.
B-pilla r, on t h e pa ssen ger side (F ig. 6). Th e belt t en - F or fu r t h er dia gn osis a n d t est in g of t h e belt t en -
sion sen sor con sist s of a m olded pla st ic h ou sin g, a sion sen sor, t h e OCM, a n d r ela t ed occu pa n t cla ssifi-
m et a l sea t belt a n ch or loop, a n d a sh or t pigt a il wir e. ca t ion syst em com pon en t s, u se a sca n t ool a n d t h e
Th e elect r on ic cir cu it r y of t h e belt t en sion sen sor is a ppr opr ia t e dia gn ost ic in for m a t ion .
con cea led a n d pr ot ect ed wit h in t h e m olded pla st ic
h ou sin g.
CH I LD REST RAI N T AN CH OR
DESCRIPTION
Th e Lo w e r An c h o rs a n d Te th e r fo r CHild re n ,
o r LATCH ch ild r est r a in t a n ch or a ge syst em pr ovides
for t h e in st a lla t ion of su it a ble ch ild r est r a in t s in cer-
t a in sea t in g posit ion s wit h ou t u sin g t h e sea t belt pr o-
vided for t h a t sea t in g posit ion . Th e secon d sea t in
t h ese m odels a r e equ ipped wit h a fixed-posit ion ch ild
r est r a in t u pper t et h er a n ch or (F ig. 7) a n d ch ild
r est r a in t lower a n ch or s (F ig. 8). Th e t h ir d sea t is
equ ipped wit h on ly a fixed-posit ion ch ild r est r a in t
u pper t et h er a n ch or in t h e m iddle sea t in g posit ion .
E xpor t veh icles a r e equ ipped wit h fixed-posit ion ch ild
r est r a in t u pper t et h er a n ch or s on ly.
Fig. 6 BELT TENSION SENSOR LOCATION

1 - A-PILLAR
2 - SEAT BELT ANCHOR/BELT TENSION SENSOR
3 - BELT TENSION SENSOR CONNECTOR
Th e belt t en sion sen sor ca n n ot be r epa ir ed a n d, if

fa u lt y or da m a ged, t h e en t ir e pa ssen ger side fr on t
sea t belt a n d r et r a ct or u n it m u st be r epla ced (Refer
t o 8 - E LE CTRICAL/RE STRAINTS/SE AT BE LT
OUTBOARD F RONT - RE MOVAL).
Fig. 7 CHILD RESTRAINT UPPER TETHER/ANCHOR
- 2ND ROW
OPERATION
Th e belt t en sion sen sor is design ed t o sen se t h e
r ela t ive cin ch loa d a pplied t o t h e pa ssen ger side fr on t
sea t belt , wh ich pr ovides a logic in pu t t o t h e m icr o-
pr ocessor of t h e Occu pa n t Cla ssifica t ion Modu le
(OCM). Wh en a loa d is a pplied t o t h e sea t belt , t h e
ch a n ges in t h e loa d a r e m ea su r ed by t h e belt t en sion
sen sor t h r ou gh t h e sea t belt lower a n ch or. As t h e
loa d ch a n ges, t h e cir cu it r y of t h e belt t en sion sen sor
ch a n ges t h e ou t pu t volt a ge of t h e sen sor.
Th e belt t en sion sen sor r eceives a n om in a l five
volt s a n d a gr ou n d fr om t h e OCM. Th e OCM t h en
m on it or s t h e belt t en sion sen sor ou t pu t volt a ge.
WARNING: Do not connect the battery before per- Fig. 8 CHILD RESTRAINT LOWER ANCHORS
forming the OCS Verification Test using the scan SECOND ROW
CH I LD REST RAI N T AN CH OR (Cont inue d)
Th e secon d r ow sea t s h a ve lower a n ch or s for ea ch
r ea r ou t boa r d sea t in g posit ion (F ig. 8). Th ese a n ch or s
a r e welded t o t h e sea t cu sh ion fr a m e. Th ey a r e ea ch
a ccessed fr om t h e fr on t of t h eir r espect ive sea t s, a t
ea ch side wh er e t h e sea t ba ck m eet s t h e sea t cu sh -
ion . Th ese lower a n ch or s ca n n ot be a dju st ed or
r epa ir ed a n d, if fa u lt y or da m a ged, t h e sea t m u st be
r epla ced a s a u n it .
WARNING: During, and following, any child restraint

anchor service, due to impact event or vehicle
repair, carefully inspect all mounting hardware,
tether straps and anchors for proper installation,
operation, or damage. If a child restraint anchor is Fig. 10 TETHER STRAP INSTALLED- REAR SEAT
found damaged in any way, the anchor must be DELETE
replaced with the seat assembly. Failure to do so
could result in personal injury or death. CLOCK SPRI N G
DESCRIPTION
REAR SEAT DELETE Th e clockspr in g is m ou n t ed on t h e st eer in g colu m n
If t h e veh icle is or der ed wit h ou t r ea r sea t s (r ea r beh in d t h e st eer in g wh eel. It is u sed t o m a in t a in a
sea t delet e), t h en t h er e will be a t et h er st r a p con t in u ou s elect r ica l cir cu it bet ween t h e wir in g h a r-
in clu ded. Th is is t o be looped u n der t h e secon d sea t n ess a n d t h e dr iver s a ir ba g.
a n ch or a n d t h en ext en ded for wa r d (F ig. 9) t o clip t o Th e clockspr in g a ssem bly is secu r ed wit h t wo in t e-
t h e t et h er st r a p of t h e ch ild sea t in t h e fr on t pa ssen - gr a l pla st ic la t ch es on t o t h e u pper st eer in g colu m n
ger sea t (F ig. 10). Th er e will be n o lower a n ch or h ou sin g n ea r t h e t op of t h e st eer in g colu m n beh in d
loops for ch ild sea t a n ch or in g in t h e fr on t pa ssen ger t h e st eer in g wh eel. Th e clockspr in g con sist s of a fla t ,
sea t . Use t h e sea t belt for lower ch ild sea t a t t a ch - r ou n d m olded pla st ic ca se wit h a st u bby t a il t h a t
m en t in t h is in st a n ce. h a n gs below t h e st eer in g colu m n . Th e t a il con t a in s
t wo con n ect or s t h a t fa ce t owa r d t h e in st r u m en t
pa n el. Wit h in t h e pla st ic ca se is a spool-like m olded
pla st ic r ot or wit h a la r ge exposed h u b a n d sever a l
pla st ic r oller s.
A r u bber bu m per block is loca t ed on ea ch side of
t h e t ower for m a t ion t h a t con t a in s t h e con n ect or
r ecept a cle a n d pigt a il wir es on t h e u pper su r fa ce of
t h e r ot or h u b. Th e lower su r fa ce of t h e r ot or h u b h a s
a m olded pla st ic t u r n sign a l ca n cel ca m wit h a sin gle
lobe t h a t is in t egr a l t o t h e r ot or. Wit h in t h e pla st ic
ca se a n d wou n d a r ou n d t h e r ot or spool is a lon g r ib-
bon -like t a pe t h a t con sist s of sever a l t h in copper wir e
lea ds sa n dwich ed bet ween t wo t h in pla st ic m em -
Fig. 9 TETHER STRAP PLACEMENT - REAR SEAT br a n es. Th e ou t er en d of t h e t a pe t er m in a t es a t t h e
DELETE con n ect or r ecept a cles t h a t fa ce t h e in st r u m en t pa n el,
wh ile t h e in n er en d of t h e t a pe t er m in a t es a t t h e pig-
OPERATION t a il wir es a n d con n ect or r ecept a cle on t h e h u b of t h e
See t h e own er ’s m a n u a l in t h e veh icle glove box for clockspr in g r ot or t h a t fa ce t h e st eer in g wh eel.
m or e in for m a t ion on t h e pr oper u se of a ll of t h e fa c-
t or y-in st a lled ch ild r est r a in t a n ch or s.
CLOCK SPRI N G (Cont inue d)
Ser vice r epla cem en t clockspr in gs a r e sh ipped pr e- wit h in it s design ed t r a vel lim it s. H owever, if t h e
cen t er ed a n d wit h a m olded pla st ic sh ield t h a t sn a ps clockspr in g is r em oved fr om t h e st eer in g colu m n or if
on t o t h e r ot or over t h e r elea se bu t t on . Th e r elea se t h e st eer in g sh a ft is discon n ect ed fr om t h e st eer in g
bu t t on secu r es t h e cen t er ed clockspr in g r ot or t o t h e gea r, t h e clockspr in g spool ca n ch a n ge posit ion r ela -
clockspr in g ca se a n d t h e sh ield pr even t s t h e r elea se t ive t o t h e m ova ble st eer in g com pon en t s a n d m u st be
bu t t on fr om bein g in a dver t en t ly depr essed du r in g r e-cen t er ed followin g com plet ion of t h e ser vice or t h e
sh ipm en t a n d h a n dlin g, bu t t h e sh ield m u st be t a pe m a y be da m a ged (Refer t o 8 - E LE CTRICAL/
r em oved fr om t h e clockspr in g a ft er it is in st a lled on RE STRAINTS/CLOCKSP RING - STANDARD P RO-
t h e st eer in g colu m n (Refer t o 8 - E LE CTRICAL/RE - CE DURE ).
STRAINTS/CLOCKSP RING - STANDARD P ROCE - Ser vice r epla cem en t clockspr in gs a r e sh ipped pr e-
DURE ). cen t er ed a n d wit h a pla st ic sh ield in st a lled over t h e
Th e clockspr in g ca n n ot be r epa ir ed. If t h e clock- clockspr in g r elea se bu t t on . Th is sh ield sh ou ld n ot be
spr in g is fa u lt y, da m a ged, or if t h e dr iver a ir ba g h a s r em oved a n d t h e r elea se bu t t on sh ou ld n ot be
been deployed, t h e clockspr in g m u st be r epla ced. depr essed u n t il t h e clockspr in g h a s been in st a lled on
t h e st eer in g colu m n . If t h e r elea se bu t t on is
OPERATION depr essed befor e t h e clockspr in g is in st a lled on a
Th e clockspr in g is a m ech a n ica l elect r ica l cir cu it st eer in g colu m n , t h e clockspr in g cen t er in g pr ocedu r e
com pon en t t h a t is u sed t o pr ovide con t in u ou s elect r i- m u st be per for m ed (Refer t o 8 - E LE CTRICAL/RE -
ca l con t in u it y bet ween t h e fixed in st r u m en t pa n el STRAINTS/CLOCKSP RING - STANDARD P ROCE -
wir e h a r n ess a n d t h e elect r ica l com pon en t s m ou n t ed DURE ).
on or in t h e r ot a t in g st eer in g wh eel. Th e r ot a t in g
elect r ica l com pon en t s in clu de t h e dr iver a ir ba g, t h e STANDARD PROCEDURE - CLOCKSPRING
h or n swit ch , t h e speed con t r ol swit ch es, a n d t h e CENTERING
r em ot e r a dio swit ch es, if t h e veh icle is so equ ipped. If t h e r ot a t in g t a pe (wir e coil) in t h e clockspr in g is
Th e clockspr in g ca se is posit ion ed a n d secu r ed t o t h e n ot posit ion ed pr oper ly wit h t h e st eer in g wh eel a n d
u pper st eer in g colu m n h ou sin g n ea r t h e t op of t h e t h e fr on t wh eels, t h e clockspr in g m a y fa il. Th e fol-
st eer in g colu m n . Th e con n ect or r ecept a cles on t h e lowin g pr ocedu r e MUST BE USE D t o cen t er t h e
t a il of t h e clockspr in g ca se con n ect t h e clockspr in g t o clockspr in g if it is n ot kn own t o be pr oper ly posi-
t h e veh icle elect r ica l syst em t h r ou gh t wo con n ect or s t ion ed, or if t h e fr on t wh eels wer e m oved fr om t h e
fr om t h e in st r u m en t pa n el wir e h a r n ess. st r a igh t a h ea d posit ion .
Th e clockspr in g r ot or is m ova ble a n d is keyed by (1) P osit ion st eer in g wh eel a n d fr on t wh eels
t h e t ower for m a t ion t h a t is m olded on t o t h e u pper st r a igh t a h ea d.
su r fa ce of t h e r ot or h u b t o a n open in g t h a t is ca st (2) Relea se h ood la t ch a n d open h ood.
in t o t h e st eer in g wh eel a r m a t u r e. Ru bber bu m per (3) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
blocks on eit h er side of t h e clockspr in g t ower for m a - ca ble.
t ion elim in a t e con t a ct n oise bet ween t h e clockspr in g (4) Wa it t wo m in u t es for t h e syst em r eser ve ca pa c-
t ower a n d t h e st eer in g wh eel. Th e lobe of t h e t u r n it or t o disch a r ge befor e begin n in g a n y a ir ba g com po-
sign a l ca n cel ca m on t h e lower su r fa ce of t h e clock- n en t ser vice.
spr in g r ot or h u b con t a ct s a t u r n sign a l ca n cel a ct u a - (5) Rem ove dr iver a ir ba g fr om st eer in g wh eel
t or of t h e m u lt i-fu n ct ion swit ch t o pr ovide a u t om a t ic (Refer t o 8 - E LE CTRICAL/RE STRAINTS/DRIVE R
t u r n sign a l ca n cella t ion . Th e yellow or bla ck-sleeved AIRBAG - RE MOVAL).
pigt a il wir es on t h e u pper su r fa ce of t h e clockspr in g (6) Discon n ect wir e con n ect or s fr om ba ck of dr iver
r ot or con n ect t h e clockspr in g t o t h e dr iver a ir ba g, a ir ba g.
wh ile a st eer in g wh eel wir e h a r n ess con n ect s t h e (7) Discon n ect t h e 2–wa y con n ect or fr om r em ot e
con n ect or r ecept a cle on t h e u pper su r fa ce of t h e r a dio con t r ol h a r n ess (if equ ipped).
clockspr in g r ot or t o t h e h or n swit ch a n d, if t h e veh i- (8) Discon n ect t h e 4–wa y h a r n ess con n ect or fr om
cle is so equ ipped, t o t h e opt ion a l speed con t r ol t h e speed con t r ol (if equ ipped)/h or n h a r n ess t o t h e
swit ch es a n d r em ot e r a dio swit ch es on t h e st eer in g clockspr in g.
wh eel. (9) Rem ove st eer in g wh eel (Refer t o 19 - STE E R-
Th e clockspr in g t a pe h a s t r a vel lim it s a n d ca n be ING/COLUMN/STE E RING WH E E L - RE MOVAL).
da m a ged by bein g wou n d t oo t igh t ly du r in g fu ll st op- (10) Rot a t e t h e clockspr in g r ot or clockwise u n t il
t o-st op st eer in g wh eel r ot a t ion . To pr even t t h is fr om t h e r ot or st ops. Do n ot a pply excessive for ce.
occu r r in g, t h e clockspr in g is cen t er ed wh en it is (11) F r om t h e en d of t r a vel, r ot a t e t h e r ot or t wo
in st a lled on t h e st eer in g colu m n . Cen t er in g t h e clock- t u r n s cou n t er clockwise u n t il t h e wir es en d u p a t t h e
spr in g in dexes t h e clockspr in g t a pe t o t h e m ova ble t op.
st eer in g com pon en t s so t h a t t h e t a pe ca n oper a t e
CLOCK SPRI N G (Cont inue d)
(12) In st a ll t h e st eer in g wh eel (Refer t o 19 - INSTALLATION
STE E RING/COLUMN/STE E RING WH E E L - (1) In st a ll t h e clockspr in g on t h e colu m n .
INSTALLATION). (2) Con n ect t h e 4-wa y a n d 6-wa y con n ect or s
(13) Con n ect t h e 4–wa y h a r n ess con n ect or t o t h e bet ween t h e clockspr in g a n d t h e in st r u m en t pa n el
speed con t r ol/h or n h a r n ess t o t h e clockspr in g. wir in g h a r n ess.
(14) Con n ect t h e 2–wa y con n ect or t o t h e r em ot e (3) In st a ll t h e st eer in g colu m n sh r ou ds a n d con -
r a dio con t r ol h a r n ess. n ect t r a ct ion con t r ol wir e con n ect or (if equ ipped)
(15) In st a ll t h e dr iver a ir ba g (Refer t o 8 - E LE C- (Refer t o 19 - STE E RING/COLUMN/LOWE R
TRICAL/RE STRAINTS/DRIVE R AIRBAG - INSTAL- SH ROUD - INSTALLATION).
LATION). Tor qu e t h e t wo scr ews t o 10 N·m (90 in . (4) In st a ll t h e st eer in g wh eel (Refer t o 19 -
lbs.). STE E RING/COLUMN/STE E RING WH E E L -
INSTALLATION).
WARNING: Do not connect the battery negative (5) Con n ect t h e 4–wa y h a r n ess con n ect or t o t h e
speed con t r ol/h or n h a r n ess t o t h e clockspr in g.
DIAGNOSIS AND TESTING). Personal injury or
(6) Con n ect t h e 2–wa y con n ect or t o t h e r em ot e
death may result if the system test is not performed
r a dio con t r ol h a r n ess (if equ ipped).
properly. (7) In st a ll t h e dr iver a ir ba g (Refer t o 8 - E LE C-
TRICAL/RE STRAINTS/DRIVE R AIRBAG - INSTAL-
LATION). Tor qu e t h e t wo scr ews t o 10 N·m (90 in .
REMOVAL
lbs.).
(1) P osit ion st eer in g wh eel a n d fr on t wh eels
st r a igh t a h ea d. WARNING: Do not connect the battery negative
(2) Relea se h ood la t ch a n d open h ood. cable (Refer to 8 - ELECTRICAL/RESTRAINTS -
(3) Discon n ect a n d isola t e t h e ba t t er y n ega t ive DIAGNOSIS AND TESTING - AIRBAG SYSTEM). Per-
ca ble. sonal injury or death may result if the system test
(4) is not performed first.
WARNING: Wait two minutes for the airbag system
reserve capacitor to discharge before beginning
any airbag system or component service. Failure to CU RTAI N AI RBAG
do so may result in accidental airbag deployment,
personal injury or death. DESCRIPTION
Cu r t a in Air ba gs (F ig. 11) a r e a va ila ble wh en it is
(5) Rem ove dr iver a ir ba g fr om st eer in g wh eel
a lso equ ipped wit h du a l fr on t a ir ba gs. Th ese a ir ba gs
(Refer t o 8 - E LE CTRICAL/RE STRAINTS/DRIVE R
a r e pa ssive a n d in fla t a ble, Su pplem en t a l Rest r a in t
AIRBAG - RE MOVAL).
Syst em (SRS) com pon en t s, a n d veh icles wit h t h is
(6) Discon n ect wir e con n ect or s fr om ba ck of dr iver
equ ipm en t ca n be r ea dily iden t ified by a m olded
a ir ba g.
iden t ifica t ion t r im bu t t on wit h t h e “SRS - AIRBAG”
(7) Discon n ect t h e 2–wa y con n ect or fr om r em ot e
logo (F ig. 12) loca t ed on t h e B-pilla r a n d C-pilla r
r a dio con t r ol h a r n ess.
u pper t r im pa n els. Th is syst em is design ed t o r edu ce
(8) Discon n ect t h e 4–wa y h a r n ess con n ect or fr om
in ju r ies t o t h e veh icle occu pa n t s in t h e even t of a
t h e speed con t r ol/h or n h a r n ess t o t h e clockspr in g.
side im pa ct collision .
(9) Rem ove st eer in g wh eel (Refer t o 19 - STE E R-
Cu r t a in a ir ba gs h a ve t wo in dividu a lly con t r olled
ING/COLUMN/STE E RING WH E E L - RE MOVAL).
cu r t a in a ir ba g u n it s. Th ese a ir ba g u n it s a r e con -
(10) Rem ove st eer in g colu m n sh r ou ds a n d discon -
cea led a n d m ou n t ed a bove t h e h ea dlin er wh er e t h ey
n ect t r a ct ion con t r ol wir e con n ect or (if equ ipped)
a r e ea ch secu r ed t o on e of t h e r oof side r a ils (F ig.
(Refer t o 19 - STE E RING/COLUMN/LOWE R
13). E a ch a ir ba g cu sh ion is con t a in ed wit h in a fa br ic
SH ROUD - RE MOVAL).
wr a p t h a t ext en ds a lon g t h e r oof r a il fr om t h e A-pil-
(11) Discon n ect 4-wa y a n d 6-wa y con n ect or s
la r a t t h e fr on t of t h e veh icle t o ju st beh in d t h e
bet ween t h e clockspr in g a n d t h e in st r u m en t pa n el
D-pilla r a t t h e r ea r of t h e veh icle. On e t et h er ext en ds
wir in g h a r n ess.
down t h e A-pilla r fr om t h e fr on t of t h e a ir ba g cu sh -
(12) Rem ove clockspr in g fr om colu m n a ssem bly by
ion , a n d a secon d t et h er ext en ds t o t h e r oof r a il a t
r em ovin g t h e t wo r et a in in g scr ews t h a t a t t a ch t h e
t h e D-pilla r. Th e en d of t h e A-pilla r t et h er is secu r ed
clock spr in g t o t h e colu m n .
t o a slot in t h e sh eet m et a l wit h a m et a l h ook
r et a in ed by a bolt . Th e D-pilla r t et h er is a t t a ch ed t o
t h e d-pilla r.
CU RTAI N AI RBAG (Cont inue d)
Fig. 11 CURTAIN AIRBAG

Th e cu r t a in a ir ba gs a lso con t a in H ea d Im pa ct
Cou n t er Mea su r es (F ig. 14). Th ese in ject ion m olded
pla st ic com pon en t s h elp t o r edu ce t h e likelih ood of
in ju r y or dea t h in t h e even t of a side im pa ct even t .
Th ey a r e a t t a ch ed t o t h e cu r t a in a ir ba g a n d a r e a lso
u sed t o m ou n t t h e cu r t a in t o t h e in side r oof r a il.
Th eir pu r pose is t o m a in t a in a fla t su r fa ce in wh ich
t h e deployed a ir ba g t o be pr essed a ga in st wh en in t e-
r ior occu pa n t s/for ces a r e pu sh in g ou t wa r ds.
OPERATION
E a ch cu r t a in a ir ba g is deployed in dividu a lly by a n
elect r ica l sign a l gen er a t ed by t h e Occu pa n t Rest r a in t
Con t r oller (ORC) t o wh ich it is con n ect ed t h r ou gh
left or r igh t cu r t a in a ir ba g lin e 1 a n d lin e 2 (or
squ ib) cir cu it s. Th e h ybr id-t ype in fla t or a ssem bly for
Fig. 12 SRS LOGO ea ch a ir ba g con t a in s a sm a ll ca n ist er of h igh ly com -
Th e h ybr id-t ype in fla t or for ea ch a ir ba g is secu r ed pr essed in er t ga s. Wh en t h e ORC sen ds t h e pr oper
t o t h e r oof r a il ju st beh in d t h e C-pilla r. Th e in fla t or elect r ica l sign a l t o t h e a ir ba g in fla t or, t h e elect r ica l
br a cket a n d t h e a ir ba g cu sh ion a r e secu r ed wit h bot h en er gy cr ea t es en ou gh h ea t t o ign it e ch em ica l pellet s
pla st ic pu sh -in fa st en er s a n d scr ews t o t h e r oof r a il. wit h in t h e in fla t or. On ce ign it ed, t h ese ch em ica ls
A sh or t pigt a il wir e h a r n ess con n ect s t h e cu r t a in a ir- bu r n r a pidly a n d pr odu ce t h e pr essu r e n ecessa r y t o
ba g in fla t or t o t h e body wir e h a r n ess. r u pt u r e a con t a in m en t disk in t h e in er t ga s ca n ist er.
Th e cu r t a in a ir ba g ca n n ot be a dju st ed or r epa ir ed Th e in fla t or a n d in er t ga s ca n ist er a r e sea led a n d
a n d m u st be r epla ced if deployed, fa u lt y, or in a n y con n ect ed t o a t u bu la r m a n ifold so t h a t a ll of t h e
wa y da m a ged. On ce a cu r t a in a ir ba g h a s been r elea sed ga s is dir ect ed in t o t h e folded cu r t a in a ir ba g
deployed, t h e com plet e a ir ba g u n it (Refer t o 8 - cu sh ion , ca u sin g t h e cu sh ion t o in fla t e.
E LE CTRICAL/RE STRAINTS - STANDARD P ROCE -
DURE - SE RVICE AF TE R AN AIRBAG DE P LOY-
ME NT), h ea dlin er, u pper A/B/C a n d D-pilla r t r im ,
a n d a ll ot h er visibly da m a ged com pon en t s m u st be
r epla ced (Refer t o Sect ion 23 - BODY/INTE RIOR for
com plet e body in t er ior Rem ova l a n d In st a lla t ion pr o-
cedu r es). Refer t o t h e a ppr opr ia t e dia gn ost ic in for m a -
t ion for com plet e dia gn osis a n d t est in g or t h e cu r t a in
a ir ba gs.
Fig. 13 CURTAIN AIRBAG LOCATION - TYPICAL

As t h e a ir ba g cu sh ion in fla t es it will dr op down
fr om t h e r oof r a il bet ween t h e edge of t h e h ea dlin er
a n d t h e side gla ss/body pilla r s t o for m a cu r t a in -like
cu sh ion t o pr ot ect t h e veh icle occu pa n t s du r in g a side
im pa ct collision . Th e fr on t a n d r ea r t et h er s keep t h e
side cu r t a in ba g t a u t , t h u s en su r in g t h a t t h e ba g will
deploy in t h e pr oper posit ion . F ollowin g t h e a ir ba g
deploym en t , t h e a ir ba g cu sh ion qu ickly defla t es by
ven t in g t h e in er t ga s t h r ou gh t h e loose wea ve of t h e
cu sh ion fa br ic, a n d t h e defla t ed cu sh ion h a n gs down
loosely fr om t h e r oof r a il.
REMOVAL
(1) Open h ood, discon n ect a n d isola t e t h e ba t t er y
n ega t ive ca ble.
(2)
Fig. 14 HEAD IMPACT COUNTER MEASURES
1 - SLIDING DOOR OPENING/ROOF RAIL WARNING: Wait two minutes for the airbag system
2 - CURTIAN AIRBAG reserve capacitor to discharge before beginning
3 - HEAD IMPACT COUNTER MEASURES any airbag system or component service. Failure to
personal injury or death.
(3) Rem ove t h e h ea dlin er fr om t h e veh icle (Refer (6) Rem ove t h e scr ews t h a t secu r e t h e cu r t a in a ir-
to 23 - BODY/INTE RIOR/H E ADLINE R - ba g t o t h e spr in g n u t s in t h e r oof side r a il (F ig. 17).
RE MOVAL).
(4) Discon n ect t h e cu r t a in a ir ba g squ ib con n ect or
(F ig. 15).
Fig. 17 CURTAIN AIRBAG REMOVE/INSTALL

1 - CURTAIN AIRBAG ATTACHMENT LOCATIONS
2 - SLIDING DOOR OPENING/ROOF RAIL
3 - CURTAIN AIRBAG
(7) Rem ove t h e bolt fr om t h e cu r t a in a ir ba g in fla -

t or m ou n t in g br a cket (F ig. 18).
Fig. 15 CURTAIN AIRBAG SQUIB CONNECTION

1 - CURTAIN AIRBAG INFLATOR
2 - CURTAIN AIRBAG SQUIB CONNECTOR
3 - C-PILLAR
(5) Rem ove t h e bolt fr om t h e cu r t a in a ir ba g fr on t

t et h er a n d u n clip fr om t h e A-pilla r (F ig. 16).
Fig. 18 CURTAIN AIRBAG INFLATOR MOUNTING

BRACKET ATTACHMENT
1 - CURTAIN AIRBAG INFLATOR MOUNTING BRACKET
2 - CURTAIN AIRBAG SQUIB CONNECTOR
3 - C-PILLAR
(8) Rem ove t h e bolt s r et a in in g t h e cu r t a in a ir ba g

t o t h e r oof r a il in t h e d-pilla r a r ea (F ig. 19).
(9) Gr a sp t h e cu r t a in a ir ba g, u sin g a t r im st ick
(specia l t ool #C-4755) or equ iva len t , gen t ly pr y ou t on
pu sh fa st en er s t o disen ga ge t h e cu r t a in a ir ba g a n d
Fig. 16 CURTAIN AIRBAG FRONT TETHER r em ove it fr om it s m ou n t in g loca t ion in t h e side r oof
ATTACHMENT r a il (F ig. 17).
1 - A-PILLAR (10) Rem ove t h e cu r t a in a ir ba g fr om t h e veh icle a s
2 - CURTAIN AIRBAG PUSH FASTENER a u n it .
3 - CURTAIN AIRBAG FRONT TETHER
4 - CURTAIN AIRBAG FRONT TETHER ATTACHMENT HOOK/
BOLT
folded a ir ba g cu sh ion , t h e a ir ba g cu sh ion r et a in er,
t h e a ir ba g h ou sin g, t h e a ir ba g in fla t or, a n d t h e
r et a in er s t h a t secu r e t h e in fla t or t o t h e a ir ba g h ou s-
in g. Th e a ir ba g cu sh ion , h ou sin g, a n d in fla t or a r e
secu r ed wit h in a n in t egr a l r ecept a cle m olded in t o t h e
ba ck of t h e t r im cover.
Th e r esist ive m em br a n e-t ype h or n swit ch is
secu r ed wit h h ea t st a kes t o t h e in side su r fa ce of t h e
dr iver a ir ba g t r im cover, bet ween t h e t r im cover a n d
t h e folded a ir ba g cu sh ion . Th e h or n swit ch gr ou n d
pigt a il wir e h a s a fem a le spa de t er m in a l con n ect or
t h a t r eceives a pa t h t o gr ou n d t h r ou gh a m a le spa de
t er m in a l t h a t is in t egr a l t o t h e dr iver a ir ba g h ou sin g
st a m pin g a n d is loca t ed n ea r t h e u pper r igh t cor n er
on t h e ba ck of t h e h ou sin g. Th e h or n swit ch feed pig-
t a il wir e h a s a wh it e, m olded pla st ic in su la t or t h a t is
Fig. 19 CURTAIN AIRBAG D-PILLAR ATTACHMENT secu r ed by a n in t egr a l r et a in er t o a m ou n t in g h ole
1 - CURTAIN AIRBAG D-PILLAR ATTACHMENT LOCATIONS loca t ed n ea r t h e lower left cor n er on t h e ba ck of t h e
2 - D-PILLAR h ou sin g, a n d is con n ect ed t o t h e veh icle elect r ica l
3 - ROOF RAIL AT REAR QUARTER GLASS syst em t h r ou gh a t a ke ou t a n d con n ect or of t h e st eer-
in g wh eel wir e h a r n ess.
INSTALLATION Th e a ir ba g is a m u lt ist a ge u n it t h a t deploys wit h
(1) P osit ion cu r t a in a ir ba g over r et a in in g h oles in less for ce t h a n t h ose pr eviou sly u sed. Th e a ir ba g
r oof r a il a n d fir m ly sn a p in t o pla ce (F ig. 17). in fla t or is a du a l-in it ia t or, n on -a zide, pyr ot ech n ic-
(2) In st a ll t h e cu r t a in a ir ba g r et a in in g bolt s (F ig. t ype u n it wit h fou r m ou n t in g st u ds a n d is secu r ed t o
17). t h e st a m ped m et a l a ir ba g h ou sin g u sin g fou r h ex
(3) E n ga ge t h e side cu r t a in a ir ba g fr on t t et h er in n u t s wit h wa sh er s. Two keyed a n d color-coded con -
t h e A-pilla r a n d in st a ll r et a in in g bolt (F ig. 16). n ect or r ecept a cles on t h e dr iver a ir ba g in fla t or con -
(4) In st a ll t h e bolt in t h e cu r t a in a ir ba g in fla t or n ect t h e t wo in fla t or in it ia t or s t o t h e veh icle
m ou n t in g br a cket (F ig. 18). elect r ica l syst em t h r ou gh t wo yellow or bla ck-ja ck-
(5) In st a ll t h e r et a in in g bolt s a t t h e d-pilla r (F ig. et ed, t wo-wir e pigt a il h a r n esses of t h e clockspr in g.
19). Th e dr iver a ir ba g, t r im cover, a n d h or n swit ch u n it
(6) Con n ect t h e cu r t a in a ir ba g squ ib con n ect or ca n n ot be r epa ir ed, a n d m u st be r epla ced if deployed
(F ig. 15). or in a n y wa y da m a ged.
(7) In st a ll t h e h ea dlin er in t o t h e veh icle (Refer t o
23 - BODY/INTE RIOR/H E ADLINE R - INSTALLA- OPERATION
TION). Th e Dr iver Air ba g Tr im Cover con t a in s t h e h or n
swit ch , in fla t or device, a n d a fa br ic ba g. Th e dr iver
a ir ba g t r im cover /h or n swit ch is n ot ser viced sepa -
r a t ely fr om t h e dr iver a ir ba g com pon en t s.
Wh en t h e fr on t a ir ba g syst em is deployed, t h e fol-
lowin g MU S T be r epla ced:
• Com plet e St eer in g Colu m n Assem bly
(8) Ver ify veh icle a n d syst em oper a t ion . • Lower St eer in g Colu m n Cou pler
(9) Close h ood. • St eer in g Wh eel.
• Clockspr in g.
• Dr iver Air ba g
DRI V ER AI RBAG • P a ssen ger Air ba g
• Kn ee Blocker Air ba g
DESCRIPTION • Upper In st r u m en t P a n el wit h P a d
Th e in ject ion m olded, t h er m opla st ic dr iver a ir ba g • F r on t Sea t Belt Bu ckles, bot h dr iver a n d pa ssen -
pr ot ect ive t r im cover is t h e m ost visible pa r t of t h e ger wit h in t egr a l t en sion er s.
dr iver a ir ba g. Th e dr iver a ir ba g is loca t ed in t h e cen -
t er of t h e st eer in g wh eel, wh er e it is secu r ed t o t h e
st eer in g wh eel a r m a t u r e. Con cea led ben ea t h t h e
dr iver a ir ba g t r im cover a r e t h e h or n swit ch , t h e
DRI V ER AI RBAG (Cont inue d)
CARE OF UNDEPLOYED AIRBAGS event of a driver airbag deployment. Personal injury
or death may result if not replaced.
WARNING: Airbags must be stored in their original
special container until used for service. At no time UNDEPLOYED AIRBAG
should a source of electricity be permitted near the (1) Relea se h ood la t ch a n d open h ood.
inflator on the back of an airbag. When carrying or (2) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
handling an undeployed airbag, the trim side of the ca ble.
airbag should be pointing toward the body to mini-
mize possibility of injury if accidental deployment WARNING: Wait two minutes for the system reserve
occurs. Do not place undeployed airbag face down capacitor to discharge before beginning any airbag
on a solid surface, the airbag will propel into the air component service. Personal injury or death may
if accidental deployment occurs. result.
(3) Rem ove t wo scr ews r et a in in g dr iver a ir ba g t o

REMOVAL st eer in g wh eel.
(4) Discon n ect wir e con n ect or s fr om ba ck of dr iver
DEPLOYED AIRBAG a ir ba g (F ig. 20).
(1) Clea n powder r esidu e fr om in t er ior of veh icle
(F ig. 4).
(2) P osit ion st eer in g wh eel a n d fr on t wh eels
st r a igh t a h ea d.
ca ble.
(5)

any airbag system or component service. Failure to
(6) Rem ove t wo scr ews r et a in in g dr iver a ir ba g t o

st eer in g wh eel.
(7) Discon n ect wir e con n ect or s fr om ba ck of dr iver Fig. 20 DRIVER AIRBAG WIRE CONNECTIONS
a ir ba g. 1 - AIRBAG SQUIB CONNECTORS
2 - DRIVER AIRBAG
(8) Discon n ect t h e 2–wa y con n ect or fr om r em ot e 3 - HORN/SPEED CONTROL CONNECTOR
r a dio con t r ol h a r n ess. 4 - CLOCK SPRING
(9) Discon n ect t h e 4–wa y h a r n ess con n ect or fr om
t h e speed con t r ol/h or n h a r n ess t o t h e clockspr in g. (5) Discon n ect t h e 2–wa y con n ect or fr om r em ot e
(10) Rem ove st eer in g wh eel (Refer t o 19 - STE E R- r a dio con t r ol h a r n ess.
ING/COLUMN/STE E RING WH E E L - RE MOVAL). (6) Discon n ect t h e 4–wa y h a r n ess con n ect or fr om
(11) Rem ove st eer in g colu m n sh r ou ds a n d discon - t h e speed con t r ol/h or n h a r n ess t o t h e clockspr in g.
n ect t r a ct ion con t r ol wir e con n ect or (if equ ipped) (7) Rem ove dr iver a ir ba g fr om veh icle.
SH ROUD - RE MOVAL). WARNING: When carrying or handling an unde-
(12) Discon n ect 4-wa y a n d 6-wa y con n ect or s ployed airbag, the trim side of the airbag should be
bet ween t h e clockspr in g a n d t h e in st r u m en t pa n el pointing toward the body to minimize the possibility
wir in g h a r n ess. of injury if accidental deployment occurs. Do not
(13) Rem ove clockspr in g fr om colu m n a ssem bly by place undeployed airbag face down on a solid sur-
r em ovin g t h e t wo r et a in in g scr ews t h a t a t t a ch t h e face, the airbag will propel into the air if accidental
clockspr in g t o t h e colu m n . deployment occurs. Failure to do this may result in
WARNING: The clockspring, steering wheel, and
complete steering column assembly w/lower steer-
ing column coupler must be replaced also in the
DRI V ER AI RBAG (Cont inue d)
INSTALLATION I M PACT SEN SOR

DEPLOYED AIRBAG DESCRIPTION
(1) P er for m clea n u p pr ocedu r e (Refer t o 8 - E LE C-
TRICAL/RE STRAINTS - STANDARD P ROCE DURE FRONT IMPACT SENSORS
- SE RVICE AF TE R AN AIRBAG DE P LOYME NT).
(2) In st a ll a n ew st eer in g colu m n a ssem bly a n d
lower st eer in g colu m n cou pler (Refer t o 19 - STE E R-
ING/COLUMN - INSTALLATION).
(3) In st a ll t h e n ew clockspr in g.
(4) Con n ect t h e 4-wa y a n d 6-wa y con n ect or s
bet ween t h e clockspr in g a n d t h e in st r u m en t pa n el
wir in g h a r n ess.
(5) In st a ll t h e st eer in g colu m n sh r ou ds a n d con -
n ect t r a ct ion con t r ol wir e con n ect or (if equ ipped)
SH ROUD - INSTALLATION).
(6) In st a ll t h e st eer in g wh eel (Refer t o 19 -
STE E RING/COLUMN/STE E RING WH E E L -
INSTALLATION). Fig. 21 FRONT IMPACT SENSOR
(7) Con n ect t h e 4–wa y h a r n ess con n ect or t o t h e Th er e a r e t wo fr on t im pa ct sen sor s (F ig. 21), on e
speed con t r ol/h or n h a r n ess t o t h e clockspr in g. on t h e left , a n d on e on t h e r igh t fr on t sides of t h e
(8) Con n ect t h e 2–wa y con n ect or t o t h e r em ot e veh icle. Th ese sen sor s a r e m ou n t ed r em ot ely fr om
r a dio con t r ol h a r n ess. t h e im pa ct sen sor t h a t is in t er n a l t o t h e Occu pa n t
(9) In st a ll t h e dr iver a ir ba g a n d t h e t wo scr ews Rest r a in t Con t r oller (ORC). Th e r igh t a n d left fr on t
r et a in in g t h e a ir ba g. Tigh t en scr ews t o 10 N·m (90 a n d side im pa ct sen sor s a r e iden t ica l in con st r u ct ion
in . lbs.) a n d ca libr a t ion a n d ea ch fr on t im pa ct sen sor is
secu r ed wit h t wo scr ews. Th e fr on t im pa ct sen sor s
WARNING: Do not connect the battery negative a r e secu r ed wit h t wo scr ews t o t h e ou t boa r d sides of
cable (Refer to 8 - ELECTRICAL/RESTRAINTS - t h e r igh t a n d left fr on t r a il t ips.
DIAGNOSIS AND TESTING - AIRBAG SYSTEM). Per- Th e im pa ct sen sor h ou sin g h a s a n in t egr a l con n ec-
sonal injury or death may result if the system test t or a n d t wo m ou n t in g ea r s, ea ch wit h a m et a l sleeve
is not performed first. t o pr ovide cr u sh pr ot ect ion . A ca vit y in t h e cen t er of
t h e m olded bla ck pla st ic im pa ct sen sor h ou sin g con -
t a in s t h e elect r on ic cir cu it r y of t h e sen sor wh ich
UNDEPLOYED AIRBAG in clu des a n elect r on ic com m u n ica t ion ch ip a n d a n
(1) Con n ect t h e h a r n ess con n ect or on t h e dr iver elect r on ic im pa ct sen sor. P ot t in g m a t er ia l fills t h e
a ir ba g t r im cover (h or n , speed con t r ols) t o t h e clock- ca vit y t o sea l a n d pr ot ect t h e in t er n a l elect r on ic cir-
spr in g. cu it r y a n d com pon en t s. Th e fr on t im pa ct sen sor s a r e
(2) Con n ect t h e squ ib con n ect or s t o t h e dr iver a ir- ea ch con n ect ed t o t h e veh icle elect r ica l syst em
ba g. t h r ou gh t h e h ea dla m p t o da sh wir e h a r n ess.
(3) P osit ion t h e dr iver a ir ba g in t o t h e st eer in g Th e fr on t im pa ct sen sor s ca n n ot be r epa ir ed or
wh eel. a dju st ed a n d, if da m a ged or fa u lt y, t h ey m u st be
(4) In st a ll t h e t wo scr ews r et a in in g t h e a ir ba g. r epla ced. If a fr on t im pa ct sen sor is fa u lt y, on ly t h e
Tigh t en scr ews t o 10 N·m (90 in . lbs.) sen sor n eeds t o be r epla ced. If t h e sen sor is da m a ged
or fa u lt y, or if pr oper t igh t en in g t or qu e of t h e scr ews
t h a t secu r e t h e sen sor t o t h e br a cket ca n n ot be
a ch ieved, t h e sen sor a n d br a cket m u st be r epla ced.
Refer t o t h e pr oper body dia gn ost ic in for m a t ion for
dia gn osis a n d t est in g.
I M PACT SEN SOR (Cont inue d)
SIDE IMPACT SENSORS in t h e lower door t r a ck a r ea (F ig. 23). Th e t h ir d r ow
side im pa ct sen sor is loca t ed beh in d t h e qu a r t er t r im
pa n el, a bove t h e r ea r t ir e wh eel well, bet ween t h e C
a n d D-pilla r s (F ig. 23).
Th e im pa ct sen sor h ou sin g h a s a n in t egr a l con n ec-
t or. A ca vit y in t h e cen t er of t h e m olded bla ck pla st ic
im pa ct sen sor h ou sin g con t a in s t h e elect r on ic cir-
cu it r y of t h e sen sor wh ich in clu des a n elect r on ic com -
m u n ica t ion ch ip a n d a n elect r on ic im pa ct sen sor.
P ot t in g m a t er ia l fills t h e ca vit y t o sea l a n d pr ot ect
t h e in t er n a l elect r on ic cir cu it r y a n d com pon en t s. Th e
side im pa ct sen sor s a r e ea ch con n ect ed t o t h e veh icle
elect r ica l syst em t h r ou gh a con n ect or of t h e body
h a r n ess.
Th e side im pa ct sen sor s ca n n ot be r epa ir ed or
a dju st ed. If da m a ged or fa u lt y, t h ey m u st be
r epla ced. Refer t o t h e pr oper body dia gn ost ic in for-
m a t ion for dia gn osis a n d t est in g.
REMOVAL
Fig. 22 SIDE IMPACT SENSOR
FRONT IMPACT SENSOR
Th r ee side im pa ct sen sor s (F ig. 22) a r e u sed on Th e r igh t a n d left fr on t im pa ct sen sor s a r e
ea ch side of t h e veh icle. Th ese sen sor s a r e m ou n t ed m ou n t ed iden t ica lly on t h e fr on t r a il t ips.
r em ot ely fr om t h e bi-dir ect ion a l sa fin g sen sor t h a t is (1) Open h ood, discon n ect a n d isola t e t h e ba t t er y
in t er n a l t o t h e Occu pa n t Rest r a in t Con t r oller (ORC). n ega t ive ca ble.
Th e side a n d fr on t im pa ct sen sor s a r e iden t ica l in (2)
con st r u ct ion a n d ca libr a t ion a n d ea ch im pa ct sen sor
is secu r ed wit h t wo scr ews. E a ch side im pa ct sen sor WARNING: Wait two minutes for the airbag system
is secu r ed wit h t wo scr ews. Th e fir st r ow side im pa ct reserve capacitor to discharge before beginning
sen sor is loca t ed in t h e B-pilla r, ju st a bove t h e fr on t any airbag system or component service. Failure to
sea t belt r et r a ct or (F ig. 23). Th e secon d r ow side do so may result in accidental airbag deployment,
im pa ct sen sor is loca t ed in t h e slidin g door open in g, personal injury or death.
Fig. 23 SIDE IMPACT SENSOR LOCATION

1 - FRONT ROW SIDE IMPACT SENSOR 3 - THIRD ROW SIDE IMPACT SENSOR
2 - SECOND ROW SIDE IMPACT SENSOR
(3) H oist veh icle.
(4) Discon n ect elect r ica l con n ect or (F ig. 24).
(5) Rem ove t h e t wo scr ews a t t a ch in g fr on t im pa ct
sen sor t o ou t er r a ils (F ig. 24).
Fig. 25 FRONT ROW SIDE IMPACT SENSOR AND

Fig. 24 FRONT IMPACT SENSOR REMOVE/INSTALL BRACKET
1 - B-PILLAR
1 - FRONT IMPACT SENSOR WIRE HARNESS RETAINER
2 - FRONT ROW SIDE IMPACT SENSOR ELECTRICAL
2 - FRONT IMPACT SENSOR RETAINING SCREW CONNECTOR
3 - FRONT IMPACT SENSOR WIRE HARNESS 3 - FRONT ROW SIDE IMPACT SENSOR AND MOUNTING
4 - FRONT IMPACT SENSOR BRACKET
5 - LOWER RADIATOR SUPPORT 4 - FRONT ROW SIDE IMPACT SENSOR RETAINING SCREW
(6) Rem ove sen sor fr om veh icle.
SIDE IMPACT SENSORS

B-PILLAR MOUNTED
Th e r igh t a n d left fr on t r ow side im pa ct sen sor s,
a r e m ou n t ed iden t ica lly, on opposit e sides of t h e veh i-
cle, in t h e b-pilla r.
(1) Open h ood, discon n ect a n d isola t e t h e ba t t er y
n ega t ive ca ble.
(2)
WARNING: Wait two minutes for the system reserve

capacitor to discharge before beginning any airbag
component service. Personal injury or death may
result.
(3) Rem ove t h e B-pilla r lower t r im for t h e side of

t h e veh icle t h a t you a r e r epla cin g t h e side im pa ct
sen sor (Refer t o 23 - BODY/INTE RIOR/B-P ILLAR
Fig. 26 FRONT ROW SIDE IMPACT SENSOR/
LOWE R TRIM - RE MOVAL).
BRACKET
(4) Discon n ect t h e elect r ica l con n ect or fr om t h e
im pa ct sen sor (F ig. 25). 1 - FRONT ROW SIDE IMPACT SENSOR
2 - SENSOR TO BRACKET ATTACHMENT
(5) Rem ove t h e fou r r et a in in g scr ews t o t h e im pa ct 3 - FRONT ROW SIDE IMPACT SENSOR MOUNTING BRACKET
sen sor br a cket (F ig. 25).
(6) Rem ove im pa ct sen sor fr om veh icle (F ig. 26). cle, in t h e slidin g door open in g lower r ea r wh er e t h e
lower r oller a r m m ou n t s in t h e lower door t r a ck.
SLIDING DOOR OPENING MOUNTED (1) Open h ood, discon n ect a n d isola t e t h e ba t t er y
Th e r igh t a n d left secon d r ow side im pa ct sen sor s, n ega t ive ca ble.
a r e m ou n t ed iden t ica lly, on opposit e sides of t h e veh i- (2)
WARNING: Wait two minutes for the system reserve
capacitor to discharge before beginning any airbag
result.
(3) Open slidin g door t o t h e fu llest open posit ion .

(4) Rem ove t h e t wo r et a in in g scr ews t o t h e im pa ct
sen sor (F ig. 27).
Fig. 28 3RD ROW SIDE IMPACT SENSOR

1 - 3RD ROW SIDE IMPACT SENSOR
2 - 3RD ROW SIDE IMPACT SENSOR MOUNTING SCREWS
3 - REAR SPEAKER
4 - REAR WHEEL WELL
INSTALLATION
FRONT IMPACT SENSOR
Fig. 27 2ND ROW SIDE IMPACT SENSOR (1) P osit ion sen sor in veh icle (F ig. 24).
1 - 2ND ROW SIDE IMPACT SENSOR ELECTRICAL CONNECTOR (2) In st a ll t h e t wo r et a in in g scr ews t o t h e im pa ct
2 - 2ND ROW SIDE IMPACT SENSOR RETAINING SCREWS
3 - SLIDING DOOR LOWER ROLLER ARM
sen sor (F ig. 24). Tor qu e scr ews t o 7 N·m (62 in . lbs.).
(3) Con n ect elect r ica l con n ect or (F ig. 24).
(5) Discon n ect t h e elect r ica l con n ect or fr om t h e (4) Lower veh icle fr om h oist .
im pa ct sen sor a n d r em ove fr om veh icle (F ig. 27).
QUARTER PANEL MOUNTED cable (Refer to 8 - ELECTRICAL/RESTRAINTS -
(1) Open h ood, discon n ect a n d isola t e t h e ba t t er y DIAGNOSIS AND TESTING - AIRBAG SYSTEM). Per-
n ega t ive ca ble. sonal injury or death may result if the system test
(2) is not performed first.
WARNING: Wait two minutes for the system reserve (5) Ver ify veh icle a n d syst em oper a t ion .
capacitor to discharge before beginning any airbag (6) Close h ood.
result. SIDE IMPACT SENSORS
(3) Rem ove t h e qu a r t er t r im pa n el for t h e side of B-PILLAR MOUNTED

t h e veh icle t h a t you a r e r epla cin g t h e side im pa ct (1) P osit ion sen sor br a cket in veh icle (F ig. 25).
sen sor (Refer t o 23 - BODY/INTE RIOR/QUARTE R (2) In st a ll t h e fou r r et a in in g scr ews t o t h e im pa ct
TRIM PANE L - RE MOVAL). sen sor br a cket (F ig. 25). Tor qu e scr ews t o 7 N·m (62
(4) Rem ove t h e t wo r et a in in g scr ews t o t h e im pa ct in . lbs.).
sen sor (F ig. 28). (3) Con n ect t h e elect r ica l con n ect or (F ig. 25).
(5) Discon n ect t h e elect r ica l con n ect or fr om t h e (4) In st a ll t h e B-pilla r lower t r im for t h e side of
im pa ct sen sor a n d r em ove fr om veh icle (F ig. 28). t h e veh icle t h a t you a r e r epla cin g t h e side im pa ct
sen sor (Refer t o 23 - BODY/INTE RIOR/B-P ILLAR
LOWE R TRIM - INSTALLATION).

(6) Close h ood.
SLIDING DOOR OPENING MOUNTED

(1) Con n ect elect r ica l con n ect or (F ig. 27).
(2) P osit ion sen sor in veh icle (F ig. 27).
(3) In st a ll t h e t wo r et a in in g scr ews t o t h e im pa ct
sen sor (F ig. 27). Tor qu e scr ews t o 7 N·m (62 in . lbs.). Fig. 29 KNEE BLOCKER AIRBAG
WARNING: Do not connect the battery negative OPERATION
cable (Refer to 8 - ELECTRICAL/RESTRAINTS - Th e kn ee blocker a ir ba g is equ ipped wit h a sin gle
DIAGNOSIS AND TESTING - AIRBAG SYSTEM). Per- in fla t or. Wh en t h e Occu pa n t Rest r a in t Con t r oller
sonal injury or death may result if the system test (ORC) sen ds t h e pr oper elect r ica l sign a ls t o t h e in it i-
is not performed first. a t or, t h e elect r ica l en er gy gen er a t es en ou gh h ea t t o
in it ia t e a sm a ll pyr ot ech n ic ch a r ge wh ich , in t u r n
(4) Ver ify veh icle a n d syst em oper a t ion . ign it es ch em ica l pellet s wit h in t h e in fla t or. On ce
(5) Close h ood. ign it ed, t h ese ch em ica l pellet s bu r n r a pidly a n d pr o-
du ce a la r ge qu a n t it y of in er t ga s. Th e in fla t or is
QUARTER PANEL MOUNTED sea led t o t h e ba ck of t h e a ir ba g h ou sin g a n d a dif-
(1) P osit ion sen sor in veh icle (F ig. 28). fu ser in t h e in fla t or dir ect s a ll of t h e in er t ga s in t o
(2) Con n ect elect r ica l con n ect or (F ig. 28). t h e a ir ba g cu sh ion , ca u sin g t h e cu sh ion t o in fla t e. As
(3) In st a ll t h e t wo r et a in in g scr ews t o t h e im pa ct t h e cu sh ion in fla t es, t h e kn ee blocker a ir ba g t r im
sen sor (F ig. 28). Tor qu e scr ews t o 7 N·m (62 in . lbs.). deploy. F ollowin g a n a ir ba g deploym en t , t h e a ir ba g
(4) In st a ll t h e qu a r t er t r im pa n el for t h e side of cu sh ion qu ickly defla t es by ven t in g t h e in er t ga s
t h e veh icle t h a t you a r e r epla cin g t h e side im pa ct t owa r ds t h e in st r u m en t pa n el t h r ou gh ven t h oles
sen sor (Refer t o 23 - BODY/INTE RIOR/QUARTE R wit h in t h e fa br ic u sed t o con st r u ct t h e ba ck pa n el of
TRIM PANE L - INSTALLATION). t h e a ir ba g cu sh ion .
Som e of t h e ch em ica ls u sed t o cr ea t e t h e in er t ga s
WARNING: Do not connect the battery negative m a y be con sider ed h a za r dou s wh ile in t h eir solid
cable (Refer to 8 - ELECTRICAL/RESTRAINTS - st a t e befor e t h ey a r e bu r n ed, bu t t h ey a r e secu r ely
DIAGNOSIS AND TESTING - AIRBAG SYSTEM). Per- sea led wit h in t h e a ir ba g in fla t or. Typica lly, t h e pot en -
sonal injury or death may result if the system test t ia lly h a za r dou s ch em ica ls a r e bu r n ed du r in g a n a ir-
is not performed first. ba g deploym en t even t .
(5) Ver ify veh icle a n d syst em oper a t ion . WARNING: The inert gas that is produced when the
(6) Close h ood. chemicals are burned is harmless. However, a small
amount of residue from the burned chemicals may
cause some temporary discomfort if it contacts the
K N EE BLOCK ER AI RBAG skin, eyes, or breathing passages. If skin or eye irri-
tation is noted, rinse the affected area with plenty
DESCRIPTION of cool, clean water. If breathing passages are irri-
Th e Kn ee Blocker Air ba g (F ig. 29) is loca t ed on t h e tated, move to another area where there is plenty of
dr iver side of t h e veh icle ben ea t h t h e in st r u m en t clean, fresh air to breath. If the irritation is not alle-
pa n el u n der st eer in g colu m n cover (F ig. 30). viated by these actions, contact a physician.
Th e kn ee blocker a ir ba g in clu des on e r ea ct ion pla t e
a n d on e loa d pla t e, wit h in wh ich t h e cu sh ion a n d
in fla t or a r e m ou n t ed a n d sea led. F ollowin g a kn ee
blocker a ir ba g deploym en t , t h e kn ee blocker a ir ba g
a n d in st r u m en t pa n el a ssem bly m u st be r epla ced.
Refer t o t h e pr oper dia gn ost ic in for m a t ion for dia gn o-
sis a n d t est in g.
K N EE BLOCK ER AI RBAG (Cont inue d)
Fig. 30 KNEE BLOCKER AIRBAG LOCATION

1 - KNEE BLOCKER AIRBAG 3 - UNDER STEERING COLUMN COVER RETAINING SCREWS
2 - UNDER STEERING C0LUMN COVER
(1) Open h ood, discon n ect a n d isola t e t h e ba t t er y (1) P la ce t h e kn ee blocker a ir ba g in t o posit ion in
n ega t ive ca ble. t h e in st r u m en t pa n el open in g (F ig. 33).
(2) (2) Con n ect t h e on e elect r ica l con n ect or (F ig. 32).
(3) In st a ll t h e five kn ee blocker a ir ba g r et a in in g
WARNING: Wait two minutes for the airbag system bolt s (F ig. 33).
reserve capacitor to discharge before beginning (4) P osit ion t h e st eer in g colu m n open in g cover
any airbag system or component service. Failure to over r et a in in g slot s a n d fir m ly sn a p in t o pla ce (F ig.
do so may result in accidental airbag deployment, 31). In st a ll t h e t wo r et a in in g scr ews (F ig. 31) (Refer
personal injury or death. t o 23 - BODY/INSTRUME NT PANE L/STE E RING
COLUMN OP E NING COVE R - INSTALLATION).
(3) Rem ove t h e st eer in g colu m n open in g cover t wo
r et a in in g scr ews (F ig. 31) a n d u n sn a p cover fr om WARNING: Do not connect the battery negative
in st r u m en t pa n el (Refer t o 23 - BODY/INSTRU- cable (Refer to 8 - ELECTRICAL/RESTRAINTS -
ME NT PANE L/STE E RING COLUMN OP E NING DIAGNOSIS AND TESTING - AIRBAG SYSTEM). Per-
COVE R - RE MOVAL). sonal injury or death may result if the system test
(4) Discon n ect t h e kn ee blocker a ir ba g elect r ica l is not performed first.
(5) Rem ove five kn ee blocker a ir ba g r et a in in g bolt s (5) Ver ify veh icle a n d syst em oper a t ion .
fr om a ir ba g (F ig. 33). (6) Close h ood.
(6) Rem ove kn ee blocker a ir ba g fr om veh icle.
K N EE BLOCK ER AI RBAG (Cont inue d)
Fig. 31 STEERING COLUMN OPENING COVER

1 - KNEE BLOCKER AIRBAG 3 - UNDER STEERING COLUMN COVER RETAINING SCREWS
2 - UNDER STEERING C0LUMN COVER
Fig. 32 KNEE BLOCKER AIRBAG ELECTRICAL Fig. 33 KNEE BLOCKER AIRBAG - REMOVE/
CONNECTOR INSTALL
1 - KNEE BLOCKER AIRBAG 1 - KNEE BLOCKER AIRBAG RETAINING SCREWS
2 - INSTRUMENT PANEL 2 - KNEE BLOCKER AIRBAG
3 - KNEE BLOCKER AIRBAG ELECTRICAL CONNECTOR 3 - KNEE BLOCKER AIRBAG ELECTRICAL CONNECTOR
4 - INSTRUMENT PANEL
OCCU PAN T CLASSI FI CAT I ON

M ODU LE
DESCRIPTION
Fig. 35 OCM LOCATION

1 - OCCUPANT CLASSIFICATION MODULE (OCM)
Fig. 34 OCCUPANT CLASSIFICATION MODULE 2 - LOCK TOWER
3 - LOCK PIN
(OCM) - TYPICAL 4 - CONNECTOR
1 - OCCUPANT CLASSIFICATION MODULE 5 - SCREW (2)
2 - CONNECTOR LOCK TOWER 6 - BRACKET
3 - CONNECTOR RECEPTACLE
4 - MOUNTING TAB (2) Th e OCM ca n n ot be a dju st ed or r epa ir ed a n d, if
da m a ged or fa u lt y, it m u st be r epla ced. Th e com po-
Th e Occu pa n t Cla ssifica t ion Modu le (OCM) (F ig. n en t s of t h e pa ssen ger fr on t sea t cu sh ion a r e ser-
34) is secu r ed wit h t wo scr ews t o a st a m ped st eel viced on ly a s a fa ct or y-ca libr a t ed, a ssem bled a n d
m ou n t in g br a cket welded on t o t h e u n der side of t h e t a m per-eviden t u n it . On ly t h e OCM a n d t h e sea t
pa ssen ger fr on t sea t cu sh ion fr a m e n ea r t h e in boa r d cu sh ion t r im a r e a va ila ble for sepa r a t e ser vice
fr on t cor n er (F ig. 35). Con cea led wit h in a h ollow in r epla cem en t . On ce a ser vice r epla cem en t pa cka ge h a s
t h e cen t er of t h e m olded pla st ic OCM h ou sin g is a been in st a lled in a veh icle, t h e OCM ca n t h er ea ft er
m icr opr ocessor a n d t h e ot h er elect r on ic cir cu it r y of be ser viced on ly by r epla cin g t h e en t ir e pa ssen ger
t h e m odu le. Th e m odu le h ou sin g is sea led t o en close fr on t sea t cu sh ion wit h a n ot h er com plet e ser vice
a n d pr ot ect t h e in t er n a l elect r on ic cir cu it r y. Th e r epla cem en t pa cka ge.
OCM soft wa r e is fla sh pr ogr a m m a ble.
A n on -ca libr a t ed OCM is t h e on ly com pon en t of t h e OPERATION
Occu pa n t Cla ssifica t ion Syst em (OCS) t h a t is a va il- Th e m icr opr ocessor in t h e Occu pa n t Cla ssifica t ion
a ble for sepa r a t e ser vice r epla cem en t . Th e OCS com - Modu le (OCM) con t a in s t h e Occu pa n t Cla ssifica t ion
pon en t s of t h e pa ssen ger side fr on t sea t cu sh ion Syst em (OCS) logic cir cu it s. Th e OCM u ses On -Boa r d
in clu din g t h e cu sh ion fr a m e, in su la t or pa d, sea t Dia gn ost ics (OBD) a n d ca n com m u n ica t e wit h ot h er
weigh t bla dder a n d pr essu r e sen sor, sea t cu sh ion elect r on ic m odu les in t h e veh icle a s well a s wit h a
foa m , wir in g h a r n ess a n d t h e OCM a r e a fa ct or y-ca l- sca n t ool u sin g t h e P r ogr a m m a ble Com m u n ica t ion s
ibr a t ed a n d a ssem bled u n it . On ce t h is u n it is con - In t er fa ce (P CI) da t a bu s n et wor k. Th is m et h od of
n ect ed t o a veh icle elect r ica lly, t h e ca libr a t ion com m u n ica t ion is a lso u sed for OCS dia gn osis a n d
set t in gs a r e u ploa ded fr om t h e ca libr a t ed OCM a n d t est in g t h r ou gh t h e 16-wa y Da t a Lin k Con n ect or
st or ed in t h e m em or y of t h e Occu pa n t Rest r a in t Con - (DLC), loca t ed on t h e dr iver side lower edge of t h e
t r oller (ORC). If on ly t h e OCM is su bsequ en t ly in st r u m en t pa n el.
r epla ced, t h e n ew, n on -ca libr a t ed OCM lea r n s t h e Th e OCM pr ovides a n om in a l five volt s t o bot h t h e
pr oper ca libr a t ion set t in gs fr om t h e ORC a ft er it is pr essu r e sen sor of t h e sea t weigh t bla dder ben ea t h
con n ect ed t o t h e veh icle elect r ica lly. t h e pa ssen ger fr on t sea t cu sh ion a n d t o t h e belt t en -
sion sen sor on t h e pa ssen ger fr on t sea t belt lower
OCCU PAN T CLASSI FI CAT I ON M ODU LE (Cont inue d)
a n ch or. Th e OCM t h en m on it or s t h e r et u r n volt a ge (OCM) h a ve been r epla ced wit h t h e ser vice r epla ce-
fr om ea ch of t h e sen sor s. Th e bla dder pr essu r e sen - m en t pa cka ge com pon en t s, t h e OCM ca n on ly be ser-
sor in pu t a llows t h e OCM t o det er m in e wh et h er t h e viced by r epla cin g t h e en t ir e pa ssen ger fr on t sea t
pa ssen ger fr on t sea t is occu pied a n d t h e r ela t ive size cu sh ion u n it wit h a n ot h er com plet e ser vice r epla ce-
of t h e occu pa n t by pr ovidin g a weigh t -sen sin g r efer- m en t pa cka ge (Refer t o 23 - BODY/SE ATS/SE AT
en ce t o t h e loa d on t h e sea t cu sh ion . Th e belt t en sion CUSH ION - F RONT - RE MOVAL).
sen sor pr ovides a n a ddit ion a l logic in pu t t o t h e OCM
m icr opr ocessor t h a t a llows it t o dist in gu ish bet ween WARNING: Never replace both the Occupant
t h e lower sea t belt cin ch loa ds of a belt ed occu pa n t Restraint Controller (ORC) and the Occupant Clas-
a n d t h e h igh er loa ds a ssocia t ed wit h a belt ed ch ild sification Module (OCM) at the same time. If both
sea t . require replacement, replace one, then perform the
P r e-pr ogr a m m ed decision a lgor it h m s a n d OCS ca l- Airbag System test (Refer to 8 - ELECTRICAL/RE-
ibr a t ion a llow t h e OCM m icr opr ocessor t o det er m in e STRAINTS - DIAGNOSIS AND TESTING - AIRBAG
wh en t h e sea t cu sh ion loa d a s sign a led by t h e bla d- SYSTEM) before replacing the other. Both the ORC
der pr essu r e sen sor a n d t h e sea t belt cin ch loa d a s and the OCM store Occupant Classification System
sign a led by t h e belt t en sion sen sor in dica t e t h a t pa s- (OCS) calibration data, which they transfer to one
sen ger a ir ba g pr ot ect ion is a ppr opr ia t e. Wh en t h e another when one of them is replaced. If both are
pr ogr a m m ed con dit ion s a r e m et , t h e OCM sen ds t h e replaced at the same time, an irreversible fault will
pr oper elect r on ic occu pa n t cla ssifica t ion m essa ges be set in both modules and the OCS may malfunc-
over t h e P CI da t a bu s t o t h e Occu pa n t Rest r a in t tion and result in personal injury or death.
Con t r oller (ORC), a n d t h e ORC en a bles or disa bles
t h e deploym en t cir cu it s for t h e pa ssen ger fr on t su p- (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
plem en t a l r est r a in t s. Th e ORC a lso pr ovides a con - ca ble.
t r ol ou t pu t for t h e P a ssen ger Air ba g Disa bled (PAD) (2)
in dica t or in t h e in st r u m en t pa n el cen t er st a ck, ba sed
u pon t h e elect r on ic occu pa n t cla ssifica t ion m essa ges
it r eceives fr om t h e OCM.
Th e OCM m icr opr ocessor con t in u ou sly m on it or s a ll
of t h e OCS elect r ica l cir cu it s a n d com pon en t s t o
det er m in e t h e syst em r ea din ess. If t h e OCM det ect s
a m on it or ed syst em fa u lt , it set s a n a ct ive a n d st or ed (3) Rea ch u n der t h e fr on t edge of t h e pa ssen ger
Dia gn ost ic Tr ou ble Code (DTC) a n d sen ds t h e a ppr o- side fr on t sea t cu sh ion t o a ccess a n d r em ove t h e lock
pr ia t e elect r on ic m essa ges t o t h e ORC over t h e P CI pin fr om t h e con n ect or lock t ower on t h e Occu pa n t
da t a bu s. Th en t h e ORC set s a DTC a n d sen ds m es- Cla ssifica t ion Modu le (OCM) (F ig. 36).
sa ges t o con t r ol t h e a ir ba g in dica t or oper a t ion (4) Discon n ect t h e pa ssen ger fr on t sea t wir e h a r-
a ccor din gly. An a ct ive fa u lt on ly r em a in s for t h e n ess con n ect or for t h e OCM.
du r a t ion of t h e fa u lt , or in som e ca ses for t h e du r a - (5) Rem ove t h e t wo scr ews t h a t secu r e t h e OCM t o
t ion of t h e cu r r en t ign it ion swit ch cycle, wh ile a t h e OCM br a cket .
st or ed fa u lt ca u ses a DTC t o be st or ed in m em or y by (6) Rem ove t h e OCM fr om u n der t h e pa ssen ger
t h e OCM a n d t h e ORC. F or som e DTC’s, if a fa u lt fr on t sea t .
does n ot r ecu r for a n u m ber of ign it ion cycles, t h e
OCM will a u t om a t ica lly er a se t h e st or ed DTC. F or INSTALLATION
ot h er in t er n a l fa u lt s, t h e st or ed DTC is la t ch ed for-
ever. WARNING: To avoid personal injury or death on
Th e OCM r eceives ba t t er y cu r r en t fr om a n IP M vehicles equipped with the Occupant Classification
h igh side dr iver (Ru n /St a r t ). Th e OCM r eceives System (OCS), only the Occupant Classification
gr ou n d t h r ou gh a gr ou n d cir cu it of t h e body wir e Module (OCM) and the seat cushion trim may be
h a r n ess, wh ich it sh a r es wit h t h e ORC. Th ese con - serviced separately. All other components of the
n ect ion s a llow t h e OCM t o be oper a t ion a l wh en ever passenger front seat cushion must be serviced only
t h e ign it ion swit ch is in t h e St a r t or ON posit ion s. as a complete factory-calibrated, assembled and
To dia gn ose a n d t est t h e OCS, u se a sca n t ool a n d tamper-evident service replacement package.
t h e a ppr opr ia t e dia gn ost ic in for m a t ion .
On ce a n y of t h e or igin a l fa ct or y-in st a lled com po-
REMOVAL n en t s except t h e OCM h a ve been r epla ced wit h t h e
On ce a n y of t h e or igin a l fa ct or y-in st a lled com po- ser vice r epla cem en t pa cka ge com pon en t s, t h e OCM
n en t s except t h e Occu pa n t Cla ssifica t ion Modu le ca n on ly be ser viced by r epla cin g t h e en t ir e pa ssen -
OCCU PAN T CLASSI FI CAT I ON M ODU LE (Cont inue d)
(4) In st a ll t h e lock pin in t o t h e con n ect or lock
t ower on t h e OCM.


Airbag System test procedure, the Occupant Classi-
using a scan tool and the appropriate diagnostic
information.

(6) Close h ood.
OCCU PAN T REST RAI N T

CON T ROLLER
Fig. 36 OCM - REMOVE/INSTALL
1 - OCCUPANT CLASSIFICATION MODULE (OCM)
DESCRIPTION
2 - LOCK TOWER
3 - LOCK PIN
4 - CONNECTOR
5 - SCREW (2)
6 - BRACKET
ger side fr on t sea t cu sh ion u n it wit h a n ot h er com -

plet e ser vice r epla cem en t pa cka ge. (Refer t o 23 -
BODY/SE ATS/SE AT CUSH ION - F RONT -
RE MOVAL).
WARNING: Never replace both the Occupant

Restraint Controller (ORC) and the Occupant Clas-
sification Module (OCM) at the same time. If both
require replacement, replace one, then perform the
Airbag System test (Refer to 8 - ELECTRICAL/RE-
STRAINTS - DIAGNOSIS AND TESTING - AIRBAG
SYSTEM) before replacing the other. Both the ORC
and the OCM store Occupant Classification System
(OCS) calibration data, which they transfer to one
another when one of them is replaced. If both are
replaced at the same time, an irreversible fault will
be set in both modules and the OCS may malfunc-
tion may result in personal injury or death.
Fig. 37 OCCUPANT RESTRAINT CONTROLLER -
(1) Ca r efu lly posit ion t h e Occu pa n t Cla ssifica t ion TYPICAL
Modu le (OCM) t o t h e OCM br a cket (F ig. 36). Wh en 1 - ORC
2 - ORIENTATION ARROW UPON INSTALLATION
t h e OCM is cor r ect ly posit ion ed, t h e con n ect or on t h e 3 - LABEL
m odu le will be poin t ed t o r igh t side of t h e veh icle. 4 - ORC ELECTRICAL CONNECTORS
(2) In st a ll t h e t wo scr ews t o t h e OCM. Tor qu e t h e
scr ews t o 2 N·m (20 in . lbs.). Th e Occu pa n t Rest r a in t Con t r oller (ORC) (F ig. 37)
(3) Con n ect t h e sea t wir e h a r n ess con n ect or for t h e is a lso som et im es r efer r ed t o a s t h e Air ba g Con t r ol
OCM. Be cer t a in t h a t t h e la t ch es on t h e con n ect or Modu le (ACM).
a r e ea ch fu lly en ga ged.
OCCU PAN T REST RAI N T CON T ROLLER (Cont inue d)
Th e ORC is secu r ed wit h scr ews t o a st a m ped st eel wit h ot h er elect r on ic m odu les in t h e veh icle a s well
m ou n t in g br a cket welded on t o t h e t op of t h e floor a s wit h t h e dia gn ost ic sca n t ool u sin g t h e P r ogr a m -
pa n el t r a n sm ission t u n n el ju st beh in d a n d u n der- m a ble Com m u n ica t ion In t er fa ce (P CI) da t a bu s. Th is
n ea t h t h e in st r u m en t pa n el cen t er st a ck in t h e pa s- m et h od of com m u n ica t ion is u sed for con t r ol of t h e
sen ger com pa r t m en t of t h e veh icle (F ig. 38). a ir ba g in dica t or in t h e E lect r oMech a n ica l In st r u m en t
Con cea led wit h in a h ollow in t h e cen t er of t h e die Clu st er (E MIC) a n d for su pplem en t a l r est r a in t sys-
ca st a lu m in u m ORC h ou sin g is t h e elect r on ic cir- t em dia gn osis a n d t est in g t h r ou gh t h e 16-wa y Da t a
cu it r y of t h e ORC wh ich in clu des a m icr opr ocessor, Lin k Con n ect or (DLC) loca t ed on t h e dr iver side
a n elect r on ic im pa ct sen sor, a n elect r on ic sa fin g sen - lower edge of t h e in st r u m en t pa n el.
sor, a n d a n en er gy st or a ge ca pa cit or. A st a m ped Th e ORC m icr opr ocessor con t in u ou sly m on it or s a ll
m et a l cover pla t e is secu r ed t o t h e bot t om of t h e of t h e su pplem en t a l r est r a in t syst em elect r ica l cir-
ORC h ou sin g wit h fou r scr ews t o en close a n d pr ot ect cu it s t o det er m in e t h e syst em r ea din ess. If t h e ORC
t h e in t er n a l elect r on ic cir cu it r y a n d com pon en t s. det ect s a m on it or ed syst em fa u lt , it set s a n a ct ive
a n d st or ed Dia gn ost ic Tr ou ble Code (DTC) a n d sen ds
elect r on ic m essa ges t o t h e E MIC over t h e P CI da t a
bu s t o t u r n on t h e a ir ba g in dica t or. An a ct ive fa u lt
on ly r em a in s for t h e du r a t ion of t h e fa u lt , or in som e
ca ses for t h e du r a t ion of t h e cu r r en t ign it ion swit ch
cycle, wh ile a st or ed fa u lt ca u ses a DTC t o be st or ed
in m em or y by t h e ORC. F or som e DTC’s, if a fa u lt
does n ot r ecu r for a n u m ber of ign it ion cycles, t h e
ORC will a u t om a t ica lly er a se t h e st or ed DTC. F or
ot h er in t er n a l fa u lt s, t h e st or ed DTC is la t ch ed for-
ever.
On m odels equ ipped wit h t h e Occu pa n t Cla ssifica -
t ion Syst em (OCS), t h e ORC com m u n ica t es wit h t h e
Occu pa n t Cla ssifica t ion Modu le (OCM) over t h e P CI
da t a bu s. Th e ORC will in t er n a lly disa ble t h e pa s-
sen ger a ir ba g a n d sea t belt t en sion er deploym en t cir-
Fig. 38 ORC LOCATION cu it s if t h e OCM det ect s t h a t t h e pa ssen ger side
fr on t sea t is u n occu pied or t h a t it is occu pied by a
1 - ORC ELECTRICAL CONNECTORS
2 - ORC loa d t h a t is in a ppr opr ia t e for a n a ir ba g deploym en t .
3 - ORC MOUNTING SCREWS Th e ORC a lso pr ovides a con t r ol ou t pu t t o t h e P a s-
sen ger Air ba g Disa bled (PAD) in dica t or t h r ou gh t h e
An a r r ow pr in t ed on t h e la bel on t h e t op of t h e pa ssen ger a ir ba g in dica t or dr iver cir cu it . Th e OCM
ORC h ou sin g pr ovides a visu a l ver ifica t ion of t h e n ot ifies t h e ORC wh en it h a s det ect ed a m on it or ed
pr oper or ien t a t ion of t h e u n it , a n d sh ou ld a lwa ys be syst em fa u lt a n d st or ed a DTC in it s m em or y for a n y
poin t ed t owa r d t h e fr on t of t h e veh icle. Th e ORC fa u lt y OCS com pon en t or cir cu it , t h en t h e ORC set s
h ou sin g h a s in t egr a l m ou n t in g fla n ges. t h e ORC h a s a DTC a n d con t r ols t h e a ir ba g in dica t or oper a t ion
t wo m olded pla st ic elect r ica l con n ect or s t h a t exit s t h e a ccor din gly.
r igh t fa cin g side of t h e ORC h ou sin g. Th ese t er m in a l Th e ORC r eceives ba t t er y cu r r en t t h r ou gh t wo cir-
pin s con n ect t h e ORC t o t h e veh icle elect r ica l syst em . cu it s; a fu sed ign it ion swit ch ou t pu t (RUN) cir cu it
Th e im pa ct sen sor a n d sa fin g sen sor in t er n a l t o t h r ou gh a fu se in t h e J u n ct ion Block (J B), a n d a
t h e ORC a r e ca libr a t ed for t h e specific veh icle, a n d fu sed ign it ion swit ch ou t pu t (RUN/START) cir cu it
a r e on ly ser viced a s a u n it wit h t h e ORC. In a ddi- t h r ou gh a secon d fu se in t h e J B. Th e ORC r eceives
t ion , t h er e a r e u n iqu e ver sion s of t h e ORC for veh i- gr ou n d t h r ou gh a gr ou n d cir cu it of t h e in st r u m en t
cles wit h or wit h ou t cu r t a in a ir ba gs. Th e ORC ca n n ot pa n el wir e h a r n ess. Th ese con n ect ion s a llow t h e ORC
be r epa ir ed or a dju st ed a n d, if da m a ged or fa u lt y, it t o be oper a t ion a l wh en ever t h e ign it ion swit ch is in
m u st be r epla ced. t h e START or ON posit ion s.
Th e ORC a lso con t a in s a n en er gy-st or a ge ca pa cit or.
OPERATION Wh en t h e ign it ion swit ch is in t h e START or ON
Th e m icr opr ocessor in t h e Occu pa n t Rest r a in t Con - posit ion s, t h is ca pa cit or is con t in u a lly bein g ch a r ged
t r oller (ORC) con t a in s t h e su pplem en t a l r est r a in t wit h en ou gh elect r ica l en er gy t o deploy t h e fr on t su p-
syst em logic cir cu it s a n d con t r ols a ll of t h e su pple- plem en t a l r est r a in t com pon en t s for u p t o on e secon d
m en t a l r est r a in t syst em com pon en t s. Th e ORC u ses followin g a ba t t er y discon n ect or fa ilu r e. Th e pu r pose
On -Boa r d Dia gn ost ics (OBD) a n d ca n com m u n ica t e of t h e ca pa cit or is t o pr ovide ba cku p su pplem en t a l
r est r a in t syst em pr ot ect ion in ca se t h er e is a loss of SYSTEM) before replacing the other. Both the ORC
ba t t er y cu r r en t su pply t o t h e ORC du r in g a n im pa ct . and the OCM store Occupant Classification System
Two sen sor s a r e con t a in ed wit h in t h e ORC, a n (OCS) calibration data, which they transfer to one
elect r on ic im pa ct sen sor a n d a sa fin g sen sor. Th e another when one of them is replaced. If both are
ORC a lso m on it or s in pu t s fr om eigh t r em ot e im pa ct replaced at the same time, an irreversible fault will
sen sor s. Two fr on t im pa ct sen sor s a r e loca t ed on ea ch be set in both modules and the OCS may malfunc-
ou t boa r d side of t h e lower r a dia t or su ppor t , a n d tion and result in personal injury or death.
t h r ee side im pa ct sen sor s a r e loca t ed on ea ch side of (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
t h e veh icle a t t h e B-pilla r, in t h e lower slidin g door ca ble.
open in g in fr on t of t h e C-pilla r, a n d over t h e r ea r (2)
wh eel well bet ween t h e C a n d D-pilla r s. Th e elec-
t r on ic im pa ct sen sor s a r e a cceler om et er s t h a t sen se WARNING: Wait two minutes for the airbag system
t h e r a t e of veh icle deceler a t ion , wh ich pr ovides ver i- reserve capacitor to discharge before beginning
fica t ion of t h e dir ect ion a n d sever it y of a n im pa ct . any airbag system or component service. Failure to
Th e sa fin g sen sor is a n elect r on ic a cceler om et er do so may result in accidental airbag deployment,
sen sor wit h in t h e ORC t h a t pr ovides a n a ddit ion a l personal injury or death.
logic in pu t t o t h e ORC m icr opr ocessor. Th e sa fin g
sen sor is u sed t o ver ify t h e n eed for a su pplem en t a l (3) Rem ove st or a ge bin fr om in st r u m en t pa n el
r est r a in t deploym en t by det ect in g im pa ct en er gy of a (Refer t o 23 - BODY/INSTRUME NT PANE L/STOR-
lesser m a gn it u de t h a n t h a t of t h e pr im a r y elect r on ic AGE BIN - RE MOVAL).
im pa ct sen sor s, a n d m u st exceed a sa fin g t h r esh old (4) Rem ove t h r ee bolt s h oldin g ORC t o floor
in or der for t h e a ir ba gs t o deploy. Veh icles equ ipped br a cket (F ig. 39).
wit h cu r t a in a ir ba gs, t h er e is a secon d sa fin g sen sor
wit h in t h e ORC t o pr ovide con fir m a t ion t o t h e ORC
m icr opr ocessor of side im pa ct for ces. Th is secon d sa f-
in g sen sor is a bi-dir ect ion a l u n it t h a t det ect s im pa ct
for ces fr om eit h er side of t h e veh icle.
P r e-pr ogr a m m ed decision a lgor it h m s in t h e ORC
m icr opr ocessor det er m in e wh en t h e deceler a t ion r a t e
a s sign a led by t h e im pa ct sen sor s a n d t h e sa fin g sen -
sor s in dica t e a n im pa ct t h a t is sever e en ou gh t o
r equ ir e su pplem en t a l r est r a in t syst em pr ot ect ion
a n d, ba sed u pon t h e sever it y of t h e m on it or ed
im pa ct , det er m in es t h e level of fr on t a ir ba g deploy-
m en t for ce r equ ir ed for ea ch fr on t sea t in g posit ion .
Wh en t h e pr ogr a m m ed con dit ion s a r e m et , t h e ORC
sen ds t h e pr oper elect r ica l sign a ls t o deploy t h e du a l
m u lt ist a ge fr on t a ir ba gs a t t h e pr ogr a m m ed for ce
levels, t h e fr on t sea t belt t en sion er s a n d, if t h e veh i- Fig. 39 ORC - REMOVE/INSTALL
cle is so equ ipped, eit h er cu r t a in a ir ba g. F or veh icles 1 - ORC ELECTRICAL CONNECTORS
equ ipped wit h t h e OCS, t h e pa ssen ger fr on t a ir ba g 2 - ORC
a n d sea t belt t en sion er will be deployed by t h e ORC 3 - ORC MOUNTING SCREWS
on ly if en a bled by t h e OCM m essa ges (PAD in dica t or
(5) Discon n ect t h e wir e con n ect or s fr om t h e ORC
OF F ) a t t h e t im e of t h e im pa ct .
(F ig. 39).
To dia gn ose a n d t est t h e ORC a n d a ll a ir ba g sys-
(6) Rem ove t h e ORC fr om veh icle.
t em com pon en t s, u se a sca n t ool a n d t h e a ppr opr ia t e
dia gn ost ic in for m a t ion .
INSTALLATION
REMOVAL WARNING: Do not install ORC if mounting location
is deformed or damaged. This will cause the ORC
WARNING: Never replace both the Occupant
to be improperly located and could result in occu-
Restraint Controller (ORC) and the Occupant Clas-
pant personal injury or death.
sification Module (OCM) at the same time. If both
Airbag System test (Refer to 8 - ELECTRICAL/RE- WARNING: Use correct screws when installing the
STRAINTS - DIAGNOSIS AND TESTING - AIRBAG ORC.
WARNING: Never replace both the Occupant r epla ced. Th e pa ssen ger a ir ba g ca n n ot be r epa ir ed,
Restraint Controller (ORC) and the Occupant Clas- a n d m u st be r epla ced if deployed or da m a ged in a n y
sification Module (OCM) at the same time. If both wa y.
Airbag System test (Refer to 8 - ELECTRICAL/RE- OPERATION
STRAINTS - DIAGNOSIS AND TESTING - AIRBAG Th e pa ssen ger a ir ba g is equ ipped wit h t wo in fla -
SYSTEM) before replacing the other. Both the ORC t or s, ea ch wit h t h r ee levels of pr essu r e ou t pu t . Th e
and the OCM store Occupant Classification System in fla t or s sea l t h e h ole in t h e a ir ba g cu sh ion so it ca n
(OCS) calibration data, which they transfer to one disch a r ge t h e ga s it pr odu ces dir ect ly in t o t h e cu sh -
another when one of them is replaced. If both are ion wh en su pplied wit h t h e pr oper elect r ica l sign a l.
replaced at the same time, an irreversible fault will F ollowin g a n a ir ba g deploym en t , t h e a ir ba g cu sh ion
be set in both modules and the OCS may malfunc- qu ickly defla t es by ven t in g t h is ga s t h r ou gh t h e
tion and result in personal injury or death. cu sh ion m a t er ia l t owa r ds t h e in st r u m en t pa n el.
Th e pa ssen ger a ir ba g is secu r ed wit h scr ews t o t h e
(1) In st a ll t h e ORC in t o veh icle (F ig. 39). in st r u m en t pa n el ben ea t h t h e in st r u m en t pa n el t op
(2) Con n ect t h e wir e con n ect or t o t h e ORC (F ig. pa d a n d a bove t h e glove box open in g. Th e in st r u m en t
39). pa n el t op pa d a bove t h e glove box open in g con cea ls
(3) In st a ll t h r ee bolt s h oldin g ORC t o floor br a cket t h e a ir ba g door a n d a pr edet er m in ed h in ge lin e
(F ig. 39). Tor qu e bolt s t o 7.3 - 9.6 N·m (65 t o 85 in . ben ea t h it s decor a t ive cover. Upon a ir ba g deploy-
lbs.) m en t , t h e t op pa d will ben d a t t h e h in ge lin e a n d t h e
(4) In st a ll t h e st or a ge bin on t o t h e in st r u m en t door will fold ba ck ou t of t h e wa y on t o t h e t op of t h e
pa n el (Refer t o 23 - BODY/INSTRUME NT PANE L/ in st r u m en t pa n el.
STORAGE BIN - INSTALLATION). Wh en t h e fr on t a ir ba g syst em is deployed, t h e fol-
lowin g MU S T be r epla ced:
• Com plet e St eer in g Colu m n Assem bly.
• Lower St eer in g Colu m n Cou pler.
• St eer in g Wh eel.
• Clock Spr in g.
• Dr iver Air ba g.
(5) Ver ify veh icle a n d syst em oper a t ion . • P a ssen ger Air ba g.
(6) Close h ood. • Upper In st r u m en t P a n el wit h P a d.
CARE OF UNDEPLOYED AIRBAGS

PASSEN GER AI RBAG Air ba gs m u st be st or ed in t h eir or igin a l specia l
con t a in er u n t il u sed for ser vice. At n o t im e sh ou ld a
DESCRIPTION sou r ce of elect r icit y be per m it t ed n ea r t h e in fla t or on
t h e ba ck of a n a ir ba g. Wh en ca r r yin g or h a n dlin g a n
WARNING: Never disassemble the passenger air- u n deployed a ir ba g, t h e t r im side of t h e a ir ba g sh ou ld
bag. The passenger airbag has no serviceable be poin t in g a wa y fr om t h e body t o m in im ize possibil-
parts. If tampered with internally, the airbag could it y of in ju r y if a cciden t a l deploym en t occu r s. Do n ot
deploy and result in personal injury or death. pla ce u n deployed a ir ba g fa ce down on a solid su r fa ce,
t h e a ir ba g will pr opel in t o t h e a ir if a cciden t a l
Th e P a ssen ger Air ba g is loca t ed ben ea t h t h e deploym en t occu r s.
in st r u m en t pa n el a n d pa d a ssem bly. Th e a ir ba g is
m ou n t ed t o t h e ba ck side of t h e in st r u m en t pa n el REMOVAL
r ein for cem en t .
Th e in st r u m en t pa n el t op pa d is t h e m ost visible DEPLOYED AIRBAG
pa r t of t h e pa ssen ger a ir ba g syst em . Loca t ed u n der (1) Open h ood.
t h e in st r u m en t pa n el t op pa d a r e t h e a ir ba g door, t h e (2) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
pa ssen ger a ir ba g cu sh ion a n d t h e a ir ba g cu sh ion ca ble.
su ppor t in g com pon en t s. (3)
Th e pa ssen ger a ir ba g in clu des a m a gn esiu m h ou s-
in g wit h in wh ich t h e cu sh ion a n d in fla t or a r e
m ou n t ed a n d sea led.
F ollowin g a pa ssen ger a ir ba g deploym en t , t h e pa s-
sen ger a ir ba g a n d t h e in st r u m en t pa n el m u st be
PASSEN GER AI RBAG (Cont inue d)
WARNING: Wait two minutes for the airbag system (17) Rem ove t wo r igh t side n u t s a t in st r u m en t
reserve capacitor to discharge before beginning pa n el cen t er st a ck su ppor t t o floor.
any airbag system or component service. Failure to (18) Rem ove r igh t fr on t door sill pla t e u sin g a t r im
do so may result in accidental airbag deployment, st ick or equ iva len t , a n d gen t ly pr yin g u p on sill
personal injury or death. pla t e.
(19) Rem ove r igh t cowl pa n el u sin g a t r im st ick or
(4) Clea n powder r esidu e fr om in t er ior of veh icle equ iva len t , a n d gen t ly pr yin g ou t on cowl pa n el.
(Refer t o 8 - E LE CTRICAL/RE STRAINTS - STAN- (20) Usin g a t r im st ick or equ iva len t , gen t ly pr y
DARD P ROCE DURE - SE RVICE AF TE R AN AIR- ou t on r igh t in st r u m en t pa n el en d ca p.
BAG DE P LOYME NT). (21) Un sn a p r igh t A-pilla r lower ext en sion t r im
(5) Rem ove in st r u m en t pa n el (Refer t o 23 - BODY/ u sin g a t r im st ick or equ iva len t .
INSTRUME NT PANE L/INSTRUME NT PANE L (22) Rem ove t h r ee r igh t side in st r u m en t pa n el
ASSE MBLY - RE MOVAL). A-pilla r r et a in in g bolt s a n d loosen t h e in st r u m en t
(6) Rem ove a ll r eu sa ble com pon en t s fr om t h e pa n el r oll down bolt .
u pper in st r u m en t pa n el a n d t r a n sfer t o t h e n ew (23) Usin g a t r im st ick or equ iva len t , gen t ly pr y
in st r u m en t pa n el. off r igh t side u pper A-pilla r t r im .
(24) Open glove box, pin ch in sides a n d r oll down
UNDEPLOYED AIRBAG t owa r ds floor. Wit h a fir m pu ll, sn a p glove box door
(1) Open h ood. off h in ges a n d r em ove.
(2) Discon n ect a n d isola t e t h e ba t t er y n ega t ive (25) Usin g a t r im st ick or equ iva len t , gen t ly pr y
ca ble. u p on r ea r of in st r u m en t pa n el t op cover a n d t h en
(3) pu ll r ea r wa r d a n d ou t .
(26) Usin g a t r im st ick or equ iva len t , gen t ly pr y
WARNING: Wait two minutes for the airbag system off t h e filler bezel ju st a bove t h e cu p h older t o expose
reserve capacitor to discharge before beginning t h e lower scr ews t o cen t er bezel.
any airbag system or component service. Failure to (27) Rem ove t wo scr ews a n d t h en u sin g a t r im
do so may result in accidental airbag deployment, st ick or equ iva len t , gen t ly pr y off in st r u m en t pa n el
personal injury or death. cen t er bezel.
(28) Rem ove cen t er bezel wir in g con n ect or s t o
(4) Rem ove cen t er con sole bin bet ween fr on t sea t s.
H VAC con t r ol a n d swit ch a ssem bly (h a za r d, r ea r
(5) Rem ove left fr on t door sill pla t e u sin g a t r im
wiper /wa sh er, h ea t ed sea t s) a n d r em ove bezel.
st ick (specia l t ool #C-4755) or equ iva len t , a n d gen t ly
(29) Slide cu p h older a ssem bly fr om in st r u m en t
pr yin g u p on sill pla t e.
pa n el.
(6) Rem ove left cowl pa n el u sin g a t r im st ick or
(30) Rem ove n in et een scr ews t o r igh t lower in st r u -
equ iva len t , a n d gen t ly pr yin g ou t on cowl pa n el.
m en t pa n el t r im (glove box su r r ou n d), u n plu g glove
(7) Rem ove fou r scr ews t o lower st eer in g colu m n
box la m p wir e con n ect or, a n d r em ove pa n el.
cover a n d r em ove cover.
(31) Rem ove fou r scr ews a n d wir in g con n ect or s t o
(8) Un sn a p pa r kin g br a ke lever fr om kn ee blocker
r a dio a n d r em ove r a dio.
r ein for cem en t .
(32) Rem ove on e fa r left in st r u m en t pa n el spea ker
(9) Rem ove Da t a Lin k Con n ect or (DLC) fr om kn ee
r et a in in g scr ew.
blocker.
(33) Rem ove fou r scr ews a lon g t op fr on t edge of
(10) Rem ove scr ews t o kn ee blocker.
in st r u m en t pa n el cover /pa d.
(11) Un sn a p left A-pilla r lower ext en sion t r im
(34) Rem ove seven lower in st r u m en t pa n el cover /
u sin g a t r im st ick or equ iva len t .
pa d r et a in in g scr ews st a r t in g fr om r igh t of veh icle
(12) Rem ove t h r ee left side in st r u m en t pa n el A-pil-
a n d on ly r em ovin g t h ese seven , n ot a ll of t h em .
la r r et a in in g bolt s a n d loosen t h e in st r u m en t pa n el
(35) Rem ove six u pper fen ce lin e in st r u m en t pa n el
r oll down bolt .
r et a in in g bolt s.
(13) Rem ove fou r n u t s a t br a ke peda l su ppor t
(36) Roll ba ck in st r u m en t pa n el ju st en ou gh t o
br a cket t o in st r u m en t pa n el.
in cr ea se a ccess t o t h e pa ssen ger a ir ba g r et a in in g
(14) Usin g a t r im st ick or equ iva len t , gen t ly pr y
bolt s a t t h e r ein for cem en t . Lift t h e in st r u m en t pa n el
off left side u pper A-pilla r t r im .
u p sligh t ly so a s n ot t o da m a ge t h e a ir dist r ibu t ion t o
(15) Rem ove six scr ews a n d t wo wir in g con n ect or s
H VAC u n it sea l.
t o lower in st r u m en t pa n el cu bby bin a t bot t om of
(37) Discon n ect t h e pa ssen ger a ir ba g elect r ica l
cen t er st a ck.
con n ect or. Usin g a t r im st ick or equ iva len t , gen t ly
(16) Rem ove t wo left side n u t s a t in st r u m en t pa n el
pr y elect r ica l con n ect or off of in st r u m en t pa n el r ein -
cen t er st a ck su ppor t t o floor.
for cem en t .
(38) Rem ove t h e t wo pa ssen ger a ir ba g t o in st r u - (5) Con n ect t h e pa ssen ger a ir ba g elect r ica l con n ec-
m en t pa n el cover /pa d r et a in in g scr ews. t or. In st a ll t h e con n ect or on t o t h e in st r u m en t pa n el
(39) Rem ove t h e t h r ee pa ssen ger a ir ba g t o in st r u - r ein for cem en t wit h t h e pu sh -pin fa st en er s.
m en t pa n el r ein for cem en t r et a in in g bolt s. (6) Roll t h e in st r u m en t pa n el for wa r d lift in g
(40) P u ll r ea r wa r d sligh t ly on t h e in st r u m en t sligh t ly so a s t o sea t t h e in st r u m en t pa n el a ir dist r i-
pa n el cover /pa d t o m a n eu ver pa ssen ger a ir ba g ou t bu t ion du ct on t op of t h e H VAC u n it pr oper ly t o
fr om r ein for cem en t a n d in st r u m en t pa n el. a void a n y lea ks or da m a ge t o t h e sea l.
(7) In st a ll six u pper fen ce lin e in st r u m en t pa n el
INSTALLATION r et a in in g bolt s.
(8) In st a ll t h r ee r igh t side in st r u m en t pa n el A-pil-
DEPLOYED AIRBAG la r r et a in in g bolt s a n d t igh t en t h e r igh t in st r u m en t
Tr a n sfer a ll r eu sa ble com pon en t s t o t h e n ew pa n el r oll down bolt . In st a ll t h e sm a ller 10 m m bolt
in st r u m en t pa n el. fir st t o a lign t h e in st r u m en t pa n el pr oper ly.
(1) In st a ll n ew P a ssen ger Air ba g in t o in st r u m en t (9) In st a ll t h r ee left side in st r u m en t pa n el A-pilla r
pa n el. r et a in in g bolt s a n d t igh t en t h e left in st r u m en t pa n el
(2) In st a ll a ir ba g a t t a ch in g bolt s t o t h e in st r u m en t r oll down bolt . In st a ll t h e sm a ller 10 m m bolt fir st t o
pa n el. a lign t h e in st r u m en t pa n el pr oper ly.
(a ) Tor qu e t h e t wo bolt s a t in st r u m en t pa n el (10) In st a ll seven lower in st r u m en t pa n el cover /
r et a in er bosses t o 2.7 ± .5 N·m (24 ± 5 in . lbs.). pa d r et a in in g scr ews.
(b) Tor qu e t h e t h r ee bolt s t h a t a t t a ch t h e pa s- (11) In st a ll fou r scr ews a lon g t op fr on t edge of
sen ger a ir ba g t o cr oss-ca r bea m t o 10 ± 2 N·m (90 in st r u m en t pa n el cover /pa d.
± 15 in . lbs.). (12) In st a ll on e fa r left in st r u m en t pa n el spea ker
(3) Con n ect yellow wir e con n ect or t o pa ssen ger a ir- r et a in in g scr ew.
ba g a n d a ffix con n ect or t o in st r u m en t pa n el r ein - (13) In st a ll wir in g con n ect or s t o r a dio. In st a ll
for cem en t wit h pu sh pin s. r a dio a n d fou r r et a in in g scr ews.
(4) In st a ll In st r u m en t pa n el (Refer t o 23 - BODY/ (14) Con n ect glove box la m p wir in g con n ect or a n d
INSTRUME NT PANE L/INSTRUME NT PANE L pla ce r igh t lower in st r u m en t pa n el t r im (glove box
ASSE MBLY - INSTALLATION). su r r ou n d) in t o posit ion .
(15) In st a ll n in et een r igh t lower in st r u m en t pa n el
WARNING: Do not connect the battery negative t r im (glove box su r r ou n d) a n d in st a ll pa n el scr ews.
cable (Refer to 8 - ELECTRICAL/RESTRAINTS - (16) Slide cu p h older a ssem bly in t o in st r u m en t
DIAGNOSIS AND TESTING - AIRBAG SYSTEM). Per- pa n el.
sonal injury or death may result if the system test (17) In st a ll cen t er bezel wir in g con n ect or s t o
is not performed first. H VAC con t r ol a n d swit ch a ssem bly (h a za r d, r ea r
wiper /wa sh er, h ea t ed sea t s).
(18) In st a ll in st r u m en t pa n el cen t er bezel by a lign -
UNDEPLOYED AIRBAG in g slot s a n d fir m ly sn a ppin g in t o pla ce.
(1) P u ll r ea r wa r d sligh t ly on t h e in st r u m en t pa n el (19) In st a ll t wo scr ews t o in st r u m en t pa n el cen t er
cover /pa d t o m a n eu ver pa ssen ger a ir ba g u p on t o bezel.
r ein for cem en t a n d in st r u m en t pa n el. (20) Align filler bezel a bove cu p h older over r et a in -
(2) In st a ll t h e t h r ee pa ssen ger a ir ba g t o in st r u - in g slot s a n d fir m ly sn a p in t o pla ce.
m en t pa n el r ein for cem en t r et a in in g bolt s bu t lea ve (21) P la ce in st r u m en t pa n el t op cover in t o posit ion
loose. Th is will h elp a lign t h e pa ssen ger a ir ba g for a n d fir m ly sn a p down r ea r edge of t op cover.
t h e cover /pa d fit . (22) In st a ll glove box. Align h in ges, sn a p in t o
(3) In st a ll t h e t wo pa ssen ger a ir ba g t o in st r u m en t pla ce, r oll glove box u pwa r ds a n d pu sh in sides t o
pa n el cover /pa d r et a in in g scr ews. Tor qu e scr ews t o fu lly in st a ll.
2.7 ±.5 N·m (24 ± 5 in . lbs.). (23) Align r igh t side u pper A-pilla r t r im over
r et a in in g slot s a n d fir m ly sn a p in t o pla ce.
NOTE: Insure that the instrument panel cover/pad (24) Align r igh t A-pilla r lower ext en sion t r im over
locator pins are indexed properly at center stack
area prior to reassembly.
(25) Align r igh t in st r u m en t pa n el en d ca p over
(4) Tigh t en t h e t h r ee pa ssen ger a ir ba g t o in st r u -
(26) Align r igh t cowl pa n el over r et a in in g slot s a n d
m en t pa n el r ein for cem en t r et a in in g bolt s. Tor qu e
bolt s t o 10 ± 2 N·m (90 ± 15 in . lbs.). fir m ly sn a p in t o pla ce.
(27) Align r igh t fr on t door sill pla t e over r et a in in g
slot s a n d fir m ly sn a p in t o pla ce.
(28) In st a ll t wo r igh t side n u t s a t in st r u m en t Th e PAD in dica t or con sist s of a m olded pla st ic
pa n el cen t er st a ck su ppor t t o floor. h ou sin g wit h a n in t egr a l con n ect or a t t h e ba ck. An
(29) In st a ll t wo left side n u t s a t in st r u m en t pa n el a m ber Ligh t E m it t in g Diode (LE D) beh in d t h e len s
cen t er st a ck su ppor t t o floor. ca u ses t h e “PASS AIR BAG OF F ” t ext a n d icon t o
(30) Con n ect t h e t wo wir in g con n ect or s t o lower a ppea r silh ou et t ed a ga in st a n a m ber field t h r ou gh
in st r u m en t pa n el cu bby bin a t bot t om of cen t er st a ck t h e t r a n slu cen t len s wh en t h e in dica t or is illu m i-
a n d in st a ll six scr ews. n a t ed fr om beh in d by t h e LE D. Th e PAD in dica t or is
(31) Align left side u pper A-pilla r t r im over r et a in - a va ila ble for sepa r a t e ser vice r epla cem en t .
in g slot s a n d fir m ly sn a p in t o pla ce.
(32) In st a ll fou r n u t s a t br a ke peda l su ppor t OPERATION
br a cket t o in st r u m en t pa n el. In veh icles equ ipped wit h t h e Occu pa n t Cla ssifica -
(33) Align left A-pilla r lower ext en sion t r im over t ion Syst em (OCS), t h e P a ssen ger Air ba g Disa bled
r et a in in g slot s a n d fir m ly sn a p in t o pla ce. (PAD) in dica t or gives a n in dica t ion wh en t h e pa ssen -
(34) In st a ll kn ee blocker a n d r et a in in g scr ews. ger a ir ba g a n d sea t belt t en sion er deploym en t cir-
(35) In st a ll Da t a Lin k Con n ect or (DLC) in t o bot - cu it s a r e disa bled by t h e Occu pa n t Rest r a in t
t om of kn ee blocker. Con t r oller (ORC). Th e PAD in dica t or is con t r olled by
(36) Align pa r kin g br a ke lever a n d sn a p in t o pla ce a t r a n sist or wit h in t h e ORC t h r ou gh a h a r d wir ed
on kn ee blocker r ein for cem en t . ou t pu t ba sed u pon ORC pr ogr a m m in g a n d elect r on ic
(37) In st a ll lower st eer in g colu m n cover a n d fou r occu pa n t cla ssifica t ion m essa ges r eceived by t h e ORC
r et a in in g scr ews over t h e P r ogr a m m a ble Com m u n ica t ion s In t er fa ce
(38) Align left cowl pa n el over r et a in in g slot s a n d (P CI) da t a bu s fr om t h e Occu pa n t Cla ssifica t ion
fir m ly sn a p in t o pla ce. Modu le (OCM). Th e PAD in dica t or Ligh t E m it t in g
(39) Align left fr on t door sill pla t e over r et a in in g Diode (LE D) is com plet ely con t r olled by t h e ORC.
slot s a n d fir m ly sn a p in t o pla ce. Th e LE D r eceives a ba t t er y cu r r en t in pu t on t h e
(40) In st a ll cen t er con sole bin bet ween fr on t sea t s. fu sed ign it ion swit ch ou t pu t (RUN/START) cir cu it .
Th er efor e, t h e LE D will a lwa ys be OF F wh en t h e
WARNING: Do not connect the battery negative ign it ion swit ch is in a n y posit ion except ON or
cable (Refer to 8 - ELECTRICAL/RESTRAINTS - START. Th e LE D on ly illu m in a t es wh en it is pr o-
DIAGNOSIS AND TESTING - AIRBAG SYSTEM). Per- vided a pa t h t o gr ou n d by t h e ORC t r a n sist or. Th e
sonal injury or death may result if the system test ORC will t u r n on t h e PAD in dica t or for t h e followin g
is not performed first. r ea son s:
• B u lb Te s t - E a ch t im e t h e ign it ion swit ch is
(41) Close h ood.
t u r n ed t o t h e ON posit ion t h e PAD in dica t or is illu -
(42) Ver ify syst em a n d veh icle oper a t ion .
m in a t ed for a bou t six secon ds.
• Ch ild S e a t D e te c te d Oc c u p a n t Cla s s ific a -
PASSEN GER AI RBAG tio n Me s s a g e - E a ch t im e t h e ORC r eceives a m es-
sa ge fr om t h e OCM in dica t in g a ch ild sea t h a s been
DI SABLED I N DI CAT OR det ect ed in t h e pa ssen ger fr on t sea t , t h e pa ssen ger
a ir ba g a n d sea t belt t en sion er deploym en t cir cu it s
DESCRIPTION a r e dea ct iva t ed a n d t h e PAD in dica t or will be illu m i-
n a t ed. Th e in dica t or r em a in s illu m in a t ed u n t il t h e
ORC r eceives a n occu pa n t cla ssifica t ion m essa ge
in dica t in g t h a t :
• Th e pa ssen ger fr on t sea t is em pt y.
• Th e sea t is occu pied by a loa d equ a l t o or
gr ea t er t h a n a fift h per cen t ile fem a le.
• OR, Un t il t h e ign it ion swit ch is t u r n ed t o t h e
Fig. 40 PASSENGER AIRBAG DISABLED (PAD) OF F posit ion , wh ich ever of t h ese t h r ee occu r s fir st .
INDICATOR • Lo a d Le s s Th a n F ifth P e rc e n tile F e m a le
Oc c u p a n t Cla s s ific a tio n Me s s a g e - E a ch t im e t h e
Veh icles equ ipped wit h t h e Occu pa n t Cla ssifica t ion ORC r eceives a m essa ge fr om t h e OCM in dica t in g
Syst em (OCS) in clu de a P a ssen ger Air ba g Disa bled t h a t a loa d less t h a n a fift h per cen t ile fem a le h a s
(PAD) in dica t or (F ig. 40) wh ich is loca t ed in t h e been det ect ed in t h e pa ssen ger fr on t sea t , t h e pa s-
in st r u m en t pa n el cen t er st a ck, a bove t h e r a dio. Th e sen ger a ir ba g a n d sea t belt t en sion er deploym en t cir-
PAD in dica t or is pr esen t on ly in veh icles equ ipped cu it s a r e dea ct iva t ed a n d t h e PAD in dica t or will be
wit h t h e OCS. illu m in a t ed. Th e in dica t or r em a in s illu m in a t ed u n t il:
PASSEN GER AI RBAG DI SABLED I N DI CAT OR (Cont inue d)
• Th e ORC r eceives a n occu pa n t cla ssifica t ion REMOVAL
m essa ge in dica t in g t h a t t h e pa ssen ger fr on t sea t is (1) Open h ood.
em pt y. (2) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
• Th e sea t is occu pied by a loa d equ a l t o or ca ble.
gr ea t er t h a n a fift h per cen t ile fem a le. (3)
• OR, u n t il t h e ign it ion swit ch is t u r n ed t o t h e
OF F posit ion , wh ich ever of t h ese t h r ee occu r s fir st . WARNING: Wait two minutes for the airbag system
• Lo a d U n d e te rm in e d Oc c u p a n t Cla s s ific a - reserve capacitor to discharge before beginning
tio n Me s s a g e - E a ch t im e t h e ORC r eceives a m es- any airbag system or component service. Failure to
sa ge fr om t h e OCM in dica t in g t h a t a loa d ca n n ot be do so may result in accidental airbag deployment,
det er m in ed in t h e pa ssen ger fr on t sea t , t h e pa ssen - personal injury or death.
ger a ir ba g a n d sea t belt t en sion er deploym en t cir-
cu it s a r e dea ct iva t ed a n d t h e PAD in dica t or will be (4) Rem ove in st r u m en t pa n el cen t er bezel (Refer t o
illu m in a t ed. Th e in dica t or r em a in s illu m in a t ed u n t il: 23 - BODY/INSTRUME NT PANE L/INSTRUME NT
• Th e ORC r eceives a n occu pa n t cla ssifica t ion PANE L CE NTE R BE ZE L - RE MOVAL).
m essa ge in dica t in g t h a t t h e pa ssen ger fr on t sea t is (5) F r om t h e ba ck of t h e cen t er bezel, depr ess t h e
em pt y. t wo la t ch es t owa r d t h e in dica t or h ou sin g a n d pu sh
• Th e sea t is occu pied by a loa d equ a l t o or t h e in dica t or ou t t h r ou gh t h e fa ce of t h e cen t er bezel.
• OR, u n t il t h e ign it ion swit ch is t u r n ed t o t h e INSTALLATION
OF F posit ion , wh ich ever of t h ese t h r ee occu r s fir st . (1) F r om t h e fa ce of t h e in st r u m en t pa n el cen t er
• Co m m u n ic a tio n Erro r - If t h e ORC r eceives bezel, a lign t h e P a ssen ger Air ba g Disa bled (PAD)
in va lid occu pa n t cla ssifica t ion m essa ges or n o m esin dica t or h ou sin g wit h t h e m ou n t in g h ole.
sa ges fr om t h e OCM, t h e PAD in dica t or is illu m i- (2) F ir m ly pu sh t h e in dica t or in t o t h e cen t er bezel
n a t ed. Th e in dica t or r em a in s illu m in a t ed u n t il: u n t il t h e t wo la t ch es a r e fu lly en ga ged on t h e ba ck of
• Th e ORC r eceives a n occu pa n t cla ssifica t ion t h e ca p a n d a r e sn a pped in .
m essa ge in dica t in g t h a t t h e pa ssen ger fr on t sea t is (3) In st a ll t h e in st r u m en t pa n el cen t er bezel (Refer
em pt y. t o 23 - BODY/INSTRUME NT PANE L/INSTRUME NT
• Th e sea t is occu pied by a loa d equ a l t o or PANE L CE NTE R BE ZE L - INSTALLATION).
• OR, u n t il t h e ign it ion swit ch is t u r n ed t o t h e WARNING: Do not connect the battery negative
OF F posit ion , wh ich ever of t h ese t h r ee occu r s fir st . cable (Refer to 8 - ELECTRICAL/RESTRAINTS -
Th e ORC con t in u a lly m on it or s t h e occu pa n t cla ssi- DIAGNOSIS AND TESTING - AIRBAG SYSTEM). Per-
fica t ion m essa ges fr om t h e OCM t o decide wh et h er sonal injury or death may result if the system test
t h e pa ssen ger a ir ba g a n d sea t belt t en sion er deploy- is not performed first.
m en t cir cu it s sh ou ld be a ct iva t ed or dea ct iva t ed.
Not e t h a t t h er e m a y be sever a l secon ds of dela y
bet ween ch a n ges in t h e det ect ed occu pa n t st a t u s a n d
Airbag System test procedure, the Occupant Classi-
PAD in dica t ion s. Th is is a pr ogr a m m ed fea t u r e of t h e
OCM u sed t o pr even t a fla sh in g in dica t or con dit ion
using a scan tool and the appropriate diagnostic
r esu lt in g fr om t h e n or m a l sh ift in g of occu pa n t weigh t
information.
on t h e pa ssen ger sea t cu sh ion . Th e ORC t h en pr o-
vides t h e pr oper con t r ol ou t pu t t o t u r n t h e PAD in di- (4) Close h ood.
ca t or ON or OF F. (5) Ver ify syst em a n d veh icle oper a t ion .
Th e ORC will st or e a Dia gn ost ic Tr ou ble Code
(DTC) for a n y m a lfu n ct ion it det ect s. F or pr oper
dia gn osis of t h e OCM, t h e ORC, t h e P CI da t a bu s, or
t h e elect r on ic m essa ge in pu t s t o t h e ORC t h a t con -
t r ol t h e PAD in dica t or, u se a sca n t ool a n d t h e a ppr o-
pr ia t e dia gn ost ic in for m a t ion .
SEAT BELT BU CK LE - FRON T must be done using a scan tool and the appropriate
diagnostic information.
I N BOARD (6) Close h ood.
(7) Ver ify syst em a n d veh icle oper a t ion .
REMOVAL
Th e sea t belt t en sion er s a r e in t egr a l t o t h e fr on t
sea t belt bu ckles. Th ey a r e n ot ser vicea ble a n d m u st SEAT BELT BU CK LE - FI RST
be r epla ced a ft er a fr on t a l im pa ct even t . Th e en t ir e ROW I N BOARD - QU AD
fr on t sea t belt bu ckle a ssem bly m u st be r epla ced a s
a n a ssem bly. BU CK ET
(1) Open h ood.
(2) Discon n ect a n d isola t e t h e ba t t er y n ega t ive REMOVAL
ca ble.
(3) QUAD BUCKET
(1) Rem ove sea t fr om veh icle.
WARNING: Wait two minutes for the airbag system (2) Rem ove scr ews a t t a ch in g in boa r d side cover t o
reserve capacitor to discharge before beginning sea t cu sh ion .
any airbag system or component service. Failure to (3) Rem ove side cover fr om sea t .
do so may result in accidental airbag deployment, (4) Rem ove bolt s a t t a ch in g r eclin er br a cket t o sea t
personal injury or death. cu sh ion .
(5) Rem ove r eclin er br a cket fr om sea t .
(4) Rem ove scr ews a t t a ch in g fr on t in boa r d side (6) Rem ove bolt a t t a ch in g sea t belt bu ckle t o sea t
cover t o sea t cu sh ion fr a m e. t r a ck (F ig. 41).
(5) Rem ove side cover fr om fr on t sea t .
(6) Discon n ect t h e t en sion er wir e con n ect or fr om
sea t belt bu ckle.
(7) Rem ove bolt a t t a ch in g sea t belt bu ckle t o fr on t
sea t t r a ck.
(8) Rem ove bu ckle fr om sea t .
INSTALLATION
Th e sea t belt t en sion er s a r e in t egr a l t o t h e fr on t
sea t belt bu ckles. Th ey a r e n ot ser vicea ble a n d m u st
be r epla ced a ft er a fr on t a l im pa ct even t . Th e en t ir e
fr on t sea t belt bu ckle a ssem bly m u st be r epla ced a s
a n a ssem bly.
(1) P la ce bu ckle in t o posit ion .
(2) In st a ll bolt a t t a ch in g sea t belt bu ckle t o fr on t
sea t t r a ck. Tor qu e bolt t o 39 N·m (29 ft . lbs.).
(3) Con n ect t h e sea t belt t en sion er elect r ica l con -
n ect or.
(4) In st a ll side cover in t o posit ion .
(5) In st a ll scr ews a t t a ch in g fr on t in boa r d side
cover t o sea t cu sh ion fr a m e.
Fig. 41 1ST ROW INBOARD BUCKLE - QUAD
WARNING: Do not connect the battery negative BUCKET
cable (Refer to 8 - ELECTRICAL/RESTRAINTS - 1 - SEAT CUSHION
DIAGNOSIS AND TESTING - AIRBAG SYSTEM). Per- 2 - SEAT BELT BUCKLE
sonal injury or death may result if the system test 3 - SEAT TRACK
(7) Rem ove bu ckle fr om veh icle.
WARNING: If equipped with the Occupant Classifi- QUAD BUCKET - FOLD IN FLOOR
cation System (OCS) and replacing the passenger (1) F old in floor t h e sea t n ot h a vin g t h e bu ckle
front seat belt buckle: Following successful com- r epla ced.
pletion of the Airbag System test procedure, the (2) Rem ove t h e h in ge cover r et a in in g scr ew a n d
Occupant Classification System Verification Test h in ge cover.
SEAT BELT BU CK LE - FI RST ROW I N BOARD - QU AD BU CK ET (Cont inue d)
(3) Rem ove t h e h in ge r et a in in g bolt s u n der t h e (5) Rem ove bu ckle h a lf fr om sea t .
cu sh ion cover side pa n el (F ig. 42).
INSTALLATION
QUAD BUCKET
(1) P la ce bu ckle in t o posit ion .
(2) In st a ll bolt a t t a ch in g sea t belt bu ckle t o sea t
t r a ck. Tor qu e bolt t o 39 N·m (29 ft . lbs.).
(3) In st a ll r eclin er br a cket on t o t h e sea t .
(4) In st a ll bolt s a t t a ch in g r eclin er br a cket t o sea t
cu sh ion .
(5) In st a ll side cover fr om sea t .
(6) In st a ll scr ews a t t a ch in g in boa r d side cover t o
sea t cu sh ion .
(7) In st a ll sea t in t o posit ion .
QUAD BUCKET - FOLD IN FLOOR

(1) Gen t ly lift h in ge u pwa r ds a n d pla ce bu ckle in
bet ween t h e cu sh ion fr a m e a n d t h e h in ge it self (F ig.
43).
(2) In st a ll t h e h in ge r et a in in g bolt s u n der t h e
Fig. 42 1ST ROW INBOARD BUCKLE RETAINING cu sh ion cover side pa n el (F ig. 42).
BOLTS - FOLD IN FLOOR (3) In st a ll t h e h in ge cover r et a in in g scr ew a n d
h in ge cover.
1 - SEAT BELT BUCKLE
2 - SEAT BACK INBOARD HINGE
3 - SEAT RISER
4
5
-
-
INBOARD HINGE RETAINING BOLTS
SEAT CUSHION COVER SIDE PANEL
SEAT BELT BU CK LE - FI RST
ROW - BEN CH
(4) Gen t ly lift h in ge u pwa r ds t o fr ee bu ckle fr om
bet ween t h e cu sh ion fr a m e a n d t h e h in ge it self (F ig. REMOVAL
43). (1) Rem ove sea t fr om veh icle.
(2) Rem ove bolt a t t a ch in g in boa r d sea t belt bu ckle
t o sea t fr a m e (F ig. 44).
(3) Rem ove belt fr om sea t .
Fig. 43 1ST ROW INBOARD BUCKLE - FOLD IN Fig. 44 SEAT BELT BUCKLE - FIRST ROW - BENCH
FLOOR
1 - ANCHOR BOLT
1 - SEAT BACK HINGE 2 - TWO (2) PASS REAR SEAT BELT BUCKLE
2 - SEAT BELT BUCKLE 3 - RISER
3 - SEAT CUSHION FRAME 4 - REAR FRAME
SEAT BELT BU CK LE - FI RST ROW - BEN CH (Cont inue d)
INSTALLATION (2) Rem ove t h e h in ge cover r et a in in g scr ew (F ig.

(1) P la ce sea t belt in t o posit ion t o t h e sea t . 46).
(2) In st a ll bolt a t t a ch in g in boa r d sea t belt bu ckle
t o sea t fr a m e. Tigh t en a ll sea t belt a n ch or bolt s t o 39
N·m (29 ft . lbs.) t or qu e.
(3) In st a ll sea t in t o posit ion .
SEAT BELT BU CK LE - SECON D

ROW I N BOARD - 5 0 /5 0 BEN CH
REMOVAL
SECOND ROW 50/50 BENCH
(1) Open r ea r lift ga t e.
(2) P u ll h a n dle #1 a n d fold sea t ba ck for wa r d.
(3) P u ll h a n dle #2, a n d lift sea t bot t om u p.
(4) P u ll #3 st r a p a n d r em ove sea t fr om la t ch in g
a r ea .
(5) Wh ile lookin g a t t h e bot t om of t h e sea t , loca t e
r et a in in g bolt on t h e left side of t h e sea t r iser.
Rem ove r et a in in g bolt fr om sea t r iser (F ig. 45). Fig. 46 FIRST ROW BUCKLE - INBOARD - COVER
RETAINING SCREW
2 - HINGE COVER
3 - HINGE COVER RETAINING SCREW
4 - CUSHION COVER SIDE PANEL
(3) P u ll h in ge cover ou t ju st fa r en ou gh t o ga in
a ccess t o bu ckle r et a in in g n u t (F ig. 47). Rem ove n u t
a n d slide bu ckle ou t fr om u n der cu sh ion cover side
pa n el.
Fig. 45 SEAT BELT BUCKLE - SECOND ROW

INBOARD - 50/50 BENCH
2 - BUCKLE RETAINING BOLT
3 - 50/50 SPLIT BENCH RISER
4 - BOTTOM OF SEAT CUSHION
(6) P u ll belt t h r ou gh sea t cu sh ion . Fig. 47 FIRST ROW BUCKLE - INBOARD -

RETAINING NUT
SECOND ROW - FOLD IN FLOOR 1 - SEAT BELT BUCKLE
2 - HINGE COVER
(1) F old in floor t h e sea t n ot h a vin g t h e bu ckle 3 - SEAT BELT BUCKLE RETAINING NUT
r epla ced. 4 - CUSHION COVER SIDE PANEL
SEAT BELT BU CK LE - SECON D ROW I N BOARD - 5 0 /5 0 BEN CH (Cont inue d)
INSTALLATION SEAT BELT & RET RACT OR -

(1) P u sh belt t h r ou gh sea t cu sh ion .
(2) Wh ile lookin g a t t h e bot t om of t h e sea t , loca t e
OU T BOARD - FRON T
r et a in in g bolt h ole on t h e left side of t h e sea t r iser.
In st a ll r et a in in g bolt in t o sea t r iser (F ig. 45). Tor qu e REMOVAL
a n ch or bolt t o 39 N·m (29 ft . lbs.). (1) Open door.
(3) P la ce sea t in t o t r a ck a n d on fr on t a n ch or s. (2) Move sea t a ll t h e wa y for wa r d.
(4) P u ll #3 st r a p a n d in st a ll sea t on t o la t ch in g (3) Open h ood.
a r ea . (4) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
(5) P u ll sea t a ssem bly down fir m ly a n d sn a p in t o ca ble.
t r a ck. (5)
(6) P u ll h a n dle #1 a n d fold sea t ba ck r ea r wa r d.
(7) Close r ea r lift ga t e.
SEAT BELT H EI GH T do so may result in accidental airbag deployment,
ADJ U ST ER - B OR C-PI LLAR
(6) Rem ove sh ou lder h a r n ess h eigh t a dju st er kn ob
REMOVAL by pu llin g it st r a igh t a wa y fr om a dju st er (F ig. 48).
(1) Rem ove t u r n in g loop r et a in in g bolt .
(2) Rem ove B or C-pilla r t r im cover.
(3) Rem ove t wo scr ews a t t a ch in g sh ou lder belt
h eigh t a dju st er t o pilla r.
(4) Rem ove h eigh t a dju st er fr om veh icle.
INSTALLATION
(1) P la ce h eigh t a dju st er in t o posit ion .
(2) In st a ll scr ews a t t a ch in g sh ou lder belt h eigh t
a dju st er t o pilla r.
(3) In st a ll B or C-pilla r t r im cover.
(4) In st a ll t u r n in g loop t o h eigh t a dju st er. Tor qu e
a n ch or bolt t o 39 N·m (29 ft . lbs.).
SEAT BELT H EI GH T
ADJ U ST ER K N OB Fig. 48 SEAT BELT - OUTBOARD FRONT
1 - B-PILLAR TRIM LOWER
REMOVAL 2 - BELT
3 - B-PILLAR TRIM UPPER
(1) Disen ga ge clips a t t a ch in g cla m sh ell cover t o 4 - HEIGHT ADJUSTER
sea t belt t u r n in g loop a n d open cover. 5 - KNOB
6 - B-PILLAR TRIM LOWER
(2) Usin g a t r im t ool (specia l t ool #C-4755), gen t ly 7 - FLOOR ANCHOR
pr y kn ob fr om sea t belt h eigh t a dju st er. 8 - FLOOR ANCHOR
9 - 30° OUTBOARD
10 - RETRACTOR
INSTALLATION
(1) P la ce sea t belt h eigh t a dju st er kn ob in posit ion (7) Rem ove cover fr om sea t belt t u r n in g loop (F ig.
on h eigh t a dju st er. 48).
(2) F ir m ly pu sh kn ob on u n t il r et a in er s en ga ge. (8) Rem ove bolt a t t a ch in g t u r n in g loop t o sh ou lder
(3) Rein st a ll t u r n in g loop cla m sh ell cover. belt h eigh t a dju st er (F ig. 48).
(4) Ver ify sea t belt oper a t ion . Ma ke su r e it m oves (9) Rem ove u pper B-pilla r t r im cover (F ig. 48).
t h r ou gh loop wit h ou t bin din g.
NOTE: If equipped with the Occupant Classification
System (OCS), there is a Belt Tension Sensor
located on the lower seat belt anchor on the pas-
senger front seat belt.
SEAT BELT & RET RACT OR - OU T BOARD - FRON T (Cont inue d)
(10) Rem ove t h e lower sea t belt a n ch or bolt (F ig. (7) In st a ll t h e lower sea t belt a n ch or bolt (F ig. 49).
49). Tor qu e bolt t o 39 N·m (29 ft . lbs.).
NOTE: If equipped with the Occupant Classification

System (OCS), there is a Belt Tension Sensor
located on the lower seat belt anchor on the pas-
senger front seat belt.
(8) Con n ect t h e belt t en sion sen sor con n ect or (if
equ ipped wit h OCS) (F ig. 49).
(9) In st a ll t h e u pper B-pilla r t r im cover (F ig. 48).
(10) In st a ll t h e bolt a t t a ch in g t u r n in g loop t o
sh ou lder belt h eigh t a dju st er (F ig. 48). Tor qu e bolt t o
39 N·m (29 ft . lbs.).
(11) In st a ll t h e cover t o t h e sea t belt t u r n in g loop
(F ig. 48).
(12) In st a ll t h e sh ou lder h a r n ess h eigh t a dju st er
kn ob by pu sh in g it st r a igh t on t o t h e a dju st er (F ig.
48).
(13) Move sea t ba ck t o a ppr oxim a t e cu st om er posi-
t ion .
Fig. 49 BELT TENSION SENSOR/LOWER SEAT WARNING: If equipped with the OCS, do not con-
BELT ANCHOR nect the battery negative cable (Refer to 8 - ELEC-
1 - A-PILLAR TRICAL/RESTRAINTS - DIAGNOSIS AND TESTING -
2 - SEAT BELT ANCHOR/BELT TENSION SENSOR AIRBAG SYSTEM). Personal injury or death may
3 - BELT TENSION SENSOR CONNECTOR
result if the system test is not performed first.
(11) Discon n ect t h e elect r ica l con n ect or if equ ipped
wit h OCS (F ig. 49). WARNING: If equipped with the OCS, following suc-
(12) Rem ove fr on t door sill pla t e (F ig. 48). cessful completion of the Airbag System test proce-
(13) Rem ove slidin g door sill pla t e (F ig. 48). dure, the Occupant Classification System
(14) Rem ove lower B-pilla r t r im cover (F ig. 48). Verification Test must be done using a scan tool
(15) Discon n ect t h e sea t belt r et r a ct or elect r ica l and the appropriate diagnostic information.
(16) Rem ove sea t belt r et r a ct or a t t a ch in g bolt (F ig. (14) Ver ify veh icle a n d syst em oper a t ion .
48). (15) Close h ood.
(17) Rem ove t h e sea t belt a n d r et r a ct or fr om veh i-
cle.
SEAT BELT & RET RACT OR -
INSTALLATION FI RST ROW - OU T BOARD
WARNING: Inspect the condition of the shoulder
belt and lap belt. Replace any belt that is cut,
REMOVAL
frayed, torn, or damaged in any way. Also, replace (1) Rem ove fir st a n d secon d r ow sea t s.
the shoulder belt if the retractor is either damaged (2) Rem ove fir st r ow sea t belt lower a n ch or bolt .
or inoperative. (3) Rem ove fir st r ow sea t belt u pper t u r n in g loop
a n ch or bolt .
(1) P la ce sea t belt a n d r et r a ct or in t o posit ion (F ig. (4) Rem ove lift ga t e sill pla t e.
48). (5) Rem ove u pper lift ga t e t r im .
(2) In st a ll bolt a t t a ch in g sea t belt r et r a ct or t o (6) Rem ove secon d sea t lower a n ch or bolt .
B-pilla r (F ig. 48). Tor qu e bolt t o 39 N·m (29 ft . lbs.). (7) Rem ove secon d sea t u pper t u r n in g loop a n ch or
(3) Con n ect t h e sea t belt r et r a ct or elect r ica l con - bolt .
n ect or (F ig. 48). (8) Rem ove D-pilla r t r im cover.
(4) In st a ll t h e lower B-pilla r t r im cover (F ig. 48). (9) Discon n ect spea ker con n ect or. Th e left side h a s
(5) In st a ll t h e slidin g door sill pla t e (F ig. 48). t h e spea ker m ou n t ed in t h e D-pilla r t r im cover a n d
(6) In st a ll t h e fr on t door sill pla t e (F ig. 48). t h e r igh t side will h a ve t h e spea ker m ou n t ed in t h e
r ea r of t h e qu a r t er t r im pa n el, bu t t h e con n ect or is
SEAT BELT & RET RACT OR - FI RST ROW - OU T BOARD (Cont inue d)
a ccessible fr om t h e r ea r a ft er t h e D-pilla r t r im is
r em oved.
(10) Rem ove qu a r t er t r im bolst er.
(11) Rem ove qu a r t er t r im pa n el scr ews.
(12) Rem ove qu a r t er t r im pa n el.
(13) Rem ove fir st r ow sea t belt a n d r et r a ct or
r et a in in g bolt .
(14) Rem ove fir st r ow sea t belt a n d r et r a ct or fr om
veh icle.
INSTALLATION
(1) In st a ll fir st r ow sea t belt a n d r et r a ct or. Tor qu e
bolt t o 39 N·m (29 ft . lbs.).
(2) In st a ll qu a r t er t r im pa n el.
(3) In st a ll qu a r t er t r im pa n el scr ews.
(4) In st a ll qu a r t er t r im bolst er.
(5) Con n ect spea ker con n ect or. Th e left side h a s Fig. 50 SEAT BELT BUCKLE - SECOND ROW -
t h e spea ker m ou n t ed in t h e D-pilla r t r im cover a n d THREE PASSENGER BENCH
t h e r igh t side will h a ve t h e spea ker m ou n t ed in t h e 1 - ANCHOR BOLT
r ea r of t h e qu a r t er t r im pa n el, bu t t h e con n ect or is 2 - SEAT BELTS
3 - ANCHOR
a ccessible fr om t h e r ea r a ft er t h e D-pilla r t r im is 4 - RISER
r em oved.
(6) In st a ll D-pilla r t r im cover.
(7) In st a ll secon d sea t belt lower a n ch or bolt .
Tor qu e bolt t o 39 N·m (29 ft . lbs.). SECON D ROW - RI GH T
(8) In st a ll secon d sea t belt u pper t u r n in g loop OU T BOARD
a n ch or bolt . Tor qu e bolt t o 39 N·m (29 ft . lbs.).
(9) In st a ll u pper lift ga t e t r im .
REMOVAL
(10) In st a ll lift ga t e sill pla t e.
(1) Rem ove fir st a n d secon d r ow sea t s.
(11) In st a ll fir st r ow sea t belt u pper t u r n in g loop
(2) Rem ove fir st r ow sea t belt lower a n ch or bolt .
(3) Rem ove fir st r ow sea t belt u pper a n ch or bolt .
(12) In st a ll fir st r ow sea t belt lower a n ch or bolt .
(4) Rem ove lift ga t e sill pla t e.
Tor qu e bolt t o 39 N·m (29 ft . lbs.).
(5) Rem ove u pper lift ga t e t r im .
(13) In st a ll fir st a n d secon d r ow sea t s.
(6) Rem ove secon d sea t belt lower a n ch or bolt .
(7) Rem ove secon d sea t belt u pper a n ch or bolt .
SEAT BELT BU CK LE - SECON D (8) Rem ove D-pilla r t r im cover.
(9) Discon n ect spea ker con n ect or. Th e left side h a s
ROW - T H REE PASSEN GER t h e spea ker m ou n t ed in t h e D-pilla r t r im cover a n d
BEN CH t h e r igh t side will h a ve t h e spea ker m ou n t ed in t h e
REMOVAL a ccessible fr om t h e r ea r a ft er t h e D-pilla r t r im is
(1) Rem ove bolt a t t a ch in g sea t belt bu ckle t o sea t r em oved.
r ea r fr a m e r a il (F ig. 50). (10) Rem ove qu a r t er t r im bolst er.
(2) Rem ove sea t belt bu ckle fr om sea t . (11) Rem ove qu a r t er t r im pa n el scr ews.
(12) Rem ove qu a r t er t r im pa n el.
INSTALLATION (13) Rem ove r et r a ct or r et a in in g bolt .
(1) P la ce sea t belt bu ckle in posit ion on sea t . (14) Rem ove secon d r ow sea t belt a n d r et r a ct or.
(2) In st a ll bolt t o a t t a ch sea t belt bu ckle t o sea t
r ea r fr a m e r a il. Tigh t en a ll sea t belt bolt s t o 39 N·m INSTALLATION
(29 ft . lbs.) t or qu e. (1) In st a ll secon d r ow sea t belt a n d r et r a ct or.
(2) In st a ll qu a r t er t r im pa n el.
(3) In st a ll qu a r t er t r im pa n el scr ews.
(4) In st a ll qu a r t er t r im bolst er.
(5) Con n ect spea ker con n ect or. Th e left side h a s
t h e spea ker m ou n t ed in t h e D-pilla r t r im cover a n d
SEAT BELT & RET RACT OR - SECON D ROW - RI GH T OU T BOARD (Cont inue d)
t h e r igh t side will h a ve t h e spea ker m ou n t ed in t h e
r em oved.
(8) In st a ll secon d sea t belt u pper t u r n in g loop
Fig. 51 TRIM PANEL MOUNTING BRACKET
1 - TRIM PANEL MOUNTING BRACKET
SECON D ROW - RI GH T
OU T BOARD WI T H REAR H VAC
- LWB
REMOVAL
(8) Rem ove D-pilla r t r im cover.
t h e r igh t side will h a ve t h e spea ker m ou n t ed in t h e Fig. 52 LOWER HEATER DUCT
r ea r of t h e qu a r t er t r im pa n el, bu t t h e con n ect or is 1 - LOWER HEAT DUCT MOUNTING
r em oved. INSTALLATION
(10) Rem ove qu a r t er t r im bolst er. (1) P osit ion secon d r ow sea t belt a n d r et r a ct or t o
(11) Rem ove qu a r t er t r im pa n el scr ews. veh icle.
(12) Rem ove qu a r t er t r im pa n el. (2) P u ll ou t wa r d on H VAC u n it a n d in st a ll bolt
(13) Loosen H VAC u n it en ou gh t o ga in a ccess t o a t t a ch in g r et r a ct or t o in n er qu a r t er pa n el. Tor qu e
sea t belt r et r a ct or fa st en er s. bolt t o 39 N·m (29 ft . lbs.).
(a ) Rem ove br a cket a r ou n d H VAC u n it (F ig. 51). (3) In st a ll bolt s a t t a ch in g sea t belt gu ide loop t o
(b) Rem ove a ir du ct (F ig. 52). in n er qu a r t er pa n el.
(c) Rem ove fa st en er s a t t a ch in g H VAC u n it t o (4) In st a ll fa st en er s a t t a ch in g H VAC u n it t o in n er
in n er qu a r t er pa n el (F ig. 53). qu a r t er pa n el.
(d) Gen t ly pr y ou t on r ea r H VAC u n it t o ga in (5) In st a ll a ir du ct .
a ccess t o t h e sea t belt a n d r et r a ct or. (6) In st a ll t r im pa n el r et a in in g br a cket a r ou n d
(14) Rem ove bolt s a t t a ch in g sea t belt gu ide loop t o H VAC u n it .
in n er qu a r t er pa n el. (7) In st a ll qu a r t er t r im pa n el.
(15) P u ll ou t wa r d on H VAC u n it a n d r em ove bolt (8) In st a ll qu a r t er t r im pa n el scr ews.
a t t a ch in g r et r a ct or t o in n er qu a r t er pa n el. (9) In st a ll qu a r t er t r im bolst er.
(16) Rem ove secon d r ow sea t belt a n d r et r a ct or (10) Con n ect spea ker con n ect or. Th e left side h a s
fr om veh icle. t h e spea ker m ou n t ed in t h e D-pilla r t r im cover a n d
SEAT BELT & RETRACTOR - SECOND ROW - RIGHT OUTBOARD WITH REAR HVAC - LWB (Continued)

SECON D ROW - LEFT
OU T BOARD
REMOVAL
(8) Rem ove D-pilla r t r im cover.
Fig. 53 REAR HVAC MOUNTING t h e r igh t side will h a ve t h e spea ker m ou n t ed in t h e
1 - REAR HVAC MODULE MOUNTING r ea r of t h e qu a r t er t r im pa n el, bu t t h e con n ect or is
2 - REAR EVAPORATOR LOWER HOUSING
3 - REAR EVAPORATOR UPPER HOUSING
r em oved.
t h e r igh t side will h a ve t h e spea ker m ou n t ed in t h e (10) Rem ove qu a r t er t r im bolst er.
r ea r of t h e qu a r t er t r im pa n el, bu t t h e con n ect or is (11) Rem ove qu a r t er t r im pa n el scr ews.
a ccessible fr om t h e r ea r a ft er t h e D-pilla r t r im is (12) Rem ove qu a r t er t r im pa n el.
r em oved. (13) Rem ove r et r a ct or r et a in in g bolt .
(11) In st a ll D-pilla r t r im cover. (14) Rem ove secon d r ow sea t belt a n d r et r a ct or
(12) In st a ll secon d sea t belt lower a n ch or bolt . fr om veh icle.
(13) In st a ll secon d sea t belt u pper t u r n in g loop INSTALLATION
a n ch or bolt . Tor qu e bolt t o 39 N·m (29 ft . lbs.). (1) In st a ll secon d r ow sea t belt a n d r et r a ct or.
(14) In st a ll u pper lift ga t e t r im . Tor qu e bolt t o 39 N·m (29 ft . lbs.).
(15) In st a ll lift ga t e sill pla t e. (2) In st a ll qu a r t er t r im pa n el.
(16) In st a ll fir st r ow sea t belt u pper t u r n in g loop (3) In st a ll qu a r t er t r im pa n el scr ews.
a n ch or bolt . Tor qu e bolt t o 39 N·m (29 ft . lbs.). (4) In st a ll qu a r t er t r im bolst er.
(17) In st a ll fir st r ow sea t belt lower a n ch or bolt . (5) Con n ect spea ker con n ect or. Th e left side h a s
Tor qu e bolt t o 39 N·m (29 ft . lbs.). t h e spea ker m ou n t ed in t h e D-pilla r t r im cover a n d
(18) In st a ll fir st a n d secon d r ow sea t s. t h e r igh t side will h a ve t h e spea ker m ou n t ed in t h e
r em oved.
(8) In st a ll secon d sea t belt u pper t u r n in g loop
SEAT BELT T EN SI ON ER SEAT WEI GH T BLADDER &

PRESSU RE SEN SOR
DESCRIPTION
Th e sea t belt syst em in cor por a t es Sea t Belt Ten - DESCRIPTION
sion er s. Th e t en sion er is design ed t o h old t h e occu -
pa n t in t h eir r espect ive sea t by r et r a ct in g t h e sea t
belt u p t o fou r in ch es. Th ey a r e in t egr a l t o t h e fr on t
sea t belt bu ckles a n d ca n n ot be ser viced. If fou n d
defect ive t h ey m u st be r epla ced. Aft er a n a ir ba g
deploym en t , t h e t en sion er m u st be r epla ced.
Sea t Belt Ten sion er s su pplem en t t h e du a l fr on t a ir-
ba g syst em . Th e sea t belt t en sion er s a r e in t egr a l t o
t h e fr on t sea t belt bu ckles, wh ich a r e secu r ed t o t h e
sea t cu sh ion fr a m e on t h e in boa r d side. Th e sea t belt
t en sion er s a r e con t r olled by t h e Occu pa n t Rest r a in t
Con t r oller (ORC) a n d a r e con n ect ed t o t h e veh icle
elect r ica l syst em t h r ou gh t h e body wir e h a r n ess.
Th e sea t belt t en sion er s ca n n ot be r epa ir ed a n d, if
fa u lt y or da m a ged, t h e en t ir e fr on t sea t belt bu ckle
m u st be r epla ced. Th e sea t belt t en sion er s a r e n ot
in t en ded for r eu se a n d m u st be r epla ced followin g
a n y fr on t a ir ba g deploym en t . Fig. 54 SEAT WEIGHT BLADDER AND PRESSURE
SENSOR - TYPICAL
OPERATION 1 - FASTENER (2)
2 - BLADDER
3 - PAD
WARNING: When the front airbag is deployed, the 4 - TUBE
tensioner will have deployed also and should be 5 - PRESSURE SENSOR
replaced. Failure to do so could result in occupant
personal injury or death. Veh icles equ ipped wit h t h e Occu pa n t Cla ssifica t ion
Syst em (OCS) h a ve a sea t weigh t bla dder a n d pr es-
Th e sea t belt t en sion er s a r e deployed by a sign a l su r e sen sor u n it (F ig. 54) t h a t is in t egr a l t o t h e pa s-
gen er a t ed by t h e Occu pa n t Rest r a in t Con t r oller sen ger fr on t sea t cu sh ion . Th e bla dder is sa n dwich ed
(ORC) t h r ou gh t h e dr iver or pa ssen ger sea t belt t en - bet ween t h e sea t cu sh ion pa n a n d sea t cu sh ion foa m .
sion er lin e 1 a n d lin e 2 (or squ ib) cir cu it s. Wh en t h e Th e bla dder con sist s of t wo r ect a n gu la r sh eet s of
ORC sen ds t h e pr oper elect r ica l sign a l t o t h e t en sion - a n ela st om er ic m a t er ia l a n d a m olded pla st ic elbow
er s, t h e elect r ica l en er gy gen er a t es en ou gh h ea t t o fit t in g. Th e t wo sh eet s of m a t er ia l a r e sea led
in it ia t e a sm a ll pyr ot ech n ic ga s gen er a t or. t oget h er a r ou n d t h eir per im et er a n d h ea t st a ked t o
Rem ovin g excess sla ck fr om t h e fr on t sea t belt s n ot ea ch ot h er a t n u m er ou s r egu la r poin t s wit h in t h eir
on ly keeps t h e occu pa n t s pr oper ly posit ion ed for a n field. Th e elbow fit t in g is sea led t o a sm a ll r ou n d
a ir ba g deploym en t followin g a fr on t a l im pa ct of t h e h ole in t h e lower su r fa ce of t h e bla dder a n d is
veh icle, bu t a lso h elps t o r edu ce in ju r ies t h a t t h e poin t ed down wa r d wh er e it pa sses t h r ou gh a clea r-
occu pa n t s of t h e fr on t sea t m igh t exper ien ce in t h ese a n ce h ole in t h e in su la t or pa d a n d ext en ds t o ju st
sit u a t ion s a s a r esu lt of a h a r m fu l con t a ct wit h t h e below t h e sea t cu sh ion . Th e bla dder is t h en filled
st eer in g wh eel, st eer in g colu m n , in st r u m en t pa n el wit h a silicon e flu id t o becom e a plia ble, qu ilt ed
a n d/or win dsh ield. m em br a n e.
Th e ORC m on it or s t h e con dit ion of t h e sea t belt Un der t h e sea t cu sh ion a sh or t t u be is secu r ely
t en sion er s t h r ou gh cir cu it r esist a n ce, a n d will illu m i- cla m ped a t on e en d t o t h e bla dder n ipple, a n d a t t h e
n a t e t h e a ir ba g in dica t or in t h e E lect r oMech a n ica l ot h er en d t o a n ipple on t h e elect r on ic pr essu r e sen -
In st r u m en t Clu st er (E MIC) a n d st or e a Dia gn ost ic sor. Th e sen sor h ou sin g fea t u r es a n in t egr a l m ou n t
Tr ou ble Code (DTC) for a n y fa u lt t h a t is det ect ed. t h a t sn a ps over a t a b in t egr a l t o t h e st a m ped st eel
F or pr oper dia gn osis of t h e sea t belt t en sion er s, u se a Occu pa n t Cla ssifica t ion Modu le (OCM) m ou n t in g
sca n t ool a n d t h e a ppr opr ia t e dia gn ost ic in for m a t ion . br a cket welded t o t h e u n der side of t h e pa ssen ger
fr on t sea t cu sh ion fr a m e.
SEAT WEI GH T BLADDER & PRESSU RE SEN SOR (Cont inue d)
Th e sea t weigh t bla dder a n d pr essu r e sen sor ca n - Occu pa n t Cla ssifica t ion Modu le (OCM). Wh en a loa d
n ot be a dju st ed or r epa ir ed. Th e com pon en t s of t h e is a pplied t o t h e sea t cu sh ion , flu id wit h in t h e bla d-
pa ssen ger fr on t sea t cu sh ion of a veh icle equ ipped der becom es pr essu r ized. Th ese ch a n ges in bla dder
wit h t h e OCS in clu din g t h e cu sh ion fr a m e, sea t flu id pr essu r e a r e m ea su r ed by t h e pr essu r e sen sor
weigh t bla dder a n d pr essu r e sen sor, sea t cu sh ion u n der t h e sea t cu sh ion t h r ou gh t h e bla dder t u be. As
foa m , wir e h a r n ess a n d t h e OCM a r e ser viced on ly a s t h e pr essu r e wit h in t h e bla dder ch a n ges, t h e cir-
a fa ct or y-ca libr a t ed, a ssem bled a n d t a m per-eviden t cu it r y of t h e pr essu r e sen sor ch a n ges t h e ou t pu t volt -
u n it . On ly t h e OCM a n d t h e sea t cu sh ion t r im a r e a ge of t h e sen sor.
a va ila ble for sepa r a t e ser vice r epla cem en t . On ce a Th e pr essu r e sen sor r eceives a n om in a l five volt s
ser vice r epla cem en t pa cka ge h a s been in st a lled in a a n d a gr ou n d t h r ou gh h a r d wir ed cir cu it s fr om t h e
veh icle, t h e OCM ca n t h er ea ft er be ser viced on ly by OCM. Th e OCM t h en m on it or s t h e pr essu r e sen sor
r epla cin g t h e en t ir e pa ssen ger fr on t sea t cu sh ion u n it ou t pu t volt a ge on t h e P r ogr a m m a ble Com m u n ica t ion
wit h a n ot h er com plet e ser vice r epla cem en t pa cka ge. In t er fa ce (P CI) da t a bu s cir cu it .
To pr oper ly dia gn ose t h e sea t weigh t bla dder a n d
OPERATION pr essu r e sen sor, it s com m u n ica t ion wit h /bet ween t h e
Th e sea t weigh t bla dder a n d pr essu r e sen sor u n it OCM, a n d a ll ot h er com pon en t s wit h in t h e OCS, u se
is design ed t o sen se t h e r ela t ive weigh t of a loa d a sca n t ool a n d t h e a ppr opr ia t e dia gn ost ic
a pplied t o t h e pa ssen ger fr on t sea t cu sh ion , wh ich in for m a t ion .
pr ovides a logic in pu t t o t h e m icr opr ocessor of t h e
RS SPEED CONTROL 8P - 1
SPEED CONTROL
page page
SPEED CONTROL OPERATION . . . . . .......................4

DESCRIPTION . . . . . . . . . . . . . . . . . . . . ......1 REMOVAL ...... .......................4
OPERATION INSTALLATION . . . .......................4
OPERATION . . . . . . . . . . . . . . . . . . . . ......1 SWITCH
OPERATION - INTERACTIVE SPEED DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . .5
CONTROL (4 Speed EATX Only) . . . . . ......2 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
DIAGNOSIS AND TESTING - ROAD TEST .....3 REMOVAL ...... . . . . . . . . . . . . . . . . . . . . . . .5
SPECIFICATIONS - TORQUE . . . . . . . . . ......3 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . .6
CABLE VACUUM RESERVOIR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . .4 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . .6
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
REMOVAL ....................... . . . . . .4 REMOVAL ...... . . . . . . . . . . . . . . . . . . . . . . .6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . .4 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . .6
SERVO
DESCRIPTION . . . . . . . . . . . . . . . . . . . . ......4
SPEED CON T ROL Th e syst em is design ed t o oper a t e a t speeds a bove

30 m ph (48 km /h ).
DESCRIPTION WARNING: THE USE OF SPEED CONTROL IS NOT
Th e speed con t r ol syst em is elect r on ica lly con - RECOMMENDED WHEN DRIVING CONDITIONS DO
t r olled a n d va cu u m oper a t ed. Th e elect r on ic con t r ol NOT PERMIT MAINTAINING A CONSTANT SPEED,
is in t egr a t ed in t o t h e P ower t r a in Con t r ol Modu le. SUCH AS IN HEAVY TRAFFIC OR ON ROADS THAT
Th e con t r ols a r e loca t ed on t h e st eer in g wh eel. Th e ARE WINDING, ICY, SNOW COVERED, OR SLIP-
ON/OF F, a n d SE T bu t t on s a r e loca t ed on t h e left side PERY.
of t h e a ir ba g m odu le. Th e RE SUME /ACCE L, CAN-
CE L a n d COAST bu t t on s a r e loca t ed on t h e r igh t
side of t h e a ir ba g m odu le (F ig. 1).
OPERAT I ON
OPERATION
Wh en speed con t r ol is a ct iva t ed by depr essin g t h e
ON swit ch , t h e P CM a llows a set speed t o be st or ed
in RAM for speed con t r ol. To st or e a set speed,
depr ess a n d r elea se t h e SE T swit ch wh ile t h e veh icle
is m ovin g a t a speed bet ween 25 a n d 85 m ph . In
or der for t h e speed con t r ol t o en ga ge, t h e br a kes ca n -
n ot be a pplied, n or ca n t h e gea r select or be in dica t -
in g t h e t r a n sm ission is in P a r k or Neu t r a l (ATX) or
1st /2n d gea r (MTX). Th e speed con t r ol ca n be disen -
ga ged m a n u a lly by:
• St eppin g on t h e br a ke peda l
• Depr essin g t h e OF F swit ch
• Depr essin g t h e CANCE L swit ch .
• Depr essin g t h e clu t ch peda l
• Oper a t in g in 1st or 2n d gea r (a u t ost ick, if
equ ipped)
Fig. 1 SPEED CONTROL SWITCHES - Typical
8P - 2 SPEED CONTROL RS
SPEED CON T ROL (Cont inue d)
NOTE: Turning the system off by depressing the t h r ot t le open in g, wh ile in h ibit in g/dela yin g down -
OFF switch or turning off the ignition switch will sh ift s.
erase the set speed stored in the PCM.
OPERATION
F or a dded sa fet y, t h e speed con t r ol syst em is pr o- If open in g t h e t h r ot t le a lon e ca n n ot m a in t a in t h e
gr a m m ed t o disen ga ge for a n y of t h e followin g con di- set speed a n d t h e veh icle speed dr ops m or e t h a n
t ion s: t h r ee m ph below t h e set speed, t h e t r a n sm ission will
• An in dica t ion of P a r k or Neu t r a l down sh ift t o t h ir d gea r. If t h e veh icle con t in u es t o
• A r a pid in cr ea se r pm (in dica t es t h a t t h e clu t ch lose speed, by m or e t h a n 6 m ph , t h e t r a n sm ission
h a s been disen ga ged) will down sh ift a ga in t o m a in t a in t h e set speed. Aft er
• E xcessive en gin e r pm (in dica t es t h a t t h e t r a n s- t h e veh icle en cou n t er s a less-st eep gr a de, or h a s
m ission m a y be in a low gea r ) cr est ed t h e gr a de (r edu ced t h e loa d on t h e power-
• Th e speed sign a l in cr ea ses a t a r a t e of 10 m ph t r a in ) a n d ca n m a in t a in t h e set speed a t a r edu ced
per secon d (in dica t es t h a t t h e co-efficien t of fr ict ion t h r ot t le posit ion , t h e t r a n sm ission will u psh ift , a s
bet ween t h e r oa d su r fa ce a n d t ir es is ext r em ely low) a ppr opr ia t e, u n t il t h e set speed ca n be m a in t a in ed in
• Th e speed sign a l decr ea ses a t a r a t e of 10 m ph Over dr ive.
per secon d (in dica t es t h a t t h e veh icle m a y h a ve
deceler a t ed a t a n ext r em ely h igh r a t e) GRADE HUNTING
• If t h e a ct u a l speed is gr ea t er t h a n 20 m ph over
t h e set speed. DESCRIPTION
• Au t ost ick sh ift s in t o 1st or 2n d gea r (a u t ost ick, All veh icles equ ipped wit h a fou r speed a u t om a t ic
if equ ipped) t r a n sm ission h a ve a gr a de h u n t in g fea t u r e for t h e
On ce t h e speed con t r ol h a s been disen ga ged, 2n d t o 3r d gea r u psh ift a n d t h e 3r d t o Over dr ive
depr essin g t h e RE SUME swit ch wh en speed is u psh ift .
gr ea t er t h a n 20 m ph a llows t h e veh icle t o r esu m e
con t r ol t o t h e t a r get speed t h a t wa s st or ed in t h e OPERATION
P CM. Th e P CM on NGC veh icles iden t ifies t h e power-
Wh ile t h e speed con t r ol is en ga ged, t h e dr iver ca n t r a in loa din g con dit ion s a n d select s t h e pr oper gea r
in cr ea se t h e veh icle speed by depr essin g t h e ACCE L t o m a in t a in t h e cu r r en t veh icle speed. Un der m oder-
swit ch . Th e n ew t a r get speed is st or ed in t h e P CM a t e loa din g con dit ion s t h e t r a n sa xle will st a y in 3r d
wh en t h e ACCE L swit ch is r elea sed. Th e P CM a lso gea r u n t il t h e t op of t h e gr a de is r ea ch ed or t h e pow-
h a s a %t a p-u p% fea t u r e in wh ich t a r get speed er t r a in loa din g is r edu ced.
in cr ea ses by 2 m ph for ea ch m om en t a r y swit ch a ct i- If power t r a in loa din g is sever e, t h e t r a n sa xle m a y
va t ion of t h e ACCE L swit ch . Th e P CM a lso pr ovides sh ift in t o 2n d gea r a n d r em a in t h er e u n t il power-
a m ea n s t o deceler a t e t o a n ew lower t a r get speed t r a in loa din g is r edu ced, t h en a 2n d t o 3r d gea r
wit h ou t disen ga gin g speed con t r ol. Depr ess a n d h old u psh ift will be sch edu led. Gr a de h u n t in g fea t u r es
t h e COAST swit ch u n t il t h e desir ed speed is r ea ch ed, a lwa ys oper a t e r ega r dless of wh et h er or n ot t h e
t h en r elea se t h e swit ch . in t er a ct ive speed con t r ol is en ga ged. If th e in te ra c -
Th e P CM a lso h a s a “Ta p Down ” fea t u r e in wh ich tiv e s p e e d c o n tro l is n o t e n g a g e d a n d p o w e r-
t a r get speed decr ea ses a t 1 m ph for ea ch m om en t a r y tra in lo a d in g is n o t re d u c e d , th e d riv e r m a y
swit ch a ct iva t ion of t h e coa st swit ch . h a v e to c o m p le te ly lift o ff o f th e th ro ttle be fo re
a n u p s h ift w ill o c c u r. If t h e dr iver does lift off t h e
OPERATION - INTERACTIVE SPEED CONTROL t h r ot t le t o in du ce a n u psh ift u n der t h ese con dit ion s,
(4 Speed EATX Only) veh icle speed will r edu ce a n d t h e Over dr ive t o 3r d
In t er a ct ive m ea n s t h a t com m u n ica t ion bet ween t h e a n d 3r d t o 2n d gea r down sh ift s will r eoccu r wh en t h e
P CM a n d t h e TCM is t a kin g pla ce, t h is com m u n ica - t h r ot t le is r ea pplied. If gr a de h u n t in g is r epea t edly
t ion is in t er n a l t o t h e P CM on NGC veh icles. In t er- in du ced by t h e dr iver, t r a n sa xle da m a ge m a y r esu lt .
a ct ive speed con t r ol a voids u n n ecessa r y sh ift in g for
sm oot h er, qu iet er oper a t ion a n d wh en down sh ift s a r e AUTOMATIC SPEED CONTROL OVERSPEED
r equ ir ed, m a kes t h e sh ift s sm oot h er. REDUCTION
CLIMBING A GRADE DESCRIPTION

Tr a n sm ission con t r ol soft wa r e in clu des a n a u t o-
DESCRIPTION m a t ic speed con t r ol over speed r edu ct ion fea t u r e. Th is
Wh en clim bin g a gr a de t h e in t er a ct ive speed con - m a in t a in s veh icle speed a t t h e select ed set poin t
t r ol t r ies t o m a in t a in t h e set speed by in cr ea sin g t h e wh en descen din g a gr a de.
SPEED CON T ROL (Cont inue d)
OPERATION F lu t t er in t h e speedom et er in dica t es a pr oblem
Th e P CM on NGC veh icles fir st sen ses t h a t t h e wh ich m igh t ca u se su r gin g in t h e speed con t r ol sys-
speed con t r ol is set . If t h e set speed is exceeded by t em . Th e ca u se of a n y speedom et er pr oblem s sh ou ld
m or e t h a n 4 m ph (6.5 km /h r ) a n d t h e t h r ot t le is be cor r ect ed befor e pr oceedin g. Refer t o t h e In st r u -
closed, t h e P CM on NGC veh icles ca u ses t h e t r a n s- m en t Clu st er for speedom et er dia gn osis.
a xle t o down sh ift t o TH IRD gea r. Aft er down sh ift in g, If a r oa d t est ver ifies a n in oper a t ive syst em , a n d
t h e a u t om a t ic speed con t r ol r esu m es n or m a l oper a - t h e speedom et er oper a t es pr oper ly, ch eck for :
t ion . To en su r e t h a t a n u psh ift is a ppr opr ia t e a ft er • A Dia gn ost ic Tr ou ble Code (DTC). If a DTC
t h e set speed is r ea ch ed, t h e P CM on NGC veh icles exist s, con du ct t est s per t h e P ower t r a in Dia gn ost ic
wa it s u n t il t h e speed con t r ol syst em open s t h e t h r ot - P r ocedu r es m a n u a l.
t le a t lea st 6 degr ees befor e u psh ift in g t o OVE R- • A m isa dju st ed br a ke (st op) la m p swit ch . Th is
DRIVE a ga in . cou ld a lso ca u se a n in t er m it t en t pr oblem .
If t h e dr iver a pplies t h e br a kes, ca n celin g a u t o- • Loose or cor r oded elect r ica l con n ect ion s a t t h e
m a t ic speed con t r ol oper a t ion wit h t h e t r a n sa xle st ill ser vo. Cor r osion sh ou ld be r em oved fr om elect r ica l
in TH IRD gea r, t h e P CM on NGC veh icles m a in t a in s t er m in a ls a n d a ligh t coa t in g of Mopa r Mu lt ipu r pose
t h is gea r u n t il t h e dr iver open s t h e t h r ot t le a t lea st 6 Gr ea se, or equ iva len t , a pplied.
degr ees t o a void a n in a ppr opr ia t e u psh ift . Th e • Lea kin g va cu u m r eser voir.
u psh ift is a lso dela yed for 2.5 secon ds a ft er r ea ch in g • Loose or lea kin g va cu u m h oses or con n ect ion s.
t h e 6 degr ees t h r ot t le open in g in a n t icipa t ion t h a t • Defect ive on e-wa y va cu u m ch eck va lve.
t h e dr iver m igh t open t h e t h r ot t le en ou gh t o r equ ir e • Secu r e a t t a ch m en t a t bot h en ds of t h e speed
TH IRD gea r. Th is will a void u n n ecessa r y a n d discon t r ol ser vo ca ble.
t u r bin g t r a n sm ission cyclin g. If t h e a u t om a t ic speed • Sm oot h oper a t ion of t h r ot t le lin ka ge a n d t h r ot t le
con t r ol RE SUME fea t u r e is u sed a ft er br a kin g, t h e body a ir va lve.
u psh ift is dela yed u n t il t h e set speed is a ch ieved t o • Con du ct elect r ica l t est a t P CM.
r edu ce cyclin g a n d pr ovide bet t er r espon se. • F a iled speed con t r ol ser vo. Do t h e ser vo va cu u m
t est .
DIAGNOSIS AND TESTING - ROAD TEST
P er for m a veh icle r oa d t est t o ver ify r epor t s of CAUTION: When test probing for voltage or conti-
speed con t r ol syst em m a lfu n ct ion . Th e r oa d t est nuity at electrical connectors, care must be taken
sh ou ld in clu de a t t en t ion t o t h e speedom et er. Speed- not to damage connector, terminals or seals. If
om et er oper a t ion sh ou ld be sm oot h a n d wit h ou t flu t - these components are damaged, intermittent or
t er a t a ll speeds. complete system failure may occur.
SPECIFICATIONS - TORQUE

Servo Mounting Bracket 14 10.3 123.9
Nuts
Servo Mounting Bracket 14 10.3 123.9
Bolts
Servo Mounting Nuts 6.7 60
CABLE OPERATION
Th e P CM con t r ols t h e solen oid va lve body. Th e
DESCRIPTION solen oid va lve body con t r ols t h e a pplica t ion a n d
Th e speed con t r ol ser vo ca ble is con n ect ed bet ween r elea se of va cu u m t o t h e dia ph r a gm of t h e va cu u m
t h e speed con t r ol va cu u m ser vo dia ph r a gm a n d t h e ser vo. Th e ser vo u n it ca n n ot be r epa ir ed a n d is ser-
t h r ot t le body con t r ol lin ka ge. viced on ly a s a com plet e a ssem bly.
P ower is su pplied t o t h e ser vo by t h e P CM t h r ou gh
OPERATION t h e br a ke swit ch . Th e P CM con t r ols t h e gr ou n d pa t h
Th is ca ble ca u ses t h e t h r ot t le con t r ol lin ka ge t o for t h e va cu u m a n d ven t solen oids.
open or close t h e t h r ot t le va lve in r espon se t o m ove- Th e du m p solen oid is en er gized a n yt im e it r eceives
m en t of t h e va cu u m ser vo dia ph r a gm . power. If power t o t h e du m p solen oid is in t er r u pt ed,
t h e solen oid du m ps va cu u m in t h e ser vo. Th is pr o-
REMOVAL vides a sa fet y ba cku p t o t h e ven t a n d va cu u m sole-
(1) Discon n ect t h e n ega t ive ba t t er y ca ble. n oids.
(2) Rem ove speed con t r ol ca ble fr om t h r ot t le ca m Th e va cu u m a n d ven t solen oids m u st be gr ou n ded
by slidin g cla sp ou t h ole u sed for t h r ot t le ca ble. by t h e P CM t o oper a t e. Wh en t h e P CM gr ou n ds t h e
(3) Com pr ess t h e r et a in in g t a bs on t h e ca ble a n d va cu u m ser vo solen oid, t h e solen oid a llows va cu u m
slide ca ble ou t of br a cket . t o en t er t h e ser vo a n d pu ll open t h e t h r ot t le pla t e
(4) Discon n ect elect r ica l con n ect or s a n d va cu u m u sin g t h e ca ble. Wh en t h e P CM br ea ks t h e gr ou n d,
h ose fr om ser vo. t h e solen oid closes a n d n o m or e va cu u m is a llowed t o
(5) Rem ove t wo n u t s a t t a ch in g speed con t r ol ca ble en t er t h e ser vo. Th e P CM a lso oper a t es t h e ven t sole-
a n d m ou n t in g br a cket t o ser vo. n oid via gr ou n d. Th e ven t solen oid open s a n d closes a
(6) P u ll ca ble a wa y fr om ser vo t o expose r et a in in g pa ssa ge t o bleed or h old va cu u m in t h e ser vo a s
clip a n d r em ove clip a t t a ch in g ca ble t o ser vo. r equ ir ed.
(7) Rem ove speed con t r ol ca ble. Th e P CM cycles t h e va cu u m a n d ven t solen oids t o
m a in t a in t h e set speed, or t o a cceler a t e a n d deceler-
a t e t h e veh icle. To in cr ea se t h r ot t le open in g, t h e
INSTALLATION
P CM gr ou n ds t h e va cu u m a n d ven t solen oids. To
(1) Slide ca ble in t o t h r ot t le ca ble br a cket a n d
decr ea se t h r ot t le open in g, t h e P CM r em oves t h e
en ga ge r et a in in g t a bs.
gr ou n ds fr om t h e va cu u m a n d ven t solen oids.
(2) Rot a t e t h e t h r ot t le ca m for wa r d t o t h e wide
open posit ion a n d in st a ll speed con t r ol ca ble cla sp.
(3) Rot a t e t h e t h r ot t le ca m for wa r d t o t h e wide
REMOVAL
open posit ion a n d in st a ll t h r ot t le ca ble cla sp.
(4) In st a ll r et a in in g clip t h a t a t t a ch es ca ble t o (2) Discon n ect t h e n ega t ive ba t t er y ca ble.
(3) Discon n ect t h e t h r ot t le a n d speed con t r ol ca ble
ser vo.
en ds fr om t h r ot t le body (F ig. 2).
(5) In ser t ser vo st u ds t h r ou gh h oles in t h e m ou n t -
(4) Depr ess lock t a bs h oldin g speed con t r ol a n d
in g br a cket a n d speed con t r ol ca ble.
(6) In st a ll n u t s, t igh t en t o 6.7 N·m (60 in . lbs.). t h r ot t le ca ble ca sin g t o ca ble m ou n t br a cket .
(5) Discon n ect va cu u m lin e fr om speed con t r ol
(7) Con n ect va cu u m h ose t o ser vo.
ser vo t h a t lea ds t o t h e ba t t er y t r a y/va cu u m r eser voir.
(8) Con n ect elect r ica l con n ect or.
(6) Rem ove ba t t er y t r a y/va cu u m r eser voir, r efer t o
(9) In st a ll ser vo a n d br a cket a n d t igh t en n u t s a n d
t h e Ba t t er y sect ion for m or e in for m a t ion (F ig. 3).
bolt .
(10) Con n ect n ega t ive ba t t er y ca ble. (7) Rem ove speed con t r ol ser vo a n d br a cket (F ig.
4).
(8) Discon n ect wir e con n ect or fr om speed con t r ol
SERV O ser vo.
(9) Rem ove speed con t r ol ser vo.
DESCRIPTION
Th e ser vo u n it con sist s of a solen oid va lve body, INSTALLATION
a n d a va cu u m ch a m ber. Th e solen oid va lve body con - Tr a n sfer speed con t r ol ca ble t o r epla cem en t speed
t a in s t h r ee solen oids: con t r ol ser vo.
• Va cu u m (1) In st a ll r et a in in g clip t o ca ble a t ser vo.
• Ven t (2) In st a ll 2 n u t s a t ca ble t o ser vo a n d ser vo
• Du m p br a cket , t igh t en t o 7 N·m (60 in s. lbs.).
Th e va cu u m ch a m ber con t a in s a dia ph r a gm wit h a (3) Con n ect elect r ica l con n ect or t o ser vo.
ca ble a t t a ch ed t o con t r ol t h e t h r ot t le lin ka ge.
SERV O (Cont inue d)
Fig. 2 Speed Control Cable End Fig. 4 SPEED CONTROL SERVO

1 - SPEED CONTROL VACUUM HOSE
2 - THROTTLE BODY SWI T CH
3 - SPEED CONTROL CABLE
DESCRIPTION
Th er e a r e t wo sepa r a t e swit ch pods t h a t oper a t e
t h e speed con t r ol syst em a n d a r e loca t ed on t h e
st eer in g wh eel.
OPERATION
Th e speed con t r ol syst em h a s five sepa r a t e r esis-
t ive swit ch es t h a t pr ovide a sin gle m u lt iplexed
(MUX) volt a ge in pu t s t o t h e P CM.Th e swit ch n a m es
a r e: ON, OF F, SE T, COAST, RE SUME , ACCE L, TAP -
UP, COAST, a n d CANCE L. Ba sed on con dit ion s wh en
t h e bu t t on s a r e pu sh ed (a n d r elea sed), t h e five volt -
a ge r a n ges pr ovided t o t h e P CM r esu lt in t h e follow-
in g fu n ct ion s: ON, OF F, SE T, COAST, RE SUME ,
ACCE L, TAP -UP, TAP -DOWN, COAST, a n d CAN-
CE L. Refer t o t h e Speed Con t r ol Sect ion for m or e
in for m a t ion
Also t h e P CM r eceives a n in pu t fr om t h e br a ke
swit ch t o sen se wh et h er t h e br a ke peda l h a s been
depr essed. Wh en t h e P CM r eceives t h e br a ke
Fig. 3 BATTERY TRAY/VACUUM RESERVOIR
depr essed in pu t , it t u r n s off power t o t h e speed con -
(4) Con n ect va cu u m lin e t o speed con t r ol ser vo t r ol ser vo a n d disen ga ges speed con t r ol. Also t h e
t h a t lea ds t o t h e ba t t er y t r a y/va cu u m r eser voir. power t o t h e ser vo is su pplied t h r ou gh t h e br a ke
(5) In st a ll speed con t r ol ser vo a n d br a cket . swit ch , wh ich open s t h e cir cu it wh en t h e br a ke peda l
(6) In st a ll ba t t er y t r a y/va cu u m r eser voir, r efer t o is depr essed.
t h e Ba t t er y sect ion for m or e in for m a t ion . Th e in dividu a l swit ch es ca n n ot be r epa ir ed. If on e
(7) In st a ll speed con t r ol a n d t h r ot t le ca ble ca sin g swit ch fa ils, t h e en t ir e swit ch m odu le m u st be
t o ca ble m ou n t br a cket . r epla ced.
(8) Con n ect t h e t h r ot t le a n d speed con t r ol ca ble
en ds t o t h r ot t le body. REMOVAL
(9) Con n ect t h e n ega t ive ba t t er y ca ble. Th e speed con t r ol swit ch es a r e m ou n t ed in t h e
st eer in g wh eel a n d wir ed t h r ou gh t h e clock spr in g
device u n der t h e a ir ba g m odu le.
SWI T CH (Cont inue d)
WARNING: IF REMOVAL OF AIRBAG MODULE IS OPERATION
NECESSARY, REFER TO THE RESTRAINT SYS- Th e r eser voir st or es en gin e va cu u m . Ma n ifold va c-
TEMS SECTION FOR MORE INFORMATION. u u m is su pplied fr om t h e br a ke boost er ch eck va lve.
Th e speed con t r ol va cu u m su pply h ose h a s a ch eck
(1) Rem ove t h e n ega t ive ba t t er y ca ble.
va lve a t t h e sou r ce (br a ke boost er ) t o m a in t a in t h e
(2) Tu r n off ign it ion . h igh est a va ila ble va cu u m level in t h e ser vo, r eser voir
(3) Rem ove t h e a ir ba g, r efer t o t h e r est r a in t sec-
a n d va cu u m h oses. Wh en en gin e va cu u m dr ops, a s in
clim bin g a gr a de wh ile dr ivin g, t h e r eser voir su pplies
(4) Rem ove t h e scr ew fr om bot t om of t h e swit ch .
t h e va cu u m n eeded t o m a in t a in pr oper speed con t r ol
(5) Rem ove swit ch fr om st eer in g wh eel.
oper a t ion . Th e va cu u m r eser voir ca n n ot be r epa ir ed
(6) Discon n ect t wo-wa y elect r ica l con n ect or.
a n d m u st be r epla ced if fa u lt y.
(7) Repea t for t h e ot h er swit ch .
REMOVAL
INSTALLATION (1) Relea se h ood la t ch a n d open h ood.
Th e speed con t r ol swit ch es a r e m ou n t ed in t h e
st eer in g wh eel a n d wir ed t h r ou gh t h e clock spr in g
(3) Discon n ect t h e va cu u m lin e t o t h e ba t t er y t r a y/
device u n der t h e a ir ba g m odu le.
va cu u m r eser voir.
WARNING: IF REMOVAL OF AIRBAG MODULE IS (4) Rem ove ba t t er y t r a y/va cu u m r eser voir, r efer t o
NECESSARY, REFER TO THE RESTRAINT SYS- t h e Ba t t er y sect ion for m or e in for m a t ion .
TEMS SECTION FOR MORE INFORMATION.
INSTALLATION
(1) Con n ect t wo-wa y elect r ica l con n ect or. (1) In st a ll ba t t er y t r a y/va cu u m r eser voir, r efer t o
(2) In st a ll swit ch . t h e Ba t t er y sect ion for m or e in for m a t ion .
(3) In st a ll scr ew for t h e swit ch . (2) Con n ect va cu u m lin e t h a t lea ds t o t h e ba t t er y
(4) Repea t for t h e ot h er swit ch . t r a y/va cu u m r eser voir.
(5) In st a ll t h e a ir ba g, r efer t o t h e r est r a in t sect ion (3) Con n ect t h e n ega t ive ba t t er y ca ble.
(6) In st a ll t h e n ega t ive ba t t er y ca ble.
VACU U M RESERV OI R
DESCRIPTION
Th e va cu u m r eser voir is loca t ed in t h e en gin e com -
pa r t m en t . It is m a de of pla st ic.
RS VEHICLE THEFT SECURITY 8Q - 1
VEHICLE THEFT SECURITY

page page
VEHICLE THEFT SECURITY OPERATION . . . . . . . . . . . . . . . . . . . . . . . . ....4

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . ....1 DIAGNOSIS AND TESTING - SENTRY KEY
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . ....1 REMOTE ENTRY MODULE . . . . . . . . . . . ....5
DIAGNOSIS AND TESTING REMOVAL ......................... ....6
DIAGNOSIS AND TESTING - SENTRY KEY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . ....6
REMOTE ENTRY SYSTEM . . . . . . . . . . . ....3 TRANSPONDER KEY
DIAGNOSIS AND TESTING - VEHICLE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . ....6
THEFT SECURITY SYSTEM . . . . . . . . . . ....3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . ....6
HOOD AJAR SWITCH - EXPORT STANDARD PROCEDURE - TRANSPONDER
REMOVAL ......................... ....3 PROGRAMMING . . . . . . . . . . . . . . . . . . . ....6
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . ....3 VTSS/SKIS INDICATOR LAMP
SENTRY KEY REMOTE ENTRY MODULE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . ....8
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . ....3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . ....8
V EH I CLE T H EFT SECU RI T Y OPERATION
DESCRIPTION VEHICLE THEFT SECURITY SYSTEM

Upon fa ilu r e of pr oper Sen t r y Key Rem ot e E n t r y
VEHICLE THEFT SECURITY SYSTEM Modu le (SKRE E M) com m u n ica t ion t o t h e P CM, t h e
Th e Veh icle Th eft Secu r it y Syst em (VTSS) is P CM will sh u t off fu el a ft er t wo secon ds of r u n t im e.
design ed t o pr ot ect a ga in st wh ole veh icle t h eft . Th e Th e en gin e will n ot r e-cr a n k on t h e key cycle t h a t
syst em m on it or s veh icle door s, a n d ign it ion a ct ion for t h e fa ilu r e occu r r ed, a fu ll key down sequ en ce m u st
u n a u t h or ized oper a t ion (h ood a n d lift ga t e for RG - be per for m ed for t h e en gin e t o cr a n k a ga in . Aft er six
E xpor t ). Th e a la r m a ct iva t es: con secu t ive fu el sh u t -offs, t h e en gin e will n o lon ger
• Sou n din g of t h e h or n cr a n k on su bsequ en t key cycles. Th e fa ilu r e m u st be
• F la sh in g of t h e h ea dla m ps/pa r k/t a il la m ps cor r ect ed a n d a va lid com m u n ica t ion pr ocess bet ween
• F la sh in g of t h e h ea dla m ps t h e SKRE E M a n d t h e P CM m u st occu r for t h e
• An en gin e kill fea t u r e (wit h SKRE E S) en gin e t o cr a n k a n d st a r t a ga in .
Th e elect r on ics for t h e VTSS a r e pa r t of t h e Body
SENTRY KEY REMOTE ENTRY SYSTEM Con t r ol Modu le (BCM). Th e syst em is a r m ed wh en
Th e Sen t r y Key Rem ot e E n t r y Syst em (SKRE E S) t h e veh icle is locked u sin g t h e:
is a va ila ble a s a fa ct or y-in st a lled opt ion on t h is veh i- • P ower door lock swit ch es (wit h a n y door a ja r )
cle. It is design ed t o pr ovide pa ssive pr ot ect ion • Rem ot e Keyless E n t r y in t egr a t ed key.
a ga in st u n a u t h or ized veh icle u se by disa blin g t h e • Door Cylin der Lock Swit ch es (RG on ly).
en gin e, a ft er t wo (2) secon ds of r u n n in g, wh en ever a n F or veh icles equ ipped wit h Sen t r y Key Rem ot e
in va lid key is u sed t o st a r t t h e veh icle. Th e SKIS is E n t r y Syst em (SKRE E S), t h e door s do n ot h a ve t o be
a ct ive wh en ever t h e ign it ion is on a n d does n ot locked t o en a ble t h e fu el sh u t off fea t u r e.
r equ ir e a n y cu st om er in t er ven t ion . Th e pr im a r y com - Aft er t h e veh icle is locked a n d t h e la st door is
pon en t s of t h e syst em a r e t h e Sen t r y Key Rem ot e closed, t h e set LE D in dica t or in t h e Mech a n ica l
E n t r y Modu le (SKRE E M), Sen t r y Key (in t egr a t ed In st r u m en t Clu st er (MIC) will fla sh qu ickly for 16
key wit h t r a n pon der a n d RKE on a cir cu it boa r d), secon ds, in dica t in g t h a t a r m in g is in pr ogr ess. If n o
in dica t or ligh t , Body Con t r ol Modu le (BCM), a n d t h e m on it or ed syst em s a r e a ct iva t ed du r in g t h is per iod,
P ower t r a in Con t r ol Modu le (P CM). Th e SKRE E M is t h e syst em will a r m . Th e LE D will ext in gu ish u n less
m ou n t ed t o t h e st eer in g colu m n wit h t h e m olded, t h e lift ga t e is open . If t h e lift ga t e is open , t h e LE D
in t egr a l a n t en n a m ou n t ed on t h e ign it ion h ou sin g. will fla sh a t a slower r a t e. Th is in dica t es t h a t t h e
Th e in dica t or ligh t , is loca t ed in t h e Mech a n ica l syst em is a r m ed.
In st r u m en t Clu st er (MIC).
8Q - 2 VEHICLE THEFT SECURITY RS
V EH I CLE T H EFT SECU RI T Y (Cont inue d)
RG On ly - If fa u lt is det ect ed on t h e dr iver key (3) Aft er t h e la st door is closed, a n a r m in g t im e-
cylin der in pu t , t h e in dica t or LE D will r em a in solid ou t per iod of sixt een secon ds will st a r t , t h en t h e
du r in g t h e a r m in g pr ocess, a lt h ou gh t h e syst em will VTSS will becom e a r m ed.
st ill a r m .
If t h e in dica t or LE D does n ot illu m in a t e a t a ll ARMING THE VTSS - METHOD B
u pon door closin g it in dica t es t h a t t h e syst em is n ot Act u a t in g t h e key fob t r a n sm it t er LOCK bu t t on ,
a r m in g. key lockin g t h e fr on t door s wit h t h e door s closed a n d
P a ssive disa r m in g occu r s u pon n or m a l veh icle t h e ign it ion locked will begin t h e a r m in g t im e-ou t
en t r y by u n lockin g eit h er door wit h t h e r em ot e t r a n s- per iod. If m et h od A, 16 secon d t im e-ou t sequ en ce wa s
m it t er (RG - ign it ion key or r em ot e t r a n sm it t er ). Th is in pr ocess wh en m et h od B wa s a ct u a t ed, t h e 16 sec-
disa r m in g will a lso h a lt t h e a la r m on ce it h a s been on d t im e-ou t will r est a r t fr om t h e t im e of t h e secon d
a ct iva t ed. a ct u a t ion .
A t a m per a ler t exist s t o n ot ify t h e dr iver t h a t t h e If t h e secu r it y la m p does n ot illu m in a t e a t a ll u pon
VTSS h a d been a ct iva t ed. Th is a ler t con sist s of 3 fin a l door closu r e, it in dica t es t h a t t h e syst em is n ot
h or n pu lses wh en t h e veh icle is disa r m ed. a r m in g.
Th e cu r r en t VTSS st a t u s a r m ed or disa r m ed sh a ll
NOTE: The VTSS will not arm by pushing down the be m a in t a in ed in m em or y t o pr even t ba t t er y discon -
door lock mechanism. This will manually override n ect s fr om disa r m in g t h e syst em .
the system.
TRIGGERING THE VTSS
RG On ly - F or Door Cylin der Lock Swit ch Aft er t h e VTSS is a r m ed, t h e followin g a ct ion s will
Rem ova l a n d In st a lla t ion , r efer t o E lect r ica l, P ower t r igger t h e a la r m :
Locks, Door Cylin der Lock Swit ch . • Open in g a n y door (lift ga t e - on ly if open in g via
If t h e VTSS is t r igger ed, t h e h or n will pu lse, h ea d- lift ga t e bu t t on on key fob).
la m ps/m a r ker la m ps will fla sh , a n d t h e VTSS wa r n - • Open in g t h e h ood (RG - E xpor t )
in g la m p will fla sh . If BCM det er m in es t h e t h r ea t t o • Tu r n in g t h e ign it ion t o t h e RUN posit ion .
be fa lse a n d t h e VTSS is n ot t r igger ed a ga in , t h e sys-
t em will sh u t down a n d r ea r m it self a ft er t h r ee m in - NOTE: When the VTSS is ARMED, the interior
u t es. If a t r igger is st ill a ct ive, t h e a la r m will power door lock switch “UNLOCK” will be disabled
con t in u e for a n a ddit ion a l 15 m in u t es wit h ou t t h e until the vehicle is disarmed.
h or n . Th e VTSS m on it or s t h e pa ssen ger com pa r t -
m en t (for RG - E xpor t it a lso m on it or s t h e en gin e
com pa r t m en t . If a m a lfu n ct ion occu r s in t h e en gin e CAUTION: The VTSS indicator LED will trigger and
com pa r t m en t , t h e pa ssen ger com pa r t m en t wou ld st ill engine will continue to run if the vehicle is
a r m a n d fu n ct ion n or m a lly). equipped with SKREES and the proper key is used
to start the vehicle. This condition will occur if the
NOTE: System will not arm if passenger compart- VTSS has been triggered. If valid key is used, VTSS
ment is not secure. will disarm
NOTE: (RG - Export - If hood is not secure during SENTRY KEY REMOTE ENTRY SYSTEM
the arming sequence, the lamp will stay lit and not Th e SKRE E S in clu des keys fr om t h e fa ct or y wh ich
flash. The system will arm with hood not secured a r e pr e-pr ogr a m m ed. E a ch SKRE E M will r ecogn ize a
and the liftgate open). m a xim u m of eigh t Sen t r y Keys. If t h e cu st om er
wou ld like t o own a ddit ion a l keys ot h er t h a n t h ose
pr ovided wit h t h e veh icle, t h ey ca n be pu r ch a sed
ARMING THE VTSS - METHOD A fr om a n y a u t h or ized dea ler. Th ese keys m u st be pr o-
(1) Wit h t h e key r em oved fr om t h e ign it ion lock gr a m m ed t o t h e SKRE E M on t h e veh icle in or der for
a n d a n y door open (exclu din g lift ga t e), a ct u a t e on e of t h e syst em t o r ecogn ize t h em a s va lid keys. Th is ca n
t h e followin g: be don e by t h e dea ler wit h a DRBlll! sca n t ool or by
• P ower door lock bu t t on t o LOCK, a cu st om er if t h is fea t u r e is a va ila ble in t h eir m a r ket
• Key fob LOCK bu t t on a n d t h ey h a ve t wo (2) va lid keys a lr ea dy a va ila ble t o
• Dr iver door lock key cylin der t o locked posit ion t h em . Refer t o t h e Ser vice P r ocedu r es por t ion of t h is
(RG On ly). syst em for a ddit ion a l det a ils. Th e SKRE E S per for m s
(2) Close a ll open ed door s. Lift ga t e ca n r em a in a self-t est ea ch t im e t h e ign it ion swit ch is t u r n ed t o
open . t h e ON posit ion a n d will st or e Dia gn ost ic Tr ou ble
Codes (DTC’s) if a syst em m a lfu n ct ion is det ect ed.
V EH I CLE T H EFT SECU RI T Y (Cont inue d)
Th e SKRE E S ca n be dia gn osed a n d a n y st or ed DTC’s com plet e t h e dia gn osis of t h e SKRE E S. If n ot OK,
ca n be r et r ieved u sin g a DRBlll! sca n t ool a s r epa ir t h e open cir cu it t o t h e fu se in t h e IP M a s
descr ibed in t h e a ppr opr ia t e Body Dia gn ost ic P r oce- r equ ir ed.
du r es in for m a t ion .
DIAGNOSIS AND TESTING - VEHICLE THEFT
DI AGN OSI S AN D T EST I N G SECURITY SYSTEM
Refer t o t h e a ppr opr ia t e wir in g in for m a t ion . Th e
wir in g in for m a t ion in clu des wir in g dia gr a m s, pr oper
DIAGNOSIS AND TESTING - SENTRY KEY
wir e a n d con n ect or r epa ir pr ocedu r es, fu r t h er det a ils
REMOTE ENTRY SYSTEM on wir e h a r n ess r ou t in g a n d r et en t ion , a s well a s
pin -ou t a n d loca t ion views for t h e va r iou s wir e h a r-
WARNING: On vehicles equipped with airbags, refer
n ess con n ect or s, splices a n d gr ou n ds. Usin g a
to electrical, restraints, warnings, before attempting
DRBIII! sca n t ool. Refer t o t h e pr oper Body Dia gn os-
component diagnosis or service. Failure to take the
t ic P r ocedu r es in for m a t ion for t est pr ocedu r es.
proper precautions could result in accidental airbag
deployment and possible personal injury or death.
H OOD AJ AR SWI T CH -
NOTE: The following tests may not prove conclu- EX PORT
sive in the diagnosis of this system. The most reli-
able, efficient, and accurate means to diagnose the REMOVAL
Sentry Key Remote Entry System (SKREES) (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
involves the use of a DRBIII" scan tool. Refer to the ca ble.
proper Body Diagnostic Procedures information. (2) Usin g a sm a ll fla t bla de scr ewdr iver, pr y t r ig-
ger swit ch fr om t h e br a cket on t h e left fen der well.
Th e Sen t r y Key Rem ot e E n t r y Syst em (SKRE E S) (3) Discon n ect t h e h ood a ja r swit ch fr om t h e wir e
a n d t h e P r ogr a m m a ble Com m u n ica t ion In t er fa ce con n ect or a n d r em ove fr om veh icle.
(P CI) bu s n et wor k sh ou ld be dia gn osed u sin g a sca n
t ool. Th e sca n t ool will a llow con fir m a t ion t h a t t h e INSTALLATION
P CI bu s is fu n ct ion a l, t h a t t h e Sen t r y Key Rem ot e (1) Con n ect t h e h ood a ja r swit ch t o t h e wir e con ec-
E n t r y Modu le (SKRE E M) is pla cin g t h e pr oper m es- t or.
sa ges on t h e P CI bu s, a n d t h a t t h e P ower t r a in Con - (2) P r ess t h e h ood a ja r swit ch in t o posit ion on t h e
t r ol Modu le (P CM) is r eceivin g t h e P CI bu s br a cket loca t ed on t h e left in n er fen der well.
m essa ges. Refer t o t h e pr oper Body Dia gn ost ic P r oce- (3) Recon n ect t h e ba t t er y n ega t ive ca ble.
du r es in for m a t ion , a n d Wir in g Dia gr a m s for com plet e (4) Close t h e h ood a n d ch eck for pr oper oper a t ion .
cir cu it descr ipt ion s a n d dia gr a m s.
(1) Ch eck t h e fu ses in t h e In t egr a t ed P ower Mod-
u le (IP M). If OK, go t o St ep 2. If n ot OK, r epa ir t h e SEN T RY K EY REM OT E EN T RY
sh or t ed cir cu it or com pon en t a s r equ ir ed a n d r epla ce
t h e fa u lt y fu se. M ODU LE
r em ot e ca ble fr om t h e r em ot e t er m in a l. Un plu g t h e DESCRIPTION
wir e h a r n ess con n ect or a t t h e SKRE E M. Ch eck for Th e Sen t r y Key Rem ot e E n t r y Modu le (SKRE E M)
con t in u it y bet ween t h e gr ou n d cir cu it ca vit y of t h e per for m s t h e fu n ct ion s of t h e Sen t r y Key Im m obilizer
SKRE E M wir e h a r n ess con n ect or a n d a good gr ou n d. Modu le (SKIM), Rem ot e Keyless E n t r y (RKE ) Mod-
Th er e sh ou ld be con t in u it y. If OK, go t o St ep 3. If n ot u le, a n d t h e Tir e P r essu r e Mon it or in g (TP M) Syst em
OK, r epa ir t h e open cir cu it t o gr ou n d a s r equ ir ed. (pr eviou sly pa r t of t h e E lect r on ic Veh icle In for m a t ion
(3) Con n ect t h e ba t t er y n ega t ive ca ble. Ch eck for Cen t er (E VIC).
ba t t er y volt a ge a t t h e fu sed B(+) cir cu it ca vit y of t h e Th e SKRE E M is loca t ed in t h e sa m e loca t ion a s
SKRE E M wir e h a r n ess con n ect or. If OK, go t o St ep t h e SKIM wa s a n d is m ou n t ed t h e sa m e wa y. It looks
4. If n ot OK, r epa ir t h e open cir cu it t o t h e fu se in t h e iden t ica l, bu t h a s a dded ca pa bilit ies.
IP M a s r equ ir ed.
(4) Tu r n t h e ign it ion swit ch t o t h e ON posit ion . SENTRY KEY IMMOBILIZER
Ch eck for ba t t er y volt a ge a t t h e fu sed ign it ion swit ch Th e Sen t r y Key Im m obilizer Syst em (SKIS)
ou t pu t (r u n /st a r t ) cir cu it ca vit y of t h e SKRE E M wir e a u t h en t ica t es a n elect r on ica lly coded Tr a n spon der
h a r n ess con n ect or. If OK, u se a sca n t ool a n d t h e Key pla ced in t o t h e ign it ion a n d sen ds a va lid/in va lid
pr oper Body Dia gn ost ic P r ocedu r es in for m a t ion t o key m essa ge t o t h e P ower t r a in Con t r ol Modu le
SEN T RY K EY REM OT E EN T RY M ODU LE (Cont inue d)
(P CM) ba sed u pon t h e r esu lt s. Th e “VALID/INVALID on t h e t r a n sm it t er, it sen ds a specific r equ est t o t h e
KE Y” m essa ge com m u n ica t ion is per for m ed u sin g a SKRE E M. In t u r n t h e SKRE E M sen ds t h e a ppr opr i-
r ollin g code a lgor it h m via t h e P r ogr a m m a ble Com - a t e r equ est over t h e P CI Bu s t o t h e:
m u n ica t ion In t er fa ce (P CI) da t a bu s. A “VALID KE Y” • Body Con t r ol Modu le (BCM) t o con t r ol t h e door
m essa ge m u st be sen t t o t h e P ower t r a in Con t r ol lock a n d u n lock fu n ct ion s, t h e lift ga t e lock a n d
Modu le (P CM) wit h in t wo secon ds of ign it ion ON t o u n lock fu n ct ion s, t h e a r m in g a n d disa r m in g of t h e
fr ee t h e en gin e fr om im m obiliza t ion . Veh icle Th eft Secu r it y Syst em (VTSS) (if equ ipped),
Th e SKRE E M con t a in s a Ra dio F r equ en cy (RF ) a n d t h e a ct iva t ion of illu m in a t ed en t r y.
t r a n sceiver a n d a m icr opr ocessor. Th e SKRE E M • In t egr a t ed P ower Modu le (IP M) t o a ct iva t e t h e
r et a in s in m em or y t h e ID n u m ber s of a n y Sen t r y Key pa r k la m ps, t h e h ea dla m ps, a n d t h e h or n for h or n
t h a t is pr ogr a m m ed t o it . Th e m a xim u m n u m ber of ch ir p. If r equ est ed, t h e BCM sen ds a r equ est over
keys t h a t m a y be pr ogr a m m ed t o ea ch m odu le is t h e P CI Bu s t o t h e:
eigh t (8). Th e SKRE E M a lso com m u n ica t es over t h e
P r ogr a m m a ble Com m u n ica t ion In t er fa ce (P CI) da t a TIRE PRESSURE MONITORING (TPM)
bu s wit h t h e P ower t r a in Con t r ol Modu le (P CM), t h e If equ ipped wit h t h e Tir e P r essu r e Mon it or in g
Body Con t r ol Modu le (BCM), t h e Mech a n ica l In st r u - (TP M) Syst em , ea ch of t h e veh icles fou r wh eels will
m en t Clu st er (MIC), a n d t h e DRB III! sca n t ool. Th e h a ve a va lve st em wit h a pr essu r e sen sor a n d r a dio
SKRE E M t r a n sm it s a n d r eceives RF sign a ls t h r ou gh t r a n sm it t er bu ilt in . Sign a ls fr om t h e t ir e pr essu r e
a t u n ed a n t en n a en closed wit h in a m olded pla st ic sen sor /t r a n sm it t er a r e r eceived a n d in t er pr et ed by
r in g for m a t ion t h a t is in t egr a l t o t h e SKRE E M h ou s- t h e SKRE E M.
in g. Wh en t h e SKRE E M is pr oper ly in st a lled on t h e A sen sor /t r a n sm it t er in a m ou n t ed wh eel will
st eer in g colu m n , t h e a n t en n a r in g fit s sn u gly a r ou n d br oa dca st it s det ect ed pr essu r e on ce per m in u t e
t h e cir cu m fer en ce of t h e ign it ion lock cylin der h ou s- wh en t h e veh icle is m ovin g fa st er t h a n 15 m ph (24
in g. If t h is r in g is n ot m ou n t ed pr oper ly, com m u n ica - km /h ). E a ch sen sor /t r a n sm it t er ’s br oa dca st is
t ion pr oblem s m a y a r ise in t h e for m of t r a n spon der- u n iqu ely coded so t h a t t h e SKRE E M ca n det er m in e
r ela t ed fa u lt s. t h e loca t ion .
F or a dded syst em secu r it y, ea ch SKRE E M is pr o-
gr a m m ed wit h a u n iqu e %Secr et Key% code. Th is code OPERATION
is st or ed in m em or y a n d is sen t over t h e P CI bu s t o
t h e P CM a n d t o ea ch key t h a t is pr ogr a m m ed t o SENTRY KEY IMMOBILIZER
wor k wit h t h e veh icle. Th e %Secr et Key% code is t h er e- Th e Sen t r y Key Rem ot e E n t r y Modu le (SKRE E M)
for e a com m on elem en t fou n d in a ll com pon en t s of r eceives a n en cr ypt ed Ra dio F r equ en cy (RF ) sign a l
t h e Sen t r y Key Im m obilizer Syst em (SKIS). In t h e fr om t h e t r a n spon der key. Th e SKRE E M t h en
even t t h a t a SKRE E M r epla cem en t is r equ ir ed, t h e decr ypt s t h e sign a l a n d br oa dca st s t h e r equ est ed
%Secr et Key% code ca n be r est or ed fr om t h e P CM by r em ot e com m a n ds t o t h e a ppr opr ia t e m odu les in t h e
followin g t h e SKIM r epla cem en t pr ocedu r e fou n d in veh icle over t h e P r ogr a m m a ble Com m u n ica t ion
t h e DRB III! sca n t ool. P r oper com plet ion of t h is In t er fa ce (P CI) da t a bu s. A va lid t r a n spon der key ID
t a sk will a llow t h e exist in g ign it ion keys t o be r epr o- m u st be in cor por a t ed in t o t h e RF sign a l in or der for
gr a m m ed. Th er efor e, n ew keys will NOT be n eeded. t h e SKRE E M t o pa ss t h e m essa ge on t o t h e a ppr o-
In t h e even t t h a t t h e or igin a l %Secr et Key% code ca n pr ia t e m odu les.
n ot be r ecover ed, n ew ign it ion keys will be r equ ir ed. Au t om a t ic t r a n spon der key syn ch r on iza t ion is don e
Th e DRB III! sca n t ool will a ler t t h e t ech n icia n if by t h e SKRE E M if a va lid t r a n spon der key is
key r epla cem en t is n ecessa r y. An ot h er secu r it y code, in ser t ed in t o t h e ign it ion cylin der, a n d t h e ign it ion is
ca lled a P IN, is u sed t o ga in secu r ed a ccess t o t h e t u r n ed ON. Th is pr ovides a m a xim u m oper a t ion win -
SKRE E M for ser vice. Th e SKRE E M a lso st or es in it s dow for RKE fu n ct ion s.
m em or y t h e Veh icle Iden t ifica t ion Nu m ber (VIN), E a ch Sen t r y Key Rem ot e E n t r y Syst em (SKRE E S)
wh ich it lea r n s t h r ou gh a bu s m essa ge fr om t h e con sist s of a SKRE E M a n d a t r a n spon der key. E a ch
a ssem bly pla n t t est er. Th e SKIS scr a m bles t h e in for- syst em h a s a secr et key code u n iqu e t o t h a t syst em .
m a t ion t h a t is com m u n ica t ed bet ween it s com pon en t s Th e secr et key is elect r on ica lly coded in t h e
in or der t o r edu ce t h e possibilit y of u n a u t h or ized SKRE E M a n d in a ll pr ogr a m m ed t r a n spon der keys.
SKRE E M a ccess a n d/or disa blin g. It is u sed for im m obiliza t ion a n d RKE fu n ct ion s for
da t a secu r it y. In a ddit ion , ea ch t r a n spon der key will
REMOTE KEYLESS ENTRY (RKE) h a ve a u n iqu e iden t ifica t ion . F or Nor t h Am er ica , t h e
Th e RKE t r a n sm it t er u ses r a dio fr equ en cy sign a ls opt ion s a r e a 3-bu t t on or 6 bu t t on in t egr a t ed keys.
t o com m u n ica t e wit h t h e SKRE E M. Th e SKRE E M is F or E xpor t , t h e opt ion s a r e 2-bu t t on or 5 bu t t on key
on t h e P CI bu s. Wh en t h e oper a t or pr esses a bu t t on fobs. (E xpor t does n ot get t h e in t egr a t ed key).
Wh en t h e ign it ion swit ch is m oved t o t h e RUN Th e SKRE E M is ca pa ble of r et a in in g u p t o 8 in di-
posit ion , t h e SKRE E M t r a n sm it s a n Ra dio F r equ en cy vidu a l a ccess codes (8 t r a n sm it t er s). If t h e P RNDL is
(RF ) sign a l t o t h e t r a n spon der in t h e ign it ion key. in a n y posit ion except pa r k, t h e SKRE E M will dis-
Th e SKRE E M t h en wa it s for a r espon se RF sign a l a ble t h e RKE . Th e 4 bu t t on t r a n sm it t er u ses
fr om t h e t r a n spon der in t h e key. If t h e r espon se 1-CR2032 ba t t er y. Th e m in im u m ba t t er y life is
r eceived iden t ifies t h e key a s va lid, t h e SKRE E M a ppr oxim a t ely 4.7 yea r s ba sed on 20 t r a n sm ission s a
sen ds a %va lid key% m essa ge t o t h e P ower t r a in Con - da y a t 84°F (25°C). Use t h e DRBIII! sca n t ool or t h e
t r ol Modu le (P CM) over t h e P r ogr a m m a ble Com m u - Miller Tool 9001 RF Det ect or t o t est t h e RKE t r a n s-
n ica t ion In t er fa ce (P CI) da t a bu s. If t h e r espon se m it t er. Use t h e DRBIII! or t h e cu st om er pr ogr a m -
r eceived iden t ifies t h e key a s in va lid or n o r espon se m in g m et h od t o pr ogr a m t h e RKE syst em . H owever,
is r eceived fr om t h e t r a n spon der in t h e ign it ion key, t h e SKRE E M will on ly a llow RKE pr ogr a m m in g
t h e SKRE E M sen ds a n %in va lid key% m essa ge t o t h e wh en t h e ign it ion is in t h e ON posit ion , t h e P RNDL
P CM. Th e P CM will en a ble or disa ble en gin e oper a - is in pa r k posit ion , a n d t h e VTSS (if equ ipped) is dis-
t ion ba sed u pon t h e st a t u s of t h e SKRE E M m es- a r m ed.
sa ges. It is im por t a n t t o n ot e t h a t t h e defa u lt
con dit ion in t h e P CM is %in va lid key.% Th er efor e, if n o TIRE PRESSURE MONITORING (TPM)
r espon se is r eceived by t h e P CM, t h e en gin e will be Th e SKRE E M m on it or s t h e sign a ls fr om t h e t ir e
im m obilized a ft er t wo (2) secon ds of r u n n in g. pr essu r e sen sor /t r a n sm it t er s a n d det er m in es if a n y
Th e SKRE E M a lso sen ds in dica t or ligh t st a t u s t ir e h a s gon e below t h e low pr essu r e t h r esh old LOW
m essa ges t o t h e Mech a n ica l In st r u m en t Clu st er TIRE P RE SSURE TH RE SH OLDS t a ble.
(MIC) t o oper a t e t h e ligh t . Th is is t h e m et h od u sed t o
t u r n t h e ligh t ON solid or t o fla sh it a ft er t h e in di- LOW T I RE PRESSU RE T H RESH OLDS
ca t or ligh t t est is com plet e t o sign ify a fa u lt in t h e
SKRE E S. If t h e ligh t com es ON a n d st a ys ON solid SYSTEM STATUS
a ft er t h e in dica t or ligh t t est , t h is sign ifies t h a t t h e TIRE PRESSURE
INDICATOR
SKRE E M h a s det ect ed a syst em m a lfu n ct ion a n d/or
t h a t t h e SKRE E S h a s becom e in oper a t ive. If t h e ON 193 kPa (28 PSI)
SKRE E M det ect s a n in va lid key OR a key-r ela t ed OFF 227 kPa (33 PSI)
fa u lt exist s, t h e in dica t or ligh t will fla sh followin g
t h e in dica t or ligh t t est . Th e SKRE E M m a y a lso CRITICAL AND NON-CRITICAL SYSTEM ALERTS
r equ est a n a u dible ch im e if t h e cu st om er key pr o- CRITICAL: A cr it ica l a ler t will be t r igger ed wh en
gr a m m in g fea t u r e is a va ila ble a n d t h e pr ocedu r e is a t ir e pr essu r e h a s gon e below a set t h r esh old pr es-
bein g u t ilized (Refer t o 8 - E LE CTRICAL/VE H ICLE su r e. Th e E VIC displa y will displa y “X TIRE (S) LOW
TH E F T SE CURITY/TRANSP ONDE R KE Y - STAN- P RE SSURE ”. “X” will be t h e n u m ber of t ir es r epor t -
DARD P ROCE DURE ). in g low pr essu r e. Th e m essa ge will displa y for t h e
du r a t ion of t h e cu r r en t ign it ion cycle or u n t il a n
REMOTE KEYLESS ENTRY (RKE) E VIC bu t t on is pr essed. If t h e displa y is r em oved
Aft er pr essin g t h e lock bu t t on on t h e RKE t r a n s- wit h ou t cor r ect in g t h e con dit ion , it will r ea ppea r 300
m it t er, a ll of t h e door locks will lock, t h e illu m in a t ed secon ds t o wa r n t h e dr iver of t h e low pr essu r e con di-
en t r y will t u r n off (pr ovidin g a ll door s a r e closed), t ion .
a n d t h e VTSS (if equ ipped) will a r m . Aft er pr essin g N ON -CRITICAL: A n on -cr it ica l a ler t will be t r ig-
t h e u n lock bu t t on , on t h e RKE t r a n sm it t er, on e t im e, ger ed wh en n o sign a l is r eceived fr om a sen sor /t r a n s-
t h e dr iver door lock will u n lock, t h e illu m in a t ed m it t er. Th e E VIC displa y in t h e clu st er will displa y
en t r y will t u r n on t h e cou r t esy la m ps, a n d t h e VTSS “SE RVICE TIRE SYSTE M SOON.”
(if equ ipped) will disa r m . Aft er pr essin g t h e u n lock
bu t t on a secon d t im e, t h e r em a in in g door locks will DIAGNOSIS AND TESTING - SENTRY KEY
u n lock. Th e E lect r on ic Veh icle In for m a t ion Cen t er
(E VIC) or t h e DRBIII! sca n t ool ca n r epr ogr a m t h is REMOTE ENTRY MODULE
fea t u r e t o u n lock a ll of t h e door locks wit h on e pr ess F or pr oper dia gn osis a n d t est in g of t h e Sen t r y Key
of t h e u n lock bu t t on . If t h e veh icle is equ ipped wit h Rem ot e E n t r y Modu le (SKRE E M), u se a DRBlll! a n d
t h e m em or y syst em , t h e m em or y m essa ge will iden - r efer t o t h e pr oper Body Dia gn ost ic P r ocedu r es in for-
t ify wh ich t r a n sm it t er (1 or 2) sen t t h e sign a l. m a t ion .
REMOVAL OPERATION
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive E a ch Sen t r y Key h a s a u n iqu e t r a n spon der iden t i-
ca ble. fica t ion code per m a n en t ly pr ogr a m m ed in t o it by t h e
(2) Rem ove t h e St eer in g Colu m n Open in g Cover m a n u fa ct u r er. Likewise, t h e Sen t r y Key Rem ot e
(Refer t o 23 - BODY/INSTRUME NT PANE L/STE E R- E n t r y Modu le (SKRE E M) h a s a u n iqu e %Secr et Key%
ING COLUMN OP E NING COVE R - RE MOVAL). code pr ogr a m m ed in t o it by t h e m a n u fa ct u r er a s
(3) Rem ove t h e st eer in g colu m n u pper a n d lower well. Wh en a Sen t r y Key is pr ogr a m m ed in t o t h e
sh r ou ds (Refer t o 19 - STE E RING/COLUMN/UP P E R m em or y of t h e SKRE E M, t h e SKRE E M st or es t h e
SH ROUD - RE MOVAL) a n d (Refer t o 19 - STE E R- t r a n spon der iden t ifica t ion code fr om t h e Sen t r y Key,
ING/COLUMN/LOWE R SH ROUD - RE MOVAL). a n d t h e Sen t r y Key lea r n s t h e %Secr et Key% code fr om
(4) Disen ga ge t h e st eer in g colu m n wir e h a r n ess t h e SKRE E M. On ce t h e Sen t r y Key lea r n s t h e
fr om t h e Sen t r y Key Rem ot e E n t r y Modu le %Secr et Key% code of t h e SKRE E M, it is a lso per m a -
(SKRE E M). n en t ly pr ogr a m m ed in t o t h e t r a n spon der ’s m em or y.
(5) Rem ove t h e on e scr ews secu r in g t h e SKRE E M Th er efor e, bla n k keys for t h e Sen t r y Key Rem ot e
t o t h e st eer in g colu m n . E n t r y Syst em (SKRE E S) m u st be pr ogr a m m ed by
(6) Rot a t e t h e SKRE E M u pwa r ds a n d t h en t o t h e t h e SKRE E M in a ddit ion t o bein g cu t t o m a t ch t h e
side a wa y fr om t h e st eer in g colu m n t o slide t h e m ech a n ica l codin g of t h e ign it ion lock cylin der. Refer
SKRE E M a n t en n a r in g fr om a r ou n d t h e ign it ion t o E lect r ica l, Veh icle Th eft Secu r it y, Tr a n spon der
swit ch lock cylin der h ou sin g. Key, St a n da r d P r ocedu r e - Tr a n spon der P r ogr a m -
(7) Rem ove t h e SKRE E M fr om t h e veh icle. m in g.
Th e Sen t r y Key’s t r a n spon der is wit h in t h e r a n ge
INSTALLATION of t h e SKRE E M’s t r a n sceiver a n t en n a r in g wh en it is
(1) Slip t h e Sen t r y Key Rem ot e E n t r y Modu le in ser t ed in t o t h e ign it ion lock cylin der. Wh en t h e
(SKRE E M) a n t en n a r in g a r ou n d t h e ign it ion swit ch ign it ion swit ch is t u r n ed t o t h e ON posit ion , t h e
lock cylin der h ou sin g. Rot a t e t h e SKRE E M down - SKRE E M com m u n ica t es wit h t h e Sen t r y Key via a
wa r ds a n d t h en t owa r ds t h e st eer in g colu m n . r a dio fr equ en cy (RF ) sign a l. Th e SKRE E M det er-
(2) In st a ll t h e on e scr ews secu r in g t h e SKRE E M t o m in es if a va lid key is pr esen t ba sed on t h e in for m a -
t h e st eer in g colu m n . t ion it r eceives fr om t h e Sen t r y Key. If a va lid key is
(3) Con n ect t h e st eer in g colu m n wir e h a r n ess t o det ect ed, t h a t fa ct is com m u n ica t ed t o t h e P CM via
t h e SKRE E M. t h e P CI bu s a n d t h e veh icle is a llowed t o con t in u e
(4) In st a ll t h e st eer in g colu m n u pper a n d lower r u n n in g. If a n in va lid key is r eceived by t h e P CM or
sh r ou ds (Refer t o 19 - STE E RING/COLUMN/UP P E R n o st a t u s a t a ll is com m u n ica t ed, t h e veh icle will
SH ROUD - INSTALLATION) a n d (Refer t o 19 - st a ll a ft er t wo (2) secon ds of r u n n in g. Th e in dica t or
STE E RING/COLUMN/LOWE R SH ROUD - INSTAL- ligh t will be fla sh in g a t t h is poin t . Th e Sen t r y Key’s
LATION). t r a n spon der ca n n ot be r epa ir ed. If it is fa u lt y or
(5) In st a ll t h e St eer in g Colu m n Open in g Cover da m a ged, it m u st be r epla ced.
(Refer t o 23 - BODY/INSTRUME NT PANE L/STE E R- Com m on com m u n ica t ion pr oblem s:
ING COLUMN OP E NING COVE R - INSTALLA- • Two t r a n spon der keys t oo close t oget h er.
TION) • Speed P a ss t oo close t o t r a n spon der key.
(6) Con n ect t h e ba t t er y n ega t ive ca ble. Solid in dica t or t h a t t h er e is a syst em fa ilu r e.
• Loss of P CM com m u n ica t ion .
• F a iled a n t en n a cir cu it .
T RAN SPON DER K EY
STANDARD PROCEDURE - TRANSPONDER
DESCRIPTION PROGRAMMING
Th e Sen t r y Key Rem ot e E n t r y Syst em (SKRE E S)
u ses a t r a n spon der ch ip t h a t is in t egr a l t o t h e cir cu it USING A DRBIII" SCAN TOOL
boa r d of t h e in t egr a t ed ign it ion key (SKRE E S a n d All Sen t r y Keys in clu ded wit h t h e veh icle a r e pr e-
RKE in cor por a t ed) t o com m u n ica t e wit h t h e Sen t r y pr ogr a m m ed t o wor k wit h t h e Sen t r y Key Rem ot e
Key Rem ot e E n t r y Modu le (SKRE E M). Ign it ion keys E n t r y Syst em (SKRE E S) wh en it is sh ipped fr om t h e
a r e su pplied wit h t h e veh icle wh en it is sh ipped fr om fa ct or y. Th e Sen t r y Key Rem ot e E n t r y Modu le
t h e fa ct or y. (SKRE E M) ca n be pr ogr a m m ed t o r ecogn ize u p t o a
F or expor t veh icles equ ipped wit h SKRE E S, t h e t ot a l of eigh t Sen t r y Keys. Wh en pr ogr a m m in g a
t r a n spon der ch ip is u n der m olded wit h in t h e h ea d of bla n k Sen t r y Key t r a n spon der, t h e key m u st fir st be
t h e key. cu t t o m a t ch t h e ign it ion lock cylin der of t h e veh icle
for wh ich it will be u sed. Th e veh icle’s fou r digit P IN
T RAN SPON DER K EY (Cont inue d)
code will be r equ ir ed t o com plet e t h is t a sk sin ce you t h e OF F posit ion . Repla ce t h e fir st va lid Sen t r y Key
will n eed it t o en t er t h e Secu r ed Access Mode in t h e in t h e ign it ion lock cylin der wit h t h e secon d va lid
SKRE E M. Th e followin g st eps m u st be com plet ed Sen t r y Key a n d t u r n t h e ign it ion swit ch ba ck t o t h e
u sin g a DRBIII! sca n t ool: ON posit ion . Th e secon d va lid Sen t r y Key m u st be
(1) In ser t t h e bla n k key in t o t h e ign it ion a n d t u r n in ser t ed wit h in 15 secon ds of r em ovin g t h e fir st va lid
it t o t h e RUN posit ion . Sen t r y key.
(2) Usin g a DRBIII! sca n t ool, select %Th eft (4) Abou t t en secon ds a ft er t h e com plet ion of St ep
Ala r m ,% %SKRE E M,% %Miscella n eou s,% a n d t h en %P r o- 3, t h e in dica t or ligh t will st a r t t o fla sh a n d a sin gle
gr a m New Key.% a u dible ch im e t on e will sou n d t o in dica t e t h a t t h e
(3) E n t er t h e fou r digit P IN code u sin g t h e syst em h a s en t er ed t h e %Cu st om er Lea r n % pr ogr a m -
DRBIII! sca n t ool. Wh en pr ogr a m m in g is com plet ed, m in g m ode.
t h e SKRE E M will exit Secu r ed Access Mode a n d t h e (5) Wit h in sixt y secon ds of en t er in g t h e %Cu st om er
DRBIII! sca n t ool will displa y t h e r esu lt s of you r Lea r n % pr ogr a m m in g m ode, t u r n t h e ign it ion swit ch
a t t em pt t o pr ogr a m t h e key. On e of five dist in ct t o t h e OF F posit ion , r epla ce t h e va lid Sen t r y Key
r esu lt s m a y be displa yed. All five a r e list ed below: wit h a bla n k Sen t r y Key t r a n spon der, a n d t u r n t h e
• $P ro g ra m m in g S u c c e s s fu l$ is displa yed if t h e ign it ion swit ch ba ck t o t h e ON posit ion .
Sen t r y Key pr ogr a m m in g is su ccessfu l. (6) Abou t t en secon ds a ft er t h e com plet ion of St ep
• $Le a rn e d Ke y in Ig n itio n $ is displa yed if t h e 5, a sin gle a u dible ch im e t on e will sou n d a n d t h e
key in t h e ign it ion h a s a lr ea dy been pr ogr a m m ed in dica t or ligh t will st op fla sh in g a n d st a y on solid for
in t o t h a t veh icle’s SKRE E M. t h r ee secon ds a n d t h en t u r n off t o in dica t e t h a t t h e
• $Eig h t Ke y s Alre a d y Le a rn e d (At Th e Ma x i- bla n k Sen t r y Key h a s been su ccessfu lly pr ogr a m m ed.
m u m ) P ro g ra m m in g N o t D o n e $ is displa yed if Th e SKRE E S will im m edia t ely exit t h e %Cu st om er
eigh t keys h a ve a lr ea dy been pr ogr a m m ed in t o t h e Lea r n % pr ogr a m m in g m ode a n d t h e veh icle m a y be
SKRE E M. In t h is ca se, if a n ew key n eeds t o be st a r t ed u sin g t h e n ewly pr ogr a m m ed Sen t r y Key.
a dded du e t o a lost or defect ive key, t h e %E r a se All
Keys% com m a n d (wh ich r equ ir es en t er in g t h e Secu r ed NOTE: The Remote Keyless Entry (RKE) Transmitter
Access Mode) h a s t o be per for m ed. F ollowin g t h e will also be programmed during this procedure.
%E r a se All Keys% com m a n d, a ll keys t h a t will be u sed
t o oper a t e t h e veh icle MU S T be r epr ogr a m m ed t o Th ese st eps m u st be com plet ed in t h eir en t ir et y for
t h e SKRE E M. ea ch a ddit ion a l Sen t r y Key t o be pr ogr a m m ed. If a n y
• $P ro g ra m m in g N o t Atte m p te d $ is displa yed of t h e a bove st eps a r e n ot com plet ed in t h e given
a ft er a n %E r a se All Keys% fu n ct ion is execu t ed. sequ en ce, or wit h in t h e a llot t ed t im e, t h e SKRE E S
• $P ro g ra m m in g Ke y F a ile d $ is displa yed if fu r- will exit t h e %Cu st om er Lea r n % pr ogr a m m in g m ode
t h er dia gn osis is r equ ir ed. a n d t h e pr ogr a m m in g will be u n su ccessfu l. Th e
To lea r n a ddit ion a l keys, t u r n t h e ign it ion OF F, SKRE E S will a lso a u t om a t ica lly exit t h e %Cu st om er
r em ove t h e lea r n ed key, in ser t t h e n ext n ew bla n k Lea r n % pr ogr a m m in g m ode if:
key, a n d r epea t t h e st eps fr om t h e begin n in g. • It sees a n on -bla n k Sen t r y Key wh en it sh ou ld
see a bla n k.
“CUSTOMER LEARN” MODE • If it h a s a lr ea dy pr ogr a m m ed fou r (4) va lid Sen -
Th is fea t u r e is on ly a va ila ble on dom est ic veh icles t r y Keys.
or t h ose wh ich h a ve a U.S. cou n t r y code design a t or. • If t h e ign it ion swit ch is t u r n ed t o t h e OF F posi-
Th is pr ocedu r e r equ ir es a ccess t o a t lea st t wo va lid t ion for m or e t h a n a bou t fift y (50) secon ds.
Sen t r y Keys. If t wo va lid Sen t r y Keys a r e n ot a va il-
NOTE: If you attempt to start the vehicle while in
a ble, Sen t r y Key pr ogr a m m in g will r equ ir e t h e u se of
“Customer Learn” mode (LED flashing), the vehicle
a DRBIII! sca n t ool.
will behave as though an invalid key is being used
Th e st eps r equ ir ed t o pr ogr a m Sen t r y Keys wit h
(i.e. the engine will stall after two (2) seconds of
t wo va lid Sen t r y Keys follows:
running). No faults will be logged.
(1) Obt a in t h e bla n k Sen t r y Key(s) t h a t n eed t o be
pr ogr a m m ed. Cu t t h e keys t o m a t ch t h e ign it ion lock
cylin der m ech a n ica l key codes. NOTE: Once a Sentry Key has been programmed to
(2) In ser t on e of t h e t wo va lid Sen t r y Keys in t o t h e a particular vehicle, it cannot be used on any other
ign it ion swit ch a n d t u r n t h e ign it ion swit ch t o t h e vehicle.
ON posit ion .
(3) Aft er t h e ign it ion swit ch h a s been in t h e ON
posit ion for lon ger t h a n t h r ee secon ds, bu t n o m or e
t h a n fift een secon ds, cycle t h e ign it ion swit ch ba ck t o
V T SS/SK I S I N DI CAT OR LAM P ligh t ba sed u pon t h e r esu lt s of t h e Sen t r y Key

Rem ot e E n t r y Syst em (SKRE E S) self t est s. Th e ligh t
m a y be a ct u a t ed in t wo possible wa ys, fla sh in g or on
DESCRIPTION
solid. If t h e ligh t com es on a n d st a ys on solid a ft er a
Th e Sen t r y Key Rem ot e E n t r y Syst em (SKRE E S)
power-u p t est , t h is in dica t es t h a t t h e SKRE E M h a s
u ses a n in dica t or ligh t t o con vey in for m a t ion on t h e
det ect ed a syst em m a lfu n ct ion . If t h e SKRE E M
st a t u s of t h e syst em t o t h e cu st om er. Th is ligh t is
det ect s a n in va lid key wh en t h e ign it ion swit ch is
sh a r ed wit h t h e Veh icle Th eft Secu r it y Syst em
m oved t o t h e ON posit ion , it sen ds a m essa ge on t h e
(VTSS). Th e ligh t is loca t ed in t h e Mech a n ica l
P CI bu s t o t h e MIC, t o fla sh t h e ligh t . Th e SKRE E M
In st r u m en t Clu st er (MIC). Th e VTSS st a t u s is con -
ca n a lso sen d a m essa ge t o fla sh t h e ligh t a n d gen -
t r olled by t h e Body Con t r ol Modu le (BCM), via P r o-
er a t e a sin gle a u dible ch im e a t t h e sa m e t im e. Th ese
gr a m m a ble Com m u n ica t ion In t er fa ce (P CI) da t a bu s
t wo even t s occu r r in g sim u lt a n eou sly in dica t e t h a t
com m u n ica t ion wit h t h e MIC, ba sed u pon m essa ges
t h e SKIS h a s been pla ced in t o t h e %Cu st om er Lea r n %
it r eceives fr om t h e Sen t r y Key Rem ot e E n t r y Mod-
m ode (Refer t o 8 - E LE CTRICAL/VE H ICLE TH E F T
u le (SKRE E M) on t h e P CI da t a bu s.
SE CURITY/TRANSP ONDE R KE Y - STANDARD
P ROCE DURE ). If t h e ligh t com es on a n d st a ys on
OPERATION a ft er t h e power-u p t est , dia gn osis of t h e SKRE E S
Th e Mech a n ica l In st r u m en t Clu st er (MIC) per-
sh ou ld be per for m ed u sin g a DRBIII! sca n t ool a n d
for m s a fou r secon d bu lb ch eck via P CI com m u n ica -
t h e a ppr opr ia t e Body Dia gn ost ic P r ocedu r es in for m a -
t ion wit h t h e Sen t r y Key Rem ot e E n t r y Modu le t ion . Th e ligh t is a Ligh t E m it t in g Diode (LE D) a n d
(SKRE E M). Aft er t h e bu lb ch eck, t h e la m p is con -
is n ot a ser vicea ble com pon en t .
t r olled a ccor din g t o SKRE E M m essa ges. Th en , t h e
SKRE E M sen ds m essa ges t o t h e BCM t o oper a t e t h e
RS WIPERS/WASHERS 8R - 1
WIPERS/WASHERS
page page
WIPERS/WASHERS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 10
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1 REAR WIPER/WASHER SWITCH
DIAGNOSIS AND TESTING - FRONT WIPER WASHER FLUID LEVEL SWITCH
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
DIAGNOSIS AND TESTING - FRONT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11
WIPER/WASHER SWITCH . . . . . . . . . . . . . . . . 2 WASHER HOSES
DIAGNOSIS AND TESTING - FAILED PARK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
DIAGNOSIS AND TESTING - REAR WIPER WASHER PUMP MOTOR
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DIAGNOSIS AND TESTING - WASHER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 12
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 WASHER RESERVOIR
FRONT WIPER ARMS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
STANDARD PROCEDURE - FRONT WIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13
ARM ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . 9 WIPER BLADES
REMOVAL .............................9 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
FRONT WIPER MOTOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 13
REMOVAL .............................9 WIPER LINKAGE
REAR WIPER ARM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 WIPER MODULE
REAR WIPER MOTOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
WI PERS/WASH ERS REAR WIPER/WASHER SYSTEM

Th e r ea r win dsh ield wiper a n d wa sh er s ca n be
DESCRIPTION oper a t ed wh en t h e ign it ion swit ch is in t h e RUN
posit ion .
FRONT WIPER/WASHER SYSTEM If equ ipped wit h Ma n u a l Tem per a t u r e Con t r ols
Th e win dsh ield wiper s ca n be oper a t ed wit h t h e (MTC), t h e r ea r wiper /wa sh er swit ch is in t egr a l t o
win dsh ield wiper swit ch wh en t h e ign it ion swit ch is t h e H VAC con t r ol u n it . It r epla ces wh a t wa s for m er ly
in t h e RUN or ACCE SSORY posit ion s. Th e win d- t h e ON/OF F swit ch . If equ ipped wit h Au t om a t ic Tem -
sh ield wiper syst em is pr ot ect ed by a 30 a m p fu se (9) per a t u r e Con t r ols (ATC), t h e r ea r wiper /wa sh er
loca t ed in t h e P ower Dist r ibu t ion Cen t er (P DC) pa r t swit ch is loca t ed on t h e a ccessor y swit ch pa n el in t h e
of t h e In t egr a t ed P ower Modu le (IP M) in t h e en gin e cen t er st a ck of t h e in st r u m en t pa n el.
com pa r t m en t . Th e wiper /wa sh er swit ch is in t egr a l t o
t h e m u lt i-fu n ct ion swit ch . It is a r esist ive MUX
swit ch t h a t sen ds in pu t s t o t h e BCM t o oper a t e t h e
wiper /wa sh er syst em .
8R - 2 WIPERS/WASHERS RS
WI PERS/WASH ERS (Cont inue d)
OPERATION Th e win dsh ield wiper cir cu it s a r e con t in u ou sly

m on it or ed a n d con t r olled by t h e Body Con t r ol Mod-
FRONT WIPER/WASHER SYSTEM u le (BCM). If a pr oblem occu r s in t h e elect r on ic com -
Th e win dsh ield wa sh er cir cu it is pr ot ect ed by a 15 pon en t s, wir in g, swit ch (except in t egr a l m ot or pa r k
a m p Ca r t r idge F u se loca t ed in t h e IP M. Th e wiper swit ch ) a n d wiper m ot or a Dia gn ost ic Tr ou ble Code
m ot or h a s per m a n en t m a gn et ic fields. Th e speeds a r e (DTC) will be st or ed in t h e BCM m em or y. DTC’s ca n
det er m in ed by cu r r en t flow t o t h e a ppr opr ia t e set of be r et r ieved u sin g a DRB III! sca n t ool. Refer t o t h e
br u sh es in side t h e m ot or. Th e cu r r en t flow is con - pr oper Body Dia gn ost ic P r ocedu r es m a n u a l for DTC
t r olled by t h e m u lt i-fu n ct ion swit ch . Th e h igh speed/ descr ipt ion s a n d r et r ieva l in for m a t ion .
low speed r ela ys a r e loca t ed in t h e IP M. Th e speed Th e win dsh ield wiper pa r k swit ch a n d cir cu it is
sen sit ive in t er m it t en t wiper is con t r olled by t h e Body m on it or ed by t h e BCM. Th e pa r k swit ch a n d cir cu it
Con t r ol Modu le (BCM). Th e in t er m it t en t m ode, wit h ca n be t est ed u sin g t h e Wiper Syst em Dia gn osis
t h e veh icle t r a velin g gr ea t er t h a n 10.4 m ph , h a s a t a ble.
r a n ge of 0.5 t o 18 secon ds. Wit h t h e veh icle t r a velin g
less t h a n 10.4 m ph , t h e t im e dela y dou bles t o a DIAGNOSIS AND TESTING - FRONT
r a n ge of 1 t o 36 secon ds. Th e wiper a r m s will pa r k a t WIPER/WASHER SWITCH
t h e ba se of t h e win dsh ield ju st a bove t h e cowl cover (1) Rem ove t h e m u lt i-fu n ct ion swit ch (Refer t o 8 -
a ft er t h e wiper swit ch is t u r n ed OF F. E LE CTRICAL/LAMP S/LIGH TING - E XTE RIOR/
Th e win dsh ield wiper m ot or a n d lin ka ge is loca t ed MULTI-F UNCTION SWITCH - RE MOVAL).
in a n in t egr a l wiper u n it a t t h e r ea r of t h e en gin e (2) Usin g a n oh m m et er ch eck r esist a n ce r ea din gs
com pa r t m en t . Th e wiper u n it m u st be r em oved t o bet ween swit ch pin s. Refer t o t h e WIP E R/WASH E R
ga in a ccess t o t h e wiper m ot or. SWITCH RE SISTANCE t a ble.
Th e fr on t a n d r ea r wa sh er syst em s sh a r e t h e sa m e
wa sh er pu m p m ot or. WI PER/WASH ER SWI T CH RESI STAN CE
REAR WIPER/WASHER SYSTEM SWITCH POSITION RESISTANCE BETWEEN

Wh en r ea r wiper oper a t ion is r equ ir ed, t h e BCM
will pr ovide ign it ion ON volt a ge t o t h e r ea r wiper OFF 1 AND 2 = 23.9K " ± 5%
m ot or (E xpor t a n d ATC equ ipped veh icles on ly). DELAY POSITION
Wh en t h e wiper swit ch is t u r n ed OF F, t h e BCM pr o- 1ST 1 AND 2 = 7.9K " ± 5%
vides cir cu it gr ou n d t o oper a t e t h e m ot or u n t il t h e
2ND 1 AND 2 = 4.6K " ± 5%
wipe cycle is com plet e a n d t h e wiper a r m r et u r n s t o
t h e ba se of t h e r ea r win dow. 3RD 1 AND 2 = 2.9K " ± 5%
Swit ch on ly offer s a n in t er m it t en t r ea r wiper 4TH 1 AND 2 = 1.9K " ± 5%
m ode. Th e wiper m ot or will cycle ever y 7 secon ds.
5TH 1 AND 2 = 1.3K " ± 5%
Th e in t er m it t en t dela y t im e is a lso a dju st ed ba sed
u pon veh icle speed. Wit h t h e veh icle t r a velin g LOW 1 AND 2 = 670 " ± 5%
gr ea t er t h a n 50 m ph , t h e cycle ch a n ges t o ever y 5 HIGH 1 AND 2 = 240 " ± 5%
secon ds. WASH 1 AND 4 = 5.9K " ± 5%
Wh en r ea r wa sh er is r equ est ed by depr essin g a n d
h oldin g down t h e swit ch , t h e BCM t h en pr ovides a
DIAGNOSIS AND TESTING - FAILED PARK
gr ou n d for t h e wa sh er m ot or. Un t il t h e swit ch is
r elea sed, t h e m ot or will be in a con t in u ou s wipe SWITCH
m ode, t h en r et u r n t o a n in t er m it t en t wipe m ode. If t h e wiper pa r k swit ch h a s fa iled, t h e win dsh ield
wiper s will oper a t e a s follows:
• S WITCH OF F - Wiper s st op in cu r r en t loca t ion
DI AGN OSI S AN D T EST I N G r ega r dless of t h e pa r k sign a l.
• IN TERMITTEN T MOD E - Wiper s oper a t e con -
DIAGNOSIS AND TESTING - FRONT WIPER t in u ou sly or a t low speed for on e or m or e ext r a
SYSTEM wipes.
Th e win dsh ield wiper syst em oper a t es in sever a l • LOW S P EED - Wiper s oper a t e a t low speed.
m odes: • HIGH S P EED - Wiper s oper a t e a t h igh speed.
• Low a n d h igh speed n or m a l wipe
• Speed sen sit ive in t er m it t en t wipe
• Wipe a ft er wa sh
• P a r k (swit ch OF F )
• WIP E AF TER WAS H - Wiper s oper a t e a t low Th e win dsh ield wiper pa r k swit ch a n d cir cu it is
speed in a n y m ode set t in g. Wiper s oper a t e on ly wh ile m on it or ed by t h e BCM. Th e pa r k swit ch a n d cir cu it
t h e wa sh bu t t on is depr essed wit h swit ch in t h e OF F ca n be t est ed u sin g t h e WIP E R SYSTE M DIAGNO-
m ode a n d wiper s st op in m id-cycle wh en bu t t on is SIS t a ble.
r elea sed.
WI PER SY ST EM DI AGN OSI S
WIPER BLADES DO NOT 1. WIPER ARMS IMPROPERLY 1. REMOVE WIPER ARMS AND REPARK.
PARK PROPERLY PARKED. REFER TO WIPER ARM REMOVAL AND
INSTALLATION.
2. WIPER ARMS ARE LOOSE ON 2. REMOVE WIPER ARM AND REPARK.
PIVOT SHAFT. REFER TO WIPER ARM REMOVAL AND
INSTALLATION.
3. MOTOR CRANK LOOSE AT 3. REMOVE WIPER ARM, RUN WIPER
OUTPUT SHAFT. MOTOR TO PARK POSITION AND
REMOVE THE MODULE. WITHOUT
ROTATING THE MOTOR OUTPUT SHAFT,
REMOVE THE CRANK AND CLEAN ANY
FOREIGN MATTER FROM THE MOTOR
SHAFT. INSTALL THE MOTOR CRANK IN
ITS ORIGINAL POSITION.
4. STRIPPED WIPER ARM HEAD. 4. REPLACE WIPER ARM.
MOTOR STOPS IN ANY OPEN PARK CIRCUIT. CHECK PARK SWITCH BY

POSITION WHEN THE DISCONNECTING THE WIRE
SWITCH IS TURNED OFF CONNECTOR AND APPLY BATTERY
VOLTAGE TO PIN 4. PLACE A JUMPER
WIRE FROM PIN 2 TO PIN 3 AND THEN
TO AN EXTERNAL GROUND. REPLACE
MOTOR IF MOTOR DOES NOT PARK.
MOTOR WILL NOT STOP 1. FAULTY SWITCH. 1. CHECK SWITCH IN LOW, HIGH AND
WHEN THE SWITCH IS INTERMITTENT POSITION.
TURNED OFF
2. LACK OF DYNAMIC BRAKE ON 2. ENSURE PARK SWITCH HAS CLEAN
WET GLASS. GROUND.
WIPER BLADES SLAP WIPER ARMS ARE PARKED PARK WIPER ARMS. REFER TO WIPER
AGAINST COWL SCREEN INCORRECTLY. ARM ADJUSTMENT.
OR WINDOW MOLDINGS.
BLADES CHATTER 1. FOREIGN SUBSTANCE SUCH 1. CLEAN GLASS AND BLADE ELEMENT
AS POLISH ON GLASS OR WITH NON-ABRASIVE CLEANER.
BLADES.
2. ARMS TWISTED, BLADE AT 2. REPLACE ARM.
WRONG ANGLE ON GLASS.
3. BLADE STRUCTURE BENT. 3. REPLACE BLADE.
4. BLADE ELEMENT HAS 4. REPLACE BLADE.
PERMANENT SET.
WIPER KNOCK AT 1. LINKAGE BUSHINGS WORN. 1. REPLACE WORN LINK. REFER TO

REVERSAL WIPER LINKAGE REMOVAL AND
INSTALLATION.
2. ARMATURE ENDPLAY IN 2. REPLACE WIPER MOTOR. REFER TO
MOTOR. WIPER MOTOR REMOVAL AND
INSTALLATION.
WIPER MOTOR WILL NOT 1. BLOWN FUSE. 1. REPLACE FUSE, AND RUN SYSTEM.
RUN
2. NEW FUSE BLOWS. 2. CHECK FOR SHORT IN WIRING OR
SWITCH.
3. NEW FUSE BLOWS. 3. REPLACE FUSE, REMOVE MOTOR
CONNECTOR, TURN SWITCH ON, FUSE
DOES NOT BLOW, REPLACE MOTOR.
4. NO VOLTAGE AT MOTOR. 4. CHECK SWITCH AND WIRING
HARNESS. REFER TO WIRING
DIAGRAMS.
5. POOR GROUND. 5. REPAIR GROUND WIRE CONNECTION
AS NECESSARY.
DIAGNOSIS AND TESTING - REAR WIPER • Wipe a ft er wa sh

Th e win dsh ield wiper cir cu it s a r e con t in u ou sly
SYSTEM
m on it or ed a n d con t r olled by t h e Body Con t r ol Mod-
Th e r ea r win dow wiper syst em oper a t es in sever a l
u le (BCM). If a pr oblem occu r s in t h e elect r on ic com -
m odes:
pon en t s, wir in g, swit ch (except in t egr a l m ot or pa r k
• Con t in u ou s wipe (E xpor t a n d ATC equ ipped
swit ch ) a n d wiper m ot or a Dia gn ost ic Tr ou ble Code
veh icles on ly)
(DTC) will be st or ed in t h e BCM m em or y. Th e
• In t er m it t en t wipe
DTC(s) ca n be r et r ieved u sin g a DRB III! sca n t ool.
• Wa sh
DIAGNOSIS AND TESTING - WASHER SYSTEM

WASH ER SY ST EM DI AGN OSI S
WASHER MOTOR 1. IPM FUSE #33 BLOWN OR 1. CHECK FUSE #33 IN THE IPM.
DEFECTIVE. REPLACE IF NOT OK.
2. IPM FUSE #33 LOOSE. 2. PROPERLY INSTALL IPM FUSE #33 IN

SOCKET.
BLOWN FUSE WHEN 1. SHORT IN IPM BETWEEN 1. REFER TO IPM DIAGNOSTIC

IGNITION SWITCH IS IN FUSE #33 AND PIN 11 OR PIN PROCEDURES IN WIRING DIAGRAMS.
THE RUN OR ACCESSORY 1.
POSITION.
2. SHORT IN MOTOR POWER 2. SHORT OR DEFECTIVE CIRCUIT
CIRCUIT. BETWEEN IPM PIN 11 AND WASHER
MOTOR CONNECTOR POSITIVE
TERMINAL 2. IF NOT OK, REPAIR CIRCUIT.
3. SHORT IN WASHER PUMP 3. REPLACE WASHER PUMP MOTOR.
MOTOR.
WASHER MOTOR RUNS 1. SHORT IN IPM BETWEEN 1. REFER TO IPM DIAGNOSTIC

WHEN IGNITION SWITCH WASHER PUMP MOTOR LSD PROCEDURES IN WIRING DIAGRAMS.
IN RUN OR ACCESSORY AND PIN 20.
POSITION. 2. DEFECTIVE FRONT 2. REFER TO IPM DIAGNOSTIC
WASHER LSD IN IPM. PROCEDURES IN WIRING DIAGRAMS.
3. SHORT IN MOTOR GROUND 3. SHORT OR DEFECTIVE CIRCUIT
CIRCUIT. BETWEEN IPM PIN 20 AND MOTOR
CONNECTOR NEGATIVE TERMINAL 1. IF
NOT OK, REPAIR CIRCUIT.
WASHER SYSTEM WILL 1. NO WASHER FLUID IN 1. FILL WASHER RESERVOIR.

NOT FLOW WASHER RESERVOIR.
FLUID. 2. IPM FUSE #33 BLOWN. 2. SHORT OR DEFECTIVE CIRCUIT
BETWEEN IPM PIN 11 AND WASHER
PUMP MOTOR CONNECTOR POSITIVE
TERMINAL 2. INTERNAL SHORT IN IPM. IF
NOT OK, REPAIR CIRCUIT OR REFER TO
IPM DIAGNOSTIC PROCEDURES IN
WIRING DIAGRAMS.
3. WASHER HOSE NOT 3. ASSURE WASHER HOSE IS NOT
FLOWING WASHER FLUID. PINCHED, LOOSE, BROKEN OR
DISCONNECTED. IF NOT OK, PROPERLY
ROUTE OR REPAIR WASHER HOSE.
4. MOTOR CONNECTOR 4. PROPERLY SEAT AND LOCK
LOOSE. CONNECTOR TO MOTOR.
5. MOTOR CONNECTOR 5. REPAIR TERMINALS AND PROPERLY
TERMINALS BENT. SEAT CONNECTOR TO MOTOR.
6. OPEN CIRCUIT TO OR 6. OPEN OR DEFECTIVE CIRCUIT
FROM WASHER SELECT BETWEEN IPM BODY CONTROLLER PIN
SWITCH (EXPORT AND ATC 27 AND WASHER SELECT SWITCH PIN 4,
EQUIPPED VEHICLES ONLY). OR OPEN OR DEFECTIVE CIRCUIT
BETWEEN IPM BODY CONTROLLER PIN
22 AND WASHER SELECT SWITCH PIN 2.
IF NOT OK, REPAIR CIRCUIT.
7. OPEN OR DEFECTIVE 7. REFERO TO THE PROPER BODY
WASHER SELECT SWITCH. DIAGNOSTIC PROCEDURES
INFORMATION ON MANUAL
TEMPERATURE CONTROLS.
8. OPEN POWER CIRCUIT TO 8. OPEN OR DEFECTIVE CIRCUIT
MOTOR. BETWEEN IPM CONNECTOR TERMINAL 11
AND WASHER MOTOR CONNECTOR
POSITIVE TERMINAL 2. INTERNAL OPEN
IN IPM. IF NOT OK, REPAIR CIRCUIT OR
REFER TO IPM DIAGNOSTIC
PROCEDURES IN WIRING DIAGRAMS.
9. OPEN OR DEFECTIVE 9. OPEN OR DEFECTIVE CIRCUIT
MOTOR GROUND CIRCUIT. BETWEEN IPM CONNECTOR TERMINAL
20 AND WASHER MOTOR CONNECTOR
NEGATIVE TERMINAL 1. INTERNAL OPEN
IN IPM. IF NOT OK, REPAIR CIRCUIT OR
REFER TO IPM DIAGNOSTIC
10. OPEN CIRCUIT IN MOTOR. 10. CHECK FOR OPEN CIRCUIT IN MOTOR
BETWEEN POSITIVE TERMINAL 2 AND
NEGATIVE TERMINAL 1. IF NOT OK,
REPLACE WASHER MOTOR.
11. SEIZED MOTOR BEARINGS. 11. APPLY DIRECT BATTERY VOLTAGE TO
MOTOR TERMINALS. IF MOTOR DOES
NOT RUN, REPLACE MOTOR.
12. NO BUS MESSAGE FROM 12. CHECK FOR CORRECT PCI BUS
MTC CONTROL (MANUAL MESSAGE WITH DRBIII".
TEMP. CONTROL ONLY).
COWL GRILLE NOZZLE 1. FROZEN NOZZLE. 1. MOVE VEHICLE INTO HEATED AREA TO
WILL NOT FLOW. ALLOW TIME TO THAW NOZZLE. ASSURE
WASHER FLUID IS PROPERLY BLENDED
FOR AMBIENT OUTSIDE TEMPERATURES.
2. NOZZLE HOSE NOT 2. ASSURE NOZZLE HOSE IS NOT

FLOWING. PINCHED, LOOSE, BROKEN, OR
DISCONNECTED. IF NOT OK, PROPERLY
ROUTE OR REPAIR NOZZLE HOSE.
3. NOZZLE HOSE PLUGGED 3. CLEAN NOZZLE HOSE OF
BY CONTAMINATION. CONTAMINATION. DETERMINE SOURCE
OF CONTAMINATION. INSPECT
RESERVOIR FOR EXCESSIVE
CONTAMINATION. CLEAN SYSTEM AS
REQUIRED.
4. NOZZLE PLUGGED BY 4. CLEAN NOZZLE OF CONTAMINATION
CONTAMINATION. OR REPLACE NOZZLE. DETERMINE
SOURCE OF CONTAMINATION. INSPECT
RESERVOIR FOR EXCESSIVE
CONTAMINATION. CLEAN SYSTEM AS
REQUIRED.
5. DEFECTIVE WASHER HOSE 5. REPLACE COWL GRILLE PANEL
CHECK VALVE. WASHER HOSE/CHECK VALVE ASSEMBLY.
WASHER FLUID OUTPUT IS 1. PARTIALLY PINCHED HOSE. 1. ASSURE WASHER HOSE IS NOT
LOW. PARTIALLY PINCHED. IF NOT OK,
PROPERLY ROUTE HOSE.
2. FRONT REAR VALVE 2. REPLACE WASHER PUMP.

DEFECTIVE.
3. WORN OUT WASHER PUMP. 3. REPLACE WASHER PUMP.
COWL GRILLE NOZZLE 1. NOZZLE NOT SEATED IN 1. ASSURE NOZZLE IS SNAPPED IN

STREAM OVERSHOOTS COWL GRILLE. PLACE.
WINDSHIELD.
WIPER WILL NOT CYCLE 1. DEFECTIVE IPM. 1. REFER TO IPM DIAGNOSTIC

WHEN WASHER SELECT PROCEDURES IN WIRING DIAGRAMS.
SWITCH IS DEPRESSED. 2. DEFECTIVE IPM/BODY 2. REFER TO IPM/BODY CONTROLLER
CONTROLLER. DIAGNOSTIC PROCEDURES IN WIRING
DIAGRAMS.
3. REAR WIPER OUTPUT 3. A GROUND SHORT DETECTED
SHORT FAULT. BETWEEN BCM AND REAR WIPER
MOTOR. CLEAR FAULT. IF IT WON’T
CLEAR, REPAIR SHORT
4. REAR WIPER OUTPUT 4. AN OPEN CIRCUIT DETECTED
OPEN FAULT. BETWEEN BCM AND REAR WIPER
MOTOR. CLEAR FAULT. IF IT WON’T
CLEAR, REPAIR OPEN CIRCUIT.
5. NO BUS MESSAGE FROM 5. REFER TO PROPER BODY DIAGNOSTIC

MTC CONTROL (MANUAL INFORMATION OR USE DRBIII" TO CHECK
TEMP. CONTROL ONLY). PROPER MESSAGE STATUS.
WASHER OPERATES 1. INTERMITTENT MOTOR INTERMITTENT GROUND BETWEEN

INTERMITTENTLY. GROUND. MOTOR CONNECTOR TERMINAL 1 AND
IPM PIN 20.
2. INTERMITTENT OPEN IN 2. (Refer to 8 - ELECTRICAL/LAMPS/

WASHER SELECT SWITCH. LIGHTING - EXTERIOR/MULTI-FUNCTION
SWITCH - DIAGNOSIS AND TESTING).
3. DEFECTIVE WASHER 3. REPLACE WASHER PUMP.
MOTOR.
LOW WASHER FLUID 1. LOOSE FLUID LEVEL 1. PROPERLY SEAT CONNECTOR TO LOW
LEVEL INDICATOR SENSOR CONNECTOR. FLUID LEVEL SENSOR AND LOCK.
INOPERATIVE.
2. OPEN POWER CIRCUIT TO 2. OPEN OR DEFECTIVE CIRCUIT
FLUID LEVEL SENSOR. BETWEEN IPM CONNECTOR TERMINAL 7
AND THE LOW FLUID LEVEL SENSOR
CONNECTOR TERMINAL 2. IF NOT OK,
REPAIR CIRCUIT.
3. OPEN GROUND CIRCUIT. 3. OPEN OR DEFECTIVE CIRCUIT
BETWEEN FLUID LEVEL SENSOR
CONNECTOR TERMINAL 1 AND FLOOR
GROUND 1.
4. DEFECTIVE IPM. 4. REFER TO IPM DIAGNOSTIC
5. FLUID LEVEL SENSOR 5. APPLY OHMMETER TO THE SWITCH
SWITCH OPEN OR TERMINALS TO CHECK FOR COMPLETE
DEFECTIVE. CIRCUIT. CYCLE SWITCH FLOAT BACK
AND FORTH BY FILLING AND DEPLETING
RESERVOIR OF WASHER FLUID TO
CHECK FOR PROPER SWITCH FUNCTION.
IF NOT OK, REPLACE LOW FLUID LEVEL
SENSOR SWITCH.
LEAKING WASHER FLUID. 1. PUMP OR SENSOR 1. PROPERLY SEAT PUMP OR SENSOR IN

GROMMET DEFECTIVE. GROMMET. IF NOT OK, REPLACE PUMP
OR SENSOR GROMMET.
2. LEAKING WASHER PUMP. 2. REPLACE WASHER PUMP.
3. LEAKING FLUID LEVEL 3. REPLACE FLUID LEVEL SENSOR.
SENSOR.
4. LEAKING OR DEFECTIVE 4. REPLACE RESERVOIR BODY.
RESERVOIR BODY.
FRON T WI PER ARM S

STANDARD PROCEDURE - FRONT WIPER ARM
ALIGNMENT
(1) Ver ify wiper bla de elem en t con dit ion a n d wiper
a r m spr in g t en sion . Ru n wiper s in low speed m ode
wh ile a pplyin g wa t er t o t h e win dsh ield. Obser ve t h e
wiper bla de t h a t is ch a t t er in g or skippin g a cr oss t h e
win dsh ield. If t h e wiper elem en t is n ot r ollin g over
wh en t h e wiper dir ect ion r ever ses, a lign t h e wiper
a r m . Th e ext en sion ba r por t ion of t h e wiper a r m
m u st be t wist ed in t h e pr oper dir ect ion t o a llow t h e
wiper elem en t t o r oll over wh en t h e dir ect ion
r ever ses.
(2) P la ce t wo sm a ll a dju st a ble wr en ch es pla ced 50
m m (2 in .) a pa r t on t h e wiper a r m ext en sion r od.
(3) Twist t h e ext en sion r od sligh t ly in t h e opposit e Fig. 1 WIPER ARM REMOVAL
dir ect ion t h a t t h e elem en t is la yin g on t h e win d- 1 - WASHER NOZZLE
2 - HOOD
sh ield wh ile h oldin g t h e wr en ch closest t o t h e pivot 3 - COWL COVER
st a t ion a r y. 4 - WINDSHIELD
(4) Repea t St ep 1, a n d a lign a s n ecessa r y u n t il 5 - TWO JAW PULLER
6 - ARM CAP
wiper st ops ch a t t er in g a n d wipes t h e win dsh ield 7 - WINDSHIELD WIPER ARM
clea r.
REMOVAL
CAUTION: The driver side wiper arm must be
parked above the passenger side. Failure to do so
will result in damage to the arms, blades or system.
(1) Lift t h e a r m ca p u pwa r d.

(2) Rem ove t h e n u t h oldin g wiper a r m t o t h e wiper
pivot .
(3) Usin g a su it a ble t wo ja w pu ller, sepa r a t e t h e
wiper a r m fr om t h e wiper pivot (F ig. 1).
INSTALLATION
(1) Ver ify t h a t t h e wiper m ot or a n d lin ka ge a r e in
t h e pa r k posit ion .
(2) P la ce t h e wiper a r m in posit ion over t h e wiper
Fig. 2 WIPER ARM ADJUSTMENT
pivot (F ig. 2).
1 - WIPER BLADES
(3) In st a ll t h e n u t t o h old t h e wiper a r m t o t h e 2 - WINDSHIELD
wiper pivot . Tor qu e n u t t o 35 N·m (26 ft . lbs.). 3 - WASHER NOZZLES
4 - WIPER ARMS
CAUTION: It is important to torque the wiper arm
nut properly to insure that the wiper arm head does FRON T WI PER M OT OR
not strip and damage the arm, blade, and pivot of
both wiper arms. REMOVAL
(1) Rem ove t h e fr on t wiper m ot or fr om veh icle
(4) P u sh t h e a r m ca p cover down .
(Refer t o 8 - E LE CTRICAL/WIP E RS/WASH E RS/
WIP E R MODULE - RE MOVAL).
(2) Rem ove fou r ba ckwa ll bolt s a n d fou r br a ce
n u t s.
(3) Rem ove wiper lin ka ge fr om wiper m odu le.
(4) Discon n ect wir e con n ect or s fr om ba ck of wiper
m ot or.
FRON T WI PER M OT OR (Cont inue d)
(5) Rem ove wiper lin ka ge fr om m ot or cr a n k. DO (4) In st a ll t h e lift ga t e t r im pa n el. (Refer t o 23 -
NOT r em ove cr a n k fr om m ot or. BODY/DE CKLID/H ATCH /LIF TGATE /TAILGATE /
(6) Rem ove bolt s h oldin g wiper m ot or a n d r em ove TRIM PANE L - INSTALLATION).
m ot or. (5) Con n ect wir e con n ect or t o r ea r wiper m ot or.
(6) In st a ll t h e scr ews h oldin g r ea r wiper m ot or t o
INSTALLATION lift ga t e.
(1) P la ce wiper m odu le on a su it a ble wor k su r fa ce. (7) In st a ll t h e wiper m ot or t o t h e lift ga t e.
(2) In st a ll wiper lin ka ge in t o wiper u n it . (8) Close t h e lift ga t e.
(3) Con n ect wir e con n ect or s t o wiper m ot or. (9) In st a ll t h e wiper a r m . (Refer t o 8 - E LE CTRI-
(4) P la ce t h e wiper m odu le in t o en gin e com pa r t - CAL/WIP E RS/WASH E RS/RE AR WIP E R ARM -
m en t a n d con n ect wiper m odu le wir e con n ect or t o INSTALLATION) in t h is sect ion .
en gin e wir e h a r n ess (F ig. 7). (10) Con n ect t h e ba t t er y n ega t ive ca ble.
(5) In st a ll t h e fou r ba ckwa ll bolt s a n d fou r br a ce
n u t s t o wiper m odu le.
(6) Oper a t e wiper m ot or a n d ver ify t h a t t h e wiper REAR WI PER/WASH ER
m ot or pa r ks wh en wiper swit ch is t u r n ed OF F. SWI T CH
REAR WI PER ARM DESCRIPTION

On Au t om a t ic Tem per a t u r e Con t r ol (ATC) veh icles
on ly, t h e r ea r win dow wiper /wa sh er swit ch es a r e
REMOVAL loca t ed on t h e cen t er bezel wit h t h e h a za r d a n d
(1) Rem ove a r m n u t ca p. h ea t ed sea t swit ch es (F ig. 3). Th ey a r e n ot ser vice-
(2) Rem ove wiper a r m n u t . a ble sepa r a t ely fr om t h e h a za r d a n d h ea t ed sea t
(3) P u ll wiper fr om pivot by r ockin g ba ck a n d swit ch es. If defect ive, t h e en t ir e swit ch a ssem bly
for t h . m u st be r epla ced.
INSTALLATION
(1) Ver ify t h a t wiper s a r e in pa r ked posit ion .
(2) P osit ion a r m on pivot .
(3) In st a ll wiper a r m n u t a n d t or qu e t o 20 N·m
(175 in . lbs.).
REAR WI PER M OT OR
REMOVAL
ca ble.
(2) Rem ove r ea r wiper a r m . (Refer t o 8 - E LE C-
TRICAL/WIP E RS/WASH E RS/RE AR WIP E R ARM -
RE MOVAL) in t h is sect ion .
(3) Open lift ga t e.
(4) Rem ove lift ga t e t r im pa n el. (Refer t o 23 - Fig. 3 INSTRUMENT PANEL CENTER BEZEL
BODY/DE CKLID/H ATCH /LIF TGATE /TAILGATE / 1 - TRIM BEZEL
TRIM PANE L - RE MOVAL). 2 - IN CAR TEMPERATURE SENSOR
3 - A/C REQUEST SWITCH
(5) Discon n ect wir e con n ect or fr om r ea r wiper 4 - REAR WINDOW DEFOGGER/HEATED MIRRORS SWITCH
m ot or. COMBO
5 - FRONT WINDOW DEFROSTER MODE SELECTOR
(6) Rem ove scr ews h oldin g r ea r wiper m ot or t o lift -
ga t e.
On Ma n u a l Tem per a t u r e Con t r ol (MTC) veh icles
(7) Rem ove wiper m ot or fr om lift ga t e.
on ly, t h e r ea r win dow wiper /wa sh er swit ch is loca t ed
on t h e H VAC con t r ol h ea d (F ig. 4) a t t a ch ed t o t h e
INSTALLATION cen t er bezel. Th ey a r e n ot ser vicea ble sepa r a t ely
(1) P osit ion t h e wiper m ot or in t h e lift ga t e. fr om t h e con t r ol h ea d. If fou n d fa u lt y, t h e en t ir e
(2) In st a ll t h e r et a in in g scr ews. MTC h ea d m u st be r epla ced.
REAR WI PER/WASH ER SWI T CH (Cont inue d)
con n ect in g t h e win dsh ield wa sh er h ose fr om t h e
fr on t (ou t boa r d) wa sh er pu m p por t a llowin g t h e
wa sh er flu id t o dr a in in t o a con t a in er t h r ou gh a t em -
por a r y ju m per h ose con n ect ed t o t h e fr on t wa sh er
pu m p.
(6) Discon n ect t h e elect r ica l body h a r n ess con n ec-
t or t o t h e t h e flu id level sen sor. Slide t h e r ed lock on
t h e con n ect or t o t h e r elea se posit ion , t h en , depr ess
t h e bla ck t a b a n d pu ll t h e con n ect or off t h e sen sor.
(7) Rem ove t h e sen sor fr om r eser voir by u sin g a
side foot t o gen t ly pr y t h e sen sor fr om t h e body of
t h e r eser voir. Do n ot da m a ge t h e r eser voir /sen sor
sea lin g su r fa ce or pu n ct u r e r eser voir du r in g r em ova l.
CAUTION: To avoid damage to the sensor, assure

the reservoir is in an upright position before remov-
Fig. 4 REAR WIPER/WASHER SWITCH LOCATION ing the sensor from the reservoir. Do not rotate the
1 - REAR WIPER/WASHER SWITCH sensor during removal.
2 - HVAC CONTROL UNIT
OPERATION INSTALLATION
Wh en r ea r wiper oper a t ion is r equ ir ed, t h e BCM (1) Use a n ew gr om m et wh en in st a llin g a n ew sen -
will pr ovide ign it ion ON volt a ge t o t h e r ea r wiper sor a ssem bly.
m ot or. Wh en t h e wiper swit ch is t u r n ed OF F, t h e (2) Assu r e t h a t t h e fla t of t h e sen sor is a lign ed
BCM pr ovides cir cu it gr ou n d t o oper a t e t h e m ot or u n der t h e r idge of t h e r eser voir a n d t h a t t h e sen sor
u n t il t h e wipe cycle is com plet e a n d t h e wiper a r m con n ect or is fa cin g down in t h e fu lly sea t ed posit ion .
r et u r n s t o t h e ba se of t h e r ea r win dow. Th is will a llow for pr oper oper a t ion of t h e sen sor
Th e r ea r wiper /wa sh er swit ch on ly offer s a n in t er- floa t swit ch .
m it t en t r ea r wiper m ode. Th e wiper m ot or will cycle (3) Con n ect t h e elect r ica l body h a r n ess con n ect or s
ever y 7 secon ds. Th e in t er m it t en t dela y t im e is a lso t o t h e flu id level sen sor. Slide t h e r ed lock on t h e
a dju st ed ba sed u pon veh icle speed. Wit h t h e veh icle con n ect or t o t h e closed or locked posit ion .
t r a velin g gr ea t er t h a n 50 m ph , t h e cycle ch a n ges t o (4) Assu r e t h a t wa sh er h ose is pr oper ly r ou t ed t o
ever y 5 secon ds. pr even t pin ch in g a n d possible in oper a t ive wa sh er s.
Wh en r ea r wa sh er is r equ est ed by depr essin g a n d (5) Con n ect t h e left r igh t fr on t wh eelh ou se spla sh
h oldin g down t h e swit ch , t h e BCM t h en pr ovides a sh ield a n d m ove a side (Refer t o 23 - BODY/E XTE RI-
gr ou n d for t h e r ea r wa sh er m ot or. Un t il t h e swit ch is OR/WH E E LH OUSE SP LASH SH IE LD - INSTALLA-
r elea sed, t h e m ot or will be in a con t in u ou s wipe TION).
m ode, t h en r et u r n t o a n in t er m it t en t wipe m ode. (6) In st a ll t h e r igh t fr on t wh eel a n d t ir e a ssem bly
(Refer t o 22 - TIRE S/WH E E LS - INSTALLATION).
(7) lower veh icle fr om h oist or ja ck st a n ds.
WASH ER FLU I D LEV EL (8) Con n ect t h e ba t t er y n ega t ive ca ble.
SWI T CH
REMOVAL WASH ER H OSES
ca ble. REMOVAL
(2) H oist a n d su ppor t veh icle on h oist or ja ck (1) Rem ove wa sh er r eser voir fr om veh icle (Refer t o
st a n ds. 8 - E LE CTRICAL/WIP E RS/WASH E RS/WASH E R
(3) If n ecessa r y, r em ove t h e r igh t fr on t wh eel a n d RE SE RVOIR - RE MOVAL).
t ir e a ssem bly (Refer t o 22 - TIRE S/WH E E LS - (2) Discon n ect wa sh er h ose fr on t t h e r eser voir ca v-
RE MOVAL). it y.
(4) Discon n ect t h e r igh t fr on t wh eelh ou se spla sh (3) Discon n ect t h e wa sh er h ose fr om t h e r eser voir
sh ield a n d m ove a side (Refer t o 23 - BODY/E XTE RI- pu m p.
OR/WH E E LH OUSE SP LASH SH IE LD - RE MOVAL). (4) Rem ove pa r t s a s n ecessa r y t o r epla ce wa sh er
(5) Dr a in wa sh er flu id fr om t h e r eser voir a n d in t o h ose (en gin e com pa r t m en t , in t er ior com pon en t s, et c.).
a su it a ble clea n con t a in er. Th is ca n be don e by dis-
WASH ER H OSES (Cont inue d)
INSTALLATION (5) Con n ect t h e left r igh t fr on t wh eelh ou se spla sh

(1) In st a ll pa r t s a s n ecessa r y t o a ft er r epla cin g sh ield a n d m ove a side (Refer t o 23 - BODY/E XTE RI-
wa sh er h ose (en gin e com pa r t m en t , in t er ior com po- OR/WH E E LH OUSE SP LASH SH IE LD - INSTALLA-
n en t s, et c.). TION).
(2) Con n ect t h e wa sh er h ose t o t h e r eser voir (6) In st a ll t h e r igh t fr on t wh eel a n d t ir e a ssem bly
pu m p. (Refer t o 22 - TIRE S/WH E E LS - INSTALLATION).
(3) Con n ect wa sh er h ose t o t h e r eser voir ca vit y. (7) lower veh icle fr om h oist or ja ck st a n ds.
(4) In st a ll t h e wa sh er r eser voir in t o veh icle (Refer (8) Con n ect t h e ba t t er y n ega t ive ca ble.
t o 8 - E LE CTRICAL/WIP E RS/WASH E RS/WASH E R (9) Ver ify syst em oper a t ion .
RE SE RVOIR - INSTALLATION).
WASH ER RESERV OI R
WASH ER PU M P M OT OR
REMOVAL
REMOVAL (1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive
ca ble. (2) Rem ove t h e en gin e fr esh a ir h ou sin g in side t h e
(2) H oist a n d su ppor t veh icle on h oist or ja ck en gin e com pa r t m en t (Refer t o 9 - E NGINE /AIR
st a n ds. INTAKE SYSTE M/AIR CLE ANE R H OUSING -
(3) If n ecessa r y, r em ove t h e r igh t fr on t wh eel a n d RE MOVAL).
t ir e a ssem bly (Refer t o 22 - TIRE S/WH E E LS - (3) Discon n ect t h e wa sh er h ose a t t h e in -lin e con -
RE MOVAL). n ect or for wa r d of t h e cowl gr ille so t h a t t h e in -lin e
(4) Discon n ect t h e r igh t fr on t wh eelh ou se spla sh con n ect or r em a in s wit h t h e wa sh er h ose fr om t h e
sh ield a n d m ove a side (Refer t o 23 - BODY/E XTE RI- fr esh a ir plen u m .
OR/WH E E LH OUSE SP LASH SH IE LD - RE MOVAL). (4) Discon n ect t h e wa sh er h ose fr om t h e h ose clip
(5) Dr a in wa sh er flu id fr om t h e r eser voir a n d in t o loca t ed on t h e fr on t fen der side sh ield.
a su it a ble clea n con t a in er. Th is ca n be don e by dis- (5) Rem ove t h e filler t u be scr ew.
con n ect in g t h e win dsh ield wa sh er h ose fr om t h e (6) H oist a n d su ppor t veh icle on h oist or ja ck
fr on t (ou t boa r d) wa sh er pu m p por t a n d a llowin g t h e st a n ds.
wa sh er flu id t o dr a in in t o a con t a in er t h r ou gh a t em - (7) Rem ove t h e r igh t fr on t wh eel a n d t ir e a ssem bly
por a r y ju m per h ose con n ect ed t o t h e fr on t wa sh er (Refer t o 22 - TIRE S/WH E E LS - RE MOVAL).
pu m p por t . (8) Discon n ect t h e left r igh t fr on t wh eelh ou se
(6) Discon n ect t h e elect r ica l body h a r n ess con n ec- spla sh sh ield a n d m ove a side (Refer t o 23 - BODY/
t or s t o t h e wa sh er pu m p m ot or. Slide t h e r ed lock on E XTE RIOR/WH E E LH OUSE SP LASH SH IE LD -
t h e con n ect or t o t h e r elea se posit ion , t h en , depr ess RE MOVAL).
t h e bla ck t a b a n d pu ll t h e con n ect or off t h e pu m p. (9) Dr a in wa sh er flu id fr om t h e r eser voir a n d in t o
(7) Rem ove pu m p fr om r eser voir by pu llin g pu m p a su it a ble clea n con t a in er. Th is ca n be don e by dis-
u pper r et en t ion t a b a wa y fr om r eser voir ca vit y a n d con n ect in g t h e win dsh ield wa sh er h ose fr om t h e
t h en lift in g pu m p u p fr om m ou n t in g gr om m et . Do fr on t (ou t boa r d) wa sh er pu m p por t a llowin g t h e
n ot da m a ge r eser voir /pu m p sea lin g su r fa ce or pu n c- wa sh er flu id t o dr a in in t o a con t a in er t h r ou gh a t em -
t u r e r eser voir du r in g r em ova l. por a r y ju m per h ose con n ect ed t o t h e wa sh er pu m p
(8) Rem ove pu m p gr om m et a n d disca r d. por t .
(10) Discon n ect t h e elect r ica l body h a r n ess con n ec-
INSTALLATION t or s t o t h e wa sh er pu m p m ot or a n d t h e flu id level
(1) Use n ew gr om m et wh en in st a llin g a n ew pu m p sen sor. Slide t h e r ed lock on t h e con n ect or t o t h e
a ssem bly. r elea se posit ion , t h en , depr ess t h e bla ck t a b a n d pu ll
(2) Assu r e pu m p u pper r et en t ion t a b is pr essed t h e con n ect or off t h e pu m p or sen sor.
in t o r eser voir slot a n d t h a t pu m p is r ot a t ed fla t (11) Rem ove t h e t wo r eser voir m ou n t in g scr ews.
a ga in st t h e r eser voir a n d t h a t pu m p con n ect or is fa c- (12) Discon n ect t h e r eser voir fr om t h e body m ou n t
in g u p in t h e fu lly sea t ed posit ion . Assu r e t h e pu m p by r a isin g t h e r eser voir u pwa r d sligh t ly a n d t h en
is a lign ed t o a n d fu lly sea t ed in t h e r eser voir ca vit y. down so t h a t t h e r eser voir filler n eck a n d fr on t
(3) Con n ect t h e elect r ica l body h a r n ess con n ect or s wa sh er h ose pu ll t h r ou gh t h e open in g in t h e fr on t
t o t h e wa sh er pu m p m ot or. Slide t h e r ed lock on t h e fen der side sh ield.
con n ect or t o t h e closed or locked posit ion .
(4) Assu r e t h a t wa sh er h ose is pr oper ly r ou t ed t o
pr even t pin ch in g a n d possible in oper a t ive wa sh er s.
WASH ER RESERV OI R (Cont inue d)
INSTALLATION
(1) P u sh filler n eck a n d fr on t wa sh er h ose t h r ou gh
t h e open in g in t h e fr on t fen der side sh ield. Con n ect
t h e r eser voir t o t h e body m ou n t by lower in g t h e r es-
er voir down .
(2) In st a ll t h e t wo r eser voir m ou n t in g scr ews.
Tor qu e scr ews t o 8.5 - 11.3 N·m (75 - 100 in . lbs.).
(3) Con n ect t h e elect r ica l body h a r n ess con n ect or s
t o t h e wa sh er pu m p m ot or a n d t h e flu id level sen sor.
Slide t h e r ed lock on t h e con n ect or t o t h e closed or
locked posit ion .
Fig. 6 REAR WIPER
(4) Assu r e t h a t wa sh er is pr oper ly r ou t ed t o pr e-
1 - WIPER ARM
ven t pin ch in g a n d possible in oper a t ive wa sh er s. 2 - BLADE LATCH
(5) In st a ll t h e left r igh t fr on t wh eelh ou se spla sh
sh ield (Refer t o 23 - BODY/E XTE RIOR/WH E E L- CLEANING
H OUSE SP LASH SH IE LD - INSTALLATION).
Wiper bla des exposed t o t h e wea t h er for a lon g
(6) In st a ll t h e r igh t fr on t wh eel a n d t ir e a ssem bly
per iod of t im e t en d t o lose t h eir wipin g effect iven ess.
(Refer t o 22 - TIRE S/WH E E LS - INSTALLATION).
P er iodic clea n in g of t h e wiper bla de is r ecom m en ded
(7) lower veh icle fr om h oist or ja ck st a n ds.
t o r em ove t h e a ccu m u la t ion of sa lt a n d r oa d gr im e.
(8) In st a ll t h e filler t u be scr ew. Tor qu e scr ew t o 8.5
Th e wiper bla des, a r m s a n d win dsh ield sh ou ld be
- 11.3 N·m (75 - 100 in . lbs.).
clea n ed wit h a spon ge or clot h a n d a m ild det er gen t
(9) Con n ect t h e wa sh er h ose t o t h e h ose clip
or n on a br a sive clea n er. If t h e wiper bla des con t in u e
loca t ed on t h e fr on t fen der side sh ield.
t o st r ea k or sm ea r, t h ey sh ou ld be r epla ced. Th e
(10) Con n ect t h e wa sh er h ose a t t h e in -lin e con -
wiper bla de sh ou ld r u n sm oot h ly a cr oss t h e win d-
n ect or for wa r d of t h e cowl gr ille.
sh ield in bot h dir ect ion s. Th e wiper bla de sh ou ld
(11) In st a ll t h e en gin e fr esh a ir h ou sin g in side t h e
sligh t ly r oll over cen t er wh en t h e bla de r ever ses
en gin e com pa r t m en t (Refer t o 9 - E NGINE /AIR
dir ect ion . A wiper bla de in ser t t h a t h a s lost flexibilit y
INTAKE SYSTE M/AIR CLE ANE R H OUSING -
or a wiper a r m t h a t h a s lost spr in g t en sion , will
INSTALLATION).
ca u se t h e bla de t o skip or ch a t t er a cr oss t h e win d-
sh ield. If t h e wiper bla des a r e n ew a n d t h e wiper
a r m spr in g t en sion is OK a n d a ch a t t er in g sou n d is
em it t ed fr om t h e wiper (s), t h e wiper bla de is n ot r oll-
WI PER BLADES in g over cen t er. If t h is con dit ion exist s, (r efer t o 8 -
E LE CTRICAL/WIP E RS/WASH E RS/WIP E R ARMS -
ADJ USTME NTS).
REMOVAL
(1) Lift t h e wiper a r m a wa y fr om t h e gla ss.
INSTALLATION
(2) Disen ga ge t h e r elea se t a b h oldin g t h e wiper
(1) P osit ion t h e bla de on t o t h e a r m .
bla de t o t h e wiper a r m a n d r em ove t h e wiper bla de
(2) E n ga ge t h e bla de t o t h e r et a in er by pu llin g u p
fr om t h e wiper a r m (F ig. 5) a n d (F ig. 6).
on t h e bla de u n t il t h e t a bs sn a p in t o posit ion (F ig. 5).
WI PER LI N K AGE
REMOVAL
(1) Rem ove t h e fr on t win dsh ield wiper u n it fr om
veh icle (Refer t o 8 - E LE CTRICAL/WIP E RS/WASH -
E RS/WIP E R MODULE - RE MOVAL).
(2) P la ce t h e wiper u n it on a su it a ble wor k su r-
fa ce.
(3) Rem ove n u t s h oldin g t h e cowl cover br a cket s t o
t h e wiper u n it .
(4) Rem ove cowl cover br a cket s fr om t h e wiper
Fig. 5 WINDSHIELD WIPER BLADE u n it .
1 - RELEASE TAB (5) Rem ove n u t s h oldin g lin ka ge t o t h e wiper u n it .
(6) Rem ove t h e wiper lin ka ge fr om t h e wiper u n it .
WI PER LI N K AGE (Cont inue d)
(7) Discon n ect t h e wir e con n ect or s fr om ba ck of (9) Rem ove n u t s h oldin g wiper m odu le t o lower
t h e wiper m ot or. win dsh ield fen ce.
(10) Rem ove bolt s h oldin g t h e wiper m odu le t o t h e
INSTALLATION da sh pa n el (F ig. 8).
(2) In st a ll t h e lin ka ge on t h e wiper u n it .
(3) In st a ll t h e n u t h oldin g t h e lin ka ge t o t h e wiper
u n it .
(4) In st a ll t h e cowl cover br a cket s t o t h e wiper
nut.
(5) In st a ll t h e fr on t wiper u n it (Refer t o 8 - E LE C-
TRICAL/WIP E RS/WASH E RS/WIP E R MODULE -
INSTALLATION).
(6) In st a ll t h e cowl cover.
(7) In st a ll t h e wiper a r m s a n d bla des.
WI PER M ODU LE
REMOVAL Fig. 8 WIPER MODULE
(1) Relea se t h e h ood la t ch a n d open h ood.
1 - BOLT
(2) Discon n ect a n d isola t e t h e ba t t er y n ega t ive 2 - NUTS
ca ble. 3 - BOLT
(3) Rem ove t h e wiper a r m s. 4 - WIPER MODULE
5 - WINDSHIELD
(4) Rem ove t h e cowl cover (Refer t o 23 - BODY/
E XTE RIOR/COWL GRILLE - RE MOVAL). (11) Lift wiper m odu le fr om weld-st u ds on lower
(5) Discon n ect t h e posit ive lock on t h e wiper m od- win dsh ield fen ce.
u le wir e con n ect or (F ig. 7).
CAUTION: Do not allow wiper module to rest on
brake master cylinder reservoir, damage to brake
system can result.
(12) Rem ove wiper m odu le.
INSTALLATION
(1) P osit ion t h e wiper m odu le in t o t h e cowl.
(2) In st a ll t h e bolt s t h a t secu r e t h e wiper m odu le
t o t h e da sh (F ig. 8).
(3) In st a ll t h e n u t s t h a t r et a in t h e wiper m odu le.
(4) Con n ect t h e dr a in t u bes t o t h e n ipples on t h e
wiper m odu le.
(5) Con n ect t h e win dsh ield wa sh er t u be.
(6) Con n ect t h e wir e h a r n ess con n ect or t o t h e
wiper m odu le (F ig. 8).
Fig. 7 WIPER MODULE WIRE CONNECTOR (7) Con n ect t h e posit ive lock on t h e wiper m odu le
1 - WIPER SYSTEM WIRE CONNECTOR
wir e con n ect or (F ig. 7).
2 - LOCK TAB
3 - POSITIVE LOCK CAUTION: Do not allow wiper module to rest on
4 - WIPER MODULE brake master cylinder reservoir, damage to brake
system can result.
(6) Discon n ect t h e wiper m odu le wir e con n ect or
fr om t h e en gin e com pa r t m en t wir e h a r n ess. (8) In st a ll t h e cowl cover (Refer t o 23 - BODY/E X-
(7) Discon n ect t h e win dsh ield wa sh er h ose fr om TE RIOR/COWL GRILLE - INSTALLATION).
cou plin g ou t side t h e m odu le. (9) In st a ll t h e wiper a r m s a n d bla des.
(8) Discon n ect t h e dr a in t u bes fr om n ipples on bot - (10) Con n ect t h e ba t t er y n ega t ive ca ble.
t om of t h e wiper m odu le. (11) Close t h e h ood.
RS NAVIGATION/TELECOMMUNICATION 8T - 1
NAVIGATION/TELECOMMUNICATION
page page
NAVIGATION/TELECOMMUNICATION HANDS FREE MODULE

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1 REMOVAL .............................3
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DIAGNOSIS AND TESTING
TELECOMMUNICATION . . . . . . . . . . . . . . . . . 1
N AV I GAT I ON / OPERATION
T ELECOM M U N I CAT I ON TELECOMMUNICATION
Two bu t t on s on t h e r ea r view m ir r or, iden t ified wit h
DESCRIPTION ISO icon s, con t r ol t h e syst em : A %ph on e% bu t t on t u r n s
t h e syst em on a n d off; a %voice r ecogn it ion % (or voice
TELECOMMUNICATIONS com m a n d) bu t t on pr om pt s t h e h a n ds-fr ee syst em t o
A h a n ds-fr ee cellu la r syst em is a n a va ila ble opt ion list en for a voice com m a n d. Th e syst em in clu des t h e
on t h is veh icle. It u ses Blu et oot h ™ t ech n ology t o pr o- followin g fea t u r es:
vide wir eless com m u n ica t ion bet ween t h e oper a t or ’s • P h on ebook - St or es t eleph on e n u m ber s for la t er
com pa t ible cellu la r t eleph on e a n d t h e veh icle’s r eca ll by n a m e or ot h er ver ba l iden t ifica t ion , ca lled a
on -boa r d r eceiver. voice t a g, a n d m em or y loca t ion .
Th e syst em u ses voice r ecogn it ion t ech n ology t o • F ou r m em or y loca t ion s - H om e, Wor k, Mobile
con t r ol oper a t ion . Th e in com in g voice is br oa dca st a n d P a ger. A m a xim u m of 32 u n iqu e n a m es or voice
t h r ou gh t h e veh icle’s r a dio spea ker s, a u t om a t ica lly t a gs m a y be st or ed a t t h e sa m e t im e, wit h a differ en t
over r idin g a n y ot h er a u dio sign a ls on t h e spea ker s n u m ber in ea ch of t h e fou r m em or y loca t ion s.
wh en t h e h a n ds-fr ee syst em is in u se. A m icr oph on e • Voice t a g dia lin g - Dia ls t h e n u m ber a ssocia t ed
in t h e r ea r view m ir r or picks u p veh icle occu pa n t ’s wit h a voice t a g a n d m em or y loca t ion .
voices. If a ca ll is in pr ogr ess wh en t h e ign it ion is • Digit dia lin g - Dia ls t h e t eleph on e n u m ber by
swit ch ed off, t h e h a n ds-fr ee syst em will con t in u e t o r ecogn izin g t h e n a m es of t h e digit s a s t h ey a r e spo-
oper a t e for u p t o 45 secon ds a s pa r t of t h e Accessor y ken .
Rela y Dela y fu n ct ion . Th er ea ft er, t h e ca ll ca n con - • Receivin g ca lls - A voice pr om pt n ot ifies t h e u ser
t in u e on t h e h a n d-h eld t eleph on e. of a n in com in g ca ll. P r essin g t h e “ph on e” bu t t on
Th e cen t er con sole fr on t st or a ge com pa r t m en t a n swer s t h e ca ll.
in clu des a cellu la r t eleph on e h older, bu t t h e syst em • P r iva cy Mode - Swit ch es t h e ca ll t o t h e h a n d-
will com m u n ica t e wit h a t eleph on e t h a t is a n ywh er e h eld t eleph on e a n d t h e h a n ds-fr ee syst em a n d ba ck
wit h in t h e veh icle. H owever, cover in g t h e h a n d h eld a ga in u sin g t h e “voice r ecogn it ion ” (or “voice com -
ph on e or t h e h a n ds-fr ee ph on e m odu le wit h a m et a l m a n d”) bu t t on a n d a voice com m a n d, if desir ed.
object m a y block t h e sign a l. Th e syst em will r ecog-
n ize u p t o seven t eleph on es, ea ch of wh ich is given a
spoken iden t ifica t ion by t h e u ser du r in g t h e set u p DI AGN OSI S AN D T EST I N G
pr ocess. Th e syst em in clu des Spa n ish voice r ecogn i-
t ion in a ddit ion t o E n glish . TELECOMMUNICATION
Two bu t t on s on t h e r ea r view m ir r or, iden t ified wit h An y d ia g n o s is o f th e Te le c o m m u n ic a tio n s y s -
ISO icon s, con t r ol t h e syst em : A %ph on e% bu t t on t u r n s te m s h o u ld be g in w ith th e u s e o f th e D RB III!
t h e syst em on a n d off; a %voice r ecogn it ion % (or voice d ia g n o s tic to o l. F o r in fo rm a tio n o n th e u s e o f
com m a n d) bu t t on pr om pt s t h e h a n ds-fr ee syst em t o th e D RB III!, re fe r to th e a p p ro p ria te D ia g n o s -
list en for a voice com m a n d. tic S e rv ic e In fo rm a tio n .
F or com plet e cir cu it dia gr a m s, r efer t o t h e a ppr o-
pr ia t e wir in g in for m a t ion .
8T - 2 NAVIGATION/TELECOMMUNICATION RS
N AV I GAT I ON /T ELECOM M U N I CAT I ON (Cont inue d)
WARNING: ON VEHICLES EQUIPPED WITH AIR- COMPONENT DIAGNOSIS OR SERVICE. FAILURE
BAGS, REFER TO ELECTRICAL, RESTRAINTS TO TAKE THE PROPER PRECAUTIONS COULD
BEFORE ATTEMPTING ANY STEERING WHEEL, RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT
STEERING COLUMN, OR INSTRUMENT PANEL AND POSSIBLE PERSONAL INJURY.
T ELECOM M U N I CAT I ON SY ST EM DI AGN OSI S

Phone Not 1. Bluetooth phone not 1. Ensure that phone(s) are paired to the system.
Available paired to the system.
2. Bluetooth phone not 2. Make sure paired phone is present, turned ON and that the
present or turned OFF. Bluetooth option is enabled on the phone.
3. Bluetooth phone has 3. At low battery levels, some phones will turn off Bluetooth
low battery. functionality. Ensure cellular phone is charged to an adequate
level.
Phone Pairing 1. Phone does not 1. The Telecommunication system requires the cellular phone to
Failed support Hands Free be Bluetooth™ enabled, as well as supporting the Hands Free
Profile Profile. The customer will have to upgrade their phone to one
supporting Hands Free Profile. A list of suggested phones is
available at: http://www.chrysler.com/uconnect.
2. Phone not Bluetooth 2. The Telecommunication system requires the cellular phone to
enabled. be Bluetooth™ enabled. A list of suggested phones is available
at: http://www.chrysler.com/uconnect.
3. PIN entered on the 3. The PIN spoken to the system must be the same PIN entered
phone is not the same into the phone.
as PIN spoken to the
system.
4. Phone has reached 4. Remove one of the previously paired devices from it’s list.
maximum number of
allowed devices paired.
Poor Voice 1. Microphone failure 1. Using a scan tool, check for microphone fault codes.
Recognition
2. Customer not waiting 2. Ensure customer is waiting for the system %beep% prior to
for the beep before beginning the speech to be recognized.
speaking.
3. Customer not 3. Verify that the customer is attempting to use the system with a
speaking in a smooth smooth consistent voice. The system is designed to accept
normal manner. normal speech spoken at a normal tone, some people tend to
speak to a computer loud and slow, which results in reduced
performance.
4. Rear view mirror not 4. Mirror must be firmly mounted to the mounting location. Ensure
properly attached to that mirror is tightened to the specified torque.
mounting.
5. High levels of noise in 5. System performance is increased when noise conditions in the
vehicle compartment vehicle are lowered. Ideal conditions include windows closed.
6. Object interfering with 6. Verify that there is no object, hanging from the mirror, that
microphone input could be obstructing the microphone.
7. User not saying %send% 7. User must say %send% at the end of a Pager Dialing request.
after a pager dialing
request
RS NAVIGATION/TELECOMMUNICATION 8T - 3
N AV I GAT I ON /T ELECOM M U N I CAT I ON (Cont inue d)

8. Other passengers 8. Although designed for primary use by the driver, the
talking while customer is microphone will pick up passengers in any seat of the vehicle.
attempting to use the System performance is increased in low noise environments.
system
Phonebook 1. Phonebook names 1. For increased system performance, it is recommended that the
names not recorded in high noise phone book entries are recorded in a low noise environment. That
recognized conditions is, vehicle in park, with windows up.
consistently
2. Phonebook name(s) 2. For increased performance it is recommended that the user
short use both first and last name as a phonebook entry. Example %
Daniel James% as opposed to %Dan%.
3. Phonebook names 3. It is recommended that each user of the system record their
recorded by another user own phonebook entries. This will increase the recognition
performance.
4. Similar names in 4. For increased system performance it is recommended that the
phonebook user do not enter similar sounding names in the phonebook.
5. Object interfering with 5. Object interfering with microphone input.
microphone input
Poor Phone 1. Microphone failure 1. Use a scan tool, and check for Microphone faults.
audio quality.
2. Rear view mirror not 2. Mirror must be firmly mounted to the mounting location. Tighten
properly fixed to mirror to the specified torque.
mounting button
3. System being used in 3. System performance is increased when noise conditions in the
high noise conditions vehicle are lowered. Ideal conditions include windows closed.
No Phone Audio 1. Phone setting cause 1. Route audio to %Hands free% device.
phone audio to be routed
to handset.
H AN DS FREE M ODU LE
REMOVAL
ca ble.
(2) Rem ove t h e in st r u m en t pa n el lower con sole
(Refer t o 23 - BODY/INSTRUME NT PANE L/STOR-
AGE BIN - RE MOVAL).
(3) Rem ove t h e m ou n t in g fa st en er s (F ig. 1).
(4) Discon n ect t h e elect r ica l h a r n ess con n ect or a n d
r em ove m odu le.
INSTALLATION
(1) Con n ect elect r ica l h a r n ess con n ect or a n d posi-
t ion m odu le.
(2) In st a ll m ou n t in g fa st en er s.
Fig. 1 HANDS FREE MODULE
(3) In st a ll in st r u m en t pa n el lower con sole (Refer t o
23 - BODY/INSTRUME NT PANE L/STORAGE BIN - (4) Con n ect ba t t er y n ega t ive ca ble.
INSTALLATION).
RS WIRING 8W - 1
WIRING
page page
WIRING DIAGRAM INFORMATION. . . . . . . 8W-01-1 REAR WINDOW DEFOGGER. . . . . . . . . . . . 8W-48-1

COMPONENT INDEX. . . . . . . . . . . . . . . . . . 8W-02-1 OVERHEAD CONSOLE. . . . . . . . . . . . . . . . . 8W-49-1
POWER DISTRIBUTION . . . . . . . . . . . . . . . 8W-10-1 FRONT LIGHTING. . . . . . . . . . . . . . . . . . . . 8W-50-1
GROUND DISTRIBUTION . . . . . . . . . . . . . . 8W-15-1 REAR LIGHTING. . . . . . . . . . . . . . . . . . . . . 8W-51-1
BUS COMMUNICATIONS . . . . . . . . . . . . . . 8W-18-1 TURN SIGNALS. . . . . . . . . . . . . . . . . . . . . . 8W-52-1
CHARGING SYSTEM. . . . . . . . . . . . . . . . . . 8W-20-1 WIPERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-1
STARTING SYSTEM . . . . . . . . . . . . . . . . . . 8W-21-1 TRAILER TOW. . . . . . . . . . . . . . . . . . . . . . . 8W-54-1
FUEL/IGNITION SYSTEM . . . . . . . . . . . . . . 8W-30-1 NAVIGATION/TELECOMMUNICATIONS. . . . 8W-55-1
TRANSMISSION CONTROL SYSTEM . . . . . 8W-31-1 CONVENIENCE SYSTEMS. . . . . . . . . . . . . . 8W-56-1
VEHICLE SPEED CONTROL . . . . . . . . . . . . 8W-33-1 POWER WINDOWS. . . . . . . . . . . . . . . . . . . 8W-60-1
ANTILOCK BRAKES. . . . . . . . . . . . . . . . . . . 8W-35-1 POWER DOOR LOCKS . . . . . . . . . . . . . . . . 8W-61-1
VEHICLE THEFT SECURITY SYSTEM. . . . . 8W-39-1 POWER MIRRORS . . . . . . . . . . . . . . . . . . . 8W-62-1
INSTRUMENT CLUSTER. . . . . . . . . . . . . . . 8W-40-1 POWER SEATS . . . . . . . . . . . . . . . . . . . . . . 8W-63-1
HORN/CIGAR LIGHTER/POWER OUTLET. . 8W-41-1 POWER SUNROOF . . . . . . . . . . . . . . . . . . . 8W-64-1
AIR CONDITIONING-HEATER . . . . . . . . . . . 8W-42-1 SPLICE INFORMATION. . . . . . . . . . . . . . . . 8W-70-1
OCCUPANT RESTRAINT SYSTEM. . . . . . . . 8W-43-1 CONNECTOR PIN-OUTS . . . . . . . . . . . . . . . 8W-80-1
INTERIOR LIGHTING. . . . . . . . . . . . . . . . . . 8W-44-1 CONNECTOR/GROUND/SPLICE
BODY CONTROL MODULE. . . . . . . . . . . . . 8W-45-1 LOCATION . . . . . . . . . . . . . . . . . . . . . . . . 8W-91-1
MESSAGE CENTER. . . . . . . . . . . . . . . . . . . 8W-46-1 POWER DISTRIBUTION SYSTEM. . . . . . . . 8W-97-1
AUDIO SYSTEM . . . . . . . . . . . . . . . . . . . . . 8W-47-1
RS 8W-01 WIRING DIAGRAM INFORMATION 8W - 01 - 1
8 W-0 1 WI RI N G DI AGRAM I N FORM AT I ON
TABLE OF CONTENTS
page page
WIRING DIAGRAM INFORMATION STANDARD PROCEDURE - TESTING FOR A

DESCRIPTION SHORT TO GROUND . . . . . . . . . . . . . . . . . . . 9
DESCRIPTION - HOW TO USE WIRING STANDARD PROCEDURE - TESTING FOR A
DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . ...1 SHORT TO GROUND ON FUSES
DESCRIPTION - CIRCUIT INFORMATION . ...5 POWERING SEVERAL LOADS . . . . . . . . . . . 10
DESCRIPTION - CIRCUIT FUNCTIONS . . . ...6 STANDARD PROCEDURE - TESTING FOR A
DESCRIPTION - SECTION IDENTIFICATION VOLTAGE DROP . . . . . . . . . . . . . . . . . . . . . . 10
AND INFORMATION . . . . . . . . . . . . . . . . . ...6 SPECIAL TOOLS
DESCRIPTION - CONNECTOR, GROUND WIRING/TERMINAL . . . . . . . . . . . . . . . . . . . . 10
AND SPLICE INFORMATION . . . . . . . . . . . ...7 CONNECTOR
WARNING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
WARNINGS - GENERAL . . . . . . . . . . . . . . ...7 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 11
DIAGNOSIS AND TESTING - WIRING DIODE
HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . ...7 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
STANDARD PROCEDURE - TERMINAL
ELECTROSTATIC DISCHARGE (ESD) REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
SENSITIVE DEVICES . . . . . . . . . . . . . . . . ...8 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 14
STANDARD PROCEDURE - TESTING OF WIRE
VOLTAGE POTENTIAL . . . . . . . . . . . . . . . . ...9 STANDARD PROCEDURE - WIRE SPLICING . . 15
STANDARD PROCEDURE - TESTING FOR
CONTINUITY . . . . . . . . . . . . . . . . . . . . . . . ...9
WI RI N G DI AGRAM Com pon en t s a r e sh own t wo wa ys. A solid lin e

a r ou n d a com pon en t in dica t es t h a t t h e com pon en t is
I N FORM AT I ON com plet e. A da sh ed lin e a r ou n d t h e com pon en t in di-
ca t es t h a t t h e com pon en t is bein g sh own is n ot com -
plet e. In com plet e com pon en t s h a ve a r efer en ce
DESCRI PT I ON n u m ber t o in dica t e t h e pa ge wh er e t h e com pon en t is
sh own com plet e.
DESCRIPTION - HOW TO USE WIRING It is im por t a n t t o r ea lize t h a t n o a t t em pt is m a de
DIAGRAMS on t h e dia gr a m s t o r epr esen t com pon en t s a n d wir in g
Da im ler Ch r ysler Cor por a t ion wir in g dia gr a m s a r e a s t h ey a ppea r on t h e veh icle. F or exa m ple, a sh or t
design ed t o pr ovide in for m a t ion r ega r din g t h e veh i- piece of wir e is t r ea t ed t h e sa m e a s a lon g on e. In
cles wir in g con t en t . In or der t o effect ively u se t h e a ddit ion , swit ch es a n d ot h er com pon en t s a r e sh own
wir in g dia gr a m s to dia gn ose and r epa ir a s sim ply a s possible, wit h r ega r d t o fu n ct ion on ly.
Da im ler Ch r ysler Cor por a t ion veh icles, it is im por t a n t
t o u n der st a n d a ll of t h eir fea t u r es a n d ch a r a ct er is- SYMBOLS
t ics. In t er n a t ion a l sym bols a r e u sed t h r ou gh ou t t h e wir-
Dia gr a m s a r e a r r a n ged su ch t h a t t h e power (B+) in g dia gr a m s. Th ese sym bols a r e con sist en t wit h
side of t h e cir cu it is pla ced n ea r t h e t op of t h e pa ge, t h ose bein g u sed a r ou n d t h e wor ld (F ig. 3).
a n d t h e gr ou n d (B-) side of t h e cir cu it is pla ced n ea r
t h e bot t om of t h e pa ge (F ig. 1).
All swit ch es, com pon en t s, a n d m odu les a r e sh own
in t h e a t r est posit ion wit h t h e door s closed a n d t h e
key r em oved fr om t h e ign it ion (F ig. 2).
8W - 01 - 2 8W-01 WIRING DIAGRAM INFORMATION RS
WI RI N G DI AGRAM I N FORM AT I ON (Cont inue d)
Fig. 1 WIRING DIAGRAM EXAMPLE 1

Fig. 2 WIRING DIAGRAM EXAMPLE 2

Fig. 3 WIRING DIAGRAM SYMBOLS

TERMINOLOGY WI RE COLOR CODE CH ART
Th is is a list of t er m s a n d defin it ion s u sed in t h e
wir in g dia gr a m s. COLOR CODE COLOR
BL BLUE
LH D . . . . . . . . . . . . . . . . . Left H a n d Dr ive Veh icles
RH D . . . . . . . . . . . . . . . Righ t H a n d Dr ive Veh icles BK BLACK
ATX . . Au t om a t ic Tr a n sm ission s-F r on t Wh eel Dr ive BR BROWN
MTX . . . Ma n u a l Tr a n sm ission s-F r on t Wh eel Dr ive DB DARK BLUE
AT . . . . Au t om a t ic Tr a n sm ission s-Rea r Wh eel Dr ive
DG DARK GREEN
MT . . . . . Ma n u a l Tr a n sm ission s-Rea r Wh eel Dr ive
SOH C . . . . . . . . . . . Sin gle Over H ea d Ca m E n gin e GY GRAY
DOH C . . . . . . . . . . Dou ble Over H ea d Ca m E n gin e LB LIGHT BLUE
E xpor t . . Veh icles Bu ilt F or Sa le In Ma r ket s Ot h er LG LIGHT GREEN
Th a n Nor t h Am er ica
OR ORANGE
E xcept E xpor t . . . . Veh icles Bu ilt F or Sa le In Nor t h
Am er ica PK PINK
RD RED
DESCRIPTION - CIRCUIT INFORMATION
TN TAN
E a ch wir e sh own in t h e dia gr a m s con t a in s a code
wh ich iden t ifies t h e m a in cir cu it , pa r t of t h e m a in VT VIOLET
cir cu it , ga ge of wir e, a n d color (F ig. 4). WT WHITE
YL YELLOW
* WITH TRACER
Fig. 4 WIRE CODE IDENTIFICATION

1 - COLOR OF WIRE (LIGHT BLUE WITH YELLOW TRACER
2 - GAGE OF WIRE (18 GAGE)
3 - PART OF MAIN CIRCUIT (VARIES DEPENDING ON
EQUIPMENT)
4 - MAIN CIRCUIT IDENTIFICATION
DESCRIPTION - CIRCUIT FUNCTIONS DESCRIPTION - SECTION IDENTIFICATION AND

All cir cu it s in t h e dia gr a m s u se a n a lph a /n u m er ic INFORMATION
code t o iden t ify t h e wir e a n d it ’s fu n ct ion . To iden t ify Th e wir in g dia gr a m s a r e gr ou ped in t o in dividu a l
wh ich cir cu it code a pplies t o a syst em , r efer t o t h e sect ion s. If a com pon en t is m ost likely fou n d in a pa r-
Cir cu it Iden t ifica t ion Code Ch a r t . Th is ch a r t sh ows t icu la r gr ou p, it will be sh own com plet e (a ll wir es,
t h e m a in cir cu it s on ly a n d does n ot sh ow t h e secon d- con n ect or s, a n d pin s) wit h in t h a t gr ou p. F or exa m -
a r y codes t h a t m a y a pply t o som e m odels. ple, t h e Au t o Sh u t down Rela y is m ost likely t o be
fou n d in Gr ou p 30, so it is sh own t h er e com plet e. It
CI RCU I T I DEN T I FI CAT I ON CODE CH ART
ca n , h owever, be sh own pa r t ia lly in a n ot h er gr ou p if
it con t a in s som e a ssocia t ed wir in g.
CIRCUIT FUNCTION Splice dia gr a m s in Sect ion 8W-70 sh ow t h e en t ir e
A BATTERY FEED splice a n d pr ovide r efer en ces t o ot h er sect ion s t h e
B BRAKE CONTROLS splices ser ves. Sect ion 8W-70 on ly con t a in s splice dia -
gr a m s t h a t a r e n ot sh own in t h eir en t ir et y som e-
C CLIMATE CONTROLS wh er e else in t h e wir in g dia gr a m s.
D DIAGNOSTIC CIRCUITS Sect ion 8W-80 sh ows ea ch con n ect or a n d t h e cir-
E DIMMING ILLUMINATION cu it s in volved wit h t h a t con n ect or. Th e con n ect or s
CIRCUITS a r e iden t ified u sin g t h e n a m e/n u m ber on t h e dia -
gr a m pa ges.
F FUSED CIRCUITS
G MONITORING CIRCUITS WI RI N G SECT I ON CH ART
(GAUGES)
H MULTIPLE GROUP TOPIC
I NOT USED 8W-01 thru General information and Diagram
J OPEN 8W-09 Overview
K POWERTRAIN CONTROL 8W-10 thru Main Sources of Power and
MODULE 8W-19 Vehicle Grounding
L EXTERIOR LIGHTING 8W-20 thru Starting and Charging
M INTERIOR LIGHTING 8W-29
N MULTIPLE 8W-30 thru Powertrain/Drivetrain Systems
8W-39
O NOT USED
8W-40 thru Body Electrical items and A/C
P POWER OPTION (BATTERY 8W-49
FEED)
8W-50 thru Exterior Lighting, Wipers and
Q POWER OPTIONS (IGNITION 8W-59 Trailer Tow
FEED)
8W-60 thru Power Accessories
R PASSIVE RESTRAINT 8W-69
S SUSPENSION/STEERING 8W-70 Splice Information
T TRANSMISSION/TRANSAXLE/ 8W-80 Connector Pin Outs
TRANSFER CASE
8W-91 Connector, Ground and Splice
U OPEN Locations
V SPEED CONTROL, WIPER/
WASHER
W WIPERS
X AUDIO SYSTEMS
Y TEMPORARY
Z GROUNDS
DESCRIPTION - CONNECTOR, GROUND AND WARNING: BE SURE THAT THE IGNITION SWITCH
ALWAYS IS IN THE OFF POSITION, UNLESS THE
SPLICE INFORMATION
PROCEDURE REQUIRES IT TO BE ON.
CAUTION: Not all connectors are serviced. Some
connectors are serviced only with a harness. A typ- WARNING: SET THE PARKING BRAKE WHEN
ical example might be the Supplemental Restraint WORKING ON ANY VEHICLE. AN AUTOMATIC
System connectors. Always check parts availability TRANSMISSION SHOULD BE IN PARK. A MANUAL
before attempting a repair. TRANSMISSION SHOULD BE IN NEUTRAL.
IDENTIFICATION WARNING: OPERATE THE ENGINE ONLY IN A

In -lin e con n ect or s a r e iden t ified by a n u m ber, a s WELL-VENTILATED AREA.
follows:
• In -lin e con n ect or s loca t ed in t h e en gin e com pa r t -
m en t a r e C100 ser ies n u m ber s WARNING: KEEP AWAY FROM MOVING PARTS
• In -lin e con n ect or s loca t ed in t h e In st r u m en t WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
P a n el a r ea a r e C200 ser ies n u m ber s. FAN AND BELTS.
• In -lin e con n ect or s loca t ed in t h e body a r e C300
ser ies n u m ber s.
WARNING: TO PREVENT SERIOUS BURNS, AVOID
• J u m per h a r n ess con n ect or s a r e C400 ser ies
CONTACT WITH HOT PARTS SUCH AS THE RADIA-
n u m ber s.
TOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATA-
• Gr ou n ds a n d gr ou n d con n ect or s a r e iden t ified
LYTIC CONVERTER AND MUFFLER.
wit h a “G” a n d follow t h e sa m e ser ies n u m ber in g a s
t h e in -lin e con n ect or s.
• Splices a r e iden t ified wit h a n “S” a n d follow t h e WARNING: DO NOT ALLOW FLAME OR SPARKS
sa m e ser ies n u m ber in g a s t h e in -lin e con n ect or s. NEAR THE BATTERY. GASES ARE ALWAYS
• Com pon en t con n ect or s a r e iden t ified by t h e com - PRESENT IN AND AROUND THE BATTERY.
pon en t n a m e in st ea d of a n u m ber. Mu lt iple con n ec-
t or s on a com pon en t u se a C1, C2, et c. iden t ifier.
WARNING: ALWAYS REMOVE RINGS, WATCHES,
LOCATIONS LOOSE HANGING JEWELRY AND AVOID LOOSE
Sect ion 8W-91 con t a in s con n ect or /gr ou n d/splice CLOTHING.
loca t ion illu st r a t ion s. Th e illu st r a t ion s con t a in t h e
con n ect or n a m e (or n u m ber )/gr ou n d n u m ber /splice
n u m ber a n d com pon en t iden t ifica t ion . Con n ect or / DIAGNOSIS AND TESTING - WIRING HARNESS
gr ou n d/splice loca t ion ch a r t s in sect ion 8W-91 r efer-
en ce t h e figu r e n u m ber s of t h e illu st r a t ion s. TROUBLESHOOTING TOOLS
Th e a bbr evia t ion T/O is u sed in t h e com pon en t Wh en dia gn osin g a pr oblem in a n elect r ica l cir cu it
loca t ion sect ion t o in dica t e a poin t in wh ich t h e wir- t h er e a r e sever a l com m on t ools n ecessa r y. Th ese t ools
in g h a r n ess br a n ch es ou t t o a com pon en t . Th e a bbr e- a r e list ed a n d expla in ed below.
via t ion N/S m ea n s Not Sh own in t h e illu st r a t ion s • J u m per Wir e - Th is is a t est wir e u sed t o con -
n ect t wo poin t s of a cir cu it . It ca n be u sed t o bypa ss
a n open in a cir cu it .
WARN I N G
WARNING: NEVER USE A JUMPER WIRE ACROSS
WARNINGS - GENERAL A LOAD, SUCH AS A MOTOR, CONNECTED
WARN IN GS pr ovide in for m a t ion t o pr even t per- BETWEEN A BATTERY FEED AND GROUND.
son a l in ju r y a n d veh icle da m a ge. Below is a list of
gen er a l wa r n in gs t h a t sh ou ld be followed a n y t im e a • Volt m et er - Used t o ch eck for volt a ge on a cir-
veh icle is bein g ser viced. cu it . Alwa ys con n ect t h e bla ck lea d t o a kn own good
gr ou n d a n d t h e r ed lea d t o t h e posit ive side of t h e
WARNING: ALWAYS WEAR SAFETY GLASSES FOR cir cu it .
EYE PROTECTION.
CAUTION: Most of the electrical components used
in today’s vehicles are Solid State. When checking
WARNING: USE SAFETY STANDS ANYTIME A PRO- voltages in these circuits, use a meter with a 10 -
CEDURE REQUIRES BEING UNDER A VEHICLE. megohm or greater impedance rating.
• Oh m m et er - Used t o ch eck t h e r esist a n ce fa ct or y it em s a dded t o t h e veh icle befor e doin g a n y
bet ween t wo poin t s of a cir cu it . Low or n o r esist a n ce dia gn osis. If t h e veh icle is equ ipped wit h t h ese it em s,
in a cir cu it m ea n s good con t in u it y. discon n ect t h em t o ver ify t h ese a dd-on it em s a r e n ot
t h e ca u se of t h e pr oblem .
CAUTION: Most of the electrical components used (1) Ver ify t h e pr oblem .
in today’s vehicles are Solid State. When checking (2) Ver ify a n y r ela t ed sym pt om s. Do t h is by per-
resistance in these circuits use a meter with a 10 - for m in g oper a t ion a l ch ecks on com pon en t s t h a t a r e
megohm or greater impedance rating. In addition, in t h e sa m e cir cu it . Refer t o t h e wir in g dia gr a m s.
make sure the power is disconnected from the cir- (3) An a lyze t h e sym pt om s. Use t h e wir in g dia -
cuit. Circuits that are powered up by the vehicle’s gr a m s t o det er m in e wh a t t h e cir cu it is doin g, wh er e
electrical system can cause damage to the equip- t h e pr oblem m ost likely is occu r r in g a n d wh er e t h e
ment and provide false readings. dia gn osis will con t in u e.
(4) Isola t e t h e pr oblem a r ea .
• P r obin g Tools - Th ese t ools a r e u sed for pr obin g (5) Repa ir t h e pr oblem a r ea .
t er m in a ls in con n ect or s (F ig. 5). Select t h e pr oper (6) Ver ify t h e pr oper oper a t ion . F or t h is st ep,
size t ool fr om Specia l Tool P a cka ge 6807, a n d in ser t ch eck for pr oper oper a t ion of a ll it em s on t h e
it in t o t h e t er m in a l bein g t est ed. Use t h e ot h er en d r epa ir ed cir cu it . Refer t o t h e wir in g dia gr a m s.
of t h e t ool t o in ser t t h e m et er pr obe.

STANDARD PROCEDURE - ELECTROSTATIC
DISCHARGE (ESD) SENSITIVE DEVICES
All E SD sen sit ive com pon en t s a r e solid st a t e a n d a
sym bol (F ig. 6) is u sed t o in dica t e t h is. Wh en h a n -
dlin g a n y com pon en t wit h t h is sym bol, com ply wit h
t h e followin g pr ocedu r es t o r edu ce t h e possibilit y of
Fig. 5 PROBING TOOL elect r ost a t ic ch a r ge bu ild u p on t h e body a n d in a d-
ver t en t disch a r ge in t o t h e com pon en t . If it is n ot
2 - PROBING END kn own wh et h er t h e pa r t is E SD sen sit ive, a ssu m e
t h a t it is.
INTERMITTENT AND POOR CONNECTIONS (1) Alwa ys t ou ch a kn own good gr ou n d befor e h a n -
Most in t er m it t en t elect r ica l pr oblem s a r e ca u sed dlin g t h e pa r t . Th is sh ou ld be r epea t ed wh ile h a n -
by fa u lt y elect r ica l con n ect ion s or wir in g. It is a lso dlin g t h e pa r t a n d m or e fr equ en t ly a ft er slidin g
possible for a st ickin g com pon en t or r ela y t o ca u se a a cr oss a sea t , sit t in g down fr om a st a n din g posit ion ,
pr oblem . Befor e con dem n in g a com pon en t or wir in g or wa lkin g a dist a n ce.
a ssem bly, ch eck t h e followin g it em s. (2) Avoid t ou ch in g elect r ica l t er m in a ls of t h e pa r t ,
• Con n ect or s a r e fu lly sea t ed u n less in st r u ct ed t o do so by a wr it t en pr ocedu r e.
• Spr ea d t er m in a ls, or t er m in a l pu sh ou t (3) Wh en u sin g a volt m et er, be su r e t o con n ect t h e
• Ter m in a ls in t h e wir in g a ssem bly a r e fu lly sea t ed gr ou n d lea d fir st .
in t o t h e con n ect or /com pon en t a n d locked in t o posit ion (4) Do n ot r em ove t h e pa r t for m it ’s pr ot ect ive
• Dir t or cor r osion on t h e t er m in a ls. An y a m ou n t pa ckin g u n t il it is t im e t o in st a ll t h e pa r t .
of cor r osion or dir t cou ld ca u se a n in t er m it t en t pr ob- (5) Befor e r em ovin g t h e pa r t fr om it ’s pa ka ge,
lem gr ou n d t h e pa ka ge t o a kn own good gr ou n d on t h e
• Da m a ged con n ect or /com pon en t ca sin g exposin g veh icle.
t h e it em t o dir t or m oist u r e
• Wir e in su la t ion t h a t h a s r u bbed t h r ou gh ca u sin g
a sh or t t o gr ou n d
• Som e or a ll of t h e wir in g st r a n ds br oken in side
of t h e in su la t ion
• Wir in g br oken in side of t h e in su la t ion
TROUBLESHOOTING WIRING PROBLEMS

Wh en t r ou blesh oot in g wir in g pr oblem s t h er e a r e
six st eps wh ich ca n a id in t h e pr ocedu r e. Th e st eps
a r e list ed a n d expla in ed below. Alwa ys ch eck for n on - Fig. 6 ELECTROSTATIC DISCHARGE SYMBOL
STANDARD PROCEDURE - TESTING OF STANDARD PROCEDURE - TESTING FOR

VOLTAGE POTENTIAL CONTINUITY
(1) Con n ect t h e gr ou n d lea d of a volt m et er t o a (1) Rem ove t h e fu se for t h e cir cu it bein g ch ecked
kn own good gr ou n d (F ig. 7). or, discon n ect t h e ba t t er y.
(2) Con n ect t h e ot h er lea d of t h e volt m et er t o t h e (2) Con n ect on e lea d of t h e oh m m et er t o on e side
select ed t est poin t . Th e veh icle ign it ion m a y n eed t o of t h e cir cu it bein g t est ed (F ig. 8).
be t u r n ed ON t o ch eck volt a ge. Refer t o t h e a ppr opr i- (3) Con n ect t h e ot h er lea d t o t h e ot h er en d of t h e
a t e t est pr ocedu r e. cir cu it bein g t est ed. Low or n o r esist a n ce m ea n s good
con t in u it y.
Fig. 7 TESTING FOR VOLTAGE POTENTIAL

Fig. 8 TESTING FOR CONTINUITY
1 - FUSE REMOVED FROM CIRCUIT
STANDARD PROCEDURE - TESTING FOR A

SHORT TO GROUND
(1) Rem ove t h e fu se a n d discon n ect a ll it em s
in volved wit h t h e fu se.
(2) Con n ect a t est ligh t or a volt m et er a cr oss t h e
t er m in a ls of t h e fu se.
(3) St a r t in g a t t h e fu se block, wiggle t h e wir in g
h a r n ess a bou t six t o eigh t in ch es a pa r t a n d wa t ch
t h e volt m et er /t est la m p.
(4) If t h e volt m et er r egist er s volt a ge or t h e t est
la m p glows, t h er e is a sh or t t o gr ou n d in t h a t gen -
er a l a r ea of t h e wir in g h a r n ess.
STANDARD PROCEDURE - TESTING FOR A SPECI AL T OOLS

SHORT TO GROUND ON FUSES POWERING
SEVERAL LOADS WIRING/TERMINAL
(1) Refer t o t h e wir in g dia gr a m s a n d discon n ect or
isola t e a ll it em s on t h e su spect ed fu sed cir cu it s.
(2) Repla ce t h e blown fu se.
(3) Su pply power t o t h e fu se by t u r n in g ON t h e
ign it ion swit ch or r e-con n ect in g t h e ba t t er y.
(4) St a r t con n ect in g or en er gizin g t h e it em s in t h e
fu se cir cu it on e a t a t im e. Wh en t h e fu se blows t h e
cir cu it wit h t h e sh or t t o gr ou n d h a s been isola t ed.
STANDARD PROCEDURE - TESTING FOR A

VOLTAGE DROP PROBING TOOL PACKAGE 6807
(1) Con n ect t h e posit ive lea d of t h e volt m et er t o
t h e side of t h e cir cu it closest t o t h e ba t t er y (F ig. 9).
(2) Con n ect t h e ot h er lea d of t h e volt m et er t o t h e
ot h er side of t h e swit ch , com pon en t or cir cu it .
(3) Oper a t e t h e it em .
(4) Th e volt m et er will sh ow t h e differ en ce in volt -
a ge bet ween t h e t wo poin t s.
TERMINAL PICK TOOL SET 6680
Fig. 9 TESTING FOR VOLTAGE DROP TERMINAL REMOVING TOOLS 6932 AND 8638
TERMINAL REMOVING TOOL 6934

CON N ECT OR INSTALLATION

(1) In ser t t h e r em oved t er m in a l in t h e sa m e ca vit y
REMOVAL on t h e r epa ir con n ect or.
(1) Discon n ect ba t t er y. (2) Repea t st eps for ea ch t er m in a l in t h e con n ec-
(2) Relea se Con n ect or Lock (F ig. 10). t or, bein g su r e t h a t a ll wir es a r e in ser t ed in t o t h e
(3) Discon n ect t h e con n ect or bein g r epa ir ed fr om pr oper ca vit ies. F or a ddit ion a l con n ect or pin -ou t
it s m a t in g h a lf/com pon en t . iden t ifica t ion , r efer t o t h e wir in g dia gr a m s.
(4) Rem ove t h e dr ess cover (if a pplica ble) (F ig. 10). (3) Wh en t h e con n ect or is r e-a ssem bled, t h e sec-
on da r y t er m in a l lock m u st be pla ced in t h e locked
posit ion t o pr even t t er m in a l pu sh ou t .
(4) Repla ce dr ess cover (if a pplica ble).
(5) Con n ect con n ect or t o it s m a t in g h a lf/com po-
n en t .
(6) Con n ect ba t t er y a n d t est a ll a ffect ed syst em s.
Fig. 10 REMOVAL OF DRESS COVER

1 - DRESS COVER
2 - CONNECTOR LOCK
3 - CONNECTOR
(5) Relea se t h e Secon da r y Ter m in a l Lock, if

r equ ir ed (F ig. 11).
(6) P osit ion t h e con n ect or lockin g fin ger a wa y fr om
t h e t er m in a l u sin g t h e pr oper specia l t ool. P u ll on
t h e wir e t o r em ove t h e t er m in a l fr om t h e con n ect or
(F ig. 12).
CON N ECT OR (Cont inue d)
Fig. 11 EXAMPLES OF CONNECTOR SECONDARY TERMINAL LOCKS

1 - Secondary Terminal Lock
CON N ECT OR (Cont inue d)
Fig. 12 TERMINAL REMOVAL

1 - TYPICAL CONNECTOR 7 - MOLEX CONNECTOR
2 - PICK FROM SPECIAL TOOL KIT 6680 8 - SPECIAL TOOL 6742
3 - APEX CONNECTOR 9 - THOMAS AND BETTS CONNECTOR
4 - PICK FROM SPECIAL TOOL KIT 6680 10 - SPECIAL TOOL 6934
5 - AUGAT CONNECTOR 11 - TYCO CONNECTOR
6 - SPECIAL TOOL 6932 12 - SPECIAL TOOL 8638
DI ODE T ERM I N AL
REMOVAL REMOVAL
(1) Discon n ect t h e ba t t er y. (1) F ollow st eps for r em ovin g t er m in a ls descr ibed
(2) Loca t e t h e diode in t h e h a r n ess, a n d r em ove in t h e con n ect or r em ova l sect ion .
t h e pr ot ect ive cover in g. (2) Cu t t h e wir e 6 in ch es fr om t h e ba ck of t h e con -
(3) Rem ove t h e diode fr om t h e h a r n ess, pa y a t t en - n ect or.
t ion t o t h e cu r r en t flow dir ect ion (F ig. 13).
INSTALLATION
(1) Select a wir e fr om t h e t er m in a l r epa ir kit t h a t
best m a t ch es t h e color a n d ga ge of t h e wir e bein g
r epa ir ed.
(2) Cu t t h e r epa ir wir e t o t h e pr oper len gt h a n d
r em ove on e–h a lf (1/2) in ch of in su la t ion .
(3) Splice t h e r epa ir wir e t o t h e wir e h a r n ess (see
wir e splicin g pr ocedu r e).
(4) In ser t t h e r epa ir ed wir e in t o t h e con n ect or.
(5) In st a ll t h e con n ect or lockin g wedge, if r equ ir ed,
a n d r econ n ect t h e con n ect or t o it s m a t in g h a lf/com po-
n en t .
(6) Re-t a pe t h e wir e h a r n ess st a r t in g a t 1–1/2
in ch es beh in d t h e con n ect or a n d 2 in ch es pa st t h e
r epa ir.
Fig. 13 DIODE IDENTIFICATION (7) Con n ect ba t t er y a n d t est a ll a ffect ed syst em s.
1 - CURRENT FLOW
2 - BAND AROUND DIODE INDICATES CURRENT FLOW
3 - DIODE AS SHOWN IN THE DIAGRAMS
INSTALLATION
(1) Rem ove t h e in su la t ion fr om t h e wir es in t h e
h a r n ess. On ly r em ove en ou gh in su la t ion t o solder in
t h e n ew diode.
(2) In st a ll t h e n ew diode in t h e h a r n ess, m a kin g
su r e cu r r en t flow is cor r ect . If n ecessa r y, r efer t o t h e
a ppr opr ia t e wir in g dia gr a m for cu r r en t flow (F ig. 13).
(3) Solder t h e con n ect ion t oget h er u sin g r osin cor e
t ype solder on ly. D o n o t u s e a c id c o re s o ld e r.
(4) Ta pe t h e diode t o t h e h a r n ess u sin g elect r ica l
t a pe. Ma ke su r e t h e diode is com plet ely sea led fr om
t h e elem en t s.
(5) Re-con n ect t h e ba t t er y a n d t est a ffect ed sys-
t em s.
WI RE (5) Solder t h e con n ect ion t oget h er u sin g r osin cor e

t ype solder on ly (F ig. 16).
STANDARD PROCEDURE - WIRE SPLICING CAUTION: DO NOT USE ACID CORE SOLDER.
Wh en splicin g a wir e, it is im por t a n t t h a t t h e cor-
r ect ga ge be u sed a s sh own in t h e wir in g dia gr a m s.
(1) Rem ove on e-h a lf (1/2) in ch of in su la t ion fr om
ea ch wir e t h a t n eeds t o be spliced.
(2) P la ce a piece of a dh esive lin ed h ea t sh r in k t u b-
in g on on e side of t h e wir e. Ma ke su r e t h e t u bin g will
be lon g en ou gh t o cover a n d sea l t h e en t ir e r epa ir
a r ea .
(3) P la ce t h e st r a n ds of wir e over la ppin g ea ch
ot h er in side of t h e splice clip (F ig. 14).
Fig. 16 SOLDER SPLICE

1 - SOLDER
2 - SPLICE BAND
3 - SOLDERING IRON
(6) Cen t er t h e h ea t sh r in k t u bin g over t h e join t

a n d h ea t u sin g a h ea t gu n . H ea t t h e join t u n t il t h e
t u bin g is t igh t ly sea led a n d sea la n t com es ou t of bot h
en ds of t h e t u bin g (F ig. 17).
Fig. 14 SPLICE BAND

1 - SPLICE BAND
(4) Usin g cr im pin g t ool, Mopa r p/n 05019912AA,

cr im p t h e splice clip a n d wir es t oget h er (F ig. 15).
Fig. 17 HEAT SHRINK TUBE

1 - SEALANT
2 - HEAT SHRINK TUBE
Fig. 15 CRIMPING TOOL

1 - CRIMPING TOOL
RS 8W-02 COMPONENT INDEX 8W - 02 - 1
8 W-0 2 COM PON EN T I N DEX

Co m p o n e n t P age Co m p o n e n t P age
A/C Com pr essor Clu t ch . . . . . . . . . . . . . . . . . 8W-42 Dosin g P u m p . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
A/C Com pr essor Clu t ch Rela y . . . . . . . . . . . . 8W-42 DVD Scr een . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47
A/C P r essu r e Sen sor . . . . . . . . . . . . . . . . . . . 8W-42 DVD/CD Ch a n ger . . . . . . . . . . . . . . . . . . . . . 8W-47
A/C-H ea t er Con t r ol . . . . . . . . . . . . . . . . . . . . 8W-42 E CM/P CM Rela y . . . . . . . . . . . . . . . . . . . . . . 8W-30
Acceler a t or P eda l P osit ion Sen sor . . . . . . . . . 8W-30 E GR Solen oid . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
Accessor y Rela y . . . . . . . . . . . . . . . . . . . . . . . 8W-10 E lect r on ic Con t r ol Un it . . . . . . . . . . . . . . . . . 8W-64
Adju st a ble P eda ls Mot or . . . . . . . . . . . . . . . . 8W-56 E n gin e Con t r ol Modu le . . . . . . . . . . . . . . . . . 8W-30
Adju st a ble P eda ls Rela y . . . . . . . . . . . . . . . . 8W-56 E n gin e Coola n t Tem p Sen sor . . . . . . . . . . . . . 8W-30
Adju st a ble P eda ls Sen sor . . . . . . . . . . . . . . . 8W-56 E n gin e Oil P r essu r e Sen sor . . . . . . . . . . . . . . 8W-30
Adju st a ble P eda ls Swit ch . . . . . . . . . . . . . . . 8W-56 E n gin e Oil P r essu r e Swit ch . . . . . . . . . . . . . . 8W-30
Air ba g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43 E VAP /P u r ge Solen oid . . . . . . . . . . . . . . . . . . 8W-30
Air ba g On /Off In dica t or La m p . . . . . . . . . . . . 8W-43 E va por a t or Tem per a t u r e Sen sor . . . . . . . . . . 8W-42
Air ba g Squ ibs . . . . . . . . . . . . . . . . . . . . . . . . 8W-43 F loor Con sole La m p . . . . . . . . . . . . . . . . . . . 8W-44
Am bien t Tem per a t u r e Sen sor . . . . . . . . . . . . 8W-49 F og La m ps . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50
Am plifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47 F oldin g Mir r or Rela y . . . . . . . . . . . . . . . . . . . 8W-62
An t en n a . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47 F r on t Blower Modu le . . . . . . . . . . . . . . . . . . 8W-42
ATC Rem ot e Sen sor . . . . . . . . . . . . . . . . . . . . 8W-42 F r on t Ciga r Ligh t er . . . . . . . . . . . . . . . . . . . . 8W-41
Au t o Sh u t Down Rela y . . . . . . . . . . . . . . . . . 8W-30 F r on t Con t r ol Modu le . . . . . . . . . . . . . . . . . . 8W-10
Au t o Tem p Con t r ol . . . . . . . . . . . . . . . . . . . . 8W-42 F r on t F og La m p Rela y . . . . . . . . . . . . . . . . . 8W-50
B-P illa r Swit ch es . . . . . . . . . . . . . . . . . . . . . . 8W-61 F r on t In t r u sion Sen sor . . . . . . . . . . . . . . . . . 8W-39
Ba ck-Up La m p Swit ch . . . . . . . . . . . . . . . . . . 8W-51 F r on t Rea din g La m ps/Swit ch . . . . . . . . . . . . 8W-44
Ba t t er y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20 F r on t Wiper H igh /Low Rela y . . . . . . . . . . . . . 8W-53
Ba t t er y Tem per a t u r e Sen sor . . . . . . . . . . . . . 8W-20 F r on t Wiper On /Off Rela y . . . . . . . . . . . . . . . 8W-53
Belt Ten sion Sen sor . . . . . . . . . . . . . . . . . . . . 8W-43 F u el H ea t er . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
Blen d Door Act u a t or s . . . . . . . . . . . . . . . . . . 8W-42 F u el H ea t er Rela y . . . . . . . . . . . . . . . . . . . . . 8W-30
Blower Mot or s . . . . . . . . . . . . . . . . . . . . . . . . 8W-42 F u el In ject or s . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
Blower Mot or Rela ys . . . . . . . . . . . . . . . . . . . 8W-42 F u el P r essu r e Sen sor . . . . . . . . . . . . . . . . . . 8W-30
Blower Mot or Resist or . . . . . . . . . . . . . . . . . . 8W-42 F u el P r essu r e Solen oid . . . . . . . . . . . . . . . . . 8W-30
Body Con t r ol Modu le . . . . . . . . . . . . . . . . . . . 8W-45 F u el P u m p Modu le . . . . . . . . . . . . . . . . . . . . 8W-30
Boost P r essu r e Sen sor . . . . . . . . . . . . . . . . . . 8W-30 F u el P u m p Rela y . . . . . . . . . . . . . . . . . . . . . . 8W-30
Br a ke F lu id Level Swit ch . . . . . . . . . . . . . . . 8W-35 F u ll Open Swit ch es . . . . . . . . . . . . . . . . . . . . 8W-61
Br a ke La m p Swit ch . . . . . . . . . . . . . . . . . 8W-30, 51 F u selin k . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10
Br a ke Tr a n sm ission Sh ift In t er lock F u ses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10
Solen oid . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31 Gen er a t or . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20
Ca bin H ea t er Assist . . . . . . . . . . . . . . . . . . . 8W-30 Glow P lu g Rela y . . . . . . . . . . . . . . . . . . . . . . 8W-30
Ca m sh a ft P osit ion Sen sor . . . . . . . . . . . . . . . 8W-30 Glow P lu gs . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30
CD Ch a n ger . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47 Gr ou n ds . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15
Cen t er H igh Mou n t ed St op La m p . . . . . . . . . 8W-51 H a n ds F r ee Modu le . . . . . . . . . . . . . . . . . 8W-47, 55
Cin ch /Relea se Mot or s . . . . . . . . . . . . . . . . . . 8W-61 H ea dla m p Levelin g Mot or s . . . . . . . . . . . . . . 8W-50
Clockspr in g . . . . . . . . . . . . . . 8W-30, 33, 41, 43, 47 H ea dla m p Swit ch . . . . . . . . . . . . . . . . . . . . . 8W-50
Clu t ch P eda l In t er lock Swit ch . . . . . . . . . . . . 8W-21 H ea dla m p Wa sh er P u m p Mot or . . . . . . . . . . 8W-53
Clu t ch P eda l Upst op Swit ch . . . . . . . . . . . . . 8W-30 H ea dla m p Wa sh er Rela y . . . . . . . . . . . . . . . . 8W-53
Con t r oller An t ilock Br a ke . . . . . . . . . . . . . . . 8W-35 H ea dla m ps . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50
Cr a n k Ca se Ven t ila t ion H ea t er . . . . . . . . . . . 8W-30 H ea t ed Sea t Ba cks . . . . . . . . . . . . . . . . . . . . 8W-63
Cr a n ksh a ft P osit ion Sen sor . . . . . . . . . . . . . . 8W-30 H ea t ed Sea t Cu sh ion s . . . . . . . . . . . . . . . . . . 8W-63
Cylin der Lock Swit ch es . . . . . . . . . . . . . . . . . 8W-39 H ea t ed Sea t Modu les . . . . . . . . . . . . . . . . . . 8W-63
Da t a Lin k Con n ect or . . . . . . . . . . . . . . . . . . . 8W-18 H igh Bea m La m ps . . . . . . . . . . . . . . . . . . . . . 8W-50
Defogger Rela y . . . . . . . . . . . . . . . . . . . . . . . 8W-48 H igh Not e H or n . . . . . . . . . . . . . . . . . . . . . . . 8W-41
Door Aja r Swit ch es . . . . . . . . . . . . . . . . . . . . 8W-39 H ood Aja r Swit ch . . . . . . . . . . . . . . . . . . . . . 8W-39
Door Cou r t esy La m ps . . . . . . . . . . . . . . . . . . 8W-44 H or n Rela y . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41
Door Lock Mot or /Aja r Swit ch es . . . . . . . . . . . 8W-61 H or n Swit ch . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41
Door Lock Swit ch es . . . . . . . . . . . . . . . . . . . . 8W-61 Idle Air Con t r ol Mot or . . . . . . . . . . . . . . . . . . 8W-30
8W - 02 - 2 8W-02 COMPONENT INDEX RS
Ign it ion Coil . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30 Ra dia t or F a n s . . . . . . . . . . . . . . . . . . . . . . . . 8W-42
Ign it ion Swit ch . . . . . . . . . . . . . . . . . . . . . . . 8W-10 Ra dio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47
Im pa ct Sen sor s . . . . . . . . . . . . . . . . . . . . . . . 8W-43 Rea din g La m ps . . . . . . . . . . . . . . . . . . . . . . . 8W-44
In let Air Tem per a t u r e Sen sor . . . . . . . . . . . . 8W-30 Rea r A/C-H ea t er Un it . . . . . . . . . . . . . . . . . . 8W-42
In st r u m en t Clu st er . . . . . . . . . . . . . . . . . . . . 8W-40 Rea r Au t o Tem p Con t r ol Swit ch . . . . . . . . . . 8W-42
In st r u m en t P a n el Swit ch Rea r Blower Con t r ol Swit ch es . . . . . . . . . . . . 8W-42
Ba n k . . . . . . . . . . . . . . . . . . 8W-43, 44, 52, 53, 63 Rea r Blower Mot or P ower Modu le . . . . . . . . . 8W-42
In t egr a t ed P ower Modu le . . . . . . . . . . . . . . . 8W-10 Rea r Dom e La m p . . . . . . . . . . . . . . . . . . . . . 8W-44
Kn ock Sen sor . . . . . . . . . . . . . . . . . . . . . . . . 8W-30 Rea r In t r u sion Sen sor . . . . . . . . . . . . . . . . . . 8W-39
La m p Assem blies . . . . . . . . . . . . . . . . . . . . . . 8W-51 Rea r Mode Mot or . . . . . . . . . . . . . . . . . . . . . 8W-42
Licen se La m p . . . . . . . . . . . . . . . . . . . . . 8W-51, 61 Rea r Tem per a t u r e Mot or . . . . . . . . . . . . . . . . 8W-42
Lift P u m p Mot or . . . . . . . . . . . . . . . . . . . . . . 8W-30 Rea r View Mir r or . . . . . . . . . . . . . . . . 8W-49, 55, 62
Lift P u m p Rela y . . . . . . . . . . . . . . . . . . . . . . 8W-30 Rea r Win dow Defogger Gr id . . . . . . . . . . . . . 8W-48
Lift ga t e Aja r Swit ch . . . . . . . . . . . . . . . . 8W-39, 61 Rea r Wiper Mot or . . . . . . . . . . . . . . . . . . . . . 8W-53
Lift ga t e Cin ch /Relea se Mot or . . . . . . . . . . . . 8W-61 Recir cu la t ion Door Act u a t or . . . . . . . . . . . . . 8W-42
Lift ga t e F lood La m ps . . . . . . . . . . . . . . . . . . 8W-44 Rem ot e Ra dio Swit ch es . . . . . . . . . . . . . . . . . 8W-47
Lift ga t e P in ch Sen sor s . . . . . . . . . . . . . . . . . 8W-61 Repea t er La m ps . . . . . . . . . . . . . . . . . . . . . . 8W-52
Low Bea m La m ps . . . . . . . . . . . . . . . . . . . . . 8W-50 Sea t Belt Swit ch es . . . . . . . . . . . . . . . . . . . . 8W-43
Ma n ifold Absolu t e P r essu r e Sen sor . . . . . . . . 8W-30 Sea t Belt Ten sion er s . . . . . . . . . . . . . . . . . . . 8W-43
Ma ss Air F low Sen sor . . . . . . . . . . . . . . . . . . 8W-30 Sea t Weigh t Sen sor . . . . . . . . . . . . . . . . . . . . 8W-43
Mem or y Sea t /Mir r or /Adju st a ble P eda ls Sen t r y Key Rem ot e E n t r y Modu le . . . . . . . . . 8W-39
Modu le . . . . . . . . . . . . . . . . . . . . . . 8W-56, 62, 63 Sir en . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39
Mem or y Set Swit ch . . . . . . . . . . . . . . . . . . . . 8W-63 Slidin g Door Con t r ol Modu les . . . . . . . . . . . . 8W-61
Messa ge Cen t er . . . . . . . . . . . . . . . . . . . . 8W-40, 46 Slidin g Door La t ch Sen sin g Swit ch es . . . . . . 8W-61
Mode Door Act u a t or . . . . . . . . . . . . . . . . . . . 8W-42 Slidin g Door Lock Mot or s . . . . . . . . . . . . . . . 8W-61
Mu lt i-F u n ct ion Swit ch . . . . . . . . . . . . 8W-50, 52, 53 Slidin g Door Mot or s . . . . . . . . . . . . . . . . . . . 8W-61
Na t u r a l Va cu u m Lea k Det ect ion Assem bly . . 8W-30 Spea ker s . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47
Occu pa n t Cla ssifica t ion Modu le . . . . . . . . . . 8W-43 Speed Con t r ol Ser vo . . . . . . . . . . . . . . . . . . . 8W-33
Occu pa n t Rest r a in t Con t r oller . . . . . . . . . . . 8W-43 Speed Con t r ol Swit ch es . . . . . . . . . . . . . . . . . 8W-33
Over h ea d Con sole . . . . . . . . . . . . . . . . . . . . . 8W-49 Speed Sen sor s . . . . . . . . . . . . . . . . . . . . . . . . 8W-31
Oxygen Sen sor s . . . . . . . . . . . . . . . . . . . . . . . 8W-30 Splices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70
P a r k Assist Displa y . . . . . . . . . . . . . . . . . . . . 8W-56 St a r t er Mot or . . . . . . . . . . . . . . . . . . . . . . . . 8W-21
P a r k Assist Modu le . . . . . . . . . . . . . . . . . . . . 8W-56 St a r t er Mot or Rela y . . . . . . . . . . . . . . . . . . . 8W-21
P a r k Assist Sen sor s . . . . . . . . . . . . . . . . . . . . 8W-56 Su n r oof Modu le . . . . . . . . . . . . . . . . . . . . . . . 8W-64
P a r k La m p Rela y . . . . . . . . . . . . . . . . . . . . . 8W-10 Su n r oof Swit ch . . . . . . . . . . . . . . . . . . . . . . . 8W-64
P a r k La m ps . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50 Th a t ch a m Ala r m In dica t or . . . . . . . . . . . . . . 8W-39
P a r k/Tu r n Sign a l La m ps . . . . . . . . . . . . . . . . 8W-50 Th a t ch a m Ala r m Modu le . . . . . . . . . . . . . . . . 8W-39
P a r kin g Br a ke Swit ch . . . . . . . . . . . . . . . . . . 8W-40 Th r ot t le P osit ion Sen sor . . . . . . . . . . . . . . . . 8W-30
P ower F oldin g Mir r or Swit ch . . . . . . . . . . . . 8W-62 Tr a ct ion Con t r ol Swit ch . . . . . . . . . . . . . . . . . 8W-35
P ower Lift ga t e Modu le . . . . . . . . . . . . . . . . . 8W-61 Tr a iler Tow Con n ect or . . . . . . . . . . . . . . . . . . 8W-54
P ower Lift ga t e Mot or . . . . . . . . . . . . . . . . . . 8W-61 Tr a n sm ission Con t r ol Modu le . . . . . . . . . . . . 8W-31
P ower Mir r or Swit ch . . . . . . . . . . . . . . . . . . . 8W-62 Tr a n sm ission Con t r ol Rela y . . . . . . . . . . . . . 8W-31
P ower Mir r or s . . . . . . . . . . . . . . . . . . . . . . . . 8W-62 Tr a n sm ission Ra n ge Sen sor . . . . . . . . . . . . . . 8W-31
P ower Ou t let s . . . . . . . . . . . . . . . . . . . . . . . . 8W-41 Tr a n sm ission Solen oid/P r essu r e Swit ch
P ower Sea t Cir cu it Br ea ker . . . . . . . . . . . . . . 8W-10 Assem bly . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31
P ower Sea t Mot or s . . . . . . . . . . . . . . . . . . . . 8W-63 Tu r n Sign a l La m ps . . . . . . . . . . . . . . . . . . . . 8W-52
P ower Sea t P osit ion Sen sor s . . . . . . . . . . . . . 8W-63 Veh icle Speed Sen sor . . . . . . . . . . . . . . . . . . . 8W-30
P ower Sea t Swit ch es . . . . . . . . . . . . . . . . . . . 8W-63 Ven t Mot or s . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-60
P ower Win dow Cir cu it Br ea ker . . . . . . . . . . . 8W-10 Visor /Va n it y La m ps . . . . . . . . . . . . . . . . . . . . 8W-44
P ower Win dow Mot or s . . . . . . . . . . . . . . . . . . 8W-60 Wa sh er F lu id Level Swit ch . . . . . . . . . . . . . . 8W-53
P ower Win dow Swit ch es . . . . . . . . . . . . . . . . 8W-60 Wa sh er P u m p Mot or . . . . . . . . . . . . . . . . . . . 8W-53
P ower t r a in Con t r ol Modu le . . . . . . . . . . . 8W-30, 31 Wa t er In F u el Sen sor . . . . . . . . . . . . . . . . . . 8W-30
P TCs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10 Wh eel Speed Sen sor s . . . . . . . . . . . . . . . . . . . 8W-35
Ra dia t or F a n Rela ies . . . . . . . . . . . . . . . . . . . 8W-42 Wiper Modu le . . . . . . . . . . . . . . . . . . . . . . . . 8W-53
RS 8W-10 POWER DISTRIBUTION 8W - 10 - 1
8 W-1 0 POWER DI ST RI BU T I ON
A/C Com pr essor Clu t ch . . . . . . 8W-10-22, 24, 45, 48 F r on t Wiper On /Off Rela y . . . . . . . 8W-10-16, 30, 60
A/C Com pr essor F u el H ea t er . . . . . . . . . . . . . . . . . . . . . . . 8W-10-49
Clu t ch Rela y . . . . . . . . . 8W-10-22, 24, 44, 45, 48 F u el H ea t er Rela y . . . . . . . . . . . . . 8W-10-24, 48, 65
Accessor y Rela y . . . . . . . . . . . . . . . 8W-10-16, 31, 65 F u el In ject or No. 1 . . . . . . . . . . . . . . . . . . 8W-10-42
Adju st a ble P eda ls Rela y . . . . . . . . . . . 8W-10-47, 60 F u el In ject or No. 2 . . . . . . . . . . . . . . . . . . 8W-10-42
Adju st a ble P eda ls Swit ch . . . . . . . . . . 8W-10-40, 47 F u el In ject or No. 3 . . . . . . . . . . . . . . . . . . 8W-10-42
Am bien t Tem per a t u r e Sen sor . . . . . . . . . . 8W-10-62 F u el In ject or No. 4 . . . . . . . . . . . . . . . . . . 8W-10-42
Am plifier . . . . . . . . . . . . . . . . . . . . . . . 8W-10-32, 50 F u el In ject or No. 5 . . . . . . . . . . . . . . . . . . 8W-10-42
Au t o Sh u t Down Rela y . . . . . . . . . . . . 8W-10-21, 41 F u el In ject or No. 6 . . . . . . . . . . . . . . . . . . 8W-10-42
Au t o Tem p Con t r ol . . . . . . . . . . . . . . . . . . 8W-10-40 F u el P r essu r e Solen oid . . . . . . . . . . . . . . . 8W-10-44
Ba ck-Up La m p Swit ch . . . . . . . . . . . . . . . 8W-10-66 F u el P u m p Modu le . . . . . . . . . . . . . . . 8W-10-22, 45
Ba t t er y . . . . . . . . . . . . . . . 8W-10-13, 14, 15, 41, 48 F u el P u m p Rela y . . . . . . . . . . . . . 8W-10-22, 45, 65
Blower Mot or Resist or . . . . . . . . . . . . 8W-10-19, 38 F u se 1 . . . . . . . . . . . . . . . . . . . . . . 8W-10-15, 16, 27
Body Con t r ol Modu le . . . . . . . 8W-10-25, 40, 45, 49, F u se 2 . . . . . . . . . . . . . . . . . . . . . . 8W-10-15, 28, 29
50, 52, 54, 55, 56, 57, 67, 68 F u se 3 . . . . . . . . . . . . . . . . . . . . . . 8W-10-15, 28, 29
Br a ke F lu id Level Swit ch . . . . . . . . . . . . . 8W-10-65 F u se 4 . . . . . . . . . . . . . . . . . . . 8W-10-15, 16, 17, 30
Br a ke La m p Swit ch . . . . . . . . . . . 8W-10-26, 52, 67 F u se 5 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-16, 31
Br a ke Tr a n sm ission Sh ift In t er lock F u se 6 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-16, 31
Solen oid . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-63 F u se 8 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-17, 35
Ca bin H ea t er Assist . . . . . . . . . . . 8W-10-23, 43, 60 F u se 9 . . . . . . . . . . . . . . . . 8W-10-17, 18, 19, 36, 37
Ca m sh a ft P osit ion Sen sor . . . . . . . . . . . . . 8W-10-44 F u se 10 . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-19, 38
Cen t er H igh Mou n t ed St op La m p . . . . . . . 8W-10-67 F u se 11 . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-16, 31
Clockspr in g . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-61 F u se 12 . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-19, 38
Clu t ch P eda l In t er lock F u se 13 . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-20, 39
Swit ch . . . . . . . . . . . . . . 8W-10-18, 37, 54, 55, 61 F u se 14 . . . . . . . . . . . . 8W-10-20, 21, 23, 39, 47, 60
Con t r oller An t ilock F u se 15 . . . . . . . . . 8W-10-20, 21, 22, 23, 24, 41, 43
Br a ke . . . . . . 8W-10-18, 25, 36, 37, 50, 56, 62, 67 F u se 16 . . . . . . . . . . . . . . . . . . 8W-10-21, 23, 41, 43
Cr a n k Ca se Ven t ila t ion H ea t er . . . . . . . . . 8W-10-49 F u se 17 . . . . . . . . . . . . 8W-10-21, 22, 23, 24, 45, 48
Da t a Lin k Con n ect or . . . . . . . . . . . 8W-10-35, 62, 68 F u se 18 . . . . . . . . . . . . . . . 8W-10-22, 24, 25, 45, 48
Defogger Rela y . . . . . . . . . . . . 8W-10-19, 20, 39, 64 F u se 19 . . . . . . . . . . . . . . . 8W-10-22, 24, 25, 26, 50
Dr iver H ea t ed Sea t Modu le . . . . . . . . . . . 8W-10-50 F u se 20 . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-25, 50
Dr iver P ower Sea t Swit ch . . . . . . . . . . . . 8W-10-50 F u se 21 . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-25, 50
Dr iver P ower Win dow Swit ch . . . . . . . 8W-10-33, 34 F u se 22 . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-25, 50
DVD/CD Ch a n ger . . . . . . . . . . . . . . . . . . . 8W-10-40 F u se 23 . . . . . . . . . . . . . . . . . . . . . 8W-10-25, 54, 55
E CM/P CM Rela y . . . . . . . . . . . . . . . . . 8W-10-23, 43 F u se 24 . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-25, 52
E GR Solen oid . . . . . . . . . . . . . . . . . . . . . . 8W-10-44 F u se 26 . . . . . . . . . . . . . . . . . . . . . 8W-10-25, 26, 52
E n gin e Con t r ol Modu le . . . 8W-10-18, 23, 24, 37, 43, F u se 27 . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-26, 52
44, 48, 62, 67 F u se 28 . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-16, 31
F loor Con sole La m p . . . . . . . . . . . . . . . . . 8W-10-32 F u se 30 . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-26, 53
F loor Con sole P ower Ou t let . . . . . . . . 8W-10-32, 35 F u se 31 . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-26, 53
F r on t Blower Modu le . . . . . . . . . . . . . 8W-10-19, 38 F u se 32 . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-26, 53
F r on t Blower Mot or Rela y . . . . 8W-10-18, 19, 38, 64 F u selin k . . . . . . . . . . . . . . . . . . . . . . . 8W-10-13, 14
F r on t Ciga r Ligh t er . . . . . . . . . . . . . . 8W-10-16, 32 G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-56
F r on t Con t r ol Modu le . . . . . . . 8W-10-15, 16, 17, 18, G101 . . . . . . . . . . . . . . . . . . . . . . . 8W-10-41, 48, 68
19, 20, 22, 24, 26, 27, G103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-68
28, 29, 30, 31, 35, 36, G300 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-58, 59
37, 38, 39, 45, 47, 48, Gen er a t or . . . . . . . . . . . . . . . . . . . 8W-10-13, 14, 44
53, 54, 55, 58, 59, 60, Glow P lu g Rela y . . . . . . . . . . . . . . . . . 8W-10-13, 44
61, 62, 63, 64, 65, 66,
H a n ds F r ee Modu le . . . . . . . . . . . . . . . . . 8W-10-40
67, 68, 69
H ea dla m p Swit ch . . . . . . . . . . . . . . . . 8W-10-29, 63
F r on t F og La m p Rela y . . . . . . . . . 8W-10-15, 27, 64
H ea dla m p Wa sh er P u m p Mot or . . . . . 8W-10-26, 53
F r on t Wiper H igh /Low Rela y . . . . 8W-10-16, 30, 65
H ea dla m p Wa sh er Rela y . . . . . . . . 8W-10-26, 53, 64
8W - 10 - 2 8W-10 POWER DISTRIBUTION RS
H igh Not e H or n . . . . . . . . . . . . . . . . . 8W-10-17, 35 P ower Win dow Cir cu it Br ea ker . . . . . . 8W-10-16, 31
H or n Rela y . . . . . . . . . . . . . . . . . . 8W-10-17, 35, 60 P ower Win dow Swit ch . . . . . . . . . . . . . . . 8W-10-33
Ign it ion Coil . . . . . . . . . . . . . . . . . . . . . . . 8W-10-42 P ower t r a in Con t r ol Modu le . . 8W-10-18, 21, 22, 36,
Ign it ion Swit ch . . . 8W-10-18, 25, 36, 37, 45, 46, 49, 41, 42, 45, 56, 62, 63, 68
54, 55, 61 P TC 4 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-20, 39
In st r u m en t Clu st er . . . . . . . . . . . . . . . 8W-10-25, 52 P TC 7 . . . . . . . . . . . . . . . . . . . 8W-10-16, 17, 18, 35
In st r u m en t P a n el Swit ch Ba n k . . . . . . . . 8W-10-69 Ra dia t or F a n Rela y . . . . . . . . . . . . 8W-10-26, 52, 56
In t egr a t ed P ower Modu le . 8W-10-3, 4, 5, 13, 15, 16, Ra dia t or F a n Rela y No. 1 . . . . . . . . . . 8W-10-13, 44
17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, Ra dia t or F a n Rela y No. 2 . . . . . . . 8W-10-26, 44, 52
30, 31, 32, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, Ra dia t or F a n Rela y No. 3 . . . . . . . . . . . . . 8W-10-44
45, 47, 48, 49, 50, 52, 53, 54, 55, 56, 57, 58, 59, Ra dio . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-32, 40
60, 61, 62, 63, 64, 65, 66, 67, 68, 69 Rea r A/C-H ea t er Un it . . . . . . . . . . . . . 8W-10-19, 38
Left F og La m p . . . . . . . . . . . . . . . . . . 8W-10-15, 27 Rea r Blower Mot or P ower Modu le . . . 8W-10-19, 38
Left F r on t P a r k/Tu r n Rea r Blower Mot or Rela y . . . . 8W-10-19, 20, 38, 64
Sign a l La m p . . . . . . . . . . . . 8W-10-15, 28, 57, 66 Rea r P ower Ou t let . . . . . . . . . . . . 8W-10-16, 31, 32
Left H ea dla m p . . . . . . . . . . . . . . . . . . . . . 8W-10-58 Rea r Win dow Defogger Gr id . . . . . . . . 8W-10-20, 39
Left H ea dla m p Levelin g Mot or . . . 8W-10-29, 63, 66 Rea r Wiper Mot or . . . . . . . . . . . . . . . . 8W-10-16, 31
Left H igh Bea m La m p . . . . . . . . . . . . . . . 8W-10-59 Righ t F og La m p . . . . . . . . . . . . . . . . . 8W-10-15, 27
Left Low Bea m La m p . . . . . . . . . . . . . . . . 8W-10-59 Righ t F r on t P a r k/Tu r n
Left P a r k La m p . . . . . . . . . . . . . . 8W-10-29, 59, 66 Sign a l La m p . . . . . . . . . . . . 8W-10-15, 28, 57, 61
Left P ower Mir r or . . . . . . . . . . . . . . . . . . . 8W-10-39 Righ t H ea dla m p . . . . . . . . . . . . . . . . . . . . 8W-10-58
Left Rea r La m p Assem bly . . . . . . . 8W-10-28, 29, 66 Righ t H ea dla m p Levelin g Mot or . . 8W-10-29, 61, 63
Left Repea t er La m p . . . . . . . . . . . . . . . . . 8W-10-52 Righ t H igh Bea m La m p . . . . . . . . . . . . . . 8W-10-59
Left Slidin g Door Con t r ol Modu le . . . . 8W-10-26, 53 Righ t Low Bea m La m p . . . . . . . . . . . . . . . 8W-10-59
Left Tu r n Sign a l La m p . . . . . . . . . . . . . . . 8W-10-57 Righ t P a r k La m p . . . . . . . . . . . . . 8W-10-29, 59, 61
Licen se La m p . . . . . . . . . . . . . . . . 8W-10-28, 29, 66 Righ t P ower Mir r or . . . . . . . . . . . . . . . . . 8W-10-39
Lift P u m p Mot or . . . . . . . . . . . . . . . . . 8W-10-23, 43 Righ t Rea r La m p
Lift P u m p Rela y . . . . . . . . . . . . . . . . . 8W-10-23, 43 Assem bly . . . . . . . . . . . . 8W-10-15, 28, 29, 61, 67
Ma ss Air F low Sen sor . . . . . . . . . . . . . . . . 8W-10-44 Righ t Repea t er La m p . . . . . . . . . . . . . . . . 8W-10-52
Mem or y Sea t /Mir r or /Adju st a ble P eda ls Righ t Slidin g Door Con t r ol Modu le . . . 8W-10-26, 53
Modu le . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-50 Righ t Tu r n Sign a l La m p . . . . . . . . . . . . . . 8W-10-57
Messa ge Cen t er . . . . . . . . . . . . . . . . . . . . 8W-10-52 Sen t r y Key Rem ot e E n t r y
Occu pa n t Cla ssifica t ion Modu le . . . . . . . . 8W-10-69 Modu le . . . . . . . . . . . . . . 8W-10-40, 46, 49, 54, 55
Occu pa n t Rest r a in t Con t r oller . . . . . . 8W-10-64, 69 Sir en . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-40
Over h ea d Con sole . . . . . . . . . . . . . . . . . . . 8W-10-40 St a r t er Mot or . . . . . . . . . . 8W-10-13, 14, 18, 36, 37
P a r k Assist Modu le . . . . . . . . . . . . . . . 8W-10-45, 54 St a r t er Mot or Rela y . . . . . . 8W-10-18, 36, 37, 54, 55
P a r k La m p Rela y . . . . . . . . . . 8W-10-15, 28, 29, 60 Su n r oof Modu le . . . . . . . . . . . . . . . . . . 8W-10-31, 53
P a ssen ger Air ba g On /Off In dica t or Th a t ch a m Ala r m Modu le . . 8W-10-40, 46, 49, 55, 68
La m p . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-69 Tr a iler Tow Con n ect or . . . . . . . . . . . . 8W-10-28, 66
P a ssen ger F oldin g Mir r or Tr a n sm ission Con t r ol Modu le . . . . . . . 8W-10-13, 62
Rela y . . . . . . . . . . . . . . . . . . 8W-10-22, 24, 45, 48 Tr a n sm ission Con t r ol Rela y . . . . . 8W-10-13, 21, 41
P a ssen ger H ea t ed Sea t Modu le . . . . . . . . 8W-10-51 Tr a n sm ission Solen oid/P r essu r e Swit ch
P a ssen ger P ower Sea t Swit ch . . . . . . . . . . 8W-10-51 Assem bly . . . . . . . . . . . . . . . . . . . . . . . 8W-10-41
P a ssen ger P ower Win dow Swit ch . . . . . . . 8W-10-31 Veh icle Speed Sen sor . . . . . . . . . . . . . . . . 8W-10-43
P ower Lift ga t e Modu le . . . . . . . . . . . . 8W-10-26, 53 Wa sh er F lu id Level Swit ch . . . . . . . . . . . . 8W-10-61
P ower Mir r or Swit ch . . . . . . . . 8W-10-22, 24, 47, 48 Wa sh er P u m p Mot or . . . . . . . . . . . . . . . . . 8W-10-69
P ower Ou t let . . . . . . . . . . . . . . . . . . . . . . 8W-10-35 Wiper Modu le . . . . . . . . . . . . . . . . 8W-10-16, 30, 60
P ower Sea t Cir cu it Br ea ker . . . . . . . . 8W-10-25, 50
RS 8W-15 GROUND DISTRIBUTION 8W - 15 - 1
8 W-1 5 GROU N D DI ST RI BU T I ON
A/C Com pr essor Clu t ch . . . . . . . . . . . . . . . . . . . 8W-15-2, 9 Left Tu r n Sign a l La m p . . . . . . . . . . . . . . . . . . . . 8W-15-19
A/C-H ea t er Con t r ol . . . . . . . . . . . . . . . . . . . . 8W-15-10, 12 Left Visor /Va n it y La m p . . . . . . . . . . . . . . . . . . . . 8W-15-23
Adju st a ble P eda ls Swit ch . . . . . . . . . . . . . . . . . . . 8W-15-11 Licen se La m p . . . . . . . . . . . . . . . . . . . . . . . 8W-15-26, 29
Am plifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-27 Lift P u m p Mot or . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-28
Au t o Tem p Con t r ol . . . . . . . . . . . . . . . . . . . . . . 8W-15-10 Lift ga t e Aja r Swit ch . . . . . . . . . . . . . . . . . . . . . . 8W-15-30
Ba ck-Up La m p Swit ch . . . . . . . . . . . . . . . . . . . 8W-15-2, 4 Lift ga t e Cin ch /Relea se Mot or . . . . . . . . . . . . . . 8W-15-26, 30
Ba t t er y . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2, 3, 4 Lift ga t e Righ t P in ch Sen sor . . . . . . . . . . . . . . . . . 8W-15-26
Body Con t r ol Modu le . . . . . . . . . . . . . . . . . . . . . 8W-15-24 Mem or y Sea t /Mir r or /Adju st a ble P eda ls Modu le . . . . . 8W-15-17
Br a ke F lu id Level Swit ch . . . . . . . . . . . . . . . . . . 8W-15-18 Na t u r a l Va cu u m Lea k Det ect ion Assem bly . . . . . . . 8W-15-2, 3
Br a ke La m p Swit ch . . . . . . . . . . . . . . . . . . . . . . 8W-15-18 Occu pa n t Cla ssifica t ion Modu le . . . . . . . . . . . . . . . 8W-15-24
Ca bin H ea t er Assist . . . . . . . . . . . . . . . . . . . . . . 8W-15-9 Occu pa n t Rest r a in t Con t r oller . . . . . . . . . . . . . . . 8W-15-13
CD Ch a n ger . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-13 Over h ea d Con sole . . . . . . . . . . . . . . . . . . . . . . . 8W-15-22
Cen t er H igh Mou n t ed St op La m p . . . . . . . . . . . . . 8W-15-30 Oxygen Sen sor 1/1 Upst r ea m . . . . . . . . . . . . . . . . . 8W-15-3
Clu t ch P eda l In t er lock Swit ch . . . . . . . . . . . . . . . . 8W-15-18 Oxygen Sen sor 1/2 Down st r ea m . . . . . . . . . . . . . . . 8W-15-3
Clu t ch P eda l Upst op Swit ch . . . . . . . . . . . . . . . . . 8W-15-19 P a r k Assist Displa y . . . . . . . . . . . . . . . . . . . . . . 8W-15-28
Con t r oller An t ilock Br a ke . . . . . . . . . . . . . . . . . 8W-15-2, 4 P a r k Assist Modu le . . . . . . . . . . . . . . . . . . . . . . 8W-15-28
Cr a n k Ca se Ven t ila t ion H ea t er . . . . . . . . . . . . . . . . 8W-15-9 P a ssen ger Door Cou r t esy La m p . . . . . . . . . . . . 8W-15-16, 21
Cr a n ksh a ft P osit ion Sen sor . . . . . . . . . . . . . . . . . . 8W-15-4 P a ssen ger Door Lock Swit ch . . . . . . . . . . . . . . 8W-15-16, 21
Da t a Lin k Con n ect or . . . . . . . . . . . . . . . . . . 8W-15-3, 4, 18 P a ssen ger H ea t ed Sea t Ba ck . . . . . . . . . . . . . . . . 8W-15-25
Dosin g P u m p . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-9 P a ssen ger H ea t ed Sea t Cu sh ion . . . . . . . . . . . . . . 8W-15-25
Dr iver Door Cou r t esy La m p . . . . . . . . . . . . . . . 8W-15-15, 21 P a ssen ger H ea t ed Sea t Modu le . . . . . . . . . . . . . . . 8W-15-25
Dr iver Door Lock Swit ch . . . . . . . . . . . . . . . . . 8W-15-15, 21 P a ssen ger P ower Sea t Swit ch . . . . . . . . . . . . . . . . 8W-15-25
Dr iver H ea t ed Sea t Cu sh ion . . . . . . . . . . . . . . . . . 8W-15-17 P ower F oldin g Mir r or Swit ch . . . . . . . . . . . . . . . . 8W-15-12
Dr iver H ea t ed Sea t Modu le . . . . . . . . . . . . . . . . . 8W-15-17 P ower Lift ga t e Modu le . . . . . . . . . . . . . . . . . . 8W-15-26, 28
Dr iver P ower Sea t Swit ch . . . . . . . . . . . . . . . . . . 8W-15-17 P ower Lift ga t e Mot or . . . . . . . . . . . . . . . . . . . . . 8W-15-26
Dr iver P ower Win dow Swit ch . . . . . . . . . . . . . . 8W-15-15, 21 P ower Mir r or Swit ch . . . . . . . . . . . . . . . . . . . . . 8W-15-12
DVD/CD Ch a n ger . . . . . . . . . . . . . . . . . . . . . . . 8W-15-11 P ower Ou t let . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-10
E GR Solen oid . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-3 P ower Win dow Swit ch . . . . . . . . . . . . . . . . . . . . 8W-15-15
E n gin e Con t r ol Modu le . . . . . . . . . . . . . . . . . . . . . 8W-15-4 P ower t r a in Con t r ol Modu le . . . . . . . . . . . . . . . . . . 8W-15-3
F loor Con sole La m p . . . . . . . . . . . . . . . . . . . . . . 8W-15-28 Ra dia t or F a n No. 1 . . . . . . . . . . . . . . . . . . . . . . . 8W-15-5
F loor Con sole P ower Ou t let . . . . . . . . . . . . . . . . . 8W-15-28 Ra dia t or F a n No. 2 . . . . . . . . . . . . . . . . . . . . . . . 8W-15-5
F r on t Blower Modu le . . . . . . . . . . . . . . . . . . . . . 8W-15-12 Ra dia t or F a n Rela y . . . . . . . . . . . . . . . . . . . . . . . 8W-15-5
F r on t Ciga r Ligh t er . . . . . . . . . . . . . . . . . . . . . . 8W-15-10 Ra dia t or F a n Rela y No. 3 . . . . . . . . . . . . . . . . . . . 8W-15-5
F r on t Con t r ol Modu le . . . . . . . . . . . . . . . . 8W-15-2, 8, 9, 19 Ra dio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-13
F r on t Rea din g La m ps/Swit ch . . . . . . . . . . . . . . . . 8W-15-22 Rea r Au t o Tem p Con t r ol Swit ch . . . . . . . . . . . . . . 8W-15-18
F u el H ea t er . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-28 Rea r Blower F r on t Con t r ol Swit ch . . . . . . . . . . . . . 8W-15-12
F u el H ea t er Rela y . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-4 Rea r Blower Mot or P ower Modu le . . . . . . . . . . . . . 8W-15-28
F u el P u m p Modu le . . . . . . . . . . . . . . . . . . . . . . 8W-15-28 Rea r Blower Rea r Con t r ol Swit ch . . . . . . . . . . . . . 8W-15-18
G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2, 4 Rea r Dom e La m p . . . . . . . . . . . . . . . . . . . . . 8W-15-22, 23
G101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2, 4 Rea r P ower Ou t let . . . . . . . . . . . . . . . . . . . . . . . 8W-15-28
G102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-5, 6, 7 Rea r View Mir r or . . . . . . . . . . . . . . . . . . . . . 8W-15-11, 22
G103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-9 Rea r Win dow Defogger Gr id . . . . . . . . . . . . . . . . . 8W-15-30
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-10, 11, 12 Rea r Wiper Mot or . . . . . . . . . . . . . . . . . . . . . . . 8W-15-29
G201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-13 Righ t B-P illa r Swit ch . . . . . . . . . . . . . . . . . . . . . 8W-15-24
G202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-13 Righ t Cin ch /Relea se Mot or . . . . . . . . . . . . . . . . . . 8W-15-20
G300 . . . . . . . . . . . . . . . . . . . . 8W-15-12, 14, 16, 17, 18, 19 Righ t Cylin der Lock Swit ch . . . . . . . . . . . . . . . . . 8W-15-21
G301 . . . . . . . . . . . . . . . . . . . . . . 8W-15-20, 21, 22, 24, 25 Righ t F og La m p . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-6
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-26, 27, 28 Righ t F r on t Door Aja r Swit ch . . . . . . . . . . . . . . . . 8W-15-21
G303 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-28, 29, 30 Righ t F r on t Door Lock Mot or /Aja r Swit ch . . . . . . . . 8W-15-21
Gen er a t or . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2 Righ t F r on t P a r k/Tu r n Sign a l La m p . . . . . . . . . . . . 8W-15-6
H a n ds F r ee Modu le . . . . . . . . . . . . . . . . . . . . . . 8W-15-11 Righ t F u ll Open Swit ch . . . . . . . . . . . . . . . . . . . 8W-15-20
H ea dla m p Swit ch . . . . . . . . . . . . . . . . . . . . . . . 8W-15-10 Righ t H ea dla m p . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-19
H ea dla m p Wa sh er P u m p Mot or . . . . . . . . . . . . . . . 8W-15-7 Righ t H ea dla m p Levelin g Mot or . . . . . . . . . . . . . . . 8W-15-7
H igh Not e H or n . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-6 Righ t H igh Bea m La m p . . . . . . . . . . . . . . . . . . 8W-15-8, 19
H ood Aja r Swit ch . . . . . . . . . . . . . . . . . . . . . . . 8W-15-19 Righ t Lift ga t e F lood La m p . . . . . . . . . . . . . . . . . . 8W-15-29
H or n Swit ch . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-12 Righ t Low Bea m La m p . . . . . . . . . . . . . . . . . . 8W-15-8, 19
In st r u m en t Clu st er . . . . . . . . . . . . . . . . . . . . . . 8W-15-10 Righ t Mid Rea din g La m p . . . . . . . . . . . . . . . . . . 8W-15-23
In st r u m en t P a n el Swit ch Ba n k . . . . . . . . . . . . . . . 8W-15-10 Righ t P a r k La m p . . . . . . . . . . . . . . . . . . . . . . 8W-15-8, 19
In t egr a t ed P ower Modu le . . . . . . . . . . . 8W-15-2, 3, 4, 8, 9, 19 Righ t P ower Mir r or . . . . . . . . . . . . . . . . . . . . 8W-15-11, 12
Left B-P illa r Swit ch . . . . . . . . . . . . . . . . . . . . . . 8W-15-18 Righ t Rea r La m p Assem bly . . . . . . . . . . . . . . . 8W-15-27, 28
Left Cin ch /Relea se Mot or . . . . . . . . . . . . . . . . . . 8W-15-14 Righ t Rea r Rea din g La m p . . . . . . . . . . . . . . . . . . 8W-15-23
Left Cylin der Lock Swit ch . . . . . . . . . . . . . . . . 8W-15-15, 16 Righ t Slidin g Door Con t r ol Modu le . . . . . . . . . . . . 8W-15-20
Left F og La m p . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-6 Righ t Slidin g Door La t ch Sen sin g Swit ch . . . . . . . . . 8W-15-20
Left F r on t Door Aja r Swit ch . . . . . . . . . . . . . . . . . 8W-15-16 Righ t Slidin g Door Lock Mot or . . . . . . . . . . . . . . . 8W-15-20
Left F r on t Door Lock Mot or /Aja r Swit ch . . . . . . . 8W-15-15, 16 Righ t Slidin g Door Lock Mot or /Aja r Swit ch . . . . . . . 8W-15-20
Left F r on t P a r k/Tu r n Sign a l La m p . . . . . . . . . . . . . 8W-15-6 Righ t Slidin g Door Mot or . . . . . . . . . . . . . . . . . . 8W-15-20
Left F u ll Open Swit ch . . . . . . . . . . . . . . . . . . . . 8W-15-14 Righ t Tu r n Sign a l La m p . . . . . . . . . . . . . . . . . . . 8W-15-19
Left H ea dla m p . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-19 Righ t Visor /Va n it y La m p . . . . . . . . . . . . . . . . . . . 8W-15-23
Left H ea dla m p Levelin g Mot or . . . . . . . . . . . . . . . . 8W-15-7 Sen t r y Key Rem ot e E n t r y Modu le . . . . . . . . . . . . . 8W-15-11
Left H igh Bea m La m p . . . . . . . . . . . . . . . . . . . 8W-15-8, 19 Sir en . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-11
Left Lift ga t e F lood La m p . . . . . . . . . . . . . . . . . . . 8W-15-29 Speed Con t r ol Ser vo . . . . . . . . . . . . . . . . . . . . . . 8W-15-2
Left Low Bea m La m p . . . . . . . . . . . . . . . . . . . 8W-15-8, 19 Su n r oof Modu le . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-27
Left Mid Rea din g La m p . . . . . . . . . . . . . . . . . . . 8W-15-23 Su n r oof Swit ch . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-23
Left P a r k La m p . . . . . . . . . . . . . . . . . . . . . . . 8W-15-8, 19 Th a t ch a m Ala r m Modu le . . . . . . . . . . . . . . . . . . . 8W-15-11
Left P ower Mir r or . . . . . . . . . . . . . . . . . . . . . . . 8W-15-12 Tr a ct ion Con t r ol Swit ch . . . . . . . . . . . . . . . . . . . 8W-15-11
Left Rea r La m p Assem bly . . . . . . . . . . . . . . . . . . 8W-15-28 Tr a iler Tow Con n ect or . . . . . . . . . . . . . . . . . . . . 8W-15-27
Left Rea r Rea din g La m p . . . . . . . . . . . . . . . . . . . 8W-15-23 Tr a n sm ission Con t r ol Modu le . . . . . . . . . . . . . . . . . 8W-15-4
Left Slidin g Door Con t r ol Modu le . . . . . . . . . . . . . 8W-15-14 Tr a n sm ission Con t r ol Rela y . . . . . . . . . . . . . . . . 8W-15-3, 4
Left Slidin g Door La t ch Sen sin g Swit ch . . . . . . . . . . 8W-15-14 Wa sh er F lu id Level Swit ch . . . . . . . . . . . . . . . . . . 8W-15-5
Left Slidin g Door Lock Mot or . . . . . . . . . . . . . . . . 8W-15-14 Wiper Modu le . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-18
Left Slidin g Door Lock Mot or /Aja r Swit ch . . . . . . . . 8W-15-14
Left Slidin g Door Mot or . . . . . . . . . . . . . . . . . . . 8W-15-14
RS 8W-18 BUS COMMUNICATIONS 8W - 18 - 1
8 W-1 8 BU S COM M U N I CAT I ON S

A/C-H ea t er Con t r ol . . . . . . . . . . . . . . . . . . . 8W-18-6 In t egr a t ed P ower Modu le . . . . . . . . 8W-18-2, 3, 4, 5
Am plifier . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-5 Left Slidin g Door Con t r ol Modu le . . . . . . . . 8W-18-5
Au t o Tem p Con t r ol . . . . . . . . . . . . . . . . . . . 8W-18-6 Mem or y Sea t /Mir r or /Adju st a ble P eda ls
Ba t t er y . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-2 Modu le . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-5
Body Con t r ol Modu le . . . . . . . . . . . . . 8W-18-3, 4, 5 Occu pa n t Cla ssifica t ion Modu le . . . . . . . . . 8W-18-5
Ca bin H ea t er Assist . . . . . . . . . . . . . . . . . . 8W-18-4 Occu pa n t Rest r a in t Con t r oller . . . . . . . . . . 8W-18-6
CD Ch a n ger . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-6 Over h ea d Con sole . . . . . . . . . . . . . . . . . . . . 8W-18-5
Con t r oller An t ilock Br a ke . . . . . . . . . . . . 8W-18-3, 4 P a r k Assist Modu le . . . . . . . . . . . . . . . . . . 8W-18-5
Da t a Lin k Con n ect or . . . . . . . . . . . 8W-18-2, 3, 4, 5 P ower Lift ga t e Modu le . . . . . . . . . . . . . . . . 8W-18-5
DVD/CD Ch a n ger . . . . . . . . . . . . . . . . . . . . 8W-18-6 P ower t r a in Con t r ol Modu le . . . . . . . . . . . . 8W-18-3
E n gin e Con t r ol Modu le . . . . . . . . . . . . . . . . 8W-18-4 P TC 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-2
F r on t Con t r ol Modu le . . . . . . . . . . . . . 8W-18-3, 4, 5 Ra dio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-6
G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-2 Righ t Slidin g Door Con t r ol Modu le . . . . . . 8W-18-5
G101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-2 Sen t r y Key Rem ot e E n t r y Modu le . . . . . . . 8W-18-6
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-2 Th a t ch a m Ala r m Modu le . . . . . . . . . . 8W-18-3, 4, 6
H a n ds F r ee Modu le . . . . . . . . . . . . . . . . . . 8W-18-6 Tr a n sm ission Con t r ol Modu le . . . . . . . . . . . 8W-18-4
In st r u m en t Clu st er . . . . . . . . . . . . . . . . . . . 8W-18-6
RS 8W-20 CHARGING SYSTEM 8W - 20 - 1
8 W-2 0 CH ARGI N G SY ST EM
Au t o Sh u t Down Rela y . . . . . . . . . . . . . . . . 8W-20-2 F u selin k . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2, 4
Ba t t er y . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2, 4 G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2, 4
Ba t t er y Tem per a t u r e Sen sor . . . . . . . . . 8W-20-2, 4 G101 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2, 3, 4
E CM/P CM Rela y . . . . . . . . . . . . . . . . . . . . 8W-20-4 Gen er a t or . . . . . . . . . . . . . . . . . . . . . . 8W-20-2, 3, 4
E n gin e Con t r ol Modu le . . . . . . . . . . . . . . . . 8W-20-4 In t egr a t ed P ower Modu le . . . . . . . . . . . . 8W-20-2, 4
F u se 16 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2, 4 P ower t r a in Con t r ol Modu le . . . . . . . . . . 8W-20-2, 3
F u se 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-20-2 St a r t er Mot or . . . . . . . . . . . . . . . . . . . . . 8W-20-2, 4
RS 8W-21 STARTING SYSTEM 8W - 21 - 1
8 W-2 1 START I N G SY ST EM
Ba t t er y . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-2, 3 G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-2
Br a ke La m p Swit ch . . . . . . . . . . . . . . . . . . 8W-21-2 Gen er a t or . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-2, 3
Clu t ch P eda l In t er lock Swit ch . . . . . . . . 8W-21-2, 3 Ign it ion Swit ch . . . . . . . . . . . . . . . . . . . . 8W-21-2, 3
E n gin e Con t r ol Modu le . . . . . . . . . . . . . . . . 8W-21-3 In t egr a t ed P ower Modu le . . . . . . . . . . . . 8W-21-2, 3
F r on t Con t r ol Modu le . . . . . . . . . . . . . . . . . 8W-21-2 P ower t r a in Con t r ol Modu le . . . . . . . . . . . . 8W-21-2
F u se 9 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-2, 3 St a r t er Mot or . . . . . . . . . . . . . . . . . . . . . 8W-21-2, 3
F u selin k . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-2, 3 St a r t er Mot or Rela y . . . . . . . . . . . . . . . . 8W-21-2, 3
G101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-21-2, 3
RS 8W-30 FUEL/IGNITION SYSTEM 8W - 30 - 1
8 W-3 0 FU EL/I GN I T I ON SY ST EM
A/C Com pr essor Clu t ch . . . . . . . . . . . . . . 8W-30-20 G100 . . . . . . . . . . . . . . . . . . . . . . 8W-30-2, 6, 15, 21
A/C Com pr essor Clu t ch Rela y . . . . . . . . 8W-30-4, 20 G101 . . . . . . . . . . . . . . . . . 8W-30-2, 6, 7, 10, 15, 20
A/C P r essu r e Sen sor . . . . . . . . . . . 8W-30-13, 18, 27 G103 . . . . . . . . . . . . . . . . . . . . . . . 8W-30-20, 21, 24
Acceler a t or P eda l P osit ion Sen sor . . . . 8W-30-32, 34 G300 . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-7, 23, 32
Am bien t Tem per a t u r e Sen sor . . . . . . . . . . . 8W-30-8 G302 . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-5, 21, 31
Au t o Sh u t Down Rela y . . . . 8W-30-4, 11, 14, 16, 19 Gen er a t or . . . . . . . . . . . . . . . . . . . . . . . 8W-30-4, 21
Ba t t er y . . . . . . . . . . . . . . 8W-30-2, 6, 10, 15, 20, 28 Glow P lu g No. 1 . . . . . . . . . . . . . . . . . . . . 8W-30-28
Ba t t er y Tem per a t u r e Sen sor . . . . . . . . . 8W-30-8, 27 Glow P lu g No. 2 . . . . . . . . . . . . . . . . . . . . 8W-30-28
Body Con t r ol Modu le . . . . . . . . . . . . . . 8W-30-5, 21 Glow P lu g No. 3 . . . . . . . . . . . . . . . . . . . . 8W-30-28
Boost P r essu r e Sen sor . . . . . . . . . . . . . . . 8W-30-27 Glow P lu g No. 4 . . . . . . . . . . . . . . . . . . . . 8W-30-28
Br a ke La m p Swit ch . . . . . . . . . . . . 8W-30-7, 23, 33 Glow P lu g Rela y . . . . . . . . . . . . . . . . . . . . 8W-30-28
Ca bin H ea t er Assist . . . . . . . . . . . . . . . . . 8W-30-24 Idle Air Con t r ol Mot or . . . . . . . . . . . . . . . . 8W-30-9
Ca m sh a ft P osit ion Sen sor . . . . . . . . . . . 8W-30-8, 26 Ign it ion Coil . . . . . . . . . . . . . . . . . . . . 8W-30-11, 16
Clockspr in g . . . . . . . . . . . . . . . . . . . 8W-30-5, 25, 32 Ign it ion Swit ch . . . . . . . . . . . . . . . . . . . . . 8W-30-10
Clu t ch P eda l In t er lock Swit ch . . . . . . . . . . 8W-30-7 In let Air Tem per a t u r e Sen sor . . . . . . . 8W-30-12, 17
Clu t ch P eda l Upst op Swit ch . . . . . . . . . . . 8W-30-32 In t egr a t ed P ower Modu le . . 8W-30-2, 3, 4, 5, 10, 11,
Cr a n k Ca se Ven t ila t ion H ea t er . . . . . . . . . 8W-30-21 14, 16, 19, 20, 21, 22, 24,
Cr a n ksh a ft P osit ion Sen sor . . . . . . 8W-30-12, 17, 26 26, 28, 30, 31, 32, 33
Da t a Lin k Con n ect or . . . . . . . . . . . . . . 8W-30-3, 24 Kn ock Sen sor . . . . . . . . . . . . . . . . . . . . . . . 8W-30-9
Dosin g P u m p . . . . . . . . . . . . . . . . . . . . . . 8W-30-24 Left Speed Con t r ol Swit ch . . . . . . . . . . 8W-30-5, 25
E CM/P CM Rela y . . . . . . . . 8W-30-20, 22, 26, 28, 30 Lift P u m p Mot or . . . . . . . . . . . . . . . . . . . . 8W-30-31
E GR Solen oid . . . . . . . . . . . . . . . . . . . 8W-30-15, 30 Lift P u m p Rela y . . . . . . . . . . . . . . . . . . . . 8W-30-31
E n gin e Con t r ol Modu le . . . 8W-30-20, 21, 22, 23, 24, Ma n ifold Absolu t e P r essu r e Sen sor . . . 8W-30-13, 18
25, 26, 27, 28, 29, 30, 31, 32, 33, 34, 35 Ma ss Air F low Sen sor . . . . . . . . . . . . . . . . 8W-30-22
E n gin e Coola n t Tem p Sen sor . . . . 8W-30-13, 18, 27 Na t u r a l Va cu u m Lea k Det ect ion
E n gin e Oil P r essu r e Sen sor . . . . . . . . . . . 8W-30-23 Assem bly . . . . . . . . . . . . . . . . . . . . . . . 8W-30-10
E n gin e Oil P r essu r e Swit ch . . . . . . . . . . . . 8W-30-7 Oxygen Sen sor 1/1 Upst r ea m . . . . . . . . . . . 8W-30-6
E VAP /P u r ge Solen oid . . . . . . . . . . . . . . . . . 8W-30-4 Oxygen Sen sor 1/2 Down st r ea m . . . . . . . . . 8W-30-6
F r on t Con t r ol Modu le . . . . . . . . . 8W-30-2, 5, 24, 32 P ower t r a in Con t r ol Modu le . . 8W-30-2, 3, 4, 5, 6, 7,
F u el H ea t er . . . . . . . . . . . . . . . . . . . . . . . 8W-30-31 8, 9, 10, 11, 12, 13, 14,
F u el H ea t er Rela y . . . . . . . . . . . . . . . . 8W-30-21, 31 15, 16, 17, 18, 19
F u el In ject or No. 1 . . . . . . . . . . . . 8W-30-14, 19, 29 Ra dia t or F a n Rela y . . . . . . . . . . . . . . . 8W-30-11, 16
F u el In ject or No. 2 . . . . . . . . . . . . 8W-30-14, 19, 29 Ra dia t or F a n Rela y No. 1 . . . . . . . . . . . . . 8W-30-33
F u el In ject or No. 5 . . . . . . . . . . . . . . . . . . 8W-30-19 Righ t Speed Con t r ol Swit ch . . . . . . . . . 8W-30-5, 25
F u el In ject or No. 6 . . . . . . . . . . . . . . . . . . 8W-30-19 Speed Con t r ol Ser vo . . . . . . . . . . . . . . . . . . 8W-30-7
F u el P r essu r e Sen sor . . . . . . . . . . . . . . . . 8W-30-33 St a r t er Mot or Rela y . . . . . . . . . . . . . . . 8W-30-5, 21
F u el P r essu r e Solen oid . . . . . . . . . . . . . . . 8W-30-22 Th r ot t le P osit ion Sen sor . . . . . . . . . . . 8W-30-12, 17
F u el P u m p Modu le . . . . . . . . . . . . . . . . 8W-30-5, 21 Tr a n sm ission Con t r ol
F u el P u m p Rela y . . . . . . . . . . . . . . . . . . . . 8W-30-5 Modu le . . . . . . . . . . . . . . . . 8W-30-28, 32, 34, 35
F u se 15 . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-24, 31 Tr a n sm ission Con t r ol Rela y . . . . . . . . . . . 8W-30-28
F u se 16 . . 8W-30-4, 11, 14, 16, 19, 20, 22, 26, 28, 30 Tr a n sm ission Ra n ge Sen sor . . . . . . . . . . . 8W-30-32
F u se 17 . . . . . . . . . . . . . . . . . . . . 8W-30-2, 5, 21, 31 Veh icle Speed Sen sor . . . . . . . . . . . . . . 8W-30-9, 30
F u se 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-20 Wa t er In F u el Sen sor . . . . . . . . . . . . . . . . 8W-30-32
F u se 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-33
F u selin k . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-28
RS 8W-31 TRANSMISSION CONTROL SYSTEM 8W - 31 - 1
8 W-3 1 T RAN SM I SSI ON CON T ROL SY ST EM

Acceler a t or P eda l P osit ion Sen sor . . . . . . 8W-31-12 In pu t Speed Sen sor . . . . . . . . . . . . . . . . 8W-31-4, 9
Ba t t er y . . . . . . . . . . . . . . . . 8W-31-2, 5, 6, 7, 10, 11 In t egr a t ed P ower Modu le . . . 8W-31-2, 3, 5, 6, 8, 12
Br a ke Tr a n sm ission Sh ift In t er lock Ou t pu t Speed Sen sor . . . . . . . . . . . . . . . 8W-31-4, 9
Solen oid . . . . . . . . . . . . . . . . . . . . . . . 8W-31-3, 8 P ower t r a in Con t r ol Modu le . . . . . 8W-31-2, 3, 4, 5, 6
Da t a Lin k Con n ect or . . . . . . . . . . . . . . . . 8W-31-12 Tr a n sm ission Con t r ol
E n gin e Con t r ol Modu le . . . . . . . . . . . . . 8W-31-8, 12 Modu le . . . . . . . . . . . . . . 8W-31-7, 8, 9, 10, 11, 12
F r on t Con t r ol Modu le . . . . . . . . . . 8W-31-3, 6, 8, 12 Tr a n sm ission Con t r ol Rela y . . 8W-31-2, 5, 7, 10, 11
F u se 15 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-2, 5 Tr a n sm ission Ra n ge Sen sor . . . . . . 8W-31-3, 4, 8, 9
F u selin k . . . . . . . . . . . . . . . . . . . . . 8W-31-7, 10, 11 Tr a n sm ission Solen oid/P r essu r e Swit ch
G101 . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-2, 5, 6, 7 Assem bly . . . . . . . . . . . . . 8W-31-2, 5, 6, 7, 10, 11
RS 8W-33 VEHICLE SPEED CONTROL 8W - 33 - 1
8 W-3 3 V EH I CLE SPEED CON T ROL

Br a ke La m p Swit ch . . . . . . . . . . . . . . . . . . 8W-33-3 P ower t r a in Con t r ol Modu le . . . . . . . . . . 8W-33-2, 3
Clockspr in g . . . . . . . . . . . . . . . . . . . . . . . 8W-33-2, 4 Righ t Speed Con t r ol Swit ch . . . . . . . . . . 8W-33-2, 4
E n gin e Con t r ol Modu le . . . . . . . . . . . . . . . . 8W-33-4 Speed Con t r ol Ser vo . . . . . . . . . . . . . . . . . . 8W-33-3
G101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-33-3 Tr a n sm ission Con t r ol Modu le . . . . . . . . . . . 8W-33-4
In pu t Speed Sen sor . . . . . . . . . . . . . . . . . . 8W-33-2 Tr a n sm ission Ra n ge Sen sor . . . . . . . . . . . . 8W-33-4
Left Speed Con t r ol Swit ch . . . . . . . . . . . 8W-33-2, 4 Veh icle Speed Sen sor . . . . . . . . . . . . . . . . . 8W-33-2
Ou t pu t Speed Sen sor . . . . . . . . . . . . . . . . . 8W-33-2
RS 8W-35 ANTILOCK BRAKES 8W - 35 - 1
8 W-3 5 AN T I LOCK BRAK ES

Body Con t r ol Modu le . . . . . . . . . . . . . . . . . 8W-35-2 G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-2
Br a ke F lu id Level Swit ch . . . . . . . . . . . . . . 8W-35-3 G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-3
Br a ke La m p Swit ch . . . . . . . . . . . . . . . . . . 8W-35-3 In t egr a t ed P ower Modu le . . . . . . . . . . . . 8W-35-2, 3
Clu t ch P eda l In t er lock Swit ch . . . . . . . . . . 8W-35-3 Left F r on t Wh eel Speed Sen sor . . . . . . . . . 8W-35-4
Con t r oller An t ilock Br a ke . . . . . . . . . . 8W-35-2, 3, 4 Left Rea r Wh eel Speed Sen sor . . . . . . . . . . 8W-35-4
E n gin e Con t r ol Modu le . . . . . . . . . . . . . . . . 8W-35-3 P ower t r a in Con t r ol Modu le . . . . . . . . . . . . 8W-35-3
F r on t Con t r ol Modu le . . . . . . . . . . . . . . . . . 8W-35-3 Righ t F r on t Wh eel Speed Sen sor . . . . . . . . 8W-35-4
F u se 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-2 Righ t Rea r Wh eel Speed Sen sor . . . . . . . . . 8W-35-4
F u se 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-2 Tr a ct ion Con t r ol Swit ch . . . . . . . . . . . . . . . 8W-35-2
F u se 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-3 Tr a n sm ission Con t r ol Modu le . . . . . . . . . . . 8W-35-3
G100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-35-2
RS 8W-39 VEHICLE THEFT SECURITY SYSTEM 8W - 39 - 1
8 W-3 9 V EH I CLE T H EFT SECU RI T Y SY ST EM

Body Con t r ol Modu le . . . . . . . . . . . 8W-39-2, 3, 6, 7, Left Slidin g Door Con t r ol Modu le . . . . . . 8W-39-8, 9
8, 9, 10, 11, 12, 13 Left Slidin g Door La t ch Sen sin g Swit ch . . . 8W-39-8
Clockspr in g . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-5 Left Slidin g Door Lock Mot or . . . . . . . . . . . 8W-39-9
Dr iver Door Lock Swit ch . . . . . . . . . . . 8W-39-11, 12 Left Slidin g Door Lock Mot or /Aja r
F r on t Con t r ol Modu le . . . . . . . . . . . . . 8W-39-2, 3, 5 Swit ch . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-10
F r on t In t r u sion Sen sor . . . . . . . . . . . . . . . . 8W-39-4 Lift ga t e Aja r Swit ch . . . . . . . . . . . . . . . . . 8W-39-13
F u se 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-5 Lift ga t e Cin ch /Relea se Mot or . . . . . . . . . . 8W-39-13
F u se 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-2 P a ssen ger Door Lock Swit ch . . . . . . . . 8W-39-11, 12
G102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-5 P ower Lift ga t e Modu le . . . . . . . . . . . . . . . 8W-39-13
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-2, 3, 5 Rea r In t r u sion Sen sor . . . . . . . . . . . . . . . . 8W-39-4
G300 . . . . . . . . . . . . . . 8W-39-6, 7, 8, 10, 11, 12, 13 Righ t Cylin der Lock Swit ch . . . . . . . . 8W-39-11, 12
G301 . . . . . . . . . . . . . . . . . 8W-39-6, 7, 8, 10, 11, 12 Righ t F r on t Door Aja r Swit ch . . . . . . . . . . . 8W-39-6
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-13 Righ t F r on t Door Lock Mot or /Aja r
G303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-13 Swit ch . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-6, 7
H igh Not e H or n . . . . . . . . . . . . . . . . . . . . . 8W-39-5 Righ t Slidin g Door Con t r ol Modu le . . . . 8W-39-8, 9
H ood Aja r Swit ch . . . . . . . . . . . . . . . . . . . 8W-39-13 Righ t Slidin g Door La t ch Sen sin g Swit ch . . 8W-39-8
H or n Rela y . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-5 Righ t Slidin g Door Lock Mot or . . . . . . . . . . 8W-39-9
H or n Swit ch . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-5 Righ t Slidin g Door Lock Mot or /Aja r
Ign it ion Swit ch . . . . . . . . . . . . . . . . . . . . 8W-39-2, 3 Swit ch . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-10
In t egr a t ed P ower Modu le . . . . . . . . . . 8W-39-2, 3, 5 Sen t r y Key Rem ot e E n t r y Modu le . . . . . . . 8W-39-2
Left Cylin der Lock Swit ch . . . . . . . . . 8W-39-11, 12 Sir en . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-3
Left F r on t Door Aja r Swit ch . . . . . . . . . . . . 8W-39-6 Th a t ch a m Ala r m In dica t or . . . . . . . . . . . . . 8W-39-4
Left F r on t Door Lock Mot or /Aja r Th a t ch a m Ala r m Modu le . . . . . . . . . . . . 8W-39-3, 4
Swit ch . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-6, 7
RS 8W-40 INSTRUMENT CLUSTER 8W - 40 - 1
8 W-4 0 I N ST RU M EN T CLU ST ER
Body Con t r ol Modu le . . . . . . . . . . . . . . . 8W-40-3, 4 In t egr a t ed P ower Modu le . . . . . . . . . . . . . . 8W-40-2
F u se 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-2 Messa ge Cen t er . . . . . . . . . . . . . . . . . . . . . 8W-40-5
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-40-4 Occu pa n t Rest r a in t Con t r oller . . . . . . . . . . 8W-40-3
In st r u m en t Clu st er . . . . . . . . . . . . . 8W-40-2, 3, 4, 5 P a r kin g Br a ke Swit ch . . . . . . . . . . . . . . . . 8W-40-5
RS 8W-41 HORN/CIGAR LIGHTER/POWER OUTLET 8W - 41 - 1
8 W-4 1 H ORN /CI GAR LI GH T ER/POWER OU T LET

Accessor y Rela y . . . . . . . . . . . . . . . . . . . 8W-41-3, 4 G200 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2, 3, 4
Clockspr in g . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2 G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-3, 4
Da t a Lin k Con n ect or . . . . . . . . . . . . . . . . . 8W-41-4 H igh Not e H or n . . . . . . . . . . . . . . . . . . . . . 8W-41-2
F loor Con sole La m p . . . . . . . . . . . . . . . . . . 8W-41-4 H or n Rela y . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2
F loor Con sole P ower Ou t let . . . . . . . . . . . . 8W-41-4 H or n Swit ch . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2
F r on t Ciga r Ligh t er . . . . . . . . . . . . . . . . . . 8W-41-3 In t egr a t ed P ower Modu le . . . . . . . . . . 8W-41-2, 3, 4
F r on t Con t r ol Modu le . . . . . . . . . . . . . 8W-41-2, 3, 4 P ower Ou t let . . . . . . . . . . . . . . . . . . . . . . . 8W-41-4
F u se 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-3 P TC 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-4
F u se 6 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-3, 4 Ra dio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-3
F u se 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2 Rea r P ower Ou t let . . . . . . . . . . . . . . . . . . . 8W-41-3
G102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-41-2
RS 8W-42 AIR CONDITIONING-HEATER 8W - 42 - 1
8 W-4 2 AI R CON DI T I ON I N G-H EAT ER

A/C Com pr essor Clu t ch . . . . . . . . . . . . 8W-42-16, 19 G200 . . . . . . . . . . . 8W-42-2, 3, 4, 5, 6, 8, 10, 11, 13
A/C Com pr essor Clu t ch Rela y . . . . . . . 8W-42-16, 19 G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-9, 15
A/C P r essu r e Sen sor . . . . . . . . . . . . . . 8W-42-16, 19 G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-14
A/C-H ea t er Con t r ol . . . . . . . 8W-42-2, 3, 4, 5, 6, 7, 9 In t egr a t ed P ower Modu le . . . . 8W-42-2, 3, 8, 10, 13,
ATC Rem ot e Sen sor . . . . . . . . . . . . . . . . . 8W-42-13 14, 16, 17, 18, 19, 20
Au t o Tem p Con t r ol . . . . 8W-42-10, 11, 12, 13, 14, 15 Mode Door Act u a t or . . . . . . . . . . . . . . . 8W-42-7, 12
Ba t t er y . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-17 P a ssen ger Blen d Door Act u a t or . . . . . . 8W-42-7, 12
Blower Mot or Resist or . . . . . . . . . . . . . . 8W-42-2, 3 P ower t r a in Con t r ol Modu le . . . . . . . . . 8W-42-19, 20
Body Con t r ol Modu le . . . . . . . . . . 8W-42-6, 9, 11, 15 Ra dia t or F a n No. 1 . . . . . . . . . . . . 8W-42-17, 18, 20
Dr iver Blen d Door Act u a t or . . . . . . . . . 8W-42-7, 12 Ra dia t or F a n No. 2 . . . . . . . . . . . . . . . 8W-42-18, 20
E CM/P CM Rela y . . . . . . . . . . . . . . . . . . . 8W-42-17 Ra dia t or F a n Rela y . . . . . . . . . . . . . . . . . 8W-42-20
E n gin e Con t r ol Modu le . . . . . . . . . . . . 8W-42-16, 17 Ra dia t or F a n Rela y No. 1 . . . . . . . . . . 8W-42-17, 18
E va por a t or Tem per a t u r e Sen sor . . . . . . 8W-42-7, 12 Ra dia t or F a n Rela y No. 2 . . . . . . . . . . . . . 8W-42-18
F r on t Blower Modu le . . . . . . . . . . . . . . . . 8W-42-13 Ra dia t or F a n Rela y No. 3 . . . . . . . . . . . . . 8W-42-18
F r on t Blower Mot or . . . . . . . . . . . . . 8W-42-2, 3, 13 Rea r A/C-H ea t er Un it . . . . . . . . . . . . . . . 8W-42-8, 9
F r on t Blower Mot or Rela y . . . . . . . . 8W-42-2, 3, 13 Rea r Au t o Tem p Con t r ol Swit ch . . . . . . . . 8W-42-15
F r on t Con t r ol Modu le . . . . . . . 8W-42-2, 3, 8, 13, 14 Rea r Blower F r on t Con t r ol Swit ch . . . . . . . 8W-42-8
F u se 10 . . . . . . . . . . . . . . . . . . . . . . . 8W-42-2, 3, 13 Rea r Blower Mot or . . . . . . . . . . . . . . . . . . 8W-42-14
F u se 12 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-8, 14 Rea r Blower Mot or P ower Modu le . . . . . . 8W-42-14
F u se 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-10 Rea r Blower Mot or Rela y . . . . . . . . . . . 8W-42-8, 14
F u se 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-17 Rea r Blower Rea r Con t r ol Swit ch . . . . . . 8W-42-8, 9
F u se 18 . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-16, 19 Rea r Mode Mot or . . . . . . . . . . . . . . . . . . . 8W-42-14
F u se 27 . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-18, 20 Rea r Tem per a t u r e Mot or . . . . . . . . . . . . . 8W-42-14
F u selin k . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-17 Rea r Wiper /Wa sh er In dica t or . . . . . . . . . . . 8W-42-4
G101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-19 Rea r Wiper /Wa sh er Swit ch . . . . . . . . . . . . . 8W-42-4
G102 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-18, 20 Recir cu la t ion Door Act u a t or . . . . . . . . . 8W-42-7, 12
G103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-16
RS 8W-43 OCCUPANT RESTRAINT SYSTEM 8W - 43 - 1
8 W-4 3 OCCU PAN T REST RAI N T SY ST EM

Belt Ten sion Sen sor . . . . . . . . . . . . . . . . . . 8W-43-8 Left Side Im pa ct Sen sor 1 . . . . . . . . . . . . . 8W-43-6
Clockspr in g . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-4 Left Side Im pa ct Sen sor 2 . . . . . . . . . . . . . 8W-43-6
Dr iver Air ba g Squ ib 1 . . . . . . . . . . . . . . . . 8W-43-4 Left Side Im pa ct Sen sor 3 . . . . . . . . . . . . . 8W-43-6
Dr iver Air ba g Squ ib 2 . . . . . . . . . . . . . . . . 8W-43-4 Occu pa n t Cla ssifica t ion Modu le . . . . . . . 8W-43-2, 8
Dr iver Kn ee Blocker Air ba g Squ ib . . . . . . . 8W-43-4 Occu pa n t Rest r a in t
Dr iver Sea t Belt Swit ch . . . . . . . . . . . . . . . 8W-43-3 Con t r oller . . . . . . . . . . . . 8W-43-2, 3, 4, 5, 6, 7, 8
Dr iver Sea t Belt Ten sion er . . . . . . . . . . . . . 8W-43-3 P a ssen ger Air ba g . . . . . . . . . . . . . . . . . . . . 8W-43-5
F r on t Con t r ol Modu le . . . . . . . . . . . . . . . 8W-43-2, 8 P a ssen ger Air ba g On /Off In dica t or La m p . . 8W-43-2
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-2 P a ssen ger Sea t Belt Swit ch . . . . . . . . . . . . 8W-43-5
G201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-2 P a ssen ger Sea t Belt Ten sion er . . . . . . . . . . 8W-43-5
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-43-8 P a ssen ger Sea t Weigh t Sen sor . . . . . . . . . . 8W-43-8
In st r u m en t Clu st er . . . . . . . . . . . . . . . . . . . 8W-43-2 Righ t Cu r t a in Air ba g Squ ib . . . . . . . . . . . . 8W-43-7
In st r u m en t P a n el Swit ch Ba n k . . . . . . . . . 8W-43-2 Righ t F r on t Im pa ct Sen sor . . . . . . . . . . . . . 8W-43-7
In t egr a t ed P ower Modu le . . . . . . . . . . . . 8W-43-2, 8 Righ t Side Im pa ct Sen sor 1 . . . . . . . . . . . . 8W-43-7
Left Cu r t a in Air ba g Squ ib . . . . . . . . . . . . . 8W-43-6 Righ t Side Im pa ct Sen sor 2 . . . . . . . . . . . . 8W-43-7
Left F r on t Im pa ct Sen sor . . . . . . . . . . . . . . 8W-43-6 Righ t Side Im pa ct Sen sor 3 . . . . . . . . . . . . 8W-43-7
RS 8W-44 INTERIOR LIGHTING 8W - 44 - 1
8 W-4 4 I N T ERI OR LI GH T I N G
A/C-H ea t er Con t r ol . . . . . . . . . . . . . . . . . . . 8W-44-8 In st r u m en t P a n el Swit ch Ba n k . . . . . . . . . 8W-44-7
Accessor y Rela y . . . . . . . . . . . . . . . . . . . . . 8W-44-4 In t egr a t ed P ower Modu le . . . . . . . . . . . . . . 8W-44-4
Au t o Tem p Con t r ol . . . . . . . . . . . . . . . . . . . 8W-44-8 Left Lift ga t e F lood La m p . . . . . . . . . . . 8W-44-9, 10
Body Con t r ol Modu le . . . 8W-44-2, 3, 4, 5, 7, 8, 9, 10 Left Mid Rea din g La m p . . . . . . . . . . . . . . . 8W-44-3
Dr iver Door Cou r t esy La m p . . . . . . . . . . . . 8W-44-2 Left Rea r Rea din g La m p . . . . . . . . . . . . . . 8W-44-3
F loor Con sole La m p . . . . . . . . . . . . . . . . 8W-44-4, 5 Left Visor /Va n it y La m p . . . . . . . . . . . . . 8W-44-5, 6
F loor Con sole P ower Ou t let . . . . . . . . . . . . 8W-44-4 Over h ea d Con sole . . . . . . . . . . . . . . . . . . . . 8W-44-5
F r on t Con t r ol Modu le . . . . . . . . . . . . . . . . . 8W-44-4 P a ssen ger Door Cou r t esy La m p . . . . . . . . . 8W-44-2
F r on t Rea din g La m ps/Swit ch . . . . . . . 8W-44-2, 4, 5 Ra dio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-7
F u se 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-4 Rea r Au t o Tem p Con t r ol Swit ch . . . . . . . . . 8W-44-8
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-7, 8 Rea r Blower Rea r Con t r ol Swit ch . . . . . . . . 8W-44-8
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-2, 8 Rea r Dom e La m p . . . . . . . . . . . . . . . . . . 8W-44-3, 5
G301 . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-2, 3, 5, 6 Rea r P ower Ou t let . . . . . . . . . . . . . . . . . . . 8W-44-4
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-4 Righ t Lift ga t e F lood La m p . . . . . . . . . . 8W-44-9, 10
G303 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-9, 10 Righ t Mid Rea din g La m p . . . . . . . . . . . . . . 8W-44-3
H ea dla m p Swit ch . . . . . . . . . . . . . . . . . . . . 8W-44-3 Righ t Rea r Rea din g La m p . . . . . . . . . . . 8W-44-3, 4
In st r u m en t Clu st er . . . . . . . . . . . . . . . . . . . 8W-44-7 Righ t Visor /Va n it y La m p . . . . . . . . . . . . 8W-44-5, 6
RS 8W-45 BODY CONTROL MODULE 8W - 45 - 1
8 W-4 5 BODY CON T ROL M ODU LE

A/C-H ea t er Con t r ol . . . . . . . . . . . . . . . 8W-45-16, 19 Licen se La m p . . . . . . . . . . . . . . . . . . . . . . . 8W-45-8
Au t o Tem p Con t r ol . . . . . . . . . . . . . . . 8W-45-16, 19 Lift ga t e Aja r Swit ch . . . . . . . . . . . . . . . . . 8W-45-12
Body Con t r ol Modu le . . . 8W-45-2, 3, 4, 5, 6, 7, 8, 9, Lift ga t e Cin ch /Relea se Mot or . . . . . . . . . . 8W-45-12
10, 11, 12, 13, 15, 16, 17, 18, 19, 20 Mem or y Set Swit ch . . . . . . . . . . . . . . . . . . 8W-45-4
Clockspr in g . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-17 Messa ge Cen t er . . . . . . . . . . . . . . . . . . . . 8W-45-18
Con t r oller An t ilock Br a ke . . . . . . . . . . . . . 8W-45-13 Mu lt i-F u n ct ion Swit ch . . . . . . . . . . . . . . . 8W-45-16
Dr iver Door Cou r t esy La m p . . . . . . . . . . . 8W-45-15 Over h ea d Con sole . . . . . . . . . . . . . . . . . 8W-45-4, 11
Dr iver Door Lock Swit ch . . . . . . . . . . . 8W-45-12, 15 P a ssen ger Door Cou r t esy La m p . . . . . . . . 8W-45-15
Dr iver H ea t ed Sea t Modu le . . . . . . . . . . . 8W-45-11 P a ssen ger Door Lock Swit ch . . . . . . . . 8W-45-12, 15
F loor Con sole La m p . . . . . . . . . . . . . . . . . 8W-45-13 P a ssen ger F oldin g Mir r or Rela y . . . . . . . . 8W-45-20
F r on t Con t r ol Modu le . . . . . . . . . . . . . . . . . 8W-45-3 P a ssen ger H ea t ed Sea t Modu le . . . . . . . . 8W-45-11
F r on t Rea din g La m ps/Swit ch . . . . . . . 8W-45-13, 15 P ower F oldin g Mir r or Swit ch . . . . . . . . . . 8W-45-20
F u el P u m p Modu le . . . . . . . . . . . . . . . . . . 8W-45-15 P ower Lift ga t e Modu le . . . . . . . . . . . . . 8W-45-8, 12
F u se 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-3 Ra dio . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-17
F u se 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-2 Rea r Au t o Tem p Con t r ol Swit ch . . . . . 8W-45-10, 19
F u se 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-2 Rea r Blower Rea r Con t r ol Swit ch . . . . . . . 8W-45-10
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-2, 8 Rea r Dom e La m p . . . . . . . . . . . . . . . . . . . . 8W-45-9
H ea dla m p Swit ch . . . . . . . . . . . . . 8W-45-11, 16, 20 Rea r View Mir r or . . . . . . . . . . . . . . . . . . . 8W-45-11
H ood Aja r Swit ch . . . . . . . . . . . . . . . . . . . 8W-45-12 Rea r Wiper Mot or . . . . . . . . . . . . . . . . . . . . 8W-45-8
Ign it ion Swit ch . . . . . . . . . . . . . . . . . . . . . . 8W-45-3 Righ t B-P illa r Swit ch . . . . . . . . . . . . . . . . . 8W-45-9
In st r u m en t Clu st er . . . . . . . . . . 8W-45-2, 16, 18, 19 Righ t Cylin der Lock Swit ch . . . . . . . . . . . 8W-45-10
In st r u m en t P a n el Swit ch Righ t F r on t Door Aja r Swit ch . . . . . . . . . . . 8W-45-9
Ba n k . . . . . . . . . . . . . . . . . . 8W-45-10, 11, 17, 19 Righ t F r on t Door Lock Mot or /Aja r
In t egr a t ed P ower Modu le . . . . . 8W-45-2, 3, 5, 6, 13 Swit ch . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-7, 9
Left B-P illa r Swit ch . . . . . . . . . . . . . . . . . . 8W-45-9 Righ t Lift ga t e F lood La m p . . . . . . . . . . . . 8W-45-12
Left Cylin der Lock Swit ch . . . . . . . . . . . . 8W-45-10 Righ t Mid Rea din g La m p . . . . . . . . . . . 8W-45-9, 14
Left F r on t Door Aja r Swit ch . . . . . . . . . . . . 8W-45-9 Righ t P ower Mir r or . . . . . . . . . . . . . . . . . 8W-45-20
Left F r on t Door Lock Mot or /Aja r Righ t Rea r La m p Assem bly . . . . . . . . . . 8W-45-5, 6
Swit ch . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-7, 9 Righ t Rea r Rea din g La m p . . . . . . . . . . 8W-45-9, 14
Left Lift ga t e F lood La m p . . . . . . . . . . . . . 8W-45-12 Righ t Rem ot e Ra dio Swit ch . . . . . . . . . . . 8W-45-17
Left Mid Rea din g La m p . . . . . . . . . . . . 8W-45-9, 14 Righ t Repea t er La m p . . . . . . . . . . . . . . . . 8W-45-20
Left P ower Mir r or . . . . . . . . . . . . . . . . . . . 8W-45-20 Righ t Slidin g Door Con t r ol Modu le . . . . 8W-45-8, 10
Left Rea r La m p Assem bly . . . . . . . . . . . 8W-45-5, 6 Righ t Slidin g Door Lock Mot or . . . . . . . . . . 8W-45-7
Left Rea r Rea din g La m p . . . . . . . . . . . 8W-45-9, 14 Righ t Slidin g Door Lock Mot or /Aja r
Left Rem ot e Ra dio Swit ch . . . . . . . . . . . . 8W-45-17 Swit ch . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-7, 8
Left Repea t er La m p . . . . . . . . . . . . . . . . . 8W-45-20 Righ t Visor /Va n it y La m p . . . . . . . . . . . . . 8W-45-13
Left Slidin g Door Con t r ol Modu le . . . . . 8W-45-8, 10 Sen t r y Key Rem ot e E n t r y Modu le . . . . . . . 8W-45-3
Left Slidin g Door Lock Mot or . . . . . . . . . . . 8W-45-7 Th a t ch a m Ala r m Modu le . . . . . . . . . . . . . 8W-45-10
Left Slidin g Door Lock Mot or /Aja r Tr a ct ion Con t r ol Swit ch . . . . . . . . . . . . . . 8W-45-17
Swit ch . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-7, 8 Tr a iler Tow Con n ect or . . . . . . . . . . . . . . . . 8W-45-5
Left Visor /Va n it y La m p . . . . . . . . . . . . . . 8W-45-13
RS 8W-46 MESSAGE CENTER 8W - 46 - 1
8 W-4 6 M ESSAGE CEN T ER

Body Con t r ol Modu le . . . . . . . . . . . . . . . . . 8W-46-2 In t egr a t ed P ower Modu le . . . . . . . . . . . . . . 8W-46-2
F u se 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-46-2 Messa ge Cen t er . . . . . . . . . . . . . . . . . . . . . 8W-46-2
In st r u m en t Clu st er . . . . . . . . . . . . . . . . . . . 8W-46-2
RS 8W-47 AUDIO SYSTEM 8W - 47 - 1
8 W-4 7 AU DI O SY ST EM
Accessor y Rela y . . . . . . . . . . . . . . . . . . . . . 8W-47-2 G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-6
Am plifier . . . . . . . . . . . . . . . . . . . . 8W-47-2, 6, 7, 8 H a n ds F r ee Modu le . . . . . . . . . . . . . . 8W-47-12, 15
An t en n a . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-2 In t egr a t ed P ower Modu le . . . . . . . . . 8W-47-2, 6, 13
Body Con t r ol Modu le . . . . . . . . . . . . . . . 8W-47-2, 9 Left Door Spea ker . . . . . . . . . . . . . . 8W-47-3, 4, 7, 8
CD Ch a n ger . . . . . . . . . . . . . . . . . 8W-47-10, 11, 12 Left In st r u m en t P a n el Spea ker . . . 8W-47-3, 4, 7, 8
Clockspr in g . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-9 Left Rea r P illa r Spea ker . . . . . . . . . . . . . 8W-47-7, 8
Da t a Lin k Con n ect or . . . . . . . . . . . . . . . . . 8W-47-6 Left Rea r Spea ker . . . . . . . . . . . . . . . 8W-47-5, 7, 8
DVD Scr een . . . . . . . . . . . . . . . . . . . . . . . 8W-47-14 Left Rem ot e Ra dio Swit ch . . . . . . . . . . . . . 8W-47-9
DVD/CD Ch a n ger . . . . . . . . . . . . . 8W-47-13, 14, 15 Over h ea d Con sole . . . . . . . . . . . . . . . . . . . . 8W-47-6
F r on t Ciga r Ligh t er . . . . . . . . . . . . . . . . . . 8W-47-2 Ra dio . . . . . . . 8W-47-2, 3, 4, 5, 6, 10, 11, 12, 13, 15
F r on t Con t r ol Modu le . . . . . . . . . . . . . . . . . 8W-47-2 Righ t Door Spea ker . . . . . . . . . . . . 8W-47-3, 4, 7, 8
F u se 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-2 Righ t In st r u m en t P a n el Spea ker . . 8W-47-3, 4, 7, 8
F u se 14 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-2, 13 Righ t Rea r P illa r Spea ker . . . . . . . . . . . 8W-47-7, 8
F u se 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-6 Righ t Rea r Spea ker . . . . . . . . . . . . . . 8W-47-5, 7, 8
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-13 Righ t Rem ot e Ra dio Swit ch . . . . . . . . . . . . 8W-47-9
G202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-2 Righ t Slidin g Door Con t r ol Modu le . . . . . . 8W-47-6
RS 8W-48 REAR WINDOW DEFOGGER 8W - 48 - 1
8 W-4 8 REAR WI N DOW DEFOGGER

Defogger Rela y . . . . . . . . . . . . . . . . . . . . . . 8W-48-2 Left P ower Mir r or . . . . . . . . . . . . . . . . . . . 8W-48-3
F r on t Con t r ol Modu le . . . . . . . . . . . . . . . . . 8W-48-2 P TC 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-48-2
F u se 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-48-2 Rea r Win dow Defogger Gr id . . . . . . . . . . . . 8W-48-2
F u se 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-48-2 Rea r Wiper Mot or . . . . . . . . . . . . . . . . . . . . 8W-48-2
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-48-3 Righ t P ower Mir r or . . . . . . . . . . . . . . . . . . 8W-48-3
G303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-48-2
RS 8W-49 OVERHEAD CONSOLE 8W - 49 - 1
8 W-4 9 OV ERH EAD CON SOLE

Am bien t Tem per a t u r e Sen sor . . . . . . . . . . . 8W-49-2 H a n ds F r ee Modu le . . . . . . . . . . . . . . . . . . 8W-49-3
Body Con t r ol Modu le . . . . . . . . . . . . . 8W-49-2, 3, 4 In t egr a t ed P ower Modu le . . . . . . . . . . . . . . 8W-49-2
F r on t Con t r ol Modu le . . . . . . . . . . . . . . . . . 8W-49-2 Left P ower Mir r or . . . . . . . . . . . . . . . . . . . 8W-49-3
F r on t Rea din g La m ps/Swit ch . . . . . . . . . . . 8W-49-4 Over h ea d Con sole . . . . . . . . . . . . . . . . 8W-49-2, 3, 4
F u se 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-49-2 P ower t r a in Con t r ol Modu le . . . . . . . . . . . . 8W-49-2
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-49-4 Rea r View Mir r or . . . . . . . . . . . . . . . . . . 8W-49-3, 4
RS 8W-50 FRONT LIGHTING 8W - 50 - 1
8 W-5 0 FRON T LI GH T I N G
Body Con t r ol Modu le . . . . . . . . . . . . . 8W-50-2, 4, 5 Left H ea dla m p . . . . . . . . . . . . . . . . . . . . . . 8W-50-3
F r on t Con t r ol Modu le . . . . 8W-50-3, 4, 6, 7, 8, 9, 10 Left H ea dla m p Levelin g Mot or . . . . . . . . 8W-50-6, 9
F r on t F og La m p Rela y . . . . . . . . . . . . . . . 8W-50-10 Left H igh Bea m La m p . . . . . . . . . . . . . . 8W-50-6, 7
F u se 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-10 Left Low Bea m La m p . . . . . . . . . . . . . . . . . 8W-50-7
F u se 2 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-4, 6 Left P a r k La m p . . . . . . . . . . . . . . . . . . . 8W-50-6, 7
F u se 3 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-4, 6 Mu lt i-F u n ct ion Swit ch . . . . . . . . . . . . . . . . 8W-50-5
G102 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-4, 6, 10 P a r k La m p Rela y . . . . . . . . . . . . . . . . . . 8W-50-4, 6
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-2, 9 Righ t F og La m p . . . . . . . . . . . . . . . . . . . . 8W-50-10
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-50-3 Righ t F r on t P a r k/Tu r n Sign a l La m p . . . . . 8W-50-4
H ea dla m p Swit ch . . . . . . . . . . . . . . . . . . 8W-50-2, 9 Righ t H ea dla m p . . . . . . . . . . . . . . . . . . . . . 8W-50-3
In t egr a t ed P ower Righ t H ea dla m p Levelin g Mot or . . . . . . 8W-50-6, 9
Modu le . . . . . . . . . . . 8W-50-3, 4, 5, 6, 7, 8, 9, 10 Righ t H igh Bea m La m p . . . . . . . . . . . . . 8W-50-6, 8
Left F og La m p . . . . . . . . . . . . . . . . . . . . . 8W-50-10 Righ t Low Bea m La m p . . . . . . . . . . . . . . . . 8W-50-8
Left F r on t P a r k/Tu r n Sign a l La m p . . . . . . . 8W-50-4 Righ t P a r k La m p . . . . . . . . . . . . . . . . . . 8W-50-6, 8
RS 8W-51 REAR LIGHTING 8W - 51 - 1
8 W-5 1 REAR LI GH T I N G
Ba ck-Up La m p Swit ch . . . . . . . . . . . . . . . . 8W-51-6 G101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-6
Ba t t er y . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-6 G302 . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-3, 4, 5, 6
Body Con t r ol Modu le . . . . . . . . . 8W-51-2, 3, 4, 5, 6 G303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-7
Br a ke La m p Swit ch . . . . . . . . . . . . . . . . 8W-51-2, 5 In t egr a t ed P ower Modu le . . . . . . . . 8W-51-2, 3, 5, 6
Cen t er H igh Mou n t ed St op La m p . . . . . . . 8W-51-7 Left Rea r La m p Assem bly . . . . . . . . 8W-51-2, 4, 5, 6
F r on t Con t r ol Modu le . . . . . . . . . . . . . 8W-51-2, 5, 6 Licen se La m p . . . . . . . . . . . . . . . . . . . . . . . 8W-51-7
F u se 2 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-2, 5 P a r k La m p Rela y . . . . . . . . . . . . . . . . 8W-51-2, 5, 6
F u se 3 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-2, 5, 6 Righ t Rea r La m p Assem bly . . . . . . 8W-51-2, 3, 5, 6
F u se 26 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-51-2, 5 Tr a iler Tow Con n ect or . . . . . . . . . . . . . . 8W-51-3, 4
RS 8W-52 TURN SIGNALS 8W - 52 - 1
8 W-5 2 T U RN SI GN ALS
Body Con t r ol Modu le . . . . . . . . . . . 8W-52-2, 3, 4, 5 Left Rea r La m p Assem bly . . . . . . . . . . . . . 8W-52-4
F u se 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-5 Left Repea t er La m p . . . . . . . . . . . . . . . . . . 8W-52-5
G102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-2 Left Tu r n Sign a l La m p . . . . . . . . . . . . . . . . 8W-52-3
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-2, 3 Mu lt i-F u n ct ion Swit ch . . . . . . . . . . . . . . 8W-52-2, 3
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-52-4 Righ t F r on t P a r k/Tu r n Sign a l La m p . . . . . 8W-52-2
In st r u m en t Clu st er . . . . . . . . . . . . . . . . . . . 8W-52-5 Righ t Rea r La m p Assem bly . . . . . . . . . . . . 8W-52-4
In st r u m en t P a n el Swit ch Ba n k . . . . . . . 8W-52-2, 3 Righ t Repea t er La m p . . . . . . . . . . . . . . . . . 8W-52-5
In t egr a t ed P ower Modu le . . . . . . . . . . 8W-52-2, 3, 5 Righ t Tu r n Sign a l La m p . . . . . . . . . . . . . . . 8W-52-3
Left F r on t P a r k/Tu r n Sign a l La m p . . . . . . . 8W-52-2 Tr a iler Tow Con n ect or . . . . . . . . . . . . . . . . 8W-52-4
RS 8W-53 WIPERS 8W - 53 - 1
8 W-5 3 WI PERS
A/C-H ea t er Con t r ol . . . . . . . . . . . . . . . . . . . 8W-53-7 G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-5
Body Con t r ol Modu le . . . . . . . . . . . 8W-53-3, 5, 6, 7 H ea dla m p Wa sh er P u m p Mot or . . . . . . . . . 8W-53-4
F r on t Con t r ol Modu le . . . . . . . . . . . 8W-53-2, 3, 4, 5 H ea dla m p Wa sh er Rela y . . . . . . . . . . . . . . 8W-53-4
F r on t Wiper H igh /Low Rela y . . . . . . . . . . . 8W-53-2 In st r u m en t P a n el Swit ch Ba n k . . . . . . . . . 8W-53-6
F r on t Wiper On /Off Rela y . . . . . . . . . . . . . 8W-53-2 In t egr a t ed P ower Modu le . . . . . . . . 8W-53-2, 3, 4, 5
F u se 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-2 Mu lt i-F u n ct ion Swit ch . . . . . . . . . . . . . . . . 8W-53-5
F u se 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-3 Rea r Wiper Mot or . . . . . . . . . . . . . . . . . . . . 8W-53-3
F u se 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-4 Wa sh er F lu id Level Swit ch . . . . . . . . . . . . . 8W-53-4
G102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-4 Wa sh er P u m p Mot or . . . . . . . . . . . . . . . . . . 8W-53-3
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-7 Wiper Modu le . . . . . . . . . . . . . . . . . . . . . . . 8W-53-2
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-53-2
RS 8W-54 TRAILER TOW 8W - 54 - 1
8 W-5 4 T RAI LER T OW

Body Con t r ol Modu le . . . . . . . . . . . . . . . 8W-54-2, 3 In t egr a t ed P ower Modu le . . . . . . . . . . . . 8W-54-2, 3
F r on t Con t r ol Modu le . . . . . . . . . . . . . . . 8W-54-2, 3 Left Rea r La m p Assem bly . . . . . . . . . . . . . 8W-54-2
F u se 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-2 P a r k La m p Rela y . . . . . . . . . . . . . . . . . . 8W-54-2, 3
F u se 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-3 Righ t Rea r La m p Assem bly . . . . . . . . . . . . 8W-54-3
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-54-2, 3 Tr a iler Tow Con n ect or . . . . . . . . . . . . . . 8W-54-2, 3
RS 8W-55 NAVIGATION/TELECOMMUNICATIONS 8W - 55 - 1
8 W-5 5 N AV I GAT I ON /T ELECOM M U N I CAT I ON S

CD Ch a n ger . . . . . . . . . . . . . . . . . . . . . . . . 8W-55-5 H a n ds F r ee Modu le . . . . . . . . . . . . 8W-55-2, 3, 4, 5
DVD/CD Ch a n ger . . . . . . . . . . . . . . . . . . 8W-55-2, 4 In t egr a t ed P ower Modu le . . . . . . . . . . . . . . 8W-55-2
F u se 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-55-2 Ra dio . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-55-4, 5
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-55-2 Rea r View Mir r or . . . . . . . . . . . . . . . . . . 8W-55-2, 3
RS 8W-56 CONVENIENCE SYSTEMS 8W - 56 - 1
8 W-5 6 CON V EN I EN CE SY ST EM S
Adju st a ble P eda ls Mot or . . . . . . . . . . . . . 8W-56-2, 3 In t egr a t ed P ower Modu le . . . . . . . . . . 8W-56-2, 3, 4
Adju st a ble P eda ls Rela y . . . . . . . . . . . . . . . 8W-56-2 Left Slidin g Door Con t r ol Modu le . . . . . . . . 8W-56-2
Adju st a ble P eda ls Sen sor . . . . . . . . . . . . . . 8W-56-3 Mem or y Sea t /Mir r or /Adju st a ble P eda ls
Adju st a ble P eda ls Swit ch . . . . . . . . . . . . . . 8W-56-2 Modu le . . . . . . . . . . . . . . . . . . . . . . . . 8W-56-2, 3
Dr iver H ea t ed Sea t Modu le . . . . . . . . . . . . 8W-56-3 P a r k Assist Displa y . . . . . . . . . . . . . . . . . . 8W-56-4
F r on t Con t r ol Modu le . . . . . . . . . . . . . . . 8W-56-2, 4 P a r k Assist Modu le . . . . . . . . . . . . . . . 8W-56-4, 5, 6
F u se 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-56-2 P a r k Assist Sen sor No. 1 . . . . . . . . . . . . 8W-56-5, 6
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-56-2 P a r k Assist Sen sor No. 4 . . . . . . . . . . . . 8W-56-5, 6
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-56-3 P ower Sea t Cir cu it Br ea ker . . . . . . . . . . . . 8W-56-3
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-56-4 Sen t r y Key Rem ot e E n t r y Modu le . . . . . . . 8W-56-4
Ign it ion Swit ch . . . . . . . . . . . . . . . . . . . . . . 8W-56-4
RS 8W-60 POWER WINDOWS 8W - 60 - 1
8 W-6 0 POWER WI N DOWS

Dr iver P ower Win dow Mot or . . . . . . . 8W-60-3, 4, 6 Left Rea r Ven t Mot or . . . . . . . . . . . . . . . 8W-60-3, 6
Dr iver P ower Win dow Swit ch . . . 8W-60-3, 4, 5, 6, 7 P a ssen ger P ower Win dow Mot or . . . . . . 8W-60-5, 7
F r on t Con t r ol Modu le . . . . . . . . . . . . . . . . . 8W-60-2 P a ssen ger P ower Win dow Swit ch . . . . 8W-60-2, 5, 7
F u se 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-60-2 P ower Win dow Cir cu it Br ea ker . . . . . . . . . 8W-60-2
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-60-3, 4 P ower Win dow Swit ch . . . . . . . . . . . . . . 8W-60-4, 5
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-60-6 Righ t Rea r Ven t Mot or . . . . . . . . . . . . . . 8W-60-3, 6
RS 8W-61 POWER DOOR LOCKS 8W - 61 - 1
8 W-6 1 POWER DOOR LOCK S

Am plifier . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-7 Left Slidin g Door Mot or . . . . . . . . . . . . . . . 8W-61-9
Body Con t r ol Modu le . . . . . . 8W-61-2, 3, 4, 5, 8, 11, Licen se La m p . . . . . . . . . . . . . . . . . . . 8W-61-19, 20
14, 15, 16, 17, 20 Lift ga t e Aja r Swit ch . . . . . . . . . . . . . . . . . 8W-61-16
Dr iver Door Lock Swit ch . . . . . . . . . . . . 8W-61-2, 3 Lift ga t e Cin ch /Relea se Mot or . . . . . . . . . . 8W-61-19
F r on t Con t r ol Modu le . . . . . . . . . . . . . . 8W-61-6, 17 Lift ga t e Left P in ch Sen sor . . . . . . . . . . . . 8W-61-19
F u se 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-5 Lift ga t e Righ t P in ch Sen sor . . . . . . . . . . . 8W-61-19
F u se 19 . . . . . . . . . . . . . . . . . . . . . 8W-61-2, 3, 4, 15 Mem or y Sea t /Mir r or /Adju st a ble P eda ls
F u se 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-8 Modu le . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-6
F u se 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-17 Over h ea d Con sole . . . . . . . . . . . . . . . . . . . . 8W-61-7
G200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-5 P a ssen ger Door Lock Swit ch . . . . . . . . . 8W-61-2, 3
G300 . . . . . . . . . . . . . . . . 8W-61-2, 3, 4, 8, 9, 10, 15 P ower Lift ga t e Modu le . . . . . . 8W-61-17, 18, 19, 20
G301 . . . . . . . . . . . . . . 8W-61-2, 3, 4, 11, 12, 13, 15 P ower Lift ga t e Mot or . . . . . . . . . . . . . . . . 8W-61-18
G302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-17 Righ t B-P illa r Swit ch . . . . . . . . . . . . . . . . 8W-61-11
G303 . . . . . . . . . . . . . . . . . . . . . . . 8W-61-16, 19, 20 Righ t Cin ch /Relea se Mot or . . . . . . . . . . . . 8W-61-12
In t egr a t ed P ower Righ t F r on t Door Lock Mot or /Aja r
Modu le . . . . . . . . 8W-61-2, 3, 4, 5, 6, 8, 11, 15, 17 Swit ch . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-4
Left B-P illa r Swit ch . . . . . . . . . . . . . . . . . . 8W-61-8 Righ t F u ll Open Swit ch . . . . . . . . . . . . . . 8W-61-12
Left Cin ch /Relea se Mot or . . . . . . . . . . . . . . 8W-61-9 Righ t Slidin g Door Con t r ol
Left F r on t Door Lock Mot or /Aja r Swit ch . . 8W-61-4 Modu le . . . . . . . . . . . . . . . 8W-61-7, 11, 12, 13, 14
Left F u ll Open Swit ch . . . . . . . . . . . . . . . . 8W-61-9 Righ t Slidin g Door La t ch Sen sin g
Left Slidin g Door Con t r ol Swit ch . . . . . . . . . . . . . . . . . . . . . . . 8W-61-11, 13
Modu le . . . . . . . . . . . . . . . . 8W-61-6, 8, 9, 10, 14 Righ t Slidin g Door Lock Mot or . . . . . . . . . 8W-61-14
Left Slidin g Door La t ch Righ t Slidin g Door Lock Mot or /Aja r
Sen sin g Swit ch . . . . . . . . . . . . . . . . . 8W-61-8, 10 Swit ch . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-15
Left Slidin g Door Lock Mot or . . . . . . . . . . 8W-61-14 Righ t Slidin g Door Mot or . . . . . . . . . . . . . 8W-61-12
Left Slidin g Door Lock Mot or /Aja r Sen t r y Key Rem ot e E n t r y Modu le . . . . . . . 8W-61-5
Swit ch . . . . . . . . . . . . . . . . . . . . . . . . . 8W-61-15
RS 8W-62 POWER MIRRORS 8W - 62 - 1
8 W-6 2 POWER M I RRORS

Body Con t r ol Modu le . . . . . . . . . . . . . 8W-62-2, 3, 9 Mem or y Set Swit ch . . . . . . . . . . . . . . . . . . 8W-62-3
Defogger Rela y . . . . . . . . . . . . . . . . . . . . . 8W-62-10 P a ssen ger F oldin g Mir r or Rela y . . . . . 8W-62-2, 4, 9
F r on t Con t r ol Modu le . . . . . . . . . . . . . . . . . 8W-62-3 P a ssen ger P ower Sea t Swit ch . . . . . . . . . . . 8W-62-3
F u se 18 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-62-2, 4 P ower F oldin g Mir r or Swit ch . . . . . . . . . . . 8W-62-2
F u se 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-62-3 P ower Mir r or Swit ch . . . . . . . . . . . 8W-62-2, 4, 5, 6
G200 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-62-2, 4, 10 P ower Sea t Cir cu it Br ea ker . . . . . . . . . . . . 8W-62-3
G300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-62-3, 4 P TC 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-62-10
In t egr a t ed P ower Modu le . . . . . 8W-62-2, 3, 4, 9, 10 Rea r View Mir r or . . . . . . . . . . . . . . . . . . . . 8W-62-8
Left P ower Mir r or . . . . . . . . . 8W-62-2, 4, 7, 8, 9, 10 Righ t P ower Mir r or . . . . . . . . . . 8W-62-2, 5, 7, 9, 10
Mem or y Sea t /Mir r or /Adju st a ble P eda ls
Modu le . . . . . . . . . . . . . . . . . . . . 8W-62-3, 6, 7, 8
RS 8W-63 POWER SEATS 8W - 63 - 1
8 W-6 3 POWER SEAT S

Body Con t r ol Modu le . . . . . . . . . . . . . . . 8W-63-5, 9 F u se 22 . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-2, 4
Dr iver H ea t ed Sea t Ba ck . . . . . . . . . . . . . . 8W-63-9 G300 . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-2, 4, 6, 9
Dr iver H ea t ed Sea t Cu sh ion . . . . . . . . . . . . 8W-63-9 G301 . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-3, 10, 11
Dr iver H ea t ed Sea t Modu le . . . . . . . . 8W-63-3, 4, 9 In st r u m en t P a n el Swit ch Ba n k . . . . . . . . . 8W-63-9
Dr iver P ower Sea t F r on t Riser Mot or . . . 8W-63-2, 7 In t egr a t ed P ower Modu le . . . . . . . . . . 8W-63-2, 4, 5
Dr iver P ower Sea t F r on t Riser P osit ion Left Slidin g Door Con t r ol Modu le . . . . . . . . 8W-63-5
Sen sor . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-8 Mem or y Sea t /Mir r or /Adju st a ble P eda ls
Dr iver P ower Sea t H or izon t a l Mot or . . . 8W-63-2, 7 Modu le . . . . . . . . . . . . . . . . . . 8W-63-4, 5, 6, 7, 8
Dr iver P ower Sea t H or izon t a l P osit ion Mem or y Set Swit ch . . . . . . . . . . . . . . . . . . 8W-63-5
Sen sor . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-8 P a ssen ger H ea t ed Sea t Ba ck . . . . . . . 8W-63-10, 11
Dr iver P ower Sea t Rea r Riser Mot or . . . 8W-63-2, 7 P a ssen ger H ea t ed Sea t Cu sh ion . . . . . 8W-63-10, 11
Dr iver P ower Sea t Rea r Riser P osit ion P a ssen ger H ea t ed Sea t Modu le . . . . . . 8W-63-10, 11
Sen sor . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-8 P a ssen ger P ower Sea t F r on t Riser Mot or . . 8W-63-3
Dr iver P ower Sea t Reclin er Mot or . . . . . 8W-63-2, 7 P a ssen ger P ower Sea t H or izon t a l Mot or . . 8W-63-3
Dr iver P ower Sea t Reclin er P osit ion P a ssen ger P ower Sea t Rea r Riser Mot or . . 8W-63-3
Sen sor . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-8 P a ssen ger P ower Sea t Reclin er Mot or . . . . 8W-63-3
Dr iver P ower Sea t Swit ch . . . . . . . . . . . 8W-63-2, 6 P a ssen ger P ower Sea t Swit ch . . . . . . . . . . . 8W-63-3
F r on t Con t r ol Modu le . . . . . . . . . . . . . . . . . 8W-63-5 P ower Sea t Cir cu it Br ea ker . . . . . . . . 8W-63-2, 3, 4
RS 8W-64 POWER SUNROOF 8W - 64 - 1
8 W-6 4 POWER SU N ROOF

E lect r on ic Con t r ol Un it . . . . . . . . . . . . . . . 8W-64-3 In t egr a t ed P ower Modu le . . . . . . . . . . . . . . 8W-64-2
F u se 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-64-2 Su n r oof Modu le . . . . . . . . . . . . . . . . . . . 8W-64-2, 3
F u se 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-64-2 Su n r oof Swit ch . . . . . . . . . . . . . . . . . . . . . . 8W-64-3
G301 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-64-3
RS 8W-70 SPLICE INFORMATION 8W - 70 - 1
8 W-7 0 SPLI CE I N FORM AT I ON

S101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-20 S303 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-35
S103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-4 S304 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-67
S106 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2 S305 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-8
S107 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-43, 45 S306 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-5, 6
S111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-3, 4 S307 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-8
S112 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-42 S310 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-2
S113 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-3 S311 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-8
S114 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-41 S312 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-17
S115 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-4 S313 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-28, 29
S116 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-2, 6 S316 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-53
S118 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-3 S317 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-40
S119 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-9 S318 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-32
S121 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-4 S319 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-6
S122 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-14 S321 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-3, 4
S124 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-42 S322 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-31
S125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-3 S323 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-31
S126 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-29 S324 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-28
S127 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-13 S325 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-32
S128 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-29 S326 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-45, 49
S129 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-13 S330 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-13
S130 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-13 S331 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-26
S131 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-56 S332 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-8
S132 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-13 S333 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-8
S134 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-29 S334 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-11
S135 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-30 S335 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-9
S136 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-18 S336 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-44-3
S137 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-28 S337 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-23
S139 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-44 S338 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-13
S141 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-2, 4 S339 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-23
S142 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-4 S342 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-21
S144 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-44 S343 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-15
S148 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-6 S344 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-8
S150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-67 S345 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-20
S151 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-18 S346 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-33, 34
S152 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-63 S347 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-20
S157 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-27 S348 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-14
S177 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-19 S349 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-39-8
S179 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-19 S350 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-14
S187 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-30-22 S352 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-26
S188 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-44 S354 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-29
S190 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-13 S355 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-25
S191 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-8 S356 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-52
S192 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-9 S359 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-53
S193 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-31-7 S361 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-17
S201 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-40 S362 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-50
S202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-19 S363 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-9
S203 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-17 S364 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-21
S204 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-39 S365 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-16
S205 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-9 S366 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-51
S206 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-52 S367 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-67
S207 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-6 S368 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-49
S208 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-45-10 S370 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-47
S209 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-42-7 S371 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-15
S210 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-46, 49 S373 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-69
S211 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-9 S374 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-70-3, 5
S212 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-9 S376 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-32
S222 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-47-14 S378 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-50
S223 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-69 S380 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-10-50
S224 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-11 S381 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-27
S225 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-55-2 S382 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-63-10
S226 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-15-11 S383 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-56-6
S302 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-18-5 S384 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-56-5
RS 8W-80 CONNECTOR PIN-OUTS 8W - 80 - 1
8 W-8 0 CON N ECT OR PI N -OU T S

A/C Com pr essor Clu t ch . . . . . . . . . . . . . . . 8W-80-6 C107 (E xpor t ) . . . . . . . . . . . . . . . . . . . . . . 8W-80-22
A/C P r essu r e Sen sor . . . . . . . . . . . . . . . . . . 8W-80-6 C111 (E ATX) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-22
A/C-H ea t er Con t r ol C1 (MTC) . . . . . . . . . . 8W-80-6 C111 (E ATX) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-22
A/C-H ea t er Con t r ol C2 (MTC) . . . . . . . . . . 8W-80-7 C112 (Ga s) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-22
Acceler a t or P eda l P osit ion Sen sor C112 (Ga s) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-22
(Diesel) . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-7 C200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-23
Adju st a ble P eda ls Mot or C200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-25
(E xcept E xpor t ) . . . . . . . . . . . . . . . . . . . 8W-80-7 C202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-27
Adju st a ble P eda ls Rela y (E xcept C202 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-27
E xpor t /E xcept Mem or y) . . . . . . . . . . . . . 8W-80-8 C204 (P r em iu m ) . . . . . . . . . . . . . . . . . . . . 8W-80-27
Adju st a ble P eda ls Sen sor C204 (P r em iu m ) . . . . . . . . . . . . . . . . . . . . 8W-80-28
(E xcept E xpor t ) . . . . . . . . . . . . . . . . . . . 8W-80-8 C206 (E xcept Ba se) . . . . . . . . . . . . . . . . . . 8W-80-28
Adju st a ble P eda ls Swit ch C206 (E xcept Ba se) . . . . . . . . . . . . . . . . . . 8W-80-28
(E xcept E xpor t ) . . . . . . . . . . . . . . . . . . . 8W-80-8 C207 (DVD) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-28
Am bien t Tem per a t u r e Sen sor . . . . . . . . . . . 8W-80-8 C207 (H a n ds F r ee) . . . . . . . . . . . . . . . . . . 8W-80-29
Am plifier C1 (H igh lin e Au dio) . . . . . . . . . . 8W-80-9 C300 (LH D) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-29
Am plifier C2 (H igh lin e Au dio) . . . . . . . . . . 8W-80-9 C300 (LH D) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-29
ATC Rem ot e Sen sor (ATC) . . . . . . . . . . . . 8W-80-10 C300 (RH D) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-30
Au t o Tem p Con t r ol C1 . . . . . . . . . . . . . . . 8W-80-10 C300 (RH D) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-30
Au t o Tem p Con t r ol C2 . . . . . . . . . . . . . . . 8W-80-10 C301 (Lu xu r y/E xpor t ) . . . . . . . . . . . . . . . . 8W-80-30
Au t o Tem p Con t r ol C3 . . . . . . . . . . . . . . . 8W-80-11 C301 (Lu xu r y/E xpor t ) . . . . . . . . . . . . . . . . 8W-80-30
Ba ck-Up La m p Swit ch (MTX) . . . . . . . . . . 8W-80-11 C302 (E xpor t ) . . . . . . . . . . . . . . . . . . . . . . 8W-80-31
Ba t t er y Tem per a t u r e Sen sor . . . . . . . . . . . 8W-80-11 C302 (E xpor t ) . . . . . . . . . . . . . . . . . . . . . . 8W-80-31
Belt Ten sion Sen sor C302 (Lu xu r y/E xcept E xpor t ) . . . . . . . . . . 8W-80-31
(Occu pa n t Sen sin g) . . . . . . . . . . . . . . . . 8W-80-11 C302 (Lu xu r y/E xcept E xpor t ) . . . . . . . . . . 8W-80-31
Blower Mot or Resist or C1 (MTC) . . . . . . . 8W-80-12 C303 (LH D) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-32
Blower Mot or Resist or C2 (MTC) . . . . . . . 8W-80-12 C303 (LH D) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-32
Body Con t r ol Modu le C1 . . . . . . . . . . . . . . 8W-80-12 C303 (RH D) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-32
Body Con t r ol Modu le C2 . . . . . . . . . . . . . . 8W-80-13 C303 (RH D) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-33
Body Con t r ol Modu le C3 . . . . . . . . . . . . . . 8W-80-14 C304 (LH D) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-33
Body Con t r ol Modu le C4 . . . . . . . . . . . . . . 8W-80-15 C304 (LH D) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-33
Body Con t r ol Modu le C5 . . . . . . . . . . . . . . 8W-80-16 C305 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-33
Boost P r essu r e Sen sor (Diesel) . . . . . . . . . 8W-80-16 C305 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-34
Br a ke F lu id Level Swit ch . . . . . . . . . . . . . 8W-80-17 C306 (RH D) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-34
Br a ke La m p Swit ch . . . . . . . . . . . . . . . . . 8W-80-17 C306 (RH D) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-34
Br a ke Tr a n sm ission Sh ift In t er lock C307 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-34
Solen oid . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-17 C307 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-35
C100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-17 C308 (E xcept Side Air ba g) . . . . . . . . . . . . 8W-80-35
C100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-18 C308 (Side Air ba g) . . . . . . . . . . . . . . . . . . 8W-80-35
C101 (Diesel) . . . . . . . . . . . . . . . . . . . . . . 8W-80-18 C308 (E xcept Side Air ba g) . . . . . . . . . . . . 8W-80-36
C101 (Diesel) . . . . . . . . . . . . . . . . . . . . . . 8W-80-19 C308 (Side Air ba g) . . . . . . . . . . . . . . . . . . 8W-80-36
C101 (Ga s) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-19 C309 (Side Air ba g) . . . . . . . . . . . . . . . . . . 8W-80-36
C101 (Ga s) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-19 C309 (Side Air ba g) . . . . . . . . . . . . . . . . . . 8W-80-37
C102 (Ga s) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-19 C309 (E xcept Side Air ba g) . . . . . . . . . . . . 8W-80-37
C102 (Ga s) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-20 C309 (E xcept Side Air ba g) . . . . . . . . . . . . 8W-80-37
C103 (Diesel) . . . . . . . . . . . . . . . . . . . . . . 8W-80-20 C310 (F r on t Con sole) . . . . . . . . . . . . . . . . 8W-80-38
C103 (Diesel) . . . . . . . . . . . . . . . . . . . . . . 8W-80-20 C310 (F r on t Con sole) . . . . . . . . . . . . . . . . 8W-80-38
C104 (E xcept E xpor t ) . . . . . . . . . . . . . . . . 8W-80-20 C311 (3 Zon e H VAC/E xcept
C104 (E xcept E xpor t ) . . . . . . . . . . . . . . . . 8W-80-21 Side Air ba g) . . . . . . . . . . . . . . . . . . . . . 8W-80-38
C106 (E xpor t ) . . . . . . . . . . . . . . . . . . . . . . 8W-80-21 C311 (3 Zon e H VAC/E xcept
C106 (E xpor t ) . . . . . . . . . . . . . . . . . . . . . . 8W-80-21 Side Air ba g) . . . . . . . . . . . . . . . . . . . . . 8W-80-38
C107 (E xpor t ) . . . . . . . . . . . . . . . . . . . . . . 8W-80-21 C311 (3 Zon e H VAC/Side Air ba g) . . . . . . . 8W-80-39
8W - 80 - 2 8W-80 CONNECTOR PIN-OUTS RS
C311 (3 Zon e H VAC/Side Air ba g) . . . . . . . 8W-80-39 Clockspr in g C4 (Rem ot e Au dio) . . . . . . . . 8W-80-55
C312 (Side Air ba g) . . . . . . . . . . . . . . . . . . 8W-80-40 Clu t ch P eda l In t er lock Swit ch (MTX) . . . . 8W-80-55
C312 (E xcept Side Air ba g) . . . . . . . . . . . . 8W-80-40 Clu t ch P eda l Upst op Swit ch (Diesel) . . . . 8W-80-56
C312 (E xcept Side Air ba g) . . . . . . . . . . . . 8W-80-41 Con t r oller An t ilock Br a ke . . . . . . . . . . . . . 8W-80-56
C312 (Side Air ba g) . . . . . . . . . . . . . . . . . . 8W-80-41 Cr a n k Ca se Ven t ila t ion H ea t er (Diesel) . . 8W-80-57
C313 (Rea r Con sole) . . . . . . . . . . . . . . . . . 8W-80-42 Cr a n ksh a ft P osit ion Sen sor (Diesel) . . . . . 8W-80-57
C313 (Rea r Con sole) . . . . . . . . . . . . . . . . . 8W-80-42 Cr a n ksh a ft P osit ion Sen sor (Ga s) . . . . . . . 8W-80-57
C314 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-42 Da t a Lin k Con n ect or . . . . . . . . . . . . . . . . 8W-80-57
C314 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-43 Dosin g P u m p (Diesel) . . . . . . . . . . . . . . . . 8W-80-58
C315 (P ower Lift ga t e) . . . . . . . . . . . . . . . . 8W-80-43 Dr iver Air ba g Squ ib 1 . . . . . . . . . . . . . . . . 8W-80-58
C315 (P ower Lift ga t e) . . . . . . . . . . . . . . . . 8W-80-43 Dr iver Air ba g Squ ib 2 . . . . . . . . . . . . . . . . 8W-80-58
C316 (P ower Slidin g Door ) . . . . . . . . . . . . 8W-80-44 Dr iver Blen d Door Act u a t or . . . . . . . . . . . 8W-80-58
C316 (P ower Slidin g Door ) . . . . . . . . . . . . 8W-80-44 Dr iver Door Cou r t esy La m p (Lu xu r y/
C317 (P ower Slidin g Door ) . . . . . . . . . . . . 8W-80-44 E xpor t ) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-59
C317 (P ower Slidin g Door ) . . . . . . . . . . . . 8W-80-45 Dr iver Door Lock Swit ch . . . . . . . . . . . . . 8W-80-59
C318 (Tr a iler Tow) . . . . . . . . . . . . . . . . . . 8W-80-45 Dr iver H ea t ed Sea t Ba ck . . . . . . . . . . . . . 8W-80-59
C318 (Tr a iler Tow) . . . . . . . . . . . . . . . . . . 8W-80-45 Dr iver H ea t ed Sea t Cu sh ion . . . . . . . . . . . 8W-80-59
C319 (Tr a iler Tow) . . . . . . . . . . . . . . . . . . 8W-80-46 Dr iver H ea t ed Sea t Modu le C1 . . . . . . . . . 8W-80-59
C319 (Tr a iler Tow) . . . . . . . . . . . . . . . . . . 8W-80-46 Dr iver H ea t ed Sea t Modu le C2 . . . . . . . . . 8W-80-60
C320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-46 Dr iver H ea t ed Sea t Modu le C3 . . . . . . . . . 8W-80-60
C320 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-46 Dr iver Kn ee Blocker
C321 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-47 Air ba g Squ ib (LH D) . . . . . . . . . . . . . . . 8W-80-60
C321 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-47 Dr iver P ower Sea t F r on t Riser Mot or . . . . 8W-80-60
C322 (Mem or y) . . . . . . . . . . . . . . . . . . . . . 8W-80-47 Dr iver P ower Sea t F r on t Riser P osit ion
C322 (Mem or y) . . . . . . . . . . . . . . . . . . . . . 8W-80-48 Sen sor . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-61
C324 (Ma n u a l Slidin g Door ) . . . . . . . . . . . 8W-80-48 Dr iver P ower Sea t H or izon t a l Mot or . . . . 8W-80-61
C324 (Ma n u a l Slidin g Door ) . . . . . . . . . . . 8W-80-48 Dr iver P ower Sea t H or izon t a l P osit ion
C325 (Ma n u a l Slidin g Door ) . . . . . . . . . . . 8W-80-49 Sen sor . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-61
C325 (Ma n u a l Slidin g Door ) . . . . . . . . . . . 8W-80-49 Dr iver P ower Sea t Rea r Riser Mot or . . . . 8W-80-61
C328 (Su n r oof) . . . . . . . . . . . . . . . . . . . . . 8W-80-49 Dr iver P ower Sea t Rea r Riser P osit ion
C328 (Su n r oof) . . . . . . . . . . . . . . . . . . . . . 8W-80-49 Sen sor . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-62
C329 (Diesel) . . . . . . . . . . . . . . . . . . . . . . 8W-80-50 Dr iver P ower Sea t Reclin er Mot or . . . . . . 8W-80-62
C329 (Diesel) . . . . . . . . . . . . . . . . . . . . . . 8W-80-50 Dr iver P ower Sea t Reclin er P osit ion
C330 (Diesel) . . . . . . . . . . . . . . . . . . . . . . 8W-80-50 Sen sor . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-62
C330 (Diesel) . . . . . . . . . . . . . . . . . . . . . . 8W-80-50 Dr iver P ower Sea t Swit ch . . . . . . . . . . . . 8W-80-62
C331 (Diesel) . . . . . . . . . . . . . . . . . . . . . . 8W-80-51 Dr iver P ower Win dow Mot or . . . . . . . . . . 8W-80-63
C331 (Diesel) . . . . . . . . . . . . . . . . . . . . . . 8W-80-51 Dr iver P ower Win dow Swit ch
C332 (3 Zon e ATC) . . . . . . . . . . . . . . . . . . 8W-80-51 (LH D E xcept Lowlin e) . . . . . . . . . . . . . 8W-80-63
C332 (3 Zon e ATC) . . . . . . . . . . . . . . . . . . 8W-80-51 Dr iver P ower Win dow Swit ch (LH D
C333 (E xcept E xpor t /E xcept Mem or y) . . . 8W-80-52 Lowlin e) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-63
C333 (E xcept E xpor t /E xcept Mem or y) . . . 8W-80-52 Dr iver P ower Win dow Swit ch (RH D) . . . . 8W-80-64
C334 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-52 Dr iver Sea t Belt Swit ch . . . . . . . . . . . . . . 8W-80-64
C334 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-52 Dr iver Sea t Belt Ten sion er . . . . . . . . . . . . 8W-80-64
C335 (F old-In -F loor ) . . . . . . . . . . . . . . . . . 8W-80-53 DVD Scr een . . . . . . . . . . . . . . . . . . . . . . . 8W-80-65
C335 (F old-In -F loor ) . . . . . . . . . . . . . . . . . 8W-80-53 DVD/CD Ch a n ger C1 . . . . . . . . . . . . . . . . 8W-80-65
Ca bin H ea t er Assist C1 (Diesel) . . . . . . . . 8W-80-53 DVD/CD Ch a n ger C2 . . . . . . . . . . . . . . . . 8W-80-65
Ca bin H ea t er Assist C2 (Diesel) . . . . . . . . 8W-80-53 E GR Solen oid (3.3L) . . . . . . . . . . . . . . . . . 8W-80-66
Ca m sh a ft P osit ion Sen sor (Diesel) . . . . . . 8W-80-53 E GR Solen oid (Diesel) . . . . . . . . . . . . . . . 8W-80-66
Ca m sh a ft P osit ion Sen sor (Ga s) . . . . . . . . 8W-80-54 E n gin e Con t r ol Modu le C1 (Diesel) . . . . . 8W-80-66
CD Ch a n ger . . . . . . . . . . . . . . . . . . . . . . . 8W-80-54 E n gin e Con t r ol Modu le C2 (Diesel) . . . . . 8W-80-68
Cen t er H igh Mou n t ed St op La m p . . . . . . . 8W-80-54 E n gin e Coola n t Tem p Sen sor (Diesel) . . . . 8W-80-69
Clockspr in g C1 . . . . . . . . . . . . . . . . . . . . . 8W-80-54 E n gin e Coola n t Tem p Sen sor (Ga s) . . . . . 8W-80-69
Clockspr in g C2 . . . . . . . . . . . . . . . . . . . . . 8W-80-55 E n gin e Oil P r essu r e Sen sor (Diesel) . . . . . 8W-80-69
Clockspr in g C3 . . . . . . . . . . . . . . . . . . . . . 8W-80-55 E n gin e Oil P r essu r e Swit ch (Ga s) . . . . . . 8W-80-69
E VAP /P u r ge Solen oid (Ga s) . . . . . . . . . . . 8W-80-70
E va por a t or Tem per a t u r e Sen sor . . . . . . . . 8W-80-70 Left B-P illa r Swit ch (P ower Slidin g
F loor Con sole La m p . . . . . . . . . . . . . . . . . 8W-80-70 Door ) . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-86
F loor Con sole P ower Ou t let (E xpor t ) . . . . 8W-80-70 Left Cin ch /Relea se Mot or (P ower Slidin g
F r on t Blower Modu le C1 (ATC) . . . . . . . . 8W-80-71 Door ) . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-86
F r on t Blower Modu le C2 (ATC) . . . . . . . . 8W-80-71 Left Cu r t a in Air ba g Squ ib . . . . . . . . . . . . 8W-80-86
F r on t Ciga r Ligh t er . . . . . . . . . . . . . . . . . 8W-80-71 Left Cylin der Lock Swit ch (E xpor t ) . . . . . 8W-80-86
F r on t Con t r ol Modu le . . . . . . . . . . . . . . . . 8W-80-72 Left Door Spea ker . . . . . . . . . . . . . . . . . . 8W-80-87
F r on t In t r u sion Sen sor (Un it ed Left F og La m p . . . . . . . . . . . . . . . . . . . . . 8W-80-87
Kin gdom ) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-73 Left F r on t Door Aja r Swit ch (Ba se) . . . . . 8W-80-87
F r on t Rea din g La m ps/Swit ch . . . . . . . . . . 8W-80-73 Left F r on t Door Lock Mot or /Aja r Swit ch
F u el H ea t er (Diesel) . . . . . . . . . . . . . . . . . 8W-80-73 (E xcept Ba se) . . . . . . . . . . . . . . . . . . . . 8W-80-87
F u el In ject or No. 1 (2.4L/3.3L/3.8L) . . . . . 8W-80-73 Left F r on t Im pa ct Sen sor (E xpor t ) . . . . . . 8W-80-87
F u el In ject or No. 1 (Diesel) . . . . . . . . . . . . 8W-80-73 Left F r on t Im pa ct Sen sor (E xcept
F u el In ject or No. 2 (2.4L/3.3L/3.8L) . . . . . 8W-80-74 E xpor t ) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-88
F u el In ject or No. 2 (Diesel) . . . . . . . . . . . . 8W-80-74 Left F r on t P a r k/Tu r n Sign a l La m p . . . . . . 8W-80-88
F u el In ject or No. 3 (2.4L/3.3L/3.8L) . . . . . 8W-80-74 Left F r on t Wh eel Speed Sen sor . . . . . . . . 8W-80-88
F u el In ject or No. 3 (Diesel) . . . . . . . . . . . . 8W-80-74 Left F u ll Open Swit ch (P ower Slidin g
F u el In ject or No. 4 (2.4L/3.3L/3.8L) . . . . . 8W-80-75 Door ) . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-88
F u el In ject or No. 4 (Diesel) . . . . . . . . . . . . 8W-80-75 Left H ea dla m p (Ca r a va n /Voya ger E xcept
F u el In ject or No. 5 (3.3L/3.8L) . . . . . . . . . 8W-80-75 E xpor t ) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-89
F u el In ject or No. 6 (3.3L/3.8L) . . . . . . . . . 8W-80-75 Left H ea dla m p (Town An d Cou n t r y) . . . . . 8W-80-89
F u el P r essu r e Sen sor (Diesel) . . . . . . . . . . 8W-80-76 Left H ea dla m p Levelin g Mot or (E xpor t ) . . 8W-80-89
F u el P r essu r e Solen oid (Diesel) . . . . . . . . 8W-80-76 Left H igh Bea m La m p (E xpor t ) . . . . . . . . 8W-80-89
F u el P u m p Modu le . . . . . . . . . . . . . . . . . . 8W-80-76 Left In st r u m en t P a n el Spea ker . . . . . . . . 8W-80-90
Gen er a t or . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-76 Left Lift ga t e F lood La m p (E xpor t ) . . . . . . 8W-80-90
Glow P lu g Rela y (Diesel) . . . . . . . . . . . . . 8W-80-77 Left Low Bea m La m p (E xpor t ) . . . . . . . . . 8W-80-90
H a n ds F r ee Modu le C1 . . . . . . . . . . . . . . . 8W-80-77 Left Mid Rea din g La m p (P r em iu m /
H a n ds F r ee Modu le C2 . . . . . . . . . . . . . . . 8W-80-77 Lu xu r y) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-90
H a n ds F r ee Modu le C3 . . . . . . . . . . . . . . . 8W-80-78 Left P a r k La m p (E xpor t ) . . . . . . . . . . . . . 8W-80-91
H ea dla m p Swit ch . . . . . . . . . . . . . . . . . . . 8W-80-78 Left P ower Mir r or . . . . . . . . . . . . . . . . . . . 8W-80-91
H ea dla m p Wa sh er P u m p Mot or (E xpor t ) . 8W-80-78 Left Rea r La m p Assem bly . . . . . . . . . . . . 8W-80-91
H igh Not e H or n . . . . . . . . . . . . . . . . . . . . 8W-80-79 Left Rea r P illa r Spea ker (H igh lin e
H ood Aja r Swit ch (E xpor t ) . . . . . . . . . . . . 8W-80-79 Au dio) . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-92
Idle Air Con t r ol Mot or (Ga s) . . . . . . . . . . . 8W-80-79 Left Rea r Rea din g La m p (Lu xu r y) . . . . . . 8W-80-92
Ign it ion Coil (2.4L) . . . . . . . . . . . . . . . . . . 8W-80-79 Left Rea r Spea ker . . . . . . . . . . . . . . . . . . 8W-80-92
Ign it ion Coil (3.3L/3.8L) . . . . . . . . . . . . . . 8W-80-80 Left Rea r Ven t Mot or . . . . . . . . . . . . . . . . 8W-80-92
Ign it ion Swit ch . . . . . . . . . . . . . . . . . . . . . 8W-80-80 Left Rea r Wh eel Speed Sen sor . . . . . . . . . 8W-80-93
In let Air Tem per a t u r e Sen sor . . . . . . . . . . 8W-80-80 Left Rem ot e Ra dio Swit ch . . . . . . . . . . . . 8W-80-93
In pu t Speed Sen sor . . . . . . . . . . . . . . . . . 8W-80-80 Left Repea t er La m p (E xpor t ) . . . . . . . . . . 8W-80-93
In st r u m en t Clu st er . . . . . . . . . . . . . . . . . . 8W-80-81 Left Side Im pa ct Sen sor 1 (E xpor t ) . . . . . 8W-80-93
In st r u m en t P a n el Swit ch Ba n k Left Side Im pa ct Sen sor 1 (E xcept
(E xcept H ea t ed Sea t s) . . . . . . . . . . . . . 8W-80-81 E xpor t ) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-94
In st r u m en t P a n el Swit ch Ba n k Left Side Im pa ct Sen sor 2 . . . . . . . . . . . . 8W-80-94
(H ea t ed Sea t s) . . . . . . . . . . . . . . . . . . . 8W-80-81 Left Side Im pa ct Sen sor 3 . . . . . . . . . . . . 8W-80-94
In t egr a t ed P ower Modu le C1 . . . . . . . . . . 8W-80-82 Left Slidin g Door Con t r ol Modu le C1
In t egr a t ed P ower Modu le C2 . . . . . . . . . . 8W-80-82 (P ower Slidin g Door ) . . . . . . . . . . . . . . 8W-80-94
In t egr a t ed P ower Modu le C3 . . . . . . . . . . 8W-80-83 Left Slidin g Door Con t r ol Modu le C2
In t egr a t ed P ower Modu le C5 . . . . . . . . . . 8W-80-84 Left Slidin g Door La t ch Sen sin g Swit ch
In t egr a t ed P ower Modu le C7 . . . . . . . . . . 8W-80-84 Left Slidin g Door Lock Mot or (P ower Slidin g
In t egr a t ed P ower Modu le C8 . . . . . . . . . . 8W-80-85 Door ) . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-95
In t egr a t ed P ower Modu le C9 . . . . . . . . . . 8W-80-85 Left Slidin g Door Lock Mot or /Aja r Swit ch
(Ma n u a l Slidin g Door ) . . . . . . . . . . . . . 8W-80-96
Kn ock Sen sor (E xcept E xpor t ) . . . . . . . . . 8W-80-85
Left Slidin g Door Mot or (P ower Slidin g P a ssen ger F oldin g Mir r or Rela y
Door ) . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-96 (E xpor t ) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-108
Left Speed Con t r ol Swit ch . . . . . . . . . . . . 8W-80-96 P a ssen ger H ea t ed Sea t Ba ck . . . . . . . . . 8W-80-108
Left Tu r n Sign a l La m p (E xpor t ) . . . . . . . . 8W-80-96 P a ssen ger H ea t ed Sea t Cu sh ion . . . . . . . 8W-80-109
Left Visor /Va n it y La m p (P r em iu m /Lu xu r y P a ssen ger H ea t ed Sea t Modu le (E xcept
E xcept E xpor t ) . . . . . . . . . . . . . . . . . . . 8W-80-97 E xpor t ) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-109
Licen se La m p (Ma n u a l Relea se) . . . . . . . . 8W-80-97 P a ssen ger H ea t ed Sea t Modu le C1
Licen se La m p (P ower Lift ga t e) . . . . . . . . . 8W-80-97 (E xpor t ) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-109
Licen se La m p (P ower Relea se) . . . . . . . . . 8W-80-97 P a ssen ger H ea t ed Sea t Modu le C2
Lift P u m p Mot or (Diesel) . . . . . . . . . . . . . 8W-80-98 (E xpor t ) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-109
Lift ga t e Aja r Swit ch (Ma n u a l Relea se) . . . 8W-80-98 P a ssen ger H ea t ed Sea t Modu le C3
Lift ga t e Aja r Swit ch (P ower Relea se) . . . . 8W-80-98 (E xpor t ) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-110
Lift ga t e Cin ch /Relea se Mot or (P ower P a ssen ger P ower Sea t F r on t Riser
Lift ga t e) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-98 Mot or . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-110
Lift ga t e Left P in ch Sen sor (P ower P a ssen ger P ower Sea t
Lift ga t e) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-99 H or izon t a l Mot or . . . . . . . . . . . . . . . . 8W-80-110
Lift ga t e Righ t P in ch Sen sor (P ower P a ssen ger P ower Sea t
Lift ga t e) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-99 Rea r Riser Mot or . . . . . . . . . . . . . . . . 8W-80-110
Ma n ifold ABSolu t e P r essu r e Sen sor P a ssen ger P ower Sea t Reclin er Mot or . . . 8W-80-111
(Ga s) . . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-99 P a ssen ger P ower Sea t Swit ch . . . . . . . . . 8W-80-111
Ma ss Air F low Sen sor (Diesel) . . . . . . . . . 8W-80-99 P a ssen ger P ower Win dow Mot or . . . . . . . 8W-80-111
Mem or y Sea t /Mir r or /Adju st a ble P a ssen ger P ower Win dow Swit ch . . . . . . 8W-80-111
P eda ls Modu le C1 . . . . . . . . . . . . . . . . 8W-80-100 P a ssen ger Sea t Belt Swit ch (Occu pa n t
Mem or y Sea t /Mir r or /Adju st a ble Sen sin g) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-112
P eda ls Modu le C2 . . . . . . . . . . . . . . . . 8W-80-100 P a ssen ger Sea t Belt Ten sion er . . . . . . . . 8W-80-112
Mem or y Sea t /Mir r or /Adju st a ble P a ssen ger Sea t Weigh t Sen sor . . . . . . . . 8W-80-112
P eda ls Modu le C3 . . . . . . . . . . . . . . . . 8W-80-101 P ower F oldin g Mir r or Swit ch (E xpor t ) . . 8W-80-113
Mem or y Sea t /Mir r or /Adju st a ble P ower Lift ga t e Modu le C1 . . . . . . . . . . . 8W-80-113
P eda ls Modu le C4 . . . . . . . . . . . . . . . . 8W-80-101 P ower Lift ga t e Modu le C2 . . . . . . . . . . . 8W-80-113
Mem or y Set Swit ch . . . . . . . . . . . . . . . . . 8W-80-101 P ower Lift ga t e Mot or . . . . . . . . . . . . . . . 8W-80-114
Messa ge Cen t er (E xpor t ) . . . . . . . . . . . . 8W-80-101 P ower Mir r or Swit ch . . . . . . . . . . . . . . . . 8W-80-114
Mode Door Act u a t or . . . . . . . . . . . . . . . . 8W-80-102 P ower Ou t let (E xcept Lowlin e) . . . . . . . . 8W-80-114
Mu lt i-F u n ct ion Swit ch . . . . . . . . . . . . . . 8W-80-102 P ower Sea t Cir cu it Br ea ker (30A) . . . . . . 8W-80-115
Na t u r a l Va cu u m Lea k Det ect ion Assem bly P ower Win dow Cir cu it Br ea ker (25A) . . . 8W-80-115
(E xcept E xpor t ) . . . . . . . . . . . . . . . . . . 8W-80-102 P ower Win dow Swit ch (LH D Lowlin e) . . 8W-80-115
Occu pa n t Cla ssifica t ion Modu le . . . . . . . 8W-80-102 P ower t r a in Con t r ol Modu le C1 . . . . . . . . 8W-80-116
Occu pa n t Rest r a in t Con t r oller C1 . . . . . 8W-80-103 P ower t r a in Con t r ol Modu le C2 . . . . . . . . 8W-80-117
Occu pa n t Rest r a in t Con t r oller C2 . . . . . 8W-80-104 P ower t r a in Con t r ol Modu le C3 . . . . . . . . 8W-80-118
Ou t pu t Speed Sen sor . . . . . . . . . . . . . . . 8W-80-104 P ower t r a in Con t r ol Modu le C4 . . . . . . . . 8W-80-119
Over h ea d Con sole (E xcept Ba se) . . . . . . 8W-80-105 Ra dia t or F a n No. 1 (Diesel) . . . . . . . . . . 8W-80-120
Oxygen Sen sor 1/1 Upst r ea m (Ga s) . . . . 8W-80-105 Ra dia t or F a n No. 1 (Ga s) . . . . . . . . . . . . 8W-80-120
Oxygen Sen sor 1/2 Down st r ea m (Ga s) . . 8W-80-105 Ra dia t or F a n No. 2 (Diesel) . . . . . . . . . . 8W-80-120
P a r k Assist Displa y . . . . . . . . . . . . . . . . 8W-80-105 Ra dia t or F a n No. 2 (Ga s) . . . . . . . . . . . . 8W-80-120
P a r k Assist Modu le . . . . . . . . . . . . . . . . . 8W-80-106 Ra dia t or F a n Rela y (Ga s) . . . . . . . . . . . . 8W-80-121
P a r k Assist Sen sor No. 1 . . . . . . . . . . . . 8W-80-106 Ra dia t or F a n Rela y No. 1 (Diesel) . . . . . 8W-80-121
P a r k Assist Sen sor No. 4 . . . . . . . . . . . . 8W-80-107 Ra dio C1 . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-122
P a ssen ger Air ba g . . . . . . . . . . . . . . . . . . 8W-80-107 Ra dio C2 (CD Ch a n ger ) . . . . . . . . . . . . . 8W-80-123
P a ssen ger Air ba g On /Off In dica t or Ra dio C2 (DVD/CD Ch a n ger ) . . . . . . . . . 8W-80-123
La m p . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-107 Ra dio C2 (H a n ds F r ee) . . . . . . . . . . . . . . 8W-80-123
P a ssen ger Blen d Door Act u a t or . . . . . . . 8W-80-107 Rea r A/C-H ea t er Un it (3 Zon e MTC) . . . 8W-80-124
P a ssen ger Door Cou r t esy La m p Rea r Au t o Tem p Con t r ol Swit ch (3 Zon e
(Lu xu r y/E xpor t ) . . . . . . . . . . . . . . . . . 8W-80-108 ATC) . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-124
P a ssen ger Door Lock Swit ch . . . . . . . . . . 8W-80-108
Rea r Blower F r on t Con t r ol Swit ch (3 Zon e Righ t Rea r Rea din g La m p (Lu xu r y) . . . . 8W-80-134
MTC) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-124 Righ t Rea r Spea ker . . . . . . . . . . . . . . . . 8W-80-134
Rea r Blower Mot or P ower Modu le C1 (3 Zon e Righ t Rea r Ven t Mot or . . . . . . . . . . . . . . 8W-80-135
ATC) . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-125 Righ t Rea r Wh eel Speed Sen sor . . . . . . . 8W-80-135
Rea r Blower Mot or P ower Modu le C2 (3 Zon e Righ t Rem ot e Ra dio Swit ch . . . . . . . . . . 8W-80-135
ATC) . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-125 Righ t Repea t er La m p (E xpor t ) . . . . . . . . 8W-80-135
Rea r Blower Rea r Con t r ol Swit ch C1 (3 Zon e Righ t Side Im pa ct Sen sor 1 (E xpor t ) . . . 8W-80-135
MTC) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-125 Righ t Side Im pa ct Sen sor 1 (E xcept
Rea r Blower Rea r Con t r ol Swit ch C2 (3 Zon e E xpor t ) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-136
MTC) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-125 Righ t Side Im pa ct Sen sor 2 . . . . . . . . . . 8W-80-136
Rea r Dom e La m p (E xcept Lu xu r y) . . . . . 8W-80-126 Righ t Side Im pa ct Sen sor 3 . . . . . . . . . . 8W-80-136
Rea r In t r u sion Sen sor (Un it ed Righ t Slidin g Door Con t r ol Modu le C1 (P ower
Kin gdom ) . . . . . . . . . . . . . . . . . . . . . . 8W-80-126 Slidin g Door ) . . . . . . . . . . . . . . . . . . . 8W-80-136
Rea r Mode Mot or (3 Zon e ATC) . . . . . . . 8W-80-126 Righ t Slidin g Door Con t r ol Modu le C2 (P ower
Rea r P ower Ou t let . . . . . . . . . . . . . . . . . 8W-80-126 Slidin g Door ) . . . . . . . . . . . . . . . . . . . 8W-80-137
Rea r Tem per a t u r e Mot or (3 Zon e ATC) . . 8W-80-127 Righ t Slidin g Door La t ch Sen sin g Swit ch (P ower
Rea r View Mir r or C1 (Lu xu r y) . . . . . . . . 8W-80-127 Slidin g Door ) . . . . . . . . . . . . . . . . . . . 8W-80-137
Rea r View Mir r or C2 (H a n ds F r ee) . . . . . 8W-80-127 Righ t Slidin g Door Lock Mot or (P ower Slidin g
Rea r Wiper Mot or . . . . . . . . . . . . . . . . . . 8W-80-128 Door ) . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-137
Recir cu la t ion Door Act u a t or . . . . . . . . . . 8W-80-128 Righ t Slidin g Door Lock Mot or /Aja r Swit ch (Ma n u a l
Righ t B-P illa r Swit ch (P ower Slidin g Slidin g Door ) . . . . . . . . . . . . . . . . . . . 8W-80-138
Door ) . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-128 Righ t Slidin g Door Mot or (P ower Slidin g
Righ t Cin ch /Relea se Mot or (P ower Slidin g Door ) . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-138
Door ) . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-128 Righ t Speed Con t r ol Swit ch . . . . . . . . . . 8W-80-138
Righ t Cu r t a in Air ba g Squ ib . . . . . . . . . . 8W-80-129 Righ t Tu r n Sign a l La m p (E xpor t ) . . . . . . 8W-80-138
Righ t Cylin der Lock Swit ch (E xpor t ) . . . 8W-80-129 Righ t Visor /Va n it y La m p (E xcept Ba se/
Righ t Door Spea ker . . . . . . . . . . . . . . . . 8W-80-129 E xpor t ) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-139
Righ t F og La m p . . . . . . . . . . . . . . . . . . . 8W-80-129 Sen t r y Key Rem ot e E n t r y Modu le
Righ t F r on t Door Aja r Swit ch (Ba se) . . . 8W-80-130 (SKRE E M) . . . . . . . . . . . . . . . . . . . . . 8W-80-139
Righ t F r on t Door Lock Mot or /Aja r Swit ch (E xcept Sir en (Un it ed Kin gdom ) . . . . . . . . . . . . . 8W-80-139
Ba se) . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-130 Speed Con t r ol Ser vo (Ga s) . . . . . . . . . . . 8W-80-139
Righ t F r on t Im pa ct Sen sor . . . . . . . . . . . 8W-80-130 Su n r oof Modu le (E xcept E xpor t ) . . . . . . . 8W-80-140
Righ t F r on t P a r k/Tu r n Sign a l La m p . . . . 8W-80-130 Su n r oof Swit ch (E xcept E xpor t ) . . . . . . . 8W-80-140
Righ t F r on t Wh eel Speed Sen sor . . . . . . 8W-80-131 Th a t ch a m Ala r m Modu le (Un it ed
Righ t F u ll Open Swit ch (P ower Slidin g Kin gdom ) . . . . . . . . . . . . . . . . . . . . . . 8W-80-140
Door ) . . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-131 Th r ot t le P osit ion Sen sor (Ga s) . . . . . . . . 8W-80-141
Righ t H ea dla m p (Ca r a va n /Voya ger E xcept Tr a ct ion Con t r ol Swit ch . . . . . . . . . . . . . 8W-80-141
E xpor t ) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-131 Tr a iler Tow Con n ect or (E xcept E xpor t ) . . 8W-80-141
Righ t H ea dla m p (Town An d Cou n t r y) . . . 8W-80-131 Tr a n sm ission Con t r ol Modu le (Diesel) . . 8W-80-141
Righ t H ea dla m p Levelin g Mot or Tr a n sm ission Con t r ol Rela y (Diesel) . . . . 8W-80-143
(E xpor t ) . . . . . . . . . . . . . . . . . . . . . . . 8W-80-132 Tr a n sm ission Ra n ge Sen sor . . . . . . . . . . 8W-80-143
Righ t H igh Bea m La m p (E xpor t ) . . . . . . 8W-80-132 Tr a n sm ission Solen oid/P r essu r e Swit ch
Righ t In st r u m en t P a n el Spea ker . . . . . . 8W-80-132 Assem bly . . . . . . . . . . . . . . . . . . . . . . 8W-80-143
Righ t Lift ga t e F lood La m p . . . . . . . . . . . 8W-80-132 Veh icle Speed Sen sor (MTX) . . . . . . . . . . 8W-80-144
Righ t Low Bea m La m p (E xpor t ) . . . . . . . 8W-80-133 Wa sh er F lu id Level Swit ch . . . . . . . . . . . 8W-80-144
Righ t Mid Rea din g La m p (P r em iu m / Wa sh er P u m p Mot or . . . . . . . . . . . . . . . . 8W-80-144
Lu xu r y) . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-133 Wa t er In F u el Sen sor (Diesel) . . . . . . . . . 8W-80-144
Righ t P a r k La m p (E xpor t ) . . . . . . . . . . . 8W-80-133 Wiper Modu le . . . . . . . . . . . . . . . . . . . . . 8W-80-144
Righ t P ower Mir r or . . . . . . . . . . . . . . . . 8W-80-133
Righ t Rea r La m p Assem bly . . . . . . . . . . 8W-80-134
Righ t Rea r P illa r Spea ker (H igh lin e
Au dio) . . . . . . . . . . . . . . . . . . . . . . . . . 8W-80-134
A/C COMPRESSOR CLUTCH - LT. GRAY 2 WAY

CAV CIRCUIT FUNCTION
1 C3 20DB/YL (DIESEL) A/C COMPRESSOR CLUTCH RELAY OUTPUT
1 C3 20DB/YL (GAS) A/C CLUTCH RELAY OUTPUT
2 Z153 18BK/GY GROUND
A/C PRESSURE SENSOR - GRAY 4 WAY

1 C918 20BK/LB (DIESEL) A/C PRESSURE SENSOR GROUND
1 K900 18DB/DG (GAS) SENSOR GROUND
2 F855 20PK/YL (2.4L) 5 VOLT SUPPLY
2 F855 18PK/YL (3.3L/3.8L) 5 VOLT SUPPLY
2 F851 20LB/PK (DIESEL) SENSOR REFERENCE VOLTAGE B
3 C18 20LB/BR (DIESEL) A/C PRESSURE SENSOR SIGNAL
3 C18 18LB/BR (GAS) A/C PRESSURE SIGNAL
4 - -
A/C-HEATER CONTROL C1 (MTC) - BLACK/RED 20 WAY

1 Z24 18BK/OR GROUND
2 C121 20DB/DG SENSOR GROUND
3 C22 20LB/WT (3 ZONE) REAR TEMPERATURE FEEDBACK SIGNAL
4 - -
5 F850 20LB/PK (3 ZONE) 5 VOLT SUPPLY
6 - -
7 C32 22DB/TN RECIRCULATION DOOR DRIVER (A)
8 C54 22LB/YL (3 ZONE) REAR BLEND DOOR DRIVER
9 C34 22DB/LB COMMON DOOR DRIVER (B)
10 D25 20WT/VT PCI BUS
11 - -
12 C121 20DB/DG (3 ZONE) REAR TEMPERATURE RETURN
13 F504 20GY/PK IGNITION SWITCH OUTPUT (RUN)
14 E12 20OR/GY PANEL LAMPS DRIVER
15 C21 22LB EVAPORATOR TEMPERATURE SENSOR SIGNAL
16 C33 22LB/BR PASSENGER BLEND DOOR DRIVER (A)
17 C61 22DB/LG (EXCEPT BASE) DRIVER BLEND DOOR DRIVER (A)
18 C35 22LB/LG MODE DOOR DRIVER (A)
19 C53 22LB (3 ZONE) REAR MODE DOOR DRIVER
20 C154 20LB/OR (3 ZONE) REAR COMMON DOOR DRIVER
A/C-HEATER CONTROL C2 (MTC) - BLACK/BLUE 10 WAY

1 - -
2 C75 12DB/GY BLOWER MOTOR HIGH DRIVER
3 C73 14DB/VT (EXCEPT EXPORT) BLOWER MOTOR M2 DRIVER
3 C74 12DB/WT (EXPORT) BLOWER MOTOR M3 DRIVER
4 Z134 12BK/LG GROUND
5 C71 16DB/BR (EXPORT) BLOWER MOTOR LOW DRIVER
6 - -
7 - -
8 - -
9 C72 16DB/OR (EXCEPT EXPORT) BLOWER MOTOR M1 DRIVER
9 C73 14DB/VT (EXPORT) BLOWER MOTOR M2 DRIVER
10 C71 16DB/BR (EXCEPT EXPORT) BLOWER MOTOR LOW DRIVER
10 C72 16DB/OR (EXPORT) BLOWER MOTOR M1 DRIVER
ACCELERATOR PEDAL POSITION SENSOR (DIESEL) - 10 WAY

A - -
B - -
C - -
D K4 20BK/LB SENSOR GROUND
E K151 20WT LOW IDLE POSITION SWITCH SENSE
F - -
G K22 20OR/DB ACCELERATOR PEDAL POSITION SENSOR SIGNAL
NO.1
H K23 20BR/WT ACCELERATOR PEDAL POSITION SENSOR SIGNAL
NO.2
J K900 20DB/DG SENSOR GROUND
K F852 20VT/PK ACCELERATOR PEDAL POSITION SENSOR 5 VOLT
SUPPLY
ADJUSTABLE PEDALS MOTOR (EXCEPT EXPORT) - 2 WAY

1 P205 18LG/DB ADJUSTABLE PEDALS MOTOR FORWARD
2 P206 18LG/TN ADJUSTABLE PEDALS MOTOR REARWARD
ADJUSTABLE PEDALS RELAY (EXCEPT EXPORT/EXCEPT MEMORY) - 9 WAY

1 - -
2 - -
3 - -
4 A108 18LG/RD FUSED B(+)
5 A128 18RD/OR ADJUSTABLE PEDALS RELAY OUTPUT
6 P201 20LG/DB ADJUSTABLE PEDALS RELAY CONTROL
7 - -
9 - -
ADJUSTABLE PEDALS SENSOR (EXCEPT EXPORT) - 3 WAY

1 G11 18VT/TN (EXCEPT MEMORY) ADJUSTABLE PEDALS SENSOR FEED
1 G11 20VT/TN (MEMORY) ADJUSTABLE PEDALS SENSOR FEED
2 G12 18VT/BR (EXCEPT MEMORY) ADJUSTABLE PEDALS SENSOR SIGNAL
2 G12 22VT/BR (MEMORY) ADJUSTABLE PEDALS SENSOR SIGNAL
3 G912 18VT/WT (EXCEPT MEMORY) ADJUSTABLE PEDALS SENSOR RETURN
3 G912 20VT/WT (MEMORY) ADJUSTABLE PEDALS SENSOR RETURN
ADJUSTABLE PEDALS SWITCH (EXCEPT EXPORT) - 4 WAY

1 A128 18RD/OR (EXCEPT MEMORY) ADJUSTABLE PEDALS RELAY OUTPUT
1 A114 18GY/RD (MEMORY) FUSED B(+) (I.O.D.)
2 Z146 18BK/YL GROUND
3 Q102 18OR/LB ADJUSTABLE PEDALS SWITCH REARWARD
4 Q103 18OR/LG ADJUSTABLE PEDALS SWITCH FORWARD
AMBIENT TEMPERATURE SENSOR - BLACK 2 WAY

1 G31 18VT/LG (DIESEL) AMBIENT TEMPERATURE SENSOR SIGNAL
1 G31 18VT/LG (GAS) AAT SIGNAL
2 G931 18VT/BR (DIESEL) AMBIENT TEMPERATURE SENSOR RETURN
AMPLIFIER C1 (HIGHLINE AUDIO) - NATURAL 14 WAY

1 X201 18DG (EXCEPT EXPORT) AMPLIFIED LEFT FRONT DOOR SPEAKER (+)
1 X201 20DG (EXPORT) AMPLIFIED LEFT FRONT DOOR SPEAKER (+)
2 X202 18GY (EXCEPT EXPORT) AMPLIFIED RIGHT FRONT DOOR SPEAKER (+)
2 X202 20GY (EXPORT) AMPLIFIED RIGHT FRONT DOOR SPEAKER (+)
3 X205 18GY/LG (EXCEPT EXPORT) AMPLIFIED LEFT REAR SPEAKER (+)
3 X205 20GY/LG (EXPORT) AMPLIFIED LEFT REAR SPEAKER (+)
4 X206 18DG/LG (EXCEPT EXPORT) AMPLIFIED RIGHT REAR SPEAKER (+)
4 X206 20DG/LG (EXPORT) AMPLIFIED RIGHT REAR SPEAKER (+)
5 X214 18DG/DB (EXCEPT EXPORT) AMPLIFIED LEFT REAR TWEETER (+)
5 X214 20DG/DB (EXPORT) AMPLIFIED LEFT REAR TWEETER (+)
6 X212 18GY/DB (EXCEPT EXPORT) AMPLIFIED RIGHT REAR TWEETER (+)
6 X212 20GY/DB (EXPORT) AMPLIFIED RIGHT REAR TWEETER (+)
7 X291 18DG/BR (EXCEPT EXPORT) AMPLIFIED LEFT FRONT DOOR SPEAKER (-)
7 X291 20DG/BR (EXPORT) AMPLIFIED LEFT FRONT DOOR SPEAKER (-)
8 X292 18GY/BR (EXCEPT EXPORT) AMPLIFIED RIGHT FRONT DOOR SPEAKER (-)
8 X292 20GY/BR (EXPORT) AMPLIFIED RIGHT FRONT DOOR SPEAKER (-)
9 X295 18GY/DG (EXCEPT EXPORT) AMPLIFIED LEFT REAR SPEAKER (-)
9 X295 20GY/DG (EXPORT) AMPLIFIED LEFT REAR SPEAKER (-)
10 - -
11 - -
12 X296 18DG/GY (EXCEPT EXPORT) AMPLIFIED RIGHT REAR SPEAKER (-)
12 X296 20DG/GY (EXPORT) AMPLIFIED RIGHT REAR SPEAKER (-)
13 X284 18DG/TN (EXCEPT EXPORT) AMPLIFIED LEFT REAR TWEETER (-)
13 X284 20DG/TN (EXPORT) AMPLIFIED LEFT REAR TWEETER (-)
14 X282 18GY/TN (EXCEPT EXPORT) AMPLIFIED RIGHT REAR TWEETER (-)
14 X282 20GY/TN (EXPORT) AMPLIFIED RIGHT REAR TWEETER (-)
AMPLIFIER C2 (HIGHLINE AUDIO) - 20 WAY

1 X153 18DG/YL (EXCEPT EXPORT) LEFT INSTRUMENT PANEL SPEAKER (+)
1 X153 20DG/YL (EXPORT) LEFT INSTRUMENT PANEL SPEAKER (+)
2 X154 18GY/YL (EXCEPT EXPORT) RIGHT INSTRUMENT PANEL SPEAKER (+)
2 X154 20GY/YL (EXPORT) RIGHT INSTRUMENT PANEL SPEAKER (+)
3 - -
4 A116 16YL/RD FUSED B (+)
5 - -
7 X51 20DG/DB LEFT REAR SPEAKER (+)
8 X52 20GY/DB RIGHT REAR SPEAKER (+)
9 Z513 16BK GROUND
10 X155 18DG/LB (EXCEPT EXPORT) LEFT INSTRUMENT PANEL SPEAKER (-)
10 X155 20DG/LB (EXPORT) LEFT INSTRUMENT PANEL SPEAKER (-)
11 X156 18GY/LB (EXCEPT EXPORT) RIGHT INSTRUMENT PANEL SPEAKER (-)
11 X156 20GY/LB (EXPORT) RIGHT INSTRUMENT PANEL SPEAKER (-)
12 - -
13 A116 16YL/RD FUSED B (+)
14 - -
15 - -
16 - -
17 F306 20DB/PK FUSED ACCESSORY RELAY OUTPUT
18 X57 20DG/OR LEFT REAR SPEAKER (-)
19 X58 20GY/OR RIGHT REAR SPEAKER (-)
20 Z513 16BK GROUND
ATC REMOTE SENSOR (ATC) - 4 WAY

1 F600 20LB/PK PROTECTED IGNITION
2 D40 20WT/LB KDB NO. 2 CLOCK
3 C905 20BR/LB SENSOR RETURN
4 D18 20WT/YL KDB NO. 2 DATA
AUTO TEMP CONTROL C1 - NATURAL 13 WAY

1 C161 22LB/WT DRIVER BLEND DOOR DRIVER (B)
2 C61 22DB/LG DRIVER BLEND DOOR DRIVER (A)
3 C133 22DB/WT PASSENGER BLEND DOOR DRIVER (B)
4 C33 22LB/BR PASSENGER BLEND DOOR DRIVER (A)
5 C132 22DB/YL RECIRCULATION DOOR DRIVER (B)
6 C32 22DB/TN RECIRCULATION DOOR DRIVER (A)
7 C135 22DB/GY MODE DOOR DRIVER (B)
8 C35 22LB/LG MODE DOOR DRIVER (A)
9 C53 22LB REAR MODE DOOR DRIVER (A)
10 C154 22LB/OR REAR MODE DOOR DRIVER (B)
11 C54 22LB/YL REAR BLEND DOOR DRIVER (A)
12 C169 22DB/OR REAR BLEND DOOR DRIVER (B)
13 - -
AUTO TEMP CONTROL C2 - BLACK 13 WAY

1 C21 22LB EVAPORATOR TEMPERATURE SENSOR SIGNAL
2 C121 20DB/DG (LHD) SENSOR GROUND
2 C121 22DB/DG (RHD) SENSOR GROUND
4 A114 18GY/RD FUSED B(+) (I.O.D.)
5 F504 20GY/PK FUSED IGNITION SWITCH OUTPUT (RUN)
7 C56 22DB/VT (LHD) BLOWER MOTOR CONTROL
7 C56 22DB/LB (RHD) BLOWER MOTOR CONTROL
8 C59 22DB/LB REAR BLOWER MOTOR CONTROL
9 D22 20WT/TN (3 ZONE) KDB CLOCK
10 D17 22WT/DG KDB DATA
12 - -
13 - -
AUTO TEMP CONTROL C3 - 4 WAY

1 F600 20LB/PK PROTECTED IGNITION
2 D40 20WT/LB KDB NO. 2 CLOCK
3 C905 20BR/LB SENSOR RETURN
4 D18 20WT/YL KDB NO. 2 DATA
BACK-UP LAMP SWITCH (MTX) - BLACK 2 WAY

1 T2 18DG/WT TRS REVERSE SENSE
2 Z252 18BK/WT GROUND
BATTERY TEMPERATURE SENSOR - BLACK 2 WAY

1 K25 20BR/TN (DIESEL) BATTERY TEMPERATURE SENSOR SIGNAL
1 K91 18DB/YL (GAS) BATTERY TEMP SIGNAL
2 K900 20DB/DG (DIESEL) SENSOR GROUND
BELT TENSION SENSOR (OCCUPANT SENSING) - BLACK 3 WAY

1 R86 20LG/LB BELT TENSION SENSOR FEED
2 R986 20LG/BR BELT TENSION SENSOR GROUND
3 D105 20WT/OR BELT TENSION SENSOR SIGNAL
BLOWER MOTOR RESISTOR C1 (MTC) - BLACK 6 WAY

1 C75 12DB/GY (EXPORT) BLOWER MOTOR HIGH DRIVER
2 C75 12DB/GY (EXCEPT EXPORT) BLOWER MOTOR HIGH DRIVER
2 C74 12DB/WT (EXPORT) BLOWER MOTOR M3 DRIVER
3 C73 14DB/VT BLOWER MOTOR M2 DRIVER
4 C7 12DB FUSED FRONT BLOWER MOTOR RELAY OUTPUT
5 C72 16DB/OR BLOWER MOTOR M1 DRIVER
6 C71 16DB/BR BLOWER MOTOR LOW DRIVER
BLOWER MOTOR RESISTOR C2 (MTC) - BLACK 2 WAY

1 C70 12DG REAR BLOWER HIGH SPEED
2 C7 12BK HIGH SPEED BLOWER MOTOR
BODY CONTROL MODULE C1 - BLACK/BLACK 6 WAY

1 A101 12VT/RD FUSED B(+)
2 A701 16BR/RD FUSED B(+) (HAZARD)
3 Z100 12BK/TN GROUND
4 - -
6 - -
BODY CONTROL MODULE C2 - BLACK/GREEN 34 WAY

1 L61 20WT/LB LEFT FRONT TURN SIGNAL DRIVER
2 L63 18WT/DG LEFT REAR TURN SIGNAL DRIVER
3 L60 18WT/TN RIGHT FRONT TURN SIGNAL DRIVER
4 L62 18WT/BR RIGHT REAR TURN SIGNAL DRIVER
5 F20 20PK/WT FUSED IGNITION SWITCH OUTPUT (RUN-START)
6 G25 22VT/TN LIFTGATE SWITCH MUX
8 - -
9 L1 18WT/LG BACK-UP LAMP FEED
10 P3 20TN/WT LEFT FRONT DOOR LOCK DRIVER
11 P2 20TN/GY RIGHT FRONT DOOR LOCK DRIVER
12 P38 20TN/DB RIGHT SLIDING DOOR LOCK DRIVER
13 - -
14 - -
16 G920 20VT/YL (MEMORY) MEMORY SELECT SWITCH RETURN
17 G153 20VT/DG (POWER LIFTGATE) LIFTGATE MODULE WAKE UP SIGNAL
18 P32 20TN/VT LEFT SLIDING DOOR LOCK DRIVER
20 P5 20TN/OR LEFT SLIDING DOOR UNLOCK DRIVER
21 P164 18LG/DB (EXPORT) PASSENGER FOLDING MIRROR RELAY INPUT
22 P30 20TN/DG LIFTGATE HANDLE SWITCH SENSE
23 - -
24 G200 20VT/BR (MEMORY) MEMORY SELECT SWITCH MUX
25 M22 20YL/OR COURTESY LAMPS DRIVER
26 P4 20TN/BR RIGHT FRONT DOOR UNLOCK DRIVER
27 P34 20TN/LB RIGHT SLIDING DOOR UNLOCK DRIVER
28 P1 20TN/LG LEFT FRONT DOOR UNLOCK DRIVER
29 P159 20TN/DG (EXPORT) DRIVER FOLDING MIRROR FOLD DRIVER
30 P174 20TN/LB (EXPORT) RIGHT FOLDING MIRROR UNFOLD DRIVER
31 P171 20TN/YL (EXPORT) LEFT FOLDING MIRROR UNFOLD DRIVER
32 W13 18BR/LG REAR WIPER MOTOR CONTROL
33 - -
34 L38 20WT/YL (EXPORT) REAR FOG LAMP SWITCH OUTPUT
BODY CONTROL MODULE C3 - BLACK/WHITE 34 WAY

1 G23 22VT/DB (POWER SLIDING SLIDING DOORS OVERHEAD SWITCH MUX
DOOR)
2 D123 20WT/BR FLASH PROGRAM ENABLE
3 G152 22VT/GY (POWER SLIDING RIGHT SLIDING DOOR WAKE UP SIGNAL
DOOR)
4 G151 22VT/BR (POWER SLIDING LEFT SLIDING DOOR WAKE UP SIGNAL
DOOR)
5 G76 20VT/YL RIGHT SLIDING DOOR AJAR SWITCH SENSE
6 G75 20VT (LHD) LEFT FRONT DOOR AJAR SWITCH SENSE
6 G74 20VT/WT (RHD) RIGHT FRONT DOOR AJAR SWITCH SENSE
7 G74 20VT/WT (LHD) RIGHT FRONT DOOR AJAR SWITCH SENSE
7 G75 20VT (RHD) LEFT FRONT DOOR AJAR SWITCH SENSE
8 G77 22VT/GY LEFT SLIDING DOOR AJAR SWITCH SENSE
9 E10 20OR/DG (3 ZONE HVAC) PANEL LAMPS DRIVER
10 - -
11 L162 20WT/VT (EXPORT) RIGHT SIDE REPEATER LAMP FEED
12 G42 22VT/YL (POWER SLIDING RIGHT SLIDING DOOR PILLAR SWITCH MUX
DOOR)
13 - -
14 G163 20VT/LB (EXPORT) LEFT CYLINDER LOCK SWITCH MUX
15 G162 20VT/TN (EXPORT) RIGHT CYLINDER LOCK SWITCH MUX
16 L50 18WT/TN (EXCEPT EXPORT) BRAKE LAMP SWITCH OUTPUT
17 F503 20WT/PK (EXCEPT BASE) FUSED IGNITION SWITCH OUTPUT (RUN)
18 G41 22VT/DG (POWER SLIDING LEFT SLIDING DOOR PILLAR SWITCH MUX
DOOR)
19 L163 20WT/BR (EXPORT) LEFT SIDE REPEATER LAMP FEED
20 N4 20DB/WT FUEL LEVEL SENSOR SIGNAL
21 G161 20VT/DG (LHD) LEFT DOOR LOCK SWITCH MUX
21 G160 20VT/LG (RHD) RIGHT DOOR LOCK SWITCH MUX
22 G160 20VT/LG (LHD) RIGHT DOOR LOCK SWITCH MUX
22 G161 20VT/DG (RHD) LEFT DOOR LOCK SWITCH MUX
24 - -
25 M11 20YL/VT COURTESY LAMPS DRIVER
26 P31 20TN/YL (POWER RELEASE) LIFTGATE RELEASE DRIVER
27 - -
28 - -
29 G78 20VT/OR LIFTGATE AJAR SWITCH SENSE
30 G70 22VT/LB (EXPORT) HOOD AJAR SWITCH SENSE
31 F500 18DG/PK (ABS) FUSED IGNITION SWITCH OUTPUT (RUN)
32 - -
33 M21 20YL/BR COURTESY LAMPS DRIVER
34 M27 20YL/LB READING LAMPS DRIVER
BODY CONTROL MODULE C4 - BLACK/GRAY 34 WAY

1 - -
3 E19 20OR/BR (AUTOMATIC HEAD- HEADLAMP SWITCH DIMMER SIGNAL
LAMPS)
4 - -
5 G150 22VT/BR INSTRUMENT CLUSTER WAKE UP SENSE
6 - -
7 P162 20LG/DG (EXPORT) PASSENGER FOLDING MIRROR RELAY CONTROL
8 - -
9 L161 20WT/LG LEFT TURN INDICATOR DRIVER
11 E14 20OR/TN PANEL LAMPS DRIVER
12 E13 20OR/WT PANEL LAMPS DRIVER
13 X920 22GY/OR (REMOTE AUDIO) RADIO CONTROL MUX RETURN
14 G900 20VT/DB IGNITION SWITCH SENSE RETURN
15 - -
16 - -
17 L160 20WT/TN RIGHT TURN INDICATOR DRIVER
18 - -
19 - -
20 - -
21 - -
22 G902 22VT/LB MULTI-FUNCTION SWITCH MUX RETURN
23 - -
24 - -
25 - -
26 - -
27 - -
28 - -
29 - -
30 - -
31 - -
32 B27 20DG/WT (TRACTION CONTROL) TRACTION CONTROL SWITCH SENSE
33 P136 20TN/YL (EXPORT) FOLDING MIRROR SWITCH SENSE
34 G26 22VT/OR CHIME DRIVER
BODY CONTROL MODULE C5 - BLACK/BLACK 34 WAY

1 L91 22WT/DB (LHD) HAZARD SWITCH SENSE
1 L91 20WT/DB (RHD) HAZARD SWITCH SENSE
2 - -
3 - -
4 - -
5 - -
6 - -
7 - -
8 - -
9 - -
10 G20 20VT/BR IGNITION SWITCH SENSE
11 - -
12 - -
13 - -
14 - -
15 - -
16 G926 22VT/WT (ATC/EXPORT MTC) REAR WIPER SWITCH MUX RETURN
17 L900 22WT/YL HEADLAMP SWITCH MUX RETURN
18 L307 20WT/BR HEADLAMP SWITCH MUX
19 - -
20 - -
21 - -
22 - -
23 - -
24 - -
25 L36 20WT/DB (EXPORT) REAR FOG LAMP INDICATOR DRIVER
26 X20 22GY/WT (REMOTE AUDIO) RADIO CONTROL MUX
27 G194 22VT/LG HIGH BEAM/FRONT WASHER SWITCH MUX
28 W26 22BR/DB (PREMIUM/LUXURY/ REAR WIPER SWITCH MUX
EXPORT)
29 W52 22BR/YL FRONT WIPER SWITCH MUX
30 E2 22OR/BR PANEL LAMPS DIMMER SIGNAL
31 L305 20WT/LB TURN SIGNAL SWITCH MUX
32 - -
33 - -
34 L39 22WT/OR (HIGHLINE) FRONT FOG LAMP INDICATOR DRIVER
BOOST PRESSURE SENSOR (DIESEL) - 4 WAY

1 K121 20DB BOOST PRESSURE SENSOR GROUND
2 K21 20DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL
3 F851 20LB/PK SENSOR REFERENCE VOLTAGE B
4 K37 20DB/YL BOOST PRESSURE SENSOR SIGNAL
BRAKE FLUID LEVEL SWITCH - 2 WAY

1 B20 20DG/OR BRAKE FLUID LEVEL SWITCH SENSE
BRAKE LAMP SWITCH - BLACK 6 WAY

1 A103 18GY/RD FUSED B(+)
2 L50 18WT/TN (DIESEL) PRIMARY BRAKE SWITCH SIGNAL
2 L50 18WT/TN (GAS) BRAKE LAMP SWITCH OUTPUT
3 V30 20VT/WT (GAS) S/C BRAKE SWITCH OUTPUT
4 V32 20VT/YL (GAS) SPEED CONTROL SUPPLY
6 B29 20DG/WT SECONDARY BRAKE SWITCH SIGNAL
BRAKE TRANSMISSION SHIFT INTERLOCK SOLENOID - BLACK 2 WAY

1 K32 18DB/YL BRAKE TRANSMISSION SHIFT INTERLOCK SOLENOID
CONTROL
2 F2 18PK/YL FCM OUTPUT (UNLOCK-RUN-START)
C100 - BLACK (BODY SIDE)

CAV CIRCUIT
1 D21 20WT/DG
2 D123 20WT/BR
3 D15 20DG/YL (DIESEL)
3 D20 20WT/LG (GAS)
4 R80 20VT/LB (DIESEL)
4 T141 20YL/OR (GAS MTX EXPORT)
5 Z111 20BK/WT
6 N1 16DB/OR (DIESEL)
6 G31 18VT/LG (GAS/EXCEPT SIDE AIRBAG)
6 G31 18WT/LG (GAS/SIDE AIRBAG)
7 N2 18DB/YL (DIESEL)
7 D15 20DG/YL (GAS)
8 K22 20OR/DB (DIESEL)
8 V32 20VT/YL (GAS)
9 B29 20DG/WT
10 V37 20VT
11 R82 20WT/LB (DIESEL)
11 V30 20VT/WT (GAS)
12 K900 20DB/DG
13 B1 18DG/OR (ABS)
14 B2 18DG/LB (ABS)
C100 - BLACK (POWERTRAIN SIDE)

CAV CIRCUIT
1 D21 20WT/DG (2.4L/DIESEL)
1 D21 20WT/BR (3.3L/3.8L)
2 D123 20WT/BR (2.4L EATX)
2 D123 20WT/OR (3.3L/3.8L)
3 D15 20DG/YL (DIESEL EATX)
3 D20 20WT/LG (GAS)
4 R80 18VT/LB (DIESEL)
4 T141 18YL (GAS MTX EXPORT)
5 Z111 20BK/WT
6 N1 18DB/OR (DIESEL)
6 G31 18VT/LG (GAS)
7 N2 18DB/YL (DIESEL)
7 D15 18DG/YL (GAS EATX)
8 K22 20OR/DB (DIESEL)
8 V32 18VT/YL (GAS)
9 B29 20DG/WT (DIESEL)
9 B29 18DG/WT (GAS)
10 V37 20VT/TN (DIESEL)
10 V37 18VT (GAS)
11 R82 18WT/LB (DIESEL)
11 V30 20VT/WT (GAS)
12 K900 20DB/DG
13 B1 18DG/OR (ABS)
14 B2 18DG/LB (ABS)
C101 (DIESEL) - LT. GRAY (BODY SIDE)

CAV CIRCUIT
1 L50 18WT/TN
2 K23 20BR/WT (EATX)
3 F853 20LG/PK
4 K119 20DB/LG (MTX)
5 B4 18DG/GY (ANTILOCK BRAKES)
6 B3 18DG/YL (ANTILOCK BRAKES)
7 F500 18DG/PK
8 K4 20BK/LB
9 F852 20VT/PK
10 K151 20WT
C101 (DIESEL) - LT. GRAY (POWERTRAIN SIDE)

CAV CIRCUIT
1 L50 20WT/TN
2 K23 20BR/OR (EATX)
3 F853 20LG/PK
4 K119 20DB/LG (MTX)
5 B4 18DG/GY (ANTILOCK BRAKES)
6 B3 18DG/YL (ANTILOCK BRAKES)
7 F500 18DG/PK
8 K4 20BK/LB
9 F852 20VT/PK
10 K151 20WT
C101 (GAS) - LT. GRAY (BODY SIDE)

CAV CIRCUIT
1 L50 18WT/TN
2 B4 18DG/GY
3 B3 18DG/YL
4 F500 18DG/PK
C101 (GAS) - LT. GRAY (POWERTRAIN SIDE)

CAV CIRCUIT
1 L50 18WT/TN
2 B4 18DG/GY
3 B3 18DG/YL
4 F500 18DG/PK
C102 (GAS) - BLACK (FUEL RAIL SIDE)

CAV CIRCUIT
1 K11 16BR/YL (2.4L)
1 K342 16BR/WT (3.3L/3.8L)
2 K12 16BR/DB (2.4L)
2 K1 18VT/BR (3.3L/3.8L)
3 K13 16BR/LB (2.4L)
3 K11 16BR/YL (3.3L/3.8L)
4 K14 16BR/TN (2.4L)
4 K12 16BR/DB (3.3L/3.8L)
5 K342 16BR/WT (2.4L)
5 K13 16BR/LB (3.3L/3.8L)
6 K900 18DB/DG (2.4L)
6 K14 16BR/TN (3.3L/3.8L)
7 K2 18VT/OR (2.4L)
7 K900 18DB/DG (3.3L/3.8L)
8 K1 18VT/BR (2.4L)
8 K38 16BR/OR (3.3L/3.8L)
9 K58 16BR/VT (3.3L/3.8L)
10 F855 18PK/YL
C102 (GAS) - BLACK (POWERTRAIN SIDE)

CAV CIRCUIT
1 K11 16BR/YL (2.4L)
1 K342 16BR/WT (3.3L/3.8L)
2 K12 16BR/DB (2.4L)
2 K1 18VT/BR (3.3L/3.8L)
3 K13 16BR/LB (2.4L)
3 K11 16BR/YL (3.3L/3.8L)
4 K14 16BR/TN (2.4L)
4 K12 16BR/DB (3.3L/3.8L)
5 K342 16BR/WT (2.4L)
5 K13 16BR/LB (3.3L/3.8L)
6 K900 18DB/DG (2.4L)
6 K14 16BR/TN (3.3L/3.8L)
7 K2 18VT/OR (2.4L)
7 K900 18DB/DG (3.3L/3.8L)
8 K1 18VT/BR (2.4L)
8 K38 16BR/OR (3.3L/3.8L)
9 K58 16BR/VT (3.3L/3.8L)
10 F855 20PK/YL
C103 (DIESEL) - BLACK (FRONT END LIGHTING

SIDE)
CAV CIRCUIT
1 K342 16BR/WT
2 R80 18VT/LB
3 N122 20DB/YL
4 N210 18DB/DG
5 A201 12RD/LG
6 R82 18WT/LB
C103 (DIESEL) - BLACK (POWERTRAIN SIDE)

CAV CIRCUIT
1 K342 16BR/WT
2 R80 18VT/LB
3 N122 20DB/YL
4 N210 20DB/DG
5 A201 12RD/LG
6 R82 18WT/LB
C104 (EXCEPT EXPORT) - (ENGINE SIDE)

CAV CIRCUIT
1 Z166 18BK/WT
2 K107 20VT/WT
3 K106 20VT/LB
C104 (EXCEPT EXPORT) - LT. GRAY (JUMPER

SIDE)
CAV CIRCUIT
1 Z166 18BK/WT
2 K107 18VT/WT
3 K106 18VT/GY
C106 (EXPORT) - BLACK (FRONT END LIGHT-

ING SIDE)
CAV CIRCUIT
1 L43 18WT/DB
2 L33 18WT/LG
3 L77 18WT/BR
4 L61 18WT/LB
5 Z343 18BK/LG
6 L13 20WT/YL
7 Z203 20BK/YL
8 Z377 18BK/BR
C106 (EXPORT) - BLACK/YELLOW (COMPONENT

SIDE)
CAV CIRCUIT
1 L43 16WT
2 L33 16GY
3 L77 16BK
4 L61 16YL
5 Z343 16BR
6 L13 16RD
7 Z203 16BR
8 Z377 18BK/BR
C107 (EXPORT) - BLACK (FRONT END LIGHT-

ING SIDE)
CAV CIRCUIT
1 L44 16WT/TN
2 L34 16WT/GY
3 L78 18WT/OR
4 L60 18WT/TN
5 Z344 16BK/TN
6 L13 20WT/YL
7 Z203 20BK/YL
8 Z378 18BK/TN
C107 (EXPORT) - BLACK/YELLOW (COMPONENT

SIDE)
CAV CIRCUIT
1 L44 16WT
2 L34 16GY
3 L78 16BK
4 L60 16YL
5 Z344 16BR
6 L13 16RD
7 Z203 16BR
8 Z378 18BK/TN
C111 (EATX) - LT. GRAY (ENGINE SIDE)

CAV CIRCUIT
1 Z133 16BK/LG
2 T15 18YL/BR
3 -
4 Z133 16BK/LG
5 T16 18YL/OR
6 -
C111 (EATX) - LT. GRAY (TRANSMISSION SIDE)

CAV CIRCUIT
1 Z133 16BK/LG
2 T15 18YL/BR
3 -
4 Z133 16BK/LG
5 T16 18YL/OR
6 -
C112 (GAS) - BLACK (BODY SIDE)

CAV CIRCUIT
1 R80 20VT/LB
2 R82 20WT/LB
3 G31 18VT/LG (EXCEPT OCCUPANT
SENSING)
3 G31 18WT/LG (OCCUPANT SENSING)
4 K900 20DB/DG
C112 (GAS) - BLACK (FRONT END LIGHTING

SIDE)
CAV CIRCUIT
1 R80 18VT/LB
2 R82 18WT/LB
3 G31 18VT/LG
4 K900 18DB/DG
C200 - GRAY (BODY SIDE)

CAV CIRCUIT
1 C151 18LB/DG (3 ZONE MTC EXCEPT EXPORT)
1 B25 20DG/WT (EXPORT)
2 A106 20LB/RD
3 A108 18LG/RD (POWER MIRROR EXCEPT EXPORT)
3 A108 20LG/RD (POWER MIRROR EXPORT)
4 C59 20DB/LB (3 ZONE ATC)
4 C152 16LB/LG (3 ZONE MTC)
5 P159 20TN/DG (EXPORT)
6 K32 18DB/YL
7 C53 20LB (3 ZONE HVAC)
8 C16 20DB/GY
9 D17 20WT/DG (3 ZONE ATC)
9 C22 20LB/WT (3 ZONE MTC)
10 C50 12DB/OR (3 ZONE MTC)
10 L13 20WT/YL (EXPORT)
11 C7 12DB
12 C153 12DB/BR (3 ZONE MTC)
12 D123 20WT/BR (RHD)
13 Z849 12BK/OR (MEMORY DIESEL)
13 Z408 18BK/LG (MEMORY EXCEPT EXPORT)
14 A105 18DB/RD
15 A114 16GY/RD
16 F306 20DB/PK (HIGHLINE AUDIO/EXCEPT EXPORT)
16 F306 16DB/PK (LOWLINE AUDIO/EXPORT)
17 C169 20DB/OR (3 ZONE ATC)
17 C154 20LB/OR (3 ZONE MTC)
18 D22 20WT/TN (3 ZONE ATC)
18 C121 20DB/DG (3 ZONE MTC)
19 P160 18TN/LG (EXPORT)
20 -
21 F2 18PK/YL
22 Q102 18OR/LB (EXCEPT EXPORT)
22 L78 18WT/OR (EXPORT)
23 Q103 18OR/LG (EXCEPT EXPORT)
23 P174 20TN/LB (EXPORT)
24 D25 20WT/VT
25 P64 22TN (LHD MEMORY)
25 R79 20LB/VT (RHD)
26 P65 22TN/VT (LHD MEMORY)
26 R81 20LB/WT (RHD)
27 P66 22TN/LG (RHD MEMORY)
28 P67 22TN/OR (RHD MEMORY)
29 F20 20PK/WT
30 F100 18PK/VT
31 F201 20PK/OR (ORC)
32 F504 20GY/PK (3 ZONE ATC)
32 F850 20LB/PK (3 ZONE MTC)
33 P68 22TN/YL (RHD MEMORY)
34 P69 22TN/DB (LHD MEMORY)
35 R21 20LB/WT (SIDE AIRBAG)
36 R23 20LB/YL (SIDE AIRBAG)
37 R22 20WT/LB (SIDE AIRBAG)
38 R24 20YL/LB (SIDE AIRBAG)
39 R79 20LB/VT (LHD)

CAV CIRCUIT
39 D96 18WT/LB (RHD)
40 R80 20VT/LB (LHD)
40 Z109 18BK/GY (RHD)
41 R81 20LB/WT (LHD)
41 A645 20RD/VT (RHD)
42 R82 20WT/LB (LHD)
42 G945 20VT/DG (RHD)
43 A128 18RD/OR (EXCEPT MEMORY/EXCEPT EXPORT)
44 P70 20TN/LB (RHD MEMORY)
45 P71 20TN/DG (LHD MEMORY)
46 P72 20TN/GY (RHD MEMORY)
47 P73 20TN/YL (LHD MEMORY)
48 P74 20TN/DB (RHD MEMORY)
49 P75 20TN/LG (LHD MEMORY)
49 R80 20VT/LB (RHD)
50 P112 22TN/OR (LUXURY EXCEPT HANDS FREE/EXCEPT
EXPORT)
50 R82 20WT/LB (RHD)
51 P171 20TN/YL (EXPORT)
51 P114 22TN/WT (LUXURY EXCEPT HANDS FREE/EXCEPT
EXPORT)
52 P7 22LG/DG (HEATED SEATS)
53 P8 22LG/WT (HEATED SEATS)
54 C154 20LB/OR (3 ZONE HVAC)
55 X156 20GY/LB (EXPORT)
55 X156 18GY/LB (HIGHLINE AUDIO EXCEPT EXPORT)
56 X154 20GY/YL (EXPORT)
56 X154 18GY/YL (HIGHLINE AUDIO EXCEPT EXPORT)
57 P162 18LG/DG (EXPORT)
58 T751 20YL
59 -
60 A701 18BR/RD
61 X3 20DG/VT
62 X153 20DG/YL (EXPORT LOWLINE AUDIO)
62 X53 20DG (LOWLINE AUDIO)
63 X154 20GY/YL (EXPORT LOWLINE AUDIO)
63 X54 20GY (LOWLINE AUDIO)
64 X155 20DG/LB (EXPORT LOWLINE AUDIO)
64 X55 20DG/BR (LOWLINE AUDIO)
65 X156 20GY/LB (EXPORT LOWLINE AUDIO)
65 X56 20GY/BR (LOWLINE AUDIO)
66 C54 20LB/YL (3 ZONE HVAC)
67 V37 20VT
68 X51 20DG/DB
69 X52 20GY/DB
70 X57 20DG/OR
71 X58 20GY/OR
72 X153 20DG/YL (EXPORT)
72 X153 18DG/YL (HIGHLINE AUDIO EXCEPT EXPORT)
73 K900 20DB/DG
74 X155 20DG/LB (EXPORT)
74 X155 18DG/LB (HIGHLINE AUDIO EXCEPT EXPORT)
C200 - GRAY (INSTRUMENT PANEL SIDE)

CAV CIRCUIT
1 C151 18LB/DG (3 ZONE MTC EXCEPT EXPORT)
1 B25 20DG/WT (EXPORT)
2 A106 20LB/RD
3 A108 20LG/RD (POWER MIRROR)
4 C59 22DB/LB (3 ZONE ATC)
4 C152 16LB/LG (3 ZONE MTC)
5 P159 20TN/DG (EXPORT)
6 K32 18DB/YL
7 C53 22LB (3 ZONE HVAC)
8 C16 20DB/GY (HEATED MIRROR)
9 D17 22WT/DG (3 ZONE ATC)
9 C22 20LB/WT (3 ZONE MTC)
10 C50 12DB/OR (3 ZONE MTC)
10 L13 20WT/YL (EXPORT)
11 C7 12DB
12 C153 12DB/BR (3 ZONE MTC)
12 D23 20WT/BR (RHD)
13 Z408 18BK/LG (MEMORY EXCEPT EXPORT)
13 Z849 12BK/OR (MEMORY EXPORT)
14 A105 16DB/RD (EXCEPT LOWLINE)
15 A114 16GY/RD
16 F306 18DB/PK
17 C169 22DB/OR (3 ZONE ATC)
18 D22 20WT/TN (3 ZONE ATC)
18 C121 20DB/DG (3 ZONE MTC)
19 P160 20TN/LG (EXPORT)
20 -
21 F2 18PK/YL
22 Q102 18OR/LB (EXCEPT EXPORT)
22 L78 20WT/OR (EXPORT)
23 Q103 18OR/LG (EXCEPT EXPORT)
23 P174 20TN/LB (EXPORT)
24 D25 20WT/VT
25 P64 20TN (LHD MEMORY)
26 P65 20TN/VT (LHD MEMORY)
28 P67 20TN/OR (RHD MEMORY)
29 F20 20PK/WT
30 F100 18PK/VT
31 F201 20PK/OR (ORC)
32 F504 20GY/PK (3 ZONE ATC)
32 F850 20LB/PK (3 ZONE MTC)
33 P68 20TN/YL (RHD MEMORY)
34 P69 20TN/WT (LHD MEMORY)
35 R21 20LB/WT (SAB)
36 R23 20LB/YL (SAB)
37 R22 20WT/LB (SAB)
38 R24 20YL/LB (SAB)
39 R79 20LB/VT (LHD)
39 D96 20WT/LB (RHD)
40 R80 20VT/LB (LHD)

CAV CIRCUIT
40 Z109 20BK/GY (RHD)
41 R81 20LB/WT (LHD)
41 A645 20RD/VT (RHD)
42 R82 20WT/LB (LHD)
42 G945 20VT/DG (RHD)
43 A128 18RD/OR (EXCEPT EXPORT/EXCEPT MEMORY)
44 P70 20/LB (RHD MEMORY)
45 P71 20TN/DG (LHD MEMORY)
47 P73 20TN/YL (LHD MEMORY)
48 P74 20TN/DB (RHD MEMORY)
49 P75 20TN/LG (LHD MEMORY)
49 R80 20VT/LB (RHD)
50 P112 22TN/OR (LUXURY/EXCEPT EXPORT)
50 R82 20WT/LB (RHD)
51 P171 20TN/YL (EXPORT)
51 P114 22TN/WT (LUXURY/EXCEPT EXPORT)
53 P8 20LG/WT (HEATED SEATS)
54 C154 22LB/OR (3 ZONE ATC)
55 X156 20GY/LB (EXPORT)
55 X156 18GY/LB (HIGHLINE AUDIO EXCEPT EXPORT)
56 X154 20GY/YL (EXPORT)
56 X154 18GY/YL (HIGHLINE AUDIO EXCEPT EXPORT)
57 P162 20LG/DG (EXPORT)
58 T751 20YL
59 X15 16GY/DG (EXPORT)
60 A701 18BR/RD
61 X3 22DG/VT
62 X153 20DG/YL (LOWLINE AUDIO)
62 X53 20DG (LOWLINE AUDIO/EXPORT)
63 X154 20GY/YL (LOWLINE AUDIO)
63 X54 20GY (LOWLINE AUDIO/EXPORT)
64 X155 20DG/LB (LOWLINE AUDIO)
64 X55 20DG/BR (LOWLINE AUDIO/EXPORT)
65 X56 20GY/BR (LOWLINE AUDIO/EXPORT)
66 C54 22LB/YL (3 ZONE HVAC)
67 V37 22VT
68 X51 22DG/DB
69 X52 22GY/DB
70 X57 22DG/OR
71 X58 22GY/OR
72 X153 20DG/YL (EXPORT)
72 X153 18DG/YL (HIGHLINE AUDIO EXCEPT EXPORT)
73 K900 20DB/DG
74 X155 20DG/LB (EXPORT)
74 X155 22DG/LB (HIGHLINE AUDIO EXCEPT EXPORT)
C202 - GRAY (COMPONENT SIDE)

CAV CIRCUIT
1 Z134 12BK/OR (ATC)
2 C56 20DB/LB (ATC)
2 C34 20DB/LB (MTC)
3 C32 20DB/TN
4 C33 20LB/BR
5 C61 20DB/LG (ATC)
5 C61 20LB/WT (MTC)
6 C35 20LB/OR
7 C7 12DB (ATC)
8 C132 20DB/YL (ATC)
9 C133 20DB/WT (ATC)
10 C161 20LB/WT (ATC)
11 C135 20DB/GY (ATC)
12 C21 20DB/LG
13 C121 20DB/DG

CAV CIRCUIT
1 Z134 12BK/LG
2 C56 22DB/VT (ATC LHD)
2 C56 22DB/LB (ATC RHD)
2 C34 22DB/LB (MTC)
3 C32 22DB/TN
4 C33 22LB/BR
5 C61 22DB/LG
6 C35 22LB/LG
7 C7 12DB (ATC)
8 C132 22DB/YL (ATC)
9 C133 22DB/WT (ATC)
10 C161 22LB/WT (ATC)
11 C135 22DB/GY (ATC)
12 C21 22LB
13 C121 20DB/DG
C204 (PREMIUM) - NATURAL (DVD SCREEN

JUMPER SIDE)
CAV CIRCUIT
1 X515 22GY/OR
2 X915 22GY/LB
3 -
4 -
5 X211 20YL/GY
6 X114 20GY/LB
7 X955 20BK/GY
8 -
9 X555 20VT/OR
10 X530 20GY/DB
C204 (PREMIUM) - NATURAL (DVD/CD

CHANGER SIDE)
CAV CIRCUIT
1 X515 22GY/OR
2 X915 22GY/LB
3 -
4 -
5 X211 20YL/GY
6 X114 20GY/LB
7 X955 20BK/GY
8 -
9 X555 20VT/OR
10 X530 20GY/DB
C206 (EXCEPT BASE) - (INSTRUMENT PANEL

JUMPER SIDE)
CAV CIRCUIT
1 A114 20GY/RD
2 Z530 20GY/BK
3 -
C206 (EXCEPT BASE) - (INSTRUMENT PANEL

SIDE)
CAV CIRCUIT
1 A114 20GY/RD
2 Z530 20GY/BK
3 -
C207 (DVD) - (INSTRUMENT PANEL JUMPER

SIDE)
CAV CIRCUIT
1 A114 20GY/RD
1 A114 20GY/RD
2 -
3 Z530 20GY/BK
3 Z530 20GY/BK
C207 (HANDS FREE) - (HANDS FREE MODULE SIDE)

CAV CIRCUIT
1 A114 20GY/RD
2 -
3 Z530 20GY/BK
C300 (LHD) - BLACK (BODY SIDE)

CAV CIRCUIT
1 G75 20VT
2 Z821 12BK/BR
3 X201 18DG (HIGHLINE AUDIO EXCEPT EXPORT)
3 X201 20DG (HIGHLINE AUDIO EXPORT)
3 X53 20DG (LOWLINE AUDIO)
4 X291 18DG/BR (HIGHLINE AUDIO EXCEPT EXPORT)
4 X291 20DG/BR (HIGHLINE AUDIO EXPORT)
4 X55 20DG/BR (LOWLINE AUDIO)
5 G161 20VT/DG
6 P1 20TN/LG
7 P3 20TN/WT
8 F302 18GY/PK (EXCEPT POWER WINDOWS)
8 F304 12WT/PK (POWER WINDOWS)
9 Q16 12OR/TN (POWER WINDOWS)
10 Q26 14OR/GY (POWER WINDOWS)
11 Q13 16OR/DB (POWER WINDOWS)
12 Q23 16OR/LB (POWER WINDOWS)
13 Q14 16OR/BR
14 Q24 16OR/DG (POWER WINDOWS)
C300 (LHD) - BLACK (LEFT DOOR SIDE)

CAV CIRCUIT
1 G75 20VT
2 Z75 20BK/VT (BASE)
2 Z821 12BK/BR (EXCEPT BASE)
3 X53 20DG
4 X55 20DG/BR
5 G161 20VT/DG (POWER LOCKS)
6 P1 20TN/LG (POWER LOCKS)
7 P3 20TN/WT (POWER LOCKS)
10 Q26 14OR/GY (POWER WINDOWS EXCEPT MEMORY)
10 Q26 12OR/GY (POWER WINDOWS MEMORY)
13 Q14 16OR/BR (POWER WINDOWS)
C300 (RHD) - BLACK (BODY SIDE)

CAV CIRCUIT
1 G75 20VT
2 Z822 20BK/BR
3 X53 20DG
4 X55 20DG/BR
5 G161 20VT/DG
6 P1 20TN/LG
7 P3 20TN/WT
8 F304 12WT/PK
C300 (RHD) - BLACK (LEFT DOOR SIDE)

CAV CIRCUIT
1 G75 20VT
2 Z822 20BK/BR
3 X53 20DG
4 X55 20DG/BR
5 G161 20VT/DG
6 P1 20TN/LG
7 P3 20TN/WT
8 F304 12WT/PK
C301 (LUXURY/EXPORT) - LT. GRAY (BODY SIDE)

CAV CIRCUIT
1 M21 20YL/BR
2 -
3 G200 20VT/BR (MEMORY)
4 G920 20VT/YL (MEMORY)
5 -
6 G163 20VT/LB (EXPORT)
C301 (LUXURY/EXPORT) - LT. GRAY (LEFT DOOR SIDE)

CAV CIRCUIT
1 M21 20YL/BR
2 -
3 G200 20VT/BR (MEMORY EXCEPT EXPORT)
3 G200 22VT/BR (MEMORY EXPORT)
4 G920 20VT/YL (MEMORY EXCEPT EXPORT)
4 G920 22VT/YL (MEMORY EXPORT)
5 -
6 G163 20VT/LB (EXPORT)
C302 (EXPORT) - LT. GRAY (BODY SIDE)

CAV CIRCUIT
1 M21 20YL/BR
2 -
3 G200 22VT/BR (MEMORY)
4 G920 22VT/YL (MEMORY)
5 -
6 G162 20VT/WT
C302 (EXPORT) - LT. GRAY (RIGHT DOOR

SIDE)
CAV CIRCUIT
1 M21 20YL/BR
2 -
3 G200 20VT/BR
4 G920 20VT/YL
5 -
6 G162 20VT/WT
C302 (LUXURY/EXCEPT EXPORT) - LT. GRAY

(BODY SIDE)
CAV CIRCUIT
1 M21 16YL/BR
2 -
C302 (LUXURY/EXCEPT EXPORT) - LT. GRAY

(RIGHT DOOR SIDE)
CAV CIRCUIT
1 M21 14YL/BR
2 -
C303 (LHD) - BLACK (BODY SIDE)

CAV CIRCUIT
1 G74 20VT/WT
2 Z822 20BK/BR
3 X202 20GY (HIGHLINE AUDIO EXPORT)
3 X202 18GY (HIGHLINE AUDIO EXCEPT EXPORT)
3 X54 20GY (LOWLINE AUDIO)
4 X292 18GY/BR (HIGHLINE AUDIO EXCEPT EXPORT)
4 X292 20GY/BR (HIGHLINE AUDIO EXPORT)
5 G160 20VT/LG
6 P2 20TN/GY
7 P4 20TN/BR
8 F304 18GY/PK (EXCEPT POWER WINDOWS)
C303 (LHD) - BLACK (RIGHT DOOR SIDE)

CAV CIRCUIT
1 G74 20VT/WT
2 Z74 20BK/WT (BASE)
2 Z822 20BK/BR (EXCEPT BASE)
3 X54 20GY
4 X56 20GY/BR
5 G160 20VT/LG (POWER LOCKS)
6 P2 20TN/GY (POWER LOCKS)
7 P4 20TN/BR (POWER LOCKS)
8 F304 16WT/PK (EXCEPT POWER WINDOWS)
C303 (RHD) - BLACK (BODY SIDE)

CAV CIRCUIT
1 G74 20VT/WT
2 Z821 12BK/BR
3 X202 20GY
4 X292 20GY/BR
5 G160 20VT/LG
6 P2 20TN/GY
7 P4 20TN/BR
8 F304 12WT/PK
C303 (RHD) - BLACK (RIGHT DOOR SIDE)

CAV CIRCUIT
1 G74 20VT/WT
2 Z821 12BK/BR
3 X54 20GY
4 X56 20GY/BR
5 G160 20VT/LG
6 P2 20TN/GY
7 P4 20TN/BR
8 F304 12WT/PK
C304 (LHD) - YELLOW (BODY SIDE)

CAV CIRCUIT
1 R53 20LG/YL
2 R55 20LG/DG
3 -
4 -
C304 (LHD) - YELLOW (SEAT SIDE)

CAV CIRCUIT
1 R53 18LG/YL
2 R55 18LG/DG
3 -
4 -

CAV CIRCUIT
1 Z849 12BK/OR (POWER SEAT)
2 R57 20LG/GY
3 R59 20LG/TN
5 A210 14OR/RD (HEATED SEATS)
6 F503 20WT/PK (HEATED SEATS)
7 A110 12OR/RD (POWER SEAT)
8 -
9 -
10 -
11 -
12 -
13 -
C305 - GRAY (SEAT SIDE)

CAV CIRCUIT
2 R57 18LG/GY
3 R59 18LG/TN
4 P7 20LG/DG (HEATED SEAT)
5 A210 14OR/RD (HEATED SEAT)
6 F503 20WT/PK (HEATED SEAT)
7 A110 12OR/RD (POWER SEAT)
8 -
9 -
10 -
11 -
12 -
13 -
C306 (RHD) - YELLOW (BODY SIDE)

CAV CIRCUIT
1 R53 20LG/YL
2 R55 20LG/DG
3 -
4 -
C306 (RHD) - YELLOW (SEAT SIDE)

CAV CIRCUIT
1 R53 18LG/YL
2 R55 18LG/DG
3 -
4 -
C307 - YELLOW (BODY SIDE)

CAV CIRCUIT
1 Z848 12BK/OR POWER SEAT)
2 P8 22LG/WT (HEATED SEAT)
3 F201 20PK/OR (EXCEPT EXPORT)
4 R54 20LB/YL
5 R56 20LB/DG
6 R986 20LG/BR (EXCEPT EXPORT)
7 D105 20WT/OR (EXCEPT EXPORT)
8 A210 16OR/RD (POWER SEAT/EXCEPT EXPORT)
8 A210 14OR/RD (POWER SEAT/EXPORT)
9 -
10 D25 20WT/VT (EXCEPT EXPORT)
11 Z104 18BK/LG (EXCEPT EXPORT)
12 -
13 -
14 R86 20LG/LB (EXCEPT EXPORT)
16 -
C307 - YELLOW (SEAT SIDE)

CAV CIRCUIT
2 P8 20LG/DG (HEATED SEAT)
3 F201 20PK/OR (OCCUPANT SENSING/EXCEPT EXPORT)
4 R54 18LB/YL
5 R56 18LB/DG
6 R986 20LG/BR (OCCUPANT SENSING/EXCEPT EXPORT)
7 D105 20LG/LB (OCCUPANT SENSING/EXCEPT EXPORT)
8 A210 14OR/RD
9 R60 16LB/TN
10 D25 20WT/VT (OCCUPANT SENSING/EXCEPT EXPORT)
11 Z104 20BK/LG (OCCUPANT SENSING/EXCEPT EXPORT)
12 -
13 -
14 R86 20LG/LB (OCCUPANT SENSING/EXCEPT EXPORT)
16 R58 16LB/GY
C308 (EXCEPT SIDE AIRBAG) - GREEN (BODY SIDE)

CAV CIRCUIT
1 Z77 22BK/GY (MANUAL SLIDING DOOR)
1 Z825 14BK/WT (POWER SLIDING DOOR)
2 P32 20TN/VT
3 G77 22VT/GY
4 P5 20TN/OR
5 G151 22VT/BR (POWER SLIDING DOOR)
6 D25 20WT/VT (MEMORY)
6 D25 20WT/VT (POWER SLIDING DOOR)
7 -
8 A113 12WT/RD (POWER SLIDING DOOR)
C308 (EXCEPT SIDE AIRBAG) - GREEN (LEFT DOOR WIRE TRACK

ASSEMBLY SIDE)
CAV CIRCUIT
1 Z76 20BK (MANUAL SLIDING DOOR)
1 Z824 14BK (POWER SLIDING DOOR)
2 P34 20BK/DB
3 G77 20BK/DG
4 P38 20BK/DB
5 G151 20BK/GY (POWER SLIDING DOOR)
6 D25 20BK/VT (MEMORY)
6 D25 20BK/VT (POWER SLIDING DOOR)
7 -
8 A113 14BK/RD (POWER SLIDING DOOR)
C308 (SIDE AIRBAG) - BLUE (BODY SIDE)

CAV CIRCUIT
1 Z77 22BK/GY (MANUAL SLIDING
DOOR)
1 Z825 14BK/ WT (POWER SLIDING
DOOR)
2 P32 20TN/VT
3 G77 22VT/GY
4 P5 20TN/OR
5 R17 20LG
6 A113 12WT/RD (POWER SLIDING
DOOR)
7 G151 22VT/BR (POWER SLIDING
DOOR)
8 D25 20WT/VT (MEMORY)
8 D25 20WT/VT (POWER SLIDING
DOOR)
9 -
10 R19 20LG/WT
C308 (SIDE AIRBAG) - BLUE (LEFT DOOR WIRE

TRACK ASSEMBLY SIDE)
CAV CIRCUIT
2 P34 20BK/TN
3 G77 20BK/DG
4 P38 20BK/DB
5 R17 18LG
6 A113 14BK/RD (POWER SLIDING
DOOR)
7 G151 20BK/GY (POWER SLIDING
DOOR)
8 D25 20BK/VT (MEMORY)
9 -
10 R19 18LG/WT
C309 (EXCEPT SIDE AIRBAG) - GRAY (BODY

SIDE)
CAV CIRCUIT
1 Z76 22BK/YL (MANUAL SLIDING
DOOR)
1 Z824 14BK/WT (POWER SLIDING
DOOR)
2 P34 20TN/LB
3 G76 20VT/YL
4 P38 20TN/DB
5 G152 22VT/GY (POWER SLIDING
DOOR)
6 D25 20WT/VT (HIGHLINE AUDIO
POWER SLIDING DOOR)
DOOR)
7 -
DOOR)
C309 (EXCEPT SIDE AIRBAG) - GRAY (RIGHT

DOOR WIRE TRACK ASSEMBLY SIDE)
CAV CIRCUIT
2 P34 20BK/TN
3 G76 20BK/DG
4 P38 20BK/DB
DOOR)
7 -
DOOR)
C309 (SIDE AIRBAG) - GREEN (BODY SIDE)

CAV CIRCUIT
1 Z76 22BK/YL (MANUAL SLIDING
DOOR)
1 Z824 14BK/WT (POWER SLIDING
DOOR)
2 P34 20TN/LB
3 G76 20VT/YL
4 P38 20TN/DB
5 R18 20LB
DOOR)
7 G152 22VT/GY (POWER SLIDING
DOOR)
8 D25 20WT/VT (HIGHLINE AUDIO
POWER SLIDING DOOR)
DOOR)
10 R20 20WT/LG
C309 (SIDE AIRBAG) - GREEN (RIGHT DOOR

WIRE TRACK ASSEMBLY SIDE)
CAV CIRCUIT
2 P34 20BK/TN
3 G76 20BK/DG
4 P38 20BK/DB
5 R18 18LB
DOOR)
DOOR)
9 -
10 R20 18WT/LG
C310 (FRONT CONSOLE) - BLACK (BODY SIDE)

CAV CIRCUIT
1 Z746 18BK/DB
2 M27 20YL/LB
3 A105 18DB/RD
C310 (FRONT CONSOLE) - BLACK (FRONT CON-

SOLE SIDE)
CAV CIRCUIT
1 Z746 16BK
1 Z746 16BK
2 M27 18OR
3 A105 16RD
C311 (3 ZONE HVAC/EXCEPT SIDE AIRBAG) -

GRAY (BODY SIDE)
CAV CIRCUIT
1 C153 12DB/BR (MTC)
2 F504 20GY/PK (ATC)
2 F850 20LB/PK (MTC)
3 D22 20WT/TN (ATC)
3 C121 20DB/DG (MTC)
4 D17 20WT/DG (ATC)
4 C22 20LB/WT (MTC)
5 C151 18LB/DG (MTC)
6 -
7 C152 16LB/LG (MTC)
8 E10 20OR/DG
9 Z27 18BK/DG (ATC)
9 Z409 20BK/OR (MTC)
10 C50 12DB/OR (MTC)
C311 (3 ZONE HVAC/EXCEPT SIDE AIRBAG) -

GRAY (REAR A/C JUMPER SIDE)
CAV CIRCUIT
1 C153 12 DB/BR (MTC)
3 D22 22WT/TN (ATC)
4 D17 22WT/DG (ATC)
4 C22 20LB/DB (MTC)
6 -
8 E10 20OR/DG
9 Z27 18BK/DG (ATC)
C311 (3 ZONE HVAC/SIDE AIRBAG) - GRAY

(BODY SIDE)
CAV CIRCUIT
3 D22 20WT/TN (ATC)
4 D17 20WT/DG (ATC)
4 C22 20LB/WT (MTC)
6 -
8 E10 20OR/DG
9 Z27 18BK/DG (ATC)
C311 (3 ZONE HVAC/SIDE AIRBAG) - GRAY

(REAR A/C JUMPER SIDE)
CAV CIRCUIT
3 D22 22WT/TN (ATC)
4 D17 22WT/DG (ATC)
4 C22 20LB/DB (MTC)
6 -
8 E10 20OR/DG
9 Z27 18BK/DG (ATC)
C312 (EXCEPT SIDE AIRBAG) - GRAY (BODY SIDE)

CAV CIRCUIT
1 M27 20YL/LB
1 M27 20YL/LB (FRONT CONSOLE)
2 M22 20YL/OR
3 G23 22VT/DB (POWER SLIDING DOOR)
4 G25 22VT/TN (HIGHLINE)
5 D25 20WT/VT (DRIVER SIDE POWER SLIDING DOOR/EX-
CEPT EXPORT)
5 D25 20WT/VT (HIGHLINE)
6 A114 18GY/RD (HIGHLINE)
7 F503 20WT/PK (HIGHLINE)
8 X777 20DG/GY (REAR PARK ASSIST)
9 P112 22TN/OR (LUXURY)
10 P114 22TN/WT (LUXURY)
11 M21 20YL/BR
12 Z837 20BK/WT
12 Z113 20BK/WT (HIGHLINE)
13 Z13 20BK/WT
14 Z113 20BK/WT (HIGHLINE)
15 Q3 20OR/TN (SUNROOF)
16 Q4 20OR/YL (SUNROOF)
17 Q5 20OR/LB (SUNROOF)
18 Z171 20BK/GY (REAR PARK ASSIST)
19 D777 20WT/GY (REAR PARK ASSIST)
20 -
C312 (EXCEPT SIDE AIRBAG) - GRAY (HEADLINER SIDE)

CAV CIRCUIT
1 M27 20YL/LB
1 M27 20YL/LB (EXCEPT BASE)
2 M22 20YL/OR
3 G23 22VT/DB
3 G23 20VT/DB (EXCEPT BASE)
4 G25 22VT/TN
4 G25 20VT/TN (EXCEPT BASE)
5 D25 20WT/VT (EXCEPT BASE)
6 A114 20GY/RD (EXCEPT BASE)
7 F503 20BK/PK
7 F503 20WT/PK (EXCEPT BASE)
9 P112 22BK/OR (LUXURY)
10 P114 22BK/LB (LUXURY)
11 M21 20YL/BR
12 Z837 20BK/OR
12 Z327 20BK/OR
12 Z137 20BK/LB (EXCEPT BASE)
13 Z13 20BK/WT (EXCEPT BASE)
14 Z113 20BK/DB (EXCEPT BASE)
14 Z113 20BK/WT (EXPORT)
14 Z113 20BK (LUXURY)
15 Q3 20OR/TN
16 Q4 20OR/YL
17 Q5 20OR/LB
20 -
C312 (SIDE AIRBAG) - (BODY SIDE)

CAV CIRCUIT
1 M27 20YL/LB
1 M27 20YL/LB (FRONT CONSOLE)
2 M22 20YL/OR
3 G23 22VT/DB (POWER SLIDING DOOR)
4 G25 22VT/TN (HIGHLINE)
5 D25 20WT/VT (DRIVER SIDE POWER
SLIDING DOOR/EXCEPT EXPORT)
5 D25 20WT/VT (HIGHLINE)
6 A114 18GY/RD (HIGHLINE)
7 F503 20WT/PK (HIGHLINE)
9 P112 22TN/OR (LUXURY)
10 P114 22TN/WT (LUXURY)
11 M21 20YL/BR
12 Z837 20BK/WT
13 Z13 20BK/WT
C312 (SIDE AIRBAG) - (HEADLINER SIDE)

CAV CIRCUIT
1 M27 20YL/LB
1 M27 20YL/LB (EXCEPT BASE)
2 M22 20YL/OR
3 G23 20VT/DB (EXCEPT BASE)
3 G23 22VT/DB (PREMIUM/LUXURY)
4 G25 20VT/TN (EXCEPT BASE)
4 G25 22VT/TN (PREMIUM/LUXURY)
5 D25 20WT/VT (EXCEPT BASE)
6 A114 20GY/RD (EXCEPT BASE)
7 F503 20WT/PK (EXCEPT BASE)
7 F503 20BK/PK (PREMIUM/LUXURY)
9 P112 22BK/OR (LUXURY)
10 P114 22BK/LB (LUXURY)
11 M21 20YL/BR
12 Z837 20BK/OR (EXCEPT BASE/EXCEPT
EXPORT)
12 Z327 20BK/OR (EXCEPT BASE/EXCEPT
EXPORT)
12 Z137 20BK/LB (EXPORT/BASE)
14 Z113 20BK/DB (EXCEPT BASE)
14 Z113 20BK/WT (EXPORT)
14 Z113 20BK (LUXURY)
C313 (REAR CONSOLE) - BLACK (BODY SIDE)

CAV CIRCUIT
1 Z747 18BK/LB
2 F307 18LB/PK
3 F307 18LB/PK
C313 (REAR CONSOLE) - BLACK (REAR CON-

SOLE SIDE)
CAV CIRCUIT
1 Z747 16BK
1 Z747 16BK
2 F307 18OR
3 F307 16RD

CAV CIRCUIT
1 C15 12DB/WT (EXCEPT POWER LIFT-
GATE/EXCEPT EXPORT)
1 G32 20VT/LB (POWER LIFTGATE)
2 L77 18WT/BR
3 L50 18WT/TN
4 P30 20TN/DG
5 P31 20TN/YL (POWER RELEASE)
6 G78 20VT/OR (EXCEPT POWER LIFT-
GATE)
6 Q60 22OR/YL (POWER LIFTGATE)
7 M11 20YL/VT (EXCEPT POWER LIFT-
GATE/EXCEPT EXPORT)
7 Q84 18TN/GY (POWER LIFTGATE)
8 W13 18BR/LG (EXCEPT POWER LIFT-
GATE)
8 Z87 20BK/LG (POWER LIFTGATE)
9 F302 18GY/PK (EXCEPT POWER LIFT-
GATE/EXCEPT EXPORT)
9 Q83 18OR/GY (POWER LIFTGATE)
10 Z800 12BK
C314 - BLACK (LIFTGATE SIDE)

CAV CIRCUIT
1 C15 12DB/WT (EXCEPT POWER LIFT-
GATE)
1 G32 20VT/LB (POWER LIFTGATE)
2 L77 18WT/BR
3 L50 18WT/TN
4 P30 20TN/DG
5 P31 20TN/YL (POWER RELEASE)
6 G78 20VT/OR (EXCEPT POWER LIFT-
GATE)
6 Q60 20OR/YL (POWER LIFTGATE)
7 M11 20YL/VT (EXCEPT POWER LIFT-
GATE)
7 Q84 18TN/GY (POWER LIFTGATE)
8 W13 18BR/LG (EXCEPT POWER LIFT-
GATE)
8 Z87 20BK/LG (POWER LIFTGATE)
9 F302 18GY/PK (EXCEPT POWER LIFT-
GATE)
9 Q83 18OR/GY (POWER LIFTGATE)
10 Z800 12BK
C315 (POWER LIFTGATE) - BLACK (BODY SIDE)

CAV CIRCUIT
1 C15 12DB/WT
2 Q76 22OR/LB
3 G78 20VT/OR
4 M11 20YL/VT
5 -
6 Q85 18TN/WT
7 Q94 22TN/LG
8 W13 18BR/LG
9 F302 18GY/PK
10 -
C315 (POWER LIFTGATE) - BLACK (LIFTGATE

SIDE)
CAV CIRCUIT
1 C15 12DB/WT
2 Q76 20OR/LB
3 G78 20VT/OR
4 M11 20YL/VT
5 -
6 Q85 18TN/WT
7 Q94 20TN/LG
8 W13 18BR/LG
9 F302 18GY/PK
10 -
C316 (POWER SLIDING DOOR) - BLACK (LEFT

CAV CIRCUIT
1 P5 20BK/DB
2 P32 20BK/TN
3 G77 20BK/DG
4 Z825 14BK
5 -
6 -
7 G151 20BK/GY
8 D25 20WT/VT
9 -
10 A113 14BK/RD
C316 (POWER SLIDING DOOR) - BLACK (LEFT

SLIDING DOOR SIDE)
CAV CIRCUIT
1 P5 20TN/OR
2 P32 20TN/VT
3 G77 20TN/OR
4 Z825 14BK/WT
5 -
6 -
7 G151 20VT/BR
8 D25 20WT/VT
9 -
10 A113 14WT/RD
C317 (POWER SLIDING DOOR) - BLACK (RIGHT

CAV CIRCUIT
1 P38 20BK/DB
2 P34 20BK/TN
3 G76 20BK/DG
4 Z824 14BK
5 -
6 -
7 G152 20BK/GY
8 D25 20WT/VT
9 -
10 A113 14BK/RD
C317 (POWER SLIDING DOOR) - BLACK (RIGHT

SLIDING DOOR SIDE)
CAV CIRCUIT
1 P38 20TN/DB
2 P34 20TN/LB
3 G76 20TN/OR
4 Z824 14BK/WT
5 -
6 -
7 G152 20VT/GY
8 D25 20WT/VT
9 -
10 A113 14WT/RD
C318 (TRAILER TOW) - BLACK (BODY SIDE)

CAV CIRCUIT
1 L63 18WT/DG
2 -
3 L77 18WT/BR
4 L1 18WT/LG
5 Z363 18BK/DG
6 -
C318 (TRAILER TOW) - BLACK (LEFT HARNESS

SIDE)
CAV CIRCUIT
1 L63 18WT/DG
1 L63 18YL
2 -
3 L77 18BR
3 L77 18WT/BR
4 L1 18WT/BR
5 Z363 18BK/DG
6 -
C319 (TRAILER TOW) - BLACK (BODY SIDE)

CAV CIRCUIT
1 L62 18WT/BR
2 -
3 L78 18WT/TN
4 L1 18WT/LG
5 Z362 18BK/BR
6 -
C319 (TRAILER TOW) - BLACK (RIGHT HAR-

NESS SIDE)
CAV CIRCUIT
1 L62 18LG
1 L62 18WT/BR
2 -
3 L78 18WT/TN
4 L1 18WT/PK
5 Z362 18WT
5 Z362 18BR/OR
6 -
C320 - DK. GRAY (POWER SEAT SIDE)

CAV CIRCUIT
1 Z849 14BK/OR
2 A210 14OR/RD
C320 - DK. GRAY (SEAT SIDE)

CAV CIRCUIT
1 Z849 14BK/OR
2 A210 14OR/RD
C321 - DK. GRAY (SEAT SIDE)

CAV CIRCUIT
1 Z848 18BK/OR
2 A210 14OR/RD
C321 - DK. GRAY (POWER SEAT SIDE)

CAV CIRCUIT
1 Z848 14BK/OR
2 A210 14OR/RD
C322 (MEMORY) - BLACK (BODY SIDE)

CAV CIRCUIT
1 P69 22TN/DB (LHD)
1 P66 22TN/LG (RHD)
2 -
3 P64 22TN (LHD)
3 P67 22TN/OR (RHD)
4 -
5 -
6 P65 22TN/VT (LHD)
6 P68 22TN/YL (RHD)
7 D25 20WT/VT
8 P73 20TN/YL (LHD)
8 P70 20TN/LB (RHD)
9 P75 20TN/LG (LHD)
9 P74 20TN/DB (RHD)
10 P71 20TN/DG (LHD)
10 P72 20TN/GY (RHD)
11 -
12 -
13 -
14 -
C322 (MEMORY) - BLACK (POWER SEAT SIDE)

CAV CIRCUIT
1 P69 22TN/WT (LHD)
1 P66 22WT (RHD)
2 -
3 P64 22TN/OR (LHD)
3 P67 22OR (RHD)
4 -
5 -
6 P65 22TN/YL (LHD)
6 P68 22YL (RHD)
7 D25 20WT/VT
8 P73 18TN/LB (LHD)
8 P70 18LB (RHD)
9 P75 18DB (LHD)
9 P74 18TN/DB (RHD)
10 P71 18TN/GY (LHD)
10 P72 18GY (RHD)
11 -
12 -
13 -
14 -
C324 (MANUAL SLIDING DOOR) - BLACK (LEFT

CAV CIRCUIT
1 P38 20BK/DB
2 P34 20BK/TN
3 G76 20BK/DG
4 Z76 20BK
C324 (MANUAL SLIDING DOOR) - BLACK (LEFT

MANUAL SLIDING DOOR SIDE)
CAV CIRCUIT
1 P5 20BK/DB
2 P32 20BK/TN
3 G77 20BK/DG
4 Z77 20BK
C325 (MANUAL SLIDING DOOR) - BLACK

(RIGHT DOOR WIRE TRACK ASSEMBLY SIDE)
CAV CIRCUIT
1 P38 20BK/DB
2 P34 20BK/TN
3 G76 20BK/DG
4 Z76 20BK
C325 (MANUAL SLIDING DOOR) - BLACK

(RIGHT MANUAL SLIDING DOOR SIDE)
CAV CIRCUIT
1 P38 20BK/DB
2 P34 20BK/TN
3 G76 20BK/DG
4 Z76 20BK
C328 (SUNROOF) - (BODY SIDE)

CAV CIRCUIT
1 Q3 20OR/TN
2 Q5 20OR/LB
3 Q4 20OR/YL
4 F302 18GY/PK
5 A115 12YL/RD
6 Z138 12BK/DB
7 -
C328 (SUNROOF) - (SUNROOF SIDE)

CAV CIRCUIT
1 Q3 20OR/TN
2 Q5 20OR/LB
3 Q4 20OR/YL
4 F302 18GY/PK
5 A115 14YL/RD
6 Z138 14BK/DB
7 -
C329 (DIESEL) - BLACK (BODY SIDE)

CAV CIRCUIT
1 N2 18DB/YL
2 Z201 18BK/OR
3 N1 16DB/OR
4 Z201 18BK/OR
5 F853 20LG/PK
6 K900 18DB/DG
C329 (DIESEL) - BLACK (LIFT PUMP SIDE)

CAV CIRCUIT
1 N2 18OR
2 Z201 18OR
3 N1 16RD
4 Z201 18RD
5 F853 20RD
6 K900 18RD
C330 (DIESEL) - LT. GRAY (CABIN HEATER

JUMPER SIDE)
CAV CIRCUIT
1 A119 16RD/OR
2 C41 20LB/DG
3 D21 20WT
4 Z149 16BK/DB
C330 (DIESEL) - LT. GRAY (POWERTRAIN SIDE)

CAV CIRCUIT
1 A119 16RD/OR
2 C41 20LB/DG
3 D21 20WT/DG
4 Z149 16BK/DB
C331 (DIESEL) - BLACK (CABIN HEATER COM-

PONENT SIDE)
CAV CIRCUIT
1 A119 14RD/OR
2 C41 20DB/OR
3 D21 20WT/DB
4 Z149 14BK/DB
C331 (DIESEL) - BLACK (CABIN HEATER

JUMPER SIDE)
CAV CIRCUIT
1 A119 16RD/OR
2 C41 20LB/DG
3 D21 20WT
4 Z149 16BK/DB
C332 (3 ZONE ATC) - BLACK (COMPONENT

SIDE)
CAV CIRCUIT
1 C53 18LB
2 C169 18LB/TN
3 C51 12DB/BR
4 C59 18DB/LB
5 -
6 Z135 12BK/LB
7 C54 18LB/YL
8 C154 18LB/GY
9 -
10 -
C332 (3 ZONE ATC) - LT. GREEN (BODY SIDE)

CAV CIRCUIT
1 C53 20LB
2 C169 20DB/OR
3 C51 12LB/BR
4 C59 20DB/LB
5 -
6 Z135 12BK/LB
7 C54 20LB/YL
8 C154 20LB/OR
9 -
10 -
C333 (EXCEPT EXPORT/EXCEPT MEMORY) -

(ASSEMBLY SIDE)
CAV CIRCUIT
1 -
2 -
3 -
4 -
5 -
6 -
7 Q102 18OR/LB
8 Q103 18OR/LG
C333 (EXCEPT EXPORT/EXCEPT MEMORY) -

DK. GRAY (BODY SIDE)
CAV CIRCUIT
1 -
2 -
3 -
4 -
5 -
6 -
7 Q102 18OR/LB
8 Q103 18OR/LG

CAV CIRCUIT
1 D700 20WT/GY
2 D701 20WT/LB
3 D703 20WT/OR
4 D704 20WT/DB
5 X700 20GY/LB
6 X750 20GY/LB
C334 - BLACK (REAR FASCIA SIDE)

CAV CIRCUIT
1 D700 20WT/GY
2 D701 20WT/LB
3 D703 20WT/OR
4 D704 20WT/DB
5 X700 20GY/LB
6 X750 20GY/LB
C335 (FOLD-IN-FLOOR) - LT. GRAY (BODY

SIDE)
CAV CIRCUIT
1 Z201 18BK/OR
2 Z201 20BK/DB
3 N4 20DB/WT
4 N1 18DB/OR
C335 (FOLD-IN-FLOOR) - LT. GRAY (FUEL

PUMP JUMPER SIDE)
CAV CIRCUIT
1 Z201 18BK/OR
2 Z201 20BK/DB
3 N4 20DB/WT
4 N1 18DB/OR
CABIN HEATER ASSIST C1 (DIESEL) - BLACK 6 WAY

1 - -
2 D21 20WT/DB SCI TRANSMIT
3 - -
4 - -
5 C41 20DB/OR CABIN HEATER ASSIST CONTROL
6 18RD DOSING PUMP CONTROL
CABIN HEATER ASSIST C2 (DIESEL) - BLACK 2 WAY

1 A119 14RD/OR FUSED B(+)
2 Z149 14BK/DB GROUND
CAMSHAFT POSITION SENSOR (DIESEL) - BLACK 3 WAY

1 K944 20BK/GY CAMSHAFT POSITION SENSOR GROUND
2 K44 20DB/GY CAMSHAFT POSITION SENSOR SIGNAL
3 K342 16BR/WT ECM/PCM RELAY OUTPUT
CAMSHAFT POSITION SENSOR (GAS) - BLACK 3 WAY

2 K900 20DB/DG SENSOR GROUND
3 K44 18DB/GY CMP SIGNAL
CD CHANGER - 8 WAY
1 X40 22GY/WT (EXCEPT EXPORT) AUDIO OUT RIGHT
1 X40 20GY/WT (EXPORT) AUDIO OUT RIGHT
2 E14 22OR/TN (EXCEPT EXPORT) PANEL LAMPS DRIVER
2 E14 18OR/TN (EXPORT) PANEL LAMPS DRIVER
3 D25 20WT/VT (EXCEPT EXPORT) PCI BUS
3 D25 20VT/YL (EXPORT) PCI BUS
4 X112 20DG/GY (EXCEPT EXPORT) IGNITION SWITCH SIGNAL
4 X112 20RD (EXPORT) IGNITION SWITCH SIGNAL
5 X41 22DG/WT (EXCEPT EXPORT) AUDIO OUT LEFT
5 X41 20DG/WT (EXPORT) AUDIO OUT LEFT
6 X140 22GY/OR (EXCEPT EXPORT) COMMON AUDIO
6 Z140 18BK/OR (EXPORT) GROUND
7 Z141 20BK/TN (EXCEPT EXPORT) GROUND
7 Z141 18BK/TN (EXPORT) GROUND
8 X160 20GY/YL FUSED B(+)
CENTER HIGH MOUNTED STOP LAMP - BLACK 2 WAY

CLOCKSPRING C1 - WHITE 6 WAY

1 X920 22GY/OR (REMOTE AUDIO) RADIO CONTROL MUX RETURN
2 X20 22GY/WT (REMOTE AUDIO) RADIO CONTROL MUX
3 X3 22DG/VT HORN SWITCH SENSE
4 V37 22VT SPEED CONTROL SWITCH SIGNAL
6 - -
CLOCKSPRING C2 - YELLOW 4 WAY

1 R61 20LG/VT (EXCEPT EXPORT) DRIVER SQUIB 2 LINE 2
1 R61 20LB/VT (EXPORT) DRIVER SQUIB 2 LINE 2
2 R63 20LG/WT DRIVER SQUIB 2 LINE 1
3 R43 20LG/BR DRIVER SQUIB 1 LINE 2
4 R45 20LG/OR DRIVER SQUIB 1 LINE 1
CLOCKSPRING C3 - BLACK 4 WAY

1 - -
2 Z23 20BK/VT LEFT SPEED CONTROL SWITCH GROUND
2 Z23 20BK/VT RIGHT SPEED CONTROL SWITCH GROUND
3 V37 20VT (DIESEL) SPEED CONTROL SWITCH SIGNAL
3 V37 20VT (DIESEL) SPEED CONTROL SWITCH SIGNAL
3 V37 20VT (GAS) S/C SWITCH NO. 1 SIGNAL
3 V37 20VT (GAS) S/C SWITCH NO. 1 SIGNAL
CLOCKSPRING C4 (REMOTE AUDIO) - 2 WAY

1 X10 20RD/DB RADIO CONTROL MUX
2 X20 20RD/BK RADIO CONTROL MUX RETURN
CLUTCH PEDAL INTERLOCK SWITCH (MTX) - BLACK 2 WAY

1 T141 20YL/OR FUSED IGNITION SWITCH OUTPUT (START)
2 T751 20YL (DIESEL) FUSED IGNITION SWITCH OUTPUT (START)
2 Z429 20BK/OR (GAS) GROUND
CLUTCH PEDAL UPSTOP SWITCH (DIESEL) - RED 2 WAY

1 K119 20DB/LG CLUTCH PEDAL UPSTOP SWITCH SENSE
CONTROLLER ANTILOCK BRAKE - BLACK 24 WAY

1 Z107 12BK/DG GROUND
2 B1 18DG/OR RIGHT REAR WHEEL SPEED SENSOR SIGNAL
3 B2 18DG/LB RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUP-
PLY
4 - -
6 B6 18DG/WT RIGHT FRONT WHEEL SPEED SENSOR SIGNAL
7 B7 18DG/VT RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT
SUPPLY
8 - -
9 A111 12DG/RD FUSED B(+)
10 F500 18DG/PK FUSED IGNITION SWITCH OUTPUT (RUN)
11 - -
12 - -
13 - -
14 - -
15 - -
17 - -
19 B3 18DG/YL LEFT REAR WHEEL SPEED SENSOR SIGNAL
20 B4 18DG/GY LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUP-
PLY
21 - -
22 B8 18DG/TN LEFT FRONT WHEEL SPEED SENSOR SIGNAL
23 B9 18DG/WT (3.3L/3.8L) LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUP-
PLY
23 B9 18DG/LG (EXCEPT 3.3L/3.8L) LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUP-
PLY
24 A107 12TN/RD FUSED B(+)
CRANK CASE VENTILATION HEATER (DIESEL) - BLACK 2 WAY

2 N1 18DB/OR FUEL HEATER RELAY OUTPUT
CRANKSHAFT POSITION SENSOR (DIESEL) - 2 WAY

1 K3 20BR/OR CRANKSHAFT POSITION SENSOR SIGNAL NO. 1
2 K24 20BR/LB CRANKSHAFT POSITION SENSOR SIGNAL NO. 2
CRANKSHAFT POSITION SENSOR (GAS) - BLACK 3 WAY

3 K24 18BR/LB CKP SIGNAL
DATA LINK CONNECTOR - BLACK 16 WAY

1 - -
3 - -
6 - -
7 D21 20WT/DG (DIESEL) SCI TRANSMIT (ECM)
7 D21 20WT/DG (GAS) SCI TRANSMIT (PCM)
8 - -
10 - -
11 - -
12 D20 20WT/LG (GAS) SCI RECEIVE (PCM)
13 - -
14 - -
15 D15 20DG/YL (EATX) SCI TRANSMIT (TCM)
16 A105 20DB/RD FUSED B(+)
DOSING PUMP (DIESEL) - BLACK 2 WAY

1 18RD DOSING PUMP CONTROL
DRIVER AIRBAG SQUIB 1 - BROWN/YELLOW 2 WAY

1 R43 20OR/LB DRIVER SQUIB 1 LINE 2
2 R45 20TN/LB DRIVER SQUIB 1 LINE 1
DRIVER AIRBAG SQUIB 2 - BLACK/YELLOW 2 WAY

1 R61 20LG/VT DRIVER SQUIB 2 LINE 2
2 R63 20OR/LB DRIVER SQUIB 2 LINE 1
DRIVER BLEND DOOR ACTUATOR - GRAY 2 WAY

1 C61 20DB/LG (ATC) DRIVER BLEND DOOR DRIVER (A)
1 C61 20LB/WT (LHD) DRIVER BLEND DOOR DRIVER (A)
1 C34 20DB/LB (RHD) COMMON DOOR DRIVER (B)
2 C161 20LB/WT (ATC) DRIVER BLEND DOOR DRIVER (B)
2 C34 20DB/LB (LHD) COMMON DOOR DRIVER (B)
2 C61 20LB/WT (RHD) DRIVER BLEND DOOR DRIVER (A)
DRIVER DOOR COURTESY LAMP (LUXURY/EXPORT) - GRAY 3 WAY

1 Z321 20BK/BR (LHD) GROUND
1 Z322 20BK/BR (RHD) GROUND
2 - -
DRIVER DOOR LOCK SWITCH - BLACK 3 WAY

1 - -
2 G161 20VT/DG (LHD) LEFT DOOR LOCK SWITCH MUX
2 G160 20VT/LG (RHD) RIGHT DOOR LOCK SWITCH MUX
3 Z461 20BK/DG (LHD) GROUND
3 Z460 20BK/LG (RHD) GROUND
DRIVER HEATED SEAT BACK - LT. GREEN 2 WAY

A S1 18DB (LHD) SEAT BACK HEATER B(+) DRIVER
A S1 18RD (RHD) SEAT BACK HEATER B(+) DRIVER
B S2 18DG (LHD) SEAT BACK HEATER GROUND
B S2 18BK (RHD) SEAT BACK HEATER GROUND
DRIVER HEATED SEAT CUSHION - BLACK 4 WAY

1 P87 16RD SEAT TEMP SENSOR INPUT
2 P89 20GR SEAT SENSOR 5 VOLT SUPPLY
4 P88 16GR SEAT CUSHION HEATER B(+) DRIVER
DRIVER HEATED SEAT MODULE C1 - GRAY 4 WAY

2 P7 20LG/DG DRIVER SEAT HEATER MUX SWITCH
3 F503 20WT/PK FUSED IGNITION SWITCH OUTPUT (RUN)
4 A210 14OR/RD FUSED B(+)
DRIVER HEATED SEAT MODULE C2 - GRAY 2 WAY

1 S1 18DB (LHD) SEAT BACK HEATER B(+) DRIVER
1 S1 18RD (RHD) SEAT BACK HEATER B(+) DRIVER
2 S2 18DG (LHD) SEAT BACK HEATER GROUND
2 S2 18BK (RHD) SEAT BACK HEATER GROUND
DRIVER HEATED SEAT MODULE C3 - GREEN 4 WAY

1 P87 16RD SEAT TEMP SENSOR INPUT
2 P89 20GR SEAT SENSOR 5 VOLT SUPPLY
4 P88 16GR SEAT CUSHION HEATER B(+) DRIVER
DRIVER KNEE BLOCKER AIRBAG SQUIB (LHD) - YELLOW 4 WAY

1 -
2 -
3 R9 20LB/YL DRIVER KNEE BLOCKER SQUIB LINE 1
4 R11 20LB/DB DRIVER KNEE BLOCKER SQUIB LINE 2
DRIVER POWER SEAT FRONT RISER MOTOR - RED 2 WAY

1 P19 14LG/LB (EXCEPT MEMORY) DRIVER FRONT UP SWITCH SENSE
1 P121 14LG/DB (MEMORY EXCEPT SEAT FRONT DOWN DRIVER
EXPORT)
1 P119 14LG/DG (MEMORY EXPORT) SEAT FRONT UP DRIVER
2 P21 14LG/TN (EXCEPT MEMORY) DRIVER FRONT DOWN SWITCH SENSE
2 P121 14LG/DB (MEMORY EXCEPT SEAT FRONT DOWN DRIVER
EXPORT)
2 P119 14LG/DG (MEMORY EXPORT) SEAT FRONT UP DRIVER
DRIVER POWER SEAT FRONT RISER POSITION SENSOR - BLACK 3 WAY

A P28 20LG/BR SEAT POSITION SENSOR GROUND
B P26 20LG FRONT RISER POSITION SIGNAL
C P29 20LG/WT SEAT SENSOR 5 VOLT SUPPLY
DRIVER POWER SEAT HORIZONTAL MOTOR - BLACK 2 WAY

1 P17 14LG/DG (EXCEPT MEMORY) DRIVER SEAT HORIZONTAL REARWARD SWITCH
SENSE
1 P117 14LG/LB (MEMORY EXCEPT SEAT HORIZONTAL REARWARD DRIVER
EXPORT)
1 P115 14LG (MEMORY EXPORT) SEAT HORIZONTAL FORWARD DRIVER
2 P15 14LG/WT (EXCEPT MEMORY) DRIVER SEAT HORIZONTAL FORWARD SWITCH
SENSE
2 P115 14LG/OR (MEMORY EXCEPT SEAT HORIZONTAL FORWARD DRIVER
EXPORT)
2 P117 14LG/LB (MEMORY EXPORT) SEAT HORIZONTAL REARWARD DRIVER
DRIVER POWER SEAT HORIZONTAL POSITION SENSOR - BLACK 3 WAY

A P29 20LG/WT SEAT SENSOR 5 VOLT SUPPLY
B P25 20LG/VT SEAT HORIZONTAL POSITION SIGNAL
C P28 20LG/BR SEAT POSITION SENSOR GROUND
DRIVER POWER SEAT REAR RISER MOTOR - RED 2 WAY

1 P11 14LG/YL (EXCEPT MEMORY) DRIVER SEAT REAR UP SWITCH SENSE
1 P111 14LG/YL (MEMORY EXCEPT SEAT REAR UP DRIVER
EXPORT)
1 P113 14LG/WT (MEMORY EXPORT) SEAT REAR DOWN DRIVER
2 P13 14LG/OR (EXCEPT MEMORY) DRIVER SEAT REAR DOWN SWITCH SENSE
2 P113 14LG/VT (MEMORY EXCEPT SEAT REAR DOWN DRIVER
EXPORT)
2 P111 14LG/YL (MEMORY EXPORT) SEAT REAR UP DRIVER
DRIVER POWER SEAT REAR RISER POSITION SENSOR - BLACK 3 WAY

A P28 20LG/BR SEAT POSITION SENSOR GROUND
B P27 20LG/LB REAR RISER POSITION SIGNAL
C P29 20LG/WT SEAT SENSOR 5 VOLT SUPPLY
DRIVER POWER SEAT RECLINER MOTOR - GREEN 2 WAY

1 P41 14LG/GY (EXCEPT MEMORY) DRIVER SEAT RECLINER DOWN SWITCH SENSE
1 P141 14LG/BR (MEMORY EXCEPT SEAT RECLINER DOWN DRIVER
EXPORT)
1 P143 14LG/GY (MEMORY EXPORT) SEAT RECLINER UP DRIVER
2 P43 14LG/VT (EXCEPT MEMORY) DRIVER SEAT RECLINER UP SWITCH SENSE
2 P143 14LG/GY (MEMORY EXCEPT SEAT RECLINER UP DRIVER
EXPORT)
2 P141 14LG/BR (MEMORY EXPORT) SEAT RECLINER DOWN DRIVER
DRIVER POWER SEAT RECLINER POSITION SENSOR - BLACK 3 WAY

A P29 20LG/WT SEAT SENSOR 5 VOLT SUPPLY
B P47 20LG/LB RECLINER POSITION SIGNAL
C P28 20LG/BR SEAT POSITION SENSOR GROUND
DRIVER POWER SEAT SWITCH - GREEN 10 WAY

1 Z849 14BK/OR (EXCEPT MEMORY) GROUND
1 Z849 20BK/OR (MEMORY) GROUND
2 P43 14LG/VT (EXCEPT MEMORY) DRIVER SEAT RECLINER UP SWITCH SENSE
2 P43 14LG/VT (MEMORY) DRIVER SEAT RECLINER UP SWITCH SENSE
3 P17 14LG/DG (EXCEPT MEMORY) DRIVER SEAT HORIZONTAL REARWARD SWITCH
SENSE
3 P17 20LG/DG (MEMORY) DRIVER SEAT HORIZONTAL REARWARD SWITCH
SENSE
4 P41 14LG/GY (EXCEPT MEMORY) DRIVER SEAT RECLINER DOWN SWITCH SENSE
4 P41 14LG/GY (MEMORY) DRIVER SEAT RECLINER DOWN SWITCH SENSE
5 A210 14OR/RD (EXCEPT MEMORY) FUSED SEAT SWITCH DRIVER
5 P9 20LG/OR (MEMORY) SEAT SWITCH B(+) SUPPLY
6 P15 14LG/WT (EXCEPT MEMORY) DRIVER SEAT HORIZONTAL FORWARD SWITCH
SENSE
6 P15 20LG/WT (MEMORY) DRIVER SEAT HORIZONTAL FORWARD SWITCH
SENSE
7 P19 14LG/LB (EXCEPT MEMORY) DRIVER SEAT FRONT UP SWITCH SENSE
7 P19 20LG/LB (MEMORY) DRIVER SEAT FRONT UP SWITCH SENSE
8 P11 14LG/YL (EXCEPT MEMORY) DRIVER SEAT REAR UP SWITCH SENSE
8 P11 20LG/YL (MEMORY) DRIVER SEAT REAR UP SWITCH SENSE
9 P13 14LG/OR (EXCEPT MEMORY) DRIVER SEAT REAR DOWN SWITCH SENSE
9 P13 20LG/OR (MEMORY) DRIVER SEAT REAR DOWN SWITCH SENSE
10 P21 14LG/TN (EXCEPT MEMORY) DRIVER SEAT FRONT DOWN SWITCH SENSE
10 P21 20LG/TN (MEMORY) DRIVER SEAT FRONT DOWN SWITCH SENSE
DRIVER POWER WINDOW MOTOR - RED 2 WAY

1 Q11 16OR/LG DRIVER WINDOW SWITCH DRIVER (UP)
2 Q21 16OR/WT DRIVER WINDOW SWITCH DRIVER (DOWN)
DRIVER POWER WINDOW SWITCH (LHD EXCEPT LOWLINE) - GREEN 14 WAY

1 Q24 16OR/DG PASSENGER SIDE REAR WINDOW OPEN
2 Q16 12OR/TN MASTER WINDOW SWITCH PASSENGER (UP)
3 Q13 16OR/DB DRIVER SIDE REAR WINDOW CLOSE
4 Q26 14OR/GY (EXCEPT MEMORY) MASTER WINDOW SWITCH PASSENGER (DOWN)
4 Q26 12OR/GY (MEMORY) MASTER WINDOW SWITCH PASSENGER (DOWN)
5 Q14 16OR/BR PASSENGER SIDE REAR WINDOW CLOSE
6 Q11 16OR/LG MASTER WINDOW SWITCH DRIVER (UP)
7 Q23 16OR/LB DRIVER SIDE REAR WINDOW OPEN
8 Q21 16OR/WT MASTER WINDOW SWITCH DRIVER (DOWN)
9 F304 12WT/PK FUSED WINDOW CIRCUIT BREAKER OUTPUT
10 - -
12 - -
13 Z421 12BK/BR GROUND
DRIVER POWER WINDOW SWITCH (LHD LOWLINE) - LT. GRAY 8 WAY

4 - -
6 - -
7 - -
DRIVER POWER WINDOW SWITCH (RHD) - NATURAL 14 WAY

1 Q23 16OR/LB DRIVER SIDE REAR WINDOW OPEN
3 Q14 16OR/BR PASSENGER SIDE REAR WINDOW CLOSE
5 Q13 16OR/DB DRIVER SIDE REAR WINDOW CLOSE
7 Q24 16OR/DG PASSENGER SIDE REAR WINDOW OPEN
10 - -
12 - -
DRIVER SEAT BELT SWITCH - WHITE 2 WAY

1 R57 18LG/GY DRIVER SEAT BELT SWITCH SENSE
2 R59 18LG/TN DRIVER SEAT BELT SWITCH GROUND
DRIVER SEAT BELT TENSIONER - YELLOW 2 WAY

1 R53 18LG/YL DRIVER SEAT BELT TENSIONER LINE 2
2 R55 18LG/DG DRIVER SEAT BELT TENSIONER LINE 1
DVD SCREEN - BLACK 12 WAY

1 X114 20GY/LB IGNITION RUN/ACC SIGNAL
2 X211 20YL/GY IGNITION SWITCH SENSE
3 - -
4 - -
5 X915 22GY/LB VIDEO RETURN
6 X515 22GY/OR VIDEO SIGNAL
7 X530 20GY/DB GROUND
8 - -
9 X555 20VT/OR VIDEO PLAY SIGNAL
10 - -
11 - -
12 - -
DVD/CD CHANGER C1 - BLACK 16 WAY

1 - -
2 - -
4 - -
5 - -
6 - -
8 X40 22GY/WT AUDIO OUT RIGHT
9 Z530 20GY/BK GROUND
10 - -
11 X112 20DG/GY IGNITION SWITCH SIGNAL
13 - -
14 - -
15 X140 22GY/OR COMMON AUDIO
16 X41 22DG/WT AUDIO OUT LEFT
DVD/CD CHANGER C2 - 12 WAY

1 X114 20GY/LB IGNITION RUN/ACC SIGNAL
2 X211 20YL/GY IGNITION SWITCH SENSE
3 - -
4 - -
5 X915 22GY/LB VIDEO RETURN
6 X515 22GY/OR VIDEO SIGNAL
7 X530 20GY/DB GROUND
8 - -
9 - -
10 X555 20VT/OR VIDEO PLAY SIGNAL
11 - -
12 X955 20BK/GY SHIELD
EGR SOLENOID (3.3L) - BLACK 6 WAY

1 K34 18DB/LG EGR SOLENOID SIGNAL
2 F855 18PK/YL 5 VOLT SUPPLY
5 - -
6 K35 18DB/VT EGR SOLENOID CONTROL
EGR SOLENOID (DIESEL) - LT. GRAY 2 WAY

1 K35 20GY/YL EGR SOLENOID CONTROL
ENGINE CONTROL MODULE C1 (DIESEL) - BLACK 81 WAY

3 K20 14BR/GY GENERATOR FIELD CONTROL
6 - -
8 K944 20BK/GY CAMSHAFT POSITION SENSOR SHIELD GROUND
9 K44 20DB/GY CAMSHAFT POSITION SENSOR SIGNAL
10 - -
11 K37 20DB/YL BOOST PRESSURE SENSOR SIGNAL
12 K55 20DB/OR MASS AIR FLOW SENSOR SIGNAL
13 K78 20GY FUEL PRESSURE SENSOR SIGNAL
14 - -
15 K22 20OR/DB ACCELERATOR PEDAL POSITION SENSOR SIGNAL
NO. 1
16 K80 20DB/TN FUEL PRESSURE SENSOR GROUND
17 - -
18 - -
22 F202 20PK/GY FUSED IGNITION SWITCH OUTPUT (RUN-START)
23 F851 20LB/PK SENSOR REFERENCE VOLTAGE B
24 K3 20BR/OR CRANKSHAFT POSITION SENSOR SIGNAL NO. 1
25 - -
26 - -
27 - -
28 - -
29 - -
30 G6 20VT/GY ENGINE OIL PRESSURE SENSOR SIGNAL
31 F853 20LG/PK WATER IN FUEL SENSOR SIGNAL
32 K25 20BR/TN BATTERY TEMPERATURE SENSOR SIGNAL

33 - -
34 K4 20BK/LB SENSOR GROUND
35 F852 20VT/PK ACCELERATOR PEDAL POSITION SENSOR 5 VOLT
SUPPLY
36 C18 20LB/BR A/C PRESSURE SENSOR SIGNAL
37 - -
38 V37 20VT/TN SPEED CONTROL SWITCH SIGNAL
39 - -
40 K2 20TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
41 K21 20DB/LG INTAKE AIR TEMPERATURE SENSOR SIGNAL
42 Z122 18WT GROUND (DRAIN)
43 K24 20BR/LB CRANKSHAFT POSITION SENSOR SIGNAL NO. 2
44 - -
45 - -
46 - -
47 L50 20WT/TN PRIMARY BRAKE SWITCH SIGNAL
48 B29 20DG/WT SECONDARY BRAKE SWITCH SIGNAL
49 T751 20YL FUSED IGNITION SWITCH OUTPUT (START)
50 F855 20PK/YL SENSOR REFERENCE VOLTAGE A
51 - -
52 K121 20DB BOOST PRESSURE SENSOR GROUND
53 - -
54 K957 20BK/OR MASS AIR FLOW SENSOR GROUND
55 N7 20DB/OR VEHICLE SPEED SENSOR SIGNAL
56 C918 20BK/LB A/C PRESSURE SENSOR GROUND
57 T10 20DG/LG (EATX) TORQUE MANAGEMENT REQUEST SENSE
58 - -
59 - -
60 K9 20LB FUEL PRESSURE SENSOR 5 VOLT SUPPLY
61 K51 20BR/WT ECM/PCM RELAY CONTROL
62 - -
63 D21 20WT/DG SCI TRANSMIT (ECM)
64 K151 20WT LOW IDLE POSITION SWITCH SENSE
65 - -
66 K936 20BR/YL ENGINE OIL PRESSURE SENSOR GROUND
67 - -
68 - -
69 C13 20LB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL
70 N210 20DB/DG LOW SPEED RADIATOR FAN RELAY CONTROL
71 - -
72 N21 20DB/TN LIFT PUMP RELAY CONTROL
73 - -
74 T752 20DG/OR STARTER MOTOR RELAY CONTROL
75 - -
76 - -
77 K152 20DB/WT GLOW PLUG RELAY CONTROL
78 N122 20DB/YL HIGH SPEED RADIATOR FAN DUAL RELAY CONTROL
79 - -
80 K87 20BR FUEL PRESSURE SOLENOID CONTROL

80 - -
81 - -
82 - -
83 K24 20BR/LB (EATX) CRANKSHAFT POSITION SENSOR SIGNAL NO. 2
84 - -
85 - -
86 - -
87 - -
90 - -
91 - -
92 - -
93 - -
94 - -
95 - -
96 - -
97 - -
98 - -
99 - -
100 - -
101 - -
102 - -
103 - -
104 - -
105 - -
106 - -
107 - -
108 - -
109 - -
110 - -
111 - -
112 T41 20DG/GY (EATX) TRS T41 SENSE
112 K119 20DB/LG (MTX) CLUTCH PEDAL UPSTOP SWITCH SENSE
113 - -
114 - -
115 K14 14LB/BR FUEL INJECTOR NO. 4 CONTROL
116 K111 14DB/LB COMMON INJECTOR DRIVER
117 - -
118 K11 14WT/DB FUEL INJECTOR NO. 1 CONTROL
119 K12 14TN FUEL INJECTOR NO. 2 CONTROL
120 K13 14BR/LB FUEL INJECTOR NO. 3 CONTROL
121 - -
ENGINE COOLANT TEMP SENSOR (DIESEL) - BLUE 2 WAY

1 K2 20TN/BK ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
ENGINE COOLANT TEMP SENSOR (GAS) - BLACK 2 WAY

2 K2 18VT/OR ECT SIGNAL
ENGINE OIL PRESSURE SENSOR (DIESEL) - BLACK 3 WAY

3 K936 20BR/YL ENGINE OIL PRESSURE SENSOR GROUND
ENGINE OIL PRESSURE SWITCH (GAS) - LT. GREEN 2 WAY

1 G6 16VT/GY OIL PRESSURE SIGNAL
2 - -
EVAP/PURGE SOLENOID (GAS) - BLACK 2 WAY

1 K52 18DB/WT EVAP PURGE CONTROL
2 K70 18DB/BR EVAP PURGE RETURN
EVAPORATOR TEMPERATURE SENSOR - BLACK 2 WAY

1 C21 20DB/LG EVAPORATOR TEMPERATURE SENSOR SIGNAL
2 C121 20DB/DG SENSOR GROUND
FLOOR CONSOLE LAMP - BLACK 2 WAY

1 M27 18OR (FRONT POSITION) READING LAMPS DRIVER
1 F307 18OR (REAR POSITION/ACCES- FUSED ACCESSORY RELAY OUTPUT
SORY RELAY POSITION)
1 F307 18OR (REAR POSITION/BATTERY FUSED B(+)
POSITION)
2 Z746 16BK (FRONT POSITION) GROUND
2 Z747 16BK (REAR POSITION) GROUND
FLOOR CONSOLE POWER OUTLET (EXPORT) - RED 3 WAY

1 A105 16RD (FRONT POSITION) FUSED B(+)
1 F307 16RD (REAR POSITION/ACCES- FUSED ACCESSORY RELAY OUTPUT
SORY RELAY POSITION)
1 F307 16RD (REAR POSITION/BATTERY FUSED B(+)
POSITION)
2 - -
3 Z746 16BK (FRONT POSITION) GROUND
3 Z747 16BK (REAR POSITION) GROUND
FRONT BLOWER MODULE C1 (ATC) - BLACK 4 WAY

1 - -
3 C56 20DB/LB BLOWER MOTOR CONTROL
FRONT BLOWER MODULE C2 (ATC) - BLACK 2 WAY

1 C7 12DB (EXCEPT EXPORT) HIGH SPEED BLOWER MOTOR
1 C7 12DG (EXPORT) HIGH SPEED BLOWER MOTOR
2 C70 12DB/YL (EXCEPT EXPORT) BLOWER MOTOR DRIVER
2 C70 12BK (EXPORT) BLOWER MOTOR DRIVER
FRONT CIGAR LIGHTER - RED/NATURAL 3 WAY

2 - -
FRONT CONTROL MODULE - BLACK 49 WAY

1 A1 B(+)
2 A1 B(+)
3 L43 LEFT LOW BEAM DRIVER
4 L34 RIGHT HIGH BEAM DRIVER
5 L33 LEFT HIGH BEAM DRIVER
6 L44 RIGHT LOW BEAM DRIVER
7 - -
8 Z117, Z118, Z343, Z344 GROUND
9 A1 B(+)
10 FCM 10 HORN RELAY CONTROL
11 - -
12 P201 (EXCEPT EXPORT) ADJUSTABLE PEDALS RELAY CONTROL
13 FCM 13 PARK LAMP RELAY CONTROL
14 FCM 14 FRONT WIPER ON/OFF RELAY CONTROL
15 C41 (DIESEL) CABIN HEATER ASSIST CONTROL
16 W7 FRONT WIPER PARK SWITCH SENSE
17 X3 HORN SWITCH SENSE
18 W1 WASHER FLUID LEVEL SWITCH SENSE
19 FCM 19 FUSED IGNITION SWITCH OUTPUT (START)
20 FCM 20 FUSED (+)
21 L78 FUSED PARK LAMP RELAY OUTPUT (RIGHT)
22 D25 PCI BUS
23 G931 (DIESEL) AMBIENT TEMPERATURE SENSOR RETURN
24 - NOT USED
25 G31 (DIESEL) AMBIENT TEMPERATURE SENSOR SIGNAL
26 L13 (EXPORT) HEADLAMP ADJUST SIGNAL
27 F1, F2 FCM OUTPUT (UNLOCK-RUN-START)
28 - NOT USED
29 F100 ORC RUN ONLY DRIVER
30 FCM 30 FRONT/REAR BLOWER MOTOR RELAY CONTROL
31 FCM 31 DEFOGGER RELAY CONTROL
32 FCM 32 (EXPORT) HEADLAMP WASHER RELAY CONTROL
33 FCM 33 FRONT FOG LAMP RELAY CONTROL
34 FCM 34 FRONT WIPER HIGH/LOW RELAY CONTROL
35 FCM 35 ACCESSORY RELAY CONTROL (RUN-ACC)
36 B20 BRAKE FLUID LEVEL SWITCH SENSE
37 F20 FUSED IGNITION SWITCH OUTPUT (RUN-START)
38 A1 B(+) (WHEN IPM C5 CPA IS NOT ENGAGED)
39 T2 (MTX) TRS REVERSE SENSE
40 - NOT USED
41 L77 FUSED PARK LAMP RELAY OUTPUT (LEFT)
42 D123 FLASH PROGRAM ENABLE
43 Z116 GROUND
44 L50 (DIESEL) PRIMARY BRAKE SWITCH SIGNAL
44 L50 (GAS) BRAKE LAMP SWITCH OUTPUT
45 W10 FRONT WASHER PUMP MOTOR CONTROL
46 W20 REAR WASHER PUMP MOTOR CONTROL
47 K32 BRAKE TRANSMISSION SHIFT INTERLOCK SOLENOID
CONTROL
48 F201 ORC RUN-START DRIVER
49 - -
FRONT INTRUSION SENSOR (UNITED KINGDOM) - 3 WAY

1 G460 20DG/VT FRONT INTRUSION SENSOR SIGNAL
2 - -
3 G946 20LG/VT SENSOR GROUND
FRONT READING LAMPS/SWITCH - BLACK 6 WAY

1 E15 20OR/DB (EXCEPT BASE) ASH/RECEIVER LAMP FEED
2 Z137 20BK/LB GROUND
3 - -
6 - -
FUEL HEATER (DIESEL) - BLACK 2 WAY

1 N1 16RD FUEL HEATER RELAY OUTPUT
2 Z201 18RD GROUND
FUEL INJECTOR NO. 1 (2.4L/3.3L/3.8L) - BLACK 2 WAY

1 K342 16BR/WT ASD RELAY OUTPUT
2 K11 16BR/YL INJECTOR CONTROL NO. 1
FUEL INJECTOR NO. 1 (DIESEL) - BLACK 2 WAY

2 K11 14WT/DB FUEL INJECTOR NO. 1 CONTROL

2 K12 16BR/DB INJECTOR CONTROL NO. 2

2 K12 14TN FUEL INJECTOR NO. 2 CONTROL

2 K13 16BR/LB INJECTOR CONTROL NO. 3

2 K13 14BR/LB FUEL INJECTOR NO. 3 CONTROL

2 K14 16BR/TN INJECTOR CONTROL NO. 4

2 K14 14LB/BR FUEL INJECTOR NO. 4 CONTROL
FUEL INJECTOR NO. 5 (3.3L/3.8L) - BLACK 2 WAY

2 K38 16BR/OR INJECTOR CONTROL NO. 5
FUEL INJECTOR NO. 6 (3.3L/3.8L) - BLACK 2 WAY

2 K58 16BR/VT INJECTOR CONTROL NO. 6
FUEL PRESSURE SENSOR (DIESEL) - BLACK 3 WAY

1 K80 20DB/TN FUEL PRESSURE SENSOR GROUND
2 K78 20GY FUEL PRESSURE SENSOR SIGNAL
3 K9 20LB FUEL PRESSURE SENSOR 5 VOLT SUPPLY
FUEL PRESSURE SOLENOID (DIESEL) - 2 WAY

FUEL PUMP MODULE - LT. GRAY 4 WAY

2 Z201 20BK/OR (DIESEL) GROUND
2 Z201 20BK/DB (GAS) GROUND
3 N4 20DB/WT FUEL LEVEL SENSOR SIGNAL
4 N1 18DB/OR (GAS) FUEL PUMP RELAY OUTPUT
GENERATOR - BLACK 2 WAY

1 K342 16BR/WT (DIESEL) ECM/PCM RELAY OUTPUT
1 Z20 18BK (GAS) GROUND
2 K20 14BR/GY (DIESEL) GENERATOR FIELD CONTROL
2 K20 18BR/GY (GAS) GEN FIELD CONTROL
GLOW PLUG RELAY (DIESEL) - BLACK 4 WAY

1 A202 10RD/WT FUSED B(+)
2 K152 20DB/WT GLOW PLUG RELAY CONTROL
4 K154 10BR/OR GLOW PLUG RELAY OUTPUT
HANDS FREE MODULE C1 - 22 WAY

1 A114 18GY/RD FUSED(+) (I.O.D.)
2 - -
3 - -
4 - -
5 X722 20BK/LB MICROPHONE 2 IN (+)
6 - -
7 - -
8 - -
9 - -
10 - -
11 - -
12 L1 20BK/WT (AUTOMATIC DAY/NIGHT BACK-UP LAMP FEED
MIRROR)
13 - -
14 - -
15 X730 20BK/VT VOICE RECOGNITION/PHONE SWITCH SIGNAL
16 X712 20BK/GY MICROPHONE 1 IN (+)
17 X792 20BK/WT MICROPHONE IN (-)
18 - -
19 - -
20 X793 20DB IGNITION RUN/ACC SIGNAL
21 X835 20BK SENSOR GROUND
22 Z530 18GY/BK (LUXURY) GROUND
HANDS FREE MODULE C2 - BLACK 10 WAY

1 X112 20DG/GY IGNITION RUN/ACC SIGNAL
3 - -
4 X795 22GY/OR AUDIO GROUND
5 X704 22GY/WT RIGHT AUDIO OUTPUT
8 - -
10 X703 22DG/WT LEFT AUDIO OUTPUT
HANDS FREE MODULE C3 - 10 WAY

3 X235 20GY/LB (CD CHANGER) SHIELD
3 X955 22 (DVD/CD CHANGER) SHIELD
7 Z141 20BK/TN (CD CHANGER) GROUND
8 - -
10 X160 20GY/YL (CD CHANGER) FUSED B(+)
HEADLAMP SWITCH - BLACK 13 WAY

1 Z403 20BK/YL (EXPORT) GROUND
2 L78 20WT/OR (EXPORT) FUSED PARK LAMP RELAY OUTPUT (RIGHT)
3 - -
5 L36 20WT/DB (EXPORT) REAR FOG LAMP INDICATOR DRIVER
6 L900 22WT/YL HEADLAMP SWITCH RETURN
7 L13 20WT/YL (EXPORT) HEADLAMP ADJUST SIGNAL
8 E19 20OR/BR (AUTOMATIC HEAD- HEADLAMP SWITCH DIMMER SIGNAL
LAMPS)
9 - -
10 L39 22WT/OR (HIGHLINE) FRONT FOG LAMP INDICATOR DRIVER
11 L307 20WT/BR HEADLAMP SWITCH MUX
12 E2 22OR/BR PANEL LAMPS DIMMER SIGNAL
13 - -
HEADLAMP WASHER PUMP MOTOR (EXPORT) - BLACK 2 WAY

1 V53 12BR/OR HEADLAMP WASHER RELAY OUTPUT
HIGH NOTE HORN - BLACK 2 WAY

2 X2 18DG/OR HORN RELAY OUTPUT
HOOD AJAR SWITCH (EXPORT) - BLACK 2 WAY

1 G70 22VT/LB HOOD AJAR SWITCH SENSE
IDLE AIR CONTROL MOTOR (GAS) - BLACK 2 WAY

1 K61 18VT/GY IAC MOTOR CONTROL
2 K961 18BR/VT IAC RETURN
IGNITION COIL (2.4L) - BLACK 3 WAY

1 K17 16DB/TN COIL CONTROL NO. 2
3 K19 16DB/DG COIL CONTROL NO. 1
IGNITION COIL (3.3L/3.8L) - DK. GRAY 4 WAY

1 K18 16BR/OR COIL CONTROL NO. 3
4 K17 16DB/TN COIL CONTROL NO. 2
IGNITION SWITCH - BLACK 5 WAY

1 G900 20VT/DB IGNITION SWITCH SENSE RETURN
2 G20 20VT/BR IGNITION SWITCH SENSE
3 F20 20PK/WT (LHD) FUSED IGNITION SWITCH OUTPUT (RUN-START)
5 A106 20LB/RD FUSED B(+)
INLET AIR TEMPERATURE SENSOR - BLACK 2 WAY

1 K21 18DB/LG IAT SIGNAL
INPUT SPEED SENSOR - GRAY 2 WAY

1 T13 18DG/VT SPEED SENSOR GROUND
2 T52 18DG/WT INPUT SPEED SENSOR SIGNAL
INSTRUMENT CLUSTER - BLACK 13 WAY

1 E13 20OR/WT PANEL LAMPS DRIVER
2 L160 20WT/TN (EXCEPT EXPORT) RIGHT TURN INDICATOR DRIVER
3 G7 20VT/GY (EXPORT) LOW OIL PRESSURE INDICATOR DRIVER
4 G3 20VT/LB (EXPORT) MALFUNCTION INDICATOR LAMP DRIVER
5 L134 20WT/GY (EXPORT) HIGH BEAM INDICATOR DRIVER
8 G700 20VT/YL (DIESEL) SUPPLEMENTAL HEAT INDICATOR SENSE
8 L161 20WT/LG (EXCEPT EXPORT) LEFT TURN INDICATOR DRIVER
10 B25 16DG/WT (EXCEPT EXPORT) PARK BRAKE SWITCH SENSE
10 B25 18DG/WT (LHD EXPORT) PARK BRAKE SWITCH SENSE
10 B25 20DG/WT (RHD) PARK BRAKE SWITCH SENSE
11 G26 22VT/OR CHIME DRIVER
12 G150 22VT/BR INSTRUMENT CLUSTER WAKE UP SENSE
INSTRUMENT PANEL SWITCH BANK (EXCEPT HEATED SEATS) - 6 WAY

2 G104 20VT/GY (OCCUPANT SENSING) PASSENGER AIRBAG ON/OFF INDICATOR LAMP
GROUND
3 F201 20PK/OR ORC RUN-START DRIVER
4 L91 22WT/DB HAZARD SWITCH SENSE
5 - -
INSTRUMENT PANEL SWITCH BANK (HEATED SEATS) - BLACK 13 WAY

1 - -
2 - -
3 F201 20PK/OR (EXCEPT EXPORT) ORC RUN-START DRIVER
3 P8 22LG/WT (LHD EXPORT) PASSENGER HEATED SEAT SWITCH MUX
3 P7 20LG/DG (RHD) DRIVER HEATED SEAT SWITCH MUX
5 P7 20LG/DG (LHD) DRIVER HEATED SEAT SWITCH MUX
5 P8 22LG/WT (RHD) PASSENGER HEATED SEAT SWITCH MUX
6 - -
7 - -
8 L91 22WT/DB (LHD) HAZARD SWITCH SENSE
8 L91 20WT/DB (RHD) HAZARD SWITCH SENSE
9 W26 22BR/DB REAR WIPER SWITCH MUX
11 G926 22VT/WT REAR WIPER SWITCH MUX RETURN
13 - -
INTEGRATED POWER MODULE C1 - 20 WAY

1 - -
2 - -
3 - -
4 L43 18WT/DB LEFT LOW BEAM DRIVER
6 L34 16WT/GY RIGHT HIGH BEAM DRIVER
7 W1 18BR/TN WASHER FLUID LEVEL SWITCH SENSE
8 L33 18WT/LG LEFT HIGH BEAM DRIVER
9 G31 18VT/LG (DIESEL) AMBIENT TEMPERATURE SENSOR SIGNAL
10 L44 16WT/TN RIGHT LOW BEAM DRIVER
11 - -
12 - -
14 - -
15 L78 18WT/OR FUSED PARK LAMP RELAY OUTPUT (RIGHT)
16 L77 18WT/BR FUSED PARK LAMP RELAY OUTPUT (LEFT)
17 - -
18 G931 18VT/BR (DIESEL) AMBIENT TEMPERATURE SENSOR RETURN
19 W20 18BR/YL REAR WASHER PUMP MOTOR CONTROL
20 W10 18BR FRONT WASHER PUMP MOTOR CONTROL
INTEGRATED POWER MODULE C2 - GREEN/BLUE 10 WAY

1 N173 18DB/VT (GAS) RAD FAN RELAY CONTROL
2 V53 12BR/OR (EXPORT) HEADLAMP WASHER RELAY OUTPUT
5 X2 18DG/OR HORN RELAY OUTPUT
6 L90 18WT/OR (FOG LAMPS) FRONT FOG LAMP RELAY OUTPUT
8 - -
10 L89 18WT/YL (FOG LAMPS) FRONT FOG LAMP RELAY OUTPUT

1 N21 20DB/TN (DIESEL) LIFT PUMP RELAY CONTROL
2 F1 18PK/WT FCM OUTPUT (UNLOCK-RUN-START)
3 T751 20YL (DIESEL) FUSED IGNITION SWITCH OUTPUT (START)
3 T751 18YL (GAS) FUSED IGNITION SWITCH OUTPUT (START)
4 T2 18DG/WT (MTX) TRS REVERSE SENSE
5 N2 18DB/YL (DIESEL) LIFT PUMP RELAY OUTPUT
5 T16 18YL/OR (GAS EATX) TRANSMISSION CONTROL RELAY OUTPUT
6 F202 20PK/GY (DIESEL) FUSED IGNITION SWITCH OUTPUT (RUN-START)
6 T15 18YL/BR (GAS EATX) TRANSMISSION CONTROL RELAY CONTROL
7 C3 20DB/YL A/C CLUTCH RELAY OUTPUT
8 Z114 18BK/LG (DIESEL) GROUND
8 K31 18BR (GAS) FUEL PUMP RELAY CONTROL
9 C13 20LB/OR (DIESEL) A/C COMPRESSOR CLUTCH RELAY CONTROL
9 C13 18LB/OR (GAS) A/C COMPRESSOR CLUTCH RELAY CONTROL
10 A119 16RD/OR (DIESEL) FUSED B(+)
11 C41 20LB/DG (DIESEL) CABIN HEATER ASSIST CONTROL
12 - -
13 D25 20WT/VT (DIESEL MTX) PCI BUS
13 D25 18WT/VT (GAS/DIESEL EATX) PCI BUS
14 T752 20DG/OR (DIESEL) STARTER MOTOR RELAY CONTROL
14 T752 18DG/OR (GAS) STARTER RELAY CONTROL
15 Z116 18BK/VT GROUND
16 K51 20BR/WT (DIESEL) ECM/PCM RELAY CONTROL
16 K51 18BR/WT (GAS) ASD RELAY CONTROL
18 K173 18BR/VT (GAS) RAD FAN RELAY CONTROL
19 F202 20PK/GY (GAS) FUSED IGNITION SWITCH OUTPUT (RUN-START)
20 A109 18OR/RD (GAS) FUSED B(+)
INTEGRATED POWER MODULE C4 - BLUE 10 WAY

1 Z127 12BK (ASSY. PLANT EVAC & GROUND
FILL)
2 T750 12YL/GY STARTER MOTOR RELAY OUTPUT
3 K342 16BR/WT (GAS) ASD RELAY OUTPUT
4 F500 16DG/PK (ASSY. PLANT EVAC & FUSED IGNITION SWITCH OUTPUT (RUN)
FILL)
5 - -
6 D25 18WT/VT (ABS) PCI BUS
7 A107 12TN/RD (ABS) FUSED B(+)
8 A111 12DG/RD (ABS) FUSED B(+)
9 - -
10 - -
INTEGRATED POWER MODULE C5 - BLACK 4 WAY

1 A1 4RD B(+)
2 - -
3 - -
4 - -
INTEGRATED POWER MODULE C6 - NATURAL 10 WAY

3 Z118 16BK/WT (LWB/EXPORT) GROUND
3 Z118 16BK/YL (SWB/EXCEPT EXPORT) GROUND
4 A110 12OR/RD (POWER SEAT) FUSED B(+)
5 - -
6 - -
8 F307 18LB/PK (ACCESSORY RELAY FUSED ACCESSORY RELAY OUTPUT
POSITION)
8 F307 18LB/PK (BATTERY POSITION) FUSED B(+)
9 A113 12WT/RD (POWER SLIDING FUSED B(+)
DOOR)
10 - -

1 C16 20DB/GY FUSED DEFOGGER RELAY OUTPUT
2 T141 20YL/OR (DIESEL) FUSED IGNITION SWITCH OUTPUT (START)
2 T751 20YL (GAS) FUSED IGNITION SWITCH OUTPUT (START)
5 K32 18DB/YL BRAKE TRANSMISSION SHIFT INTERLOCK SOLENOID
CONTROL
6 - -
7 W7 20BR/GY WIPER PARK SWITCH SENSE
8 B20 20DG/OR BRAKE FLUID LEVEL SWITCH SENSE
10 - -
11 A106 20LB/RD FUSED B(+)
12 P201 20LG/DB (EXCEPT EXPORT/EX- ADJUSTABLE PEDALS RELAY CONTROL
CEPT MEMORY)
13 F2 18PK/YL FCM OUTPUT (UNLOCK-RUN-START)
14 - -
18 - -
20 F100 18PK/VT ORC RUN ONLY DRIVER
INTEGRATED POWER MODULE C8 - ORANGE 10 WAY

1 W3 14BR/WT FRONT WIPER HIGH/LOW RELAY LOW SPEED OUT-
PUT
2 N1 16DB/OR (DIESEL) FUEL HEATER RELAY OUTPUT
2 N1 18DB/OR (GAS) FUEL PUMP RELAY OUTPUT
3 A108 18LG/RD (EXCEPT EXPORT) FUSED B(+)
3 A108 20LG/RD (EXPORT) FUSED B(+)
3 A108 20LG/RD (EXPORT) FUSED B(+)
4 A103 18GY/RD FUSED B(+)
6 W4 14BR/OR FRONT WIPER HIGH/LOW RELAY HIGH SPEED OUT-
PUT
7 C51 12LB/BR (3 ZONE HVAC) FUSED REAR BLOWER MOTOR RELAY OUTPUT
8 - -
INTEGRATED POWER MODULE C9 - BLACK 10 WAY

1 A116 14YL/RD (HIGHLINE AUDIO) FUSED B(+)
3 C15 12DB/WT FUSED DEFOGGER RELAY OUTPUT
5 L61 20WT/LB LEFT FRONT TURN SIGNAL DIVER
8 F30 12PK/YL (POWER WINDOWS) FUSED ACCESSORY RELAY OUTPUT
9 A115 12YL/RD FUSED B(+)
10 F302 18GY/PK FUSED ACCESSORY RELAY OUTPUT
KNOCK SENSOR (EXCEPT EXPORT) - BLACK 2 WAY

1 K42 18DB/YL KS SIGNAL
2 K942 18BR/LG KS RETURN
LEFT B-PILLAR SWITCH (POWER SLIDING DOOR) - GRAY 3 WAY

2 - -
3 G41 22VT/DG LEFT SLIDING DOOR PILLAR SWITCH MUX
LEFT CINCH/RELEASE MOTOR (POWER SLIDING DOOR) - GRAY 4 WAY

1 Q49 18TN/WT LEFT CINCH/RELEASE MOTOR UNLATCH DRIVER
3 Q45 18OR/GY LEFT CINCH/RELEASE MOTOR CLUTCH DRIVER
4 Q47 18TN/GY LEFT CINCH/RELEASE MOTOR LATCH DRIVER
LEFT CURTAIN AIRBAG SQUIB - 2 WAY

1 R1 20LB/WT LEFT CURTAIN SQUIB LINE 2
2 R3 20LB/OR LEFT CURTAIN SQUIB LINE 1
LEFT CYLINDER LOCK SWITCH (EXPORT) - BLACK 2 WAY

2 G163 20VT/LB LEFT CYLINDER LOCK SWITCH MUX
LEFT DOOR SPEAKER - 3 WAY

1 X291 18DG/BR (HIGHLINE) AMPLIFIED LEFT FRONT SPEAKER (-)
1 X55 20DG/BR (LOWLINE) LEFT FRONT SPEAKER (-)
2 - -
3 X201 18DG (HIGHLINE) AMPLIFIED LEFT FRONT SPEAKER (+)
3 X53 20DG (LOWLINE) LEFT FRONT SPEAKER (+)
LEFT FOG LAMP - BLACK 2 WAY

A L89 18WT/YL FRONT FOG LAMP RELAY OUTPUT
B Z349 18BK/YL GROUND
LEFT FRONT DOOR AJAR SWITCH (BASE) - BLACK 2 WAY

1 G75 20VT LEFT FRONT DOOR AJAR SWITCH SENSE
LEFT FRONT DOOR LOCK MOTOR/AJAR SWITCH (EXCEPT BASE) - BLACK 4 WAY
1 G75 20VT LEFT FRONT DOOR AJAR SWITCH SENSE
3 P1 20TN/LG LEFT FRONT DOOR UNLOCK DRIVER
4 P3 20TN/WT LEFT FRONT DOOR LOCK DRIVER
LEFT FRONT IMPACT SENSOR (EXCEPT EXPORT) - 2 WAY

1 R81 20LB/WT LEFT FRONT IMPACT SENSOR GROUND
2 R79 20LB/VT LEFT FRONT IMPACT SENSOR SIGNAL
LEFT FRONT IMPACT SENSOR (EXPORT) - BLACK 2 WAY

LEFT FRONT PARK/TURN SIGNAL LAMP - DK. GRAY 3 WAY

LEFT FRONT WHEEL SPEED SENSOR - GRAY 2 WAY

1 B9 18DG/WT (3.3L/3.8L) LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUP-
PLY
1 B9 18DG/LG (EXCEPT 3.3L/3.8L) LEFT FRONT WHEEL SPEED SENSOR 12 VOLT SUP-
PLY
2 B8 18DG/TN LEFT FRONT WHEEL SPEED SENSOR SIGNAL
LEFT FULL OPEN SWITCH (POWER SLIDING DOOR) - BLACK 2 WAY

1 Q53 20OR LEFT FULL OPEN SWITCH SENSE
LEFT HEADLAMP (CARAVAN/VOYAGER EXCEPT EXPORT) - BLACK 3 WAY

LEFT HEADLAMP (TOWN AND COUNTRY) - GREEN 3 WAY

LEFT HEADLAMP LEVELING MOTOR (EXPORT) - WHITE 3 WAY

1 Z203 16BR GROUND
2 L77 16BK FUSED PARK LAMP RELAY OUTPUT (LEFT)
3 L13 16RD HEADLAMP ADJUST SIGNAL
LEFT HIGH BEAM LAMP (EXPORT) - BLACK 2 WAY

1 Z343 16BR GROUND
1 Z343 16BR GROUND
2 L33 16GY LEFT HIGH BEAM DRIVER
LEFT INSTRUMENT PANEL SPEAKER - WHITE 2 WAY

1 X153 18DG/YL (HIGHLINE EXCEPT LEFT INSTRUMENT PANEL SPEAKER (+)
EXPORT)
1 X153 20DG/YL (HIGHLINE EXPORT/ LEFT INSTRUMENT PANEL SPEAKER (+)
LOWLINE)
2 X155 18DG/LB (HIGHLINE EXCEPT LEFT INSTRUMENT PANEL SPEAKER (+)
EXPORT)
2 X155 20DG/LB (HIGHLINE EXPORT/ LEFT INSTRUMENT PANEL SPEAKER (-)
LOWLINE)
LEFT LIFTGATE FLOOD LAMP (EXPORT) - GRAY 3 WAY

2 - -
3 M11 20YL/VT (EXCEPT POWER LIFT- COURTESY LAMPS DRIVER EXPORT
GATE)
LEFT LOW BEAM LAMP (EXPORT) - BLACK 2 WAY

1 Z343 16BR GROUND
2 L43 16WT LEFT LOW BEAM DRIVER
LEFT MID READING LAMP (PREMIUM/LUXURY) - GRAY 3 WAY

LEFT PARK LAMP (EXPORT) - BLACK 2 WAY

1 Z343 16BR GROUND
2 L77 16BK FUSED PARK LAMP RELAY OUTPUT (LEFT)
LEFT POWER MIRROR - BLACK 12 WAY

1 P171 20TN/YL (EXPORT) LEFT FOLDING MIRROR UNFOLD DRIVER
2 P112 22TN/OR (AUTOMATIC DAY/ MIRROR B(+)
NIGHT MIRROR)
3 P114 22TN/WT (AUTOMATIC DAY/ MIRROR B(-)
NIGHT MIRROR)
4 P65 20TN/VT (MEMORY) LEFT MIRROR HORIZONTAL POSITION SIGNAL
5 P69 20TN/WT (MEMORY) LEFT MIRROR SENSOR GROUND
6 P64 20TN (MEMORY) LEFT MIRROR VERTICAL POSITION SIGNAL
7 P159 20TN/DG (LHD EXPORT) DRIVER FOLDING MIRROR FOLD DRIVER
7 P160 20TN/LG (RHD EXPORT) PASSENGER FOLDING MIRROR RELAY OUTPUT
9 C16 20DB/GY (HEATED MIRRORS) FUSED DEFOGGER RELAY OUTPUT
10 P73 20TN/YL LEFT MIRROR COMMON DRIVER (RIGHT/DOWN)
11 P71 20TN/DG LEFT MIRROR UP DRIVER
12 P75 20TN/LG LEFT MIRROR LEFT DRIVER
LEFT REAR LAMP ASSEMBLY - BLACK 6 WAY

1 L63 18WT/DG (EXCEPT EXPORT) LEFT REAR TURN SIGNAL DRIVER
1 Z363 18BK/DG (EXPORT) GROUND
2 L63 18WT/DG (EXPORT) LEFT REAR TURN SIGNAL DRIVER
3 L50 18WT/TN (DIESEL EXPORT) PRIMARY BRAKE SWITCH SIGNAL
3 L77 18WT/BR (EXCEPT EXPORT) FUSED PARK LAMP RELAY OUTPUT (LEFT)
3 L50 18WT/TN (GAS EXPORT) BRAKE LAMP SWITCH OUTPUT
4 L1 18WT/LG (EXCEPT TRAILER TOW) BACK-UP LAMP FEED
4 L1 18WT/BR (TRAILER TOW) BACK-UP LAMP FEED
5 Z363 18BK/DG (EXCEPT EXPORT) GROUND
6 L77 18WT/BR (EXPORT) FUSED PARK LAMP RELAY OUTPUT (LEFT)
LEFT REAR PILLAR SPEAKER (HIGHLINE AUDIO) - BLACK 2 WAY

1 X214 18DG/DB (EXCEPT EXPORT) AMPLIFIED LEFT REAR TWEETER (-)
1 X214 20DG/DB (EXPORT) AMPLIFIED LEFT REAR TWEETER (-)
2 X284 18DG/TN (EXCEPT EXPORT) AMPLIFIED LEFT REAR TWEETER (+)
2 X284 20DG/TN (EXPORT) AMPLIFIED LEFT REAR TWEETER (+)
LEFT REAR READING LAMP (LUXURY) - GRAY 3 WAY

LEFT REAR SPEAKER - 3 WAY

1 X295 18GY/DG (HIGHLINE EXCEPT AMPLIFIED LEFT REAR SPEAKER (-)
EXPORT)
1 X295 20GY/DG (HIGHLINE EXPORT) AMPLIFIED LEFT REAR SPEAKER (-)
1 X57 20DG/OR (LOWLINE) LEFT REAR SPEAKER (-)
2 - -
3 X205 18GY/LG (HIGHLINE EXCEPT AMPLIFIED LEFT REAR SPEAKER (+)
EXPORT)
3 X205 20GY/LG (HIGHLINE EXPORT) AMPLIFIED LEFT REAR SPEAKER (+)
3 X51 20DG/DB (LOWLINE) LEFT REAR SPEAKER (+)
LEFT REAR VENT MOTOR - NATURAL 3 WAY

1 Q13 16OR/DB (LHD) DRIVER SIDE REAR WINDOW CLOSE
1 Q14 16OR/BR (RHD) PASSENGER SIDE REAR WINDOW CLOSE
2 Q23 16OR/LB (LHD) DRIVER SIDE REAR WINDOW OPEN
2 Q24 16OR/DG (RHD) PASSENGER SIDE REAR WINDOW OPEN
3 - -
LEFT REAR WHEEL SPEED SENSOR - BLACK 2 WAY

1 B4 18DG/GY LEFT REAR WHEEL SPEED SENSOR 12 VOLT SUP-
PLY
2 B3 18DG/YL LEFT REAR WHEEL SPEED SENSOR SIGNAL
LEFT REMOTE RADIO SWITCH - BLACK 2 WAY

LEFT REPEATER LAMP (EXPORT) - GRAY 2 WAY

1 A701 18BR/RD FUSED B(+)
2 L163 20WT/BR LEFT SIDE REPEATER LAMP FEED
LEFT SIDE IMPACT SENSOR 1 (EXCEPT EXPORT) - 2 WAY

1 R15 20DB LEFT SIDE IMPACT SENSOR 1 GROUND
2 R13 20LB LEFT SIDE IMPACT SENSOR 1 SIGNAL
LEFT SIDE IMPACT SENSOR 1 (EXPORT) - BLACK 2 WAY

1 R15 20DB (EXCEPT RHD LWB) LEFT SIDE IMPACT SENSOR 1 GROUND
1 R15 20LB (RHD LWB) LEFT SIDE IMPACT SENSOR 1 GROUND
2 R13 20LB LEFT SIDE IMPACT SENSOR 1 SIGNAL
LEFT SIDE IMPACT SENSOR 2 - 2 WAY

1 R19 18LG/WT LEFT SIDE IMPACT SENSOR 2 GROUND
2 R17 18LG LEFT SIDE IMPACT SENSOR 2 SIGNAL
LEFT SIDE IMPACT SENSOR 3 - BLACK 2 WAY

1 R23 20LB/YL LEFT SIDE IMPACT SENSOR 3 GROUND
2 R21 20LB/WT LEFT SIDE IMPACT SENSOR 3 SIGNAL
LEFT SLIDING DOOR CONTROL MODULE C1 (POWER SLIDING DOOR) - BLACK 8 WAY
1 Q45 18OR/GY LEFT CINCH/RELEASE MOTOR CLUTCH DRIVER
2 Q67 16TN/BR LEFT SLIDING DOOR OPEN DRIVER
3 Q69 16TN/OR LEFT SLIDING DOOR CLOSE DRIVER
4 - -
5 A113 14WT/RD FUSED B(+)
6 - -
7 - -
LEFT SLIDING DOOR CONTROL MODULE C2 (POWER SLIDING DOOR) - 20 WAY

1 Q71 20TN/VT LEFT DOOR MOTOR HALL EFFECT SUPPLY
2 - -
3 Q35 20OR/GY LEFT DOOR LOCK SENSE
4 Q55 20OR/BR LEFT DOOR IN/OUT HANDLE SWITCH SENSE
5 - -
6 - -
7 Q63 18OR/TN LEFT DOOR MOTOR CLUTCH DRIVER
8 Q47 18TN/GY LEFT CINCH/RELEASE MOTOR LATCH DRIVER
9 Q49 18TN/WT LEFT CINCH/RELEASE MOTOR UNLATCH DRIVER
10 - -
12 G77 20TN/OR LEFT SLIDING DOOR AJAR SWITCH SENSE
13 Q59 20OR/YL LEFT PAWL SWITCH SENSE
14 Q53 20OR LEFT FULL OPEN SWITCH SENSE
15 Z25 20BK/TN GROUND-DRIVER SIDE IDENTIFIER (LHD/RHD)
16 - -
17 Q73 20TN/YL LEFT DOOR MOTOR HALL EFFECT SIGNAL
18 - -
19 G151 20VT/BR LEFT SLIDING DOOR WAKE UP SIGNAL
LEFT SLIDING DOOR LATCH SENSING SWITCH (POWER SLIDING DOOR) - BLACK 6 WAY
2 Q59 20OR/YL LEFT PAWL SWITCH SENSE
3 G77 20TN/OR LEFT SLIDING DOOR AJAR SWITCH SENSE
5 Q55 20OR/BR LEFT DOOR IN/OUT HANDLE SWITCH SENSE
6 - -
LEFT SLIDING DOOR LOCK MOTOR (POWER SLIDING DOOR) - BLACK 4 WAY
1 P5 20TN/OR LEFT SLIDING DOOR LOCK UNLOCK DRIVER
2 P32 20TN/VT LEFT SLIDING DOOR LOCK DRIVER
3 Q35 20OR/GY LEFT DOOR LOCK SENSE
LEFT SLIDING DOOR LOCK MOTOR/AJAR SWITCH (MANUAL SLIDING DOOR) - BLACK 4 WAY
1 P5 20BK/DB LEFT SLIDING DOOR UNLOCK DRIVER
2 P32 20BK/TN LEFT SLIDING DOOR LOCK DRIVER
3 G77 20BK/DG LEFT SLIDING DOOR AJAR SWITCH SENSE
4 Z77 20BK GROUND
LEFT SLIDING DOOR MOTOR (POWER SLIDING DOOR) - BLACK 8 WAY

1 - -
2 Q71 20TN/VT LEFT DOOR MOTOR HALL EFFECT SUPPLY
3 Q69 16TN/OR LEFT SLIDING DOOR CLOSE DRIVER
5 Q63 18OR/TN LEFT DOOR MOTOR CLUTCH DRIVER
6 Q67 16TN/BR LEFT SLIDING DOOR OPEN DRIVER
8 Q73 20TN/YL LEFT DOOR MOTOR HALL EFFECT SIGNAL
LEFT SPEED CONTROL SWITCH - WHITE 2 WAY

A V37 20VT (DIESEL) SPEED CONTROL SWITCH SIGNAL
A V37 20VT (GAS) S/C SWITCH NO. 1 SIGNAL
B Z23 20BK/VT LEFT SPEED CONTROL SWITCH GROUND
LEFT TURN SIGNAL LAMP (EXPORT) - ORANGE 2 WAY

1 Z343 16BR GROUND
2 L61 16YL LEFT FRONT TURN SIGNAL DRIVER
LEFT VISOR/VANITY LAMP (PREMIUM/LUXURY EXCEPT EXPORT) - BLACK 2 WAY

A Z327 20BK/OR GROUND
B M27 20YL/LB READING LAMP DRIVER
LICENSE LAMP (MANUAL RELEASE) - DK. GRAY 2 WAY

LICENSE LAMP (POWER LIFTGATE) - DK. GRAY 8 WAY

5 Q94 20TN/LG LIFTGATE CHIME DRIVER
7 G32 20VT/LB LIFTGATE TEMPERATURE SENSOR SIGNAL
LICENSE LAMP (POWER RELEASE) - DK. GRAY 4 WAY

LIFT PUMP MOTOR (DIESEL) - BLACK 2 WAY

1 N2 18OR LIFT PUMP RELAY OUTPUT
2 Z201 18OR GROUND
LIFTGATE AJAR SWITCH (MANUAL RELEASE) - BLACK 2 WAY

LIFTGATE AJAR SWITCH (POWER RELEASE) - BLACK 4 WAY

3 P31 20TN/YL LIFTGATE RELEASE DRIVER
LIFTGATE CINCH/RELEASE MOTOR (POWER LIFTGATE) - BLUE 7 WAY

3 Q60 20OR/YL LIFTGATE PAWL SWITCH SENSE
5 Q85 18TN/WT LIFTGATE LATCH RELEASE DRIVER
6 Q84 18TN/GY LIFTGATE LATCH CINCH DRIVER
7 Q83 18OR/GY LIFTGATE LATCH CLUTCH DRIVER
LIFTGATE LEFT PINCH SENSOR (POWER LIFTGATE) - BLACK 2 WAY

1 Q77 20OR/DB RIGHT PINCH SENSOR SIGNAL
2 Q76 20OR/LB PINCH SENSOR SIGNAL
LIFTGATE RIGHT PINCH SENSOR (POWER LIFTGATE) - BLACK 2 WAY

1 Q77 20OR/DB RIGHT PINCH SENSOR SIGNAL
MANIFOLD ABSOLUTE PRESSURE SENSOR (GAS) - BLACK 3 WAY

1 K1 18VT/BR MAP SIGNAL
MASS AIR FLOW SENSOR (DIESEL) - ORANGE 5 WAY

1 - -
3 K957 20BK/OR MASS AIR FLOW SENSOR GROUND
5 K55 20DB/OR MASS AIR FLOW SENSOR SIGNAL
MEMORY SEAT/MIRROR/ADJUSTABLE PEDALS MODULE C1 - GRAY 26 WAY

1 P205 14LG/DB ADJUSTABLE PEDALS MOTOR FORWARD
2 - -
3 P69 22TN/DB (LHD) LEFT MIRROR SENSOR GROUND
3 P66 20TN/LG (RHD) RIGHT MIRROR SENSOR GROUND
4 - -
5 P64 22TN (LHD) LEFT MIRROR VERTICAL POSITION SIGNAL
5 P67 22TN/OR (RHD) RIGHT MIRROR VERTICAL POSITION SIGNAL
6 Q103 18OR/LG (EXCEPT EXPORT) ADJUSTABLE PEDALS SWITCH FORWARD
7 Q102 18OR/LB (EXCEPT EXPORT) ADJUSTABLE PEDALS SWITCH REARWARD
8 P65 22TN/VT (LHD) LEFT MIRROR HORIZONTAL POSITION SIGNAL
8 P68 20TN/YL (RHD) RIGHT MIRROR HORIZONTAL POSITION SIGNAL
9 P73 20TN/YL (LHD) LEFT MIRROR COMMON DRIVER (RIGHT/DOWN)
9 P70 20TN/LB (RHD) RIGHT MIRROR COMMON DRIVER (RIGHT/DOWN)
10 - -
12 - -
13 P206 14LG/TN (EXCEPT EXPORT) ADJUSTABLE PEDALS MOTOR REARWARD
14 - -
15 - -
16 G11 20VT/TN (EXCEPT EXPORT) ADJUSTABLE PEDALS SENSOR FEED
17 P75 20TN/LG (LHD) LEFT MIRROR LEFT DRIVER
17 P74 20TN/DB (RHD) RIGHT MIRROR LEFT DRIVER
18 P71 20TN/DG (LHD) LEFT MIRROR UP DRIVER
18 P72 20TN/GY (RHD) RIGHT MIRROR UP DRIVER
19 G12 22VT/BR (EXCEPT EXPORT) ADJUSTABLE PEDALS SENSOR SIGNAL
20 G912 20VT/WT (EXCEPT EXPORT) ADJUSTABLE PEDALS SENSOR RETURN
21 - -
22 - -
23 - -
24 - -
25 - -
26 - -

1 P19 20LG/LB DRIVER SEAT FRONT UP SWITCH SENSE
2 P11 20LG/YL DRIVER SEAT REAR UP SWITCH SENSE
3 P25 20LG/VT DRIVER SEAT HORIZONTAL POSITION SIGNAL
4 P47 20LG/LB DRIVER SEAT RECLINER POSITION SIGNAL
5 P26 20LG DRIVER SEAT FRONT RISER POSITION SIGNAL
6 P27 20LG/DB DRIVER SEAT REAR RISER POSITION SIGNAL
7 P21 20LG/TN DRIVER SEAT FRONT DOWN SWITCH SENSE
8 P13 20LG/OR DRIVER SEAT REAR DOWN SWITCH SENSE
9 P15 20LG/WT DRIVER SEAT HORIZONTAL FORWARD SWITCH
SENSE
10 P43 20LG/VT DRIVER SEAT RECLINER UP SWITCH SENSE
11 P29 20LG/WT DRIVER SEAT SENSOR 5 VOLT SUPPLY
12 P28 20LG/BR DRIVER SEAT POSITION SENSOR GROUND
13 - -
14 P17 20LG/DG DRIVER SEAT HORIZONTAL REARWARD SWITCH
SENSE
15 P41 20LG/DB DRIVER SEAT RECLINER DOWN SWITCH SENSE
16 - -
MEMORY SEAT/MIRROR/ADJUSTABLE PEDALS MODULE C3 - WHITE 12 WAY

1 P141 14LG/BR DRIVER SEAT RECLINER DOWN DRIVER
2 P115 14LG DRIVER SEAT HORIZONTAL FORWARD DRIVER
3 P117 14LG/LB DRIVER SEAT HORIZONTAL REARWARD DRIVER
4 P111 14LG/YL DRIVER SEAT REAR UP DRIVER
5 P119 14LG/DG DRIVER SEAT FRONT UP DRIVER
6 - -
7 - -
8 P143 14LG/GY DRIVER SEAT RECLINER UP DRIVER
9 P9 20LG/OR DRIVER SEAT SWITCH B(+) SUPPLY
10 - -
11 P113 14LG/WT DRIVER SEAT REAR DOWN DRIVER
12 P121 14LG/DB DRIVER SEAT FRONT DOWN DRIVER

MEMORY SET SWITCH - BLACK 2 WAY

1 G200 20VT/BR (EXCEPT EXPORT) MEMORY SELECT SWITCH MUX
1 G200 22VT/BR (EXPORT) MEMORY SELECT SWITCH MUX
2 G920 20VT/YL (EXCEPT EXPORT) MEMORY SELECT SWITCH RETURN
2 G920 22VT/YL (EXPORT) MEMORY SELECT SWITCH RETURN
MESSAGE CENTER (EXPORT) - WHITE 14 WAY

1 L160 20WT/TN (LHD) RIGHT TURN INDICATOR DRIVER
1 G700 20VT/YL (RHD DIESEL) SUPPLEMENTAL HEAT INDICATOR SENSE
2 G3 20VT/LB (LHD) MALFUNCTION INDICATOR LAMP DRIVER
3 L134 20WT/GY (RHD) HIGH BEAM INDICATOR DRIVER
4 L160 20WT/TN (RHD) RIGHT TURN INDICATOR DRIVER
5 - -
6 G7 20VT/GY (LHD) LOW OIL PRESSURE INDICATOR DRIVER
7 A701 18BR/RD (LHD) FUSED B(+) (HAZARD)
8 A701 18BR/RD (RHD) FUSED B(+) (HAZARD)
9 G7 20VT/GY (RHD) LOW OIL PRESSURE INDICATOR DRIVER
10 - -
11 L161 20WT/LG (LHD) LEFT TURN INDICATOR DRIVER
12 L134 20WT/GY (LHD) HIGH BEAM INDICATOR DRIVER
13 G3 20VT/LB (RHD) MALFUNCTION INDICATOR LAMP DRIVER
14 G700 20VT/YL (LHD DIESEL) SUPPLEMENTAL HEAT INDICATOR SENSE
14 L161 20WT/LG (RHD) LEFT TURN INDICATOR DRIVER
MODE DOOR ACTUATOR - GRAY 2 WAY

1 C135 20DB/GY (ATC) MODE DOOR DRIVER (B)
1 C34 20DB/LB (MTC) COMMON DOOR DRIVER (B)
2 C35 20LB/OR MODE DOOR DRIVER (A)
MULTI-FUNCTION SWITCH - BLACK 4 WAY

1 W52 22BR/YL FRONT WIPER SWITCH MUX
2 G902 22VT/LB MULTI-FUNCTION SWITCH MUX RETURN
3 L305 20WT/LB TURN SIGNAL SWITCH MUX
4 G194 22VT/LG HIGH BEAM/FRONT WASHER SWITCH MUX
NATURAL VACUUM LEAK DETECTION ASSEMBLY (EXCEPT EXPORT) - LT. GRAY 3 WAY
2 K107 20VT/WT NVLD SWITCH SIGNAL
3 K106 20VT/LB NVLD SOL CONTROL
OCCUPANT CLASSIFICATION MODULE - BLACK 18 WAY

1 - -
2 - -
3 - -
4 D105 20LG/LB BELT TENSION SENSOR SIGNAL
6 R741 20LG/VT PASSENGER BLADDER PRESSURE SENSOR SIGNAL
7 R740 20LG/OR PASSENGER BLADDER PRESSURE SENSOR POWER
10 - -
11 - -
12 - -
13 - -
14 R986 20LG/BR BELT TENSION SENSOR GROUND
15 R941 20LG/DG PASSENGER BLADDER PRESSURE SENSOR GROUND
16 R86 20LG/LB BELT TENSION SENSOR FEED
17 - -
18 - -
OCCUPANT RESTRAINT CONTROLLER C1 - YELLOW 32 WAY

1 R53 20LG/YL DRIVER SEAT BELT TENSIONER LINE 2
2 R55 20LG/DG DRIVER SEAT BELT TENSIONER LINE 1
3 R56 20LB/DG (EXCEPT OCCUPANT PASSENGER SEAT BELT TENSIONER LINE 1
SENSING)
4 R54 20LB/YL (EXCEPT OCCUPANT PASSENGER SEAT BELT TENSIONER LINE 2
SENSING)
5 - -
6 - -
7 R4 20OR/LB (SIDE AIRBAG/OCCUPANT RIGHT CURTAIN SQUIB 1 LINE 1
SENSING)
8 R2 20WT/LB (SIDE AIRBAG/OCCUPANT RIGHT CURTAIN SQUIB 1 LINE 2
SENSING)
9 R57 20LG/GY DRIVER SEAT BELT SWITCH SENSE
10 R58 20LB/GY (OCCUPANT SENSING) PASSENGER SEAT BELT SWITCH SENSE
11 R59 20LG/TN DRIVER SEAT BELT SWITCH GROUND
12 R60 20LG/TN (OCCUPANT SENSING) PASSENGER SEAT BELT SWITCH GROUND
13 - -
14 - -
15 R13 20LB (SIDE AIRBAG) LEFT SIDE IMPACT SENSOR 1 SIGNAL
16 R16 20BR/LG (SIDE AIRBAG) RIGHT SIDE IMPACT SENSOR 1 GROUND
17 - -
18 - -
19 R15 20DB (EXCEPT RHD LWB/SIDE LEFT SIDE IMPACT SENSOR 1 GROUND
AIRBAG)
19 R15 20LB (RHD LWB/SIDE AIRBAG) LEFT SIDE IMPACT SENSOR 1 GROUND
20 R19 20LG/WT (SIDE AIRBAG) LEFT SIDE IMPACT SENSOR 2 GROUND
21 R20 20WT/LG (SIDE AIRBAG) RIGHT SIDE IMPACT SENSOR 2 GROUND
22 R17 20LG (SIDE AIRBAG) LEFT SIDE IMPACT SENSOR 2 SIGNAL
23 R18 20LB (SIDE AIRBAG) RIGHT SIDE IMPACT SENSOR 2 SIGNAL
24 R14 20TN/LG (SIDE AIRBAG) RIGHT SIDE IMPACT SENSOR 1 SIGNAL
25 R1 20LB/WT (SIDE AIRBAG) LEFT CURTAIN SQUIB 1 LINE 2
26 R3 20LB/OR (SIDE AIRBAG) LEFT CURTAIN SQUIB 1 LINE 1
27 R4 20OR/LB (SIDE AIRBAG/EXCEPT RIGHT CURTAIN SQUIB 1 LINE 1
OCCUPANT SENSING)
28 R2 20WT/LB (SIDE AIRBAG/EXCEPT RIGHT CURTAIN SQUIB 1 LINE 2
OCCUPANT SENSING)
29 - -
30 - -
31 R56 20LB/DG (OCCUPANT SENSING) PASSENGER SEAT BELT TENSIONER LINE 1
32 R54 20LB/YL (OCCUPANT SENSING) PASSENGER SEAT BELT TENSIONER LINE 2
OCCUPANT RESTRAINT CONTROLLER C2 - YELLOW 32 WAY

1 R43 20LG/BR DRIVER SQUIB 1 LINE 2
2 R45 20LG/OR DRIVER SQUIB 1 LINE 1
3 R63 20LG/WT DRIVER SQUIB 2 LINE 1
4 R61 20LG/VT (EXCEPT EXPORT) DRIVER SQUIB 2 LINE 2
4 R61 20LB/VT (EXPORT) DRIVER SQUIB 2 LINE 1
5 R9 20LB/YL (LHD) DRIVER KNEE BLOCKER SQUIB LINE 1
6 R11 20LB/DB (LHD) DRIVER KNEE BLOCKER SQUIB LINE 2
7 - -
8 - -
9 G104 20VT/GY (OCCUPANT SENSING) PASSENGER AIRBAG ON/OFF INDICATOR LAMP
GROUND
10 R22 20WT/LB (SIDE AIRBAG) RIGHT SIDE IMPACT SENSOR 3 SIGNAL
11 - -
12 R82 20WT/LB RIGHT FRONT IMPACT SENSOR GROUND
13 - -
14 R23 20LB/YL (SIDE AIRBAG) LEFT SIDE IMPACT SENSOR 3 GROUND
17 - -
18 - -
19 R24 20YL/LB (SIDE AIRBAG) RIGHT SIDE IMPACT SENSOR 3 GROUND
21 - -
23 - -
24 F100 20PK/VT ORC RUN ONLY DRIVER
26 R80 20VT/LB RIGHT FRONT IMPACT SENSOR SIGNAL
27 - -
28 R21 20LB/WT (SIDE AIRBAG) LEFT SIDE IMPACT SENSOR 3 SIGNAL
29 R42 20LB/BR PASSENGER SQUIB 1 LINE 2
30 R44 20LB/OR PASSENGER SQUIB 1 LINE 1
31 R64 20LB/WT PASSENGER SQUIB 2 LINE 1
32 R62 20LB/VT PASSENGER SQUIB 2 LINE 2
OUTPUT SPEED SENSOR - GRAY 2 WAY

2 T14 18DG/BR OUTPUT SPEED SENSOR SIGNAL
OVERHEAD CONSOLE (EXCEPT BASE) - BLACK 12 WAY

1 G23 22VT/DB SLIDING DOORS OVERHEAD SWITCH MUX
2 G25 22VT/TN LIFTGATE SWITCH MUX
8 E15 20OR/DB ASH/RECEIVER LAMP FEED
9 - -
10 - -
11 L24 20BK/GY (EXCEPT EXPORT/PRE- AUTOMATIC HEADLAMP SWITCH SENSOR
MIUM/LUXURY)
12 L1 20BK/WT (PREMIUM/LUXURY) BACK-UP LAMP FEED
OXYGEN SENSOR 1/1 UPSTREAM (GAS) - 4 WAY

2 K99 18BR/LG O2 1/1 HEATER CONTROL
3 K902 18BR/DG O2 RETURN (UP)
4 K41 18DB/LB O2 1/1 SIGNAL
OXYGEN SENSOR 1/2 DOWNSTREAM (GAS) - 4 WAY

2 K299 18BR/WT O2 1/2 HEATER CONTROL
3 K904 18DB/DG (2.4L) O2 RETURN (DOWN)
3 K904 18BR/DG (3.3L/3.8L) O2 RETURN (DOWN)
4 K141 18DB/YL O2 1/2 SIGNAL
PARK ASSIST DISPLAY - 3 WAY

1 X777 20DG/GY PARK ASSIST DISPLAY SUPPLY
3 D777 20WT/GY PARK ASSIST DISPLAY SIGNAL
PARK ASSIST MODULE - 18 WAY

1 X700 20GY/OR PARK ASSIST SENSOR SUPPLY
2 D703 20WT/OR PARK ASSIST SENSOR NO. 3 SIGNAL
3 D704 20WT/DB PARK ASSIST SENSOR NO. 4 SIGNAL
4 X777 20DG/GY PARK ASSIST DISPLAY SUPPLY
5 D777 20WT/GY PARK ASSIST DISPLAY SIGNAL
7 - -
8 - -
9 - -
11 Z177 20DG/BK GROUND
13 - -
14 - -
15 - -
16 D700 20WT/GY PARK ASSIST SENSOR NO. 1 SIGNAL
17 D701 20WT/LB PARK ASSIST SENSOR NO. 2 SIGNAL
18 X750 20GY/LB PARK ASSIST SENSOR GROUND
PARK ASSIST SENSOR NO. 1 - 3 WAY

1 D700 20WT/GY PARK ASSIST SENSOR NO. 1 SIGNAL

1 D701 20WT/LB PARK ASSIST SENSOR NO. 2 SIGNAL

1 D703 20WT/BK PARK ASSIST SENSOR NO. 3 SIGNAL

1 D704 20WT/DB PARK ASSIST SENSOR NO. 4 SIGNAL
PASSENGER AIRBAG - YELLOW 4 WAY

1 R42 20LB/BR PASSENGER SQUIB 1 LINE 2
2 R44 20LB/OR PASSENGER SQUIB 1 LINE 1
3 R62 20LB/VT PASSENGER SQUIB 2 LINE 2
4 R64 20LB/WT PASSENGER SQUIB 2 LINE 1
PASSENGER AIRBAG ON/OFF INDICATOR LAMP - BLACK 2 WAY

2 G104 20VT/GY PASSENGER AIRBAG ON/OFF INDICATOR LAMP
GROUND
PASSENGER BLEND DOOR ACTUATOR - GRAY 2 WAY

1 C133 20DB/WT (ATC) PASSENGER BLEND DOOR DRIVER (B)
1 C34 20DB/LB (LHD MTC) COMMON DOOR DRIVER (B)
1 C33 20LB/BR (RHD MTC) PASSENGER BLEND DOOR DRIVER (A)
2 C33 20LB/BR (ATC/LHD MTC) PASSENGER BLEND DOOR DRIVER (A)
2 C34 20DB/LB (RHD MTC) COMMON DOOR DRIVER (B)
PASSENGER DOOR COURTESY LAMP (LUXURY/EXPORT) - GRAY 3 WAY

1 Z322 20BK/BR (LHD) GROUND
1 Z321 20BK/BR (RHD) GROUND
2 - -
3 M21 14YL/BR (EXCEPT EXPORT) COURTESY LAMPS DRIVER
3 M21 20YL/BR (EXPORT) COURTESY LAMPS DRIVER
PASSENGER DOOR LOCK SWITCH - BLACK 3 WAY

1 - -
2 G160 20VT/LG (LHD) RIGHT DOOR LOCK SWITCH MUX
2 G161 20VT/DG (RHD) LEFT DOOR LOCK SWITCH MUX
3 Z460 20BK/LG (LHD) GROUND
3 Z461 20BK/DG (RHD) GROUND
PASSENGER FOLDING MIRROR RELAY (EXPORT) - BLUE 9 WAY

1 - -
2 - -
3 - -
5 P164 18LG/DB PASSENGER FOLDING MIRROR RELAY INPUT
6 P162 18LG/DG PASSENGER FOLDING MIRROR RELAY CONTROL
7 - -
8 P160 18TN/LG PASSENGER FOLDING MIRROR RELAY OUTPUT
9 - -
PASSENGER HEATED SEAT BACK - LT. GREEN 2 WAY

A S1 16DB (EXCEPT EXPORT) SEAT HEATER B(+) DRIVER
A S1 18WT (EXPORT) SEAT HEATER B(+) DRIVER
B Z848 16BK/OR (EXCEPT EXPORT) GROUND
B S2 18GY (EXPORT) SEAT HEATER GROUND
PASSENGER HEATED SEAT CUSHION - BLACK 4 WAY

A S1 16DB (EXCEPT EXPORT) SEAT HEATER B(+) DRIVER
A P88 16LG/LB (EXPORT) SEAT HEATER B(+) DRIVER
B S2 20DG (EXCEPT EXPORT) SEAT HEATER GROUND
B Z848 18BK/OR (EXPORT) GROUND
C Z848 20BK/OR (EXCEPT EXPORT) GROUND
C P89 20LG/BR (EXPORT) SEAT SENSOR 5 VOLT SUPPLY
D Z848 16BK/OR (EXCEPT EXPORT) GROUND
D P87 16LG/OR (EXPORT) SEAT TEMP SENSOR INPUT
PASSENGER HEATED SEAT MODULE (EXCEPT EXPORT) - BLACK 8 WAY

1 - -
2 - -
3 P8 20LG/DG PASSENGER HEATED SEAT SWITCH MUX
5 A210 14OR/RD (EXCEPT POWER FUSED (+)
SEAT)
5 A210 16OR/RD (POWER SEAT) FUSED B(+)
6 S2 20DG SEAT HEATER GROUND
7 S1 16DB SEAT HEATER B(+) DRIVER
PASSENGER HEATED SEAT MODULE C1 (EXPORT) - GRAY 4 WAY

2 P8 20LG/WT PASSENGER HEATED SEAT SWITCH MUX
4 A210 14OR/RD FUSED (B+)
PASSENGER HEATED SEAT MODULE C2 (EXPORT) - GRAY 2 WAY

1 S1 18WT SEAT BACK HEATER B(+) DRIVER
2 S2 18GY SEAT BACK HEATER GROUND
PASSENGER HEATED SEAT MODULE C3 (EXPORT) - GREEN 4 WAY

1 P87 16LG/OR SEAT TEMP SENSOR INPUT
2 P89 20LG/BR SEAT SENSOR 5 VOLT SUPPLY
4 P88 16LG/LB SEAT CUSHION HEATER B(+) DRIVER
PASSENGER POWER SEAT FRONT RISER MOTOR - RED 2 WAY

1 P18 14LG/OR PASSENGER FRONT UP SWITCH SENSE
2 P20 14LG/LB PASSENGER FRONT DOWN SWITCH SENSE
PASSENGER POWER SEAT HORIZONTAL MOTOR - BLACK 2 WAY

1 P14 14LG/OR PASSENGER HORIZONTAL FORWARD SWITCH SENSE
2 P16 14LG/WT PASSENGER HORIZONTAL REARWARD SWITCH
SENSE
PASSENGER POWER SEAT REAR RISER MOTOR - RED 2 WAY

1 P10 14LG/TN PASSENGER REAR UP SWITCH SENSE
2 P12 14LG/YL PASSENGER REAR DOWN SWITCH SENSE
PASSENGER POWER SEAT RECLINER MOTOR - GREEN 2 WAY

1 P44 14LG/VT PASSENGER RECLINER UP SWITCH SENSE
2 P42 14LG/GY PASSENGER RECLINER DOWN SWITCH SENSE
PASSENGER POWER SEAT SWITCH - GREEN 10 WAY

2 P44 14LG/VT PASSENGER RECLINER UP SWITCH SENSE
3 P16 14LG/WT PASSENGER HORIZONTAL REARWARD SWITCH
SENSE
4 P42 14LG/GY PASSENGER RECLINER DOWN SWITCH SENSE
6 P14 14LG/OR PASSENGER HORIZONTAL FORWARD SWITCH SENSE
7 P20 14LG/LB PASSENGER FRONT DOWN SWITCH SENSE
8 P12 14LG/YL PASSENGER REAR DOWN SWITCH SENSE
9 P10 14LG/TN PASSENGER REAR UP SWITCH SENSE
10 P18 14LG/OR PASSENGER FRONT UP SWITCH SENSE
PASSENGER POWER WINDOW MOTOR - RED 2 WAY

1 Q12 14OR/BR PASSENGER WINDOW DRIVER (UP)
2 Q22 14OR/VT PASSENGER WINDOW DRIVER (DOWN)
PASSENGER POWER WINDOW SWITCH - BLACK 8 WAY

3 Q16 12OR/TN MASTER WINDOW SWITCH RIGHT PASSENGER (UP)
4 - -
5 Q22 14OR/VT (RHD) RIGHT FRONT WINDOW DRIVER (DOWN)
6 - -
7 - -
8 Q12 14OR/BR (RHD) RIGHT FRONT WINDOW DRIVER (UP)
PASSENGER SEAT BELT SWITCH (OCCUPANT SENSING) - YELLOW 2 WAY

1 R58 16LB/GY PASSENGER SEAT BELT SWITCH SENSE
2 R60 16LB/TN PASSENGER SEAT BELT SWITCH GROUND
PASSENGER SEAT BELT TENSIONER - 2 WAY

1 R56 18LB/DG (EXCEPT EXPORT) PASSENGER SEAT BELT TENSIONER LINE 1
1 R54 18LB/YL (EXPORT) PASSENGER SEAT BELT TENSIONER LINE 2
2 R54 18LB/YL (EXCEPT EXPORT) PASSENGER SEAT BELT TENSIONER LINE 2
2 R56 18LB/DG (EXPORT) PASSENGER SEAT BELT TENSIONER LINE 1
PASSENGER SEAT WEIGHT SENSOR - BLACK 3 WAY

A R941 20LG/DG PASSENGER BLADDER PRESSURE SENSOR GROUND
B R741 20LG/VT PASSENGER BLADDER PRESSURE SENSOR SIGNAL
C R740 20LG/OR PASSENGER BLADDER PRESSURE SENSOR POWER
POWER FOLDING MIRROR SWITCH (EXPORT) - BLACK 2 WAY

1 P136 20TN/YL FOLDING MIRROR SWITCH SENSE
POWER LIFTGATE MODULE C1 - BLACK 8 WAY

1 Q83 18OR/GY LIFTGATE LATCH CLUTCH DRIVER
2 Q88 16TN/BR LIFTGATE OPEN DRIVER
3 Q89 16TN/OR LIFTGATE CLOSE DRIVER
4 - -
6 - -
7 - -
POWER LIFTGATE MODULE C2 - 20 WAY

1 Q90 20TN/VT LIFTGATE HALL EFFECT SUPPLY
2 - -
3 Q151 22TN/DB (EXCEPT EXPORT) LIFTGATE ENGAGE/DISENGAGE SWITCH SENSE
3 Q151 20TN/DB (EXPORT) LIFTGATE ENGAGE/DISENGAGE SWITCH SENSE
4 - -
5 Q76 22OR/LB PINCH SENSOR SIGNAL
6 - -
7 Q86 18OR/DB LIFTGATE GEAR ENGAGE DRIVER
8 Q84 18TN/GY LIFTGATE LATCH CINCH DRIVER
9 Q85 18TN/WT LIFTGATE LATCH RELEASE DRIVER
10 Q87 18OR/LG LIFTGATE GEAR DISENGAGE DRIVER
13 Q60 22OR/YL LIFTGATE PAWL SWITCH SENSE
14 Q51 22OR LIFTGATE FULL OPEN SWITCH SENSE
15 - -
16 G32 20VT/LB LIFTGATE TEMPERATURE SENSOR SIGNAL
17 Q91 20TN/YL LIFTGATE HALL EFFECT SIGNAL
18 Q94 22TN/LG LIFTGATE CHIME DRIVER
19 G153 20VT/DG LIFTGATE MODULE WAKE UP SIGNAL
POWER LIFTGATE MOTOR - BLACK 10 WAY

2 Q51 22OR LIFTGATE FULL OPEN SWITCH SENSE
3 Q151 22TN/DB (EXCEPT EXPORT) LIFTGATE ENGAGE/DISENGAGE SWITCH SENSE
3 Q151 20TN/DB (EXPORT) LIFTGATE ENGAGE/DISENGAGE SWITCH SENSE
4 Q87 18OR/LG LIFTGATE GEAR DISENGAGE DRIVER
5 Q86 18OR/DB LIFTGATE GEAR ENGAGE DRIVER
6 Q88 16TN/BR LIFTGATE OPEN DRIVER
7 Q90 20TN/VT LIFTGATE HALL EFFECT SUPPLY
8 Q91 20TN/YL LIFTGATE HALL EFFECT SIGNAL
10 Q89 16TN/OR LIFTGATE CLOSE DRIVER
POWER MIRROR SWITCH - BLACK 13 WAY

1 P70 20TN/LB RIGHT MIRROR COMMON DRIVER (RIGHT/DOWN)
1 P70 20TN/LB (MEMORY) RIGHT MIRROR COMMON DRIVER (RIGHT/DOWN)
2 - -
3 - -
4 - -
5 - -
6 P73 20TN/YL LEFT MIRROR COMMON DRIVER (RIGHT/DOWN)
6 P73 20TN/YL (MEMORY) LEFT MIRROR COMMON DRIVER (RIGHT/DOWN)
7 P75 20TN/LG LEFT MIRROR LEFT DRIVER
7 P75 20TN/LG (MEMORY) LEFT MIRROR LEFT DRIVER
8 P74 20TN/DB RIGHT MIRROR LEFT DRIVER
8 P74 20TN/DB (MEMORY) RIGHT MIRROR LEFT DRIVER
10 - -
12 P71 20TN/DG LEFT MIRROR UP DRIVER
12 P71 20TN/DG (MEMORY) LEFT MIRROR UP DRIVER
13 P72 20TN/GY RIGHT MIRROR UP DRIVER
13 P72 20TN/GY (MEMORY) RIGHT MIRROR UP DRIVER
POWER OUTLET (EXCEPT LOWLINE) - BLACK 3 WAY

2 - -
POWER SEAT CIRCUIT BREAKER (30A) - GRAY 2 WAY

2 A210 14OR/RD FUSED SEAT SWITCH DRIVER
2 A210 14OR/RD FUSED SEAT SWITCH DRIVER
POWER WINDOW CIRCUIT BREAKER (25A) - GRAY 2 WAY

1 F30 12PK/YL FUSED IGNITION SWITCH OUTPUT (RUN-ACC)
POWER WINDOW SWITCH (LHD LOWLINE) - BLACK 8 WAY

4 - -
8 Q26 14OR/GY MASTER WINDOW SWITCH PASSENGER (DOWN)
POWERTRAIN CONTROL MODULE C1 - BLACK 38 WAY

1 - -
2 - -
3 - -
4 - -
5 - -
6 - -
7 - -
8 - -
10 - -
12 F1 18PK/WT (EATX) FCM OUTPUT (UNLOCK-RUN-START)
13 N7 18DB/OR (MTX) VEHICLE SPEED SENSOR SIGNAL
14 - -
15 - -
16 - -
17 - -
19 - -
21 - -
22 G31 18VT/LG AAT SIGNAL
23 - -
24 - -
25 D20 20WT/LG SCI RECEIVE (PCM)
26 D123 20WT/BR (2.4L EATX) SCI RECEIVE (TCM)
26 D123 20WT/OR (3.3L/3.8L) SCI RECEIVE (TCM)
27 - -
28 - -
31 K141 18DB/YL O2 1/2 SIGNAL
32 K904 18DB/DG (2.4L) O2 RETURN (DOWN)
32 K904 18BR/DG (3.3L/3.8L) O2 RETURN (DOWN)
33 - -
34 - -
35 - -
36 D21 20WT/DG (2.4L) SCI TRANSMIT (PCM)
36 D21 20WT/BR (3.3L/3.8L) SCI TRANSMIT (PCM)
37 D15 18DG/YL (EATX) SCI TRANSMIT (TCM)
POWERTRAIN CONTROL MODULE C2 - ORANGE 38 WAY

1 - -
2 - -
3 - -
4 K58 16BR/VT (3.3L/3.8L) INJECTOR CONTROL NO. 6
5 K38 16BR/OR (3.3L/3.8L) INJECTOR CONTROL NO. 5
6 - -
7 K18 16BR/OR (3.3L/3.8L) COIL CONTROL NO. 3
8 K35 18DB/VT (3.3L) EGR SOLENOID CONTROL
9 K17 16DB/TN IGNITION COIL NO. 2 DRIVER
11 K14 16 BR/TN INJECTOR CONTROL NO. 4
12 K13 16BR/LB INJECTOR CONTROL NO. 3
13 K12 16BR/DB INJECTOR CONTROL NO. 2
14 K11 16BR/YL INJECTOR CONTROL NO. 1
15 - -
16 - -
17 - -
18 K99 18BR/LG O2 1/1 HEATER CONTROL
19 K20 18BR/GY GEN FIELD CONTROL
20 K2 18VT/OR ECT SIGNAL
21 K22 18BR/OR TP SIGNAL
22 K34 18DB/LG (3.3L) EGR SOLENOID SIGNAL
23 K1 18VT/BR MAP SIGNAL
24 K942 18BR/LG (EXCEPT 3.3L) KS RETURN
25 K42 18DB/YL (EXCEPT 3.3L) KS SIGNAL
26 - -
28 K961 18BR/VT IAC RETURN
30 K21 18DB/LG IAT SIGNAL
31 K41 18DB/LB O2 1/1 SIGNAL
32 K902 18BR/DG O2 RETURN (UP)
33 - -
34 K44 18DB/GY CMP SIGNAL
35 K24 18BR/LB CKP SIGNAL
36 - -
37 - -
38 K61 18VT/GY IAC MOTOR CONTROL
POWERTRAIN CONTROL MODULE C3 - NATURAL 38 WAY

1 - -
2 - -
3 K51 18BR/WT ASD RELAY CONTROL
4 - -
5 V35 18VT/OR S/C VENT CONTROL
6 K173 18BR/VT RAD FAN RELAY CONTROL
7 V32 18VT/YL SPEED CONTROL SUPPLY
8 K106 20VT/LB (EXCEPT EXPORT) NVLD SOL CONTROL
9 K299 18BR/WT O2 1/2 HEATER CONTROL
10 - -
11 C13 18LB/OR A/C CLUTCH RELAY CONTROL
12 V36 18VT/YL S/C VACUUM CONTROL
13 - -
14 - -
15 - -
16 - -
17 - -
18 - -
20 K52 18DB/WT EVAP PURGE CONTROL
21 T141 18YL (MTX EXPORT) FUSED IGNITION SWITCH OUTPUT (START)
22 - -
23 B29 18DG/WT BRAKE SWITCH SIGNAL
24 - -
25 - -
26 - -
27 - -
29 K70 18DB/BR EVAP PURGE SIGNAL
30 - -
31 C18 18LB/BR A/C PRESSURE SIGNAL
32 K91 18DB/YL BATTERY TEMP SIGNAL
33 - -
34 V37 18VT S/C SWITCH NO. 1 SIGNAL
35 K107 20VT/WT (EXCEPT EXPORT) NVLD SWITCH SIGNAL
36 - -
37 K31 18BR FUEL PUMP RELAY CONTROL
38 T752 18DG/OR STARTER RELAY CONTROL
POWERTRAIN CONTROL MODULE C4 - GREEN 38 WAY

1 T60 18YL/GY OVERDRIVE SOLENOID CONTROL
2 T59 18DB/LB UNDERDRIVE SOLENOID CONTROL
3 - -
4 - -
5 - -
6 T19 18YL/DB 2-4 SOLENOID CONTROL
7 - -
8 - -
9 - -
10 T20 18DG/WT LOW/REVERSE SOLENOID CONTROL
11 - -
12 - -
15 T1 18DG/LB TRS T1 SENSE
16 T3 18DG/DB TRS T3 SENSE
17 - -
18 T15 18YL/BR TRANSMISSION CONTROL RELAY CONTROL
19 T16 18YL/OR TRANSMISSION CONTROL RELAY OUTPUT
20 - -
21 - -
22 T9 18DG/TN OVERDRIVE PRESSURE SWITCH SENSE
23 - -
24 - -
25 - -
26 - -
27 T41 18DG/GY TRS T41 SENSE
29 T50 18YL/TN LOW/REVERSE PRESSURE SWITCH SENSE
30 T47 18YL/DG 2-4 PRESSURE SWITCH SENSE
31 - -
35 T54 18DG/OR TRANSMISSION TEMPERATURE SENSOR SIGNAL
36 - -
37 T42 18DG/YL TRS T42 SENSE
RADIATOR FAN NO. 1 (DIESEL) - GRAY 2 WAY

1 N201 12DB/LG RADIATOR FAN RELAY NO. 1 OUTPUT
2 N202 12DB/OR RADIATOR FAN NO. 1 CONTROL
RADIATOR FAN NO. 1 (GAS) - BLACK 2 WAY

1 N23 12DB/DG RADIATOR FAN RELAY OUTPUT
RADIATOR FAN NO. 2 (DIESEL) - GRAY 2 WAY

1 N112 12DB/OR RADIATOR FAN RELAY NO. 2 AND NO. 3 COMMON
OUTPUT
RADIATOR FAN NO. 2 (GAS) - BLACK 2 WAY

RADIATOR FAN RELAY (GAS) - 4 WAY

4 N173 18DB/VT RAD FAN RELAY CONTROL
RADIATOR FAN RELAY NO. 1 (DIESEL) - BLUE 9 WAY

1 - -
2 N201 12DB/LG RADIATOR FAN RELAY NO. 1 OUTPUT
3 - -
5 - -
6 N210 18DB/DG LOW SPEED RADIATOR FAN RELAY CONTROL
7 - -
8 A201 12RD/LG FUSED B(+)
9 - -

1 - -
OUTPUT
3 - -
5 - -
7 - -
9 - -

1 - -
3 - -
OUTPUT
7 - -
8 N202 12DB/OR RADIATOR FAN NO. 1 CONTROL
9 - -
RADIO C1 - 22 WAY
4 - -
5 - -
6 - -
7 X54 20GY (LOWLINE) RIGHT FRONT SPEAKER (+)
8 X56 20GY/BR (LOWLINE) RIGHT FRONT SPEAKER (-)
9 X55 20DG/BR (LOWLINE) LEFT FRONT SPEAKER (-)
10 X53 20DG (LOWLINE) LEFT FRONT SPEAKER (+)
13 X60 20GY/YL (EXPORT) RADIO 12 VOLT OUTPUT
15 - -
16 - -
17 - -
18 X51 22DG/DB LEFT REAR SPEAKER (+)
19 X57 22DG/OR LEFT REAR SPEAKER (-)
20 X58 22GY/OR RIGHT REAR SPEAKER (-)
21 X52 22GY/DB RIGHT REAR SPEAKER (+)
22 Z515 16BK GROUND
RADIO C2 (CD CHANGER) - 10 WAY

1 X40 22GY/WT (EXCEPT EXPORT) AUDIO OUT RIGHT
1 X40 20GY/WT (EXPORT) AUDIO OUT RIGHT
2 X140 22GY/OR (EXCEPT EXPORT) COMMON AUDIO
2 Z140 18BK/OR (EXPORT) GROUND
3 X235 20GY/LB (EXCEPT EXPORT) SHIELD
4 D25 20WT/VT (EXCEPT EXPORT) PCI BUS
4 D25 20VT/YL (EXPORT) PCI BUS
5 X112 20DG/GY (EXCEPT EXPORT) IGNITION SWITCH SIGNAL
5 X112 20RD (EXPORT) IGNITION SWITCH SIGNAL
6 X41 22DG/WT (EXCEPT EXPORT) AUDIO OUT LEFT
6 X41 20DG/WT (EXPORT) AUDIO OUT LEFT
7 Z141 20BK/TN (EXCEPT EXPORT) GROUND
7 Z141 18BK/TN (EXPORT) GROUND
8 - -
9 E14 22OR/TN (EXCEPT EXPORT) PANEL LAMPS DRIVER
9 E14 18OR/TN (EXPORT) PANEL LAMPS DRIVER
RADIO C2 (DVD/CD CHANGER) - DK. GRAY 10 WAY

3 X235 20GY/LB SHIELD
7 - -
8 - -
10 - -
RADIO C2 (HANDS FREE) - 10 WAY

1 X704 22GY/WT RIGHT AUDIO OUTPUT
2 X795 22GY/OR AUDIO GROUND
3 X207 20GY/LB (CD CHANGER) SHIELD
3 X955 22 (DVD/CD CHANGER) SHIELD
5 X112 20DG/GY IGNITION RUN/ACC SIGNAL
6 X703 22DG/WT LEFT AUDIO OUTPUT
8 - -
REAR A/C-HEATER UNIT (3 ZONE MTC) - LT. GREEN 10 WAY

1 C53 20LB REAR MODE DOOR DRIVER
2 C154 20LB/OR REAR COMMON DOOR DRIVER
3 C51 12LB/BR FUSED REAR BLOWER MOTOR RELAY OUTPUT
4 C152 16LB/LG REAR BLOWER MOTOR MED
5 C151 18LB/DG REAR BLOWER MOTOR LOW
6 C153 12DB/BR REAR BLOWER MOTOR HIGH
7 C54 20LB/YL REAR BLEND DOOR DRIVER
8 C154 20LB/OR REAR COMMON DOOR DRIVER
9 - -
10 - -
REAR AUTO TEMP CONTROL SWITCH (3 ZONE ATC) - BLACK 13 WAY

3 D22 22WT/TN KDB CLOCK
4 D17 22WT/DG KDB DATA
5 E10 20OR/DG PANEL LAMPS DRIVER
6 - -
7 - -
8 - -
9 - -
10 - -
11 - -
12 - -
13 - -
REAR BLOWER FRONT CONTROL SWITCH (3 ZONE MTC) - BLACK 8 WAY

1 - -
3 - -
5 - -
8 C50 12DB/OR REAR BLOWER FRONT CONTROL FEED
REAR BLOWER MOTOR POWER MODULE C1 (3 ZONE ATC) - RED/BLACK 4 WAY

1 C51 12DB/BR FUSED REAR BLOWER MOTOR RELAY OUTPUT
2 C59 18DB/LB BLOWER MOTOR CONTROL
4 - -
REAR BLOWER MOTOR POWER MODULE C2 (3 ZONE ATC) - BLACK 2 WAY

1 12BK GROUND
2 12DG POWER FEED
REAR BLOWER REAR CONTROL SWITCH C1 (3 ZONE MTC) - BLACK 4 WAY

4 C50 12DB/OR REAR BLOWER FRONT CONTROL FEED
REAR BLOWER REAR CONTROL SWITCH C2 (3 ZONE MTC) - BLACK 6 WAY

1 - -
2 C22 20LB/DB REAR TEMPERATURE FEEDBACK SIGNAL
3 E10 20OR/DG PANEL LAMPS DRIVER
4 F850 20LB/PK 5 VOLT SUPPLY
5 C121 20DB/DG REAR TEMPERATURE RETURN
REAR DOME LAMP (EXCEPT LUXURY) - GRAY 3 WAY

3 - -
REAR INTRUSION SENSOR (UNITED KINGDOM) - 3 WAY

1 A645 20RD/VT REAR INTRUSION SENSOR SIGNAL
2 - -
3 G945 20VT/DG SENSOR GROUND
REAR MODE MOTOR (3 ZONE ATC) - GRAY 2 WAY

1 C154 18LB/GY REAR MODE DOOR DRIVER (B)
2 C53 18LB REAR MODE DOOR DRIVER (A)
REAR POWER OUTLET - GRAY 3 WAY

1 F307 18LB/PK (ACCESSORY RELAY FUSED ACCESSORY RELAY OUTPUT
POSITION)
1 F307 18LB/PK (BATTERY POSITION) FUSED B(+)
2 - -
REAR TEMPERATURE MOTOR (3 ZONE ATC) - GRAY 2 WAY

1 C54 18LB/YL REAR BLEND DOOR DRIVER (A)
2 C169 18LB/TN REAR BLEND DOOR DRIVER (B)
REAR VIEW MIRROR C1 (LUXURY) - BLACK 7 WAY

1 F503 20BK/PK (EXCEPT HANDS FREE) FUSED IGNITION SWITCH OUTPUT (RUN)
1 X793 20DB (HANDS FREE) IGNITION RUN/ACC SIGNAL
2 Z113 20BK (EXCEPT HANDS FREE) GROUND
2 Z530 18GY/BK (HANDS FREE) GROUND
3 L1 20BK/WT BACK-UP LAMP FEED
4 P112 22BK/OR (EXCEPT HANDS FREE) MIRROR B(+)
5 P114 22BK/LB (EXCEPT HANDS FREE) MIRROR B(-)
6 - -
7 L24 20BK/GY (EXCEPT HANDS FREE) AUTOMATIC HEADLAMP SWITCH SENSOR
REAR VIEW MIRROR C2 (HANDS FREE) - BLACK 12 WAY

1 - -
2 - -
3 - -
4 X722 20BK/LB MICROPHONE 2 IN (+)
5 - -
6 X712 20BK/GY MICROPHONE 1 IN (+)
7 X793 20DB IGNITION RUN/ACC SIGNAL
8 - -
9 X730 20BK/VT VOICE RECOGNITION/PHONE SWITCH SIGNAL
10 - -
11 X835 20BK SENSOR GROUND
12 X792 20BK/WT MICROPHONE IN (-)
REAR WIPER MOTOR - 3 WAY

1 W13 18BR/LG REAR WIPER MOTOR CONTROL
RECIRCULATION DOOR ACTUATOR - GRAY 2 WAY

1 C132 20DB/YL (ATC) RECIRCULATION DOOR DRIVER (B)
1 C34 20DB/LB (LHD) COMMON DOOR DRIVER (B)
1 C32 20DB/TN (RHD) RECIRCULATION DOOR DRIVER (A)
2 C32 20DB/TN (ATC) RECIRCULATION DOOR DRIVER (A)
2 C32 20DB/TN (LHD) RECIRCULATION DOOR DRIVER (A)
2 C34 20DB/LB (RHD) COMMON DOOR DRIVER (B)
RIGHT B-PILLAR SWITCH (POWER SLIDING DOOR) - GRAY 3 WAY

2 - -
3 G42 22VT/YL RIGHT SLIDING DOOR PILLAR SWITCH MUX
RIGHT CINCH/RELEASE MOTOR (POWER SLIDING DOOR) - GRAY 4 WAY

1 Q46 18TN/GY RIGHT CINCH/RELEASE MOTOR LATCH DRIVER
3 Q44 18OR/GY RIGHT CINCH/RELEASE MOTOR CLUTCH DRIVER
4 Q48 18TN/WT RIGHT CINCH/RELEASE MOTOR UNLATCH DRIVER
RIGHT CURTAIN AIRBAG SQUIB - 2 WAY

1 R2 20WT/LB RIGHT CURTAIN SQUIB LINE 2
2 R4 20OR/LB RIGHT CURTAIN SQUIB LINE 1
RIGHT CYLINDER LOCK SWITCH (EXPORT) - BLACK 2 WAY

2 G162 20VT/WT RIGHT CYLINDER LOCK SWITCH MUX
RIGHT DOOR SPEAKER - 3 WAY

1 X292 18GY/BR (HIGHLINE) AMPLIFIED RIGHT FRONT SPEAKER (-)
1 X56 20GY/BR (LOWLINE) RIGHT FRONT SPEAKER (-)
2 - -
3 X202 18GY (HIGHLINE) AMPLIFIED RIGHT FRONT SPEAKER (+)
3 X54 20GY (LOWLINE) RIGHT FRONT SPEAKER (+)
RIGHT FOG LAMP - BLACK 2 WAY

A L90 18WT/OR FRONT FOG LAMP RELAY OUTPUT
B Z348 18BK/OR GROUND
RIGHT FRONT DOOR AJAR SWITCH (BASE) - BLACK 2 WAY

1 G74 20VT/WT RIGHT FRONT DOOR AJAR SWITCH SENSE
RIGHT FRONT DOOR LOCK MOTOR/AJAR SWITCH (EXCEPT BASE) - BLACK 4 WAY
1 G74 20VT/WT RIGHT FRONT DOOR AJAR SWITCH SENSE
3 P4 20TN/BR RIGHT FRONT DOOR UNLOCK DRIVER
4 P2 20TN/GY RIGHT FRONT DOOR LOCK DRIVER
RIGHT FRONT IMPACT SENSOR - BLACK 2 WAY

1 R82 18WT/LB RIGHT FRONT IMPACT SENSOR GROUND
2 R80 18VT/LB RIGHT FRONT IMPACT SENSOR SIGNAL
RIGHT FRONT PARK/TURN SIGNAL LAMP - BLACK 3 WAY

RIGHT FRONT WHEEL SPEED SENSOR - GRAY 2 WAY

1 B7 18DG/VT RIGHT FRONT WHEEL SPEED SENSOR 12 VOLT
SUPPLY
2 B6 18DG/WT RIGHT FRONT WHEEL SPEED SENSOR SIGNAL
RIGHT FULL OPEN SWITCH (POWER SLIDING DOOR) - BLACK 2 WAY

1 Q52 20OR RIGHT FULL OPEN SWITCH SENSE
RIGHT HEADLAMP (CARAVAN/VOYAGER EXCEPT EXPORT) - BLACK 3 WAY

RIGHT HEADLAMP (TOWN AND COUNTRY) - GREEN 3 WAY

RIGHT HEADLAMP LEVELING MOTOR (EXPORT) - WHITE 3 WAY

1 Z203 16BR GROUND
2 L78 16BK FUSED PARK LAMP RELAY OUTPUT (RIGHT)
3 L13 16RD HEADLAMP ADJUST SIGNAL
RIGHT HIGH BEAM LAMP (EXPORT) - BLACK 2 WAY

1 Z344 16BR GROUND
1 Z344 16BR GROUND
2 L34 16GY RIGHT HIGH BEAM DRIVER
RIGHT INSTRUMENT PANEL SPEAKER - WHITE 2 WAY

1 X154 20GY/YL (EXPORT/LOWLINE) RIGHT INSTRUMENT PANEL SPEAKER (+)
1 X154 18GY/YL (HIGHLINE EXCEPT RIGHT INSTRUMENT PANEL SPEAKER (+)
EXPORT)
2 X156 20GY/LB (EXPORT/LOWLINE) RIGHT INSTRUMENT PANEL SPEAKER (-)
2 X156 18GY/LB (HIGHLINE EXCEPT RIGHT INSTRUMENT PANEL SPEAKER (-)
EXPORT)
RIGHT LIFTGATE FLOOD LAMP - GRAY 3 WAY

2 - -
3 M11 20YL/VT (EXPORT POWER LIFT- COURTESY LAMPS DRIVER
GATE)
RIGHT LOW BEAM LAMP (EXPORT) - BLACK 2 WAY

1 Z344 16BR GROUND
2 L44 16WT RIGHT LOW BEAM DRIVER
RIGHT MID READING LAMP (PREMIUM/LUXURY) - GRAY 3 WAY

RIGHT PARK LAMP (EXPORT) - BLACK 2 WAY

1 Z344 16BR GROUND
2 L78 16BK FUSED PARK LAMP RELAY OUTPUT (RIGHT)
RIGHT POWER MIRROR - BLACK 12 WAY

1 P174 20TN/LB (EXPORT) RIGHT FOLDING MIRROR UNFOLD DRIVER
2 - -
3 - -
4 P68 20TN/YL (MEMORY) RIGHT MIRROR HORIZONTAL POSITION SIGNAL
5 P66 20TN/LG (MEMORY) RIGHT MIRROR SENSOR GROUND
6 P67 20TN/OR (MEMORY) RIGHT MIRROR VERTICAL POSITION SIGNAL
7 P160 20TN/LG (LHD EXPORT) PASSENGER FOLDING MIRROR RELAY OUTPUT
7 P159 20TN/DG (RHD) DRIVER FOLDING MIRROR FOLD DRIVER
9 C16 20DB/GY (HEATED MIRRORS) FUSED DEFOGGER RELAY OUTPUT
10 P70 20TN/LB RIGHT MIRROR COMMON DRIVER (RIGHT/DOWN)
11 P72 20TN/GY RIGHT MIRROR UP DRIVER
12 P74 20TN/DB RIGHT MIRROR LEFT DRIVER
RIGHT REAR LAMP ASSEMBLY - BLACK 6 WAY

1 L62 18WT/BR (EXCEPT EXPORT) RIGHT REAR TURN SIGNAL DRIVER
1 Z362 18BK/BR (EXPORT) GROUND
2 L62 18WT/BR (EXPORT) RIGHT REAR TURN SIGNAL DRIVER
3 L78 18WT/OR (EXCEPT EXPORT/EX- FUSED PARK LAMP RELAY OUTPUT (RIGHT)
CEPT TRAILER TOW)
3 L50 18WT/TN (GAS EXPORT) BRAKE LAMP SWITCH OUTPUT
3 L78 18WT/TN (TRAILER TOW) FUSED PARK LAMP RELAY OUTPUT (RIGHT)
4 L1 18WT/LG (EXCEPT TRAILER TOW) BACK-UP LAMP FEED
4 L1 18 WT/PK (TRAILER TOW) BACK-UP LAMP FEED
5 Z362 18BK/BR (EXCEPT EXPORT/EX- GROUND
CEPT TRAILER TOW)
5 Z362 18BR/OR (TRAILER TOW) GROUND
6 L78 18WT/OR (EXPORT) FUSED PARK LAMP RELAY OUTPUT (RIGHT)
RIGHT REAR PILLAR SPEAKER (HIGHLINE AUDIO) - BLACK 2 WAY

1 X212 18GY/DB (EXCEPT EXPORT) AMPLIFIED RIGHT REAR TWEETER (-)
1 X212 20GY/DB (EXPORT) AMPLIFIED RIGHT REAR TWEETER (-)
2 X282 18GY/TN (EXCEPT EXPORT) AMPLIFIED RIGHT REAR TWEETER (+)
2 X282 20GY/TN (EXPORT) AMPLIFIED RIGHT REAR TWEETER (+)
RIGHT REAR READING LAMP (LUXURY) - GRAY 3 WAY

RIGHT REAR SPEAKER - 3 WAY

1 X296 18DG/GY (HIGHLINE EXCEPT AMPLIFIED RIGHT REAR SPEAKER (-)
EXPORT)
1 X296 20DG/GY (HIGHLINE EXPORT) AMPLIFIED RIGHT REAR SPEAKER (-)
1 X58 20GY/OR (LOWLINE) RIGHT REAR SPEAKER (-)
2 - -
3 X206 18GY/DB (HIGHLINE EXCEPT AMPLIFIED RIGHT REAR SPEAKER (+)
EXPORT
3 X206 20GY/DB (HIGHLINE EXPORT) AMPLIFIED RIGHT REAR SPEAKER (+)
3 X52 20GY/DB (LOWLINE) RIGHT REAR SPEAKER (+)
RIGHT REAR VENT MOTOR - NATURAL 3 WAY

1 - -
2 Q14 16OR/BR (LHD) PASSENGER SIDE REAR WINDOW CLOSE
2 Q13 16OR/DB (RHD) DRIVER SIDE REAR WINDOW CLOSE
3 Q24 16OR/DG (LHD) PASSENGER SIDE REAR WINDOW OPEN
3 Q23 16OR/LB (RHD) DRIVER SIDE REAR WINDOW OPEN
RIGHT REAR WHEEL SPEED SENSOR - BLACK 2 WAY

1 B2 18DG/LB RIGHT REAR WHEEL SPEED SENSOR 12 VOLT SUP-
PLY
2 B1 18DG/OR RIGHT REAR WHEEL SPEED SENSOR SIGNAL
RIGHT REMOTE RADIO SWITCH - BLACK 2 WAY

RIGHT REPEATER LAMP (EXPORT) - GRAY 2 WAY

2 L162 20WT/VT RIGHT SIDE REPEATER LAMP FEED
RIGHT SIDE IMPACT SENSOR 1 (EXCEPT EXPORT) - 2 WAY

1 R16 20BR/LG RIGHT SIDE IMPACT SENSOR 1 GROUND
2 R14 20TN/LG RIGHT SIDE IMPACT SENSOR 1 SIGNAL
RIGHT SIDE IMPACT SENSOR 1 (EXPORT) - BLACK 2 WAY

1 R16 20BR/LG RIGHT SIDE IMPACT SENSOR 1 GROUND
2 R14 20TN/LG RIGHT SIDE IMPACT SENSOR 1 SIGNAL
RIGHT SIDE IMPACT SENSOR 2 - 2 WAY

1 R20 18WT/LG RIGHT SIDE IMPACT SENSOR 2 GROUND
2 R18 18LB RIGHT SIDE IMPACT SENSOR 2 SIGNAL
RIGHT SIDE IMPACT SENSOR 3 - BLACK 2 WAY

1 R24 20YL/LB RIGHT SIDE IMPACT SENSOR 3 GROUND
2 R22 20WT/LB RIGHT SIDE IMPACT SENSOR 3 SIGNAL
RIGHT SLIDING DOOR CONTROL MODULE C1 (POWER SLIDING DOOR) - BLACK 8 WAY
1 Q44 18OR/GY RIGHT CINCH/RELEASE MOTOR CLUTCH DRIVER
2 Q68 16TN/BR RIGHT SLIDING DOOR OPEN DRIVER
3 Q70 16TN/OR RIGHT SLIDING DOOR CLOSE DRIVER
4 - -
5 A113 14WT/RD FUSED B(+)
6 - -
7 - -
8 Z124 14BK GROUND
RIGHT SLIDING DOOR CONTROL MODULE C2 (POWER SLIDING DOOR) - 20 WAY

1 Q72 20TN/VT RIGHT DOOR MOTOR HALL EFFECT SUPPLY
2 - -
3 Q34 20OR/GY RIGHT DOOR LOCK SENSE
4 Q54 20OR/BR RIGHT DOOR IN/OUT HANDLE SWITCH SENSE
5 - -
6 - -
7 Q64 18OR/TN RIGHT DOOR MOTOR CLUTCH DRIVER
8 Q46 18TN/GY RIGHT CINCH/RELEASE MOTOR LATCH DRIVER
9 Q48 18TN/WT RIGHT CINCH/RELEASE MOTOR UNLATCH DRIVER
10 - -
12 G76 20TN/OR RIGHT SLIDING DOOR AJAR SWITCH SENSE
13 Q58 20OR/YL RIGHT PAWL SWITCH SENSE
14 Q52 20OR RIGHT FULL OPEN SWITCH SENSE
15 - GROUND-DRIVER SIDE IDENTIFIER (LHD/RHD)
16 - -
17 Q74 20TN/YL RIGHT DOOR MOTOR HALL EFFECT SIGNAL
18 - -
19 G152 20VT/GY RIGHT SLIDING DOOR WAKE UP SIGNAL
RIGHT SLIDING DOOR LATCH SENSING SWITCH (POWER SLIDING DOOR) - BLACK 6 WAY
2 Q58 20OR/YL RIGHT PAWL SWITCH SENSE
3 G76 20TN/OR RIGHT SLIDING DOOR AJAR SWITCH SENSE
5 Q54 20OR/BR RIGHT DOOR IN/OUT HANDLE SWITCH SENSE
6 - -
RIGHT SLIDING DOOR LOCK MOTOR (POWER SLIDING DOOR) - BLACK 4 WAY
1 P38 20TN/DB RIGHT SLIDING DOOR LOCK DRIVER
2 P34 20TN/LB RIGHT SLIDING DOOR UNLOCK DRIVER
3 Q34 20OR/GY RIGHT DOOR LOCK SENSE
RIGHT SLIDING DOOR LOCK MOTOR/AJAR SWITCH (MANUAL SLIDING DOOR) - BLACK 4 WAY
1 P38 20BK/DB RIGHT SLIDING DOOR LOCK DRIVER
2 P34 20BK/TN RIGHT SLIDING DOOR UNLOCK DRIVER
3 G76 20BK/DG RIGHT SLIDING DOOR AJAR SWITCH SENSE
4 Z76 20BK GROUND
RIGHT SLIDING DOOR MOTOR (POWER SLIDING DOOR) - BLACK 8 WAY

1 - -
2 Q72 20TN/VT RIGHT DOOR MOTOR HALL EFFECT SUPPLY
3 Q68 16TN/BR RIGHT SLIDING DOOR OPEN DRIVER
5 Q64 18OR/TN RIGHT DOOR MOTOR CLUTCH DRIVER
6 Q70 16TN/OR RIGHT SLIDING DOOR CLOSE DRIVER
8 Q74 20TN/YL RIGHT DOOR MOTOR HALL EFFECT SIGNAL
RIGHT SPEED CONTROL SWITCH - WHITE 2 WAY

A V37 20VT (DIESEL) SPEED CONTROL SWITCH SIGNAL
A V37 20VT (GAS) S/C SWITCH NO. 1 SIGNAL
B Z23 20BK/VT RIGHT SPEED CONTROL SWITCH GROUND
RIGHT TURN SIGNAL LAMP (EXPORT) - ORANGE 2 WAY

1 Z344 16BR GROUND
2 L60 16YL RIGHT FRONT TURN SIGNAL DRIVER
RIGHT VISOR/VANITY LAMP (EXCEPT BASE/EXPORT) - BLACK 2 WAY

A Z327 20BK/OR GROUND
B M27 20YL/LB READING LAMPS DRIVER
SENTRY KEY REMOTE ENTRY MODULE (SKREEM) - BLACK 6 WAY

1 - -
3 - -
SIREN (UNITED KINGDOM) - BLACK 4 WAY

1 - -
2 D96 18WT/LB SIREN SIGNAL CONTROL
SPEED CONTROL SERVO (GAS) - BLACK 4 WAY

1 V36 18VT/YL S/C VACUUM CONTROL
2 V35 18VT/OR S/C VENT CONTROL
3 V30 20VT/WT S/C BRAKE SWITCH OUTPUT
SUNROOF MODULE (EXCEPT EXPORT) - BLACK 12 WAY

1 Q3 20OR/TN SUNROOF OPEN
2 Q5 20OR/LB SUNROOF CLOSE
3 Q4 20OR/YL SUNROOF VENT
7 - -
8 - -
9 - -
10 - -
11 - -
12 - -
SUNROOF SWITCH (EXCEPT EXPORT) - NATURAL 4 WAY

1 Q3 20OR/TN SUNROOF OPEN
2 Q4 20OR/YL SUNROOF VENT
4 Q5 20OR/LB SUNROOF CLOSE
THATCHAM ALARM MODULE (UNITED KINGDOM) - BLACK 16 WAY

1 A645 20RD/VT REAR INTRUSION SENSOR SIGNAL
2 G460 20DG/VT FRONT INTRUSION SENSOR SIGNAL
3 G22 20YL VTSS INDICATOR SUPPLY
5 - -
6 D96 20WT/LB SIREN SIGNAL CONTROL
9 G945 20VT/DG SENSOR GROUND
10 G946 20LG/VT SENSOR GROUND
11 G922 20GY VTSS INDICATOR DRIVER
12 - -
14 - -
15 L91 20WT/DB HAZARD SWITCH SENSE
THROTTLE POSITION SENSOR (GAS) - GRAY 3 WAY

2 K22 18BR/OR TP SIGNAL
TRACTION CONTROL SWITCH - BLACK 2 WAY

1 B27 20DG/WT TRACTION CONTROL SWITCH SENSE
TRAILER TOW CONNECTOR (EXCEPT EXPORT) - 4 WAY

1 L62 18LG RIGHT REAR TURN SIGNAL DRIVER
2 Z362 18WT GROUND
3 L77 18BR FUSED PARK LAMP RELAY OUTPUT (LEFT)
4 L63 18YL LEFT REAR TURN SIGNAL DRIVER
TRANSMISSION CONTROL MODULE (DIESEL) - BLACK

2 - -
4 - -
5 - -
6 K24 20BR/LB CRANKSHAFT POSITION SENSOR SIGNAL NO.2
7 D15 20DG/YL SCI TRANSMIT (TCM)
10 T10 20DG/LG TORQUE MANAGEMENT REQUEST SENSE
11 F1 18PK/WT FCM OUTPUT (UNLOCK-RUN-START)
12 K23 20BR/OR ACCELERATOR PEDAL POSITION SENSOR SIGNAL
NO.2
18 - -
20 T20 18DG/WT L/R SOLENOID CONTROL
21 - -
22 - -
TRANSMISSION CONTROL MODULE (DIESEL) - BLACK

23 - -
24 - -
25 - -
26 - -
27 - -
28 - -
29 - -
30 - -
31 - -
32 - -
33 - -
34 - -
35 - -
36 - -
37 - -
38 - -
39 - -
40 - -
41 T41 18DG/GY TRS T41 SENSE
44 -
45 -
46 D123 20WT/OR SCI RECIEVE (TCM)
48 - -
49 - -
55 - -
58 N7 20DB/OR VEHICLE SPEED SENSOR SIGNAL
59 T59 18YL/LB UNDERDRIVE SOLENOID CONTROL
TRANSMISSION CONTROL RELAY (DIESEL) - 9 WAY

1 - -
3 - -
5 - -
7 - -
9 - -
TRANSMISSION RANGE SENSOR - DK. GRAY 10 WAY

1 - -
2 - -
5 T41 18DG/GY (DIESEL) TRS T41 SENSE
6 - -
10 T41 20DG/GY (DIESEL) TRS T41 SENSE
10 T41 18DG/GY (GAS) TRS T41 SENSE
TRANSMISSION SOLENOID/PRESSURE SWITCH ASSEMBLY - BLACK 8 WAY

5 T59 18DB/LB UNDERDRIVE SOLENOID CONTROL
7 T20 18DG/WT LOW/REVERSE SOLENOID CONTROL
VEHICLE SPEED SENSOR (MTX) - BLACK 3 WAY

1 F202 18PK/GY (DIESEL) FUSED IGNITION SWITCH OUTPUT (RUN-START)
2 K900 18DB/DG (2.4L) SENSOR GROUND
2 K900 20DB/DG (DIESEL) SENSOR GROUND
3 N7 18DB/OR (2.4L) VEHICLE SPEED SIGNAL
3 N7 20DB/OR (DIESEL) VEHICLE SPEED SENSOR SIGNAL
WASHER FLUID LEVEL SWITCH - BLACK 2 WAY

1 Z401 18BK/LB (EXCEPT EXPORT) GROUND
1 Z401 20BK/LB (EXPORT) GROUND
2 W1 18BR/TN WASHER FLUID LEVEL SWITCH SENSE
WASHER PUMP MOTOR - BLACK 2 WAY

1 W20 18BR/YL REAR WASHER PUMP MOTOR CONTROL
2 W10 18BR FRONT WASHER PUMP MOTOR CONTROL
WATER IN FUEL SENSOR (DIESEL) - BLACK 2 WAY

1 F853 20LG/RD WATER IN FUEL SENSOR SIGNAL
2 K900 18RD SENSOR GROUND
WIPER MODULE - DK. GRAY 4 WAY

1 W3 14BR/WT FRONT WIPER HIGH/LOW RELAY LOW SPEED OUT-
PUT
2 W7 20BR/GY WIPER PARK SWITCH SENSE
3 W4 14BR/OR FRONT WIPER HIGH/LOW RELAY HIGH SPEED OUT-
PUT
RS 8W-91 CONNECTOR/GROUND/SPLICE LOCATION 8W - 91 - 1
8 W-9 1 CON N ECT OR/GROU N D/SPLI CE LOCAT I ON
TABLE OF CONTENTS
page
CONNECTOR/GROUND/SPLICE LOCATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1
CON N ECT OR/GROU N D/SPLI CE Con n ect or, gr ou n d, a n d splice in dexes a r e pr ovided.
Use t h e wir in g dia gr a m s in ea ch sect ion for con n ec-
LOCAT I ON t or, gr ou n d, a n d splice iden t ifica t ion . Refer t o t h e
a ppr opr ia t e in dex for t h e pr oper figu r e n u m ber. F or
DESCRIPTION it em s t h a t a r e n ot sh own in t h is sect ion N/S is pla ced
Th is sect ion pr ovides illu st r a t ion s iden t ifyin g con - in t h e F ig. colu m n .
n ect or, gr ou n d, a n d splice loca t ion s in t h e veh icle.
CON N ECT ORS
CONNECTOR NAME/NUMBER COLOR LOCATION FIG.

A/C Compressor Clutch LTGY Top of A/C Compressor 10, 11, 15, 17, 18
A/C Pressure Sensor GY At Throttle Body 9, 10, 15, 16, 17
A/C-Heater Control C1 (MTC) BK/RD Rear of Control 20, 23, 25
A/C-Heater Control C2 (MTC) BK/BL Rear of Control 20, 23, 25
Accelerator Pedal Position At Accelerator Pedal 42
Sensor (Diesel)
Adjustable Pedals Module Near Brake Lamp Switch N/S
(Except Export)
Adjustable Pedals Motor On Pedal Support N/S
Adjustable Pedals Relay (Except Left Side Engine Compartment 6
Export)
Adjustable Pedals Sensor On Adjustable Pedals Motor N/S
Adjustable Pedals Switch (Except Left Side Kick Panel 41
Export)
Ambient Temperature Sensor BK On Radiator Closure Panel 1
(Except Base)
Amplifier C1 NAT Right Quarter Panel 48
Amplifier C2 NAT Right Quarter Panel 48
ATC Remote Sensor Above ATC Control N/S
Auto Temp Control C1 NAT Rear of Control 20
Auto Temp Control C2 BK Rear of Control 20
Auto Temp Control C3 (MTX) Rear of Control N/S
Back-Up Lamp Switch BK On Transmission 16
Battery Temperature Sensor BK At Battery N/S
Blower Motor Resistor C1 (MTC) BK Right Side of HVAC N/S
Blower Motor Resistor C2 (MTC) BK Right Side of HVAC N/S
Body Control Module C1 BK Under Left Instrument Panel 41, 42
8W - 91 - 2 8W-91 CONNECTOR/GROUND/SPLICE LOCATION RS
CON N ECT OR/GROU N D/SPLI CE LOCAT I ON (Cont inue d)

Body Control Module C2 BK/GN Under Left Instrument Panel 41, 42
Body Control Module C3 BK/WT Under Left Instrument Panel 41, 42
Body Control Module C4 BK/GY Under Left Instrument Panel 20, 21, 30
Body Control Module C5 BK Under Left Instrument Panel 20, 21, 30
Boost Pressure Sensor (Diesel) BK Top Left of Engine 15
Brake Fuid Level Switch BK On Master Cylinder 6
Brake Lamp Switch BK At Top Of Brake Pedal 41, 42
Brake Transmission Shift BK Near Steering Column 20, 21, 22, 31
Interlock Solenoid (EATX)
C100 BK Left Fender Shield 5, 11
C101 LTGY Left Fender Shield 5
C102 (Gas) BK At Fuel Rail 11, 17
C103 (Diesel) BK Left Side Engine Compartment N/S
C104 (Except Export LTGY Near Controller Antilock Brake 18
C106 (Export) BK/YL Near Left Headlamp Leveling Motor N/S
C107 (Export) BK/YL Near Right Headlamp Leveling N/S
Motor
C111 (EATX) LTGY Left Front Engine 11
C112 (Gas) BK Near T/O for C101 N/S
C200 GY Left Side Instrument Panel 20, 21, 30, 41, 42
C202 GY Right Side Instrument Panel A/C 20, 24, 29
Heater Unit
C204 (Premium NAT Rear of Radio 50
C206 BK Near Radio 20
C207 Near Radio N/S
C300 (LHD) BK Left Front Door Lower 36, 43
C300 (RHD) BK Right Front Door Lower N/S
C301 LTGY Left Front Door Upper 36, 43
C302 LTGY Right Front Door Upper 8, 39, 44
C303 BK Right Front Door Lower 8, 39, 44
C304 (LHD) YL Left Wire Track Seat to Body 32
C305 GY Left Wire Track Seat to Body 32 33
C306 (RHD) YL Right Wire Track Seat to Body 33
C307 YL Right Wire Track Seat to Body N/S
C308 (Except Side Airbags) GN Left Rear Sliding Door 40
C309 (Except Side Airbags) GN/GY Right Rear Sliding Door 32, 33, 39
C310 (Front Console) BK At Front Console 34
C311 (3 Zone HVAC) GY Rear A/C Switch 40
C312 GY Right B Pillar 33, 39, 50
C313 (Rear Console/Export) BK At Rear Console 34
C314 BK Left Side Liftgate 49
C315 (Power Liftgate) BK Right Side Liftgate 49
C316 (Power Sliding Door) BK Wire Track to Sliding Door N/S

C317 (Power Sliding Door) BK Right Sliding Door 32, 45
C318 (Trailer Tow) BK Left Quarter N/S
C319 (Trailer Tow)
C320 DKGY Driver Power Seat on Seat Harness N/S
C321 DKGY Under Passenger Seat N/S
C322 (Memory) BK On Seat Harness to Body 32
C324 (Manual Sliding Door) BK Left Sliding Door N/S
C325 (Manual Sliding Door) BK Right Sliding Door 32
C328 (Sunroof) Left Quarter Panel 47
C329 (Diesel) BK Near Fuel Tank N/S
C330 (Diesel) LTGY Near Throttle Body 15, 16
C331 (Diesel) BK Left Rear Engine Compartment N/S
C332 (3 Zone ATC) BK/LTGN Near T/O for Right Rear Lamp 48
Assembly
C333 (Except Export DKGY Left Side Instrument Panel 21
C334 BK Right Quarter Panel 48
C335 LTGY Near Fuel Tank 34
Cabin Heater Assist C1 (Diesel) BK Top of Engine N/S
Cabin Heater Assist C2 (Diesel) BK Top of Engine N/S
Camshaft Position Sensor (Gas) BK Rear of Cylinder Head 11, 17
Right Side of Engine
Camshaft Position Sensor BK Rear of Cylinder Head 15, 16
(Diesel)
CD Changer Behind CD Changer N/S
Center High Mounted Stop Lamp BK At Lamp 49
Clockspring - C1 WT Steering Column 20, 21, 22, 23, 31
Clockspring - C2 YL Steering Column 20, 21, 22, 23, 31
Clockspring - C3 BK Steering Column N/S
Clockspring - C4 Steering Column N/S
Clutch Pedal Interlock Switch BK At Switch/Driver Side 42
(MTX)
Clutch Pedal Upstop Switch RD At Switch/Driver Side 42
(Diesel)
Controller Anti-Lock Brake BK Right Side of Engine Compartment 11, 16, 17, 18
Crank Case Ventilation Heater BK Top of Cylinder Head 15
(Diesel)
Crankshaft Position Sensor BK Rear of Engine 16
(Diesel)
Crankshaft Position Sensor (Gas) BK Rear of Engine 13, 17
Data Link Connector BK Lower Instrument Panel Near 41, 42
Steering Column
Dosing Pump (Diesel) BK Top of Engine N/S
Driver Airbag Squib1 BN/YL Steering Column N/S
Driver Airbag Squib2 BK/YL Steering Column N/S

Driver Blend Door Actuator GY On HVAC N/S
Driver Door Courtesy Lamp GY At Lamp 43
Driver Door Lock Switch BK At Switch 43
Driver Heated Seat Back LTGN At Seat N/S
Driver Heated Seat Cushion BK At Seat N/S
Driver Heated Seat Module C1 GY Driver Heated Seat N/S
Driver Heated Seat Module C2 GY Driver Heated Seat Back N/S
Driver Heated Seat Module C3 GN At Seat N/S
Driver Knee Blocker Airbag Squib YL Below Steering Column 20
Driver Power Seat Front Riser RD At Seat N/S
Motor
Driver Power Seat Front Riser BK At Seat N/S
Position Sensor
Driver Power Seat Horizontal BK At Seat N/S
Motor
Driver Power Seat Horizontal BK At Seat N/S
Position Sensor
Driver Power Seat Rear Riser RD At Seat N/S
Motor
Driver Power Seat Rear Riser BK At Seat N/S
Position Sensor
Driver Power Seat Recliner Motor GN At Seat N/S
Driver Power Seat Recliner BK At Seat N/S
Position Sensor
Driver Power Seat Switch GN At Switch N/S
Driver Power Window Motor RD At Motor 43
Driver Power Window Switch LTGY At Switch 43
(LHD Low Line)
Driver Power Window Switch LTGN At Switch N/S
(LHD Except Low Line)
Driver Power Window Switch NAT At Switch N/S
(RHD)
Driver Seat Belt Switch WT At Switch on Seat Harness N/S
Driver Seat Belt Tensioner YL On Seat Harness N/S
DVD Screen BK Headliner 50
DVD/CD Changer C1 BK Below Radio N/S
DVD/CD Changer C2 Below Radio N/S
EGR Solenoid (Diesel) LTGY Above Transmission 15
Right Side of Engine
EGR Solenoid (3.3L) BK Above A/C Compressor Right Side 18
of Engine
Engine Control Module C1 BK Right Side of Engine N/S
(Diesel)
Engine Control Module C2 BK Right Side of Engine N/S
(Diesel)

Engine Coolant Temp Sensor BK On Cylinder Block N/S
(Gas)
Engine Oil Pressure Sensor BK Rear of Engine 16
(Diesel)
Engine Coolant Temp Sensor BL On Cylinder Block 15
(Diesel)
Engine Oil Pressure Switch (Gas) LTGN On Cylinder Block 12, 18
Engine Starter Motor At Starter Motor 13, 15, 18
EVAP/Purge Solenoid (Gas) BK Right Motor Mount 10, 17
Evaporator Temperature Sensor BK Right Side of HVAC N/S
Floor Console Lamp BK At Lamp N/S
Floor Console Power Outlet RD At Front Console N/S
Front Blower Module C1 (ATC) BK On HVAC N/S
Front Blower Module C2 (ATC) BK On HVAC N/S
Front Cigar Lighter RD/NAT Rear of Lighter 20, 23, 25
Front Control Module BK In Integrated Power Module N/S
Front Intrusion Sensor (United BK At Sensor N/S
Kingdom)
Front Reading Lamps/Switch BK At Switch N/S
Fuel Heater (Diesel) BK Left Rear Engine Compartment N/S
Fuel Injector No.1 (2.4L/3.3L/ BK At Fuel Injector N/S
3.8L)
Fuel Injector No.1 (Diesel) BK At Fuel Injector 15
3.8L)
3.8L)
3.8L)
Fuel Injector No.5 (3.3L/3.8L) BK At Fuel Injector N/S
Fuel Injector No.6 (3.3L/3.8L) BK At Fuel Injector N/S
Fuel Pressure Sensor (Diesel) BK Top Left of Engine 15
Fuel Pressure Solenoid (Diesel) Right Front Engine 15
Fuel Pump Module LTGY Side of Fuel Tank 34
Generator BK Rear of Generator 11, 15, 17, 18
Glow Plug No.1 (Diesel) Top of Engine N/S
Glow Plug No.2 (Diesel) Top of Engine 15
Glow Plug Relay (Diesel) BK Near Transmission 15, 16
Hands Free Module C1 Instrument Panel N/S

Hands Free Module C2 BK Instrument Panel N/S
Hands Free Module C3 Instrument Panel N/S
Headlamp Switch BK Rear of Switch 20, 21, 30
Headlamp Washer Pump Motor BK At Motor 3
(Export)
High Note Horn BK Left Frame Rail 5
Hood Ajar Switch (Export) BK Left Fender 6
Idle Air Control Motor (Gas) BK On Throttle Body 10, 11 17
Ignition Coil (2.4L) BK Top of Valve Cover 10, 11
Ignition Coil (3.3L/ 3.8L) DKGY Top of Engine 17, 18
Ignition Switch BK Rear of Switch at Steering Column 20, 21, 22, 23, 31
Inlet Air Temperature Sensor BK Top Left of Engine 9, 10, 11, 17
Input Speed Sensor GY Front of Transmission 14, 19
Instrument Cluster BK Rear of Cluster 20, 21, 28
Instrument Panel Switch Bank BK Right Center of Instrument Panel 20, 23, 25
(Heated Seats)
Instrument Panel Switch Bank Right Center of Instrument Panel 20, 23, 25
(Except Heated Seats)
Integrated Power Module C1 Left Fender Shield 7
Integrated Power Module C2 GN/BL Left Fender Shield 7
Integrated Power Module C3 Left Fender Shield 7, 11
Integrated Power Module C4 BL Left Fender Shield 7, 11
Integrated Power Module C5 BK Left Fender Shield 7
Integrated Power Module C6 NAT Left Fender Shield 7
Integrated Power Module C7 Left Fender Shield 7
Integrated Power Module C8 OR Left Fender Shield 7
Integrated Power Module C9 BK Left Fender Shield 7
Knock Sensor (Except Export) BK At Engine Block 11
Left B Pillar Switch (Power GY Left B Pillar 40
Sliding Door)
Left Cinch/Release Motor (Power GY Left Sliding Door N/S
Sliding Door)
Left Curtain Airbag Squib Rear of Left Roof Rail 47
Left Cylinder Lock Switch BK At Switch 43
Left Door Speaker BK At Speaker 43
Left Fog Lamp BK At Lamp 5
Left Front Door Ajar Switch BK At Switch N/S
(Base)
Left Front Door Lock Motor/Ajar BK Left Door 43
Switch (Except Base)
Left Front Impact Sensor BK Near T/O for C101 5
Left Front Park/Turn Signal Lamp DKGY At Lamp 1
(Except Export)
Left Front Wheel Speed Sensor GY Left Fender Side Shield 5, 11

Left Full Open Switch (Power BK Left Sliding Door N/S
Sliding Door)
Left Headlamp Caravan/Voyager BK At Lamp 1
(Except Export)
Left Headlamp (Town & Country) GN At Lamp 1
Left Headlamp Leveling Motor WT At Motor N/S
(Export)
Left High Beam Lamp (Export) BK At Lamp N/S
Left Instrument Panel Speaker WT At Speaker 20, 21, 27
Left Liftgate Flood Lamp (Power GY At Lamp 49
Liftgate)
Left Low Beam Lamp (Export) BK At Lamp N/S
Left Mid Reading Lamp GY At Lamp N/S
(Premium/Luxury)
Left Park Lamp (Export) BK At Lamp NS
Left Power Mirror BK At Mirror 27
Left Rear Lamp Assembly BK At Lamp 47
Left Rear Pillar Speaker (Highline BK Left of Liftgate 47
Audio)
Left Rear Reading Lamp (Luxury) GY At Lamp N/S
Left Rear Speaker (Highline) BK/RD At Speaker 47
Left Rear Speaker (Lowline) At Speaker N/S
Left Rear Vent Motor NAT At Motor 46, 47
Left Rear Wheel Speed Sensor BK Center Rear of Floor Pan 47
Left Remote Radio Switch BK Steering Wheel N/S
Left Repeater Lamp (Export) GY Left Front Fender 4, 36
Left Side Impact Sensor 1 DKGY Left B Pillar 40
Left Side Impact Sensor 2 Left Sliding Door N/S
Left Side Impact Sensor 3 BK Left Quarter Panel 47
Left Sliding Door Control Module BK Left Sliding Door N/S
C1
Left Sliding Door Control Module Left Sliding Door N/S
C2
Left Sliding Door Latch Sensing BK Left Sliding Door N/S
Switch
Left Sliding Door Lock Motor BK Left Sliding Door N/S
Left Sliding Door Lock Motor/Ajar BK Left Sliding Door N/S
Switch (Manual Sliding Door)
Left Sliding Door Motor BK Left Sliding Door N/S
Left Speed Control Switch WT Steering Wheel N/S
Left Turn Signal Lamp (Export) OR AT Lamp N/S
Left Visor/Vanity Lamp BK At Lamp N/S
License Lamp DKGY At Lamp 49
Lift Pump Motor (Diesel) BK Left Rear Engine Compartment N/S

Liftgate Ajar Switch (Manual BK At Latch 49
Release)
Liftgate Ajar Switch (Power BK Lower Liftgate 49
Release)
Liftgate Cinch/Release Motor BL Liftgate 49
(Power Liftgate)
Liftgate Left Pinch Sensor (Power BK Left Side of Liftgate 49
Liftgate)
Liftgate Right Pinch Sensor BK Right Side of Liftgate 49
(Power Liftgate)
Manifold Absolute Pressure BK On Intake N/S
Sensor (Gas)
Mass Air Flow Sensor (Diesel) OR Top of Engine 15, 16
Memory Seat/Mirror/Adjustable GY Under Driver Seat N/S
Pedals Module C1
Memory Seat/Mirror/ Adjustable GY Under Driver Seat N/S
Pedals Module C2
Memory Seat/Mirror/ Adjustable WT Under Driver Seat N/S
Pedals Module C3
Memory Seat/Mirror/ Adjustable GY Under Driver Seat N/S
Pedals Module C4
Memory Set Switch BK At Switch Driver Door 43
Message Center (Highline) WT Rear of Message Center 20, 21, 28
Mode Door Actuator GY Left Side of HVAC N/S
Multi Function Switch BK At Steering Column 20, 21, 22, 23, 31
Natural Vacuum Leak Detection LTGY Top of Engine 12
Assembly (Except Export)
Occupant Classification Module BK Passenger Seat N/S
Occupant Restraint Controller C1 YL Right Side Instrument Panel
Occupant Restraint Controller C2 YL Right Side Instrument Panel 20, 24, 25
Output Speed Sensor GY Front of Transmission 14, 19
Overhead Console (Except Base) BK Front of Console N/S
Oxygen Sensor 1/1 Upstream Rear of Engine 11, 12, 18
(Gas)
Oxygen Sensor 1/2 Downstream Rear of Engine 11, 12,18
(Gas)
Park Brake Switck Bottoom Left Side of Instrument 20, 21
Panel
Park Sensor No.1 (Parktronics) Rear Fascia N/S
Passenger Airbag YL Passenger Side of Instrument Panel 20, 23, 24, 29
Passenger Airbag On/Off Right Center of Instrument Panel 20, 23, 25
Indicator Lamp
Passenger Blend Door Actuator GY On HVAC N/S

Passenger Door Courtesy Lamp GY At Lamp 44
Passenger Door Lock Switch BK At Switch 44
Passenger Folding Mirror Relay BL Left Kick Panel 7
(Export)
Passenger Heated Seat Back GN At Seat N/S
Passenger Heated Seat Cushion BK At Seat N/S
Passenger Heated Seat Module GY At Heated Seat N/S
Passenger Power Seat Front RD Under Seat N/S
Riser Motor
Passenger Power Seat Horizontal BK Under Seat N/S
Motor
Passenger Power Seat Rear RD Under Seat N/S
Riser Motor
Passenger Power Seat Recliner GN Under Seat N/S
Motor
Passenger Power Seat Switch GN At Switch N/S
Passenger Power Window Motor RD At Motor 44
Passenger Power Window Switch BK At Switch 44
Passenger Seat Belt Switch YL On Seat Harness N/S
(Occupant Sensing)
Passenger Seat Belt Tensioner On Seat Harness N/S
Passenger Seat Weight Sensor BK Passenger Seat N/S
Power Folding Mirror Switch BK Near Steering Column 31
(Export)
Power Liftgate Module C1 BK Left Quarter 46, 47
Power Liftgate Module C2 Left Quarter 46, 47
Power Liftgate Motor BK Left Quarter 47
Power Mirror Switch BK Rear of Switch 30
Power Outlet (Except Lowline) BK Instrument Panel 20, 23, 25
Power Seat Circuit Breaker GY Under Seat N/S
Powertrain Control Module C1 BK Left Front Engine Compartment 11
Powertrain Control Module C2 OR Left Front Engine Compartment 11
Powertrain Control Module C3 NAT Left Front Engine Compartment 11
Powertrain Control Module C4 GN Left Front Engine Compartment 11
Power Window Circuit Breaker GY Left Side Kick Panel 41 42
Radiator Fan No.1 (Gas) BK Left Side At Motor 1
Radiator Fan No.1 (Diesel) GY Left Side At Motor 1
Radiator Fan No.2 (Gas) BK Right Side At Motor 1, 2
Radiator Fan No.2 (Diesel) GY Right Side At Motor 1, 2
Radiator Fan Relay (Gas) Top of Left Front Frame Rail 1
Radiator Fan Relay No. 1 BL Left Front Engine Compartment 2
(Diesel)
(Diesel)

(Diesel)
Radio C1 Rear of Radio 20
Radio C2 (CD Changer) Rear of Radio 20
Radio C2 (DVD/CD Changer) Rear of Radio 20
Radio C2 (Hands Free) Rear of Radio 20
Rear A/C-Heater Unit (3 Zone LTGN Right Quarter Panel NS
MTC)
Rear Auto Temp Control Switch BK Rear of Switch 50
(3 Zone ATC)
Rear Blower Front Control Switch BK Rear of Switch N/S
(3 Zone MTC)
Rear Blower Motor Power Module RD/BK Right Quarter N/S
C1 (3 Zone ATC)
Rear Blower Motor Power Module BK Right Quarter N/S
C2 (3 Zone ATC)
Rear Blower Rear Control Switch BK Overhead 50
C1 (3 Zone MTC)
Rear Blower Rear Control Switch BK Overhead 50
C2 (3 Zone MTC)
Rear Dome Lamp (Except GY At Lamp N/S
Luxury)
Rear Intrusion Sensor (United At Sensor N/S
Kingdom)
Rear Mode Motor (3 Zone ATC) GY At Motor N/S
Rear Park Assist Display Module Overhead Console N/S
Rear Park Assist Module Left Quarter Panel 47
Rear Power Outlet GY Left Quarter Panel 47
Rear Temperature Motor (3 Zone GY Right Quarter N/S
ATC)
Rear View Mirror C1 BK At Mirror NS
Rear View Mirror C2 At Mirror N/S
Rear Window Defogger C1 Right Side of Liftgate 49
Rear Window Defogger C2 Left Side of Liftgate 49
Rear Wiper Motor At Motor 49
Recirculation Door Actuator GY Right Side of HVAC N/S
Right B-Pillar Switch (Power GY Right B Pillar 39
Sliding Door)
Right Cinch/Release Motor GY Right Sliding Door 45
(Power Sliding Door)
Right Curtain Airbag Squib Rear of Right Roof Rail 48
Right Cylinder Lock Switch BK Right Front Door 44
(Export)
Right Door Speaker At Speaker N/S
Right Fog Lamp WT At Lamp 3

Right Front Door Ajar Switch BK At B Pillar N/S
(Base)
Right Front Door Lock Motor/Ajar BK Right Front Door 44
Switch (Except Base)
Right Front Impact Sensor BK Near T/O for C303 N/S
Right Front Park/Turn Signal BK At Lamp 1, 3
Lamp (Except Export)
Right Front Wheel Speed Sensor GY Right Fender Side Shield 3,10, 16, 17
Right Full Open Switch (Power BK Right Sliding Door 45
Sliding Door)
Right Headlamp (Caravan/ BK At Lamp 1, 3
Voyager Except Export)
Right Headlamp Leveling Motor WT At Right Headlamp N/S
(Export)
Right High Beam Lamp (Export) BK At Right Headlamp N/S
Right Instrument Panel Speaker WT At Speaker 20, 23, 24
Right Liftgate Flood Lamp (Power GY At Lamp 49
Liftgate)
Right Low Beam Lamp (Export) BK At Right Headlamp N/S
Right Mid Reading Lamp GY At Lamp N/S
(Premium/ Luxury)
Right Park Lamp (Export) BK AT Lamp N/S
Right Power Mirror BK At Mirror 20, 24, 28
Right Rear Lamp Assembly BK At Lamp 48
Right Rear Pillar Speaker BK At Speaker 48
(Highline Audio)
Right Rear Reading Lamp GY At Lamp N/S
(Luxury)
Right Rear Speaker) At Speaker 48
Right Rear Vent Motor NAT At Motor 48
Right Rear Wheel Speed Sensor BK Right Rear of Floor Pan 48
Right Remote Radio Switch BK At Steering Wheel N/S
Right Repeater Lamp (Export) GY Right Front Fender 39
Right Side Impact Sensor 1 Right B Pillar 39
Right Side Impact Sensor 2 Right Sliding Door 32
Right Side Impact Sensor 3 BK Right Quarter Panel 48
Right Sliding Door Control BK Right Sliding Door 45, 46
Module C1
Right Sliding Door Control Right Sliding Door 45, 46
Module C2
Right Sliding Door Latch Sensing BK Right Sliding Door 45
Switch
Right Sliding Door Lock Motor BK Right Sliding Door 45
Right Sliding Door Lock BK Right Sliding Door N/S
Motor/Ajar Switch (Manual Sliding
Door)

Right Sliding Door Motor BK At Sliding Door 45
Right Speed Control Switch WT At Steering Wheel N/S
Right Turn Signal Lamp (Export) OR At Lamp N/S
Right Visor/Vanity Lamp BK At Lamp N/S
Sentry Key Remote Entry Module BK At Steering Column 20, 21, 22, 23, 31
(SKREEM)
Siren (United Kingdom) BK Left Front Body N/S
Speed Control Servo (Gas) BK Near Controller Antilock Brake 11, 17, 18
Sunroof Module (Except Export) BK At Sunroof N/S
Sunroof Switch (Except Export) NAT Near Overhead Console N/S
Thatcham Alarm Module (United BK Top Right Side of Instrument Panel N/S
Kingdom) Near Speaker
Throttle Position Sensor (Gas) GY On Throttle Body 10, 11, 17
Traction Control Switch BK Rear of Swtich 21, 22, 31
Trailer Tow Connector (Except Left Quarter Panel N/S
Export)
Transmission Control Relay Near Transmission 16
(Diesel)
Transmission Range Sensor DKGY Top of Transmission 14, 19
Transmission Solenoid/Pressure BK Side of Transmission 14, 19
Switch Assembly
Vehicle Speed Sensor (MTX) BK Rear of Transmission 16
Washer Fluid Level Switch BK Bottom of Reservoir 3
Washer Pump Motor BK Right Fender Well 3
Water in Fuel Sensor (Diesel) BK Left Rear Engine Compartment N/S
Wiper Module DKGY Left Side Cowl 6
GROU N DS
GROUND NUMBER LOCATION FIG.

G100 Body Ground Near Powertrain Control Module N/S
G101 Above Starter 13, 15, 18
G102 Left Headlamp Area 1
G103 Above Starter 15
G200 Left Side of Instrument Panel 20, 21 29
G201 Right Side of Instrument Panel 20, 24, 29
G202 Near Radio N/S
G300 Left B Pillar 32
G301 Right B Pillar 33, 39
G302 Left Rear Quarter 47
G303 Liftgate Ground 49
SPLI CES
SPLICE NUMBER LOCATION FIG.

S101 (Gas) Near T/O for Radiator Fan No.1 1
S103 (Diesel) Between T/O for Battery Temperature Sensor and T/O 15
for C102
S106 (2.5L) Near T/O for Battery Temperature Sensor 15
S106 (3.3L/3.8L) Near T/O for G103 18
S107 (Gas) Near T/O for Integrated Power Module C3 11
S107 (Diesel) In T/O for Integrated Power Module C3 7
S111 (2.4L) Near T/O for C101 11
S111 (Diesel) In T/O for Battery (-) N/S
S111 (3.3L/3.8L) Near T/O for Battery Temperature Sensor N/S
S112 (Gas) Near T/O for Integrated Power Module - C3 19, 5, 11
S113 (2.4L) Near T/O for Park/Neutral Position Switch 11
S114 (2.4L) Near T/O for Powertrain Control Module C4 11
S114 (3.3L/3.8L) In T/O to Transmission Control Module N/S
S115 (2.4L) Near T/O for Powertrain Control Module C4 11
S115 (3.3L/3.8L) In T/O to Transmission Control Module N/S
S116 (2.4L) 180mm from T/O for Torque Converter Clutch Solenoid 11, 13
S116 (Diesel) Near T/O for Mass Air Flow Sensor 16
S116 (3.3L/3.8L) Near T/O for G103 18
S118 (2.4L) Near T/O for Knock Sensor 11, 13
S119 (Diesel) Near T/O for Engine Starter Motor 15
S121 (3.3L/3.8L) Near T/O for Output Speed Sensor 18
S122 (2.4L) In T/O to Engine Starter Motor 13
S122 (3.3L/3.8L) In T/O to Engine Starter Motor 18
S124 (2.4L) Near T/O for Fuel Injector No.2 N/S
S124 (3.3L/3.8L) Near T/O for Fuel Injector No.5 and No.6 N/S
S125 (2.4L) In T/O for Manifold Absolute Pressure Sensor N/S
S126 In Right Headlamp Leveling Assembly N/S
S127 (Diesel) In T/O for Engine Starter Motor N/S
S128 (Diesel) Near T/O for Engine Starter Motor N/S
S129 (Diesel) Near T/O for Battery (+) N/S
S131 (2.4L) Near T/O for Transmission Control Module 11
S131 (3.3L/3.8L) Near T/O for C110 N/S
S134 (Diesel) IN T/O for Engine Control Module N/S
S135 (Diesel) Near T/O for Glow Plug No.2 N/S
S136 (Diesel) In T/O for Radiator Fan Relays 2
S137 (Diesel) Above Starter 15
S138 (Diesel) Between T/O for Radiator Fan No.2 and T/O for G102 N/S

S139 (Diesel) Between T/O for Engine Starter Motor and T/O for 15, 16
Engine Control Module C1
S141 (2.4L) Near T/O for Controller Anti-Lock Brake 11
S141 (3.3L/3.8L ABS Except Near T/O for G100 N/S
Export)
S141 (Diesel) Near T/O for G100 N/S
S141 (3.3L/3.8L) Near T/O for Powertrain Control Module N/S
S142 (3.3L/3.8L) Near T/O for A/C Compressor Clutch 18
S144 (Diesel) Between T/O for Battery Temperature Sensor and T/O N/S
for C103
S148 (Diesel) Near T/O for Engine Starter Motor 5
S150 (Diesel) Near T/O for Controller Anti-Lock Brake N/S
S151 (Diesel) Near T/O for Radiator Fan Relays 2
S152 (Diesel) Near T/O for Radiator Fan No.1 N/S
S157 (Diesel) Near T/O for Glow Plug No.4 15
S177 In Right Headlamp Wiring Assembly N/S
S179 In Left Headlamp Wiring Assembly N/S
S187 (Diesel) In T/O for Engine Control Module C1 15
S188 (Diesel) Near T/O for Radiator Fan Relays 2
S189 (Diesel EATX) Near T/O for Battery (+) N/S
S190 (Diesel EATX) Near T/O for Transmission Control Module N/S
S191 (Diesel EATX) Near T/O for Transmission Control Module N/S
S192 (Diesel EATX) In T/O for Transmission Control Module N/S
S193 (Diesel EATX) In T/O for Transmission Control Module N/S
S201 In T/O to Instrument Panel Speaker 20, 26
S202 Near T/O for Instrument Panel Switch Bank 20, 26
S203 Near T/O for Instrument Panel Switch Bank 20, 26
S204 Near T/O to Instrument Panel Speaker 20, 26
S205 Near T/O for C201 N/S
S206 Near T/O for Instrument Cluster 20
S207 Near T/O for A/C Heater Control 20, 26
S208 (RHD) Between T/O for Antenna Connector and T/O for Front 26
Cigar Lighter
S209 Near T/O for Evaporator Temperature Sensor N/S
S210 (RHD) Near T/O for C203 26
S211 In Steering Column Wiring Assembly N/S
S212 In Steering Column Wiring Assembly N/S
S223 Near T/O for Multi-Function Switch 20
S224 Near T/O for Siren N/S
S225 (Hands Free) Near T/O for Rear View Mirror N/S
S226 (Hands Free) In T/O for C207 N/S
S302 In Floor Pan Track Wiring 37

S303 In T/O to Data Link Connector 37, 41, 42
S304 (Export) In Floor Pan Track Wiring 38
S305 Near T/O for Memory Seat/Mirror Module - C2 N/S
S307 Near T/O for Memory Power Seat Switch N/S
S309 In Floor Pan Track Wiring N/S
S310 Near T/O for C301 35, 36, 37
S313 Near T/O for Power Liftgate Module 47
S317 Near T/O for Body Control Module 42
S318 Near T/O for Power Seat Circuit Breaker 34
S321 Ner T/O for C301 35, 36, 37
S322 Near T/O for C301 37
S326 Near T/O for C101 35, 36
S330 Near T/O for Power Liftgate Module 47
S331 Near T/O for Power Liftgate Motor 47
S333 (3 Zone MTC) In Floor Pan Track Wiring 37
S334 Near T/O to G301 34
S335 Near T/O for Left Rear Reading Lamp N/S
S336 Near T/O for Left Rear Reading Lamp N/S
S337 Near T/O for Right Mid Reading Lamp N/S
S338 Near T/O for Right Visor/Vanity Lamp N/S
S342 (LHD) Near T/O for Passenger Power Window Motor 44
S343 (LHD) Near T/O for Driver Power Window Motor 43
S344 In T/O to Right Sliding Door Control Module C2 45, 46
S345 Near T/O for Right Sliding Door Motor 45, 46
S346 Near T/O for Driver Power Window Switch 43
S347 Near T/O for Right Sliding Door Lock Motor 45, 46
S348 Near T/O for Left Sliding Door Lock Motor 46
S349 In T/O to Left Sliding Door Control Module - C2 46
S350 Near T/O for Left Sliding Door Motor 46
S352 Near T/O for Liftgate Cinch/Release Motor 49
S354 (Export) Near T/O for C301 36, 37
S354 (Except Export) Near T/O for C101 37

S355 In T/O for C307 N/S
S356 (Except Export) Near T/O for Passenger Heated Seat Back N/S
S359 Left Quarter Panel 47
S364 (RHD) Near T/O for Passenger Power Window Window 44
S365 (LHD) Near T/O for Driver Power Window Window N/S
S366 In Passenger Power Heated Seat Wiring Assembly N/S
S367 Near T/O for C301 37
S368 (Diesel) Near T/O for C101 35, 36
S370 (Except Export) In T/O for Integrated Power Module C6 7
S371 In T/O to Power Window Switch N/S
S372 Near T/O for Data Link Connector 41
S373 (Except Export In Floor Pan Track Wiring 37
S374 Near T/O for Body Control Module N/S
S376 (Highline Audio) In Floor Pan Track Wiring 34
S378 Near T/O for C301 35, 36, 37
S380 (Highline Audio) Right Quarter Panel 48
S381 (Highline Audio) Right Quarter Panel 48
S382 (Passenger Heated Near T/O for Passenger Seat Weight Sensor N/S
Seat)
S383 (Parktronics) Rear Fascia N/S
S384 (Parktronics) Rear Fascia N/S
Fig. 1 HEADLAMP CONNECTORS

Fig. 2 LEFT FRONT ENGINE COMPARTMENT
Fig. 3 WASHER PUMP CONNECTORS

Fig. 4 LEFT REPEATER LAMP

Fig. 5 LEFT FENDER SHIELD

Fig. 6 LEFT SIDE ENGINE COMPARTMENT

Fig. 7 INTEGRATED POWER MODULE

Fig. 8 RIGHT FRONT WHEEL HOUSING

Fig. 9 INLET AIR SENSORS

Fig. 10 2.4 LITER ENGINE CONNECTORS REAR

Fig. 11 2.4 LITER ENGINE FRONT

Fig. 12 OXYGEN SENSORS

Fig. 13 STARTER CONNECTORS

Fig. 14 TRANSMISSION CONNECTORS

Fig. 15 2.5 LITER DIESEL ENGINE FRONT

Fig. 16 2.5 LITER DIESEL ENGINE REAR

Fig. 17 3.3-3.8 LITER ENGINE REAR

Fig. 18 3.3-3.8 LITER ENGINE FRONT

Fig. 19 AUTOMATIC TRANSMISSION

Fig. 20 INSTRUMENT PANEL HARNESS LHD

Fig. 21 LEFT SIDE INSTRUMENT PANEL LHD

Fig. 22 STEERING COLUMN

Fig. 23 CENTER INSTRUMENT PANEL

Fig. 24 RIGHT SIDE INSTRUMENT PANEL

Fig. 25 CENTER INSTRUMENT PANEL RHD

Fig. 26 INSTRUMENT PANEL RHD
Fig. 27 LEFT SIDE INSTRUMENT PANEL UPPER RHD

Fig. 28 RIGHT SIDE INSTRUMENT PANEL UPPER RHD
Fig. 29 LEFT SIDE INSTRUMENT PANEL LOWER RHD

Fig. 30 RIGHT SIDE INSTRUMENT PANEL LOWER RHD
Fig. 31 STEERING COLUMN CONNECTORS RHD

Fig. 32 LEFT SIDE BODY LHD

Fig. 33 RIGHT SIDE BODY RHD

Fig. 34 BODY HARNESS SPLICES

Fig. 35 BODY HARNESS SPLICES

Fig. 36 LEFT FRONT LAMP SPLICES

Fig. 37 LEFT FRONT BODY SPLICES

Fig. 38 REAR BODY SPLICES

Fig. 39 RIGHT B PILLAR
Fig. 40 LEFT B PILLAR

Fig. 41 LEFT SIDE KICK PANEL LHD

Fig. 42 RIGHT SIDE KICK PANEL RHD

Fig. 43 DRIVER DOOR
Fig. 44 PASSENGER DOOR

Fig. 45 RIGHT SLIDING DOOR

Fig. 46 LIFTGATE AND SLIDING DOOR MODULES

Fig. 47 LEFT REAR BODY

Fig. 48 RIGHT QUARTER

Fig. 49 LIFTGATE
Fig. 50 HEADLINER
RS 8W-97 POWER DISTRIBUTION SYSTEM 8W - 97 - 1
8 W-9 7 POWER DI ST RI BU T I ON SY ST EM
TABLE OF CONTENTS
page page
POWER DISTRIBUTION SYSTEM IOD FUSE

DESCRIPTION . . . . . . . . . . . . . . . . ..........1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . ...3
OPERATION . . . . . . . . . . . . . . . . . . ..........1 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . ...3
SPECIAL TOOLS POWER OUTLET
POWER DISTRIBUTION SYSTEMS .........1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . ...3
INTEGRATED POWER MODULE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . ...3
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . .1 DIAGNOSIS AND TESTING
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 DIAGNOSIS & TESTING - POWER OUTLET ..3
REMOVAL ................... . . . . . . . . . .2 REMOVAL .......................... ...4
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . .2 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . ...4
POWER DI ST RI BU T I ON elect r ica l cu r r en t n eeded t o oper a t e m a n y a ccessor ies

t h a t t h e veh icle own er m a y ch oose t o h a ve in st a lled.
SY ST EM
DESCRIPTION SPECI AL T OOLS
Th e power dist r ibu t ion syst em for t h is veh icle con -
sist s of t h e followin g com pon en t s: POWER DISTRIBUTION SYSTEMS
• In t egr a t ed P ower Modu le (IP M)
• F r on t Con t r ol Modu le (F CM)
• P ower Ou t let s
Refer t o Wir in g Dia gr a m s for com plet e cir cu it sch e-
m a t ics.
Th e power dist r ibu t ion syst em a lso in cor por a t es
va r iou s t ypes of cir cu it con t r ol a n d pr ot ect ion fea -
t u r es, in clu din g:
• Au t om a t ic r eset t in g cir cu it br ea ker s
• Bla de-t ype fu ses
• Bu s ba r s
• Ca r t r idge fu ses
• Cir cu it splice blocks
• F la sh er s
• F u sible lin ks
• Rela ys Terminal Pick Kit 6680
OPERATION I N T EGRAT ED POWER M ODU LE

Th e power dist r ibu t ion syst em for t h is veh icle is
design ed t o pr ovide sa fe, r elia ble, a n d cen t r a lized dis- DESCRIPTION
t r ibu t ion poin t s for t h e elect r ica l cu r r en t r equ ir ed t o Th e In t egr a t ed P ower Modu le (IP M) is a com bin a -
oper a t e a ll of t h e m a n y st a n da r d a n d opt ion a l fa ct o- t ion of t h e P ower Dist r ibu t ion Cen t er (P DC) a n d t h e
r y-in st a lled elect r ica l a n d elect r on ic power t r a in , F r on t Con t r ol Modu le (F CM). Th e IP M is loca t ed in
ch a ssis, sa fet y, secu r it y, com for t a n d con ven ien ce sys- t h e en gin e com pa r t m en t , n ext t o t h e ba t t er y. (F ig. 1).
t em s. At t h e sa m e t im e, t h e power dist r ibu t ion sys- Th e P DC m a t es dir ect ly wit h t h e F CM t o for m t h e
t em wa s design ed t o pr ovide r ea dy a ccess t o t h ese IP M. Th e P DC is a pr in t ed cir cu it boa r d ba sed m od-
elect r ica l dist r ibu t ion poin t s for t h e veh icle t ech n i- u le t h a t con t a in s fu ses a n d r ela ys, wh ile t h e F CM
cia n t o u se wh en con du ct in g dia gn osis a n d r epa ir of con t a in s t h e elect r on ics con t r ollin g t h e IP M a n d
fa u lt y cir cu it s. Th e power dist r ibu t ion syst em ca n ot h er fu n ct ion s. Th is IP M con n ect s dir ect ly t o t h e
a lso pr ove u sefu l for t h e sou r cin g of a ddit ion a l elec- ba t t er y posit ive t h r ou gh a fou r pin con n ect or. Th e
t r ica l cir cu it s t h a t m a y be r equ ir ed t o pr ovide t h e gr ou n d con n ect ion is t h r ou gh t wo ot h er con n ect or s.
8W - 97 - 2 8W-97 POWER DISTRIBUTION SYSTEM RS
I N T EGRAT ED POWER M ODU LE (Cont inue d)

1 - BATTERY THERMAL GUARD
2 - INTEGRATED POWER MODULE
Th e IP M pr ovides t h e pr im a r y m ea n s of volt a ge dis-

t r ibu t ion a n d pr ot ect ion for t h e en t ir e veh icle.
OPERATION
All of t h e cu r r en t fr om t h e ba t t er y a n d t h e gen er-
a t or ou t pu t en t er s t h e In t egr a t ed P ower Modu le
(IP M) t h r ou gh a fou r- pin con n ect or on t h e bot t om of
t h e m odu le. In t er n a l con n ect ion s of a ll of t h e power
dist r ibu t ion cen t er cir cu it s is a ccom plish ed by a com -
bin a t ion of bu s ba r s a n d a pr in t ed cir cu it boa r d.
REMOVAL
(1) Discon n ect t h e n ega t ive a n d posit ive ba t t er y
ca bles.
(2) Rem ove t h e ba t t er y t h er m a l gu a r d.
(3) Rem ove t h e ba t t er y (Refer t o 8 - E LE CTRI-
CAL/BATTE RY SYSTE M/BATTE RY - RE MOVAL).
(4) Usin g a fla t -bla ded scr ewdr iver, t wist t h e In t e- Fig. 3 DISCONNECTING IPM
gr a t ed P ower Modu le (IP M) br a cket r et a in in g la t ch
1 - INTEGRATED POWER MODULE
ou t wa r d t o fr ee t h e IP M fr om it s m ou n t in g br a cket
(F ig. 2). NOTE: Ensure that the Connector Positive Assur-
(5) Rot a t e t h e IP M cou n t er-clockwise t o a ccess a n d ance (CPA) on the five-pin B+ connector is posi-
discon n ect t h e elect r ica l con n ect or s (F ig. 3). tively engaged to prevent generating a Diagnostic
(6) Rem ove t h e IP M br a cket clips fr om t h e h in ge. Trouble Code (DTC).
INSTALLATION (2) Rot a t e t h e IP M clock-wise u n t il secu r ed in

(1) Sn a p t h e left side of t h e In t egr a t ed P ower Mod- m ou n t in g br a cket . An a u dible click m a y be h ea r d.
u le (IP M) h ou sin g in it s m ou n t in g br a cket a n d con - (3) In st a ll t h e ba t t er y (Refer t o 8 - E LE CTRICAL/
n ect t h e va r iou s elect r ica l con n ect or s. BATTE RY SYSTE M/BATTE RY - INSTALLATION).
(4) In st a ll t h e ba t t er y t h er m a l gu a r d.
RS 8W-97 POWER DISTRIBUTION SYSTEM 8W - 97 - 3
I N T EGRAT ED POWER M ODU LE (Cont inue d)
(5) Con n ect t h e n ega t ive a n d posit ive ba t t er y be r em em ber ed t h a t r em ovin g t h e IOD fu se will n ot
ca bles. elim in a t e IOD, bu t on ly r edu ce t h is n or m a l con dit ion .
(6) Usin g a sca n t ool, ch eck for a n y st or ed dia gn os- If a veh icle will be st or ed for m or e t h a n t h ir t y da ys,
t ic t r ou ble codes. E n su r e t h a t a ll veh icle opt ion s a r e t h e ba t t er y n ega t ive ca ble sh ou ld be discon n ect ed t o
oper a t ion a l. elim in a t e n or m a l IOD; a n d, t h e ba t t er y sh ou ld be
t est ed a n d r ech a r ged a t r egu la r in t er va ls du r in g t h e
veh icle st or a ge per iod t o pr even t t h e ba t t er y fr om
I OD FU SE becom in g disch a r ged or da m a ged.
DESCRIPTION
All veh icles a r e equ ipped wit h a n Ign it ion -Off POWER OU T LET
Dr a w (IOD) fu se t h a t is r em oved fr om it s n or m a l
ca vit y in t h e In t egr a t ed P ower Modu le (IP M) wh en DESCRIPTION
t h e veh icle is sh ipped fr om t h e fa ct or y. Dea ler per- Two power ou t let s a r e in st a lled in t h e in st r u m en t
son n el a r e t o r em ove t h e IOD fu se fr om t h e st or a ge pa n el cen t er lower bezel. Two a ddit ion a l power ou t -
loca t ion a n d in st a ll it in t o t h e IP M fu se ca vit y let s a r e in cor por a t ed in t o t h e left r ea r C-pilla r a n d
m a r ked IOD a s pa r t of t h e pr epa r a t ion pr ocedu r es t h e cen t er con sole (if equ ipped). Th e power ou t let s
per for m ed ju st pr ior t o n ew veh icle deliver y. ba ses a r e secu r ed by a sn a p fit . A h in ged plu g flips
Th e IOD fu se is a 20 a m per e bla de-t ype m in i fu se closed t o con cea l a n d pr ot ect t h e power ou t let ba se
a n d, wh en r em oved, it is st or ed in a fu se ca vit y a dja - wh en n ot in u se.
cen t t o t h e wa sh er fu se wit h in t h e IP M.
OPERATION
OPERATION Th e power ou t let ba se or r ecept a cle sh ell is con -
Th e t er m ign it ion -off dr a w (IOD) iden t ifies a n or- n ect ed t o gr ou n d, a n d a n in su la t ed con t a ct in t h e
m a l con dit ion wh er e power is bein g dr a in ed fr om t h e bot t om of t h e sh ell is con n ect ed t o ba t t er y cu r r en t .
ba t t er y wit h t h e ign it ion swit ch in t h e Off posit ion . Th e power ou t let on t h e in st r u m en t pa n el m a r ked
Th e IOD fu se feeds t h e m em or y a n d sleep m ode fu n c- wit h a ba t t er y r eceives ba t t er y volt a ge fr om a fu se in
t ion s for som e of t h e elect r on ic m odu les in t h e veh icle t h e In t egr a t ed P ower Modu le (IP M) a t a ll t im es. Th e
a s well a s va r iou s ot h er a ccessor ies t h a t r equ ir e ba t - ot h er power ou t let on t h e in st r u m en t pa n el m a r ked
t er y cu r r en t wh en t h e ign it ion swit ch is in t h e Off wit h a key r eceives ba t t er y volt a ge on ly wh en t h e
posit ion , in clu din g t h e clock. Th e on ly r ea son t h e key is in t h e on posit ion .
IOD fu se is r em oved is t o r edu ce t h e n or m a l IOD of Th e power ou t let loca t ed in t h e cen t er con sole
t h e veh icle elect r ica l syst em du r in g n ew veh icle r eceives ba t t er y volt a ge a ll t h e t im e wh en posit ion ed
t r a n spor t a t ion a n d pr e-deliver y st or a ge t o r edu ce bet ween t h e fro n t s e a ts a n d key-on volt a ge wh en
ba t t er y deplet ion , wh ile st ill a llowin g veh icle oper a - posit ion ed bet ween t h e re a r s e a ts . Th e power ou t let
t ion so t h a t t h e veh icle ca n be loa ded, u n loa ded a n d loca t ed on t h e C-pilla r r eceives ba t t er y volt a ge on ly
m oved a s n eeded by bot h veh icle t r a n spor t a t ion com - wh en t h e key is in t h e ON posit ion .
pa n y a n d dea ler per son n el.
Th e IOD fu se is r em oved fr om t h e In t egr a t ed
P ower Modu le (IP M) fu se ca vit y wh en t h e veh icle is DI AGN OSI S AN D T EST I N G
sh ipped fr om t h e a ssem bly pla n t . Dea ler per son n el
m u st in st a ll t h e IOD fu se wh en t h e veh icle is bein g DIAGNOSIS & TESTING - POWER OUTLET
pr epa r ed for deliver y in or der t o r est or e fu ll elect r ica l
syst em oper a t ion . On ce t h e veh icle is pr epa r ed for WARNING: ON VEHICLES EQUIPPED WITH AIR-
deliver y, t h e IOD fu n ct ion of t h is fu se becom es t r a n s- BAGS, REFER TO RESTRAINTS BEFORE ATTEMPT-
pa r en t a n d t h e fu se t h a t h a s been a ssign ed t h e IOD ING ANY STEERING WHEEL, STEERING COLUMN,
design a t ion becom es on ly a n ot h er F u sed B(+) cir cu it SEAT OR INSTRUMENT PANEL COMPONENT DIAG-
fu se. Th e IOD fu se ser ves n o u sefu l pu r pose t o t h e NOSIS OR SERVICE. FAILURE TO TAKE THE
dea ler t ech n icia n in t h e ser vice or dia gn osis of a n y PROPER PRECAUTIONS COULD RESULT IN ACCI-
veh icle syst em or con dit ion , ot h er t h a n t h e sa m e pu r- DENTAL AIRBAG DEPLOYMENT AND POSSIBLE
pose a s t h a t of a n y ot h er st a n da r d cir cu it pr ot ect ion PERSONAL INJURY.
device.
(1) Ch eck t h e fu sed B(+) fu se in t h e In t egr a t ed
Th e IOD fu se ca n be u sed by t h e veh icle own er a s
P ower Modu le (IP M). If OK, go t o St ep 2. If n ot OK,
a con ven ien t m ea n s of r edu cin g ba t t er y deplet ion
r epa ir t h e sh or t ed cir cu it or com pon en t a s r equ ir ed
wh en a veh icle is t o be st or ed for per iods n ot t o
a n d r epla ce t h e fa u lt y fu se.
exceed a ppr oxim a t ely t h ir t y da ys. H owever, it m u st
8W - 97 - 4 8W-97 POWER DISTRIBUTION SYSTEM RS
POWER OU T LET (Cont inue d)
(2) Ch eck for ba t t er y volt a ge a t t h e fu sed B(+) fu se
in t h e IP M. If OK, go t o St ep 3. If n ot OK, r epa ir t h e
open fu sed B(+) cir cu it t o t h e IP M fu se a s r equ ir ed.
(3) Open t h e power ou t let door. Ch eck for con t in u -
it y bet ween t h e in side cir cu m fer en ce of t h e power
ou t let r ecept a cle a n d a good gr ou n d. Th er e sh ou ld be
con t in u it y. If OK, go t o St ep 4. If n ot OK, go t o St ep
5.
(4) Ch eck for ba t t er y volt a ge a t t h e in su la t ed con -
t a ct loca t ed a t t h e ba ck of t h e power ou t let r ecept a -
cle. If n ot OK, go t o St ep 5.
ca ble. Rem ove t h e a ppr opr ia t e bezel. Ch eck for con t i-
n u it y bet ween t h e gr ou n d cir cu it ca vit y of t h e power
ou t let wir e h a r n ess con n ect or a n d a good gr ou n d.
Th er e sh ou ld be con t in u it y. If OK, go t o St ep 6. If n ot
OK, r epa ir t h e open gr ou n d cir cu it t o gr ou n d a s
r equ ir ed.
(6) Con n ect t h e ba t t er y n ega t ive ca ble. Ch eck for
ba t t er y volt a ge a t t h e fu sed B(+) cir cu it ca vit y of t h e
power ou t let wir e h a r n ess con n ect or. If OK, r epla ce
t h e fa u lt y power ou t let r ecept a cle. If n ot OK, r epa ir
t h e open fu sed B(+) cir cu it t o t h e IP M fu se a s Fig. 4 POWER OUTLET
r equ ir ed. 1 - RETAINING BOSSES-ENGAGE PLIERS HERE
2 - PARTIALLY REMOVED
3 - EXTERNAL SNAP-RING PLIERS
REMOVAL 4 - PULL BASE OUT-THROUGH MOUNTING RING
ca ble. ca p a n d t h e m ou n t in g r in g wit h t h e in dex t a b a t t h e
(2) Not e posit ion of t h e r et a in in g bosses (F ig. 4). 9 o’clock posit ion t o t h e key in t h e in st r u m en t pa n el.
(3) Usin g ext er n a l sn a p r in g plier s wit h 90 degr ee In st a ll t h e r in g.
t ips. In ser t plier s wit h t ips a ga in st bosses a n d (2) Con n ect t h e wir es t o t h e ba se. Or ien t a t e t h e
squ eeze for cin g bosses ou t of ba se. ba se a lign m en t r ib a t t h e 11 o’clock posit ion t o m a t e
(4) P u ll ou t t h e ba se t h r ou gh m ou n t in g r in g by t h e gr oove in t h e m ou n t in g r in g t o t h e ba se.
gen t ly r ockin g plier s. (3) P u sh t h e ba se in t o t h e bezel u n t il it locks in
(5) Discon n ect t h e ba se wir es. pla ce.
(6) Rem ove ligh t r in g a n d discon n ect wir e. (4) Ch eck oper a t ion of ou t let or elem en t a n d
in st a ll t h e ou t let ca p.
INSTALLATION
(1) P osit ion t h e m ou n t in g r in g on t h e in st r u m en t
pa n el a n d feed t h e wir es t h r ou gh t h e r in g. In dex t h e
RS ENGINE 9-1
ENGINE
page page
ENGINE 2.4L. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ENGINE 3.3/3.8L . . . . . . . . . . . . . . . . . . . . . . . . . 76
EN GI N E 2 .4 L
TABLE OF CONTENTS
page page
ENGINE 2.4L INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 24

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 3 AIR CLEANER HOUSING
DIAGNOSIS AND TESTING - ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25
DIAGNOSIS - INTRODUCTION . . . . . . . . . . . . 3 CYLINDER HEAD
DIAGNOSIS AND TESTING - ENGINE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 25
DIAGNOSIS - PERFORMANCE . . . . . . . . . . . . 4 DIAGNOSIS AND TESTING—CYLINDER HEAD
DIAGNOSIS AND TESTING - ENGINE GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
DIAGNOSIS - MECHANICAL . . . . . . . . . . . . . . 6 REMOVAL - CYLINDER HEAD . . . . . . . . . . . . . 26
DIAGNOSIS AND TESTING - ENGINE OIL CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
LEAK INSPECTION . . . . . . . . . . . . . . . . . . . . . 8 INSPECTION ......................... . 27
DIAGNOSIS AND TESTING - CYLINDER INSTALLATION - CYLINDER HEAD . . . . . . . . . . 27
COMPRESSION PRESSURE TEST . . . . . . . . . 9 CAMSHAFT OIL SEAL(S)
DIAGNOSIS AND TESTING - CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
COMBUSTION PRESSURE LEAKAGE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 29
TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 CAMSHAFT(S)
STANDARD PROCEDURE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 29
STANDARD PROCEDURE - ENGINE CORE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
AND OIL GALLERY PLUGS . . . . . . . . . . . . . . 10 STANDARD PROCEDURE - MEASURING
STANDARD PROCEDURE - REPAIR OF CAMSHAFT END PLAY . . . . . . . . . . . . . . . . . 29
DAMAGED OR WORN THREADS . . . . . . . . . 10 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
HYDROSTATIC LOCKED ENGINE . . . . . . . . . 10 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
FORM-IN-PLACE GASKETS AND SEALERS . 11 INSPECTION ......................... . 30
STANDARD PROCEDURE - ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 31
GASKET SURFACE PREPARATION . . . . . . . . 11 CYLINDER HEAD COVER
STANDARD PROCEDURE - MEASURING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
BEARING CLEARANCE USING CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
PLASTIGAGE . . . . . . . . . . . . . . . . . . . . . . . . 12 INSPECTION ......................... . 31
REMOVAL - ENGINE ASSEMBLY . . . . . . . . . . . 12 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 32
INSTALLATION - ENGINE ASSEMBLY . . . . . . . . 14 INTAKE/EXHAUST VALVES & SEATS
SPECIFICATIONS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 33
SPECIFICATIONS - 2.4L ENGINE . . . . . . . . . 16 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
SPECIFICATIONS - TORQUE . . . . . . . . . . . . 20 VALVE SPRINGS & SEALS
SPECIAL TOOLS REMOVAL
2.4L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . 21 REMOVAL - CYLINDER HEAD ON . . . . . . . . . 33
AIR CLEANER ELEMENT REMOVAL - CYLINDER HEAD OFF . . . . . . . . 33
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 INSPECTION ......................... . 33
9-2 ENGINE 2.4L RS
INSTALLATION - CYLINDER HEAD ON . . . . . 33 REAR MOUNT
INSTALLATION - CYLINDER HEAD OFF . . . . 33 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
HYDRAULIC LASH ADJUSTERS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 52
DIAGNOSIS AND TESTING - HYDRAULIC RIGHT MOUNT
LASH ADJUSTER NOISE DIAGNOSIS . . . . . . 34 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 35 LUBRICATION
ROCKER ARMS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 53
INSPECTION ........................ . . 35 DIAGNOSIS AND TESTING - CHECKING
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 35 ENGINE OIL PRESSURE . . . . . . . . . . . . . . . . 53
ENGINE BLOCK OIL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 36 STANDARD PROCEDURE
STANDARD PROCEDURE - CYLINDER BORE ENGINE OIL LEVEL CHECK . . . . . . . . . . . . . 54
HONING .......................... . . 36 STANDARD PROCEDURE - ENGINE OIL
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 AND FILTER CHANGE . . . . . . . . . . . . . . . . . . 54
INSPECTION ........................ . . 37 OIL FILTER
CRANKSHAFT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 54
STANDARD PROCEDURE - CRANKSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
END PLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 54
REMOVAL - CRANKSHAFT . . . . . . . . . . . . . . . . 37 OIL PAN
INSPECTION ........................ . . 38 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
INSTALLATION - CRANKSHAFT . . . . . . . . . . . . 39 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 55
CRANKSHAFT OIL SEAL - FRONT OIL PRESSURE SWITCH
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
CRANKSHAFT OIL SEAL - REAR OIL PUMP
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 42 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 57
PISTON & CONNECTING ROD CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 44 INSPECTION ..................... . . . . . 58
STANDARD PROCEDURE - PISTON TO ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
CYLINDER BORE FITTING . . . . . . . . . . . . . . 44 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 59
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 INTAKE MANIFOLD
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 45 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 60
CONNECTING ROD BEARINGS DIAGNOSIS AND TESTING - INTAKE
STANDARD PROCEDURE MANIFOLD LEAKS . . . . . . . . . . . . . . . . . . . . . 60
CONNECTING ROD - FITTING . . . . . . . . . . . 46 INTAKE MANIFOLD - UPPER
PISTON RINGS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
STANDARD PROCEDURE INSPECTION ..................... . . . . . 61
PISTON RING - FITTING . . . . . . . . . . . . . . . . 47 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 61
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 INTAKE MANIFOLD - LOWER
VIBRATION DAMPER INSPECTION ..................... . . . . . 62
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 49 EXHAUST MANIFOLD
STRUCTURAL COLLAR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 49 INSPECTION ..................... . . . . . 63
ENGINE MOUNTING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 63
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 50 TIMING BELT COVER(S)
FRONT MOUNT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 50 TIMING BELT AND SPROCKET(S)
LEFT MOUNT REMOVAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 REMOVAL - TIMING BELT . . . . . . . . . . . . . . . 65
RS ENGINE 2.4L 9-3
REMOVAL - CAMSHAFT SPROCKETS . . . . . 66 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 70

REMOVAL - CRANKSHAFT SPROCKET . . . . 66 BALANCE SHAFTS AND CARRIER ASSEMBLY
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 71
INSTALLATION OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
INSTALLATION - CRANKSHAFT SPROCKET . 67 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
INSTALLATION - CAMSHAFT SPROCKETS . . 67 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 73
INSTALLATION - TIMING BELT . . . . . . . . . . . 67
TIMING BELT TENSIONER & PULLEY
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
EN GI N E 2 .4 L DI AGN OSI S AN D T EST I N G
DESCRIPTION DIAGNOSIS AND TESTING - ENGINE

Th e 2.4 Lit er (148 cu . in .) in -lin e fou r cylin der DIAGNOSIS - INTRODUCTION
en gin e is a dou ble over h ea d ca m sh a ft wit h h ydr a u lic E n gin e dia gn osis is h elpfu l in det er m in in g t h e
la sh a dju st er s a n d fou r va lve per cylin der design . ca u ses of m a lfu n ct ion s n ot det ect ed a n d r em edied by
Th e en gin e is fr ee-wh eelin g; m ea n in g it h a s pr ovi- r ou t in e m a in t en a n ce.
sion s for pist on -t o-va lve clea r a n ce. H owever va lve-t o- Th ese m a lfu n ct ion s m a y be cla ssified a s eit h er
va lve in t er fer en ce ca n occu r, if ca m sh a ft s a r e r ot a t ed m ech a n ica l (e.g., a st r a n ge n oise), or per for m a n ce
in depen den t ly. (e.g., en gin e idles r ou gh a n d st a lls).
Th e cylin der s a r e n u m ber ed fr om fr on t of t h e Refer t o t h e E n gin e Mech a n ica l a n d t h e E n gin e
en gin e t o t h e r ea r. Th e fir in g or der is 1–3–4–2. P er for m a n ce dia gn ost ic ch a r t s, for possible ca u ses
Th e en gin e iden t ifica t ion n u m ber is loca t ed on t h e a n d cor r ect ion s of m a lfu n ct ion s (Refer t o 9 - E NGINE
r ea r of t h e cylin der block (F ig. 1). - DIAGNOSIS AND TE STING - ME CH ANICAL)
(Refer t o 9 - E NGINE - DIAGNOSIS AND TE STING
- P E RF ORMANCE ).
F or fu el syst em dia gn osis, (Refer t o 14 - F UE L
SYSTE M/F UE L DE LIVE RY - DIAGNOSIS AND
TE STING).
Addit ion a l t est s a n d dia gn ost ic pr ocedu r es m a y be
n ecessa r y for specific en gin e m a lfu n ct ion s t h a t ca n -
n ot be isola t ed wit h t h e Ser vice Dia gn osis ch a r t s.
In for m a t ion con cer n in g a ddit ion a l t est s a n d dia gn o-
sis is pr ovided wit h in t h e followin g:
• Cylin der Com pr ession P r essu r e Test
• Cylin der Com bu st ion P r essu r e Lea ka ge Test
• E n gin e Cylin der H ea d Ga sket F a ilu r e Dia gn osis
Fig. 1 Engine Identification • In t a ke Ma n ifold Lea ka ge Dia gn osis
1 - ENGINE IDENTIFICATION LOCATION • H ydr a u lic La sh Adju st er Noise Dia gn osis
• E n gin e Oil Lea k In spect ion
9-4 ENGINE 2.4L RS
EN GI N E 2 .4 L (Cont inue d)
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - PERFORMANCE
ENGINE WILL NOT START 1. Weak battery. 1. Test battery. Charge or replace
as necessary. (Refer to 8 -
ELECTRICAL/BATTERY SYSTEM -
DIAGNOSIS AND TESTING)
2. Corroded or loose battery 2. Clean and tighten battery
connections. connections. Apply a coat of light
mineral grease to terminals.
3. Faulty starter. 3. Test starting system. (Refer to 8 -
ELECTRICAL/STARTING -
4. Faulty coil(s) or control unit. 4. Test and replace as needed.
(Refer to Appropriate Diagnostic
Information)
5. Incorrect spark plug gap. 5. Set gap. (Refer to 8 -
ELECTRICAL/IGNITION CONTROL
- SPECIFICATIONS)
6. Contamination in fuel system. 6. Clean system and replace fuel
filter.
7. Faulty fuel pump. 7. Test fuel pump and replace as
needed. (Refer to Appropriate
Diagnostic Information)
8. Incorrect engine timing. 8. Check for a skipped timing
belt/chain.
ENGINE STALLS OR IDLES 1. Idle speed too low. 1. Test minimum air flow. (Refer to
ROUGH Appropriate Diagnostic Information)
2. Incorrect fuel mixture. 2. (Refer to Appropriate Diagnostic

Information)
3. Intake manifold leakage. 3. Inspect intake manifold, manifold
gasket, and vacuum hoses.
4. Faulty ignition coil(s). 4. Test and replace as necessary.
Information)
RS ENGINE 2.4L 9-5
ENGINE LOSS OF POWER 1. Dirty or incorrectly gapped plugs. 1. Clean plugs and set gap.

filter.
3. Faulty fuel pump. 3. Test and replace as necessary.
Information)
4. Incorrect valve timing. 4. Correct valve timing.
5. Leaking cylinder head gasket. 5. Replace cylinder head gasket.
6. Low compression. 6. Test compression of each
cylinder.
7. Burned, warped, or pitted valves. 7. Replace valves.
8. Plugged or restricted exhaust 8. Perform exhaust restriction test.
system. (Refer to 11 - EXHAUST SYSTEM -
DIAGNOSIS AND TESTING) Install
new parts, as necessary.
Information)
ENGINE MISSES ON 1. Dirty or incorrectly gapped spark 1. Clean spark plugs and set gap.
ACCELERATION plugs.
2. Contamination in Fuel System. 2. Clean fuel system and replace

fuel filter.
Information)
ENGINE MISSES AT HIGH SPEED 1. Dirty or incorrect spark plug gap. 1. Clean spark plugs and set gap.
Information)
3. Dirty fuel injector(s). 3. Test and replace as necessary.
Information)
filter.
9-6 ENGINE 2.4L RS
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICAL
NOISY VALVES 1. High or low oil level in 1. Check and correct engine oil
crankcase. level.
2. Thin or diluted oil. 2. Change oil to correct viscosity.

3. Thick oil 3. (a) Change engine oil and filter.
(b) Run engine to operating
temperature.
(c) Change engine oil and filter
again.
4. Low oil pressure. 4. Check and correct engine oil
pressure problem.
5. Dirt in hydraulic lifters/lash 5. Replace hydraulic lifters/lash
adjusters. adjusters.
6. Worn rocker arms. 6. Inspect oil supply to rocker arms.
7. Worn hydraulic lifters/lash 7. Replace hydraulic lifters/lash
8. Worn valve guides. 8. Replace cylinder head assembly.
9. Excessive runout of valve seats 9. Grind valve seats and valves.
on valve faces.
CONNECTING ROD NOISE 1. Insufficient oil supply. 1. Check engine oil level.
2. Low oil pressure. 2. Check engine oil level. Inspect oil

pump relief valve and spring.
temperature.
again.
5. Excessive bearing clearance. 5. Measure bearings for correct
clearance. Repair as necessary.
6. Connecting rod journal 6. Replace crankshaft or grind
out-of-round. surface.
7. Misaligned connecting rods. 7. Replace bent connecting rods.
RS ENGINE 2.4L 9-7
MAIN BEARING NOISE 1. Insufficient oil supply. 1. Check engine oil level.

temperature.
again.
6. Excessive end play. 6. Check thrust bearing for wear on
flanges.
7. Crankshaft journal out-of-round 7. Replace crankshaft or grind
or worn. journals.
8. Loose flywheel or torque 8. Tighten to correct torque.
converter.
OIL PRESSURE DROP 1. Low oil level. 1. Check engine oil level.
2. Faulty oil pressure sensor/switch. 2. Replace oil pressure sensor/

switch.
3. Low oil pressure. 3. Check oil pressure sensor/switch
and main bearing oil clearance.
4. Clogged oil filter. 4. Install new oil filter.
5. Worn parts in oil pump. 5. Replace worn parts or pump.
7. Oil pump relief valve stuck. 7. Remove valve and inspect, clean,
or replace.
8. Oil pump suction tube loose. 8. Remove oil pan and install new
tube or clean, if necessary.
9. Oil pump cover warped or 9. Install new oil pump.
cracked.
clearance.
OIL LEAKS 1. Misaligned or deteriorated 1. Replace gasket(s).

gaskets.
2. Loose fastener, broken or porous 2. Tighten, repair or replace the

metal part. part.
3. Misaligned or deteriorated cup or 3. Replace as necessary.
threaded plug.
9-8 ENGINE 2.4L RS
OIL CONSUMPTION OR SPARK 1. PCV system malfunction. 1. Check system and repair as
PLUGS FOULED necessary. (Refer to 25 -
EMISSIONS CONTROL/
EVAPORATIVE EMISSIONS/PCV
VALVE - DIAGNOSIS AND
TESTING)
2. Worn, scuffed or broken rings. 2. Hone cylinder bores. Install new
rings.
3. Carbon in oil ring slots. 3. Install new rings.
4. Rings fitted too tightly in grooves. 4. Remove rings and check
grooves. If groove is not proper
width, replace piston.
5. Worn valve guide(s). 5. Replace cylinder head assembly.
6. Valve stem seal(s) worn or 6. Replace seal(s).
damaged.
DIAGNOSIS AND TESTING - ENGINE OIL LEAK • Gr a du a lly a pply a ir pr essu r e fr om 1 psi t o 2.5
psi m a xim u m wh ile a pplyin g soa py wa t er a t t h e su s-
INSPECTION
pect ed sou r ce. Adju st t h e r egu la t or t o t h e su it a ble
Begin wit h a t h or ou gh visu a l in spect ion of t h e
t est pr essu r e t h a t pr ovides t h e best bu bbles wh ich
en gin e, pa r t icu la r ly a t t h e a r ea of t h e su spect ed lea k.
will pin poin t t h e lea k sou r ce. If t h e oil lea k is
If a n oil lea k sou r ce is n ot r ea dily iden t ifia ble, t h e
det ect ed a n d iden t ified, r epa ir per ser vice m a n u a l
followin g st eps sh ou ld be followed:
pr ocedu r es.
(1) Do n ot clea n or degr ea se t h e en gin e a t t h is
• If t h e lea ka ge occu r s a t t h e cr a n ksh a ft r ea r oil
t im e beca u se som e solven t s m a y ca u se r u bber t o
sea l a r ea , r efer t o t h e sect ion , In spect ion for Rea r
swell, t em por a r ily st oppin g t h e lea k.
Sea l Ar ea Lea k.
(2) Add a n oil solu ble dye (u se a s r ecom m en ded by
(6) If n o lea ks a r e det ect ed, t u r n off t h e a ir su pply.
m a n u fa ct u r er ). St a r t t h e en gin e a n d let idle for
Rem ove t h e a ir h ose, a ll plu gs, a n d ca ps. In st a ll t h e
a ppr oxim a t ely 15 m in u t es. Ch eck t h e oil dipst ick t o
P CV va lve a n d fr esh a ir h ose (m a ke-u p a ir ). P r oceed
m a ke su r e t h e dye is t h or ou gh ly m ixed a s in dica t ed
t o n ext st ep.
wit h a br igh t yellow color u n der a bla ck ligh t .
(7) Clea n t h e oil off t h e su spect oil lea k a r ea u sin g
(3) Usin g a bla ck ligh t , in spect t h e en t ir e en gin e
a su it a ble solven t . Dr ive t h e veh icle a t va r iou s
for flu or escen t dye, pa r t icu la r ly a t t h e su spect ed a r ea
speeds a ppr oxim a t ely 24 km (15 m iles). In spect t h e
of oil lea k. If t h e oil lea k is fou n d a n d iden t ified,
en gin e for sign s of a n oil lea k by u sin g a bla ck ligh t .
r epa ir a s n ecessa r y.
(4) If dye is n ot obser ved, dr ive t h e veh icle a t va r- NOTE: If oil leakage is observed at the dipstick tube
iou s speeds for a ppr oxim a t ely 24 km (15 m iles), a n d to block location; remove the tube, clean and reseal
r epea t in spect ion . using Mopar" Stud & Bearing Mount (press fit tube
(5) If th e o il le a k s o u rc e is n o t p o s itiv e ly applications only), and for O-ring style tubes,
id e n tifie d a t th is tim e , pr oceed wit h t h e a ir lea k remove tube and replace the O-ring seal.
det ect ion t est m et h od a s follows:
• Discon n ect t h e fr esh a ir h ose (m a ke-u p a ir ) a t
t h e cylin der h ea d cover a n d plu g or ca p t h e ou t let on INSPECTION FOR REAR SEAL AREA LEAKS
t h e cover. Sin ce it is som et im es difficu lt t o det er m in e t h e
• Rem ove t h e P CV va lve h ose fr om t h e cylin der sou r ce of a n oil lea k in t h e r ea r sea l a r ea of t h e
h ea d cover. Ca p or plu g t h e P CV va lve ou t let on t h e en gin e, a m or e in volved in spect ion is n ecessa r y. Th e
cover. followin g st eps sh ou ld be followed t o h elp pin poin t
• At t a ch a n a ir h ose wit h pr essu r e ga u ge a n d r eg- t h e sou r ce of t h e lea k.
u la t or t o t h e dipst ick t u be. If t h e lea ka ge occu r s a t t h e cr a n ksh a ft r ea r oil sea l
a r ea :
CAUTION: Do not subject the engine assembly to (1) Discon n ect t h e ba t t er y.
more than 20.6 kpa (3 PSI) of test pressure. (2) Ra ise t h e veh icle.
RS ENGINE 2.4L 9-9
(3) Rem ove t or qu e con ver t er or clu t ch h ou sin g (4) Rem ove t h e Au t o Sh u t down (ASD) r ela y fr om
cover a n d in spect r ea r of block for eviden ce of oil. t h e P DC.
Use a bla ck ligh t t o ch eck for t h e oil lea k. If a lea k is (5) Be su r e t h r ot t le bla de is fu lly open du r in g t h e
pr esen t in t h is a r ea , r em ove t r a n sm ission for fu r t h er com pr ession ch eck.
in spect ion . (6) In ser t com pr ession ga u ge a da pt or Specia l Tool
(a ) Cir cu la r spr a y pa t t er n gen er a lly in dica t es 8116 or t h e equ iva len t , in t o t h e #1 spa r k plu g h ole in
sea l lea ka ge or cr a n ksh a ft da m a ge. cylin der h ea d. Con n ect t h e 0–500 psi (Blu e) pr essu r e
(b) Wh er e lea ka ge t en ds t o r u n st r a igh t down , t r a n sdu cer (Specia l Tool CH 7059) wit h ca ble a da p-
possible ca u ses a r e a por ou s block, oil ga ller y cu p t or s t o t h e DRBIII!. F or Specia l Tool iden t ifica t ion ,
plu g, bedpla t e t o cylin der block m a t in g su r fa ces (Refer t o 9 - E NGINE - SP E CIAL TOOLS).
a n d sea l bor e. See pr oper r epa ir pr ocedu r es for (7) Cr a n k en gin e u n t il m a xim u m pr essu r e is
t h ese it em s. r ea ch ed on ga u ge. Recor d t h is pr essu r e a s #1 cylin -
(4) If n o lea ks a r e det ect ed, pr essu r ize t h e cr a n k- der pr essu r e.
ca se a s pr eviou sly descr ibed. (8) Repea t t h e pr eviou s st ep for a ll r em a in in g cyl-
in der s.
CAUTION: Do not exceed 20.6 kPa (3 psi). (9) Com pr ession sh ou ld n ot be less t h a n 689 kP a
(100 psi) a n d n ot va r y m or e t h a n 25 per cen t fr om cyl-
(5) If t h e lea k is n ot det ect ed, ver y slowly t u r n t h e in der t o cylin der.
cr a n ksh a ft a n d wa t ch for lea ka ge. If a lea k is (10) If on e or m or e cylin der s h a ve a bn or m a lly low
det ect ed bet ween t h e cr a n ksh a ft a n d sea l wh ile com pr ession pr essu r es, r epea t t h e com pr ession t est .
slowly t u r n in g t h e cr a n ksh a ft , it is possible t h e (11) If t h e sa m e cylin der or cylin der s r epea t a n
cr a n ksh a ft sea l su r fa ce is da m a ged. Th e sea l a r ea on a bn or m a lly low r ea din g on t h e secon d com pr ession
t h e cr a n ksh a ft cou ld h a ve m in or n icks or scr a t ch es t est , it cou ld in dica t e t h e exist en ce of a pr oblem in
t h a t ca n be polish ed ou t wit h em er y clot h . t h e cylin der in qu est ion . Th e re c o m m e n d e d c o m -
p re s s io n p re s s u re s a re to be u s e d o n ly a s a
CAUTION: Use extreme caution when crankshaft
g u id e to d ia g n o s in g e n g in e p ro ble m s . An e n g in e
polishing is necessary to remove minor nicks and
s h o u ld n o t be d is a s s e m ble d to d e te rm in e th e
scratches. The crankshaft seal flange is especially
c a u s e o f lo w c o m p re s s io n u n le s s s o m e m a lfu n c -
machined to complement the function of the rear oil
tio n is p re s e n t.
seal.
(6) F or bu bbles t h a t r em a in st ea dy wit h sh a ft DIAGNOSIS AND TESTING - CYLINDER

r ot a t ion , n o fu r t h er in spect ion ca n be don e u n t il dis- COMBUSTION PRESSURE LEAKAGE TEST
a ssem bled. Th e com bu st ion pr essu r e lea ka ge t est pr ovides a n
(7) Aft er t h e oil lea k r oot ca u se a n d a ppr opr ia t e a ccu r a t e m ea n s for det er m in in g en gin e con dit ion .
cor r ect ive a ct ion h a ve been iden t ified, r epla ce com po- Com bu st ion pr essu r e lea ka ge t est in g will det ect :
n en t (s) a s n ecessa r y. • E xh a u st a n d in t a ke va lve lea ks (im pr oper sea t -
in g).
DIAGNOSIS AND TESTING - CYLINDER • Lea ks bet ween a dja cen t cylin der s or in t o wa t er
COMPRESSION PRESSURE TEST ja cket .
Th e r esu lt s of a cylin der com pr ession pr essu r e t est • An y ca u ses for com bu st ion /com pr ession pr essu r e
ca n be u t ilized t o dia gn ose sever a l en gin e m a lfu n c- loss.
t ion s.
WARNING: DO NOT REMOVE THE PRESSURE CAP
E n su r e t h e ba t t er y is com plet ely ch a r ged a n d t h e
en gin e st a r t er m ot or is in good oper a t in g con dit ion .
Ot h er wise t h e in dica t ed com pr ession pr essu r es m a y
OCCUR.
n ot be va lid for dia gn osis pu r poses.
(1) Ch eck en gin e oil level a n d a dd oil if n ecessa r y. Ch eck t h e coola n t level a n d fill a s r equ ir ed. DO
(2) Dr ive t h e veh icle u n t il en gin e r ea ch es n or m a l NOT in st a ll t h e pr essu r e ca p.
oper a t in g t em per a t u r e. Select a r ou t e fr ee fr om t r a f- St a r t a n d oper a t e t h e en gin e u n t il it a t t a in s n or-
fic a n d ot h er for m s of con gest ion , obser ve a ll t r a ffic m a l oper a t in g t em per a t u r e, t h en t u r n t h e en gin e
la ws, a n d a cceler a t e t h r ou gh t h e gea r s sever a l t im es OF F.
br iskly. Clea n spa r k plu g r ecesses wit h com pr essed a ir.
(3) Rem ove a ll spa r k plu gs fr om en gin e. As spa r k Rem ove t h e spa r k plu gs.
plu gs a r e bein g r em oved, ch eck elect r odes for a bn or- Rem ove t h e oil filler ca p.
m a l fir in g in dica t or s fou led, h ot , oily, et c. Recor d cyl- Rem ove t h e a ir clea n er.
in der n u m ber of spa r k plu g for fu t u r e r efer en ce.
9 - 10 ENGINE 2.4L RS
Ca libr a t e t h e t est er a ccor din g t o t h e m a n u fa ct u r- is clea n ed of a ll oil or gr ea se. Usin g pr oper dr ive
er ’s in st r u ct ion s. Th e sh op a ir sou r ce for t est in g plu g, dr ive plu g in t o h ole so t h a t t h e sh a r p edge of
sh ou ld m a in t a in 483 kP a (70 psi) m in im u m , 1,379 t h e plu g is a t lea st 0.5 m m (0.020 in .) in side t h e
kP a (200 psi) m a xim u m , wit h 552 kP a (80 psi) r ec- lea d-in ch a m fer.
om m en ded. It is n ot n ecessa r y t o wa it for cu r in g of t h e sea la n t .
P er for m t h e t est pr ocedu r es on ea ch cylin der Th e coolin g syst em ca n be r efilled a n d t h e veh icle
a ccor din g t o t h e t est er m a n u fa ct u r er ’s in st r u ct ion s. pla ced in ser vice im m edia t ely.
Wh ile t est in g, list en for pr essu r ized a ir esca pin g
t h r ou gh t h e t h r ot t le body, t a ilpipe a n d oil filler ca p STANDARD PROCEDURE - REPAIR OF
open in g. Ch eck for bu bbles in t h e coola n t . DAMAGED OR WORN THREADS
All ga u ge pr essu r e in dica t ion s sh ou ld be equ a l, Da m a ged or wor n t h r ea ds (exclu din g spa r k plu g
wit h n o m or e t h a n 25% lea ka ge per cylin der. a n d ca m sh a ft bea r in g ca p a t t a ch in g t h r ea ds) ca n be
F OR EXAMP LE: At 552 kP a (80 psi) in pu t pr es- r epa ir ed. E ssen t ia lly, t h is r epa ir con sist s of dr illin g
su r e, a m in im u m of 414 kP a (60 psi) sh ou ld be m a in - ou t wor n or da m a ged t h r ea ds, t a ppin g t h e h ole wit h
t a in ed in t h e cylin der. a specia l H eli-Coil Ta p, (or equ iva len t ) a n d in st a llin g
a n in ser t in t o t h e t a pped h ole. Th is br in gs t h e h ole
STAN DARD PROCEDU RE ba ck t o it s or igin a l t h r ea d size.
CAUTION: Be sure that the tapped holes maintain

STANDARD PROCEDURE - ENGINE CORE AND the original center line.
OIL GALLERY PLUGS
Usin g a blu n t t ool su ch a s a dr ift a n d a h a m m er, H eli-Coil t ools a n d in ser t s a r e r ea dily a va ila ble
st r ike t h e bot t om edge of t h e cu p plu g. Wit h t h e cu p fr om a u t om ot ive pa r t s jobber s.
plu g r ot a t ed, gr a sp fir m ly wit h plier s or ot h er su it -
a ble t ool a n d r em ove plu g (F ig. 2). HYDROSTATIC LOCKED ENGINE
Wh en a n en gin e is su spect ed t o be h ydr ost a t ica lly
locked, r ega r dless of wh a t ca u sed t h e pr oblem , t h e
followin g st eps sh ou ld be u sed.
CAUTION: DO NOT use starter motor to rotate the

engine, severe damage may occur.
(1) In spect a ir clea n er, in du ct ion syst em a n d

in t a ke m a n ifold t o in su r e syst em is dr y a n d clea r of
for eign m a t er ia l.
(2) Rem ove n ega t ive ba t t er y ca ble.
(3) P la ce a sh op t owel a r ou n d t h e spa r k plu gs
wh en r em ovin g t h em fr om t h e en gin e. Th is will ca t ch
a n y flu id t h a t m a y possibly be in t h e cylin der u n der
pr essu r e.
(4) Wit h a ll spa r k plu gs r em oved, r ot a t e en gin e
cr a n ksh a ft u sin g a br ea ker ba r a n d socket .
Fig. 2 Core Hole Plug Removal (5) Iden t ify t h e flu id in t h e cylin der (s) (i.e., cool-
a n t , fu el, oil or ot h er ).
1 - CYLINDER BLOCK
2 - REMOVE PLUG WITH PLIERS (6) Ma ke su r e a ll flu id h a s been r em oved fr om t h e
3 - STRIKE HERE WITH HAMMER cylin der s. In spect en gin e for da m a ge (i.e., con n ect in g
4 - DRIFT PUNCH r ods, pist on s, va lves, et c.)
5 - CUP PLUG
(7) Repa ir en gin e or com pon en t s a s n ecessa r y t o
CAUTION: Do not drive cup plug into the casting as pr even t t h is pr oblem fr om r e-occu r r in g.
restricted cooling can result and cause serious
CAUTION: Squirt approximately one teaspoon of oil
engine problems.
into the cylinders, rotate engine to lubricate the cyl-
Th or ou gh ly clea n in side of cu p plu g h ole in cylin - inder walls to prevent damage on restart.
der block or h ea d. Be su r e t o r em ove old sea ler.
(8) In st a ll n ew spa r k plu gs.
Ligh t ly coa t in side of cu p plu g h ole wit h Mopa r !
(9) Dr a in en gin e oil a n d r em ove oil filt er.
St u d a n d Bea r in g Mou n t . Ma ke cer t a in t h e n ew plu g
(10) In st a ll a n ew oil filt er.
RS ENGINE 2.4L 9 - 11
(11) F ill en gin e wit h specified a m ou n t of a ppr oved a ga in st lea ka ge of oil a n d coola n t . Ca n be u sed on
oil. t h r ea ded a n d m a ch in ed pa r t s u n der a ll t em per a -
(12) Con n ect n ega t ive ba t t er y ca ble. t u r es. Th is m a t er ia l is u sed on en gin es wit h m u lt i-
(13) St a r t en gin e a n d ch eck for a n y lea ks. la yer st eel (MLS) cylin der h ea d ga sket s. Th is
m a t er ia l a lso will pr even t cor r osion . Mopa r ! Ga sket
FORM-IN-PLACE GASKETS AND SEALERS Sea la n t is a va ila ble in a 13 oz. a er osol ca n or 4oz./16
Th er e a r e n u m er ou s pla ces wh er e for m -in -pla ce oz. ca n w/a pplica t or.
ga sket s a r e u sed on t h e en gin e. Ca r e m u st be t a ken
wh en a pplyin g for m -in -pla ce ga sket s t o a ssu r e SEALER APPLICATION
obt a in in g t h e desir ed r esu lt s. D o n o t u s e fo rm -in - Mopa r ! Ga sket Ma ker m a t er ia l sh ou ld be a pplied
p la c e g a s k e t m a te ria l u n le s s s p e c ifie d . Bea d size, spa r in gly 1 m m (0.040 in .) dia m et er or less of sea la n t
con t in u it y, a n d loca t ion a r e of gr ea t im por t a n ce. Too t o on e ga sket su r fa ce. Be cer t a in t h e m a t er ia l su r-
t h in a bea d ca n r esu lt in lea ka ge wh ile t oo m u ch ca n r ou n ds ea ch m ou n t in g h ole. E xcess m a t er ia l ca n ea s-
r esu lt in spill-over wh ich ca n br ea k off a n d obst r u ct ily be wiped off. Com pon en t s sh ou ld be t or qu ed in
flu id feed lin es. A con t in u ou s bea d of t h e pr oper pla ce wit h in 15 m in u t es. Th e u se of a loca t in g dowel
widt h is essen t ia l t o obt a in a lea k-fr ee ga sket . is r ecom m en ded du r in g a ssem bly t o pr even t sm ea r-
Th er e a r e n u m er ou s t ypes of for m -in -pla ce ga sket in g m a t er ia l off t h e loca t ion .
m a t er ia ls t h a t a r e u sed in t h e en gin e a r ea . Mopa r ! Mopa r ! E n gin e RTV GE N II or ATF RTV ga sket
E n gin e RTV GE N II, Mopa r ! ATF -RTV, a n d Mopa r ! m a t er ia l sh ou ld be a pplied in a con t in u ou s bea d
Ga sket Ma ker ga sket m a t er ia ls, ea ch h a ve differ en t a ppr oxim a t ely 3 m m (0.120 in .) in dia m et er. All
pr oper t ies a n d ca n n ot be u sed in pla ce of t h e ot h er. m ou n t in g h oles m u st be cir cled. F or cor n er sea lin g, a
MOPAR! EN GIN E RTV GEN II is u sed t o sea l 3.17 or 6.35 m m (1/8 or 1/4 in .) dr op is pla ced in t h e
com pon en t s exposed t o en gin e oil. Th is m a t er ia l is a cen t er of t h e ga sket con t a ct a r ea . Un cu r ed sea la n t
specia lly design ed bla ck silicon e r u bber RTV t h a t m a y be r em oved wit h a sh op t owel. Com pon en t s
r et a in s a dh esion a n d sea lin g pr oper t ies wh en sh ou ld be t or qu ed in pla ce wh ile t h e sea la n t is st ill
exposed t o en gin e oil. Moist u r e in t h e a ir ca u ses t h e wet t o t h e t ou ch (wit h in 10 m in u t es). Th e u sa ge of a
m a t er ia l t o cu r e. Th is m a t er ia l is a va ila ble in t h r ee loca t in g dowel is r ecom m en ded du r in g a ssem bly t o
ou n ce t u bes a n d h a s a sh elf life of on e yea r. Aft er on e pr even t sm ea r in g m a t er ia l off t h e loca t ion .
yea r t h is m a t er ia l will n ot pr oper ly cu r e. Alwa ys Mopa r ! Ga sket Sea la n t in a n a er osol ca n sh ou ld be
in spect t h e pa cka ge for t h e expir a t ion da t e befor e a pplied u sin g a t h in , even coa t spr a yed com plet ely
u se. over bot h su r fa ces t o be join ed, a n d bot h sides of a
MOPAR! ATF RTV is a specifica lly design ed ga sket . Th en pr oceed wit h a ssem bly. Ma t er ia l in a
bla ck silicon e r u bber RTV t h a t r et a in s a dh esion a n d ca n w/a pplica t or ca n be br u sh ed on even ly over t h e
sea lin g pr oper t ies t o sea l com pon en t s exposed t o sea lin g su r fa ces. Ma t er ia l in a n a er osol ca n sh ou ld be
a u t om a t ic t r a n sm ission flu id, en gin e coola n t s, a n d u sed on en gin es wit h m u lt i-la yer st eel ga sket s.
m oist u r e. Th is m a t er ia l is a va ila ble in t h r ee ou n ce
t u bes a n d h a s a sh elf life of on e yea r. Aft er on e yea r STANDARD PROCEDURE - ENGINE GASKET
t h is m a t er ia l will n ot pr oper ly cu r e. Alwa ys in spect SURFACE PREPARATION
t h e pa cka ge for t h e expir a t ion da t e befor e u se. To en su r e en gin e ga sket sea lin g, pr oper su r fa ce
MOPAR! GAS KET MAKER is a n a n a er obic t ype pr epa r a t ion m u st be per for m ed, especia lly wit h t h e
ga sket m a t er ia l. Th e m a t er ia l cu r es in t h e a bsen ce of u se of a lu m in u m en gin e com pon en t s a n d m u lt i-la yer
a ir wh en squ eezed bet ween t wo m et a llic su r fa ces. It st eel cylin der h ea d ga sket s.
will n ot cu r e if left in t h e u n cover ed t u be. Th e N e v e r u se t h e followin g t o clea n ga sket su r fa ces:
a n a er obic m a t er ia l is for u se bet ween t wo m a ch in ed • Met a l scr a per
su r fa ces. Do n ot u se on flexible m et a l fla n ges. • Abr a sive pa d or pa per t o clea n cylin der block
MOPAR! B ED P LATE S EALAN T is a u n iqu e a n d h ea d
(gr een -in -color ) a n a er obic t ype ga sket m a t er ia l t h a t • H igh speed power t ool wit h a n a br a sive pa d or a
is specia lly m a de t o sea l t h e a r ea bet ween t h e bed wir e br u sh (F ig. 3)
pla t e a n d cylin der block wit h ou t dist u r bin g t h e bea r-
in g clea r a n ce or a lign m en t of t h ese com pon en t s. Th e NOTE: Multi-Layer Steel (MLS) head gaskets require
m a t er ia l cu r es slowly in t h e a bsen ce of a ir wh en a scratch free sealing surface.
t or qu ed bet ween t wo m et a llic su r fa ces, a n d will r a p-
idly cu r e wh en h ea t is a pplied. On ly u se t h e followin g for clea n in g ga sket su r fa ces:
MOPAR! GAS KET S EALAN T is a slow dr yin g, • Solven t or a com m er cia lly a va ila ble ga sket
per m a n en t ly soft sea ler. Th is m a t er ia l is r ecom - r em over
m en ded for sea lin g t h r ea ded fit t in gs a n d ga sket s • P la st ic or wood scr a per (F ig. 3)
• Dr ill m ot or wit h 3M Roloc™ Br ist le Disc (wh it e
or yellow) (F ig. 3)
CAUTION: Excessive pressure or high RPM (beyond

the recommended speed), can damage the sealing
surfaces. The mild (white, 120 grit) bristle disc is
recommended. If necessary, the medium (yellow, 80
grit) bristle disc may be used on cast iron surfaces
with care.
Fig. 4 Plastigage Placed in Lower Shell—Typical

1 - PLASTIGAGE
9 - E NGINE - SP E CIF ICATIONS). P la s tig a g e g e n -

e ra lly is a c c o m p a n ie d by tw o s c a le s . On e s c a le
is in in c h e s , th e o th e r is a m e tric s c a le .
NOTE: Plastigage is available in a variety of clear-

ance ranges. Use the most appropriate range for
the specifications you are checking.
(4) In st a ll t h e pr oper cr a n ksh a ft bea r in gs to

Fig. 3 Proper Tool Usage For Surface Preparation a ch ieve t h e specified bea r in g clea r a n ces.
1 - ABRASIVE PAD
2 - 3M ROLOC™ BRISTLE DISC REMOVAL - ENGINE ASSEMBLY
3 - PLASTIC/WOOD SCRAPER (1) P er for m fu el pr essu r e r elea se pr ocedu r e (Refer
t o 14 - F UE L SYSTE M/F UE L DE LIVE RY - STAN-
STANDARD PROCEDURE - MEASURING DARD P ROCE DURE )
BEARING CLEARANCE USING PLASTIGAGE (2) Discon n ect ba t t er y n ega t ive ca ble.
E n gin e cr a n ksh a ft bea r in g clea r a n ces ca n be det er- (3) Rem ove a ir clea n er h ou sin g a n d in let t u be.
m in ed by u se of P la st iga ge or equ iva len t . Th e follow- (4) Discon n ect t h e fu el lin e fr om fu el r a il. (Refer t o
in g is t h e r ecom m en ded pr ocedu r e for t h e u se of 14 - F UE L SYSTE M/F UE L DE LIVE RY/F UE L LINE S
P la st iga ge: - STANDARD P ROCE DURE )
(1) Rem ove oil film fr om su r fa ce t o be ch ecked. (5) Discon n ect a ll va cu u m h oses.
P la st iga ge is solu ble in oil. (6) Dr a in coolin g syst em . (Refer t o 7 - COOLING -
(2) P la ce a piece of P la st iga ge a cr oss t h e en t ir e STANDARD P ROCE DURE )
widt h of t h e bea r in g sh ell in t h e ca p a ppr oxim a t ely (7) Rem ove r a dia t or fa n s. (Refer t o 7 - COOLING/
6.35 m m (1/4 in .) off cen t er a n d a wa y fr om t h e oil E NGINE /RADIATOR FAN - RE MOVAL)
h oles (F ig. 4). (In a ddit ion , su spect ed a r ea s ca n be (8) Rem ove r a dia t or u pper a n d lower h oses.
ch ecked by pla cin g t h e P la st iga ge in t h e su spect ed
a r ea ). Tor qu e t h e bea r in g ca p/bed pla t e bolt s of t h e NOTE: When the transaxle cooler lines are removed
bea r in g bein g ch ecked t o t h e pr oper specifica t ion s. from the rolled-groove type fittings at the transaxle,
(3) Rem ove t h e bea r in g ca p a n d com pa r e t h e damage to the inner wall of the hose will occur. To
widt h of t h e fla t t en ed P la st iga ge wit h t h e m et r ic prevent prevent potential leakage, the cooler hoses
sca le pr ovided on t h e pa cka ge. Loca t e t h e ba n d clos- must be cut off flush at the transaxle fitting, and a
est t o t h e sa m e widt h . Th is ba n d sh ows t h e a m ou n t service cooler hose splice kit must be installed
of clea r a n ce in t h ou sa n dt h s of a m illim et er. Differ- upon reassembly.
en ces in r ea din gs bet ween t h e en ds in dica t e t h e
a m ou n t of t a per pr esen t . Recor d a ll r ea din gs t a ken .
Com pa r e t h e clea r a n ce m ea su r em en t s t o specsifica -
t ion s fou n d in t h e en gin e specifica t ion s t a ble(Refer t o
Fig. 5 HEATER HOSES - 2.4L

1 - HEATER HOSES TO HEATER 3 - HEATER HOSE TO ENGINE - SUPPLY AND RETURN
2 - BOLT - HEATER TUBE SUPPORT
(9) Usin g a bla de or su it a ble h ose cu t t er, cu t t r a n s- (19) Dr a in en gin e oil a n d r em ove oil filt er. (Refer
a xle oil cooler lin es off flu sh wit h fit t in gs. P lu g cooler t o 9 - E NGINE /LUBRICATION/OIL - STANDARD
lin es a n d fit t in gs t o pr even t debr is fr om en t er in g P ROCE DURE )
t r a n sa xle or cooler cir cu it . A ser vice splice kit will be (20) Rem ove cr ossm em ber cr a dle pla t e (F ig. 6).
in st a lled u pon r ea ssem bly.
(10) Discon n ect t r a n sm ission sh ift lin ka ge a n d
elect r ica l con n ect or s.
(11) Discon n ect t h r ot t le body lin ka ge.
(12) Discon n ect en gin e wir in g h a r n ess.
(13) Discon n ect h ea t er h oses fr om h ea t er (F ig. 5).
(14) Disch a r ge a ir con dit ion in g syst em . (Refer t o
24 - H E ATING & AIR CONDITIONING/P LUMBING
(15) H oist veh icle a n d r em ove fr on t wh eels a n d
t ir es.
(16) Rem ove a ccessor y dr ive belt spla sh sh ield.
(17) Rem ove a ccessor y dr ive belt s. (Refer t o 7 -
RE MOVAL)
(18) Rem ove a xle sh a ft s. (Refer t o 3 - DIF F E RE N-
TIAL & DRIVE LINE /H ALF SH AF T - RE MOVAL)
Fig. 6 Crossmember Cradle Plate
1 - CRADLE PLATE
(21) Discon n ect exh a u st pipe fr om m a n ifold (F ig. Tigh t en m ou n t s t o cr a dle fr a m e. Th is will keep
7). m ou n t s fr om m ovin g wh en r em ovin g or in st a llin g
en gin e a n d t r a n sm ission .
(33) In st a ll sa fet y st r a ps a r ou n d t h e en gin e t o cr a -
dle. Tigh t en st r a ps a n d lock.
(34) Lower veh icle so t h e weigh t of ON LY THE
EN GIN E AN D TRAN S MIS S ION a r e on t h e cr a dle.
(35) Rem ove en gin e a n d t r a n sm ission m ou n t bolt s.
(36) Ra ise veh icle slowly. It m a y be n ecessa r y t o
m ove t h e en gin e/t r a n sm ission a ssem bly wit h t h e
dolly t o a llow for r em ova l a r ou n d t h e body.
INSTALLATION - ENGINE ASSEMBLY

(1) P osit ion en gin e a n d t r a n sm ission a ssem bly
u n der veh icle a n d slowly lower t h e veh icle over t h e
en gin e a n d t r a n sm ission .
(2) Align en gin e a n d t r a n sm ission m ou n t s t o
a t t a ch in g poin t s. In st a ll m ou n t in g bolt s a t t h e r igh t
(F ig. 9) a n d left m ou n t s (F ig. 10).
(3) Rem ove sa fet y st r a ps.
(4) Slowly r a ise veh icle en ou gh t o r em ove t h e
en gin e dolly a n d cr a dle Specia l Tools 6135 a n d 6710.
Fig. 7 Catalytic Converter to Exhaust Manifold
(5) In st a ll r ea r m ou n t br a cket a n d r ea r m ou n t
1 - CATALYTIC CONVERTER
2 - BOLT
t h r ou gh bolt . (Refer t o 9 - E NGINE /E NGINE
3 - GASKET MOUNTING/RE AR MOUNT - INSTALLATION)
4 - FLAG NUT (6) In st a ll t h e flex pla t e t o t or qu e con ver t er bolt s.
(7) In st a ll st r u ct u r a l colla r. (Refer t o 9 - E NGINE /
(22) Rem ove en gin e fr on t m ou n t a n d br a cket fr om E NGINE BLOCK/STRUCTURAL COVE R - INSTAL-
en gin e. (Refer t o 9 - E NGINE /E NGINE MOUNTING/ LATION)
F RONT MOUNT - RE MOVAL) (8) In st a ll fr on t m ou n t br a cket a n d fr on t m ou n t
(23) Rem ove st r u ct u r a l colla r. (Refer t o 9 - t h r ou gh bolt . (Refer t o 9 - E NGINE /E NGINE
E NGINE /E NGINE BLOCK/STRUCTURAL COVE R - MOUNTING/F RONT MOUNT - INSTALLATION)
RE MOVAL) (9) Con n ect exh a u st syst em t o m a n ifold (F ig. 7).
(24) Rem ove r ea r en gin e m ou n t br a cket . (Refer t o (10) In st a ll cr ossm em ber cr a dle pla t e (F ig. 6).
9 - E NGINE /E NGINE MOUNTING/RE AR MOUNT - (11) In st a ll n ew oil filt er.
RE MOVAL) (12) In st a ll power st eer in g pu m p a n d br a cket .
(25) Ma r k flex pla t e t o t or qu e con ver t er a n d (13) Con n ect power st eer in g su pply lin e t o pu m p
r em ove t or qu e con ver t er bolt s. a n d r em ove pin ch -off plier s.
(26) P in ch -off power st eer in g su pply h ose a t pu m p. (14) Con n ect A/C com pr essor h oses t o com pr essor.
Rem ove h ose fr om pu m p. (15) In st a ll a ccessor y dr ive belt s. (Refer t o 7 -
(27) Rem ove a n d set a side t h e power st eer in g COOLING/ACCE SSORY DRIVE /DRIVE BE LTS -
pu m p a n d br a cket . Do n ot discon n ect pr essu r e lin e. INSTALLATION)
(28) Lower veh icle. (16) In st a ll a xle sh a ft s. (Refer t o 3 - DIF F E RE N-
(29) Rem ove A/C lin es a t com pr essor a n d ca p open - TIAL & DRIVE LINE /H ALF SH AF T - INSTALLA-
in gs. TION)
(30) Rem ove en gin e gr ou n d st r a ps (st r a p a t en gin e (17) In st a ll a ccessor y dr ive belt spla sh sh ield.
r igh t m ou n t a n d a t st a r t er ). (18) In st a ll fr on t wh eels a n d t ir es.
(31) Ra ise veh icle en ou gh t o a llow en gin e dolly (19) Rem ove plu gs fr om t r a n sm ission cooler h oses
Specia l Tool 6135, cr a dle Specia l Tool 6710 wit h a n d in st a ll t r a n sa xle oil cooler lin e ser vice splice kit .
P ost s Specia l Tool 6848 t o be in st a lled u n der veh icle Refer t o in st r u ct ion s in clu ded wit h kit .
(F ig. 8). (20) Con n ect t h e t r a n sa xle sh ift lin ka ge a n d elec-
(32) Loosen cr a dle post s t o a llow m ovem en t for t r ica l con n ect or s.
pr oper posit ion in g. Loca t e t wo r ea r post s (r igh t side (21) Con n ect h ea t er h oses (F ig. 5).
of en gin e) in t o t h e h oles on t h e en gin e bedpla t e. (22) In st a ll gr ou n d st r a ps.
Loca t e t h e t wo fr on t post s (left side of en gin e) on t h e (23) Con n ect a ll en gin e a n d t h r ot t le body elect r ica l
oil pa n r a ils (F ig. 8). Lower veh icle a n d posit ion cr a - con n ect ion s.
dle m ou n t s u n t il t h e en gin e is r est in g on m ou n t s.
Fig. 8 Positioning Engine Cradle Support Post Mounts

1 - SPECIAL TOOL POSTS 6848 4 - SPECIAL TOOL 6710 CRADLE
2 - SPECIAL TOOL 6135 DOLLY 5 - SPECIAL TOOL 6848 - POST CONTACT ON PAN RAIL
3 - SPECIAL TOOL POSTS 6848
(24) Con n ect a ll va cu u m lin es.
(25) Con n ect t h e t h r ot t le ca bles.
(26) Con n ect t h e fu el lin e. (Refer t o 14 - F UE L
SYSTE M/F UE L DE LIVE RY/QUICK CONNE CT F IT-
TING - STANDARD P ROCE DURE )
(27) Con n ect r a dia t or lower a n d u pper h oses.
(28) In st a ll r a dia t or fa n s. (Refer t o 7 - COOLING/
E NGINE /RADIATOR FAN - INSTALLATION)
(30) Con n ect ba t t er y ca bles.
(31) In st a ll a ir clea n er a n d in let h ose.
(32) F ill en gin e cr a n kca se wit h pr oper oil t o cor-
r ect level.
(33) St a r t en gin e a n d r u n u n t il oper a t in g t em per-
a t u r e is r ea ch ed.
(34) Adju st t r a n sm ission lin ka ge, if n ecessa r y.
SPECI FI CAT I ON S
SPECIFICATIONS - 2.4L ENGINE
GEN ERAL SPECI FI CAT I ON S
Fig. 9 RIGHT MOUNT TO RAIL AND ENGINE DESCRIPTION SPECIFICATION

1 - BOLT - MOUNT TO RAIL 68 N·m (50 ft. lbs.) Type In-Line OHV, DOHC
2 - BOLT - MOUNT TO ENGINE 54 N·m (40 ft. lbs.) Number of
3 - BOLT - MOUNT TO RAIL (HORIZONTAL) 68 N·m (50 ft. lbs.) 4
4 - RIGHT ENGINE MOUNT Cylinders
5 - RIGHT FRAME RAIL
Firing Order 1-3-4-2
Compression 9.5:1
Ratio
Max. Variation
Between 25%
Cylinders
Metric Standard
Displacement 2.4 Liters 148 cu. in.
Bore 87.5 mm 3.445 in.
Stroke 101.0 mm 3.976 in.
Compression
1172-1551 kPa 170-225 psi
Pressure
CY LI N DER BLOCK
DESCRIPTION SPECIFICATIONS
Metric Standard
Fig. 10 LEFT MOUNT TO FRAME BRACKET Cylinder Bore 87.4924 - 3.4446 - 3.4452
Diameter 87.5076 mm in.
1 - FRAME BRACKET
2 - FRAME RAIL - LEFT Out-of-Round 0.051 mm 0.002 in.
3 - BOLT
4 - TRANSAXLE MOUNT
(Max.)
Taper (Max.) 0.051 mm 0.002 in.
PI ST ON S PI ST ON RI N GS
DESCRIPTION SPECIFICATION DESCRIPTION SPECIFICATION

Metric Standard Metric Standard
Piston Diameter 87.463 - 87.481 3.4434 -3.4441 Ring Gap
mm in. Top 0.25 - 0.51 mm 0.0098 - 0.020
Clearance @ 14 0.024 - 0.057 0.0009 - 0.0022 Compression in.
mm (0.551 in.) mm in. Ring
from bottom of
Wear Limit 0.8 mm 0.031 in.
skirt
2nd 0.23 - 0.48 mm 0.009 - 0.018 in.
Weight 331 - 339 11.67- 11.95 oz.
Compression
grams
Ring
Land Clearance 0.614 - 0.664 0.024 - 0.026 in.
(Diametrical) mm
Oil Control Steel 0.25 - 0.64 mm 0.0098 - 0.025
Piston Length 66.25 mm 2.608 in.
Rails in.
Piston Ring 4.640 - 4.784 0.182 - 0.188 in.
Groove Depth mm Wear Limit 1.00 mm 0.039 in.
No. 1 Compression 0.030 - 0.080 0.0011 - 0.0031
Piston Ring 4.575 - 4.719 (0.180 - 0.185 Rings mm in.
Groove Depth mm in.) Wear Limit 0.10 mm 0.004 in.
No. 2 Ring Side 0.012 - 0.178 0.0004 - 0.0070
Piston Ring 4.097 - 4.236 0.161 - 0.166 in. Clearance - Oil mm in.
Groove Depth mm Ring Pack
No. 3 Ring Width - 1.47 - 1.50 mm 0.057 - 0.059 in.
Compression
PI ST ON PI N S Rings
Ring Width - Oil 2.72 - 2.88 mm 0.107 - 0.1133
DESCRIPTION SPECIFICATION Ring Pack in.
Metric Standard
Clearance in 0.005 - 0.018 0.0002 - 0.0008 CON N ECT I N G ROD
Piston mm in.
Clearance in Interference DESCRIPTION SPECIFICATION
Connecting Rod Metric Standard
Diameter 21.998 - 22.003 0.8660 - 0.8662 Bearing 0.025 - 0.071 0.0009 - 0.0027
mm in. Clearance mm in.
End Play None Wear Limit 0.075 mm 0.003 in.
Length 72.75 - 73.25 2.864 - 2.883 in. Bore Diameter - 20.96 - 20.98 0.8252 - 0.8260
mm Piston Pin mm in.
Bore Diameter - 53.007 - 52.993 2.0868 - 2.0863
Crankshaft End mm in.
Side Clearance 0.13 - 0.38 mm 0.005 - 0.015 in.
Weight - Total 565.8 grams 19.96 oz.
(Less Bearing)
CRAN K SH AFT CAM SH AFT

Connecting Rod 49.984 - 50.000 1.968 - 1.9685 Journal 25.951 - 25.970 1.021 - 1.022 in.
Journal mm in. Diameter No. 1 mm
Diameter -6
Main Bearing 59.992 - 60.008 2.362 - 2.3625 Bearing 0.069 - 0.071 0.0027 - 0.003
Journal mm in. Clearance - mm in.
Diameter Diametrical
Journal 0.0035 mm 0.0003 in. End Play 0.05 - 0.17 mm 0.0019 - 0.0066
Out-of-Round in.
(Max.) Lift (Zero Lash)
Journal Taper 0.007 mm 0.0001 in. Intake 8.25 mm 0.324 in.
(Max.)
Exhaust 6.60 mm 0.259 in.
End Play 0.09 - 0.24 mm 0.0035 - 0.0094
in. Intake Valve
Timing*
Closes (ABDC) 51°
Main Bearing 0.018 - 0.062 0.0007 - 0.0024
Diametrical mm in. Opens (BTDC) 1°
Clearance Duration 232°
Exhaust Valve
H Y DRAU LI C LASH ADJ U ST ER Timing*
Closes (ATDC) 7°
Opens (BBDC) 47°
Metric Standard
Duration 234°
Body Diameter 15.901 - 15.913 0.626 - 0.6264
Valve Overlap 8°
mm in.
*
Plunger Travel 3.0 mm 0.118 in.
All reading in degrees. Timing points @4° from top of
Minimum (Dry)
ramp.
CY LI N DER H EAD CAM SH AFT BEARI N G BORE

CY LI N DER H EAD
DI AM ET ER
DSECRIPTION SPECIFICATION
Metric Standard
Metric Standard
Material Cast Aluminum
Journals No.1 - 26.020 - 26.041 1.024 - 1.025 in.
6 mm Gasket 0.71 mm 0.028 in.
Thickness
(Compressed)
VALV E SEAT DESCRIPTION SPECIFICATION

Metric Standard
DESCRIPTION SPECIFICATION Valve Stem
Metric Standard Diameter
Angle 44.5 - 45° Intake 5.934 - 5.952 0.2337 - 0.2344
Seat Diameter - 34.37 - 34.63 1.353 - 1.363 in. mm in.
Intake mm Exhaust 5.906 - 5.924 0.2326 - 0.2333
Seat Diameter - 27.06 - 27.32 1.065 - 1.075 in. mm in.
Exhaust mm
Runout (Max.) 0.05 mm 0.002 in. VALV E M ARGI N
Valve Seat 0.9 - 1.3 mm 0.035 - 0.051 in.
Width - Intake DESCRIPTION SPECIFICATION
and Exhaust Metric Standard
Service Limit - 2.0 mm 0.079 in. Intake 1.2 - 1.7 mm 0.047 - 0.066 in.
Intake
Service Limit 0.95 mm .0037 in.
Service Limit - 2.5 mm 0.098 in.
Exhaust Exhaust 0.985 - 1.315 0.038 - 0.051 in.
mm
VALV E GU I DE Service Limit 1.05 mm .039 in.
DESCRIPTION SPECIFICATION VALV E ST EM T I P

Metric Standard
Diameter I.D. 5.975 - 6.000 0.235 - 0.236 in.
mm Metric Standard
Guide Bore 11.0 - 11.02 0.4330 - 0.4338 Intake 48.04 mm 1.891 in.
Diameter mm in. Exhaust 47.99 mm 1.889 in.
Guide Height 13.25 - 13.75 0.521 - 0.541 in.
(spring seat to mm VALV E ST EM T O GU I DE CLEARAN CE
guide tip)
VALV ES
Metric Standard
DESCRIPTION SPECIFICATION Intake 0.048 - 0.066 0.0018 - 0.0025
Metric Standard mm in.
Face Angle - 44.5 - 45° Max. Allowable 0.076 mm 0.003 in.
Intake and Service Limit 0.25 mm 0.010 in.
Exhaust
Head Diameter 34.67 - 34.93 1.364 - 1.375 in. Exhaust 0.0736 - 0.094 0.0029 - 0.0037
- Intake mm mm in.
Head Diameter 28.32 - 28.52 1.114 - 1.122 in. Max. Allowable 0.101 mm 0.004 in.
- Exhaust mm Service Limit 0.25 mm 0.010 in.
Valve Length
(Overall)
Intake 112.76 - 113.32 4.439 - 4.461 in.
mm
Exhaust 110.89 - 111.69 4.365 - 4.397 in.
mm
VALV E SPRI N GS SPECIFICATIONS - TORQUE
DESCRIPTION SPECIFICATION DESCRIPTION N·m Ft. In.

Metric Standard Lbs. Lbs.
Free Length 48.4 mm 1.905 in. Balance Shaft Carrier to 54 40 —
(Approx.) Block—Bolts
Nominal Force 338 N @ 38.0 75.98 lbs. @ Balance Shaft Gear 12 — 105
(Valve Closed) mm 1.496 in. Cover—Double Ended
Fastener
Nominal Force 607 N @ 29.75 136 lbs. @
(Valve Open) mm 1.172 in. Balance Shaft Sprocket— 28 — 250
Bolt
Installed Height 38.00 mm 1.496 in.
Balance Shaft Chain 12 — 105
Number of Coils 7.82 Tensioner—Bolts
Wire Diameter 3.86 mm 1.496 in Balance Shaft Carrier 12 — 105
Cover—Bolts
OI L PU M P Camshaft Sprocket—Bolt 101 75 —
Connecting Rod 27 +1⁄4 20 —
DESCRIPTION SPECIFICATION Cap—Bolts turn +1⁄4
Metric Standard turn
Clearance Over 0.10 mm 0.004 in. Crankshaft Main Bearing
Rotors (Max.) Cap/Bedplate
Cover 0.025 mm 0.001 in. —M8 Bolts 28 250
Out-of-Flat —M11 Bolts 41 +1⁄4 30 —
(Max.) Turn +1⁄4
Inner Rotor 9.40 mm 0.370 in. Turn
Thickness (Min.) Crankshaft Damper 136 100 —
Outer Rotor 9.40 mm 0.370 in. Cylinder Head—Bolts (Refer to 9 - ENGINE/
Thickness (Min.) CYLINDER HEAD -
Outer Rotor 0.039 mm 0.015 in. INSTALLATION)
Clearance Cylinder Head Cover— 12 — 105
(Max.) Bolts
Outer Rotor 79.95 mm 3.148 in. Flex Plate to Crankshaft 95 70 —
Diameter (Min.)
Engine Mount Bracket 61 45 —
Tip Clearance 0.20 mm 0.008 in. Right—Bolts
Between Rotors
(Max.) Engine Mounting—Bolts (Refer to 9 ENGINE/
ENGINE MOUNTING)
Exhaust Manifold to 19 — 170
OI L PRESSU RE Cylinder Head—Bolts
Exhaust Manifold Heat 12 — 105
DESCRIPTION SPECIFICATION Shield—Bolts
Metric Standard Intake Manifold - Lower 28 — 250
At Curb Idle 25 kPa 4 psi —Bolts
Speed* Intake Manifold - 28 — 250
At 3000 rpm 170 - 550 kPa 25 - 80 psi Upper—Bolts
CAUTION: Oil Filter 12 — 105
*If pressure is ZERO at curb idle, DO NOT run engine Oil Pan—Bolts 12 — 105
at 3000 rpm.
Oil Pan Drain—Plug 28 20 —
Oil Pressure Switch 21 — 190
DESCRIPTION N·m Ft. In.

Lbs. Lbs.
Oil Pump to Block—Bolts 28 20 —
Oil Pump Cover 12 — 105
Plate—Bolts
Oil Pump Pick-up 28 20 —
Tube—Bolt
Oil Pump Relief 41 30 —
Valve—Cap Dolly 6135
Spark Plugs 18 13 —
Structural Collar (Refer to 9 - ENGINE/
ENGINE BLOCK/
STRUCTURAL COVER -
INSTALLATION)
Timing Belt Covers
- Front Covers to Rear 6 — 50
Cover—Bolts
- Rear Cover—M6 Bolts 12 — 105 Cradle 6710A
—M8 Bolts 28 — 250
Timing Belt Idler Pulley 61 45 —
Timing Belt Tensioner 25 — 220
Lock Bolt
Timing Belt Tensioner 61 45 —
Assembly—Bolts
SPECI AL T OOLS
Post Kit Engine Cradle 6848
2.4L ENGINE
Camshaft Sprocket Holder 6847
Puller 1026
Camshaft Seal Remover C-4679A
Crankshaft Damper Removal Insert 6827A

Camshaft Seal Installer MD-998306

Valve Spring Compressor MD998772A
Crankshaft Damper/Sprocket Installer 6792

Valve Spring Compressor Adapter 6779
Valve Spring Compressor 8215-A Indicator, Cylinder Bore C-119
Connecting Rod Guides 8189
Adaptor 8436
Crankshaft Sprocket Remover 6793

Rear Crankshaft Oil Seal Installer 6926

Crankshaft Sprocket Remover Insert C-4685-C2
Front Crankshaft Oil Seal Remover 6771
Driver Handle C-4171
Front Crankshaft Oil Seal Installer 6780
Balance Shaft Sprocket Installer 6052
Oil Pressure Gauge C-3292
Adapter 8406
DRB III" with PEP Module OT-CH6010A

AI R CLEAN ER ELEM EN T
REMOVAL
(1) Un sn a p 2 clips.
(2) Lift cover a n d pu ll t owa r d t h e en gin e a n d
r em ove cover t a bs fr om a ir box.
(3) Lift cover a n d r em ove t h e elem en t (F ig. 11).
Combustion Leak Tester C-3685-A
Pressure Transducer CH7059
Fig. 11 Air Box Cover

INSTALLATION
(1) In st a ll t h e a ir filt er elem en t in t o a ir box (F ig.
11).
(2) Move cover so t h a t t h e t a bs in ser t in t o t h e a ir
Cylinder Compression Pressure Adaptor 8116 box.
(3) P u sh cover down a n d sn a p t h e 2 clips.
AI R CLEAN ER H OU SI N G In t egr a l oil ga ller ies pr ovide lu br ica t ion pa ssa ges
t o t h e h ydr a u lic la sh a dju st er s, ca m sh a ft s, a n d va lve
m ech a n ism s.
REMOVAL
(2) Discon n ect t h e in let a ir t em per a t u r e sen sor
(F ig. 12).
Fig. 12 IAT Sensor 2.4L

(3) Rem ove t h e in let h ose t o t h r ot t le body (F ig. 11). Fig. 13 Cylinder Head and Camshafts
(4) Rem ove t h e bolt for a ir box a t u pper r a dia t or
1 - CAMSHAFT BEARING CAPS
cr oss m em ber. 2 - PLUG
(5) P u ll a ir box u p a n d off over t h e sin gle loca t in g 3 - CAMSHAFT
pin . 4 - CYLINDER HEAD
5 - CAMSHAFT OIL SEAL
(6) Rem ove a ir box fr om veh icle
INSTALLATION DIAGNOSIS AND TESTING—CYLINDER HEAD

(1) In st a ll a ir box in t o veh icle a n d on t o t h e loca t - GASKET
in g pin . A cylin der h ea d ga sket lea k ca n be loca t ed bet ween
(2) In st a ll bolt t o h old a ir box t o t h e u pper r a dia - a dja cen t cylin der s or bet ween a cylin der a n d t h e
t or cr oss m em ber. a dja cen t wa t er ja cket .
(3) In st a ll t h e in let h ose t o t h e t h r ot t le body. P ossible in dica t ion s of t h e cylin der h ea d ga sket
(4) Con n ect t h e in let a ir t em per a t u r e sen sor (F ig. lea kin g bet ween a dja cen t cylin der s a r e:
12). • Loss of en gin e power
(5) Con n ect t h e n ega t ive ba t t er y ca ble. • E n gin e m isfir in g
• P oor fu el econ om y
P ossible in dica t ion s of t h e cylin der h ea d ga sket
CY LI N DER H EAD lea kin g bet ween a cylin der a n d a n a dja cen t wa t er
ja cket a r e:
DESCRIPTION • E n gin e over h ea t in g
Th e cr oss flow design ed, a lu m in u m cylin der h ea d • Loss of coola n t
con t a in s du a l over-h ea d ca m sh a ft s wit h fou r va lves • E xcessive st ea m (wh it e sm oke) em it t in g fr om
per cylin der (F ig. 13). Th e va lves a r e a r r a n ged in t wo exh a u st
in -lin e ba n ks. Th e in t a ke va lves fa ce t owa r d t h e • Coola n t foa m in g
fr on t of t h e veh icle. Th e exh a u st va lves fa ce t h e da sh
pa n el. Th e cylin der h ea d in cor por a t es powder ed
m et a l va lve gu ides a n d sea t s. Th e cylin der h ea d is
sea led t o t h e block u sin g a m u lt i-la yer st eel h ea d
ga sket a n d r et a in in g bolt s.
CY LI N DER H EAD (Cont inue d)
CYLINDER-TO-CYLINDER LEAKAGE TEST (6) Rem ove h ea t er t u be su ppor t br a cket fr om cyl-
To det er m in e if a n en gin e cylin der h ea d ga sket is in der h ea d.
lea kin g bet ween a dja cen t cylin der s, follow t h e pr oce- (7) Discon n ect r a dia t or u pper a n d h ea t er su pply
du r es in Cylin der Com pr ession P r essu r e Test (Refer h oses fr om in t a ke m a n ifold wa t er ou t let con n ect ion s.
t o 9 - E NGINE - DIAGNOSIS AND TE STING). An (8) Rem ove a ccessor y dr ive belt s. (Refer t o 7 -
en gin e cylin der h ea d ga sket lea kin g bet ween a dja - COOLING/ACCE SSORY DRIVE /DRIVE BE LTS -
cen t cylin der s will r esu lt in a ppr oxim a t ely a 50–70% RE MOVAL)
r edu ct ion in com pr ession pr essu r e. (9) Ra ise veh icle a n d r em ove exh a u st pipe fr om
m a n ifold.
CYLINDER-TO-WATER JACKET LEAKAGE TEST (10) Rem ove power st eer in g pu m p r eser voir a n d
lin e su ppor t br a cket fr om lower in t a ke m a n ifold a n d
WARNING: USE EXTREME CAUTION WHEN THE set a side. Do n ot discon n ect lin es.
ENGINE IS OPERATING WITH COOLANT PRES- (11) Rem ove ign it ion coil a n d wir es fr om en gin e.
SURE CAP REMOVED. (12) Discon n ect ca m sen sor a n d fu el in ject or wir-
in g con n ect or s.
(13) Rem ove t im in g belt a n d ca m sh a ft spr ocket s.
VISUAL TEST METHOD (Refer t o 9 - E NGINE /VALVE TIMING/TIMING
Wit h t h e en gin e cool, r em ove t h e coola n t pr essu r e BE LT/CH AIN AND SP ROCKE TS - RE MOVAL)
ca p. St a r t t h e en gin e a n d a llow it t o wa r m u p u n t il (14) Rem ove t im in g belt idler pu lley a n d r ea r t im -
t h er m ost a t open s. in g belt cover. (Refer t o 9 - E NGINE /VALVE TIM-
If a la r ge com bu st ion /com pr ession pr essu r e lea k ING/TIMING BE LT / CH AIN COVE R(S) -
exist s, bu bbles will be visible in t h e coola n t . RE MOVAL)
(15) Rem ove cylin der h ea d cover. (Refer t o 9 -
COOLING SYSTEM TESTER METHOD E NGINE /CYLINDE R H E AD/CYLINDE R H E AD
COVE R(S) - RE MOVAL)
WARNING: WITH COOLING SYSTEM TESTER IN (16) Rem ove ca m sh a ft s (Refer t o 9 - E NGINE /
PLACE, PRESSURE WILL BUILD UP FAST. EXCES- CYLINDE R H E AD/CAMSH AF T(S) - RE MOVAL).
SIVE PRESSURE BUILT UP, BY CONTINUOUS
ENGINE OPERATION, MUST BE RELEASED TO A NOTE: Identify rocker arm position to ensure cor-
SAFE PRESSURE POINT. NEVER PERMIT PRES- rect re-installation in original position, if reused.
SURE TO EXCEED 138 kPa (20 psi).
(17) Rem ove r ocker a r m s. (Refer t o 9 - E NGINE /
In st a ll Coolin g Syst em Test er 7700 or equ iva len t t o CYLINDE R H E AD/ROCKE R ARMS - RE MOVAL)
pr essu r e ca p n eck. St a r t t h e en gin e a n d obser ve t h e (18) Rem ove cylin der h ea d bolt s in RE VE RSE
t est er ’s pr essu r e ga u ge. If ga u ge pu lsa t es wit h ever y sequ en ce of t igh t en in g (F ig. 19).
power st r oke of a cylin der a com bu st ion pr essu r e (19) Rem ove cylin der h ea d fr om en gin e block.
lea k is eviden t . (20) In spect a n d clea n cylin der h ea d. (Refer t o 9 -
E NGINE /CYLINDE R H E AD - INSP E CTION) (Refer
CHEMICAL TEST METHOD t o 9 - E NGINE /CYLINDE R H E AD - CLE ANING)
Com bu st ion lea ks in t o t h e coolin g syst em ca n a lso
be ch ecked by u sin g Bloc-Ch ek Kit C-3685-A or CLEANING
equ iva len t . P er for m t est followin g t h e pr ocedu r es To en su r e en gin e ga sket sea lin g, pr oper su r fa ce
su pplied wit h t h e t ool kit . pr epa r a t ion m u st be per for m ed, especia lly wit h t h e
u se of a lu m in u m en gin e com pon en t s a n d m u lt i-la yer
REMOVAL - CYLINDER HEAD st eel cylin der h ea d ga sket s.
(1) P er for m fu el syst em pr essu r e r elea se pr ocedu r e
be fo re a tte m p tin g a n y re p a irs . (Refer t o 14 - NOTE: Multi-Layer Steel (MLS) head gaskets require
F UE L SYSTE M/F UE L DE LIVE RY - SP E CIF ICA- a scratch free sealing surface.
TIONS)
(2) Discon n ect ba t t er y n ega t ive ca ble. Rem ove a ll ga sket m a t er ia l fr om cylin der h ea d a n d
(3) Dr a in coolin g syst em . (Refer t o 7 - COOLING - block (Refer t o 9 - E NGINE - STANDARD P ROCE -
STANDARD P ROCE DURE ) DURE ). Be ca r efu l n ot t o gou ge or scr a t ch t h e a lu m i-
(4) Rem ove a ir filt er h ou sin g a n d in let t u be. n u m h ea d sea lin g su r fa ce.
(5) Rem ove u pper in t a ke m a n ifold. (Refer t o 9 - Clea n a ll en gin e oil pa ssa ges.
E NGINE /MANIF OLDS/INTAKE MANIF OLD -
RE MOVAL)
INSPECTION
(1) Cylin der h ea d m u st be fla t wit h in 0.1 m m
(0.004 in .) (F ig. 14).
(2) In spect ca m sh a ft bea r in g jou r n a ls for scor in g.
Fig. 16 Valve Guide Height

1 - VALVE GUIDE
2 - 13.25 - 13.75 MM (0.521 - 0.541 IN.)
3 - SPRING SEAT
Neckin g ca n be ch ecked by h oldin g a sca le or

Fig. 14 Checking Cylinder Head Flatness st r a igh t edge a ga in st t h e t h r ea ds. If a ll t h e t h r ea ds
1 - FEELER GAUGE do n ot con t a ct t h e sca le, t h e bolt sh ou ld be r epla ced.
2 - STRAIGHT EDGE
(3) Rem ove ca r bon a n d va r n ish deposit s fr om

in side of va lve gu ides wit h a r elia ble gu ide clea n er.
(4) Usin g a sm a ll h ole ga u ge a n d a m icr om et er,
m ea su r e va lve gu ides in 3 pla ces t op, m iddle a n d bot -
t om (F ig. 15). (Refer t o 9 - E NGINE - SP E CIF ICA-
TIONS) Repla ce gu ides if t h ey a r e n ot wit h in
specifica t ion .
(5) Ch eck va lve gu ide h eigh t (F ig. 16).
Fig. 17 Checking Bolts for Stretching (Necking)

1 - STRETCHED BOLT
2 - THREADS ARE NOT STRAIGHT ON LINE
3 - THREADS ARE STRAIGHT ON LINE
4 - UNSTRETCHED BOLT
(1) Befor e in st a llin g t h e bolt s, t h e t h r ea ds sh ou ld

be coa t ed wit h en gin e oil.
(2) P osit ion cylin der h ea d ga sket on en gin e block
(F ig. 18).
Fig. 15 Checking Wear on Valve Guide—Typical (3) In st a ll cylin der h ea d on en gin e block.
(4) Tigh t en t h e cylin der h ea d bolt s in t h e sequ en ce
1 - TOP
2 - MIDDLE sh own in (F ig. 19). Usin g t h e 4 st ep t or qu e t u r n
3 - BOTTOM m et h od, t igh t en a ccor din g t o t h e followin g va lu es:
4 - CUT AWAY VIEW OF VALVE GUIDE MEASUREMENT • F ir st All t o 34 N·m (25 ft . lbs.)
LOCATIONS
• Secon d All t o 68 N·m (50 ft . lbs.)
INSTALLATION - CYLINDER HEAD • Th ir d All t o 68 N·m (50 ft . lbs.)
CAUTION: Do not use a torque wrench for the fol-

NOTE: The Cylinder head bolts should be examined
lowing step.
BEFORE reuse. If the threads are necked down, the
bolts must be replaced (Fig. 17). • F ou r t h Tu r n a n a ddit ion a l 1/4 Tu r n ,
(14) In st a ll a ccessor y dr ive belt s. (Refer t o 7 -
INSTALLATION)
(15) In st a ll h ea t er t u be su ppor t br a cket t o cylin der
h ea d.
(16) Con n ect r a dia t or u pper a n d h ea t er h oses t o
in t a ke m a n ifold wa t er ou t let con n ect ion s.
(17) In st a ll u pper in t a ke m a n ifold. (Refer t o 9 -
INSTALLATION)
(18) Usin g n ew ga sket s, in st a ll E GR t u be a n d
t igh t en fa st en er s t o 11 N·m (95 in . lbs.).
(19) In st a ll a ir in let t u be a n d h ou sin g.
Fig. 18 Cylinder Head Gasket Positioning (20) Con n ect a ll va cu u m lin es, elect r ica l wir in g,
gr ou n d st r a ps a n d fu el lin e.
1 - PART NUMBER FACES UP
2 - NO. 1 CYLINDER (21) F ill coolin g syst em . (Refer t o 7 - COOLING -
CAM SH AFT OI L SEAL(S)

REMOVAL
(1) Rem ove t im in g belt (Refer t o 9 - E NGINE /
VALVE TIMING/TIMING BE LT AND SP ROCKE TS -
RE MOVAL).
(2) H old ea ch ca m sh a ft spr ocket wit h Specia l Tool
6847 wh ile r em ovin g cen t er bolt (F ig. 20).
(3) Rem ove ca m sh a ft spr ocket s.
(4) Rem ove r ea r t im in g belt cover (Refer t o 9 -
E NGINE /VALVE TIMING/TIMING BE LT COVE R(S)
Fig. 19 Cylinder Head Tightening Sequence
- RE MOVAL).
(5) In st a ll r ocker a r m s. (Refer t o 9 - E NGINE / (5) Rem ove ca m sh a ft sea l u sin g Specia l Tool
CYLINDE R H E AD/ROCKE R ARMS - INSTALLA- C-4679A (F ig. 21).
TION)
(6) In st a ll ca m sh a ft s. (Refer t o 9 - E NGINE /CYL-
INDE R H E AD/CAMSH AF T(S) - INSTALLATION).
(7) In st a ll cylin der h ea d cover. (Refer t o 9 -
E NGINE /CYLINDE R H E AD/CYLINDE R H E AD
COVE R(S) - INSTALLATION)
(8) In st a ll t im in g belt r ea r cover a n d t im in g belt
idler pu lley. (Refer t o 9 - E NGINE /VALVE TIMING/
TIMING BE LT / CH AIN COVE R(S) - INSTALLA-
TION)
(9) In st a ll t im in g belt a n d ca m sh a ft spr ocket s.
(Refer t o 9 - E NGINE /VALVE TIMING/TIMING
BE LT/CH AIN AND SP ROCKE TS - INSTALLATION)
(10) Con n ect ca m sen sor a n d fu el in ject or s wir in g
con n ect or s.
(11) In st a ll ign it ion coil a n d wir es. Con n ect ign i-
t ion coil wir in g con n ect or.
(12) In st a ll power st eer in g pu m p r eser voir a n d
lin e su ppor t br a cket t o cylin der h ea d.
(13) Ra ise veh icle a n d in st a ll t h e exh a u st pipe t o Fig. 20 Camshaft Sprocket - Removal/Installation
t h e m a n ifold.
CAM SH AFT OI L SEAL(S) (Cont inue d)
SP ROCKE TS - INSTALLATION) (Refer t o 9 -
E NGINE /VALVE TIMING/TIMING BE LT COVE R(S)
- INSTALLATION).
CAM SH AFT (S)

DESCRIPTION
Bot h ca m sh a ft s h a ve six bea r in g jou r n a l su r fa ces
a n d t wo ca m lobes per cylin der (F ig. 23). F la n ges a t
t h e r ea r jou r n a ls con t r ol ca m sh a ft en d pla y. P r ovision
for a ca m posit ion sen sor is loca t ed on t h e in t a ke
ca m sh a ft on t h e r ea r of t h e cylin der h ea d. A h ydr o-
dyn a m ic oil sea l is u sed for oil con t r ol a t t h e fr on t of
t h e ca m sh a ft .
Fig. 21 Camshaft Oil Seal - Removal With C-4679A

CAUTION: Do not nick shaft seal surface or seal

bore.
INSTALLATION
(1) Sh a ft sea l su r fa ce m u st be fr ee of va r n ish , dir t
or n icks. P olish wit h 400 gr it pa per if n ecessa r y.
(2) In st a ll ca m sh a ft sea ls in t o cylin der h ea d u sin g
Specia l Tool MD-998306 u n t il flu sh wit h h ea d (F ig.
22).
Fig. 23 Camshafts
1 - CAMSHAFT BEARING CAPS
2 - PLUG
3 - CAMSHAFT
4 - CYLINDER HEAD
5 - CAMSHAFT OIL SEAL
OPERATION
Th e ca m sh a ft is dr iven by t h e cr a n ksh a ft via dr ive
Fig. 22 Camshaft Seal - Installation spr ocket s a n d belt . Th e ca m sh a ft h a s pr ecisely
m a ch in ed lobes t o pr ovide a ccu r a t e va lve t im in g a n d
1 - SPECIAL TOOL MD-998306
du r a t ion .
(3) In st a ll t im in g belt r ea r cover (Refer t o 9 -
E NGINE /VALVE TIMING/TIMING BE LT COVE R(S) STANDARD PROCEDURE - MEASURING
- INSTALLATION). CAMSHAFT END PLAY
(4) In st a ll ca m sh a ft spr ocket s. H old ea ch spr ocket (1) Oil ca m sh a ft jou r n a ls a n d in st a ll ca m sh a ft
wit h Specia l Tool 6847 a n d t igh t en cen t er bolt t o 101 WITHOU T r ocker a r m s. In st a ll r ea r ca m ca ps a n d
N·m (75 ft . lbs.) (F ig. 20). t igh t en scr ews t o specified t or qu e.
(5) In st a ll t im in g belt a n d fr on t cover s (Refer t o 9 - (2) Usin g a su it a ble t ool, m ove ca m sh a ft a s fa r
E NGINE /VALVE TIMING/TIMING BE LT AND r ea r wa r d a s it will go.
CAM SH AFT (S) (Cont inue d)
(3) Zer o dia l in dica t or (F ig. 24).
(4) Move ca m sh a ft a s fa r for wa r d a s it will go.
(5) Recor d r ea din g on dia l in dica t or. F or en d pla y
specifica t ion , (Refer t o 9 - E NGINE - SP E CIF ICA-
TIONS).
(6) If en d pla y is excessive, ch eck cylin der h ea d
a n d ca m sh a ft for wea r ; r epla ce a s n ecessa r y.
Fig. 25 Camshaft Bearing Cap Identification
Fig. 24 Camshaft End Play - Typical

REMOVAL
(1) Rem ove cylin der h ea d cover (Refer t o 9 -
COVE R - RE MOVAL).
(2) Rem ove ca m sh a ft posit ion sen sor a n d ca m sh a ft
t a r get m a gn et (Refer t o 8 - E LE CTRICAL/IGNITION
CONTROL/CAMSH AF T P OSITION SE NSOR -
RE MOVAL).
Fig. 26 Camshaft Bearing Cap - Removal
1 - REMOVE OUTSIDE BEARING CAPS FIRST
RE MOVAL).
(4) Rem ove ca m sh a ft spr ocket s a n d t im in g belt CLEANING
r ea r cover (Refer t o 9 - E NGINE /VALVE TIMING/ Clea n ca m sh a ft wit h a su it a ble solven t .
TIMING BE LT COVE R(S) - RE MOVAL).
(5) Bea r in g ca ps a r e iden t ified for loca t ion . INSPECTION
Rem ove t h e ou t side bea r in g ca ps fir st (F ig. 25). (1) In spect ca m sh a ft bea r in g jou r n a ls for da m a ge
(6) Loosen t h e ca m sh a ft bea r in g ca p a t t a ch in g a n d bin din g (F ig. 27). If jou r n a ls a r e bin din g, ch eck
fa st en er s in sequ en ce sh own (F ig. 26) on e ca m sh a ft t h e cylin der h ea d for da m a ge. Also ch eck cylin der
a t a t im e. h ea d oil h oles for cloggin g.
(2) Ch eck t h e ca m lobe a n d bea r in g su r fa ces for
CAUTION: Camshafts are not interchangeable. The a bn or m a l wea r a n d da m a ge. Repla ce ca m sh a ft if
intake cam number 6 thrust bearing face spacing is defect ive.
wider.
NOTE: If camshaft is replaced due to lobe wear or
(7) Iden t ify t h e ca m sh a ft s befor e r em ovin g fr om damage, always replace the rocker arms.
t h e h ea d. Th e ca m sh a ft s a r e n ot in t er ch a n gea ble.
(8) Rem ove ca m sh a ft s fr om cylin der h ea d. (3) Mea su r e t h e lobe a ct u a l wea r (u n wor n a r ea -
wea r zon e = a ct u a l wea r ) (F ig. 27) a n d r epla ce ca m -
NOTE: If removing rocker arms, identify for reinstal- sh a ft if ou t of lim it . St a n da r d va lu e is 0.0254 m m
lation in the original position. (0.001 in .), wea r lim it is 0.254 m m (0.010 in .).
CAM SH AFT (S) (Cont inue d)
Fig. 27 Checking Camshaft(s) for Wear Fig. 29 Camshaft Bearing Cap Sealing
1 - UNWORN AREA 1 - 1.5 mm (.060 in.) DIAMETER BEAD OF MOPAR GASKET
2 - ACTUAL WEAR MAKER
3 - BEARING JOURNAL
4 - LOBE (6) In st a ll ca m sh a ft t a r get m a gn et a n d ca m sh a ft
5 - WEAR ZONE
posit ion sen sor.
(7) In st a ll cylin der h ea d cover (Refer t o 9 -
INSTALLATION
CAUTION: Ensure that NONE of the pistons are at COVE R - INSTALLATION).
top dead center when installing the camshafts. (8) In st a ll t im in g belt r ea r cover a n d ca m sh a ft
spr ocket s (Refer t o 9 - E NGINE /VALVE TIMING/
(1) Lu br ica t e a ll ca m sh a ft bea r in g jou r n a ls, r ocker TIMING BE LT COVE R(S) - INSTALLATION).
a r m s a n d ca m sh a ft lobes. (9) In st a ll t im in g belt (Refer t o 9 - E NGINE /
(2) In st a ll a ll r ocker a r m s in or igin a l posit ion s, if VALVE TIMING/TIMING BE LT AND SP ROCKE TS -
r eu sed. INSTALLATION).
(3) P osit ion ca m sh a ft s on cylin der h ea d bea r in g
jou r n a ls. In st a ll r igh t a n d left ca m sh a ft bea r in g ca ps
No. 2 – 5 a n d r igh t No. 6. Tigh t en M6 fa st en er s t o 12 CY LI N DER H EAD COV ER
N·m (105 in . lbs.) in sequ en ce sh own in (F ig. 28).
(4) Apply Mopa r ! Ga sket Ma ker t o No. 1 a n d No. REMOVAL
6 bea r in g ca ps (F ig. 29). In st a ll bea r in g ca ps a n d (1) Rem ove u pper in t a ke m a n ifold. (Refer t o 9 -
t igh t en M8 fa st en er s t o 28 N·m (250 in . lbs.). E NGINE /MANIF OLDS/INTAKE MANIF OLD -
RE MOVAL)
(2) Rem ove u pper m a n ifold su ppor t br a cket .
(3) Rem ove ign it ion coil a n d spa r k plu g wir es.
(4) Discon n ect P CV a n d m a ke-u p a ir h oses fr om
cylin der h ea d cover.
(5) Rem ove cylin der h ea d cover bolt s.
(6) Rem ove cylin der h ea d cover fr om cylin der
h ea d.
CLEANING
Clea n cylin der h ea d a n d cover m a t in g su r fa ces
u sin g a su it a ble solven t .
Fig. 28 Camshaft Bearing Cap Tightening Sequence INSPECTION

NOTE: Bearing end caps must be installed before In spect cover r a ils for fla t n ess.
seals can be installed.
(5) In st a ll ca m sh a ft oil sea ls (Refer t o 9 -

E NGINE /CYLINDE R H E AD/CAMSH AF T OIL
SE AL(S) - INSTALLATION).
CY LI N DER H EAD COV ER (Cont inue d)
INSTALLATION
NOTE: Replace spark plug well seals and bolt
assemblies when installing a new cylinder head
cover gasket.
(1) In st a ll n ew cylin der h ea d cover ga sket s a n d

spa r k plu g well sea ls (F ig. 30).
Fig. 30 Spark Plug Well Seals

(2) Repla ce cylin der h ea d cover bolt a ssem blies.
CAUTION: Do not allow oil or solvents to contact

the timing belt as they can deteriorate the rubber Fig. 31 Sealer Locations
and cause tooth skipping.
1 – SEALER LOCATION
(3) Apply Mopa r ! E n gin e RTV GE N II a t t h e

ca m sh a ft ca p cor n er s a n d a t t h e t op edges of t h e 1/2
r ou n d sea l (F ig. 31).
(4) In st a ll cylin der h ea d cover a ssem bly t o cylin -
der h ea d. In st a ll a ll bolt s, en su r in g t h e sin gle (1)
st u d u sed t o a t t a ch t h e u pper in t a ke m a n ifold su p-
por t br a cket is loca t ed in t h e #8 loca t ion a s sh own in
t or qu e sequ en ce dia gr a m (F ig. 32). Tigh t en bolt s in
sequ en ce sh own in (F ig. 32). Usin g a 3 st ep t or qu e
m et h od a s follows:
(a ) Tigh t en a ll bolt s t o 4.5 N·m (40 in . lbs.).
(b) Tigh t en a ll bolt s t o 9.0 N·m (80 in . lbs.).
(c) Tigh t en a ll bolt s t o 12 N·m (105 in . lbs.). Fig. 32 Cylinder Head Cover Tightening Sequence
(5) In st a ll ign it ion coil a n d spa r k plu g wir es. (Typical Cover Shown)
Tigh t en fa st en er s t o 12 N·m (105 in . lbs.).
(6) If t h e P CV va lve wa s r em oved, a pply Mopa r ! (8) In st a ll u pper in t a ke m a n ifold. (Refer t o 9 -
Th r ea d Sea la n t wit h Teflon t o t h r ea ds a n d in st a ll E NGINE /MANIF OLDS/INTAKE MANIF OLD -
va lve t o cylin der h ea d cover. Tigh t en P CV va lve t o 8 INSTALLATION)
N·m (70 in . lbs.).
(7) Con n ect P CV a n d m a ke-u p a ir h oses t o cylin -
der h ea d cover.
I N TAK E/EX H AU ST VALV ES & REMOVAL - CYLINDER HEAD OFF

(1) Wit h cylin der h ea d r em oved fr om cylin der
SEAT S block, com pr ess va lve spr in gs u sin g a u n iver sa l va lve
spr in g com pr essor.
DESCRIPTION (2) Rem ove va lve r et a in in g locks, va lve spr in g
Th e va lves a r e m a de of h ea t r esist a n t st eel. Th ey r et a in er s, va lve st em sea ls a n d va lve spr in gs.
h a ve ch r om e pla t ed st em s t o pr even t scu ffin g. Vit on (3) Befor e r em ovin g va lves, re m o v e a n y bu rrs
r u bber va lve st em sea ls a r e in t egr a l wit h t h e spr in g fro m v a lv e s te m lo c k g ro o v e s to p re v e n t d a m -
sea t s. Th e va lves h a ve t h r ee-bea d lock keeper s t o a g e to th e v a lv e g u id e s . Iden t ify va lves, locks a n d
r et a in spr in gs a n d t o pr om ot e va lve r ot a t ion . r et a in er s t o in su r e in st a lla t ion in or igin a l loca t ion .
(4) In spect t h e va lves. (Refer t o 9 - E NGINE /CYL-
CLEANING INDE R H E AD/VALVE SP RINGS - INSP E CTION)
(1) Clea n a ll va lves t h or ou gh ly and disca r d
bu r n ed, wa r ped a n d cr a cked va lves. INSPECTION
(1) Wh en ever va lves h a ve been r em oved for in spec-
t ion , r econ dit ion in g or r epla cem en t , va lve spr in gs
VALV E SPRI N GS & SEALS sh ou ld be t est ed for cor r ect t en sion . Disca r d t h e
spr in gs t h a t do n ot m eet specifica t ion s. Th e followin g
REM OVAL specifica t ion s a pply t o bot h in t a ke a n d exh a u st
va lves spr in gs:
REMOVAL - CYLINDER HEAD ON • Va lve Closed Nom in a l Ten sion —76 lbs. @ 38.0
(1) Rem ove cylin der h ea d cover (Refer t o 9 - m m (1.50 in .)
E NGINE /CYLINDE R H E AD/CYLINDE R H E AD • Va lve Open Nom in a l Ten sion —136 lbs. @ 29.75
COVE R(S) - RE MOVAL). m m (1.17 in .)
(2) Rem ove ca m sh a ft s (Refer t o 9 - E NGINE /CYL- (2) In spect ea ch va lve spr in g for squ a r en ess wit h a
INDE R H E AD/CAMSH AF T(S) - RE MOVAL). st eel squ a r e a n d su r fa ce pla t e, t est spr in gs fr om bot h
(3) Rot a t e cr a n ksh a ft u n t il pist on is a t TDC on en ds. If t h e spr in g is m or e t h a n 1.5 m m (1/16 in ch )
com pr ession . ou t of squ a r e, in st a ll a n ew spr in g.
(4) Wit h a ir h ose a t t a ch ed t o a da pt er t ool in st a lled
in spa r k plu g h ole, a pply 90-120 psi a ir pr essu r e. I N STALLAT I ON
(5) Usin g Specia l Tool MD-998772-A wit h a da pt er
6779 (F ig. 33), com pr ess va lve spr in gs a n d r em ove INSTALLATION - CYLINDER HEAD ON
va lve locks. (1) In st a ll va lve sea l/va lve spr in g sea t a ssem bly
(6) Rem ove va lve spr in g(s). (F ig. 34). P u sh t h e a ssem bly down t o sea t it on t o t h e
(7) Rem ove va lve st em sea l(s) by a u sin g va lve va lve gu ide.
st em sea l t ool (F ig. 35). (2) In st a ll va lve spr in g a n d r et a in er, u se Specia l
Tool MD-998772-A wit h a da pt er 6779 t o com pr ess
va lve spr in gs on ly en ou gh t o in st a ll locks (F ig. 33).
Cor r ect a lign m en t of t ool is n ecessa r y t o a void n ick-
in g va lve st em s.
(3) Rem ove a ir h ose a n d in st a ll spa r k plu gs.
(4) In st a ll ca m sh a ft s (Refer t o 9 - E NGINE /CYL-
INDE R H E AD/CAMSH AF T(S) - INSTALLATION).
(5) In st a ll cylin der h ea d cover (Refer t o 9 -
COVE R - INSTALLATION).
INSTALLATION - CYLINDER HEAD OFF

(1) Coa t va lve st em s wit h clea n en gin e oil a n d
in ser t in cylin der h ea d.
(2) In st a ll n ew va lve st em sea ls on a ll va lves
u sin g a va lve st em sea l t ool (F ig. 35). Th e va lve st em
Fig. 33 Valve Spring - Removal/Installation sea ls sh ou ld be pu sh ed fir m ly a n d squ a r ely over
1 - VALVE SPRING COMPRESSOR MD 998772A va lve gu ide.
2 - AIR HOSE
VALV E SPRI N GS & SEALS (Cont inue d)
bot t om su r fa ce of spr in g r et a in er. If h eigh t is gr ea t er
t h a n 38.75 m m (1.525 in .), in st a ll a 0.762 m m (0.030
in .) spa cer u n der t h e va lve spr in g sea t t o br in g
spr in g h eigh t ba ck wit h in specifica t ion .
Fig. 34 Valve Stem Seal/Valve Spring Seat Fig. 36 Checking Spring Installed Height and Valve
Tip Height Dimensions
1 - VALVE RETAINING LOCKS
2 - VALVE SPRING 1 - GARTER SPRING
3 - VALVE SEAL AND VALVE SPRING SEAT ASSEMBLY 2 - VALVE SPRING SEAT
4 - VALVE SPRING RETAINER 3 - CYLINDER HEAD SURFACE
CAUTION: When oversize valves are used, the cor- H Y DRAU LI C LASH
responding oversize valve seal must also be used.
Excessive guide wear may result if oversize seals ADJ U ST ERS
are not used with oversize valves.
DIAGNOSIS AND TESTING - HYDRAULIC LASH
ADJUSTER NOISE DIAGNOSIS
A t a ppet -like n oise m a y be pr odu ced fr om sever a l
it em s. Ch eck t h e followin g it em s.
(1) E n gin e oil level t oo h igh or t oo low. Th is m a y
ca u se a er a t ed oil t o en t er t h e a dju st er s a n d ca u se
t h em t o be spon gy.
(2) In su fficien t r u n n in g t im e a ft er r ebu ildin g cylin -
der h ea d. Low speed r u n n in g u p t o 1 h ou r m a y be
r equ ir ed.
(3) Du r in g t h is t im e, t u r n en gin e off a n d let set for
a few m in u t es befor e r est a r t in g. Repea t t h is sever a l
t im es a ft er en gin e h a s r ea ch ed n or m a l oper a t in g
t em per a t u r e.
Fig. 35 Valve Stem Oil Seal Tool
(4) Low oil pr essu r e.
1 - VALVE SEAL TOOL (5) Th e oil r est r ict or (in t egr a l t o t h e h ea d ga sket )
2 - VALVE STEM
in t h e ver t ica l oil pa ssa ge t o t h e cylin der h ea d is
(3) In st a ll va lve spr in gs a n d r et a in er s. Com pr ess plu gged wit h debr is.
va lve spr in gs on ly en ou gh t o in st a ll locks, t a kin g (6) Air in gest ed in t o oil du e t o br oken or cr a cked
ca r e n ot t o m isa lign t h e dir ect ion of com pr ession . oil pu m p pick u p.
Nicked va lve st em s m a y r esu lt fr om m isa lign m en t of (7) Wor n va lve gu ides.
t h e va lve spr in g com pr essor. (8) Rocker a r m ea r s con t a ct in g va lve spr in g
r et a in er.
CAUTION: When depressing the valve spring retain- (9) Rocker a r m loose, a dju st er st u ck or a t m a xi-
ers with valve spring compressor the locks can m u m ext en sion a n d st ill lea ves la sh in t h e syst em .
become dislocated. Ensure both locks are in the (10) F a u lt y la sh a dju st er.
correct location after removing tool. • Ch eck la sh a dju st er s for spon gin ess wh ile
in st a lled in cylin der h ea d. Depr ess pa r t of r ocker
(4) Ch eck t h e va lve spr in g in st a lled h eigh t B a ft er a r m over a dju st er. Nor m a l a dju st er s sh ou ld feel ver y
r efa cin g t h e va lve a n d sea t (F ig. 36). Ma ke su r e m ea - fir m . Spon gy a dju st er s ca n be bot t om ed ou t ea sily.
su r em en t s a r e t a ken fr om t op of spr in g sea t t o t h e
H Y DRAU LI C LASH ADJ U ST ERS (Cont inue d)
• Rem ove su spect ed la sh a dju st er s, a n d r epla ce a s (1) Rem ove cylin der h ea d cover. (Refer t o 9 -
n ecessa r y. E NGINE /CYLINDE R H E AD/CYLINDE R H E AD
REMOVAL (2) Rem ove spa r k plu gs.
(3) Rot a t e en gin e u n t il t h e ca m sh a ft lobe, on t h e
NOTE: This procedure is for in-vehicle service with follower bein g r em oved, is posit ion ed on it s ba se cir-
camshafts installed. cle (h eel). Also, t h e pist on sh ou ld be a m in im u m of
6.3 m m (0.25 in ) below TDC posit ion .
(1) Rem ove cylin der h ea d cover. (Refer t o 9 -
E NGINE /CYLINDE R H E AD/CYLINDE R H E AD CAUTION: If cam follower assemblies are to be
COVE R(S) - RE MOVAL) reused, always mark position for reassembly in
(2) Rem ove r ocker a r m . (Refer t o 9 - E NGINE / their original positions.
CYLINDE R H E AD/ROCKE R ARMS - RE MOVAL)
(3) Rem ove h ydr a u lic la sh a dju st er (F ig. 37). (4) Usin g Specia l Tools 8215A a n d 8436 slowly
(4) Repea t r em ova l pr ocedu r e for ea ch h ydr a u lic depr ess va lve a ssem bly u n t il r ocker a r m ca n be
la sh a dju st er. r em oved (F ig. 38).
(5) If r eu sin g, m a r k ea ch h ydr a u lic la sh a dju st er (5) Repea t r em ova l pr ocedu r e for ea ch r ocker a r m .
for r ea ssem bly in or igin a l posit ion . La sh a dju st er s
a r e ser viced a s a n a ssem bly.
Fig. 37 Hydraulic Lash Adjuster

INSTALLATION
(1) In st a ll h ydr a u lic la sh a dju st er (F ig. 37).
E n su r e t h e la sh a dju st er s a r e a t lea st pa r t ia lly fu ll of
en gin e oil. Th is is in dica t ed by lit t le or n o plu n ger Fig. 38 Rocker Arm - Removal/Installation
t r a vel wh en t h e lift er is depr essed. 1 - SPECIAL TOOL 8215A
(2) In st a ll r ocker a r m . (Refer t o 9 - E NGINE /CYL- 2 - SPECIAL TOOL 8436
3 - 3/8% DRIVE RACHET
INDE R H E AD/ROCKE R ARMS - INSTALLATION)
(3) Repea t in st a lla t ion pr ocedu r e for ea ch h ydr a u -
INSPECTION
lic la sh a dju st er.
In spect t h e r ocker a r m for wea r or da m a ge (F ig.
39). Repla ce a s n ecessa r y.
INSTALLATION
(1) Lu br ica t e r ocker a r m wit h clea n en gin e oil.
ROCK ER ARM S (2) Usin g Specia l Tools 8215A a n d 8436 slowly
depr ess va lve a ssem bly u n t il r ocker a r m ca n be
REMOVAL in st a lled on t h e h ydr a u lic lift er a n d va lve st em (F ig.
38).
NOTE: This procedure is for in-vehicle service with (3) Repea t in st a lla t ion pr ocedu r e for ea ch r ocker
camshafts installed. arm.
ROCK ER ARM S (Cont inue d)
t a per a n d ou t -of-r ou n d a s well a s r em ovin g ligh t
scu ffin g, scor in g or scr a t ch es. Usu a lly a few st r okes
will clea n u p a bor e a n d m a in t a in t h e r equ ir ed lim -
it s.
(2) Degla zin g of t h e cylin der wa lls m a y be don e
u sin g a cylin der su r fa cin g h on e, r ecom m en ded t ool
C-3501 or equ iva len t , equ ipped wit h 280 gr it st on es,
if t h e cylin der bor e is st r a igh t a n d r ou n d. 20–60
st r okes depen din g on t h e bor e con dit ion , will be su f-
ficien t t o pr ovide a sa t isfa ct or y su r fa ce. Use a ligh t
h on in g oil. D o n o t u s e e n g in e o r tra n s m is s io n o il,
m in e ra l s p irits o r k e ro s e n e . In spect cylin der wa lls
Fig. 39 Rocker Arm a ft er ea ch 20 st r okes.
(3) H on in g sh ou ld be don e by m ovin g t h e h on e u p
1 - TIP
2 - LASH ADJUSTER POCKET a n d down fa st en ou gh t o get a cr oss-h a t ch pa t t er n .
3 - ROLLER Wh en h on e m a r ks in te rs e c t a t 40-60 degr ees, t h e
cr oss h a t ch a n gle is m ost sa t isfa ct or y for pr oper sea t -
(4) In st a ll spa r k plu gs. in g of r in gs (F ig. 41).
EN GI N E BLOCK
DESCRIPTION
Th e ca st ir on cylin der block is a t wo-piece a ssem -
bly, con sist in g of t h e cylin der block a n d bed pla t e
(F ig. 40). Th e bed pla t e in cor por a t es t h e m a in bea r-
in g ca ps a n d bolt s t o t h e cylin der block. Th is design
offer s a m u ch st r on ger lower en d a n d in cr ea sed cyl-
in der block r igidit y. Th e r ea r oil sea l r et a in er is in t e-
gr a l wit h t h e block. Th e bed pla t e a n d block a r e
ser viced a s a n a ssem bly.
Fig. 41 Cylinder Bore Cross-Hatch Pattern

1 - CROSS-HATCH PATTERN
2 - 40°–60°
(4) A con t r olled h on e m ot or speed bet ween

200–300 RP M is n ecessa r y t o obt a in t h e pr oper cr oss-
h a t ch a n gle. Th e n u m ber of u p a n d down st r okes per
m in u t e ca n be r egu la t ed t o get t h e desir ed 40–60
degr ee a n gle. F a st er u p a n d down st r okes in cr ea se
Fig. 40 Cylinder Block and Bed plate t h e cr oss-h a t ch a n gle.
1 - CYLINDER BLOCK
(5) Aft er h on in g, it is n ecessa r y t h a t t h e block be
2 - BED PLATE clea n ed a ga in t o r em ove a ll t r a ces of a br a sive.
STANDARD PROCEDURE - CYLINDER BORE

HONING
(1) Used ca r efu lly, t h e cylin der bor e r esizin g h on e,
r ecom m en ded t ool C-823 or equ iva len t , equ ipped
wit h 220 gr it st on es, is t h e best t ool for t h is h on in g
pr ocedu r e. In a ddit ion t o degla zin g, it will r edu ce
EN GI N E BLOCK (Cont inue d)
CAUTION: Ensure all abrasives are removed from
engine parts after honing. It is recommended that a
solution of soap and hot water be used with a
brush and the parts then thoroughly dried. The bore
can be considered clean when it can be wiped
clean with a white cloth and cloth remains clean.
Oil the bores after cleaning to prevent rusting.
CLEANING
Clea n cylin der block t h or ou gh ly u sin g a su it a ble
clea n in g solven t .
INSPECTION
ENGINE BLOCK
(1) Clea n cylin der block t h or ou gh ly a n d ch eck a ll
cor e h ole plu gs for eviden ce of lea kin g.
(2) If n ew cor e plu gs a r e t o be in st a lled, (Refer t o 9
- E NGINE - STANDARD P ROCE DURE - E NGINE
CORE AND OIL GALLE RY P LUGS).
(3) E xa m in e block a n d cylin der bor es for cr a cks or
fr a ct u r es. Fig. 42 Checking Cylinder Bore Size
(4) Ch eck block deck su r fa ces for fla t n ess. Deck (4) Move cr a n ksh a ft a ll t h e wa y t o t h e fr on t a n d
su r fa ce m u st be wit h in ser vice lim it of 0.1 m m (0.004 r ea d t h e dia l in dica t or. Refer t o E n gin e Specifica -
in .). t ion s.
CYLINDER BORE
NOTE: The cylinder bores should be measured at
normal room temperature, 21°C (70°F).
Th e cylin der wa lls sh ou ld be ch ecked for ou t -of-

r ou n d a n d t a per wit h Tool C119 or equ iva len t (F ig.
42) (Refer t o 9 - E NGINE - SP E CIF ICATIONS). If
t h e cylin der wa lls a r e ba dly scu ffed or scor ed, t h e
cylin der block sh ou ld be r epla ced, a n d n ew pist on s
a n d r in gs fit t ed.
Mea su r e t h e cylin der bor e a t t h r ee levels in dir ec-
t ion s A a n d B (F ig. 42). Top m ea su r em en t sh ou ld be
10 m m (3/8 in .) down a n d bot t om m ea su r em en t
sh ou ld be 10 m m (3/8 in .) u p fr om bot t om of bor e.
(Refer t o 9 - E NGINE - SP E CIF ICATIONS). Fig. 43 Checking Crankshaft End Play - Typical
REMOVAL - CRANKSHAFT
CRAN K SH AFT
NOTE: Crankshaft can not be removed when engine
STANDARD PROCEDURE - CRANKSHAFT END is in vehicle.
PLAY (1) Rem ove en gin e a ssem bly fr om veh icle (Refer t o
(1) Usin g Dia l In dica t or C-3339 a n d Mou n t in g 9 - E NGINE - RE MOVAL).
P ost L-4438, a t t a ch t o fr on t of en gin e, loca t in g pr obe (2) Sepa r a t e t r a n sa xle fr om en gin e.
per pen dicu la r on n ose of cr a n ksh a ft (F ig. 43). (3) Rem ove dr ive pla t e/flex pla t e.
(2) Move cr a n ksh a ft a ll t h e wa y t o t h e r ea r of it s (4) Rem ove cr a n ksh a ft r ea r oil sea l (Refer t o 9 -
t r a vel. E NGINE /E NGINE BLOCK/CRANKSH AF T OIL
(3) Zer o t h e dia l in dica t or. SE AL - RE AR - RE MOVAL).
(5) Mou n t en gin e on a su it a ble r epa ir st a n d.
CRAN K SH AFT (Cont inue d)
(6) Dr a in en gin e oil a n d r em ove oil filt er. (19) Rem ove a ll bed pla t e bolt s fr om t h e en gin e
(7) Rem ove cr a n ksh a ft vibr a t ion da m per (Refer t o block (F ig. 45).
9 - E NGINE /E NGINE BLOCK/VIBRATION (20) Usin g a m a llet gen t ly t a p t h e bed pla t e loose
DAMP E R - RE MOVAL). fr om t h e en gin e block dowel pin s.
(8) Rem ove en gin e m ou n t su ppor t br a cket .
(9) Rem ove fr on t t im in g belt cover s (Refer t o 9 - CAUTION: Do not pry up on one side of the bed
E NGINE /VALVE TIMING/TIMING BE LT COVE R(S) plate. Damage may occur to cylinder block to bed
- RE MOVAL). plate alignment and thrust bearing.
(10) Rem ove t h e t im in g belt (Refer t o 9 - E NGINE /
VALVE TIMING/TIMING BE LT AND SP ROCKE TS - (21) Bed pla t e sh ou ld be r em oved even ly fr om t h e
RE MOVAL). cylin der block dowel pin s t o pr even t da m a ge t o t h e
(11) Rem ove t h e r ea r t im in g belt cover (Refer t o 9 dowel pin s a n d t h r u st bea r in g.
CAUTION: Use extreme care when handling crank-
E R(S) - RE MOVAL).
shaft. Tone wheel damage can occur if crankshaft is
(12) Rem ove t h e oil pa n (Refer t o 9 - E NGINE /LU-
mis-handled.
BRICATION/OIL PAN - RE MOVAL).
(13) Rem ove oil pu m p pick-u p t u be. (22) Lift ou t cr a n ksh a ft fr om cylin der block. Do
(14) Rem ove t h e cr a n ksh a ft spr ocket a n d oil pu m p n ot da m a ge t h e m a in bea r in gs or jou r n a ls wh en
(Refer t o 9 - E NGINE /LUBRICATION/OIL P UMP - r em ovin g t h e cr a n ksh a ft .
RE MOVAL).
(15) Rem ove ba la n ce sh a ft s a n d h ou sin g a ssem bly
(Refer t o 9 - E NGINE /VALVE TIMING/BALANCE
SH AF T - RE MOVAL).
(16) Rem ove cr a n ksh a ft posit ion sen sor.
NOTE: If piston/connecting rod replacement is nec-

essary, remove cylinder head (Refer to 9 - ENGINE/
CYLINDER HEAD - REMOVAL).
(17) Usin g a per m a n en t in k or pa in t m a r ker, iden -

t ify cylin der n u m ber on ea ch con n ect in g r od ca p (F ig.
44).
CAUTION: DO NOT use a number stamp or a punch

to mark connecting rods. Damage to connecting
rod could occur.
(18) Rem ove a ll con n ect in g r od bolt s a n d ca ps.

Ca r e sh ou ld be t a ken n ot t o da m a ge t h e fr a ct u r e r od
a n d ca p su r fa ces.
NOTE: Do not reuse connecting rod bolts.

Fig. 45 Bed Plate Bolt Removal Sequence
(23) Rem ove t h e t a r get r in g m ou n t in g scr ews a n d
disca r d.
(24) Rem ove t h e t a r get r in g fr om t h e cr a n ksh a ft .
INSPECTION
F or cr a n ksh a ft specifica t ion s (Refer t o 9 - E NGINE
- SP E CIF ICATIONS).
Th e cr a n ksh a ft jou r n a ls sh ou ld be ch ecked for
excessive wea r, t a per a n d scor in g (F ig. 46). Lim it s of
t a per or ou t of r ou n d on a n y cr a n ksh a ft jou r n a ls
Fig. 44 Identify Connecting Rod to Cylinder-Typical sh ou ld be h eld t o 0.025 m m (0.001 in .). J ou r n a l
gr in din g sh ou ld n ot exceed 0.305 m m (0.012 in .)
u n der t h e st a n da r d jou r n a l dia m et er. DO NOT gr in d
t h r u st fa ces of No. 3 m a in bea r in g. DO NOT n ick (1) In st a ll t h e m a in bea r in g u pper sh ells wit h t h e
cr a n k pin or bea r in g fillet s. Aft er gr in din g, r em ove lu br ica t ion gr oove a n d oil h ole in t h e en gin e block
r ou gh edges fr om cr a n ksh a ft oil h oles a n d clea n ou t (F ig. 48).
a ll pa ssa ges.
CAUTION: With the nodular cast iron crankshafts, it

is important that the final paper or cloth polish be
in the same direction as normal rotation in the
engine.
Fig. 48 Installing Main Bearing Upper Shell

1 - LUBRICATION GROOVES
2 - OIL HOLES
(2) Ma ke cer t a in oil h oles in block lin e u p wit h oil

Fig. 46 Crankshaft Journal Measurements - Typical
h ole in bea r in gs a n d bea r in g t a bs sea t in t h e block
INSTALLATION - CRANKSHAFT t a b slot s.
CRANKSHAFT MAIN BEARING LOCATION NOTE: If the crankshaft is sent out for machine
Th e cr a n ksh a ft is su ppor t ed in five m a in bea r in gs. work, it must be balenced as an assembly with the
All u pper bea r in g sh ells in t h e cr a n kca se h a ve oil target ring installed.
gr ooves a n d h oles. All lower bea r in g sh ells e x c e p t
(3) Clea n cr a n ksh a ft a n d t a r get r in g wit h
for t h e t h r u st bea r in g h a lf h a ve oil gr ooves a n d h oles
MOPAR! br a ke pa r t s clea n er a n d dr y wit h com -
(F ig. 47). Cr a n ksh a ft en d pla y is con t r olled by a
pr essed a ir t o en su r e t h a t t h e cr a n ksh a ft m a t in g su r-
fla n ged bea r in g on t h e n u m ber t h r ee m a in bea r in g
fa ce a n d t a r get r in g m ou n t in g h oles a r e fr ee fr om oil
jou r n a l.
a n d lock pa t ch debr is.
NOTE: Always use NEW mounting screws whether

installing original or new target ring.
(4) In st a ll N EW m ou n t in g scr ews fin ger t igh t

st a r t in g wit h t h e #1 loca t ion . (F ig. 49) Ma ke su r e
en ga gm en t occu r s wit h t h e sh ou lder of t h e scr ew a n d
m ou n t in g h ole befor e st a r t in g a ll ot h er scr ews.
(5) Tor qu e a ll m ou n t in g scr ews wit h T30 t or x bit
t o 13 Nm (110 in -lbs) followin g t h e t or qu e sequ en ce.
CAUTION: Use extreme care when handling crank-

shaft. Tone wheel damage can occur if crankshaft is
Fig. 47 Main Bearing Identification mis-handled.
1 - OIL GROOVE
2 - MAIN BEARINGS
3 - OIL HOLE CAUTION: Do not get oil on the bed plate mating
4 - LOWER THRUST BEARING PLAIN (NO OIL HOLE OR surface. It will affect the ability of the sealer to seal
GROOVE) the bed plate to cylinder block.
Fig. 49 Target Ring Torque Sequence Fig. 50 Bed Plate Sealing

(6) Oil t h e bea r in gs a n d jou r n a ls. In st a ll cr a n k-
sh a ft in t h e en gin e block.
CAUTION: Use only Mopar" Bed Plate Sealant on

the bed plate or damage may occur to the engine.
(7) In st a ll lower m a in bea r in gs in t o m a in bea r in g

ca p/bed pla t e. Ma ke cer t a in t h e bea r in g t a bs a r e
sea t ed in t o t h e bed pla t e slot s a n d a pply oil.
(8) Apply 1.5 t o 2.0 m m (0.059 t o 0.078 in .) bea d of
Mopa r ! Bed P la t e Sea la n t t o bed pla t e a s sh own in
(F ig. 50).
(9) In st a ll t h e m a in bea r in g/bed pla t e in t o en gin e
block.
(10) Befor e in st a llin g t h e bolt s t h e t h r ea ds sh ou ld
be oiled wit h clea n en gin e oil, wipe off a n y excess oil.
(11) In st a ll m a in bea r in g bed pla t e t o en gin e
block bolt s 11, 17, a n d 20 fin ger t igh t . Tigh t en t h ese
bolt s down t oget h er u n t il t h e bed pla t e con t a ct s t h e
cylin der block.
(12) To en su r e cor r ect t h r u st bea r in g a lign m en t ,
per for m t h e followin g st eps:
• St ep 1: Rot a t e cr a n ksh a ft u n t il n u m ber 4 pist on Fig. 51 Main Bearing Caps/Bed Plate Bolt Torque
is a t TDC. Sequence
• St ep 2: Move cr a n ksh a ft r ea r wa r d t o lim it s of
t r a vel. • St ep 5: In st a ll a n d t igh t en bolt s (1–10) in
• St ep 3: Th en , m ove cr a n ksh a ft for wa r d t o lim it s sequ en ce sh own in (F ig. 51) t o 41 N·m (30 ft . lbs.).
of t r a vel. • St ep 6: Rem ove wedge t ool u sed t o h old cr a n k-
• St ep 4: Wedge a n a ppr opr ia t e t ool bet ween t h e sh a ft .
r ea r of t h e cylin der block (N OT B ED P LATE) a n d (13) Tigh t en bolt s (1–10) a ga in t o 41 N·m (30 ft .
t h e r ea r cr a n ksh a ft cou n t er weigh t . Th is will h old t h e lbs.) in sequ en ce sh own in (F ig. 51).
cr a n ksh a ft in it ’s fu r t h est for wa r d posit ion .
CAUTION: Do Not use a torque wrench for the fol-
lowing step.
(14) Tu r n bolt s (1–10) a n a ddit ion a l 1/4 t u r n in CRAN K SH AFT OI L SEAL -
sequ en ce sh own in (F ig. 51).
(15) In st a ll m a in bea r in g bed pla t e t o en gin e FRON T
block bolt s (11–20), a n d t or qu e ea ch bolt t o 28 N·m
(250 in . lbs.) in sequ en ce sh own in . (F ig. 51) REMOVAL
(16) Tigh t en bolt s (11–20) a ga in t o 28 N·m (250 in . (1) Rem ove t h e cr a n ksh a ft vibr a t ion da m per.
lbs.) in sequ en ce sh own in (F ig. 51). (Refer t o 9 - E NGINE /E NGINE BLOCK/VIBRATION
(17) Aft er t h e m a in bea r in g bed pla t e is in st a lled, DAMP E R - RE MOVAL)
ch eck t h e cr a n ksh a ft t u r n in g t or qu e. Th e t u r n in g (2) Rem ove t im in g belt . (Refer t o 9 - E NGINE /
t or qu e sh ou ld n ot exceed 5.6 N·m (50 in . lbs.). VALVE TIMING/TIMING BE LT/CH AIN AND
(18) Ch eck cr a n ksh a ft en d pla y (Refer t o 9 - SP ROCKE TS - RE MOVAL)
E NGINE /E NGINE BLOCK/CRANKSH AF T - STAN- (3) Rem ove cr a n ksh a ft spr ocket u sin g Specia l Tool
DARD P ROCE DURE ). 6793 a n d in ser t C-4685-C2 (F ig. 52).
(19) In st a ll con n ect in g r od bea r in gs a n d ca ps. D o
N o t Re u s e Co n n e c tin g Ro d B o lts . Tor qu e con n ect - CAUTION: Do not nick shaft seal surface or seal
in g r od bolt s t o 27 N·m (20 ft . lbs.) plu s 1/4 t u r n . bore.
(20) In st a ll ba la n ce sh a ft s a n d h ou sin g a ssem bly
(Refer t o 9 - E NGINE /VALVE TIMING/BALANCE
SH AF T - INSTALLATION).
(21) In st a ll t h e oil pu m p (Refer t o 9 - E NGINE /
LUBRICATION/OIL P UMP - INSTALLATION).
(22) In st a ll oil pu m p pick-u p t u be. Tor qu e fa st en er
t o 28 N·m (20 ft .. lbs.).
(23) In st a ll t h e oil pa n (Refer t o 9 - E NGINE /LU-
BRICATION/OIL PAN - INSTALLATION).
(24) In st a ll cr a n ksh a ft posit ion sen sor.
(25) In st a ll cylin der h ea d if it wa s r em oved (Refer
t o 9 - E NGINE /CYLINDE R H E AD - INSTALLA-
TION).
(26) In st a ll t h e t im in g belt r ea r cover (Refer t o 9 - Fig. 52 Crankshaft Sprocket - Removal
E NGINE /VALVE TIMING/TIMING BE LT COVE R(S) 1 - SPECIAL TOOL 6793
- INSTALLATION). 2 - SPECIAL TOOL C-4685–C2
(27) In st a ll cr a n ksh a ft spr ocket (Refer t o 9 - 3 - CRANKSHAFT SPROCKET
E NGINE /VALVE TIMING/TIMING BE LT AND
SP ROCKE TS - INSTALLATION). (4) Usin g Tool 6771 t o r em ove fr on t cr a n ksh a ft oil
(28) In st a ll t h e t im in g belt (Refer t o 9 - E NGINE / sea l (F ig. 53). Be ca r efu l n ot t o da m a ge t h e sea l su r-
VALVE TIMING/TIMING BE LT AND SP ROCKE TS - fa ce of cover.
INSTALLATION).
(29) In st a ll t h e t im in g belt fr on t cover s (Refer t o 9
E R(S) - INSTALLATION).
(30) In st a ll en gin e m ou n t su ppor t br a cket .
(31) In st a ll N EW oil filt er.
(32) In st a ll cr a n ksh a ft r ea r oil sea l (Refer t o 9 -
E NGINE /E NGINE BLOCK/CRANKSH AF T OIL
SE AL - RE AR - INSTALLATION).
(33) In st a ll flex pla t e. Apply Mopa r ! Lock & Sea l
Adh esive t o bolt t h r ea ds a n d t igh t en t o 95 N·m (70
ft . lbs.).
(34) At t a ch t r a n sa xle t o en gin e. Tigh t en a t t a ch in g
bolt s t o 101 N·m (75 ft . lbs.).
(35) In st a ll t h e en gin e a ssem bly (Refer t o 9 -
E NGINE - INSTALLATION).
Fig. 53 Front Crankshaft Oil Seal - Removal
2 - REAR TIMING BELT COVER
CRAN K SH AFT OI L SEAL - FRON T (Cont inue d)
INSTALLATION
(1) In st a ll n ew sea l by u sin g Specia l Tool 6780
(F ig. 54).
(2) P la ce sea l in t o open in g wit h sea l spr in g
t owa r ds t h e in side of en gin e. In st a ll sea l u n t il flu sh
wit h cover.
Fig. 55 Crankshaft Sprocket - Installation

2 - TIGHTEN NUT TO INSTALL
CRAN K SH AFT OI L SEAL -

REAR
REMOVAL
(1) Rem ove t r a n sa xle. Refer t o TRANSMISSION/
TRANSAXLE - RE MOVAL for pr ocedu r e.
(2) Rem ove flex pla t e.
(3) In ser t a 3/16 fla t bla ded scr ewdr iver bet ween
t h e du st lip a n d t h e m et a l ca se of t h e cr a n ksh a ft
sea l. An gle t h e scr ewdr iver (F ig. 56)t h r ou gh t h e du st
lip a ga in st m et a l ca se of t h e sea l. P r y ou t sea l.
CAUTION: Do not permit the screwdriver blade to

contact crankshaft seal surface. Contact of the
Fig. 54 Crankshaft Front Oil Seal - Installation screwdriver blade against crankshaft edge (cham-
1 - PROTECTOR fer) is permitted.
2 - SEAL
(3) In st a ll cr a n ksh a ft spr ocket u sin g Specia l Tool INSTALLATION

6792 (F ig. 55).
(4) In st a ll t im in g belt . (Refer t o 9 - E NGINE / CAUTION: If a burr or scratch is present on the
VALVE TIMING/TIMING BE LT/CH AIN AND crankshaft edge (chamfer), cleanup with 400 grit
SP ROCKE TS - INSTALLATION) sand paper to prevent seal damage during installa-
(5) In st a ll cr a n ksh a ft vibr a t ion da m per. (Refer t o 9 tion of new seal.
- E NGINE /E NGINE BLOCK/VIBRATION DAMP E R -
INSTALLATION)
CRAN K SH AFT OI L SEAL - REAR (Cont inue d)
Fig. 56 Rear Crankshaft Oil Seal - Removal Fig. 57 Rear Crankshaft Seal and Special Tool
6926-1
1 - REAR CRANKSHAFT SEAL
2 - ENGINE BLOCK 1 - SPECIAL TOOL 6926–1 PILOT
3 - ENGINE BLOCK 2 - SEAL
4 - REAR CRANKSHAFT SEAL METAL CASE
5 - PRY IN THIS DIRECTION
6 - CRANKSHAFT
7 - SCREWDRIVER
8 - REAR CRANKSHAFT SEAL DUST LIP
9 - SCREWDRIVER
NOTE: When installing seal, no lube on seal is

needed.
(1) P la ce Specia l Tool 6926-1 Sea l Gu ide on cr a n k-

sh a ft (F ig. 57).
(2) P osit ion sea l over gu ide t ool (F ig. 57). Gu ide
t ool sh ou ld r em a in on cr a n ksh a ft du r in g in st a lla t ion
of sea l. E n su r e t h a t t h e lip of t h e sea l is fa cin g
t owa r ds t h e cr a n kca se du r in g in st a lla t ion .
CAUTION: If the seal is driven into the block past

flush, this may cause an oil leak.
(3) Dr ive t h e sea l in t o t h e block u sin g Specia l Tool

6926-2 a n d h a n dle C-4171 (F ig. 58) u n t il t h e t ool bot -
t om s ou t a ga in st t h e block (F ig. 59).
(4) In st a ll flex pla t e. Apply Mopa r ! Lock & Sea l
Adh esive t o bolt t h r ea ds a n d t igh t en bolt s t o 95 N·m Fig. 58 Crankshaft Seal and Special Tools 6926-2 &
(70 ft . lbs.). C-4171
(5) In st a ll t r a n sa xle. Refer t o TRANSMISSION/ 1 - SPECIAL TOOL 6926–1 PILOT
TRANSAXLE - INSTALLATION for pr ocedu r e. 2 - SEAL
3 - SPECIAL TOOL 6926–2 INSTALLER
Cylin der bor es sh ou ld be m ea su r ed h a lfwa y down
t h e cylin der bor e a n d t r a n sver se (m ea su r em en t loca -
t ion B) t o t h e en gin e cr a n ksh a ft cen t er lin e sh own in
(F ig. 61). Refer t o for E n gin e Specifica t ion s (Refer t o
9 - E NGINE - SP E CIF ICATIONS). Cor r ect pist on t o
bor e clea r a n ce m u st be est a blish ed in or der t o a ssu r e
qu iet a n d econ om ica l oper a t ion .
Fig. 60 Piston Measurement

1 - PISTON DIAMETER
2 - 14 mm (0.551 in.)
Fig. 59 Rear Crankshaft Seal - Installation

1 - SPECIAL TOOL 6926–2 INSTALLER
PI ST ON & CON N ECT I N G ROD

DESCRIPTION
Th e pist on s a r e m a de of a ca st a lu m in u m a lloy.
Th e pist on s h a ve pr essed-in pin s a t t a ch ed t o for ged
powder ed m et a l con n ect in g r ods. Th e pist on s pin is
offset 1 m m (0.0394 in .) t owa r ds t h e t h r u st side of
t h e pist on . Th e con n ect in g r ods a r e a cr a cked ca p
design a n d a r e n ot r epa ir a ble. H ex h ea d ca p scr ews
a r e u sed t o pr ovide a lign m en t a n d du r a bilit y in t h e
a ssem bly. Th e pist on s a n d con n ect in g r ods a r e ser-
viced a s a n a ssem bly.
STANDARD PROCEDURE - PISTON TO

CYLINDER BORE FITTING
Fig. 61 Checking Cylinder Bore
NOTE: Pistons and cylinder bores should be mea- REMOVAL
sured at normal room temperature, 21°C (70°F). (1) Rem ove cylin der h ea d (Refer t o 9 - E NGINE /
CYLINDE R H E AD - RE MOVAL).
P ist on a n d cylin der wa ll m u st be clea n a n d dr y.
(2) Rem ove oil pa n (Refer t o 9 - E NGINE /LUBRI-
P ist on dia m et er sh ou ld be m ea su r ed 90 degr ees t o
CATION/OIL PAN - RE MOVAL).
pist on pin .
(3) Rem ove Ba la n ce Sh a ft Ca r r ier Assem bly (Refer
P ist on m ea su r em en t sh ou ld be t a ken a ppr oxi-
t o 9 - E NGINE /VALVE TIMING/BALANCE SH AF T
m a t ely 14 m m (0.551 in .) fr om t h e bot t om of t h e skir t
CARRIE R - RE MOVAL).
a s sh own in (F ig. 60)
PI ST ON & CON N ECT I N G ROD (Cont inue d)
(4) Rem ove t op r idge of cylin der bor es wit h a r eli- (11) Repea t pr ocedu r e for ea ch pist on a n d con n ect -
a ble r idge r ea m er befor e r em ovin g pist on s fr om cylin g r od a ssem bly.
in der block. B e s u re to k e e p to p s o f p is to n s (12) Rem ove pist on r in gs (Refer t o 9 - E NGINE /
c o v e re d d u rin g th is o p e ra tio n . E NGINE BLOCK/P ISTON RINGS - RE MOVAL).
Fig. 63 Identify Connectng Rod to Cylinder - Typical
Fig. 62 Piston Markings

1 - DIRECTIONAL ARROW WILL BE IMPRINTED IN THIS AREA
(5) P ist on s h a ve a dir ect ion a l st a m pin g in t h e

fr on t h a lf of t h e pist on fa cin g t owa r ds t h e fro n t of
en gin e (F ig. 62).
(6) P ist on s a n d con n ect in g r ods m u st be r em oved
fr om t op of cylin der block. Rot a t e cr a n ksh a ft so t h a t
ea ch con n ect in g r od is cen t er ed in cylin der bor e.
(7) Usin g a per m a n en t in k or pa in t m a r ker, iden -
t ify cylin der n u m ber on ea ch con n ect in g r od ca p (F ig.
63).
CAUTION: DO NOT use a number stamp or a punch

to mark connecting rods. Damage to connecting
rod could occur.
(8) Rem ove con n ect in g r od bolt s a n d ca p. Ca r e Fig. 64 Connecting Rod Guides - Typical
sh ou ld be t a ken n ot t o da m a ge t h e fr a ct u r e r od a n d 1 - SPECIAL TOOL 8189 CONNECTING ROD GUIDES
ca p su r fa ces.
INSTALLATION
NOTE: Do not reuse connecting rod bolts. (1) In st a ll pist on r in gs on pist on (Refer t o 9 -
E NGINE /E NGINE BLOCK/P ISTON RINGS -
CAUTION: Care must be taken not to damage the INSTALLATION)
fractured rod and cap joint surfaces, as engine (2) Befor e in st a llin g pist on s a n d con n ect in g r od
damage many occur. a ssem blies in t o t h e bor e, be su r e t h a t com pr ession
r in g ga ps a r e st a gger ed so t h a t n eit h er is in lin e wit h
(9) To pr ot ect cr a n ksh a ft jou r n a l a n d fr a ct u r ed r od oil r in g r a il ga p (F ig. 65).
su r fa ces, in st a ll Specia l Tool 8189, con n ect in g r od (3) Befor e in st a llin g t h e r in g com pr essor, m a ke
gu ides on t o con n ect in g r od (F ig. 64). Ca r efu lly pu sh su r e t h e oil r in g expa n der en ds a r e bu t t ed a n d t h e
ea ch pist on a n d r od a ssem bly ou t of cylin der bor e. r a il ga ps loca t ed a s sh own in (F ig. 65). As viewed
(10) Rem ove Specia l Tool 8189, con n ect in g r od fr om t op.
gu ides a n d r e-in st a ll bea r in g ca p on t h e m a t in g r od. (4) Im m er se t h e pist on h ea d a n d r in gs in clea n
en gin e oil, slide t h e r in g com pr essor, over t h e pist on
NOTE: Piston and rods are serviced as an assem- (F ig. 66). B e s u re p o s itio n o f rin g s d o e s n o t
bly. c h a n g e d u rin g th is o p e ra tio n .
(5) Th e dir ect ion a l st a m p on t h e pist on sh ou ld fa ce
t owa r d t h e fr on t of t h e en gin e (F ig. 62).
(12) In st a ll ea ch bolt fin ger t igh t t h en a lt er n a t ely
t or qu e ea ch bolt t o a ssem ble t h e ca p pr oper ly.
(13) Tigh t en t h e con n ect in g r od bolt s u sin g t h e 2
st ep t or qu e-t u r n m et h od. Tigh t en a ccor din g t o t h e
followin g va lu es:
CAUTION: Do not use a torque wrench for the sec-

ond step.
1. Tigh t en t h e bolt s t o 27 N·m (20 ft . lbs.).

2. Tigh t en t h e con n ect in g r od bolt s a n a ddit ion a l
1/4 TU RN .
(14) Usin g a feeler ga u ge, ch eck con n ect in g r od
side clea r a n ce (F ig. 67). (Refer t o 9 - E NGINE -
SP E CIF ICATIONS) for con n ect in g r od side clea r a n ce.
Fig. 65 Piston Ring End Gap Position

1 - GAP OF LOWER SIDE RAIL
2 - NO. 1 RING GAP
3 - GAP OF UPPER SIDE RAIL
4 - NO. 2 RING GAP AND SPACER EXPANDER GAP
Fig. 67 Checking Connecting Rod Side Clearance -

Typical
(15) In st a ll Ba la n ce Sh a ft Ca r r ier Assem bly (Refer
t o 9 - E NGINE /VALVE TIMING/BALANCE SH AF T
Fig. 66 Piston—Installation CARRIE R - INSTALLATION).
(6) Rot a t e cr a n ksh a ft so t h a t t h e con n ect in g r od (16) In st a ll oil pa n (Refer t o 9 - E NGINE /LUBRI-
jou r n a l is on t h e cen t er of t h e cylin der bor e. Lu br i- CATION/OIL PAN - INSTALLATION).
ca t e con n ect in g r od jou r n a l wit h clea n en gin e oil. (17) In st a ll cylin der h ea d (Refer t o 9 - E NGINE /
(7) In st a ll con n ect in g r od u pper bea r in g h a lf in t o CYLINDE R H E AD - INSTALLATION).
con n ect in g r od. In st a ll Specia l Tool 8189, con n ect in g
r od gu ides on t o con n ect in g r od (F ig. 64).
(8) Ta p t h e pist on down in cylin der bor e, u sin g a CON N ECT I N G ROD BEARI N GS
h a m m er h a n dle. At t h e sa m e t im e, gu ide con n ect in g
r od in t o posit ion on con n ect in g r od jou r n a l.
(9) Rem ove Specia l Tool 8189, con n ect in g r od
gu ides.
CONNECTING ROD - FITTING
NOTE: The connecting rod cap bolts should not be (1) F or m ea su r in g con n ect in g r od bea r in g clea r-
reused. a n ce pr ocedu r e a n d u se of P la st iga ge(Refer t o 9 -
E NGINE - STANDARD P ROCE DURE ). F or bea r in g
(10) Befor e in st a llin g t h e N EW bolt s, t h e t h r ea ds clea r a n ce r efer t o E n gin e Specifica t ion s. (Refer t o 9 -
sh ou ld be coa t ed wit h clea n en gin e oil. E NGINE - SP E CIF ICATIONS)
(11) In st a ll con n ect in g r od lower bea r in g h a lf in t o
con n ect in g r od ca p. In st a ll con n ect in g r od ca p.
CON N ECT I N G ROD BEARI N GS (Cont inue d)
NOTE: The rod bearing bolts should not be reused.
(2) Befor e in st a llin g t h e N EW bolt s t h e t h r ea ds

sh ou ld be oiled wit h clea n en gin e oil.
(3) In st a ll ea ch bolt fin ger t igh t t h en a lt er n a t ely
t or qu e ea ch bolt t o a ssem ble t h e ca p pr oper ly.
(4) Tigh t en t h e con n ect in g r od bolt s u sin g t h e 2
st ep t or qu e-t u r n m et h od. Tigh t en a ccor din g t o t h e
followin g va lu es:
CAUTION: Do not use a torque wrench for the sec-

ond step.
1. Tigh t en t h e bolt s t o 27 N·m (20 ft . lbs.).

2. Tigh t en t h e con n ect in g r od bolt s a n a ddit ion a l
1/4 TU RN .
(5) Usin g a feeler ga u ge, ch eck con n ect in g r od side
clea r a n ce (F ig. 68). Refer t o clea r a n ce specifica t ion s Fig. 69 Piston Ring Gap
(Refer t o 9 - E NGINE - SP E CIF ICATIONS). 1 - FEELER GAUGE
Fig. 68 Connecting Rod Side Clearance - Typical

PI ST ON RI N GS Fig. 70 Piston Ring Side Clearance
1 - FEELER GAUGE
(3) Clea n r in g gr ooves of a n y ca r bon deposit s.
PISTON RING - FITTING INSTALLATION
(1) Wipe cylin der bor e clea n . In ser t r in g a n d pu sh
down wit h pist on t o en su r e it is squ a r e in bor e. Th e NOTE: The identification mark on face of upper and
r in g ga p m ea su r em en t m u st be m a de wit h t h e r in g intermediate piston rings must point toward top of
posit ion in g a t lea st 12 m m (0.50 in ch ) fr om bot t om of piston.
cylin der bor e. Ch eck ga p wit h feeler ga u ge (F ig. 69).
Refer t o E n gin e Specifica t ion s. In st a ll r in gs wit h m a n u fa ct u r er s iden t ifica t ion
(2) Ch eck pist on r in g t o gr oove side clea r a n ce (F ig. m a r k fa cin g u p, t o t h e t op of t h e pist on (F ig. 72).
70). Refer t o E n gin e Specifica t ion s.
CAUTION: Install piston rings in the following
REMOVAL order:
(1) Usin g a su it a ble r in g expa n der, r em ove u pper
a n d in t er m edia t e pist on r in gs (F ig. 71). 1. Oil r in g expa n der.
(2) Rem ove t h e u pper oil r in g side r a il, lower oil 2. Upper oil r in g side r a il.
r in g side r a il a n d t h en oil r in g expa n der fr om pist on . 3. Lower oil r in g side r a il.
PI ST ON RI N GS (Cont inue d)
Fig. 73 Installing Side Rail

Fig. 71 Piston Rings—Removing and Installing 1 - SIDE RAIL END
(4) P osit ion pist on r in g en d ga ps a s sh own in (F ig.

74).
(5) P osit ion oil r in g expa n der ga p a t lea st 45° fr om
t h e side r a il ga ps bu t n o t on t h e pist on pin cen t er or
on t h e t h r u st dir ect ion . St a gger in g r in g ga p is im por-
t a n t for oil con t r ol.
Fig. 72 Piston Ring Installation Fig. 74 Piston Ring End Gap Position
1 - NO. 1 PISTON RING
2 - NO. 1 RING GAP
3 - SIDE RAIL
4 - OIL RING
5 - SPACER EXPANDER
4. No. 2 In t er m edia t e pist on r in g. V I BRAT I ON DAM PER

5. No. 1 Upper pist on r in g.
(1) In st a ll oil r in g expa n der (F ig. 72). REMOVAL
(2) In st a ll u pper side r a il fir st a n d t h en t h e lower (1) Rem ove a ccesor y dr ive belt s. (Refer t o 7 -
side r a il. In st a ll t h e side r a ils by pla cin g on e en d COOLING/ACCE SSORY DRIVE /DRIVE BE LTS -
bet ween t h e pist on r in g gr oove a n d t h e oil r in g RE MOVAL)
expa n der. H old en d fir m ly a n d pr ess down t h e por- (2) Rem ove cr a n ksh a ft da m per bolt .
t ion t o be in st a lled u n t il side r a il is in posit ion . D o (3) Rem ove da m per u sin g Specia l Tool 3-J a w
n o t u s e a p is to n rin g e x p a n d e r (F ig . 73). P u ller 1026 a n d In ser t 6827–A (F ig. 75).
(3) In st a ll No. 2 pist on r in g a n d t h en No. 1 pist on
r in g (F ig. 72).
V I BRAT I ON DAM PER (Cont inue d)
(3) Rem ove st r u ct u r a l colla r a t t a ch in g bolt s (F ig.
77).
(4) Rem ove colla r.
INSTALLATION
CAUTION: Torque procedure for the structural collar
must be followed or damage could occur to oil pan
and collar.
(1) P er for m t h e followin g st eps for in st a llin g st r u c-

t u r a l colla r. Refer t o (F ig. 77):
Fig. 75 Crankshaft Vibration Damper - Removal

1 - SPECIAL TOOL 1026 3-JAW PULLER
2 - SPECIAL TOOL 6827–A INSERT
INSTALLATION
(1) In st a ll cr a n ksh a ft vibr a t ion da m per u sin g M12
1.75 x 150 m m bolt , wa sh er, t h r u st bea r in g a n d n u t
fr om Specia l Tool 6792 (F ig. 76).
(2) In st a ll cr a n ksh a ft vibr a t ion da m per bolt a n d
t igh t en t o 142 N·m (105 ft . lbs.).
(3) In st a ll a ccessor y dr ive belt s. (Refer t o 7 -
INSTALLATION)
Fig. 77 Structural Collar

1 - BOLT - COLLAR TO OIL PAN
2 - BOLT - COLLAR TO TRANSAXLE
3 - STRUCTURAL COLLAR
4 - OIL PAN
• St ep 1: P osit ion colla r bet ween t r a n sa xle a n d oil

pa n . In st a ll colla r t o t r a n sa xle bolt , h a n d s ta rt
o n ly .
• St ep 2: In st a ll colla r t o oil pa n bolt s, h a n d s n u g
o n ly.
Fig. 76 Crankshaft Vibration Damper - Installation • St ep 3: F in a l t or qu e colla r t o t r a n sa xle bolt s t o
1 - M12–1.75 × 150 MM BOLT, WASHER AND THRUST BEARING 101 N·m (75 ft . lbs.)
FROM SPECIAL TOOL 6792
• St ep 4: F in a l t or qu e colla r t o oil pa n bolt s t o 54
N·m (40 ft . lbs.).
ST RU CT U RAL COLLAR (2) In st a ll en gin e fr on t m ou n t br a cket a n d in su la -
t or. (Refer t o 9 - E NGINE /E NGINE MOUNTING/
REMOVAL F RONT MOUNT - INSTALLATION)
(1) Ra ise veh icle on h oist . (3) Lower veh icle.
(2) Rem ove en gin e fr on t m ou n t br a cket a n d fr on t
in su la t or m ou n t . (Refer t o 9 - E NGINE /E NGINE
MOUNTING/F RONT MOUNT - RE MOVAL)
EN GI N E M OU N T I N G
DESCRIPTION
Th e en gin e m ou n t in g syst em con sist of fou r
m ou n t s; r igh t a n d a left side su ppor t t h e power t r a in ,
a n d a fr on t a n d a r ea r m ou n t con t r ol power t r a in
t or qu e. Th e r igh t side m ou n t is a h ydr o-t ype (F ig.
78), a ll ot h er s a r e of m olded r u bber m a t er ia l.
Fig. 79 Front Mount and Bracket

1 - BRACKET - FRONT MOUNT
2 - NUT - 68 N·m (50 ft. lbs.)
3 - BOLT - 54 N·m (40 ft. lbs.)
4 - MOUNT - FRONT INSULATOR
5 - BOLT - 68 N·m (50 ft. lbs.)
6 - BOLT - 68 N·m (50 ft. lbs.)
7 - FRONT CROSSMEMBER
LEFT M OU N T
Fig. 78 Engine Hydro-type Mount - Right Side
1 - BOLT REMOVAL
2 - BOLT (1) Ra ise t h e veh icle on h oist .
3 - FRAME RAIL
4 - RIGHT MOUNT - 2.4L ENGINE (2) Rem ove t h e left fr on t wh eel.
5 - RIGHT MOUNT - 3.3/3.8L ENGINE (3) Rem ove t h e left m ou n t t h r ou gh bolt a ccess
cover.
FRON T M OU N T (4) Su ppor t t h e t r a n sa xle wit h a su it a ble ja ck.
(5) Rem ove t h e en gin e fr on t m ou n t t h r ou gh bolt t o
REMOVAL a llow left m ou n t r em ova l clea r a n ce (F ig. 79).
(1) Ra ise veh icle on h oist . (6) Rem ove t h e left m ou n t t h r ou gh fr a m e r a il bolt
(2) Rem ove t h e fr on t en gin e m ou n t t h r ou gh bolt (F ig. 80).
fr om t h e in su la t or (F ig. 79). (7) Lower t r a n sa xle for a ccess t o h or izon t a l bolt s.
(3) Rem ove t h e en gin e fr on t m ou n t bolt s a n d (8) Rem ove t h e h or izon t a l bolt s fr om t h e m ou n t t o
r em ove t h e in su la t or a ssem bly (F ig. 79). t h e t r a n sa xle (F ig. 81).
(4) Rem ove t h e fr on t m ou n t in g br a cket fr om
NOTE: To remove mount, additional lowering of
en gin e, if n ecessa r y (F ig. 79).
transaxle may be required.
INSTALLATION (9) Rem ove left m ou n t .
(1) In st a ll t h e fr on t m ou n t br a cket t o en gin e, if
r em oved (F ig. 79). INSTALLATION
(2) In st a ll t h e in su la t or m ou n t a ssem bly (F ig. 79). (1) In st a ll left m ou n t on t r a n sa xle (F ig. 81).
(3) In st a ll t h e fr on t en gin e m ou n t t h r ou gh bolt t o (2) Ra ise t r a n sa xle wit h ja ck u n t il left m ou n t is in
t h e in su la t or (F ig. 79). posit ion .
(4) Lower t h e veh icle. (3) In st a ll left m ou n t t h r ou gh bolt (F ig. 80).
LEFT M OU N T (Cont inue d)
REAR M OU N T
REMOVAL
(2) Rem ove t h e r ea r m ou n t h ea t sh ield (F ig. 82).
Fig. 80 Left Mount To Bracket

1 - BOLT - BRACKET TO FRAME RAIL 68 N·m (50 ft. lbs.)
2 - BOLT - MOUNT TO RAIL THRU 75 N·m (55 ft. lbs.)
3 - BOLT - LEFT MOUNT TO TRANSAXLE 54 N·m (40 ft. lbs.) Fig. 82 Rear Mount Heat Shield
4 - TRANSAXLE
5 - MOUNT - LEFT 1 - BOLT - HEAT SHIELD 11 N·m (100 in. lbs.)
6 - BRACKET - LEFT MOUNT 2 - HEAT SHIELD
3 - CLIP
4 - REAR MOUNT
(3) Rem ove t h e t h r ou gh bolt fr om t h e m ou n t a n d

r ea r m ou n t br a cket (F ig. 83).
(4) Rem ove t h e m ou n t bolt s (F ig. 83).
(5) Rem ove t h e r ea r m ou n t (F ig. 83).
Fig. 81 Left Mount - 41TE Transaxle

1 - LEFT MOUNT ASSEMBLY
2 - BOLT - 54 N·m (40 ft. lbs.)
3 - TRANSAXLE - 41TE
(4) In st a ll left m ou n t t h r ou gh bolt a ccess cover.

(5) In st a ll fr on t m ou n t t h r ou gh bolt (F ig. 79). Fig. 83 Rear Mount
(6) In st a ll left fr on t wh eel.
1 - BOLT 54 N·m (40 ft. lbs.)
(7) Lower veh icle. 2 - REAR MOUNT BRACKET
3 - THRU-BOLT 54 N·m (40 ft. lbs.)
4 - REAR MOUNT
(6) F or r ea r m ou n t br a cket r em ova l, r em ove t h e

bolt s a t t a ch in g br a cket t o t r a n sa xle (F ig. 84).
(7) Rem ove r ea r m ou n t br a cket .
REAR M OU N T (Cont inue d)
Fig. 84 Rear Mount Bracket - (all engines)

1 - BOLT - VERTICAL 102 N·m (75 ft. lbs.) 3 - BOLT - HORIZONTAL 102 N·m (75 ft. lbs.)
2 - BRACKET - REAR MOUNT
INSTALLATION (6) Rem ove t h e ver t ica l bolt s a t t a ch in g t h e en gin e

(1) In st a ll r ea r m ou n t br a cket , if r em oved (F ig. m ou n t t o t h e fr a m e r a il (F ig. 85).
84). (7) Loosen t h e h or izon t a l bolt a t t a ch in g t h e en gin e
(2) In st a ll t h e r ea r m ou n t a n d bolt s (F ig. 83). m ou n t t o t h e fr a m e r a il (F ig. 85).
Tigh t en bolt s t o 54 N·m (40 ft . lbs.). (8) Rem ove t h e bolt s a t t a ch in g t h e en gin e m ou n t
(3) In st a ll t h e m ou n t t h r ou gh bolt t o t h e m ou n t t o t h e en gin e br a cket (F ig. 85).
a n d br a cket (F ig. 83). Tigh t en t h r ou gh bolt t o 54 N·m (9) Rem ove t h e r igh t en gin e m ou n t (F ig. 85).
(40 ft . lbs.).
(4) In st a ll t h e r ea r m ou n t h ea t sh ield (F ig. 82). INSTALLATION
(5) Lower veh icle on h oist . (1) P osit ion r igh t en gin e m ou n t a n d in st a ll fr a m e
r a il t o m ou n t ver t ica l bolt s (F ig. 85).
(2) Tigh t en en gin e r igh t m ou n t t o r a il h or izon t a l
RI GH T M OU N T bolt (F ig. 85).
(3) In st a ll m ou n t t o en gin e br a cket bolt s (F ig. 85).
REMOVAL (4) Con n ect elect r ica l h a r n ess su ppor t clips t o
(1) Rem ove a ir clea n er h ou sin g lid a n d clea n a ir en gin e m ou n t br a cket .
h ose fr om t h r ot t le body. (5) Rem ove ja ck fr om u n der en gin e.
(2) Rem ove a ir clea n er elem en t a n d h ou sin g. (6) Con n ect m a ke-u p a ir h ose t o cylin der h ea d
(3) Discon n ect m a ke-u p a ir h ose fr om cylin der cover.
h ea d cover. (7) In st a ll a ir clea n er h ou sin g a n d elem en t .
(4) Rem ove t h e loa d on t h e r igh t en gin e m ou n t by (8) In st a ll a ir clea n er h ou sin g lid a n d clea n a ir
ca r efu lly su ppor t in g t h e en gin e a ssem bly wit h a floor t u be t o t h r ot t le body.
ja ck.
(5) Discon n ect elect r ica l h a r n ess su ppor t clips fr om
en gin e m ou n t br a cket .
RI GH T M OU N T (Cont inue d)
sh a ft jou r n a ls a r e pa r t ia lly slot t ed t o a llow a pr ede-
t er m in ed a m ou n t of pr essu r ized oil t o pa ss in t o t h e
bea r in g ca p ca vit ies. Lu br ica t ion of t h e ca m sh a ft
lobes a r e pr ovided by sm a ll h oles in t h e ca m sh a ft
bea r in g ca ps t h a t a r e dir ect ed t owa r ds ea ch lobe. Oil
r et u r n in g t o t h e pa n fr om pr essu r ized com pon en t s
su pplies lu br ica t ion t o t h e va lve st em s. Cylin der
bor es a n d wr ist pin s a r e spla sh lu br ica t ed fr om
dir ect ed slot s on t h e con n ect in g r od t h r u st colla r s
(F ig. 86).
Fig. 85 Right Mount to Rail and Engine

1 - BOLT - MOUNT TO RAIL 68 N·m (50 ft. lbs.)
2 - BOLT - MOUNT TO ENGINE 54 N·m (40 ft. lbs.)
3 - BOLT - MOUNT TO RAIL (HORIZONTAL) 68 N·m (50 ft. lbs.)
4 - RIGHT ENGINE MOUNT
LU BRI CAT I ON
Fig. 86 Engine Lubrication System
DESCRIPTION
Th e lu br ica t ion syst em is a fu ll-flow filt r a t ion , DIAGNOSIS AND TESTING - CHECKING
pr essu r e feed t ype. Th e oil pu m p is m ou n t ed in t h e ENGINE OIL PRESSURE
fr on t en gin e cover a n d dr iven by t h e cr a n ksh a ft . (1) Discon n ect a n d r em ove oil pr essu r e swit ch .
(Refer t o 9 - E NGINE /LUBRICATION/OIL P RE S-
OPERATION SURE SE NSOR/SWITCH - RE MOVAL)
E n gin e oil dr a wn u p t h r ou gh t h e picku p t u be a n d (2) In st a ll Specia l Tools C-3292 Ga u ge wit h 8406
is pr essu r ized by t h e oil pu m p a n d r ou t ed t h r ou gh Ada pt or fit t in g.
t h e fu ll-flow filt er t o t h e m a in oil ga ller y r u n n in g t h e (3) St a r t en gin e a n d r ecor d oil pr essu r e. Refer t o
len gt h of t h e cylin der block. A dia gon a l h ole in ea ch Specifica t ion s for cor r ect oil pr essu r e r equ ir em en t s.
bu lkh ea d feeds oil t o ea ch m a in bea r in g. Dr illed pa s- (Refer t o 9 - E NGINE - SP E CIF ICATIONS)
sa ges wit h in t h e cr a n ksh a ft r ou t e oil fr om m a in bea r-
in g jou r n a ls t o con n ect in g r od jou r n a ls. Ba la n ce sh a ft CAUTION: If oil pressure is 0 at idle, do not perform
lu br ica t ion is pr ovided t h r ou gh a n oil pa ssa ge fr om the 3000 RPM test
t h e n u m ber on e m a in bea r in g ca p t h r ou gh t h e ba l-
(4) If oil pr essu r e is 0 a t idle. Sh u t off en gin e,
a n ce sh a ft ca r r ier su ppor t leg. Th is pa ssa ge dir ect ly
ch eck for pr essu r e r elief va lve st u ck open , a clogged
su pplies oil t o t h e fr on t bea r in gs a n d in t er n a l
oil pick-u p scr een or a da m a ged oil pick-u p t u be
m a ch in ed pa ssa ges in t h e sh a ft s t h a t r ou t es oil fr om
O-r in g.
fr on t t o t h e r ea r sh a ft bea r in g jou r n a ls. A ver t ica l
(5) Aft er t est is com plet e, r em ove t est ga u ge a n d
h ole a t t h e n u m ber five bu lkh ea d r ou t es pr essu r ized
fit t in g.
oil t h r ou gh a r est r ict or (in t egr a l t o t h e cylin der h ea d
ga sket ) u p pa st a cylin der h ea d bolt t o a n oil ga ller y
r u n n in g t h e len gt h of t h e cylin der h ea d. Th e ca m -
LU BRI CAT I ON (Cont inue d)
(6) In st a ll oil pr essu r e swit ch a n d con n ect or. (Refer (3) H oist a n d su ppor t veh icle on sa fet y st a n ds.
t o 9 - E NGINE /LUBRICATION/OIL P RE SSURE Refer t o H oist in g a n d J a ckin g Recom m en da t ion s.
SE NSOR/SWITCH - INSTALLATION) (Refer t o LUBRICATION & MAINTE NANCE /H OIST-
(4) P la ce a su it a ble dr a in pa n u n der cr a n kca se
OI L dr a in .
(5) Rem ove dr a in plu g fr om cr a n kca se a n d a llow
oil t o dr a in in t o pa n . In spect dr a in plu g t h r ea ds for
STAN DARD PROCEDU RE st r et ch in g or ot h er da m a ge. Repla ce dr a in plu g a n d
ga sket if da m a ged.
ENGINE OIL LEVEL CHECK (6) Rem ove oil filt er. (Refer t o 9 - E NGINE /LUBRI-
Th e best t im e t o ch eck en gin e oil level is a ft er it CATION/OIL F ILTE R - RE MOVAL)
h a s sa t over n igh t , or if t h e en gin e h a s been r u n n in g, (7) In st a ll a n d t igh t en dr a in plu g in cr a n kca se.
a llow t h e en gin e t o be sh u t off for a t lea st 5 m in u t es (8) In st a ll n ew oil filt er. (Refer t o 9 - E NGINE /LU-
befor e ch eckin g oil level. BRICATION/OIL F ILTE R - INSTALLATION)
Ch eckin g t h e oil wh ile t h e veh icle is on level (9) Lower veh icle a n d fill cr a n kca se wit h specified
gr ou n d will im pr ove t h e a ccu r a cy of t h e oil level t ype a n d a m ou n t of en gin e oil. (Refer t o LUBRICA-
r ea din g. Rem ove dipst ick a n d obser ve oil level. Add TION & MAINTE NANCE /F LUID TYP E S -
oil on ly wh en t h e level is a t or below t h e ADD m a r k DE SCRIP TION)
(F ig. 87). (10) In st a ll oil fill ca p.
(11) St a r t en gin e a n d in spect for lea ks.
(12) St op en gin e a n d in spect oil level.
NOTE: Care should be exercised when disposing

used engine oil after it has been drained from a
vehicle engine. Refer to the WARNING listed above.
Fig. 87 Oil Level
1 - ENGINE OIL LEVEL DIPSTICK OI L FI LT ER
STANDARD PROCEDURE - ENGINE OIL AND DESCRIPTION
FILTER CHANGE Th e en gin e oil filt er (F ig. 88) is a h igh qu a lit y fu ll-
Ch a n ge en gin e oil a t m ilea ge a n d t im e in t er va ls flow, disposa ble t ype. Repla ce t h e oil filt er wit h a
descr ibed in t h e Ma in t en a n ce Sch edu le. (Refer t o Mopa r ! or t h e equ iva len t .
LUBRICATION & MAINTE NANCE /MAINTE -
NANCE SCH E DULE S - DE SCRIP TION) REMOVAL
WARNING: NEW OR USED ENGINE OIL CAN BE (2) P osit ion a n oil collect in g con t a in er u n der oil fil-
IRRITATING TO THE SKIN. AVOID PROLONGED OR t er loca t ion .
REPEATED SKIN CONTACT WITH ENGINE OIL.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY CAUTION: When servicing the oil filter avoid
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO deforming the filter can by installing the remove/in-
YOUR HEALTH. THOROUGHLY WASH EXPOSED stall tool band strap against the can to base lock
SKIN WITH SOAP AND WATER. DO NOT WASH seam. The lock seam joining the can to the base is
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR reinforced by the base plate.
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO
NOT POLLUTE, DISPOSE OF USED ENGINE OIL (3) Usin g a su it a ble filt er wr en ch , t u r n oil filt er
PROPERLY. CONTACT YOUR DEALER OR GOVERN- (F ig. 88) cou n t er clockwise t o r em ove.
MENT AGENCY FOR LOCATION OF COLLECTION
CENTER IN YOUR AREA. INSTALLATION
(1) Clea n a n d ch eck filt er m ou n t in g su r fa ce. Th e
Ru n en gin e u n t il a ch ievin g n or m a l oper a t in g t em - su r fa ce m u st be sm oot h , fla t a n d fr ee of debr is or
per a t u r e. pieces of ga sket .
(1) P osit ion t h e veh icle on a level su r fa ce a n d t u r n (2) Lu br ica t e n ew oil filt er ga sket wit h clea n
en gin e off. en gin e oil.
(2) Rem ove oil fill ca p.
OI L FI LT ER (Cont inue d)
Fig. 89 Left Front Pry Point

1 - BED PLATE
2 - OIL PAN
3 - PRY POINT
Fig. 88 Oil Filter

(3) Scr ew oil filt er (F ig. 88) on u n t il t h e ga sket
con t a ct s ba se. Tigh t en t o 12 N·m (105 in . lbs.).
OI L PAN
REMOVAL
(1) Discon n ect n ega t ive ba t t er y ca ble.
(2) Ra ise veh icle on h oist a n d dr a in en gin e oil.
(3) Rem ove st r u ct u r a l colla r. (Refer t o 9 -
E NGINE /E NGINE BLOCK/STRUCTURAL COVE R -
RE MOVAL)
(4) Rem ove a ir con dit ion in g com pr essor br a cket t o
oil pa n bolt .
NOTE: The oil pan is sealed with rtv and may need
to be pryed apart. Fig. 90 Right Front Pry Point
1 - OIL FILTER ADAPTER
(5) Rem ove bolt s a t t a ch in g oil pa n . 2 - PRY POINT
(6) In ser t pr y ba r a t specified loca t ion s (F ig. 89) 3 - OIL PAN
(F ig. 90) (F ig. 91) a n d gen t ly pr y oil pa n a wa y fr om
t h e en gin e. INSTALLATION
(7) Clea n oil pa n a n d block su r fa ces.Clea n cu r ed
RTV fr om oil pa n a n d bed pla t e wit h a pla st ic or NOTE: You must assemble oil pan to bed plate
br a ss scr a per. before RTV “skins over”. If RTV skins before
(8) Clea n a ll sea lin g su r fa ces wit h MOPAR! Br a ke assembly, parts must be cleaned and a new bead of
P a r t s Clea n er. RTV applied.
(9) In spect su r fa ces for da m a ge, r epla ce a s n eeded.
OI L PAN (Cont inue d)
(5) In st a ll st r u ct u r a l colla r (Refer t o 9 - E NGINE /
E NGINE BLOCK/STRUCTURAL COVE R - INSTAL-
LATION).
(6) Lower veh icle a n d fill en gin e cr a n kca se wit h
pr oper oil t o cor r ect level.
(7) Con n ect n ega t ive ba t t er y ca ble.
(8) St a r t en gin e a n d ch eck for lea ks.
OI L PRESSU RE SWI T CH
REMOVAL
(2) P osit ion oil collect in g con t a in er u n der pr essu r e
swit ch loca t ion .
(3) Discon n ect oil pr essu r e swit ch elect r ica l con -
n ect or a n d r em ove swit ch (F ig. 93).
Fig. 91 Left Rear Pry Point

1 - PPRY POINT
2 - OIL PAN
3 - BED PLATE
Fig. 93 Engine Oil Pressure Switch

INSTALLATION
(1) In st a ll oil pr essu r e swit ch . Tor qu e swit ch t o 21
N·m (190 in . lbs.) (F ig. 93).
(2) Con n ect elect r ica l con n ect or
(3) Lower veh icle.
(4) St a r t en gin e a n d a llow t o r u n a m in im u m of 2
m in u t es.
(5) Sh u t en gin e off a n d ch eck en gin e oil level.
Fig. 92 Oil Pan Sealing
Adju st level a s n ecessa r y.
1 - 1 mm FROM CHAMFER
2 - RTV BEAD
(1) Apply 3 - 4 m m dia m et er bea d of MOPAR! OI L PU M P

E n gin e RTV a r ou n d t h e per im et er of t h e oil pa n
fla n ge, 1 m m a wa y fr om t h e ch a m fer on t h e in n er REMOVAL
edge of t h e oil pa n (F ig. 92). (1) Discon n ect n ega t ive ca ble fr om ba t t er y.
(2) P osit ion oil pa n on bedpla t e. (2) Rem ove t im in g belt (Refer t o 9 - E NGINE /
(3) In st a ll oil pa n a t t a t ch in g bolt s a n d t igh t en t o VALVE TIMING/TIMING BE LT AND SP ROCKE TS -
12 N·m (105 in . lbs.). RE MOVAL).
(4) In st a ll a ir con dit ion in g com pr essor br a cket t o (3) Rem ove t im in g belt r ea r cover (Refer t o 9 -
oil pa n bolt . E NGINE /VALVE TIMING/TIMING BE LT COVE R(S)
- RE MOVAL).
OI L PU M P (Cont inue d)
(5) Rem ove cr a n ksh a ft spr ocket u sin g Specia l
Tools 6793 a n d C-4685-C2 (F ig. 94).
(6) Rem ove cr a n ksh a ft key (F ig. 95).
Fig. 94 Crankshaft Sprocket - Removal

1 - SPECIAL TOOL 6793 Fig. 96 Oil Pump
2 - SPECIAL TOOL C-4685–C2 1 - BOLTS
3 - CRANKSHAFT SPROCKET 2 - BOLTS
3 - OIL PUMP
Fig. 95 Crankshaft Key

Fig. 97 Oil Pressure Relief Valve
1 - CRANKSHAFT KEY
1 - PLUG
2 - OIL PUMP BODY
(7) Rem ove oil pick-u p t u be. 3 - RELIEF VALVE
(8) Rem ove oil pu m p (F ig. 96) a n d fr on t cr a n ksh a ft 4 - SPRING
sea l. 5 - SEAL
DISASSEMBLY (4) Wa sh a ll pa r t s in a su it a ble solven t a n d

(1) To r em ove t h e r elief va lve, pr oceed a s follows: in spect ca r efu lly for da m a ge or wea r.
(a ) Rem ove t h e t h r ea ded plu g a n d ga sket fr om
t h e oil pu m p (F ig. 97). CLEANING
(b) Rem ove spr in g a n d r elief va lve (F ig. 97). (1) Clea n a ll pa r t s t h or ou gh ly in a su it a ble sol-
(2) Rem ove oil pu m p cover fa st en er s, a n d lift off ven t .
cover (F ig. 98).
(3) Rem ove pu m p r ot or s (F ig. 98).
Fig. 98 Oil Pump Fig. 99 Checking Oil Pump Cover Flatness

1 - O-RING 1 - STRAIGHT EDGE
2 - SEAL 2 - FEELER GAUGE
3 - INNER ROTOR 3 - OIL PUMP COVER
4 - OIL PUMP COVER
5 - FASTENER
6 - OUTER ROTOR
7 - OIL PUMP BODY
INSPECTION
(1) In spect t h e m a t in g su r fa ces of t h e oil pu m p
cover. Su r fa ce sh ou ld be sm oot h . Repla ce pu m p cover
if scr a t ch ed or gr ooved.
(2) La y a st r a igh t edge a cr oss t h e pu m p cover su r-
fa ce (F ig. 99). If a 0.025 m m (0.001 in .) feeler ga u ge
ca n be in ser t ed bet ween cover a n d st r a igh t edge,
cover sh ou ld be r epla ced.
(3) Mea su r e t h ickn ess a n d dia m et er of ou t er r ot or.
If ou t er r ot or t h ickn ess m ea su r es 9.40 m m (0.370 in .)
or less (F ig. 100), or if t h e dia m et er is 79.95 m m
(3.148 in .) or less, r epla ce ou t er r ot or.
(4) If in n er r ot or m ea su r es 9.40 m m (0.370 in .) or
Fig. 100 Measuring Outer Rotor Thickness
less r epla ce in n er r ot or (F ig. 101).
ASSEMBLY
(1) Assem ble pu m p, u sin g n ew pa r t s a s r equ ir ed.
In s ta ll th e in n e r ro to r w ith c h a m fe r fa c in g th e
c a s t iro n o il p u m p c o v e r.
(2) P r im e oil pu m p befor e in st a lla t ion by fillin g
r ot or ca vit y wit h en gin e oil.
(3) In st a ll cover a n d t igh t en fa st en er s t o 12 N·m
(105 in . lbs.) (F ig. 98).
CAUTION: Oil pump pressure relief valve must be

installed as shown in (Fig. 97) or serious engine
damage may occur.
(4) In st a ll r elief va lve, spr in g, ga sket a n d ca p a s

sh own in (F ig. 97). Tigh t en ca p t o 41 N·m (30 ft .
lbs.). Fig. 101 Measuring Inner Rotor Thickness
INSTALLATION
(1) Ma ke su r e a ll su r fa ces a r e clea n a n d fr ee of oil
a n d dir t .
(2) Apply Mopa r ! Ga sket Ma ker t o oil pu m p a s
sh own in (F ig. 102). In st a ll O-r in g in t o oil pu m p body
disch a r ge pa ssa ge.
Fig. 102 Oil Pump Sealing

1 - O-RING
2 - SEALER LOCATION
(3) P r im e oil pu m p wit h en gin e oil befor e in st a lla -

t ion .
(4) Align oil pu m p r ot or fla t s wit h fla t s on cr a n k- Fig. 103 Front Crankshaft Seal - Installation
sh a ft . In st a ll t h e oil pu m p t o t h e block (F ig. 96). 1 - PROTECTOR
2 - SEAL
CAUTION: To align, the front crankshaft seal MUST
be out of pump, or damage may result.
(5) In st a ll n ew fr on t cr a n ksh a ft sea l u sin g Specia l

Tool 6780 (F ig. 103).
(6) In st a ll cr a n ksh a ft key (F ig. 95).
CAUTION: The crankshaft sprocket is set to a pre-

determined depth from the factory for correct tim-
ing belt tracking. If removed, use of Special Tool
6792 is required to set the sprocket to original
installation depth. An incorrectly installed sprocket
will result in timing belt and engine damage.
(7) In st a ll cr a n ksh a ft spr ocket u sin g Specia l Tool

6792 (F ig. 104).
(8) In st a ll oil pu m p pick-u p t u be.
(9) In st a ll oil pa n (Refer t o 9 - E NGINE /LUBRI-
CATION/OIL PAN - INSTALLATION). Fig. 104 Crankshaft Sprocket - Installation
(10) In st a ll t im in g belt r ea r cover (Refer t o 9 - 1 - SPECIAL TOOL 6792
E NGINE /VALVE TIMING/TIMING BE LT COVE R(S) 2 - TIGHTEN NUT TO INSTALL
- INSTALLATION).
(11) In st a ll t im in g belt (Refer t o 9 - E NGINE /
INSTALLATION).
I N TAK E M AN I FOLD (2) Discon n ect con n ect or fr om in let a ir t em per a -

t u r e sen sor (F ig. 106).
DESCRIPTION
Th e in t a ke m a n ifold is a t wo piece a lu m in u m ca st -
in g (F ig. 105) t h a t a t t a ch es t o t h e cylin der h ea d wit h
fa st en er s. Th e m a n ifold is a lon g br a n ch design t o
en h a n ce low a n d m id-r a n ge t or qu e
Fig. 106 Inlet Air Temperature Sensor - 2.4L

(3) Discon n ect a ir in t a ke t u be a t t h r ot t le body a n d
r em ove u pper a ir clea n er h ou sin g.
(4) Discon n ect con n ect or fr om t h r ot t le posit ion
sen sor (TP S) (F ig. 108).
(5) Discon n ect con n ect or fr om idle a ir con t r ol (IAC)
m ot or (F ig. 108).
(6) Discon n ect con n ect or fr om MAP sen sor (F ig.
Fig. 105 Intake Manifold - Upper and Lower 107).
1 - UPPER INTAKE MANIFOLD
2 - LOWER INTAKE MANIFOLD
DIAGNOSIS AND TESTING - INTAKE

MANIFOLD LEAKS
An in t a ke m a n ifold a ir lea k is ch a r a ct er ized by
lower t h a n n or m a l m a n ifold va cu u m . Also, on e or
m or e cylin der s m a y n ot be fu n ct ion in g.
WARNING: USE EXTREME CAUTION WHEN THE

ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
(1) St a r t t h e en gin e.
(2) Spr a y a sm a ll st r ea m of wa t er (Spr a y Bot t le) a t
t h e su spect ed lea k a r ea .
(3) If en gin e RP M’S ch a n ge, t h e a r ea of t h e su s-
pect ed lea k h a s been fou n d. Fig. 107 Map Sensor - 2.4L
(4) Repa ir a s r equ ir ed.
1 - MAP SENSOR
(7) Rem ove va cu u m lin es for pu r ge solen oid a n d

I N TAK E M AN I FOLD - U PPER P CV va lve a t in t a ke m a n ifold.
(8) Rem ove va cu u m lin es for power br a ke boost er,
REMOVAL LDP, E GR t r a n sdu cer, a n d speed con t r ol va cu u m r es-
(1) Discon n ect n ega t ive ca ble fr om ba t t er y. er voir (if equ ipped) a t u pper in t a ke m a n ifold fit t in gs.
I N TAK E M AN I FOLD - U PPER (Cont inue d)
INSPECTION
(1) Ch eck m a n ifold su r fa ces for fla t n ess wit h
st r a igh t edge. Su r fa ce m u st be fla t wit h in 0.15 m m
per 300 m m (0.006 in . per foot ) of m a n ifold len gt h .
(2) In spect m a n ifold for cr a cks or dist or t ion .
Repla ce m a n ifold if n ecessa r y.
INSTALLATION
(1) Clea n m a n ifold sea lin g su r fa ces.
(2) Apply a 1.5 m m (0.060 in .) bea d Mopa r ! Ga s-
ket Ma ker t o t h e per im et er of t h e lower in t a ke m a n -
ifold r u n n er open in gs.
(3) In st a ll u pper in t a ke m a n ifold a n d t igh t en fa s-
t en er s t o 28 N·m (250 in . lbs.) in sequ en ce sh own in
(F ig. 110). Repea t t h is pr ocedu r es u n t il a ll fa st en er s
a r e a t specified t or qu e.
Fig. 108 Throttle Body Electrical Connectors -
Typical
1 - IDLE AIR CONTROL MOTOR CONNECTOR
2 - TPS CONNECTOR
(9) Discon n ect t h r ot t le a n d speed con t r ol (if

equ ipped) ca bles fr om t h r ot t le lever a n d br a cket .
(Refer t o 14 - F UE L SYSTE M/F UE L INJ E CTION/
TH ROTTLE CONTROL CABLE - RE MOVAL)
(10) Rem ove t h e E GR t u be. (Refer t o 25 - E MIS-
SIONS CONTROL/E XH AUST GAS RE CIRCULA-
TION/TUBE - RE MOVAL)
(11) Rem ove t h e u pper m a n ifold su ppor t br a cket
bolt t o m a n ifold (F ig. 109).
Fig. 110 Upper Intake Manifold Tightening Sequence
- 2.4L
(4) In st a ll en gin e oil dipst ick.
(5) In st a ll u pper bolt in in t a ke m a n ifold t o fr on t
su ppor t br a cket (F ig. 109). Tor qu e t o 28 N·m (250 in .
lbs.).
(6) In st a ll E GR t u be. (Refer t o 25 - E MISSIONS
CONTROL/E XH AUST GAS RE CIRCULATION/
TUBE - INSTALLATION)
(7) In st a ll t h r ot t le ca bles in br a cket .
(8) Con n ect t h r ot t le a n d speed con t r ol (if equ ipped)
ca bles t o t h r ot t le lever.
(9) Con n ect va cu u m lin es for power br a ke boost er,
LDP, E GR t r a n sdu cer, a n d speed con t r ol va cu u m r es-
er voir (if equ ipped) a t u pper in t a ke m a n ifold fit t in gs.
(10) Con n ect va cu u m lin es for pu r ge solen oid a n d
Fig. 109 Upper Intake Manifold Support Bracket P CV va lve.
1 - NUT - BRACKET TO CYLINDER HEAD COVER (11) Con n ect elect r ica l con n ect or s for MAP sen sor,
2 - BOLT - BRACKET TO UPPER INTAKE MANIFOLD t h r ot t le posit ion sen sor (TP S), a n d idle a ir con t r ol
3 - UPPER INTAKE MANIFOLD SUPPORT BRACKET
(IAC) m ot or.
(12) In st a ll a ir clea n er u pper h ou sin g a n d a ir
(12) Rem ove en gin e oil dipst ick fr om t u be.
in t a ke t u be t o t h r ot t le body.
(13) Rem ove u pper in t a ke m a n ifold bolt s (F ig.
(13) Con n ect in let a ir t em per a t u r e sen sor con n ec-
110). Rem ove u pper in t a ke m a n ifold.
t or (F ig. 106).
CAUTION: Cover intake manifold to prevent foreign (14) Con n ect n ega t ive ca ble t o ba t t er y.
material from entering engine.
I N TAK E M AN I FOLD - LOWER (12) In spect t h e m a n ifold. (Refer t o 9 - E NGINE /

MANIF OLDS/INTAKE MANIF OLD - INSP E CTION)
REMOVAL
(1) P er for m fu el syst em pr essu r e r elea se pr oce-
INSPECTION
(1) Ch eck m a n ifold su r fa ces for fla t n ess wit h
du r e be fo re a tte m p tin g a n y re p a irs . (Refer t o 14 -
st r a igh t edge. Su r fa ce m u st be fla t wit h in 0.15 m m
F UE L SYSTE M/F UE L DE LIVE RY - STANDARD
per 300 m m (0.006 in . per foot ) of m a n ifold len gt h .
P ROCE DURE )
(2) In spect m a n ifold for cr a cks or dist or t ion .
(2) Rem ove u pper in t a ke m a n ifold. (Refer t o 9 -
Repla ce m a n ifold if n ecessa r y.
RE MOVAL)
INSTALLATION
CAUTION: Cover intake manifold openings to pre- If t h e followin g it em s wer e r em oved, in st a ll a n d
vent foreign material from entering engine. t or qu e t o specifica t ion s:
• F u el r a il bolt s - 22 N·m (200 in . lbs.)
(3) Discon n ect fu el lin e. (Refer t o 14 - F UE L SYS- • Coola n t ou t let con n ect or bolt s - 28 N·m (250 in .
TE M/F UE L DE LIVE RY/QUICK CONNE CT F IT- lbs.)
TING - STANDARD P ROCE DURE ) • Coola n t t em per a t u r e sen sor - 7 N·m (60 in . lbs.)
(4) Dr a in t h e coolin g syst em . (Refer t o 7 - COOL- (1) P osit ion a n ew ga sket on cylin der h ea d a n d
ING - STANDARD P ROCE DURE ) in st a ll lower m a n ifold.
(5) Rem ove h ea t er su pply a n d r a dia t or u pper (2) In st a ll a n d t igh t en in t a ke m a n ifold fa st en er s t o
h oses a t in t a ke m a n ifold. 28 N·m (250 in . lbs.) in t h e sequ en ce sh own in (F ig.
(6) Discon n ect coola n t t em per a t u r e sen sor /fu el 112). Repea t pr ocedu r e u n t il a ll bolt s a r e a t specified
in ject or wir e h a r n ess con n ect or. t or qu e.
(7) Rem ove lower in t a ke m a n ifold su ppor t br a cket
u pper bolt s (F ig. 111).
(8) Loosen t h e lower in t a ke m a n fold su ppor t
br a cket lower bolt (F ig. 111).
Fig. 112 Lower Intake Manifold Tightening Sequence

(3) In st a ll lower in t a ke m a n ifold su ppor t br a cket
bolt s (F ig. 111) a n d t igh t en t o:
• Bolt s t o in t a ke 28 N·m (250 in . lbs.)
• Bolt t o en gin e block 54 N·m (40 ft . lbs.)
Fig. 111 Lower Intake Manifold Support Bracket (4) P osit ion power st eer in g r eser voir on m a n ifold
1 - SUPPORT BRACKET a n d in st a ll bolt s.
2 - BOLTS - UPPER TO MANIFOLD (5) Con n ect t h e fu el lin e. (Refer t o 14 - F UE L SYS-
3 - BOLT - LOWER TO ENGINE BLOCK TE M/F UE L DE LIVE RY/QUICK CONNE CT F IT-
TING - STANDARD P ROCE DURE )
(9) Discon n ect fu el in ject or h a r n ess. (6) Con n ect coola n t t em per a t u r e sen sor /fu el in jec-
(10) Rem ove t h e bolt s a t t a ch in g t h e power st eer in g t or wir in g h a r n ess elect r ica l con n ect or.
r eser voir t o m a n ifold. Set r eser voir a side. D o n o t (7) In st a ll t h e r a dia t or u pper a n d h ea t er su pply
discon n ect lin e fr om r eser voir. h oses.
(11) Rem ove lower in t a ke m a n ifold fa st en er s (F ig.
112). Rem ove t h e m a n ifold fr om en gin e.
I N TAK E M AN I FOLD - LOWER (Cont inue d)
(8) In st a ll t h e u pper in t a ke m a n ifold. (Refer t o 9 -
INSTALLATION)
EX H AU ST M AN I FOLD
REMOVAL
(1) Ra ise veh icle a n d discon n ect exh a u st pipe fr om
t h e exh a u st m a n ifold.
(2) Discon n ect u pst r ea m oxygen sen sor con n ect or
a t t h e r ea r of exh a u st m a n ifold.
(3) Rem ove t h e bolt s a t t a ch in g t h e m a n ifold t o t h e
cylin der h ea d.
(4) Rem ove exh a u st m a n ifold.
(5) In spect t h e m a n ifold. (Refer t o 9 - E NGINE /
MANIF OLDS/E XH AUST MANIF OLD - INSP E C-
Fig. 113 Exhaust Manifold Tightening Sequence
TION)
(2) Rem ove gen er a t or dr ive belt t en sion er a ssem -
CLEANING bly (Refer t o 7 - COOLING/ACCE SSORY DRIVE /
(1) Disca r d ga sket (if equ ipped) a n d clea n a ll su r- BE LT TE NSIONE RS - RE MOVAL).
fa ces of m a n ifold a n d cylin der h ea d. (3) Rem ove t im in g belt fr on t cover bolt s (F ig. 114)
a n d r em ove cover s.
INSPECTION
(1) In spect m a n ifold ga sket su r fa ces for fla t n ess
wit h st r a igh t edge. Su r fa ce m u st be fla t wit h in 0.15
m m per 300 m m (0.006 in . per foot ) of m a n ifold
len gt h .
(2) In spect m a n ifolds for cr a cks or dist or t ion .
Repla ce m a n ifold a s n ecessa r y.
INSTALLATION
(1) In st a ll exh a u st m a n ifold wit h a n ew ga sket .
Tigh t en a t t a ch in g n u t s in t h e sequ en ce sh own in
(F ig. 113) t o 19 N·m (170 in . lbs.).
(2) At t a ch exh a u st pipe t o exh a u st m a n ifold a n d
t igh t en fa st en er s t o 37 N·m (27 ft . lbs.).
(3) In st a ll a n d con n ect t h e oxygen sen sor. (Refer t o
14 - F UE L SYSTE M/F UE L INJ E CTION/O2 SE NSOR
- COMP ONE NT LOCATION)
T I M I N G BELT COV ER(S)

REMOVAL
FRONT COVER - UPPER
(1) Rem ove u pper t im in g belt cover fa st en er s (F ig.
114) a n d r em ove cover.
FRONT COVER - LOWER

(1) Rem ove cr a n ksh a ft vibr a t ion da m per (Refer t o Fig. 114 Front Timing Belt Covers
9 - E NGINE /E NGINE BLOCK/VIBRATION 1 - BOLTS - UPPER FRONT COVER 6 N·m (50 in. lbs.)
DAMP E R - RE MOVAL). 2 - BOLTS - LOWER FRONT COVER 6 N·m (50 in. lbs.)
T I M I N G BELT COV ER(S) (Cont inue d)
REAR COVER
(1) Rem ove fr on t cover s.
(2) Rem ove en gin e m ou n t br a cket (F ig. 115).
Fig. 116 Camshaft Sprocket - Removal/Installation

Fig. 115 Engine Mount Bracket

1 - ENGINE MOUNT BRACKET
2 - BOLTS - 61 N·m (45 ft. lbs.)

RE MOVAL).
(4) Rem ove ca m sh a ft spr ocket s. H old ca m sh a ft
spr ocket wit h Specia l Tool 6847 wh ile r em ovin g cen -
t er bolt (F ig. 116).
(5) Rem ove t im in g belt idler pu lley (F ig. 117).
(6) Rem ove r ea r cover fa st en er s a n d r em ove cover
fr om en gin e (F ig. 118).
Fig. 117 Timing Belt Idler Pulley
1 - IDLER PULLEY
INSTALLATION 2 - BOLT
FRONT COVER - UPPER (2) In st a ll gen er a t or dr ive belt t en sion er (Refer t o

(1) In st a ll t im in g belt cover. Tor qu e fa st en er s t o 6 7 - COOLING/ACCE SSORY DRIVE /BE LT TE N-
N·m (50 in . lbs.) (F ig. 114). SIONE RS - INSTALLATION).
(3) In st a ll cr a n ksh a ft vibr a t ion da m per (Refer t o 9
FRONT COVER - LOWER - E NGINE /E NGINE BLOCK/VIBRATION DAMP E R -
(1) In st a ll t im in g belt fr on t cover s (F ig. 114). INSTALLATION).
Tigh t en fa st en er s t o 6 N·m (50 in . lbs.).
T I M I N G BELT COV ER(S) (Cont inue d)
T I M I N G BELT AN D
SPROCK ET (S)
REM OVAL
REMOVAL - TIMING BELT
(1) Rem ove a ir clea n er u pper cover, h ou sin g, a n d
clea n a ir t u be.
(2) Rem ove m a ke-u p a ir h ose fr om cylin der h ea d
cover.
(4) Rem ove r igh t fr on t wh eel.
(5) Rem ove r igh t in n er spla sh sh ield.
(6) Rem ove a ccessor y dr ive belt s (Refer t o 7 -
RE MOVAL).
(7) Rem ove cr a n ksh a ft vibr a t ion da m per (Refer t o
9 - E NGINE /E NGINE BLOCK/VIBRATION
DAMP E R - RE MOVAL).
(8) Rem ove a ir con dit ion er /gen er a t or belt t en sion er
a n d pu lley a ssem bly (Refer t o 7 - COOLING/ACCE S-
SORY DRIVE /BE LT TE NSIONE RS - RE MOVAL).
(9) Rem ove t im in g belt lower fr on t cover bolt s a n d
Fig. 118 Rear Timing Belt Cover Fasteners r em ove cover (Refer t o 9 - E NGINE /VALVE TIMING/
TIMING BE LT COVE R(S) - RE MOVAL).
1 - M6 BOLTS - 12 N·m (105 in. lbs.)
2 - M8 BOLTS - 28 N·m (250 in. lbs.) (10) Lower veh icle.
3 - TIMING BELT TENSIONER (11) Rem ove bolt s a t t a ch in g t im in g belt u pper
fr on t cover a n d r em ove cover (Refer t o 9 - E NGINE /
REAR COVER VALVE TIMING/TIMING BE LT COVE R(S) -
(1) In st a ll r ea r t im in g belt cover a n d fa st en er s. RE MOVAL).
Tor qu e fa st en er s t o specified va lu es (F ig. 118). (12) Rem ove r igh t en gin e m ou n t (Refer t o 9 -
E NGINE /E NGINE MOUNTING/RIGH T MOUNT -
CAUTION: Do not use an impact wrench for tighten- RE MOVAL).
ing camshaft sprocket bolt. Damage to the timing (13) Rem ove en gin e m ou n t br a cket (F ig. 119).
locating pin can occur. Hand tighten using a
wrench ONLY. CAUTION: When aligning crankshaft and camshaft
timing marks always rotate engine from crankshaft.
(2) In st a ll ca m sh a ft spr ocket s. H old spr ocket s wit h Camshaft should not be rotated after timing belt is
Specia l Tool 6848 a n d t igh t en cen t er bolt t o 101 N·m removed. Damage to valve components may occur.
(75 ft . lbs.) (F ig. 116). Always align timing marks before removing timing
(3) In st a ll t im in g belt idler pu lley a n d t igh t en belt.
m ou n t in g bolt t o 61 N·m (45 ft . lbs.) (F ig. 117).
(4) In st a ll t im in g belt (Refer t o 9 - E NGINE / (14) Befor e t h e r em ova l of t h e t im in g belt , r ot a t e
VALVE TIMING/TIMING BE LT AND SP ROCKE TS - cr a n ksh a ft u n t il t h e TDC m a r k on oil pu m p h ou sin g
INSTALLATION). a lign s wit h t h e TDC m a r k on cr a n ksh a ft spr ocket
(5) In st a ll en gin e m ou n t br a cket a n d t igh t en bolt s (t r a ilin g edge of spr ocket t oot h ) (F ig. 120).
t o 61 N·m (45 ft . lbs.) (F ig. 115).
(6) In st a ll fr on t cover s. NOTE: The crankshaft sprocket TDC mark is
located on the trailing edge of the sprocket tooth.
Failure to align trailing edge of sprocket tooth to
TDC mark on oil pump housing will cause the cam-
shaft timing marks to be misaligned.
(15) Loosen t im in g belt t en sion er lock bolt (F ig.

121).
T I M I N G BELT AN D SPROCK ET (S) (Cont inue d)
Fig. 120 Crankshaft and Camshaft Timing

1 - CAMSHAFT TIMING MARKS
2 - CRANKSHAFT TDC MARKS
Fig. 119 Engine Mount Bracket 3 - TRAILING EDGE OF SPROCKET TOOTH
2 - BOLTS - 61 N·m (45 ft. lbs.)
(16) In ser t a 6 m m Allen wr en ch in t o t h e h exa gon

open in g loca t ed on t h e t op pla t e of t h e belt t en sion er
pu lley (F ig. 121). Rot a t e t h e t op pla t e CLOCKWIS E
u n t il t h er e is en ou gh sla ck in t im in g belt t o a llow for
r em ova l.
(17) Rem ove t im in g belt .
CAUTION: If timing belt was damaged due to incor-

rect tracking (alignment), the belt tensioner pulley
and bracket must be replaced as an assembly
(Refer to 9 - ENGINE/VALVE TIMING/TIMING BELT
TENSIONER & PULLEY - REMOVAL).
REMOVAL - CAMSHAFT SPROCKETS

VALVE TIMING/TIMING BE LT AND SP ROCKE TS - Fig. 121 Timing Belt Tensioner
RE MOVAL).
1 - LOCK BOLT
(3) H old ca m sh a ft spr ocket s wit h Specia l Tool 6847 2 - TOP PLATE
wh ile r em ovin g cen t er bolt s (F ig. 122).
REMOVAL - CRANKSHAFT SPROCKET VALVE TIMING/TIMING BE LT AND SP ROCKE TS -
(1) Discon n ect n ega t ive ba t t er y ca ble. RE MOVAL).
6792 is required to set the sprocket to original
installation depth. An incorrectly installed sprocket
will result in timing belt and engine damage.
(1) In st a ll cr a n ksh a ft spr ocket u sin g Specia l Tool
6792 (F ig. 124).
Fig. 122 Camshaft Sprocket - Removal/Installation

(3) Rem ove cr a n ksh a ft spr ocket u sin g Specia l Fig. 124 Crankshaft Sprocket - Installation
Tools 6793 a n d in ser t C-4685-C2 (F ig. 123). 1 - SPECIAL TOOL 6792
2 - TIGHTEN NUT TO INSTALL
(2) In st a ll t im in g belt . (Refer t o 9 - E NGINE /

VALVE TIMING/TIMING BE LT/CH AIN AND
SP ROCKE TS - INSTALLATION)
INSTALLATION - CAMSHAFT SPROCKETS

(1) In st a ll ca m sh a ft spr ocket s. H old ca m sh a ft
spr ocket s wit h Specia l Tool 6847 wh ile t igh t en in g
cen t er bolt s t o 115 N·m (85 ft . lbs.) (F ig. 122).
(2) In st a ll t im in g belt (Refer t o 9 - E NGINE /
INSTALLATION).
(3) Con n ect n ega t ive ba t t er y ca ble.
Fig. 123 Crankshaft Sprocket - Removal
1 - SPECIAL TOOL 6793 INSTALLATION - TIMING BELT
2 - SPECIAL TOOL C-4685–C2 (1) Set cr a n ksh a ft spr ocket t o TDC by a lign in g t h e
3 - CRANKSHAFT SPROCKET
spr ocket wit h t h e a r r ow on t h e oil pu m p h ou sin g.
(2) Set ca m sh a ft s t im in g m a r ks so t h a t t h e
CLEANING exh a u st ca m sh a ft spr ocket is a 1/2 n ot ch below t h e
Do Not a t t em pt t o clea n a t im in g belt . If con t a m i-
in t a ke ca m sh a ft spr ocket (F ig. 125).
n a t ion fr om oil, gr ea se, or coola n t s h a ve occu r r ed, t h e
t im in g belt sh ou ld be r epla ced. CAUTION: Ensure that the arrows on both camshaft
Clea n a ll spr ocket s u sin g a su it a ble solven t . Clea n sprockets are facing up.
a ll spr ocket gr ooves of a n y debr is.
(3) In st a ll t im in g belt . St a r t in g a t t h e cr a n ksh a ft ,
go a r ou n d t h e wa t er pu m p spr ocket , idler pu lley,
I N STALLAT I ON ca m sh a ft spr ocket s a n d t h en a r ou n d t h e t en sion er
(F ig. 126).
INSTALLATION - CRANKSHAFT SPROCKET (4) Move t h e exh a u st ca m sh a ft spr ocket cou n t er-
clockwise (F ig. 126) t o a lign m a r ks a n d t a ke u p belt
CAUTION: The crankshaft sprocket is set to a pre-
sla ck.
determined depth from the factory for correct tim-
ing belt tracking. If removed, use of Special Tool
(5) In ser t a 6 m m Allen wr en ch in t o t h e h exa gon
open in g loca t ed on t h e t op pla t e of t h e belt t en sion er
pu lley. Rot a t e t h e t op pla t e COU N TERCLOCK-
WIS E. Th e t en sion er pu lley will m ove a ga in st t h e
belt a n d t h e t en sion er set t in g n ot ch will even t u a lly
st a r t t o m ove clockwise. Wa t ch in g t h e m ovem en t of
t h e set t in g n ot ch , con t in u e r ot a t in g t h e t op pla t e
cou n t er clockwise u n t il t h e set t in g n ot ch is a lign ed
wit h t h e spr in g t a n g (F ig. 127). Usin g t h e a llen
wr en ch t o pr even t t h e t op pla t e fr om m ovin g, t or qu e
t h e t en sion er lock bolt t o 25 N·m (220 in . lbs.). Set -
t in g n ot ch a n d spr in g t a n g sh ou ld r em a in a lign ed
a ft er lock n u t is t or qu ed.
(6) Rem ove a llen wr en ch a n d t or qu e wr en ch .
Fig. 125 Camshaft Sprocket Alignment

1 - CAMSHAFT SPROCKET-EXHAUST
2 - CAMSHAFT SPROCKET-INTAKE
3 - 1/2 NOTCH LOCATION
Fig. 127 Timing Belt Tension Adjustment

1 - ALIGN SETTING NOTCH WITH SPRING TANG
2 - TOP PLATE
3 - 6mm ALLEN WRENCH
4 - LOCK BOLT
5 - SETTING NOTCH
6 - SPRING TANG
NOTE: Repositioning the crankshaft to the TDC

position must be done only during the CLOCKWISE
rotation movement. If TDC is missed, rotate a fur-
ther two revolutions until TDC is achieved. DO NOT
rotate crankshaft counterclockwise as this will
make verification of proper tensioner setting impos-
sible.
Fig. 126 Timing Belt Installation
1 - CAMSHAFT TIMING MARKS 1/2 NOTCH LOCATION
2 - CRANKSHAFT AT TDC
3 - INSTALL BELT IN THIS DIRECTION
4 - ROTATE CAMSHAFT SPROCKET TO TAKE UP BELT SLACK
(7) Rot a t e t h e cr a n ksh a ft CLOCKWISE t wo com -
plet e r evolu t ion s m a n u a lly for sea t in g of t h e belt ,
u n t il t h e cr a n ksh a ft is r eposit ion ed a t t h e TDC posi-
t ion . Ver ify t h a t t h e ca m sh a ft a n d cr a n ksh a ft t im in g
m a r ks a r e in pr oper posit ion (F ig. 128).
Fig. 129 Timing Belt Tension Verification

1 - SPRING TANG
2 - TOLERANCE WINDOW
(14) In st a ll a ccessor y dr ive belt s (Refer t o 7 -

INSTALLATION).
(15) In st a ll dr ive belt spla sh sh ield.
(16) In st a ll r igh t fr on t wh eel.
Fig. 128 Crankshaft and Camshaft Timing (17) Con n ect m a ke-u p a ir h ose t o cylin der h ea d
1 - CAMSHAFT TIMING MARKS cover.
2 - CRANKSHAFT TDC MARKS (18) In st a ll a ir clea n er h ou sin g, u pper cover, a n d
3 - TRAILING EDGE OF SPROCKET TOOTH
clea n a ir t u be.
(8) Ch eck if t h e spr in g t a n g is wit h in t h e t oler a n ce
win dow (F ig. 129). If t h e spr in g t a n g is wit h in t h e
t oler a n ce win dow, t h e in st a lla t ion pr ocess is com plet e
T I M I N G BELT T EN SI ON ER &
a n d n ot h in g fu r t h er is r equ ir ed. If t h e spr in g t a n g is PU LLEY
n ot wit h in t h e t oler a n ce win dow, r epea t St eps 5
t h r ou gh 7. REMOVAL
(9) In st a ll en gin e m ou n t br a cket t o en gin e (F ig. (1) Rem ove t h e t im in g belt (Refer t o 9 - E NGINE /
119). VALVE TIMING/TIMING BE LT AND SP ROCKE TS -
(10) In st a ll t im in g belt fr on t cover s a n d bolt s RE MOVAL).
(Refer t o 9 - E NGINE /VALVE TIMING/TIMING (2) Rem ove t im in g belt idler pu lley (F ig. 130).
BE LT COVE R(S) - INSTALLATION). (3) H old ca m sh a ft spr ocket wit h Specia l Tool 6847
(11) In st a ll a ir con dit ion in g/gen er a t or belt t en - wh ile r em ovin g bolt (F ig. 131). Rem ove bot h ca m
sion er a n d pu lley (Refer t o 7 - COOLING/ACCE S- spr ocket s.
SORY DRIVE /BE LT TE NSIONE RS - (4) Rem ove r ea r t im in g belt cover fa st en er s a n d
INSTALLATION). r em ove cover fr om en gin e (F ig. 132).
(12) In st a ll r igh t en gin e m ou n t (Refer t o 9 - (5) Rem ove lower bolt a t t a ch in g t im in g belt t en -
E NGINE /E NGINE MOUNTING/RIGH T MOUNT - sion er a ssem bly t o en gin e a n d r em ove t en sion er a s
INSTALLATION). a n a s s e m bly (F ig. 133).
(13) In st a ll cr a n ksh a ft vibr a t ion da m per (Refer t o
9 - E NGINE /E NGINE BLOCK/VIBRATION
DAMP E R - INSTALLATION).
T I M I N G BELT T EN SI ON ER & PU LLEY (Cont inue d)
Fig. 130 Timing Belt Idler Pulley

1 - IDLER PULLEY
2 - BOLT
Fig. 132 Rear Timing Belt Cover Fasteners
1 - M6 BOLTS - 12 N·m (105 in. lbs.)
2 - M8 BOLTS - 28 N·m (250 in. lbs.)
3 - TIMING BELT TENSIONER
INSTALLATION
(1) Align t im in g belt t en sion er a ssem bly t o en gin e
a n d in st a ll lower m ou n t in g bolt bu t d o n o t tig h te n
(F ig. 133). To pr oper ly a lign t en sion er a ssem bly—in -
st a ll on e of t h e en gin e br a cket m ou n t in g bolt s (M10)
5 t o 7 t u r n s in t o t h e t en sion er ’s u pper m ou n t in g loca -
t ion (F ig. 133).
(2) Tor qu e t h e t en sion er ’s lower m ou n t in g bolt t o
61 N·m (45 ft . lbs.). Rem ove t h e u pper bolt u sed for
t en sion er a lign m en t .
(3) In st a ll r ea r t im in g belt cover a n d fa st en er s.
Tor qu e fa st en er s t o va lu es specified in (F ig. 132).
(4) In st a ll t im in g belt idler pu lley a n d t or qu e
m ou n t in g bolt t o 61 N·m (45 ft . lbs.) (F ig. 130).
(5) In st a ll ca m sh a ft spr ocket s. Use Specia l Tool
Fig. 131 Camshaft Sprocket - Removal/Installation 6847 t o h old spr ocket s (F ig. 131), t or qu e bolt s t o 101
1 - SPECIAL TOOL 6847 N·m (75 ft . lbs.).
(6) In st a ll t h e t im in g belt (Refer t o 9 - E NGINE /
INSTALLATION).
T I M I N G BELT T EN SI ON ER & PU LLEY (Cont inue d)
REMOVAL
BALANCE SHAFTS/CHAIN/SPROCKETS
NOTE: For service procedures requiring only tem-
porary relocation of carrier assembly refer to BAL-
ANCE SHAFT CARRIER procedure below.
(1) Dr a in en gin e oil.

(2) Rem ove t h e oil pa n a n d pick-u p t u be (Refer t o
9 - E NGINE /LUBRICATION/OIL PAN - RE MOVAL).
(3) If r epla cin g cr a n ksh a ft spr ocket , r em ove oil
pu m p (Refer t o 9 - E NGINE /LUBRICATION/OIL
P UMP - RE MOVAL).
(4) Rem ove ch a in cover, gu ide a n d t en sion er. Dis-
ca r d pivot scr ew a n d a dju st er scr ew. (F ig. 135).
(5) Rem ove scr ew r et a in in g ba la n ce sh a ft dr ive
spr ocket (F ig. 136). Rem ove ch a in a n d spr ocket .
(6) Usin g t wo wide pr y ba r s, wor k t h e cr a n ksh a ft
spr ocket ba ck a n d for t h u n t il it is off t h e cr a n ksh a ft -
sh a ft .
(7) Rem ove gea r cover r et a in in g st u d (dou ble
en ded t o a lso r et a in ch a in gu ide). Rem ove cover a n d
ba la n ce sh a ft gea r s (F ig. 137).
(8) Rem ove r ea r cover a n d ba la n ce sh a ft s (F ig.
Fig. 133 Timing Belt Tensioner/Bracket Assembly 138).
1 - BOLT (9) Rem ove fou r ca r r ier t o cr a n kca se a t t a ch in g
2 - TENSIONER ASSEMBLY bolt s t o sepa r a t e ca r r ier fr om en gin e bedpla t e.
3 - BOLT-INSTALL FOR PROPER ALIGNMENT
BALANCE SHAFT CARRIER
BALAN CE SH AFT S AN D Th e followin g com pon en t s will r em a in in t a ct du r-
CARRI ER ASSEM BLY in g ca r r ier r em ova l: Gea r cover, gea r s, ba la n ce sh a ft s
a n d t h e r ea r cover (F ig. 134).
DESCRIPTION (2) Rem ove t h e oil pa n a n d pick-u p t u be (Refer t o
Th e 2.4L en gin e is equ ipped wit h t wo n odu la r ca st
9 - E NGINE /LUBRICATION/OIL PAN - RE MOVAL).
ir on ba la n ce sh a ft s in st a lled in a ca st a lu m in u m ca r-
(3) Rem ove ch a in cover, gu ide a n d t en sion er (F ig.
r ier a t t a ch ed t o t h e lower cylin der block (F ig. 134).
135).
(4) Rem ove scr ew r et a in in g ba la n ce sh a ft dr ive
OPERATION spr ocket (F ig. 136).
Th e ba la n ce sh a ft s a r e dr iven by t h e cr a n ksh a ft (5) Move ba la n ce sh a ft in boa r d t h r ou gh dr ive
via a r oller ch a in a n d spr ocket s. Th e ba la n ce sh a ft s ch a in spr ocket . Spr ocket will h a n g in lower ch a in
a r e con n ect ed by h elica l gea r s. Th e du a l cou n t er loop.
r ot a t in g sh a ft s decr ea se secon d or der ver t ica l sh a k- (6) Rem ove ca r r ier t o cr a n kca se a t t a ch in g bolt s t o
in g for ces ca u sed by com pon en t m ovem en t . r em ove ca r r ier.
BALAN CE SH AFT S AN D CARRI ER ASSEM BLY (Cont inue d)
Fig. 134 Balance Shafts and Carrier Assembly

1 - SPROCKET 7 - GEARS
2 - TENSIONER 8 - GEAR COVER
3 - PLUG 9 - CHAIN COVER
4 - CARRIER 10 - SPROCKET
5 - REAR COVER 11 - GUIDE
6 - BALANCE SHAFTS 12 - CHAIN
Fig. 135 Chain Cover, Guide and Tensioner

1 - STUD Fig. 136 Drive Chain and Sprockets
2 - TENSIONER (ADJUSTER)
3 - GEAR COVER 1 - NICKEL PLATED LINK AND MARK
4 - ADJUSTER SCREW 2 - GEAR/SPROCKET SCREWS
5 - SHOULDERED PIVOT SCREW 3 - NICKEL PLATED LINK AND DOT
6 - CHAIN COVER (CUTAWAY)
7 - GUIDE
INSTALLATION
BALANCE SHAFT INSTALLATION/TIMING
Ba la n ce sh a ft a n d ca r r ier a ssem bly in st a lla t ion is
t h e r ever se of t h e r em ova l pr ocedu r e. D u rin g in s ta l-
la tio n c ra n k s h a ft-to -ba la n c e s h a ft tim in g m u s t
be e s ta blis h e d . Re fe r to Tim in g p ro c e d u re in
th is s e c tio n .
(1) Wit h ba la n ce sh a ft s in st a lled in ca r r ier (F ig.
134) posit ion ca r r ier on cr a n kca se a n d in st a ll fou r
a t t a ch in g bolt s a n d t igh t en t o 54 N·m (40 ft . lbs.).
(2) Tu r n ba la n ce sh a ft s u n t il bot h sh a ft key wa ys
a r e u p, pa r a llel t o ver t ica l cen t er lin e of en gin e.
In st a ll sh or t h u b dr ive gea r on spr ocket dr iven sh a ft
a n d lon g h u b gea r on gea r dr iven sh a ft . Aft er in st a l-
la t ion gea r a n d ba la n ce sh a ft keywa ys m u st be u p
Fig. 137 Gear Cover and Gears wit h gea r t im in g m a r ks m esh ed a s sh own in (F ig.
1 - STUD (DOUBLE ENDED) 139).
2 - DRIVE GEAR
3 - DRIVEN GEAR
4 - CARRIER DOWEL
5 - GEAR(S)
6 - GEAR COVER
Fig. 139 Gear Timing

1 - KEY WAYS UP
2 - GEAR ALIGNMENT DOTS
(3) In st a ll gea r cover a n d t igh t en dou ble en ded

st u d/wa sh er fa st en er t o 12 N·m (105 in . lbs.).
(4) Align fla t on ba la n ce sh a ft dr ive spr ocket t o t h e
fla t on cr a n ksh a ft (F ig. 140).
(5) In st a ll ba la n ce sh a ft dr ive spr ocket on cr a n k-
sh a ft u sin g Specia l Tool 6052 (F ig. 141).
Fig. 138 Balance Shaft - Removal/Installation

1 - REAR COVER
2 - CARRIER
3 - BALANCE SHAFT
(7) P la ce ch a in over cr a n ksh a ft spr ocket so t h a t
t h e pla t ed lin k of t h e ch a in is over t h e n u m ber 1 cyl-
in der t im in g m a r k on t h e ba la n ce sh a ft cr a n ksh a ft
spr ocket (F ig. 142).
(8) P la ce ba la n ce sh a ft spr ocket in t o t h e t im in g
ch a in (F ig. 142) a n d a lign t h e t im in g m a r k on t h e
spr ocket (dot ) wit h t h e (lower ) pla t ed lin k on t h e
ch a in .
NOTE: The lower plated link is 8 links from the

upper link.
(9) Wit h ba la n ce sh a ft keywa ys poin t in g u p (12

o’clock) slide t h e ba la n ce sh a ft spr ocket on t o t h e n ose
of t h e ba la n ce sh a ft . Th e ba la n ce sh a ft m a y h a ve t o
be pu sh ed in sligh t ly t o a llow for clea r a n ce.
Fig. 140 Balance Shaft Sprocket Alignment to

Crankshaft
1 - ALIGN FLATS
Fig. 141 Balance Shaft Drive

1 - SPROCKET
2 - SPECIAL TOOL 6052 Fig. 142 Balance Shaft Timing
1 - MARK ON SPROCKET
(6) Tu r n cr a n ksh a ft u n t il n u m ber 1 cylin der is a t 2 - KEYWAYS UP
3 - ALIGN MARKS
t op dea d cen t er (TDC). Th e t im in g m a r ks on t h e 4 - PLATED LINK
ch a in spr ocket sh ou ld lin e u p wit h t h e pa r t in g lin e 5 - PARTING LINE (BEDPLATE TO BLOCK)
on t h e left side of n u m ber on e m a in bea r in g ca p. 6 - PLATED LINK
(F ig. 142).
NOTE: THE TIMING MARK ON THE SPROCKET, THE (13) In st a ll pick-u p t u be a n d oil pa n (Refer t o 9 -
(LOWER) NICKEL PLATED LINK, AND THE ARROW E NGINE /LUBRICATION/OIL PAN - INSTALLA-
ON THE SIDE OF THE GEAR COVER SHOULD LINE TION).
UP WHEN THE BALANCE SHAFTS ARE TIMED (14) F ill en gin e cr a n kca se wit h pr oper oil t o cor-
CORRECTLY. r ect level.
(10) If t h e spr ocket s a r e t im ed cor r ect ly, in st a ll t h e

ba la n ce sh a ft bolt s a n d t igh t en t o 28 N·m (250 in .
lbs.). A wood block pla ced bet ween cr a n kca se a n d
cr a n ksh a ft cou n t er ba la n ce will pr even t cr a n ksh a ft
a n d gea r r ot a t ion .
(11) CHAIN TEN S ION IN G:
(a ) In st a ll ch a in t en sion er loosely a ssem bled
wit h n e w sh ou lder ed pivot scr ew a n d a dju st er
scr ew.
(b) P osit ion gu ide on dou ble en ded st u d m a kin g
su r e t a b on t h e gu ide fit s in t o slot on t h e gea r
cover. In st a ll a n d t igh t en n u t /wa sh er a ssem bly t o
12 N·m (105 in . lbs.).
(c) P la ce a sh im 1 m m (0.039 in .) t h ick x 70 m m
(2.75 in .) lon g bet ween t en sion er a n d ch a in . P u sh
t en sion er a n d sh im u p a ga in st t h e ch a in . Ap p ly
firm p re s s u re 2.5–3 Kg (5.5–6.6 lbs .) d ire c tly
be h in d th e a d ju s tm e n t s lo t to ta k e u p a ll
s la c k . Ch a in m u st h a ve sh oe r a diu s con t a ct a s
(d) Wit h t h e loa d a pplied, t igh t en t op t en sion er
bolt fir st , t h en bot t om pivot bolt . Tigh t en bolt s t o Fig. 143 Chain Tension Adjustment
12 N·m (105 in . lbs.). Rem ove sh im .
1 - 1MM (0.039 IN.) SHIM
(e) In st a ll ca r r ier cover s a n d t igh t en scr ews t o 2 - TENSIONER (ADJUSTER) BOLT
12 N·m (105 in . lbs.). 3 - PIVOT BOLT
(12) If r em oved, in st a ll oil pu m p (Refer t o 9 -
E NGINE /LUBRICATION/OIL P UMP - INSTALLA-
TION).
9 - 76 ENGINE 3.3/3.8L RS
EN GI N E 3 .3 /3 .8 L
TABLE OF CONTENTS
page page
ENGINE 3.3/3.8L CYLINDER HEAD COVER(S)

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 78 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 105
DIAGNOSIS AND TESTING CYLINDER HEAD COVER - RIGHT
DIAGNOSIS AND TESTING - ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
DIAGNOSIS - INTRODUCTION . . . . . . . . . . . 78 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 106
DIAGNOSIS AND TESTING - ENGINE CYLINDER HEAD COVER - LEFT
DIAGNOSIS - PERFORMANCE . . . . . . . . . . . 80 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
DIAGNOSIS AND TESTING - ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 107
DIAGNOSIS - MECHANICAL . . . . . . . . . . . . . 82 INTAKE/EXHAUST VALVES & SEATS
DIAGNOSIS AND TESTING - ENGINE OIL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 107
LEAK INSPECTION . . . . . . . . . . . . . . . . . . . . 84 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 107
DIAGNOSIS AND TESTING - CYLINDER STANDARD PROCEDURE - REFACING
COMPRESSION PRESSURE TEST . . . . . . . . 85 VALVES AND VALVE SEATS . . . . . . . . . . . . 107
DIAGNOSIS AND TESTING - CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
COMBUSTION PRESSURE LEAKAGE CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 108
STANDARD PROCEDURE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 109
STANDARD PROCEDURE - MEASURING VALVE SPRINGS
BEARING CLEARANCE USING DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 109
PLASTIGAGE . . . . . . . . . . . . . . . . . . . . . . . . 86 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 109
FORM-IN-PLACE GASKETS AND SEALERS . 86 REMOVAL
STANDARD PROCEDURE - ENGINE REMOVAL - CYLINDER HEAD OFF . . . . . . . 109
GASKET SURFACE PREPARATION . . . . . . . . 87 REMOVAL - CYLINDER HEAD ON . . . . . . . . 111
HYDROSTATIC LOCKED ENGINE . . . . . . . . . 87 INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 111
STANDARD PROCEDURE - REPAIR OF INSTALLATION
DAMAGED OR WORN THREADS . . . . . . . . . 88 INSTALLATION - CYLINDER HEAD OFF . . . 111
STANDARD PROCEDURE - ENGINE CORE INSTALLATION - CYLINDER HEAD ON . . . . 111
AND OIL GALLERY PLUGS . . . . . . . . . . . . . . 88 ROCKER ARMS
REMOVAL - ENGINE ASSEMBLY . . . . . . . . . . . 88 DESCRIPTION
INSTALLATION - ENGINE ASSEMBLY . . . . . . . . 91 DESCRIPTION - ROCKER ARMS . . . . . . . . . 112
SPECIFICATIONS DESCRIPTION - PUSHRODS . . . . . . . . . . . . 112
3.3/3.8L ENGINE . . . . . . . . . . . . . . . . . . . . . . 93 OPERATION
SPECIFICATIONS - TORQUE . . . . . . . . . . . . 97 OPERATION - ROCKER ARMS . . . . . . . . . . 112
SPECIAL TOOLS OPERATION - PUSHRODS . . . . . . . . . . . . . 112
3.3/3.8L ENGINE . . . . . . . . . . . . . . . . . . . . . . 98 REMOVAL - ROCKER ARMS AND SHAFT . . . . 112
AIR CLEANER ELEMENT DISASSEMBLY - ROCKER ARMS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 AND SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . 113
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 101 ASSEMBLY - ROCKER ARMS AND SHAFT . . . 113
AIR CLEANER HOUSING INSTALLATION - ROCKER ARMS
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 AND SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . 113
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 102 VALVE STEM SEALS
CYLINDER HEAD DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 114
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 102 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
DIAGNOSIS AND TESTING—CYLINDER HEAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 115
GASKET . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 ENGINE BLOCK
REMOVAL - CYLINDER HEAD . . . . . . . . . . . . 103 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 115
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 STANDARD PROCEDURE - CYLINDER BORE
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 104 HONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
INSTALLATION - CYLINDER HEAD . . . . . . . . . 104 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
RS ENGINE 3.3/3.8L 9 - 77
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 115 FLEX PLATE

HYDRAULIC LIFTERS (CAM IN BLOCK) REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 116 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 133
DIAGNOSIS AND TESTING - HYDRAULIC ENGINE MOUNTING
LIFTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 134
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117 FRONT MOUNT
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 117 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
CAMSHAFT & BEARINGS (IN BLOCK) INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 134
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 118 LEFT MOUNT
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 118 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 136
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . 118 REAR MOUNT
PISTON & CONNECTING ROD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 137
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 119 RIGHT MOUNT
STANDARD PROCEDURE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
STANDARD PROCEDURE - FITTING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 138
CONNECTING RODS . . . . . . . . . . . . . . . . . . 119 LUBRICATION
STANDARD PROCEDURE - FITTING DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 138
PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 138
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120 DIAGNOSIS AND TESTING - ENGINE OIL
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 121 PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . 138
CONNECTING ROD BEARINGS OIL
STANDARD PROCEDURE - MEASURING STANDARD PROCEDURE
CONNECTING ROD BEARING STANDARD PROCEDURE - ENGINE OIL
CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . 123 AND FILTER CHANGE . . . . . . . . . . . . . . . . . 139
PISTON RINGS STANDARD PROCEDURE - ENGINE OIL
STANDARD PROCEDURE - PISTON RING LEVEL CHECK . . . . . . . . . . . . . . . . . . . . . . . 140
FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 OIL COOLER & LINES
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 141
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 124 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 141
CRANKSHAFT MAIN BEARINGS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
STANDARD PROCEDURE - MAIN BEARING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 141
FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 OIL FILTER
REMOVAL - CRANKSHAFT MAIN BEARINGS . 127 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
INSTALLATION - CRANKSHAFT MAIN INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 141
BEARINGS . . . . . . . . . . . . . . . . . . . . . . . . . . 127 OIL FILTER ADAPTER
CRANKSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
DESCRIPTION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 142
DESCRIPTION - 3.3L . . . . . . . . . . . . . . . . . . 128 OIL PAN
DESCRIPTION - 3.8L . . . . . . . . . . . . . . . . . . 128 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
STANDARD PROCEDURE - MEASURING CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
CRANKSHAFT END PLAY . . . . . . . . . . . . . . 128 INSPECTION ..................... . . . . 143
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 129 OIL PRESSURE RELIEF VALVE
CRANKSHAFT OIL SEAL - FRONT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 130 OIL PRESSURE SWITCH
CRANKSHAFT OIL SEAL - REAR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 144
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 144
CRANKSHAFT REAR OIL SEAL RETAINER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 144
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 OIL PUMP
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 132 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 144
VIBRATION DAMPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 145
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 132 CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
9 - 78 ENGINE 3.3/3.8L RS
INSPECTION ....................... . . 145 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 153

ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 146 EXHAUST MANIFOLD - LEFT
INTAKE MANIFOLD CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 147 INSPECTION ....................... . . 155
DIAGNOSIS AND TESTING - INTAKE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 155
MANIFOLD LEAKS . . . . . . . . . . . . . . . . . . . . 147 VALVE TIMING
INTAKE MANIFOLD - UPPER STANDARD PROCEDURE
STANDARD PROCEDURE STANDARD PROCEDURE - VALVE TIMING
STANDARD PROCEDURE - MANIFOLD VERIFICATION . . . . . . . . . . . . . . . . . . . . . . . 155
STRIPPED THREAD REPAIR . . . . . . . . . . . . 147 STANDARD PROCEDURE - MEASURING
STANDARD PROCEDURE - INTAKE TIMING CHAIN WEAR . . . . . . . . . . . . . . . . . 155
MANIFOLD VACUUM PORT REPAIR . . . . . . 148 TIMING CHAIN COVER
REMOVAL - UPPER INTAKE MANIFOLD . . . . . 148 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 148 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 157
INSPECTION ....................... . . 149 TIMING CHAIN AND SPROCKETS
INSTALLATION - UPPER INTAKE MANIFOLD . 149 REMOVAL
INTAKE MANIFOLD - LOWER REMOVAL - TIMING CHAIN AND
REMOVAL - LOWER INTAKE MANIFOLD . . . . 150 CAMSHAFT SPROCKET . . . . . . . . . . . . . . . 159
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 151 REMOVAL - CRANKSHAFT SPROCKET . . . 159
INSPECTION ....................... . . 151 INSTALLATION
INSTALLATION - LOWER INTAKE MANIFOLD . 151 INSTALLATION - CRANKSHAFT
EXHAUST MANIFOLD - RIGHT SPROCKET . . . . . . . . . . . . . . . . . . . . . . . . . 160
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 INSTALLATION - TIMING CHAIN AND
CLEANING . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 CAMSHAFT SPROCKET . . . . . . . . . . . . . . . 160
INSPECTION ....................... . . 153
EN GI N E 3 .3 /3 .8 L Th ese m a lfu n ct ion s m a y be cla ssified a s eit h er

m ech a n ica l (e.g., a st r a n ge n oise), or per for m a n ce
(e.g., en gin e idles r ou gh a n d st a lls).
DESCRIPTION
Refer t o t h e E n gin e Mech a n ica l a n d t h e E n gin e
Th e 3.3 Lit er (201 cu . in .) a n d 3.8 Lit er (231 cu .
P er for m a n ce dia gn ost ic ch a r t s, for possible ca u ses
in .) en gin es a r e 60° V-6 en gin es wit h ca st ir on cylin -
a n d cor r ect ion s of m a lfu n ct ion s (Refer t o 9 - E NGINE
der blocks a n d a lu m in u m cylin der h ea ds (F ig. 1). Th e
- DIAGNOSIS AND TE STING - ME CH ANICAL)
en gin e u ses a sin gle, block m ou n t ed ca m sh a ft wit h
(Refer t o 9 - E NGINE - DIAGNOSIS AND TE STING
pu sh r ods t o a ct u a t e t h e va lves. Th ese en gin es do n ot
- P E RF ORMANCE ).
h a ve pr ovision s for a fr ee wh eelin g va lve t r a in .
F or fu el syst em dia gn osis, (Refer t o 14 - F UE L
Th e fir in g or der is 1–2–3–4–5–6. Th e cylin der s a r e
SYSTE M/F UE L DE LIVE RY - DIAGNOSIS AND
n u m ber ed fr om t h e fr on t of t h e en gin e t o t h e r ea r.
TE STING).
Th e fr on t cylin der ba n k is n u m ber ed 2, 4, a n d 6. Th e
Addit ion a l t est s a n d dia gn ost ic pr ocedu r es m a y be
r ea r cylin der ba n k is n u m ber ed 1, 3, a n d 5.
n ecessa r y for specific en gin e m a lfu n ct ion s t h a t ca n -
Th e en gin e iden t ifica t ion n u m ber is loca t ed on t h e
n ot be isola t ed wit h t h e Ser vice Dia gn osis ch a r t s.
r ea r of t h e cylin der block ju st below t h e cylin der
In for m a t ion con cer n in g a ddit ion a l t est s a n d dia gn o-
h ea d (F ig. 2).
sis is pr ovided wit h in t h e followin g:
• Cylin der Com pr ession P r essu r e Test
DI AGN OSI S AN D T EST I N G • Cylin der Com bu st ion P r essu r e Lea ka ge Test
• E n gin e Cylin der H ea d Ga sket F a ilu r e Dia gn osis
DIAGNOSIS AND TESTING - ENGINE • In t a ke Ma n ifold Lea ka ge Dia gn osis
• H ydr a u lic La sh Adju st er Noise Dia gn osis
DIAGNOSIS - INTRODUCTION • E n gin e Oil Lea k In spect ion
E n gin e dia gn osis is h elpfu l in det er m in in g t h e
ca u ses of m a lfu n ct ion s n ot det ect ed a n d r em edied by
r ou t in e m a in t en a n ce.
RS ENGINE 3.3/3.8L 9 - 79
EN GI N E 3 .3 /3 .8 L (Cont inue d)
Fig. 1 3.3/3.8L V-6 Engines
Fig. 2 Engine Identification

9 - 80 ENGINE 3.3/3.8L RS
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - PERFORMANCE
ENGINE WILL NOT START 1. Weak battery. 1. Test battery. Charge or replace
as necessary. (Refer to 8 -
ELECTRICAL/BATTERY SYSTEM -
2. Corroded or loose battery 2. Clean and tighten battery
connections. connections. Apply a coat of light
mineral grease to terminals.
3. Faulty starter. 3. Test starting system. (Refer to 8 -
ELECTRICAL/STARTING -
4. Faulty coil(s) or control unit. 4. Test and replace as needed.
Information)
5. Incorrect spark plug gap. 5. Set gap. (Refer to 8 -
ELECTRICAL/IGNITION CONTROL
- SPECIFICATIONS)
filter.
7. Faulty fuel pump. 7. Test fuel pump and replace as
needed. (Refer to Appropriate
Diagnostic Information)
8. Incorrect engine timing. 8. Check for a skipped timing
belt/chain.
ENGINE STALLS OR IDLES 1. Idle speed too low. 1. Test minimum air flow. (Refer to
ROUGH Appropriate Diagnostic Information)
2. Incorrect fuel mixture. 2. (Refer to Appropriate Diagnostic

Information)
3. Intake manifold leakage. 3. Inspect intake manifold, manifold
gasket, and vacuum hoses.
Information)
RS ENGINE 3.3/3.8L 9 - 81
ENGINE LOSS OF POWER 1. Dirty or incorrectly gapped plugs. 1. Clean plugs and set gap.

filter.
3. Faulty fuel pump. 3. Test and replace as necessary.
Information)
4. Incorrect valve timing. 4. Correct valve timing.
5. Leaking cylinder head gasket. 5. Replace cylinder head gasket.
6. Low compression. 6. Test compression of each
cylinder.
8. Plugged or restricted exhaust 8. Perform exhaust restriction test.
system. (Refer to 11 - EXHAUST SYSTEM -
DIAGNOSIS AND TESTING) Install
new parts, as necessary.
Information)
ENGINE MISSES ON 1. Dirty or incorrectly gapped spark 1. Clean spark plugs and set gap.
ACCELERATION plugs.
2. Contamination in Fuel System. 2. Clean fuel system and replace

fuel filter.
Information)
ENGINE MISSES AT HIGH SPEED 1. Dirty or incorrect spark plug gap. 1. Clean spark plugs and set gap.
Information)
3. Dirty fuel injector(s). 3. Test and replace as necessary.
Information)
filter.
9 - 82 ENGINE 3.3/3.8L RS
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - MECHANICAL
NOISY VALVES 1. High or low oil level in 1. Check and correct engine oil
crankcase. level.

temperature.
again.
4. Low oil pressure. 4. Check and correct engine oil
pressure problem.
5. Dirt in hydraulic lifters/lash 5. Replace hydraulic lifters/lash
6. Worn rocker arms. 6. Inspect oil supply to rocker arms.
7. Worn hydraulic lifters/lash 7. Replace hydraulic lifters/lash
8. Worn valve guides. 8. Replace cylinder head assembly.
9. Excessive runout of valve seats 9. Grind valve seats and valves.
on valve faces.
CONNECTING ROD NOISE 1. Insufficient oil supply. 1. Check engine oil level.

temperature.
again.
6. Connecting rod journal 6. Replace crankshaft or grind
out-of-round. surface.
7. Misaligned connecting rods. 7. Replace bent connecting rods.
RS ENGINE 3.3/3.8L 9 - 83
MAIN BEARING NOISE 1. Insufficient oil supply. 1. Check engine oil level.

temperature.
again.
6. Excessive end play. 6. Check thrust bearing for wear on
flanges.
7. Crankshaft journal out-of-round 7. Replace crankshaft or grind
or worn. journals.
8. Loose flywheel or torque 8. Tighten to correct torque.
converter.
OIL PRESSURE DROP 1. Low oil level. 1. Check engine oil level.
2. Faulty oil pressure sensor/switch. 2. Replace oil pressure sensor/

switch.
3. Low oil pressure. 3. Check oil pressure sensor/switch
and main bearing oil clearance.
4. Clogged oil filter. 4. Install new oil filter.
5. Worn parts in oil pump. 5. Replace worn parts or pump.
7. Oil pump relief valve stuck. 7. Remove valve and inspect, clean,
or replace.
8. Oil pump suction tube loose. 8. Remove oil pan and install new
tube or clean, if necessary.
9. Oil pump cover warped or 9. Install new oil pump.
cracked.
clearance.
OIL LEAKS 1. Misaligned or deteriorated 1. Replace gasket(s).

gaskets.
2. Loose fastener, broken or porous 2. Tighten, repair or replace the

metal part. part.
3. Misaligned or deteriorated cup or 3. Replace as necessary.
threaded plug.
9 - 84 ENGINE 3.3/3.8L RS
OIL CONSUMPTION OR SPARK 1. PCV system malfunction. 1. Check system and repair as
PLUGS FOULED necessary. (Refer to 25 -
EMISSIONS CONTROL/
EVAPORATIVE EMISSIONS/PCV
VALVE - DIAGNOSIS AND
TESTING)
2. Worn, scuffed or broken rings. 2. Hone cylinder bores. Install new
rings.
3. Carbon in oil ring slots. 3. Install new rings.
4. Rings fitted too tightly in grooves. 4. Remove rings and check
grooves. If groove is not proper
width, replace piston.
5. Worn valve guide(s). 5. Replace cylinder head assembly.
6. Valve stem seal(s) worn or 6. Replace seal(s).
damaged.
DIAGNOSIS AND TESTING - ENGINE OIL LEAK • Gr a du a lly a pply a ir pr essu r e fr om 1 psi t o 2.5
psi m a xim u m wh ile a pplyin g soa py wa t er a t t h e su s-
INSPECTION
pect ed sou r ce. Adju st t h e r egu la t or t o t h e su it a ble
Begin wit h a t h or ou gh visu a l in spect ion of t h e
t est pr essu r e t h a t pr ovides t h e best bu bbles wh ich
en gin e, pa r t icu la r ly a t t h e a r ea of t h e su spect ed lea k.
will pin poin t t h e lea k sou r ce. If t h e oil lea k is
If a n oil lea k sou r ce is n ot r ea dily iden t ifia ble, t h e
det ect ed a n d iden t ified, r epa ir per ser vice m a n u a l
followin g st eps sh ou ld be followed:
pr ocedu r es.
(1) Do n ot clea n or degr ea se t h e en gin e a t t h is
• If t h e lea ka ge occu r s a t t h e cr a n ksh a ft r ea r oil
t im e beca u se som e solven t s m a y ca u se r u bber t o
sea l a r ea , r efer t o t h e sect ion , In spect ion for Rea r
swell, t em por a r ily st oppin g t h e lea k.
Sea l Ar ea Lea k.
(2) Add a n oil solu ble dye (u se a s r ecom m en ded by
(6) If n o lea ks a r e det ect ed, t u r n off t h e a ir su pply.
m a n u fa ct u r er ). St a r t t h e en gin e a n d let idle for
Rem ove t h e a ir h ose, a ll plu gs, a n d ca ps. In st a ll t h e
a ppr oxim a t ely 15 m in u t es. Ch eck t h e oil dipst ick t o
P CV va lve a n d fr esh a ir h ose (m a ke-u p a ir ). P r oceed
m a ke su r e t h e dye is t h or ou gh ly m ixed a s in dica t ed
t o n ext st ep.
wit h a br igh t yellow color u n der a bla ck ligh t .
(7) Clea n t h e oil off t h e su spect oil lea k a r ea u sin g
(3) Usin g a bla ck ligh t , in spect t h e en t ir e en gin e
a su it a ble solven t . Dr ive t h e veh icle a t va r iou s
for flu or escen t dye, pa r t icu la r ly a t t h e su spect ed a r ea
speeds a ppr oxim a t ely 24 km (15 m iles). In spect t h e
of oil lea k. If t h e oil lea k is fou n d a n d iden t ified,
en gin e for sign s of a n oil lea k by u sin g a bla ck ligh t .
r epa ir a s n ecessa r y.
(4) If dye is n ot obser ved, dr ive t h e veh icle a t va r- NOTE: If oil leakage is observed at the dipstick tube
iou s speeds for a ppr oxim a t ely 24 km (15 m iles), a n d to block location; remove the tube, clean and reseal
r epea t in spect ion . using Mopar" Stud & Bearing Mount (press fit tube
(5) If th e o il le a k s o u rc e is n o t p o s itiv e ly applications only), and for O-ring style tubes,
id e n tifie d a t th is tim e , pr oceed wit h t h e a ir lea k remove tube and replace the O-ring seal.
det ect ion t est m et h od a s follows:
• Discon n ect t h e fr esh a ir h ose (m a ke-u p a ir ) a t
t h e cylin der h ea d cover a n d plu g or ca p t h e ou t let on INSPECTION FOR REAR SEAL AREA LEAKS
t h e cover. Sin ce it is som et im es difficu lt t o det er m in e t h e
• Rem ove t h e P CV va lve h ose fr om t h e cylin der sou r ce of a n oil lea k in t h e r ea r sea l a r ea of t h e
h ea d cover. Ca p or plu g t h e P CV va lve ou t let on t h e en gin e, a m or e in volved in spect ion is n ecessa r y. Th e
cover. followin g st eps sh ou ld be followed t o h elp pin poin t
• At t a ch a n a ir h ose wit h pr essu r e ga u ge a n d r eg- t h e sou r ce of t h e lea k.
u la t or t o t h e dipst ick t u be. If t h e lea ka ge occu r s a t t h e cr a n ksh a ft r ea r oil sea l
a r ea :
CAUTION: Do not subject the engine assembly to (1) Discon n ect t h e ba t t er y.
more than 20.6 kpa (3 PSI) of test pressure. (2) Ra ise t h e veh icle.
RS ENGINE 3.3/3.8L 9 - 85
(3) Rem ove t or qu e con ver t er or clu t ch h ou sin g (4) Rem ove t h e Au t o Sh u t down (ASD) r ela y fr om
cover a n d in spect r ea r of block for eviden ce of oil. t h e P DC.
Use a bla ck ligh t t o ch eck for t h e oil lea k. If a lea k is (5) Be su r e t h r ot t le bla de is fu lly open du r in g t h e
pr esen t in t h is a r ea , r em ove t r a n sm ission for fu r t h er com pr ession ch eck.
in spect ion . (6) In ser t com pr ession ga u ge a da pt or Specia l Tool
(a ) Cir cu la r spr a y pa t t er n gen er a lly in dica t es 8116 or t h e equ iva len t , in t o t h e #1 spa r k plu g h ole in
sea l lea ka ge or cr a n ksh a ft da m a ge. cylin der h ea d. Con n ect t h e 0–500 psi (Blu e) pr essu r e
(b) Wh er e lea ka ge t en ds t o r u n st r a igh t down , t r a n sdu cer (Specia l Tool CH 7059) wit h ca ble a da p-
possible ca u ses a r e a por ou s block, oil ga ller y cu p t or s t o t h e DRBIII!. F or Specia l Tool iden t ifica t ion ,
plu g, bedpla t e t o cylin der block m a t in g su r fa ces (Refer t o 9 - E NGINE - SP E CIAL TOOLS).
a n d sea l bor e. See pr oper r epa ir pr ocedu r es for (7) Cr a n k en gin e u n t il m a xim u m pr essu r e is
t h ese it em s. r ea ch ed on ga u ge. Recor d t h is pr essu r e a s #1 cylin -
(4) If n o lea ks a r e det ect ed, pr essu r ize t h e cr a n k- der pr essu r e.
ca se a s pr eviou sly descr ibed. (8) Repea t t h e pr eviou s st ep for a ll r em a in in g cyl-
in der s.
CAUTION: Do not exceed 20.6 kPa (3 psi). (9) Com pr ession sh ou ld n ot be less t h a n 689 kP a
(100 psi) a n d n ot va r y m or e t h a n 25 per cen t fr om cyl-
(5) If t h e lea k is n ot det ect ed, ver y slowly t u r n t h e in der t o cylin der.
cr a n ksh a ft a n d wa t ch for lea ka ge. If a lea k is (10) If on e or m or e cylin der s h a ve a bn or m a lly low
det ect ed bet ween t h e cr a n ksh a ft a n d sea l wh ile com pr ession pr essu r es, r epea t t h e com pr ession t est .
slowly t u r n in g t h e cr a n ksh a ft , it is possible t h e (11) If t h e sa m e cylin der or cylin der s r epea t a n
cr a n ksh a ft sea l su r fa ce is da m a ged. Th e sea l a r ea on a bn or m a lly low r ea din g on t h e secon d com pr ession
t h e cr a n ksh a ft cou ld h a ve m in or n icks or scr a t ch es t est , it cou ld in dica t e t h e exist en ce of a pr oblem in
t h a t ca n be polish ed ou t wit h em er y clot h . t h e cylin der in qu est ion . Th e re c o m m e n d e d c o m -
p re s s io n p re s s u re s a re to be u s e d o n ly a s a
CAUTION: Use extreme caution when crankshaft
g u id e to d ia g n o s in g e n g in e p ro ble m s . An e n g in e
polishing is necessary to remove minor nicks and
s h o u ld n o t be d is a s s e m ble d to d e te rm in e th e
scratches. The crankshaft seal flange is especially
c a u s e o f lo w c o m p re s s io n u n le s s s o m e m a lfu n c -
machined to complement the function of the rear oil
tio n is p re s e n t.
seal.
(6) F or bu bbles t h a t r em a in st ea dy wit h sh a ft DIAGNOSIS AND TESTING - CYLINDER

r ot a t ion , n o fu r t h er in spect ion ca n be don e u n t il dis- COMBUSTION PRESSURE LEAKAGE TEST
a ssem bled. Th e com bu st ion pr essu r e lea ka ge t est pr ovides a n
(7) Aft er t h e oil lea k r oot ca u se a n d a ppr opr ia t e a ccu r a t e m ea n s for det er m in in g en gin e con dit ion .
cor r ect ive a ct ion h a ve been iden t ified, r epla ce com po- Com bu st ion pr essu r e lea ka ge t est in g will det ect :
n en t (s) a s n ecessa r y. • E xh a u st a n d in t a ke va lve lea ks (im pr oper sea t -
in g).
DIAGNOSIS AND TESTING - CYLINDER • Lea ks bet ween a dja cen t cylin der s or in t o wa t er
COMPRESSION PRESSURE TEST ja cket .
Th e r esu lt s of a cylin der com pr ession pr essu r e t est • An y ca u ses for com bu st ion /com pr ession pr essu r e
ca n be u t ilized t o dia gn ose sever a l en gin e m a lfu n c- loss.
t ion s.
WARNING: DO NOT REMOVE THE PRESSURE CAP
E n su r e t h e ba t t er y is com plet ely ch a r ged a n d t h e
en gin e st a r t er m ot or is in good oper a t in g con dit ion .
Ot h er wise t h e in dica t ed com pr ession pr essu r es m a y
OCCUR.
n ot be va lid for dia gn osis pu r poses.
(1) Ch eck en gin e oil level a n d a dd oil if n ecessa r y. Ch eck t h e coola n t level a n d fill a s r equ ir ed. DO
(2) Dr ive t h e veh icle u n t il en gin e r ea ch es n or m a l NOT in st a ll t h e pr essu r e ca p.
oper a t in g t em per a t u r e. Select a r ou t e fr ee fr om t r a f- St a r t a n d oper a t e t h e en gin e u n t il it a t t a in s n or-
fic a n d ot h er for m s of con gest ion , obser ve a ll t r a ffic m a l oper a t in g t em per a t u r e, t h en t u r n t h e en gin e
la ws, a n d a cceler a t e t h r ou gh t h e gea r s sever a l t im es OF F.
br iskly. Clea n spa r k plu g r ecesses wit h com pr essed a ir.
(3) Rem ove a ll spa r k plu gs fr om en gin e. As spa r k Rem ove t h e spa r k plu gs.
plu gs a r e bein g r em oved, ch eck elect r odes for a bn or- Rem ove t h e oil filler ca p.
m a l fir in g in dica t or s fou led, h ot , oily, et c. Recor d cyl- Rem ove t h e a ir clea n er.
in der n u m ber of spa r k plu g for fu t u r e r efer en ce.
9 - 86 ENGINE 3.3/3.8L RS
Ca libr a t e t h e t est er a ccor din g t o t h e m a n u fa ct u r- est t o t h e sa m e widt h . Th is ba n d sh ows t h e a m ou n t
er ’s in st r u ct ion s. Th e sh op a ir sou r ce for t est in g of clea r a n ce in t h ou sa n dt h s of a m illim et er. Differ-
sh ou ld m a in t a in 483 kP a (70 psi) m in im u m , 1,379 en ces in r ea din gs bet ween t h e en ds in dica t e t h e
kP a (200 psi) m a xim u m , wit h 552 kP a (80 psi) r ec- a m ou n t of t a per pr esen t . Recor d a ll r ea din gs t a ken .
om m en ded. Com pa r e t h e clea r a n ce m ea su r em en t s t o specsifica -
P er for m t h e t est pr ocedu r es on ea ch cylin der t ion s fou n d in t h e en gin e specifica t ion s t a ble(Refer t o
a ccor din g t o t h e t est er m a n u fa ct u r er ’s in st r u ct ion s. 9 - E NGINE - SP E CIF ICATIONS). P la s tig a g e g e n -
Wh ile t est in g, list en for pr essu r ized a ir esca pin g e ra lly is a c c o m p a n ie d by tw o s c a le s . On e s c a le
t h r ou gh t h e t h r ot t le body, t a ilpipe a n d oil filler ca p is in in c h e s , th e o th e r is a m e tric s c a le .
open in g. Ch eck for bu bbles in t h e coola n t .
All ga u ge pr essu r e in dica t ion s sh ou ld be equ a l, NOTE: Plastigage is available in a variety of clear-
wit h n o m or e t h a n 25% lea ka ge per cylin der. ance ranges. Use the most appropriate range for
F OR EXAMP LE: At 552 kP a (80 psi) in pu t pr es- the specifications you are checking.
su r e, a m in im u m of 414 kP a (60 psi) sh ou ld be m a in -
t a in ed in t h e cylin der. (4) In st a ll t h e pr oper cr a n ksh a ft bea r in gs to
a ch ieve t h e specified bea r in g clea r a n ces.
STAN DARD PROCEDU RE FORM-IN-PLACE GASKETS AND SEALERS

Th er e a r e n u m er ou s pla ces wh er e for m -in -pla ce
STANDARD PROCEDURE - MEASURING ga sket s a r e u sed on t h e en gin e. Ca r e m u st be t a ken
BEARING CLEARANCE USING PLASTIGAGE wh en a pplyin g for m -in -pla ce ga sket s t o a ssu r e
E n gin e cr a n ksh a ft bea r in g clea r a n ces ca n be det er- obt a in in g t h e desir ed r esu lt s. D o n o t u s e fo rm -in -
m in ed by u se of P la st iga ge or equ iva len t . Th e follow- p la c e g a s k e t m a te ria l u n le s s s p e c ifie d . Bea d size,
in g is t h e r ecom m en ded pr ocedu r e for t h e u se of con t in u it y, a n d loca t ion a r e of gr ea t im por t a n ce. Too
P la st iga ge: t h in a bea d ca n r esu lt in lea ka ge wh ile t oo m u ch ca n
(1) Rem ove oil film fr om su r fa ce t o be ch ecked. r esu lt in spill-over wh ich ca n br ea k off a n d obst r u ct
P la st iga ge is solu ble in oil. flu id feed lin es. A con t in u ou s bea d of t h e pr oper
(2) P la ce a piece of P la st iga ge a cr oss t h e en t ir e widt h is essen t ia l t o obt a in a lea k-fr ee ga sket .
widt h of t h e bea r in g sh ell in t h e ca p a ppr oxim a t ely Th er e a r e n u m er ou s t ypes of for m -in -pla ce ga sket
6.35 m m (1/4 in .) off cen t er a n d a wa y fr om t h e oil m a t er ia ls t h a t a r e u sed in t h e en gin e a r ea . Mopa r !
h oles (F ig. 3). (In a ddit ion , su spect ed a r ea s ca n be E n gin e RTV GE N II, Mopa r ! ATF -RTV, a n d Mopa r !
ch ecked by pla cin g t h e P la st iga ge in t h e su spect ed Ga sket Ma ker ga sket m a t er ia ls, ea ch h a ve differ en t
a r ea ). Tor qu e t h e bea r in g ca p/bed pla t e bolt s of t h e pr oper t ies a n d ca n n ot be u sed in pla ce of t h e ot h er.
bea r in g bein g ch ecked t o t h e pr oper specifica t ion s. MOPAR! EN GIN E RTV GEN II is u sed t o sea l
com pon en t s exposed t o en gin e oil. Th is m a t er ia l is a
specia lly design ed bla ck silicon e r u bber RTV t h a t
r et a in s a dh esion a n d sea lin g pr oper t ies wh en
exposed t o en gin e oil. Moist u r e in t h e a ir ca u ses t h e
m a t er ia l t o cu r e. Th is m a t er ia l is a va ila ble in t h r ee
ou n ce t u bes a n d h a s a sh elf life of on e yea r. Aft er on e
yea r t h is m a t er ia l will n ot pr oper ly cu r e. Alwa ys
in spect t h e pa cka ge for t h e expir a t ion da t e befor e
u se.
MOPAR! ATF RTV is a specifica lly design ed
bla ck silicon e r u bber RTV t h a t r et a in s a dh esion a n d
sea lin g pr oper t ies t o sea l com pon en t s exposed t o
a u t om a t ic t r a n sm ission flu id, en gin e coola n t s, a n d
m oist u r e. Th is m a t er ia l is a va ila ble in t h r ee ou n ce
t u bes a n d h a s a sh elf life of on e yea r. Aft er on e yea r
t h is m a t er ia l will n ot pr oper ly cu r e. Alwa ys in spect
t h e pa cka ge for t h e expir a t ion da t e befor e u se.
Fig. 3 Plastigage Placed in Lower Shell—Typical
MOPAR! GAS KET MAKER is a n a n a er obic t ype
1 - PLASTIGAGE
ga sket m a t er ia l. Th e m a t er ia l cu r es in t h e a bsen ce of
a ir wh en squ eezed bet ween t wo m et a llic su r fa ces. It
(3) Rem ove t h e bea r in g ca p a n d com pa r e t h e
will n ot cu r e if left in t h e u n cover ed t u be. Th e
widt h of t h e fla t t en ed P la st iga ge wit h t h e m et r ic
a n a er obic m a t er ia l is for u se bet ween t wo m a ch in ed
sca le pr ovided on t h e pa cka ge. Loca t e t h e ba n d clos-
su r fa ces. Do n ot u se on flexible m et a l fla n ges.
RS ENGINE 3.3/3.8L 9 - 87
MOPAR! B ED P LATE S EALAN T is a u n iqu e • Abr a sive pa d or pa per t o clea n cylin der block
(gr een -in -color ) a n a er obic t ype ga sket m a t er ia l t h a t a n d h ea d
is specia lly m a de t o sea l t h e a r ea bet ween t h e bed • H igh speed power t ool wit h a n a br a sive pa d or a
pla t e a n d cylin der block wit h ou t dist u r bin g t h e bea r- wir e br u sh (F ig. 4)
in g clea r a n ce or a lign m en t of t h ese com pon en t s. Th e
m a t er ia l cu r es slowly in t h e a bsen ce of a ir wh en NOTE: Multi-Layer Steel (MLS) head gaskets require
t or qu ed bet ween t wo m et a llic su r fa ces, a n d will r a p- a scratch free sealing surface.
idly cu r e wh en h ea t is a pplied.
MOPAR! GAS KET S EALAN T is a slow dr yin g, On ly u se t h e followin g for clea n in g ga sket su r fa ces:
per m a n en t ly soft sea ler. Th is m a t er ia l is r ecom - • Solven t or a com m er cia lly a va ila ble ga sket
m en ded for sea lin g t h r ea ded fit t in gs a n d ga sket s r em over
a ga in st lea ka ge of oil a n d coola n t . Ca n be u sed on • P la st ic or wood scr a per (F ig. 4)
t h r ea ded a n d m a ch in ed pa r t s u n der a ll t em per a - • Dr ill m ot or wit h 3M Roloc™ Br ist le Disc (wh it e
t u r es. Th is m a t er ia l is u sed on en gin es wit h m u lt i- or yellow) (F ig. 4)
la yer st eel (MLS) cylin der h ea d ga sket s. Th is
CAUTION: Excessive pressure or high RPM (beyond
m a t er ia l a lso will pr even t cor r osion . Mopa r ! Ga sket
the recommended speed), can damage the sealing
Sea la n t is a va ila ble in a 13 oz. a er osol ca n or 4oz./16
surfaces. The mild (white, 120 grit) bristle disc is
oz. ca n w/a pplica t or.
recommended. If necessary, the medium (yellow, 80
grit) bristle disc may be used on cast iron surfaces
SEALER APPLICATION
with care.
Mopa r ! Ga sket Ma ker m a t er ia l sh ou ld be a pplied
spa r in gly 1 m m (0.040 in .) dia m et er or less of sea la n t
t o on e ga sket su r fa ce. Be cer t a in t h e m a t er ia l su r-
r ou n ds ea ch m ou n t in g h ole. E xcess m a t er ia l ca n ea s-
ily be wiped off. Com pon en t s sh ou ld be t or qu ed in
pla ce wit h in 15 m in u t es. Th e u se of a loca t in g dowel
is r ecom m en ded du r in g a ssem bly t o pr even t sm ea r-
in g m a t er ia l off t h e loca t ion .
Mopa r ! E n gin e RTV GE N II or ATF RTV ga sket
m a t er ia l sh ou ld be a pplied in a con t in u ou s bea d
a ppr oxim a t ely 3 m m (0.120 in .) in dia m et er. All
m ou n t in g h oles m u st be cir cled. F or cor n er sea lin g, a
3.17 or 6.35 m m (1/8 or 1/4 in .) dr op is pla ced in t h e
cen t er of t h e ga sket con t a ct a r ea . Un cu r ed sea la n t
m a y be r em oved wit h a sh op t owel. Com pon en t s
sh ou ld be t or qu ed in pla ce wh ile t h e sea la n t is st ill
wet t o t h e t ou ch (wit h in 10 m in u t es). Th e u sa ge of a
loca t in g dowel is r ecom m en ded du r in g a ssem bly t o
pr even t sm ea r in g m a t er ia l off t h e loca t ion .
Mopa r ! Ga sket Sea la n t in a n a er osol ca n sh ou ld be
Fig. 4 Proper Tool Usage For Surface Preparation
a pplied u sin g a t h in , even coa t spr a yed com plet ely
1 - ABRASIVE PAD
over bot h su r fa ces t o be join ed, a n d bot h sides of a 2 - 3M ROLOC™ BRISTLE DISC
ga sket . Th en pr oceed wit h a ssem bly. Ma t er ia l in a 3 - PLASTIC/WOOD SCRAPER
ca n w/a pplica t or ca n be br u sh ed on even ly over t h e
sea lin g su r fa ces. Ma t er ia l in a n a er osol ca n sh ou ld be HYDROSTATIC LOCKED ENGINE
u sed on en gin es wit h m u lt i-la yer st eel ga sket s. Wh en a n en gin e is su spect ed t o be h ydr ost a t ica lly
locked, r ega r dless of wh a t ca u sed t h e pr oblem , t h e
STANDARD PROCEDURE - ENGINE GASKET followin g st eps sh ou ld be u sed.
SURFACE PREPARATION
To en su r e en gin e ga sket sea lin g, pr oper su r fa ce CAUTION: DO NOT use starter motor to rotate the
pr epa r a t ion m u st be per for m ed, especia lly wit h t h e engine, severe damage may occur.
u se of a lu m in u m en gin e com pon en t s a n d m u lt i-la yer
(1) In spect a ir clea n er, in du ct ion syst em a n d
st eel cylin der h ea d ga sket s.
in t a ke m a n ifold t o in su r e syst em is dr y a n d clea r of
N e v e r u se t h e followin g t o clea n ga sket su r fa ces:
for eign m a t er ia l.
• Met a l scr a per
(2) Rem ove n ega t ive ba t t er y ca ble.
9 - 88 ENGINE 3.3/3.8L RS
(3) P la ce a sh op t owel a r ou n d t h e spa r k plu gs
wh en r em ovin g t h em fr om t h e en gin e. Th is will ca t ch
a n y flu id t h a t m a y possibly be in t h e cylin der u n der
pr essu r e.
(4) Wit h a ll spa r k plu gs r em oved, r ot a t e en gin e
cr a n ksh a ft u sin g a br ea ker ba r a n d socket .
(5) Iden t ify t h e flu id in t h e cylin der (s) (i.e., cool-
a n t , fu el, oil or ot h er ).
(6) Ma ke su r e a ll flu id h a s been r em oved fr om t h e
cylin der s. In spect en gin e for da m a ge (i.e., con n ect in g
r ods, pist on s, va lves, et c.)
(7) Repa ir en gin e or com pon en t s a s n ecessa r y t o
pr even t t h is pr oblem fr om r e-occu r r in g.
CAUTION: Squirt approximately one teaspoon of oil

into the cylinders, rotate engine to lubricate the cyl-
inder walls to prevent damage on restart.
Fig. 5 Core Hole Plug Removal
(8) In st a ll n ew spa r k plu gs. 1 - CYLINDER BLOCK
(9) Dr a in en gin e oil a n d r em ove oil filt er. 2 - REMOVE PLUG WITH PLIERS
3 - STRIKE HERE WITH HAMMER
(10) In st a ll a n ew oil filt er. 4 - DRIFT PUNCH
(11) F ill en gin e wit h specified a m ou n t of a ppr oved 5 - CUP PLUG
oil.
(12) Con n ect n ega t ive ba t t er y ca ble. is clea n ed of a ll oil or gr ea se. Usin g pr oper dr ive
(13) St a r t en gin e a n d ch eck for a n y lea ks. plu g, dr ive plu g in t o h ole so t h a t t h e sh a r p edge of
t h e plu g is a t lea st 0.5 m m (0.020 in .) in side t h e
STANDARD PROCEDURE - REPAIR OF lea d-in ch a m fer.
DAMAGED OR WORN THREADS It is n ot n ecessa r y t o wa it for cu r in g of t h e sea la n t .
Da m a ged or wor n t h r ea ds (exclu din g spa r k plu g Th e coolin g syst em ca n be r efilled a n d t h e veh icle
a n d ca m sh a ft bea r in g ca p a t t a ch in g t h r ea ds) ca n be pla ced in ser vice im m edia t ely.
r epa ir ed. E ssen t ia lly, t h is r epa ir con sist s of dr illin g
ou t wor n or da m a ged t h r ea ds, t a ppin g t h e h ole wit h REMOVAL - ENGINE ASSEMBLY
a specia l H eli-Coil Ta p, (or equ iva len t ) a n d in st a llin g (1) P er for m fu el pr essu r e r elea se pr ocedu r e (Refer
a n in ser t in t o t h e t a pped h ole. Th is br in gs t h e h ole t o 14 - F UE L SYSTE M/F UE L DE LIVE RY - STAN-
ba ck t o it s or igin a l t h r ea d size. DARD P ROCE DURE ).
CAUTION: Be sure that the tapped holes maintain (3) Rem ove a ir clea n er a n d h oses.
the original center line. (4) Discon n ect t h e fu el lin e fr om fu el r a il (Refer t o
14 - F UE L SYSTE M/F UE L DE LIVE RY/QUICK
H eli-Coil t ools a n d in ser t s a r e r ea dily a va ila ble CONNE CT F ITTING - STANDARD P ROCE DURE ).
fr om a u t om ot ive pa r t s jobber s. (5) Rem ove t h e wiper m odu le (Refer t o 8 - E LE C-
STANDARD PROCEDURE - ENGINE CORE AND RE MOVAL).
OIL GALLERY PLUGS (6) Block off h ea t er h oses t o t h e r ea r h ea t er sys-
Usin g a blu n t t ool su ch a s a dr ift a n d a h a m m er, t em u sin g pin ch -off plier s (if equ ipped).
st r ike t h e bot t om edge of t h e cu p plu g. Wit h t h e cu p (7) Dr a in t h e coolin g syst em (Refer t o 7 - COOL-
plu g r ot a t ed, gr a sp fir m ly wit h plier s or ot h er su it - ING - STANDARD P ROCE DURE ).
a ble t ool a n d r em ove plu g (F ig. 5). (8) Discon n ect t h e h ea t er h oses.
(9) Rem ove t h e r a dia t or u pper su ppor t cr ossm em -
CAUTION: Do not drive cup plug into the casting as ber (Refer t o 23 - BODY/E XTE RIOR/GRILLE OP E N-
restricted cooling can result and cause serious ING RE INF ORCE ME NT - RE MOVAL).
engine problems. (10) Rem ove t h e r a dia t or fa n s (Refer t o 7 - COOL-
ING/E NGINE /RADIATOR FAN - RE MOVAL).
Th or ou gh ly clea n in side of cu p plu g h ole in cylin - (11) Discon n ect t h e t h r ot t le ca bles fr om t h e t h r ot -
der block or h ea d. Be su r e t o r em ove old sea ler. t le body.
Ligh t ly coa t in side of cu p plu g h ole wit h Mopa r ! (12) Discon n ect t h e MAP, IAC, a n d TP S elect r ica l
St u d a n d Bea r in g Mou n t . Ma ke cer t a in t h e n ew plu g con n ect or s.
RS ENGINE 3.3/3.8L 9 - 89
(13) Discon n ect t h e E GR t r a n sdu cer elect r ica l con -
n ect or (if equ ipped).
(14) Discon n ect t h e va cu u m h oses fr om t h r ot t le
body.
(15) Discon n ect t h e br a ke boost er a n d speed con -
t r ol va cu u m h oses.
(16) Disen ga ge wir e h a r n ess clip fr om t h e r igh t
side en gin e m ou n t .
(17) Rem ove t h e power st eer in g r eser voir fr om
m ou n t in g posit ion a n d set a side. D o n o t discon n ect
h ose.
(18) Discon n ect gr ou n d st r a p fr om r ea r of cylin der
h ea d.
(19) Discon n ect en gin e coola n t t em per a t u r e (E CT)
sen sor a n d ign it ion coil elect r ica l con n ect or s.
(20) Discon n ect t h e fu el in ject or elect r ica l h a r n ess
con n ect or a n d disen ga ge clip fr om su ppor t br a cket . Fig. 6 Crossmember Cradle Plate
(21) Discon n ect ca m sh a ft a n d cr a n ksh a ft posit ion 1 - CRADLE PLATE
sen sor elect r ica l con n ect or s.
(22) E va cu a t e a ir con dit ion in g syst em . Refer t o 24
- H E ATING & AIR CONDITIONING.
(23) Discon n ect A/C com pr essor elect r ica l con n ec-
t or.
(24) Discon n ect t h e A/C lin es fr om com pr essor.
Cover a n d sea l a ll open in gs of h oses a n d com pr essor.
(25) Rem ove t h e r a dia t or u pper h ose.
(26) Disen ga ge elect r ica l h a r n ess clip a t t r a n sa xle
dipst ick t u be.
(27) Rem ove t r a n sa xle dipst ick t u be. Sea l open in g
u sin g a su it a ble plu g.
NOTE: When the transaxle cooler lines are removed

from the rolled-groove type fittings at the transaxle,
damage to the inner wall of the hose will occur. To
prevent prevent potential leakage, the cooler hoses
must be cut off flush at the transaxle fitting, and a
service cooler hose splice kit must be installed
upon reassembly.
(28) Usin g a bla de or su it a ble h ose cu t t er, cu t

t r a n sa xle oil cooler lin es off flu sh wit h fit t in gs. P lu g
cooler lin es a n d fit t in gs t o pr even t debr is fr om en t er-
in g t r a n sa xle or cooler cir cu it . A ser vice splice kit will Fig. 7 Catalytic Converter to Exhaust Manifold
be in st a lled u pon r ea ssem bly. 1 - FLAG NUT
2 - GASKET
(29) Discon n ect t r a n sa xle sh ift lin ka ge a n d elect r i- 3 - BOLT
ca l con n ect or s. 4 - CATALYTIC CONVERTER
(30) Ra ise veh icle on h oist a n d dr a in t h e en gin e
oil. (35) Rem ove fr on t en gin e m ou n t a n d br a cket a s a n
(31) Rem ove t h e a xle sh a ft s. (Refer t o 3 - DIF F E R- a ssem bly.
E NTIAL & DRIVE LINE /H ALF SH AF T - RE MOVAL) (36) Rem ove t h e en gin e r ea r m ou n t br a cket .
(32) Rem ove cr ossm em ber cr a dle pla t e (F ig. 6). (37) Rem ove t h e en gin e t o t r a n sa xle st r u t s (F ig. 8).
(33) AWD e qu ip p e d : Rem ove t h e power t r a n sfer (38) Rem ove t r a n sa xle ca se cover (F ig. 8).
u n it (P TU) (Refer t o 21 - TRANSMISSION/TRANS- (39) Rem ove flex pla t e t o t or qu e con ver t er bolt s.
AXLE /P OWE R TRANSF E R UNIT - RE MOVAL). Ma r k t or qu e con ver t er t o flex pla t e for or ien t a t ion for
(34) Discon n ect exh a u st pipe fr om t h e m a n ifold r ea ssem bly.
(F ig. 7). (40) Rem ove t h e power st eer in g pr essu r e h ose su p-
por t clip a t t a ch in g bolt .
9 - 90 ENGINE 3.3/3.8L RS
Fig. 9 ADAPTER TOOLS MOUNTED ON BLOCK

(54) Ra ise veh icle en ou gh t o a llow en gin e dolly

Specia l Tool 6135 a n d cr a dle Specia l Tool 6710 wit h
Fig. 8 POWERTRAIN SUPPORTS AND DUST COVER post Specia l Tool 6848 a n d a da pt or Specia l Tool 6909
t o be in st a lled u n der veh icle (F ig. 12).
1 - BRACKET - ENGINE REAR MOUNT
2 - BOLT - TRANSAXLE CASE COVER (55) Loosen cr a dle/post m ou n t s t o a llow m ovem en t
3 - STRUT - TRANSAXLE TO ENGINE HORIZONTAL for posit ion in g post s in t o loca t in g h oles on t h e en gin e
4 - BOLT - HORIZONTAL STRUT (F ig. 10) a n d (F ig. 11). Slowly lower veh icle a n d posi-
5 - BOLT - STRUT TO TRANSAXLE
6 - COVER - TRANSAXLE CASE LOWER t ion cr a dle/post m ou n t s u n t il t h e en gin e is r est in g on
7 - STRUT - TRANSAXLE TO ENGINE post s. Tigh t en a ll cr a dle/post m ou n t s t o cr a dle fr a m e.
8 - BOLT - STRUT TO ENGINE Th is will keep m ou n t s fr om m ovin g wh en r em ovin g
9 - BOLT - ENGINE REAR MOUNT BRACKET
or in st a llin g en gin e a n d t r a n sm ission .
(41) Discon n ect t h e kn ock sen sor elect r ica l con n ec-
t or (3.8L on ly).
(42) Discon n ect t h e en gin e block h ea t er elect r ica l
con n ect or (if equ ipped).
(43) Rem ove t h e a ccessor y belt spla sh sh ield.
(44) Rem ove a ccessor y dr ive belt (Refer t o 7 -
RE MOVAL).
(45) Discon n ect t h e r a dia t or lower h ose.
(46) Rem ove a ir con dit ion in g com pr essor fr om
en gin e.
(47) Rem ove t h e gen er a t or (Refer t o 8 - E LE CTRI-
CAL/CH ARGING/GE NE RATOR - RE MOVAL).
(48) Rem ove t h e wa t er pu m p pu lley a t t a ch in g Fig. 10 Positioning Special Tool 6848 for use with
bolt s a n d posit ion pu lley bet ween pu m p h u b a n d Adapters 8444 & 6912
h ou sin g. 1 - SLOTS
(49) Discon n ect t h e oil pr essu r e swit ch elect r ica l 2 - SPECIAL TOOLS 6848
con n ect or.
(50) Discon n ect wir in g h a r n ess su ppor t clip fr om (56) Lower veh icle so t h e weigh t of ON LY THE
en gin e oil dipst ick t u be. EN GIN E AN D TRAN S MIS S ION is on t h e cr a dle.
(51) In st a ll Specia l Tools 6912 a n d 8444 Ada pt er s (57) In st a ll a n d secu r e t h e sa fet y st r a ps t o t h e cr a -
on t h e r igh t side (r ea r ) of en gin e block (F ig. 9). dle fixt u r e a n d a r ou n d t h e en gin e (F ig. 12).
(52) Lower t h e veh icle. (58) Rem ove t h e en gin e r igh t side m ou n t t o en gin e
(53) Rem ove t h e power st eer in g pu m p a n d set a t t a ch in g bolt s (F ig. 13).
a side. (59) Rem ove t h e left m ou n t t h r ou gh bolt (F ig. 14).
RS ENGINE 3.3/3.8L 9 - 91
INSTALLATION - ENGINE ASSEMBLY

(1) P osit ion en gin e a n d t r a n sm ission a ssem bly
u n der veh icle. Slowly lower t h e veh icle down over t h e
en gin e a n d t r a n sm ission . It is n ecessa r y t o m ove t h e
en gin e/t r a n sm ission a ssem bly wit h t h e dolly for
clea r a n ce a r ou n d body fla n ges.
(2) Align en gin e a n d t r a n sm ission m ou n t s t o
a t t a ch in g poin t s. In st a ll m ou n t in g bolt s a t t h e r igh t
en gin e m ou n t (F ig. 13) a n d left t r a n sm ission m ou n t
(F ig. 14).
(3) Rem ove t h e sa fet y st r a ps fr om a r ou n d en gin e.
(4) Slowly r a ise veh icle en ou gh t o r em ove t h e
en gin e dolly a n d cr a dle Specia l Tools 6135, 6710,
Fig. 11 Special Tools 6848 with Adapters 6909 6848 a n d 6909 (F ig. 12).
1 - OIL FILTER (5) Rem ove Specia l Tools 6912 a n d 8444 (F ig. 9).
2 - SPECIAL TOOLS 6909 (6) Lower t h e veh icle.
3 - OIL PAN
4 - SPECIAL TOOLS 6848
(7) In st a ll power st eer in g pu m p a n d pr essu r e lin e
su ppor t .
(60) Ra ise veh icle slowly. It is n ecessa r y t o m ove (8) In st a ll t h e gen er a t or a n d wir in g h a r n ess (Refer
t h e en gin e/t r a n sm ission a ssem bly wit h t h e dolly t o t o 8 - E LE CTRICAL/CH ARGING/GE NE RATOR -
a llow for r em ova l a r ou n d body fla n ges. INSTALLATION).
Fig. 12 Positioning Engine Cradle Support Post Mounts

1 - SPECIAL TOOL 8444 5 - SPECIAL TOOLS 6848
2 - SPECIAL TOOLS 6848 6 - SAFETY STRAPS
3 - SPECIAL TOOL 6912 7 - SPECIAL TOOLS 6909
4 - SPECIAL TOOLS 6135 & 6710
9 - 92 ENGINE 3.3/3.8L RS
(16) Con n ect t h e en gin e block h ea t er elect r ica l con -
n ect or (if equ ipped).
(17) Con n ect t h e kn ock sen sor elect r ica l con n ect or
(3.8L on ly).
(18) In st a ll t h e t or qu e con ver t er t o flex pla t e bolt s.
(19) In st a ll t h e t r a n sa xle ca se cover (F ig. 8).
(20) In st a ll t h e power t r a in st r u t s (F ig. 8).
(21) In st a ll t h e en gin e r ea r m ou n t br a cket .
(22) In st a ll t h e en gin e fr on t m ou n t a n d br a cket
a ssem bly.
(23) AWD e qu ip p e d ; In st a ll t h e power t r a n sfer
u n it (P TU) (Refer t o 21 - TRANSMISSION/TRANS-
AXLE /P OWE R TRANSF E R UNIT - INSTALLA-
TION).
(24) In st a ll t h e a xle sh a ft s (Refer t o 3 - DIF F E R-
E NTIAL & DRIVE LINE /H ALF SH AF T - INSTALLA-
Fig. 13 Right Mount to Engine TION).
1 - BOLT
(25) Con n ect exh a u st pipe t o m a n ifold (F ig. 7).
2 - MOUNT BRACKET (26) In st a ll cr ossm em ber cr a dle pla t e (F ig. 6).
3 - ENGINE RIGHT MOUNT ASSEMBLY (27) Lower veh icle.
(28) Con n ect t r a n sa xle sh ift lin ka ge.
(29) Con n ect t r a n sa xle elect r ica l con n ect or s.
(30) Rem ove plu gs fr om t r a n sm ission cooler h oses
a n d in st a ll t r a n sa xle oil cooler lin e ser vice splice kit .
Refer t o in st r u ct ion s in clu ded wit h kit .
(31) In st a ll t r a n sa xle dipst ick t u be a n d a t t a ch
elect r ica l h a r n ess clip.
(32) Con n ect t h e A/C lin es t o com pr essor.
(33) Con n ect t h e A/C com pr essor elect r ica l con n ec-
t or.
(34) E va cu a t e a n d r ech a r ge A/C syst em .
(35) Con n ect cr a n ksh a ft a n d ca m sh a ft posit ion
sen sor s.
(36) Con n ect t h e fu el in ject or elect r ica l h a r n ess
con n ect or a n d en ga ge clip t o su ppor t br a cket .
(37) Con n ect en gin e coola n t t em per a t u r e (E CT)
sen sor a n d ign it ion coil elect r ica l con n ect or s.
(38) Con n ect t h e gr ou n d st r a p t o r ea r of cylin der
h ea d.
(39) In st a ll power st eer in g r eser voir.
Fig. 14 LEFT MOUNT TO FRAME BRACKET (40) E n ga ge wir e h a r n ess clip t o en gin e r igh t side
1 - FRAME BRACKET m ou n t .
2 - FRAME RAIL - LEFT (41) Con n ect t h e br a ke boost er a n d speed con t r ol
3 - BOLT
4 - TRANSAXLE MOUNT va cu u m h oses.
(42) Con n ect t h e va cu u m h oses t o t h e t h r ot t le
(9) Ra ise veh icle. body.
(10) At t a ch wir in g h a r n ess su ppor t clip t o t h e (43) Con n ect t h e E GR t r a n sdu cer elect r ica l con n ec-
en gin e oil dipst ick t u be. t or (if equ ipped).
(11) Con n ect oil pr essu r e swit ch elect r ica l con n ec- (44) Con n ect t h e TP S, IAC, a n d MAP sen sor elec-
t or. t r ica l con n ect or s.
(12) In st a ll t h e A/C com pr essor. (45) Con n ect t h r ot t le ca bles t o t h r ot t le body.
(13) In st a ll t h e wa t er pu m p pu lley. (46) In st a ll t h e r a dia t or fa n s (Refer t o 7 - COOL-
(14) Con n ect t h e r a dia t or lower h ose. ING/E NGINE /RADIATOR FAN - INSTALLATION).
(15) In st a ll t h e a ccessor y dr ive belt a n d spla sh (47) Con n ect t h e r a dia t or u pper h ose.
sh ield (Refer t o 7 - COOLING/ACCE SSORY DRIVE / (48) Con n ect t h e h ea t er h oses. Rem ove pin ch -off
DRIVE BE LTS - INSTALLATION). plier s fr om t h e r ea r h ea t er h oses (if equ ipped).
RS ENGINE 3.3/3.8L 9 - 93
(49) In st a ll t h e r a dia t or u pper su ppor t cr ossm em - CY LI N DER BLOCK
ber (Refer t o 23 - BODY/E XTE RIOR/GRILLE OP E N-
ING RE INF ORCE ME NT - INSTALLATION).
(50) In st a ll t h e wiper m odu le (Refer t o 8 - E LE C- DESCRIPTION SPECIFICATION
TRICAL/WIP E RS/WASH E RS/WIP E R MODULE - Metric Standard
INSTALLATION). Cylinder Bore 92.993-93.007 3.661-3.6617 in.
(51) Con n ect t h e fu el lin e t o fu el r a il (Refer t o 14 - Diameter mm
F UE L SYSTE M/F UE L DE LIVE RY/F UE L LINE S - (Standard) 3.3L
Cylinder Bore 95.993-96.007 3.7792-3.780 in.
(52) In st a ll t h e a ir clea n er a n d h oses.
Diameter mm
(53) In st a ll n ew oil filt er. F ill en gin e cr a n kca se
(Standard) 3.8L
wit h pr oper oil t o cor r ect level.
(54) Con n ect n ega t ive ca ble t o ba t t er y. Out of Round 0.076 mm 0.003 in.
(55) F ill t h e coolin g syst em (Refer t o 7 - COOLING (Service Limits)
- STANDARD P ROCE DURE ). Taper (Service 0.051 mm 0.002 in.
(56) St a r t en gin e a n d r u n u n t il oper a t in g t em per- Limits)
a t u r e is r ea ch ed. Lifter Bore 22.980-23.010 0.905-0.906 in.
(57) Adju st t r a n sm ission lin ka ge, if n ecessa r y. Diameter mm
Deck Surface 0.1 mm 0.004 in.
SPECI FI CAT I ON S Flatness (Max.)
3.3/3.8L ENGINE CRAN K SH AFT

GEN ERAL DESCRI PT I ON
Metric Standard
Metric Standard
Connecting Rod 57.979-58.005 2.2827-2.2837
Engine Type 60° V-6 Engine Journal mm in.
Number of 6 Diameter
Cylinders Main Bearing 63.993-64.013 2.5194-2.5202
Displacement 3.3Liters 201 cu.in. Journal mm in.
3.3L Diameter
Displacement 3.8 Liters 231 cu. in. Journal 0.025 mm 0.001 in.
3.8L Out-of-Round
Bore 3.3L 93.0 mm 201 cu.in. (Max.)
Bore 3.8L 96.0 mm 3.779 cu.in. Journal Taper 0.025 mm 0.001 in
(Max.)
Stroke 3.3L 81 mm 3.188 in.
End Play 0.09-0.24 mm 0.0036-0.0095
Stroke 87 mm 3.425 in.
in.
Compression - 9.35:1
Ratio 3.3L
Main Bearing 0.011-0.055 0.0005-0.0022
Compression - 9.6:1
Diametrical mm in.
Ratio 3.8L
Clearance
Firing Order - 1-2-3-4-5-6 1-2-3-4
Compression 689.5 kPa 100 psi. Wear Limit 0.076 mm 0.003 in.
Pressure-
Minimum
Cylinder - 25%
Compression
(Max. Difference
Between
Cylinders
9 - 94 ENGINE 3.3/3.8L RS
CON N ECT I N G RODS PI ST ON RI N GS

Bearing 0.019-0.065 0.017-0.020 in. Ring End Gap
Clearance mm. Top 0.18-0.38 mm 0.007-0.015 in.
Wear Limit 0.074 mm 0.003 in. Compression
Side Clearance 0.13-0.32 mm 0.005-0.013 in. Ring
Wear Limit 0.38 mm 0.015 in. Second 0.28-0.57 mm 0.011-0.022 in.
Compression
Ring
PI ST ON S
Oil Control 0.23-0.78 mm 0.009-0.030 in.
(Steel Rails)
Wear Limit- 1.0 mm 0.039 in.
Metric Standard
Compression
Piston Diameter 92.968-92.998 3.660-3.661 in. Rings
3.3L-Measured mm.
Wear Limit-Oil 1.88 mm 0.074 in.
39.8 mm (1.567
Control Steel
in) From Piston
Rails
Top
Ring Side
Piston Diameter 95.968-95.998 3.778-3.779 in.
Clearance
3.8L-Measured mm.
33.01 mm (1.30 Top 0.030-0.080 0.0012-0.0031
in) From Piston Compression mm in.
Top Ring 3.3L
Clearance in -0.005-0.039 -0.0002–0.0015 Top 0.030-0.069 0.0012-0.0027
Bore @ Size mm in. Compression mm in.
Location (New) Ring 3.8L
Weight 3.3L 362 ± 5 grams 12.77 ± 0.1764 Second 0.030-0.095 0.0012-0.0037
oz. Compression mm in.
Weight 3.8L 426 ± 5 grams 15.03 ± 0.1764 Ring 3.3L
oz. Second 0.041-0.085 0.0016-0.0033
Compression mm in.
PI ST ON PI N S Ring 3.8L
Oil Ring (Steel 0.039-0.200 0.0015-0.0078
DESCRIPTION SPECIFICATION Ring) mm in.
Metric Standard Wear Limit- Top 0.10 mm 0.004 in.
Type Press Fit in Rod (Serviced as a Ring
Assembly) Wear Limit-2nd 0.13 mm 0.005
Clearance in 0.006-0.019 0.0002-0.0007 Ring
Piston @ 21C mm in. Wear Limit Oil 0.266 mm 0.009
(70°F) Ring Pack
Clearance in Interference Fit Ring Width-Top 1.46-1.49 mm 0.0575-0.058 in.
Connecting Rod Compression
Diameter 22.87-22.88 0.9007-0.9009 Ring 3.3L
mm in. Ring Width-Top 1.175-1.190 0.0462-0.0468
Length 3.3L 67.25-67.75 2.648-2.667 in. Compression mm
mm Ring 3.8L
Length 3.8L 71.25-71.75 2.805-2.824 in.
mm
RS ENGINE 3.3/3.8L 9 - 95
DESCRIPTION SPECIFICATION Closes-3.3L - 13°

Metric Standard (ATDC)
Ring Width-2nd 1.46-1.49 mm 0.0575-0.058 in. Closes-3.8L - 18°
Compression (ATDC)
Ring 3.3L and Opens-3.3L - 43°
3.8L (BBDC)
Ring Width-Oil 0.435-0.490 -.017-0.019 in. Opens-3.8L - 46°
Ring (Steel mm (BBDC)
Rails) 3.3L Duration-3.3L - 236°
Ring Width-Oil 0.435-0.510 0.017-0.020 Duration-3.8L - 244°
Ring (Steel mm
Intake Valve
Rails) 3.8L
Timing
Closes-3.3L - 52°
CAM SH AFT (ABDC)
Closes-3.8L - 63°
DESCRIPTION SPECIFICATION (ABDC)
Metric Standard Opens-3.3L - 6°
Journal (ATDC)
Diameter Opens-3.8L - 1°
#1 50.724-50.775 1.997-1.999 in. (ATDC)
mm Duration-3.3L - 226°
#2 50.317-50.368 1.9809-1.9829 Duration-3.8L - 242°
mm in.
Valve Overlap- - 7°
#3 49.936-49.987 1.9659-1.9679 3.3L
mm in.
Valve Overlap- - 17°
#4 49.530-49.581 1.9499-1.9520 3.8L
mm in.
Bearing 0.025-0.101 0.001-0.004 in.
H Y DRAU LI C LI FT ER
Clearance- mm
Diametrical
Bearing 0.127 mm 0.005 in.
Clearance Metric Standard
(Max.Allowable) Type Hydraulic Roller
End Play 0.254-0.508 0.010-0.020 in. Outside 22.949-22.962 0.903-0.904 in.
mm Diameter mm
Camshaft Clearance in 0.020-0.061 0.0007-0.0024
Bearing Block mm in.
Diameter
#1 50.800-50.825 1.9999-2.0009 CY LI N DER H EAD
in.
#2 50.393-50.419 1.9839-1.9849 DESCRIPTION SPECIFICATION
mm in.
Metric Standard
#3 50.013-50.038 1.9690-1.9699
mm in. Gasket 0.65-0.75 mm 0.0007-0.0024
Thickness in.
#4 49.606-49.632 1.9529-1.954 in. (Compressed)
mm
Exhaust Valve
Timing
9 - 96 ENGINE 3.3/3.8L RS
VALV ES VALV E GU I DE

Face Angle- - 45-45.5° Guide Bore 6.975-7.00 mm 0.274-0.275 in.
Intake Diameter (Std.)
Face Angle- - 45-45.5°
Exhaust VALV E M ARGI N
Head Diameter- 47.87-48.13 1.88-1.89 in.
Intake mm DESCRIPTION SPECIFICATION
Head Diameter- 35.37-35.63 1.39-1.40 in. Metric Standard
Exhaust mm
Intake 0.825-0.973 0.032-0.038 in.
Valve Lift (Zero 9.80 mm 0.385 in. mm
Lash)-Intake
Exhaust 1.565-1.713 0.061-0.067 in.
and Exhaust-
mm
3.3L
Valve Lift (Zero 11.0 mm 0.433 in.
Lash)-Intake VALV E ST EM DI AM ET ER
and Exhaust-
3.8L DESCRIPTION SPECIFICATION
Valve Length- 125.84-126.6 4.95-4.98 in. Metric Standard
Intake mm Intake 6.935-6.953 0.2718-0.2725
Valve Length- 127.20-127.96 5.00-5.04 in. (Standard) mm in.
Exhaust Exhaust 6.906-6.924 0.2718-0.2725
Valve Stem to 48.1-49.7 mm 1.89-1.95 in. (Standard) mm in.
Tip Height
(valve tip to
VALV E ST EM T O GU I DE CLEARAN CE
spring seat
washer)-Intake
Valve Stem to 48.53-50.09 1.91-1.97 in.
Tip Height mm Metric Standard
(valve tip to Intake 0.025-0.065 0.001-0.0025 in.
spring seat mm
washer)- Exhaust 0.059-0.094 0.002-0.0037 in.
Exhaust mm
Max Allowable- 0.247 mm 0.010 in.
VALV E SEAT Intake (Rocking
Method)
DESCRIPTION SPECIFICATION Max Allowable- 0.414 mm 0.016 in.
Metric Standard Exhaust
(Rocking
Angle - 44.5-45°
Method)
Run Out 0.0762 mm 0.003 in.
(Service Limits)
PU SH RODS
Width-Intake 1.50-2.00 mm 0.057-0.078 in.
and Exhaust
Metric Standard
Length 135.438 mm 5.33 in.
RS ENGINE 3.3/3.8L 9 - 97
VALV E SPRI N G OI L PU M P

Free Length- 51.4 mm 2.02 in. Clearance Over 0.10 mm 0.004 in.
Type A rotors-Inner and
Free Length- 53.4 mm 2.10 in. Outer
Type B Cover 0.025 mm 0.001 in.
Wire Diameter 3.95-4.77 mm 0.15-0.19 in. Out-Of-Flat
Type A (Max.)
Wire Diameter 4.19-4.29 mm 0.16-0.17 in. Inner Rotor 7.64 mm 0.301 in.
Type B Thickness
Number of Coils 7.52 Outer Rotor 7.64 mm 0.301 in.
Type A Thickness (Min)
Number of Coils 7.25 Outer Rotor 0.039 mm 0.015 in.
Type B Clearance
(Max)
Spring Tension 376.4-424.4 N 84.6-95.6 lbs.
(Valve Closed) @ 41.9 mm @ 1.65 in. Outer Rotor 79.95 mm 3.148 in.
Type A Diameter (Min)
Spring Tension 863.9-959.9 N 194.2-215.8 lbs. Tip Clearance 0.20 mm 0.008 in.
(Valve Open) @ 41.9 mm @ 1.65 in. Between Rotors
Type A (Max)
Spring Tension 377-423 N @ 84.8-95.2 lbs.
(Valve Closed) 41.9 mm @ 1.65 in.
Type B
Spring Tension 880-962 N @ 197.9-216.3 lbs. DESCRIPTION N·m Ft. In.
(Valve Open) 30.91 mm @ 122 in. Lbs. Lbs.
Type B Camshaft Sprocket—Bolt 54 40 —
Installed Height 41.1-42.7 mm 1.61-1.68 in Camshaft Thrust 12 — 105
Plate—Bolts
LU BRI CAT I ON Connecting Rod 54 +1⁄4 40 —
Cap—Bolts turn +1⁄4
DESCRIPTION SPECIFICATION turn
Metric Standard Crankshaft Main Bearing 41 +1⁄4 30 —
At Curb Idle 34.47 kPa 5 psi Cap—Bolts turn +1⁄4
Speed* turn
(Minimum with Crankshaft Main Bearing 61 45 —
engine at Cap Cross Bolts (3.8L)
operating Crankshaft Oil Seal 12 — 105
temperature) Retainer Rear—Bolts
At 3000 RPM 205-551 kPa 30-80 psi Crankshaft Damper—Bolt 54 40 —
Oil Filter 62-103 kPa 9-15 psi Cylinder Block Drain 20 15 —
By-Pass Valve Plugs
Setting
Cylinder Head—Bolts (Refer to 9 - ENGINE/
Oil Pressure 14-28 Kpa 2-4 psi CYLINDER HEAD -
Switch Actuating INSTALLATION)
Pressure
Cylinder Head Cover— 12 — 105
caution: Bolts
*If pressure is ZERO at curb idle, DO NOT run engine
Flex Plate to Crankshaft 95 70 —
at 3000 rpm.
9 - 98 ENGINE 3.3/3.8L RS
DESCRIPTION N·m Ft. In. SPECI AL T OOLS

Lbs. Lbs.
Engine Mounting (Refer to 9 - ENGINE/ 3.3/3.8L ENGINE
ENGINE MOUNTING)
Exhaust Manifold—Bolts 23 — 200
Exhaust Crossover 54 40 —
Pipe—Bolts
Intake Manifold - 23 — 200
Lower—Bolts
Intake Manifold - Lower 12 — 105
Gasket Retainer—Bolts
Intake Manifold 12 — 105 Dolly 6135
Upper—Bolts
Lifter Yoke Retainer— 12 — 105
Bolts
Oil Filter Attaching Fitting 54 40 —
Oil Cooler Attaching 27 20 —
Fitting
Oil Filter 20 15 —
Oil Filter Adapter—Bolts 28 — 250
Oil Gallery Plug 27 20 — Cradle 6710A
Oil Pan—Bolts 12 — 105
Oil Pan Drain—Plug 27 20 —
Oil Pressure Switch 23 — 200
Oil Pump Cover 12 — 105
Plate—Screws
Oil Pump Pick-up 28 — 250
Tube—Bolt
Oil Dipstick Housing— 48 35 —
Bolts Adapter 6909A
Rocker Arm Shaft—Bolts 23 — 200
Spark Plug 16 12 —
Timing Chain Case Cover
—M8 Bolt 27 20 —
—M10 Bolt 54 40 —
Water Pump—Bolts 12 — 105
Water Pump Pulley— 28 — 250
Bolts
Adapter 8444
RS ENGINE 3.3/3.8L 9 - 99
Indicator, Cylinder Bore C-119

Adapter 6912
Puller 1026
Tester - Valve Spring C-647
Insert, Crankshaft 8450
Compressor, Valve Spring In-vehicle 8453
Crankshaft Damper/Sprocket Installer 8452

9 - 100 ENGINE 3.3/3.8L RS
Valve Spring Compressor Off-vehicle C-3422-D

Remover and Installer, Crankshaft Main Bearing
C-3059
Rear Crankshaft Oil Seal Installer 6926
Adapter, Valve Spring Compressor Off-vehicle 8464
Oil Pressure Gauge C-3292
Remover, Valve Tappet C-4129-A
Adapter 8406
Remover, Crankshaft Front Seal 6341A
Cooling System Tester 7700
Installer, Crankshaft Front Seal C-4992

RS ENGINE 3.3/3.8L 9 - 101
DRB III" with PEP Module OT-CH6010A

AI R CLEAN ER ELEM EN T
REMOVAL
(1) Un sn a p 2 clips.
(2) Lift cover a n d pu ll t owa r d t h e en gin e a n d
r em ove cover t a bs fr om a ir box.
(3) Lift cover a n d r em ove t h e elem en t (F ig. 15).
Combustion Leak Tester C-3685-A
Fig. 15 AIR BOX COVER

INSTALLATION
(1) In st a ll t h e a ir filt er elem en t in t o a ir box (F ig.
15).
(2) Move cover so t h a t t h e t a bs in ser t in t o t h e a ir
Compression Test Adapter 8116 box.
(3) P u sh cover down a n d sn a p t h e 2 clips.
AI R CLEAN ER H OU SI N G
REMOVAL
9 - 102 ENGINE 3.3/3.8L RS
AI R CLEAN ER H OU SI N G (Cont inue d)
(2) Discon n ect t h e in let a ir t em per a t u r e sen sor DIAGNOSIS AND TESTING—CYLINDER HEAD
(F ig. 16).
GASKET
A cylin der h ea d ga sket lea k ca n be loca t ed bet ween
a dja cen t cylin der s or bet ween a cylin der a n d t h e
a dja cen t wa t er ja cket .
lea kin g bet ween a dja cen t cylin der s a r e:
• Loss of en gin e power
• E n gin e m isfir in g
• P oor fu el econ om y
lea kin g bet ween a cylin der a n d a n a dja cen t wa t er
ja cket a r e:
• E n gin e over h ea t in g
• Loss of coola n t
• E xcessive st ea m (wh it e sm oke) em it t in g fr om
exh a u st
• Coola n t foa m in g
CYLINDER-TO-CYLINDER LEAKAGE TEST

To det er m in e if a n en gin e cylin der h ea d ga sket is
Fig. 16 Inlet Air Temperature Sensor lea kin g bet ween a dja cen t cylin der s, follow t h e pr oce-
(3) Rem ove t h e in let h ose t o t h r ot t le body. du r es in Cylin der Com pr ession P r essu r e Test (Refer
(4) Rem ove t h e bolt for a ir box a t u pper r a dia t or t o 9 - E NGINE - DIAGNOSIS AND TE STING). An
cr oss m em ber. en gin e cylin der h ea d ga sket lea kin g bet ween a dja -
(5) P u ll a ir box u p a n d off over t h e sin gle loca t in g cen t cylin der s will r esu lt in a ppr oxim a t ely a 50–70%
pin . r edu ct ion in com pr ession pr essu r e.
(6) Rem ove a ir box fr om veh icle
CYLINDER-TO-WATER JACKET LEAKAGE TEST
INSTALLATION WARNING: USE EXTREME CAUTION WHEN THE
(1) In st a ll a ir box in t o veh icle a n d on t o t h e loca t -
ENGINE IS OPERATING WITH COOLANT PRES-
in g pin .
SURE CAP REMOVED.
(2) In st a ll bolt t o h old a ir box t o t h e u pper r a dia -
t or cr oss m em ber.
(3) In st a ll t h e in let h ose t o t h e t h r ot t le body. VISUAL TEST METHOD
(4) Con n ect t h e in let a ir t em per a t u r e sen sor (F ig. Wit h t h e en gin e cool, r em ove t h e coola n t pr essu r e
16). ca p. St a r t t h e en gin e a n d a llow it t o wa r m u p u n t il
(5) Con n ect t h e n ega t ive ba t t er y ca ble. t h er m ost a t open s.
If a la r ge com bu st ion /com pr ession pr essu r e lea k
exist s, bu bbles will be visible in t h e coola n t .
CY LI N DER H EAD
COOLING SYSTEM TESTER METHOD
DESCRIPTION
Th e a lu m in u m cylin der h ea ds (F ig. 17) a r e WARNING: WITH COOLING SYSTEM TESTER IN
design ed t o cr ea t e h igh flow com bu st ion ch a m ber s t o PLACE, PRESSURE WILL BUILD UP FAST. EXCES-
im pr ove per for m a n ce, wh ile m in im izin g t h e ch a n ge SIVE PRESSURE BUILT UP, BY CONTINUOUS
t o t h e bu r n r a t e in t h e ch a m ber. Th e cylin der h ea d ENGINE OPERATION, MUST BE RELEASED TO A
in cor por a t es t h e com bu st ion ch a m ber. Two va lves SAFE PRESSURE POINT. NEVER PERMIT PRES-
per-cylin der a r e u sed wit h in ser t ed va lve sea t s a n d SURE TO EXCEED 138 kPa (20 psi).
gu ides. A m u lt i-la yer st eel (MLS) t ype ga sket is u sed
bet ween t h e cylin der h ea d a n d en gin e block. In st a ll Coolin g Syst em Test er 7700 or equ iva len t t o
pr essu r e ca p n eck. St a r t t h e en gin e a n d obser ve t h e
t est er ’s pr essu r e ga u ge. If ga u ge pu lsa t es wit h ever y
power st r oke of a cylin der a com bu st ion pr essu r e
lea k is eviden t .
RS ENGINE 3.3/3.8L 9 - 103
Fig. 17 Cylinder Head and Components

1 - VALVE LOCKS 5 - SPRING SEATS
2 - RETAINERS 6 - CYLINDER HEAD
3 - VALVE SPRINGS 7 - VALVE - EXHAUST
4 - VALVE STEM SEALS 8 - VALVE - INTAKE
CHEMICAL TEST METHOD (6) Rem ove t h e dipst ick a n d t u be (F ig. 18).
Com bu st ion lea ks in t o t h e coolin g syst em ca n a lso (7) Rem ove exh a u st m a n ifold(s). (Refer t o 9 -
be ch ecked by u sin g Bloc-Ch ek Kit C-3685-A or E NGINE /MANIF OLDS/E XH AUST MANIF OLD -
equ iva len t . P er for m t est followin g t h e pr ocedu r es RE MOVAL)
su pplied wit h t h e t ool kit . (8) Rem ove r ocker a r m a n d sh a ft a ssem blies.(Refer
t o 9 - E NGINE /CYLINDE R H E AD/ROCKE R ARMS -
REMOVAL - CYLINDER HEAD RE MOVAL) Rem ove pu sh r ods a n d m a rk p o s itio n s
(1) Dr a in t h e coolin g syst em . (Refer t o 7 - COOL- to e n s u re in s ta lla tio n in o rig in a l lo c a tio n s .
ING - STANDARD P ROCE DURE ) (9) Rem ove t h e eigh t h ea d bolt s fr om ea ch cylin der
(2) Discon n ect n ega t ive ca ble fr om ba t t er y. h ea d a n d r em ove cylin der h ea ds (F ig. 22).
(3) Rem ove u pper a n d lower in t a ke m a n ifolds.
(Refer t o 9 - E NGINE /MANIF OLDS/INTAKE MANI- CLEANING
F OLD - RE MOVAL) To en su r e en gin e ga sket sea lin g, pr oper su r fa ce
pr epa r a t ion m u st be per for m ed, especia lly wit h t h e
WARNING: INTAKE MANIFOLD GASKET IS MADE u se of a lu m in u m en gin e com pon en t s a n d m u lt i-la yer
OF VERY THIN METAL AND MAY CAUSE PER- st eel cylin der h ea d ga sket s.
SONAL INJURY, HANDLE WITH CARE.
NOTE: Multi-Layer Steel (MLS) head gaskets require
(4) Rem ove t h e cylin der h ea d cover s. (Refer t o 9 - a scratch free sealing surface.
(5) Rem ove t h e spa r k plu gs fr om cylin der h ea d.
9 - 104 ENGINE 3.3/3.8L RS
Fig. 19 Checking Cylinder Head Flatness—Typical

INSTALLATION - CYLINDER HEAD
(1) Clea n a ll sea lin g su r fa ces of en gin e block a n d
cylin der h ea ds. (Refer t o 9 - E NGINE - STANDARD
P ROCE DURE )
(2) P osit ion n ew ga sket (s) on en gin e block (F ig.
Fig. 18 DIPSTICK & TUBE
20). Th e left ba n k ga sket is iden t ified wit h t h e “L”
1 - DIPSTICK
2 - BOLT
st a m ped in t h e exposed a r ea of t h e ga sket loca t ed a t
3 - TUBE fr on t of en gin e (sh own in (F ig. 20)). Th e r igh t ba n k
ga sket is iden t ified wit h a “R” st a m ped in t h e
Rem ove a ll ga sket m a t er ia l fr om cylin der h ea d a n d exposed a r ea of t h e ga sket a lso, bu t is loca t ed a t t h e
block (Refer t o 9 - E NGINE - STANDARD P ROCE - r ea r of t h e en gin e.
DURE ). Be ca r efu l n ot t o gou ge or scr a t ch t h e a lu m i-
n u m h ea d sea lin g su r fa ce.
Clea n a ll en gin e oil pa ssa ges.
INSPECTION
(1) Befor e clea n in g, ch eck for lea ks, da m a ge a n d
cr a cks.
(2) Clea n cylin der h ea d a n d oil pa ssa ges.
(3) Ch eck cylin der h ea d for fla t n ess (F ig. 19).
(4) Cylin der h ea d m u st be fla t wit h in :
• St a n da r d dim en sion = less t h a n 0.05 m m (0.002
in ch .)
• Ser vice Lim it = 0.2 m m (0.008 in ch .)
• Gr in din g Lim it = Ma xim u m of 0.2 m m (0.008
in ch .) is per m it t ed.
Fig. 20 Head Gasket Installation
CAUTION: 0.20 mm (0.008 in.) MAX is a combined 1 - CYLINDER HEAD GASKET
total dimension of the stock removal limit from cyl- 2 - LOCATION IDENTIFICATION (L = LEFT BANK, R = RIGHT
inder head and block top surface (Deck) together. BANK)
(3) Th e c y lin d e r h e a d bo lts a re to rqu e d u s in g

th e to rqu e y ie ld m e th o d , th e y s h o u ld be e x a m -
in e d B EF ORE re u s e . If th e th re a d s a re n e c k e d
d o w n , th e bo lts m u s t be re p la c e d (F ig. 21).
RS ENGINE 3.3/3.8L 9 - 105
(4) Neckin g ca n be ch ecked by h oldin g a sca le or (11) In st a ll n ew O-r in g on dipst ick t u be. In st a ll
st r a igh t edge a ga in st t h e t h r ea ds. If a ll t h e t h r ea ds dipst ick t u be a ssem bly (F ig. 18).
do n ot con t a ct t h e sca le t h e bolt sh ou ld be r epla ced. (12) In st a ll t h e spa r k plu gs.
(13) In st a ll u pper a n d lower in t a ke m a n ifolds.
(Refer t o 9 - E NGINE /MANIF OLDS/INTAKE MANI-
F OLD - INSTALLATION)
(14) F ill t h e coolin g syst em . (Refer t o 7 - COOL-
CY LI N DER H EAD COV ER(S)

DESCRIPTION
Fig. 21 Checking Bolts for Stretching (Necking) Th e cylin der h ea d cover s a r e m a de of st a m ped
1 - STRETCHED BOLT
st eel. Th e cover s a r e sea led wit h st eel r ein for ced sil-
2 - THREADS ARE NOT STRAIGHT ON LINE icon r u bber ga sket s. Th e cylin der h ea d cover u ses
3 - THREADS ARE STRAIGHT ON LINE r u bber isola t or s a t ea ch fa st en er loca t ion (F ig. 23).
NOTE: Due to the tight packaging near the cylinder
(5) Tigh t en t h e cylin der h ea d bolt s 1–8 in t h e head covers, which makes spill clean-up difficult, a
sequ en ce sh own in (F ig. 22). Usin g t h e 4 st ep t or qu e spill during an engine oil change may be misinter-
t u r n m et h od, t igh t en a ccor din g t o t h e followin g va l- preted as an oil leak. When investigating an oil leak
u es: in the location of the cylinder head covers and
• St ep 1: Bolt s 1 – 8 t o 61 N·m (45 ft . lbs.) intake manifold, follow the procedure found in Oil
• St ep 2: Bolt s 1 – 8 t o 88 N·m (65 ft . lbs.) Leak Diagnosis (Refer to 9 - ENGINE - DIAGNOSIS
• St ep 3: Bolt s 1 – 8 (a ga in ) t o 88 N·m (65 ft . lbs.) AND TESTING) for determining the source of a leak.
• St ep 4: Bolt s 1 – 8 t u r n a n a ddit ion a l 1/4 Tu r n .
(D o n o t u s e a to rqu e w re n c h fo r th is s te p .)
NOTE: Bolt torque after 1/4 turn should be over 122

N·m (90 ft. lbs.). If not, replace the bolt.
Fig. 22 CYLINDER HEAD TIGHTENING SEQUENCE

(6) In spect pu sh r ods a n d r epla ce wor n or ben t
r ods.
(7) In st a ll t h e pu sh r ods.
(8) In st a ll t h e r ocker a r m a n d sh a ft a ssem blies. Fig. 23 Cylinder Head Cover
(Refer t o 9 - E NGINE /CYLINDE R H E AD/ROCKE R 1 - CYLINDER HEAD COVER
ARMS - INSTALLATION) 2 - BOLT
(9) In st a ll t h e cylin der h ea d cover s. (Refer t o 9 -
(10) In st a ll t h e exh a u st m a n ifolds. (Refer t o 9 -
E NGINE /MANIF OLDS/E XH AUST MANIF OLD -
INSTALLATION)
9 - 106 ENGINE 3.3/3.8L RS
CY LI N DER H EAD COV ER - (3) Assem ble ga sket t o cylin der cover by in ser t in g
t h e bolt a ssem blies t h r ou gh ea ch bolt h ole on t h e
RI GH T cover a n d ga sket (F ig. 25).
REMOVAL
(2) Rem ove t h e wiper m odu le. (Refer t o 8 - E LE C-
RE MOVAL)
(3) Discon n ect spa r k plu g wir es fr om plu gs.
(4) Discon n ect P CV h ose fr om cylin der h ea d cover
(F ig. 24).
(6) Rem ove cylin der h ea d cover a n d ga sket (F ig.
23).
Fig. 25 CYLINDER HEAD COVER GASKET

1 - CYLINDER HEAD COVER
2 - BOLT
3 - SEAL (SERVICED WITH BOLT)
4 - GASKET
(4) In st a ll cylin der h ea d cover a n d bolt s (F ig. 26).

(5) Tigh t en cylin der h ea d cover bolt s t o 12 N·m
(105 in . lbs.) (F ig. 26).
Fig. 24 PCV Hose

1 - HOSE - PCV
2 - PCV VALVE
INSTALLATION Fig. 26 Cylinder Head Cover

(1) Clea n cylin der h ea d a n d cover m a t in g su r fa ces. 1 - CYLINDER HEAD COVER
In spect cylin der h ea d cover su r fa ce for fla t n ess. 2 - BOLT
Repla ce ga sket a s n ecessa r y.
(2) In spect sea l on t h e cover bolt for wea r or da m - (6) Con n ect P CV h ose t o cylin der h ea d cover.
a ge (F ig. 25). Repla ce bolt a ssem bly a s n ecessa r y. (7) Con n ect spa r k plu g wir es t o spa r k plu gs.
(8) In st a ll wiper m odu le. (Refer t o 8 - E LE CTRI-
NOTE: The cylinder head cover bolts contain a CAL/WIP E RS/WASH E RS/WIP E R MODULE -
torque limiter sleeve and a seal (Fig. 25). The seal INSTALLATION)
and torque sleeve is replaced with the bolt. (9) Con n ect n ega t ive ca ble t o ba t t er y.
RS ENGINE 3.3/3.8L 9 - 107
CY LI N DER H EAD COV ER -

LEFT
REMOVAL
(1) Discon n ect spa r k plu g wir es fr om spa r k plu gs.
(2) Discon n ect cr a n kca se ven t h ose fr om cylin der
h ea d cover.
(4) Rem ove cylin der h ea d cover a n d ga sket .
INSTALLATION
(1) Clea n cylin der h ea d a n d cover m a t in g su r fa ces.
In spect cylin der h ea d cover su r fa ce for fla t n ess.
Repla ce ga sket a s n ecessa r y.
(2) Assem ble ga sket t o cylin der cover by in ser t in g
t h e fa st en er s t h r ou gh ea ch bolt h ole on cover a n d
ga sket (F ig. 25).
(3) In st a ll t h e cylin der h ea d cover a n d bolt s (F ig.
26).
(4) Tigh t en cylin der h ea d cover bolt s t o 12 N·m
(105 in . lbs.) (F ig. 26).
(5) Con n ect cr a n kca se ven t h ose. Fig. 27 VALVE FACE AND SEAT
(6) Con n ect spa r k plu g wir es t o spa r k plu gs. 1 - VALVE FACE WIDTH
2 - VALVE FACE ANGLE
3 - SEAT ANGLE
I N TAK E/EX H AU ST VALV ES & 4 - SEAT CONTACT AREA
SEAT S
DESCRIPTION
Th e va lves h a ve ch r om e pla t ed va lve st em s wit h
fou r-bea d lock gr ooves. Th e va lve st em sea ls a r e
m a de of Vit on r u bber.
OPERATION
Th e t wo va lves per cylin der a r e open ed u sin g
h ydr a u lic lift er s, pu sh r ods, a n d r ocker a r m s.
STANDARD PROCEDURE - REFACING VALVES

Fig. 28 Valve Margin
AND VALVE SEATS 1 - VALVE FACE
Th e in t a ke a n d exh a u st va lves a n d sea t s a r e 2 - VALVE MARGIN
m a ch in ed t o specific a n gles (F ig. 27).
(2) Mea su r e t h e con cen t r icit y of va lve sea t u sin g
VALVES dia l in dica t or (F ig. 30). Tot a l r u n ou t sh ou ld n ot
(1) In spect t h e r em a in in g m a r gin a ft er t h e va lves exceed 0.051 m m (0.002 in .) t ot a l in dica t or r ea din g.
a r e r efa ced (F ig. 28). (Refer t o 9 - E NGINE - SP E C- (3) In spect t h e va lve sea t u sin g P r u ssia n blu e t o
IF ICATIONS) det er m in e wh er e t h e va lve con t a ct s t h e sea t . To do
t h is, coa t va lve sea t LIGHTLYwit h P r u ssia n blu e
VALVE SEATS t h en set va lve in pla ce. Rot a t e t h e va lve wit h ligh t
pr essu r e. If t h e blu e is t r a n sfer r ed t o t h e cen t er of
CAUTION: Remove metal from valve seat only. Do va lve fa ce, con t a ct is sa t isfa ct or y. If t h e blu e is t r a n s-
not remove material from cylinder head (Fig. 29). fer r ed t o t op edge of va lve fa ce, lower va lve sea t wit h
(1) Wh en r efa cin g va lve sea t s, it is im por t a n t t h a t a 15 degr ee st on e. If t h e blu e is t r a n sfer r ed t o t h e
t h e cor r ect size va lve gu ide pilot be u sed for r esea t - bot t om edge of va lve fa ce r a ise va lve sea t wit h a 65
in g st on es. A t r u e a n d com plet e su r fa ce m u st be degr ees st on e.
obt a in ed.
9 - 108 ENGINE 3.3/3.8L RS
I N TAK E/EX H AU ST VALV ES & SEAT S (Cont inue d)
(6) Ch eck t h e va lve spr in g in st a lled h eigh t a ft er
r efa cin g t h e va lve a n d sea t (F ig. 31).
If v a lv e s a n d /o r s e a ts a re re g ro u n d , m e a s u re
th e in s ta lle d h e ig h t o f s p rin g s (F ig . 31), m a k e
s u re m e a s u re m e n ts a re ta k e n fro m to p o f
s p rin g s e a t to th e bo tto m s u rfa c e o f s p rin g
re ta in e r. If h e ig h t is g re a te r th a n s p e c ific a -
tio n s , in s ta ll a 0.794 m m (0.0312 in .) s p a c e r in
h e a d c o u n te rbo re to brin g s p rin g h e ig h t ba c k
w ith in s p e c ific a tio n s .
Fig. 29 Refacing Valve Seats

1 - REFACING STONE MUST NOT CUT INTO CYLINDER HEAD
2 - STONE
3 - PILOT
4 - SEAT
Fig. 31 Checking Valve and Spring Installed Height

1 - SPRING RETAINER
2 - VALVE INSTALLED HEIGHT* - 48.1–49.7 mm (1.89–1.95 in.)
3 - CYINDER HEAD SURFACE
4 - SPRING INSTALLED HEIGHT* - 41.1–42.7 mm (1.61–1.68 in.)
*(MEASURED FROM TOP OF SPRING SEAT)
REMOVAL
(1) Wit h cylin der h ea d r em oved, com pr ess va lve
spr in gs u sin g Va lve Spr in g Com pr essor Tool
C-3422-D wit h a da pt er 8464 (Refer t o 9 - E NGINE -
Fig. 30 Measurement of Valve Seat Runout SP E CIAL TOOLS).
(2) Rem ove va lve r et a in in g locks.
1 - DIAL INDICATOR
(3) Slowly r elea se va lve spr in g com pr essor.
NOTE: Valve seats which are worn or burned can Rem ove va lve spr in g r et a in er, va lve spr in g, a n d va lve
be reworked, provided that correct angle and seat st em sea l.
width are maintained. Otherwise cylinder head must (4) Befor e r em ovin g va lves, re m o v e a n y bu rrs
be replaced. fro m v a lv e s te m lo c k g ro o v e s to p re v e n t d a m -
a g e to th e v a lv e g u id e s . Iden t ify va lves t o in su r e
(4) Wh en sea t is pr oper ly posit ion ed t h e widt h of in st a lla t ion in or igin a l loca t ion .
in t a ke a n d exh a u st sea t s sh ou ld be 1.50–2.00 m m
(0.059–0.078 in .) (F ig. 27). CLEANING
(5) Aft er gr in din g t h e va lve sea t s or fa ces, in st a ll (1) Clea n a ll va lves t h or ou gh ly and disca r d
t h e va lve in cylin der h ea d a n d ch eck va lve in st a lled bu r n ed, wa r ped a n d cr a cked va lves.
h eigh t by m ea su r in g fr om va lve t ip t o spr in g sea t
(F ig. 31). Rem ove va lve fr om cylin der h ea d a n d gr in d INSPECTION
va lve t ip u n t il wit h in specifica t ion s. Ch eck va lve t ip
for scor in g. Th e t ip ch a m fer sh ou ld be r egr ou n d (if VALVES
n ecessa r y) t o pr even t sea l da m a ge wh en t h e va lve is (1) Clea n a n d in spect va lves t h or ou gh ly. Repla ce
in st a lled. bu r n ed, wa r ped a n d cr a cked va lves.
RS ENGINE 3.3/3.8L 9 - 109
I N TAK E/EX H AU ST VALV ES & SEAT S (Cont inue d)
(2) Mea su r e va lve st em s for wea r (F ig. 32). F or
va lve specifica t ion s, (Refer t o 9 - E NGINE - SP E CI-
F ICATIONS).
NOTE: Valve stems are chrome plated and should

not be polished (Fig. 32).
Fig. 33 Measuring Valve Guide Wear - Typical

(4) In st a ll t h e va lve spr in gs. (Refer t o 9 -
E NGINE /CYLINDE R H E AD/VALVE SP RINGS -
INSTALLATION)
Fig. 32 Intake and Exhaust Valves VALV E SPRI N GS

1 - MARGIN
2 - FACE DESCRIPTION
3 - STEM
4 - VALVE SPRING RETAINER LOCK GROOVES Th er e a r e t wo in t er ch a n gea ble, floa t in g (spr in g
r ot a t es du r in g oper a t ion ), va lve spr in g design s. Type
VALVE GUIDES A m a y be iden t ified by t h e cou n t er clockwise (spr in g
(1) Rem ove ca r bon a n d va r n ish deposit s fr om spir a ls down a n d t o t h e left ) a ppea r a n ce, An d Type B
in side of va lve gu ides wit h a r elia ble gu ide clea n er. m a y be iden t ified by t h e clockwise (spr in g spir a ls
(2) Mea su r e va lve st em -t o-gu ide clea r a n ce a s fol- down a n d t o t h e r igh t ) a ppea r a n ce. Bot h of t h e va lve
lows: spr in gs a r e a bee-h ive sh a ped design bu t h a ve differ-
(3) In st a ll va lve in t o cylin der h ea d so it is 15 m m en t specifica t ion s (F ig. 34). Th e spr in gs a r e sea t ed on
(0.590 in ch .) off t h e va lve sea t . A sm a ll piece of h ose a st eel wa sh er on t h e cylin der h ea d wit h r et a in er s
m a y be u sed t o h old va lve in pla ce. a n d locks r et a in in g t h e spr in gs (F ig. 35). Th e spr in gs
(4) At t a ch dia l in dica t or Tool C-3339 t o cylin der a r e in st a lled wit h t h e sm a ller dia m et er a ga in st
h ea d a n d set it a t r igh t a n gle of va lve st em bein g spr in g r et a in er (F ig. 34).
m ea su r ed (F ig. 33).
(5) Move va lve t o a n d fr om t h e in dica t or. F or cler- OPERATION
a n ce specifica t ion s, (Refer t o 9 - E NGINE - SP E CIF I- Th e va lve spr in g r et u r n s t h e va lve a ga in st it s sea t
CATIONS). for a posit ive sea l of t h e com bu st ion ch a m ber.
NOTE: Replace cylinder head if stem-to-guide clear-

ance exceeds specifications, or if guide is loose in REM OVAL
cylinder head.
REMOVAL - CYLINDER HEAD OFF
(1) Wit h t h e cylin der h ea d on a ben ch , posit ion
INSTALLATION Specia l Tool C-3422-D wit h 8464 Ada pt er on t h e
(1) Coa t va lve st em s wit h clea n en gin e oil a n d va lve a n d spr in g r et a in er (F ig. 36).
in ser t t h em in cylin der h ea d. (2) Com pr ess t h e spr in g on ly en ou gh t o r em ove t h e
(2) In st a ll va lve spr in g sea t on h ea d (F ig. 35). va lve r et a in er locks.
(3) In st a ll n ew sea ls on a ll va lve st em s a n d over (3) Slowly r elea se t h e spr in g t en sion a n d r em ove
va lve gu ides (F ig. 35). In st a ll va lve spr in gs a n d va lve t h e va lve spr in g a n d r et a in er.
r et a in er s (F ig. 35). (4) F or r em ova l of t h e va lve st em sea l (Refer t o 9 -
E NGINE /CYLINDE R H E AD/VALVE STE M SE ALS -
RE MOVAL).
9 - 110 ENGINE 3.3/3.8L RS
VALV E SPRI N GS (Cont inue d)
Fig. 34 Valve Spring - Type A Fig. 36 VALVE SPRING - REMOVE/INSTALL

1 - VALVE SPRING (TOP - SMALLER DIAMETER) 1 - SPECIAL TOOL C-3422-D SPRING COMPRESSOR
2 - SPECIAL TOOL 8464 ADAPTER
Fig. 35 VALVE COMPONENTS

1 - VALVE LOCKS 5 - SPRING SEATS
2 - RETAINERS 6 - CYLINDER HEAD
3 - VALVE SPRINGS 7 - VALVE - EXHAUST
4 - VALVE STEM SEALS 8 - VALVE - INTAKE
RS ENGINE 3.3/3.8L 9 - 111
REMOVAL - CYLINDER HEAD ON Wh en ever va lves h a ve been r em oved for in spect ion ,
(1) Discon n ect n ega t ive ca ble fr om ba t t er y. r econ dit ion in g or r epla cem en t , va lve spr in gs sh ou ld
(2) Rem ove spa r k plu g wir es a n d a ll spa r k plu gs. be t est ed (F ig. 38). As a n e x a m p le ; t h e com pr ession
(3) Rem ove cylin der h ea d cover (s). (Refer t o 9 - len gt h of a spr in g t o be t est ed is 38.00 m m (1.496
E NGINE /CYLINDE R H E AD/CYLINDE R H E AD in .). Tu r n t h e t a ble of Tool C-647 u n t il su r fa ce is in
COVE R(S) - RE MOVAL) lin e wit h t h e 38.00 m m (1.496 in .) m a r k on t h e
(4) Rem ove r ocker a r m s a n d sh a ft . (Refer t o 9 - t h r ea ded st u d a n d t h e zer o m a r k on t h e fr on t . P la ce
E NGINE /CYLINDE R H E AD/ROCKE R ARMS - spr in g over st u d on t h e t a ble a n d lift com pr essin g
RE MOVAL) lever t o set t on e device. P u ll on t or qu e wr en ch u n t il
(5) Rot a t e en gin e u n t il t h e pist on in t h e cylin der pin g is h ea r d. Ta ke r ea din g on t or qu e wr en ch a t t h is
bor e r equ ir in g spr in g r em ova l is a t TDC. in st a n t . Mu lt iply t h is r ea din g by t wo. Th is will give
(6) In st a ll Specia l Tool 8453 t o t h e cylin der h ea d t h e spr in g loa d a t t est len gt h . F r a ct ion a l m ea su r e-
(F ig. 37). Tigh t en t h e a t t a ch in g bolt s t o 23 N·m (200 m en t s a r e in dica t ed on t h e t a ble for fin er a dju st -
in . lbs.). m en t s. Refer t o E n gin e Specifica t ion s t o obt a in
(7) In st a ll a spa r k plu g a da pt er in t h e spa r k plu g specified h eigh t a n d a llowa ble t en sion s (Refer t o 9 -
h ole. Con n ect a ir h ose t h a t ca n su pply 620.5–689 kP a E NGINE - SP E CIF ICATIONS). Repla ce a n y spr in gs
(90–100 psi) of a ir pr essu r e t o a da pt er. Th is is t o t h a t do n ot m eet specifica t ion s.
h old va lves in pla ce wh ile ser vicin g com pon en t s.
(8) Loca t e t h e for cin g scr ew a n d spr in g r et a in er
a da pt er a ssem bly over t h e spr in g r equ ir in g r em ova l
(F ig. 37).
(9) Slowly t u r n t h e for cin g scr ew clockwise (com -
pr essin g t h e va lve spr in g) u n t il t h e va lve keeper s ca n
be r em oved.
(10) Tu r n for cin g scr ew cou n t er clockwise t o r elieve
spr in g t en sion . Rem ove r et a in er a n d va lve spr in g.
(11) Repea t pr ocedu r e for ea ch cylin der r equ ir in g
va lve spr in g r em ova l.
Fig. 38 TESTING VALVE SPRING

I N STALLAT I ON
INSTALLATION - CYLINDER HEAD OFF
(1) If r em oved, in st a ll a n ew va lve st em sea l (Refer
t o 9 - E NGINE /CYLINDE R H E AD/VALVE STE M
Fig. 37 VALVE SPRING - REMOVE/INSTALL (HEAD SE ALS - INSTALLATION).
ON) (2) P osit ion va lve spr in g a n d r et a in er on spr in g
1 - SPECIAL TOOL 8453 sea t .
2 - BOLTS - SPECIAL TOOL ATTACHING (3) Usin g Specia l Tool C-3422-D wit h 8464 Ada pt er
3 - AIR SUPPLY HOSE ADAPTER
(F ig. 36), com pr ess t h e spr in g on ly en ou gh t o in st a ll
t h e va lve r et a in er locks. In st a ll va lve r et a in er locks.
INSPECTION (4) Slowly r elea se t h e spr in g t en sion . E n su r e t h e
r et a in er locks a r e sea t ed pr oper ly (F ig. 39).
NOTE: The are two different types of valve springs
used that are interchangable, but have different
specifications(Refer to 9 - ENGINE/CYLINDER
INSTALLATION - CYLINDER HEAD ON
(1) Th e in t a ke va lve st em sea ls sh ou ld be pu sh ed
HEAD/VALVE SPRINGS - DESCRIPTION).
fir m ly a n d squ a r ely over t h e va lve gu ide u sin g t h e
9 - 112 ENGINE 3.3/3.8L RS
DESCRIPTION - PUSHRODS
Th e pu sh r ods a r e m a de of st eel a n d a r e a h ollow
design . Th e pu sh r ods a r e posit ion ed bet ween t h e
h ydr a u lic lift er a n d t h e r ocker a r m .
OPERAT I ON
OPERATION - ROCKER ARMS
Th e r ocker a r m pivot s on t h e r ocker sh a ft . Rocker
a r m s a r e u sed t o t r a n sla t e u p a n d down m ot ion s pr o-
vided by t h e ca m sh a ft , h ydr a u lic lift er, a n d pu sh r od
on on e en d, in t o a down a n d u p m ot ion s on t h e va lve
st em on t h e opposin g en d.
OPERATION - PUSHRODS
Fig. 39 VALVE SPRING INSTALLED Th e pu sh r od is a solid lin k bet ween t h e h ydr a u lic
1 - VALVE SPRING RETAINER lift er a n d t h e r ocker a r m . Also, t h e pu sh r od su pplies
2 - VALVE INSTALLED HEIGHT en gin e oil fr om t h e h ydr a u lic lift er t o t h e r ocker a r m .
3 - CYLINDER HEAD SURFACE
4 - VALVE SPRING SEAT SURFACE
5 - VALVE SPRING INSTALLED HEIGHT REMOVAL - ROCKER ARMS AND SHAFT
(1) Rem ove t h e cylin der h ea d cover (s). (Refer t o 9 -
va lve st em a s gu ide. D o N o t F o rc e sea l a ga in st t op E NGINE /CYLINDE R H E AD/CYLINDE R H E AD
of gu ide. Wh en in st a llin g t h e va lve r et a in er locks, COVE R(S) - RE MOVAL)
com pr ess t h e spr in g o n ly e n o u g h t o in st a ll t h e locks
(F ig. 39). NOTE: Rocker arm shaft bolts are captured to the
shaft.
CAUTION: Do not pinch seal between retainer and
top of valve guide. (2) Loosen t h e r ocker sh a ft bolt s (F ig. 40), r ot a t in g
on e t u r n ea ch , u n t il a ll va lve spr in g pr essu r e is
(2) F ollow t h e sa m e pr ocedu r e on t h e r em a in in g 5 r elieved.
cylin der s u sin g t h e fir in g sequ en ce 1-2-3-4-5-6. Ma k e (3) Rem ove t h e r ocker a r m s a n d sh a ft a ssem bly
s u re p is to n in c y lin d e r is a t TD C o n th e v a lv e (F ig. 40).
s p rin g th a t is be in g c o v e re d . (4) F or r ocker a r m disa ssem bly pr ocedu r es, (Refer
(3) Rem ove spa r k plu g a da pt er t ool. t o 9 - E NGINE /CYLINDE R H E AD/ROCKE R ARMS -
(4) In st a ll r ocker a r m s a n d sh a ft a ssem bly. (Refer DISASSE MBLY).
t o 9 - E NGINE /CYLINDE R H E AD/ROCKE R ARMS -
INSTALLATION)
(5) In st a ll cylin der h ea d cover s. (Refer t o 9 -
(6) In st a ll spa r k plu gs a n d con n ect wir es.
ROCK ER ARM S
DESCRI PT I ON
DESCRIPTION - ROCKER ARMS Fig. 40 ROCKER ARMS AND SHAFT
Th e r ocker a r m s a r e in st a lled on t h e r ocker a r m 1 - ROCKER ARMS AND SHAFT ASSEMBLY
sh a ft . Th e r ocker a r m s a n d sh a ft a ssem bly is 2 - ROCKER SHAFT BOLTS
a t t a ch ed t o t h e cylin der h ea d wit h seven billet ed
bolt s a n d r et a in er s. Th e r ocker a r m s a r e m a de of
st a m ped st eel.
RS ENGINE 3.3/3.8L 9 - 113
DISASSEMBLY - ROCKER ARMS AND SHAFT (2) In st a ll r ocker a r m s a n d sh a ft t o t h e cylin der

h ea d. (Refer t o 9 - E NGINE /CYLINDE R H E AD/
CAUTION: Do not attempt to drive the billeted bolt ROCKE R ARMS - INSTALLATION)
from the rocker shaft. This can damage the rocker
arm retainer and bolt assembly. INSTALLATION - ROCKER ARMS AND SHAFT
(1) Rem ove t h e r ocker a r m r et a in er a n d bolt by CAUTION: Ensure the longer shaft retaining bolt is
per for m in g t h e followin g pr ocedu r e: installed in the proper location on the rocker shaft.
(a ) Usin g a dju st a ble plier s, gr ip t h e edges of t h e (Refer to 9 - ENGINE/CYLINDER HEAD/ROCKER
r et a in er (F ig. 41). ARMS - ASSEMBLY)
(b) Apply a n u pwa r d for ce wit h a sligh t r ockin g
m ot ion u n t il t h e r et a in er disen ga ges fr om sh a ft (1) P osit ion t h e r ocker a r m a n d sh a ft a ssem blies
(F ig. 41). on t h e pedest a l m ou n t s.
(2) Rem ove r ocker a r m s (F ig. 42). Iden t ify t h e
com pon en t loca t ion s for r ea ssem bly in or igin a l loca - CAUTION: Ensure all pushrods are properly located
t ion s. on the lifter and the rocker arm socket.
(2) Align ea ch r ocker a r m socket wit h ea ch pu sh -

ASSEMBLY - ROCKER ARMS AND SHAFT r od en d.
(1) In st a ll r ocker a r m s on t h e sh a ft (F ig. 42).
In st a ll in t h e or gin a l posit ion s if r e-u sed. En s u re t h e CAUTION: The rocker arm shaft should be tight-
r ocker sh a ft , a ll t h e r et a in er s a n d wa sh er s a r e pr opened down slowly, starting with the center bolts.
er ly posit ion ed a n d in st a lled in t h e cor r ect loca t ion s Allow 20 minutes lifter bleed down time after instal-
(F ig. 42). lation of the rocker shafts before engine operation.
Fig. 41 ROCKER ARM RETAINER - REMOVAL

1 - ADJUSTABLE PLIERS 3 - ROCKER ARM RETAINER
2 - BILLETED ROCKER SHAFT BOLT
9 - 114 ENGINE 3.3/3.8L RS
Fig. 42 ROCKER ARMS AND SHAFT

1 - BOLT (ROCKER SHAFT OIL FEED - LONGER LENGTH) 5 - ROCKER ARM - EXHAUST
2 - SHAFT RETAINER/SPACER - 21.5 mm (0.84 in.) 6 - WASHER
3 -SHAFT RETAINER/SPACER - 37.5 mm (1.47 in.) 7 - ROCKER ARM - INTAKE (LARGER OFFSET)
4 - SHAFT RETAINER/SPACER - 40.9 mm (1.61 in.) 8 - ROCKER ARMS LUBRICATION FEED HOLE (POSITION
UPWARD & TOWARD VALVE SPRING)
(3) Slowly t igh t en r ocker sh a ft bolt s even ly u n t il VALV E ST EM SEALS

sh a ft is sea t ed. Tigh t en bolt s t o 23 N·m (200 in . lbs.)
(F ig. 43).
DESCRIPTION
Th e va lve st em sea ls a r e m a de of Vit on r u bber. Th e
sea ls a r e posit ion ed over t h e va lve st em a n d sea t ed
on t h e va lve gu ide (F ig. 44).
Fig. 43 ROCKER ARMS AND SHAFT

1 - ROCKER ARMS AND SHAFT ASSEMBLY
2 - ROCKER SHAFT BOLTS
(4) In st a ll t h e cylin der h ea d cover (s). (Refer t o 9 -

Fig. 44 Valve Stem Seal
RS ENGINE 3.3/3.8L 9 - 115
VALV E ST EM SEALS (Cont inue d)
REMOVAL
(1) Rem ove t h e va lve spr in gs. (Refer t o 9 -
E NGINE /CYLINDE R H E AD/VALVE SP RINGS -
RE MOVAL)
(2) Rem ove t h e va lve st em sea l (F ig. 44).
INSTALLATION
(1) In st a ll t h e va lve st em sea l squ a r ely over t h e
va lve gu ide, u sin g t h e va lve st em a s a gu ide (F ig.
44). Do n ot for ce t h e sea l a ga in st t op of t h e va lve
gu ide.
(2) In st a ll t h e va lve spr in g. (Refer t o 9 - E NGINE /
CYLINDE R H E AD/VALVE SP RINGS - INSTALLA-
TION)
EN GI N E BLOCK
DESCRIPTION
Th e cylin der block is m a de of ca st ir on a n d is a Fig. 45 Cylinder Bore Cross-Hatch Pattern
deep skir t design . 1 - CROSS-HATCH PATTERN
2 - 40°–60°
STANDARD PROCEDURE - CYLINDER BORE
CAUTION: Ensure all abrasives are removed from
HONING engine parts after honing. It is recommended that a
(1) Used ca r efu lly, t h e cylin der bor e r esizin g h on e, solution of soap and hot water be used with a
r ecom m en ded t ool C-823 or equ iva len t , equ ipped brush and the parts then thoroughly dried. The bore
wit h 220 gr it st on es, is t h e best t ool for t h is h on in g can be considered clean when it can be wiped
pr ocedu r e. In a ddit ion t o degla zin g, it will r edu ce clean with a white cloth and cloth remains clean.
t a per a n d ou t -of-r ou n d a s well a s r em ovin g ligh t Oil the bores after cleaning to prevent rusting.
scu ffin g, scor in g or scr a t ch es. Usu a lly a few st r okes
will clea n u p a bor e a n d m a in t a in t h e r equ ir ed lim -
it s. CLEANING
(2) Degla zin g of t h e cylin der wa lls m a y be don e Clea n cylin der block t h or ou gh ly u sin g a su it a ble
u sin g a cylin der su r fa cin g h on e, r ecom m en ded t ool clea n in g solven t .
C-3501 or equ iva len t , equ ipped wit h 280 gr it st on es,
if t h e cylin der bor e is st r a igh t a n d r ou n d. 20–60 INSPECTION
st r okes depen din g on t h e bor e con dit ion , will be su f-
ficien t t o pr ovide a sa t isfa ct or y su r fa ce. Use a ligh t ENGINE BLOCK
h on in g oil. D o n o t u s e e n g in e o r tra n s m is s io n o il, (1) Clea n cylin der block t h or ou gh ly a n d ch eck a ll
m in e ra l s p irits o r k e ro s e n e . In spect cylin der wa lls cor e h ole plu gs for eviden ce of lea kin g.
a ft er ea ch 20 st r okes. (2) If n ew cor e plu gs a r e t o be in st a lled, (Refer t o 9
(3) H on in g sh ou ld be don e by m ovin g t h e h on e u p - E NGINE - STANDARD P ROCE DURE - E NGINE
a n d down fa st en ou gh t o get a cr oss-h a t ch pa t t er n . CORE AND OIL GALLE RY P LUGS).
Wh en h on e m a r ks in te rs e c t a t 40-60 degr ees, t h e (3) E xa m in e block a n d cylin der bor es for cr a cks or
cr oss h a t ch a n gle is m ost sa t isfa ct or y for pr oper sea t - fr a ct u r es.
in g of r in gs (F ig. 45). (4) Ch eck block deck su r fa ces for fla t n ess. Deck
(4) A con t r olled h on e m ot or speed bet ween su r fa ce m u st be wit h in ser vice lim it of 0.1 m m (0.004
200–300 RP M is n ecessa r y t o obt a in t h e pr oper cr oss- in .).
h a t ch a n gle. Th e n u m ber of u p a n d down st r okes per
m in u t e ca n be r egu la t ed t o get t h e desir ed 40–60 CYLINDER BORE
degr ee a n gle. F a st er u p a n d down st r okes in cr ea se
t h e cr oss-h a t ch a n gle. NOTE: The cylinder bores should be measured at
(5) Aft er h on in g, it is n ecessa r y t h a t t h e block be normal room temperature, 21°C (70°F).
clea n ed a ga in t o r em ove a ll t r a ces of a br a sive.
Th e cylin der wa lls sh ou ld be ch ecked for ou t -of-
r ou n d a n d t a per wit h Tool C119 or equ iva len t (F ig.
9 - 116 ENGINE 3.3/3.8L RS
EN GI N E BLOCK (Cont inue d)
46) (Refer t o 9 - E NGINE - SP E CIF ICATIONS). If t o 9 - E NGINE /LUBRICATION - DIAGNOSIS AND
t h e cylin der wa lls a r e ba dly scu ffed or scor ed, t h e TE STING)
cylin der block sh ou ld be r epla ced, a n d n ew pist on s Ch eck en gin e oil level. Th e oil level in t h e pa n
a n d r in gs fit t ed. sh ou ld n ever be a bove t h e MAX m a r k on dipst ick, or
below t h e MIN m a r k. E it h er of t h ese t wo con dit ion s
cou ld ca u se n oisy lift er s.
OIL LEVEL TOO HIGH

If oil level is a bove t h e MAX m a r k on dipst ick, it is
possible for t h e con n ect in g r ods t o dip in t o t h e oil
wh ile en gin e is r u n n in g a n d cr ea t e foa m in g. F oa m in
oil pa n wou ld be fed t o t h e h ydr a u lic lift er s by t h e oil
pu m p ca u sin g t h em t o becom e soft a n d a llow va lves
t o sea t n oisily.
OIL LEVEL TOO LOW

Low oil level m a y a llow pu m p t o t a ke in a ir wh ich
wh en fed t o t h e lift er s it ca u ses t h em t o becom e soft
a n d a llows va lves t o sea t n oisily. An y lea ks on in t a ke
side of pu m p, t h r ou gh wh ich a ir ca n be dr a wn , will
cr ea t e t h e sa m e lift er n oise. Ch eck t h e lu br ica t ion
syst em fr om t h e in t a ke st r a in er t o t h e oil pu m p
cover, in clu din g t h e r elief va lve r et a in er ca p. Wh en
lift er n oise is du e t o a er a t ion , it m a y be in t er m it t en t
or con st a n t , a n d u su a lly m or e t h a n on e lift er will be
n oisy. Wh en oil level a n d lea ks h a ve been cor r ect ed,
Fig. 46 Checking Cylinder Bore Size t h e en gin e sh ou ld be oper a t ed a t fa st idle t o a llow a ll
of t h e a ir in side of t h e lift er s t o be bled ou t .
Mea su r e t h e cylin der bor e a t t h r ee levels in dir ec-
t ion s A a n d B (F ig. 46). Top m ea su r em en t sh ou ld be VALVE TRAIN NOISE
10 m m (3/8 in .) down a n d bot t om m ea su r em en t To det er m in e sou r ce of va lve t r a in n oise, oper a t e
sh ou ld be 10 m m (3/8 in .) u p fr om bot t om of bor e. en gin e a t idle wit h cylin der h ea d cover s r em oved a n d
(Refer t o 9 - E NGINE - SP E CIF ICATIONS). list en for sou r ce of t h e n oise.
NOTE: Worn valve guides or cocked springs are

H Y DRAU LI C LI FT ERS (CAM I N sometimes mistaken for noisy lifters. If such is the
BLOCK ) case, noise may be dampened by applying side
thrust on the valve spring. If noise is not apprecia-
DESCRIPTION bly reduced, it can be assumed the noise is in the
Th e h ydr a u lic lift er s a r e a r oller t ype design a n d tappet. Inspect the rocker arm push rod sockets
a r e posit ion ed in t h e cylin der block. Th e lift er s a r e and push rod ends for wear.
a lign ed a n d r et a in ed by a yoke a n d a r et a in er (F ig.
Va lve lift er n oise r a n ges fr om ligh t n oise t o a
48).
h ea vy click. A ligh t n oise is u su a lly ca u sed by exces-
Lift er a lign m en t is m a in t a in ed by m a ch in ed fla t s
sive lea k-down a r ou n d t h e u n it plu n ger wh ich will
on lift er body. Lift er s a r e fit t ed in pa ir s in t o six
n ecessit a t e r epla cin g t h e lift er, or by t h e plu n ger pa r-
a lign in g yokes. Th e a lign in g yokes a r e secu r ed by a
t ia lly st ickin g in t h e lift er body cylin der. A h ea vy
yoke r et a in er (F ig. 48).
click is ca u sed eit h er by a lift er ch eck va lve n ot sea t -
in g, or by for eign pa r t icles becom in g wedged bet ween
DIAGNOSIS AND TESTING - HYDRAULIC t h e plu n ger a n d t h e lift er body ca u sin g t h e plu n ger
LIFTERS t o st ick in t h e down posit ion . Th is h ea vy click will be
a ccom pa n ied by excessive clea r a n ce bet ween t h e
HYDRAULIC LIFTERS DIAGNOSIS - PRELIMINARY va lve st em a n d r ocker a r m a s va lve closes. In eit h er
STEP ca se, lift er a ssem bly sh ou ld be r em oved for in spec-
Befor e disa ssem blin g a n y pa r t of t h e en gin e t o cor- t ion .
r ect lift er n oise, ch eck t h e en gin e oil pr essu r e. (Refer
RS ENGINE 3.3/3.8L 9 - 117
H Y DRAU LI C LI FT ERS (CAM I N BLOCK ) (Cont inue d)
REMOVAL
(1) Rem ove t h e cylin der h ea d(s). (Refer t o 9 -
E NGINE /CYLINDE R H E AD - RE MOVAL)
(2) Rem ove t h e yoke r et a in er a n d a lign in g yokes
(F ig. 48).
(3) Rem ove t h e h ydr a u lic lift er s. If n ecessa r y u se
Specia l Tool C-4129, or equ iva len t t o r em ove lift er s
fr om bor es. If lift er s a r e t o be r eu sed, iden t ify ea ch
lift er t o en su r e in st a lla t ion in or igin a l loca t ion .
INSTALLATION
(1) Lu br ica t e t h e lift er s wit h en gin e oil.
NOTE: Position the lifter in bore with the lubrication

hole facing upward (Fig. 47).
(2) In st a ll t h e h ydr a u lic lift er s wit h t h e lu br ica t ion

h ole fa cin g u pwa r d t owa r ds m iddle of block (F ig. 47).
In st a ll lift er s in or igin a l posit ion s, if r eu sed.
Fig. 48 Lifter Aligning Yoke and Retainer

1 - YOKE RETAINER
2 - BOLT - YOKE RETAINER
3 - ALIGNING YOKE
4 - HYDRAULIC LIFTER
CAUTION: To prevent damage to valve mechanism,

engine must not be run above fast idle until all
Fig. 47 LIFTER LUBRICATION HOLE hydraulic lifters have filled with oil and have
become quiet.
(3) In st a ll lift er a lign in g yokes (F ig. 48).
(4) In st a ll yoke r et a in er a n d t or qu e scr ews t o 12
N·m (105 in . lbs.) (F ig. 48).
(5) In st a ll t h e cylin der h ea ds. (Refer t o 9 -
E NGINE /CYLINDE R H E AD - INSTALLATION)
(6) St a r t a n d oper a t e en gin e. Wa r m u p t o n or m a l
oper a t in g t em per a t u r e.
9 - 118 ENGINE 3.3/3.8L RS
CAM SH AFT & BEARI N GS (I N OPERATION

Th e ca m sh a ft is dr iven by t h e cr a n ksh a ft t h r ou gh
BLOCK ) a t im in g ch a in a n d spr ocket s. Th e ca m sh a ft h a s pr e-
cisely m a ch in ed (egg-sh a ped) lobes t o pr ovide a ccu -
DESCRIPTION r a t e va lve t im in g a n d du r a t ion .
Th e n odu la r ir on ca m sh a ft is m ou n t ed in t h e
en gin e block a n d su ppor t ed wit h fou r st eel ba cked REMOVAL
a lu m in u m bea r in gs (F ig. 49). A t h r u st pla t e, loca t ed (1) Rem ove t h e en gin e a ssem bly fr om veh icle
in fr on t of t h e fir st bea r in g, is bolt ed t o t h e block a n d (Refer t o 9 - E NGINE - RE MOVAL).
con t r ols t h e ca m sh a ft en d pla y (F ig. 49). To dist in - (2) Rem ove t h e cylin der h ea ds (Refer t o 9 -
gu ish ca m sh a ft s bet ween t h e 3.3L a n d 3.8L en gin es, E NGINE /CYLINDE R H E AD - RE MOVAL).
a ca st -in r in g is loca t ed bet ween t h e r ea r bea r in g (3) Rem ove t h e t im in g ch a in a n d ca m sh a ft
jou r n a l a n d r ea r lobe (F ig. 50). Th e 3.3L en gin e spr ocket (Refer t o 9 - E NGINE /VALVE TIMING/TIM-
a pplica t ion is a s-ca st on ly. Th e 3.8L en gin e a pplica - ING BE LT/CH AIN AND SP ROCKE TS - RE MOVAL).
t ion t h e ca st r in g is m a ch in ed off. (4) Rem ove t h e h ydr a u lic lift er s (Refer t o 9 -
E NGINE /E NGINE BLOCK/H YDRAULIC LIF TE RS
(CAM IN BLOCK) - RE MOVAL). Iden t ify ea ch t a ppet
for r ein st a lla t ion in or igin a l loca t ion .
(5) Rem ove ca m sh a ft t h r u st pla t e (F ig. 49).
(6) In st a ll a lon g bolt in t o fr on t of ca m sh a ft t o
fa cilit a t e r em ova l of t h e ca m sh a ft .
(7) Rem ove t h e ca m sh a ft (F ig. 49), bein g ca r efu l
n ot t o da m a ge ca m bea r in gs wit h t h e ca m lobes.
NOTE: The camshaft bearings are serviced with the

engine block.
Fig. 49 CAMSHAFT AND BEARINGS

INSPECTION
(1) Ch eck t h e ca m lobes a n d bea r in g su r fa ces for
1 - CAMSHAFT
2 - THRUST PLATE a bn or m a l wea r a n d da m a ge (F ig. 51). Repla ce ca m -
3 - BOLT sh a ft a s r equ ir ed.
4 - CAMSHAFT BEARINGS (SERVICED WITH BLOCK)
NOTE: If camshaft is replaced due to lobe wear or
damage, always replace the lifters.
(2) Mea su r e t h e lobe a ct u a l wea r (u n wor n a r ea -

wea r zon e = a ct u a l wea r ) (F ig. 51) a n d r epla ce ca m -
sh a ft if ou t of lim it . St a n da r d va lu e is 0.0254 m m
(0.001 in .), wea r lim it is 0.254 m m (0.010 in .).
INSTALLATION
(1) Lu br ica t e ca m sh a ft lobes a n d ca m sh a ft bea r in g
jou r n a ls wit h en gin e oil.
(2) In st a ll a lon g bolt in t o t h e ca m sh a ft t o a ssist in
t h e in st a lla t ion of t h e ca m sh a ft .
(3) Ca r efu lly in st a ll t h e ca m sh a ft in en gin e block.
(4) In st a ll ca m sh a ft t h r u st pla t e a n d bolt s (F ig.
49). Tigh t en t o 12 N·m (105 in . lbs.) t or qu e.
Fig. 50 CAMSHAFT IDENTIFICATION
(5) Mea su r e ca m sh a ft en d pla y. (Refer t o 9 -
1 - CAMSHAFT - 3.3L ENGINE E NGINE - SP E CIF ICATIONS) If n ot wit h in specifi-
2 - CAST-IN RING
3 - CAMSHAFT - 3.8L ENGINE ca t ion s, r epla ce t h r u st pla t e.
4 - MACHINED CAST-IN RING (6) In st a ll t h e t im in g ch a in a n d spr ocket s. (Refer
t o 9 - E NGINE /VALVE TIMING/TIMING BE LT/
CH AIN AND SP ROCKE TS - INSTALLATION)
RS ENGINE 3.3/3.8L 9 - 119
CAM SH AFT & BEARI N GS (I N BLOCK ) (Cont inue d)
PI ST ON & CON N ECT I N G ROD

DESCRIPTION
Th e pist on s a r e m a de of ca st a lu m in u m a lloy a n d
a r e a st r u t less, sh or t skir t design . Th e pist on r in gs
con sist of t wo com pr ession r in gs a n d a t h r ee piece oil
r in g. P ist on pin s con n ect t h e pist on t o t h e for ged
st eel con n ect in g r ods. Th e pist on pin s a r e a pr ess fit
in t o t h e con n ect in g r od.

STANDARD PROCEDURE - FITTING
Fig. 51 Checking Camshaft for Wear (Typical) CONNECTING RODS
1 - UNWORN AREA Th e bea r in g ca ps a r e n ot in t er ch a n gea ble or
2 - ACTUAL WEAR r ever sible, a n d sh ou ld be m a r ked a t r em ova l t o
3 - BEARING JOURNAL en su r e cor r ect r ea ssem bly. Th e bea r in g sh ells m u st
4 - LOBE
5 - WEAR ZONE be in st a lled wit h t h e t a n gs in ser t ed in t o t h e
m a ch in ed gr ooves in t h e r ods a n d ca ps. In st a ll ca p
NOTE: When camshaft is replaced, all of the wit h t h e t a n gs on t h e sa m e side a s t h e r od. F or con -
hydraulic lifters must be replaced also. n ect in g r od bea r in g fit t in g (Refer t o 9 - E NGINE /E N-
GINE BLOCK/CONNE CTING ROD BE ARINGS -
(7) In st a ll t h e h ydr a u lic lift er s (Refer t o 9 - STANDARD P ROCE DURE ). F it a ll con n ect in g r ods
E NGINE /E NGINE BLOCK/H YDRAULIC LIF TE RS on on e ba n k u n t il com plet e.
(CAM IN BLOCK) - INSTALLATION). E a ch lift er
r eu sed m u st be in st a lled in t h e sa m e posit ion fr om NOTE: The connecting rod cap bolts should be
wh ich it wa s r em oved. examined before reuse. Bolt stretch can be checked
(8) In st a ll t h e t im in g ch a in cover. (Refer t o 9 - by holding a scale or straight edge against the
E NGINE /VALVE TIMING/TIMING BE LT / CH AIN threads. If all the threads do not contact the scale
COVE R(S) - INSTALLATION) the bolt must be replaced (Fig. 52).
(9) In st a ll t h e cylin der h ea ds. (Refer t o 9 -
E NGINE /CYLINDE R H E AD - INSTALLATION)
(10) In st a ll t h e cylin der h ea d cover s. (Refer t o 9 -
(11) In st a ll t h e lower a n d u pper in t a ke m a n ifolds.
F OLD - INSTALLATION)
(12) In st a ll t h e en gin e a ssem bly. (Refer t o 9 -
E NGINE - INSTALLATION)
Fig. 52 Check for Stretched (Necked) Bolts

1 - STRETCHED BOLT
9 - 120 ENGINE 3.3/3.8L RS
(1) Befor e in st a llin g t h e n u t s t h e t h r ea ds sh ou ld
be oiled wit h en gin e oil.
(2) In st a ll n u t s fin ger t igh t on ea ch bolt t h en a lt er-
n a t ely t or qu e ea ch n u t t o a ssem ble t h e ca p pr oper ly.
(3) Tigh t en t h e n u t s t o 54 N·m P LUS 1/4 t u r n (40
ft . lbs. P LUS 1/4 t u r n ).
(4) Usin g a feeler ga u ge, ch eck con n ect in g r od side
clea r a n ce (F ig. 53). Refer t o E n gin e Specifica t ion s
(Refer t o 9 - E NGINE - SP E CIF ICATIONS).
Fig. 55 Checking Cylinder Bore Size

REMOVAL
Fig. 53 Checking Connecting Rod Side Clearance (2) Rem ove t h e cylin der h ea ds. (Refer t o 9 -
STANDARD PROCEDURE - FITTING PISTONS E NGINE /CYLINDE R H E AD - RE MOVAL)
(3) Rem ove t h e oil pa n . (Refer t o 9 - E NGINE /LU-
Th e pist on a n d cylin der wa ll m u st be clea n a n d
BRICATION/OIL PAN - RE MOVAL)
dr y. P ist on dia m et er sh ou ld be m ea su r ed 90 degr ees
(4) Rem ove t h e t op r idge of cylin der bor es wit h a
t o pist on pin a t size loca t ion sh own in (F ig. 54). Cyl-
r elia ble r idge r ea m er, if n ecessa r y, befor e r em ovin g
in der bor es sh ou ld be m ea su r ed h a lfwa y down t h e
pist on s fr om cylin der block. B e s u re to k e e p to p s
cylin der bor e a n d t r a n sver se t o t h e en gin e cr a n ksh a ft
o f p is to n s c o v e re d d u rin g th is o p e ra tio n . P is -
cen t er lin e sh own in (F ig. 55). Refer t o E n gin e Spec-
to n s a n d c o n n e c tin g ro d s m u s t be re m o v e d
ifica t ion s (Refer t o 9 - E NGINE - SP E CIF ICA-
fro m to p o f c y lin d e r blo c k . Wh e n re m o v in g p is -
TIONS). P is to n s a n d c y lin d e r bo re s s h o u ld be
to n a n d c o n n e c tin g ro d a s s e m blie s fro m th e
m e a s u re d a t n o rm a l ro o m te m p e ra tu re , 21°C
e n g in e , ro ta te c ra n k s h a ft s o th a t e a c h c o n n e c t-
(70°F ).
in g ro d is c e n te re d in c y lin d e r bo re .
(5) In spect con n ect in g r ods a n d con n ect in g r od
ca ps for cylin der iden t ifica t ion . Iden t ify t h em , if n ec-
essa r y (F ig. 56).
Fig. 54 Piston Measurement Locations - Typical

1 - 39.8 mm (1.56 in. ) 3.3L ENGINE
2 - 33.0 mm (1.29 in.) 3.8L ENGINE
Fig. 56 Identify Connecting Rod to Cylinder

1 - CYLINDER NUMBER
RS ENGINE 3.3/3.8L 9 - 121
(6) Rem ove con n ect in g r od ca p. In st a ll con n ect in g (2) Befor e in st a llin g t h e r in g com pr essor, en su r e
r od bolt pr ot ect or s on con n ect in g r od bolt s (F ig. 57). t h e oil r in g expa n der en ds a r e bu t t ed a n d t h e r a il
(7) Rem ove ea ch pist on a n d con n ect in g r od a ssem - ga ps loca t ed a s sh own in (F ig. 58).
bly ou t of t h e cylin der bor e. (3) Lu br ica t e t h e pist on a n d r in gs wit h clea n
en gin e oil. P osit ion a r in g com pr essor over t h e pist on
NOTE: Be careful not to nick crankshaft journals. a n d r in gs, a n d t igh t en t h e com pr essor (F ig. 59). B e
s u re p o s itio n o f rin g s d o e s n o t c h a n g e d u rin g
(8) Aft er r em ova l, in st a ll bea r in g ca p on t h e m a t - th is o p e ra tio n .
in g r od. (4) P osit ion u pper bea r in g on t o con n ect in g r od.
Lu br ica t e bea r in g wit h oil.
(5) In st a ll con n ect in g r od bolt pr ot ect or s (r u bber
h ose or equ iva len t ) on t h e con n ect in g r od bolt s (F ig.
59).
(6) Th e pist on s a r e m a r ked wit h a “F ” loca t ed n ea r
t h e pist on pin . In st a ll pist on wit h t h is m a r k posi-
t ion ed t o fr on t of en gin e on bot h cylin der ba n ks. Th e
con n ect in g r od oil squ ir t h ole fa ces t h e m a jor t h r u st
(r igh t ) side of t h e en gin e block (F ig. 60).
(7) Rot a t e cr a n ksh a ft u n t il t h e con n ect in g r od
jou r n a l is loca t ed in t h e cen t er of t h e cylin der bor e.
In ser t con n ect in g r od a n d pist on in t o cylin der bor e.
Ca r efu lly gu ide con n ect in g r od over t h e cr a n ksh a ft
jou r n a l (F ig. 59).
(8) Ta p t h e pist on down in cylin der bor e, u sin g a
h a m m er h a n dle. At t h e sa m e t im e, gu ide con n ect in g
r od in t o posit ion on con n ect in g r od jou r n a l.
Fig. 57 Connecting Rod Protectors
(9) In st a ll lower bea r in g sh ell a n d con n ect in g r od
1 - COVER ROD BOLTS WITH A SUITABLE COVERING WHEN
REMOVING OR INSTALLING PISTON ASSEMBLY ca p (F ig. 59). In st a ll n u t s on clea n ed a n d oiled r od
bolt s a n d t igh t en t o 54 N·m (40 ft . lbs.) P LUS 1 ⁄4
INSTALLATION turn.
(1) Befor e in st a llin g pist on s a n d con n ect in g r od (10) Repea t pr ocedu r e for ea ch pist on a n d con n ect -
a ssem blies in t o t h e bor e, en su r e t h a t com pr ession in g r od in st a lla t ion .
r in g ga ps a r e st a gger ed so t h a t n eit h er is in lin e wit h (11) In st a ll t h e cylin der h ea ds. (Refer t o 9 -
oil r in g r a il ga p (F ig. 58). E NGINE /CYLINDE R H E AD - INSTALLATION)
(12) In st a ll t h e oil pa n . (Refer t o 9 - E NGINE /LU-
BRICATION/OIL PAN - INSTALLATION)
(13) F ill en gin e cr a n kca se wit h pr oper oil t o cor-
r ect level.

1 - SIDE RAIL UPPER
2 - NO. 1 RING GAP
3 - PISTON PIN
4 - SIDE RAIL LOWER
9 - 122 ENGINE 3.3/3.8L RS
Fig. 59 PISTON AND CONNECTING ROD INSTALLATION

1 - RING - OIL CONTROL 7 - CAP - CONNECTING ROD
2 - RING - NO. 2 COMPRESSION 8 - BEARING - CONNECTING ROD LOWER
3 - RING - NO. 1 COMPRESSION 9 - CRANKSHAFT JOURNAL PROTECTOR (RUBBER HOSE)
4 - RING - SIDE RAIL UPPER & LOWER 10 - BEARING - CONNECTING ROD UPPER
5 - PISTON RING COMPRESSOR 11 - PISTON AND CONNECTING ROD ASSEMBLY
6 - NUT - CONNECTING ROD 12 - PISTON LOCATION MARK (F = FRONT)
RS ENGINE 3.3/3.8L 9 - 123
Fig. 60 Piston and Connecting Rod Positioning (Front View of Engine)

1 - MAJOR THRUST SIDE OF PISTON 2 - OIL SQUIRT HOLE
CON N ECT I N G ROD BEARI N GS Th e con n ect in g r od bea r in g clea r a n ces ca n be

det er m in ed by u se of P la st iga ge or t h e equ iva len t .
Th e followin g is t h e r ecom m en ded pr ocedu r e for t h e
STANDARD PROCEDURE - MEASURING
u se of P la st iga ge:
CONNECTING ROD BEARING CLEARANCE (1) Rot a t e t h e cr a n ksh a ft u n t il t h e con n ect in g r od
Th e bea r in g ca ps a r e n ot in t er ch a n gea ble a n d t o be ch ecked is a t t h e bot t om of it s st r oke.
sh ou ld be m a r ked a t r em ova l t o en su r e cor r ect (2) Rem ove oil film fr om su r fa ce t o be ch ecked.
a ssem bly. Th e bea r in g sh ells m u st be in st a lled wit h P la st iga ge is solu ble in oil.
t h e t a n gs in ser t ed in t o t h e m a ch in ed gr ooves in t h e (3) P la ce a piece of P la st iga ge a cr oss t h e en t ir e
r ods a n d ca ps. In st a ll ca p wit h t h e t a n gs on t h e sa m e widt h of t h e bea r in g sh ell in t h e bea r in g ca p a ppr ox-
side a s t h e r od. F it a ll r ods on on e ba n k u n t il com - im a t ely 6.35 m m (1/4 in .) off cen t er a n d a wa y fr om
plet e. Con n ect in g r od bea r in gs a r e a va ila ble in t h e t h e oil h ole. In a ddit ion , su spect a r ea s ca n be
st a n da r d size a n d t h e followin g u n der sizes: 0.025 ch ecked by pla cin g P la st iga ge in t h a t a r ea .
m m (0.001 in .) a n d 0.250 m m (0.010 in .). (4) Assem ble t h e r od ca p wit h P la st iga ge in pla ce.
Tigh t en t h e r od ca p t o t h e specified t or qu e. D o n o t
CAUTION: Install the bearings in pairs. Do not use a
ro ta te th e c ra n k s h a ft w h ile a s s e m blin g th e c a p
new bearing half with an old bearing half. Do not
o r th e P la s tig a g e m a y be s m e a re d , g iv in g in a c -
file the rods or bearing caps. c u ra te re s u lts .
(5) Rem ove t h e bea r in g ca p a n d com pa r e t h e
Mea su r e con n ect in g r od jou r n a l for t a per a n d ou t -
widt h of t h e fla t t en ed P la st iga ge wit h t h e sca le pr o-
of-r ou n d. (Refer t o 9 - E NGINE /E NGINE BLOCK/
CRANKSH AF T - INSP E CTION) vided on t h e pa cka ge (F ig. 61). Loca t e t h e ba n d clos-
est t o t h e sa m e widt h . Th is ba n d in dica t es t h e
9 - 124 ENGINE 3.3/3.8L RS
CON N ECT I N G ROD BEARI N GS (Cont inue d)
a m ou n t of oil clea r a n ce. Differ en ces in r ea din gs
bet ween t h e en ds in dica t e t h e a m ou n t of t a per
pr esen t . Recor d a ll r ea din gs t a ken . Refer t o E n gin e
Specifica t ion s (Refer t o 9 - E NGINE - SP E CIF ICA-
TIONS). P la s tig a g e g e n e ra lly is a c c o m p a n ie d by
tw o s c a le s . On e s c a le is in in c h e s , th e o th e r is a
m e tric s c a le . If th e be a rin g c le a ra n c e e x c e e d s
w e a r lim it s p e c ific a tio n , re p la c e th e be a rin g .
Fig. 62 Piston Ring Gap

1 - FEELER GAUGE
Fig. 61 Measuring Connecting Rod Bearing

Clearance
PI ST ON RI N GS
STANDARD PROCEDURE - PISTON RING
FITTING Fig. 63 Piston Ring Side Clearance
(1) Wipe cylin der bor e clea n . In ser t t h e r in g a n d
1 - FEELER GAUGE
pu sh down wit h pist on t o en su r e squ a r en ess in bor e
t o a ppr oxim a t ely 12 m m (0.50 in .) fr om t op of cylin -
der bor e. Ch eck r in g ga p wit h a feeler ga u ge (F ig. INSTALLATION
62). F or clea r a n ce specifica t ion (Refer t o 9 - E NGINE (1) In st a ll r in gs wit h m a n u fa ct u r er s I.D. m a r k (if
- SP E CIF ICATIONS). pr esen t ) fa cin g u p, t o t h e t op of t h e pist on (F ig. 64).
(2) Ch eck pist on r in g t o gr oove side clea r a n ce (F ig.
CAUTION: Install piston rings in the following
63). F or clea r a n ce specifica t ion (Refer t o 9 - E NGINE
order:
- SP E CIF ICATIONS)
1. Oil r in g expa n der.
REMOVAL 2. Upper oil r in g side r a il.
(1) Rem ove pist on a n d con n ect in g r od. (Refer t o 9 - 3. Lower oil r in g side r a il.
E NGINE /E NGINE BLOCK/P ISTON & CONNE CT- 4. No. 2 In t er m edia t e pist on r in g.
ING ROD - RE MOVAL) 5. No. 1 Upper pist on r in g.
(2) Rem ove No. 1 a n d No.2 pist on r in gs fr om pis- (2) In st a ll t h e side r a il by pla cin g on e en d
t on u sin g a r in g expa n der t ool (F ig. 66). bet ween t h e pist on r in g gr oove a n d t h e expa n der.
(3) Rem ove u pper oil r in g side r a il (F ig. 65). H old en d fir m ly a n d pr ess down t h e por t ion t o be
(4) Rem ove lower oil r in g side r a il (F ig. 65). in st a lled u n t il side r a il is in posit ion . D o n o t u s e a
(5) Rem ove oil r in g expa n der (F ig. 65). p is to n rin g e x p a n d e r (F ig. 65).
RS ENGINE 3.3/3.8L 9 - 125
PI ST ON RI N GS (Cont inue d)
Fig. 64 Piston Ring Installation Fig. 66 Piston Ring Installation

3 - SIDE RAIL
4 - OIL RING
5 - SPACER EXPANDER
(3) In st a ll u pper side r a il fir st a n d t h en t h e lower

side r a il.

2 - NO. 1 RING GAP
CRAN K SH AFT M AI N
Fig. 65 Oil Ring Side Rail - Typical
1 - SIDE RAIL END
BEARI N GS
(4) In st a ll No. 2 pist on r in g a n d t h en No. 1 pist on STANDARD PROCEDURE - MAIN BEARING
r in g (F ig. 66). FITTING
(5) P osit ion pist on r in g en d ga ps a s sh own in (F ig. Bea r in g ca ps a r e n ot in t er ch a n gea ble a n d sh ou ld
67). be m a r ked a t r em ova l t o in su r e cor r ect a ssem bly
(6) P osit ion oil r in g expa n der ga p a t lea st 45° (F ig. 68). Upper a n d lower bea r in g h a lves a r e NOT
fr om t h e side r a il ga ps bu t n o t on t h e pist on pin cen - in t er ch a n gea ble. Lower m a in bea r in g h a lves of 1, 3
t er or on t h e t h r u st dir ect ion . St a gger in g r in g ga p is a n d 4 a r e in t er ch a n gea ble. Upper m a in bea r in g
im por t a n t for oil con t r ol. h a lves of 1, 3 a n d 4 a r e in t er ch a n gea ble.
9 - 126 ENGINE 3.3/3.8L RS
CRAN K SH AFT M AI N BEARI N GS (Cont inue d)
P la st iga ge wit h t h e en gin e in t h e veh icle or en gin e
on a r epa ir st a n d.
PLASTIGAGE METHOD—ENGINE IN-VEHICLE
NOTE: The total clearance of the main bearings can

only be determined with the engine in the vehicle
by removing the weight of the crankshaft. This can
be accomplished by either of two following meth-
ods:
(1) P r efer r ed m et h od:

a . Sh im t h e bea r in gs a dja cen t t o t h e bea r in g t o be
ch ecked in or der t o r em ove t h e clea r a n ce bet ween
u pper bea r in g sh ell a n d t h e cr a n ksh a ft . Th is ca n be
a ccom plish ed by pla cin g a m in im u m of 0.254 m m
Fig. 68 Main Bearing Cap Identification (0.010 in .) sh im (e. g. ca r dboa r d, m a t ch book cover,
et c.) bet ween t h e bea r in g sh ell a n d t h e bea r in g ca p
Upper a n d lower n u m ber 2 bea r in g h a lves a r e on t h e a dja cen t bea r in gs a n d t igh t en in g bolt s t o
fla n ged t o ca r r y t h e cr a n ksh a ft t h r u st loa ds a n d a r e 14–20 N·m (10–15 ft . lbs.).
NOT in t er ch a n gea ble wit h a n y ot h er bea r in g h a lves • Wh en ch eckin g #1 m a in bea r in g sh im #2 m a in
in t h e en gin e (F ig. 69). All bea r in g ca p bolt s r em oved bea r in g.
du r in g ser vice pr ocedu r es a r e t o be clea n ed a n d • Wh en ch eckin g #2 m a in bea r in g sh im #1 & #3
lu br ica t ed wit h en gin e oil befor e in st a lla t ion . Bea r in g m a in bea r in g.
sh ells a r e a va ila ble in st a n da r d a n d t h e followin g • Wh en ch eckin g #3 m a in bea r in g sh im #2 & #4
u n der sizes: 0.025 m m (0.001 in .) a n d 0.254 m m m a in bea r in g.
(0.010 in ). Never in st a ll a n u n der size bea r in g t h a t • Wh en ch eckin g #4 m a in bea r in g sh im #3 m a in
will r edu ce clea r a n ce below specifica t ion s. bea r in g.
NOTE: Remove all shims before reassembling

engine.
(2) Alt er n a t ive Met h od:

a . Su ppor t t h e weigh t of t h e cr a n ksh a ft wit h a
ja ck u n der t h e cou n t er weigh t a dja cen t t o t h e bea r in g
bein g ch ecked.
(3) Rem ove oil film fr om su r fa ce t o be ch ecked.
P la st iga ge is solu ble in oil.
(4) P la ce a piece of P la st iga ge a cr oss t h e en t ir e
widt h of t h e bea r in g sh ell in t h e ca p a ppr oxim a t ely
6.35 m m (1/4 in .) off cen t er a n d a wa y fr om t h e oil
h oles (F ig. 70). (In a ddit ion , su spect ed a r ea s ca n be
ch ecked by pla cin g t h e P la st iga ge in t h e su spect ed
a r ea ). Tor qu e t h e bea r in g ca p bolt s of t h e bea r in g
bein g ch ecked t o t h e pr oper specifica t ion s.
Fig. 69 Main Bearing Identification
(5) Rem ove t h e bea r in g ca p a n d com pa r e t h e widt h
1 - OIL GROOVES
2 - OIL HOLES
of t h e fla t t en ed P la st iga ge (F ig. 71) wit h t h e sca le
3 - UPPER BEARINGS pr ovided on t h e pa cka ge. Loca t e t h e ba n d closest t o
4 - LOWER BEARINGS t h e sa m e widt h . Th is ba n d sh ows t h e a m ou n t of
clea r a n ce in t h ou sa n dt h s. Differ en ces in r ea din gs
CRANKSHAFT BEARING OIL CLEARANCE bet ween t h e en ds in dica t e t h e a m ou n t of t a per
In spect t h e cr a n ksh a ft bea r in g jou r n a ls. (Refer t o 9 pr esen t . Recor d a ll r ea din gs t a ken . (Refer t o 9 -
- E NGINE /E NGINE BLOCK/CRANKSH AF T - E NGINE - SP E CIF ICATIONS) P la s tig a g e g e n e r-
INSP E CTION) a lly is a c c o m p a n ie d by tw o s c a le s . On e s c a le is
E n gin e cr a n ksh a ft bea r in g clea r a n ces ca n be det er- in in c h e s , th e o th e r is a m e tric s c a le .
m in ed by u se of P la st iga ge or t h e equ iva len t . Th e fol-
lowin g is t h e r ecom m en ded pr ocedu r es for t h e u se of
RS ENGINE 3.3/3.8L 9 - 127
NOTE: Plastigage is available in a variety of clear- (2) Iden t ify m a in bea r in g ca ps befor e r em ova l.
ance ranges. Use the most appropriate range for (3) Rem ove bea r in g ca ps on e a t a t im e. Rem ove
the specifications you are checking. u pper h a lf of bea r in g by in ser t in g Specia l Ma in Bea r-
in g Tool C-3059 (F ig. 72) in t o t h e oil h ole of cr a n k-
sh a ft .
(4) Slowly r ot a t e cr a n ksh a ft clockwise, for cin g ou t
u pper h a lf of bea r in g sh ell.
Fig. 70 Plastigage Placed in Lower

1 - PLASTIGAGE
Fig. 72 Upper Main Bearing Removing/Installing

With Special Tool C-3059
2 - BEARING
4 - BEARING
Fig. 71 Clearance Measurement
PLASTIGAGE METHOD—ENGINE OUT-OF-VEHICLE INSTALLATION - CRANKSHAFT MAIN
(1) Wit h en gin e in t h e in ver t ed posit ion (cr a n k- BEARINGS
sh a ft u p) a n d m ou n t ed on a r epa ir st a n d, r em ove
m a in jou r n a l ca p. NOTE: One main bearing should be selectively fit-
(2) Rem ove oil fr om jou r n a l a n d bea r in g sh ell. ted while all other main bearing caps are properly
(3) Cu t P la st iga ge t o sa m e len gt h a s widt h of t h e tightened.
bea r in g a n d pla ce it in pa r a llel wit h t h e jou r n a l a xis
(1) F or m a in bea r in g fit t in g pr ocedu r e, (Refer t o 9
(F ig. 70).
- E NGINE /E NGINE BLOCK/CRANKSH AF T MAIN
(4) Ca r efu lly in st a ll t h e m a in bea r in g ca p a n d
BE ARINGS - STANDARD P ROCE DURE )
t igh t en t h e bolt s t o specified t or qu e.
(2) St a r t bea r in g in pla ce, a n d in ser t Ma in Bea r in g
CAUTION: Do not rotate crankshaft or the Plasti- Tool C-3059 in t o oil h ole of cr a n ksh a ft (F ig. 72).
gage will be smeared. (3) Slowly r ot a t e cr a n ksh a ft cou n t er clockwise slid-
in g t h e bea r in g in t o posit ion . Rem ove Specia l Ma in
(5) Ca r efu lly r em ove t h e bea r in g ca p a n d m ea su r e Bea r in g Tool C-3059.
t h e widt h of t h e P la st iga ge a t t h e widest pa r t u sin g (4) In spect m a in ca p bolt s for st r et ch in g (F ig. 73).
t h e sca le on t h e P la st iga ge pa cka ge (F ig. 71). Refer Repla ce bolt s t h a t a r e st r et ch ed.
t o E n gin e Specifica t ion s for pr oper clea r a n ces (Refer
t o 9 - E NGINE - SP E CIF ICATIONS). If t h e clea r a n ce NOTE: The main cap bolts should be examined
exceeds t h e specified lim it s, r epla ce t h e m a in bea r- before reuse. Bolt stretch can be checked by hold-
in g(s) wit h t h e a ppr opr ia t e size, a n d if n ecessa r y, ing a scale or straight edge against the threads. If
h a ve t h e cr a n ksh a ft m a ch in ed t o n ext u n der size. all the threads do not contact the scale the bolt
must be replaced (Fig. 73).
REMOVAL - CRANKSHAFT MAIN BEARINGS (5) In st a ll ea ch m a in ca p a n d t igh t en bolt s fin ger
(1) Rem ove t h e oil pa n . (Refer t o 9 - E NGINE /LU- t igh t .
BRICATION/OIL PAN - RE MOVAL)
9 - 128 ENGINE 3.3/3.8L RS
r igidit y t o t h e lower en gin e block (F ig. 77). Cr a n k-
sh a ft en d sea lin g is pr ovided by fr on t a n d r ea r r u b-
ber sea ls.
STANDARD PROCEDURE - MEASURING

CRANKSHAFT END PLAY
(1) Mou n t a dia l in dica t or t o fr on t of en gin e wit h
t h e loca t in g pr obe on n ose of cr a n ksh a ft (F ig. 74).
(2) Move cr a n ksh a ft a ll t h e wa y t o t h e r ea r of it s
t r a vel.
(3) Zer o t h e dia l in dica t or.
Fig. 73 Check for Stretched (Necked) Bolts
(4) Move cr a n ksh a ft a ll t h e wa y t o t h e fr on t a n d
1 - STRETCHED BOLT
r ea d t h e dia l in dica t or. (Refer t o 9 - E NGINE -
3 - THREADS ARE STRAIGHT ON LINE SP E CIF ICATIONS) for en d pla y specifica t ion .
(6) Tigh t en n u m ber 1, 3 a n d 4 m a in ca p bolt s t o 41

N·m + 1/4 Tu r n (30 ft . lbs.+ 1/4 Tu r n ).
(7) Rot a t e t h e cr a n ksh a ft u n t il t h e n u m ber 6 pis-
t on is a t TDC.
(8) To en su r e cor r ect t h r u st bea r in g a lign m en t t h e
followin g pr ocedu r e m u st be don e:
a . Move cr a n ksh a ft a ll t h e wa y t o t h e r ea r of it s
t r a vel.
b. Th en , m ove cr a n ksh a ft a ll t h e wa y t o t h e fr on t
of it s t r a vel.
c. Wedge a n a ppr opr ia t e t ool bet ween t h e r ea r of
t h e cylin der block a n d r ea r cr a n ksh a ft cou n t er-
weigh t . Th is will h old t h e cr a n ksh a ft in it ’s m ost for-
wa r d posit ion .
d. Tigh t en t h e #2 Th r u st Bea r in g ca p bolt s t o 41
N·m + 1/4 Tu r n (30 ft . lbs.+ 1/4 Tu r n ). Rem ove t h e
Fig. 74 Checking Crankshaft End Play - Typical
h oldin g t ool. REMOVAL
(9) In st a ll oil pa n . (Refer t o 9 - E NGINE /LUBRI- (1) Rem ove t h e en gin e a ssem bly (Refer t o 9 -
CATION/OIL PAN - INSTALLATION) E NGINE - RE MOVAL).
(10) F ill en gin e cr a n kca se wit h pr oper oil t o cor- (2) Sepa r a t e t r a n sa xle fr om en gin e.
r ect level. (3) Mou n t en gin e on a n en gin e st a n d.
(4) Rem ove t h e oil filt er.
(5) Rem ove t h e oil pa n a n d oil pick-u p t u be (Refer
CRAN K SH AFT t o 9 - E NGINE /LUBRICATION/OIL PAN -
RE MOVAL).
DESCRI PT I ON (6) Rem ove t h e t im in g ch a in cover (Refer t o 9 -
E NGINE /VALVE TIMING/TIMING CH AIN COVE R -
RE MOVAL).
DESCRIPTION - 3.3L (7) Rem ove t im in g ch a in a n d spr ocket s (Refer t o 9
Th e n odu la r ir on cr a n ksh a ft is su ppor t ed by fou r
- E NGINE /VALVE TIMING/TIMING CH AIN AND
m a in bea r in gs, wit h n u m ber t wo posit ion t h e t h r u st
SP ROCKE TS - RE MOVAL).
bea r in g (F ig. 76). Cr a n ksh a ft en d sea lin g is pr ovided
(8) Rem ove cr a n ksh a ft r ea r oil sea l a n d r et a in er
by fr on t a n d r ea r r u bber sea ls.
(Refer t o 9 - E NGINE /E NGINE BLOCK/CRANK-
SH AF T OIL SE AL - RE AR - RE MOVAL).
DESCRIPTION - 3.8L (9) Rot a t e t h e cr a n ksh a ft u n t il con n ect in g r od ca p
Th e n odu la r ir on cr a n ksh a ft is su ppor t ed by fou r is a ccessible.
m a in bea r in gs, wit h n u m ber t wo posit ion pr ovidin g (10) Ma r k con n ect in g r od ca p posit ion u sin g a su it -
t h r u st bea r in g loca t ion (F ig. 77). E a ch m a in bea r in g a ble m a r ker /scr ibe t ool.
ca p h a s t wo ver t ica l r et a in in g bolt s. Th e t wo cen t er
m a in ca ps h a ve h or izon t a l bolt s t o a dd in cr ea sed
RS ENGINE 3.3/3.8L 9 - 129
(11) Rem ove con n ect in g r od bea r in g ca p. Use ca r e (6) In st a ll a n d t igh t en t h e NE W cr oss bolt s a n d
t o pr even t da m a ge t o t h e cr a n ksh a ft bea r in g su r- wa sh er a ssem blies (3.8L en gin e on ly) t o 61 N·m (45
fa ces. ft . lbs.) (F ig. 77).
(12) Repea t r em ova l pr ocedu r e for ea ch con n ect in g
r od ca p.
(13) Rem ove a n d disca r d t h e m a in bea r in g cr oss
bolt s a n d wa sh er s (3.8L en gin e on ly) (F ig. 77).
NOTE: Install new cross bolt and washer assembly

(3.8L engine only) upon reassembly.
(14) Rem ove t h e m a in bea r in g ca p bolt s

(15) Rem ove t h e m a in bea r in g ca ps.
(16) Rem ove t h e cr a n ksh a ft fr om en gin e block
(F ig. 76) or (F ig. 77).
INSTALLATION
(1) F or m a in bea r in g iden t ifica t ion , r efer t o (F ig.
69). Lu br ica t e wit h en gin e oil a n d in st a ll t h e cr a n k-
sh a ft m a in bea r in g h a lves in t h e en gin e block.
(2) P osit ion t h e cr a n ksh a ft in en gin e block (F ig.
76) or (F ig. 77).
(3) P er for m m a in bea r in g fit t in g pr ocedu r e (Refer
t o 9 - E NGINE /E NGINE BLOCK/CRANKSH AF T
MAIN BE ARINGS - STANDARD P ROCE DURE ).
(4) In spect m a in ca p bolt s for st r et ch in g (F ig. 75).
Repla ce bolt s t h a t a r e st r et ch ed.
NOTE: The main cap bolts should be examined

before reuse. Bolt stretch can be checked by hold-
ing a scale or straight edge against the threads. If
all the threads do not contact the scale the bolt
must be replaced (Fig. 75). Fig. 76 CRANKSHAFT AND BLOCK - 3.3L
1 - MAIN BEARING CAP No. 4
4 - MAIN BEARING CAP BOLT (QTY. 2 PER CAP)
6 - LOWER MAIN BEARING - THRUST
7 - UPPER MAIN BEARING - THRUST
8 - ENGINE BLOCK
9 - UPPER MAIN BEARINGS
10 - CRANKSHAFT
11 - LOWER MAIN BEARINGS
(7) P osit ion a n d in st a ll t h e con n ect in g r od a n d

bea r in g ca ps on t h e cr a n ksh a ft (Refer t o 9 -
Fig. 75 Check for Stretched (Necked) Bolts E NGINE /E NGINE BLOCK/CONNE CTING ROD
1 - STRETCHED BOLT BE ARINGS - STANDARD P ROCE DURE ).
(8) In st a ll t h e cr a n ksh a ft r ea r oil sea l (Refer t o 9 -
4 - UNSTRETCHED BOLT E NGINE /E NGINE BLOCK/CRANKSH AF T OIL
SE AL - RE AR - INSTALLATION).
(5) In st a ll t h e m a in bea r in g ca ps a n d bolt s. (9) In st a ll t h e cr a n ksh a ft spr ocket (Refer t o 9 -
Tigh t en bolt s t o 41 N·m (30 ft . lbs.) plu s 1 ⁄4 t u r n . E NGINE /VALVE TIMING/TIMING CH AIN AND
SP ROCKE TS - INSTALLATION).
NOTE: Install new cross bolt and washer assembly (10) In st a ll t h e t im in g ch a in a n d ca m sh a ft
(3.8L engine only) upon reassembly. spr ocket (Refer t o 9 - E NGINE /VALVE TIMING/TIM-
ING CH AIN AND SP ROCKE TS - INSTALLATION).
9 - 130 ENGINE 3.3/3.8L RS
(2) Ra ise veh icle on h oist . Rem ove r igh t wh eel a n d
in n er spla sh sh ield.
(3) Rem ove a ccessor y dr ive belt . (Refer t o 7 -
RE MOVAL)
(4) Rem ove cr a n ksh a ft da m per. (Refer t o 9 -
E NGINE /E NGINE BLOCK/VIBRATION DAMP E R -
RE MOVAL)
(5) P osit ion Specia l Tool 6341A on cr a n ksh a ft n ose.
Ca r efu lly scr ew t h e t ool in t o t h e sea l u n t il it en ga ges
fir m ly (F ig. 78). Be ca r efu l n ot t o da m a ge t h a t cr a n k-
sh a ft sea l su r fa ce of cover
(6) Rem ove oil sea l by t u r n in g t h e for cin g scr ew
u n t il t h e sea l disen ga ges fr om t h e cover (F ig. 79).
Fig. 77 CRANKSHAFT AND BLOCK - 3.8L

2 - MAIN BEARING CAP No. 3 Fig. 78 Engaging Tool into Seal
4 - MAIN BEARING CAP BOLT 1 - SEAL
5 - MAIN BEARING CAP No. 1 2 - SPECIAL TOOL 6341A
6 - THRUST MAIN BEARING - LOWER
7 - THRUST MAIN BEARING - UPPER
8 - MAIN BEARING CAP CROSS BOLT
9 - ENGINE BLOCK
10 - MAIN BEARING - UPPER
11 - CRANKSHAFT
12 - MAIN BEARING - LOWER
(11) In st a ll t h e t im in g ch a in cover (Refer t o 9 -

E NGINE /VALVE TIMING/TIMING CH AIN COVE R -
INSTALLATION).
(12) In st a ll t h e oil pick-u p t u be a n d oil pa n (Refer
t o 9 - E NGINE /LUBRICATION/OIL PAN - INSTAL-
LATION).
(13) In st a ll t h e t r a n sa xle t o t h e en gin e.
(14) In st a ll t h e en gin e a ssem bly (Refer t o 9 -
E NGINE - INSTALLATION). Fig. 79 Crankshaft Front Seal Removal
1 - SEAL
CRAN K SH AFT OI L SEAL -
INSTALLATION
FRON T (1) P osit ion Specia l Tool C-4992-2 Gu ide, on t h e
cr a n ksh a ft n ose (F ig. 80).
REMOVAL
RS ENGINE 3.3/3.8L 9 - 131
CRAN K SH AFT OI L SEAL - FRON T (Cont inue d)
(2) P osit ion n ew sea l over t h e gu ide wit h t h e sea l CAUTION: Do not permit the pry tool blade to con-
spr in g in t h e dir ect ion of t h e en gin e fr on t cover (F ig. tact crankshaft seal surface. Contact of the pry tool
80). blade against crankshaft edge (chamfer) is permit-
(3) In st a ll sea l u sin g Specia l Tool C-4992-1 u n t il ted.
sea l is flu sh wit h cover. (F ig. 80).
Fig. 80 CRANKSHAFT FRONT SEAL INSTALLATION

1 - SPECIAL TOOL C-4992-1
2 - SEAL
3 - SPECIAL TOOL C-4992-2
4 - CRANKSHAFT
(4) In st a ll cr a n ksh a ft da m per. (Refer t o 9 - Fig. 81 Crankshaft Rear Oil Seal - Removal
E NGINE /E NGINE BLOCK/VIBRATION DAMP E R - 1 - REAR CRANKSHAFT SEAL
2 - ENGINE BLOCK
INSTALLATION) 3 - ENGINE BLOCK
(5) In st a ll a ccessor y dr ive belt . (Refer t o 7 - COOL- 4 - REAR CRANKSHAFT SEAL METAL CASE
ING/ACCE SSORY DRIVE /DRIVE BE LTS - INSTAL- 5 - PRY IN THIS DIRECTION
6 - CRANKSHAFT
LATION) 7 - SCREWDRIVER
(6) In st a ll in n er spla sh sh ield a n d r igh t fr on t 8 - REAR CRANKSHAFT SEAL DUST LIP
wh eel. 9 - SCREWDRIVER
(7) Lower veh icle a n d con n ect n ega t ive ca ble t o
ba t t er y. INSTALLATION
CAUTION: If burr or scratch is present on the
CRAN K SH AFT OI L SEAL - crankshaft edge (chamfer), cleanup with 400 grit
sand paper to prevent seal damage during installa-
REAR tion of new seal.
REMOVAL (1) P la ce Specia l Tool 6926-1 m a gn et ic pilot t ool on

(1) Rem ove t h e t r a n sa xle. Refer t o TRANSAXLE cr a n ksh a ft (F ig. 82).
AND P OWE R TRANSF E R UNIT for pr ocedu r e. (2) P la ce sea l over Specia l Tool 6926-1 P ilot . Usin g
(2) Rem ove t h e flex pla t e. (Refer t o 9 - E NGINE / Specia l Tool 6926-2 In st a ller wit h C-4171 H a n dle,
E NGINE BLOCK/F LE X P LATE - RE MOVAL) dr ive sea l in t o t h e r et a in er h ou sin g (F ig. 82).
(3) In ser t a 3/16 fla t bla ded pr y t ool bet ween t h e (3) In st a ll t h e flex pla t e. (Refer t o 9 - E NGINE /
du st lip a n d t h e m et a l ca se of t h e cr a n ksh a ft sea l. E NGINE BLOCK/F LE X P LATE - INSTALLATION)
An gle t h e pr y t ool (F ig. 81) t h r ou gh t h e du st lip (4) In st a ll t r a n sa xle. Refer t o TRANSAXLE AND
a ga in st m et a l ca se of t h e sea l. P r y ou t sea l. P OWE R TRANSF E R UNIT for pr ocedu r e.
9 - 132 ENGINE 3.3/3.8L RS
Fig. 83 CRANKSHAFT REAR OIL SEAL

1 - OIL SEAL
2 - BOLT
3 - RETAINER - OIL SEAL
4 - GASKET
V I BRAT I ON DAM PER

Fig. 82 Rear Crankshaft Oil Seal—Installation REMOVAL
1 - SPECIAL TOOLS: (1) Discon n ect n ega t ive ca ble fr om ba t t er y.
2 - C-4171 HANDLE (2) Ra ise veh icle on h oist .
3 - 6926–2 INSTALLER (3) Rem ove t h e r igh t fr on t wh eel a n d in n er spla sh
4 - 6926–1 GUIDE
5 - SEAL sh ield.
(4) Rem ove t h e a ccessor y dr ive belt . (Refer t o 7 -
CRAN K SH AFT REAR OI L SEAL COOLING/ACCE SSORY DRIVE /DRIVE BE LTS -
RE MOVAL)
RETAI N ER (5) Rem ove vibr a t ion da m per bolt .
(6) In ser t Specia l Tool 8450 in t o cr a n ksh a ft n ose
REMOVAL (F ig. 84).
(1) Rem ove cr a n ksh a ft r ea r oil sea l (Refer t o 9 - (7) P osit ion 3-ja w pu ller Specia l Tool 1026 on
E NGINE /E NGINE BLOCK/CRANKSH AF T OIL da m per a s sh own in (F ig. 84). Tu r n pu ller for cin g
SE AL - RE AR - RE MOVAL). scr ew u n t il da m per r elea ses fr om cr a n ksh a ft .
(2) Rem ove oil pa n (Refer t o 9 - E NGINE /LUBRI- (8) Rem ove t h e cr a n ksh a ft vibr a t ion da m per.
(3) Rem ove oil sea l r et a in er scr ews (F ig. 83). INSTALLATION
(4) Rem ove oil sea l r et a in er (F ig. 83). (1) In st a ll cr a n ksh a ft vibr a t ion da m per u sin g t h e
(5) Clea n en gin e block a n d r et a in er of oil a n d ga s- for cin g scr ew, n u t , a n d t h r u st bea r in g/wa sh er fr om
ket m a t er ia l. Ma ke su r e su r fa ces a r e clea n a n d fr ee Specia l Tool 8452 (F ig. 85).
of oil.
NOTE: To minimize friction and prolong tool life,
INSTALLATION lubricate the threads on the forcing screw of Spe-
(1) P osit ion n ew ga sket a n d in st a ll r et a in er on cial Tool 8452.
block (F ig. 83). Tigh t en a t t a ch in g scr ews t o 12 N·m
(105 in . lbs.). (2) P osit ion vibr a t ion da m per on cr a n ksh a ft .
(2) In st a ll oil pa n (Refer t o 9 - E NGINE /LUBRI- (3) Scr ew Specia l Tool 8452 in t o cr a n ksh a ft u n t il
CATION/OIL PAN - INSTALLATION). t h e bolt sea t s. Tu r n t h e n u t t o in st a ll da m per u n t il it
(3) In st a ll oil sea l (Refer t o 9 - E NGINE /E NGINE sea t s fu lly.
BLOCK/CRANKSH AF T OIL SE AL - RE AR - (4) Rem ove Specia l Tool 8452.
INSTALLATION). (5) In st a ll vibr a t ion da m per bolt . Tor qu e bolt t o 54
N·m (40 ft . lbs.).
RS ENGINE 3.3/3.8L 9 - 133
V I BRAT I ON DAM PER (Cont inue d)
FLEX PLAT E
REMOVAL
(1) Rem ove t h e t r a n sa xle (Refer t o 21 - TRANS-
MISSION/TRANSAXLE /AUTOMATIC - 41TE -
RE MOVAL).
(2) Rem ove flex pla t e a t t a ch in g bolt s.
(3) Rem ove t h e flex pla t e (F ig. 86).
Fig. 84 Vibration Damper - Removal

1 - SPECIAL TOOL 8450 - INSERT
2 - SPECIAL TOOL 1026 - 3 JAW PULLER
Fig. 86 FLEX PLATE

1 - FLEX PLATE
2 - BOLT (QTY. 8)
3 - BACKING PLATE
INSTALLATION
(1) P osit ion flex pla t e wit h ba ckin g pla t e on t h e
cr a n ksh a ft (F ig. 86).
(2) Apply Mopa r ! Lock & Sea l Adh esive t o t h e flex
pla t e bolt s.
(3) In st a ll flex pla t e bolt s (F ig. 86). Tigh t en bolt s
t o 95 N·m (70 ft . lbs.).
(4) In st a ll t h e t r a n sa xle (Refer t o 21 - TRANSMIS-
SION/TRANSAXLE /AUTOMATIC - 41TE - INSTAL-
Fig. 85 Vibration Damper - Installation LATION).
1 - FORCING SCREW / NUT FROM SPECIAL TOOL 8452
2 - VIBRATION DAMPER
3 - THRUST BEARING / WASHER
(6) In st a ll t h e a ccessor y dr ive belt . (Refer t o 7 -

INSTALLATION)
(7) In st a ll in n er spla sh sh ield a n d r igh t fr on t
wh eel.
9 - 134 ENGINE 3.3/3.8L RS
EN GI N E M OU N T I N G FRON T M OU N T
DESCRIPTION REMOVAL
Th e en gin e m ou n t in g syst em con sist of fou r (1) Su ppor t t h e en gin e a n d t r a n sm ission a ssem bly
m ou n t s; r igh t a n d a left side su ppor t t h e power t r a in , wit h a floor ja ck so it will n ot r ot a t e.
a n d a fr on t a n d a r ea r m ou n t con t r ol power t r a in (2) Rem ove t h e fr on t en gin e m ou n t t h r ou gh bolt
t or qu e. Th e r igh t side m ou n t is a h ydr o-t ype (F ig. fr om t h e in su la t or a n d fr on t cr ossm em ber m ou n t in g
87), a ll ot h er s a r e of m olded r u bber m a t er ia l. br a cket (F ig. 88).
(3) Rem ove six scr ews fr om a ir da m t o a llow
a ccess t o t h e fr on t m ou n t scr ews.
(4) Rem ove t h e fr on t en gin e m ou n t scr ews a n d
r em ove t h e in su la t or a ssem bly (F ig. 88).
(5) Rem ove t h e fr on t m ou n t in g br a cket , if n eces-
sa r y (F ig. 88).
INSTALLATION
(1) In st a ll t h e fr on t m ou n t in g br a cket , if r em oved
(F ig. 88).
(2) In st a ll t h e fr on t en gin e m ou n t t h r ou gh bolt
fr om t h e in su la t or a n d fr on t cr ossm em ber m ou n t in g
(3) In st a ll t h e in su la t or a ssem bly a n d m ou n t in g
scr ews (F ig. 88).
Fig. 87 Engine Hydro-type Mount - Right Side

1 - BOLT
2 - BOLT
3 - FRAME RAIL
4 - RIGHT MOUNT - 2.4L ENGINE
5 - RIGHT MOUNT - 3.3/3.8L ENGINE
RS ENGINE 3.3/3.8L 9 - 135
FRON T M OU N T (Cont inue d)
Fig. 88 Engine Mounting - Front

1 - CROSSMEMBER 5 - BOLT 54 N·m (40 ft. lbs.)
2 - BOLT - 68 N·m (50 ft. lbs.) 6 - NUT - 68 N·m (50 ft. lbs.)
3 - BOLT - 102 N·m (75 ft. lbs.) 7 - MOUNT - ENGINE FRONT
4 - BOLT - 68 N·m (50 ft. lbs.) 8 - BRACKET - ENGINE FRONT MOUNT
9 - 136 ENGINE 3.3/3.8L RS
LEFT M OU N T
REMOVAL
(1) Ra ise t h e veh icle on h oist .
(2) Rem ove t h e left fr on t wh eel.
(3) Rem ove t h e left m ou n t t h r ou gh bolt a ccess
cover.
(4) Su ppor t t h e t r a n sa xle wit h a su it a ble ja ck.
(5) Rem ove t h e en gin e fr on t m ou n t t h r ou gh bolt t o
a llow left m ou n t r em ova l clea r a n ce (F ig. 88).
(6) Rem ove t h e left m ou n t t h r ou gh fr a m e r a il bolt
(F ig. 89).
Fig. 90 LEFT MOUNT - 41TE TRANSAXLE

1 - LEFT MOUNT ASSEMBLY
2 - BOLT - 54 N·m (40 ft. lbs.)
3 - TRANSAXLE - 41TE
REAR M OU N T
REMOVAL
(2) Rem ove t h e r ea r m ou n t h ea t sh ield (F ig. 91).
Fig. 89 LEFT MOUNT TO BRACKET

3 - BOLT - LEFT MOUNT TO TRANSAXLE 54 N·m (40 ft. lbs.)
4 - TRANSAXLE
5 - MOUNT - LEFT
6 - BRACKET - LEFT MOUNT
(7) Lower t r a n sa xle for a ccess t o h or izon t a l bolt s.

(8) Rem ove t h e h or izon t a l bolt s fr om t h e m ou n t t o
t h e t r a n sa xle (F ig. 90).
NOTE: To remove mount, additional lowering of Fig. 91 Rear Mount Heat Shield
transaxle may be required. 1 - BOLT - HEAT SHIELD 11 N·m (100 in. lbs.)
2 - HEAT SHIELD
(9) Rem ove left m ou n t . 3 - CLIP
4 - REAR MOUNT
INSTALLATION (3) Rem ove t h e t h r ou gh bolt fr om t h e m ou n t a n d

(1) In st a ll left m ou n t on t r a n sa xle (F ig. 90).
r ea r m ou n t br a cket (F ig. 92).
(2) Ra ise t r a n sa xle wit h ja ck u n t il left m ou n t is in
(4) Rem ove t h e m ou n t bolt s (F ig. 92).
posit ion .
(5) Rem ove t h e r ea r m ou n t (F ig. 92).
(3) In st a ll left m ou n t t h r ou gh bolt (F ig. 89).
(6) F or r ea r m ou n t br a cket r em ova l, r em ove t h e
(4) In st a ll left m ou n t t h r ou gh bolt a ccess cover.
bolt s a t t a ch in g br a cket t o t r a n sa xle (F ig. 93).
(5) In st a ll fr on t m ou n t t h r ou gh bolt (F ig. 88).
(7) Rem ove r ea r m ou n t br a cket .
(6) In st a ll left fr on t wh eel.
(7) Lower veh icle.
RS ENGINE 3.3/3.8L 9 - 137
REAR M OU N T (Cont inue d)
INSTALLATION
(1) In st a ll r ea r m ou n t br a cket , if r em oved (F ig.
93).
(2) In st a ll t h e r ea r m ou n t a n d bolt s (F ig. 92).
Tigh t en bolt s t o 54 N·m (40 ft . lbs.).
(3) In st a ll t h e m ou n t t h r ou gh bolt t o t h e m ou n t
a n d br a cket (F ig. 92). Tigh t en t h r ou gh bolt t o 54 N·m
(40 ft . lbs.).
(4) In st a ll t h e r ea r m ou n t h ea t sh ield (F ig. 91).
(5) Lower veh icle on h oist .
Fig. 92 Rear Mount

1 - BOLT 54 N·m (40 ft. lbs.)
2 - REAR MOUNT BRACKET
3 - THRU-BOLT 54 N·m (40 ft. lbs.)
4 - REAR MOUNT
Fig. 93 Rear Mount Bracket - (all engines)

9 - 138 ENGINE 3.3/3.8L RS
RI GH T M OU N T INSTALLATION
(1) In st a ll en gin e br a cket (if r em oved). Tigh t en
REMOVAL bolt s t o 33 N·m (24 ft . lbs.).
(1) Rem ove a ir clea n er h ou sin g lid a n d clea n a ir (2) P osit ion r igh t en gin e m ou n t a n d in st a ll fr a m e
h ose fr om t h r ot t le body. r a il t o m ou n t bolt s (F ig. 94). Tigh t en bolt s t o 68 N·m
(2) Rem ove a ir clea n er elem en t a n d h ou sin g. (50 ft . lbs.).
(3) Discon n ect m a ke-u p a ir h ose fr om cylin der (3) In st a ll t h e m ou n t t o en gin e br a cket bolt s a n d
h ea d cover. t igh t en t o 54 N·m (40 ft . lbs.). (F ig. 94)
(4) Rem ove t h e loa d on t h e r igh t en gin e m ou n t by (4) Con n ect elect r ica l h a r n ess su ppor t clips t o
ca r efu lly su ppor t in g t h e en gin e a ssem bly wit h a floor en gin e m ou n t br a cket .
ja ck. (5) Rem ove ja ck fr om u n der en gin e.
(5) Discon n ect elect r ica l h a r n ess su ppor t clips fr om (6) Con n ect m a ke-u p a ir h ose t o cylin der h ea d
en gin e m ou n t br a cket . cover.
(6) Rem ove t h e bolt s a t t a ch in g t h e en gin e m ou n t (7) In st a ll a ir clea n er h ou sin g a n d elem en t .
t o t h e fr a m e r a il (F ig. 94). (8) In st a ll a ir clea n er h ou sin g lid a n d clea n a ir
(7) Rem ove t h e t h r ee bolt s a t t a ch in g t h e en gin e t u be t o t h r ot t le body.
m ou n t t o t h e en gin e br a cket (F ig. 94).
(8) Rem ove t h e r igh t en gin e m ou n t (F ig. 94).
LU BRI CAT I ON
DESCRIPTION
Th e lu br ica t ion syst em is a fu ll flow filt r a t ion pr es-
su r e feed t ype. Th e oil pu m p is m ou n t ed in t h e t im -
in g ch a in cover a n d is dr iven by t h e cr a n ksh a ft
OPERATION
Oil fr om t h e oil pa n is pu m ped by a in t er n a l gea r
t ype oil pu m p dir ect ly cou pled t o t h e cr a n ksh a ft . Th e
pr essu r e is r egu la t ed by a r elief va lve loca t ed in t h e
t im in g ch a in cover. Th e oil is pu m ped t h r ou gh a n oil
filt er a n d feeds a m a in oil ga ller y. Th is oil ga ller y
feeds oil u n der pr essu r e t o t h e m a in a n d r od bea r-
in gs, ca m sh a ft bea r in gs. P a ssa ges in t h e cylin der
block feed oil t o t h e h ydr a u lic lift er s a n d r ocker sh a ft
br a cket s wh ich feeds t h e r ocker a r m pivot s (F ig. 95).
DIAGNOSIS AND TESTING - ENGINE OIL

PRESSURE
(1) Discon n ect a n d r em ove oil pr essu r e swit ch
(Refer t o 9 - E NGINE /LUBRICATION/OIL P RE S-
SURE SE NSOR/SWITCH - RE MOVAL).
(2) In st a ll Specia l Tools C-3292 Ga u ge wit h 8406
Ada pt or. F or Specia l Tool iden t ifica t ion , (Refer t o 9 -
E NGINE - SP E CIAL TOOLS).
Fig. 94 Right Engine Mount
(3) St a r t en gin e a n d r ecor d oil pr essu r e. Refer t o
1 - RIGHT ENGINE MOUNT
2 - BOLT - MOUNT TO FRAME RAIL
Oil P r essu r e in E n gin e Specifica t ion s for t h e cor r ect
3 - BOLT - MOUNT TO ENGINE pr essu r e (Refer t o 9 - E NGINE - SP E CIF ICATIONS).
RS ENGINE 3.3/3.8L 9 - 139
LU BRI CAT I ON (Cont inue d)
Fig. 95 Engine Oiling System

1 - OIL SUPPLY FOR BALL SOCKET THROUGH PUSH ROD 7 - OUTER ROTOR
2 - OIL SUPPLY PASSAGE FROM SHAFT TO ROCKER ARM 8 - INNER ROTOR
3 - ROCKER SHAFT 9 - RELIEF VALVE
4 - OIL FLOWS TO ONLY ONE PEDASTAL ON EACH HEAD; THIRD 10 - OIL PAN
FROM REAR ON RIGHT HEAD, THIRD FROM FRONT ON LEFT
HEAD
5 - ROCKER SHAFT TOWER 11 - OIL SCREEN
6 - CRANKSHAFT 12 - OIL PUMP CASE
OI L Ru n en gin e u n t il a ch ievin g n or m a l oper a t in g t em -

per a t u r e.
(1) P osit ion t h e veh icle on a level su r fa ce a n d t u r n
STAN DARD PROCEDU RE en gin e off.
(2) Open h ood, r em ove oil fill ca p (F ig. 97).
STANDARD PROCEDURE - ENGINE OIL AND (3) H oist a n d su ppor t veh icle on sa fet y st a n ds.
Refer t o H oist in g a n d J a ckin g Recom m en da t ion s.
FILTER CHANGE
(Refer t o LUBRICATION & MAINTE NANCE /H OIST-
Ch a n ge en gin e oil a t m ilea ge a n d t im e in t er va ls
descr ibed in t h e Ma in t en a n ce Sch edu le. (Refer t o
(4) P la ce a su it a ble dr a in pa n u n der cr a n kca se
LUBRICATION & MAINTE NANCE /MAINTE -
dr a in (F ig. 96).
NANCE SCH E DULE S - DE SCRIP TION)
(5) Rem ove dr a in plu g fr om cr a n kca se (F ig. 96)
WARNING: NEW OR USED ENGINE OIL CAN BE a n d a llow oil t o dr a in in t o pa n . In spect dr a in plu g
IRRITATING TO THE SKIN. AVOID PROLONGED OR t h r ea ds for st r et ch in g or ot h er da m a ge. Repla ce
REPEATED SKIN CONTACT WITH ENGINE OIL. dr a in plu g a n d ga sket if da m a ged.
CONTAMINANTS IN USED ENGINE OIL, CAUSED BY (6) Rem ove oil filt er. (Refer t o 9 - E NGINE /LUBRI-
INTERNAL COMBUSTION, CAN BE HAZARDOUS TO CATION/OIL F ILTE R - RE MOVAL)
YOUR HEALTH. THOROUGHLY WASH EXPOSED (7) In st a ll a n d t igh t en dr a in plu g in cr a n kca se.
SKIN WITH SOAP AND WATER. DO NOT WASH (8) In st a ll n ew oil filt er. (Refer t o 9 - E NGINE /LU-
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR BRICATION/OIL F ILTE R - INSTALLATION)
SOLVENTS, HEALTH PROBLEMS CAN RESULT. DO (9) Lower veh icle a n d fill cr a n kca se wit h specified
NOT POLLUTE, DISPOSE OF USED ENGINE OIL t ype a n d a m ou n t of en gin e oil. (Refer t o LUBRICA-
PROPERLY. CONTACT YOUR DEALER OR GOVERN- TION & MAINTE NANCE /F LUID TYP E S -
MENT AGENCY FOR LOCATION OF COLLECTION DE SCRIP TION)
CENTER IN YOUR AREA. (10) In st a ll oil fill ca p.
9 - 140 ENGINE 3.3/3.8L RS
OI L (Cont inue d)
(11) St a r t en gin e a n d in spect for lea ks.
(12) St op en gin e a n d in spect oil level.
NOTE: Care should be exercised when disposing

used engine oil after it has been drained from a
vehicle engine. Refer to the WARNING listed above.
STANDARD PROCEDURE - ENGINE OIL LEVEL

CHECK
Th e best t im e t o ch eck en gin e oil level is a ft er it
h a s sa t over n igh t , or if t h e en gin e h a s been r u n n in g,
a llow t h e en gin e t o be sh u t off for a t lea st 5 m in u t es
befor e ch eckin g oil level.
Ch eckin g t h e oil wh ile t h e veh icle is on level
gr ou n d will im pr ove t h e a ccu r a cy of t h e oil level
r ea din g (F ig. 97). Add on ly wh en t h e level is a t or
Fig. 96 Engine Oil Drain Plug and Oil Filter below t h e ADD m a r k.
1 - DRAIN PLUG
2 - OIL FILTER
Fig. 97 Engine Oil Level Dipstick and Fill Locations

1 - COOLANT RECOVERY CONTAINER 3 - ENGINE OIL LEVEL DIPSTICK
2 - ENGINE OIL FILL CAP 4 - RADIATOR PRESSURE CAP
RS ENGINE 3.3/3.8L 9 - 141
OI L COOLER & LI N ES
DESCRIPTION
An en gin e oil cooler is u sed on 3.3/3.8L en gin es
(H ea vy Du t y Coolin g On ly) (F ig. 99). Th e cooler is a
coola n t -t o-oil t ype a n d m ou n t ed bet ween t h e oil filt er
a n d en gin e block.
OPERATION
E n gin e oil t r a vels fr om t h e oil filt er a n d in t o t h e
oil cooler. E n gin e oil t h en exit s t h e cooler in t o t h e
m a in ga ller y. E n gin e coola n t flows in t o t h e cooler
fr om t h e h ea t er r et u r n t u be a n d exit s in t o t h e wa t er
pu m p in let .
REMOVAL
Fig. 99 Engine Oil Cooler - 3.3/3.8L (Heavy Duty
(1) Dr a in coolin g syst em (Refer t o 7 - COOLING -
Cooling)
STANDARD P ROCE DURE - COOLING SYSTE M
DRAINING). 1 - OIL FILTER ADAPTER
2 - CONNECTOR
(2) Discon n ect oil cooler in let a n d ou t let h oses 3 - ENGINE OIL COOLER
(F ig. 98). 4 - OIL COOLER ATTACHMENT FITTING
(3) Rem ove oil filt er. 5 - OIL FILTER
(4) Rem ove oil cooler a t t a ch m en t fit t in g (F ig. 99).
(3) In st a ll oil filt er.
(5) Rem ove oil cooler.
(4) Con n ect oil cooler in let a n d ou t let h oses (F ig.
98).
(5) F ill coolin g syst em (Refer t o 7 - COOLING -
STANDARD P ROCE DURE - COOLING SYSTE M
F ILLING).
OI L FI LT ER
REMOVAL
CAUTION: When servicing the oil filter avoid
deforming the filter can by installing the remove/in-
stall tool band strap against the can-to-base lock
seam. The lock seam joining the can to the base is
reinforced by the base plate.
Fig. 98 Engine Oil Cooler Hoses (1) Usin g su it a ble oil filt er wr en ch , t u r n filt er
cou n t er clockwise t o r em ove fr om oil filt er a da pt er
1 - OIL COOLER INLET TUBE
2 - INLET HOSE (F ig. 100). P r oper ly disca r d u sed oil filt er.
3 - OIL COOLER OUTLET TUBE
4
5
-
-
OUTLET HOSE
WATER PUMP INLET TUBE
INSTALLATION
(1) Wipe oil filt er a da pt er ba se clea n a n d in spect
ga sket con t a ct su r fa ce.
INSTALLATION (2) Lu br ica t e ga sket of n ew filt er wit h clea n
(1) Lu br ica t e sea l a n d posit ion oil cooler t o con n ec-
en gin e oil.
t or fit t in g on oil filt er a da pt er (F ig. 99).
(3) In st a ll n ew filt er u n t il ga sket con t a ct s ba se
NOTE: Position the flat side of oil cooler parallel to (F ig. 100). Tigh t en filt er 1 t u r n or 20 N·m (15 ft .
oil pan rail. lbs.). Use filt er wr en ch if n ecessa r y.
(4) St a r t en gin e a n d ch eck for lea ks.
(2) In st a ll oil cooler a t t a ch m en t fit t in g a n d t igh t en
t o 27 N·m (20 ft . lbs.) (F ig. 99).
9 - 142 ENGINE 3.3/3.8L RS
OI L FI LT ER ADAPT ER OI L PAN
REMOVAL REMOVAL
(1) Ra ise veh icle on h oist . (1) Discon n ect n ega t ive ca ble fr om ba t t er y a n d
(2) Rem ove t h e oil filt er. r em ove en gin e oil dipst ick.
(3) Discon n ect oil pr essu r e swit ch elect r ica l con - (2) Ra ise veh icle on h oist a n d dr a in en gin e oil.
n ect or. (3) Rem ove dr ive belt spla sh sh ield.
(4) Rem ove oil filt er a da pt er a t t a ch in g bolt s (F ig. (4) Rem ove st r u t t o t r a n sa xle a t t a ch in g bolt (F ig.
100). 101). Loosen st r u t t o en gin e block a t t a ch in g bolt s.
(5) Rem ove oil filt er a da pt er a n d sea l (F ig. 100). (5) Rem ove t r a n sa xle ca se cover (F ig. 101).
Fig. 101 Powertrain Struts and Transaxle Case

Cover
1 - BRACKET - ENGINE REAR MOUNT
Fig. 100 OIL FILTER ADAPTER 2 - BOLT - TRANSAXLE CASE COVER
3 - STRUT - TRANSAXLE TO ENGINE HORIZONTAL
1 - SEAL 4 - BOLT - HORIZONTAL STRUT
2 - OIL FILTER ADAPTER 5 - BOLT - STRUT TO TRANSAXLE
3 - OIL FILTER 6 - COVER - TRANSAXLE CASE LOWER
4 - BOLT 7 - STRUT - TRANSAXLE TO ENGINE
5 - OIL PRESSURE SWITCH 8 - BOLT - STRUT TO ENGINE
6 - BOLT 9 - BOLT - ENGINE REAR MOUNT BRACKET
INSTALLATION (6) Rem ove oil pa n fa st en er s (F ig. 102).

(1) Clea n oil filt er a da pt er a n d in st a ll n ew sea l. (7) Rem ove t h e oil pa n a n d ga sket (F ig. 102).
(2) P osit ion a da pt er on en gin e block a n d in st a ll
bolt s (F ig. 100). CLEANING
(3) Tigh t en a da pt er bolt s t o 28 N·m (250 in . lbs.). (1) Clea n oil pa n wit h solven t a n d wipe dr y wit h a
(4) Con n ect oil pr essu r e swit ch elect r ica l con n ect or clea n clot h .
(F ig. 100). (2) Clea n a ll ga sket m a t er ia l fr om m ou n t in g su r-
(5) In st a ll t h e oil filt er. fa ces of pa n a n d block.
(6) Lower veh icle on h oist . (3) Clea n oil scr een a n d pick-u p t u be in clea n sol-
(7) St a r t en gin e a n d a llow t o r u n a ppr oxim a t ely 2 ven t .
m in u t es.
(8) Tu r n off en gin e a n d ch eck oil level. Adju st oil
level a s n ecessa r y.
RS ENGINE 3.3/3.8L 9 - 143
OI L PAN (Cont inue d)
Fig. 103 Oil Pan Sealing

1 - SEALER LOCATIONS
OI L PRESSU RE RELI EF VALV E

REMOVAL
(2) Dr ill a 3.175 m m (1/8 in .) h ole in t h e cen t er of
Fig. 102 OIL PAN t h e r et a in er ca p (F ig. 104). In ser t a self-t h r ea din g
1 - GASKET sh eet m et a l scr ew in t o t h e ca p.
2 - BOLT (3) Usin g su it a ble plier s, r em ove ca p a n d disca r d.
3 - OIL PAN
4 - NUT (4) Rem ove spr in g a n d r elief va lve (F ig. 104).
INSPECTION
(1) In spect oil dr a in plu g a n d plu g h ole for
st r ipped or da m a ged t h r ea ds a n d r epa ir a s n ecessa r y.
In st a ll a n ew dr a in plu g ga sket . Tigh t en t o 27 N·m
(20 ft . lbs.).
(2) In spect oil pa n m ou n t in g fla n ge for ben ds or
dist or t ion . St r a igh t en fla n ge if n ecessa r y.
(3) In spect con dit ion of oil scr een a n d pick-u p t u be.
INSTALLATION
(1) Clea n sea lin g su r fa ces a n d a pply a 1/8 in ch
bea d of Mopa r ! E n gin e RTV GE N II a t t h e pa r t in g
lin e of t h e ch a in ca se cover a n d t h e r ea r sea l r et a in er
(F ig. 103).
(2) P osit ion a n ew pa n ga sket on oil pa n (F ig. 102).
(3) In st a ll oil pa n a n d t igh t en fa st en er s t o 12 N·m Fig. 104 Oil Pressure Relief Valve
(105 in . lbs.) (F ig. 102). 1 - RELIEF VALVE
(4) In st a ll cover t o t r a n sa xle ca se (F ig. 101). 2 - SPRING
3 - RETAINER CAP
(5) In st a ll t h e st r u t bolt t o t r a n sa xle h ou sin g (F ig.
101). Tigh t en a ll ben din g br a ce bolt s.
(6) In st a ll t h e dr ive belt spla sh sh ield.
(7) Lower veh icle a n d in st a ll oil dipst ick.
(9) F ill cr a n kca se wit h oil t o pr oper level.
9 - 144 ENGINE 3.3/3.8L RS
OI L PRESSU RE RELI EF VALV E (Cont inue d)
INSTALLATION
(1) Clea n r elief va lve, spr in g a n d bor e.
NOTE: Lubricate relief valve with clean engine oil

before installing.
(2) In st a ll r elief va lve a n d spr in g in t o h ou sin g.

(3) In st a ll n ew r et a in er ca p u n t il flu sh wit h sea l-
in g su r fa ce.
(4) In st a ll oil pa n (Refer t o 9 - E NGINE /LUBRI-
CATION/OIL PAN - INSTALLATION).
(5) F ill cr a n kca se wit h pr oper oil t o cor r ect level.
OI L PRESSU RE SWI T CH
DESCRIPTION
Th e en gin e oil pr essu r e swit ch is loca t ed on t h e
lower left fr on t side of t h e en gin e. It scr ews in t o t h e
oil filt er a da pt er. Th e n or m a lly closed swit ch pr ovides
a n in pu t t h r ou gh a sin gle wir e t o t h e low pr essu r e
in dica t or ligh t on t h e in st r u m en t clu st er.
OPERATION
Th e oil pr essu r e swit ch pr ovides a gr ou n d for t h e
in st r u m en t clu st er low oil pr essu r e in dica t or ligh t . Fig. 105 OIL FILTER ADAPTER
Th e swit ch r eceives oil pr essu r e in pu t fr om t h e 1 - SEAL
en gin e m a in oil ga ller y. Wh en en gin e oil pr essu r e is 2 - OIL FILTER ADAPTER
gr ea t er t h a n 27.5 Kpa (4 psi), t h e swit ch con t a ct s 3 - OIL FILTER
4 - BOLT
open , pr ovidin g a open cir cu it t o t h e low pr essu r e 5 - OIL PRESSURE SWITCH
in dica t or ligh t . F or wir in g cir cu it s a n d dia gn ost ic 6 - BOLT
in for m a t ion , (Refer t o Appr opr ia t e Wir in g/Dia gn ost ic
In for m a t ion ). OI L PU M P
REMOVAL DESCRIPTION
(1) Ra ise veh icle on h oist . Th e oil pu m p is loca t ed in t h e t im in g ch a in cover.
(2) Discon n ect elect r ica l con n ect or fr om swit ch . It is dr iven by t h e cr a n ksh a ft .
(3) Rem ove oil pr essu r e swit ch (F ig. 105).
REMOVAL
INSTALLATION Th e oil pu m p is con t a in ed wit h in t h e t im in g ch a in
(1) In st a ll oil pr essu r e swit ch . Tor qu e oil pr essu r e cover h ou sin g (F ig. 106).
swit ch t o 23 N·m (200 in . lbs.) (F ig. 105). (1) Rem ove oil pa n . (Refer t o 9 - E NGINE /LUBRI-
(2) Con n ect elect r ica l con n ect or t o swit ch . CATION/OIL PAN - RE MOVAL)
(3) Lower t h e veh icle. (2) Rem ove t h e t im in g ch a in cover. (Refer t o 9 -
(4) St a r t en gin e a n d ch eck for lea ks. E NGINE /VALVE TIMING/TIMING BE LT / CH AIN
(5) Ch eck en gin e oil level. Adju st a s n ecessa r y. COVE R(S) - RE MOVAL)
(3) Disa ssem ble oil pu m p fr om t im in g ch a in cover.
(Refer t o 9 - E NGINE /LUBRICATION/OIL P UMP -
DISASSE MBLY)
(4) Clea n a n d In spect oil pu m p com pon en t s. (Refer
t o 9 - E NGINE /LUBRICATION/OIL P UMP - CLE AN-
ING) (Refer t o 9 - E NGINE /LUBRICATION/OIL
P UMP - INSP E CTION)
RS ENGINE 3.3/3.8L 9 - 145
DISASSEMBLY (4) If in n er r ot or t h ickn ess m ea su r es 7.64 m m

(1) Rem ove oil pu m p cover scr ews, a n d lift off (0.301 in .) or less, r epla ce in n er r ot or (F ig. 109).
cover (F ig. 106).
(2) Rem ove oil pu m p r ot or s (F ig. 106).
(3) Clea n a n d in spect oil pu m p com pon en t s. (Refer
t o 9 - E NGINE /LUBRICATION/OIL P UMP - CLE AN-
ING) (Refer t o 9 - E NGINE /LUBRICATION/OIL
P UMP - INSP E CTION)
Fig. 107 Checking Oil Pump Cover Flatness

1 - FEELER GAUGE
2 - OIL PUMP COVER
3 - STRAIGHT EDGE
(5) In st a ll ou t er r ot or in t o ch a in ca se cover. P r ess

r ot or t o on e side wit h fin ger s a n d m ea su r e clea r a n ce
bet ween r ot or a n d ch a in ca se cover (F ig. 110). If m ea -
su r em en t is 0.39 m m (0.015 in .) or m or e, r epla ce
ch a in ca se cover, on ly if ou t er r ot or is in specifica t ion .
Fig. 106 OIL PUMP (6) In st a ll in n er r ot or in t o ch a in ca se cover. If
1 - TIMING CHAIN COVER clea r a n ce bet ween in n er a n d ou t er r ot or s (F ig. 111) is
2 - SCREWS 0.203 m m (0.008 in .) or m or e, r epla ce bot h r ot or s.
3 - INNER ROTOR (7) P la ce a st r a igh t edge a cr oss t h e fa ce of t h e
4 - OUTER ROTOR
5 - COVER ch a in ca se cover, bet ween bolt h oles. If a feeler ga u ge
of 0.10 m m (0.004 in .) or m or e ca n be in ser t ed
CLEANING bet ween r ot or s a n d t h e st r a igh t edge, r epla ce pu m p
(1) Clea n a ll pa r t s t h or ou gh ly in a su it a ble sol- a ssem bly (F ig. 112). ON LY if r ot or s a r e in specs.
ven t .
INSPECTION
(1) In spect m a t in g su r fa ce of t h e ch a in ca se cover.
Su r fa ce sh ou ld be sm oot h . Repla ce cover if scr a t ch ed
or gr ooved.
(2) La y a st r a igh t edge a cr oss t h e pu m p cover su r-
fa ce (F ig. 107). If a 0.025 m m (0.001 in .) feeler ga u ge
ca n be in ser t ed bet ween cover a n d st r a igh t edge,
cover sh ou ld be r epla ced.
(3) Mea su r e t h ickn ess a n d dia m et er of ou t er r ot or.
If ou t er r ot or t h ickn ess m ea su r es 7.64 m m (0.301 in .)
or less (F ig. 108), or if t h e dia m et er is 79.95 m m
(3.148 in .) or less, r epla ce ou t er r ot or.
Fig. 108 Measuring Outer Rotor Thickness

9 - 146 ENGINE 3.3/3.8L RS
Fig. 109 Measuring Inner Rotor Thickness Fig. 111 Measuring Clearance Between Rotors
1 - FEELER GAUGE
2 - INNER ROTOR
3 - OUTER ROTOR
Fig. 110 Measuring Outer Rotor Clearance in

Housing
1 - FEELER GAUGE
2 - OUTER ROTOR
Fig. 112 Measuring Clearance Over Rotors
(8) Rem ove oil pr essu r e r elief va lve. (Refer t o 9 - 1 - FEELER GAUGE
E NGINE /LUBRICATION/OIL P RE SSURE RE LIE F 2 - STRAIGHT EDGE
VALVE - RE MOVAL)
(9) In spect oil pr essu r e r elief va lve a n d bor e. ASSEMBLY
In spect for scor in g, pit t in g a n d fr ee va lve oper a t ion (1) Assem ble pu m p, u sin g n ew pa r t s a s r equ ir ed.
in bor e (F ig. 113). Sm a ll m a r ks m a y be r em oved wit h In s ta ll th e in n e r ro to r w ith c h a m fe r fa c in g th e
400-gr it wet or dr y sa n dpa per. c a s t iro n o il p u m p c o v e r.
(10) Th e r elief va lve spr in g h a s a fr ee len gt h of (2) P r im e oil pu m p befor e in st a lla t ion by fillin g
a ppr oxim a t ely 49.5 m m (1.95 in ch es) it sh ou ld t est r ot or ca vit y wit h en gin e oil.
bet ween 19.5 a n d 20.5 pou n ds wh en com pr essed t o (3) In st a ll cover a n d t igh t en scr ews t o 12 N·m (105
34 m m (1-11/32 in ch es). Repla ce spr in g t h a t fa ils t o in . lbs.).
m eet specifica t ion s. (4) If r em oved, in st a ll t h e oil pr essu r e r elief va lve.
(11) If oil pr essu r e is low a n d pu m p is wit h in spec- (Refer t o 9 - E NGINE /LUBRICATION/OIL P RE S-
ifica t ion s, in spect for wor n en gin e bea r in gs or ot h er SURE RE LIE F VALVE - INSTALLATION)
r ea son s for oil pr essu r e loss.
INSTALLATION
(1) In st a ll oil pu m p. (Refer t o 9 - E NGINE /LUBRI-
CATION/OIL P UMP - ASSE MBLY)
RS ENGINE 3.3/3.8L 9 - 147
DIAGNOSIS AND TESTING - INTAKE

MANIFOLD LEAKS
An in t a ke m a n ifold a ir lea k is ch a r a ct er ized by
lower t h a n n or m a l m a n ifold va cu u m . Also, on e or
m or e cylin der s m a y n ot be fu n ct ion in g.
WARNING: USE EXTREME CAUTION WHEN THE

ENGINE IS OPERATING. DO NOT STAND IN A
DIRECT LINE WITH THE FAN. DO NOT PUT YOUR
HANDS NEAR THE PULLEYS, BELTS OR THE FAN.
DO NOT WEAR LOOSE CLOTHING.
(2) Spr a y a sm a ll st r ea m of wa t er (Spr a y Bot t le) a t
t h e su spect ed lea k a r ea .
(3) If en gin e RP M’S ch a n ge, t h e a r ea of t h e su s-
Fig. 113 Oil Pressure Relief Valve pect ed lea k h a s been fou n d.
1 - RELIEF VALVE (4) Repa ir a s r equ ir ed.
2 - SPRING
3 - RETAINER CAP
(2) In st a ll t im in g ch a in cover (Refer t o 9 -

I N TAK E M AN I FOLD - U PPER
E NGINE /VALVE TIMING/TIMING BE LT / CH AIN
COVE R(S) - INSTALLATION) a n d oil pa n (Refer t o 9 STAN DARD PROCEDU RE
- E NGINE /VALVE TIMING/TIMING BE LT / CH AIN
COVE R(S) - INSTALLATION).
STANDARD PROCEDURE - MANIFOLD
STRIPPED THREAD REPAIR
I N TAK E M AN I FOLD Th e com posit e u pper in t a ke m a n ifold t h r ea d
bosses, if st r ipped ou t , ca n be r epa ir ed by u t ilizin g a
DESCRIPTION r epa ir scr ew a va ila ble t h r ou gh Mopa r ! pa r t s. Repa ir
Th e in t a ke syst em is m a de u p of a n u pper a n d scr ews a r e a va ila ble for t h e followin g m a n ifold
lower in t a ke m a n ifold. Th e u pper in t a ke m a n ifold is a t t a ch ed com pon en t s:
m a de of a com posit e for bot h t h e 3.3L en gin e a n d for • MAP sen sor
t h e 3.8L en gin e (F ig. 118). Th e lower in t a ke m a n ifold • P ower st eer in g r eser voir
is com m on bet ween t h e t wo en gin es (F ig. 122). It a lso • E GR t u be
pr ovides coola n t cr ossover bet ween cylin der h ea ds • Th r ot t le ca ble br a cket
a n d h ou ses t h e coola n t t h er m ost a t (F ig. 122). Th e r epa ir scr ews r equ ir e a u n iqu e t igh t en in g
Th e in t a ke m a n ifold u t ilizes a com pa ct design wit h t or qu e specifica t ion fr om t h e or igin a l scr ew. Refer t o
ver y low r est r ict ion a n d ou t st a n din g flow ba la n ce. t h e followin g ch a r t for specifica t ion .
Th is design a llows t h e en gin e t o per for m wit h a wide
t or qu e cu r ve wh ile in cr ea sin g h igh er r pm h or se- DESCRIPTION TORQUE*
power. STRIP-OUT REPAIR SCREWS ONLY
If, for som e r ea son , t h e m olded-in va cu u m por t s
br ea k, t h e com posit e m a n ifold ca n be sa lva ged. Th e MAP Sensor Repair 4 N·m (35 in. lbs.)
va cu u m por t s a r e design ed t o br ea k a t t h e sh ou lder, Screw
if over loa ded. Addit ion a l m a t er ia l in t h e sh ou lder Power Steering Reservoir 9 N·m (80 in. lbs.)
a r ea pr ovides su fficien t st ock t o r epa ir. F or m or e Repair Screw
in for m a t ion a n d pr ocedu r e, (Refer t o 9 - E NGINE / EGR Tube Attaching 9 N·m (80 in. lbs.)
MANIF OLDS/INTAKE MANIF OLD - STANDARD Repair Screw
P ROCE DURE ). Also, if t h e specia l scr ews t h a t a t t a ch
Throttle Cable Bracket 9 N·m (80 in. lbs.)
t h e MAP sen sor, power st eer in g r eser voir, t h r ot t le
Repair Screw
ca ble br a cket , a n d t h e E GR t u be becom e st r ipped, a n
over sized scr ew is a va ila ble t o r epa ir t h e st r ipped-ou t *Install Slowly Using Hand Tools Only
con dit ion . F or m or e in for m a t ion a n d pr ocedu r e,
F OLD - STANDARD P ROCE DURE )
9 - 148 ENGINE 3.3/3.8L RS
STANDARD PROCEDURE - INTAKE MANIFOLD

VACUUM PORT REPAIR
Th e com posit e in t a ke m a n ifold va cu u m por t s ca n
be r epa ir ed. Alt h ou gh , if t h e m a n ifold plen u m ch a m -
ber is da m a ged or cr a cked, t h e m a n ifold m u st be
r epla ced.
To r epa ir a br oken or da m a ged va cu u m n ipple
(por t ) on t h e com posit e in t a ke m a n ifold, per for m t h e
followin g pr ocedu r e:
PARTS REQUIRED TOOLS REQUIRED

· Brass Nipple – 1/4% · Pipe Tap – 1/8% - 18
O.D. x 1/8% pipe thread NPT
(LDP/Speed Control Port) · Drill Bit – 11/32%
· File/Sandpaper
· Brass Nipple – 1/2% · Pipe Tap – 1/4% - 18
O.D. x 1/4% pipe thread NPT
(Brake Booster Port) · Drill Bit – 7/16%
· File/Sandpaper
Fig. 114 Intake Manifold Port Repair
NOTE: While performing this procedure, avoid get- 1 - BRAKE BOOSTER PORT = 1/4%–18 NPT PIPE TAP
ting the manifold material residue into the plenum 1 - LDP/SPEED CONTROL PORT = 1/8%–18 NPT PIPE TAP
chamber. 2 - DRILL BIT = 7/16% BRAKE BOOSTER PORT
2 - DRILL BIT = 11/32% LDP/SPEED CONTROL PORT
3 - INTAKE MANIFOLD
(1) F ile or sa n d t h e r em a in in g por t ba ck u n t il a
fla t su r fa ce is obt a in ed (pla n e n or m a l t o n ipple (por t ) (6) Discon n ect t h e a u t om a t ic idle speed (AIS)
a xis). m ot or a n d t h r ot t le posit ion sen sor (TP S) wir in g con -
(2) Dr ill ou t t h e n ipple (por t ) ba se u sin g a 7/16” n ect or s fr om t h r ot t le body.
(br a ke boost er por t ) or 11/32” (LDP /speed con t r ol por t (7) Discon n ect t h e m a n ifold a bsolu t e pr essu r e
) dr ill bit (F ig. 114). (MAP ) sen sor elect r ica l con n ect or.
(3) Usin g a 1/4”–18 NP T (br a ke boost er por t ) or (8) Discon n ect t h e va por pu r ge va cu u m h ose fr om
1/8”–18 NP T (LDP /speed con t r ol por t ) pipe t a p, cu t t h r ot t le body.
in t er n a l t h r ea ds (F ig. 114). Use ca u t ion t o st a r t t a p (9) Discon n ect t h e P CV h ose (F ig. 115).
in a a xis sa m e a s or igin a l n ipple. (10) Rem ove t h e power st eer in g r eser voir a t t a ch -
(4) Apply Mopa r ! Th r ea d Sea la n t t o t h r ea ds of in g bolt s a n d on ly loosen t h e n u t (F ig. 116). Lift r es-
r epa ir n ipple(s). er voir u p t o disen ga ge lower m ou n t fr om st u d. Set
(5) In st a ll r epa ir n ipple(s). Do n ot over t or qu e r eser voir a side. D o n o t discon n ect h ose.
r epa ir n ipple(s). (11) Discon n ect t h e br a ke boost er a n d lea k det ec-
t ion pu m p (LDP ) h oses fr om in t a ke m a n ifold (F ig.
REMOVAL - UPPER INTAKE MANIFOLD 117).
(1) Discon n ect ba t t er y n ega t ive ca ble. (12) Rem ove in t a ke m a n ifold bolt s a n d r em ove t h e
(2) Discon n ect in let a ir t em per a t u r e (IAT) sen sor m a n ifold (F ig. 118).
elect r ica l con n ect or. (13) Cover t h e lower in t a ke m a n ifold wit h a su it -
(3) Rem ove a ir in let r eson a t or t o t h r ot t le body a ble cover wh ile t h e u pper m a n ifold is r em oved.
h ose a ssem bly. (14) Clea n a n d in spect t h e u pper in t a ke m a n ifold
(4) Discon n ect t h r ot t le a n d speed con t r ol ca bles (Refer t o 9 - E NGINE /MANIF OLDS/INTAKE MANI-
fr om t h r ot t le body (Refer t o 14 - F UE L SYSTE M/ F OLD - CLE ANING) a n d (Refer t o 9 - E NGINE /
F UE L INJ E CTION/TH ROTTLE CONTROL CABLE - MANIF OLDS/INTAKE MANIF OLD - INSP E CTION).
RE MOVAL).
(5) Discon n ect m a ke-u p a ir h ose su ppor t clip fr om CLEANING
t h r ot t le ca ble br a cket . (1) Disca r d ga sket (s).
(2) Clea n a ll sea lin g su r fa ces.
RS ENGINE 3.3/3.8L 9 - 149
Fig. 117 BRAKE BOOSTER & LDP VACUUM HOSES

1 - LDP & SPEED CONTROL VACUUM HOSE
2 - BRAKE BOOSTER VACUUM HOSE
3 - MAP SENSOR
INSPECTION
Ch eck m a n ifold for :
Fig. 115 PCV & HOSE • Da m a ge a n d cr a cks.
1 - HOSE - PCV • Mou n t in g su r fa ce dist or t ion by u sin g a st r a igh t -
2 - PCV VALVE edge a n d t h ickn ess ga u ge.
INSTALLATION - UPPER INTAKE MANIFOLD

(1) If t h e followin g com pon en t s wer e r em oved fr om
m a n ifold, in st a ll a n d t igh t en t o specifica t ion s:
CAUTION: The special screws used for the compos-

ite manifold attached components must be installed
slowly using hand tools only. This requirement is to
prevent the melting of material that causes stripped
threads. If threads become stripped, an oversize
repair screw is available. For more information and
procedure (Refer to 9 - ENGINE/MANIFOLDS/IN-
TAKE MANIFOLD - STANDARD PROCEDURE - MAN-
IFOLD STRIPPED THREAD REPAIR).
• MAP sen sor - 1.7 N·m (15 in . lbs.)

• Th r ot t le ca ble br a cket - 5.6 N·m (50 in . lbs.)
(2) Rem ove cover in g on lower in t a ke m a n ifold a n d
clea n su r fa ces.
(3) In spect m a n ifold ga sket con dit ion . Ga sket s ca n
be r e-u sed, if n ot da m a ged. To r epla ce, r em ove ga sket
fr om u pper m a n ifold (F ig. 118). P osit ion n ew ga sket
in sea l ch a n n el a n d pr ess ligh t ly in -pla ce. Repea t
Fig. 116 POWER STEERING FLUID RESERVOIR pr ocedu r e for ea ch ga sket posit ion .
1 - POWER STEERING RESERVOIR
(4) P osit ion u pper m a n ifold on lower m a n ifold (F ig.
2 - BOLT - RESERVOIR TO MANIFOLD 118). Apply Mopa r ! Lock & Sea l Adh esive (Mediu m
3 - NUT - RESERVOIR TO COIL BRACKET St r en gt h Th r ea dlocker ) t o ea ch u pper in t a ke m a n i-
fold bolt . In st a ll a n d t igh t en bolt s t o 12 N·m (105 in .
lbs.) followin g t or qu e sequ en ce in (F ig. 119).
9 - 150 ENGINE 3.3/3.8L RS
CAUTION: The special screws used for attaching
the EGR tube and power steering reservoir to the
manifold must be installed slowly using hand tools
only. This requirement is to prevent the melting of
material that causes stripped threads. If threads
become stripped, an oversize repair screw is avail-
able. For more information and procedure (Refer to
9 - ENGINE/MANIFOLDS/INTAKE MANIFOLD - STAN-
DARD PROCEDURE - MANIFOLD STRIPPED
THREAD REPAIR).
(7) In st a ll t h e power st eer in g r eser voir (F ig. 116).

Tigh t en scr ews t o m a n ifold t o 5.6 N·m (50 in . lbs.).
(8) Con n ect t h r ot t le a n d speed con t r ol ca bles t o
t h r ot t le body (Refer t o 14 - F UE L SYSTE M/F UE L
INJ E CTION/TH ROTTLE CONTROL CABLE -
INSTALLATION)
(9) At t a ch m a ke u p a ir h ose clip in t o t h e h ole in
t h e t h r ot t le ca ble br a cket .
(10) Con n ect t h e wir in g con n ect or s t o t h e t h r ot t le
posit ion sen sor (TP S) a n d Au t om a t ic Idle Speed (AIS)
m ot or.
(11) In st a ll a ir clea n er a n d a ir in let h ose a ssem bly.
(12) Con n ect t h e in let a ir t em per a t u r e (IAT) sen -
sor elect r ica l con n ect or.
I N TAK E M AN I FOLD - LOWER

Fig. 118 INTAKE MANIFOLD - UPPER
1
2
-
-
BOLT
MAP SENSOR
REMOVAL - LOWER INTAKE MANIFOLD
3 - SCREW (1) P er for m fu el syst em pr essu r e r elea se pr ocedu r e
4 - MANIFOLD - UPPER (be fo re a tte m p tin g a n y re p a irs ). (Refer t o 14 -
5 - WIRE HARNESS
6 - GASKET (3 PER CYL. BANK)
F UE L SYSTE M/F UE L DE LIVE RY - STANDARD
P ROCE DURE )
(3) Rem ove t h e u pper in t a ke m a n ifold. (Refer t o 9
- E NGINE /MANIF OLDS/INTAKE MANIF OLD -
RE MOVAL)
(4) Rem ove t h e fu el lin e. (Refer t o 14 - F UE L SYS-
TE M/F UE L DE LIVE RY/F UE L LINE S - STANDARD
P ROCE DURE ) (Refer t o 14 - F UE L SYSTE M/F UE L
DE LIVE RY/QUICK CONNE CT F ITTING - STAN-
DARD P ROCE DURE )
(5) Rem ove ign it ion coil a n d br a cket (F ig. 120).
(6) Discon n ect h ea t er su pply h ose a n d en gin e cool-
a n t t em per a t u r e sen sor (F ig. 121).
(7) Discon n ect t h e fu el in ject or wir e h a r n ess.
(8) Rem ove t h e fu el in ject or s a n d r a il a ssem bly
(F ig. 120).
Fig. 119 UPPER MANIFOLD TIGHTENING (9) Rem ove r a dia t or u pper h ose.
SEQUENCE (10) Rem ove t h e in t a ke m a n ifold bolt s.
(11) Rem ove lower in t a ke m a n ifold (F ig. 122).
(5) Con n ect t h e MAP sen sor elect r ica l con n ect or.
(6) Con n ect t h e br a ke boost er a n d LDP va cu u m
h ose t o in t a ke m a n ifold (F ig. 117).
RS ENGINE 3.3/3.8L 9 - 151
Fig. 121 ECT SENSOR & HEATER SUPPLY

1 - ENGINE COOLANT TEMPERATURE SENSOR
2 - CONNECTOR - ENGINE COOLANT SENSOR
Fig. 120 FUEL RAIL AND IGNITION COIL & 3 - FITTING - HEATER SUPPLY
BRACKET
• Ch eck for cylin der h ea d m ou n t in g su r fa ce dist or-
1 - FUEL RAIL
2 - BOLT - FUEL RAIL t ion u sin g a st r a igh t edge a n d t h ickn ess ga u ge. (Refer
3 - NUT - IGNITION COIL t o 9 - E NGINE /CYLINDE R H E AD - INSP E CTION)
4 - BOLT - IGNITION COIL
5 - IGNITION COIL
6 - BRACKET - IGNITION COIL INSTALLATION - LOWER INTAKE MANIFOLD
7 - STUD - IGNITION COIL (1) P la ce a bea d (a ppr oxim a t ely 1/4 in . dia m et er )
8 - SEPARATOR - SPARK PLUG CABLE
9 - BRACKET - SPARK PLUG CABLE SEPARATOR
of Mopa r ! E n gin e RTV GE N II on t o ea ch of t h e fo u r
10 - BOLT - SEPARATOR BRACKET m a n ifold t o cylin der h ea d ga sket cor n er s (F ig. 123).
11 - BRACKET - SPARK PLUG CABLE SEPARATOR (2) Ca r efu lly in st a ll t h e n ew in t a ke m a n ifold ga s-
ket (F ig. 122). Tigh t en en d sea l r et a in er scr ews t o 12
WARNING: INTAKE MANIFOLD GASKET IS MADE N·m (105 in . lbs.).
OF VERY THIN METAL AND MAY CAUSE PER- (3) In st a ll lower in t a ke m a n ifold (F ig. 122). In st a ll
SONAL INJURY, HANDLE WITH CARE. t h e bolt s a n d t or qu e t o 1 N·m (10 in . lbs.). Th en
t or qu e bolt s t o 22 N·m (200 in . lbs.) in sequ en ce
(12) Rem ove in t a ke m a n ifold sea l r et a in er s scr ews
sh own in (F ig. 124). Th en t or qu e a ga in t o 22 N·m
(F ig. 122). Rem ove in t a ke m a n ifold ga sket .
(200 in . lbs.). Aft er in t a ke m a n ifold is in pla ce,
(13) In spect a n d clea n m a n ifold. (Refer t o 9 -
in s p e c t to m a k e s u re s e a ls a re in p la c e .
(4) In st a ll t h e fu el in ject or s a n d r a il a ssem bly.
INSP E CTION) (Refer t o 9 - E NGINE /MANIF OLDS/
(Refer t o 14 - F UE L SYSTE M/F UE L DE LIVE RY/
INTAKE MANIF OLD - CLE ANING)
F UE L RAIL - INSTALLATION)
(5) Con n ect fu el in ject or elect r ica l h a r n ess.
CLEANING (6) Con n ect t h e en gin e coola n t t em per a t u r e sen sor
(1) Disca r d ga sket (s). (F ig. 121).
(2) Clea n a ll sea lin g su r fa ces. (7) Con n ect t h e h ea t er su pply (F ig. 121) a n d r a di-
a t or u pper h oses t o m a n ifold.
INSPECTION (8) Con n ect t h e fu el lin e. (Refer t o 14 - F UE L SYS-
Ch eck for : TE M/F UE L DE LIVE RY/QUICK CONNE CT F IT-
• Da m a ge a n d cr a cks of ea ch sect ion . TING - STANDARD P ROCE DURE )
• Clogged wa t er pa ssa ges in en d cr oss-over s (if
equ ipped).
9 - 152 ENGINE 3.3/3.8L RS
Fig. 124 LOWER MANIFOLD TIGHTENING

SEQUENCE
(11) F ill t h e coolin g syst em . (Refer t o 7 - COOL-
EX H AU ST M AN I FOLD - RI GH T
REMOVAL
(2) Rem ove t h e wiper m odu le. (Refer t o 8 - E LE C-
Fig. 122 INTAKE MANIFOLD - LOWER RE MOVAL)
1 - INTAKE MANIFOLD - LOWER (3) Discon n ect spa r k plu g wir es.
2 - BOLT - GASKET END SEAL RETAINER
3 - GASKET (4) Rem ove bolt s fa st en in g cr ossover pipe t o
4 - BOLT - LOWER INTAKE MANIFOLD exh a u st m a n ifold (F ig. 125).
Fig. 123 Intake Manifold Gasket Sealing Fig. 125 CROSS-OVER PIPE
1 - CROSS-OVER PIPE
1 - SEALER LOCATIONS
2 - BOLT
3 - GASKET
(9) In st a ll t h e u pper in t a ke m a n ifold. (Refer t o 9 - 4 - FLAG NUT
INSTALLATION) (5) Discon n ect a n d r em ove t h e u pst r ea m oxygen
(10) Con n ect n ega t ive ba t t er y ca ble. sen sor (F ig. 128).
RS ENGINE 3.3/3.8L 9 - 153
EX H AU ST M AN I FOLD - RI GH T (Cont inue d)
(6) Rem ove t h e h ea t sh ield a t t a ch in g scr ews (F ig. (12) Lower veh icle a n d r em ove t h e power st eer in g
128). pu m p su ppor t st r u t u pper bolt (F ig. 126).
(7) Rem ove t h e u pper h ea t sh ield (F ig. 128). (13) Rem ove bolt s a t t a ch in g exh a u st m a n ifold t o
(8) Ra ise veh icle on h oist a n d r em ove dr ive belt cylin der h ea d a n d r em ove m a n ifold (F ig. 128).
sh ield.
(9) Loosen t h e power st eer in g pu m p su ppor t st r u t
lower bolt (F ig. 126).
Fig. 126 P/S PUMP STRUT Fig. 128 EXHAUST MANIFOLD - RIGHT
1 - BOLT - LOWER 1 - SCREW - HEAT SHIELD
2 - STRUT - P/S PUMP 2 - HEAT SHIELD - UPPER
3 - BOLT - UPPER 3 - BOLT - EXHAUST MANIFOLD
4 - HEAT SHIELD - LOWER
5 - EXHAUST MANIFOLD - RIGHT
(10) Discon n ect down st r ea m oxygen sen sor con n ec- 6 - OXYGEN SENSOR - UPSTREAM
t or.
(11) Discon n ect ca t a lyt ic con ver t er pipe fr om (14) In spect a n d clea n m a n ifold. (Refer t o 9 -
exh a u st m a n ifold (F ig. 127). E NGINE /MANIF OLDS/E XH AUST MANIF OLD -
CLE ANING) (Refer t o 9 - E NGINE /MANIF OLDS/
E XH AUST MANIF OLD - INSP E CTION)
CLEANING
(1) Disca r d ga sket (if equ ipped) a n d clea n a ll su r-
fa ces of m a n ifold a n d cylin der h ea d.
INSPECTION
In spect exh a u st m a n ifolds for da m a ge or cr a cks
a n d ch eck dist or t ion of t h e cylin der h ea d m ou n t in g
su r fa ce a n d exh a u st cr ossover m ou n t in g su r fa ce wit h
a st r a igh t edge a n d t h ickn ess ga u ge (F ig. 129).
Ma n ifold su r fa ce fla t n ess lim it s sh ou ld n ot exceed
1.0 m m (0.039 in .).
INSTALLATION
(1) P osit ion exh a u st m a n ifold on cylin der h ea d a n d
in st a ll bolt s t o cen t er r u n n er (cylin der #3) a n d in it ia l
t igh t en t o 2.8 N·m (25 in . lbs.) (F ig. 128)
(2) Usin g a n ew ga sket , a t t a ch cr ossover pipe t o
exh a u st m a n ifold a n d t igh t en bolt s t o 41 N·m (30 ft .
lbs.) (F ig. 125).
1 - FLAG NUT
2 - GASKET
3 - BOLT
9 - 154 ENGINE 3.3/3.8L RS
EX H AU ST M AN I FOLD - RI GH T (Cont inue d)
Fig. 129 Check Exhaust Manifold Mounting Fig. 130 CROSS-OVER PIPE
1 - STRAIGHT EDGE 1 - CROSS-OVER PIPE
2 - CROSSOVER PIPE MOUNTING SURFACE 2 - BOLT
3 - FEELER GAUGE 3 - GASKET
4 - FLAG NUT
NOTE: Inspect crossover pipe fasteners for damage
from heat and corrosion. The cross-over bolts are (4) Rem ove h ea t sh ield a t t a ch in g bolt s (F ig. 131).
made of a special stainless steel alloy. If replace- (5) Rem ove bolt s a t t a ch in g exh a u st m a n ifold t o
ment is required, OEM bolts are highly recom- cylin der h ea d (F ig. 131).
mended. (6) Rem ove t h e exh a u st m a n ifold (F ig. 131).
(3) In st a ll t h e r em a in in g m a n ifold a t t a ch in g bolt s.

Tigh t en a ll bolt s t o 23 N·m (200 in . lbs.).
(4) P osit ion t h e power st eer in g pu m p su ppor t st r u t
a n d in st a ll u pper bolt (F ig. 126).
(5) In st a ll h ea t sh ield a n d a t t a ch in g scr ews (F ig.
128).
(6) In st a ll a n d con n ect u pst r ea m oxygen sen sor
(F ig. 128).
(7) Ra ise t h e veh icle.
(8) At t a ch ca t a lyt ic con ver t er pipe t o exh a u st m a n -
ifold u sin g n ew ga sket a n d t igh t en bolt s t o 37 N·m
(27 ft . lbs.) (F ig. 127).
(9) Con n ect down st r ea m oxygen sen sor con n ect or.
(10) Tigh t en t h e power st eer in g pu m p su ppor t
st r u t lower bolt (F ig. 126).
(11) In st a ll t h e belt spla sh sh ield a n d lower t h e
veh icle. Fig. 131 EXHAUST MANIFOLD - LEFT
(12) In st a ll t h e wiper m odu le. (Refer t o 8 - E LE C- 1 - EXHAUST MANIFOLD - LEFT BANK
2 - HEAT SHIELD
TRICAL/WIP E RS/WASH E RS/WIP E R MODULE - 3 - NUT - HEAT SHIELD
INSTALLATION) 4 - BOLT - EXHAUST MANIFOLD
(7) In spect a n d clea n m a n ifold. (Refer t o 9 -
E NGINE /MANIF OLDS/E XH AUST MANIF OLD -
EX H AU ST M AN I FOLD - LEFT INSP E CTION) (Refer t o 9 - E NGINE /MANIF OLDS/
E XH AUST MANIF OLD - CLE ANING)
REMOVAL
(1) Discon n ect ba t t er y n ega t ive ca ble. CLEANING
(2) Rem ove bolt s a t t a ch in g cr ossover pipe t o (1) Disca r d ga sket (if equ ipped) a n d clea n a ll su r-
exh a u st m a n ifold (F ig. 130). fa ces of m a n ifold a n d cylin der h ea d.
(3) Discon n ect left cylin der ba n k spa r k plu g wir es.
RS ENGINE 3.3/3.8L 9 - 155
EX H AU ST M AN I FOLD - LEFT (Cont inue d)
INSPECTION VALV E T I M I N G
In spect exh a u st m a n ifolds for da m a ge or cr a cks
a n d ch eck dist or t ion of t h e cylin der h ea d m ou n t in g
su r fa ce a n d exh a u st cr ossover m ou n t in g su r fa ce wit h STAN DARD PROCEDU RE
a st r a igh t edge a n d t h ickn ess ga u ge (F ig. 132).
Ma n ifold su r fa ce fla t n ess lim it s sh ou ld n ot exceed STANDARD PROCEDURE - VALVE TIMING
1.0 m m (0.039 in .). VERIFICATION
(1) Rem ove fr on t cylin der h ea d cover a n d a ll 6
spa r k plu gs.
(2) Rot a t e en gin e u n t il t h e #2 pist on is a t TDC of
t h e com pr ession st r oke.
(3) In st a ll a degr ee wh eel on t h e cr a n ksh a ft pu lley.
(4) Wit h pr oper a da pt or, in st a ll a dia l in dica t or
in t o #2 spa r k plu g h ole. Usin g t h e in dica t or fin d TDC
on t h e com pr ession st r oke.
(5) P osit ion t h e degr ee wh eel t o zer o.
(6) Rem ove dia l in dica t or fr om spa r k plu g h ole.
(7) P la ce a 5.08 m m (0.200 in .) spa cer bet ween t h e
va lve st em t ip of #2 in t a ke va lve a n d r ocker a r m pa d.
Allow t a ppet t o bleed down t o give a solid t a ppet
effect .
(8) In st a ll a dia l in dica t or so plu n ger con t a ct s t h e
#2 in t a ke va lve spr in g r et a in er a s n ea r ly per pen dic-
Fig. 132 Check Exhaust Manifold Mounting u la r a s possible. Zer o t h e in dica t or.
1 - STRAIGHT EDGE (9) Rot a t e t h e en gin e clockwise u n t il t h e in t a ke
2 - CROSSOVER PIPE MOUNTING SURFACE va lve h a s lift ed .254 m m (0.010 in .).
3 - FEELER GAUGE
CAUTION: Do not turn crankshaft any further clock-
INSTALLATION wise as intake valve might bottom and result in
(1) P osit ion exh a u st m a n ifold on cylin der h ea d serious damage.
(F ig. 131). In st a ll bolt s t o cen t er r u n n er (cylin der #4)
a n d in it ia l t igh t en t o 2.8 N·m (25 in . lbs.). (10) Degr ee wh eel sh ou ld r ea d 6 degr ees BTDC t o
(2) Usin g a n ew ga sket , a t t a ch cr ossover pipe t o 6 degr ees ATDC.
exh a u st m a n ifold a n d t igh t en bolt s t o 41 N·m (30 ft .
lbs.) (F ig. 130). STANDARD PROCEDURE - MEASURING
TIMING CHAIN WEAR
NOTE: Inspect crossover pipe fasteners for damage
from heat and corrosion. The cross-over bolts are NOTE: This procedure must be performed with the
made of a special stainless steel alloy. If replace- timing chain cover removed (Refer to 9 - ENGINE/
ment is required, OEM bolts are highly recom- VALVE TIMING/TIMING CHAIN COVER - REMOVAL).
mended.
(1) P osit ion a sca le n ext t o t im in g ch a in so t h a t
(3) P osit ion h ea t sh ield on m a n ifold (F ig. 131). a n y m ovem en t of ch a in m a y be m ea su r ed (F ig. 133).
(4) In st a ll t h e r em a in in g m a n ifold a t t a ch in g bolt s. (2) P osit ion a t or qu e wr en ch a n d socket on t h e
Tigh t en a ll bolt s t o 23 N·m (200 in . lbs.). ca m sh a ft spr ocket a t t a ch in g bolt . Apply for ce in t h e
(5) In st a ll a n d t igh t en h ea t sh ield a t t a ch in g n u t t o dir ect ion of cr a n ksh a ft r ot a t ion t o t a ke u p sla ck t o
12 N·m (105 in . lbs.) (F ig. 131). t h e followin g t or qu e:
(6) Con n ect ba t t er y n ega t ive ca ble. • 41 N·m (30 ft . lb.) wit h cylin der h ea ds in st a lled
• 20 N·m (15 ft . lb.) wit h cylin der h ea ds r em oved
NOTE: With torque applied to the camshaft

sprocket bolt, crankshaft should not be permitted to
move. It may be necessary to block crankshaft to
prevent rotation.
(3) H oldin g a m ea su r in g sca le a lon g edge of ch a in

lin ks (F ig. 133).
9 - 156 ENGINE 3.3/3.8L RS
VALV E T I M I N G (Cont inue d)
(4) Apply for ce in t h e r ever se dir ect ion t o t h e fol-
lowin g t or qu e:
• 41 N·m (30 ft . lb.) wit h cylin der h ea ds in st a lled
• 20 N·m (15 ft . lb.) wit h cylin der h ea ds r em oved
(5) Mea su r e a m ou n t of spr ocket /ch a in m ovem en t .
(6) In st a ll a n ew t im in g ch a in a n d spr ocket s if
m ovem en t exceeds 3.175 m m (1/8 in .).
Fig. 134 OIL PICKUP TUBE

1 - BOLT
2 - OIL PICK-UP TUBE
3 - O-RING
Fig. 133 Measuring Timing Chain Wear

1 - TORQUE WRENCH
T I M I N G CH AI N COV ER
REMOVAL
(2) Dr a in coolin g syst em . (Refer t o 7 - COOLING -
(5) Rem ove r igh t wh eel a n d in n er spla sh sh ield.
(6) Rem ove oil pa n . (Refer t o 9 - E NGINE /LUBRI-
CATION/OIL PAN - RE MOVAL)
(7) Rem ove oil pick-u p t u be (F ig. 134).
(8) Rem ove a ccessor y dr ive belt . (Refer t o 7 -
RE MOVAL)
(9) Rem ove A/C com pr essor a n d set a side.
(10) Rem ove cr a n ksh a ft vibr a t ion da m per. (Refer
t o 9 - E NGINE /E NGINE BLOCK/VIBRATION
DAMP E R - RE MOVAL)
(11) Rem ove r a dia t or lower h ose. Fig. 135 HEATER RETURN HOSE (Without Engine
(12) Rem ove h ea t er h ose fr om t im in g ch a in cover Oil Cooler)
h ou sin g (F ig. 135) or wa t er pu m p in let t u be (if 1 - CAP AND CLAMP (OIL COOLER EQUIPPED ONLY)
en gin e oil cooler equ ipped) (F ig. 136). 2 - HOSE ASSEMBLY - HEATER RETURN
3 - BOLT - HEATER TUBE ATTACHING
(13) Rem ove t h e r igh t side en gin e m ou n t . (Refer t o 4 - BOLT - HEATER TUBE ATTACHING
9 - E NGINE /E NGINE MOUNTING/RIGH T MOUNT
- RE MOVAL) (16) Rem ove ca m sh a ft posit ion sen sor fr om t im in g
(14) Rem ove idler pu lley fr om en gin e br a cket (F ig. ch a in cover (F ig. 137).
137).
(15) Rem ove t h e en gin e m ou n t br a cket (F ig. 137).
RS ENGINE 3.3/3.8L 9 - 157
T I M I N G CH AI N COV ER (Cont inue d)
(17) Rem ove t h e wa t er pu m p for cover r em ova l
clea r a n ce. (Refer t o 7 - COOLING/E NGINE /WATE R
P UMP - RE MOVAL)
(18) Rem ove t h e bolt a t t a ch in g t h e power st eer in g
pu m p su ppor t st r u t t o t h e fr on t cover (F ig. 138).
(19) Rem ove t h e t im in g ch a in cover fa st en er s.
Rem ove t im in g ch a in cover (F ig. 139).
Fig. 136 HEATER HOSES 3.3/3.8L (With Engine Oil

Cooler) Fig. 138 Power Steering Pump Strut
1 - HOSE - HEATER SUPPLY
1 - BOLT - LOWER
2 - HOSE - HEATER RETURN
2 - STRUT - P/S PUMP
3 - TUBE ASSEMBLY - HEATER RETURN
3 - BOLT - UPPER
4 - BOLT - TUBE ASSEMBLY
5 - BOLT - TUBE ASSEMBLY
6 - HOSE - HEATER RETURN/OIL COOLER OUTLET INSTALLATION
(1) Be su r e m a t in g su r fa ces of ch a in ca se cover
a n d cylin der block a r e clea n a n d fr ee fr om bu r r s.
Cr a n ksh a ft oil sea l m u st be r em oved t o in su r e cor-
r ect oil pu m p en ga gem en t .
NOTE: DO NOT USE SEALER ON COVER GASKET
(2) P osit ion n ew ga sket on t im in g cover (F ig. 139).

Adh er e n ew ga sket t o ch a in ca se cover, m a kin g su r e
t h a t t h e lower edge of t h e ga sket is flu sh t o 0.5 m m
(0.020 in .) pa ssed t h e lower edge of t h e cover.
(3) Rot a t e cr a n ksh a ft so t h a t t h e oil pu m p dr ive
fla t s a r e in t h e ver t ica l posit ion .
(4) P osit ion oil pu m p in n er r ot or so t h e m a t in g
fla t s a r e in t h e sa m e posit ion a s t h e cr a n ksh a ft dr ive
fla t s (F ig. 139).
CAUTION: Make sure the oil pump is engaged on

the crankshaft correctly or severe damage may
result.
Fig. 137 Engine Mount Bracket (5) In st a ll t im in g cover (F ig. 139).
1 - CAMSHAFT SENSOR (6) In st a ll t im in g ch a in cover bolt s. Tigh t en M8
2 - BOLT - CAMSHAFT SENSOR
3 - BOLT - MOUNT BRACKET (VERTICAL) bolt s t o 27 N·m (20 ft . lbs.) a n d M10 bolt s t o 54 N·m
4 - BRACKET - ENGINE MOUNT (40 ft . lbs.) (F ig. 140).
5 - BOLT - MOUNT BRACKET (HORIZONTAL) (7) In st a ll cr a n ksh a ft fr on t oil sea l. (Refer t o 9 -
6 - PULLEY - IDLER
7 - BOLT - IDLER PULLEY E NGINE /E NGINE BLOCK/CRANKSH AF T OIL
8 - SPACER - IDLER PULLEY BOLT SE AL - F RONT - INSTALLATION)
9 - BOLT - MOUNT BRACKET (HORIZONTAL) (8) In st a ll wa t er pu m p a n d pu lley. (Refer t o 7 -
COOLING/E NGINE /WATE R P UMP - INSTALLA-
TION)
9 - 158 ENGINE 3.3/3.8L RS
(9) In st a ll cr a n ksh a ft vibr a t ion da m per. (Refer t o 9
- E NGINE /E NGINE BLOCK/VIBRATION DAMP E R -
INSTALLATION)
(10) In st a ll en gin e m ou n t br a cket (F ig. 137) a n d
t igh t en M10 t o 54 N·m (40 ft . lbs.), M8 bolt t o 28
N·m (21 ft . lb. lbs.).
(11) In st a ll idler pu lley on en gin e m ou n t br a cket
(F ig. 137).
(12) In st a ll r igh t side en gin e m ou n t . (Refer t o 9 -
E NGINE /E NGINE MOUNTING/RIGH T MOUNT -
INSTALLATION)
(13) In st a ll ca m sh a ft posit ion sen sor (Refer t o 8 -
E LE CTRICAL/IGNITION CONTROL/CAMSH AF T
P OSITION SE NSOR - INSTALLATION).
(14) Con n ect t h e h ea t er r et u r n h ose a t r ea r of t im -
in g ch a in cover (F ig. 135) or a t wa t er pu m p in let
Fig. 139 Timing Chain Cover and Gasket t u be (if en gin e oil cooler equ ipped) (F ig. 136).
1 - GASKET
(15) Con n ect t h e r a dia t or lower h ose.
2 - TIMING CHAIN COVER (16) In st a ll A/C com pr essor.
Fig. 140 TIMING CHAIN COVER BOLT LOCATIONS

1 - BOLT - M8 x 1.25 x 95 4 - BOLT - M8 x 1.25 x 80
2 - BOLT - M10 x 1.5 x 100 5 - BOLT - M8 x 1.25 x 45
3 - BOLT - M10 x 1.5 x 85
RS ENGINE 3.3/3.8L 9 - 159
(17) In st a ll a ccessor y dr ive belt . (Refer t o 7 -
INSTALLATION)
(18) In st a ll oil pu m p pick-u p t u be wit h n ew
O-r in g. Tigh t en a t t a ch in g bolt t o 28 N·m (250 in .
lbs.).
(19) In st a ll oil pa n . (Refer t o 9 - E NGINE /LUBRI-
CATION/OIL PAN - INSTALLATION)
(20) In st a ll in n er spla sh sh ield a n d r igh t fr on t
wh eel.
(21) F ill cr a n kca se wit h en gin e oil t o pr oper level.
T I M I N G CH AI N AN D
SPROCK ET S
REM OVAL
REMOVAL - TIMING CHAIN AND CAMSHAFT
SPROCKET
(2) Rem ove t h e t im in g ch a in cover. (Refer t o 9 - Fig. 141 Timing Mark Alignment
E NGINE /VALVE TIMING/TIMING BE LT / CH AIN 1 - CAMSHAFT SPROCKET TIMING MARK (DOT)
COVE R(S) - RE MOVAL) 2 - PLATED LINK
3 - CRANKSHAFT SPROCKET TIMING MARK (DOT)
(3) Rot a t e en gin e by t u r n in g cr a n ksh a ft u n t il t h e 4 - ARROWS
t im in g m a r ks a r e a lign ed a s sh own in (F ig. 141).
(4) Rem ove ca m sh a ft spr ocket a t t a ch in g bolt .
(5) Rem ove t h e t im in g ch a in wit h ca m sh a ft
spr ocket .
(6) Rem ove t h e cr a n ksh a ft spr ocket . (Refer t o 9 -
E NGINE /VALVE TIMING/TIMING BE LT/CH AIN
AND SP ROCKE TS - RE MOVAL)
REMOVAL - CRANKSHAFT SPROCKET

(1) Rem ove t h e t im in g ch a in . (Refer t o 9 -
E NGINE /VALVE TIMING/TIMING BE LT/CH AIN
AND SP ROCKE TS - RE MOVAL)
(2) Usin g Specia l Tools 8539, 5048-6, a n d 5048-1,
r em ove t h e cr a n ksh a ft spr ocket wh ile h oldin g t h e
cr a n ksh a ft fr om t u r n in g (F ig. 142). Be ca r efu l n ot t o
da m a ge t h e cr a n ksh a ft su r fa ces.
Fig. 142 CRANKSHAFT SPROCKET - REMOVAL
9 - 160 ENGINE 3.3/3.8L RS
T I M I N G CH AI N AN D SPROCK ET S (Cont inue d)
I N STALLAT I ON (3) In st a ll t h e t im in g ch a in a n d ca m sh a ft spr ocket .

(Refer t o 9 - E NGINE /VALVE TIMING/TIMING
INSTALLATION - CRANKSHAFT SPROCKET BE LT/CH AIN AND SP ROCKE TS - INSTALLATION)
(1) P osit ion t h e spr ocket on t h e cr a n ksh a ft (t im in g
m a r k ou t ) wit h t h e t im in g slot a lign ed wit h t h e t im - INSTALLATION - TIMING CHAIN AND
in g pin . CAMSHAFT SPROCKET
(2) In st a ll spr ocket u sin g Specia l Tool 8452 (F ig. (1) Rot a t e cr a n ksh a ft so t h e t im in g a r r ow is t o t h e
143). In st a ll spr ocket u n t il it is fu lly sea t s on t h e 12 o’clock posit ion (F ig. 141).
cr a n ksh a ft .
NOTE: Lubricate timing chain and sprockets with
clean engine oil before installation.
(2) Wh ile h oldin g ca m sh a ft spr ocket a n d ch a in in

h a n d, pla ce t im in g ch a in a r ou n d t h e spr ocket , a lign -
in g t h e pla t ed lin k wit h t h e dot on t h e spr ocket . P osi-
t ion t h e t im in g a r r ow t o t h e 6 o’clock posit ion (F ig.
141).
(3) P la ce t im in g ch a in a r ou n d cr a n ksh a ft spr ocket
wit h t h e pla t ed lin k lin ed u p wit h t h e dot on t h e
spr ocket . In st a ll ca m sh a ft spr ocket in t o posit ion .
(4) Use a st r a igh t edge t o ch eck a lign m en t of t im -
in g m a r ks.
(5) In st a ll ca m sh a ft spr ocket bolt a n d wa sh er.
Tigh t en bolt t o 54 N·m (40 ft . lbs.).
(6) Rot a t e cr a n ksh a ft 2 r evolu t ion s a n d ch eck t im -
in g m a r k a lign m en t (F ig. 141). If t im in g m a r ks do
Fig. 143 CRANKSHAFT SPROCKET - INSTALLATION n ot lin e u p, r em ove ca m sh a ft spr ocket a n d r ea lign .
1 - SPECIAL TOOL 8452-3 (7) In st a ll t h e t im in g ch a in cover. (Refer t o 9 -
2 - SPECIAL TOOL 8452-1 E NGINE /VALVE TIMING/TIMING BE LT / CH AIN
4 - THRUST BEARING / WASHER COVE R(S) - INSTALLATION)
RS EXHAUST SYSTEM 11 - 1
EXHAUST SYSTEM
page page
EXHAUST SYSTEM INSPECTION . . ........ .................6

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . .....1 INSTALLATION . ........ .................6
DIAGNOSIS AND TESTING CROSS-OVER PIPE - 3.3/3.8L
DIAGNOSIS AND TESTING - EXCESSIVE REMOVAL .... ........ .................6
EXHAUST SYSTEM NOISE . . . . . . . . . . .....2 INSTALLATION . ........ .................6
DIAGNOSIS AND TESTING - EXHAUST HEAT SHIELDS
SYSTEM RESTRICTION CHECK . . . . . . .....2 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . .7
INSPECTION . . . . . . . . . . . . . . . . . . . . . . .....3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . .....3 REMOVAL .... . . . . . . . . . . . . . . . . . . . . . . . . .7
SPECIFICATIONS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . .7
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . .....3 MUFFLER
SPECIAL TOOLS REMOVAL .... .........................7
EXHAUST SYSTEM . . . . . . . . . . . . . . . . .....4 INSTALLATION . .........................8
CATALYTIC CONVERTER RESONATOR
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . .....4 REMOVAL .... .........................9
OPERATION . . . . . . . . . . . . . . . . . . . . . . . .....4 INSTALLATION . .........................9
REMOVAL ........................ .....5
EX H AU ST SY ST EM com pon en t s. Th r ee su ppor t h a n ger r ods wit h r u bber

isola t or s a r e u sed t o su ppor t a n d isola t e t h e exh a u st
syst em . A flexible join t , in t egr a l t o t h e ca t a lyt ic con -
DESCRIPTION
ver t er, a llows for en gin e m ovem en t . On veh icles
Th e exh a u st syst em con sist s of a ca t a lyt ic con -
equ ipped wit h AWD, a n a ddit ion a l h ea t sh ield is
ver t er, m u ffler, a n d a r eson a t or wit h con n ect in g pipes
m ou n t ed t o t h e ca t a lyt ic con ver t er. Th e exh a u st sys-
in -bet ween (F ig. 1). Th e syst em is ser viced in t wo
t em is t u n ed for ea ch veh icle/power t r a in com bin a t ion .
sect ion s; t h e ca t a lyt ic con ver t er a n d pipe, a n d t h e
m u ffler a n d r eson a t or wit h con n ect in g pipe. A ba n d
cla m p is u sed t o con n ect t h e join t bet ween t h e t wo
Fig. 1 Exhaust System - Typical (All Vehicles)

1 - CATALYTIC CONVERTER 4 - SUPPORT - RESONATOR
2 - BAND CLAMP 5 - RESONATOR
3 - SUPPORTS - MUFFLER 6 - MUFFLER
11 - 2 EXHAUST SYSTEM RS
EX H AU ST SY ST EM (Cont inue d)
DIAGNOSIS AND TESTING - EXCESSIVE EXHAUST SYSTEM NOISE

EXCESSIVE EXHAUST NOISE 1. Exhaust manifold cracked or 1. Replace manifold.

(UNDER HOOD) broken.
2. Manifold to cylinder head leak. 2. Tighten manifold and/or replace

gasket.
3. EGR Valve to manifold gasket 3. Tighten fasteners or replace
leakage. gasket.
4. EGR Valve to EGR tube gasket 4. Tighten fasteners or replace
leakage. gasket.
5. EGR tube to manifold tube 5. Tighten tube nut.
leakage.
6. Exhaust flex-joint to manifold 6. Tighten joint fasteners and/or
leak. replace gasket.
7. Exhaust flex-joint. 7. Replace catalytic converter
assembly.
8. Pipe and shell noise from front 8. Characteristic of single wall pipe.
exhaust pipe.
EXCESSIVE EXHAUST NOISE 1. Leak at exhaust pipe joints. 1. Tighten clamps at leaking joints.
2. Burned or rusted out muffler 2. Replace muffler resonator tailpipe
assembly or exhaust pipe. assembly or exhaust pipe with
catalytic converter assembly.
3. Burned or rusted out resonator. 3. Replace muffler resonator tailpipe
assembly.
4. Restriction in exhaust system. 4. Perform Exhaust System
Restriction Check. Replace
component as necessary.
5. Converter material in muffler. 5. Replace muffler and converter
assemblies. Check fuel injection and
ignition systems for proper
operation.
DIAGNOSIS AND TESTING - EXHAUST SYSTEM NOTE: For Special Tool identification, (Refer to 11 -
EXHAUST SYSTEM - SPECIAL TOOLS).
RESTRICTION CHECK
E xh a u st syst em r est r ict ion ca n be ch ecked by m ea - (1) Discon n ect a n d r em ove t h e u pst r ea m (befor e
su r in g ba ck pr essu r e u sin g t h e DRB III! a n d P E P ca t a lyt ic con ver t er ) oxygen sen sor. (Refer t o 14 -
m odu le pr essu r e t est er. F UE L SYSTE M/F UE L INJ E CTION/O2 SE NSOR -
RE MOVAL)
WARNING: THE NORMAL OPERATING TEMPERA- (2) In st a ll t h e E xh a u st Ba ck P r essu r e F it t in g
TURE OF THE EXHAUST SYSTEM IS VERY HIGH. Ada pt or CH 8519.
THEREFORE, NEVER WORK AROUND OR ATTEMPT (3) Con n ect t h e Low P r essu r e Sen sor (15 psi)
TO SERVICE ANY PART OF THE EXHAUST SYSTEM CH 7063 t o t h e ba ck pr essu r e fit t in g.
UNTIL IT IS COOLED. SPECIAL CARE SHOULD BE (4) F ollowin g t h e P E P m odu le in st r u ct ion m a n u a l,
TAKEN WHEN WORKING NEAR THE CATALYTIC con n ect a ll r equ ir ed ca bles t o t h e DRB III! a n d P E P
CONVERTER. THE TEMPERATURE OF THE CON- m odu le. Select t h e a va ila ble m en u opt ion s on t h e
VERTER RISES TO A HIGH LEVEL AFTER A SHORT DRBIII! displa y scr een for u sin g t h e digit a l pr essu r e
PERIOD OF ENGINE OPERATION TIME. ga u ge fu n ct ion .
(5) Apply t h e pa r k br a ke a n d st a r t t h e en gin e.
(6) Wit h t r a n sm ission in P a r k or Neu t r a l, r a ise
en gin e speed t o 2000 RP M. Mon it or t h e pr essu r e
r ea din gs on t h e DRBIII!. Ba ck pr essu r e sh ou ld n ot
exceed specified lim it . Refer t o specifica t ion in t a ble
below E XH AUST BACK P RE SSURE LIMITS.
(7) If pr essu r e exceeds m a xim u m lim it s, in spect
exh a u st syst em for r est r ict ed com pon en t . F or fu r t h er
ca t a lyt ic con ver t er in spect ion pr ocedu r es, (Refer t o 11
- E XH AUST SYSTE M/CATALYTIC CONVE RTE R -
INSP E CTION). Repla ce com pon en t (s) a s n ecessa r y.
EX H AU ST BACK PRESSU RE LI M I T S
Exhaust Back Pressure Limit (Max)

Vehicle in Park/Neutral
3.45 Kpa (0.5 psi)
(no load) @2000 RPM
INSPECTION Fig. 2 Exhaust System Alignment

In spect t h e exh a u st pipes, ca t a lyt ic con ver t er s,
1 - HANGER BRACKET TO BODY
m u ffler, a n d r eson a t or s for cr a cked join t s, br oken 2 - ISOLATOR
welds a n d cor r osion da m a ge t h a t wou ld r esu lt in a 3 - HANGER - MUFFLER/RESONATOR SUPPORT
lea kin g exh a u st syst em . In spect t h e cla m ps, su ppor t 4 - 6 mm (0.25 in.)
br a cket s, a n d in su la t or s for cr a cks a n d cor r osion
da m a ge. SPECI FI CAT I ON S
NOTE: Slip joint band clamps are spot welded to TORQUE
exhaust system. If a band clamp must be replaced,
the spot weld must be ground off. DESCRIPTION N·m Ft. In.
Lbs. Lbs.
ADJUSTMENTS Band Clamp 54 40 —
A m isa lign ed exh a u st syst em is u su a lly in dica t ed Cross-over Pipe—Fastener 41 30 —
by a vibr a t ion , r a t t lin g n oise, or bin din g of exh a u st Exhaust Manifold Flange—Fastener 37 — 325
syst em com pon en t s. Th ese n oises a r e som et im es h a r d
t o dist in gu ish fr om ot h er ch a ssis n oises. In spect Heat Shield (Muffler)—Fastener 2.6 — 23
exh a u st syst em for br oken , da m a ged or loose com po- Heat Shield (Toe Board)—Fastener 2.6 — 23
n en t s su ch a s; cla m ps, h ea t sh ields, isola t or s, a n d Heat Shield (Resonator Pipe)— 2.6 — 23
h a n ger br a cket s. Repla ce or t igh t en a s n ecessa r y. It Fastener
is im por t a n t t h a t exh a u st syst em clea r a n ces a n d
Insulator Mounting Bracket—Bolts 28 — 250
a lign m en t be m a in t a in ed.
P er for m t h e followin g pr ocedu r es t o a lign t h e
exh a u st syst em :
(1) Loosen ba n d cla m p a t ca t a lyt ic con ver t er pipe
t o m u ffler /r eson a t or a ssem bly.
(2) Align t h e exh a u st syst em by in ser t in g pipe
in wa r d or ou t wa r d u n t il specifica t ion is a ch ieved a s
(3) Tigh t en ba n d cla m p t o 54 N·m (40 ft . lbs.).
SPECI AL T OOLS Th e exh a u st flex-join t cou plin g (F ig. 3) is u sed t o

secu r e t h e ca t a lyt ic con ver t er t o t h e exh a u st m a n i-
EXHAUST SYSTEM fold. Th e flex-join t h a s fou r bolt s, fou r fla g n u t s a n d
a ga sket t h a t a r e sepa r a t e pa r t s fr om t h e exh a u st
flex-join t . Th e flex-join t is welded t o t h e ca t a lyt ic
con ver t er.
CAUTION: When servicing, care must be exercised

not to dent or bend the bellows or bellows cover of
the flex-joint. Should this occur, the flex-joint will
eventually fail and require the catalytic converter be
replaced.
Back Pressure Test Adapter - CH8519
Fig. 3 Flex-joint
1 - FLANGE
2 - END CAPS
4 - FLEXIBLE BELLOWS
OPERATION
Th e t h r ee-wa y ca t a lyt ic con ver t er sim u lt a n eou sly
con ver t s t h r ee exh a u st em ission s in t o h a r m less
ga ses. Specifica lly, H C a n d CO em ission s a r e con -
ver t ed in t o wa t er (H 2O) a n d ca r bon dioxide (CO2).
Oxides of Nit r ogen (NOx) a r e con ver t ed in t o Nit r ogen
(N) a n d Oxygen . Th e t h r ee-wa y ca t a lyst is m ost effi-
cien t in con ver t in g H C, CO a n d NOx a t t h e st oich io-
DRB III & PEP Module - OT-CH6010A
m et r ic a ir fu el r a t io of 14.7:1.
CATALY T I C CON V ERT ER Th e oxygen con t en t in a ca t a lyst is im por t a n t for
efficien t con ver sion of exh a u st ga ses. Wh en a h igh
DESCRIPTION oxygen con t en t (lea n ) a ir /fu el r a t io is pr esen t for a n
Th e t oe boa r d t h r ee-wa y ca t a lyt ic con ver t er is con - ext en ded per iod, oxygen con t en t in a ca t a lyst ca n
n ect ed t o t h e exh a u st m a n ifold by t h e u se of flex r ea ch a m a xim u m . Wh en a r ich a ir /fu el r a t io is
join t a n d a ga sket . Th e ou t let con n ect s t o t h e m u ffler pr esen t for a n ext en ded per iod, t h e oxygen con t en t in
in let pipe a n d is secu r ed wit h a ba n d t ype cla m p t h e ca t a lyst ca n becom e t ot a lly deplet ed. Wh en t h is
(F ig. 1). occu r s, t h e ca t a lyst fa ils t o con ver t t h e ga ses. Th is is
kn own a s ca t a lyst %pu n ch t h r ou gh .%
CATALY T I C CON V ERT ER (Cont inue d)
Ca t a lyst oper a t ion is depen den t on it s a bilit y t o
st or e a n d r elea se t h e oxygen n eeded t o com plet e t h e
em ission s-r edu cin g ch em ica l r ea ct ion s. As a ca t a lyst
det er ior a t es, it s a bilit y t o st or e oxygen is r edu ced.
Sin ce t h e ca t a lyst ’s a bilit y t o st or e oxygen is som e-
wh a t r ela t ed t o pr oper oper a t ion , oxygen st or a ge ca n
be u sed a s a n in dica t or of ca t a lyst per for m a n ce.
Refer t o t h e a ppr opr ia t e Dia gn ost ic In for m a t ion for
dia gn osis of a ca t a lyst r ela t ed Dia gn ost ic Tr ou ble
Code (DTC).
Th e com bu st ion r ea ct ion ca u sed by t h e ca t a lyst
r elea ses a ddit ion a l h ea t in t h e exh a u st syst em , ca u s-
in g t em per a t u r e in cr ea ses in t h e a r ea of t h e r ea ct or
u n der sever e oper a t in g con dit ion s. Su ch con dit ion s
ca n exist wh en t h e en gin e m isfir es or ot h er wise does
n ot oper a t e a t pea k efficien cy. D o n o t r em ove spa r k
plu g wir es fr om plu gs or by a n y ot h er m ea n s sh or t Fig. 4 Downstream Oxygen Sensor
ou t cylin der s. F a ilu r e of t h e ca t a lyt ic con ver t er ca n 1 - OXYGEN SENSOR CONNECTOR
occu r du e t o t em per a t u r e in cr ea ses ca u sed by 2 - CATALYTIC CONVERTER
u n bu r n ed fu el pa ssin g t h r ou gh t h e con ver t er. Th is 3 - DOWNSTREAM OXYGEN SENSOR
4 - ENGINE HARNESS CONNECTOR
det er ior a t ion of t h e ca t a lyst cor e ca n r esu lt in exces-
sively h igh em ission levels, n oise com pla in t s, a n d
exh a u st r est r ict ion s.
Un lea ded ga solin e m u st be u sed t o a void r u in in g
t h e ca t a lyst cor e. Do n ot a llow en gin e t o oper a t e
a bove 1200 RP M in n eu t r a l for ext en ded per iods over
5 m in u t es. Th is con dit ion m a y r esu lt in excessive
exh a u st syst em /floor pa n t em per a t u r es beca u se of n o
a ir m ovem en t u n der t h e veh icle.
Th e flex join t a llows flexin g a s t h e en gin e m oves,
pr even t in g br ea ka ge t h a t cou ld occu r fr om t h e ba ck-
a n d-for t h m ot ion of a t r a n sver se m ou n t ed en gin e.
CAUTION: Due to exterior physical similarities of

some catalytic converters with pipe assemblies,
extreme care should be taken with replacement
parts. There are internal converter differences
required in some parts of the country (particularly
vehicles built for States with strict emission
requirements) and between model years.
REMOVAL
(1) Loosen cla m p a n d discon n ect t h e m u ffler /r eso-
n a t or a ssem bly fr om ca t a lyt ic con ver t er pipe. Fig. 5 Catalytic Converter to Exhaust Manifold
(2) Discon n ect down st r ea m oxygen sen sor elect r i- 1 - FLAG NUT
ca l con n ect or (F ig. 4). F or r em ova l of down st r ea m 2 - GASKET
3 - BOLT
oxygen sen sor, (Refer t o 14 - F UE L SYSTE M/F UE L 4 - CATALYTIC CONVERTER
INJ E CTION/O2 SE NSOR - RE MOVAL).
(3) Rem ove ca t a lyt ic con ver t er t o exh a u st m a n ifold
a t t a ch in g fa st en er s (F ig. 5).
(4) Rem ove ca t a lyt ic con ver t er a n d ga sket (F ig. 5).
CATALY T I C CON V ERT ER (Cont inue d)
INSPECTION (4) Access t h e lower r igh t ba n k pipe con n ect ion

fa st en er t h r ou gh t h e left fr on t wh eel open in g u sin g a
WARNING: THE NORMAL OPERATING TEMPERA- lon g r a t ch et ext en sion . Loosen a n d r em ove t h e lower
TURE OF THE EXHAUST SYSTEM IS VERY HIGH. fa st en er.
THEREFORE, NEVER ATTEMPT TO SERVICE ANY (5) Rem ove t h e u pper r igh t ba n k pipe con n ect ion
PART OF THE EXHAUST SYSTEM UNTIL IT IS fa st en er by a ccessin g t h ou gh t h e ca t a lyt ic con ver t er
COOLED. SPECIAL CARE SHOULD BE TAKEN floor pa n t u n n el.
WHEN WORKING NEAR THE CATALYTIC CON- (6) Lower t h e veh icle.
VERTER. THE TEMPERATURE OF THE CONVERTER (7) Rem ove t h e cr oss-over pipe (F ig. 6).
RISES TO A HIGH LEVEL AFTER A SHORT PERIOD (8) Rem ove ga sket s a n d disca r d (F ig. 6).
OF ENGINE OPERATION TIME.
Ch eck ca t a lyt ic con ver t er for a flow r est r ict ion .

(Refer t o 11 - E XH AUST SYSTE M - DIAGNOSIS
AND TE STING) E xh a u st Syst em Rest r ict ion Ch eck
for pr ocedu r e.
Visu a lly in spect t h e ca t a lyt ic con ver t er elem en t by
u sin g a bor escope or equ iva len t . Rem ove oxygen sen -
sor (s) a n d in ser t bor escope. If bor escope is n ot a va il-
a ble, r em ove con ver t er a n d in spect elem en t u sin g a
fla sh ligh t . In spect elem en t for cr a cked or m elt ed su b-
st r a t e.
NOTE: Before replacing a catalytic converter, deter-

mine the root cause of failure. Most catalytic con-
verter failures are caused by air, fuel or ignition
problems. (Refer to Appropriate Diagnostic Informa-
tion) for test procedures. Fig. 6 CROSS-OVER PIPE
1 - CROSS-OVER PIPE
2 - BOLT
3 - GASKET
INSTALLATION 4 - FLAG NUT
(1) P osit ion n ew ga sket on t o t h e m a n ifold fla n ge
a n d in st a ll ca t a lyt ic con ver t er (F ig. 5). Tigh t en fa s- INSTALLATION
t en er s t o 37 N·m (325 in . lbs.). (1) P osit ion cr oss-over pipe t o t h e m a n ifold con n ec-
t ion s (F ig. 6).
NOTE: Be careful not to twist or kink the oxygen
(2) P osit ion n ew ga sket on left ba n k (fr on t ) pipe
sensor wires.
con n ect ion a n d loosely in st a ll fa st en er s (F ig. 6).
(2) In st a ll (if r em oved) a n d con n ect t h e down - (3) Ra ise t h e veh icle.
st r ea m oxygen sen sor (F ig. 4). (4) P osit ion n ew ga sket on t h e r igh t ba n k pipe con -
(3) In st a ll t h e m u ffler /r eson a t or a ssem bly. (Refer n ect ion a n d in st a ll fa st en er s.
t o 11 - E XH AUST SYSTE M/MUF F LE R - INSTALLA- (5) Tigh t en r igh t ba n k u pper fa st en er t o 41 N·m
TION) (30 ft . lbs.).
(4) St a r t t h e en gin e a n d in spect for exh a u st lea ks. (6) Tigh t en r igh t ba n k lower fa st en er t o 41 N·m
Repa ir exh a u st lea ks a s n ecessa r y. (30 ft . lbs.) u sin g a lon g r a t ch et ext en sion a ccessin g
(5) Ch eck t h e exh a u st syst em for con t a ct wit h t h e t h r ou gh t h e left wh eel open in g.
body pa n els. Ma ke t h e n ecessa r y a dju st m en t s, if (7) In st a ll t h e left fr on t wh eel a n d lower veh icle.
n eeded. (8) Tigh t en t h e left ba n k pipe con n ect ion fa st en er s
t o 41 N·m (30 ft . lbs.) (F ig. 6).
(9) St a r t t h e en gin e a n d in spect for exh a u st lea ks.
CROSS-OV ER PI PE - 3 .3 /3 .8 L Repa ir exh a u st lea ks a s n ecessa r y.
(10) Ch eck t h e exh a u st syst em for con t a ct wit h t h e
REMOVAL body pa n els. Ma ke t h e n ecessa r y a dju st m en t s, if
(1) Discon n ect n ega t ive ca ble fr om ba t t er y. n eeded.
(2) Rem ove t h e fa st en er s a t t a ch in g t h e left ba n k
m a n ifold con n ect ion t o cr oss-over pipe (F ig. 6).
(3) Ra ise veh icle a n d r em ove t h e left fr on t wh eel.
H EAT SH I ELDS
DESCRIPTION
Th e exh a u st syst em h ea t sh ields (F ig. 7), (F ig. 8),
or (F ig. 9) a r e a t t a ch ed t o t h e u n der body of t h e veh i-
cle. On veh icles equ ipped wit h All Wh eel Dive
(AWD), a n a ddit ion a l h ea t sh ield is m ou n t ed t o t h e
ca t a lyt ic con ver t er.
Fig. 9 RESONATOR PIPE HEAT SHIELD

1 - SCREW (QTY. 3)
2 - HEAT SHIELD - RESONATOR PIPE
3 - MUFFLER
Av o id a p p lic a tio n o f ru s t p re v e n tio n c o m -

p o u n d s o r u n d e rc o a tin g m a te ria ls to e x h a u s t
s y s te m flo o r p a n h e a t s h ie ld s o n c a rs s o
e qu ip p e d . Lig h t o v e r s p ra y n e a r th e e d g e s is
p e rm itte d . Ap p lic a tio n o f c o a tin g w ill g re a tly
re d u c e th e e ffic ie n c y o f th e h e a t s h ie ld s re s u lt-
in g in e x c e s s iv e flo o r p a n te m p e ra tu re s a n d
o bje c tio n a ble fu m e s .
Fig. 7 CATALYTIC CONVERTER HEAT SHIELD
1 - HEAT SHIELD - CATALYTIC CONVERTER
2 - SCREW (QTY. 4) REMOVAL
(2) Rem ove fa st en er s a t t a ch in g a pplica ble h ea t
sh ield (F ig. 7), (F ig. 8), or (F ig. 9).
(3) Rem ove h ea t sh ield(s).
INSTALLATION
(1) P osit ion h ea t sh ield(s) t o u n der body.
(2) In st a ll h ea t sh ield fa st en er s a n d t igh t en t o 2.6
N·m (23 in . lbs.) (F ig. 7), (F ig. 8), or (F ig. 9).
(3) Lower veh icle.
Repa ir exh a u st lea ks a s n ecessa r y.
body pa n els. Ma ke t h e n ecessa r y a dju st m en t s, if
n eeded.
Fig. 8 MUFFLER HEAT SHIELD

1 - HEAT SHIELD - MUFFLER M U FFLER
2 - SCREW (QTY. 6)
REMOVAL
OPERATION (1) Ra ise veh icle on a body con t a ct t ype h oist .
H ea t sh ields a r e n eeded t o pr ot ect bot h t h e veh icle
a n d t h e en vir on m en t fr om t h e h igh t em per a t u r es NOTE: To provide removal clearance between muf-
developed n ea r t h e ca t a lyt ic con ver t er. fler/resonator pipe and rear axle parts, the rear sus-
pension must be relieved of all body weight.
(2) Apply a pen et r a t in g oil t o cla m p n u t s of com -

pon en t r equ ir in g r em ova l.
M U FFLER (Cont inue d)

1 - SCREW - RESONATOR HANGER TO BODY 3 - MUFFLER & RESONATOR ASSEMBLY
2 - SCREW - MUFFLER HANGER TO BODY 4 - CATALYTIC CONVERTER PIPE
CAUTION: When servicing the exhaust system, care • E n su r e pr oper a lign m en t wit h ot h er com pon en t s
must be exercised not to dent or bend the bellows in t h e syst em .
of the flex-joint. Should this occur, the flex-joint will • P r ovide a ccept a ble exh a u st n oise levels.
eventually fail, requiring replacement of the cata- • P r ovide pr oper exh a u st syst em ba ck pr essu r e for
lytic converter. m a in t a in in g em ission a n d per for m a n ce levels.
(3) Discon n ect t h e r igh t side a xle h a lf sh a ft fr om INSTALLATION

t h e r ea r differ en t ia l m odu le (AWD equ ipped on ly). (1) In st a ll t h e m u ffler /r eson a t or a ssem bly by gu id-
(4) Loosen t h e ba n d cla m p (F ig. 10) a t t h e m u ffler in g r eson a t or bet ween t h e r ea r a xle a n d body.
t o con ver t er pipe con n ect ion . (2) Con n ect t h e m u ffler pipe t o t h e con ver t er pipe
(5) Rem ove t h e exh a u st h a n ger s t o body scr ews bu t do n ot t igh t en ba n d cla m p (F ig. 10).
(F ig. 10). (3) P osit ion h a n ger s t o body a n d in st a ll scr ews
(6) Sepa r a t e m u ffler pipe fr om con ver t er pipe. st a r t in g a t t h e r eson a t or wor kin g for wa r d (F ig. 10).
(7) Rem ove m u ffler /r eson a t or a ssem bly by m ovin g Tigh t en h a n ger scr ews t o 28 N·m (250 in . lbs.).
a ssem bly for wa r d a n d gu idin g t h e r eson a t or t h r ou gh (4) In ser t m u ffler pipe in t o ca t a lyt ic con ver t er pipe
t h e r ea r a xle t o body open in g. u n t il t h e h a n ger s a r e posit ion ed a s sh own in (F ig. 11)
(8) Clea n en ds of pipes or m u ffler t o a ssu r e m a t -
in g of a ll pa r t s. Disca r d br oken or wor n in su la t or s, CAUTION: Band clamps should never be tightened
r u st ed cla m ps, su ppor t s a n d a t t a ch in g pa r t s. Wh e n such that the two sides of the clamps are bottomed
re p la c e m e n t is re qu ire d o n a n y c o m p o n e n t o f out against the center hourglass shaped center
th e e x h a u s t s y s te m , it is im p o rta n t th a t o rig in a l block. Once this occurs, the clamp band has been
e qu ip m e n t p a rts (o r e qu iv a le n t) be u s e d fo r th e stretched and has lost its clamping force and must
fo llo w in g c o n d itio n s : be replaced.
To replace the band clamp; remove the nut and peel
back the ends of the clamp until spot weld breaks.
Clean remaining spot weld from the pipe using a
file or grinder until surface is smooth.
M U FFLER (Cont inue d)
Fig. 12 Band Clamp

1 - BAND CLAMP
2 - TORQUE SPECIFICATION
RESON AT OR
REMOVAL
(1) (Refer t o 11 - E XH AUST SYSTE M/MUF F LE R -
Fig. 11 Exhaust System Alignment RE MOVAL)
1 - HANGER BRACKET TO BODY
2 - ISOLATOR INSTALLATION
3 - HANGER - MUFFLER/RESONATOR SUPPORT
4 - 6 mm (0.25 in.)
(1) (Refer t o 11 - E XH AUST SYSTE M/MUF F LE R -
INSTALLATION)
NOTE: Maintain proper clamp orientation when (2) St a r t t h e en gin e a n d in spect for exh a u st lea ks.
replacing with new clamp. Repa ir exh a u st lea ks a s n ecessa r y.
(5) Tigh t en t h e ba n d cla m p t o 55 N·m (40 ft . lbs.) body pa n els. Ma ke t h e n ecessa r y a dju st m en t s, if
(F ig. 12). n eeded.
(6) Con n ect t h e r igh t side h a lf sh a ft t o t h e r ea r
differ en t ia l m odu le (AWD equ ipped on ly).
Repa ir exh a u st lea ks a s n ecessa r y.
body pa n els. Ma ke t h e n ecessa r y a dju st m en t s, if
n eeded.
RS FRAME & BUMPERS 13 - 1
FRAME & BUMPERS

page page
BUMPERS FRAME
SPECIFICATIONS - TORQUE . . . ............1 SPECIFICATIONS
FRONT FASCIA SPECIFICATIONS - FRAME DIMENSIONS ...6
REMOVAL ................. ............1 SPECIFICATIONS - FRAME DIMENSIONS -
INSTALLATION . . . . . . . . . . . . . . ............1 FOLD-IN-FLOOR SEATS ONLY . . . . . . . . . . . 11
FRONT BUMPER REINFORCEMENT SPECIFICATIONS - TORQUE . . . . . . . . . . . . 14
REMOVAL ................. ............3 FRONT CRADLE CROSSMEMBER
INSTALLATION . . . . . . . . . . . . . . ............3 DESCRIPTION
REAR FASCIA DESCRIPTION - FRONT CRADLE
REMOVAL ................. ............4 CROSSMEMBER . . . . . . . . . . . . . . . . . . . . . . 14
INSTALLATION . . . . . . . . . . . . . . ............4 DESCRIPTION - FRONT CRADLE
REAR BUMPER REINFORCEMENT CROSSMEMBER THREAD REPAIR . . . . . . . . 14
REMOVAL ................. ............5 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
INSTALLATION . . . . . . . . . . . . . . ............5 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 16
REAR FASCIA - SCUFF PAD FRONT CROSSMEMBER MOUNT BUSHINGS
REMOVAL ................. ............5 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION . . . . . . . . . . . . . . ............5 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17
BU M PERS

Front bumper reinforcement attaching nut 54 40 —
Rear bumper reinforcement attaching nut 27 20 —
FRON T FASCI A (7) Rem ove t h e t wo bolt s a n d t wo n u t s a t t a ch in g

fa scia t o t h e fr on t fen der s (F ig. 1) a n d (F ig. 2).
(8) Discon n ect fog la m p wir e con n ect or s, if n eces-
REMOVAL
sa r y.
(9) Lower veh icle.
(2) Rem ove t h e h ea dla m p a ssem blies (Refer t o 8 -
(10) Rem ove t wo bolt s a t t a ch in g t h e u pper gr ille
E LE CTRICAL/LAMP S/LIGH TING - E XTE RIOR/
su ppor t t o t h e h ea dla m p m ou n t in g pa n el a t ea ch side
H E ADLAMP - RE MOVAL).
of t h e gr ille.
(3) H oist veh icle a n d su ppor t wit h sa fet y st a n ds.
(11) Rem ove bu m per fa scia fr om veh icle.
(4) Rem ove t h e five pu sh pin fa st en er s a t t a ch in g
bot t om of fa scia /a ir da m t o r a dia t or closu r e pa n el.
(5) Rem ove fr on t wh eels.
INSTALLATION
(1) P osit ion fr on t bu m per fa scia on veh icle (F ig. 1)
(6) Rem ove fr on t wh eelh ou se spla sh sh ields fa st en -
a n d (F ig. 2).
er s a s n ecessa r y t o ga in a ccess t o bolt s a t t a ch in g
(2) In st a ll t h e t wo bolt s a t t a ch in g fa scia t o h ea d-
fr on t fa scia t o fen der. (Refer t o 23 - BODY/E XTE RI-
la m p m ou n t in g pa n el a t ea ch side of gr ille.
OR/ WH E E LH OUSE SP LASH SH IE LD -
(3) H oist veh icle a n d su ppor t wit h sa fet y st a n ds.
RE MOVAL).
13 - 2 FRAME & BUMPERS RS
FRON T FASCI A (Cont inue d)
Fig. 1 FRONT FASCIA

1 - FRONT BUMPER FASCIA 4 - RADIATOR ENCLOSURE
2 - GRILLE 5 - AIR DAM
3 - BUMPER REINFORCEMENT
(4) In st a ll t h e t wo bolt s a n d t wo n u t s a t t a ch in g (7) Con n ect fog la m p wir e con n ect or s, if n ecessa r y.
fa scia t o t h e fr on t fen der s. Th e fa scia sh ou ld be flu sh (8) In st a ll t h e five pu sh pin fa st en er s a t t a ch in g
t o fen der. bot t om of fa scia t o r a dia t or closu r e pa n el.
(5) In st a ll fr on t wh eelh ou se spla sh sh ields fa st en - (9) Lower t h e veh icle.
er s. (Refer t o 23 - BODY/E XTE RIOR/ WH E E L- (10) In st a ll t h e h ea dla m p a ssem blies. (Refer t o 8 -
H OUSE SP LASH SH IE LD - INSTALLATION). E LE CTRICAL/LAMP S/LIGH TING - E XTE RIOR/
(6) In st a ll fr on t wh eels. H E ADLAMP - INSTALLATION).
FRON T FASCI A (Cont inue d)
Fig. 2 FRONT FASCIA

1 - GRILLE 4 - RADIATOR ENCLOSURE
2 - FRONT BUMPER FIASCO 5 - AIR DAM
3 - BUMPER REINFORCEMENT
FRON T BU M PER
REI N FORCEM EN T
REMOVAL
(1) Rem ove fr on t bu m per fa scia . (Refer t o 13 -
F RAME S & BUMP E RS/BUMP E RS/F RONT FASCIA
- RE MOVAL)
(2) Discon n ect t h e solid st a t e r ela y (SSR) for t h e
coolin g m odu le wir in g con n ect or. If bu m per r ein for ce-
m en t is bein g r epla ced, r em ove t h e solid st a t e r ela y.
(3) Su ppor t fr on t bu m per r ein for cem en t on a su it -
a ble lift in g device.
(4) Rem ove t h e fou r n u t s a t t a ch in g fr on t bu m per
r ein for cem en t t o fr a m e r a il (F ig. 3).
(5) Rem ove fr on t bu m per r ein for cem en t fr om veh i-
cle.
INSTALLATION
NOTE: Check position of the arrows molded into
the foam for correct orientation. Fig. 3 FRONT BUMPER REINFORCEMENT
1 - FRONT BUMPER REINFORCEMENT
2 - FRAME RAILS
FRON T BU M PER REI N FORCEM EN T (Cont inue d)
(1) Su ppor t fr on t bu m per r ein for cem en t u sin g a
su it a ble lift in g device a n d lift in t o posit ion .
(2) In st a ll t h e fou r n u t s a t t a ch in g r ein for cem en t t o
fr a m e r a ils. Tigh t en n u t s t o 54 N·m (40 ft . lbs.)
t or qu e.
(3) Con n ect t h e solid st a t e r ela y (SSR) wir in g con -
n ect or. If bu m per r ein for cem en t wa s r epla ced, in st a ll
t h e solid st a t e r ela y on t o t h e bu m per r ein for cem en t .
(4) In st a ll fr on t fa scia . (Refer t o 13 - F RAME S &
BUMP E RS/BUMP E RS/F RONT FASCIA - INSTAL-
LATION).
REAR FASCI A
REMOVAL
(2) Rem ove a t t a ch in g scr ew fr om u pper fa scia t o
t h e lift ga t e t ower, r igh t side a n d left side.
(3) H oist a n d su ppor t veh icle wit h sa fet y st a n ds.
(4) Discon n ect r ea r pa r k a ssist wir e con n ect or, if
equ ipped.
(5) Rem ove t h e t h r ee scr ews a t t a ch in g r ea r fa scia Fig. 4 REAR BUMPER FASCIA
t o r ea r fa scia br a cket s on r igh t side a n d left side 1 - REAR FASCIA
(F ig. 4). 2 - PUSH PINS
(6) Rem ove t h e fou r pla st ic pu sh pin a t t a ch in g bot - 3 - REAR BUMPER REINFORCEMENT
4 - REAR FASCIA BRACKET
t om of r ea r fa scia t o fa scia su ppor t .
(7) Rem ove r ea r fa scia fr om veh icle by lift in g sides
of fa scia u p a n d ou t boa r d t o r elea se fr om r ea r fa scia
br a cket s.
INSTALLATION
(1) H oist a n d su ppor t veh icle wit h sa fet y st a n ds.
(2) P osit ion r ea r fa scia on veh icle (F ig. 5).
(3) Con n ect t h e r ea r pa r k a ssist wir e con n ect or, if
equ ipped.
(4) E n ga ge fr on t edge of fa scia u n der t h e lift ga t e
t ower. In st a ll scr ew in lift ga t e t ower r igh t side a n d
left side.
(5) E n ga ge sides of fa scia t o t op a n d fr on t edge of
t h e r ea r fa scia br a cket s.
NOTE: Verify fascia is still engaged under the lift-

gate. Ensure acceptable and consistent gap
between liftgate and fascia.
(6) In st a ll t h r ee scr ews a t t a ch in g r ea r fa scia t o

r ea r fa scia br a cket s, r igh t side a n d left side.
(7) In st a ll t h e fou r pla st ic pu sh pin s a t t a ch in g bot -
t om of r ea r fa scia t o fa scia su ppor t .
(8) Lower veh icle. Fig. 5 REAR BUMPER FASCIA
(9) In st a ll t h e t wo scr ews a t t a ch in g t h e u pper fa s- 1 - REAR FASCIA
cia t o t h e fa scia su ppor t . 2 - PUSH PINS
3 - REAR BUMPER REINFORCEMENT
4 - REAR FASCIA BRACKET
REAR BU M PER REAR FASCI A - SCU FF PAD

REI N FORCEM EN T
REMOVAL
REMOVAL Th e scu ff pa d m a y n ot be sa lva gea ble du r in g t h e
(1) Rem ove r ea r bu m per fa scia . (Refer t o 13 - r em ova l pr ocess. Th e scu ff pa d sh ou ld be r epla ced if
F RAME S & BUMP E RS/BUMP E RS/RE AR FASCIA - da m a ged or br oken . Ch eck a va ila bilit y befor e ser vic-
RE MOVAL) in g. Th e scu ff pa d ser vicea bilit y is im pr oved if t h e
(2) Su ppor t r ea r bu m per r ein for cem en t on a su it - r ea r fa scia is t o be r em oved for ser vice.
a ble lift in g device.
NOTE: If the rear fascia is to be removed for other
(3) Rem ove t h e fou r n u t s a t t a ch in g r ea r bu m per
service issues or If the scuff pad is to be reused
r ein for cem en t t o fr a m e r a il ext en sion s (F ig. 6).
use the steps below.
(4) Rem ove r ea r bu m per r ein for cem en t fr om veh i-
cle. (1) Rem ove r ea r bu m per fa scia .(Refer t o 13 -
F RAME S & BUMP E RS/BUMP E RS/RE AR FASCIA -
RE MOVAL)
(2) Usin g a t r im st ick, pr y u p t h e r ea r edge of t h e
scu ff pa d wh ile squ eezin g t h e r ea r lockin g t a bs fr om
u n der n ea t h t h e fa scia t o r elea se t h e r ea r edge of
scu ff pa d fr om t h e r ea r bu m per fa scia . P u ll t h e scu ff
pa d u p a n d squ eeze t h e r em a in in g t a bs t o r elea se t h e
r em a in in g of t h e scu ff pa d. (F ig. 7).
NOTE: If the rear fascia is to not to be removed for

other service issues use the step below.
(3) Usin g a t r im st ick, pr y u p t h e r ea r edge of t h e

scu ff pa d t o r elea se t a bs fr om t h e r ea r bu m per fa scia
a n d pu ll scu ff pa d t o r elea se t h e for wa r d t a bs (F ig.
7).
Fig. 6 REAR BUMPER REINFORCEMENT

1 - REAR BUMPER REINFORCEMENT
2 - FRAME RAIL EXTENSIONS
3 - NUTS
INSTALLATION
(1) Su ppor t r ea r bu m per r ein for cem en t u sin g a
su it a ble lift in g device t o lift in t o posit ion .
(2) P osit ion r ea r bu m per r ein for cem en t on veh icle.
(3) In st a ll t h e fou r n u t s a t t a ch in g r ea r bu m per
r ein for cem en t t o fr a m e r a il ext en sion s a n d t igh t en t o
27 N·m (20 ft . lbs.) t or qu e (F ig. 6).
(4) In st a ll r ea r bu m per fa scia . (Refer t o 13 -
F RAME S & BUMP E RS/BUMP E RS/RE AR FASCIA - Fig. 7 SCUFF PAD
INSTALLATION). 1 - SCUFF PAD
2 - TABS
INSTALLATION
(1) Ver ify t h a t t h er e a r e fift een slot s in t h e fa scia .
(2) P la ce scu ff pa d in posit ion (F ig. 7).
REAR FASCI A - SCU FF PAD (Cont inue d)
(3) Align a n d in ser t t h e cen t er for wa r d t a b. Loca t in g P oin t (P LP ), or fr om cen t er t o cen t er of P LP
(4) Align t h e r em a in in g t a bs a n d pr ess in t o t h e a n d fa st en er loca t ion .
slot s, st a r t in g in t h e cen t er a n d wor kin g ou t boa r d.
(5) Assu r e a ll t a bs a r e fu lly en ga ged in t o t h e fa s- VEHICLE PREPARATION
cia . P osit ion t h e veh icle on a fr a m e a lign m en t r a ck,
(6) If r ea r bu m per fa scia h a s been r em oved in st a ll. r efer t o in st r u ct ion s pr ovided wit h equ ipm en t bein g
(Refer t o 13 - F RAME & BUMP E RS/BUMP E RS/ u sed. Adju st t h e veh icle P LP h eigh t s t o t h e specified
RE AR FASCIA - INSTALLATION). dim en sion a bove t h e wor k su r fa ce (da t u m lin e). Ver-
t ica l dim en sion s ca n be t a ken fr om t h e da t u m lin e t o
t h e loca t ion s in dica t ed wer e a pplica ble.
FRAM E
SPECI FI CAT I ON S
SPECIFICATIONS - FRAME DIMENSIONS
F r a m e dim en sion s a r e list ed in m et r ic sca le. All
dim en sion s a r e fr om cen t er t o cen t er of P r in cipa l
I N DEX
DESCRIPTION FIGURE
CROSSMEMBER DIMENSIONS 8
ENGINE BOX - TOP VIEW 9
ENGINE COMPARTMENT AND FRAME RAIL - SIDE VIEW 10
FULL VEHICLE - BOTTOM VIEW 11
FRAM E (Cont inue d)
Fig. 8 CROSSMEMBER DIMENSIONS

Fig. 9 ENGINE BOX - TOP VIEW

RS
FRAME & BUMPERS
Fig. 10 ENGINE COMPARTMENT AND FRAME RAIL - SIDE VIEW

13 - 9
Fig. 11 FULL VEHICLE - BOTTOM VIEW

SPECIFICATIONS - FRAME DIMENSIONS -

FOLD-IN-FLOOR SEATS ONLY
I N DEX
DESCRIPTION FIGURE
FRAME - PLAN VIEW 12
FRAME - SIDE VIEW 13
Fig. 12 FRAME - PLAN VIEW

Fig. 13 FRAME - SIDE VIEW


Front Cradle Crossmember to Fram Rail Attaching Bolts (4) 163 120 —
Reinforcement Plate to Crossmember Attaching Bolt Size M14 (9) 153 113 —
Rear Engine Mount to Crossmember Attaching Through Bolt 68 50 —
Radiator Support Crossmember Attaching Bolts 51 38 —
FRON T CRADLE Th e t h r ea ded h oles in t h e fr on t cr a dle cr ossm em -

ber, if da m a ged, ca n r epa ir ed by in st a llin g a H eli-
CROSSM EM BER Coil! t h r ea d in ser t .
Th e t h r ea ded h oles t h a t a r e r epa ir a ble u sin g t h e
t h r ea d in ser t , a r e t h e lower con t r ol a r m r ea r bu sh in g
DESCRI PT I ON r et a in er m ou n t in g bolt h oles, r ou t in g br a cket a t t a ch -
in g loca t ion s for t h e power st eer in g h oses, a n d br a ke
DESCRIPTION - FRONT CRADLE h ose a t t a ch m en t h oles.
CROSSMEMBER Th is r epa ir pr ocedu r e n ow a llows t h e t h r ea ded
Th is veh icle u ses a on e piece ca st a lu m in u m cr a dle h oles in t h e cr a dle cr ossm em ber t o be r epa ir ed, elim -
for t h e fr on t cr a dle cr ossm em ber. Th e cr a dle cr oss- in a t in g t h e n eed t o r epla ce t h e cr a dle cr ossm em ber if
m em ber is u sed a s t h e a t t a ch in g poin t s for t h e lower da m a ge occu r s t o on e of t h e t h r ea ded h oles.
con t r ol a r m s, st a bilizer ba r a n d st eer in g gea r. Th e Th e t h r ea d in ser t s for t h is a pplica t ion a r e specified
cr a dle a lso h a s t h e power st eer in g h oses a n d t h e by pa r t n u m ber in t h e Mopa r P a r t s Ca t a log. D o n o t
ch a ssis br a ke t u bes a t t a ch ed t o it . u s e a s u bs titu te th re a d in s e rt.
Th e specific t ools a n d equ ipm en t r equ ir ed t o in st a ll
WARNING: If a threaded hole in the suspension cra- t h e t h r ea d in ser t a r e list ed below. Refer t o t h e
dle needs to be repaired, only use the type of in st r u ct ion s in clu ded wit h t h e t h r ea d in ser t for t h e
thread insert and installation procedure specified det a iled pr ocedu r e u sed for t h e in st a lla t ion of t h e
for this application. t h r ea d in ser t .
Th e t h r ea ded h oles in t h e fr on t cr a dle cr ossm em - NOTE: The thread inserts for this application are for
ber t h a t a r e u sed for a t t a ch m en t of t h e lower con t r ol the repair of M8x1.25 and M10x1.5 threads. Be sure
a r m r ea r bu sh in g r et a in er, power st eer in g h ose a n d the correct tools are used for the required thread
ch a ssis br a ke t u bes ca n be r epa ir ed. Th e r epa ir is insert size.
don e by t h e in st a lla t ion of a H eli-Coil! t h r ea d in ser t
wh ich h a s been specifica lly developed for t h is a ppli-
ca t ion . Refer t o t h e Mopa r P a r t s Ca t a log for t h e spec- TOOL REQUIREMENT FOR M8x1.25 Thread
ified H eli-Coil! t h r ea d in ser t t o be u sed for t h is • 8.3m m (5/16 in .) Dr ill Bit
a pplica t ion . Th e pr ocedu r e for in st a llin g t h e H eli- • 120° Cou n t er sin k
Coil! t h r ea d in ser t is det a iled in t h e Ser vice P r oce- • H eli-Coil! Ta p #4863-8
du r es sect ion in t h is gr ou p of t h e ser vice m a n u a l. • H eli-Coil! Ga ge #4624-8
• H eli-Coil! H a n d In ser t in g Tool 7751-8
DESCRIPTION - FRONT CRADLE • Needle Nose P lier s – F or Rem ova l Of Th r ea d
CROSSMEMBER THREAD REPAIR In ser t Dr ivin g Ta n g
WARNING: When performing this procedure use TOOL REQUIREMENT FOR M10x1.5 Thread
only the thread inserts which are specified in the • 10.5m m (25/64 in .) Dr ill Bit
Mopar Parts Catalog for this repair procedure. • 120° Cou n t er sin k
These thread inserts have been specifically devel- • H eli-Coil! Ta p #4863-10
oped for this application and use of other types of • H eli-Coil! Ga ge #4624-10
thread inserts can result in an inferior long term • H eli-Coil! H a n d In ser t in g Tool 7751-10
repair. • Needle Nose P lier s – F or Rem ova l Of Th r ea d
In ser t Dr ivin g Ta n g
FRON T CRADLE CROSSM EM BER (Cont inue d)
REMOVAL (7) H oist veh icle a n d su ppor t on sa fet y st a n ds.

Th e fr on t cr a dle cr ossm em ber m u st be in st a lled in (8) P osit ion a dr a in pa n u n der power st eer in g
t h e design loca t ion t o a ch ieve pr oper fr on t en d su s- pu m p a n d oil r et u r n h ose cou plin g.
pen sion a lign m en t . If t h e cr a dle cr ossm em ber is (9) Usin g a h ose pin ch -off plier s (C-4390), pin ch
r em oved wit h ou t a pplyin g r efer en ce m a r ks on t h e power st eer in g oil r et u r n h ose off bet ween t h e cr oss-
fr a m e r a ils, a lign t h e cr a dle cr ossm em ber a ccor din g m em ber cou plin g a n d t h e pu m p.
t o t h e dim en sion s pr ovided in t h is gr ou p. (10) Loosen h ose cla m p a t t h e cr a dle cr ossm em ber
cou plin g.
NOTE: If the caged nuts in the frame rails become (11) Discon n ect r et u r n h ose fr om m et a l t u be.
damaged and cannot be reused, a replacement nut (12) Wh ile h oldin g pr essu r e r elief va lve n u t on
can be obtained through Mopar" (Fig. 14). ba ck of power st eer in g pu m p, Rem ove fla r e n u t
a t t a ch in g h igh pr essu r e h ose t o ba ck of pu m p.
(13) Rem ove h igh pr essu r e h ose fr om pu m p.
(14) Allow power st eer in g flu id t o dr a in in t o pa n .
(15) Rem ove bolt s a t t a ch in g a n t i-lock br a ke sen sor
lea ds t o cr a dle cr ossm em ber.
(16) P osit ion a n t i-lock br a ke lea ds ou t of t h e wa y.
(17) Discon n ect st a bilizer ba r lin ks fr om en ds of
st a bilizer ba r.
(18) Discon n ect lower ba ll join t s fr om lower st eer-
in g kn u ckles (Refer t o 2 - SUSP E NSION/F RONT/
LOWE R BALL J OINT - RE MOVAL).
(19) Rem ove t h e r ea r en gin e m ou n t h ea t sh ield
(F ig. 16).
(20) Rem ove t h r ou gh bolt a t t a ch in g r ea r en gin e
m ou n t t o cr a dle cr ossm em ber (F ig. 17).
(21) Usin g pa in t or gr ea se pen cil, m a r k ou t lin e of
cr a dle cr ossm em ber on fr a m e r a ils t o a id in st a lla t ion .
(22) Su ppor t cr a dle cr ossm em ber on su it a ble lift -
in g device (F ig. 19).
(23) Rem ove bolt s a t t a ch in g cr ossm em ber t o fr on t
Fig. 14 FRONT CRADLE CROSSMEMBER CAGED
fr a m e r a ils (F ig. 18).
NUT
(24) Rem ove cr a dle cr ossm em ber fr om veh icle (F ig.
1 - BRACKET
2 - CAGED NUT
19).
REMOVAL
(2) Rem ove st eer in g colu m n lower cover fr om
in st r u m en t pa n el (Refer t o 23 - BODY/INSTRU-
ME NT PANE L/STE E RING COLUMN OP E NING
COVE R - RE MOVAL).
(3) Rem ove st eer in g colu m n cover ba ckin g pla t e
(Refer t o 23 - BODY/INSTRUME NT PANE L/STE E R-
ING COLUMN COVE R BACKING P LATE -
RE MOVAL).
(4) P osit ion st eer in g so fr on t wh eels a r e st r a igh t
a h ea d.
CAUTION: Do not rotate steering wheel after disen-

gaging lower coupling from steering gear, damage
to air bag clock spring can result. Fig. 15 STEERING COUPLING
1 - STEERING SHAFT BOOT
(5) Rem ove clin ch bolt a t t a ch in g st eer in g colu m n 2 - STEERING SHAFT
cou plin g t o st eer in g gea r sh a ft (F ig. 15). 3 - CROSSMEMBER
(6) Rem ove st eer in g colu m n cou plin g fr om t ele- 4 - STEERING GEAR
5 - MOUNT
scopin g st eer in g gea r sh a ft . 6 - TRANSAXLE
Fig. 18 CRADLE CROSSMEMBER MOUNT

Fig. 16 REAR MOUNT HEAT SHIELD 1 - CROSSMEMBER MOUNT
1 - BOLT 2 - BRAKE HOSE MOUNT
2 - HEAT SHIELD 3 - STEERING TIE ROD
3 - CLIP 4 - FRONT CROSSMEMBER
4 - REAR ENGINE MOUNT 5 - FRAME RAIL
(4) P la ce u pper h a lf of bu sh in g on t op of cr oss-

m em ber a lign ed t o r eceive squ a r e t u be pr ot r u din g
u pwa r d fr om lower bu sh in g h a lf.
(5) Align cr ossm em ber t o pr eviou sly m a de m a r ks
on fr a m e r a ils.
(6) Tigh t en bolt s a t t a ch in g cr a dle cr ossm em ber t o
fr a m e r a ils.
(7) In st a ll t h r ou gh bolt a t t a ch in g r ea r en gin e
m ou n t t o cr a dle cr ossm em ber (F ig. 17) a n d t igh t en t o
68 N·m (50 ft . lbs.) t or qu e.
(8) In st a ll t h e r ea r m ou n t h ea t sh ield (F ig. 16).
(9) Con n ect lower ba ll join t s t o st eer in g kn u ckles
(Refer t o 2 - SUSP E NSION/F RONT/LOWE R BALL
J OINT - INSTALLATION)
(10) Con n ect st a bilizer ba r lin ks t o en ds of st a bi-
lizer ba r.
(11) In st a ll bolt s a t t a ch in g a n t i-lock br a ke sen sor
Fig. 17 REAR MOUNT
lea ds t o cr a dle cr ossm em ber.
1 - BOLT
2 - REAR MOUNT BRACKET (12) In st a ll h igh pr essu r e h ose t o pu m p.
3 - THROUGH BOLT (13) Con n ect r et u r n h ose t o m et a l t u be.
4 - REAR MOUNT (14) Tigh t en h ose cla m p a t t h e cr a dle cr ossm em ber
cou plin g.
INSTALLATION (15) Rem ove pin ch -off plier s.
(16) P osit ion st eer in g so fr on t wh eels a r e st r a igh t
NOTE: If cradle crossmember requires replacement. a h ea d.
Refer to Group 2, Suspension, to transfer suspen- (17) In st a ll st eer in g colu m n cou plin g t o t elescopin g
sion components and Group 19, Steering, to trans- st eer in g gea r sh a ft .
fer steering components. (18) In st a ll clin ch bolt a t t a ch in g st eer in g colu m n
cou plin g t o st eer in g gea r sh a ft .
(1) Su ppor t cr ossm em ber on su it a ble lift in g device
(19) In st a ll st eer in g colu m n cover ba ckin g pla t e
(F ig. 19).
(Refer t o 23 - BODY/INSTRUME NT PANE L/STE E R-
(2) P osit ion cr ossm em ber t o veh icle.
ING COLUMN COVE R BACKING P LATE -
(3) Loosely in st a ll bolt s a t t a ch in g cr a dle cr oss-
INSTALLATION)
m em ber t o fr on t fr a m e r a ils.
Fig. 19 CRADLE CROSSMEMBER

1 - ENGINE OIL PAN 4 - FRONT CROSSMEMBER
2 - TRANSAXLE 5 - LIFT DEVICE
3 - LOWER CONTROL ARM 6 - SPINDLE
(20) In st a ll st eer in g colu m n lower cover fr om INSTALLATION

in st r u m en t pa n el (Refer t o 23 - BODY/INSTRU- (1) Apply r u bber lu br ica t ion or soa p t o r epla ce-
ME NT PANE L/STE E RING COLUMN OP E NING m en t bu sh in g.
COVE R - INSTALLATION). (2) In ser t lower h a lf of bu sh in g in t o squ a r e h ole in
(21) Con n ect ba t t er y n ega t ive ca ble. cr a dle cr ossm em ber.
(3) P la ce u pper h a lf of bu sh in g on t op of cr oss-
m em ber a lign ed t o r eceive squ a r e t u be pr ot r u din g
FRON T CROSSM EM BER u pwa r d fr om lower bu sh in g h a lf.
M OU N T BU SH I N GS (4) Squ eeze bu sh in g h a lves t oget h er t o en su r e t h ey
a r e pr oper ly m a t ed.
REMOVAL (5) Lift cr a dle cr ossm em ber u pwa r d t o close ga p
(1) Usin g pa in t or gr ea se pen cil, m a r k ou t lin e of bet ween t h e bu sh in g a n d fr a m e.
cr a dle cr ossm em ber on fr a m e r a ils. (6) Ver ify t h a t lower bu sh in g is fu lly sea t ed in t o
(2) Loosen bolt s a t t a ch in g cr ossm em ber t o fr a m e cr a dle cr ossm em ber a n d u pper bu sh in g.
r a ils. (7) In st a ll bolt a t t a ch in g bu sh in g a n d cr ossm em ber
(3) Rem ove bolt on bu sh in g t h a t r equ ir es r epla ce- t o fr a m e r a il h a n d t igh t .
m en t . (8) Align cr a dle cr ossm em ber t o r efer en ce m a r ks
(4) Allow cr a dle cr ossm em ber t o dr op down en ou gh on fr a m e r a ils.
t o ga in clea r a n ce for bu sh in g r em ova l. (9) Tigh t en cr a dle cr ossm em ber t o fr a m e r a ils
(5) Rem ove bu sh in g fr om veh icle. a t t a ch in g bolt s t o 163 N·m (120 ft . lbs.) t or qu e.
RS FUEL SYSTEM 14 - 1
FUEL SYSTEM
page page
FUEL DELIVERY ..........................1 FUEL INJECTION . . . . . . . . . . . . . . . . . . . . . . . . 21
FU EL DELI V ERY
TABLE OF CONTENTS
page page
FUEL DELIVERY OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

DESCRIPTION FUEL PUMP MODULE
DESCRIPTION ..................... ...2 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 8
DESCRIPTION - FFV REPLACEMENT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...2 REMOVAL
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . ...2 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
DIAGNOSIS AND TESTING - FUEL DELIVERY REMOVAL - FOLD-IN-FLOOR . . . . . . . . . . . . 10
SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . ...2 INSTALLATION
STANDARD PROCEDURE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 10
STANDARD PROCEDURE - FUEL SYSTEM INSTALLATION - FOLD-IN-FLOOR . . . . . . . . . 10
PRESSURE RELEASE PROCEDURE . . . . ...2 FUEL RAIL
STANDARD PROCEDURE - DRAINING REMOVAL
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . ...2 REMOVAL - 2.4L . . . . . . . . . . . . . . . . . . . . . . 11
STANDARD PROCEDURE - FUEL REMOVAL - 3.3/3.8L . . . . . . . . . . . . . . . . . . . 11
PRESSURE GAUGE . . . . . . . . . . . . . . . . . ...3 INSTALLATION
SPECIFICATIONS INSTALLATION - 2.4L . . . . . . . . . . . . . . . . . . 11
FUEL SYSTEM PRESSURE ........... ...4 INSTALLATION - 3.3/3.8L . . . . . . . . . . . . . . . . 12
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . ...4 FUEL TANK
SPECIAL TOOLS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 12
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...4 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
FUEL LEVEL SENDING UNIT / SENSOR REMOVAL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . .5 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 REMOVAL - FOLD-IN-FLOOR . . . . . . . . . . . . 13
REMOVAL .......................... . . .5 INSTALLATION
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . .6 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . 15
FUEL LINES INSTALLATION - FOLD-IN-FLOOR . . . . . . . . . 16
DESCRIPTION - FUEL LINES/HOSES AND FUEL TANK FILLER TUBE
CLAMPS . . . . . . . . . . . . . . . . . . . . . . . . . . ...7 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
STANDARD PROCEDURE - HOSES AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17
CLAMP . . . . . . . . . . . . . . . . . . . . . . . . . . . ...7 INLET FILTER
FUEL PRESSURE REGULATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . ...7 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 17
REMOVAL .......................... ...7 QUICK CONNECT FITTING
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . ...7 STANDARD PROCEDURE - QUICK-CONNECT
FUEL PUMP FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . ...8
14 - 2 FUEL DELIVERY RS
FU EL DELI V ERY (3) At t em pt r est a r t in g en gin e u n t il it will n o

lon ger r u n .
(4) Tu r n ign it ion key t o OF F posit ion .
DESCRI PT I ON (5) Ret u r n fu el pu m p r ela y t o P DC.
(6) On e or m or e Dia gn ost ic Tr ou ble Codes (DTC’s)
DESCRIPTION m a y h a ve been st or ed in P CM m em or y du e t o fu el
Th e fr on t wh eel dr ive ca r u ses a pla st ic fu el t a n k pu m p r ela y r em ova l. Th e DRB III! sca n t ool m u st be
loca t ed r ea r cen t er of t h e veh icle. u sed t o er a se a DTC.
Th e F u el Deliver y Syst em con sist s of: t h e followin g
it em s: STANDARD PROCEDURE - DRAINING FUEL
• E lect r ic fu el pu m p m odu le TANK
• F u el filt er Two differ en t pr ocedu r es m a y be u sed t o dr a in fu el
• Tu bes/lin es/h oses t a n k (lower in g t a n k or u sin g DRBIII! sca n t ool).
• F u el in ject or s Th e qu ickest dr a in in g pr ocedu r e in volves lower in g
Th e in -t a n k fu el pu m p m odu le con t a in s t h e fu el t h e fu el t a n k.
pu m p. Th e pu m p is ser viced a s pa r t of t h e fu el pu m p
m odu le. Refer t o F u el P u m p Modu le. WARNING: RELEASE FUEL SYSTEM PRESSURE
Th e fu el filt er is r epla cea ble on ly a s pa r t of t h e BEFORE SERVICING FUEL SYSTEM COMPONENTS.
fu el pu m p m odu le. SERVICE VEHICLES IN WELL VENTILATED AREAS
AND AVOID IGNITION SOURCES. NEVER SMOKE
DESCRIPTION - FFV REPLACEMENT PARTS WHILE SERVICING THE VEHICLE. THIS MAY
Ma n y com pon en t s in a F lexible F u el Veh icle (F F V) RESULT IN PERSONAL INJURY OR DEATH.
a r e design ed t o be com pa t ible wit h et h a n ol. Alwa ys
be su r e t h a t t h e veh icle is ser viced wit h cor r ect et h a - As a n a lt er n a t ive pr ocedu r e, t h e elect r ic fu el pu m p
n ol com pa t ible pa r t s. m a y be a ct iva t ed a llowin g t a n k t o be dr a in ed a t fu el
r a il con n ect ion . Refer t o DRBIII! sca n t ool for fu el
CAUTION: Replacing fuel system components with pu m p a ct iva t ion pr ocedu r es. Befor e discon n ect in g
non-ethanol compatible components can damage fu el lin e a t fu el r a il, r elea se fu el pr essu r e. Refer t o
your vehicle and may void the warranty. t h e F u el Syst em P r essu r e Relea se P r ocedu r e in t h is
gr ou p for pr ocedu r es. Discon n ect t h e fu el lin e a t t h e
fu el r a il a n d r em ove t h e pla st ic r et a in er fr om t h e
OPERATION fu el r a il. Ta ke pla st ic r et a in er a n d in st a ll it ba ck in t o
Th e fu el syst em pr ovides fu el pr essu r e by a n t h e fu el lin e fr om body. Ch eck t h e O-r in g a n d m a ke
in -t a n k pu m p m odu le. Th e P ower t r a in Con t r ol Mod- su r e t h a t it is in pla ce a n d n ot da m a ged. At t a ch en d
u le (P CM) con t r ols t h e oper a t ion of t h e fu el syst em of specia l t est h ose t ool n u m ber 6539 a t fu el lin e con -
by pr ovidin g ba t t er y volt a ge t o t h e fu el pu m p n ect ion fr om t h e body lin e. P osit ion opposit e en d of
t h r ou gh t h e fu el pu m p r ela y. Th e P CM r equ ir es on ly t h is h ose t ool t o a n a ppr oved ga solin e dr a in in g st a -
t h r ee in pu t s a n d a good gr ou n d t o oper a t e t h e fu el t ion . Act iva t e fu el pu m p a n d dr a in t a n k u n t il em pt y.
pu m p r ela y. Th e t h r ee in pu t s a r e: Wh en don e r em ove t h e specia l t est h ose t ool n u m ber
• Ign it ion volt a ge 6539 fr om t h e body lin e. Rem ove t h e pla st ic r et a in er
• Cr a n ksh a ft P osit ion (CKP ) sen sor fr om t h e specia l t est h ose t ool n u m ber 6539 a n d r ein -
• Ca m sh a ft P osit ion (CMP ) sen sor st a ll it in t o t h e fu el lin e fr om t h e body. Ch eck t h e
O-r in g a n d m a ke su r e t h a t it is in pla ce a n d n ot
DIAGNOSIS AND TESTING - FUEL DELIVERY da m a ged. In st a ll t h e fu el lin e t o t h e fu el r a il.
SYSTEM If elect r ic fu el pu m p is n ot oper a t in g, t a n k m u st be
(Refer t o Appr opr ia t e Dia gn ost ic In for m a t ion ) lower ed for fu el dr a in in g. Refer t o followin g pr oce-
du r es.
(1) Rem ove fu el filler ca p.
STAN DARD PROCEDU RE (2) P er for m t h e F u el Syst em P r essu r e Relea se pr o-
cedu r e.
STANDARD PROCEDURE - FUEL SYSTEM (3) Discon n ect n ega t ive ca ble fr om ba t t er y.
PRESSURE RELEASE PROCEDURE
(5) Cer t a in m odels a r e equ ipped wit h a sepa r a t e
(1) Rem ove F u el P u m p r ela y fr om P ower Dist r ibu -
gr ou n din g wir e (st r a p) con n ect in g t h e fu el fill t u be
t ion Cen t er (P DC). F or loca t ion of r ela y, r efer t o la bel
a ssem bly t o t h e body. Discon n ect wir e by r em ovin g
on u n der side of P DC cover.
scr ew.
(2) St a r t a n d r u n en gin e u n t il it st a lls.
RS FUEL DELIVERY 14 - 3
FU EL DELI V ERY (Cont inue d)
(6) Open fu el fill door a n d r em ove scr ews m ou n t -
in g fu el filler t u be a ssem bly t o body. Do n ot discon -
n ect r u bber fu el fill or ven t h oses fr om t a n k a t t h is
t im e.
(7) P la ce a t r a n sm ission ja ck u n der cen t er of fu el
t a n k. Apply a sligh t a m ou n t of pr essu r e t o fu el t a n k
wit h t r a n sm ission ja ck.
(8) Rem ove fu el t a n k m ou n t in g st r a ps.
(9) Lo w e r th e ta n k ju s t e n o u g h s o th a t th e
fille r tu be fittin g is th e h ig h e s t p o in t o f th e fu e l
ta n k .
(10) Rem ove filler t u be fr om fu el t a n k. Ta n k will
be dr a in ed t h r ou gh t h is fit t in g.
NOTE: WRAP SHOP TOWELS AROUND HOSES TO

CATCH ANY GASOLINE SPILLAGE.
(11) Dr a in fu el t a n k in t o h oldin g t a n k or a pr op-

er ly la beled Ga s o lin e sa fet y con t a in er.
WARNING: GASOLINE OR GASOLINE VAPORS ARE

HIGHLY FLAMMABLE. A FIRE COULD OCCUR IF AN
IGNITION SOURCE IS PRESENT. NEVER DRAIN OR
Fig. 1 FUEL SYSTEM PRESSURE TESTER #8978
STORE GASOLINE OR DIESEL FUEL IN AN OPEN
CONTAINER, DUE TO THE POSSIBILITY OF FIRE 1 - GAUGES
2 - HANGER
OR EXPLOSION. THIS MAY RESULT IN PERSONAL 3 - RELEASE TOOL
INJURY OR DEATH. 4 - DRAIN HOSE
5 - DRAIN HOSE VALVE
6 - SHUT-OFF VALVE
(12) If fu el pu m p m odu le r em ova l is n ecessa r y,
r efer t o F u el P u m p Modu le Rem ova l/In st a lla t ion in (2) F in d a fu el lin e qu ick con n ect fit t in g t h a t is
t h is sect ion . a ccessible a n d in st a ll specia l t ool #8974.
(3) Refer t o t h e P ower t r a in Dia gn ost ic Ma n u a l for
STANDARD PROCEDURE - FUEL PRESSURE t h e pr oper oper a t ion of t h is ga u ge pa cka ge.
GAUGE (4) P r efor m t h e fu el pr essu r e r elea se pr ocedu r e,
Th is ga u ge pa cka ge (specia l t ool #8974) (F ig. 1)is r efer t o t h e F u el P r essu r e r elea se pr ocedu r e in t h is
design ed t o ch eck t h e in ject or s or fu el pu m p for lea k sect ion .
down con dit ion s a n d fu el syst em pr essu r es. Refer t o (5) Rem ove ga u ge fr om fu el syst em a n d r econ n ect
t h e P ower t r a in Dia gn ost ic Ma n u a l for m or e in for m a - fu el lin es.
t ion on t h e oper a t ion of t h is t ool. (6) Use t h e DRBIII! t o pr essu r ize t h e fu el syst em
(1) P r efor m t h e fu el pr essu r e r elea se pr ocedu r e, t o ch eck for lea ks
r efer t o t h e F u el P r essu r e r elea se pr ocedu r e in t h is
sect ion .
SPECI FI CAT I ON S
FUEL SYSTEM PRESSURE
400 kpa ±34 kpa (58 psi ± 5 psi)
TORQUE

Fuel Filler Neck Clamp 3.3 30
Fuel Rail 2.4L 22 195
Fuel Rail 3.3/3.8L 11.8 105
Fuel Tank Strap 54 40
Fuel Tank T Strap 28.2 250
Fuel Filter Bolt 4.5 40
SPECI AL T OOLS
FUEL
Spanner Wrench 6856
Pressure Gauge Assembly C–4799–B
LOCKRING REMOVER/INSTALLER #9340
Fuel Pressure Test Adapter 6539
Fuel Line Adapter 1/4

O2S (Oxygen Sensor) Remover/Installer—C-4907
Fig. 2 Fuel Pump/Level Sensor Electrical Connector

2 - RETAINING TAB
O2S (Oxygen Sensor) Remover/Installer - 8439

FU EL LEV EL SEN DI N G U N I T /
SEN SOR
DESCRIPTION
Th e fu el ga u ge level sen din g u n it is a t t a ch ed t o t h e
side of fu el pu m p m odu le. Th e level sen sor is a va r i-
a ble r esist or.
Fig. 3 Wire Terminal Locking Finger
OPERATION
1 - LOCKING FINGER
It s r esist a n ce ch a n ges wit h t h e a m ou n t of fu el in 2 - WIRE TERMINAL
t h e t a n k. Th e floa t a r m a t t a ch ed t o t h e sen sor m oves
a s t h e fu el level ch a n ges.
Th e fu el level in pu t is u sed a s a n in pu t for OBD II.
If t h e fu el level is below 15% or a bove 85% of t ot a l
t a n k ca pa cit y sever a l m on it or s a r e disa bled. Th er e
a r e dia gn ost ics for t h e level cir cu it open a n d sh or t ed.
REMOVAL
Rem ove fu el pu m p m odu le. Refer t o F u el P u m p
Modu le in t h is sect ion .
(1) Depr ess r et a in in g t a b a n d r em ove t h e fu el
pu m p/level sen sor con n ect or fr om t h e B OTTOM of
t h e fu el pu m p m odu le elect r ica l con n ect or (F ig. 2).
NOTE: The pump module harness on TOP of flange

is not serviceable or removable.
(2) P u ll off t h e lockin g wedge.

(3) Usin g a sm a ll scr ewdr iver lift lockin g fin ger
Fig. 4 Removing Wires From
a wa y fr om t er m in a l a n d pu sh t er m in a l ou t of con n ec-
1 - FUEL PUMP FEED (RED B+)
t or (F ig. 3). 2 - LEVEL SENSOR SIGNAL
(4) P u sh level sen sor sign a l a n d gr ou n d t er m in a ls 3 - LEVEL SENSOR GROUND
ou t of t h e con n ect or (F ig. 4). 4 - FUEL PUMP GROUND (BK)
FU EL LEV EL SEN DI N G U N I T / SEN SOR (Cont inue d)
(5) In ser t a scr ewdr iver bet ween t h e fu el pu m p INSTALLATION
m odu le a n d t h e t op of t h e level sen sor h ou sin g (F ig. (1) In ser t level sen sor wir es in t o bot t om of open in g
5). P u sh level sen sor down sligh t ly. in m odu le.
(2) Wr a p wir es in t o gr oove in ba ck of level sen sor
(F ig. 7).
Fig. 5 Loosening Level Sensor

1 - LEVEL SENSOR
2 - PRY DOWN ON LEVEL SENSOR Fig. 7 Groove in Back Side of Level Sensor
1 - WRAP WIRES IN GROOVE
(6) Slide level sen sor wir es t h r ou gh open in g fu el 2 - REAR VIEW OF LEVEL SENSOR
pu m p m odu le (F ig. 6).
(3) Wh ile feedin g wir es in t o gu ide gr ooves, slide
level sen sor u p in t o ch a n n el u n t il it sn a ps in t o pla ce
(F ig. 8). E n su r e t a b a t bot t om of sen sor locks in
pla ce.
Fig. 6 Level Sensor Removal/Installation

1 - OPENING IN MODULE
2 - FUEL LEVEL SENSOR
(7) Slide level sen sor ou t of in st a lla t ion ch a n n el in Fig. 8 Installation Channel
m odu le. 1 - CHANNEL FOR LEVEL SENSOR
2 - PUMP MODULE
FU EL LEV EL SEN DI N G U N I T / SEN SOR (Cont inue d)
(4) In st a ll level sen sor wir es in con n ect or. P u sh a br a sion s or scu ffin g. E n su r e t h a t r u bber h oses a r e
t h e wir es u p t h r ou gh t h e con n ect or a n d t h en pu ll pr oper ly r ou t ed a n d a void h ea t sou r ces.
t h em down u n t il t h ey lock in pla ce. E n su r e sign a l Th e h ose cla m ps h a ve r olled edges t o pr even t t h e
a n d gr ou n d wir es a r e in st a lled in t h e cor r ect posi- cla m p fr om cu t t in g in t o t h e h ose. On ly u se cla m ps
t ion . t h a t a r e or igin a l equ ipm en t or equ iva len t . Ot h er
(5) In st a ll lockin g wedge on con n ect or. t ypes of cla m ps m a y cu t in t o t h e h oses a n d ca u se
(6) P u sh con n ect or u p in t o bot t om of fu el pu m p h igh pr essu r e fu el lea ks. Tigh t en h ose cla m ps t o 1
m odu le elect r ica l con n ect or. N·m (9 in . lbs.) t or qu e.
(7) In st a ll fu el pu m p m odu le. Refer t o F u el P u m p In spect a ll h ose con n ect ion s su ch a s cla m ps, cou -
Modu le in t h is sect ion . plin gs a n d fit t in gs t o m a ke su r e t h ey a r e secu r e a n d
lea ks a r e n ot pr esen t . Th e com pon en t sh ou ld be
r epla ced im m edia t ely if t h er e is a n y eviden ce of deg-
FU EL LI N ES r a da t ion t h a t cou ld r esu lt in fa ilu r e.
Never a t t em pt t o r epa ir a pla st ic fu el lin e/t u be.
DESCRIPTION - FUEL LINES/HOSES AND Repla ce a s n ecessa r y.
CLAMPS Avoid con t a ct of a n y fu el t u bes/h oses wit h ot h er
Also r efer t o Qu ick-Con n ect F it t in gs. veh icle com pon en t s t h a t cou ld ca u se a br a sion s or
scu ffin g. Be su r e t h a t t h e pla st ic fu el lin es/t u bes a r e
WARNING: THE FUEL SYSTEM IS UNDER A CON- pr oper ly r ou t ed t o pr even t pin ch in g a n d t o a void h ea t
STANT PRESSURE (EVEN WITH THE ENGINE OFF). sou r ces.
BEFORE SERVICING ANY FUEL SYSTEM HOSES,
FITTINGS OR LINES, THE FUEL SYSTEM PRES-
SURE MUST BE RELEASED. REFER TO THE FUEL FU EL PRESSU RE REGU LAT OR
SYSTEM PRESSURE RELEASE PROCEDURE IN
THIS GROUP. THIS MAY RESULT IN PERSONAL OPERATION
INJURY OR DEATH. Th e fu el syst em u ses a n on a dju st a ble pr essu r e r eg-
u la t or t h a t m a in t a in s fu el syst em pr essu r e a t
Th e lin es/t u bes/h oses u sed on fu el in ject ed veh icles a ppr oxim a t ely 400 ±34 kP a (58 ±5 psi). Th e fu el
a r e of a specia l con st r u ct ion . Th is is du e t o t h e pr essu r e r egu la t or con t a in s a dia ph r a gm , ca libr a t ed
h igh er fu el pr essu r es a n d t h e possibilit y of con t a m i- spr in g a n d a fu el r et u r n va lve. Th e spr in g pu sh es
n a t ed fu el in t h is syst em . If it is n ecessa r y t o r epla ce down on t h e dia ph r a gm a n d closes off t h e fu el r et u r n
t h ese lin es/t u bes/h oses, u se n ew or igin a l equ ipm en t por t . Syst em fu el pr essu r e r eflect s t h e a m ou n t of fu el
lin es/t u bes/h oses. pr essu r e r equ ir ed t o open t h e r et u r n por t .
If e qu ip p e d : Th e h ose cla m ps u sed t o secu r e r u b- Th e pr essu r e r egu la t or is a m ech a n ica l device t h a t
ber h oses on veh icles a r e of a specia l r olled edge con - is NOT con t r olled by t h e P CM or en gin e va cu u m .
st r u ct ion . Th is con st r u ct ion is u sed t o pr even t t h e
edge of t h e cla m p fr om cu t t in g in t o t h e h ose. On ly REMOVAL
t h ese r olled edge t ype cla m ps m a y be u sed in t h is Th e fu el pr essu r e r egu la t or is pa r t of t h e fu el
syst em . All ot h er t ypes of cla m ps m a y cu t in t o t h e pu m p m odu le (F ig. 9). Rem ove t h e fu el pu m p m odu le
h oses a n d ca u se lea ks. fr om t h e fu el t a n k t o a ccess t h e fu el pr essu r e r egu la -
Use n ew or igin a l equ ipm en t t ype h ose cla m ps. t or. Refer t o t h e F u el P u m p Modu le r em ova l in t h is
sect ion .
STANDARD PROCEDURE - HOSES AND CLAMP (1) Squ eeze t a n gs on pr essu r e r egu la t or r et a in er
In spect a ll h ose con n ect ion s (cla m ps a n d qu ick con - a n d pu ll t o r em ove r et a in er.
n ect fit t in gs) for com plet en ess a n d lea ks. Repla ce (2) P r y fu el pr essu r e r egu la t or ou t of h ou sin g.
cr a cked, scu ffed, or swelled h oses. Repla ce h oses t h a t (3) E n su r e bot h u pper a n d lower O-r in gs wer e
r u b a ga in st ot h er veh icle com pon en t s or sh ow sign of r em oved wit h r egu la t or.
wea r.
F u el in ject ed veh icles u se specia lly con st r u ct ed INSTALLATION
h oses. Wh en r epla cin g h oses, on ly u se h oses m a r ked Th e fu el pr essu r e r egu la t or is pa r t of t h e fu el
E F M/E F I. pu m p m odu le. Rem ove t h e fu el pu m p m odu le fr om
Wh en in st a llin g h oses, en su r e t h a t t h ey a r e r ou t ed t h e fu el t a n k t o a ccess t h e fu el pr essu r e r egu la t or.
a wa y fr om con t a ct wit h ot h er veh icle com pon en t s Refer t o t h e F u el P u m p Modu le r em ova l in t h is sec-
t h a t cou ld r u b a ga in st t h em a n d ca u se fa ilu r e. Avoid t ion .
con t a ct wit h cla m ps or ot h er com pon en t s t h a t ca u se
FU EL PRESSU RE REGU LAT OR (Cont inue d)
(1) Ligh t ly lu br ica t e t h e O-r in gs wit h clea n en gin e
oil a n d pla ce t h em in t o open in g in pu m p m odu le (F ig.
9).
(2) P u sh r egu la t or in t o open in g in pu m p m odu le.
(3) Ret a in in g t a bs sn a p in t o h ou sin g.
Fig. 10 LEVEL SENSOR - FOLD-IN-FLOOR

2 - FUEL PUMP MODULE
3 - PRESSURE REGULATOR
Fig. 9 Fuel Pressure Regulator O-rings 4 - FUEL LEVEL SENDER
1 - UPPER O-RING
2 - LOWER 0-RING
FU EL PU M P
DESCRIPTION
Th e elect r ic fu el pu m p is loca t ed in a n d is pa r t of
t h e fu el pu m p m odu le. It is a posit ive displa cem en t ,
ger ot or t ype, im m er sible pu m p wit h a per m a n en t
m a gn et elect r ic m ot or. Th e fu el pu m p m odu le is su s-
pen ded in fu el in t h e fu el t a n k.
OPERATION
Th e pu m p dr a ws fu el t h r ou gh a st r a in er a n d
pu sh es it t h r ou gh t h e m ot or t o t h e ou t let . Th e pu m p
con t a in s a ch eck va lve. Th e va lve, in t h e pu m p ou t -
let , m a in t a in s pu m p pr essu r e du r in g en gin e off con -
dit ion s, for a sh or t wh ile. It is n or m a l for fu el
pr essu r e t o dr op t o zer o a ft er cooldown . Th e fu el
pu m p r ela y pr ovides volt a ge t o t h e fu el pu m p. Th e
fu el pu m p h a s a m a xim u m dea dh ea ded pr essu r e ou t - Fig. 11 REGULATOR AND WIRING - FOLD-IN-FLOOR
pu t of a ppr oxim a t ely 880 kP a (130 psi). Th e r egu la - 2 - FUEL RESERVOIR
t or a dju st s fu el syst em pr essu r e t o a ppr oxim a t ely 3 - PRESSURE REGULATOR
6 - GROUND STRAPS
400 kpa ±34 kpa (58 psi ± 5 psi).
Th e fu el pu m p m odu le con t a in s t h e followin g:
• E lect r ic fu el pu m p
FU EL PU M P M ODU LE • F u el pu m p r eser voir
• In let st r a in er
DESCRIPTION • F u el pr essu r e r egu la t or
Th e fu el pu m p m odu le is in st a lled in t h e t op of t h e • F u el ga u ge sen din g u n it
fu el t a n k (F ig. 10), (F ig. 11), a n d (F ig. 12).
FU EL PU M P M ODU LE (Cont inue d)
ELECTRICAL PUMP REPLACEMENT
Th e elect r ic fu el pu m p is n ot ser vicea ble. If t h e
fu el pu m p or elect r ica l wir in g h a r n ess n eeds r epla ce-
m en t , t h e com plet e fu el pu m p m odu le m u st be
r epla ced. P er for m t h e F u el Syst em P r essu r e Relea se
pr ocedu r e befor e ser vicin g t h e fu el pu m p.
REM OVAL
REMOVAL
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING FUEL SYSTEM COMPONENTS.
SERVICE VEHICLES IN WELL VENTILATED AREAS
AND AVOID IGNITION SOURCES. NEVER SMOKE
WHILE SERVICING THE VEHICLE.
(1) Rem ove fu el filler ca p a n d per for m F u el Sys-

Fig. 12 FUEL PUMP MODULE — NON FOLD-IN- t em P r essu r e Relea se pr ocedu r e.
FLOOR (2) Discon n ect n ega t ive ca ble fr om a u xilia r y
ju m per t er m in a l.
1 - INLET STRAINER
2 - FUEL RESERVOIR (3) Dr a in fu el t a n k, r efer t o t h e F u el Ta n k pr oce-
3 - FUEL PRESSURE REGULATOR du r e in t h e F u el Deliver y sect ion .
4 - FUEL LEVEL SENSOR (4) Rem ove fu el t a n k, r efer t o t h e F u el Ta n k
5 - FILTER
6 - GROUND STRAPS r em ova l sect ion .
(5) Clea n t op of t a n k t o r em ove loose dir t a n d
• F u el su pply lin e con n ect ion debr is.
Th e in le t s tra in e r, fu e l p re s s u re re g u la to r (6) Usin g a br a ss pu n ch a n d h a m m er r em ove lock-
a n d fu e l le v e l s e n s o r a re th e o n ly s e rv ic e a ble n u t t o r elea se pu m p m odu le (F ig. 13).
ite m s . If th e fu e l p u m p o r e le c tric a l w irin g h a r-
n e s s re qu ire s s e rv ic e , re p la c e th e fu e l p u m p
m o d u le .
Th e elect r ic fu el pu m p is loca t ed in a n d is pa r t of
t h e fu el pu m p m odu le. It is a posit ive displa cem en t ,
ger ot or t ype, im m er sible pu m p wit h a per m a n en t
m a gn et elect r ic m ot or.
OPERATION
Th e pu m p dr a ws fu el t h r ou gh a st r a in er a n d
pu sh es it t h r ou gh t h e m ot or t o t h e ou t let . Th e pu m p
con t a in s on e ch eck va lve. Th e ch eck va lve, in t h e
pu m p ou t let , m a in t a in s pu m p pr essu r e du r in g en gin e
off con dit ion s. Th e fu el pu m p r ela y pr ovides volt a ge
t o t h e fu el pu m p.
Th e fu el pu m p h a s a m a xim u m dea dh ea ded pr es-
su r e ou t pu t of a ppr oxim a t ely 880 kP a (130 psi). Th e
r egu la t or a dju st s fu el syst em pr essu r e t o a ppr oxi-
m a t ely 400 ±34 kP a (58 ±5 psi).
FUEL PUMP ELECTRICAL CONTROL

Volt a ge t o oper a t e t h e elect r ic pu m p is su pplied
t h r ou gh t h e fu el pu m p r ela y. F or a n elect r ica l oper a - Fig. 13 FUEL PUMP MODULE LOCKING RING
t ion a l descr ipt ion of t h e fu el pu m p r efer t o fu el P u m p
Rela y—P CM Ou t pu t .
FU EL PU M P M ODU LE (Cont inue d)
WARNING: THE FUEL RESERVOIR OF THE FUEL
PUMP MODULE DOES NOT EMPTY OUT WHEN THE
TANK IS DRAINED. THE FUEL IN THE RESERVOIR
MAY SPILL OUT WHEN THE MODULE IS REMOVED.
(7) Rem ove fu el pu m p m odu le a n d O-r in g fr om

t a n k (F ig. 14). Disca r d O-r in g.
Fig. 15 MODULE LOCK RING NSE

I N STALLAT I ON
INSTALLATION
NOTE: Be careful not to allow dirt/debris to fall into
the fuel tank.
Fig. 14 Fuel Pump Module Removal (1) Wipe sea l a r ea of t a n k clea n a n d pla ce a n ew
1 - FUEL PUMP MODULE O-r in g sea l in posit ion on pu m p.
2 - O-RING (2) P osit ion fu el pu m p m odu le in t a n k.
(3) Tigh t en lockr in g u sin g a br a ss pu n ch a n d h a m -
REMOVAL - FOLD-IN-FLOOR m er t o in st a ll t h e lockr in g (F ig. 13).
(4) In st a ll fu el t a n k, r efer t o t h e F u el Ta n k in st a l-
WARNING: RELEASE FUEL SYSTEM PRESSURE la t ion sect ion .
BEFORE SERVICING FUEL SYSTEM COMPONENTS. (5) Lower veh icle.
SERVICE VEHICLES IN WELL VENTILATED AREAS (6) Con n ect n ega t ive ca ble ba t t er y.
AND AVOID IGNITION SOURCES. NEVER SMOKE (7) F ill fu el t a n k. Use t h e DRB III! sca n t ool t o
WHILE SERVICING THE VEHICLE. pr essu r ize t h e fu el syst em . Ch eck for lea ks.
(8) In st a ll fu el filler ca p.
(1) Rem ove fu el filler ca p a n d per for m F u el Sys-
t em P r essu r e Relea se pr ocedu r e.
(2) Discon n ect n ega t ive ca ble.
INSTALLATION - FOLD-IN-FLOOR
(3) Dr a in fu el t a n k, r efer t o t h e F u el Ta n k pr oce-
NOTE: Be careful not to allow dirt/debris to fall into
du r e in t h e F u el Deliver y sect ion .
the fuel tank.
(4) Rem ove fu el t a n k, r efer t o t h e F u el Ta n k
r em ova l sect ion . (1) Wipe sea l a r ea of t a n k clea n a n d pla ce a n ew
(5) Use t ool #9340 t o r em ove t h e fu el pu m p m od- O-r in g sea l in posit ion on pu m p.
u le lock r in g (F ig. 15). (2) P osit ion fu el pu m p m odu le in t a n k.
(3) Tigh t en lockr in g u sin g specia l t ool #9340 t o
WARNING: THE FUEL RESERVOIR OF THE FUEL
in st a ll t h e lockr in g (F ig. 15).
PUMP MODULE DOES NOT EMPTY OUT WHEN THE
(4) In st a ll fu el t a n k, r efer t o t h e F u el Ta n k in st a l-
TANK IS DRAINED. THE FUEL IN THE RESERVOIR
la t ion sect ion .
MAY SPILL OUT WHEN THE MODULE IS REMOVED.
(5) Lower veh icle.
(6) Rem ove fu el pu m p m odu le a n d O-r in g fr om (6) Con n ect n ega t ive ca ble ba t t er y.
t a n k. Disca r d O-r in g. (7) F ill fu el t a n k. Use t h e DRB III! sca n t ool t o
pr essu r ize t h e fu el syst em . Ch eck for lea ks.
(8) In st a ll fu el filler ca p.
FU EL RAI L (4) Cover in t a ke m a n ifold wit h su it a ble cover

wh en ser vicin g.
(5) Rem ove t h e fu el h ose qu ick con n ect fit t in g fr om
REM OVAL t h e ch a ssis t u be. Re fe r to F u e l Ho s e s , Cla m p s
a n d Qu ic k Co n n e c t F ittin g s in th is S e c tio n .
REMOVAL - 2.4L
WARNING: WRAP A SHOP TOWEL AROUND HOSES
(1) P er for m fu el syst em pr essu r e r elea se pr ocedu r e
TO CATCH ANY GASOLINE SPILLAGE.
be fo re s e rv ic in g o r s ta rtin g re p a irs . Refer t o
F u el Syst em P r essu r e Relea se P r ocedu r e in t h is sec- (6) Rem ove t h e fu el r a il a t t a ch in g bolt s (F ig. 17).
t ion .
(3) Discon n ect t h e wir in g con n ect or s for fu el in jec-
t or s h a r n ess (F ig. 16).
Fig. 16 FUEL RAIL AND INJECTORS 2.4L

1 - Fuel Injectors
2 - Fuel Rail
Fig. 17 FUEL INJECTORS 3.3/3.8L
(4) Rem ove wir in g h a r n ess fr om br a cket s. (7) Rem ove fu el r a il. Be ca r efu l n ot t o da m a ge t h e
(5) Discon n ect t h e con n ect or s fr om t h e fu el in jec- in ject or O-r in gs u pon r em ova l fr om t h eir por t s.
t or s.
(6) Rem ove h a r n ess fr om veh icle.
(7) Rem ove fu el h ose qu ick con n ect fit t in g fr om t h e I N STALLAT I ON
ch a ssis t u be. Re fe r to F u e l Ho s e s , Cla m p s a n d
Qu ic k Co n n e c t F ittin g s in th is S e c tio n . P la ce a INSTALLATION - 2.4L
sh op t owel u n der t h e con n ect ion s t o a bsor b a n y fu el (1) E n su r e in ject or h oles a r e clea n . Repla ce
spilled fr om t h e fit t in g. O-r in gs if da m a ged.
(2) Lu br ica t e in ject or O-r in gs wit h a dr op of clea n
WARNING: WRAP A SHOP TOWEL AROUND HOSES en gin e oil t o ea se in st a lla t ion .
TO CATCH ANY GASOLINE SPILLAGE. (3) P u t t h e t ip of ea ch in ject or in t o t h eir por t s.
P u sh t h e a ssem bly in t o pla ce u n t il t h e in ject or s a r e
(8) Rem ove fu el r a il a t t a ch in g bolt s. sea t ed in t h e por t s.
(9) Rem ove fu el r a il. Be ca r efu l n ot t o da m a ge t h e (4) In st a ll t h e fu el r a il m ou n t in g bolt s. Tigh t en
in ject or O-r in gs u pon r em ova l fr om t h eir por t s. bolt s t o 22 N·m (200 in . lbs.) t or qu e.
(5) Con n ect t h e con n ect or s t o t h e fu el in ject or s.
REMOVAL - 3.3/3.8L (6) In st a ll wir in g h a r n ess t o br a cket s.
(1) P er for m fu el syst em pr essu r e r elea se pr ocedu r e (7) Con n ect t h e wir in g con n ect or s t o fu el in ject or s
be fo re s e rv ic in g o r s ta rtin g re p a irs . Refer t o h a r n ess (F ig. 16).
F u el Syst em P r essu r e Relea se P r ocedu r e in t h is sec- (8) Con n ect n ega t ive ba t t er y ca ble.
t ion . (9) Use t h e DRBIII! sca n t ool t o pr essu r ize t h e
(2) Discon n ect n ega t ive ca ble fr om ba t t er y. fu el syst em . Ch eck for lea ks.
(3) Rem ove u pper in t a ke m a n ifold, r efer t o t h e
E n gin e/Ma n ifolds/Upper In t a ke for m or e in for m a -
t ion ..
FU EL RAI L (Cont inue d)
INSTALLATION - 3.3/3.8L t o bein g dr a wn in t o t h e in t a ke m a n ifold). All m odels

(1) E n su r e in ject or h oles a r e clea n . Repla ce a r e equ ipped wit h a self-dia gn osin g syst em u sin g a
O-r in gs if da m a ged. Lea k Det ect ion P u m p (LDP ) or Na t u r a l Va cu u m
(2) Lu br ica t e in ject or O-r in gs wit h a dr op of clea n Lea k Det ect ion (NVLD). Refer t o t h e E m ission Con -
en gin e oil t o ea se in st a lla t ion . t r ol Syst em for a ddit ion a l in for m a t ion .
(3) P u t t h e t ip of ea ch in ject or in t o t h eir por t s.
INLET CHECK VALVE
P u sh t h e a ssem bly in t o pla ce u n t il t h e in ject or s a r e
sea t ed in t h e por t s. All veh icles h a ve a n in let ch eck va lve on t h e in side
(4) In st a ll t h e fu el r a il m ou n t in g bolt s. Tigh t en of t h e fu el t a n k a t t h e filler in let
bolt s t o 22 N·m (200 in . lbs.) t or qu e. Th e va lve pr even t s fu el fr om spla sh in g ba ck on
(5) Rem ove cover in g on lower in t a ke m a n ifold a n d cu st om er du r in g veh icle r efu elin g. Th e va lve is a
clea n su r fa ce. n on -ser vicea ble it em .
(6) In st a ll t h e Upper In t a ke Ma n ifold, r efer t o
E n gin e/Ma n ifolds/Upper In t a ke for m or e in for m a t ion . REM OVAL
(7) In st a ll fu el h ose qu ick con n ect or fit t in g t o ch a s-
sis t u bes. Re fe r to F u e l Ho s e s , Cla m p s a n d
Qu ic k Co n n e c t F ittin g s in th is S e c tio n . P u sh t h e
REMOVAL
fit t in g on t o t h e ch a ssis t u be u n t il it clicks in t o pla ce.
P u ll on t h e fit t in g t o en su r e com plet e in ser t ion .
(9) Use t h e DRBIII! sca n t ool t o pr essu r ize t h e
fu el syst em . Ch eck for lea ks.
FU EL TAN K
DESCRIPTION
Th e fu el t a n k is con st r u ct ed of a pla st ic m a t er ia l.
It s m a in fu n ct ion s a r e for fu el st or a ge a n d for pla ce-
m en t of t h e fu el pu m p m odu le. Th e t a n k is m a de
fr om H igh den sit y P olyet h ylen e (H DP E ) m a t er ia l.If
equ ipped wit h ORVR (On boa r d Refu elin g Va por
Recover y) it h a s been a dded t o t h e fu el t a n k t o con -
t r ol r efu elin g va por em ission s.
OPERATION
All m odels pa ss a fu ll 360 degr ee r ollover t est Fig. 18 Fuel Tank
wit h ou t fu el lea ka ge. To a ccom plish t h is, fu el a n d 1 - ROLLOVER VALVE
2 - FUEL FILLER INLET
va por flow con t r ols a r e r equ ir ed for a ll fu el t a n k con - 3 - ROLLOVER VALVE
n ect ion s. 4 - FUEL PUMP MODULE
All m odels a r e equ ipped wit h eit h er on e or t wo
ch eck va lves m ou n t ed in t o t h e t op of t h e fu el t a n k (or (1) Rem ove fu el filler ca p a n d per for m F u el Sys-
pu m p m odu le). t em P r essu r e Relea se pr ocedu r e (F ig. 18).
An eva por a t ion con t r ol syst em is con n ect ed t o t h e (2) Discon n ect n ega t ive ca ble fr om ba t t er y.
ch eck va lve(s)/con t r ol va lve(Refer t o 25 - E MIS- (3) In ser t fu el siph on h ose in t o fu el filler n eck a n d
SIONS CONTROL/E VAP ORATIVE E MISSIONS/ pu sh it in t o t h e t a n k.
ORVR - OP E RATION) t o r edu ce em ission s of fu el (4) Dr a in fu el t a n k dr y in t o h oldin g t a n k or a
va por s in t o t h e a t m osph er e, wh en t h e t a n k is ven t ed pr oper ly la beled GAS OLIN E sa fet y con t a in er.
du e t o va por expa n sion in t h e t a n k. Wh en fu el eva p- (5) Ra ise veh icle on h oist a n d su ppor t .
or a t es fr om t h e fu el t a n k, va por s pa ss t h r ou gh ven t (6) Use a t r a n sm ission ja ck t o su ppor t fu el t a n k.
h oses or t u bes t o a ch a r coa l ca n ist er wh er e t h ey a r e Rem ove bolt s fr om fu el t a n k st r a ps.
t em por a r ily h eld. Wh en t h e en gin e is r u n n in g, t h e (7) Lower t a n k sligh t ly.
va por s a r e dr a wn in t o t h e in t a ke m a n ifold. In a ddi- (8) Discon n ect t h e fu el filler ven t t u be. Squ eeze
t ion , fu el va por s pr odu ced du r in g veh icle r efu elin g t a bs a n d pu ll a pa r t (F ig. 19).
a r e a llowed t o pa ss t h r ou gh t h e ven t h oses/t u bes t o
t h e ch a r coa l ca n ist er (s) for t em por a r y st or a ge (pr ior
FU EL TAN K (Cont inue d)
(13) Lower t a n k fr om veh icle. Rem ove fu el filler
ven t t u be fr om fr a m e (F ig. 21).
Fig. 19 FUEL FILLER AND VENT TUBE

1 - Filler Tube
2 - Vent Tube
Fig. 21 VENT HOSE
(9) Discon n ect t h e fu el fill h ose a t t h e fu el t a n k REMOVAL - FOLD-IN-FLOOR
filler m et a l t u be N OT AT THE F U EL TAN K (F ig. (1) Rem ove fu el filler ca p a n d per for m F u el Sys-
19). t em P r essu r e Relea se pr ocedu r e.
(10) Discon n ect fu el lin e a n d va por lin e a t t h e (2) Discon n ect n ega t ive ca ble fr om ba t t er y.
fr on t of t h e fu el t a n k. (3) Dr a in fu el t a n k dr y in t o h oldin g t a n k or a
Th e fu e l p u m p m o d u le e le c tric a l c o n n e c to r pr oper ly la beled GAS OLIN E sa fet y con t a in er.
h a s a re ta in e r th a t lo c k s it in p la c e . (4) Ra ise veh icle on h oist a n d su ppor t (F ig. 22).
(11) Slide fu el pu m p m odu le elect r ica l con n ect or
lock t o u n lock.
(12) P u sh down on con n ect or r et a in er (F ig. 20) a n d
pu ll con n ect or off m odu le.
Fig. 20 Pump Module Connector Retainer and Lock Fig. 22 FUEL TANK IN VEHICLE
1 - PUSH DOWN ON RETAINER
2 - CONNECTOR LOCK
(5) Use a t r a n sm ission ja ck t o su ppor t fu el t a n k. (7) Discon n ect t h e fu el fill h ose a t t h e fu el t a n k
Rem ove bolt s fr om fu el t a n k st r a ps (F ig. 23). filler m et a l t u be N OT AT THE F U EL TAN K.
(8) Discon n ect fu el lin e a n d va por lin e a t t h e fr on t
of t h e fu el t a n k (F ig. 25), (F ig. 26).
Fig. 23 TRANS JACK

(6) Discon n ect t h e fu el filler ven t t u be. Squ eeze
t a bs a n d pu ll a pa r t (F ig. 24). Fig. 25 FUEL SUPPLY LINE & EVAP LINE
Fig. 24 FILLER TUBE LINE DISCONNECTED Fig. 26 FUEL SUPPLY & EVAP LINE
DISCONNECTED
(9) Th e fu e l p u m p m o d u le e le c tric a l c o n n e c -
to r h a s a re ta in e r th a t lo c k s it in p la c e ..Slide
fu el pu m p m odu le elect r ica l con n ect or lock t o u n lock
(F ig. 27), (F ig. 28).
Fig. 29 FILLER TUBE VENT LINE THRU RAIL

I N STALLAT I ON
INSTALLATION
Fig. 27 ELECTRICAL CONNECTION (1) P osit ion fu el t a n k on t r a n sm ission ja ck. Con -
n ect ch eck va lve h ose. Con n ect fu el filler t u be ven t
h ose t o fu el filler t u be.
(2) F eed filler ven t lin e t h r u fr a m e r a il.
(3) Ra ise t a n k in t o posit ion a n d ca r efu lly wor k fu el
filler m et a l t u be in t o t h e r u bber h ose on fu el t a n k. A
ligh t coa t in g of clea n en gin e oil on t h e t u be en d m a y
be u sed t o a id a ssem bly.
(4) Tigh t en st r a p bolt s t o 54 N·m (40 ft . lbs.)
t or qu e. Tigh t en T st r a p bolt t o 28.2 N·m (250 in .
lbs.). Rem ove t r a n sm ission ja ck.
(5) Tigh t en filler h ose cla m p t o 3.3 N·m (30 in .
lbs.).
CAUTION: Ensure straps are not twisted or bent

before or after tightening strap screws.
(6) Con n ect fu el pu m p/m odu le elect r ica l con n ect or.
P la ce r et a in er in locked posit ion .
(7) Lu br ica t e t h e fu el su pply lin e wit h clea n 30
Fig. 28 ELECTRICAL CONNECTION REMOVED weigh t en gin e oil, in st a ll t h e qu ick con n ect fu el fit -
t in g. Refer t o Tu be/F it t in g Assem bly in t h e F u el
(10) P u sh down on con n ect or r et a in er discon n ect Deliver y sect ion of t h is sect ion .
t h e elect r ica l con n ect or. (8) Con n ect t h e con t r ol va por lin es a t fr on t of
(11) Lower t a n k sligh t ly. t a n k.
(12) Rem ove fu el filler ven t t u be fr om fr a m e (F ig. (9) P u ll-pu ll-pu sh on a ll con n ect ion s t o m a ke su r e
29). of con n ect ion .
(13) Lower t a n k fr om veh icle. (10) F ill fu el t a n k, r epla ce ca p, a n d con n ect ba t -
t er y n ega t ive ca ble.
INSTALLATION - FOLD-IN-FLOOR
(1) Use a t r a n sm ission ja ck t o su ppor t fu el t a n k.
(2) Ra ise t a n k a n d in st a ll fu el filler ven t t u be t h r u
fr a m e (F ig. 29).
(3) Ra ise t a n k.
(4) Con n ect t h e fu el fill h ose a t t h e fu el t a n k filler
m et a l t u be a n d t igh t en cla m p.
CAUTION: Ensure straps are not twisted or bent

before or after tightening strap bolts.
(5) In st a ll bolt s for fu el t a n k st r a ps (F ig. 23).

(6) Tigh t en st r a p bolt s t o 54 N·m (40 ft . lbs.)
t or qu e. Rem ove t r a n sm ission ja ck.
(7) Con n ect t h e fu el filler ven t t u be.
(8) Con n ect fu el lin e a n d va por lin e a t t h e fr on t of
t h e fu el t a n k (F ig. 25), (F ig. 26).
(9) Con n ect t h e elect r ica l con n ect or.
(10) Slide fu el pu m p m odu le elect r ica l con n ect or
lock t o lock (F ig. 27), (F ig. 28).
(12) F ill fu el t a n k, r epla ce ca p, a n d con n ect ba t -
t er y n ega t ive ca ble. Fig. 31 FUEL FILLER TUBE (RS)
(7) F o r RGRem ove t h e ca n ist er fr om filler t u be
(F ig. 33).
FU EL TAN K FI LLER T U BE
REMOVAL
(2) Rem ove t h e 3 scr ews a t t h e filler door.
(3) Ra ise a n d su ppor t veh icle
(4) Rem ove t h e left r ea r t ir e.
(5) Rem ove t h e spla sh sh ield (F ig. 32) or (F ig. 31).
(6) Rem ove t h e m et a l sh ield (F ig. 30).
Fig. 32 FUEL FILLER TUBE AND VENT TUBE (RG)
Fig. 30 FILLER TUBE SHIELD

FU EL TAN K FI LLER T U BE (Cont inue d)
(6) F o r RGIn st a ll t h e ca n ist er fr om filler t u be
(F ig. 33).
(7) In st a ll t h e spla sh sh ield.
(8) In st a ll t h e left r ea r t ir e.
(9) lower veh icle.
I N LET FI LT ER
REMOVAL
(1) Rem ove fu el pu m p m odu le. Refer t o F u el P u m p
Modu le Rem ova l in t h is sect ion .
(2) Usin g a t h in st r a igh t bla de scr ewdr iver, pr y
ba ck t h e lockin g t a bs on fu el pu m p r eser voir a n d
r em ove t h e st r a in er (F ig. 35).
(3) Rem ove st r a in er O-r in g fr om t h e fu el pu m p
r eser voir body.
(4) Rem ove a n y con t a m in a n t s in t h e fu el t a n k by
wa sh in g t h e in side of t h e fu el t a n k.
Fig. 33 FUEL TUBE VENT CANISTER (RG)

(8) F o r RGDiscon n ect t h e ven t a t t h e t op of t h e
filler t u be.
(9) Rem ove t h e gr ou n d st r a p.
(10) Rem ove filler t u be a t t a n k.
INSTALLATION
(1) In st a ll filler t u be t o t a n k (F ig. 32).
(2) In st a ll filler t u be sh ield (F ig. 34).
Fig. 35 Inlet
1 - TABS
2 - INLET STRAINER
INSTALLATION
(1) Lu br ica t e t h e st r a in er O-r in g wit h clea n en gin e
oil.
(2) In ser t st r a in er O-r in g in t o ou t let of st r a in er so
t h a t it sit s even ly on t h e st ep in side t h e ou t let .
(3) P u sh st r a in er on t o t h e in let of t h e fu el pu m p
r eser voir body. Ma ke su r e t h e lockin g t a bs on t h e
r eser voir body lock over t h e lockin g t a n gs on t h e
st r a in er.
(4) In st a ll fu el pu m p m odu le. Refer t o F u el P u m p
Modu le In st a lla t ion in t h is sect ion .
Fig. 34 FILLER TUBE SHIELD
(3) In st a ll t h e gr ou n d st r a p.
(4) F o r RGCon n ect t h e ven t a t t h e t op of t h e filler
t u be.
(5) In st a ll t h e 3 scr ews a t t h e filler door.
QU I CK CON N ECT FI T T I N G
STANDARD PROCEDURE - QUICK-CONNECT
FITTINGS
REMOVAL
Wh en discon n ect in g a qu ick-con n ect fit t in g, t h e
r et a in er will r em a in on t h e fu el t u be n ipple.
WARNING: RELEASE FUEL SYSTEM PRESSURE

BEFORE DISCONNECTING A QUICK-CONNECT FIT-
TINGS. REFER TO THE FUEL PRESSURE RELEASE
PROCEDURE. THIS MAY RESULT IN PERSONAL Fig. 36 Plastic Quick-Connect Fitting/Fuel Tube
INJURY OR DEATH. Connection
1 - WINDOW
(1) P er for m F u el P r essu r e Relea se P r ocedu r e. 2 - TAB (2)
Refer t o t h e F u el P r essu r e Relea se P r ocedu r e in t h is 3 - EAR
4 - SHOULDER (ON TUBE)
sect ion .
(2) Discon n ect n ega t ive ca ble fr om ba t t er y or a u x- (6) Use t h e DRB III! sca n t ool ASD F u el Syst em
ilia r y ju m per t er m in a l. Test t o pr essu r ize t h e fu el syst em . Ch eck for lea ks.
(3) Squ eeze r et a in er t a bs t oget h er a n d pu ll fu el
t u be/qu ick-con n ect fit t in g a ssem bly off of fu el t u be TWO-TAB TYPE FITTING
n ipple. Th e r et a in er will r em a in on fu el t u be. Th is t ype of fit t in g is equ ipped wit h t a bs loca t ed on
bot h sides of t h e fit t in g (F ig. 37). Th ese t a bs a r e su p-
INSTALLATION plied for discon n ect in g t h e qu ick-con n ect fit t in g fr om
com pon en t bein g ser viced.
CAUTION: Make sure that the o-ring in installed in
fitting. Never install a quick-connect fitting without
the retainer being either on the fuel tube or already
in the quick-connect fitting. In either case, ensure
the retainer locks securely into the quick-connect
fitting by firmly push-pulling-push on fuel tube and
fitting to ensure it is secured.
(1) Usin g a clea n lin t fr ee clot h , clea n t h e fu el t u be

n ipple a n d r et a in er.
(2) P r ior t o con n ect in g t h e fit t in g t o t h e fu el t u be,
coa t t h e fu el t u be n ipple wit h clea n en gin e oil.
(3) P u sh t h e qu ick-con n ect fit t in g over t h e fu el
t u be u n t il t h e re ta in e r s e a ts a n d a c lic k is h e a rd .
(4) Th e pla st ic qu ick-con n ect fit t in g h a s win dows
in t h e sides of t h e ca sin g. Wh en t h e fit t in g com -
plet ely a t t a ch es t o t h e fu el t u be, t h e r et a in er lockin g
ea r s a n d t h e fu el t u be sh ou lder a r e visible in t h e Fig. 37 Typical Two-Tab Type Quick-Connect Fitting
win dows. If t h ey a r e n ot visible, t h e r et a in er wa s n ot 1 - TAB(S)
pr oper ly in st a lled (F ig. 36). D o n o t re ly u p o n th e 2 - QUICK-CONNECT FITTING
a u d ible c lic k to c o n firm a s e c u re c o n n e c tio n .
CAUTION: The interior components (O-rings, spac-
(5) Con n ect n ega t ive ca ble t o ba t t er y or a u xilia r y
ers) of this type of quick-connect fitting are not ser-
ju m per t er m in a l.
viced separately, but new plastic retainers are
CAUTION: When using the ASD Fuel System Test, available. Do not attempt to repair damaged fittings
the Auto Shutdown (ASD) Relay remains energized or fuel lines/tubes. If repair is necessary, replace
for several minutes, until the test is stopped, or the complete fuel tube assembly.
until the ignition switch is turned to the Off posi-
tion.
QU I CK CON N ECT FI T T I N G (Cont inue d)
WARNING: THE FUEL SYSTEM IS UNDER A CON- PLASTIC RETAINER RING TYPE FITTING
STANT PRESSURE (EVEN WITH THE ENGINE OFF). Th is t ype of fit t in g ca n be iden t ified by t h e u se of a
BEFORE SERVICING ANY FUEL SYSTEM HOSES, fu ll-r ou n d pla st ic r et a in er r in g (F ig. 38) u su a lly bla ck
FITTINGS OR LINES, THE FUEL SYSTEM PRES- in color.
SURE MUST BE RELEASED. REFER TO THE FUEL
PRESSURE RELEASE PROCEDURE IN THIS
GROUP. THIS MAY RESULT IN PERSONAL INJURY
OR DEATH.
DISCONNECTION/CONNECTION
(1) P er for m fu el pr essu r e r elea se pr ocedu r e. Refer
t o F u el P r essu r e Relea se P r ocedu r e in t h is gr ou p.
(2) Discon n ect n ega t ive ba t t er y ca ble fr om ba t t er y
or a u xilia r y ju m per t er m in a l.
(3) Clea n fit t in g of a n y for eign m a t er ia l befor e dis-
a ssem bly.
(4) To discon n ect qu ick-con n ect fit t in g, squ eeze
pla st ic r et a in er t a bs (F ig. 37) a ga in st sides of qu ick-
con n ect fit t in g wit h you r fin ger s. Tool u se is n ot
r equ ir ed for r em ova l a n d m a y da m a ge pla st ic
r et a in er. P u ll fit t in g fr om fu el syst em com pon en t
bein g ser viced. Th e pla st ic r et a in er will r em a in on
com pon en t bein g ser viced a ft er fit t in g is discon -
n ect ed. Th e O-r in gs a n d spa cer will r em a in in qu ick-
con n ect fit t in g con n ect or body.
(5) In spect qu ick-con n ect fit t in g body a n d com po-
n en t for da m a ge. Repla ce a s n ecessa r y. Fig. 38 Plastic Retainer Ring Type Fitting
1 - FUEL TUBE
CAUTION: When the quick-connect fitting was dis- 2 - QUICK CONNECT FITTING
3 - PUSH
connected, the plastic retainer will remain on the 4 - PLASTIC RETAINER
component being serviced. If this retainer must be 5 - PUSH
removed, very carefully release the retainer from 6 - PUSH
7 - PUSH
the component with two small screwdrivers. After 8 - PUSH
removal, inspect the retainer for cracks or any dam-
age. CAUTION: The interior components (O-rings, spac-
ers, retainers) of this type of quick-connect fitting
(6) P r ior t o con n ect in g qu ick-con n ect fit t in g t o are not serviced separately. Do not attempt to repair
com pon en t bein g ser viced, ch eck con dit ion of fit t in g damaged fittings or fuel lines/tubes. If repair is nec-
a n d com pon en t . Clea n pa r t s wit h a lin t -fr ee clot h . essary, replace the complete fuel tube assembly.
Lu br ica t e wit h clea n en gin e oil.
(7) In ser t qu ick-con n ect fit t in g t o com pon en t bein g
ser viced a n d in t o pla st ic r et a in er. Wh en a con n ect ion WARNING: THE FUEL SYSTEM IS UNDER A CON-
is m a de, a click will be h ea r d. STANT PRESSURE (EVEN WITH THE ENGINE OFF).
(8) Ver ify a locked con dit ion by fir m ly pu sh -pu ll- BEFORE SERVICING ANY FUEL SYSTEM HOSES,
in g-pu sh on fu el t u be a n d fit t in g (15-30 lbs.). FITTINGS OR LINES, THE FUEL SYSTEM PRES-
(9) Con n ect n ega t ive ca ble t o ba t t er y or a u xilia r y SURE MUST BE RELEASED. REFER TO THE FUEL
ju m per t er m in a l. SYSTEM PRESSURE RELEASE PROCEDURE IN
(10) Use t h e DRB III! sca n t ool ASD F u el Syst em THIS GROUP. THIS MAY RESULT IN PERSONAL
Test t o pr essu r ize t h e fu el syst em . Ch eck for lea ks. INJURY OR DEATH.
QU I CK CON N ECT FI T T I N G (Cont inue d)
DISCONNECTION/CONNECTION (5) Aft er discon n ect ion , pla st ic r et a in er r in g will
(1) P er for m fu el pr essu r e r elea se pr ocedu r e. Refer r em a in wit h qu ick-con n ect fit t in g con n ect or body.
t o F u el P r essu r e Relea se P r ocedu r e in t h is sect ion . (6) In spect fit t in g con n ect or body, pla st ic r et a in er
(2) Discon n ect n ega t ive ba t t er y ca ble fr om ba t t er y r in g a n d fu el syst em com pon en t for da m a ge. Repla ce
or a u xilia r y ju m per t er m in a l. a s n ecessa r y.
(3) Clea n fit t in g of a n y for eign m a t er ia l befor e dis- (7) P r ior t o con n ect in g qu ick-con n ect fit t in g t o
a ssem bly. com pon en t bein g ser viced, ch eck con dit ion of fit t in g
(4) To r elea se fu el syst em com pon en t fr om qu ick- a n d com pon en t . Clea n pa r t s wit h a lin t -fr ee clot h .
con n ect fit t in g, fir m ly pu sh fit t in g t owa r ds com po- Lu br ica t e wit h clea n en gin e oil.
n en t bein g ser viced wh ile fir m ly pu sh in g pla st ic (8) In ser t qu ick-con n ect fit t in g in t o com pon en t
r et a in er r in g in t o fit t in g (F ig. 38). Wit h pla st ic r in g bein g ser viced u n t il a click is felt .
depr essed, pu ll fit t in g fr om com pon en t . Th e p la s tic (9) Ver ify a locked con dit ion by fir m ly pu sh -pu ll-
re ta in e r rin g m u s t be p re s s e d s qu a re ly in to fit- in g-pu sh on fu el t u be a n d fit t in g (15-30 lbs.).
tin g bo d y. If th is re ta in e r is c o c k e d d u rin g (10) Con n ect n ega t ive ba t t er y ca ble t o ba t t er y or
re m o v a l, it m a y be d iffic u lt to d is c o n n e c t fit- a u xilia r y ju m per t er m in a l.
tin g . U s e a n o p e n -e n d w re n c h o n s h o u ld e r o f (11) Use t h e DRB III! sca n t ool ASD F u el Syst em
p la s tic re ta in e r rin g to a id in d is c o n n e c tio n . Test t o pr essu r ize t h e fu el syst em . Ch eck for lea ks.
RS FUEL INJECTION 14 - 21
FU EL I N J ECT I ON
TABLE OF CONTENTS
page page
FUEL INJECTION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

OPERATION INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 33
OPERATION - INJECTION SYSTEM . . . . . . . 22 INLET AIR TEMPERATURE SENSOR
OPERATION - MODES OF OPERATION . . . . 22 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 34
FUEL CORRECTION or ADAPTIVE MAP SENSOR
MEMORIES . . . . . . . . . . . . . . . . . . . . . . . . . . 24 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 34
PROGRAMMABLE COMMUNICATIONS OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INTERFACE (PCI) BUS . . . . . . . . . . . . . . . . . 25 REMOVAL
SYSTEM DIAGNOSIS . . . . . . . . . . . . . . . . . . 26 REMOVAL - 2.4L . . . . . . . . . . . . . . . . . . . . . . 35
SPECIFICATIONS REMOVAL - 3.3/3.8L . . . . . . . . . . . . . . . . . . . 35
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 INSTALLATION
SPECIAL TOOLS INSTALLATION - 2.4L ............... . . . 36
FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 INSTALLATION - 3.3/3.8L . . . . . . . . . . . . . . . . 36
ACCELERATOR PEDAL O2 SENSOR
CRANKSHAFT POSITION SENSOR REMOVAL
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 29 REMOVAL - UPSTREAM 1/1 - 2.4L . . . . . . . . 37
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 REMOVAL - UPSTREAM 1/1 - 3.3/3.8L .. . . . 38
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 REMOVAL - DOWNSTREAM 1/2 - 2.4/3.3/
INSTALLATION - 2.4L . . . . . . . . . . . . . . . . . . . . 30 3.8L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
ENGINE SPEED SENSOR INSTALLATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 30 INSTALLATION - UPSTREAM 1/1 - 2.4L . . . . . 38
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 INSTALLATION - UPSTREAM 1/1 - 3.3/3.8L . . 39
FUEL INJECTOR INSTALLATION DOWNSTREAM 2/1 -
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 30 2.4/3.3/3.8L . . . . . . . . . . . . . . . . . . . . . . . . . . 39
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 THROTTLE BODY
REMOVAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 39
REMOVAL - 2.4L . . . . . . . . . . . . . . . . . . . . . . 31 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
REMOVAL - 3.3/3.8L . . . . . . . . . . . . . . . . . . . 31 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
INSTALLATION - 2.4L ............. . . . . . 32 THROTTLE CONTROL CABLE
INSTALLATION - 3.3/3.8L . . . . . . . . . . . . . . . . 32 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
FUEL PUMP RELAY INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 40
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 32 THROTTLE POSITION SENSOR
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 40
IDLE AIR CONTROL MOTOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 33 REMOVAL - 3.3/3.8L . . . . . . . . . . . . . . . . . . . . . 41
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 INSTALLATION - 3.3/3.8L . . . . . . . . . . . . . . . . . 41
14 - 22 FUEL INJECTION RS
FU EL I N J ECT I ON sen sor dia gn ost ics (t h ey a r e ch ecked for sh or t ed con -

dit ion s a t a ll t im es).
Du r in g CLOSE D LOOP m odes t h e P CM m on it or s
OPERAT I ON t h e in pu t s fr om t h e u pst r ea m a n d down st r ea m
h ea t ed oxygen sen sor s. Th e u pst r ea m h ea t ed oxygen
OPERATION - INJECTION SYSTEM sen sor in pu t t ells t h e P CM if t h e ca lcu la t ed in ject or
All en gin es u sed in t h is sect ion h a ve a sequ en t ia l pu lse widt h r esu lt ed in t h e idea l a ir-fu el r a t io of 14.7
Mu lt i-P or t E lect r on ic F u el In ject ion syst em . Th e MP I t o on e. By m on it or in g t h e exh a u st oxygen con t en t
syst em is com pu t er r egu la t ed a n d pr ovides pr ecise t h r ou gh t h e u pst r ea m h ea t ed oxygen sen sor, t h e
a ir /fu el r a t ios for a ll dr ivin g con dit ion s. Th e P ower- P CM ca n fin e t u n e in ject or pu lse widt h . F in e t u n in g
t r a in Con t r ol Modu le (P CM) oper a t es t h e fu el in jec- in ject or pu lse widt h a llows t h e P CM t o a ch ieve opt i-
t ion syst em . m u m fu el econ om y com bin ed wit h low em ission s.
Th e P CM r egu la t es: F or t h e P CM t o en t er CLOSE D LOOP oper a t ion ,
• Ign it ion t im in g t h e followin g m u st occu r :
• Air /fu el r a t io (1) E n gin e coola n t t em per a t u r e m u st be over 35°F.
• E m ission con t r ol devices • If t h e coola n t is over 35°F t h e P CM will wa it 38
• Coolin g fa n secon ds.
• Ch a r gin g syst em • If t h e coola n t is over 50°F t h e P CM will wa it 15
• Idle speed secon ds.
• Veh icle speed con t r ol • If t h e coola n t is over 167°F t h e P CM will wa it 3
Va r iou s sen sor s pr ovide t h e in pu t s n ecessa r y for secon ds.
t h e P CM t o cor r ect ly oper a t e t h ese syst em s. In a ddi- (2) F or ot h er t em per a t u r es t h e P CM will in t er po-
t ion t o t h e sen sor s, va r iou s swit ch es a lso pr ovide la t e t h e cor r ect wa it in g t im e.
in pu t s t o t h e P CM. (3) O2 sen sor m u st r ea d eit h er gr ea t er t h a n 0.745
Th e P CM ca n a da pt it s pr ogr a m m in g t o m eet volt s or less t h a n 0.29 volt .
ch a n gin g oper a t in g con dit ion s. (4) Th e m u lt i-por t fu el in ject ion syst em s h a s t h e
F u el is in ject ed in t o t h e in t a ke por t a bove t h e followin g m odes of oper a t ion :
in t a ke va lve in pr ecise m et er ed a m ou n t s t h r ou gh • Ign it ion swit ch ON (Zer o RP M)
elect r ica lly oper a t ed in ject or s. Th e P CM fir es t h e • E n gin e st a r t -u p
in ject or s in a specific sequ en ce. Un der m ost oper a t - • E n gin e wa r m -u p
in g con dit ion s, t h e P CM m a in t a in s a n a ir fu el r a t io • Cr u ise
of 14.7 pa r t s a ir t o 1 pa r t fu el by con st a n t ly a dju st - • Idle
in g in ject or pu lse widt h . In ject or pu lse widt h is t h e • Acceler a t ion
len gt h of t im e t h e in ject or is open . • Deceler a t ion
Th e P CM a dju st s in ject or pu lse widt h by open in g • Wide Open Th r ot t le
a n d closin g t h e gr ou n d pa t h t o t h e in ject or. E n gin e • Ign it ion swit ch OF F
RP M (speed) a n d m a n ifold a bsolu t e pr essu r e (a ir (5) Th e en gin e st a r t -u p (cr a n k), en gin e wa r m -u p,
den sit y) a r e t h e p rim a ry in pu t s t h a t det er m in e deceler a t ion wit h fu el sh u t off a n d wide open t h r ot t le
in ject or pu lse widt h . m odes a r e OP E N LOOP m odes. Un der m ost oper a t -
in g con dit ion s, t h e a cceler a t ion , deceler a t ion (wit h
OPERATION - MODES OF OPERATION A/C on ), idle a n d cr u ise m odes, w ith th e e n g in e a t
As in pu t sign a ls t o t h e P CM ch a n ge, t h e P CM o p e ra tin g te m p e ra tu re a r e CLOSE D LOOP m odes.
a dju st s it s r espon se t o ou t pu t devices. F or exa m ple,
t h e P CM m u st ca lcu la t e a differ en t in ject or pu lse IGNITION SWITCH ON (ZERO RPM) MODE
widt h a n d ign it ion t im in g for idle t h a n it does for Wh en t h e ign it ion swit ch a ct iva t es t h e fu el in jec-
Wide Open Th r ot t le (WOT). Th er e a r e sever a l differ- t ion syst em , t h e followin g a ct ion s occu r :
en t m odes of oper a t ion t h a t det er m in e h ow t h e P CM • Th e P CM m on it or s t h e en gin e coola n t t em per a -
r espon ds t o t h e va r iou s in pu t sign a ls. t u r e sen sor a n d t h r ot t le posit ion sen sor in pu t . Th e
Th er e a r e t wo differ en t a r ea s of oper a t ion , OP E N P CM det er m in es ba sic fu el in ject or pu lse widt h fr om
LOOP a n d CLOSE D LOOP. t h is in pu t .
Du r in g OP E N LOOP m odes t h e P CM r eceives • Th e P CM det er m in es a t m osph er ic a ir pr essu r e
in pu t sign a ls a n d r espon ds a ccor din g t o pr eset P CM fr om t h e MAP sen sor in pu t t o m odify in ject or pu lse
pr ogr a m m in g. In pu t s fr om t h e u pst r ea m a n d down - widt h .
st r ea m h ea t ed oxygen sen sor s a r e n ot m on it or ed du r- Wh en t h e key is in t h e ON posit ion a n d t h e en gin e
in g OP E N LOOP m odes, except for h ea t ed oxygen is n ot r u n n in g (zer o r pm ), t h e Au t o Sh u t down (ASD)
a n d fu el pu m p r ela ys de-en er gize a ft er a ppr oxim a t ely
FU EL I N J ECT I ON (Cont inue d)
1 secon d. Th er efor e, ba t t er y volt a ge is n ot su pplied t o • Ca m sh a ft posit ion
t h e fu el pu m p, ign it ion coil, fu el in ject or s a n d h ea t ed • Kn ock sen sor
oxygen sen sor s. • Th r ot t le posit ion
• A/C swit ch st a t u s
ENGINE START-UP MODE • Ba t t er y volt a ge
Th is is a n OP E N LOOP m ode. If t h e veh icle is in • Veh icle speed
pa r k or n eu t r a l (a u t om a t ic t r a n sa xles) or t h e clu t ch • Speed con t r ol
peda l is depr essed (m a n u a l t r a n sa xles) t h e ign it ion • O2 sen sor s
swit ch en er gizes t h e st a r t er r ela y wh en t h e en gin e is Th e P CM a dju st s in ject or pu lse widt h a n d con t r ols
n ot r u n n in g. Th e followin g a ct ion s occu r wh en t h e in ject or syn ch r on iza t ion by t u r n in g t h e in dividu a l
st a r t er m ot or is en ga ged. gr ou n d pa t h s t o t h e in ject or s On a n d Off.
• If t h e P CM r eceives t h e ca m sh a ft posit ion sen sor Th e P CM a dju st s ign it ion t im in g a n d en gin e idle
a n d cr a n ksh a ft posit ion sen sor sign a ls, it en er gizes speed. E n gin e idle speed is a dju st ed t h r ou gh t h e idle
t h e Au t o Sh u t down (ASD) r ela y a n d fu el pu m p r ela y. a ir con t r ol m ot or.
If t h e P CM does n ot r eceive bot h sign a ls wit h in
a ppr oxim a t ely on e secon d, it will n ot en er gize t h e CRUISE OR IDLE MODE
ASD r ela y a n d fu el pu m p r ela y. Th e ASD a n d fu el Wh en t h e en gin e is a t oper a t in g t em per a t u r e t h is
pu m p r ela ys su pply ba t t er y volt a ge t o t h e fu el pu m p, is a CLOSE D LOOP m ode. Du r in g cr u isin g or idle
fu el in ject or s, ign it ion coil, (E GR solen oid a n d P CV t h e followin g in pu t s a r e r eceived by t h e P CM:
h ea t er if equ ipped) a n d h ea t ed oxygen sen sor s. • Ma n ifold a bsolu t e pr essu r e
• Th e P CM en er gizes t h e in ject or s (on t h e 69° • Cr a n ksh a ft posit ion (en gin e speed)
degr ee fa llin g edge) for a ca lcu la t ed pu lse widt h u n t il • In let /In t a ke a ir t em per a t u r e
it det er m in es cr a n ksh a ft posit ion fr om t h e ca m sh a ft • E n gin e coola n t t em per a t u r e
posit ion sen sor a n d cr a n ksh a ft posit ion sen sor sig- • Ca m sh a ft posit ion
n a ls. Th e P CM det er m in es cr a n ksh a ft posit ion wit h in • Kn ock sen sor
1 en gin e r evolu t ion . • Th r ot t le posit ion
• Aft er det er m in in g cr a n ksh a ft posit ion , t h e P CM • E xh a u st ga s oxygen con t en t (O2 sen sor s)
begin s en er gizin g t h e in ject or s in sequ en ce. It a dju st s • A/C swit ch st a t u s
in ject or pu lse widt h a n d con t r ols in ject or syn ch r on i- • Ba t t er y volt a ge
za t ion by t u r n in g t h e in dividu a l gr ou n d pa t h s t o t h e • Veh icle speed
in ject or s On a n d Off. Th e P CM a dju st s in ject or pu lse widt h a n d con t r ols
• Wh en t h e en gin e idles wit h in ±64 RP M of it s in ject or syn ch r on iza t ion by t u r n in g t h e in dividu a l
t a r get RP M, t h e P CM com pa r es cu r r en t MAP sen sor gr ou n d pa t h s t o t h e in ject or s On a n d Off.
va lu e wit h t h e a t m osph er ic pr essu r e va lu e r eceived Th e P CM a dju st s en gin e idle speed a n d ign it ion
du r in g t h e Ign it ion Swit ch On (zer o RP M) m ode. t im in g. Th e P CM a dju st s t h e a ir /fu el r a t io a ccor din g
On ce t h e ASD a n d fu el pu m p r ela ys h a ve been t o t h e oxygen con t en t in t h e exh a u st ga s (m ea su r ed
en er gized, t h e P CM det er m in es in ject or pu lse widt h by t h e u pst r ea m a n d down st r ea m h ea t ed oxygen sen -
ba sed on t h e followin g: sor ).
• MAP Th e P CM m on it or s for en gin e m isfir e. Du r in g
• E n gin e RP M a ct ive m isfir e a n d depen din g on t h e sever it y, t h e
• Ba t t er y volt a ge P CM eit h er con t in u ou sly illu m in a t es or fla sh es t h e
• E n gin e coola n t t em per a t u r e m a lfu n ct ion in dica t or la m p (Ch eck E n gin e ligh t on
• In let /In t a ke a ir t em per a t u r e (IAT) in st r u m en t pa n el). Also, t h e P CM st or es a n en gin e
• Th r ot t le posit ion m isfir e DTC in m em or y, if 2n d t r ip wit h fa u lt .
• Th e n u m ber of en gin e r evolu t ion s sin ce cr a n kin g Th e P CM per for m s sever a l dia gn ost ic r ou t in es.
wa s in it ia t ed Th ey in clu de:
Du r in g St a r t -u p t h e P CM m a in t a in s ign it ion t im - • Oxygen sen sor m on it or
in g a t 9° BTDC. • Down st r ea m h ea t ed oxygen sen sor dia gn ost ics
du r in g open loop oper a t ion (except for sh or t ed)
ENGINE WARM-UP MODE • F u el syst em m on it or
Th is is a n OP E N LOOP m ode. Th e followin g in pu t s • E GR m on it or (if equ ipped)
a r e r eceived by t h e P CM: • P u r ge syst em m on it or
• Ma n ifold Absolu t e P r essu r e (MAP ) • Ca t a lyst efficien cy m on it or
• Cr a n ksh a ft posit ion (en gin e speed) • All in pu t s m on it or ed for pr oper volt a ge r a n ge,
• E n gin e coola n t t em per a t u r e r a t ion a lit y.
• In let /In t a ke a ir t em per a t u r e (IAT)
• All m on it or ed com pon en t s (r efer t o t h e E m ission WIDE-OPEN-THROTTLE MODE
sect ion for On -Boa r d Dia gn ost ics). Th is is a n OP E N LOOP m ode. Du r in g wide-open -
Th e P CM com pa r es t h e u pst r ea m a n d down st r ea m t h r ot t le oper a t ion , t h e followin g in pu t s a r e u sed by
h ea t ed oxygen sen sor in pu t s t o m ea su r e ca t a lyt ic t h e P CM:
con ver t or efficien cy. If t h e ca t a lyst efficien cy dr ops • In let /In t a ke a ir t em per a t u r e
below t h e m in im u m a ccept a ble per cen t a ge, t h e P CM • E n gin e coola n t t em per a t u r e
st or es a dia gn ost ic t r ou ble code in m em or y, a ft er 2 • E n gin e speed
t r ips. • Kn ock sen sor
Du r in g cer t a in idle con dit ion s, t h e P CM m a y en t er • Ma n ifold a bsolu t e pr essu r e
a va r ia ble idle speed st r a t egy. Du r in g va r ia ble idle • Th r ot t le posit ion
speed st r a t egy t h e P CM a dju st s en gin e speed ba sed Wh en t h e P CM sen ses a wide-open -t h r ot t le con di-
on t h e followin g in pu t s. t ion t h r ou gh t h e Th r ot t le P osit ion Sen sor (TP S) it de-
• A/C st a t u s en er gizes t h e A/C com pr essor clu t ch r ela y. Th is
• Ba t t er y volt a ge disa bles t h e a ir con dit ion in g syst em a n d disa bles
• Ba t t er y t em per a t u r e or Ca lcu la t ed Ba t t er y Tem - E GR (if equ ipped).
per a t u r e Th e P CM a dju st s in ject or pu lse widt h t o su pply a
• E n gin e coola n t t em per a t u r e pr edet er m in ed a m ou n t of a ddit ion a l fu el, ba sed on
• E n gin e r u n t im e MAP a n d RP M.
• In let /In t a ke a ir t em per a t u r e
• Veh icle m ilea ge IGNITION SWITCH OFF MODE
Wh en t h e oper a t or t u r n s t h e ign it ion swit ch t o t h e
ACCELERATION MODE OF F posit ion , t h e followin g occu r s:
Th is is a CLOSE D LOOP m ode. Th e P CM r ecog- • All ou t pu t s a r e t u r n ed off, u n less 02 H ea t er
n izes a n a br u pt in cr ea se in Th r ot t le P osit ion sen sor Mon it or t est is bein g r u n . Refer t o t h e E m ission sec-
ou t pu t volt a ge or MAP sen sor ou t pu t volt a ge a s a t ion for On -Boa r d Dia gn ost ics.
dem a n d for in cr ea sed en gin e ou t pu t a n d veh icle • No in pu t s a r e m on it or ed except for t h e h ea t ed
a cceler a t ion . Th e P CM in cr ea ses in ject or pu lse widt h oxygen sen sor s. Th e P CM m on it or s t h e h ea t in g ele-
in r espon se t o in cr ea sed fu el dem a n d. m en t s in t h e oxygen sen sor s a n d t h en sh u t s down .
• Wide Open Th r ot t le-open loop
FUEL CORRECTION or ADAPTIVE MEMORIES
DECELERATION MODE
Th is is a CLOSE D LOOP m ode. Du r in g deceler a - DESCRIPTION
t ion t h e followin g in pu t s a r e r eceived by t h e P CM: In Open Loop, t h e P CM ch a n ges pu lse widt h wit h -
• A/C st a t u s ou t feedba ck fr om t h e O2 Sen sor s. On ce t h e en gin e
• Ba t t er y volt a ge wa r m s u p t o a ppr oxim a t ely 30 t o 35° F, t h e P CM
• In let /In t a ke a ir t em per a t u r e goes in t o closed loop S h o rt Te rm Co rre c tio n a n d
• E n gin e coola n t t em per a t u r e u t ilizes feedba ck fr om t h e O2 Sen sor s. Closed loop
• Cr a n ksh a ft posit ion (en gin e speed) Lo n g Te rm Ad a p tiv e Me m o ry is m a in t a in ed a bove
• E xh a u st ga s oxygen con t en t (u pst r ea m h ea t ed 170° t o 190° F u n less t h e P CM sen ses wide open
oxygen sen sor ) t h r ot t le. At t h a t t im e t h e P CM r et u r n s t o Open Loop
• Kn ock sen sor oper a t ion .
• Ma n ifold a bsolu t e pr essu r e
• Th r ot t le posit ion sen sor OPERATION
• IAC m ot or (solen oid) con t r ol ch a n ges in r espon se
t o MAP sen sor feedba ck Short Term
Th e P CM m a y r eceive a closed t h r ot t le in pu t fr om Th e fir st fu el cor r ect ion pr ogr a m t h a t begin s fu n c-
t h e Th r ot t le P osit ion Sen sor (TP S) wh en it sen ses a n t ion in g is t h e sh or t t er m fu el cor r ect ion . Th is syst em
a br u pt decr ea se in m a n ifold pr essu r e. Th is in dica t es cor r ect s fu el deliver y in dir ect pr opor t ion t o t h e r ea d-
a h a r d deceler a t ion (Open Loop). In r espon se, t h e in gs fr om t h e Upst r ea m O2 Sen sor.
P CM m a y m om en t a r ily t u r n off t h e in ject or s. Th is Th e P CM m on it or s t h e a ir /fu el r a t io by u sin g t h e
h elps im pr ove fu el econ om y, em ission s a n d en gin e in pu t volt a ge fr om t h e O2 Sen sor. Wh en t h e volt a ge
br a kin g. r ea ch es it s pr eset h igh or low lim it , t h e P CM begin s
t o a dd or r em ove fu el u n t il t h e sen sor r ea ch es it s
swit ch poin t . Th e sh or t t er m cor r ect ion s t h en begin .
Th e P CM m a kes a ser ies of qu ick ch a n ges in t h e
in ject or pu lse-widt h u n t il t h e O2 Sen sor r ea ch es it s
opposit e pr eset lim it or swit ch poin t . Th e pr ocess As t h e en gin e en t er s on e of t h ese cells t h e P CM
t h en r epea t s it self in t h e opposit e dir ect ion . looks a t t h e a m ou n t of sh or t t er m cor r ect ion bein g
Sh or t t er m fu el cor r ect ion will keep in cr ea sin g or u sed. Beca u se t h e goa l is t o keep sh or t t er m a t 0 (O2
decr ea sin g in ject or pu lse-widt h ba sed u pon t h e Sen sor swit ch in g a t 0.5 volt ), lon g t er m will u pda t e
u pst r ea m O2 Sen sor in pu t . Th e m a xim u m r a n ge of in t h e sa m e dir ect ion a s sh or t t er m cor r ect ion wa s
a u t h or it y for sh or t t er m m em or y is 25% (+/-) of ba se m ovin g t o br in g t h e sh or t t er m ba ck t o 0. On ce sh or t
pu lse-widt h . Sh or t t er m is viola t ed a n d is lost wh en t er m is ba ck a t 0, t h is lon g t er m cor r ect ion fa ct or is
ign it ion is t u r n ed OF F. st or ed in m em or y.
Th e va lu es st or ed in lon g t er m a da pt ive m em or y
Long Term a r e u sed for a ll oper a t in g con dit ion s, in clu din g open
Th e secon d fu el cor r ect ion pr ogr a m is t h e lon g loop a n d cold st a r t in g. H owever, t h e u pda t in g of t h e
t er m a da pt ive m em or y. In or der t o m a in t a in cor r ect lon g t er m m em or y occu r s a ft er t h e en gin e h a s
em ission t h r ou gh ou t a ll oper a t in g r a n ges of t h e exceeded a ppr oxim a t ely 170°-190° F, wit h fu el con t r ol
en gin e, a cell st r u ct u r e ba sed on en gin e r pm a n d loa d in closed loop a n d t wo m in u t es of en gin e r u n t im e.
(MAP ) is u sed. Th is is don e t o pr even t a n y t r a n sit ion a l t em per a t u r e
Th er n u m ber of cells va r ies u pon t h e dr ivin g con - or st a r t -u p com pen sa t ion s fr om cor r u pt in g lon g t er m
dit ion s. Two cells a r e u sed on ly du r in g idle, ba sed fu el cor r ect ion .
u pon TP S a n d P a r k/Neu t r a l swit ch in pu t s. Th er e Lon g t er m a da pt ive m em or y ca n ch a n ge t h e pu lse-
m a y be t wo ot h er cells u sed for deceler a t ion , ba sed widt h by a s m u ch a s 25%, wh ich m ea n s it ca n cor r ect
on TP S, en gin e r pm , a n d veh icle speed. Th e ot h er for a ll of sh or t t er m . It is possible t o h a ve a pr oblem
t welve cells r epr esen t a m a n ifold pr essu r e a n d a n t h a t wou ld dr ive lon g t er m t o 25% a n d sh or t t er m t o
r pm r a n ge. Six of t h e cells a r e h igh r pm a n d t h e a n ot h er 25% for a t ot a l ch a n ge of 50% a wa y fr om
ot h er six a r e low r pm . E a ch of t h ese cells h a s a spe- ba se pu lse-widt h ca lcu la t ion .
cific MAP volt a ge r a n ge Typica l Ada pt ive Mem or y
F u el Cells.
TY PI CAL ADAPT I V E M EM ORY FU EL CELLS
Open Open Open Open Open Open

Throttle Throttle Throttle Throttle Throttle Throttle Idle Decel
Vacuum 20 17 13 9 5 0
Above 1,984 1 3 5 7 9 11 13 Drive 15
rpm
Below 1,984 0 2 4 6 8 10 12 14
rpm Neutral
MAP volt = 0 1.4 2.0 2.6 3.3 3.9
Fuel Correction Diagnostics n ect ea ch m odu le a n d t h e Da t a Lin k Con n ect or

(DLC) t oget h er. E a ch m odu le is wir ed in pa r a llel t o
Th er e a r e t wo fu el cor r ect ion dia gn ost ic r ou t in es:
t h e da t a bu s t h r ou gh it s P CI ch ip set a n d u ses it s
• F u el Syst em Rich
gr ou n d a s t h e bu s r efer en ce. Th e wir in g is a m in i-
• F u el Syst em Lea n
m u m 20 ga ge wir e.
A DTC is set a n d t h e MIL is illu m in a t ed if t h e
P CM det ect s eit h er of t h ese con dit ion s. Th is is det er-
OPERATION
m in ed ba sed on t ot a l fu el cor r ect ion , sh or t t er m
Va r iou s m odu les exch a n ge in for m a t ion t h r ou gh a
t im es lon g t er m .
com m u n ica t ion s por t ca lled t h e P CI Bu s. Th e P ower-
t r a in Con t r ol Modu le (P CM) t r a n sm it s t h e Ma lfu n c-
PROGRAMMABLE COMMUNICATIONS t ion In dica t or La m p (Ch eck E n gin e) On /Off sign a l
INTERFACE (PCI) BUS a n d en gin e RP M on t h e P CI Bu s. Th e P CM r eceives
t h e Air Con dit ion in g select in pu t , t r a n sa xle gea r
DESCRIPTION posit ion in pu t s over t h e P CI Bu s. Th e P CM a lso
Th e P r ogr a m m a ble Com m u n ica t ion In t er fa ce Mu l- r eceives t h e a ir con dit ion in g eva por a t or t em per a t u r e
t iplex syst em (P CI Bu s) con sist of a sin gle wir e. Th e sign a l fr om t h e P CI Bu s.
Body Con t r ol Modu le (BCM) a ct s a s a splice t o con -
Th e followin g com pon en t s a ccess or sen d in for m a - SYSTEM DIAGNOSIS
t ion on t h e P CI Bu s.
• In st r u m en t P a n el OPERATION
• Body Con t r ol Modu le Th e P CM ca n t est m a n y of it s own in pu t a n d ou t -
• Air Ba g Syst em Dia gn ost ic Modu le pu t cir cu it s. If t h e P CM sen ses a fa u lt in a m a jor
• F u ll ATC Displa y H ea d (if equ ipped) syst em , t h e P CM st or es a Dia gn ost ic Tr ou ble Code
• ABS Modu le (DTC) in m em or y.
• Tr a n sm ission Con t r ol Modu le F or DTC in for m a t ion see On -Boa r d Dia gn ost ics
• P ower t r a in Con t r ol Modu le (Refer t o 8 - E LE CTRICAL/E LE CTRONIC CON-
• Tr a vel Modu le TROL MODULE S/P OWE RTRAIN CONTROL MOD-
• SKIM ULE - DE SCRIP TION) .
SPECI FI CAT I ON S
TORQUE

MAP SENSOR PLASTIC 1.7 15
MANIFOLD
MAP SENSOR 3.3 30
ALUMINUM MANIFOLD
POWER STEERING 5.7 50
RESERVOIR PLASTIC
MANIFOLD
POWER STEERING 11.9 105
RESERVOIR ALUMINUM
MANIFOLD
THROTTLE CABLE 5.7 50
BRACKET PLASTIC
MANIFOLD
THROTTLE CABLE 11.9 105
BRACKET ALUMINUM
MANIFOLD
EGR TUBE PLASTIC 5.7 50
MANIFOLD
EGR TUBE ALUMINUM 11.9 105
MANIFOLD
THROTTLE BODY BOLTS 28 20.65 250 ±50
2.4L
THROTTLE BODY BOLTS 11.8 8.7 105 ±20
3.3/3.8L
O2 Sensors 27 20
The composite manifolds uses special Plastic screws. The factory installed Plastic screws can be removed and
installed up to 5 times. Do not exceed the specified torque. These screws must be installed slowly (less than 600
rpms) to avoid melting the parent material. There are service repair screws avialable for repair. They require a
higher torque than the original screws..
SPECI AL T OOLS
FUEL
Fuel Line Adapter 1/4
Pressure Gauge Assembly C–4799–B
O2S (Oxygen Sensor) Remover/Installer—C-4907
Fuel Pressure Test Adapter 6539
O2S (Oxygen Sensor) Remover/Installer - 8439
Spanner Wrench 6856
LOCKRING REMOVER/INSTALLER #9340

ACCELERAT OR PEDAL (3) Rem ove n u t s fr om a cceler a t or peda l a t t a ch in g

st u ds. Rem ove a ssem bly fr om veh icle (F ig. 3).
REMOVAL
(1) H old t h e t h r ot t le body t h r ot t le lever in t h e
wide open posit ion . Rem ove t h e t h r ot t le ca ble fr om
t h e t h r ot t le body ca m (F ig. 1).
Fig. 3 ACCELERATOR PEDAL AND THROTTLE

CABLE
1 - Grommet
2 - Cable
3 - Pedal Shaft and Bracket
Fig. 1 THROTTLE CABLE RELEASE 4 - Seal
5 - Dash Panel
(2) F r om in side t h e veh icle, h old u p t h e peda l a n d 6 - Cable Assembly
r em ove t h e ca ble r et a in er a n d t h r ot t le ca ble fr om t h e
u pper en d of t h e peda l lever (F ig. 2). INSTALLATION
(1) P osit ion a cceler a t or peda l a ssem bly on da sh
pa n el. In st a ll r et a in in g n u t s. Tigh t en r et a in in g n u t s
t o 12 N·m (105 in . lbs.) t or qu e (F ig. 3).
(2) F r om in side t h e veh icle, h old u p t h e peda l a n d
in st a ll t h e t h r ot t le ca ble a n d ca ble r et a in er in t h e
u pper en d of t h e peda l lever (F ig. 2).
(3) F r om t h e en gin e com pa r t m en t , h old t h e t h r ot -
t le body lever in t h e wide open posit ion a n d in st a ll
t h e t h r ot t le ca ble (F ig. 1).
Fig. 2 CABLE CLIP AND GROMMET

1 - Retainer Clip
2 - Grommet
3 - Cable Assembly
4 - Cable Retainer
5 - Dash Panel
6 - Grommet
CRAN K SH AFT POSI T I ON OPERATION

Th e cr a n ksh a ft posit ion sen sor det ect s slot s cu t
SEN SOR in t o t h e t r a n sm ission dr ivepla t e ext en sion (F ig. 6).
Th er e a r e 3 set s of slot s. E a ch set con t a in s 4 slot s,
DESCRIPTION for a t ot a l of 12 slot s (F ig. 7). Ba sic t im in g is set by
Th e 2.4L cr a n ksh a ft sen sor is loca t ed on t h e r ea r t h e posit ion of t h e la st slot in ea ch gr ou p. On ce t h e
of t h e en gin e n ea r t h e a ccessor y dr ive belt (F ig. 4). P ower t r a in Con t r ol Modu le (P CM) sen ses t h e la st
Th e 3.3/3.8L cr a n ksh a ft sen sor is loca t ed on t h e r ea r slot , it det er m in es cr a n ksh a ft posit ion (wh ich pist on
of t h e t r a n sm ission h ou sin g, a bove t h e differ en t ia l will n ext be a t TDC) fr om t h e ca m sh a ft posit ion sen -
h ou sin g (F ig. 5). Th e bot t om of t h e sen sor is posi- sor in pu t . Th e 4 pu lses gen er a t ed by t h e cr a n ksh a ft
t ion ed n ext t o t h e dr ive pla t e. posit ion sen sor r epr esen t t h e 69°, 49°, 29°, a n d 9°
BTDC m a r ks. It m a y t a ke t h e P CM on e en gin e r ev-
olu t ion t o det er m in e cr a n ksh a ft posit ion .
Fig. 4 CRANKSHAFT SENSOR 2.4L
Fig. 6 Crankshaft Position Sensor

1 - CRANKSHAFT POSITION SENSOR
Fig. 7 Timing Slots

Fig. 5 CRANKSHAFT SENSOR 3.3/3.8L 1 - TORQUE CONVERTER DRIVE PLATE
2 - SLOTS
CRAN K SH AFT POSI T I ON SEN SOR (Cont inue d)
Th e P CM u ses cr a n ksh a ft posit ion r efer en ce t o INSTALLATION - 2.4L
det er m in e in ject or sequ en ce, ign it ion t im in g a n d t h e (1) In st a ll t h e cr a n ksh a ft sen sor.
pr esen ce of m isfir e. On ce t h e P CM det er m in es cr a n k- (2) In st a ll cr a n ksh a ft sen sor bolt a n d t igh t en .
sh a ft posit ion , it begin s en er gizin g t h e in ject or s in (3) Con n ect t h e elect r ica l con n ect or (F ig. 8).
sequ en ce. (4) Lower veh icle.
REMOVAL
(2) Ra ise veh icle a n d su ppor t . EN GI N E SPEED SEN SOR
(3) Discon n ect t h e elect r ica l con n ect or (F ig. 8).
DESCRIPTION
Th e P CM r eceives a sign a l fr om t h e TCM t o in di-
ca t e veh icle speed on a u t om a t ic t r a n sm ission ca r s.
On 4 cylin der Ma n u a l t r a n sm ission ca r s (if equ ipped)
veh icle, a dedica t ed veh icle speed sen sor is con n ect ed
t o t h e P CM.On V-6 Ma n u a l t r a n sm ission ca r s (if
equ ipped) veh icle, t h e ABS m odu le pr ovides t h e sig-
n a l t o t h e P CM for veh icle speed.
OPERATION
Th e Tr a n sm ission Con t r ol Modu le (TCM) su pplies
t h e r oa d speed a n d dist a n ce t r a veled in pu t s t o t h e
P CM. F r om t h ese in pu t s a n d t h e t h r ot t le posit ion
sen sor in pu t , t h e P CM det er m in es wh en a deceler a -
t ion con dit ion occu r s.
FU EL I N J ECT OR
Fig. 8 CRANKSHAFT SENSOR 2.4L DESCRIPTION

Th e in ject or s a r e posit ion ed in t h e in t a ke m a n ifold
(4) Rem ove cr a n ksh a ft sen sor bolt (F ig. 9). or cylin der h ea d wit h t h e n ozzle en ds dir ect ly a bove
t h e in t a ke va lve por t (F ig. 10).
Fig. 10 Fuel Injector Location - Typical

Fig. 9 CRANKSHAFT POSITION SENSOR LOCATION 1 - FUEL RAIL
2.4L 2 - INTAKE MANIFOLD
3 - FUEL INJECTORS
(5) Rem ove t h e cr a n ksh a ft sen sor.
FU EL I N J ECT OR (Cont inue d)
OPERATION
Th e fu el in ject or s a r e 12 volt elect r ica l solen oids
(F ig. 11). Th e in ject or con t a in s a pin t le t h a t closes off
a n or ifice a t t h e n ozzle en d. Wh en elect r ic cu r r en t is
su pplied t o t h e in ject or, t h e a r m a t u r e a n d n eedle
m ove a sh or t dist a n ce a ga in st a spr in g, a llowin g fu el
t o flow ou t t h e or ifice. Beca u se t h e fu el is u n der h igh
pr essu r e, a fin e spr a y is developed in t h e sh a pe of a
h ollow con e or t wo st r ea m s. Th e spr a yin g a ct ion
a t om izes t h e fu el, a ddin g it t o t h e a ir en t er in g t h e
com bu st ion ch a m ber. F u el in ject or s a r e n ot in t er-
ch a n gea ble bet ween en gin es.
Th e P CM pr ovides ba t t er y volt a ge t o ea ch in ject or
t h r ou gh t h e ASD r ela y. In ject or oper a t ion is con - Fig. 12 FUEL RAIL AND INJECTORS 2.4L
t r olled by a gr ou n d pa t h pr ovided for ea ch in ject or by 1 - Fuel Injectors
t h e P CM. In ject or on -t im e (pu lse-widt h ) is va r ia ble, 2 - Fuel Rail
a n d is det er m in ed by t h e P CM pr ocessin g a ll t h e
da t a pr eviou sly discu ssed t o obt a in t h e opt im u m
in ject or pu lse widt h for ea ch oper a t in g con dit ion . Th e
pu lse widt h is con t r olled by t h e du r a t ion of t h e
gr ou n d pa t h pr ovided.
Fig. 11 FUEL INJECTOR - TYPICAL Fig. 13 FUEL INJECTOR AND RAIL TYPICAL
1 - FUEL INJECTOR 1 - FUEL RAIL ASSEMBLY
2 - NOZZLE 2 - FUEL INJECTOR
3 - TOP (FUEL ENTRY) 3 - FUEL RAIL RECEIVER
REM OVAL pr even t da m a ge. Repla ce t h e in ject or clip if it is da m -

a ged.
REMOVAL - 2.4L (5) Repea t for r em a in in g in ject or s.
Th e fu el r a il m u st be r em oved fir st (F ig. 12). Refer
t o F u el Ra il Rem ova l in t h is sect ion . REMOVAL - 3.3/3.8L
(1) Discon n ect in ject or wir in g con n ect or fr om in jec- (1) Discon n ect t h e n ega t ive ba t t er y ca ble.
t or. (2) Rem ove t h e In t a ke Ma n ifold, (Refer t o 9 -
(2) P osit ion fu el r a il a ssem bly so t h a t t h e fu el E NGINE /MANIF OLDS/INTAKE MANIF OLD -
in ject or s a r e ea sily a ccessible (F ig. 13). RE MOVAL)
(3) Rot a t e in ject or a n d pu ll in ject or ou t of fu el r a il. (3) Discon n ect in ject or wir in g con n ect or fr om in jec-
Th e clip will st a y on t h e in ject or. t or.
(4) Ch eck in ject or O-r in g for da m a ge. If O-r in g is (4) P osit ion fu el r a il a ssem bly so t h a t t h e fu el
da m a ged, it m u st be r epla ced. If in ject or is r eu sed, a in ject or s a r e ea sily a ccessible (F ig. 13).
pr ot ect ive ca p m u st be in st a lled on t h e in ject or t ip t o
FU EL I N J ECT OR (Cont inue d)
(5) Rot a t e in ject or a n d pu ll in ject or ou t of fu el r a il. INSTALLATION - 3.3/3.8L
Th e clip will st a y on t h e in ject or. (1) Befor e in st a llin g a n in ject or t h e r u bber O-r in g
(6) Ch eck in ject or O-r in g for da m a ge. If O-r in g is m u st be lu br ica t ed wit h a dr op of clea n en gin e oil t o
da m a ged, it m u st be r epla ced. If in ject or is r eu sed, a a id in in st a lla t ion .
pr ot ect ive ca p m u st be in st a lled on t h e in ject or t ip t o (2) In st a ll in ject or clip by slidin g open en d in t o t h e
pr even t da m a ge. Repla ce t h e in ject or clip if it is da m - t op slot of t h e in ject or. Th e edge of t h e r eceiver cu p
a ged. will slide in t o t h e side slot s of clip (F ig. 13).
(7) Repea t for r em a in in g in ject or s. (3) In st a ll in ject or t op en d in t o fu el r a il r eceiver
ca p. Be ca r efu l n ot t o da m a ge O-r in g du r in g in st a lla -
t ion (F ig. 13).
I N STALLAT I ON
(4) Repea t st eps for r em a in in g in ject or s.
(5) In st a ll fu el r a il, r efer t o F u el Ra il in t h e F u el
INSTALLATION - 2.4L Deliver y sect ion .
Th e fu el r a il m u st be r em oved fir st . Refer t o F u el
(6) Con n ect fu el in ject or wir in g.
In ject or Ra il Rem ova l in t h is sect ion .
(7) In st a ll t h e In t a ke Ma n ifold, (Refer t o 9 -
(1) Befor e in st a llin g a n in ject or t h e r u bber O-r in g
m u st be lu br ica t ed wit h a dr op of clea n en gin e oil t o
INSTALLATION)
a id in in st a lla t ion .
(2) In st a ll in ject or clip by slidin g open en d in t o t h e
t op slot of t h e in ject or. Th e edge of t h e r eceiver cu p
will slide in t o t h e side slot s of clip. FU EL PU M P RELAY
(3) In st a ll in ject or t op en d in t o fu el r a il r eceiver
ca p. Be ca r efu l n ot t o da m a ge O-r in g du r in g in st a lla - DESCRIPTION
t ion (F ig. 14). Th e fu el pu m p r ela y is loca t ed in t h e P DC. Th e
(4) Repea t st eps for r em a in in g in ject or s. in side t op of t h e P DC cover h a s a la bel sh owin g r ela y
(5) Con n ect fu el in ject or wir in g. a n d fu se loca t ion .
OPERATION
Th e fu el pu m p r ela y su pplies ba t t er y volt a ge t o t h e
fu el pu m p. A bu ss ba r in t h e P ower Dist r ibu t ion Cen -
t er (P DC) su pplies volt a ge t o t h e solen oid side a n d
con t a ct side of t h e r ela y. Th e fu el pu m p r ela y power
cir cu it con t a in s a fu se bet ween t h e bu ss ba r in t h e
P DC a n d t h e r ela y. Th e fu se is loca t ed in t h e P DC.
Refer t o t h e Wir in g Dia gr a m s for cir cu it in for m a t ion .
Th e P CM con t r ols t h e fu el pu m p r ela y by swit ch -
in g t h e gr ou n d pa t h for t h e solen oid side of t h e r ela y
on a n d off. Th e P CM t u r n s t h e gr ou n d pa t h off wh en
t h e ign it ion swit ch is in t h e Off posit ion . Wh en t h e
ign it ion swit ch is in t h e On posit ion , t h e P CM en er-
gizes t h e fu el pu m p. If t h e cr a n ksh a ft posit ion sen sor
does n ot det ect en gin e r ot a t ion , t h e P CM de-en er-
gizes t h e r ela y a ft er a ppr oxim a t ely on e secon d.
Fig. 14 SERVICING FUEL INJECTOR TYPICAL
1 - FUEL INJECTOR
2 - LOCKING SLOT
3 - FUEL RAIL RECEIVER CUP
I DLE AI R CON T ROL M OT OR Th e t h r ot t le body h a s a n a ir bypa ss pa ssa ge t h a t

pr ovides a ir for t h e en gin e du r in g closed t h r ot t le idle.
Th e idle a ir con t r ol va lve r egu la t es a ir flow t h r ou gh
DESCRIPTION
t h e bypa ss pa ssa ge.
Th e idle a ir con t r ol va lve is m ou n t ed on t h e t h r ot -
Th e P CM con t r ols en gin e idle speed by a dju st in g
t le body. Th e P CM oper a t es t h e idle a ir con t r ol va lve
t h e posit ion of t h e idle a ir con t r ol va lve. Th e a dju st -
(F ig. 15) or (F ig. 16).
m en t s a r e ba sed on in pu t s t h e P CM r eceives. Th e
in pu t s a r e fr om t h e t h r ot t le posit ion sen sor, cr a n k-
sh a ft posit ion sen sor, coola n t t em per a t u r e sen sor,
MAP sen sor, veh icle speed sen sor a n d va r iou s swit ch
oper a t ion s (br a ke, pa r k/n eu t r a l, a ir con dit ion in g).
Wh en en gin e r pm is a bove idle speed, t h e IAC is
u sed for t h e followin g fu n ct ion s:
• Off-idle da sh pot
• Deceler a t ion a ir flow con t r ol
• A/C com pr essor loa d con t r ol (a lso open s t h e pa s-
sa ge sligh t ly befor e t h e com pr essor is en ga ged so
t h a t t h e en gin e r pm does n ot dip down wh en t h e
com pr essor en ga ges)
Target Idle
Ta r get idle is det er m in ed by t h e followin g in pu t s:
• Gea r posit ion
• E CT Sen sor
• Ba t t er y volt a ge
• Am bien t /Ba t t er y Tem per a t u r e Sen sor
Fig. 15 TPS/IAC 2.4L • VSS
1 - Idle Air Control Valve • TP S
2 - Throttle Position Sensor • MAP Sen sor
REMOVAL
Wh en ser vicin g t h r ot t le body com pon en t s, a lwa ys
r ea ssem ble com pon en t s wit h n ew O-r in gs a n d sea ls
wh er e a pplica ble. If a ssem bly of com pon en t is diffi-
cu lt , a ligh t coa t of en gin e oil m a y be a pplied t o t h e
O-RINGS ONLY t o a id a ssem bly. Use ca r e wh en
r em ovin g h oses t o pr even t da m a ge t o h ose or h ose
n ipple.
(2) Rem ove elect r ica l con n ect or fr om idle a ir con -
t r ol va lve (F ig. 17).
(3) Rem ove idle a ir con t r ol va lve m ou n t in g scr ew.
(4) Rem ove va lve fr om t h r ot t le body. E n su r e t h e
O-r in gs is r em oved wit h t h e va lve.
INSTALLATION
Wh en ser vicin g t h r ot t le body com pon en t s, a lwa ys
r ea ssem ble com pon en t s wit h n ew O-r in gs a n d sea ls
wh er e a pplica ble. If a ssem bly of com pon en t is diffi-
Fig. 16 TPS/IAC 3.3/3.8L
cu lt , a lig h t c o a t o f e n g in e o il m a y be a p p lie d to
1 - Idle Air Control Valve th e O-RIN GS ON LY (F ig . 18) t o a id a ssem bly. Use
2 - Throttle Position Sensor
ca r e wh en r em ovin g h oses t o pr even t da m a ge t o h ose
or h ose n ipple.
OPERATION
(1) Ca r efu lly pla ce idle a ir con t r ol m ot or in t o
Th e P CM a dju st s en gin e idle speed t h r ou gh t h e
t h r ot t le body.
idle a ir con t r ol va lve t o com pen sa t e for en gin e loa d,
coola n t t em per a t u r e or ba r om et r ic pr essu r e ch a n ges.
I DLE AI R CON T ROL M OT OR (Cont inue d)
Fig. 17 IDLE AIR CONTROL VALVE LOCATION Fig. 19 3.3/3.8L IAT SENSOR
M AP SEN SOR
DESCRIPTION
Th e MAP sen sor (F ig. 20) or (F ig. 21) m ou n t s t o
t h e in t a ke m a n ifold. Th e sen sor is con n ect s elect r i-
ca lly t o t h e P CM.
Fig. 18 O-RINGS
1 - O-rings
(2) In st a ll m ou n t in g scr ew. Tigh t en scr ew t o 7 N·m

(62 in . lbs.) t or qu e.
(3) Con n ect elect r ica l con n ect or t o idle a ir con t r ol
m ot or.
I N LET AI R T EM PERAT U RE
SEN SOR
Fig. 20 MAP SENSOR - 2.4L
DESCRIPTION
Th e IAT Sen sor is a Nega t ive Tem per a t u r e Coeffi- OPERATION
cien t (NTC) Sen sor t h a t pr ovides in for m a t ion t o t h e Th e MAP ser ves a s a P CM in pu t , u sin g a silicon
P CM r ega r din g t h e t em per a t u r e of t h e a ir en t er in g ba sed sen sin g u n it , t o pr ovide da t a on t h e m a n ifold
t h e in t a ke m a n ifold (F ig. 19). va cu u m t h a t dr a ws t h e a ir /fu el m ixt u r e in t o t h e com -
bu st ion ch a m ber. Th e P CM r equ ir es t h is in for m a t ion
t o det er m in e in ject or pu lse widt h a n d spa r k a dva n ce.
Wh en MAP equ a ls Ba r om et r ic pr essu r e, t h e pu lse
widt h will be a t m a xim u m .
M AP SEN SOR (Cont inue d)
As t h e a lt it u de in cr ea ses t h e a ir becom es t h in n er
(less oxygen ). If a veh icle is st a r t ed a n d dr iven t o a
ver y differ en t a lt it u de t h a n wh er e it wa s a t key On
t h e ba r om et r ic pr essu r e n eeds t o be u pda t ed. An y
t im e t h e P CM sees Wide Open t h r ot t le, ba sed u pon
TP S a n gle a n d RP M it will u pda t e ba r om et r ic pr es-
su r e in t h e MAP m em or y cell. Wit h per iodic u pda t es,
t h e P CM ca n m a ke it s ca lcu la t ion s m or e effect ively.
Th e P CM u ses t h e MAP sen sor t o a id in ca lcu la t -
in g t h e followin g:
• Ba r om et r ic pr essu r e
• E n gin e loa d
• Ma n ifold pr essu r e
• In ject or pu lse-widt h
• Spa r k-a dva n ce pr ogr a m s
• Sh ift -poin t st r a t egies (F 4AC1 t r a n sm ission s
on ly, via t h e P CI bu s)
• Idle speed
• Decel fu el sh u t off
Fig. 21 MAP SENSOR - 3.3/3.8L Th e P CM r ecogn izes a decr ea se in m a n ifold pr es-
Also like t h e ca m a n d cr a n k sen sor s, a 5 volt r ef- su r e by m on it or in g a decr ea se in volt a ge fr om t h e
er en ce is su pplied fr om t h e P CM a n d r et u r n s a volt - r ea din g st or ed in t h e ba r om et r ic pr essu r e m em or y
a ge sign a l t o t h e P CM t h a t r eflect s m a n ifold cell. Th e MAP sen sor is a lin ea r sen sor ; a s pr essu r e
pr essu r e. Th e zer o pr essu r e r ea din g is 0.5V a n d fu ll ch a n ges, volt a ge ch a n ges pr opor t ion a t ely. Th e r a n ge
sca le is 4.5V. F or a pr essu r e swin g of 0 — 15 psi t h e of volt a ge ou t pu t fr om t h e sen sor is u su a lly bet ween
volt a ge ch a n ges 4.0V. Th e sen sor is su pplied a r egu - 4.6 volt s a t sea level t o a s low a s 0.3 volt s a t 26 in . of
la t ed 4.8 t o 5.1 volt s t o oper a t e t h e sen sor. Like t h e H g. Ba r om et r ic pr essu r e is t h e pr essu r e exer t ed by
ca m a n d cr a n k sen sor s gr ou n d is pr ovided t h r ou gh t h e a t m osph er e u pon a n object . At sea level on a
t h e sen sor r et u r n cir cu it . st a n da r d da y, n o st or m , ba r om et r ic pr essu r e is 29.92
Th e MAP sen sor in pu t is t h e n u m ber on e con t r ibin H g. F or ever y 100 feet of a lt it u de ba r om et r ic pr es-
u t or t o pu lse widt h . Th e m ost im por t a n t fu n ct ion of su r e dr ops .10 in . H g. If a st or m goes t h r ou gh it ca n
t h e MAP sen sor is t o det er m in e ba r om et r ic pr essu r e. eit h er a dd, h igh pr essu r e, or decr ea se, low pr essu r e,
Th e P CM n eeds t o kn ow if t h e veh icle is a t sea level fr om wh a t sh ou ld be pr esen t for t h a t a lt it u de. You
or is it in Den ver a t 5000 feet a bove sea level, sh ou ld m a ke a h a bit of kn owin g wh a t t h e a ver a ge
beca u se t h e a ir den sit y ch a n ges wit h a lt it u de. It will pr essu r e a n d cor r espon din g ba r om et r ic pr essu r e is
a lso h elp t o cor r ect for va r yin g wea t h er con dit ion s. If for you r a r ea .
a h u r r ica n e wa s com in g t h r ou gh t h e pr essu r e wou ld
be ver y, ver y low or t h er e cou ld be a r ea l fa ir REM OVAL
wea t h er, h igh pr essu r e a r ea . Th is is im por t a n t
beca u se a s a ir pr essu r e ch a n ges t h e ba r om et r ic pr es- REMOVAL - 2.4L
su r e ch a n ges. Ba r om et r ic pr essu r e a n d a lt it u de h a ve
a dir ect in ver se cor r ela t ion , a s a lt it u de goes u p ba r o-
(2) Discon n ect elect r ica l con n ect or a n d va cu u m
m et r ic goes down . Th e fir st t h in g t h a t h a ppen s a s
h ose fr om MAP sen sor (F ig. 20).
t h e key is r olled on , befor e r ea ch in g t h e cr a n k posi-
(3) Rem ove t wo scr ews h oldin g sen sor t o t h e
t ion , t h e P CM power s u p, com es a r ou n d a n d looks a t
in t a ke m a n ifold.
t h e MAP volt a ge, a n d ba sed u pon t h e volt a ge it sees,
it kn ows t h e cu r r en t ba r om et r ic pr essu r e r ela t ive t o
REMOVAL - 3.3/3.8L
a lt it u de. On ce t h e en gin e st a r t s, t h e P CM looks a t
t h e volt a ge a ga in , con t in u ou sly ever y 12 m illisecon ds,
(2) Rem ove va cu u m h ose a n d m ou n t in g scr ews
a n d com pa r es t h e cu r r en t volt a ge t o wh a t it wa s a t
fr om m a n ifold a bsolu t e pr essu r e (MAP ) sen sor (F ig.
key on . Th e differ en ce bet ween cu r r en t a n d wh a t it
21).
wa s a t key on is m a n ifold va cu u m .
(3) Discon n ect elect r ica l con n ect or fr om sen sor.
Du r in g key On (en gin e n ot r u n n in g) t h e sen sor
Rem ove sen sor.
r ea ds (u pda t es) ba r om et r ic pr essu r e. A n or m a l r a n ge
ca n be obt a in ed by m on it or in g kn own good sen sor in
you wor k a r ea .
M AP SEN SOR (Cont inue d)
I N STALLAT I ON
INSTALLATION - 2.4L
(1) In st a ll sen sor.
(2) In st a ll t wo scr ews a n d t igh t en .
(3) Con n ect t h e elect r ica l con n ect or a n d va cu u m
h ose t o t h e MAP sen sor (F ig. 20).
(1) In st a ll sen sor (F ig. 21).
(2) In st a ll scr ews a n d t igh t en t o P LAS TIC MAN -
IF OLD 1.7 N ·m (15 in . lbs .) ALU MIN U M MAN I-
F OLD 3.3 N ·m (30 in . lbs .) .
(3) Con n ect t h e elect r ica l con n ect or t o t h e sen sor.
In st a ll va cu u m h ose.
O2 SEN SOR Fig. 23 O2 SENSOR UPSTREAM 1/1 - 3.3/3.8L
DESCRIPTION
Th e u pst r ea m oxygen sen sor t h r ea ds in t o t h e ou t -
let fla n ge of t h e exh a u st m a n ifold (F ig. 22) or (F ig.
23).
Fig. 24 O2 SENSOR DOWNSTREAM 1/2 - 2.4/3.3/

3.8L
det er ior a t ion , t h e fu el in ject ion syst em u ses t wo
h ea t ed oxygen sen sor s. On e sen sor u pst r ea m of t h e
ca t a lyt ic con ver t or, on e down st r ea m of t h e con ver t or.
Fig. 22 O2 SENSOR UPSTREAM 1/1 - 2.4L Th e P CM com pa r es t h e r ea din g fr om t h e sen sor s t o
Th e down st r ea m h ea t ed oxygen sen sor t h r ea ds in t o ca lcu la t e t h e ca t a lyt ic con ver t or oxygen st or a ge
t h e ou t let pipe a t t h e r ea r of t h e ca t a lyt ic con ver t or ca pa cit y a n d con ver t er efficien cy. Also, t h e P CM u ses
(F ig. 24). t h e u pst r ea m h ea t ed oxygen sen sor in pu t wh en
a dju st in g in ject or pu lse widt h .
OPERATION Wh en t h e ca t a lyt ic con ver t er efficien cy dr ops below
em ission st a n da r ds, t h e P CM st or es a dia gn ost ic
A seper a t e u pst r ea m a n d down st r ea m gr ou n ds a r e
t r ou ble code a n d illu m in a t es t h e m a lfu n ct ion in dica -
u sed on t h e NGC veh icles (4 Cyl.).
t or la m p (MIL).
As veh icles a ccu m u la t e m ilea ge, t h e ca t a lyt ic con -
Th e O2 sen sor s pr odu ce a con st a n t 2.5 volt s on
ver t or det er ior a t es. Th e det er ior a t ion r esu lt s in a
NGC veh icles, depen din g u pon t h e oxygen con t en t of
less efficien t ca t a lyst . To m on it or ca t a lyt ic con ver t or
t h e exh a u st ga s. Wh en a la r ge a m ou n t of oxygen is
O2 SEN SOR (Cont inue d)
pr esen t (ca u sed by a lea n a ir /fu el m ixt u r e, ca n be oxygen is pr esen t (ca u sed by a lea n a ir-fu el m ixt u r e),
ca u sed by m isfir e a n d exh a u st lea ks), t h e sen sor s t h e sen sor pr odu ces volt a ge a s low a s 2.5 volt . Wh en
pr odu ces a low volt a ge. Wh en t h er e is a lesser t h er e is a lesser a m ou n t of oxygen pr esen t (r ich a ir-
a m ou n t of oxygen pr esen t (ca u sed by a r ich a ir /fu el fu el m ixt u r e) t h e sen sor pr odu ces a volt a ge a s h igh
m ixt u r e, ca n be ca u sed by in t er n a l en gin e pr oblem s) a s 3.5 volt . By m on it or in g t h e oxygen con t en t a n d
it pr odu ces a h igh er volt a ge. By m on it or in g t h e oxy- con ver t in g it t o elect r ica l volt a ge, t h e sen sor a ct s a s
gen con t en t a n d con ver t in g it t o elect r ica l volt a ge, a r ich -lea n swit ch .
t h e sen sor s a ct a s a r ich -lea n swit ch . Th e h ea t in g elem en t in t h e sen sor pr ovides h ea t t o
Th e oxygen sen sor s a r e equ ipped wit h a h ea t in g t h e sen sor cer a m ic elem en t . H ea t in g t h e sen sor
elem en t t h a t keeps t h e sen sor s a t pr oper oper a t in g a llows t h e syst em t o en t er in t o closed loop oper a t ion
t em per a t u r e du r in g a ll oper a t in g m odes. Ma in t a in in g soon er. Also, it a llows t h e syst em t o r em a in in closed
cor r ect sen sor t em per a t u r e a t a ll t im es a llows t h e loop oper a t ion du r in g per iods of ext en ded idle.
syst em t o en t er in t o closed loop oper a t ion soon er. In Closed Loop, t h e P CM a dju st s in ject or pu lse
Also, it a llows t h e syst em t o r em a in in closed loop widt h ba sed on t h e u pst r ea m h ea t ed oxygen sen sor
oper a t ion du r in g per iods of ext en ded idle. in pu t a lon g wit h ot h er in pu t s. In Open Loop, t h e
In Closed Loop oper a t ion t h e P CM m on it or s t h e O2 P CM a dju st s in ject or pu lse widt h ba sed on pr epr o-
sen sor s in pu t (a lon g wit h ot h er in pu t s) a n d a dju st s gr a m m ed (fixed) va lu es a n d in pu t s fr om ot h er sen -
t h e in ject or pu lse widt h a ccor din gly. Du r in g Open sor s.
Loop oper a t ion t h e P CM ign or es t h e O2 sen sor in pu t .
Th e P CM a dju st s in ject or pu lse widt h ba sed on pr e- DOWNSTREAM OXYGEN SENSOR
pr ogr a m m ed (fixed) va lu es a n d in pu t s fr om ot h er Th e down st r ea m h ea t ed oxygen sen sor in pu t is
sen sor s. u sed t o det ect ca t a lyt ic con ver t or det er ior a t ion . As
NGC Con t r oller - H a s a com m on gr ou n d for t h e t h e con ver t or det er ior a t es, t h e in pu t fr om t h e down -
h ea t er in t h e O2S. 12 volt s is su pplied t o t h e h ea t er st r ea m sen sor begin s t o m a t ch t h e u pst r ea m sen sor
in t h e O2S by t h e NGC con t r oller. Bot h t h e u pst r ea m in pu t except for a sligh t t im e dela y. By com pa r in g
a n d down st r ea m O2 sen sor s for NGC a r e pu lse widt h t h e down st r ea m h ea t ed oxygen sen sor in pu t t o t h e
m odu la t ion (P WM). N OTE: Wh en r epla cin g a n O2 in pu t fr om t h e u pst r ea m sen sor, t h e P CM ca lcu la t es
Sen sor, t h e P CM RAM m em or y m u st be clea r ed, ca t a lyt ic con ver t or efficien cy. Also u sed t o est a blish
eit h er by discon n ect in g t h e P CM C-1 con n ect or or t h e u pst r ea m O2 goa l volt a ge (swit ch in g poin t ).
m om en t a r ily discon n ect in g t h e Ba t t er y n ega t ive t er-
m in a l. Th e NGC lea r n s t h e ch a r a ct er ist ics of ea ch O2
h ea t er elem en t a n d t h ese old va lu es sh ou ld be REM OVAL
clea r ed wh en in st a llin g a n ew O2 sen sor. Th e cu s-
t om er m a y exper ien ce dr ivea bilit y issu es if t h is is n ot REMOVAL - UPSTREAM 1/1 - 2.4L
per for m ed. (1) Discon n ect t h e n ega t ive ba t t er y ca ble.
UPSTREAM OXYGEN SENSOR (3) Discon n ect t h e elect r ica l con n ect or (F ig. 23).
Th e in pu t fr om t h e u pst r ea m h ea t ed oxygen sen sor (4) Use a socket su ch a s t h e Sn a p-On ! YA8875 or
t ells t h e P CM t h e oxygen con t en t of t h e exh a u st ga s. equ iva len t t o r em ove t h e sen sor
Ba sed on t h is in pu t , t h e P CM fin e t u n es t h e a ir-fu el (5) Wh en t h e sen sor is r em oved, t h e t h r ea ds m u st
r a t io by a dju st in g in ject or pu lse widt h . be clea n ed wit h a n 18 m m X 1.5 + 6E t a p. If u sin g
Th e sen sor in pu t swit ch es fr om 2.5 t o 3.5 volt , t h e or igin a l sen sor, coa t t h e t h r ea ds wit h Loct it e
depen din g u pon t h e oxygen con t en t of t h e exh a u st 771–64 a n t i-seize com pou n d or equ iva len t .
ga s in t h e exh a u st m a n ifold. Wh en a la r ge a m ou n t of
REMOVAL - UPSTREAM 1/1 - 3.3/3.8L

(1) Rem ove ba t t er y, r efer t o t h e Ba t t er y sect ion for
m or e in for m a t ion .
(2) Rem ove t h e ba t t er y t r a y, r efer t o t h e Ba t t er y
(3) Discon n ect t h e speed con t r ol va cu u m h a r n ess
fr om ser vo.
(4) Discon n ect t h e elect r ica l con n ect or fr om ser vo.
Fig. 26 Downstream Oxygen Sensor (1/2)

1 - OXYGEN SENSOR CONNECTOR
3 - DOWNSTREAM OXYGEN SENSOR
4 - ENGINE HARNESS CONNECTOR
Fig. 25 O2 SENSOR 1/1

(5) Rem ove t h e speed con t r ol ser vo a n d br a cket
a n d r eposit ion .
(6) Use a socket su ch a s t h e Sn a p-On ! YA8875 or
equ iva len t t o r em ove t h e sen sor (F ig. 25).
(7) Wh en t h e sen sor is r em oved, t h e t h r ea ds m u st
be clea n ed wit h a n 18 m m X 1.5 + 6E t a p. If u sin g
t h e or igin a l sen sor, coa t t h e t h r ea ds wit h Loct it e
771–64 a n t i-seize com pou n d or equ iva len t .
REMOVAL - DOWNSTREAM 1/2 - 2.4/3.3/3.8L

(2) Ra ise a n d su ppor t t h e veh icle. Fig. 27 DOWNSTREAM 2/1 O2 SENSOR
(3) Discon n ect t h e elect r ica l con n ect or (F ig. 26).
(4) Use a socket su ch a s t h e Sn a p-On ! YA8875 or I N STALLAT I ON
equ iva len t t o r em ove t h e sen sor (F ig. 27).
(5) Wh en t h e sen sor is r em oved, t h e t h r ea ds m u st INSTALLATION - UPSTREAM 1/1 - 2.4L
be clea n ed wit h a n 18 m m X 1.5 + 6E t a p. If u sin g Th e en gin es u ses t wo h ea t ed oxygen sen sor s.
t h e or igin a l sen sor, coa t t h e t h r ea ds wit h Loct it e (1) Aft er r em ovin g t h e sen sor, t h e exh a u st m a n i-
771–64 a n t i-seize com pou n d or equ iva len t . fold t h r ea ds m u st be clea n ed wit h a n 18 m m X 1.5 +
6E t a p. If r eu sin g t h e or igin a l sen sor, coa t t h e sen sor
t h r ea ds wit h a n a n t i-seize com pou n d su ch a s Loct it e
771- 64 or equ iva len t . New sen sor s h a ve com pou n d
on t h e t h r ea ds a n d do n ot r equ ir e a n a ddit ion a l coa t -
in g.
(2) In st a ll sen sor a n d t igh t en t o 27 N·m (20 ft .
lbs.) (F ig. 23).
(3) Con n ect t h e elect r ica l con n ect or for t h e O2 sen -
sor a n d in st a ll on t o br a cket .
(4) Lower veh icle.
INSTALLATION - UPSTREAM 1/1 - 3.3/3.8L

Th e en gin es u ses t wo h ea t ed oxygen sen sor s.
(1) Aft er r em ovin g t h e sen sor, t h e exh a u st m a n i-
fold t h r ea ds m u st be clea n ed wit h a n 18 m m X 1.5 +
6E t a p. If r eu sin g t h e or igin a l sen sor, coa t t h e sen sor
t h r ea ds wit h a n a n t i-seize com pou n d su ch a s Loct it e
771- 64 or equ iva len t . New sen sor s h a ve com pou n d
on t h e t h r ea ds a n d do n ot r equ ir e a n a ddit ion a l coa t -
in g.
lbs.).
(3) Con n ect t h e elect r ica l con n ect or for t h e O2 sen -
sor a n d in st a ll on t o br a cket . Fig. 28 IAC VALVE 2.4L
(4) Con n ect t h e elect r ica l con n ect or for t h e speed 1 - Idle Air Control Valve
con t r ol ser vo. 2 - Throttle Position Sensor
(5) In st a ll t h e speed con t r ol ser vo a n d br a cket
r efer t o t h e Speed Con t r ol Ser vo for m or e in for m a -
t ion .
(6) Con n ect t h e speed con t r ol va cu u m h a r n ess t o
ser vo.
(7) In st a ll t h e ba t t er y t r a y, r efer t o t h e Ba t t er y
(8) In st a ll ba t t er y, r efer t o t h e Ba t t er y sect ion for
m or e in for m a t ion .
INSTALLATION DOWNSTREAM 2/1 -

2.4/3.3/3.8L
Th e O2S is loca t ed on t h e side of t h e ca t a lyt ic con -
ver t er.
Th r ea ds of n ew oxygen sen sor s a r e fa ct or y coa t ed
wit h a n t i-seize com pou n d t o a id in r em ova l. D O
N OT a d d a n y a d d itio n a l a n ti-s e ize c o m p o u n d to
th e th re a d s o f a n e w o x y g e n s e n s o r.
lbs.). Fig. 29 IAC VALVE LOCATION 3.3/3.8L
1 - Idle Air Control Valve
(3) Lower veh icle. 2 - Throttle Position Sensor
(4) In st a ll t h e n ega t ive ba t t er y ca ble.
OPERATION
F ilt er ed a ir fr om t h e a ir clea n er en t er s t h e in t a ke
T H ROT T LE BODY m a n ifold t h r ou gh t h e t h r ot t le body. Th e t h r ot t le body
con t a in s a n a ir con t r ol pa ssa ge con t r olled by a n Idle
DESCRIPTION Air Con t r ol (IAC) m ot or. Th e a ir con t r ol pa ssa ge is
Th e t h r ot t le body is loca t ed on t h e in t a ke m a n ifold u sed t o su pply a ir for idle con dit ion s. A t h r ot t le va lve
(F ig. 28) or (F ig. 29). F u el does n ot en t er t h e in t a ke (pla t e) is u sed t o su pply a ir for a bove idle con dit ion s.
m a n ifold t h r ou gh t h e t h r ot t le body. F u el is spr a yed Cer t a in sen sor s a r e a t t a ch ed t o t h e t h r ot t le body.
in t o t h e m a n ifold by t h e fu el in ject or s. Th e a cceler a t or peda l ca ble, speed con t r ol ca ble a r e
con n ect ed t o t h e t h r ot t le body ca m .
T H ROT T LE BODY (Cont inue d)
A (fa ct or y a dju st ed) set scr ew is u sed t o m ech a n i- INSTALLATION
ca lly lim it t h e posit ion of t h e t h r ot t le body t h r ot t le (1) F r om t h e en gin e com pa r t m en t , pu sh t h e h ou s-
pla t e. N e v e r a tte m p t to a d ju s t th e e n g in e id le in g en d fit t in g a n d gr om m et in t o t h e da sh pa n el.In -
s p e e d u s in g th is s c re w. All idle speed fu n ct ion s a r e st a ll gr om m en t in t o t h e da sh pa n el.
con t r olled by t h e P CM. (2) In st a ll t h e ca ble h ou sin g (t h r ot t le body en d)
in t o t h e ca ble m ou n t in g br a cket on t h e en gin e.
REMOVAL (3) F r om in side t h e veh icle, h old u p t h e peda l a n d
(1) Discon n ect n ega t ive ca ble fr om ba t t er y ca ble. in st a ll t h r ot t le ca ble a n d ca ble r et a in er in t h e u pper
(2) Rem ove a ir in let t o t h r ot t le body h ose cla m p. en d of t h e peda l sh a ft .
(3) Rem ove t h r ot t le a n d t h e speed con t r ol (if (4) At t h e da sh pa n el, in st a ll t h e ca ble r et a in er
equ ipped) ca bles fr om lever a n d br a cket . clip bet ween t h e en d of t h e t h r ot t le ca ble fit t in g a n d
(4) Discon n ect elect r ica l con n ect or s fr om t h e idle gr om m et
a ir con t r ol m ot or a n d t h r ot t le posit ion sen sor (TP S) (5) F r om t h e en gin e com pa r t m en t , r ot a t e t h e
(F ig. 28) or (F ig. 29). t h r ot t le lever wide open a n d in st a ll t h e t h r ot t le
(5) Rem ove t h r ot t le body t o in t a ke m a n ifold ca ble.
a t t a ch in g bolt s.
(6) Rem ove t h r ot t le body a n d ga sket .
T H ROT T LE POSI T I ON SEN SOR
INSTALLATION
(1) In st a ll a n ew ga sket , if r equ ir ed. DESCRIPTION
(2) In st a ll t h r ot t le body. Th e t h r ot t le posit ion sen sor m ou n t s t o t h e side of
(3) Tigh t en t h r ot t le body m ou n t in g bolt s. Th e 2.4L t h e t h r ot t le body (F ig. 30) or (F ig. 31).Th e sen sor
t o 28.2 N·m (250 ±50 in . lbs.) t or qu e, Th e 3.3/3.8L t o con n ect s t o t h e t h r ot t le bla de sh a ft . Th e TP S is a
11.6 N·m (105 ±20 in . lbs.) t or qu e. va r ia ble r esist or t h a t pr ovides t h e P ower t r a in Con -
(4) Con n ect elect r ica l con n ect or s t o t h e idle a ir t r ol Modu le (P CM) wit h a n in pu t sign a l (volt a ge).
con t r ol m ot or a n d t h r ot t le posit ion sen sor (TP S) (F ig.
28) or (F ig. 29).
(5) In st a ll a ir in let t o t h r ot t le body h ose cla m p a n d
t igh t en .
(6) Con n ect n ega t ive ca ble t o ba t t er y ca ble.
T H ROT T LE CON T ROL CABLE

REMOVAL
(1) Wor kin g fr om t h e en gin e com pa r t m en t , h old
t h e t h r ot t le body t h r ot t le lever in t h e wide open posi-
t ion .
(2) Rem ove t h e t h r ot t le ca ble fr om t h e t h r ot t le
body ca m .
(3) F r om in side t h e veh icle, h old u p t h e peda l a n d
r em ove t h e ca ble r et a in er a n d t h r ot t le ca ble fr om t h e
u pper en d of t h e peda l sh a ft .
(4) Rem ove r et a in er clip fr om t h r ot t le ca ble a n d
gr om m et a t da sh pa n el.
Fig. 30 Throttle Position Sensor—2.4L Engine
(5) F r om t h e en gin e com pa r t m en t , pu ll t h e t h r ot t le
1 - Idle Air Control Valve
ca ble a n d gr om m en t ou t of t h e da sh pa n el. 2 - Throttle Position Sensor
(6) Rem ove t h e t h r ot t le ca ble fr om t h r ot t le br a cket
by ca r efu lly com pr essin g bot h r et a in in g ea r s sim u lt a -
n eou sly t h en gen t ly pu ll t h e t h r ot t le ca ble fr om
t h r ot t le br a cket or if it is t h e slide sn a p design you
h a ve t o slide t h e lockin g t a b ou t of t h e h ole a n d t h en
slide t h e ca ble a ssem bly ou t of t h e br a cket .
T H ROT T LE POSI T I ON SEN SOR (Cont inue d)
Alon g wit h in pu t s fr om ot h er sen sor s, t h e P CM
u ses t h e TP S in pu t t o det er m in e cu r r en t en gin e oper-
a t in g con dit ion s. Th e P CM a lso a dju st s fu el in ject or
pu lse widt h a n d ign it ion t im in g ba sed on t h ese
in pu t s.
REMOVAL - 3.3/3.8L
(2) Rem ove t h e elect r ica l con n ect or fr om t h e In let
Air Tem per a t u r e sen sor.
(3) Rem ove t h e a ir clea n er box lid. Rem ove h ose
fr om t h r ot t le body.
(4) Discon n ect t h e elect r ica l con n ect or a t TP S.
(5) Discon n ect t h e elect r ica l con n ect or a t IAC.
(6) Rem ove t h e t h r ot t le a n d speed con t r ol ca bles
fr om t h r ot t le body.
(7) Rem ove 3 m ou n t in g bolt s fr om t h r ot t le body.
(8) Rem ove t h r ot t le body.
(9) Discon n ect t h e pu r ge va cu u m lin e fr om t h e
Fig. 31 Throttle Position Sensor—3.3/3.8L Engine t h r ot t le body.
1 - Idle Air Control Valve (10) Rem ove TP S fr om t h r ot t le body.
2 - Throttle Position Sensor
OPERATION (1) In st a ll TP S t o t h r ot t le body.
Th e sign a l r epr esen t s t h r ot t le bla de posit ion . As (2) Discon n ect t h e pu r ge va cu u m lin e fr om t h e
t h e posit ion of t h e t h r ot t le bla de ch a n ges, t h e r esis- t h r ot t le body.
t a n ce of t h e TP S ch a n ges. (3) In st a ll t h r ot t le body.
Th e P CM su pplies a ppr oxim a t ely 5 volt s t o t h e (4) In st a ll 3 m ou n t in g bolt s fr om t h r ot t le body.
TP S. Th e TP S ou t pu t volt a ge (in pu t sign a l t o t h e Tigh t en bolt s.
power t r a in con t r ol m odu le) r epr esen t s t h r ot t le bla de (5) In st a ll t h e t h r ot t le a n d speed con t r ol ca bles t o
posit ion . Th e TP S ou t pu t volt a ge t o t h e P CM va r ies t h r ot t le body.
fr om a ppr oxim a t ely 0.6 volt a t m in im u m t h r ot t le (6) Con n ect t h e elect r ica l con n ect or a t TP S.
open in g (idle) t o a m a xim u m of 4.5 volt s a t wide open (7) Con n ect t h e elect r ica l con n ect or a t IAC.
t h r ot t le. (8) In st a ll t h e a ir clea n er box lid. In st a ll h ose t o
t h r ot t le body.
(9) In st a ll t h e elect r ica l con n ect or t o t h e In let Air
Tem per a t u r e sen sor.
RS STEERING 19 - 1
STEERING
page page
STEERING SPECIFICATIONS
DESCRIPTION - POWER STEERING SYSTEM ..1 POWER STEERING FASTENER TORQUE ...9
OPERATION - POWER STEERING SYSTEM ...1 SPECIAL TOOLS
DIAGNOSIS AND TESTING POWER STEERING ....................9
DIAGNOSIS AND TESTING - POWER COLUMN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
STEERING SYSTEM FLOW AND GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
PRESSURE TEST . . . . . . . . . . . . . . . . . . . ...1 PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
DIAGNOSIS AND TESTING - STEERING
SYSTEM DIAGNOSIS CHARTS . . . . . . . . . ...3
ST EERI N G DI AGN OSI S AN D T EST I N G
DESCRIPTION - POWER STEERING SYSTEM DIAGNOSIS AND TESTING - POWER STEERING

Th is veh icle com es wit h power st eer in g a s st a n - SYSTEM FLOW AND PRESSURE TEST
da r d equ ipm en t . Th e power st eer in g syst em con sist s
of t h ese m a jor com pon en t s: ALL ENGINES
• P OWE R STE E RING P UMP Th e followin g pr ocedu r e is t o be u sed t o t est t h e
• P OWE R STE E RING GE AR oper a t ion of t h e power st eer in g syst em on t h is veh i-
• P OWE R STE E RING F LUID cle. Th is t est will pr ovide t h e flow r a t e of t h e power
• P OWE R STE E RING F LUID COOLE R (If st eer in g pu m p a lon g wit h t h e m a xim u m r elief pr es-
E qu ipped) su r e. Th is t est is t o be per for m ed t o det er m in e if t h e
• P OWE R STE E RING F LUID RE SE RVOIR power st eer in g pu m p or power st eer in g gea r is n ot
• P OWE R STE E RING F LUID SUP P LY H OSE fu n ct ion in g pr oper ly. Th e followin g flow a n d pr essu r e
• P OWE R STE E RING F LUID P RE SSURE H OSE t est is per for m ed u sin g t h e P ower St eer in g An a lyzer
• P OWE R STE E RING F LUID RE TURN H OSE Kit , Specia l Tool 6815 (F ig. 1), h oses, Specia l Tools
F or in for m a t ion on t h e fir st t wo com pon en t s, r efer 6905 a n d 6959, a n d fit t in gs fr om a da pt er kit , Specia l
t o t h eir r espect ive sect ion s wit h in t h is ser vice m a n - Tool 6893.
u a l gr ou p. In for m a t ion on a ll ot h er com pon en t s ca n
be fou n d in P OWE R STE E RING P UMP.
OPERATION - POWER STEERING SYSTEM

Tu r n in g of t h e st eer in g wh eel is con ver t ed in t o lin -
ea r (side-t o-side) t r a vel t h r ou gh t h e m esh in g of t h e
h elica l pin ion t eet h wit h t h e r a ck t eet h wit h in t h e
st eer in g gea r. Th e la t er a l t r a vel pu sh es a n d pu lls t h e
t ie r ods t o ch a n ge t h e dir ect ion of t h e veh icle’s fr on t
wh eels.
P ower a ssist st eer in g is pr ovided by a belt dr iven
r ot a r y t ype pu m p. It dir ect s flu id t h r ou gh power
st eer in g flu id h oses t o t h e power st eer in g gea r wh er e
it is u sed t o a ssist t h e dr iver ’s t u r n in g effor t .
Ma n u a l st eer in g con t r ol of t h e veh icle ca n be m a in -
t a in ed if power st eer in g a ssist is lost . H owever,
u n der t h is con dit ion , st eer in g effor t is sign ifica n t ly Fig. 1 Power Steering Analyzer With Hoses Installed
in cr ea sed. 1 - OUTLET
3 - INLET
19 - 2 STEERING RS
ST EERI N G (Cont inue d)
Assem ble h oses on P ower St eer in g An a lyzer, Spe-
cia l Tool 6815, a s sh own . In st a ll P r essu r e H ose, Spe-
cia l Tool 6905 (in 6893 kit ), in t h e in let fit t in g on
P ower St eer in g An a lyzer. In st a ll P r essu r e H ose, Spe-
cia l Tool 6713 (in 6815 kit ) on P r essu r e H ose, Specia l
Tool 6905. In st a ll P r essu r e H ose, Specia l Tool 6959,
in t h e ou t let fit t in g on P ower St eer in g An a lyzer.
In st a ll t h e followin g a da pt er s fr om Ada pt er Set ,
Specia l Tool 6893 (F ig. 2), on t h e a n a lyzer h ose en ds:
In st a ll Ada pt er F it t in g, Specia l Tool 6844, on P r es-
su r e H ose, Specia l Tool 6713. In st a ll Ada pt er F it t in g,
Specia l Tool 6826, on P r essu r e H ose, Specia l Tool
6959.
Fig. 3 Pressure Hose Connection To Power Steering

Pump - 2.4L Engine
1 - POWER STEERING FLUID RETURN HOSE
2 - POWER STEERING PUMP
3 - POWER STEERING FLUID PRESSURE HOSE
Fig. 2 Power Steering Analyzer Adapters 6893

CAUTION: To prevent personal injury, safety gog-
gles should be worn at all times when performing
any test procedures on the power steering pump or
power steering gear.
Th e followin g pr ocedu r e is t o be u sed t o t est t h e

oper a t ion of t h e power st eer in g syst em on t h e veh i-
cle.
(1) Ch eck belt t en sion a n d a dju st a s n ecessa r y.
Fig. 4 Supply & Pressure Hoses At Pump - 3.3L/3.8L
(2) Discon n ect t h e power st eer in g flu id pr essu r e
Engine
h ose fr om t h e power st eer in g pu m p (F ig. 3) (F ig. 4).
(3) Con n ect Ada pt er F it t in g, Specia l Tool 6844, 1 - PRESSURE HOSE AND FITTING
2 - SUPPLY HOSE AND CLAMP
a t t a ch ed t o pr essu r e h ose fr om in let (ga u ge en d) of 3 - POWER STEERING PUMP
P ower St eer in g An a lyzer t o t h e pr essu r e fit t in g on
t h e power st eer in g pu m p. NOTE: During the next few steps, do not steer vehi-
(4) Con n ect veh icle power st eer in g flu id pr essu r e cle as air will be forced into the steering gear.
h ose t o Ada pt er F it t in g, Specia l Tool 6826, wh ich
sh ou ld be a lr ea dy in st a lled in t h e ou t let h ose (va lve (5) Com plet ely open va lve on P ower St eer in g An a -
en d) of P ower St eer in g An a lyzer. lyzer.
RS STEERING 19 - 3
(6) St a r t en gin e a n d let idle ju st lon g en ou gh t o below specifica t ion s, r epla ce pu m p. (Refer t o 19 -
cir cu la t e power st eer in g flu id t h r ou gh t h e a n a lyzer STE E RING/P UMP - RE MOVAL)
a n d h oses. Sh u t off en gin e.
(7) Ch eck power st eer in g flu id level a n d a dd flu id CAUTION: Do not force the steering to operate
a s n ecessa r y. St a r t en gin e a ga in a n d let idle u n t il t h e against the stops for more than 4 seconds at a time
a ir is ou t of t h e flu id. because pump damage can result.
(8) Ga u ge sh ou ld r ea d below 300 psi (2068 kP a ). If
a bove, in spect t h e h oses for r est r ict ion s a n d r epa ir a s (10) On ce t h e pu m p h a s been ver ified a s wor kin g
n ecessa r y. Th e in it ia l pr essu r e sh ou ld be in t h e r a n ge cor r ect ly, com plet ely open t h e va lve on t h e P ower
of 100-275 psi (689-1896 kP a ) depen din g on flu id St eer in g An a lyzer. Tu r n t h e st eer in g wh eel t o t h e
t em per a t u r e. Th e flow m et er sh ou ld r ea d a bove 1.5 ext r em e left u n t il t h e st op in t h e st eer in g gea r is
GP M. m et . H old it t h er e for 2–4 secon ds, t h en r elea se it .
Now t u r n t h e st eer in g wh eel t o t h e r igh t u n t il t h e
CAUTION: The following test procedure involves r igh t st op is m et . H old it t h er e for 2–4 secon ds, t h en
testing maximum pump pressure output and flow r elea se it . Recor d t h e st a bilized pr essu r e a t ea ch
control valve operation. Do not leave valve closed posit ion . Com pa r e t h e r ecor ded r ea din gs t o t h e spec-
for more than four seconds as the pump could be ifica t ion s. If t h e ou t pu t pr essu r es a r e n ot wit h in 100
damaged. psi (689 kP a ) of on e a n ot h er a ga in st eit h er st op or
a r e below specifica t ion s, t h e st eer in g gea r is lea kin g
in t er n a lly a n d m u st be r epla ced. (Refer t o 19 -
NOTE: Power steering pump maximum pressure for STE E RING/GE AR - RE MOVAL)
2.4L engines is 1,200 – 1,350 psi (8,274 – 9,308
kPa). Power steering pump maximum pressure for DIAGNOSIS AND TESTING - STEERING
all other engines is 1,400 – 1,500 psi (9,653 – 10,342
SYSTEM DIAGNOSIS CHARTS
kPa).
NOTE: There are three diagnosis charts following
(9) Close a n a lyzer va lve fu lly t h r ee t im es a n d
that cover POWER STEERING NOISE, STEERING
r ecor d h igh est pr essu r e in dica t ed ea ch t im e. All t h r ee
WHEEL FEEL, and POWER STEERING FLUID.
r ea din gs m u st be wit h in specifica t ion s. If a n y of t h e
t h r ee power st eer in g pu m p pr essu r es a r e a bove or
POWER STEERING NOISE
OBJECTIONABLE HISS 1. Damaged or mispositioned 1. Reposition or replace steering

OR WHISTLE* steering column shaft/coupling dash column shaft/coupling dash panel seal.
panel seal.
2. Mis-routed power steering hose. 2. Check routing of power steering
hoses. Ensure hoses do not come in
unwanted contact with other
components and objects.
3. Noisy valve in power steering 3. Replace power steering gear.
gear.
RATTLE OR EXCESSIVE 1. Power steering gear loose on front 1. Inspect power steering gear
CLUNK** suspension crossmember. mounting bolts. Replace as necessary.
Tighten to the specified torque.
2. Front suspension crossmember 2. Tighten the front suspension
mounting fasteners loose at frame. crossmember mounting fasteners to the
specified torque.
3. Loose tie rod (outer or inner). 3. Check tie rod pivot points for wear.
Replace worn/loose parts as required.
19 - 4 STEERING RS
4. Loose lower control arm mounting 4. Tighten control arm mounting bolts to
bolts at front suspension the specified torques.
crossmember.
5. Lower control arm pivot bushing 5. Replace lower control arm pivot
worn. bushing.
6. Loose strut assembly mounting 6. Tighten strut assembly fasteners to
fasteners at tower or knuckle. the specified torque.
7. Power steering fluid hose touching 7. Adjust hose to proper position by
the body of the vehicle. loosening, repositioning, and tightening
attachments to specified torque. Do not
bend tubing.
8. Damaged front suspension 8. Replace front suspension
crossmember. crossmember.
9. Stabilizer bar link ball joints worn. 9. Replace stabilizer bar link.
10. Lug nuts loose. 10. Tighten lug nuts to specifications.
11. Excessive Wheel bearing 11. Verify correct halfshaft hub nut
free-play. torque. Replace hub and bearing if
torque is okay.
12. Internal power steering gear 12. Replace power steering gear.
noise.
POPPING NOISE 1. Worn outer tie rod. 1. Check ball joint for free-play;
Replace outer tie rod.
2. Loose inner tie rod. 2. Replace power steering gear.
CHIRP OR SQUEAL 1. Loose power steering pump drive 1. Check and adjust power steering
(POWER STEERING belt. pump drive belt to specifications or
PUMP) replace automatic tensioner where
applicable. Replace belt if worn or
glazed.
2. Malfuctioning belt auto-tensioner 2. Replace belt auto-tensioner.
WHINE, GROWL, MOAN 1. Low fluid level. 1. Fill power steering fluid reservoir to
OR GROAN (POWER proper level and check for leaks (make
STEERING PUMP)*** sure all air is bled from the system
fluid).
2. Power steering hose touching 2. Adjust hose to proper position by
vehicle body or frame. loosening, repositioning, and tightening
fitting to specified torque. Do not bend
tubing. Replace hose if damaged.
3. Extremely low ambient 3. Some noise can be expected, but will
temperature. go away as vehicle warms. Replace
pump if noise is excessive.
4. Extreme wear of power steering 4. Replace power steering pump and
pump internal components. flush system as necessary.
RS STEERING 19 - 5
SUCKING AIR SOUND 1. Loose clamp on power steering 1. Tighten or replace hose clamp.
fluid return hose.
2. Missing O-Ring on power steering 2. Inspect connection and replace
hose connection. O-Ring as required.
3. Low power steering fluid level. 3. Fill power steering fluid reservoir to
proper level and check for leaks.
4. Loose clamp on fluid supply hose. 4. Tighten or replace hose clamp.
SQUEAK OR RUBBING 1. Steering column shroud rubbing. 1. Realign shrouds as necessary.

SOUND
2. Steering column shaft rubbing. 2. Move or realign item rubbing shaft.
3. Clockspring noisy. 3. Remove clockspring. Reinstall wheel.
If noise is gone, replace clockspring.
4. Seal lubrication inadequate. 4. Lube seal (if external).
5. Steering gear internally noisy. 5. Replace steering gear (if no other
cause can be found).
SCRUBBING OR 1. Incorrect tire or wheel size. 1. Replace incorrect size tire or wheel
KNOCKING NOISE. with size used as original equipment.
2. Interference between steering 2. Check for bent or misaligned
gear and other vehicle components. components and correct as necessary.
3. Steering gear internal stops worn 3. Replace steering gear.
excessively allowing tires to be
steered excessively far.
* NOTE: There is some noise in all power steering ** NOTE: A light clunk may be felt or heard during
systems. One of the most common is a hissing steering wheel reversal while vehicle is stationary.
sound evident when turning the steering wheel This results from internal steering gear rack move-
when at a standstill or when parking and the steer- ment at the bushings and in no way affects the per-
ing wheel is at the end of its travel. Hiss is a very formance of the steering system. This movement
high frequency noise similar to that experienced may be felt in the steering components during
while slowly closing a water tap. The noise is steering wheel reversal.
present in every valve and results when high veloc-
ity fluid passes valve orifice edges. There is no *** NOTE: Power steering pump growl/moan/groan
relationship between this noise and the perfor- results from the development of high pressure fluid
mance of the steering system. flow. Normally this noise level should not be high
enough to be objectionable.
19 - 6 STEERING RS
STEERING WHEEL FEEL
STEERING WHEEL/ 1. Loose steering coupling pinch 1. Replace pinch bolt and torque to
COLUMN CLICKING, bolt. specifications.
CLUNKING OR RATTLING.
2. Steering column bearings. 2. Replace steering column.
3. Excessive intermediate shaft 3. Replace intermediate shaft.
coupling free-play.
STEERING WHEEL HAS 1. Steering wheel retaining nut not 1. Tighten the steering wheel retaining nut
FORE AND AFT properly tightened and torqued. to its specified torque.
LOOSENESS.
2. Steering column lower bearing 2. Replace steering column.
spring retainer slipped on steering
column shaft.
3. Loose steering column to 3. Tighten fasteners to specified torque.
instrument panel fasteners.
STEERING WHEEL, DASH 1. Air in the fluid of the power 1. Bleed air from system following the
OR VEHICLE VIBRATES steering system. power steering pump initial operation
DURING LOW SPEED OR service procedure.*
STANDSTILL STEERING
MANEUVERS.
2. Tires not properly inflated. 2. Inflate tires to the specified pressure.
3. Excessive engine vibration. 3. Ensure that the engine is tuned properly.
4. Loose tie rod end jam nut. 4. Tighten the inner to outer tie rod jam nut
to the specified torque.
5.Overcharged air conditioning 5.Check air conditioning pump head
system. pressure and correct as necessary.
6. Grounded engine mount. 6. Repair as necessary.
7. Loose outer tie rod. 7. Replace outer tie rod.
STEERING CATCHES, 1. Low power steering fluid level. 1. Fill power steering fluid reservoir to
SURGES OR STICKS IN specified level and check for leaks.
CERTAIN POSITIONS OR
IS DIFFICULT TO TURN. ***
2. Tires not inflated to specified 2. Inflate tires to the specified pressure.
pressure.
3. Lack of lubrication in front lower 3. Lubricate ball joints if ball joints are not a
control arm ball joints. lubricated-for-life type ball joint. If ball joint
is a lubricated-for-life ball joint, replace ball
joint.
4. Worn or binding lower control arm 4. Replace lower control arm ball joint.
ball joint.
5. Lack of lubrication in steering gear 5. Lubricate tie rod ends if they are not a
outer tie rod ends. lubricated-for-life type. If tie rod end is a
lubricated-for-life type, replace tie rod end.
RS STEERING 19 - 7
6. Loose power steering pump drive 6. Tighten the power steering pump drive
belt. belt to specifications or replace automatic
tensioner where applicable. If drive belt is
worn or glazed, replace belt.
7. Faulty power steering pump 7. Replace power steering pump.
(Perform Power Steering Flow and
Pressure Test).
8. Faulty power steering gear 8. Replace power steering gear.
(Perform Power Steering Flow and
Pressure Test).
9. Excessive friction in steering 9. Isolate and correct condition.
column or intermediate shaft/coupler.
10. Excessive friction in power 10. Replace power steering gear.
steering gear.
11. Worn or binding seat and bearing 11. Replace seat and bearing in front strut
in front strut assembly. assembly.
STEERING WHEEL DOES 1. Tires not inflated properly. 1. Inflate tires to specified pressure.
NOT RETURN TO
CENTER POSITION.
2. Improper front wheel alignment. 2. Check and adjust wheel alignment as
necessary.
3. Lack of lubrication causing binding 3. Lubricate ball joints if ball joints are not a
in front lower control arm ball joints. lubricated for life type of ball joint, then
inspect ball joint for wear, replace lower
control arm as necessary. If ball joint is a
lubricated for life ball joint, replace lower
control arm ball joint.
4. Steering column coupling joints 4. Realign steering column coupling joints.
misaligned.
5. Steering wheel rubbing.** 5. Adjust steering column shrouds to
eliminate rubbing condition.
6. Damaged, mispositioned or 6. Replace, reposition, or lubricate dash
unlubricated steering column coupler seal.
to dash seal.**
7. Binding mount bearing in front 7. Replace mount bearing in front strut
strut assembly. assembly.
8. Binding shaft bearing in steering 8. Replace the steering column.
column.
9. Excessive friction in steering 9. Replace steering column coupling.
column coupling.
10. Excessive friction in power 10. Replace power steering gear.
steering gear.
19 - 8 STEERING RS
EXCESSIVE STEERING 1. Air in the fluid of the power 1. Bleed air from system following the the
WHEEL KICKBACK OR steering system. power steering pump initial operation
TOO MUCH STEERING service procedure.*
WHEEL FREE PLAY.
2. Power steering gear loose on 2. Inspect power steering gear mounting
cradle/crossmember. bolts. Replace as necessary. Tighten to the
specified torque.
3. Steering column coupling or 3. Replace steering column coupling or
intermediate shaft worn, broken or intermediate shaft.
loose.
4. Free play in steering column. 4. Check all components of the steering
column and repair or replace as required.
5. Worn lower control arm ball joints. 5. Replace lower control arm ball joints as
required.
6. Loose steering knuckle-to-ball joint 6. Inspect pinch bolt, replace as necessary,
stud pinch bolt. and tighten to specified torque.
7. Front wheel bearing loose or 7. Replace hub and bearing as necessary.
worn.
8. Loose outer tie rod end. 8. Replace outer tie rod end that has
excessive free play.
9. Loose inner tie rod. 9. Replace power steering gear.
10. Defective steering gear rotary 10. Replace power steering gear.
valve.
* NOTE: Steering shudder can be expected in new steering wheel more than one revolution in either
vehicles and vehicles with recent steering system direction and place steering wheel in original loca-
repairs. Shudder should dissipate after the vehicle tion before reconnecting coupling. If this position is
has been driven several weeks. lost, the steering column clockspring must be
recentered following the procedure found within the
procedure for steering column installation in the
** NOTE: To evaluate this condition, it may be nec- steering column section.
essary to disconnect the coupling at the base of the
steering column. Turn the steering wheel and feel or *** NOTE: Increased low speed or stationary steer-
listen for internal rubbing in steering column. To ing effort can be expected if the steering fluid is at
avoid damaging the column clockspring, note the a high temperature. High fluid temperature usually
following. Before disconnecting coupling, place results from high engine rpm due to trailer towing,
tires in the straight-ahead position and center steer- ascending grades, or racing the engine for pro-
ing wheel. Once disconnected, DO NOT rotate longed periods of time.
POWER STEERING FLUID
LOW FLUID LEVEL WITH 1. Loose power steering hose 1. Tighten the fitting to its specified torque.
VISIBLE LEAK. fittings.
2. Damaged or missing fitting seal, 2. Replace as necessary.
gasket, or O-ring.
3. Power steering component 3. Repair or replace the leaking component
leaking. as required.
RS STEERING 19 - 9
AERATED FLUID.* 1. Low fluid level. 1. Fill power steering fluid reservoir to
proper level.
2. Air leak at supply hose, power 2. Inspect for proper sealing. Repair as
steering fluid reservoir or pump. necessary.
3. Cracked power steering pump 3. Replace the power steering pump.
housing.
RESERVOIR FLUID 1. Water contamination of power 1. Drain the power steering fluid from the
OVERFLOW AND FLUID steering fluid. system. Flush the system with fresh clean
THAT IS MILKY IN COLOR power steering fluid, drain, then refill to the
proper level.
* NOTE: Extremely cold temperatures may cause SPECI AL T OOLS

power steering fluid aeration. Aeration should sub-
side as fluid warms. POWER STEERING
SPECI FI CAT I ON S
POWER STEERING FASTENER TORQUE
DESCRIPTION TORQUE
Power Steering Pump:
Flow Control Valve Power Steering Analyzer 6815
75 N·m (55 ft. lbs.)
Pressure Fitting
Mounting Bolts 54 N·m (40 ft. lbs.)
Rear Bracket To Engine
54 N·m (40 ft. lbs.)
Mounting Bolts
Steering Gear:
Mounting Bolt - Size-M14 183 N·m (135 ft. lbs.)
Mounting Bolts -
95 N·m (70 ft. lbs.)
Size-M12
Tie Rod Steering Knuckle Adapters, Power Steering Analyzer 6893
75 N·m (55 ft. lbs.)
Nut
Tie Rod Jam Nut 75 N·m (55 ft. lbs.)
Coupling Pinch Bolt 28 N·m (250 in. lbs.)
Power Steering Fluid
Hoses:
Hose Tube Nuts 31 N·m (275 in. lbs.)
Routing Bracket Bolts 23 N·m (200 in. lbs.)
Hose, Power Steering Analyzer 6959
19 - 10 COLUMN RS
COLU M N
TABLE OF CONTENTS
page page
COLUMN OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
DESCRIPTION - STEERING COLUMN . . . . . . . 10 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
WARNING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 20
WARNINGS AND CAUTIONS . . . . . . . . . . . . . 10 SHROUD - LOWER
DIAGNOSIS AND TESTING - STEERING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
COLUMN . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 SHROUD - UPPER
SPECIFICATIONS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 22
COLUMN FASTENER TORQUE . . . . . . . . . . . 17 STEERING WHEEL
IGNITION SWITCH REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19
KEY/LOCK CYLINDER
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 20
COLU M N • Key cylin der

• Ign it ion swit ch
• Mu lt i-fu n ct ion swit ch
DESCRIPTION - STEERING COLUMN
• Clockspr in g
• H a lo
• Speed con t r ol swit ch es
• Dr iver a ir ba g
• Tr im sh r ou ds
• St eer in g wh eel
• In t er m edia t e sh a ft
Th ese com pon en t s of t h e st eer in g colu m n ca n be
ser viced wit h ou t r equ ir in g r em ova l of t h e st eer in g
colu m n fr om t h e veh icle.
WARN I N G
WARNINGS AND CAUTIONS
(Refer t o 8 - E LE CTRICAL/RE STRAINTS - WARN-
ING)
WARNING: BEFORE BEGINNING ANY SERVICE

PROCEDURES THAT INVOLVES REMOVING THE
Fig. 1 Steering Column AIR BAG. REMOVE AND ISOLATE THE NEGATIVE
1 - STEERING COLUMN (-) BATTERY CABLE (GROUND) FROM THE VEHI-
2 - UPPER MOUNTING NUTS CLE BATTERY. THIS IS THE ONLY SURE WAY TO
3 - LOWER MOUNTING NUTS DISABLE THE AIR BAG SYSTEM. FAILURE TO DO
4 - MOUNTING STUDS
THIS COULD RESULT IN ACCIDENTAL AIR BAG
Th e st eer in g colu m n h a s been design ed t o be ser- DEPLOYMENT AND POSSIBLE PERSONAL INJURY.
viced a s a com plet e a ssem bly (F ig. 1) except for t h e
followin g ser vicea ble com pon en t s:
RS COLUMN 19 - 11
COLU M N (Cont inue d)
WARNING: THE AIR BAG SYSTEM IS A SENSITIVE, WARNING: WHEN AN UNDEPLOYED AIRBAG IS TO
COMPLEX ELECTRO-MECHANICAL UNIT. BEFORE BE REMOVED FROM THE VEHICLE, FIRST DISCON-
ATTEMPTING TO DIAGNOSE, REMOVE OR INSTALL NECT AND ISOLATE THE BATTERY NEGATIVE
THE AIR BAG SYSTEM COMPONENTS YOU MUST (GROUND) CABLE. ALLOW THE AIRBAG SYSTEM
FIRST DISCONNECT AND ISOLATE THE BATTERY RESERVE CAPACITOR TO DISCHARGE FOR TWO
NEGATIVE (GROUND) CABLE. THEN WAIT TWO MINUTES BEFORE BEGINNING ANY AIRBAG SYS-
MINUTES FOR THE SYSTEM CAPACITOR TO DIS- TEM OR COMPONENT SERVICE. PERSONAL
CHARGE. FAILURE TO DO SO COULD RESULT IN INJURY MAY RESULT IF THIS PROCEDURE IS NOT
ACCIDENTAL DEPLOYMENT OF THE AIR BAG AND FOLLOWED.
POSSIBLE PERSONAL INJURY. THE FASTENERS,
SCREWS, AND BOLTS, ORIGINALLY USED FOR
THE AIR BAG COMPONENTS, HAVE SPECIAL
COATINGS AND ARE SPECIFICALLY DESIGNED
FOR THE AIR BAG SYSTEM. THEY MUST NEVER
BE REPLACED WITH ANY SUBSTITUTES. ANYTIME
A NEW FASTENER IS NEEDED, REPLACE WITH
THE CORRECT FASTENERS PROVIDED IN THE
SERVICE PACKAGE OR FASTENERS LISTED IN
THE PARTS BOOKS.
WARNING: SAFETY GOGGLES SHOULD BE WORN

AT ALL TIMES WHEN WORKING ON STEERING
COLUMNS.
CAUTION: Disconnect negative (ground) cable from

the battery before servicing any column compo-
nent.
Fig. 2 Driver Airbag Mounting
1 - DRIVER AIRBAG
CAUTION: Do not attempt to remove the pivot pins 2 - MOUNTING SCREWS
to disassemble the tilting mechanism. Damage will
occur. (3) Rem ove t h e dr iver a ir ba g m ou n t in g scr ews
(F ig. 2).
(4) Lift t h e a ir ba g fr om it s m ou n t a n d discon n ect
DIAGNOSIS AND TESTING - STEERING t wo a ir ba g squ ib, speed con t r ol a n d h or n con n ect or s
COLUMN (F ig. 3). Rem ove dr iver a ir ba g. P r oper ly st or e t h e
F or dia gn osis of con dit ion s r ela t in g t o t h e st eer in g dr iver a ir ba g ou t of t h e wa y. (Refer t o 8 - E LE CTRI-
colu m n , (Refer t o 19 - STE E RING - DIAGNOSIS CAL/RE STRAINTS - WARNING)
AND TE STING). (5) Rem ove t h e st eer in g wh eel r et a in in g bolt (F ig.
4).
REMOVAL (6) Rem ove da m per (F ig. 4).
(7) If equ ipped, discon n ect t h e r em ot e a u dio con -
NOTE: Before proceeding, (Refer to 19 - STEERING/ t r ol swit ch wir in g fr om t h e clockspr in g (F ig. 4).
COLUMN - WARNING)(Refer to 8 - ELECTRICAL/RE-
STRAINTS/DRIVER AIRBAG - REMOVAL). CAUTION: Do not bump or hammer on steering col-
umn or steering column shaft when removing steer-
(1) Ma ke su r e t h e fr on t wh eels of t h e veh icle a r e ing wheel from steering column shaft.
in t h e STRAIGH T AH E AD posit ion befor e begin n in g
t h e colu m n r em ova l pr ocedu r e.
(2) Discon n ect a n d isola t e t h e n ega t ive (gr ou n d) CAUTION: When installing steering wheel puller
ca ble fr om t h e ba t t er y. Wa it a t lea st t wo m in u t es for bolts in steering wheel, do not thread bolt into
t h e a ir ba g syst em r eser ve ca pa cit or t o disch a r ge steering wheel more than a half inch. If the bolts
befor e begin n in g a n y st eer in g colu m n , in st r u m en t are threaded into the steering wheel more than a
pa n el, or a ir ba g syst em /com pon en t ser vice. half inch they will contact and damage the clock-
spring.
19 - 12 COLUMN RS
Fig. 5 Steering Wheel Removal

1 - STEERING WHEEL
2 - PULLER
Fig. 3 Driver Airbag Wiring Connections
(10) Rem ove t h e pa r kin g br a ke r elea se h a n dle
1 - DRIVER AIRBAG
2 - SQUIB CONNECTORS lin k.
3 - SPEED CONTROL/HORN WIRING CONNECTOR (11) Rem ove t h e kn ee blocker /st eer in g colu m n
4 - CLOCKSPRING
cover pla t e (Refer t o 23 - BODY/INSTRUME NT PAN-
E L/KNE E BLOCKE R - RE MOVAL).
Fig. 4 Steering Wheel Mounting

1 - STEERING WHEEL Fig. 6 Upper Shroud Mounting
2 - REMOTE AUDIO CONTROL WIRING CONNECTOR (IF 1 - UPPER SHROUD
EQUIPPED) 2 - LOWER SHROUD
3 - RETAINING BOLT 3 - MOUNTING SCREWS
4 - DAMPER
(12) Rem ove t h e u pper sh r ou d m ou n t in g scr ews
(8) Rem ove t h e st eer in g wh eel u sin g a st a n da r d
(F ig. 6). Usin g h a n ds on ea ch side of t h e colu m n ,
wh eel pu ller (F ig. 5).
gen t ly pr ess in wa r d a t sea m s bet ween t h e t wo
(9) Rem ove t h e kn ee blocker /st eer in g colu m n open -
sh r ou ds a t poin t s of con t a ct t o disen ga ge in n er lock-
in g cover (Refer t o 23 - BODY/INSTRUME NT PAN-
in g t a bs, t h en r em ove u pper sh r ou d. If t h e veh icle is
E L/STE E RING COLUMN OP E NING COVE R -
equ ipped wit h t r a ct ion con t r ol, t h e lower sh r ou d will
RE MOVAL).
n eed t o be r em oved on ce t h e u pper sh r ou d is u n fa s-
t en ed in or der t o discon n ect t h e t r a ct ion con t r ol wir-
RS COLUMN 19 - 13
in g con n ect or a n d r em ove t h e u pper sh r ou d wit h t h e
t r a ct ion con t r ol swit ch in t a ct . Refer t o t h e followin g
st eps.
Fig. 9 Traction Control And Autostick Wiring

Connections
1 - TRACTION CONTROL WIRING CONNECTOR
2 - ROUTING CLIP
Fig. 7 Adjustable Pedals Switch Mounting 3 - AUTOSTICK WIRING CONNECTOR
4 - COLUMN WIRING HARNESS
1 - LOWER SHROUD
2 - ADJUSTABLE PEDALS SWITCH
3 - WIRING CONNECTOR (F ig. 9). Rem ove t h e u pper sh r ou d wit h t r a ct ion con -
t r ol swit ch .
(13) If equ ipped wit h a dju st a ble peda ls, discon n ect (16) If equ ipped wit h Au t ost ick, discon n ect t h e
t h e wir in g con n ect or for t h e swit ch (F ig. 7). wir in g con n ect or (F ig. 9).
(17) Rem ove t h e clu st er t r im bezel. (Refer t o 23 -
BODY/INSTRUME NT PANE L/CLUSTE R BE ZE L -
RE MOVAL)
Fig. 8 Lower Shroud Mounting

1 - STEERING COLUMN
2 - LOWER SHROUD
3 - MOUNTING SCREW Fig. 10 Fixed Shroud Mounting
1 - FIXED SHROUD
(14) Rem ove t h e lower sh r ou d m ou n t in g scr ew 2 - MOUNTING SCREWS
(F ig. 8), t h en r em ove t h e lower sh r ou d.
(15) If equ ipped wit h t r a ct ion con t r ol, discon n ect (18) Rem ove t h e scr ews fa st en in g t h e fixed sh r ou d
t h e wir in g con n ect or fr om t h e colu m n wir in g h a r n ess in pla ce (F ig. 10). Rem ove t h e fixed sh r ou d.
19 - 14 COLUMN RS
(21) Discon n ect t h e colu m n h a r n ess wir in g con n ec-
t or s for t h e clockspr in g a n d SQUIB (F ig. 12).
Fig. 11 Ignition Switch And BTSI Wiring

Connections
1 - WIRING CONNECTOR Fig. 13 Sentry Key Immobilizer Module
2 - IGNITION SWITCH
3 - BTSI 1 - WIRING CONNECTOR
4 - WIRING CONNECTOR 2 - IGNITION KEY CYLINDER HALO
3 - SKIM
4 - MOUNTING SCREW
(19) Discon n ect t h e colu m n h a r n ess wir in g con n ec-
t or s fr om t h e Br a ke Tr a n sm ission Sh ift In t er lock (22) If equ ipped wit h Sen t r y Key Im m obilizer, dis-
(BTSI) a n d ign it ion swit ch (F ig. 11). con n ect t h e wir in g con n ect or fr om t h e SKIM (F ig.
13).
Fig. 12 Multi-function And Clockspring Wiring

Connections Fig. 14 Horn Ground At Column
1 - MULTI-FUNCTION SWITCH MOUNTING HOUSING
1 - STEERING COLUMN
2 - MULTI-FUNCTION WIRING CONNECTOR
2 - HORN GROUND WIRE
3 - CLOCKSPRING WIRING CONNECTOR
3 - SCREW
4 - CLOCKSPRING SQUIB WIRING CONNECTOR
(20) Discon n ect t h e colu m n h a r n ess wir in g con n ec- (23) Rem ove scr ew fa st en in g h or n gr ou n d wir e t o
t or for t h e m u lt i-fu n ct ion swit ch (F ig. 12). colu m n (F ig. 14).
RS COLUMN 19 - 15
Fig. 15 Shift Cable Attachment To Column Fig. 17 Steering Column Mounting

1 - LEVER PIN 1 - STEERING COLUMN
2 - SHIFT CABLE 2 - UPPER MOUNTING NUTS
3 - BRACKET 3 - LOWER MOUNTING NUTS
4 - MOUNTING STUDS
(24) Discon n ect t h e sh ift ca ble a t t h e lever pin
(F ig. 15). (29) Rem ove t h e st eer in g colu m n (F ig. 17).
(25) Discon n ect t h e sh ift ca ble a t t h e br a cket , t h en
feed t h e ca ble ou t t h r ou gh br a cket . (F ig. 15).
Fig. 16 Pinch Bolt

Fig. 18 Multi-Function Switch Mounting Housing
1 - PINCH BOLT
2 - STEERING COLUMN Set-Screw
1 - MULTI-FUNCTION SWITCH MOUNTING HOUSING
(26) Rem ove t h e h a ir pin , t h en t h e pin ch bolt (F ig. 2 - STEERING COLUMN
3 - SET-SCREW
16). Discon n ect t h e colu m n cou plin g.
(27) Loosen t h e colu m n lower m ou n t in g n u t s (F ig.
(30) If t h e st eer in g colu m n is bein g r epla ced,
17).
r em ove t h e set -scr ew fa st en in g t h e m u lt i-fu n ct ion
(28) Rem ove t h e colu m n u pper m ou n t in g n u t s
swit ch m ou n t in g h ou sin g t o t h e colu m n (F ig. 18).
(F ig. 17).
19 - 16 COLUMN RS
(3) If r em oved, in st a ll SKIM (F ig. 13). In st a ll t h e
m ou n t in g scr ew fa st en in g t h e SKIM t o t h e ign it ion
key cylin der h ou sin g. Tigh t en t h e scr ew t o 4 N·m (30
in . lbs.) t or qu e.
(4) If r em oved, slide t h e m u lt i-fu n ct ion swit ch
m ou n t in g h ou sin g on t o t h e colu m n (F ig. 19).
(5) If m u lt i-fu n ct ion swit ch m ou n t in g h ou sin g is
bein g in st a lled, in st a ll t h e set -scr ew fa st en in g t h e
h ou sin g t o t h e colu m n (F ig. 18). Tigh t en t h e set -
scr ew t o 14 N·m (124 in . lbs.) t or qu e.
(6) In st a ll t h e st eer in g colu m n (F ig. 17). Slide t h e
colu m n lower m ou n t in g slot s over t h e lower m ou n t -
in g st u ds (wit h n u t s st a r t ed) fir st , t h en lift colu m n
in t o pla ce over t h e u pper m ou n t in g st u ds.
(7) In st a ll t h e t wo u pper m ou n t in g n u t s (F ig. 17).
Tigh t en t h e t wo u pper m ou n t in g n u t s, t h en t h e t wo
lower m ou n t in g n u t s t o 12 N·m (105 in . lbs.) t or qu e.
(8) Ma t ch t h e colu m n sh a ft cou plin g t o t h e in t er-
m edia t e sh a ft a n d in st a ll t h e pin ch bolt (F ig. 16).
Fig. 19 Multi-Function Switch Mounting Housing Tigh t en t h e pin ch bolt n u t t o 28 N·m (250 in . lbs.)
1 - MULTI-FUNCTION SWITCH MOUNTING HOUSING t or qu e. In st a ll t h e h a ir pin in t h e en d of t h e pin ch
2 - STEERING COLUMN bolt .
(9) F eed t h e sh ift ca ble t h r ou gh t h e br a cket on t h e
(31) If t h e st eer in g colu m n is bein g r epla ced, slide colu m n (F ig. 15), t h en in st a ll t h e clip fa st en in g t h e
t h e m u lt i-fu n ct ion swit ch m ou n t in g h ou sin g off t h e ca ble h ou sin g t o t h e br a cket .
colu m n (F ig. 19). (10) Con n ect t h e sh ift ca ble t o t h e lever pin (F ig.
(32) If t h e st eer in g colu m n is bein g r epla ced, 15).
r em ove t h e m ou n t in g scr ew fa st en in g t h e SKIM t o (11) In st a ll t h e scr ew fa st en in g t h e h or n gr ou n d
t h e ign it ion key cylin der h ou sin g (F ig. 13). Rem ove wir e t o t h e colu m n (F ig. 14). Tigh t en t h e scr ew t o 7
t h e SKIM. N·m (60 in . lbs.) t or qu e.
(33) If t h e st eer in g colu m n is bein g r epla ced, (12) If equ ipped wit h Sen t r y Key Im m obilizer, con -
r em ove t h e h a lo fr om t h e ign it ion key cylin der h ou s- n ect t h e wir in g con n ect or t o t h e SKIM (F ig. 13).
in g (F ig. 13). (13) Con n ect t h e colu m n h a r n ess wir in g con n ect or s
(34) If t h e st eer in g colu m n is bein g r epla ced, for t h e clockspr in g a n d SQUIB (F ig. 12).
r em ove t h e ign it ion key lock cylin der (Refer t o 19 - (14) Con n ect t h e colu m n h a r n ess wir in g con n ect or
STE E RING/COLUMN/KE Y/LOCK CYLINDE R - for t h e m u lt i-fu n ct ion swit ch (F ig. 12).
RE MOVAL). (15) Con n ect t h e colu m n h a r n ess wir in g con n ect or s
for t h e Br a ke Tr a n sm ission Sh ift In t er lock (BTSI)
INSTALLATION a n d ign it ion swit ch (F ig. 11).
(16) In st a ll t h e fixed sh r ou d (F ig. 10). In st a ll t h e
NOTE: Before proceeding, (Refer to 19 - STEERING/ scr ews fa st en in g t h e fixed sh r ou d in pla ce a n d
COLUMN - WARNING)(Refer to 8 - ELECTRICAL/RE- t igh t en t h e scr ews t o 3 N·m (23 in . lbs.) t or qu e.
STRAINTS/DRIVER AIRBAG - REMOVAL). (17) If equ ipped wit h Au t ost ick, con n ect t h e wir in g
NOTE: Make sure the front wheels of the vehicle are (18) If equ ipped wit h t r a ct ion con t r ol, posit ion t h e
still in the STRAIGHT AHEAD position before begin- u pper sh r ou d a bove t h e colu m n a n d r ou t e t h e swit ch
ning the column installation procedure. wir in g down a r ou n d t h e colu m n . Con n ect t h e wir in g
con n ect or fr om t h e colu m n wir in g h a r n ess t o t h e
(1) If r em oved, in st a ll t h e ign it ion key lock cylin - t r a ct ion con t r ol swit ch wir in g (a t t a ch ed t o u pper
der (Refer t o 19 - STE E RING/COLUMN/KE Y/LOCK sh r ou d) (F ig. 9).
CYLINDE R - INSTALLATION).
(2) If r em oved, in st a ll t h e h a lo on t h e ign it ion key
cylin der h ou sin g (F ig. 13).
RS COLUMN 19 - 17
(19) P osit ion t h e lower sh r ou d on t h e colu m n (F ig. SPECI FI CAT I ON S
8). In st a ll t h e lower sh r ou d m ou n t in g scr ew. Tigh t en
t h e scr ew t o 2 N·m (17 in . lbs.) t or qu e. COLUMN FASTENER TORQUE
(20) If equ ipped wit h a dju st a ble peda ls, Con n ect
t h e wir in g con n ect or for t h e swit ch (F ig. 7) t o t h e col-
u m n wir in g h a r n ess. Ft. In.
DESCRIPTION N·m
(21) P osit ion t h e u pper sh r ou d on t op of t h e lower Lbs. Lbs.
sh r ou d a n d sn a p it in t o pla ce. In st a ll t h e u pper Driver Airbag Mounting Screws 10 — 90
sh r ou d m ou n t in g scr ews (F ig. 6). Tigh t en t h e scr ews Multi-Function Switch Mounting
t o 2 N·m (17 in . lbs.) t or qu e. 14 — 124
Housing Set-Screw
(22) In spect sh r ou d m a t in g su r fa ces for excessive
Shroud Attaching Screws - Fixed 3 — 23
ga ps a n d cor r ect a s n ecessa r y.
(23) In st a ll t h e clu st er t r im bezel (Refer t o 23 - Shroud Attaching Screws -
2 — 17
BODY/INSTRUME NT PANE L/CLUSTE R BE ZE L - Lower/Upper
INSTALLATION). SKIM Attaching Screw 4 — 30
(24) In st a ll t h e kn ee blocker /st eer in g colu m n cover Steering Column Coupling Pinch
pla t e. (Refer t o 23 - BODY/INSTRUME NT PANE L/ 28 — 250
Bolt
KNE E BLOCKE R - INSTALLATION)
(25) In st a ll t h e pa r kin g br a ke h a n dle lin k. Steering Column Mounting Nuts 12 — 105
(26) In st a ll t h e kn ee blocker /st eer in g colu m n open - Steering Wheel Retaining Bolt 61 45 —
in g cover. (Refer t o 23 - BODY/INSTRUME NT PAN-
E L/STE E RING COLUMN OP E NING COVE R -
INSTALLATION) I GN I T I ON SWI T CH
(27) Align t h e splin es a n d in st a ll t h e st eer in g
wh eel on t h e st eer in g colu m n sh a ft (Refer t o 19 - REMOVAL
STE E RING/COLUMN/STE E RING WH E E L - Th e ign it ion swit ch a t t a ch es t o t h e lock cylin der
INSTALLATION). h ou sin g on t h e en d opposit e t h e lock cylin der (F ig.
(28) In st a ll t h e da m per over t h e st eer in g colu m n 20). F or ign it ion swit ch t er m in a l a n d cir cu it iden t ifi-
sh a ft (F ig. 4). ca t ion , r efer t o t h e a ppr opr ia t e wir in g in for m a t ion .
(29) In st a ll t h e st eer in g wh eel r et a in in g bolt (F ig. Th e wir in g in for m a t ion in clu des wir in g dia gr a m s,
4). Tigh t en t h e bolt t o 61 N·m (45 ft . lbs.) t or qu e. pr oper wir e a n d con n ect or r epa ir pr ocedu r es, fu r t h er
(30) If t h e st eer in g wh eel is equ ipped wit h r em ot e det a ils on wir e h a r n ess r ou t in g a n d r et en t ion , a s well
a u dio con t r ols, con n ect t h e wir in g con n ect or t o t h e a s pin -ou t a n d loca t ion views for t h e va r iou s wir e
clockspr in g (F ig. 4). h a r n ess con n ect or s, splices a n d gr ou n ds.
(31) Con n ect t h e t wo squ ib con n ect or s t o t h e
dr iver a ir ba g (F ig. 3). Th e con n ect or s a r e color coded
t o a void con n ect or m ix-u p.
(32) Con n ect t h e speed con t r ol a n d h or n con n ect or
t o t h e clockspr in g (F ig. 3).
(33) In st a ll t h e a ir ba g t o t h e st eer in g wh eel.
In st a ll t h e dr iver a ir ba g m ou n t in g scr ews (F ig. 2).
Tigh t en scr ews t o 10 N·m (90 in . lbs.) t or qu e.
(34) Con n ect t h e ba t t er y n ega t ive (gr ou n d) ca ble t o
ba t t er y post followin g specia l Dia gn osis An d Test in g
pr ocedu r e. (Refer t o 8 - E LE CTRICAL/RE STRAINTS
- DIAGNOSIS AND TE STING)
(35) Ch eck oper a t ion of a ll st eer in g colu m n
m ou n t ed com pon en t s.
(36) Roa d t est veh icle t o en su r e pr oper oper a t ion
of st eer in g.
Fig. 20 Ignition Switch—Viewed From Below
Column
1 - IGNITION SWITCH
2 - LOCK CYLINDER HOUSING
3 - RETAINING TABS

19 - 18 COLUMN RS
I GN I T I ON SWI T CH (Cont inue d)
(2) Rem ove st eer in g colu m n cover r et a in in g scr ews
(F ig. 21).
Fig. 21 Steering Column Cover

1 - SCREWS
2 - STEERING COLUMN COVER
(3) Rem ove pa r kin g br a ke r elea se ca ble fr om h a n - Fig. 23 Steering Column Shroud Screws
dle (F ig. 22). 1 - STEERING WHEEL
2 - SCREWS
3 - LOWER STEERING COLUMN SHROUD
Fig. 22 Parking Brake Release Cable

1 - PARKING BRAKE CABLE
2 - PARKING BRAKE HANDLE Fig. 24 Lock Cylinder Retaining Tab
1 - IGNITION SWITCH
(4) Rem ove scr ews h oldin g st eer in g colu m n 2 - RETAINING TAB
sh r ou ds (F ig. 23)a n d r em ove lower sh r ou d.
(5) P la ce key cylin der in RUN posit ion . Depr ess
lock cylin der r et a in in g t a b a n d r em ove key cylin der
(F ig. 24).
RS COLUMN 19 - 19
(6) Rem ove ign it ion swit ch m ou n t in g scr ew (F ig.
25) wit h a #10 Tor x! t a m per pr oof bit .
Fig. 27 Removing Ignition Switch

1 - IGNITION SWITCH
Fig. 25 Ignition Switch Mounting Screw 2 - RETAINING TAB
1 - MOUNTING SCREW
2 - IGNITION SWITCH
(7) Depr ess r et a in in g t a b (F ig. 21) or (F ig. 26) a n d

gen t ly pr y ign it ion swit ch fr om st eer in g colu m n (F ig.
27).
Fig. 26 Ignition Switch Retaining Tab

Fig. 28 Ignition Switch Connectors
1 - IGNITION SWITCH
2 - RETAINING TAB 1 - KEY IN SWITCH
2 - PRNDL SWITCH
3 - IGNITION SWITCH
(8) Discon n ect elect r ica l con n ect or s fr om ign it ion
swit ch a n d r em ove swit ch (F ig. 28). (2) In st a ll elect r ica l con n ect or s t o ign it ion swit ch .
(3) Ca r efu lly in st a ll t h e ign it ion swit ch . Th e
INSTALLATION swit ch will sn a p over t h e r et a in in g t a bs (F ig. 29).
Th e ign it ion swit ch a t t a ch es t o t h e lock cylin der In st a ll m ou n t in g scr ew (F ig. 25).
h ou sin g on t h e en d opposit e t h e lock cylin der (F ig. (4) In st a ll u pper a n d lower sh r ou ds.
20). F or ign it ion swit ch t er m in a l a n d cir cu it iden t ifi- (5) In st a ll key cylin der (cylin der r et a in in g t a b will
ca t ion , r efer t o t h e Wir in g Dia gr a m s sect ion . depr ess on ly in t h e RUN posit ion ).
(1) E n su r e t h e ign it ion swit ch is in t h e RUN posi-
t ion a n d t h e a ct u a t or sh a ft in t h e lock h ou sin g is in
t h e RUN posit ion .
19 - 20 COLUMN RS
Fig. 30 Ignition Lock Cylinder Detents

Fig. 29 Ignition Switch Installation (2) Th e sh a ft a t t h e en d of t h e lock cylin der a lign s
1 - IGNITION SWITCH wit h t h e socket in t h e en d of t h e h ou sin g. To a lign
2 - ACTUATOR SHAFT t h e socket wit h t h e lock cylin der, en su r e t h e socket is
3 - RETAINING TABS
in t h e Ru n posit ion (F ig. 31).
(7) Ch eck for pr oper oper a t ion of ign it ion swit ch
a n d key-in wa r n in g swit ch .
K EY /LOCK CY LI N DER
DESCRIPTION
Th e lock cylin der is in ser t ed in t h e en d of t h e
h ou sin g opposit e t h e ign it ion swit ch .
OPERATION
Th e ign it ion key r ot a t es t h e cylin der t o 5 differ en t
det en t s (F ig. 30) :
• Accessor y
• Off (lock)
• Un lock
• On /Ru n Fig. 31 Socket in Lock Cylinder Housing
• St a r t 1 - LOCK CYLINDER HOUSING
2 - SOCKET
REMOVAL (3) Align t h e lock cylin der wit h t h e gr ooves in t h e

h ou sin g. Slide t h e lock cylin der in t o t h e h ou sin g
(2) Rem ove st eer in g colu m n cover r et a in in g
u n t il t h e t a b st icks t h r ou gh t h e open in g in t h e h ou s-
scr ews.
in g.
(3) Rem ove scr ews h oldin g st eer in g colu m n
(4) Tu r n t h e key t o t h e Off posit ion . Rem ove t h e
sh r ou ds a n d r em ove lower sh r ou d.
key.
(4) P la ce key cylin der in RUN posit ion . Depr ess
(5) In st a ll lower st eer in g colu m n sh r ou d.
lock cylin der r et a in in g t a b on t h e bot t om of t h e lock
(6) In st a ll st eer in g colu m n cover.
h ou sin g a n d r em ove key cylin der.
INSTALLATION
(1) In st a ll key in lock cylin der. Tu r n key t o r u n
posit ion (r et a in in g t a b on lock cylin der ca n be
depr essed).
RS COLUMN 19 - 21
SH ROU D - LOWER (3) Rem ove t h e lower sh r ou d-t o-colu m n m ou n t in g

scr ew (F ig. 33).
REMOVAL
Fig. 34 Adjustable Pedals Switch Mounting

Fig. 32 Upper Shroud Mounting 1 - LOWER SHROUD
2 - ADJUSTABLE PEDALS SWITCH
1 - UPPER SHROUD 3 - WIRING CONNECTOR
2 - LOWER SHROUD
3 - MOUNTING SCREWS
(4) If equ ipped wit h a dju st a ble peda ls, discon n ect
t h e wir in g con n ect or for t h e swit ch (F ig. 34).
(1) Rem ove t h e t wo sh r ou d-t o-sh r ou d m ou n t in g
(5) Rem ove t h e lower sh r ou d fr om t h e st eer in g col-
scr ews fa st en in g t h e u pper t o lower sh r ou ds (F ig.
umn.
32).
(6) If equ ipped wit h a dju st a ble peda ls, depr ess t h e
(2) Usin g h a n ds on ea ch side of t h e colu m n , gen t ly
r et a in in g t a bs on t h e swit ch a n d r em ove t h e swit ch
pr ess in wa r d a t sea m s bet ween t h e t wo sh r ou ds a t
fr om t h e lower sh r ou d (F ig. 34).
poin t s of con t a ct t o disen ga ge in n er lockin g t a bs.
INSTALLATION
(1) If t h e veh icle is equ ipped wit h a dju st a ble ped-
a ls:
(a ) P a ss t h e wir in g t h r ou gh t h e m ou n t in g h ole
a n d in st a ll t h e swit ch in t o t h e lower sh r ou d (F ig.
34), sn a ppin g it in t o pla ce.
(b) Con n ect t h e swit ch wir in g con n ect or t o t h e
colu m n wir in g h a r n ess.
(2) P osit ion t h e lower sh r ou d u n der t h e st eer in g
colu m n a n d in st a ll t h e lower sh r ou d-t o-colu m n
m ou n t in g scr ew (F ig. 33). Tigh t en t h e scr ew t o 2 N·m
(3) Align t h e u pper sh r ou d wit h t h e lower, t h en
sn a p sh r ou ds t oget h er a t lockin g t a b loca t ion s on
bot h sides of colu m n .
(4) In st a ll t h e t wo sh r ou d-t o-sh r ou d m ou n t in g
scr ews (F ig. 32). Tigh t en t h e scr ews t o 2 N·m (17 in .
lbs.) t or qu e.
Fig. 33 Lower Shroud Mounting ga ps a n d cor r ect a s n ecessa r y.
1 - STEERING COLUMN (6) Ch eck oper a t ion of a n y pr eviou sly discon n ect ed
2 - LOWER SHROUD
3 - MOUNTING SCREW
swit ch es.
19 - 22 COLUMN RS
SH ROU D - U PPER (3) If t h e veh icle is equ ipped wit h t r a ct ion con t r ol,
r em ove t h e lower sh r ou d-t o-colu m n m ou n t in g scr ew
(F ig. 36).
REMOVAL
Fig. 37 Traction Control And Autostick Wiring

Fig. 35 Upper Shroud Mounting
Connections
1 - UPPER SHROUD
2 - LOWER SHROUD 1 - TRACTION CONTROL WIRING CONNECTOR
3 - MOUNTING SCREWS 2 - ROUTING CLIP
3 - AUTOSTICK WIRING CONNECTOR
4 - COLUMN WIRING HARNESS
(1) Rem ove t h e t wo sh r ou d-t o-sh r ou d m ou n t in g
scr ews fa st en in g t h e u pper t o lower sh r ou ds (F ig. (4) If t h e veh icle is equ ipped wit h t r a ct ion con t r ol,
35). discon n ect t h e swit ch wir in g con n ect or fr om t h e col-
(2) Usin g h a n ds on ea ch side of t h e colu m n , gen t ly u m n wir in g h a r n ess (F ig. 37).
pr ess in wa r d a t sea m s bet ween t h e t wo sh r ou ds a t (5) If t h e veh icle is equ ipped wit h power folda wa y
poin t s of con t a ct t o disen ga ge in n er lockin g t a bs. m ir r or s (E xpor t ), discon n ect wir in g con n ect or a t m ir-
r or swit ch pig t a il.
(6) Rem ove t h e u pper sh r ou d fr om t h e st eer in g col-
umn.
(7) If t h e veh icle is equ ipped wit h t r a ct ion con t r ol,
r em ove t h e swit ch wir in g fr om t h e r ou t in g clip
a t t a ch ed t o t h e u pper sh r ou d (F ig. 38).
(8) If t h e veh icle is equ ipped wit h t r a ct ion con t r ol,
r em ove t h e t r a ct ion con t r ol swit ch fr om t h e u pper
sh r ou d (F ig. 39).
(9) If t h e veh icle is equ ipped wit h power folda wa y
m ir r or s (E xpor t ), r em ove power folda wa y swit ch fr om
u pper sh r ou d.
INSTALLATION
(1) If t h e veh icle is equ ipped wit h power folda wa y
m ir r or s (E xpor t ), in st a ll t h e power folda wa y swit ch
in t h e u pper sh r ou d.
(2) If veh icle is equ ipped wit h t r a ct ion con t r ol,
in st a ll t h e t r a ct ion con t r ol swit ch in t h e u pper
Fig. 36 Lower Shroud Mounting sh r ou d (F ig. 39).
1 - STEERING COLUMN (3) If t h e veh icle is equ ipped wit h t r a ct ion con t r ol,
2 - LOWER SHROUD a t t a ch t h e swit ch wir in g t o t h e r ou t in g clip a t t a ch ed
3 - MOUNTING SCREW
t o t h e u pper sh r ou d (F ig. 38).
RS COLUMN 19 - 23
SH ROU D - U PPER (Cont inue d)
(7) Align t h e u pper sh r ou d wit h t h e lower, t h en
sn a p sh r ou ds t oget h er a t lockin g t a b loca t ion s on
bot h sides of colu m n .
(8) In st a ll t h e t wo sh r ou d-t o-sh r ou d m ou n t in g
scr ews (F ig. 35). Tigh t en t h e scr ews t o 2 N·m (17 in .
lbs.) t or qu e.
ga ps a n d cor r ect a s n ecessa r y.
(10) Ch eck oper a t ion of a n y pr eviou sly discon -
n ect ed swit ch es.
ST EERI N G WH EEL
REMOVAL
NOTE: Before proceeding, (Refer to 19 - STEERING/
COLUMN - WARNING)(Refer to 8 - ELECTRICAL/RE-
STRAINTS - WARNING).
Fig. 38 Traction Control Switch Routing Clip
(1) Discon n ect a n d isola t e t h e n ega t ive (gr ou n d)
1 - ROUTING CLIP
2 - SWITCH WIRING ca ble fr om t h e ba t t er y. Wa it a t lea st t wo m in u t es for
t h e a ir ba g syst em r eser ve ca pa cit or t o disch a r ge
befor e begin n in g a n y st eer in g colu m n , in st r u m en t
pa n el, or a ir ba g syst em /com pon en t ser vice.
WARNING: WHEN AN UNDEPLOYED AIRBAG IS TO

BE REMOVED FROM THE VEHICLE, FIRST DISCON-
NECT AND ISOLATE THE BATTERY NEGATIVE
(GROUND) CABLE. ALLOW THE AIRBAG SYSTEM
RESERVE CAPACITOR TO DISCHARGE FOR TWO
MINUTES BEFORE BEGINNING ANY AIRBAG SYS-
TEM OR COMPONENT SERVICE. PERSONAL
INJURY MAY RESULT IF THIS PROCEDURE IS NOT
FOLLOWED.
Fig. 39 Traction Control Switch Mounting

1 - TRACTION CONTROL SWITCH
2 - UPPER SHROUD
(4) P osit ion t h e u pper sh r ou d on t h e colu m n (F ig.

35).
(5) If equ ipped wit h t r a ct ion con t r ol, r ou t e t h e
swit ch wir in g down a r ou n d t h e colu m n . Con n ect t h e
wir in g con n ect or fr om t h e colu m n wir in g h a r n ess t o
t h e t r a ct ion con t r ol swit ch wir in g (a t t a ch ed t o u pper
sh r ou d) (F ig. 37).
(6) If r em oved, posit ion t h e lower sh r ou d on t h e
colu m n (F ig. 36). In st a ll t h e lower sh r ou d m ou n t in g Fig. 40 Driver Airbag Mounting
scr ew. Tigh t en t h e scr ew t o 2 N·m (17 in . lbs.) t or qu e. 1 - DRIVER AIRBAG
2 - MOUNTING SCREWS
19 - 24 COLUMN RS
ST EERI N G WH EEL (Cont inue d)
(2) Rem ove t h e dr iver a ir ba g m ou n t in g scr ews (4) Rem ove t h e st eer in g wh eel r et a in in g bolt (F ig.
(F ig. 40). 42).
(5) Rem ove da m per (F ig. 42).
(6) If equ ipped, discon n ect t h e r em ot e a u dio con -
t r ol swit ch wir in g fr om t h e clockspr in g (F ig. 42).
Fig. 41 Driver Airbag Wiring Connections Fig. 43 Steering Wheel Removal

1 - DRIVER AIRBAG 1 - STEERING WHEEL
2 - SQUIB CONNECTORS 2 - PULLER
3 - SPEED CONTROL/HORN WIRING CONNECTOR
4 - CLOCKSPRING
CAUTION: Do not bump or hammer on steering col-
umn or steering column shaft when removing steer-
(3) Lift t h e a ir ba g fr om it s m ou n t a n d discon n ect
ing wheel from steering column shaft.
t wo a ir ba g squ ib, speed con t r ol a n d h or n con n ect or s
(F ig. 41). Rem ove dr iver a ir ba g. P r oper ly st or e t h e
dr iver a ir ba g ou t of t h e wa y. (Refer t o 8 - E LE CTRI- CAUTION: When installing steering wheel puller
CAL/RE STRAINTS - WARNING) bolts in steering wheel, do not thread bolt into
steering wheel more than a half inch. If the bolts
are threaded into the steering wheel more than a
half inch they will contact and damage the clock-
spring.
(7) Wh ile h oldin g t h e st eer in g wh eel fir m ly in t h e

s tra ig h t-a h e a d posit ion , r em ove t h e st eer in g wh eel
fr om st eer in g colu m n sh a ft u sin g a st eer in g wh eel
pu ller (F ig. 43).
(8) Rem ove t h e pu ller fr om t h e st eer in g wh eel.
(9) If t h e r em ot e a u dio swit ch es n eed r em oved
fr om t h e st eer in g wh eel, (Refer t o 8 - E LE CTRICAL/
AUDIO/RE MOTE SWITCH E S - RE MOVAL).
INSTALLATION
(1) If t h e r em ot e r a dio swit ch es n eed t o be
in st a lled on t h e st eer in g wh eel, (Refer t o 8 - E LE C-
TRICAL/AUDIO/RE MOTE SWITCH E S - INSTALLA-
TION).
Fig. 42 Steering Wheel Mounting
CAUTION: Do not force steering wheel onto steer-
1 - STEERING WHEEL
2 - REMOTE AUDIO CONTROL WIRING CONNECTOR (IF
ing column shaft by driving it on. Pull steering
EQUIPPED) wheel down onto shaft using only the steering
3 - RETAINING BOLT wheel retaining nut.
4 - DAMPER
RS COLUMN 19 - 25
ST EERI N G WH EEL (Cont inue d)
(2) F eed a n d r ou t e wir in g fr om clockspr in g (6) If t h e st eer in g wh eel is equ ipped wit h r em ot e
t h r ou gh u pper a ccess h ole in st eer in g wh eel. a u dio con t r ols, con n ect t h e wir in g con n ect or t o t h e
(3) Align m a st er ser r a t ion s in st eer in g wh eel wit h clockspr in g (F ig. 42).
om it t ed splin e on st eer in g colu m n sh a ft (a t 12 o’clock (7) Con n ect t h e a ir ba g squ ib wir in g con n ect or s t o
posit ion ). Slide t h e st eer in g wh eel on t o t h e st eer in g t h e a ir ba g a n d t h e h or n a n d speed con t r ol swit ch
colu m n sh a ft by h a n d (F ig. 42). Use ca r e n ot t o pin ch con n ect or t o t h e clockspr in g (F ig. 41).
a n y wir in g. (8) In st a ll t h e dr iver a ir ba g in t h e st eer in g wh eel
(F ig. 40). In st a ll a n d t igh t en t h e a ir ba g a t t a ch in g
NOTE: Before installing the damper on the steering scr ews t o 10 N·m (90 in . lbs.) t or qu e.
wheel, inspect the damper to ensure the rubber iso- (9) Con n ect t h e ba t t er y n ega t ive (gr ou n d) ca ble t o
lator on the damper is not deteriorated or damaged. ba t t er y post followin g specia l Dia gn osis An d Test in g
If the damper is installed with a damaged isolator, a pr ocedu r e. (Refer t o 8 - E LE CTRICAL/RE STRAINTS
buzz, squeak or rattle condition may develop. - DIAGNOSIS AND TE STING)
(10) Ch eck oper a t ion of a ll st eer in g wh eel m ou n t ed
(4) In st a ll t h e da m per on t h e st eer in g wh eel (F ig. com pon en t s.
42). (11) Roa d t est veh icle t o en su r e pr oper oper a t ion of
(5) In st a ll t h e st eer in g wh eel r et a in in g bolt . st eer in g.
Tigh t en t h e st eer in g wh eel r et a in in g bolt t o 61 N·m
19 - 26 GEAR RS
GEAR
TABLE OF CONTENTS
page page
GEAR INSTALLATION
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 26 INSTALLATION - LHD GEAR . . . . . . . . . . . . . 31
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 INSTALLATION - RHD GEAR . . . . . . . . . . . . . 33
WARNING SPECIAL TOOLS
WARNINGS AND CAUTIONS . . . . . . . . . . . . . 26 POWER STEERING GEAR . . . . . . . . . . . . . . 34
REMOVAL OUTER TIE ROD
REMOVAL - LHD GEAR . . . . . . . . . . . . . . . . . 26 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
REMOVAL - RHD GEAR .. . . . . . . . . . . . . . . 29 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 35
GEAR Ma n u a l st eer in g con t r ol of t h e veh icle ca n be m a in -

t a in ed if power st eer in g a ssist is lost . H owever,
u n der t h is con dit ion , st eer in g effor t is sign ifica n t ly
DESCRIPTION
in cr ea sed.
Th is veh icle is equ ipped wit h a r a ck a n d pin ion
power st eer in g gea r (F ig. 1). It is m ou n t ed t o t h e
u n der side of t h e fr on t su spen sion cr a dle/cr ossm em - WARN I N G
ber.
Th e st eer in g colu m n is a t t a ch ed t o t h e gea r WARNINGS AND CAUTIONS
t h r ou gh t h e u se of a n in t er m edia t e sh a ft a n d cou -
pler s. Th e ou t er en ds of t h e power st eer in g gea r ’s WARNING: POWER STEERING FLUID, ENGINE
ou t er t ie r ods con n ect t o t h e st eer in g kn u ckles. PARTS AND EXHAUST SYSTEM MAY BE
EXTREMELY HOT IF ENGINE HAS BEEN RUNNING.
NOTE: The power steering gear should NOT be ser- DO NOT START ENGINE WITH ANY LOOSE OR DIS-
viced or adjusted unless DaimlerChrysler Corpora- CONNECTED HOSES. DO NOT ALLOW HOSES TO
tion authorizes. If a malfunction or oil leak occurs, TOUCH HOT EXHAUST MANIFOLD OR CATALYST.
the complete steering gear should be replaced.
Only the outer tie rods may be replaced separately
from the rest of the gear. WARNING: FLUID LEVEL SHOULD BE CHECKED
WITH THE ENGINE OFF TO PREVENT PERSONAL
INJURY FROM MOVING PARTS.
OPERATION
Tu r n in g of t h e st eer in g wh eel is con ver t ed in t o lin -
ea r (side-t o-side) t r a vel t h r ou gh t h e m esh in g of t h e CAUTION: When the system is open, cap all open
h elica l pin ion t eet h wit h t h e r a ck t eet h in t h e st eer- ends of the hoses, power steering pump fittings or
in g gea r. Th is t r a vel pu sh es a n d pu lls t h e t ie r ods t o power steering gear ports to prevent entry of for-
ch a n ge t h e dir ect ion of t h e veh icle’s fr on t wh eels. eign material into the components.
P ower a ssist st eer in g pr ovided by t h e power st eer-
in g pu m p is con t r olled by a n open cen t er, r ot a r y t ype
con t r ol va lve wh ich dir ect s oil fr om t h e pu m p t o REM OVAL
eit h er side of t h e in t egr a l r a ck pist on u pon dem a n d.
Roa d feel is con t r olled by t h e dia m et er of a t or sion REMOVAL - LHD GEAR
ba r wh ich in it ia lly st eer s t h e veh icle. As r equ ir ed (1) Rem ove ca p fr om power st eer in g flu id r eser-
st eer in g effor t in cr ea ses, a s in a t u r n , t h e t or sion ba r voir.
t wist s, ca u sin g r ela t ive r ot a r y m ot ion bet ween t h e (2) Usin g a siph on pu m p, r em ove a s m u ch flu id a s
r ot a r y va lve body a n d t h e va lve spool. Th is m ove- possible fr om t h e power st eer in g flu id r eser voir. U s e
m en t dir ect s oil beh in d t h e in t egr a l r a ck pist on c a re n o t to d a m a g e th e filte r m e s h be lo w th e
wh ich , in t u r n , bu ilds h ydr a u lic pr essu r e a n d a ssist s flu id s u rfa c e .
in t h e t u r n in g effor t .
RS GEAR 19 - 27
GEAR (Cont inue d)
Fig. 1 Power Steering Gear (Typical)

1 - TIE ROD JAM NUT 7 - OUTER TIE ROD
2 - INNER TIE ROD 8 - TIE ROD JAM NUT
3 - STEERING GEAR MOUNTING BRACKET 9 - BOOT/BELLOWS
4 - POWER STEERING GEAR FLUID LINES 10 - STEERING GEAR BOOT BREATHER TUBE
5 - STEERING COLUMN INTERMEDIATE SHAFT 11 - BOOT/BELLOWS
6 - INNER TIE ROD 12 - OUTER TIE ROD
CAUTION: Locking the steering column in the

straight-ahead position will prevent the clockspring
from being accidentally over-extended when the
steering column is disconnected from the interme-
diate steering coupler.
(3) P osit ion t h e st eer in g wh eel in t h e STRAIGH T-

AH E AD posit ion . Lock t h e st eer in g wh eel in pla ce
u sin g a st eer in g wh eel h oldin g t ool.
(4) Wit h t h e veh icle on t h e gr ou n d, discon n ect t h e
st eer in g colu m n sh a ft cou pler fr om t h e st eer in g gea r
in t er m edia t e cou pler (F ig. 2).
DURE )
(6) Rem ove fr on t wh eel a n d t ir e a ssem blies.
(7) Rem ove fr on t em ission s va por ca n ist er. (Refer Fig. 2 Steering Column Shaft To Intermediate Shaft
t o 25 - E MISSIONS CONTROL/E VAP ORATIVE Attachment
E MISSIONS/VAP OR CANISTE R - RE MOVAL) 1 - STEERING COLUMN SHAFT COUPLER
(8) Rem ove a sin gle h ose a t power st eer in g cooler 2 - NUT
3 - SAFETY PIN
a n d a llow flu id t o dr a in . 4 - INTERMEDIATE SHAFT
5 - PINCH BOLT
19 - 28 GEAR RS
GEAR (Cont inue d)
(9) Rem ove 2 bolt s a t t a ch in g power st eer in g cooler (11) Rem ove bolt s fa st en in g lea k det ect ion pu m p t o
t o cr a dle cr ossm em ber r ein for cem en t (F ig. 3). cr a dle cr ossm em ber r ein for cem en t . (Refer t o 25 -
E MISSIONS CONTROL/E VAP ORATIVE E MIS-
SIONS/LE AK DE TE CTION P UMP - RE MOVAL)
(12) Rem ove bot h ou t er t ie r ods fr om st eer in g
kn u ckles, u sin g P u ller, Specia l Tool C-3894–A (F ig.
5).

(10) On bot h sides of veh icle, r em ove n u t a t t a ch in g

ou t er t ie r od en d t o st eer in g kn u ckle (F ig. 4).
Re m o v e n u t by h o ld in g tie ro d e n d s tu d w ith a
s o c k e t w h ile lo o s e n in g a n d re m o v in g n u t w ith
w re n c h .
Fig. 5 Tie Rod Removal With Tool C-3894-A

1 - OUTER TIE ROD
2 - SPECIAL TOOL C-3894-A

t r ol a r m r ea r bu sh in g.
NOTE: The bolts fastening the cradle crossmember

the location of the various sizes.
Fig. 4 Removing/Installing Tie Rod End Attaching

Nut
1 - TIE ROD END
3 - WRENCH
4 - SOCKET
RS GEAR 19 - 29
GEAR (Cont inue d)
(14) Rem ove t h e bolt s a t t a ch in g t h e cr a dle cr oss- NOTE: The next step must be done to allow the
m em ber r ein for cem en t t o t h e fr on t su spen sion cr a dle removal of the steering gear from the front suspen-
cr ossm em ber (F ig. 6). Rem ove t h e 2 bolt s fa st en in g sion cradle. The steering gear can not be removed
t h e r ein for cem en t a n d r ea r of cr a dle cr ossm em ber t o from the vehicle with the intermediate coupler
t h e body of t h e veh icle. Rem ove lower r ea r bu sh in gs, attached to the steering gear.
t h en t h e r ein for cem en t .
(18) Lower st eer in g gea r fr om su spen sion cr a dle
en ou gh t o a llow a ccess t o t h e in t er m edia t e cou pler
r oll pin (F ig. 9). In st a ll Rem over /In st a ller Specia l
Tool 6831A t h r ou gh t h e cen t er of t h e r oll pin , secu r-
in g wit h t h e kn u r led n u t (F ig. 9). H old t h r ea ded r od
st a t ion a r y wh ile t u r n in g n u t , t h is will pu ll t h e r oll
pin ou t of t h e in t er m edia t e cou pler.
(19) Sepa r a t e t h e cou pler fr om t h e sh a ft of t h e
st eer in g gea r.
(20) Rem ove t h e power st eer in g gea r fr om t h e
veh icle.
REMOVAL - RHD GEAR

(1) Rem ove ca p fr om power st eer in g flu id r eser-
voir.
(2) Usin g a siph on pu m p, r em ove a s m u ch flu id a s
possible fr om t h e power st eer in g flu id r eser voir.
CAUTION: Locking the steering column in the

straight-ahead position will prevent the clockspring
from being accidentally over-extended when the
steering column is disconnected from the interme-
diate steering coupler.
(3) P osit ion t h e st eer in g wh eel in t h e STRAIGH T-

AH E AD posit ion . Lock t h e st eer in g wh eel in pla ce
u sin g a st eer in g wh eel h oldin g t ool.
(4) Wit h t h e ign it ion key in t h e locked posit ion
t u r n t h e st eer in g wh eel t o t h e left u n t il t h e st eer in g
Fig. 6 Cradle Crossmember Reinforcement wh eel is in t h e locked posit ion .
Attachment (5) Wit h t h e veh icle on t h e gr ou n d, discon n ect t h e
1 - STEERING GEAR st eer in g colu m n sh a ft cou pler fr om t h e st eer in g gea r
2 - RIGHT LOWER CONTROL ARM in t er m edia t e cou pler (F ig. 2).
3 - LEFT LOWER CONTROL ARM
4 - CRADLE CROSSMEMBER REINFORCEMENT (6) Ra ise veh icle. (Refer t o LUBRICATION &
5 - REAR CRADLE CROSSMEMBER ISOLATOR BUSHING MAINTE NANCE /H OISTING - STANDARD P ROCE -
6 - STABILIZER BAR DURE )
7 - CRADLE CROSSMEMBER
(7) Rem ove fr on t wh eel a n d t ir e a ssem blies.
(15) If t h e veh icle is equ ipped wit h All-Wh eel- (8) If power st eer in g cooler equ ipped, r em ove a
Dr ive, r em ove t h e power t r a n sfer u n it a s n ecessa r y h ose a t power st eer in g cooler a n d a llow flu id t o
(Refer t o 21 - TRANSMISSION/TRANSAXLE / dr a in .
P OWE R TRANSF E R UNIT). (9) Rem ove 2 bolt s a t t a ch in g power st eer in g cooler
(16) Rem ove t u be n u t s a n d power st eer in g pr es- t o cr a dle cr ossm em ber r ein for cem en t (F ig. 3).
su r e a n d r et u r n h oses fr om t h e power st eer in g gea r (10) On bot h sides of veh icle, r em ove n u t a t t a ch in g
(F ig. 7). ou t er t ie r od en d t o st eer in g kn u ckle (F ig. 4).
(17) Rem ove t h e 3 bolt s a n d n u t s m ou n t in g t h e Re m o v e n u t by h o ld in g tie ro d e n d s tu d w ith a
st eer in g gea r t o t h e fr on t su spen sion cr a dle (F ig. 8). s o c k e t w h ile lo o s e n in g a n d re m o v in g n u t w ith
w re n c h .
19 - 30 GEAR RS
GEAR (Cont inue d)
Fig. 7 Hoses To Power Steering Gear - 3.3L/3.8L Engine

1 - RETURN HOSE (TO RESERVOIR) 7 - POWER STEERING GEAR
2 - PRESSURE HOSE (FROM PUMP) 8 - ABS BRACKET
3 - CRADLE CROSSMEMBER 9 - ROUTING CLIP
4 - PRESSURE HOSE ROUTING CLAMP 10 - LEAK DETECTION PUMP FILTER
5 - RETURN HOSE ROUTING CLAMP 11 - RETURN HOSE TUBE NUT
6 - PRESSURE HOSE TUBE NUT 12 - ROUTING CLIP
Fig. 8 Steering Gear Mounting To Suspension Cradle Fig. 9 Removing Roll Pin From Intermediate Coupler
1 - POWER STEERING GEAR 1 - INTERMEDIATE COUPLER
2 - MOUNTING BOLTS (12 MM) 2 - KNURLED NUT
3 - MOUNTING BOLT (14 MM) 3 - SUSPENSION CRADLE
4 - FRONT SUSPENSION CRADLE CROSSMEMBER 4 - REMOVER SPECIAL TOOL 6831A
5 - STEERING GEAR
(11) Rem ove bot h t ie r od en ds fr om st eer in g 6 - NUT
7 - ROLL PIN
kn u ckles u sin g P u ller, Specia l Tool C-3894–A (F ig. 5). 8 - THREADED ROD
RS GEAR 19 - 31
GEAR (Cont inue d)
t r ol a r m r ea r bu sh in g.
NOTE: The bolts fastening the cradle crossmember

the location of the various sizes.
(13) Rem ove t h e bolt s a t t a ch in g t h e cr a dle cr oss-

m em ber r ein for cem en t t o t h e fr on t su spen sion cr a dle
cr ossm em ber (F ig. 6). Rem ove t h e 2 bolt s fa st en in g
t h e r ein for cem en t a n d r ea r of cr a dle cr ossm em ber t o
t h e body of t h e veh icle. Rem ove t h e r ein for cem en t .
(14) If t h e veh icle is equ ipped wit h All-Wh eel-
Dr ive, r em ove t h e power t r a n sfer u n it (Refer t o 21 -
TRANSMISSION/TRANSAXLE /P OWE R TRANSF E R
UNIT - RE MOVAL).
(15) Rem ove t h e power st eer in g flu id pr essu r e a n d
r et u r n h oses fr om t h e power st eer in g gea r (F ig. 10).
Fig. 11 RHD Power Steering Gear - 2.5L Diesel

Shown
1 - RETURN HOSE
2 - PRESSURE HOSE
4 - POWER STEERING GEAR
5 - RETURN HOSE FITTING
6 - PRESSURE HOSE FITTING
7 - HOSE ROUTING CLAMP
(19) Lower st eer in g gea r fr om su spen sion cr a dle

en ou gh t o a llow a ccess t o t h e in t er m edia t e cou pler
r oll pin (F ig. 9). In st a ll Rem over /In st a ller, Specia l
Tool 6831A, t h r ou gh t h e cen t er of t h e r oll pin , secu r-
in g wit h t h e kn u r led n u t (F ig. 9). H old t h r ea ded r od
Fig. 10 RHD Gear Heat Shield And Hose Fittings
st a t ion a r y wh ile t u r n in g n u t , t h is will pu ll t h e r oll
1 - HEAT SHIELD pin ou t of t h e in t er m edia t e cou pler.
3 - RETURN HOSE FITTING (20) Sepa r a t e t h e cou pler fr om t h e st eer in g gea r
4 - PRESSURE HOSE FITTING sh a ft .
5 - POWER STEERING GEAR (21) Rem ove t h e power st eer in g gea r fr om t h e
veh icle.
(16) Rem ove t h e r ou t in g cla m p bolt secu r in g t h e
power st eer in g flu id h oses t o t h e r ea r of t h e cr a dle
cr ossm em ber (F ig. 11). Allow t h e h oses t o h a n g down I N STALLAT I ON
ou t of t h e wa y.
(17) Rem ove t h e h ea t sh ield fr om t h e st eer in g gea r INSTALLATION - LHD GEAR
(F ig. 10). (1) In st a ll t h e power st eer in g gea r u p in t h e fr on t
(18) Rem ove t h e 2 bolt s a n d n u t s m ou n t in g t h e su spen sion cr a dle, lea vin g r oom t o in st a ll in t er m edi-
st eer in g gea r t o t h e fr on t su spen sion cr a dle. a t e cou pler.
(2) St a r t t h e r oll pin in t o t h e in t er m edia t e cou pler
NOTE: The next step must be done to allow the
befor e in st a llin g cou pler on st eer in g gea r sh a ft . St a r t
removal of the steering gear from the front suspen-
r oll pin in t o cou pler, u sin g a h a m m er a n d t a ppin g it
sion cradle. The steering gear cannot be removed
in t o t h e cou pler. Th en in st a ll t h e in t er m edia t e cou -
from the vehicle with the intermediate coupler
pler on t h e sh a ft of t h e st eer in g gea r.
attached to the steering gear.
19 - 32 GEAR RS
GEAR (Cont inue d)
(3) In st a ll Rem over /In st a ller Specia l Tool 6831A (8) In st a ll t h e lower con t r ol a r m r ea r bu sh in g
t h r ou gh t h e cen t er of t h e r oll pin , secu r in g it wit h r et a in er bolt s (M-10 size) t h r ou gh r ein for cem en t on
t h e kn u r led n u t (F ig. 12). H old t h r ea ded r od st a t ion - ea ch side of ea ch lower con t r ol a r m r ea r bu sh in g.
a r y wh ile t u r n in g n u t , t h is will pu ll t h e r oll pin in t o Tigh t en bolt s t o a t or qu e of 61 N·m (45 ft . lbs.).
t h e in t er m edia t e cou pler. (9) In st a ll t h e t wo bolt s a n d bu sh in gs a t t a ch in g
t h e r ein for cem en t a n d r ea r of cr a dle cr ossm em ber t o
body of veh icle (F ig. 6). Tigh t en bolt s t o a t or qu e of
163 N·m (120 ft . lbs.).
(10) In st a ll ou t er t ie r od en d in t o st eer in g kn u ckle.
St a r t ou t er t ie r od t o st eer in g kn u ckle a t t a ch in g n u t
on t o st u d of t ie r od en d. Wh ile h oldin g st u d of t ie r od
en d st a t ion a r y u sin g a socket (F ig. 4), t igh t en t ie r od
en d t o st eer in g kn u ckle a t t a ch in g n u t . Th en u sin g a
cr owfoot a n d socket (F ig. 13), t igh t en t h e t ie r od en d
a t t a ch in g n u t t o a t or qu e of 75 N·m (55 ft . lbs.).
Fig. 12 Installing Roll Pin In Intermediate Coupler

1 - INTERMEDIATE SHAFT COUPLER
2 - SUSPENSION CRADLE CROSSMEMBER
3 - KNURLED NUT
4 - ROLL PIN
CAUTION: Proper torque on the steering gear to

suspension cradle mounting bolts is very impor-
tant.
(4) In st a ll st eer in g gea r on t h e fr on t su spen sion Fig. 13 Torquing Tie Rod End Attaching Nut
cr a dle. In st a ll t h e 3 st eer in g gea r m ou n t in g bolt s a n d 1 - STEERING KNUCKLE
n u t s (F ig. 8). Tigh t en t h e 3 m ou n t in g bolt s t o t h e fol- 2 - TIE ROD END
lowin g t or qu e va lu es: 3 - CROWFOOT
4 - SOCKET
• 14 m m bolt – 183 N·m (135 ft . lbs.) t or qu e 5 - TORQUE WRENCH
• 12 m m bolt – 95 N·m (70 ft . lbs.) t or qu e
(5) At t a ch t h e power st eer in g flu id pr essu r e a n d (11) In st a ll lea k det ect ion pu m p on cr a dle cr oss-
r et u r n h oses t o t h e cor r ect por t s on t h e power st eer- m em ber r ein for cem en t . (Refer t o 25 - E MISSIONS
in g gea r (F ig. 7). Tigh t en t h e h ose t u be n u t s a t t h e CONTROL/E VAP ORATIVE E MISSIONS/LE AK
gea r t o a t or qu e of 31 N·m (275 in . lbs.). DE TE CTION P UMP - INSTALLATION)
(6) If t h e veh icle is equ ipped wit h All-Wh eel-Dr ive, (12) In st a ll t h e power st eer in g flu id cooler on t h e
in st a ll t h e power t r a n sfer u n it a s n ecessa r y (Refer t o cr a dle cr ossm em ber r ein for cem en t (F ig. 3). In st a ll
21 - TRANSMISSION/TRANSAXLE /P OWE R t h e m ou n t in g bolt s a n d t igh t en t o 11 N·m (100 in .
TRANSF E R UNIT). lbs.). Wh en in st a llin g m ou n t in g bolt s, in clu de pr es-
su r e h ose r ou t in g cla m p.
CAUTION: Proper torque on the cradle reinforce- (13) Recon n ect pr eviou sly discon n ect ed h ose a t
ment to suspension cradle mounting bolts is very power st eer in g cooler a n d in st a ll cla m p.
important. (14) In st a ll t h e fr on t t ir e a n d wh eel a ssem blies on
veh icle. In st a ll t h e wh eel lu g n u t s a n d t or qu e t o 135
(7) In st a ll t h e r ein for cem en t on t h e fr on t su spen -
N·m (100 ft . lbs.).
sion cr a dle cr ossm em ber a n d in st a ll t h e bolt s a t t a ch -
(15) In st a ll fr on t em ission s va por ca n ist er. (Refer
in g t h e r ein for cem en t t o t h e cr a dle cr ossm em ber
t o 25 - E MISSIONS CONTROL/E VAP ORATIVE
(F ig. 6). Tigh t en t h e M-14 size bolt s t o a t or qu e of
E MISSIONS/VAP OR CANISTE R - INSTALLATION)
153 N·m (113 ft . lbs.). Tigh t en t h e M-12 size bolt s t o
(16) Lower t h e veh icle t o a level wh er e t h e in t er ior
of veh icle is a ccessible.
RS GEAR 19 - 33
GEAR (Cont inue d)
(17) Wit h t h e wh eels poin t ed a ppr oxim a t ely st u d of t ie r od en d. Wh ile h oldin g st u d of t ie r od en d
STRAIGH T-AH E AD, a lign t h e in t er m edia t e sh a ft st a t ion a r y u sin g a socket (F ig. 4), t igh t en t ie r od en d
wit h t h e st eer in g colu m n cou pler. Assem ble t h e st eer- t o st eer in g kn u ckle a t t a ch in g n u t . Th en u sin g a
in g colu m n sh a ft cou pler on t o t h e st eer in g gea r in t er- cr owfoot a n d socket (F ig. 13), t igh t en t h e t ie r od en d
m edia t e cou pler (F ig. 2). In st a ll st eer in g colu m n a t t a ch in g n u t t o a t or qu e of 75 N·m (55 ft . lbs.).
cou pler t o in t er m edia t e sh a ft r et a in in g pin ch bolt . (10) If t h e veh icle is equ ipped wit h All-Wh eel-
Tigh t en t h e pin ch bolt n u t t o a t or qu e of 28 N·m (250 Dr ive, in st a ll t h e power t r a n sfer u n it (Refer t o 21 -
in . lbs.). TRANSMISSION/TRANSAXLE /P OWE R TRANSF E R
(18) Rem ove t h e st eer in g wh eel h oldin g t ool. UNIT - INSTALLATION).
(19) F ill a n d bleed t h e power st eer in g syst em
u sin g t h e P ower St eer in g P u m p In it ia l Oper a t ion CAUTION: Proper torque on the cradle reinforce-
P r ocedu r e. (Refer t o 19 - STE E RING/P UMP - STAN- ment to suspension cradle mounting bolts is very
DARD P ROCE DURE ) important.
(20) In spect syst em for lea ks.
(21) Adju st fr on t t oe (Refer t o 2 - SUSP E NSION/ (11) In st a ll t h e r ein for cem en t on t h e fr on t su spen -
WH E E L ALIGNME NT - STANDARD P ROCE DURE ). sion cr a dle cr ossm em ber a n d in st a ll t h e bolt s a t t a ch -
in g t h e r ein for cem en t t o t h e cr a dle cr ossm em ber
INSTALLATION - RHD GEAR (F ig. 6). Tigh t en t h e M-14 size bolt s t o a t or qu e of
163 N·m (120 ft . lbs.). Tigh t en t h e M-12 size bolt s t o
(1) In st a ll t h e st eer in g gea r u p in t h e fr on t su s-
pen sion cr a dle cr ossm em ber, lea vin g r oom t o in st a ll a t or qu e of 108 N·m (80 ft . lbs.).
(12) In st a ll t h e lower con t r ol a r m r ea r bu sh in g
in t er m edia t e cou pler.
(2) St a r t t h e r oll pin in t o t h e in t er m edia t e cou pler r et a in er bolt s t h r ou gh r ein for cem en t on ea ch side of
ea ch lower con t r ol a r m r ea r bu sh in g. Tigh t en bolt s t o
befor e in st a llin g cou pler on st eer in g gea r sh a ft . St a r t
r oll pin in t o cou pler, u sin g a h a m m er a n d t a ppin g it
(13) In st a ll t h e t wo bolt s a n d bu sh in gs a t t a ch in g
in t o t h e cou pler. Th en in st a ll t h e in t er m edia t e cou -
pler on t h e sh a ft of t h e st eer in g gea r. t h e r ein for cem en t a n d r ea r of cr a dle cr ossm em ber t o
(3) In st a ll Rem over /In st a ller Specia l Tool 6831A body of veh icle (F ig. 6). Tigh t en bolt s t o a t or qu e of
163 N·m (120 ft . lbs.).
t h r ou gh t h e cen t er of t h e r oll pin , secu r in g it wit h
t h e kn u r led n u t (F ig. 12). H old t h r ea ded r od st a t ion - (14) If power st eer in g cooler equ ipped, in st a ll t h e
pr eviou sly discon n ect ed power st eer in g cooler h ose on
a r y wh ile t u r n in g n u t . Th is will pu ll t h e r oll pin in t o
t h e in t er m edia t e cou pler. t h e cooler. In st a ll t h e cla m p.
(15) If power st eer in g cooler equ ipped, in st a ll t h e
(4) In st a ll power st eer in g gea r on t h e fr on t su spen -
sion cr a dle. In st a ll t h e 2 st eer in g gea r m ou n t in g power st eer in g flu id cooler on t h e cr a dle cr ossm em -
bolt s a n d n u t s. Tigh t en t h e M-14 size st eer in g gea r ber r ein for cem en t (F ig. 3). In st a ll t h e m ou n t in g bolt s
t o su spen sion cr a dle m ou n t in g bolt t o a t or qu e of 183 a n d t igh t en t o 11 N·m (100 in . lbs.).
(16) In st a ll t h e fr on t t ir e a n d wh eel a ssem blies on
N·m (135 ft . lbs.). Tigh t en t h e M-12 size st eer in g
veh icle. In st a ll t h e wh eel m ou n t in g lu g n u t s a n d
gea r t o su spen sion cr a dle m ou n t in g bolt t o a t or qu e
of 95 N·m (70 ft . lbs.). t igh t en t o a t or qu e t o 135 N·m (100 ft . lbs.).
(17) Lower t h e veh icle t o a level wer e t h e in t er ior
CAUTION: Proper torque on the steering gear to of veh icle is a ccessible (keepin g t ir es off t h e gr ou n d).
suspension cradle mounting bolts is very impor- (18) Wit h t h e wh eels poin t ed a ppr oxim a t ely
tant. STRAIGH T-AH E AD, a lign t h e in t er m edia t e sh a ft
wit h t h e st eer in g colu m n cou pler. Assem ble t h e st eer-
(5) In st a ll t h e h ea t sh ield on t h e st eer in g gea r in g colu m n sh a ft cou pler on t o t h e st eer in g gea r in t er-
(F ig. 10). m edia t e cou pler (F ig. 2). In st a ll st eer in g colu m n
(6) At t a ch t h e power st eer in g flu id pr essu r e a n d cou pler t o in t er m edia t e sh a ft r et a in in g pin ch bolt .
r et u r n h oses t o t h e pr oper fit t in gs on t h e st eer in g Tigh t en t h e pin ch bolt n u t t o a t or qu e of 28 N·m (250
gea r (F ig. 10). Do n ot fu lly t igh t en t h e fit t in gs a t t h is in . lbs.).
t im e. (19) Rem ove t h e st eer in g wh eel h oldin g t ool.
(7) In st a ll t h e r ou t in g cla m p wit h t h e bolt secu r in g (20) P er for m t h e P OWE R STE E RING P UMP INI-
t h e power st eer in g flu id h oses t o t h e r ea r of t h e cr a - TIAL OP E RATION pr ocedu r e t o pr oper ly fill a n d
dle cr ossm em ber (F ig. 11). bleed t h e power st eer in g syst em . (Refer t o 19 -
(8) Usin g a cr owfoot wr en ch on a t or qu e wr en ch , STE E RING/P UMP - STANDARD P ROCE DURE )
t igh t en t h e power st eer in g flu id h ose t u be n u t s a t t h e (21) In spect for lea ks.
gea r t o a t or qu e of 31 N·m (275 in . lbs.). (22) Adju st fr on t wh eel t oe (Refer t o 2 - SUSP E N-
(9) In st a ll t ie r od en d in t o st eer in g kn u ckle. St a r t SION/WH E E L ALIGNME NT - STANDARD P ROCE -
t ie r od en d t o st eer in g kn u ckle a t t a ch in g n u t on t o DURE ).
19 - 34 GEAR RS
GEAR (Cont inue d)
SPECI AL T OOLS
POWER STEERING GEAR
Puller C-3894A
Fig. 15 Tie Rod End Attaching Nut (Typical)

1 - TIE ROD END
3 - WRENCH
4 - SOCKET
Remover/Installer Steering Shaft Roll Pin 6831A (3) Rem ove t h e t ie r od en d st u d fr om st eer in g
kn u ckle a r m , u sin g Rem over, Specia l Tool C-3894–A
OU T ER T I E ROD (F ig. 16).
REMOVAL
(1) Loosen in n er t ie r od t o ou t er t ie r od ja m n u t
(F ig. 14).
Fig. 14 Inner To Outer Tie Rod Jam Nut

1 - INNER TIE ROD SERRATION
2 - OUTER TIE ROD JAM NUT
3 - OUTER TIE ROD END
4 - INNER TIE ROD
Fig. 16 TIE ROD REMOVAL WITH TOOL C-3894-A
(2) Rem ove n u t a t t a ch in g ou t er t ie r od en d t o
1 - OUTER TIE ROD
st eer in g kn u ckle (F ig. 15). Th e n u t is t o be r em oved 2 - SPECIAL TOOL C-3894-A
fr om t ie r od en d by h oldin g t ie r od en d st u d wit h a 3 - STEERING KNUCKLE
11/32 socket wh ile loosen in g a n d r em ovin g n u t wit h a
wr en ch .
RS GEAR 19 - 35
OU T ER T I E ROD (Cont inue d)
(4) Rem ove ou t er t ie r od en d by u n -t h r ea din g it
fr om t h e in n er t ie r od.
INSTALLATION
NOTE: Before installing the outer tie rod, make sure
the jam nut is on inner tie rod (Fig. 14).
(1) In st a ll ou t er t ie r od on t o in n er t ie r od.
(2) Do n ot t igh t en ja m n u t .
(3) In st a ll t ie r od en d in t o t h e st eer in g kn u ckle.
St a r t t ie r od en d t o st eer in g kn u ckle a t t a ch in g n u t
on t o st u d of t ie r od en d. Wh ile h oldin g st u d of t ie r od
en d st a t ion a r y, t igh t en t ie r od en d t o st eer in g
kn u ckle a t t a ch in g n u t (F ig. 15). Th en u sin g a cr ow-
foot a n d 11/32 socket (F ig. 17), t or qu e t ie r od en d
a t t a ch in g n u t t o 75 N·m (55 ft . lbs.). Fig. 17 Torquing Tie Rod End Attaching Nut
(4) Tigh t en t ie r od ja m n u t (F ig. 14) t o 75 N·m (55 1 - STEERING KNUCKLE
ft . lbs.) t or qu e. 2 - TIE ROD END
3 - CROWFOOT
CAUTION: During this procedure do not allow the 4 - SOCKET
5 - TORQUE WRENCH
steering gear boot to become twisted.
(5) Adju st t h e fr on t t oe set t in g on t h e veh icle

(Refer t o 2 - SUSP E NSION/WH E E L ALIGNME NT -
19 - 36 PUMP RS
PU M P
TABLE OF CONTENTS
page page
PUMP REMOVAL - 3.3L/3.8L ENGINE ...... . . . . . 46

DESCRIPTION INSTALLATION
DESCRIPTION - PUMP (2.4L/3.3L/3.8L INSTALLATION - 2.4L ENGINE ...... . . . . . 47
ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 INSTALLATION - 3.3L/3.8L ENGINE . . . . . . . . 48
DESCRIPTION - PUMP (DIESEL) ....... . . 37 HOSE - POWER STEERING RETURN
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 REMOVAL
WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 REMOVAL - 2.4L ENGINE . . . . . . . . . . . . . . . 49
CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 REMOVAL - 3.3L/3.8L ENGINE ...... . . . . . 49
STANDARD PROCEDURE - POWER INSTALLATION
STEERING PUMP INITIAL OPERATION . . . . . 37 INSTALLATION - 2.4L ENGINE ...... . . . . . 50
REMOVAL INSTALLATION - 3.3L/3.8L ENGINE . . . . . . . . 50
REMOVAL - PUMP (2.4L ENGINE) . . . . . . . . . 38 HOSE - POWER STEERING SUPPLY
REMOVAL - PUMP (3.3L/3.8L ENGINE) . . . . . 40 REMOVAL
REMOVAL - PUMP (DIESEL) . . . . . . . . . . . . . 41 REMOVAL - 2.4L ENGINE . . . . . . . . . . . . . . . 51
DISASSEMBLY - PUMP (PULLEY) ........ . . 41 REMOVAL - 3.3L/3.8L ENGINE ...... . . . . . 51
ASSEMBLY - PUMP (PULLEY) . . . . . . . . . . . . . 42 INSTALLATION
INSTALLATION INSTALLATION - 2.4L ENGINE ...... . . . . . 51
INSTALLATION - PUMP (2.4L ENGINE) . . . . . 43 INSTALLATION - 3.3L/3.8L ENGINE . . . . . . . . 52
INSTALLATION - PUMP (3.3L/3.8L ENGINE) . 43 RESERVOIR - POWER STEERING FLUID
INSTALLATION - PUMP (DIESEL) . . . . . . . . . 43 DESCRIPTION
SPECIAL TOOLS DESCRIPTION - 2.4L/3.3L/3.8L ENGINE . . . . 52
POWER STEERING PUMP . . . . . . . . . . . . . . 44 DESCRIPTION - DIESEL . . . . . . . . . . . . . . . . 52
FLUID OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
STANDARD PROCEDURE - POWER REMOVAL
STEERING FLUID LEVEL CHECKING . . . . . . 44 REMOVAL - 2.4L ENGINE . . . . . . . . . . . . . . . 52
FLUID COOLER REMOVAL - 3.3L/3.8L ENGINE ...... . . . . . 52
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 45 REMOVAL - DIESEL . . . . . . . . . . . . . . . . . . . 52
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 INSTALLATION
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 INSTALLATION - 2.4L ENGINE ...... . . . . . 53
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 45 INSTALLATION - 3.3L/3.8L ENGINE . . . . . . . . 53
HOSE - POWER STEERING PRESSURE INSTALLATION - DIESEL . . . . . . . . . . . . . . . . 53
REMOVAL
REMOVAL - 2.4L ENGINE . . . . . . . . . . . . . . . 46
PU M P ou t of ca st ir on a n d st eel (F ig. 1). Th e pu m p u sed on

t h e 3.3L/3.8L en gin e is m a de of a lu m in u m (F ig. 2).
Th e pu m p for t h e 3.3L/3.8L en gin e does n ot h a ve a
DESCRI PT I ON r et u r n fit t in g a s t h e pu m p for t h e 2.4L en gin e does.
Th e power st eer in g r et u r n h ose on t h e 3.3L/3.8L
DESCRIPTION - PUMP (2.4L/3.3L/3.8L en gin e goes t o t h e r eser voir in st ea d of t h e pu m p.
ENGINE)
H ydr a u lic pr essu r e for t h e oper a t ion of t h e power
st eer in g gea r is pr ovided by a belt dr iven power
st eer in g pu m p. Th e power st eer in g pu m p is m ou n t ed
on t h e ba ck side of t h e en gin e on a ll en gin e a pplica -
t ion s. Th e pu m ps a r e differ en t depen din g on t h e
en gin e opt ion . Th e pu m p for t h e 2.4L en gin e is m a de
RS PUMP 19 - 37
PU M P (Cont inue d)
OPERATION
Th e power st eer in g pu m p is a con st a n t displa ce-
m en t va n e t ype pu m p. Th e 2.4L pu m p h a s a n in t e-
gr a l flu id r eser voir a n d t h er e is a secon da r y r em ot e
n on -flow r eser voir wh ich a ct s on ly a s a flu id fill a n d
ch eck poin t . Th e 3.3L/3.8L pu m p h ou ses ver y lit t le
flu id a n d is t h er efor e su pplied by a r em ot e flow
t h r ou gh r eser voir.
WARNING
WARNING: POWER STEERING FLUID, ENGINE
PARTS AND 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
Fig. 1 POWER STEERING PUMP (2.4L) TOUCH HOT EXHAUST MANIFOLD OR CATALYST.
1 - PULLEY
2 - BRACKET
3 - PRESSURE FITTING WARNING: FLUID LEVEL SHOULD BE CHECKED
4 - RETURN FITTING
5 - SUPPLY FITTING
WITH THE ENGINE OFF TO PREVENT PERSONAL
INJURY FROM MOVING PARTS.
CAUTION
CAUTION: When the system is open, cap all open
ends of the hoses, power steering pump fittings or
power steering gear ports to prevent entry of for-
eign material into the components.
STANDARD PROCEDURE - POWER STEERING

PUMP INITIAL OPERATION
WARNING: FLUID LEVEL SHOULD BE CHECKED
AND ADJUSTED WITH ENGINE OFF TO PREVENT
INJURY FROM MOVING ENGINE COMPONENTS.
Fig. 2 POWER STEERING PUMP (3.3L/3.8L)
1 - SUPPLY FITTING CAUTION: Use only Mopar" Automatic Transmis-
2 - PRESSURE FITTING sion Fluid (MS-9602) in power steering system. Use
3 - PULLEY
of other Mopar" power steering fluids (MS5931 and
MS9933) should be avoided to ensure peak perfor-
DESCRIPTION - PUMP (DIESEL) mance of the power steering system under all oper-
H ydr a u lic pr essu r e for t h e oper a t ion of t h e power
ating conditions. Do not overfill.
st eer in g gea r is pr ovided by a belt dr iven power
st eer in g pu m p. Th e power st eer in g pu m p is m ou n t ed
fr on t lower r igh t cor n er of t h e en gin e (F ig. 13).
Th e pu m p h a s a su pply fit t in g for flu id com in g
fr om t h e r eser voir a n d a pr essu r e por t for exit in g
flu id t h a t is h ea ded for t h e st eer in g gea r.
19 - 38 PUMP RS
Rea d t h e flu id level t h r ou gh t h e side of t h e power (6) Rem ove t h e fou r bolt s a n d fla g n u t s secu r in g
st eer in g flu id r eser voir. Th e flu id level sh ou ld in di- t h e ca t a lyt ic con ver t er fr om t h e exh a u st m a n ifold
ca t e “F ILL RAN GE” wh en t h e flu id is a t a t em per- (F ig. 3).
a t u r e of a ppr oxim a t ely 21°C t o 27°C (70°F t o 80°F ).
(1) Wipe t h e filler ca p a n d a r ea clea n , t h en r em ove
t h e ca p.
(2) F ill t h e flu id r eser voir t o t h e pr oper level a n d
let t h e flu id set t le for a t lea st t wo (2) m in u t es.
(3) St a r t t h e en gin e a n d let r u n for a few secon ds,
t h en t u r n t h e en gin e off.
(4) Add flu id if n ecessa r y. Repea t t h e a bove st eps
u n t il t h e flu id level r em a in s con st a n t a ft er r u n n in g
t h e en gin e.
(5) Ra ise t h e fr on t wh eels off t h e gr ou n d.
(7) Slowly t u r n t h e st eer in g wh eel r igh t a n d left ,
ligh t ly con t a ct in g t h e wh eel st ops.
(8) Add flu id if n ecessa r y.
(9) Lower t h e veh icle, t h en t u r n t h e st eer in g wh eel
slowly fr om lock-t o-lock.
(10) St op t h e en gin e. Ch eck t h e flu id level a n d
r efill a s r equ ir ed.
(11) If t h e flu id is ext r em ely foa m y, a llow t h e veh i-
cle t o st a bilize a few m in u t es, t h en r epea t t h e a bove
pr ocedu r e. 1 - CATALYTIC CONVERTER
2 - BOLT
3 - GASKET
4 - FLAG NUT
REM OVAL
(7) Discon n ect a ll t h e exh a u st syst em isola t or s/
REMOVAL - PUMP (2.4L ENGINE) h a n ger s fr om t h e br a cket s on t h e exh a u st syst em (2
(1) Rem ove t h e (-) n ega t ive ba t t er y ca ble fr om t h e a t t h e m u ffler s a n d 1 a t t h e r eson a t or ) (F ig. 4).
ba t t er y a n d isola t e ca ble. (8) Rem ove t h e exh a u st syst em by m ovin g it a s fa r
(2) Rem ove t h e ca p fr om t h e power st eer in g flu id r ea r wa r d, t h en lower in g t h e fr on t below t h e cr oss-
r eser voir. m em ber a n d ou t of t h e veh icle.
(3) Usin g a siph on pu m p, r em ove a s m u ch power (9) Rem ove t h e power st eer in g flu id su pply h ose
st eer in g flu id a s possible fr om t h e power st eer in g fr om t h e fit t in g on t h e power st eer in g pu m p. Dr a in
flu id r eser voir. off excess power st eer in g flu id fr om h ose.
(4) Ra ise t h e veh icle on ja ck st a n ds or cen t er ed on (10) Move t h e h ea t sleeve on t h e power st eer in g
a fr a m e con t a ct t ype h oist . See H oist in g in Lu br ica - r et u r n h ose t o expose t h e h ose con n ect ion a t t h e
t ion a n d Ma in t en a n ce. pu m p (F ig. 5). Rem ove t h e h ose fr om t h e power
(5) Discon n ect t h e oxygen sen sor wir in g h a r n ess st eer in g P u m p. Allow t h e r em a in in g power st eer in g
fr om t h e veh icle wir in g h a r n ess a t t h e r ea r en gin e flu id t o dr a in fr om t h e power st eer in g pu m p a n d r es-
m ou n t br a cket . er voir t h r ou gh t h e r em oved r et u r n h ose.
(11) Rem ove t h e power st eer in g flu id pr essu r e lin e
NOTE: The exhaust system needs to be removed fr om t h e power st eer in g pu m p (F ig. 6). Dr a in excess
from the engine to allow for an area to remove the power st eer in g flu id fr om t u be.
power steering pump from the vehicle.
RS PUMP 19 - 39

1 - CATALYTIC CONVERTER 4 - SUPPORT - RESONATOR
2 - BAND CLAMP 5 - RESONATOR
3 - SUPPORTS - MUFFLER 6 - MUFFLER
Fig. 6 Power Steering Fluid Pressure And Return

Hose
1 - POWER STEERING FLUID RETURN HOSE
3 - POWER STEERING FLUID PRESSURE HOSE
Fig. 5 Pressure And Return Hoses - 2.4L

2 - RETURN HOSE (HEAT SLEEVE COVERED)
3 - ROUTING CLAMPS
4 - PRESSURE HOSE TUBE NUT
5 - RETURN HOSE TUBE NUT
8 - PRESSURE HOSE
19 - 40 PUMP RS
(12) Rem ove t h e fa st en er s, t h en t h e a ccessor y (17) Rem ove t h e 3 bolt s a t t a ch in g t h e fr on t
dr ive spla sh sh ield. br a cket t o t h e power st eer in g pu m p a n d sepa r a t e t h e
(13) Rem ove t h e a dju st er n u t a t t a ch in g r ea r of power st eer in g pu m p fr om t h e fr on t br a cket .
power st eer in g pu m p t o t h e ca st m ou n t in g br a cket . (18) If t h e power st eer in g pu m p pu lley n eeds t o be
(F ig. 7) t r a n sfer r ed, (Refer t o 19 - STE E RING/P UMP - DIS-
ASSE MBLY).
REMOVAL - PUMP (3.3L/3.8L ENGINE)

(1) Rem ove t h e (-) n ega t ive ba t t er y ca ble fr om t h e
ba t t er y a n d isola t e ca ble.
(2) Rem ove t h e wiper m odu le (u n it )(Refer t o 8 -
E LE CTRICAL/WIP E RS/WASH E RS/WIP E R MOD-
ULE - RE MOVAL).
DURE )
(4) Rem ove t h e dr ive belt spla sh sh ield.
(5) Rem ove t h e pr essu r e h ose r ou t in g br a cket bolt
(F ig. 9).
Fig. 7 Power Steering Pump Attaching Nut

1 - POWER STEERING PUMP MOUNTING BRACKET
2 - FRONT SUSPENSION CRADLE
4 - ADJUSTER NUT
(14) Rem ove t h e fr on t a dju st er n u t a n d t h e lower

pivot bolt (F ig. 8) a t t a ch in g power st eer in g pu m p
br a cket t o ca st br a cket .
Fig. 9 Pressure Hose Routing Clamp

1 - PRESSURE HOSE TUBE
2 - STEERING GEAR
4 - DRIVESHAFT
5 - ROUTING CLAMP BRACKET
(6) lower t h e veh icle.

voir.
(8) Usin g a siph on pu m p, r em ove a s m u ch power
Fig. 8 Pump Front Mounting st eer in g flu id a s possible fr om t h e power st eer in g
flu id r eser voir.
1 - ADJUSTER NUT
2 - PIVOT BOLT (9) Discon n ect t h e pr essu r e h ose fr om t h e pu m p
3 - PUMP (F ig. 10).
(10) Discon n ect t h e flu id su pply h ose fr om t h e
(15) Rem ove t h e dr ive belt fr om t h e power st eer in g pu m p (F ig. 10).
pu m p pu lley.
(16) Rem ove t h e power st eer in g pu m p a n d t h e
fr on t br a cket fr om t h e ca st br a cket on t h e en gin e a s
a n a ssem bly t h r ou gh t h e exh a u st t u n n el.
RS PUMP 19 - 41
REMOVAL - PUMP (DIESEL)

(1) Rem ove t h e n ega t ive (-) ba t t er y ca ble fr om t h e
ba t t er y a n d isola t e ca ble.
(2) Rem ove t h e fill ca p fr om t h e power st eer in g
flu id r eser voir.
st eer in g flu id a s possible fr om t h e flu id r eser voir.
DURE )
(5) Rem ove t h e spla sh sh ields fr om below t h e
en gin e com pa r t m en t .
(6) Rem ove t h e a ccessor y dr ive belt fr om t h e power
st eer in g pu m p pu lley. (Refer t o 7 - COOLING/AC-
CE SSORY DRIVE /DRIVE BE LTS - RE MOVAL)
(7) Discon n ect t h e flu id su pply h ose fr om t h e
pu m p (F ig. 12).
(8) Discon n ect t h e pr essu r e h ose fr om t h e pu m p
(F ig. 12).
Fig. 10 Supply And Pressure Hoses At Pump

1 - PRESSURE HOSE AND FITTING
2 - SUPPLY HOSE AND CLAMP
(11) Rem ove t h e t h r ee fr on t m ou n t in g bolt s

t h r ou gh t h e pu lley (F ig. 11)
Fig. 12 Power Steering Pump - Diesel

1 - PRESSURE HOSE
2 - HOSE CLAMP
3 - SUPPLY HOSE
(9) Rem ove t h e bolt fa st en in g t h e st a m ped br a cket

Fig. 11 Pump Mounting on t h e r ea r of t h e pu m p t o t h e ca st br a cket (F ig. 13).
1 - PUMP REAR MOUNTING BOLT (2001 ONLY)
(10) Rem ove t h e t h r ee fr on t m ou n t in g bolt s
2 - PUMP FRONT MOUNTING BOLT (3) t h r ou gh t h e pu lley.
3 - TIMING CHAIN COVER AND PUMP BRACKET THRU BOLT (11) Rem ove t h e pu m p fr om t h e ca st br a cket a n d
(2001 ONLY)
4 - PUMP BELT PULLEY veh icle.
6 - BRACKET (2001 ONLY) DISASSEMBLY - PUMP (PULLEY)
Th e on ly ser vicea ble pa r t of t h e power st eer in g
(12) Rem ove t h e pu m p (wit h pu lley) t h r ou gh t h e
pu m p is t h e pu lley. Th e pr ocedu r e followin g is for
en gin e com pa r t m en t r ockin g it over t h e a lu m in u m
r em ova l a n d in st a lla t ion of t h e pu lley fr om t h e pu m p
br a cket .
on ce t h e pu m p is r em oved fr om t h e veh icle.
19 - 42 PUMP RS
ASSEMBLY - PUMP (PULLEY)

Th e on ly ser vicea ble pa r t of t h e power st eer in g
pu m p is t h e pu lley. Th e pr ocedu r e followin g is for
r em ova l a n d in st a lla t ion of t h e pu lley fr om t h e pu m p
on ce t h e pu m p is r em oved fr om t h e veh icle.
(1) In st a ll t h e pu lley wit h In st a ller C-4063 (F ig.
15). Do n ot u se t h e t ool a da pt er s.
Fig. 13 Pump And Brackets - Diesel

1 - CAST BRACKET
2 - STAMPED BRACKET
(1) Rem ove t h e power st eer in g pu m p fr om t h e Fig. 15 Pulley Installation

veh icle. Refer t o Rem ova l An d In st a lla t ion in t h is 1 - POWER STEERING PUMP DRIVE PULLEY
sect ion of t h e ser vice m a n u a l. 2 - SPECIAL TOOL
C-4063–A
(2) Rem ove t h e pu lley fr om t h e sh a ft of t h e power
st eer in g pu m p u sin g P u ller C-4333 (F ig. 14). (2) E n su r e t h a t t h e t ool a n d t h e pu lley r em a in
a lign ed wit h t h e pu m p sh a ft . P r even t t h e pu lley fr om
bein g cocked on t h e sh a ft .
(3) In st a ll t h e pu lley u n t il it is flu sh wit h t h e en d
of t h e power st eer in g pu m p sh a ft (F ig. 16).
Fig. 14 Pulley Removal

1 - POWER STEERING PUMP DRIVE PULLEY
CAUTION: Do not hammer on power steering pump

Fig. 16 Pulley To Pump Shaft Location
pulley. This will damage the pulley and the power
1 - PULLEY
steering pump. 2 - PUMP BODY
3 - PUMP SHAFT
(3) Repla ce pu lley if it is fou n d t o be ben t , cr a cked, 4 - HUB
or loose.
(4) In st a ll t h e power st eer in g pu m p on t h e veh icle.
RS PUMP 19 - 43
I N STALLAT I ON INSTALLATION - PUMP (3.3L/3.8L ENGINE)

(1) In st a ll power st eer in g pu m p ba ck in veh icle
INSTALLATION - PUMP (2.4L ENGINE) u sin g t h e r ever se or der of it s r em ova l t h r ou gh t h e
(1) In st a ll power st eer in g pu m p ba ck in veh icle en gin e com pa r t m en t of t h e veh icle.
u sin g t h e r ever se or der of it s r em ova l t h r ou gh t h e (2) In st a ll t h e power st eer in g pu m p on it s m ou n t -
exh a u st t u n n el of t h e veh icle. in g br a cket .
(2) In st a ll t h e power st eer in g pu m p on it s ca st (3) In st a ll t h e 3 fr on t power st eer in g pu m p m ou n t -
m ou n t in g br a cket (F ig. 7), t h en in st a ll t h e n u t a n d in g bolt s (F ig. 11). Tigh t en t h e 3 fr on t power st eer in g
bolt a t t a ch in g t h e fr on t br a cket t o t h e ca st br a cket pu m p m ou n t in g bolt s t o a t or qu e of 54 N·m (40 ft .
(F ig. 8). D o n o t fu lly tig h te n a t th is tim e .. lbs.).
(3) In st a ll t h e r ea r n u t (F ig. 7).
(4) In st a ll t h e power st eer in g pu m p dr ive belt on NOTE: Before installing power steering pressure
pu lley a n d a dju st (Refer t o 7 - COOLING/ACCE S- hose on power steering pump, inspect the O-ring
SORY DRIVE /DRIVE BE LTS - INSTALLATION). on the power steering pressure hose for damage
(5) Tigh t en t h e t wo a dju st m en t slot bolt s a n d t h e and replace if required.
on e pivot bolt t o 54 N·m (40 ft . lbs.) t or qu e.
(6) In st a ll t h e a ccessor y dr ive spla sh sh ield. (4) In st a ll t h e power st eer in g flu id pr essu r e lin e
in t o t h e pr essu r e ou t pu t fit t in g of t h e power st eer in g
NOTE: Before installing power steering fluid pres- pu m p (F ig. 10). D o n o t fu lly tig h te n tu be n u t a t
sure hose on power steering pump, inspect the th is tim e .
O-ring on the pressure hose for damage and (5) In st a ll t h e power st eer in g flu id su pply h ose on
replace if necessary. t h e power st eer in g pu m p su pply fit t in g (F ig. 10). B e
s u re h o s e c la m p is p ro p e rly in s ta lle d .
(7) In st a ll t h e power st eer in g flu id pr essu r e lin e (6) Ra ise t h e veh icle.
on t o t h e ou t pu t fit t in g of t h e power st eer in g pu m p (7) In st a ll t h e r ou t in g clip on t h e en gin e for t h e
(F ig. 6). Tigh t en t h e pr essu r e lin e t o pu m p fit t in g pr essu r e h ose (F ig. 9) a n d t igh t en fa st en er.
t u be n u t t o a t or qu e of 31 N·m (275 in . lbs.). (8) In st a ll t h e ser pen t in e dr ive belt (Refer t o 7 -
(8) In st a ll t h e power st eer in g flu id low pr essu r e COOLING/ACCE SSORY DRIVE /DRIVE BE LTS -
r et u r n h ose on t h e power st eer in g pu m p low pr essu r e INSTALLATION).
fit t in g (F ig. 6). B e s u re h o s e c la m p s a re p ro p e rly (9) In st a ll t h e dr ive belt spla sh sh ield.
re in s ta lle d . (10) Lower t h e veh icle.
(9) In st a ll t h e power st eer in g flu id su pply h ose on (11) Tigh t en t h e pr essu r e lin e t o pu m p pr essu r e
t h e power st eer in g pu m p flu id fit t in g. B e s u re h o s e fit t in g t u be n u t t o a t or qu e of 31 N·m (275 in . lbs.).
is c le a r o f a c c e s s o ry d riv e be lts a ll h o s e c la m p s (12) In st a ll t h e wiper m odu le (u n it )(Refer t o 8 -
a re p ro p e rly re in s ta lle d . E LE CTRICAL/WIP E RS/WASH E RS/WIP E R MOD-
ULE - INSTALLATION).
CAUTION: Heat sleeve must cover entire rubber (13) Con n ect t h e n ega t ive ba t t er y ca ble on t h e
portion of return hose to ensure desired thermal n ega t ive ba t t er y post .
protection from exhaust. (14) F ill a n d bleed t h e power st eer in g syst em
u sin g t h e P ower St eer in g P u m p In it ia l Oper a t ion
(10) P r oper ly posit ion t h e pr ot ect ive h ea t sleeve P r ocedu r e (Refer t o 19 - STE E RING/P UMP - STAN-
over t h e power st eer in g r et u r n h ose. Secu r ely t ie DARD P ROCE DURE ).
st r a p t h e h ea t sleeve t o t h e power st eer in g h ose t o (15) In spect for lea ks.
keep in it ’s pr oper posit ion .
(11) In st a ll t h e exh a u st syst em (F ig. 4). In st a ll a ll INSTALLATION - PUMP (DIESEL)
exh a u st syst em isola t or s/h a n ger s on t h e exh a u st sys- (1) In st a ll t h e power st eer in g pu m p on it s ca st
t em br a cket s, t h en t h e fou r bolt s a n d fla g n u t s (F ig. 3). m ou n t in g br a cket .
(12) Con n ect t h e oxygen sen sor wir in g h a r n ess t o (2) In st a ll t h e t h r ee fr on t power st eer in g pu m p
t h e veh icle wir in g h a r n ess. m ou n t in g bolt s. Tigh t en t h e m ou n t in g bolt s t o a
(13) Lower veh icle. t or qu e of 54 N·m (40 ft . lbs.).
(14) Con n ect t h e n ega t ive ba t t er y ca ble on t h e (3) In st a ll t h e r ea r m ou n t in g bolt fa st en in g t h e
n ega t ive ba t t er y post . st a m ped br a cket t o t h e ca st br a cket (F ig. 13).
(15) P er for m t h e P OWE R STE E RING P UMP INI- Tigh t en t h e m ou n t in g bolt t o a t or qu e of 54 N·m (40
TIAL OP E RATION pr ocedu r e t o pr oper ly fill a n d ft . lbs.).
bleed t h e power st eer in g syst em . (Refer t o 19 -
STE E RING/P UMP - STANDARD P ROCE DURE )
(16) In spect for lea ks.
19 - 44 PUMP RS
NOTE: Before installing power steering pressure FLU I D
hose on power steering pump, inspect the O-ring
on the power steering pressure hose for damage
STANDARD PROCEDURE - POWER STEERING
and replace if required.
FLUID LEVEL CHECKING
(4) In st a ll t h e power st eer in g flu id pr essu r e h ose
fit t in g in t o t h e pr essu r e por t of t h e power st eer in g WARNING: FLUID LEVEL SHOULD BE CHECKED
pu m p (F ig. 12). Tigh t en t h e pr essu r e lin e t o pu m p WITH THE ENGINE OFF TO PREVENT INJURY
fit t in g t u be n u t t o a t or qu e of 31 N·m (275 in . lbs.). FROM MOVING PARTS AND TO ENSURE ACCU-
(5) In st a ll t h e power st eer in g flu id su pply h ose on RATE FLUID LEVEL READING.
t h e power st eer in g pu m p su pply fit t in g (F ig. 12). B e
s u re h o s e c la m p is p ro p e rly re in s ta lle d . Th e flu id level ca n be r ea d on t h e ext er ior of t h e
(6) In st a ll t h e a ccessa r y dr ive belt (Refer t o 7 - power st eer in g flu id r eser voir. Th e flu id level sh ou ld
COOLING/ACCE SSORY DRIVE /DRIVE BE LTS - be wit h in t h e “F ILL RANGE ” wh en t h e flu id is a t
INSTALLATION). n or m a l a m bien t t em per a t u r e, a ppr oxim a t ely 21°C t o
(7) In st a ll t h e spla sh sh ields below t h e en gin e 27°C (70°F t o 80°F ) (F ig. 17).
com pa r t m en t . Befor e r em ovin g t h e power st eer in g filler ca p, wipe
(8) Lower t h e veh icle. t h e r eser voir filler ca p fr ee of dir t a n d debr is. Do n ot
(9) Con n ect t h e n ega t ive (-) ba t t er y ca ble on t h e over fill t h e power st eer in g syst em . U s e o n ly
n ega t ive ba t t er y post . Mo p a r! ATF +4 Au to m a tic Tra n s m is s io n F lu id
(10) F ill a n d bleed t h e power st eer in g syst em (MS -9602) in th e p o w e r s te e rin g s y s te m . F or
u sin g t h e P ower St eer in g P u m p In it ia l Oper a t ion a ddit ion a l in for m a t ion on Au t om a t ic Tr a n sm ission
P r ocedu r e (Refer t o 19 - STE E RING/P UMP - STAN- F lu id, (Refer t o LUBRICATION & MAINTE NANCE /
DARD P ROCE DURE ). F LUID TYP E S - DE SCRIP TION).
(11) In spect for lea ks.
CAUTION: Use only Mopar" ATF+4 Automatic Trans-
mission Fluid (MS-9602). Use of other Mopar"
SPECI AL T OOLS power steering fluids (MS5931 and MS9933) should
be avoided to ensure peak performance of the
POWER STEERING PUMP power steering system under all operating condi-
tions.
Installer C-4063B
Fig. 17 Power Steering Fluid Reservoir
Puller C-4333
RS PUMP 19 - 45
FLU I D COOLER (3) Rem ove t h e h ose cla m ps a t t h e cooler a n d

r em ove t h e h oses fr om t h e cooler in let a n d ou t let
t u bes.
DESCRIPTION
(4) Rem ove t h e 2 bolt s a t t a ch in g t h e power st eer-
Tr a iler Tow equ ipped veh icles a r e su pplied wit h a
in g cooler cr a dle cr ossm em ber r ein for cem en t (F ig.
cooler for t h e power st eer in g syst em flu id. Th e power
19). Rem ove t h e cooler.
st eer in g flu id cooler is loca t ed on t h e fr on t su spen -
sion cr a dle cr ossm em ber r ein for cem en t (F ig. 18).

Fig. 18 Power Steering Cooler 2 - POWER STEERING COOLER
INSTALLATION
(1) In st a ll t h e power st eer in g flu id cooler on t h e
OPERATION
cr a dle cr ossm em ber r ein for cem en t (F ig. 19). In st a ll
Th e pu r pose of t h e power st eer in g flu id cooler is t o
t h e m ou n t in g bolt s a n d t igh t en t o 11 N·m (100 in .
keep t h e t em per a t u r e of t h e power st eer in g syst em
lbs.).
flu id fr om r isin g t o a level t h a t wou ld a ffect t h e per-
(2) In st a ll power st eer in g flu id h oses on t h e cooler.
for m a n ce of t h e power st eer in g syst em .
B e s u re h o s e c la m p s a re in s ta lle d o n h o s e p a s t
Th e cooler u sed on t h is veh icle is r efer r ed t o a s a
th e u p s e t be a d o n th e p o w e r s te e rin g c o o le r
flu id-t o-a ir t ype cooler. Th is m ea n s t h a t t h e a ir flow
tu be s .
a cr oss t h e t u bes (a n d fin es su r r ou n din g t h em ) of t h e
(3) Lower t h e veh icle t o a poin t wh er e fr on t t ir es
cooler is u sed t o ext r a ct t h e h ea t fr om t h e cooler
a r e ju st off t h e gr ou n d.
wh ich it h a s a bsor bed fr om t h e power st eer in g flu id
(4) P er for m P ower St eer in g P u m p In it ia l Oper a -
flowin g t h r ou gh it . Th e cooler is pla ced in t h e power
t ion pr ocedu r e. (Refer t o 19 - STE E RING/P UMP -
st eer in g flu id r et u r n lin e, bet ween t h e st eer in g gea r
a n d t h e power st eer in g flu id r eser voir.
REMOVAL
(1) Usin g a siph on pu m p, r em ove a s m u ch flu id a s
possible fr om t h e power st eer in g flu id r eser voir.
DURE )
19 - 46 PUMP RS
H OSE - POWER ST EERI N G

PRESSU RE
REM OVAL
REMOVAL - 2.4L ENGINE
NOTE: Before proceeding, review all WARNINGS
and CAUTIONS. (Refer to 19 - STEERING/PUMP -
WARNING)(Refer to 19 - STEERING/PUMP - CAU-
TION)

voir.
st eer in g flu id a s possible fr om power st eer in g flu id
r eser voir.
DURE )
(4) Rem ove fr on t em ission s va por ca n ist er. (Refer
t o 25 - E MISSIONS CONTROL/E VAP ORATIVE Fig. 20 PRESSURE AND RETURN HOSES - 2.4L
E MISSIONS/VAP OR CANISTE R - RE MOVAL) 1 - POWER STEERING PUMP
(5) P la ce a n oil dr a in pa n u n der veh icle t o ca t ch 2 - RETURN HOSE (HEAT SLEEVE COVERED)
3 - ROUTING CLAMPS
power st eer in g flu id. 4 - PRESSURE HOSE TUBE NUT
(6) Ba ck ou t pr essu r e h ose t u be n u t a t power 5 - RETURN HOSE TUBE NUT
st eer in g pu m p pr essu r e fit t in g a n d r em ove h ose fr om 6 - CRADLE CROSSMEMBER
pu m p (F ig. 20). 8 - PRESSURE HOSE
(7) Rem ove bolt a t t a ch in g r igh t r ou t in g cla m p t o
fr on t su spen sion cr a dle cr ossm em ber (F ig. 20). (3) Ra ise veh icle. (Refer t o LUBRICATION &
Rem ove pr essu r e h ose fr om cla m p. MAINTE NANCE /H OISTING - STANDARD P ROCE -
(8) Ba ck ou t pr essu r e h ose t u be n u t a t power DURE )
st eer in g gea r a n d r em ove h ose fr om gea r (F ig. 20). (4) Rem ove fr on t em ission s va por ca n ist er. (Refer
(9) Rem ove power st eer in g flu id pr essu r e h ose t o 25 - E MISSIONS CONTROL/E VAP ORATIVE
fr om veh icle. E MISSIONS/VAP OR CANISTE R - RE MOVAL)
(5) Rem ove t wo bolt s secu r in g pr essu r e h ose r ou t -
REMOVAL - 3.3L/3.8L ENGINE in g cla m ps t o su spen sion cr a dle cr ossm em ber a n d
st eel r ein for cem en t (F ig. 21).
NOTE: Before proceeding, review all WARNINGS (6) P la ce a n oil dr a in pa n u n der veh icle t o ca t ch
and CAUTIONS. (Refer to 19 - STEERING/PUMP - dr a in in g power st eer in g flu id.
WARNING)(Refer to 19 - STEERING/PUMP - CAU- (7) Discon n ect pr essu r e h ose a t power st eer in g
TION) gea r (F ig. 21).

voir.
r eser voir.
RS PUMP 19 - 47
H OSE - POWER ST EERI N G PRESSU RE (Cont inue d)
Fig. 21 HOSES TO POWER STEERING GEAR - 3.3L/3.8L ENGINE

1 - RETURN HOSE (TO RESERVOIR) 7 - POWER STEERING GEAR
2 - PRESSURE HOSE (FROM PUMP) 8 - ABS BRACKET
3 - CRADLE CROSSMEMBER 9 - ROUTING CLIP
4 - PRESSURE HOSE ROUTING CLAMP 10 - LEAK DETECTION PUMP FILTER
5 - RETURN HOSE ROUTING CLAMP 11 - RETURN HOSE TUBE NUT
6 - PRESSURE HOSE TUBE NUT 12 - ROUTING CLIP
(8) Rem ove pr essu r e h ose r ou t in g br a cket bolt a t CAUTION: Use care not to bend tube ends of power
en gin e (F ig. 22). Bolt ca n be a ccessed t h r ou gh h ole in steering hoses when installing. Leaks and restric-
cr a dle cr ossm em ber (F ig. 23). tions may occur.
(9) Discon n ect pr essu r e h ose t u be n u t a t power
st eer in g pu m p (F ig. 22).
(10) Rem ove power st eer in g flu id pr essu r e h ose CAUTION: Power steering fluid hoses must remain
fr om veh icle. away from exhaust system and must not come in
contact with any unfriendly surfaces on vehicle.
I N STALLAT I ON (4) Rou t e h ose u p t h r ou gh cr a dle cr ossm em ber

t owa r d power st eer in g pu m p a voidin g t igh t ben ds or
INSTALLATION - 2.4L ENGINE kin kin g.
(1) Rem ove a n y u sed O-r in gs fr om en ds of power (5) In st a ll power st eer in g pr essu r e h ose en d in t o
st eer in g h ose. pu m p pr essu r e ou t let fit t in g (F ig. 20). Th r ea d t u be
(2) Usin g a lin t fr ee t owel, wipe clea n h ose en ds, n u t in t o ou t let fit t in g, bu t do n ot t igh t en a t t h is t im e.
power st eer in g pu m p pr essu r e ou t let fit t in g a n d (6) Rou t e h ose beh in d cr a dle cr ossm em ber a n d
st eer in g gea r por t . st a r t h ose en d in t o gea r por t . Do n ot t igh t en h ose
(3) In st a ll n ew O-r in gs on en ds of power st eer in g t u be n u t a t t h is t im e.
flu id pr essu r e h ose. Lu br ica t e O-r in gs u sin g clea n (7) In st a ll h ose in t o r igh t r ou t in g cla m p (F ig. 20),
power st eer in g flu id. t h en in st a ll m ou n t in g bolt in t o cr a dle cr ossm em ber.
Tigh t en bolt t o 23 N·m (200 in . lbs.) t or qu e.
19 - 48 PUMP RS
Fig. 22 RESERVOIR AND HOSES - 3.3L/3.8L

1 - RESERVOIR 5 - PRESSURE HOSE (TO GEAR)
2 - ROUTING CLIP (2001 ONLY) 6 - ROUTING BRACKET
3 - SUPPLY HOSE 7 - RETURN HOSE (FROM GEAR)
CAUTION: When tightening and torquing the pres-

sure hose at the power steering pump, the pressure
hose is to be rotated against the fluid return hose
fitting on the pump.
(8) Tigh t en pr essu r e h ose t u be n u t s a t pu m p a n d

gea r t o 31 N·m (275 in . lbs.) t or qu e.
(9) In st a ll fr on t em ission s va por ca n ist er. (Refer t o
25 - E MISSIONS CONTROL/E VAP ORATIVE E MIS-
SIONS/VAP OR CANISTE R - INSTALLATION)
(11) F ill a n d bleed t h e power st eer in g syst em
P r ocedu r e. (Refer t o 19 - STE E RING/P UMP - STAN-
DARD P ROCE DURE )
Fig. 23 PRESSURE HOSE ROUTING CLAMP
1 - PRESSURE HOSE TUBE
INSTALLATION - 3.3L/3.8L ENGINE
2 - STEERING GEAR (1) Rem ove a n y u sed O-r in gs fr om en ds of power
3 - CRADLE CROSSMEMBER st eer in g h ose.
4 - DRIVESHAFT
5 - ROUTING CLAMP BRACKET (2) Usin g a lin t fr ee t owel, wipe clea n h ose en ds,
power st eer in g pu m p pr essu r e ou t let fit t in g a n d
st eer in g gea r por t .
RS PUMP 19 - 49
(3) In st a ll n ew O-r in gs on en ds of power st eer in g (1) Rem ove ca p fr om power st eer in g flu id r eser-
flu id pr essu r e h ose. Lu br ica t e O-r in gs u sin g clea n voir.
power st eer in g flu id. (2) Usin g a siph on pu m p, r em ove a s m u ch power
CAUTION: Use care not to bend tube ends of the r eser voir.
power steering hoses when installing. Leaks and (3) Ra ise veh icle. (Refer t o LUBRICATION &
restrictions may occur. MAINTE NANCE /H OISTING - STANDARD P ROCE -
DURE )
(4) Rem ove fr on t em ission s va por ca n ist er. (Refer
CAUTION: Power steering fluid hoses must remain
away from the exhaust system and must not come
E MISSIONS/VAP OR CANISTE R - RE MOVAL)
in contact with any unfriendly surfaces on the vehi-
(5) P la ce a n oil dr a in pa n u n der veh icle t o ca t ch
cle.
power st eer in g flu id.
(4) Rou t e h ose u p beh in d en gin e t owa r d pu m p (6) Cu t t ie-st r a p secu r in g in su la t in g h ea t sleeve t o
a voidin g t igh t ben ds or kin kin g. power st eer in g flu id r et u r n h ose n ea r power st eer in g
(5) In st a ll power st eer in g pr essu r e h ose en d in t o pu m p. P u ll ba ck h ea t sleeve t o expose h ose cla m p.
pu m p pr essu r e ou t let fit t in g (F ig. 22). Th r ea d t u be (7) Rem ove cla m p, t h en r et u r n h ose fr om power
n u t in t o ou t let fit t in g, bu t do n ot t igh t en a t t h is t im e. st eer in g pu m p (F ig. 20).
(6) At t a ch pr essu r e h ose r ou t in g br a cket t o en gin e (8) Rem ove 2 bolt s a t t a ch in g power st eer in g cooler
(F ig. 22). Tigh t en bolt t o 23 N·m (200 in . lbs.) t or qu e. t o cr a dle cr ossm em ber r ein for cem en t (F ig. 24).
(7) Tigh t en h ose t u be n u t a t pu m p ou t let fit t in g t o (9) Rem ove bolt s a t t a ch in g r ou t in g cla m ps t o fr on t
31 N·m (275 in . lbs.) t or qu e. su spen sion cr a dle cr ossm em ber (F ig. 20). Rem ove
(8) Rou t e h ose beh in d cr a dle cr ossm em ber a n d r et u r n h ose fr om cla m ps.
st a r t h ose en d in t o gea r por t . Do n ot t igh t en h ose (10) Ba ck ou t r et u r n h ose t u be n u t a t power st eer-
t u be n u t a t t h is t im e. in g gea r a n d r em ove h ose (F ig. 20).
(9) At t a ch h ose t o su spen sion cr a dle cr ossm em ber
a n d st eel r ein for cem en t u sin g t wo r ou t in g cla m ps REMOVAL - 3.3L/3.8L ENGINE
a n d bolt s (F ig. 21). Tigh t en cla m p bolt a t st eel r ein -
for cem en t t o 11 N·m (100 in . lbs.) t or qu e. Tigh t en
cla m p bolt a t cr a dle cr ossm em ber t o 23 N·m (200 in .
lbs.) t or qu e.
TION)
(10) Tigh t en h ose t u be n u t a t power st eer in g gea r
por t t o 31 N·m (275 in . lbs.) t or qu e. (1) Rem ove ca p fr om power st eer in g flu id r eser-
(11) In st a ll fr on t em ission s va por ca n ist er. (Refer voir.
t o 25 - E MISSIONS CONTROL/E VAP ORATIVE (2) Usin g a siph on pu m p, r em ove a s m u ch power
E MISSIONS/VAP OR CANISTE R - INSTALLATION) st eer in g flu id a s possible fr om power st eer in g flu id
(12) Lower veh icle. r eser voir.
(13) F ill a n d bleed t h e power st eer in g syst em (3) P la ce a n oil dr a in pa n u n der veh icle t o ca t ch
u sin g t h e P ower St eer in g P u m p In it ia l Oper a t ion a n y dr a in in g power st eer in g flu id.
P r ocedu r e. (Refer t o 19 - STE E RING/P UMP - STAN- (4) Rem ove cla m p a t t a ch in g r et u r n h ose t o power
DARD P ROCE DURE ) st eer in g flu id r eser voir. Discon n ect h ose fr om r eser-
(14) In spect syst em for lea ks. voir (F ig. 22).
(5) F ollow r et u r n h ose down wa r d a n d open
H OSE - POWER ST EERI N G r et a in er a t ABS br a cket (F ig. 21). Rem ove h ose t u be
fr om r et a in er.
RET U RN (6) Ra ise veh icle. (Refer t o LUBRICATION &
DURE )
REM OVAL (7) Rem ove fr on t em ission s va por ca n ist er. (Refer
REMOVAL - 2.4L ENGINE E MISSIONS/VAP OR CANISTE R - RE MOVAL)
(8) Rem ove bolt secu r in g r et u r n h ose r ou t in g
cla m p t o su spen sion cr a dle cr ossm em ber (F ig. 21).
TION)
19 - 50 PUMP RS
H OSE - POWER ST EERI N G RET U RN (Cont inue d)
(9) Rem ove 2 bolt s a t t a ch in g power st eer in g cooler (5) At t a ch h ose t o su spen sion cr a dle cr ossm em ber
t o cr a dle cr ossm em ber r ein for cem en t (F ig. 24). u sin g t wo r ou t in g cla m ps a n d bolt s (F ig. 20). Tigh t en
cla m p bolt s t o 23 N·m (200 in . lbs.) t or qu e.
(6) Tigh t en r et u r n h ose t u be n u t a t power st eer in g
gea r por t t o 31 N·m (275 in . lbs.) t or qu e.
(7) In st a ll t h e power st eer in g flu id cooler on t h e
cr a dle cr ossm em ber r ein for cem en t (F ig. 24). In st a ll
t h e m ou n t in g bolt s a n d t igh t en t o 11 N·m (100 in .
lbs.).

cle.
(8) Rou t e pu m p en d of h ose over cr a dle cr ossm em -

ber t owa r d pu m p a voidin g t igh t ben ds or kin kin g.
(9) In st a ll r et u r n h ose on t o power st eer in g pu m p
r et u r n fit t in g a n d secu r e wit h h ose cla m p (F ig. 20).
Tigh t en t h e scr ew-t ype cla m p t o a t or qu e of 2 N·m
(18 in . lbs.).
Fig. 24 POWER STEERING COOLER CAUTION: To prevent overheating of power steering

1 - CRADLE CROSSMEMBER REINFORCEMENT fluid return hose, protective heat shield sleeve must
2 - POWER STEERING COOLER cover entire rubber hose.
(10) Discon n ect r et u r n h ose a t power st eer in g gea r (10) Slide in su la t in g h ea t sh ield u p over t h e cla m p
(F ig. 21). on t h e r et u r n h ose a n d t ie-st r a p it in pla ce.
(11) Rem ove power st eer in g flu id r et u r n h ose wit h (11) In st a ll fr on t em ission s va por ca n ist er. (Refer
cooler fr om veh icle. t o 25 - E MISSIONS CONTROL/E VAP ORATIVE
E MISSIONS/VAP OR CANISTE R - INSTALLATION)
I N STALLAT I ON (13) F ill a n d bleed t h e power st eer in g syst em
INSTALLATION - 2.4L ENGINE P r ocedu r e. (Refer t o 19 - STE E RING/P UMP - STAN-
(1) Rem ove a n y u sed O-r in gs fr om en ds of power DARD P ROCE DURE )
st eer in g h ose. (14) In spect syst em for lea ks.
(2) Usin g a lin t fr ee t owel, wipe clea n h ose en ds,
power st eer in g pu m p fit t in g a n d st eer in g gea r por t . INSTALLATION - 3.3L/3.8L ENGINE
(3) In st a ll n ew O-r in g on power st eer in g gea r en d (1) Rem ove a n y u sed O-r in gs fr om en ds of power
of r et u r n h ose. Lu br ica t e O-r in g u sin g clea n power st eer in g h ose.
st eer in g flu id. (2) Usin g a lin t fr ee t owel, wipe clea n h ose en ds
a n d power st eer in g gea r h ose por t .
CAUTION: Use care not to bend tube ends of the
(3) In st a ll a n ew O-r in g on gea r por t en d of power
power steering hoses when installing. Leaks and
st eer in g flu id h ose. Lu br ica t e O-r in g u sin g clea n
restrictions may occur.
power st eer in g flu id.
CAUTION: If a new return hose is being installed CAUTION: Use care not to bend tube ends of the
and it does not have an insulating heat sleeve power steering hoses when installing. Leaks and
installed, the heat shield from the original hose restrictions may occur.
must be transferred before hose installation.
(4) Rou t e h ose a lon g r ea r of cr a dle cr ossm em ber
a n d st a r t gea r en d of h ose in t o gea r por t . Do n ot
t igh t en h ose t u be n u t a t t h is t im e.
cle.
RS PUMP 19 - 51
H OSE - POWER ST EERI N G RET U RN (Cont inue d)
(4) Rou t e h ose (wit h cooler a t t a ch ed) u p t owa r d REMOVAL - 3.3L/3.8L ENGINE
r eser voir a voidin g t igh t ben ds or kin kin g.
(5) St a r t st eer in g gea r en d of h ose in t o gea r por t . NOTE: Before proceeding, review all WARNINGS
Do n ot t igh t en h ose t u be n u t a t t h is t im e. and CAUTIONS. (Refer to 19 - STEERING/PUMP -
(6) At t a ch r et u r n h ose t u bes t o su spen sion cr a dle WARNING)(Refer to 19 - STEERING/PUMP - CAU-
cr ossm em ber u sin g r ou t in g cla m p a n d bolt (F ig. 21). TION)
Tigh t en cla m p bolt t o 23 N·m (200 in . lbs.) t or qu e.
(7) In st a ll t h e power st eer in g flu id cooler on t h e (1) Rem ove ca p fr om power st eer in g flu id r eser-
cr a dle cr ossm em ber r ein for cem en t (F ig. 24). In st a ll voir.
t h e m ou n t in g bolt s a n d t igh t en t o 11 N·m (100 in . (2) Usin g a siph on pu m p, r em ove a s m u ch power
lbs.). Wh en in st a llin g m ou n t in g bolt s, in clu de pr es- st eer in g flu id a s possible fr om power st eer in g flu id
su r e h ose r ou t in g cla m p. r eser voir.
(8) Tigh t en h ose t u be n u t a t power st eer in g gea r (3) P la ce a n oil dr a in pa n u n der veh icle t o ca t ch
por t t o 31 N·m (275 in . lbs.) t or qu e. a n y dr a in in g power st eer in g flu id.
(9) In st a ll fr on t em ission s va por ca n ist er. (Refer t o (4) Rem ove cla m p a t t a ch in g su pply h ose t o power
25 - E MISSIONS CONTROL/E VAP ORATIVE E MIS- st eer in g flu id r eser voir. Discon n ect h ose fr om r eser-
SIONS/VAP OR CANISTE R - INSTALLATION) voir (F ig. 22).
(10) Lower veh icle. (5) P u ll u pwa r d on h ose r ou t in g clip r elea sin g it
(11) In st a ll r et u r n h ose t u be in t o r et a in er on ABS fr om br a cket on cylin der h ea d cover (F ig. 22).
br a cket (F ig. 21). Close t h e br a cket .
(12) In st a ll r et u r n h ose on t o r eser voir (F ig. 22). NOTE: It may be necessary to remove air cleaner
Slide t h e h ose cla m p in t o posit ion on flu id r eser voir housing to gain greater access to supply hose at
a n d a t t a ch it . B e s u re h o s e c la m p in in s ta lle d power steering pump. (Refer to 9 - ENGINE/AIR
p a s t be a d o n flu id re s e rv o ir fittin g . INTAKE SYSTEM/AIR CLEANER HOUSING -
(13) F ill a n d bleed power st eer in g syst em u sin g REMOVAL)
t h e P ower St eer in g P u m p In it ia l Oper a t ion P r oce-
(6) Rem ove cla m p a t t a ch in g su pply h ose t o power
du r e. (Refer t o 19 - STE E RING/P UMP - STANDARD
P ROCE DURE ) st eer in g pu m p. Discon n ect h ose fr om pu m p a n d
(14) In spect syst em for lea ks. r em ove fr om veh icle (F ig. 22).
H OSE - POWER ST EERI N G I N STALLAT I ON

SU PPLY INSTALLATION - 2.4L ENGINE
(1) In st a ll a n d cor r ect ly r ou t e power st eer in g flu id
su pply h ose fr om r em ot e flu id r eser voir t o power
REM OVAL st eer in g pu m p.
(2) In st a ll flu id su pply h ose on t o power st eer in g
REMOVAL - 2.4L ENGINE flu id r eser voir. In st a ll h ose cla m p. B e s u re h o s e
(1) Rem ove filler ca p fr om power st eer in g flu id r es- c la m p is in s ta lle d p a s t be a d o n flu id re s e rv o ir
er voir. fittin g .
(2) Usin g a siph on pu m p, r em ove a s m u ch power (3) Ra ise veh icle. (Refer t o LUBRICATION &
st eer in g flu id a s possible fr om t h e power st eer in g MAINTE NANCE /H OISTING - STANDARD P ROCE -
flu id r eser voir. DURE )
(3) Ra ise veh icle. (Refer t o LUBRICATION & (4) In st a ll power st eer in g flu id su pply h ose on
MAINTE NANCE /H OISTING - STANDARD P ROCE - power st eer in g pu m p su pply fit t in g. In st a ll h ose
DURE ) cla m p. B e s u re h o s e c la m p is in s ta lle d p a s t be a d
(4) Rem ove h ose cla m p secu r in g su pply h ose t o o n p u m p fittin g .
power st eer in g pu m p, t h en r em ove su pply h ose fr om (5) Lower veh icle.
pu m p fit t in g. (6) F ill a n d bleed power st eer in g syst em u sin g
(5) Lower veh icle. P ower St eer in g P u m p In it ia l Oper a t ion P r ocedu r e.
(6) Rem ove h ose cla m p a t t a ch in g power st eer in g (Refer t o 19 - STE E RING/P UMP - STANDARD P RO-
flu id su pply h ose t o power st eer in g flu id r eser voir, CE DURE )
t h en r em ove su pply h ose. (7) In spect syst em for lea ks.
(7) Rem ove t h e power st eer in g flu id su pply h ose
fr om t h e veh icle.
19 - 52 PUMP RS
H OSE - POWER ST EERI N G SU PPLY (Cont inue d)
INSTALLATION - 3.3L/3.8L ENGINE OPERATION

(1) In st a ll su pply h ose on t o su pply fit t in g on power Th e power st eer in g flu id r eser voir st or es a n d su p-
st eer in g pu m p (F ig. 22). Slide t h e h ose cla m p in t o plies power st eer in g flu id for t h e power st eer in g sys-
posit ion on flu id r eser voir a n d a t t a ch it . B e s u re t em .
h o s e c la m p in in s ta lle d p a s t be a d o n flu id re s -
e rv o ir fittin g .
(2) Align r ou t in g clip loca t ed t owa r d cen t er of su p- REM OVAL
ply h ose wit h h ole in br a cket on cylin der h ea d cover
a n d pu sh in t o pla ce (F ig. 22). REMOVAL - 2.4L ENGINE
(3) In st a ll su pply h ose on t o r eser voir (F ig. 22). (1) Rem ove ca p fr om power st eer in g flu id r eser-
Slide t h e h ose cla m p in t o posit ion on flu id r eser voir voir.
a n d a t t a ch it . B e s u re h o s e c la m p in in s ta lle d (2) Usin g a siph on pu m p, r em ove a s m u ch power
p a s t be a d o n flu id re s e rv o ir fittin g . st eer in g flu id a s possible fr om power st eer in g flu id
(4) F ill a n d bleed power st eer in g syst em u sin g r eser voir.
P ower St eer in g P u m p In it ia l Oper a t ion P r ocedu r e. (3) Open r et a in er on side of r eser voir a n d r em ove
(Refer t o 19 - STE E RING/P UMP - STANDARD P RO- ca bles fr om r et a in er.
CE DURE ) (4) Rem ove cla m p a t t a ch in g su pply h ose t o power
(5) In spect syst em for lea ks. st eer in g flu id r eser voir. Discon n ect h ose fr om r eser-
voir.
(5) Rem ove bolt s a n d n u t secu r in g r eser voir in
RESERV OI R - POWER pla ce.
ST EERI N G FLU I D (6) Rem ove r eser voir.
REMOVAL - 3.3L/3.8L ENGINE

DESCRI PT I ON (1) Rem ove ca p fr om power st eer in g flu id r eser-
voir.
DESCRIPTION - 2.4L/3.3L/3.8L ENGINE (2) Usin g a siph on pu m p, r em ove a s m u ch power
All veh icles u se a r em ot e m ou n t ed power st eer in g st eer in g flu id a s possible fr om power st eer in g flu id
flu id r eser voir. Th e power st eer in g flu id r eser voir is r eser voir.
m ou n t ed t o t h e en gin e n ea r t h e ba t t er y (F ig. 25). (3) Open r et a in er on side of r eser voir a n d r em ove
ca bles fr om r et a in er.
(4) Rem ove cla m p a t t a ch in g su pply h ose t o power
st eer in g flu id r eser voir. Discon n ect h ose fr om r eser-
voir (F ig. 22).
(5) Rem ove cla m p a t t a ch in g r et u r n h ose t o power
st eer in g flu id r eser voir. Discon n ect h ose fr om r eser-
voir (F ig. 22).
(6) Rem ove bolt s a n d n u t secu r in g r eser voir in
pla ce (F ig. 22).
(7) Rem ove r eser voir.
REMOVAL - DIESEL
(1) Open h ood.
(2) Rem ove en gin e cover.
(3) Rem ove t h e filler ca p fr om r em ot e power st eer-
in g flu id r eser voir.
(4) Siph on a s m u ch flu id a s possible fr om t h e flu id
Fig. 25 Power Steering Fluid Reservoir (Typical) r eser voir.
DESCRIPTION - DIESEL (5) Rem ove t h e cla m p a t t a ch in g t h e r et u r n h ose t o
All veh icles u se a r em ot e m ou n t ed power st eer in g t h e power st eer in g flu id r eser voir. Discon n ect h ose
flu id r eser voir. Th e power st eer in g flu id r eser voir is fr om r eser voir (F ig. 26).
m ou n t ed t o a br a cket on t h e en gin e m a n ifold (F ig. (6) Rem ove t h e cla m p a t t a ch in g t h e su pply h ose t o
26). t h e power st eer in g flu id r eser voir. Discon n ect h ose
fr om r eser voir (F ig. 26).
RS PUMP 19 - 53
RESERV OI R - POWER ST EERI N G FLU I D (Cont inue d)
(4) F ill a n d bleed power st eer in g syst em u sin g
P ower St eer in g P u m p In it ia l Oper a t ion P r ocedu r e.
(Refer t o 19 - STE E RING/P UMP - STANDARD P RO-
CE DURE )
INSTALLATION - 3.3L/3.8L ENGINE

(1) P la ce r eser voir in t o pla ce on en gin e (F ig. 22).
(2) In st a ll r eser voir m ou n t in g bolt s a n d n u t (F ig.
22). Tigh t en fa st en er s t o 12 N·m (105 in . lbs.) t or qu e.
(3) In st a ll su pply h ose on t o r eser voir (F ig. 22).
Slide t h e h ose cla m p in t o posit ion on flu id r eser voir
a n d a t t a ch it . B e s u re h o s e c la m p in in s ta lle d
p a s t be a d o n flu id re s e rv o ir fittin g .
(4) In st a ll r et u r n h ose on t o r eser voir (F ig. 22).
Slide t h e h ose cla m p in t o posit ion on flu id r eser voir
a n d a t t a ch it . B e s u re h o s e c la m p in in s ta lle d
p a s t be a d o n flu id re s e rv o ir fittin g .
(5) F ill a n d bleed power st eer in g syst em u sin g
P ower St eer in g P u m p In it ia l Oper a t ion P r ocedu r e.
(Refer t o 19 - STE E RING/P UMP - STANDARD P RO-
CE DURE )
Fig. 26 Reservoir And Hoses - Diesel (6) In spect syst em for lea ks.
1 - POWER STEERING FLUID RESERVOIR
2 - RESERVOIR BRACKET INSTALLATION - DIESEL
3 - SUPPLY HOSE BRACKET
4 - RETURN HOSE FROM GEAR (1) Align t h e gu ide on t h e r ea r of t h e r eser voir
5 - ROUTING CLIP wit h t h e m ou n t in g br a cket a n d pu sh r eser voir down -
6 - PRESSURE HOSE TO GEAR wa r d u n t il r eser voir clicks in t o pla ce in t h e br a cket .
7 - SUPPLY HOSE (PUMP END)
8 - PRESSURE HOSE (PUMP END) (2) In st a ll t h e su pply h ose on t o t h e r eser voir (F ig.
9 - SUPPLY HOSE 26). Slide t h e h ose cla m p in t o posit ion on t h e flu id
10 - RETURN HOSE r eser voir a n d a t t a ch it . B e s u re h o s e c la m p in
in s ta lle d p a s t be a d o n flu id re s e rv o ir fittin g .
(7) P r ess t h e t a n g on t h e r eser voir m ou n t in g (3) In st a ll t h e r et u r n h ose on t o t h e r eser voir (F ig.
br a cket r et a in in g t h e r eser voir t o t h e br a cket , t h en 26). Slide t h e h ose cla m p in t o posit ion on t h e flu id
pu ll u pwa r d on r eser voir a n d r em ove it fr om t h e r eser voir a n d a t t a ch it . B e s u re h o s e c la m p in
br a cket . in s ta lle d p a s t be a d o n flu id re s e rv o ir fittin g .
(4) F ill t h e flu id r eser voir t o t h e pr oper level wit h
I N STALLAT I ON t h e cor r ect Mopa r ! power st eer in g flu id or equ iva -
len t .
INSTALLATION - 2.4L ENGINE (5) St a r t t h e en gin e a n d let r u n for a few secon ds,
t h en t u r n t h e en gin e off.
(1) P la ce r eser voir in t o posit ion on en gin e.
(6) Add flu id a s n ecessa r y.
(2) In st a ll r eser voir m ou n t in g bolt s a n d n u t .
(7) In st a ll t h e filler ca p.
Tigh t en fa st en er s t o 12 N·m (105 in . lbs.) t or qu e.
(8) In st a ll en gin e cover.
(3) In st a ll su pply h ose on t o r eser voir. Slide t h e
h ose cla m p in t o posit ion on flu id r eser voir a n d a t t a ch
it . B e s u re h o s e c la m p in in s ta lle d p a s t be a d o n
flu id re s e rv o ir fittin g .
RS TRANSMISSION/TRANSAXLE 21 - 1
TRANSMISSION/TRANSAXLE
page page
40TE AUTOMATIC TRANSAXLE ..............1 41TE AUTOMATIC TRANSAXLE . . . . . . . . . . . . 146
4 0 T E AU T OM AT I C T RAN SAX LE
TABLE OF CONTENTS
page page
40TE AUTOMATIC TRANSAXLE FLUID

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 2 STANDARD PROCEDURE
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 FLUID LEVEL AND CONDITION CHECK . . . . 82
DIAGNOSIS AND TESTING STANDARD PROCEDURE - FLUID AND
DIAGNOSIS AND TESTING - 4XTE FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . 82
TRANSAXLE GENERAL DIAGNOSIS . . . . . . . . 5 GEAR SHIFT CABLE
DIAGNOSIS AND TESTING - ROAD TEST . . . . 5 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
DIAGNOSIS AND TESTING - HYDRAULIC HOLDING CLUTCHES
PRESSURE TESTS . . . . . . . . . . . . . . . . . . . . . 6 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 86
DIAGNOSIS AND TESTING - CLUTCH AIR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
PRESSURE TESTS . . . . . . . . . . . . . . . . . . . . . 8 INPUT CLUTCH ASSEMBLY
DIAGNOSIS AND TESTING - TORQUE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 86
CONVERTER HOUSING FLUID LEAKAGE . . . . 9 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
REMOVAL .............................9 OIL PUMP
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 12 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 110
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 110
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 51 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 110
SCHEMATICS AND DIAGRAMS ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
4XTE TRANSAXLE HYDRAULIC PLANETARY GEARTRAIN
SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . . 54 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 112
SPECIFICATIONS - 41TE TRANSAXLE . . . . . . . 66 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 112
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . 68 SEAL - OIL PUMP
ACCUMULATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 73 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 113
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 SHIFT INTERLOCK SOLENOID
DRIVING CLUTCHES DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 113
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 74 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 114
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 DIAGNOSIS AND TESTING - BRAKE/
FINAL DRIVE TRANSMISSION SHIFT INTERLOCK
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 74 SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . 115
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 75 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 116
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 SOLENOID/PRESSURE SWITCH ASSY
ADJUSTMENTS DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 117
DIFFERENTIAL BEARING PRELOAD OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 118
MEASUREMENT AND ADJUSTMENT . . . . . . 79 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 119
21 - 2 40TE AUTOMATIC TRANSAXLE RS
SPEED SENSOR - INPUT TRANSMISSION CONTROL RELAY

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 120 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 130
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 120 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 130
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 TRANSMISSION RANGE SENSOR
SPEED SENSOR - OUTPUT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 131
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 122 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 131
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 VALVE BODY
TORQUE CONVERTER OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 132
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 128 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 135
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 129 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 144
4 0 T E AU T OM AT I C • Solen oid/P r essu r e swit ch a ssem bly

• In t egr a l differ en t ia l a ssem bly
T RAN SAX LE Con t r ol of t h e t r a n sa xle is a ccom plish ed by fu lly
a da pt ive elect r on ics. Opt im u m sh ift sch edu lin g is
DESCRIPTION a ccom plish ed t h r ou gh con t in u ou s r ea l-t im e sen sor
Th e 40TE (F ig. 1) is a fou r-speed t r a n sa xle t h a t is feedba ck in for m a t ion pr ovided t o t h e P ower t r a in
a con ven t ion a l h ydr a u lic/m ech a n ica l a ssem bly wit h Con t r ol Modu le (P CM) or Tr a n sm ission Con t r ol Mod-
a n in t egr a l differ en t ia l, a n d is con t r olled wit h a da p- u le (TCM).
t ive elect r on ic con t r ols a n d m on it or s. Th e h ydr a u lic Th e P CM/TCM is t h e h ea r t of t h e elect r on ic con t r ol
syst em of t h e t r a n sa xle con sist s of t h e t r a n sa xle syst em a n d r elies on in for m a t ion fr om va r iou s dir ect
flu id, flu id pa ssa ges, h ydr a u lic va lves, a n d va r iou s a n d in dir ect in pu t s (sen sor s, swit ch es, et c.) t o det er-
lin e pr essu r e con t r ol com pon en t s. An in pu t clu t ch m in e dr iver dem a n d a n d veh icle oper a t in g con di-
a ssem bly wh ich h ou ses t h e u n der dr ive, over dr ive, t ion s. Wit h t h is in for m a t ion , t h e P CM/TCM ca n
a n d r ever se clu t ch es is u sed. It a lso u t ilizes sepa r a t e ca lcu la t e a n d per for m t im ely a n d qu a lit y sh ift s
h oldin g clu t ch es: 2n d/4t h gea r a n d Low/Rever se. Th e t h r ou gh va r iou s ou t pu t or con t r ol devices (solen oid
pr im a r y m ech a n ica l com pon en t s of t h e t r a n sa xle con - pa ck, t r a n sm ission con t r ol r ela y, et c.).
sist of t h e followin g: Th e P CM/TCM a lso per for m s cer t a in self-dia gn os-
• Th r ee m u lt iple disc in pu t clu t ch es t ic fu n ct ion s a n d pr ovides com pr eh en sive in for m a t ion
• Two m u lt iple disc h oldin g clu t ch es (sen sor da t a , DTC’s, et c.) wh ich is h elpfu l in pr oper
• F ou r h ydr a u lic a ccu m u la t or s dia gn osis a n d r epa ir. Th is in for m a t ion ca n be viewed
• Two pla n et a r y gea r set s wit h t h e DRB sca n t ool.
• H ydr a u lic oil pu m p
• Va lve body
RS 40TE AUTOMATIC TRANSAXLE 21 - 3
4 0 T E AU T OM AT I C T RAN SAX LE (Cont inue d)
Fig. 1 40TE Automatic Transaxle

1 - TRANSAXLE CASE 7 - REVERSE CLUTCH 13 - OUTPUT SHAFT GEAR
2 - TORQUE CONVERTER 8 - FRONT PLANET CARRIER 14 - TRANSFER SHAFT GEAR
3 - OIL PUMP 9 - 2/4 CLUTCH 15 - TRANSFER SHAFT
4 - INPUT SPEED SENSOR 10 - L/R CLUTCH 16 - DIFFERENTIAL
5 - UNDERDRIVE CLUTCH 11 - OUTPUT SPEED SENSOR 17 - CONVERTER DRIVE PLATE
6 - OVERDRIVE CLUTCH 12 - REAR PLANET CARRIER/OUTPUT 18 - INPUT SHAFT
SHAFT
TRANSAXLE IDENTIFICATION
Th e 40TE t r a n sa xle is iden t ified by a ba r code la bel
t h a t is fixed t o t h e t r a n sa xle ca se a s sh own in (F ig.
2).
Fig. 3 Identification Label Breakdown

1 - T=TRACEABILITY
Fig. 2 Transaxle Identification Label 2 - SUPPLIER CODE (PK=KOKOMO)
1 - IDENTIFICATION LABEL 3 - COMPONENT CODE (TK=KOKOMO TRANSMISSION)
4 - BUILD DAY (344=DEC. 9)
5 - BUILD YEAR (9=1999)
Th e la bel con t a in s a ser ies of digit s t h a t ca n be 6 - LINE/SHIFT CODE (3=3RD SHIFT)
t r a n sla t ed in t o u sefu l in for m a t ion su ch a s t r a n sa xle 7 - BUILD SEQUENCE NUMBER
pa r t n u m ber, da t e of m a n u fa ct u r e, m a n u fa ct u r in g 8 - LAST THREE OF P/N
9 - ALPHA
or igin , pla n t sh ift n u m ber, bu ild sequ en ce n u m ber, 10 - TRANSAXLE PART NUMBER
et c. Refer t o (F ig. 3) for iden t ifica t ion la bel br ea k- 11 - P=PART NUMBER
down .
If t h e t a g is n ot legible or m issin g, t h e “P K” n u m - OPERATION
ber, wh ich is st a m ped in t o t h e t r a n sa xle ca se beh in d Tr a n sm ission ou t pu t is dir ect ed t o a n in t egr a l dif-
t h e t r a n sfer gea r cover, ca n be r efer r ed t o for iden t i- fer en t ia l by a t r a n sfer gea r syst em in t h e followin g
fica t ion . Th is n u m ber differ s sligh t ly in t h a t it con - in pu t -t o-ou t pu t r a t ios:
t a in s t h e en t ir e t r a n sa xle pa r t n u m ber, r a t h er t h a n
t h e la st t h r ee digit s. F ir st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.84 : 1
Secon d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.57 : 1
Th ir d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00 : 1
Over dr ive . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.69 : 1
Rever se . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21 : 1
DI AGN OSI S AN D T EST I N G DIAGNOSIS AND TESTING - ROAD TEST

P r ior t o per for m in g a r oa d t est , ver ify t h a t t h e
DIAGNOSIS AND TESTING - 4XTE TRANSAXLE flu id level, flu id con dit ion , a n d lin ka ge a dju st m en t
GENERAL DIAGNOSIS h a ve been a ppr oved.
Du r in g t h e r oa d t est , t h e t r a n sa xle sh ou ld be oper-
NOTE: Before attempting any repair on a 4XTE four- a t ed in ea ch posit ion t o ch eck for slippin g a n d a n y
speed automatic transaxle, check for diagnostic va r ia t ion in sh ift in g.
trouble codes (DTC’s) using the DRB scan tool. If t h e veh icle oper a t es pr oper ly a t h igh wa y speeds,
Refer to the Transmission Diagnostic Procedures bu t h a s poor a cceler a t ion , t h e con ver t er st a t or over-
Manual. r u n n in g clu t ch m a y be slippin g. If a cceler a t ion is n or-
m a l, bu t h igh t h r ot t le open in g is n eeded t o m a in t a in
Tr a n sa xle m a lfu n ct ion s m a y be ca u sed by t h ese h igh wa y speeds, t h e con ver t er st a t or clu t ch m a y
gen er a l con dit ion s: h a ve seized. Bot h of t h ese st a t or defect s r equ ir e
• P oor en gin e per for m a n ce r epla cem en t of t h e t or qu e con ver t er a n d t h or ou gh
• Im pr oper a dju st m en t s t r a n sa xle clea n in g.
• H ydr a u lic m a lfu n ct ion s Slippin g clu t ch es ca n be isola t ed by com pa r in g t h e
• Mech a n ica l m a lfu n ct ion s “E lem en t s in Use” ch a r t wit h clu t ch oper a t ion
• E lect r on ic m a lfu n ct ion s en cou n t er ed on a r oa d t est . Th is ch a r t iden t ifies
Dia gn osis of t h ese pr oblem s sh ou ld a lwa ys begin wh ich clu t ch es a r e a pplied a t ea ch posit ion of t h e
by ch eckin g t h e ea sily a ccessible va r ia bles: flu id level select or lever.
a n d con dit ion , gea r sh ift ca ble a dju st m en t . Th en per- A slippin g clu t ch m a y a lso set a DTC a n d ca n be
for m a r oa d t est t o det er m in e if t h e pr oblem h a s been det er m in ed by oper a t in g t h e t r a n sa xle in a ll select or
cor r ect ed or t h a t m or e dia gn osis is n ecessa r y. If t h e posit ion s.
pr oblem per sist s a ft er t h e pr elim in a r y t est s a n d cor-
r ect ion s a r e com plet ed, h ydr a u lic pr essu r e ch ecks
sh ou ld be per for m ed.
ELEM EN T S I N U SE AT EACH POSI T I ON OF SELECT OR LEV ER
Shift Lever INPUT CLUTCHES HOLDING CLUTCHES

Position Underdrive Overdrive Reverse 2/4 Low/Reverse
P - PARK X
R - REVERSE X X
N - NEUTRAL X
OD -
OVERDRIVE
First X X
Second X X
Direct X X
Overdrive X X
D - DRIVE*
First X X
Second X X
Direct X X
L - LOW*
First X X
Second X X
Direct X X
* Vehicle upshift and downshift speeds are increased when in these selector positions.
Th e pr ocess of elim in a t ion ca n be u sed t o det ect (5) Th is t est ch ecks pu m p ou t pu t , pr essu r e r egu la -
a n y u n it wh ich slips a n d t o con fir m pr oper oper a t ion t ion a n d con dit ion of t h e low/r ever se clu t ch h ydr a u lic
of good u n it s. Roa d t est a n a lysis ca n dia gn ose slip- cir cu it a n d sh ift sch edu le.
pin g u n it s, bu t t h e ca u se of t h e m a lfu n ct ion ca n n ot
be det er m in ed. P r a ct ica lly a n y con dit ion ca n be TEST TWO-SELECTOR IN DRIVE (2nd GEAR)
ca u sed by lea kin g h ydr a u lic cir cu it s or st ickin g
NOTE: This test checks the underdrive clutch
va lves.
hydraulic circuit as well as the shift schedule.
DIAGNOSIS AND TESTING - HYDRAULIC (1) At t a ch ga u ge t o t h e u n der dr ive clu t ch t a p.
PRESSURE TESTS (2) Move select or lever t o t h e 3 posit ion .
P r essu r e t est in g is a ver y im por t a n t st ep in t h e (3) Allow veh icle wh eels t o t u r n a n d in cr ea se
dia gn ost ic pr ocedu r e. Th ese t est s u su a lly r evea l t h e t h r ot t le open in g t o a ch ieve a n in dica t ed veh icle speed
ca u se of m ost h ydr a u lic t r a n sa xle pr oblem s. of 30 m ph .
Befor e per for m in g pr essu r e t est s, be cer t a in t h a t (4) In secon d gea r t h e u n der dr ive clu t ch pr essu r e
flu id level a n d con dit ion , a n d sh ift ca ble a dju st m en t s sh ou ld r ea d 110 t o 145 psi.
h a ve been ch ecked a n d a ppr oved. F lu id m u st be a t
oper a t in g t em per a t u r e (150 t o 200 degr ees F.). TEST TWO A–SELECTOR IN OD (4th Gear)
In st a ll a n en gin e t a ch om et er, r a ise veh icle on h oist
wh ich a llows fr on t wh eels t o t u r n , a n d posit ion NOTE: This test checks the underdrive clutch
t a ch om et er so it ca n be r ea d. hydraulic circuit as well as the shift schedule.
At t a ch 300 psi ga u ge (C-3293SP ) t o por t (s)
r equ ir ed for t est (s) bein g con du ct ed. Use a da pt er set (1) At t a ch ga u ge t o t h e u n der dr ive clu t ch t a p.
L-4559 t o a da pt ga u ge(s) t o t r a n sa xle. (2) Move select or lever t o t h e (OD) posit ion .
Test por t loca t ion s a r e sh own in (F ig. 4). (3) Allow wh eels t o r ot a t e fr eely a n d in cr ea se
t h r ot t le open in g t o a ch ieve a n in dica t ed speed of 40
m ph .
(4) Un der dr ive clu t ch pr essu r e sh ou ld r ea d below
5 psi. If n ot , t h en eit h er t h e solen oid a ssem bly or
P CM/TCM is a t fa u lt .
TEST THREE-OVERDRIVE CLUTCH CHECK (3rd and

2nd Gear)
(1) At t a ch ga u ge t o t h e over dr ive clu t ch t a p.
(2) Move select or lever t o t h e (OD) posit ion .
(3) Allow veh icle wh eels t o t u r n a n d in cr ea se
t h r ot t le open in g t o a ch ieve a n in dica t ed veh icle speed
of 20 m ph . Veh icle sh ou ld be in 3r d gea r.
(4) Over dr ive clu t ch pr essu r e sh ou ld r ea d 74 t o 95
psi.
(5) Move select or lever t o t h e (3) posit ion a n d
Fig. 4 Pressure Taps in cr ea se in dica t ed veh icle speed t o 30 m ph .
1 - OVERDRIVE CLUTCH (6) Th e veh icle sh ou ld be in secon d gea r a n d over-
2 - TORQUE CONVERTER OFF dr ive clu t ch pr essu r e sh ou ld be less t h a n 5 psi.
3 - LOW/REVERSE CLUTCH
4 - 2/4 CLUTCH (7) Th is t est ch ecks t h e over dr ive clu t ch h ydr a u lic
5 - REVERSE CLUTCH cir cu it a s well a s t h e sh ift sch edu le.
6 - UNDERDRIVE CLUTCH
TEST FOUR-SELECTOR IN OVERDRIVE (4th Gear)
TEST ONE-SELECTOR IN LOW (1st GEAR) (1) At t a ch ga u ge t o t h e 2/4 clu t ch t a p.
(1) At t a ch pr essu r e ga u ge t o t h e low/r ever se clu t ch (2) Move select or lever t o t h e (OD) posit ion .
t a p. (3) Allow veh icle fr on t wh eels t o t u r n a n d in cr ea se
(2) Move select or lever t o t h e (L) posit ion . t h r ot t le open in g t o a ch ieve a n in dica t ed veh icle speed
(3) Allow veh icle wh eels t o t u r n a n d in cr ea se of 30 m ph . Veh icle sh ou ld be in 4t h gea r.
t h r ot t le open in g t o a ch ieve a n in dica t ed veh icle speed (4) Th e 2/4 clu t ch pr essu r e sh ou ld r ea d 75 t o 95
t o 20 m ph . psi.
(4) Low/r ever se clu t ch pr essu r e sh ou ld r ea d 115 t o (5) Th is t est ch ecks t h e 2/4 clu t ch h ydr a u lic cir-
145 psi. cu it .
TEST FIVE-SELECTOR IN OVERDRIVE (4th Gear-CC (4) Rever se a n d LR clu t ch pr essu r e sh ou ld r ea d
on) 165 t o 235 psi.
(1) At t a ch ga u ge t o t h e t or qu e con ver t er clu t ch off (5) Th is t est ch ecks t h e r ever se clu t ch h ydr a u lic
pr essu r e t a p. cir cu it .
(3) Allow veh icle wh eels t o t u r n a n d in cr ea se TEST RESULT INDICATIONS
t h r ot t le open in g t o a ch ieve a n in dica t ed veh icle speed (1) If pr oper lin e pr essu r e is fou n d in a n y on e t est ,
of 50 m ph . Veh icle sh ou ld be in 4t h gea r, CC on . t h e pu m p a n d pr essu r e r egu la t or a r e wor kin g pr op-
er ly.
CAUTION: Both wheels must turn at the same (2) Low pr essu r e in a ll posit ion s in dica t es a defec-
speed. t ive pu m p, a clogged filt er, or a st u ck pr essu r e r egu -
la t or va lve.
(4) Tor qu e con ver t er clu t ch off pr essu r e sh ou ld be (3) Clu t ch cir cu it lea ks a r e in dica t ed if pr essu r es
less t h a n 5 psi. do n ot fa ll wit h in t h e specified pr essu r e r a n ge.
(5) Th is t est ch ecks t h e t or qu e con ver t er clu t ch (4) If t h e over dr ive clu t ch pr essu r e is gr ea t er t h a n
h ydr a u lic cir cu it . 5 psi in St ep 4 of Test Th r ee, a wor n r ea ct ion sh a ft
sea l r in g or a defect ive solen oid a ssem bly is in di-
TEST SIX-SELECTOR IN REVERSE ca t ed.
(1) At t a ch ga u ges t o t h e r ever se a n d LR clu t ch (5) If t h e u n der dr ive clu t ch pr essu r e is gr ea t er
t a p. t h a n 5 psi in St ep 4 of Test Two A, a defect ive sole-
(2) Move select or lever t o t h e (R) posit ion . n oid a ssem bly or P CM/TCM is t h e ca u se.
(3) Rea d r ever se clu t ch pr essu r e wit h ou t pu t st a -
t ion a r y (foot on br a ke) a n d t h r ot t le open ed t o a ch ieve
1500 r pm .
PRESSU RE CH ECK SPECI FI CAT I ON S
Pressure Taps
Torque
Low/
Gear Selector Underdrive Overdrive Reverse Converter 2/4
Actual Gear Reverse
Position Clutch Clutch Clutch Clutch Clutch
Clutch
Off
Park *
PARK 0-2 0-5 0-2 60-110 0-2 115-145
0 mph
REVERSE *
REVERSE 0-2 0-7 165-235 50-100 0-2 165-235
0 mph
NEUTRAL *
NEUTRAL 0-2 0-5 0-2 60-110 0-2 115-145
0 mph
L #
FIRST 110-145 0-5 0-2 60-110 0-2 115-145
20 mph
3 #
SECOND 110-145 0-5 0-2 60-110 115-145 0-2
30 mph
3 #
DIRECT 75-95 75-95 0-2 60-90 0-2 0-2
45 mph
OD #
OVERDRIVE 0-2 75-95 0-2 60-90 75-95 0-2
30 mph
OD # OVERDRIVE
0-2 75-95 0-2 0-5 75-95 0-2
50 mph WITH TCC
* Engine speed at 1500 rpm
# CAUTION: Both front wheels must be turning at the same speed.
DIAGNOSIS AND TESTING - CLUTCH AIR

PRESSURE TESTS
In oper a t ive clu t ch es ca n be loca t ed u sin g a ser ies
of t est s by su bst it u t in g a ir pr essu r e for flu id pr essu r e
(F ig. 5) (F ig. 6). Th e clu t ch es m a y be t est ed by a pply-
in g a ir pr essu r e t o t h eir r espect ive pa ssa ges. Th e
va lve body m u st be r em oved a n d Tool 6056 in st a lled.
To m a ke a ir pr essu r e t est s, pr oceed a s follows:
NOTE: The compressed air supply must be free of

all dirt and moisture. Use a pressure of 30 psi.
Rem ove oil pa n a n d va lve body. See Va lve body

r em ova l.
Fig. 6 Testing Reverse Clutch

1 - TOOL 6056
2 - AIR NOZZLE
2/4 CLUTCH
Apply a ir pr essu r e t o t h e feed h ole loca t ed on t h e
2/4 clu t ch r et a in er. Look in t h e a r ea wh er e t h e 2/4
pist on con t a ct s t h e fir st sepa r a t or pla t e a n d wa t ch
ca r efu lly for t h e 2/4 pist on t o m ove r ea r wa r d. Th e
pist on sh ou ld r et u r n t o it s or igin a l posit ion a ft er t h e
a ir pr essu r e is r em oved.
LOW/REVERSE CLUTCH
Apply a ir pr essu r e t o t h e low/r ever se clu t ch feed
h ole (r ea r of ca se, bet ween 2 bolt h oles). Th en , look
Fig. 5 Air Pressure Test Plate in t h e a r ea wh er e t h e low/r ever se pist on con t a ct s t h e
1 - TOOL 6056 fir st sepa r a t or pla t e. Wa t ch ca r efu lly for t h e pist on t o
2 - ACCUMULATORS m ove for wa r d. Th e pist on sh ou ld r et u r n t o it s or igi-
n a l posit ion a ft er t h e a ir pr essu r e is r em oved.
OVERDRIVE CLUTCH
Apply a ir pr essu r e t o t h e over dr ive clu t ch a pply UNDERDRIVE CLUTCH
pa ssa ge a n d wa t ch for t h e pu sh /pu ll pist on t o m ove Beca u se t h is clu t ch pist on ca n n ot be seen , it s oper-
for wa r d. Th e pist on sh ou ld r et u r n t o it s st a r t in g a t ion is ch ecked by fu n ct ion . Air pr essu r e is a pplied
posit ion wh en t h e a ir pr essu r e is r em oved. t o t h e low/r ever se a n d t h e 2/4 clu t ch es. Th is locks t h e
ou t pu t sh a ft . Use a piece of r u bber h ose wr a pped
REVERSE CLUTCH a r ou n d t h e in pu t sh a ft a n d a pa ir of cla m p-on plier s
Apply a ir pr essu r e t o t h e r ever se clu t ch a pply pa s- t o t u r n t h e in pu t sh a ft . Next a pply a ir pr essu r e t o
sa ge a n d wa t ch for t h e pu sh /pu ll pist on t o m ove r ea r- t h e u n der dr ive clu t ch . Th e in pu t sh a ft sh ou ld n ot
wa r d. Th e pist on sh ou ld r et u r n t o it s st a r t in g r ot a t e wit h h a n d t or qu e. Relea se t h e a ir pr essu r e
posit ion wh en t h e a ir pr essu r e is r em oved. a n d con fir m t h a t t h e in pu t sh a ft will r ot a t e.
DIAGNOSIS AND TESTING - TORQUE

CONVERTER HOUSING FLUID LEAKAGE
Wh en dia gn osin g con ver t er h ou sin g flu id lea ks,
t h r ee a ct ion s m u st be t a ken befor e r epa ir :
(1) Ver ify pr oper t r a n sm ission flu id level.
(2) Ver ify t h a t t h e lea k or igin a t es fr om t h e con -
ver t er h ou sin g a r ea a n d is t r a n sm ission flu id.
(3) Det er m in e t h e t r u e sou r ce of t h e lea k.
F lu id lea ka ge a t or a r ou n d t h e t or qu e con ver t er a r ea
m a y or igin a t e fr om a n en gin e oil lea k (F ig. 7). Th e a r ea
sh ou ld be exa m in ed closely. F a ct or y fill flu id is r ed a n d,
t h er efor e, ca n be dist in gu ish ed fr om en gin e oil.
Fig. 8 Converter Leak Points - Typical
1 - OUTSIDE DIAMETER WELD
2 - TORQUE CONVERTER HUB WELD
3 - STARTER RING GEAR
4 - LUG
REMOVAL
NOTE: If transaxle assembly is being replaced or
overhauled (clutch and/or seal replacement), it is
necessary to perform the “Quick-Learn” Procedure.
(Refer to 8 - ELECTRICAL/ELECTRONIC CONTROL
MODULES/TRANSMISSION CONTROL MODULE -
STANDARD PROCEDURE)
(1) Discon n ect ba t t er y ca bles.

(2) Rem ove ba t t er y sh ield (F ig. 9).
Fig. 7 Converter Housing Leak Paths

1 - PUMP SEAL
2 - PUMP VENT
3 - PUMP BOLT
4 - PUMP GASKET
5 - CONVERTER HOUSING
6 - CONVERTER
7 - REAR MAIN SEAL LEAK
Som e su spect ed con ver t er h ou sin g flu id lea ks m a y n ot

be lea ks a t a ll. Th ey m a y on ly be t h e r esu lt of r esidu a l
flu id in t h e con ver t er h ou sin g, or excess flu id spilled
du r in g fa ct or y fill, or fill a ft er r epa ir. Con ver t er h ou sin g
lea ks h a ve sever a l pot en t ia l sou r ces. Th r ou gh ca r efu l
obser va t ion , a lea k sou r ce ca n be iden t ified befor e
r em ovin g t h e t r a n sm ission for r epa ir.
P u m p sea l lea ks t en d t o m ove a lon g t h e dr ive h u b
a n d on t o t h e r ea r of t h e con ver t er (F ig. 7). P u m p o-r in g
or pu m p body lea ks follow t h e sa m e pa t h a s a sea l lea k.
P u m p a t t a ch in g bolt lea ks a r e gen er a lly deposit ed on
t h e in side of t h e con ver t er h ou sin g a n d n ot on t h e con -
ver t er it self. P u m p sea l or ga sket lea ks u su a lly t r a vel
down t h e in side of t h e con ver t er h ou sin g (F ig. 7).
Fig. 9 Battery Thermal Guard
TORQUE CONVERTER LEAKAGE 1 - BATTERY THERMOWRAP (IF EQUIPPED)
P ossible sou r ces of t or qu e con ver t er lea ka ge a r e: 2 - INTEGRATED POWER MODULE
• Tor qu e con ver t er weld lea ks a t t h e ou t side dia m - 3 - FRONT CONTROL MODULE
et er weld (F ig. 8).
• Tor qu e con ver t er h u b weld (F ig. 8).
(3) Rem ove coola n t r ecover y bot t le (F ig. 10).
Fig. 11 Component Connector Location—Typical

1 - SOLENOID/PRESSURE SWITCH ASSY. CONNECTOR
2 - INPUT SPEED SENSOR CONNECTOR
Fig. 10 Coolant Recovery Bottle 3 - OUTPUT SPEED SENSOR CONNECTOR
4 - TRANSMISSION RANGE SENSOR CONNECTOR
1 - COOLANT RECOVERY CONTAINER
2 - HOSE
3 - BOLT
4 - SUB FRAME RAIL
(4) Rem ove flu id level in dica t or /t u be a ssem bly.

P lu g open in g t o pr even t debr is fr om en t er in g t r a n s-
a xle.
(5) Discon n ect t r a n sa xle oil cooler lin es u sin g Tool
8875A. (Refer t o 7 - COOLING/TRANSMISSION -
STANDARD P ROCE DURE ). In st a ll plu gs t o pr even t
debr is in t r u sion .
(6) Discon n ect in pu t a n d ou t pu t sh a ft speed sen sor
con n ect or s (F ig. 11).
(7) Discon n ect t r a n sm ission r a n ge sen sor (TRS)
(8) Discon n ect solen oid/pr essu r e swit ch a ssem bly
(9) Discon n ect gea r sh ift ca ble fr om m a n u a l va lve
lever a n d u pper m ou n t br a cket (F ig. 12).
(10) Discon n ect cr a n ksh a ft posit ion sen sor (if
equ ipped). Rem ove sen sor fr om bellh ou sin g.
(11) Reposit ion lea k det ect ion pu m p h a r n ess a n d
h oses.
Fig. 12 Gearshift Cable at Transaxle - Typical
1 - MANUAL VALVE LEVER
2 - GEAR SHIFT CABLE
3 - UPPER MOUNT BRACKET
(12) Rem ove r ea r m ou n t br a cket -t o-t r a n sa xle ca se
bolt s (F ig. 13).
(13) Rem ove t r a n sa xle u pper bellh ou sin g-t o-block
bolt s.
(15) Rem ove t r a n sa xle oil pa n a n d dr a in flu id in t o
su it a ble con t a in er.
(16) Rem ove fr on t wh eel/t ir e a ssem blies.
(17) Rem ove left a n d r igh t h a lfsh a ft a ssem blies.
(Refer t o 3 - DIF F E RE NTIAL & DRIVE LINE /H ALF
SH AF T - RE MOVAL)
(18) AWD m odels: Rem ove power t r a n sfer u n it .
(Refer t o 21 - TRANSMISSION/TRANSAXLE /
P OWE R TRANSF E R UNIT - RE MOVAL)
lower (h or izon t a l) bolt (F ig. 13).
(20) Rem ove fr on t m ou n t /br a cket a ssem bly.
(21) Rem ove st a r t er m ot or.
(22) Rem ove la t er a l ben din g br a ce.
(23) Rem ove in spect ion cover. Fig. 14 Left Mount-to-Bracket
(24) Rem ove t or qu e con ver t er-t o-dr ive pla t e bolt s. 1 - BOLT - BRACKET TO FRAME RAIL
(25) Su ppor t en gin e/t r a n sa xle a ssem bly a t en gin e 2 - BOLT - MOUNT TO RAIL THROUGH
oil pa n wit h scr ew ja ck a n d wood block. 3 - BOLT - LEFT MOUNT TO TRANSAXLE
4 - TRANSAXLE
(26) P a r t ia lly r em ove left wh eelh ou se spla sh sh ield 5 - MOUNT - LEFT
t o ga in a ccess t o a n d r em ove u pper m ou n t t h r u -bolt 6 - BRACKET - LEFT MOUNT
(F ig. 14).
Fig. 13 Rear Mount Bracket - Typical

1 - BOLT - VERTICAL 3 - BOLT - HORIZONTAL
(27) Lower en gin e/t r a n sa xle a ssem bly wit h scr ew (4) Rem ove oil pa n -t o-ca se bolt s (F ig. 16).
ja ck.
(28) Obt a in h elper a n d/or t r a n sm ission ja ck.
Secu r e t r a n sm ission ja ck t o t r a n sa xle a ssem bly.
(29) Rem ove u pper m ou n t br a cket fr om t r a n sa xle
(F ig. 14).
(30) Rem ove r em a in in g t r a n sa xle bellh ou sin g-t o-
en gin e bolt s.
(31) Rem ove t r a n sa xle a ssem bly fr om veh icle.
DISASSEMBLY
NOTE: If transaxle is being overhauled (clutch
and/or seal replacement) or replaced, it is neces-
sary to perform the PCM/TCM Quick Learn Proce-
dure. (Refer to 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/POWERTRAIN/TRANSMIS-
SION CONTROL MODULE - STANDARD PROCE-
Fig. 16 Remove Oil Pan Bolts
DURE)
1 - OIL PAN BOLTS (USE RTV UNDER BOLT HEADS)
NOTE: This procedure does not include final drive (5) Rem ove oil pa n (F ig. 17).
(differential) disassembly.
(1) Rem ove in pu t a n d ou t pu t speed sen sor s.

(2) Rem ove t h r ee (3) solen oid/pr essu r e swit ch
a ssem bly-t o-ca se bolt s.
(3) Rem ove solen oid/pr essu r e swit ch a ssem bly a n d
ga sket (F ig. 15).
Fig. 17 Remove Oil Pan

1 - OIL PAN
2 - 1/8 INCH BEAD OF MOPAR" ATF RTV (MS-GF41)
3 - OIL FILTER
Fig. 15 Solenoid/Pressure Switch Assembly and

Gasket
1 - SOLENOID/PRESSURE SWITCH ASSEMBLY
2 - GASKET
(6) Rem ove oil filt er (F ig. 18). (9) Usin g a scr ewdr iver, pu sh pa r k r od r oller s
a wa y fr om gu ide br a cket (F ig. 20) a n d r em ove va lve
body a ssem bly (F ig. 21).
Fig. 18 Remove Filter and O-Ring Fig. 20 Push Park Rod Rollers from Guide Bracket
1 - PARK SPRAG ROLLERS
1 - OIL FILTER
2 - SCREWDRIVER
2 - O-RING
3 - PARK SPRAG GUIDE BRACKET
(7) Tu r n m a n u a l va lve fu lly clock-wise t o get pa r k

r od in t o posit ion for r em ova l.
(8) Rem ove va lve body-t o-ca se bolt s (F ig. 19).
Fig. 21 Valve Body Removal/Installation

1 - VALVE BODY
Fig. 19 Remove Valve Body-to-Case Bolts

1 - VALVE BODY ATTACHING BOLTS (18)
2 - VALVE BODY
CAUTION: Do not handle the valve body assembly

from the manual valve. Damage can result.
NOTE: Depending on engine application, some (12) Rem ove low/r ever se a ccu m u la t or plu g (F ig.
accumulators will have two springs and others will 24).
have one spring. The springs are color-coded
according to application and year. When disassem-
bling, mark accumulator spring location to ease
assembly.
(10) Rem ove u n der dr ive a n d over dr ive a ccu m u la -

t or s (F ig. 22).
Fig. 24 Remove Low/Reverse Accumulator Plug

1 - ADJUSTABLE PLIERS
2 - PLUG
(13) Rem ove low/r ever se a ccu m u la t or pist on u sin g

su it a ble plier s (F ig. 25). Rem ove pist on a n d spr in gs
(F ig. 26).
Fig. 22 Underdrive and Overdrive Accumulators

1 - OVERDRIVE PISTON AND SPRING
2 - UNDERDRIVE PISTON AND SPRING
(11) Rem ove low/r ever se a ccu m u la t or sn a p r in g

(F ig. 23).
Fig. 25 Low/Reverse Accumulator Piston

1 - ACCUMULATOR PISTON
Fig. 23 Remove Low/Reverse Accumulator Snap

Ring
1 - SNAP RING
2 - PLUG
(15) Rem ove oil pu m p-t o-ca se bolt s (F ig. 28).
Fig. 26 Low/Reverse Accumulator

Fig. 28 Remove Oil Pump-to-Case Bolts
1 - PISTON
2 - RETURN SPRINGS 1 - PUMP ATTACHING BOLTS
2 - PUMP HOUSING
(14) Mea su r e in pu t sh a ft en d pla y. P la ce t r a n sa xle
CAUTION: Be sure input speed sensor is removed
so in pu t sh a ft is ver t ica l. Set u p en d pla y set a n d
before removing oil pump.
dia l in dica t or a s sh own in (F ig. 27). In p u t s h a ft e n d
p la y s h o u ld be w ith in 0.13-0.64 m m (0.005-0.025 (16) In st a ll pu ller s Tool C-3752 a s sh own in (F ig.
in .) If ou t side of t h is r a n ge, a #4 t h r u st pla t e ch a n ge 29).
is r equ ir ed. Recor d in dica t or r ea din g for r efer en ce
u pon r ea ssem bly.
Fig. 29 Install Tool C-3752

1 - PULLERS TOOL C-3752
2 - PUMP
Fig. 27 Measure Input Shaft End Play Using Tool

8266—Typical
1 - TOOL 8266–8
2 - TOOL 8266–2
3 - TOOL C-3339
(17) Rem ove oil pu m p a ssem bly (F ig. 30) (F ig. 31). (18) Rem ove oil pu m p ga sket (F ig. 32).
Fig. 30 Remove Oil Pump Fig. 32 Remove Oil Pump Gasket

1 - “PUSH IN” ON INPUT SHAFT WHILE REMOVING PUMP 1 - PUMP GASKET
CAUTION: If transaxle failure has occurred, the

cooler bypass valve must be replaced. Do not
re-use or attempt to clean valve.
(19) Rem ove cooler bypa ss va lve (F ig. 33).
Fig. 31 Oil Pump Removed

1 - OIL PUMP
2 - GASKET
Fig. 33 Remove Bypass Valve

1 - COOLER BYPASS VALVE
(20) Rem ove #1 n eedle bea r in g (F ig. 34). (22) Rem ove #4 t h r u st pla t e (F ig. 36).
Fig. 34 Remove No. 1 Caged Needle Bearing Fig. 36 No. 4 Thrust Plate
1 - #1 CAGED NEEDLE BEARING 1 - OVERDRIVE SHAFT ASSEMBLY
2 - NOTE: TANGED SIDE OUT 2 - #4 THRUST PLATE (SELECT)
3 - 3 DABS OF PETROLATUM FOR RETENTION
(21) Rem ove in pu t clu t ch a ssem bly (F ig. 35).
(23) Rem ove fr on t su n gea r a ssem bly a n d #4
t h r u st wa sh er (F ig. 37).
Fig. 35 Remove Input Clutch Assembly

1 - INPUT CLUTCH ASSEMBLY
2 - #4 THRUST WASHER Fig. 37 Remove Front Sun Gear Assembly
1 - FRONT SUN GEAR ASSEMBLY
2 - #4 THRUST WASHER (FOUR TABS)
(24) Rem ove fr on t ca r r ier /r ea r a n n u lu s a ssem bly
a n d #6 n eedle bea r in g (F ig. 38).
Fig. 40 Number 7 Bearing

1 - #7 NEEDLE BEARING
Fig. 38 Remove Front Carrier/Rear Annulus 2 - REAR SUN GEAR
Assembly
(26) Set u p t ool 5058 a s sh own in (F ig. 41). Com -
2 - FRONT CARRIER AND REAR ANNULUS ASSEMBLY (TWIST pr ess 2/4 clu t ch r et u r n spr in g (ju st en ou gh t o r em ove
AND PULL OR PUSH TO REMOVE OR INSTALL). sn a p r in g) a n d r em ove sn a p r in g.
(25) Rem ove r ea r su n gea r a n d #7 n eedle bea r in g NOTE: Verify that Tool 5058 is centered properly
(F ig. 39). over the 2/4 clutch retainer before compressing. If
necessary, fasten the 5058 bar to the bellhousing
NOTE: The number 7 needle bearing has three anti- flange with any combination of locking pliers and
reversal tabs and is common with the number five bolts to center the tool properly.
and number two position. The orientation should
allow the bearing to seat flat against the rear sun
gear (Fig. 40). A small amount of petrolatum can be
used to hold the bearing to the rear sun gear.
Fig. 41 Remove 2/4 Clutch Retainer Snap Ring

1 - TOOL 5058
2 - SCREWDRIVER
3 - SNAP RING
4 - 2/4 CLUTCH RETAINER
Fig. 39 Remove Rear Sun Gear
2 - REAR SUN GEAR
NOTE: The 2/4 Clutch Piston has bonded seals (29) Rem ove 2/4 clu t ch pa ck (F ig. 44). Ta g 2/4
which are not individually serviceable. Seal replace- c lu tc h p a c k fo r re a s s e m bly id e n tific a tio n .
ment requires replacement of the piston assembly.
(27) Rem ove 2/4 clu t ch r et a in er (F ig. 42).
Fig. 42 2/4 Clutch Retainer Fig. 44 Remove 2/4 Clutch Pack

1 - 2/4 CLUTCH RETAINER 1 - CLUTCH DISC
2 - 2/4 CLUTCH RETURN SPRING 2 - CLUTCH PLATE
(28) Rem ove 2/4 clu t ch r et u r n spr in g (F ig. 43). (30) Rem ove t a per ed sn a p r in g (F ig. 45).
Fig. 43 Remove 2/4 Clutch Return Spring

Fig. 45 Remove Tapered Snap Ring
1 - 2/4 CLUTCH RETURN SPRING
1 - LOW/REVERSE CLUTCH REACTION PLATE
2 - SCREWDRIVER
3 - LOW/REVERSE TAPERED SNAP RING (TAPERED SIDE UP)
4 - OIL PAN FACE
5 - LONG TAB
(31) Rem ove low/r ever se r ea ct ion pla t e (F ig. 46). (33) Rem ove low/r ever se r ea ct ion pla t e sn a p r in g
(F ig. 48).
Fig. 46 Remove Low/Reverse Reaction Plate

1 - LOW/REVERSE REACTION PLATE (FLAT SIDE UP) Fig. 48 Remove Low/Reverse Reaction Plate Snap
Ring
(32) Rem ove on e low/r ever se clu t ch disc (F ig. 47). 1 - SCREWDRIVER
2 - LOW/REVERSE REACTION PLATE FLAT SNAP RING
3 - DO NOT SCRATCH CLUTCH PLATE
(34) Rem ove low/r ever se clu t ch pa ck (F ig. 49).
Fig. 47 Remove One Disc

1 - ONE DISC FROM LOW/REVERSE CLUTCH
Fig. 49 Remove Low/Reverse Clutch

1 - CLUTCH PLATE
2 - CLUTCH DISC
(35) Rem ove t r a n sfer gea r cover-t o-ca se bolt s (F ig. (37) Usin g Tool 6259, r em ove t r a n sfer sh a ft gea r-
50). t o-sh a ft n u t a n d con ed wa sh er (F ig. 52) (F ig. 53).
Fig. 50 Remove Rear Cover Bolts Fig. 52 Remove Transfer Shaft Gear Nut
1 - REAR COVER BOLTS 1 - TRANSFER SHAFT GEAR
2 - REAR COVER 2 - OUTPUT GEAR
3 - USE SEALANT ON BOLTS 3 - SPECIAL TOOL 6259
(36) Rem ove t r a n sfer gea r cover (F ig. 51).
Fig. 53 Transfer Shaft Gear Nut and Coned Washer

1 - TRANSFER SHAFT
Fig. 51 Remove Rear Cover 2 - LOCK WASHER
3 - NUT
1 - REAR COVER
2 - 1/8 INCH BEAD OF MOPAR" ATF RTV (MS-GF41) AS SHOWN
(38) Usin g t ool L-4407A, r em ove t r a n sfer sh a ft (40) Rem ove bea r in g cu p r et a in er (F ig. 56).
gea r (F ig. 54).
Fig. 56 Remove Bearing Cup Retainer

Fig. 54 Remove Transfer Shaft Gear 1 - ALIGN INDEXING TAB TO SLOT
1 - SPECIAL TOOL L4407-6 2 - BEARING CUP RETAINER
2 - TRANSFER SHAFT GEAR
3 - SPECIAL TOOL L4407A (41) Rem ove t r a n sfer gea r bea r in g con e u sin g
set u p sh own in (F ig. 57).
(39) Rem ove t r a n sfer gea r sh im (select ) (F ig. 55).
Fig. 57 Remove Transfer Gear Bearing Cone

Fig. 55 Remove Transfer Shaft Gear and (Select)
1 - WRENCHES
Shim 2 - TOOL 5048 WITH JAWS TOOL 5048–4 AND BUTTON TOOL
1 - TRANSFER SHAFT GEAR L-4539–2
2 - BEARING CUP RETAINER 3 - TRANSFER SHAFT GEAR
3 - SHIM (SELECT)
(42) Rem ove t r a n sfer sh a ft bea r in g cu p fr om (44) Usin g t ool 5049A, r em ove t r a n sfer sh a ft fr om
r et a in er u sin g Tool 6062 (F ig. 58). t r a n sa xle (F ig. 60).
Fig. 58 Remove Transfer Shaft Bearing Cup Fig. 60 Remove Transfer Shaft
1 - WRENCHES 1 - SPECIAL TOOL 5049–A
2 - TOOL 6062 2 - TRANSFER SHAFT
3 - TRANSFER SHAFT BEARING CUP RETAINER 3 - OUTPUT GEAR
(43) Usin g Tool 6051, r em ove t r a n sfer sh a ft bea r- (45) Slip bea r in g cu p r et a in er a n d oil ba ffle off of
in g sn a p r in g (F ig. 59). sh a ft (F ig. 61).
Fig. 59 Remove Transfer Shaft Bearing Snap Ring

Fig. 61 Bearing Cup Removed
1 - SNAP RING PLIERS TOOL 6051
2 - TRANSFER SHAFT BEARING SNAP RING 1 - BEARING CUP
3 - TRANSFER SHAFT 2 - BEARING CONE
3 - TRANSFER SHAFT
4 - OIL BAFFLE
5 - O-RING
(46) Usin g t ool P -334, pr ess t r a n sfer sh a ft bea r in g
con e off of sh a ft (F ig. 62).
Fig. 64 Remove Stirrup Strap

1 - OUTPUT GEARBOLT
2 - RETAINING STRAP
3 - STIRRUP
Fig. 62 Remove Transfer Shaft Bearing Cone
1 - ARBOR PRESS RAM
2 - TRANSFER SHAFT
3 - TOOL P-334
4 - BEARING CONE
(47) Ben d ou t pu t gea r r et a in in g st r a p ea r s fla t t o

a llow bolt r em ova l.
(48) Rem ove ou t pu t sh a ft st ir r u p st r a p bolt s (F ig.
63).
Fig. 65 Remove Output Gear Bolt

1 - OUTPUT GEAR
2 - TOOL 6259
Fig. 63 Remove Strap Bolts

1 - RETAINING STRAP
2 - STIRRUP
3 - RETAINING STRAP BOLTS
(49) Rem ove st ir r u p a n d st r a p (F ig. 64).

(50) Usin g Tool 6259 (F ig. 65), r em ove ou t pu t sh a ft
gea r-t o-sh a ft bolt a n d wa sh er (F ig. 66).
Fig. 66 Output Gear Bolt and Washer

1 - OUTPUT GEAR
2 - BOLT
3 - CONED LOCK WASHER
(51) Usin g Tool L4407A, a n d bu t t on 6055, r em ove (53) Usin g set u p a s sh own in (F ig. 69), r em ove
ou t pu t gea r fr om sh a ft (F ig. 67). ou t pu t gea r bea r in g con e.
Fig. 69 Remove Bearing Cone

Fig. 67 Remove Output Gear
1 - TOOL 5048 WITH JAWS 5048–5 AND BUTTON L-4539–2
1 - OUTPUT GEAR 2 - WRENCHES
2 - BUTTON TOOL 6055 3 - OUTPUT GEAR
3 - WRENCHES
4 - TOOL L4407A
5 - BOLTS TOOL L4407–6 (54) Rem ove r ea r ca r r ier a ssem bly fr om t r a n sa xle
(F ig. 70).
(52) Rem ove ou t pu t gea r bea r in g sh im (select )
(F ig. 68).
Fig. 70 Remove Rear Carrier Assembly

1 - REAR CARRIER ASSEMBLY
Fig. 68 Output Gear and (Select) Shim
2 - SHIM (SELECT)
3 - OUTPUT GEAR
(55) Rem ove r ea r ca r r ier a ssem bly bea r in g con e
u sin g set u p sh own in (F ig. 71).
Fig. 73 Compressor Tool in Use

1 - LOW/REVERSE CLUTCH RETURN SPRING
2 - SNAP RING (INSTALL AS SHOWN)
Fig. 71 Remove Rear Carrier Bearing Cone 3 - TOOL 6057
1 - TOOL 5048 WITH JAWS 5048–3 AND BUTTON 6055 4 - TOOL 5059
2 - WRENCHES 5 - TOOL 5058–3
(57) Com pr ess low/r ever se pist on r et u r n spr in g
(56) In st a ll low/r ever se spr in g com pr essor t ool a s a n d r em ove sn a p r in g (F ig. 74).
sh own in (F ig. 72) (F ig. 73).
Fig. 74 Install Snap Ring

Fig. 72 Low/Reverse Spring Compressor Tool 1 - SNAP RING OPENING MUST BE BETWEEN SPRING LEVERS
(AS SHOWN)
1 - TOOL 6057
2 - TOOL 5059
3 - TOOL 6057
3 - TOOL 5058–3
(58) Rem ove low/r ever se spr in g com pr essor t ool (60) Usin g or din a r y plier s, r em ove pivot sh a ft a n d
a n d low r ever se pist on r et u r n spr in g (F ig. 75). gu ide br a cket a ssem bly (F ig. 77).
Fig. 75 Low/Reverse Piston Fig. 77 Pivot Shaft and Guide Bracket

1 - LOW/REVERSE PISTON RETURN SPRING
1 - ANTIRACHET SPRING
2 - PISTON
2 - GUIDE BRACKET
3 - PIVOT SHAFT
(59) Usin g a su it a ble pu n ch , dr ive ou t pa r k gu ide 4 - PAWL
br a cket pivot sh a ft plu g (F ig. 76).
(61) In spect gu ide br a cket com pon en t s for exces-
sive wea r a n d r epla ce if n ecessa r y (F ig. 78).
Fig. 76 Remove Anchor Shaft and Plug

1 - GUIDE BRACKET ANCHOR SHAFT
2 - PIVOT SHAFT
3 - ANCHOR SHAFT PLUG
Fig. 78 Guide Bracket Disassembled

1 - ANTIRATCHET SPRING
2 - GUIDE BRACKET
3 - SPLIT SLEEVE
4 - SPACER
5 - PAWL
6 - STEPPED SPACER
NOTE: The Low/Reverse Clutch Piston has bonded (64) Rem ove low/r ever se pist on r et a in er (F ig. 81).
seals which are not individually serviceable. Seal
replacement requires replacement of the piston
assembly.
(62) Rem ove low/r ever se clu t ch pist on (F ig. 79).
Fig. 81 Remove Piston Retainer

1 - LOW/REVERSE CLUTCH PISTON RETAINER
2 - GASKET
(65) Rem ove low/r ever se pist on r et a in er-t o-ca se

Fig. 79 Remove Low/Reverse Clutch Piston ga sket (F ig. 82).
1 - LOW/REVERSE CLUTCH PISTON
2 - BONDED SEAL
3 - BONDED SEAL

scr ews (F ig. 80).
Fig. 82 Remove Piston Retainer Gasket

1 - GASKET HOLES MUST LINE UP
2 - LOW/REVERSE CLUTCH PISTON RETAINER GASKET
Fig. 80 Remove Piston Retainer-to-Case Screws

2 - SCREWDRIVER
3 - TORX-LOC SCREWS
(66) Usin g a h a m m er a n d su it a ble dr ift , dr ive ou t NOTE: If transaxle is being overhauled (clutch
in n er ou t pu t bea r in g cu p (F ig. 83). and/or seal replacement), the TCM/PCM Quick Learn
procedure must be performed. (Refer to 8 - ELEC-
TRICAL/ELECTRONIC CONTROL MODULES/TRANS-
MISSION CONTROL MODULE - STANDARD
PROCEDURE)
(1) In st a ll bot h ou t pu t bea r in g cu ps u sin g Tool

5050 (F ig. 85).
Fig. 83 Remove Output Bearing Inner Cup

1 - OUTPUT BEARING CUPS (REPLACE IN PAIRS)
2 - HAMMER
3 - BRASS DRIFT
(67) Usin g t ool 6062, r em ove ou t er ou t pu t bea r in g

cu p (F ig. 84).
Fig. 85 Install Both Output Bearing Cups
1 - OUTPUT BEARING CUPS
2 - WRENCHES
3 - TOOL 5050
(2) In st a ll low/r ever se pist on r et a in er ga sket (F ig.

86). Ma ke su r e ga sket h oles lin e u p wit h ca se.
Fig. 84 Remove Output Bearing Outer

1 - TOOL 6062
ASSEMBLY
CAUTION: The cooler bypass valve must be
replaced if transaxle failure has occurred. Do not
Fig. 86 Install Piston Retainer Gasket
attempt to reuse or clean old valve.
1 - GASKET HOLES MUST LINE UP
(3) In st a ll low/r ever se pist on r et a in er (F ig. 87). (5) In st a ll low/r ever se clu t ch pist on (F ig. 89).
Fig. 87 Install Piston Retainer Fig. 89 Install Low/Reverse Clutch Piston

1 - LOW/REVERSE CLUTCH PISTON RETAINER 1 - LOW/REVERSE CLUTCH PISTON
2 - GASKET 2 - BONDED SEAL
3 - BONDED SEAL
(4) In st a ll low/r ever se pist on r et a in er-t o-ca se bolt s
(6) Assem ble pa r k gu ide br a cket a ssem bly (F ig.
(F ig. 88) a n d t or qu e t o 5 N·m (45 in . lbs.).
91) (F ig. 90).
Fig. 88 Install Piston Retainer-to-Case Screws

2 - SCREWDRIVER
3 - TORX-LOC SCREWS
NOTE: The Low/Reverse Clutch Piston has bonded 1 - ANTIRATCHET SPRING
seals which are not individually serviceable. Seal 2 - GUIDE BRACKET
replacement requires replacement of the piston 3 - SPLIT SLEEVE
4 - SPACER
assembly. 5 - PAWL
6 - STEPPED SPACER
(8) In st a ll a n ch or sh a ft a n d plu g (F ig. 93). Ma ke
su r e gu ide br a cket a n d split sleeve a r e in con t a ct
wit h t h e r ea r of t h e t r a n sa xle ca se.
Fig. 91 Guide Bracket

1 - GUIDE BRACKET
2 - ANTIRATCHET SPRING (MUST BE ASSEMBLED AS SHOWN)
3 - PAWL
Fig. 93 Install Anchor Shaft and Plug
(7) In st a ll gu ide br a cket in t o posit ion a n d in ser t
pivot sh a ft (F ig. 92). 2 - PIVOT SHAFT
3 - ANCHOR SHAFT PLUG
(9) In st a ll low/r ever se pist on r et u r n spr in g (F ig.

94).
Fig. 92 Pivot Shaft and Guide Bracket

2 - GUIDE BRACKET
3 - PIVOT SHAFT
4 - PAWL Fig. 94 Low/Reverse Piston Return Spring
1 - LOW/REVERSE PISTON RETURN SPRING
2 - PISTON
(10) In st a ll low/r ever se spr in g com pr essor in t o (11) In st a ll r ea r ca r r ier bea r in g con e u sin g Tool
posit ion (F ig. 95). Com pr ess low/r ever se pist on a n d 6053 (F ig. 97).
in st a ll sn a p r in g a s sh own in (F ig. 96).
Fig. 97 Install Rear Carrier Bearing Cone

1 - ARBOR PRESS RAM
1 - LOW/REVERSE CLUTCH RETURN SPRING 2 - TOOL 6053
2 - SNAP RING (INSTALL AS SHOWN) 3 - NEW BEARING CONE
3 - TOOL 6057 4 - REAR CARRIER ASSEMBLY
4 - TOOL 5059
5 - TOOL 5058–3
(12) In st a ll r ea r ca r r ier a ssem bly t o t r a n sa xle ca se
(F ig. 98).

1 - SNAP RING OPENING MUST BE BETWEEN SPRING LEVERS Fig. 98 Install Rear Carrier Assembly
(AS SHOWN)
3 - TOOL 6057
(13) In st a ll ou t pu t gea r bea r in g con e u sin g Tool
5052 (F ig. 99).
Fig. 100 Checking Output Gear Bearings End Play

1 - TOOL L-4432
Fig. 99 Install Output Gear Bearing Cone 2 - DIAL INDICATOR
3 - SPECIAL SCREWS TOOL 6260
1 - ARBOR PRESS RAM 4 - OUTPUT GEAR
2 - HANDLE C-4171
3 - TOOL 5052
4 - OUTPUT GEAR
(14) OU TP U T GEAR B EARIN G AD J U S T-

MEN T:
(a ) Wit h ou t pu t gea r In st a lld, in st a ll a 4.50 m m
(0.177 in .) ga u gin g sh im (F ig. 101) on t h e r ea r ca r-
r ier a ssem bly h u b, u sin g gr ea se t o h old t h e sh im in
pla ce.
(b) Usin g Tool 6259, in st a ll ou t pu t gea r a n d
bea r in g a ssem bly. Tor qu e t o 271 N·m (200 ft . lbs.).
(c) Mea su r e bea r in g en d pla y. At t a ch Tool L-4432
t o t h e gea r (F ig. 100).
(d) P u sh a n d pu ll t h e gea r wh ile r ot a t in g ba ck
a n d for t h t o en su r e sea t in g of bea r in g r oller s.
(e) Usin g a dia l in dica t or m ou n t ed t o t h e t r a n s-
a xle ca se, m ea su r e ou t pu t gea r en d pla y a s sh own
in (F ig. 100). Fig. 101 Output Gear and (Select) Shim
(f) Refer t o t h e ou t pu t gea r bea r in g sh im ch a r t 1 - REAR CARRIER ASSEMBLY
for t h e r equ ir ed sh im t o obt a in pr oper bea r in g set - 2 - SHIM (SELECT)
t in g. 3 - OUTPUT GEAR
(g) Use Tool 6259 t o r em ove t h e ou t pu t gea r
r et a in in g bolt a n d wa sh er. To r em ove t h e ou t pu t
gea r, u se Tool L4407A.
(h ) Rem ove t h e ga u gin g sh im a n d in st a ll t h e
pr oper sh im det er m in ed by t h e ch a r t . Use gr ea se
t o h old t h e sh im in pla ce.
OU T PU T GEAR BEARI N G SH I M CH ART
End Play Shim Needed Part Number End Play Shim Needed Part Number
0.05mm 4.42mm 0.53mm 3.94mm
4412830AB 4412818AB
(0.002 in.) (0.174 in.) (0.021 in.) (0.155 in.)
0.08mm 4.38mm 0.56mm 3.90mm
4412829AB 4412817AB
(0.003 in.) (0.172 in.) (0.022 in.) (0.154 in.)
0.10mm 4.38mm 0.58mm 3.90mm
4412829AB 4412817AB
(0.004 in.) (0.172 in.) (0.023 in.) (0.154 in.)
0.13mm 4.34mm 0.61mm 3.86mm
4412828AB 4412816AB
(0.005 in.) (0.171 in.) (0.024 in.) (0.152 in.)
0.15mm 4.30mm 0.64mm 3.82mm
4412827AB 4412815AB
(0.006 in.) (0.169 in.) (0.025 in.) (0.150 in.)
0.18mm 4.30mm 0.66mm 3.82mm
4412827AB 4412815AB
(0.007 in.) (0.169 in.) (0.026 in.) (0.150 in.)
0.20mm 4.26mm 0.69mm 3.78mm
4412826AB 4412814AB
(0.008 in.) (0.168 in.) (0.027 in.) (0.149 in.)
0.23mm 4.22mm 0.71mm 3.74mm
4412825AB 4412813AB
(0.009 in.) (0.166 in.) (0.028 in.) (0.147 in.)
0.25mm 4.22mm 0.74mm 3.74mm
4412825AB 4412813AB
(0.010 in.) (0.166 in.) (0.029 in.) (0.147 in.)
0.28mm 4.18mm 0.76mm 3.70mm
4412824AB 4412812AB
(0.011 in.) (0.165 in.) (0.030 in.) (0.146 in.)
0.30mm 4.14mm 0.79mm 3.66mm
4412823AB 4412811AB
(0.012 in.) (0.163 in.) (0.031 in.) (0.144 in.)
0.33mm 4.14mm 0.81mm 3.66mm
4412823AB 4412811AB
(0.013 in.) (0.163 in.) (0.032 in.) (0.144 in.)
0.36mm 4.10mm 0.84mm 3.62mm
4412822AB 4412810AB
(0.014 in.) (0.161 in.) (0.033 in.) (0.143 in.)
0.38mm 4.10mm 0.86mm 3.62mm
4412822AB 4412810AB
(0.015 in.) (0.161 in.) (0.034 in.) (0.143 in.)
0.41mm 4.06mm 0.89mm 3.58mm
4412821AB 4412809AB
(0.016 in.) (0.160 in.) (0.035 in.) (0.141)
0.43mm 4.02mm 0.91mm 3.54mm
4412820AB 4412808AB
(0.017 in.) (0.158 in.) (0.036in.) (0.139 in.)
0.46mm 4.02mm 0.94mm 3.54mm
4412820AB 4412808AB
(0.018 in.) (0.158 in.) (0.037 in.) (0.139 in.)
0.48mm 3.98mm 0.97mm 3.50mm
4412819AB 4412807AB
(0.019 in.) (0.157 in.) (0.038 in.) (0.138 in.)
0.51mm 3.94mm
4412818AB
(0.020 in.) (0.155 in.)
(15) In st a ll t h e ou t pu t gea r a n d bea r in g a ssem bly

u sin g Tool 6261 (F ig. 102).
Fig. 104 Tighten Output Gear to 271 N•m (200 ft. lbs.)
1 - OUTPUT GEAR
2 - TORQUE WRENCH
Fig. 102 Install Output Gear 3 - 200 FT. LBS.
4 - TOOL 6259
1 - WRENCHES
2 - TOOL 6261 WITH STUD
3 - OUTPUT GEAR (17) Usin g a n in ch pou n d t or qu e wr en ch (F ig.
105), ch eck ou t pu t sh a ft t u r n in g t or qu e. Ou tp u t
(16) In st a ll NE W ou t pu t gea r r et a in in g bolt a n d s h a ft tu rn in g to rqu e s h o u ld be w ith in 3-8 in .
wa sh er (F ig. 103). Usin g Tool 6259, t or qu e ou t pu t lbs . If t h e t u r n in g t or qu e is t oo h igh , in st a ll a 0.04
gea r r et a in in g bolt t o 271 N·m (200 ft . lbs.) (F ig. m m (0.0016 in .) t h icker sh im . If t h e t u r n in g t or qu e is
104). t oo low, in st a ll a 0.04 m m (0.0016 in .) t h in n er sh im .
Repea t u n t il t h e pr oper t u r n in g t or qu e of 3-8 in . lbs.
is obt a in ed.

1 - OUTPUT GEAR
2 - BOLT Fig. 105 Check Output Gear Bearings Turning
Torque
1 - INCH-POUND TORQUE WRENCH
2 - OUTPUT GEAR
(18) In st a ll ou t pu t gea r st ir r u p wit h ser r a t ed side (21) Rot a t e st ir r u p clockwise a ga in st fla t s of
ou t (F ig. 106). r et a in in g bolt (F ig. 108).
Fig. 106 Install Stirrup Fig. 108 Turn Stirrup Clockwise Against Flats Of
Output Gear Retaining Bolt
1 - STIRRUP
2 - OUTPUT GEAR RETAINING BOLT 1 - RETAINING STRAP
2 - STIRRUP
(19) In st a ll r et a in in g st r a p (F ig. 107).
(20) In st a ll st r a p bolt s bu t do n ot t igh t en a t t h is (22) Tor qu e st ir r u p st r a p bolt s t o 23 N·m (200 in .
t im e (F ig. 107). lbs.) (F ig. 109).
Fig. 109 Tighten Stirrup Strap Bolts to 23 N·m (200

Fig. 107 Install Strap Bolts
in. lbs.)
1 - RETAINING STRAP
2 - STIRRUP 1 - RETAINING STRAP
3 - RETAINING STRAP BOLTS 2 - STIRRUP
(23) Ben d t a bs on st r a p u p a ga in st fla t s of bolt s (25) In st a ll bea r in g cu p a n d oil ba ffle t o t r a n sfer
(F ig. 110). sh a ft (F ig. 112).
Fig. 110 Bend Tabs On Strap Up Against Flats Of Fig. 112 Install Bearing Cup to Shaft
Bolts 1 - BEARING CUP
1 - RETAINING STRAP TABS 2 - BEARING CONE
2 - RETAINING STRAP 3 - TRANSFER SHAFT
3 - STIRRUP 4 - OIL BAFFLE
5 - O-RING
(24) In st a ll t r a n sfer sh a ft bea r in g con e u sin g Tool
6052 (F ig. 111). (26) Usin g Tool 5049A, in st a ll t r a n sfer sh a ft (F ig.
113).
Fig. 111 Install Transfer Shaft Bearing Cone

1 - TOOL 6052 Fig. 113 Install Transfer Shaft
2 - NEW BEARING CONE
3 - TRANSFER SHAFT 1 - SPECIAL TOOL 5049–A
4 - ARBOR PRESS RAM 2 - TRANSFER SHAFT
3 - OUTPUT GEAR
(27) Usin g Tool 6051, in st a ll t r a n sfer sh a ft bea r in g (29) In st a ll bea r in g cu p r et a in er t o t r a n sa xle (F ig.
sn a p r in g (F ig. 114). 116).
Fig. 114 Install Transfer Shaft Bearing Snap Ring Fig. 116 Install Bearing Cup Retainer
1 - ALIGN INDEXING TAB TO SLOT
2 - TRANSFER SHAFT BEARING SNAP RING
2 - BEARING CUP RETAINER
3 - TRANSFER SHAFT
(28) In st a ll t r a n sfer sh a ft bea r in g cu p in t o r et a in er (30) In st a ll t r a n sfer gea r bea r in g con e t o t r a n sfer

u sin g Tool 6061 (F ig. 115). gea r u sin g Tool 5052 (F ig. 117).
Fig. 115 Install Transfer Shaft Bearing Cup Into Fig. 117 Install Transfer Gear Bearing Cone
Retainer 1 - ARBOR PRESS RAM
2 - HANDLE C-4171
1 - ARBOR PRESS RAM 3 - NEW BEARING CONE
2 - HANDLE C-4171 4 - TRANSFER SHAFT GEAR
3 - TOOL 6061 5 - TOOL 5052
4 - TRANSFER SHAFT BEARING CUP RETAINER
5 - USE REMOVED BEARING CUP TO SUPPORT RETAINER
(31) TRAN S F ER GEAR B EARIN G AD J U S T-
MEN T:
(a ) In st a ll a 4.66 m m (0.184 in .) ga u gin g sh im
on t h e t r a n sfer sh a ft (F ig. 118).
(b) In st a ll t r a n sfer sh a ft gea r u sin g Tool 6261.
Usin g Tool 6259, in st a ll t r a n sfer sh a ft gea r r et a in -
in g n u t t o 271 N·m (200 ft . lbs.).
(c) Mea su r e en d pla y. At t a ch Tool L4432 t o t h e
t r a n sfer gea r.
(d) Mou n t a st eel ba ll wit h gr ea se in t o t h e en d
of t h e t r a n sfer sh a ft .
(e) P u sh a n d pu ll t h e gea r wh ile r ot a t in g ba ck
a n d for t h t o en su r e sea t in g of t h e bea r in g r oller s.
(f) Usin g a dia l in dica t or, m ea su r e t r a n sfer sh a ft
en d pla y.
(g) Refer t o t h e t r a n sfer sh a ft bea r in g sh im
ch a r t for t h e r equ ir ed sh im com bin a t ion t o obt a in Fig. 118 Install Transfer Shaft Gear and
t h e pr oper bea r in g set t in g. (Select) Shim
(h ) Use Tool 6259 t o r em ove t h e r et a in in g n u t 1 - TRANSFER SHAFT GEAR
a n d wa sh er. Rem ove t h e t r a n sfer sh a ft gea r u sin g 2 - BEARING CUP RETAINER
Tool L4407A. 3 - SHIM
(SELECT)
(i) Rem ove t h e ga u gin g sh im (F ig. 118) a n d
in st a ll t h e pr oper sh im in dica t ed by t h e ch a r t .
T RAN SFER SH AFT BEARI N G SH I M CH ART
0.05mm 4.66mm 0.76mm 3.94mm
4505588AB 4412818AB
(0.002 in.) (0.183 in.) (0.030 in.) (0.155 in.)
0.08mm 4.62mm 0.79mm 3.90mm
4412835AB 4412817AB
(0.003 in.) (0.182 in.) (0.031 in.) (0.154 in.)
0.10mm 4.58mm 0.81mm 3.90mm
4412834AB 4412817AB
(0.004 in.) (0.180 in.) (0.032 in.) (0.154 in.)
0.13mm 4.58mm 0.84mm 3.86mm
4412834AB 4412816AB
(0.005 in.) (0.180 in.) (0.033 in.) (0.152 in.)
0.15mm 4.54mm 0.86mm 3.82mm
4412833AB 4412815AB
(0.006 in.) (0.178 in.) (0.034 in.) (0.150 in.)
0.18mm 4.50mm 0.89mm 3.82mm
4412832AB 4412815AB
(0.007 in.) (0.177 in.) (0.035 in.) (0.150 in.)
0.20mm 4.50mm 0.91mm 3.78mm
4412832AB 4412814AB
(0.008 in.) (0.177 in.) (0.036 in.) (0.149 in.)
0.23mm 4.46mm 0.94mm 3.74mm
4412831AB 4412813AB
(0.009 in.) (0.175 in.) (0.037 in.) (0.147 in.)
0.25mm 4.46mm 0.97mm 3.74mm
4412831AB 4412813AB
(0.010 in.) (0.175 in.) (0.038 in.) (0.147 in.)
0.28mm 4.42mm 0.99mm 3.70mm
4412830AB 4412812AB
(0.011 in.) (0.174 in.) (0.039 in.) (0.146 in.)
0.30mm 4.38mm 1.02mm 3.66mm
4412829AB 4412811AB
(0.012 in.) (0.172 in.) (0.040 in.) (0.144 in.)
0.33mm 4.38mm 1.04mm 3.66mm
4412829AB 4412811AB
(0.013 in.) (0.172 in.) (0.041 in.) (0.144 in.)
0.36mm 4.34mm 1.07mm 3.62mm
4412828AB 4412810AB
(0.014 in.) (0.171 in.) (0.042 in.) (0.143 in.)
0.38mm 4.30mm 1.08mm 3.62mm
4412827AB 4412810AB
(0.015 in.) (0.169 in.) (0.043 in.) (0.143 in.)
0.41mm 4.30mm 1.12mm 3.58mm
4412827AB 4412809AB
(0.016 in.) (0.169 in.) (0.044 in.) (0.141)
0.43mm 4.26mm 1.14mm 3.54mm
4412826AB 4412808AB
(0.017 in.) (0.168 in.) (0.045 in.) (0.139 in.)
0.46mm 4.22mm 1.17mm 3.54mm
4412825AB 4412808AB
(0.018 in.) (0.166 in.) (0.046 in.) (0.139 in.)
0.48mm 4.22mm 1.19mm 3.50mm
4412825AB 4412807AB
(0.019 in.) (0.166 in.) (0.047 in.) (0.138 in.)
0.50mm 4.18mm 1.22mm 3.46mm
4412824AB 4412806AB
(0.020 in.) (0.165 in.) (0.048 in.) (0.136 in.)
0.53mm 4.18mm 1.24mm 3.46mm
4412824AB 4412806AB
(0.021 in.) (0.165 in.) (0.049 in.) (0.136 in.)
0.56mm 4.14mm 1.27mm 3.42mm
4412823AB 4412805AB
(0.022 in.) (0.163 in.) (0.050 in.) (0.135 in.)
0.58mm 4.10mm 1.30mm 3.38mm
4412822AB 4412804AB
(0.023 in.) (0.161 in.) (0.051 in.) (0.133 in.)
0.61mm 4.10mm 1.32mm 3.38mm
4412822AB 4412804AB
(0.024 in.) (0.161 in.) (0.052 in.) (0.133 in.)
0.64mm 4.06mm 1.35mm 3.34mm
4412821AB 4412803AB
(0.025 in.) (0.160 in.) (0.053 in.) (0.132 in.)
0.66mm 4.02mm 1.37mm 3.34mm
4412820AB 4412803AB
(0.026 in.) (0.158 in.) (0.054 in.) (0.132 in.)
0.69mm 4.02mm 1.40mm 3.30mm
4412820AB 4412802AB
(0.027 in.) (0.158 in.) (0.055 in.) (0.130 in.)
0.71mm 3.98mm 1.45mm 3.26mm
4412819AB 4412801AB
(0.028 in.) (0.157 in.) (0.057 in (0.128 in.)
0.74mm 3.94mm 1.47mm 2.22mm
4412818AB 4505570AB
(0.029 in.) (0.155 in.) (0.058 in.) (0.127 in.)
(32) In st a ll t h e t r a n sfer sh a ft gea r u sin g Tool 6261 (35) Mea su r e t r a n sfer sh a ft en d pla y. Tra n s fe r
(F ig. 119). s h a ft e n d p la y s h o u ld be w ith in 0.05-0.10 m m
(0.002-0.004 in .). If t h e en d pla y is t oo h igh , in st a ll a
0.04 m m (0.0016 in .) t h icker sh im . If t h e en d pla y is
t oo low, in st a ll a 0.04 m m (0.0016 in .) t h in n er sh im .
Repea t u n t il 0.05-0.10 m m (0.002-0.004 in .) en d pla y
is obt a in ed.
(36) In st a ll a bea d of Mopa r ! ATF RTV (MS-GF 41)
t o t r a n sfer gea r cover (F ig. 121).
Fig. 119 Install Transfer Shaft Gear

1 - WRENCHES
3 - OUTPUT GEAR
CAUTION: Install a NEW retaining nut, as the origi-

nal nut MUST NOT be reused.
Fig. 121 Install Rear Cover
(33) In st a ll t h e n ew r et a in in g n u t a n d wa sh er. 1 - REAR COVER
(34) Usin g Tool 6259, t or qu e t r a n sfer gea r r et a in - 2 - 1/8 INCH BEAD OF MOPAR" ATF RTV (MS-GF41) AS SHOWN
in g n u t t o 271 N·m (200 ft . lbs.) (F ig. 120).
(37) In st a ll t r a n sfer gea r cover-t o-ca se bolt s a n d
t or qu e t o 20 N·m (175 in . lbs.) t or qu e (F ig. 122).
Fig. 120 Tighten Nut to 271 N•m (200 ft. lbs.)

2 - 200 FT. LBS. Fig. 122 Install Rear Cover Bolts
3 - TORQUE WRENCH
1 - REAR COVER BOLTS
2 - REAR COVER
3 - USE SEALANT ON BOLTS
(38) In st a ll low/r ever se clu t ch pa ck (F ig. 123). (40) In st a ll r em a in in g low/r ever se clu t ch disc (F ig.
Lea ve u pper m ost disc ou t u n t il sn a p r in g is in st a lled. 125).
Fig. 125 Install One Disc

Fig. 123 Install Low/Reverse Clutch (41) In st a ll low/r ever se r ea ct ion pla t e wit h fla t
1 - CLUTCH PLATE side u p (F ig. 126).
2 - CLUTCH DISC
(39) In st a ll low/r ever se r ea ct ion pla t e fla t sn a p

r in g (F ig. 124).
Fig. 126 Install Low/Reverse Reaction Plate

1 - LOW/REVERSE REACTION PLATE (FLAT SIDE UP)
Fig. 124 Install Low/Reverse Reaction Plate Snap

Ring
1 - SCREWDRIVER
(42) In st a ll t a per ed sn a p r in g (wit h t a per ed side
u p) a s sh own in (F ig. 127) (F ig. 128).
Fig. 129 Check Low/Reverse Clutch Clearance

1 - DIAL INDICATOR
2 - DIAL INDICATOR TIP TOOL 6268
3 - HOOK TOOL
LOW/REV ERSE REACT I ON PLAT E CH ART
PART NUMBER THICKNESS

4799846AA 5.88 mm (0.232 in.)
4799847AA 6.14 mm (0.242 in.)
4799848AA 6.40 mm (0.252 in.)
Fig. 127 Tapered Snap Ring Instructions
4799849AA 6.66 mm (0.262 in.)
4799855AA 6.92 mm (0.273 in.)
(44) In st a ll 2/4 clu t ch pa ck (F ig. 130).
Fig. 128 Snap Ring Installed

1 - SCREWDRIVER
2 - TAPERED SNAP RING (INSTALL AS SHOWN)
(43) Set u p dia l in dica t or a s sh own in (F ig. 129) t o

m ea su r e low/r ever se clu t ch clea r a n ce. P r ess down on
clu t ch pa ck wit h fin ger a n d zer o dia l in dica t or. Lo w /
Re v e rs e c lu tc h p a c k c le a ra n c e is 0.89-1.47 m m Fig. 130 Install 2/4 Clutch
(0.035-0.058 in .). Set u p in dica t or a n d r ecor d m ea - 1 - CLUTCH DISC
2 - CLUTCH PLATE
su r em en t in fou r (4) pla ces. Ta ke a ver a ge of r ea din gs
a n d select t h e pr oper low/r ever se r ea ct ion pla t e t o
a ch ieve specifica t ion s.
NOTE: The 2/4 Clutch Piston has bonded seals (46) Usin g t ool 5058, com pr ess 2/4 clu t ch r et u r n
which are not individually serviceable. Seal replace- spr in g ju st en ou gh t o in st a ll sn a p r in g (F ig. 133).
(45) Or ien t 2/4 clu t ch r et u r n spr in g t o r et a in er a s

sh own in (F ig. 131), a n d in st a ll t o t r a n sa xle (F ig.
132).
Fig. 133 Install 2/4 Clutch Retainer Snap Ring

1 - TOOL 5058
2 - SCREWDRIVER
3 - SNAP RING
Fig. 131 Proper Orientation of 2/4 Clutch Retainer

(47) In st a ll sn a p r in g.
and Spring
(48) Set u p dia l in dica t or a s sh own in (F ig. 134)
1 - NOTE POSITION a n d m ea su r e 2/4 clu t ch clea r a n ce. P r ess down on
2 - RETURN SPRING
3 - 2/4 CLUTCH RETAINER clu t ch pa ck wit h fin ger a n d zer o dia l in dica t or. 2/4
c lu tc h pack c le a ra n c e is 0.76-2.64 mm
(0.030-0.104 in .). Set u p in dica t or a n d r ecor d m ea -
su r em en t in fou r (4) pla ces. Ta ke a ver a ge of r ea d-
in gs. If clea r a n ce is ou t side t h is r a n ge, t h e clu t ch is
a ssem bled im pr oper ly. Th e re is n o a d ju s tm e n t fo r
2/4 c lu tc h c le a ra n c e .
Fig. 132 2/4 Clutch Retainer

Fig. 134 Check 2/4 Clutch Clearance

1 - DIAL INDICATOR
2 - HOOK TOOL
(49) In st a ll r ea r su n gea r a n d #7 n eedle bea r in g (50) In st a ll fr on t ca r r ier /r ea r a n n u lu s a ssem bly
(F ig. 136). a n d #6 n eedle bea r in g (F ig. 137).
NOTE: The number seven needle bearing has three

anti-reversal tabs and is common with the number
five and number two position. The orientation
should allow the bearing to seat flat against the
rear sun gear (Fig. 135). A small amount of petrola-
tum can be used to hold the bearing to the rear sun
gear.
Fig. 137 Install Front Carrier/Rear Annulus

Assembly
2 - FRONT CARRIER AND REAR ANNULUS ASSEMBLY (TWIST
AND PULL OR PUSH TO REMOVE OR INSTALL).
(51) In st a ll fr on t su n gea r a ssem bly a n d #4 t h r u st

wa sh er (F ig. 138).

2 - REAR SUN GEAR
Fig. 138 Install Front Sun Gear Assembly

Fig. 136 Install Rear Sun Gear and #7 Needle

Bearing
2 - REAR SUN GEAR
(52) D ETERMIN IN G #4 THRU S T P LATE (e) Set u p in pu t sh a ft for m ea su r em en t wit h
THICKN ES S / IN P U T S HAF T EN D P LAY: In dica t or Set C3339 a n d E n d P la y Set 8266 a s
(a ) Select t h e t h in n est #4 t h r u st pla t e t h ickn ess sh own in (F ig. 142).
a n d in st a ll t o in pu t clu t ch a ssem bly (F ig. 139). Use (f) Mea su r e t h e in pu t sh a ft en d pla y wit h t h e
pet r ola t u m t o r et a in . t r a n sa xle in t h e ver t ica l posit ion . In p u t s h a ft e n d
(b) In st a ll in pu t clu t ch a ssem bly in t o posit ion p la y m u s t be w ith in 0.005 to 0.025 in c h . F or
a n d ver ify t h a t it is com plet ely sea t ed by viewin g exa m ple, if en d pla y r ea din g is 0.055 in ch , select
t h r ou gh in pu t speed sen sor h ole. If view t h r ou gh No. 4 Th r u st P la t e wh ich is 0.071 t o 0.074 t h ick.
in pu t speed sen sor h ole is n ot a s sh own in (F ig. Th is sh ou ld pr ovide a n in pu t sh a ft en d pla y r ea d-
140), t h e in pu t clu t ch a ssem bly is n ot sea t ed pr op- in g of 0.020 in ch wh ich is wit h in specifica t ion s.
er ly. (g) Refer t o t h e No. 4 t h r u st pla t e ch a r t t o select
(c) Rem ove oil pu m p o-r in g (F ig. 141). B e s u re t h e pr oper No. 4 t h r u st pla t e:
to re in s ta ll o il p u m p o -rin g a fte r s e le c tin g th e
p ro p e r #4 th ru s t p la te .
(d) In st a ll pu m p a n d ga sket t o t r a n sm ission .
In st a ll a n d t or qu e bolt s.
Fig. 141 Remove Oil Pump O-Ring

1 - OIL PUMP ASSEMBLY
2 - O-RING
Fig. 139 Select Thinnest No. 4 Thrust Plate

1 - OVERDRIVE SHAFT ASSEMBLY
2 - #4 THRUST PLATE (SELECT)
Fig. 142 Measure Input Shaft End Play

Using Tool 8266—Typical
Fig. 140 View Through Input Speed Sensor Hole
1 - TOOL 8266–8
1 - INPUT CLUTCH RETAINER 2 - TOOL 8266–2
2 - INPUT SPEED SENSOR HOLE 3 - TOOL C-3339
3 - OIL COOLER FITTINGS
N O. 4 T H RU ST PLAT E CH ART (54) In st a ll #1 ca ged n eedle bea r in g (F ig. 144).

4431665AB 1.60mm (0.063 in.)
3836237AB 1.73mm (0.068 in.)
4431666AB 1.80mm (0.071 in.)
3836238AB 1.96mm (0.077 in.)
4431667AB 2.03mm (0.080 in.)
3836239AB 2.16mm (0.085 in.)
4431668AB 2.24mm (0.088 in.)
3836240AB 2.39mm (0.094 in.)
4431669AB 2.46mm (0.097 in.)
3836241AB 2.62mm (0.103 in.)
4446670AB 2.67mm (0.105 in.)
4446671AB 2.90mm (0.114 in.) Fig. 144 Install No. 1 Caged Needle Bearing
1 - #1 CAGED NEEDLE BEARING
2 - NOTE: TANGED SIDE OUT
(53) In st a ll in pu t clu t ch a ssem bly (F ig. 143).
(55) In st a ll cooler bypa ss va lve wit h o-r in g en d

t owa r ds r ea r of ca se (F ig. 145).
Fig. 143 Install Input Clutch Assembly

2 - #4 THRUST WASHER
Fig. 145 Install Cooler Bypass Valve

(56) In st a ll oil pu m p ga sket (F ig. 146). (58) In st a ll oil pu m p-t o-ca se bolt s a n d t or qu e t o 27
N·m (20 ft . lbs.) (F ig. 148).
Fig. 146 Install Oil Pump Gasket Fig. 148 Install Pump-to-Case Bolts
1 - PUMP GASKET 1 - PUMP ATTACHING BOLTS
2 - PUMP HOUSING
(57) In st a ll oil pu m p a ssem bly (F ig. 147).
(59) In st a ll low/r ever se a ccu m u la t or (F ig. 149).
Fig. 147 Install Oil Pump

1 - OIL PUMP
2 - GASKET 1 - PISTON
2 - RETURN SPRINGS
(60) In st a ll low/r ever se a ccu m u la t or plu g (F ig. NOTE: Depending on engine application, some
150). accumulators will have two springs, and others will
have one spring. The springs are color-coded for
application and year.
(62) In st a ll u n der dr ive a n d over dr ive a ccu m u la t or s

a n d spr in gs (F ig. 152).
Fig. 150 Install Low/Reverse Accumulator Plug

2 - PLUG
(61) In st a ll low/r ever se a ccu m u la t or sn a p r in g

(F ig. 151).

(63) In st a ll va lve body t o t r a n sa xle (F ig. 153).

Rot a t e m a n u a l va lve sh a ft fu lly clockwise t o ea se
in st a lla t ion . Ma ke su r e pa r k r od r oller s a r e posi-
t ion ed wit h in pa r k gu ide br a cket .
Fig. 151 Install Low/Reverse Accumulator Snap

Ring
1 - SNAP RING
2 - PLUG

1 - VALVE BODY
(64) In st a ll a n d t or qu e va lve body-t o-ca se bolt s t o (66) Apply a n 1/8” bea d of Mopa r ! ATF RTV (MS-
12 N·m (105 in . lbs.) (F ig. 154). GF 41) t o oil pa n a n d im m edia t ely in st a ll t o ca se (F ig.
156).
Fig. 156 Install Oil Pan

1 - OIL PAN
Fig. 154 Install Valve Body-to-Case Bolts 2 - 1/8 INCH BEAD OF MOPAR" ATF RTV (MS-GF41)
3 - OIL FILTER
2 - VALVE BODY
(67) In st a ll oil pa n -t o-ca se bolt s a n d t or qu e t o 19
(65) In st a ll oil filt er a n d n ew o-r in g (F ig. 155). N·m (165 in . lbs.).
(68) In st a ll solen oid/pr essu r e swit ch a ssem bly a n d
ga sket t o ca se (F ig. 157).
Fig. 155 Install Oil Filter and O-Ring

1 - OIL FILTER
2 - O-RING

Gasket
2 - GASKET
(69) In st a ll a n d t igh t en solen oid/pr essu r e swit ch
a ssem bly-t o-t r a n sa xle ca se bolt s t o 12 N·m (110 in .
lbs.) (F ig. 158).
Fig. 159 Left Mount to Bracket and Transaxle

Fig. 158 Attaching Bolts 4 - TRANSAXLE
1 - BOLTS 5 - MOUNT - LEFT
2 - SOLENOID AND PRESSURE SWITCH ASSEMBLY 6 - BRACKET - LEFT MOUNT
(70) In st a ll a n d t or qu e in pu t a n d ou t pu t speed (10) In st a ll fr on t m ou n t /br a cket a ssem bly.

sen sor s t o ca se t o 27 N·m (20 ft . lbs.). (11) Align a n d in st a ll r ea r m ou n t br a cket -t o-ca se
bolt s by h a n d (F ig. 160). Tor qu e h or izon t a l bolt t o
INSTALLATION 102 N·m (75 ft . lbs.).
(12) AWD m odels: In st a ll power t r a n sfer u n it .
NOTE: If transaxle assembly has been replaced or (Refer t o 21 - TRANSMISSION/TRANSAXLE /
overhauled (clutch and/or seal replacement), it is P OWE R TRANSF E R UNIT - INSTALLATION)
necessary to perfrom the “Quick-Learn” procedure. (13) In st a ll left a n d r igh t h a lfsh a ft a ssem blies.
(Refer to 8 - ELECTRICAL/ELECTRONIC CONTROL (Refer t o 3 - DIF F E RE NTIAL & DRIVE LINE /H ALF
MODULES/TRANSMISSION CONTROL MODULE - SH AF T - INSTALLATION)
STANDARD PROCEDURE) (14) In st a ll fr on t wh eel/t ir e a ssem blies.
(1) Usin g a t r a n sm ission ja ck a n d a h elper, posi- (16) Tor qu e r em a in in g r ea r m ou n t br a cket -t o-t r a n -
t ion t r a n sa xle a ssem bly t o en gin e. In st a ll a n d t or qu e sa xle ver t ica l bolt s (F ig. 160) t o 102 N·m (75 ft . lbs.).
bellh ou sin g bolt s t o 95 N·m (70 ft . lbs.). (17) In st a ll t r a n sa xle u pper bellh ou sin g-t o-block
(2) In st a ll u pper m ou n t a ssem bly t o t r a n sa xle a n d bolt s a n d t or qu e t o 95 N·m (70 ft . lbs.).
t or qu e bolt s t o 54 N·m (40 ft . lbs.) (F ig. 159). (18) In st a ll a n d con n ect cr a n k posit ion sen sor (if
(3) Ra ise en gin e/t r a n sa xle a ssem bly in t o posit ion . equ ipped).
In st a ll a n d t or qu e u pper m ou n t -t o-br a cket t h r u -bolt (19) Con n ect gea r sh ift ca ble t o u pper m ou n t
t o 75 N·m (55 ft . lbs.) (F ig. 159). br a cket a n d t r a n sa xle m a n u a l va lve lever (F ig. 161).
(4) Rem ove t r a n sm ission ja ck a n d scr ew ja ck. (20) Con n ect solen oid/pr essu r e swit ch a ssem bly
(5) Secu r e left wh eelh ou se spla sh sh ield. (F ig. 162).
(6) In st a ll t or qu e con ver t er-t o-dr ive pla t e bolt s a n d (21) Con n ect t r a n sm ission r a n ge sen sor con n ect or
t or qu e t o 88 N·m (65 ft . lbs.) (F ig. 162).
(7) In st a ll in spect ion cover. (22) Con n ect in pu t a n d ou t pu t speed sen sor con -
(8) In st a ll la t er a l ben din g br a ce. n ect or s (F ig. 162).
(9) In st a ll st a r t er m ot or.

Fig. 162 Component Connector Location - Typical

Fig. 161 Gearshift Cable at Transaxle - Typical 1 - SOLENOID/PRESSURE SWITCH ASSY. CONNECTOR
1 - MANUAL VALVE LEVER 3 - OUTPUT SPEED SENSOR CONNECTOR
2 - GEAR SHIFT CABLE 4 - TRANSMISSION RANGE SENSOR CONNECTOR
(23) Rem ove plu gs a n d con n ect t r a n sa xle oil cooler
lin es. (Refer t o 7 - COOLING/TRANSMISSION -
(24) Rem ove plu g a n d In st a ll flu id level in dica t or /
t u be a ssem bly.
(25) In st a ll coola n t r ecover y bot t le (F ig. 163).
(26) In st a ll ba t t er y sh ield.
(28) F ill t r a n sa xle wit h su it a ble a m ou n t of ATF +4
(Au t om a t ic Tr a n sm ission F lu id—Type 9602). (Refer
t o 21 - TRANSMISSION/TRANSAXLE /AUTOMATIC
- 41TE /F LUID - STANDARD P ROCE DURE )
Fig. 163 Coolant Recovery Bottle

2 - HOSE
3 - BOLT
4 - SUB FRAME RAIL
SCH EM AT I CS AN D DI AGRAM S
4XTE TRANSAXLE HYDRAULIC SCHEMATICS
Park/Neutral (Speed Under 8 MPH)

Neutral (Speed Over 8 MPH)

Reverse
Reverse Block (Shift to Reverse W/Speed Over 8 mph)

First Gear
Second Gear
Second Gear (EMCC)

Direct Gear
Direct Gear (CC On)

Overdrive
Overdrive (EMCC)
Overdrive (CC On)

SPECIFICATIONS - 41TE TRANSAXLE

Fully adaptive, electronically controlled, four speed
Transaxle Type
automatic with torque converter and integral differential
Cooling Method Air-to-oil heat exchanger
Lubrication Pump (internal-external gear-type
GEAR RAT I OS
First Gear 2.84
Second Gear 1.57
Direct Gear 1.00
Overdrive Gear 0.69
Reverse Gear 2.21
BEARI N G SET T I N GS (EN D PLAY & T U RN I N G T ORQU E)
DESCRIPTION METRIC STANDARD

Differential Assembly 0.6-2 N·m 5-18 in. lbs.
Output Hub 0.3-2 N·m 3-8 in. lbs.
Transfer Shaft (End Play) 0.051-0.102 mm 0.002-0.004 in.
Overall Drag At Output Hub 0.3-1.9 N·m 3-16 in. lbs.
CLU T CH CLEARAN CES

Low/Rev Clutch (Select Reaction
0.89-1.47 mm 0.035-0.058 in.
Plate)
Two/Four Clutch (No Selection) 0.76-2.64 mm 0.030-0.104 in.
Reverse Clutch (Select Snap Ring) 0.89-1.37 mm 0.035-0.054 in.
Overdrive Clutch (No Selection) 1.07-3.25 mm 0.042-0.128 in.
Underdrive Clutch (Select Pressure
0.94-1.50 mm 0.037-0.059 in.
Plate)
OI L PU M P CLEARAN CES

Outer Gear-to-Crescent 0.060-0.298 mm 0.0023-0.0117 in.
Inner Gear-to-Crescent 0.093-0.385 mm 0.0036-0.0151 in.
Outer Gear-to-Pocket 0.089-0.202 mm 0.0035-0.0079 in.
Outer Gear Side Clearance 0.020-0.046 mm 0.0008-0.0018 in.
Inner Gear Side Clearance 0.020-0.046 mm 0.0008-0.0018 in.
I N PU T SH AFT
DESCRIPTION METRIC SPECIFICATION

End Play 0.127-0.635mm 0.005-0.025 in.
T ORQU E SPECI FI CAT I ON S

Bolt, Differential
19 — 165
Cover-to-Case
Bolt, Differential Ring
95 70 —
Gear-to-Case
Bolt, Differential Bearing
28 21 —
Retainer-to-Case
Bolt, Driveplate-to-
95 70 —
Crankshaft
Bolt, Extension Housing/
28 21 —
Plate-to-Case
Bolt, Oil Pan-to-Case 19 — 165
Bolt, Output Gear 271 200 —
Bolt, Output Gear
23 17 —
Stirrup/Strap
Bolt, Oil Pump-to-Case 27 20 —
Bolt, Reaction Support-to-
27 20 —
Case
Bolt, Solenoid/Pressure
12 — 110
Switch Assy.-to-Case
Bolt, Torque Converter-to-
75 55 —
Driveplate
Bolt, Transfer Gear Cover 20 — 175
Bolt, Valve Body-to-Case 12 — 105
Fitting, Oil Cooler Line 12 — 105
Nut, Tranfer Gear 271 200 —
Tap, Transaxle Pressure 5 — 45
Screw, L/R Clutch
5 — 45
Retainer
Screw, Solenoid/Pressure
4 — 35
Switch Assy. Connector
Screw, Valve Body-to-
5 — 45
Transfer Plate
Sensor, Input Speed 27 20 —
Sensor, Output Speed 27 20 —
Sensor, Transmission
5 — 45
Range Sensor
SPECIAL TOOLS
Puller C-637
Universal Handle C-4171
Pressure Gauge (High) C-3293SP
Seal Installer C-4193A
Dial Indicator C-3339
Adapter C-4996
Oil Pump Puller C-3752
Remover Kit L-4406
Seal Puller C-3981B

Gear Puller L-4407A Special Jaw Set L-4518
Bearing Installer L-4410 Installer L-4520
Gear Checking Plate L-4432 Thrust Button L-4539-2
Bearing Puller L-4435 Adapter L-4559
Adapter L-4559-2
Differential Tool L-4436A
Bearing Splitter P-334 Compressor 5058A
Puller Set 5048 Compressor 5059-A
Remover/Installer 5049-A Installer 5067
Installer 5050A
Pliers 6051
Installer 5052
Installer 6052
Installer 6061
Installer 6053
Remover 6062-A
Button 6055
Holder 6259
Plate 6056
Bolt 6260
Disk 6057
Installer 6261 Installer 6536-A
Puller 7794-A
Tip 6268
End Play Socket Set 8266

Remover/Installer 6301
Input Clutch Pressure Fixture 8391

ACCU M U LAT OR
DESCRIPTION
Th e 4XTE u n der dr ive, over dr ive, low/r ever se, a n d
2/4 clu t ch h ydr a u lic cir cu it s ea ch con t a in a n a ccu m u -
la t or. An a ccu m u la t or t ypica lly con sist s of a pist on ,
r et u r n spr in g(s), a n d a cover or plu g. Th e over dr ive
a n d u n der dr ive a ccu m u la t or s a r e loca t ed wit h in t h e
t r a n sa xle ca se, a n d a r e r et a in ed by t h e va lve body
(F ig. 164).

1 - PISTON
2 - RETURN SPRINGS

Th e low r ever se a ccu m u la t or (F ig. 165) is a lso

loca t ed wit h in t h e t r a n sa xle ca se, bu t t h e a ssem bly is
r et a in ed by a cover a n d a sn a p-r in g. Fig. 166 2/4 Accumulator Assembly
Th e 2/4 a ccu m u la t or is loca t ed in t h e va lve body. It 1 - VALVE BODY
is r et a in ed by a cover a n d r et a in in g scr ews (F ig. 2 - RETAINER PLATE
166). 3 - DETENT SPRING
4 - RETURN SPRINGS
5 - PISTON
OPERATION
Th e fu n ct ion of a n a ccu m u la t or is t o cu sh ion t h e r espect ive a ccu m u la t or ch a m ber a ga in st t h e pist on
a pplica t ion of a fr ict ion a l clu t ch elem en t . Wh en pr es- a n d spr in g(s). Th e in t en ded r esu lt is a sm oot h , fir m
su r ized flu id is a pplied t o a clu t ch cir cu it , t h e a ppli- clu t ch a pplica t ion .
ca t ion for ce is da m pen ed by flu id collect in g in t h e
DRI V I N G CLU T CH ES UNDERDRIVE CLUTCH

Th e u n der dr ive clu t ch is h ydr a u lica lly a pplied in
DESCRIPTION fir st , secon d, a n d t h ir d (dir ect ) gea r s by pr essu r ized
Th r ee h ydr a u lica lly a pplied in pu t clu t ch es a r e u sed flu id a ga in st t h e u n der dr ive pist on . Wh en t h e u n der-
t o dr ive pla n et a r y com pon en t s. Th e u n der dr ive, over- dr ive clu t ch is a pplied, t h e u n der dr ive h u b dr ives t h e
dr ive, a n d r ever se clu t ch es a r e con sider ed in pu t r ea r su n gea r.
clu t ch es a n d a r e con t a in ed wit h in t h e in pu t clu t ch
a ssem bly (F ig. 167). Th e in pu t clu t ch a ssem bly a lso OVERDRIVE CLUTCH
con t a in s: Th e over dr ive clu t ch is h ydr a u lica lly a pplied in
• In pu t sh a ft t h ir d (dir ect ) a n d over dr ive gea r s by pr essu r ized flu id
• In pu t h u b a ga in st t h e over dr ive/r ever se pist on . Wh en t h e over-
• Clu t ch r et a in er dr ive clu t ch is a pplied, t h e over dr ive h u b dr ives t h e
• Un der dr ive pist on fr on t pla n et ca r r ier.
• Over dr ive/r ever se pist on
• Over dr ive h u b REVERSE CLUTCH
• Un der dr ive h u b Th e r ever se clu t ch is h ydr a u lica lly a pplied in
r ever se gea r on ly by pr essu r ized flu id a ga in st t h e
over dr ive/r ever se pist on . Wh en t h e r ever se clu t ch is
a pplied, t h e fr on t su n gea r a ssem bly is dr iven .
FI N AL DRI V E
DESCRIPTION
Th e 4XTE differ en t ia l is a con ven t ion a l open
design . It con sist s of a r in g gea r a n d a differ en t ia l
ca se. Th e differ en t ia l ca se con sist s of pin ion a n d side
gea r s, a n d a pin ion sh a ft . Th e differ en t ia l ca se is
su ppor t ed in t h e t r a n sa xle by t a per ed r oller bea r in gs
(F ig. 168).
Fig. 167 Input Clutch Assembly

1 - INPUT SHAFT
3 - OVERDRIVE CLUTCH
4 - REVERSE CLUTCH
5 - OVERDRIVE SHAFT
6 - UNDERDRIVE SHAFT
OPERATION
Th e t h r ee in pu t clu t ch es a r e r espon sible for dr ivin g Fig. 168 Differential Assembly
differ en t com pon en t s of t h e pla n et a r y gea r t r a in . 1 - DIFFERENTIAL CASE
2 - RING GEAR
NOTE: Refer to the “Elements In Use” chart in Diag- 3 - TRANSFER SHAFT
4 - PINION GEAR
nosis and Testing for a collective view of which 5 - PINION SHAFT
clutch elements are applied at each position of the 6 - SIDE GEAR
selector lever.
FI N AL DRI V E (Cont inue d)
OPERATION
Th e differ en t ia l a ssem bly is dr iven by t h e t r a n sfer
sh a ft by wa y of t h e differ en t ia l r in g gea r. Th e r in g
gea r dr ives t h e differ en t ia l ca se, a n d t h e ca se dr ives
t h e dr ivesh a ft s t h r ou gh t h e differ en t ia l gea r s. Th e
differ en t ia l pin ion a n d side gea r s a r e su ppor t ed in
t h e ca se by t h r u st wa sh er s a n d a pin ion sh a ft . Dif-
fer en t ia l pin ion a n d side gea r s m a ke it possible for
fr on t t ir es t o r ot a t e a t differ en t speeds wh ile cor n er-
in g.
DISASSEMBLY
NOTE: The differential is serviced as an assembly.
The only parts that are serviceable within the differ-
ential are the differential bearing cups and cones. If
Fig. 170 Remove Differential Cover
any other part fails within the differential, you must
1 - DIFFERENTIAL ASSEMBLY
replace the differential assembly along with the 2 - DIFFERENTIAL COVER
transfer shaft.
(2) Rem ove t h e differ en t ia l bea r in g r et a in er a n d
Th e t r a n sfer sh a ft sh ou ld be r em oved for differ en - bolt s (F ig. 171) (F ig. 172).
t ia l r epa ir a n d bea r in g t u r n in g t or qu e ch eckin g.
(1) Rem ove t h e differ en t ia l cover a n d bolt s (F ig.
169) (F ig. 170).
Fig. 171 Differential Retainer Bolts

1 - DIFFERENTIAL RETAINER BOLTS
Fig. 169 Differential Cover Bolts
1 - DIFFERENTIAL COVER BOLTS
2 - DIFFERENTIAL COVER
Fig. 172 Remove Bearing Retainer Fig. 174 Checking Side Gear End Play (Ring Gear
1 - DIFFERENTIAL BEARING RETAINER Side)
2 - TOOL L-4435 1 - SPECIAL TOOL C-4996 (NOTE POSITION)
2 - DIAL INDICATOR SET
(3) Usin g a pla st ic h a m m er, r em ove ext en sion 3 - DIFFERENTIAL ASSEMBLY
h ou sin g/a da pt er pla t e on t h e r igh t side of t h e t r a n s-
a xle. (6) Use Miller Specia l Tool 5048, 5048-3 Collet s,
a n d L-4539-2 Bu t t on t o r em ove t h e differ en t ia l bea r-
WARNING: HOLD ONTO DIFFERENTIAL ASSEMBLY in g con e on t h e ext en sion h ou sin g side.
TO PREVENT IT FROM ROLLING OUT OF HOUSING.
(4) Rem ove differ en t ia l a ssem bly.

(5) Set u p dia l in dica t or set C-3339 a n d t ool
C-4996 a s sh own in (F ig. 173) (F ig. 174) t o m ea su r e
side gea r en d pla y. S id e g e a r e n d p la y m u s t be
w ith in 0.001-0.013 in .
Fig. 173 Checking Side Gear End Play (Extension

Housing Side)
1 - SPECIAL TOOL C-4996 (NOTE POSITION)
2 - DIAL INDICATOR SET
4 - SIDE GEAR
(7) Use Miller Specia l Tool 5048, 5048-4 Collet s,
in g con e on t h e bea r in g r et a in er side (F ig. 175) (F ig.
176) (F ig. 177).
Fig. 177 Remove Differential Bearing Cone (Ring

Gear Side)
2 - RING GEAR
Fig. 175 Position Button and Collets Onto

Differential and Bearing (Ring Gear Side)
1 - SPECIAL TOOL L-4539-2
Fig. 178 Position Bearing Cup Remover Tool in

Retainer
2 - DIFFERENTIAL BEARING RETAINER
Fig. 176 Position Tool 5048 Over Button and Collets

at Differential Bearing (Ring Gear Side)
1 - SPECIAL TO0L 5048
2 - DIFFERENTIAL
(8) Usin g Miller Specia l Tool L-4518, r em ove t h e

differ en t ia l bea r in g r a ce fr om t h e ext en sion h ou sin g/
a da pt er pla t e.
(9) Usin g Miller Specia l Tool 6062A, r em ove t h e
differ en t ia l bea r in g r a ce fr om t h e bea r in g r et a in er
(F ig. 178) (F ig. 179).
Fig. 179 Remove Bearing Cup

DI FFEREN T I AL SERV I CE T OOLS
COMPONENT REMOVER INSTALLER

Diff. Bear. On 5048, 5048-4 5052, C-4171
Retainer Side Collets,
L-4539-2
Button
Diff. Bear. On 5048, 5048-3 L-4410, C-4171
Ext. Hous. Side Collets,
L-4539-2
Button
Diff. Race. On 6062-A 6061, C-4171
Retainer Side
Diff. Race. On L-4518 L-4520, C-4171
Ext. Hous. Side Fig. 180 Position Bearing Cone Onto Differential
Extension 7794-A, C-637 L-4520, C-4171 1 - DIFFERENTIAL ASSEMBLY
Housing Seal Slide Hammer 2 - DIFFERENTIAL BEARING
Bearing 794-A, C-637 L-4520, C-4171

(3) Usin g Miller Specia l Tool 6061 a n d C-4171,
Retainer Seal Slide Hammer
in st a ll differ en t ia l bea r in g r a ce t o bea r in g r et a in er
(F ig. 181).
ASSEMBLY
The only parts that are serviceable within the differ-
ential are the differential bearing cups and cones. If
any other part fails within the differential, you must
replace the differential assembly along with the
transfer shaft.
NOTE: Use Mopar" ATF RTV (MS-GF41), or equiva-

lent, on retainer and extension housing/adapter
plate to seal to case.
(1) Usin g Miller Specia l Tool L-4410, a n d C-4171,

in st a ll differ en t ia l bea r in g t o differ en t ia l (ext en sion
h ou sin g side) (F ig. 180).
(2) Usin g Miller Specia l Tool 5052 a n d C-4171, Fig. 181 Differential Bearing Retainer
in st a ll differ en t ia l bea r in g t o differ en t ia l (bea r in g 1 - DIFFERENTIAL BEARING CUP
r et a in er side).
(4) Usin g Miller Specia l Tool L–4520 a n d C-4171,
in st a ll differ en t ia l bea r in g cu p t o ext en sion h ou sin g.
(5) Mea su r e a n d a dju st differ en t ia l bea r in g pr e-
loa d (Refer t o 21 - TRANSMISSION/TRANSAXLE /
AUTOMATIC - 41TE /F INAL DRIVE -
ADJ USTME NTS) .
(6) In st a ll differ en t ia l a ssem bly t o ca se. In st a ll
ext en sion h ou sin g/a da pt er pla t e a n d bea r in g r et a in er.
(7) In st a ll bea r in g r et a in er wit h a bea d of Mopa r !
ATF RTV (MS-GF 41) a n d t or qu e bolt s (F ig. 182) t o
28 N·m (250 in . lbs.).

Fig. 182 Differential Retainer Bolts ADJ U ST M EN T S

(8) In st a ll ext en sion h ou sin g/a da pt er pla t e wit h a

DIFFERENTIAL BEARING PRELOAD
bea d of Mopa r ! ATF RTV (MS-GF 41) a n d t or qu e MEASUREMENT AND ADJUSTMENT
bolt s t o 28 N·m (250 in . lbs.).
(9) In st a ll differ en t ia l cover wit h a bea d of Mopa r ! NOTE: Perform all differential bearing preload mea-
ATF RTV (MS-GF 41) (F ig. 183) a n d t or qu e bolt s (F ig. surements with the transfer shaft and gear
184) t o 28 N·m (250 in . lbs.). removed.
DIFFERENTIAL BEARING PRELOAD ADJUSTMENT USING

EXISTING SHIM
(1) P osit ion t h e t r a n sa xle a ssem bly ver t ica lly on t h e
su ppor t st a n d, differ en t ia l bea r in g r et a in er side u p.
(2) In st a ll Tool L-4436A in t o t h e differ en t ia l a n d
on t o t h e pin ion m a t e sh a ft (F ig. 185).
Fig. 183 Install Differential Cover

Fig. 185 Tool L-4436 and Torque Wrench

1 - SPECIAL TOOL L-4436–A
2 - TORQUE WRENCH
(3) Rot a t e t h e differ en t ia l a t lea st on e fu ll r evolu - (b) Rem ove t h e bea r in g cu p fr om t h e differ en t ia l
t ion t o en su r e t h e t a per ed r oller bea r in gs a r e fu lly bea r in g r et a in er u sin g Tool 6062A.
sea t ed. (c) Rem ove t h e exist in g sh im fr om u n der t h e
(4) Usin g Tool L-4436A a n d a n in ch -pou n d t or qu e cu p.
wr en ch , ch eck t h e t u r n in g t or qu e of t h e differ en t ia l (d) Mea su r e t h e exist in g sh im .
(F ig. 186). Th e tu rn in g to rqu e s h o u ld be (e) If t h e t u r n in g t or qu e wa s t oo h igh wh en m ea -
be tw e e n 5 a n d 18 in c h -p o u n d s . su r ed, in st a ll a 0.05 m m (0.002 in ch ) t h in n er sh im .
If t h e t u r n in g t or qu e is wa s t oo low, in st a ll a 0.05
m m (0.002 in ch ) t h icker sh im . Repea t u n t il 5 t o 18
in ch -pou n ds t u r n in g t or qu e is obt a in ed. Oil Ba ffle
is n ot r equ ir ed t o be in st a lled wh en m a kin g sh im
select ion .
(f) In st a ll t h e pr oper sh im u n der t h e bea r in g
cu p. Ma ke su r e t h e oil ba ffle is in st a lled pr oper ly
in t h e bea r in g r et a in er, below t h e bea r in g sh im
a n d cu p.
(g) In st a ll t h e differ en t ia l bea r in g r et a in er u sin g
Tool 5052 a n d C-4171. Sea l t h e r et a in er t o t h e
h ou sin g wit h MOPAR! Adh esive Sea la n t a n d
t or qu e bolt s t o 28 N·m (250 in . lbs.).
(7) Usin g Tool L-4436A a n d a n in ch -pou n d t or qu e
wr en ch , r ech eck t h e t u r n in g t or qu e of t h e differ en t ia l
(F ig. 186). Th e tu rn in g to rqu e s h o u ld be
Fig. 186 Checking Differential Bearings Turning be tw e e n 5 a n d 18 in c h -p o u n d s .
Torque Sh im t h ickn ess n eed be det er m in ed on ly if a n y of
t h e followin g pa r t s a r e r epla ced:
2 - TORQUE WRENCH • Tr a n sa xle ca se
• Differ en t ia l ca r r ier
(5) If t h e t u r n in g t or qu e is wit h in specifica t ion s, • Differ en t ia l bea r in g r et a in er
r em ove t ools. Set u p is com plet e. • E xt en sion h ou sin g
(6) If t u r n in g t or qu e is n ot wit h in specifica t ion s • Differ en t ia l bea r in g cu ps a n d con es
pr oceed wit h t h e followin g st eps.
(a ) Rem ove differ en t ia l bea r in g r et a in er fr om
t h e t r a n sa xle ca se.
DI FFEREN T I AL BEARI N G SH I M CH ART
PART NUMBER SHIM THICKNESS

MM INCH
4659257 .980 0.0386
4659258 1.02 0.0402
4659259 1.06 0.0418
4659260 1.10 0.0434
4659261 1.14 0.0449
4659262 1.18 0.0465
4659263 1.22 0.0481
4659264 1.26 0.0497
4659265 1.30 0.0512
4659266 1.34 0.0528
4659267 1.38 0.0544
4659268 1.42 0.0560
4659269 1.46 0.0575
4659270 1.50 0.0591
4659271 1.54 0.0607
4659272 1.58 0.0623
4659273 1.62 0.0638
4659274 1.66 0.0654
4659275 1.70 0.0670
4659283 2.02 0.0796
4659284 2.06 0.0812
PRELOAD ADJUSTMENT W/O SHIM CAUTION: Do not damage the transaxle case and/or
differential retainer sealing surface.
(1) Rem ove t h e bea r in g cu p fr om t h e differ en t ia l
bea r in g r et a in er u sin g Miller specia l Tool 6062A. (9) Usin g t h e en d pla y m ea su r em en t t h a t wa s
(2) Rem ove exist in g sh im fr om u n der bea r in g cu p. det er m in ed, a dd 0.18m m (0.007 in ch ). Th is sh ou ld
(3) Rein st a ll t h e bea r in g cu p in t o t h e r et a in er give you bet ween 5 a n d 18 in ch pou n ds of bea r in g
u sin g Miller Specia l Tool 6061, a n d C-4171. pr eloa d. Refer t o t h e Differ en t ia l Bea r in g Sh im Ch a r t
t o det er m in e wh ich sh im t o u se.
NOTE: Oil baffle is not required when making the
(10) Rem ove t h e differ en t ia l bea r in g r et a in er.
shim calculation.
Rem ove t h e bea r in g cu p.
(4) In st a ll t h e bea r in g r et a in er in t o t h e ca se. (11) In st a ll t h e oil ba ffle. In st a ll t h e pr oper sh im
Tor qu e bolt s t o 28 N•m (250 in . lbs.). com bin a t ion u n der t h e bea r in g cu p.
(5) P osit ion t h e t r a n sa xle a ssem bly ver t ica lly on (12) In st a ll t h e differ en t ia l bea r in g r et a in er. Sea l
t h e su ppor t st a n d a n d in st a ll Miller Specia l Tool t h e r et a in er t o t h e h ou sin g wit h Mopa r ! Silicon e
L-4436-A in t o t h e bea r in g r et a in er. Ru bber Adh esive Sea la n t . Tor qu e bolt s t o 28 N•m
(6) Rot a t e t h e differ en t ia l a t lea st on e fu ll r evolu - (250 in . lbs.).
t ion t o en su r e t h e t a per ed r oller bea r in gs a r e fu lly (13) Usin g Miller Specia l Tool L-4436-A a n d a n
sea t ed. in ch -pou n d t or qu e wr en ch , ch eck t h e t u r n in g t or qu e
(7) At t a ch a dia l in dica t or t o t h e ca se a n d zer o t h e of t h e differ en t ia l (F ig. 186). Th e t u r n in g t or qu e
dia l. P la ce t h e t ip on t h e en d of Specia l Tool L-4436-A. sh ou ld be bet ween 5-18 in ch -pou n ds.
(8) P la ce a la r ge scr ewdr iver t o ea ch side of t h e
NOTE: If turning torque is too high install a 0.05mm
r in g gea r a n d lift . Ch eck t h e dia l in dica t or for t h e
(0.002 inch) thicker shim. If the turning torque is too
a m ou n t of en d pla y.
low, install a 0.05mm (0.002 inch) thinner shim.
Repeat until 5-18 inch-pounds of turning torque is
obtained.
FLU I D (3) Select sen sor s.

(4) Rea d t h e t r a n sm ission t em per a t u r e va lu e.
(5) Com pa r e t h e flu id t em per a t u r e va lu e wit h t h e
STAN DARD PROCEDU RE flu id t em per a t u r e ch a r t (F ig. 188).
(6) Adju st t r a n sm ission flu id level sh own on t h e
FLUID LEVEL AND CONDITION CHECK in dica t or a ccor din g t o t h e ch a r t .
(7) Ch eck t r a n sm ission for lea ks.
NOTE: Only transmission fluid of the type labeled Low flu id level ca n ca u se a va r iet y of con dit ion s
Mopar ATF+4 (Automatic Transmission Fluid) beca u se it a llows t h e pu m p t o t a ke in a ir a lon g wit h
should be used in this transaxle. t h e flu id. As in a n y h ydr a u lic syst em , a ir bu bbles
m a ke t h e flu id spon gy, t h er efor e, pr essu r es will be
low a n d bu ild u p slowly.
FLUID LEVEL CHECK Im pr oper fillin g ca n a lso r a ise t h e flu id level t oo
Th e t r a n sm ission su m p h a s a flu id level in dica t or h igh . Wh en t h e t r a n sa xle h a s t oo m u ch flu id, t h e
(dipst ick) t o ch eck oil sim ila r t o m ost a u t om a t ic gea r s ch u r n u p foa m a n d ca u se t h e sa m e con dit ion s
t r a n sm ission s. It is loca t ed on t h e left side of t h e wh ich occu r wit h a low flu id level.
en gin e. Be su r e t o wipe a ll dir t fr om dipst ick h a n dle In eit h er ca se, a ir bu bbles ca n ca u se over h ea t in g
befor e r em ovin g. a n d/or flu id oxida t ion , a n d va r n ish in g. Th is ca n
Th e t or qu e con ver t er fills in bot h t h e P P a r k a n d N in t er fer e wit h n or m a l va lve, clu t ch , a n d a ccu m u la t or
Neu t r a l posit ion s. P la ce t h e select or lever in P P a r k oper a t ion . F oa m in g ca n a lso r esu lt in flu id esca pin g
t o be su r e t h a t t h e flu id level ch eck is a ccu r a t e. Th e fr om t h e t r a n sa xle ven t wh er e it m a y be m ist a ken
e n g in e s h o u ld be ru n n in g a t id le s p e e d fo r a t for a lea k.
le a s t o n e m in u te , w ith th e v e h ic le o n le v e l
g ro u n d . At n or m a l oper a t in g t em per a t u r e 82° C FLUID CONDITION
(180° F ), t h e flu id level is cor r ect if it is in t h e H OT Alon g wit h flu id level, it is im por t a n t t o ch eck t h e
r egion on t h e oil level in dica t or (F ig. 187). Th e flu id con dit ion of t h e flu id. Wh en t h e flu id sm ells bu r n ed,
level sh ou ld be wit h in t h e COLD r egion of t h e dip- a n d is con t a m in a t ed wit h m et a l or fr ict ion m a t er ia l
st ick a t 27° C (80° F ) flu id t em per a t u r e. pa r t icles, a com plet e t r a n sa xle r econ dit ion is pr oba -
bly r equ ir ed. Be su r e t o exa m in e t h e flu id on t h e dip-
st ick closely. If t h er e is a n y dou bt a bou t it s con dit ion ,
dr a in ou t a sa m ple for a dou ble ch eck.
Mopa r ! ATF +4 (Au t om a t ic Tr a n sm ission F lu id)
wh en n ew is r ed in color. Th e ATF is dyed r ed so it
ca n be iden t ified fr om ot h er flu ids u sed in t h e veh icle
su ch a s en gin e oil or a n t ifr eeze. Th e r ed color is n ot
per m a n en t a n d is n ot a n in dica t or of flu id con dit ion .
As t h e veh icle is dr iven , t h e ATF will begin t o look
da r ker in color a n d m a y even t u a lly becom e br own .
Th is is n o rm a l. ATF +4 a lso h a s a u n iqu e odor t h a t
m a y ch a n ge wit h a ge. Con sequ en t ly, o d o r a n d c o lo r
c a n n o t be u s e d to in d ic a te th e flu id c o n d itio n
o r th e n e e d fo r a flu id c h a n g e .
Aft er t h e flu id h a s been ch ecked, sea t t h e dipst ick
fu lly t o sea l ou t wa t er a n d dir t .
Fig. 187 Fluid Level Indicator
1 - FLUID LEVEL INDICATOR
STANDARD PROCEDURE - FLUID AND FILTER
SERVICE
FLUID LEVEL CHECK USING DRB
NOTE: Refer to the maintenance schedules in
NOTE: Engine and Transaxle should be at normal LUBRICATION and MAINTENANCE, or the vehicle
operating temperature before performing this proce- owner’s manual, for the recommended maintenance
dure. (fluid/filter change) intervals for this transaxle.
(1) St a r t en gin e a n d a pply pa r kin g br a ke.

(2) H ook u p DRB sca n t ool a n d select t r a n sm is-
sion .
FLU I D (Cont inue d)
Fig. 188 Transmission Fluid Temperature Chart

1 - MAX. LEVEL 2 - MIN. LEVEL
NOTE: Only fluids of the type labeled Mopar" ATF+4

(Automatic Transmission Fluid) should be used. A
filter change should be made at the time of the
transmission oil change. The magnet (on the inside
of the oil pan) should also be cleaned with a clean,
dry cloth.
NOTE: If the transaxle is disassembled for any rea-

son, the fluid and filter should be changed.
FLUID/FILTER SERVICE (RECOMMENDED)

(1) Ra ise veh icle on a h oist . Refer t o LUBRICA-
TION a n d MAINTE NANCE for pr oper pr ocedu r es.
P la ce a dr a in con t a in er wit h a la r ge open in g, u n der
t r a n sa xle oil pa n .
(2) Loosen pa n bolt s a n d t a p t h e pa n a t on e cor n er
t o br ea k it loose a llowin g flu id t o dr a in , t h en r em ove
t h e oil pa n . Fig. 189 Filter and O-Ring
(3) In st a ll a n ew filt er a n d o-r in g on bot t om of t h e
1 - OIL FILTER
va lve body (F ig. 189). 2 - O-RING
(4) Clea n t h e oil pa n a n d m a gn et . Rein st a ll pa n
u sin g n ew Mopa r Silicon e Adh esive sea la n t . Tigh t en (5) P ou r fou r qu a r t s of Mopa r ! ATF +4 (Au t om a t ic
oil pa n bolt s t o 19 N·m (165 in . lbs.). Tr a n sm ission F lu id) t h r ou gh t h e dipst ick open in g.
(6) St a r t en gin e a n d a llow t o idle for a t lea st on e (7) St a r t en gin e a n d a llow t o idle for a t lea st on e
m in u t e. Th en , wit h pa r kin g a n d ser vice br a kes m in u t e. Th en , wit h pa r kin g a n d ser vice br a kes
a pplied, m ove select or lever m om en t a r ily t o ea ch a pplied, m ove select or lever m om en t a r ily t o ea ch
posit ion , en din g in t h e pa r k or n eu t r a l posit ion . posit ion , en din g in t h e pa r k or n eu t r a l posit ion .
(7) Ch eck t h e t r a n sa xle flu id level a n d a dd a n (8) Ch eck t h e t r a n sa xle flu id level a n d a dd a n
a ppr opr ia t e a m ou n t t o br in g t h e t r a n sa xle flu id level a ppr opr ia t e a m ou n t t o br in g t h e t r a n sa xle flu id level
t o 3m m (1/8 in .) below t h e lowest m a r k on t h e dip- t o 3m m (1/8 in .) below t h e lowest m a r k on t h e dip-
st ick (F ig. 190). st ick (F ig. 190).
(9) Rech eck t h e flu id level a ft er t h e t r a n sa xle h a s
r ea ch ed n or m a l oper a t in g t em per a t u r e (180°F.).
(Refer t o 21 - TRANSMISSION/TRANSAXLE /AUTO-
MATIC - 41TE /F LUID - STANDARD P ROCE DURE )
(10) To pr even t dir t fr om en t er in g t r a n sa xle, m a ke
cer t a in t h a t dipst ick is fu lly sea t ed in t o t h e dipst ick
open in g.
GEAR SH I FT CABLE
REMOVAL
(3) Rem ove ba t t er y.
(4) Rem ove speed con t r ol ser vo a n d posit ion ou t of
Fig. 190 Fluid Level Indicator wa y.
(5) Discon n ect gea r sh ift ca ble a t m a n u a l va lve
lever (F ig. 191).
(8) Rech eck t h e flu id level a ft er t h e t r a n sa xle h a s (6) Discon n ect gea r sh ift ca ble fr om u pper m ou n t
r ea ch ed n or m a l oper a t in g t em per a t u r e (180°F.). Refer br a cket (F ig. 191).
t o F lu id Level a n d Con dit ion Ch eck for t h e pr oper
flu id fill pr ocedu r e.
(9) To pr even t dir t fr om en t er in g t r a n sa xle, m a ke
cer t a in t h a t dipst ick is fu lly sea t ed in t o t h e dipst ick
open in g.
DIPSTICK TUBE FLUID SUCTION METHOD

(ALTERNATIVE)
(1) Wh en per for m in g t h e flu id su ct ion m et h od,
m a ke su r e t h e t r a n sa xle is a t fu ll oper a t in g t em per-
a t u r e.
(2) To per for m t h e dipst ick t u be flu id su ct ion
m et h od, u se a su it a ble flu id su ct ion device (Va cu la ™
or equ iva len t ).
(3) In ser t t h e flu id su ct ion lin e in t o t h e dipst ick
t u be.
NOTE: Verify that the suction line is inserted to the

lowest point of the transaxle oil pan. This will
ensure complete evacuation of the fluid in the pan.
(4) F ollow t h e m a n u fa ct u r er s r ecom m en ded pr oce-

du r e a n d eva cu a t e t h e flu id fr om t h e t r a n sa xle. Fig. 191 Gearshift Cable at Transaxle - Typical
(5) Rem ove t h e su ct ion lin e fr om t h e dipst ick t u be. 1 - MANUAL VALVE LEVER
(6) P ou r fou r qu a r t s of Mopa r ! ATF +4 (Au t om a t ic 2 - GEAR SHIFT CABLE
Tr a n sm ission F lu id) t h r ou gh t h e dipst ick open in g. 3 - UPPER MOUNT BRACKET
GEAR SH I FT CABLE (Cont inue d)
(7) Rem ove in st r u m en t pa n el lower silen cer (F ig.
192).
Fig. 192 Instrument Panel Lower Silencer

1 - INSTRUMENT PANEL LOWER SILENCER
(8) Rem ove kn ee bolst er (F ig. 193).

Fig. 194 Gearshift Cable at Column
Fig. 193 Knee Bolster

1 - KNEE BOLSTER
(9) Discon n ect gea r sh ift ca ble fr om gea r sh ift

lever (F ig. 194).
(10) Rem ove gea r sh ift ca ble fr om colu m n br a cket
(F ig. 194).
(11) Disen ga ge gr om m et fr om da sh pa n el (F ig.
195) a n d r em ove gea r sh ift ca ble fr om in side veh icle. Fig. 195 Gearshift Cable/Grommet at Dash Panel
1 - CABLE GROMMET
2 - DASH PANEL
H OLDI N G CLU T CH ES I N PU T CLU T CH ASSEM BLY

DESCRIPTION DISASSEMBLY
Two h ydr a u lica lly a pplied m u lt i-disc clu t ch es a r e (1) Mou n t in pu t clu t ch a ssem bly t o In pu t Clu t ch
u sed t o h old pla n et a r y gea r t r a in com pon en t s st a t ion - P r essu r e F ixt u r e (Tool 8391).
a r y wh ile t h e in pu t clu t ch es dr ive ot h er s. Th e 2/4 (2) Ta p down r ever se clu t ch r ea ct ion pla t e t o
a n d Low/Rever se clu t ch es a r e con sider ed h oldin g r elea se pr essu r e fr om sn a p r in g (F ig. 197).
clu t ch es a n d a r e con t a in ed a t t h e r ea r of t h e t r a n s-
a xle ca se. (F ig. 196).
Fig. 197 Tapping Reaction Plate

2 - TAP DOWN REVERSE CLUTCH REACTION PLATE TO
REMOVE OR INSTALL SNAP RING
3 - INPUT SHAFT CLUTCHES RETAINER ASSEMBLY
Fig. 196 2/4 and Low/Reverse Clutches 4 - REVERSE CLUTCH REACTION PLATE
1 - FRONT PLANET CARRIER/REAR ANNULUS
2 - 2/4 CLUTCH (3) Rem ove r ever se clu t ch sn a p r in g (F ig. 198).
3 - LOW/REVERSE CLUTCH
4 - REAR PLANET CARRIER/FRONT ANNULUS
5 - REAR SUN GEAR
OPERATION
NOTE: Refer to the “Elements In Use” chart in Diag-
nosis and Testing for a collective view of which
clutch elements are applied at each position of the
selector lever.
2/4 CLUTCH
Th e 2/4 clu t ch is h ydr a u lica lly a pplied in secon d
a n d fou r t h gea r s by pr essu r ized flu id a ga in st t h e 2/4
clu t ch pist on . Wh en t h e 2/4 clu t ch is a pplied, t h e
fr on t su n gea r a ssem bly is h eld or gr ou n ded t o t h e
t r a n sa xle ca se. Fig. 198 Reverse Clutch Snap Ring
1 - REACTION PLATE
LOW/REVERSE CLUTCH 2 - SCREWDRIVER
3 - REVERSE CLUTCH SNAP RING (SELECT)
Th e Low/Rever se clu t ch is h ydr a u lica lly a pplied in
pa r k, r ever se, n eu t r a l, a n d fir st gea r s by pr essu r ized
flu id a ga in st t h e Low/Rever se clu t ch pist on . Wh en
t h e Low/Rever se clu t ch is a pplied, t h e fr on t pla n et
ca r r ier /r ea r a n n u lu s a ssem bly is h eld or gr ou n ded t o
I N PU T CLU T CH ASSEM BLY (Cont inue d)
(4) P r y u p a n d r em ove r ever se clu t ch r ea ct ion
pla t e (F ig. 199).
(5) Rem ove r ever se clu t ch pa ck (F ig. 200). Ta g
c o m p o n e n ts fo r a s s e m bly id e n tific a tio n .
Fig. 199 Pry Reverse Clutch Reaction Plate

1 - REVERSE CLUTCH REACTION PLATE
2 - SCREWDRIVER
3 - SCREWDRIVER
Fig. 200 Reverse Clutch Assembly

1 - SNAP RING 4 - CLUTCH PLATE (1)
2 - REACTION PLATE 5 - INPUT CLUTCH ASSEMBLY
3 - CLUTCH DISC (2)
(6) Rem ove t h e OD/Rever se pr essu r e pla t e sn a p
r in g (F ig. 201).
(7) Rem ove OD/Rever se pr essu r e pla t e (F ig. 201).
(8) Rem ove OD/Rever se pr essu r e pla t e wa ve sn a p
r in g (F ig. 201).
(9) Rem ove OD clu t ch pa ck (F ig. 201). Ta g c o m -
p o n e n ts fo r a s s e m bly id e n tific a tio n .
Fig. 201 Overdrive Clutch Assembly

1 - SNAP RING 4 - CLUTCH DISC (3)
2 - OD/REVERSE PRESSURE PLATE 5 - CLUTCH STEEL (2)
3 - SNAP RING (WAVE) 6 - INPUT CLUTCH ASSEMBLY
(10) Rem ove a n d in spect OD a n d UD Sh a ft s, a s
well a s #3 t h r u st wa sh er a n d pla t e, a n d #2 n eedle
Fig. 202 Overdrive/Underdrive Shafts

1 - OVERDRIVE SHAFT 4 - UNDERDRIVE SHAFT
2 - #3 THRUST PLATE (3 TABS) 5 - #2 NEEDLE BEARING (3 TABS)
3 - #3 THRUST WASHER (5 TABS) 6 - INPUT CLUTCH ASSEMBLY
(11) Rem ove t h e OD/UD r ea ct ion pla t e t a per ed
sn a p r in g, r ea ct ion pla t e, a n d fir st fr ict ion disc (F ig.
203).
(12) Rem ove t h e UD clu t ch fla t sn a p r in g a n d r est
of UD clu t ch pa ck (F ig. 203). Ta g c lu tc h p a c k fo r
a s s e m bly id e n tific a tio n .
Fig. 203 Underdrive Clutch Assembly

1 - SNAP RING (TAPERED) 4 - SNAP RING (FLAT)
2 - OD/UD REACTION PLATE 5 - CLUTCH PLATE (3)
3 - CLUTCH DISC (3) 6 - INPUT CLUTCH ASSEMBLY
CAUTION: Compress return spring just enough to
remove or install snap ring.
(13) Usin g Tool 5059A a n d a n a r bor pr ess, com -

pr ess UD clu t ch pist on /spr in g en ou gh t o r em ove sn a p
r in g (F ig. 204) (F ig. 205).
(14) Rem ove spr in g r et a in er, spr in g, a n d pist on
(F ig. 205).
Fig. 204 UD Spring Retainer Snap Ring

2 - ARBOR PRESS RAM
3 - SNAP RING
Fig. 205 Underdrive Clutch Piston, Spring and Retainer

1 - SNAP RING 5 - SEAL, OUTER
2 - SPRING RETAINER 6 - SEAL, INNER
3 - SPRING 7 - INPUT CLUTCH ASSEMBLY
4 - UD CLUTCH PISTON
(15) Rem ove in pu t h u b t a per ed sn a p r in g (F ig. (17) Sepa r a t e clu t ch r et a in er fr om OD/Rever se pis-
206) (F ig. 212). t on (F ig. 208).
Fig. 206 Input Hub Tapered Snap Ring Fig. 208 Pull Retainer from Piston
1 - INPUT SHAFT 1 - OVERDRIVE/REVERSE PISTON
2 - INPUT HUB SNAP RING (TAPERED SIDE UP WITH TABS IN 2 - INPUT CLUTCHES RETAINER
CAVITY)
(18) Usin g Tool 6057 a n d a n a r bor pr ess, com pr ess
(16) Ta p on in pu t h u b wit h soft fa ced h a m m er a n d r et u r n OD/Rever se pist on r et u r n spr in g ju st en ou gh
sepa r a t e in pu t h u b fr om OD/Rever se pist on a n d t o r em ove sn a p r in g (F ig. 209).
clu t ch r et a in er (F ig. 207).

1 - ARBOR PRESS RAM (COMPRESS RETURN SPRING JUST
Fig. 207 Tap on Input Hub ENOUGH TO REMOVE OR INSTALL SNAP RING)
2 - SCREWDRIVER
1 - INPUT SHAFT AND HUB ASSEMBLY 3 - SNAP RING
2 - PLASTIC HAMMER 4 - SPECIAL TOOL 6057
5 - OD/REVERSE PISTON
6 - RETURN SPRING
(19) Rem ove in pu t sh a ft t o in pu t clu t ch h u b sn a p (20) Usin g a su it a bly sized socket a n d a n a r bor
r in g (F ig. 210) (F ig. 212). pr ess, r em ove in pu t sh a ft fr om in pu t sh a ft h u b (F ig.
211).
Fig. 210 Remove Input Shaft Snap Ring

Fig. 211 Remove Input Shaft
1 - INPUT SHAFT
2 - SHARP-POINTED TOOL 1 - ARBOR PRESS RAM
3 - SNAP RING 2 - SOCKET
4 - O-RINGS 3 - SEAL
5 - SEALS 4 - O-RINGS
5 - INPUT SHAFT
6 - SEAL
7 - INPUT SHAFT HUB ASSEMBLY
Fig. 212 Input Clutch Hub, Retainer, and OD/Reverse Piston

1 - SNAP RING (INPUT SHAFT) 7 - SEAL, INPUT SHAFT
2 - SNAP RING 8 - SHAFT, INPUT
3 - CLUTCH RETAINER 9 - HUB
4 - SEAL, OUTER 10 - SEAL
5 - SEAL, INNER 11 - SNAP RING
6 - OD/REVERSE PISTON 12 - BELLEVILLE SPRING
ASSEMBLY (3) Usin g a n a r bor pr ess a n d Tool 6057, In st a ll

Use pet r ola t u m on a ll sea ls t o ea se a ssem bly of OD/Rever se pist on r et u r n spr in g a n d sn a p r in g (F ig.
com pon en t s. 215) (F ig. 216).
(1) Usin g a n a r bor pr ess, in st a ll in pu t sh a ft t o
in pu t sh a ft h u b (F ig. 213).
Fig. 215 Return Spring and Snap Ring

2 - RETURN SPRING
Fig. 213 Install Input Shaft 3 - SNAP RING
1 - INPUT SHAFT 4 - O-RING
2 - ARBOR PRESS RAM
(2) In st a ll in pu t sh a ft sn a p r in g (F ig. 214).

ENOUGH TO REMOVE OR INSTALL SNAP RING)
2 - SCREWDRIVER
Fig. 214 Install Input Shaft Snap Ring 3 - SNAP RING
1 - INPUT SHAFT 4 - SPECIAL TOOL 6057
2 - SCREWDRIVER (DO NOT SCRATCH BEARING SURFACE) 5 - OD/REVERSE PISTON
3 - SNAP RING 6 - RETURN SPRING
4 - O-RINGS
5 - SEALS
(4) In st a ll t h e OD/Rever se pist on a ssem bly t o t h e (6) In st a ll in pu t h u b t a per ed sn a p r in g (F ig. 219)
in pu t clu t ch r et a in er a s sh own in (F ig. 217). (F ig. 220).
Fig. 217 Install OD/Reverse Piston Fig. 219 Install Input Hub Tapered Snap Ring
1 - PUSH DOWN TO INSTALL OVERDRIVE/REVERSE PISTON 1 - INPUT SHAFT
2 - INPUT CLUTCHES RETAINER 2 - INPUT HUB SNAP RING (TAPERED SIDE UP WITH TABS IN
CAVITY)
(5) In st a ll t h e in pu t h u b/sh a ft a ssy. t o t h e OD/Re- 3 - SNAP RING PLIERS
ver se pist on /clu t ch r et a in er a ssy. (F ig. 218).
Fig. 218 Install Input Shaft Hub Assembly

1 - PUSH DOWN TO INSTALL INPUT SHAFT HUB ASSEMBLY
(ROTATE TO ALIGN SPLINES)
2 - OD/REV. PISTON

(7) In st a ll UD clu t ch pist on (F ig. 221). (9) Usin g Tool 5059A a n d a n a r bor pr ess, In st a ll
t h e UD spr in g r et a in er a n d sn a p r in g (F ig. 223) (F ig.
224) (F ig. 225) Com pr ess ju st en ou gh t o in st a ll sn a p
r in g.

install snap ring.
Fig. 221 Underdrive Clutch Piston

1 - PISTON
(8) In st a ll UD pist on r et u r n spr in g a n d Tool 5067

a s sh own in (F ig. 222).
Fig. 223 UD Return Spring and Retainer

1 - UNDERDRIVE SPRING RETAINER
2 - SNAP RING
3 - SEAL
4 - PISTON RETURN SPRING
Fig. 222 Seal Compressor Special Tool 5067

Fig. 224 Install UD Spring Retainer and Snap Ring

1 - ARBOR PRESS RAM
3 - SNAP RING
5 - TOOL 5067
6 - TOOL 5059A

(10) In st a ll t h e UD clu t ch pa ck. Lea ve ou t u pper
disc, u n t il sn a p r in g is in st a lled (F ig. 226).
Fig. 228 Install Last UD Clutch Disc

1 - ONE UNDERDRIVE CLUTCH DISC
Fig. 226 Install Underdrive Clutch Pack

1 - CLUTCH DISC
2 - CLUTCH PLATE
(11) In st a ll t h e UD clu t ch fla t sn a p r in g (F ig. 227).
Fig. 229 OD/UD Reaction Plate

1 - OD/UD CLUTCH REACTION PLATE (TAPERED STEP SIDE UP)
Fig. 227 UD Clutch Flat Snap Ring

1 - UNDERDRIVE CLUTCH REACTION PLATE FLAT SNAP RING
2 - SCREWDRIVER
(12) In st a ll t h e la st UD clu t ch disc (F ig. 228).

(13) In st a ll t h e OD/UD clu t ch r ea ct ion pla t e a n d
sn a p r in g (F ig. 229) (F ig. 230). Th e OD/UD clu t ch es
r ea ct ion pla t e h a s a st ep on bot h sides. In st a ll t h e
OD/UD clu t ch es r ea ct ion pla t e t a per ed st ep side u p.
Fig. 230 Tapered Snap Ring
1 - OVERDRIVE/UNDERDRIVE CLUTCHES REACTION PLATE
TAPERED SNAP RING
2 - SCREWDRIVER (DO NOT SCRATCH REACTION PLATE)
NOTE: Snap ring ends must be located within one
finger of the input clutch hub. Be sure that snap
ring is fully seated, by pushing with screwdriver,
into snap ring groove all the way around.
(14) Sea t t a per ed sn a p r in g t o en su r e pr oper

in st a lla t ion (F ig. 231) (F ig. 232).
Fig. 231 Seating Tapered Snap Ring

TAPERED SNAP RING
2 - SCREWDRIVER

2 - OD/UD REACTION PLATE 5 - CLUTCH PLATE (3)
3 - CLUTCH DISC (3) 6 - INPUT CLUTCH ASSEMBLY
(15) In st a ll in pu t clu t ch a ssem bly t o t h e In pu t
Clu t ch P r essu r e F ixt u r e–Tool 8391 (F ig. 233).
Fig. 234 Set Up Dial Indicator to Measure UD Clutch

Clearance
1 - DIAL INDICATOR
Fig. 233 Input Clutch Assembly on Pressure Fixture
Tool 8391
2 - INPUT CLUTCH PRESSURE FIXTURE 8391
(16) Set u p dia l in dica t or on t h e UD clu t ch pa ck a s

(17) Usin g m oder a t e pr essu r e, pr ess down a n d
h old (n ea r in dica t or ) t h e UD clu t ch pa ck wit h scr ew-
dr iver or su it a ble t ool a n d zer o dia l in dica t or (F ig.
235). Wh en r elea sin g pr essu r e on clu t ch pa ck, in dica -
t or r ea din g sh ou ld a dva n ce 0.005–0.010.
CAUTION: Do not apply more than 30 psi (206 kPa)

to the underdrive clutch pack.
(18) Apply 30 psi (206 kP a ) t o t h e u n der dr ive h ose

on Tool 8391 a n d m ea su r e UD clu t ch clea r a n ce. Mea -
su r e a n d r ecor d UD clu t ch pa ck m ea su r em en t in fou r
(4) pla ces, 90° a pa r t .
(19) Ta ke a ver a ge of fou r m ea su r em en t s a n d com -
pa r e wit h UD clu t ch pa ck clea r a n ce specifica t ion .
U n d e rd riv e c lu tc h p a c k c le a ra n c e m u s t be 0.94-
1.50 m m (0.037-0.059 in .).
(20) If n ecessa r y, select t h e pr oper r ea ct ion pla t e Fig. 235 Press Down on UD Clutch Pack and Zero
t o a ch ieve specifica t ion s: Dial Indicator
1 - DIAL INDICATOR
UNDERDRIVE REACTION PLATE THICKNESS 2 - UNDERDRIVE CLUTCH
4659939AB 5.837-5.937 mm (0.230-0.234 in.)

4659940AB 6.147-6.248 mm (0.242-0.246 in.)
4659941AB 6.457-6.557 mm (0.254-0.258 in.)
(21) In st a ll t h e OD clu t ch pa ck (F ig. 236). (23) In st a ll t h e OD/Rever se pr essu r e pla t e wit h
la r ge st ep down (t owa r ds OD clu t ch pa ck) (F ig. 238).
Fig. 238 OD/Reverse Reaction Plate

1 - OVERDRIVE/REVERSE PRESSURE PLATE
2 - (STEP SIDE DOWN)
Fig. 236 Install Overdrive Clutch Pack (24) In st a ll OD pr essu r e pla t e fla t sn a p r in g (F ig.
1 - CLUTCH DISC 239) (F ig. 240).
2 - CLUTCH PLATE
(22) In st a ll OD pr essu r e pla t e wa ved sn a p r in g

(F ig. 237).
Fig. 239 Install Flat Snap Ring

1 - ARBOR PRESS RAM
2 - TOOL 5059A
3 - FLAT SNAP RING
Fig. 237 Install Waved Snap Ring
1 - OVERDRIVE PRESSURE PLATE WAVED SNAP RING
2 - SCREWDRIVER

(25) Mea su r e OD clu t ch pa ck clea r a n ce. Set u p
dia l in dica t or on t op of t h e OD/Rever se pr essu r e
pla t e a s sh own in (F ig. 241).
Fig. 242 Install Reverse Clutch Pack

1 - REVERSE CLUTCH PLATE
2 - REVERSE CLUTCH DISCS
Fig. 241 Measure OD Clutch Pack Clearance

1 - DIAL INDICATOR
2 - OD/REVERSE REACTION PLATE
(26) Zer o dia l in dica t or a n d a pply 30 psi (206 kP a )

a ir pr essu r e t o t h e over dr ive clu t ch h ose on Tool
8391. Mea su r e a n d r ecor d OD clu t ch pa ck m ea su r e-
m en t in fou r (4) pla ces, 90° a pa r t .
pa r e wit h OD clu t ch pa ck clea r a n ce specifica t ion .
Fig. 243 Install Reaction Plate
Th e o v e rd riv e (OD ) c lu tc h p a c k c le a ra n c e is
1.07-3.25 m m (0.042-0.128 in .). 1 - REVERSE CLUTCH REACTION PLATE (FLAT SIDE DOWN)
If n ot wit h in specifica t ion s, t h e clu t ch is n ot
a ssem bled pr oper ly. Th er e is n o a dju st m en t for t h e
OD clu t ch clea r a n ce.
(28) In st a ll r ever se clu t ch pa ck (t wo fr ict ion s/on e
st eel) (F ig. 242).
(29) In st a ll r ever se clu t ch r ea ct ion pla t e wit h t h e
fla t side down t owa r ds r ever se clu t ch (F ig. 243).
(30) Ta p r ea ct ion pla t e down t o a llow in st a lla t ion (31) P r y u p r ever se r ea ct ion pla t e t o sea t a ga in st
of t h e r ever se clu t ch sn a p r in g. In st a ll r ever se clu t ch sn a p r in g (F ig. 246).
sn a p r in g (F ig. 244) (F ig. 245).
Fig. 246 Pry Up Reaction Plate

Fig. 244 Install Reverse Clutch Snap Ring
1 - SCREWDRIVER
1 - REVERSE CLUTCH SNAP RING (SELECT) 2 - SNAP RING
2 - SCREWDRIVER 3 - SCREWDRIVER
3 - REVERSE CLUTCH REACTION PLATE 4 - MUST RAISE REVERSE REACTION PLATE TO RAISE SNAP
RING

3 - CLUTCH DISC (2)
(32) Set u p a dia l in dica t or on t h e r ever se clu t ch
pa ck a s sh own in (F ig. 247).
Fig. 248 Press Down on Reverse Clutch and Zero

Indicator
Fig. 247 Measure Reverse Clutch Pack Clearance 1 - DIAL INDICATOR
2 - REVERSE CLUTCH
1 - DIAL INDICATOR
2 - REVERSE CLUTCH
(36) To com plet e t h e a ssem bly, r ever se clu t ch a n d
(33) Usin g m oder a t e pr essu r e, pr ess down a n d over dr ive clu t ch m u st be r em oved.
h old (n ea r in dica t or ) r ever se clu t ch disc wit h scr ew- (37) In st a ll t h e #2 n eedle bea r in g (F ig. 249).
248). Wh en r elea sin g pr essu r e, in dica t or sh ou ld
a dva n ce 0.005-0.010. a s clu t ch pa ck r ela xes.
(34) Apply 30 psi (206 kP a ) a ir pr essu r e t o t h e
r ever se clu t ch h ose on Tool 8391. Mea su r e a n d r ecor d
r ever se clu t ch pa ck m ea su r em en t in fou r (4) pla ces,
90° a pa r t .
pa r e wit h r ever se clu t ch pa ck clea r a n ce specifica t ion .
Th e re v e rs e c lu tc h p a c k c le a ra n c e is 0.89-1.37
m m (0.035-0.054 in .). Select t h e pr oper r ever se
clu t ch sn a p r in g t o a ch ieve specifica t ion s:
REVERSE CLUTCH SNAP RING THICKNESS

4377195 1.53-1.58 mm (0.060-0.062 in.)
4412871 1.77-1.83 mm (0.070-0.072 in.) Fig. 249 Install No. 2 Needle Bearing
4412872 2.02-2.07 mm (0.080-0.082 in.) 1 - #2 NEEDLE BEARING (NOTE 3 SMALL TABS)
2 - TABS UP
4412873 2.27-2.32 mm (0.090-0.091 in.)
(38) In st a ll t h e u n der dr ive sh a ft a ssem bly (F ig. (40) In st a ll t h e #3 t h r u st pla t e t o t h e bot t om of t h e
250). over dr ive sh a ft a ssem bly. Ret a in wit h pet r ola t u m or
t r a n sm ission a ssem bly gel (F ig. 252).
Fig. 250 Install Underdrive Shaft Assembly

Fig. 252 Install No. 3 Thrust Plate
1 - UNDERDRIVE SHAFT ASSEMBLY
2 - #2 NEEDLE BEARING 1 - OVERDRIVE SHAFT ASSEMBLY
2 - DABS OF PETROLATUM (FOR RETENTION)
3 - #3 THRUST PLATE (NOTE 3 TABS)
(39) In st a ll t h e #3 t h r u st wa sh er t o t h e u n der dr ive
sh a ft a ssem bly. Be su r e five t a bs a r e sea t ed pr oper ly (41) In st a ll t h e over dr ive sh a ft a ssem bly (F ig. 253)
(F ig. 251). (F ig. 254).
Fig. 251 Install No. 3 Thrust Washer Fig. 253 Install Overdrive Shaft Assembly
1 - #3 THRUST WASHER (NOTE 5 TABS) 1 - OVERDRIVE SHAFT ASSEMBLY
2 - UNDERDRIVE SHAFT ASSEMBLY 2 - #3 THRUST PLATE
(42) Rein st a ll over dr ive a n d r ever se clu t ch a s

sh own . Re c h e c k in g th e s e c lu tc h c le a ra n c e s is
n o t n e c e s s a ry.

OI L PU M P
DESCRIPTION
Th e oil pu m p is loca t ed in t h e pu m p h ou sin g in side
t h e bell h ou sin g of t h e t r a n sa xle ca se (F ig. 255). Th e
oil pu m p con sist s of a n in n er a n d ou t er gea r, a h ou s-
in g, a n d a cover t h a t a lso ser ves a s t h e r ea ct ion sh a ft
su ppor t .
Fig. 256 Reaction Support-to-Pump Body Bolts

1 - BOLT (6)
2 - PUMP BODY
3 - REACTION SHAFT SUPPORT
Fig. 255 Oil Pump Assembly

1 - PUMP BODY
2 - OUTER GEAR
3 - INNER GEAR
5 - SEAL RINGS (4)
6 - REACTION SHAFT
7 - CRESCENT
OPERATION
As t h e t or qu e con ver t er r ot a t es, t h e con ver t er h u b
r ot a t es t h e in n er a n d ou t er gea r s. As t h e gea r s
r ot a t e, t h e clea r a n ce bet ween t h e gea r t eet h
in cr ea ses in t h e cr escen t a r ea , a n d cr ea t es a su ct ion
a t t h e in let side of t h e pu m p. Th is su ct ion dr a ws
flu id t h r ou gh t h e pu m p in let fr om t h e oil pa n . As t h e
clea r a n ce bet ween t h e gea r t eet h in t h e cr escen t a r ea Fig. 257 Reaction Shaft Support
decr ea ses, it for ces pr essu r ized flu id in t o t h e pu m p 1 - PUMP BODY
ou t let a n d t o t h e va lve body. 2 - PUMP GEARS
DISASSEMBLY
Wh en disa ssem blin g t h e t r a n sa xle it is n ecessa r y
t o in spect t h e oil pu m p for wea r a n d da m a ge.
(1) Rem ove t h e r ea ct ion sh a ft su ppor t -t o-pu m p
body bolt s (F ig. 256).
(2) Rem ove r ea ct ion sh a ft su ppor t fr om pu m p
h ou sin g (F ig. 257).
(3) Rem ove t h e pu m p gea r s (F ig. 258) a n d ch eck (6) Mea su r e clea r a n ce bet ween ou t er gea r a n d
for wea r a n d da m a ge on pu m p h ou sin g a n d gea r s. cr escen t (F ig. 260). Clea r a n ce sh ou ld be 0.060-0.298
m m (0.0023-0.0117 in .).

1 - PUMP BODY Fig. 260 Measuring Outer Gear-to-Crescent
2 - OUTER GEAR 1 - FEELER GAUGE
3 - INNER GEAR 2 - OUTER GEAR
4 - REACTION SHAFT SUPPORT 3 - CRESCENT
5 - SEAL RINGS (4) 4 - INNER GEAR
6 - REACTION SHAFT
7 - CRESCENT
(7) Mea su r e clea r a n ce bet ween in n er gea r a n d
(4) Re-in st a ll t h e gea r s a n d ch eck clea r a n ces. cr escen t (F ig. 261). Clea r a n ce sh ou ld be 0.093-0.385
(5) Mea su r e t h e clea r a n ce bet ween t h e ou t er gea r m m (0.0036-0.0151 in .).
a n d t h e pu m p pocket (F ig. 259). Clea r a n ce sh ou ld be
0.089–0.202 m m (0.0035-0.0079 in .).
Fig. 261 Measuring Inner Gear-to-Crescent

1 - FEELER GAUGE
Fig. 259 Measuring Outer Gear-to-Pocket 2 - OUTER GEAR
3 - CRESCENT
1 - FEELER GAUGE 4 - INNER GEAR
2 - OUTER GEAR
3 - PUMP BODY
(8) P osit ion a n a ppr opr ia t e piece of P la st iga ge
a cr oss bot h pu m p gea r s.
(9) Align t h e P la st iga ge t o a fla t a r ea on t h e r ea c-
t ion sh a ft su ppor t h ou sin g.
(10) In st a ll t h e r ea ct ion sh a ft t o t h e pu m p h ou sin g
(F ig. 256). Tigh t en t h e bolt s t o 27 N·m (20 ft . lbs.).
(11) Rem ove bolt s a n d ca r efu lly sepa r a t e t h e h ou s-
in gs. Mea su r e t h e P la st iga ge followin g t h e in st r u c-
t ion s su pplied.
(12) Clea r a n ce bet ween bot h gea r en d fa ces a n d
t h e r ea ct ion sh a ft su ppor t sh ou ld be 0.020-0.046 m m
(0.0008-0.0018 in .).
ASSEMBLY
(1) Assem ble oil pu m p a s sh own in (F ig. 262).

1 - BOLT (6)
2 - PUMP BODY

1 - PUMP BODY
2 - OUTER GEAR
3 - INNER GEAR
5 - SEAL RINGS (4)
6 - REACTION SHAFT Fig. 264 Planetary Geartrain
7 - CRESCENT
2 - #6 THRUST BEARING
(2) In st a ll a n d t or qu e r ea ct ion sh a ft su ppor t -t o-oil 3 - #7 THRUST BEARING
pu m p h ou sin g bolt s t o 28 N·m (20 ft . lbs.) t or qu e 4 - REAR CARRIER/FRONT ANNULUS ASSEMBLY
(F ig. 263). 5 - REAR SUN GEAR
6 - FRONT CARRIER/REAR ANNULUS ASSEMBLY
PLAN ETARY GEART RAI N OPERATION

Th e pla n et a r y gea r t r a in u t ilizes t wo pla n et a r y gea r
DESCRIPTION set s t h a t con n ect t h e t r a n sm ission in pu t sh a ft t o t h e
ou t pu t sh a ft . In pu t a n d h oldin g clu t ch es dr ive or lock
Th e pla n et a r y gea r t r a in is loca t ed bet ween t h e
differ en t pla n et a r y m em ber s t o ch a n ge ou t pu t r a t io
in pu t clu t ch a ssem bly a n d t h e r ea r of t h e t r a n sa xle
or dir ect ion .
ca se. Th e pla n et a r y gea r t r a in con sist s of t wo su n
gea r s, t wo pla n et a r y ca r r ier s, t wo a n n u lu s (r in g)
gea r s, a n d on e ou t pu t sh a ft (F ig. 264).
SEAL - OI L PU M P SH I FT I N T ERLOCK SOLEN OI D

REMOVAL DESCRIPTION
(1) Rem ove t r a n sa xle fr om veh icle (Refer t o 21 - Th e Br a ke/Tr a n sm ission Sh ift In t er lock syst em
TRANSMISSION/TRANSAXLE /AUTOMATIC - 41TE con sist s of a n elect r o-m a gn et ic solen oid m ou n t ed t o
- RE MOVAL). t h e st eer in g colu m n (F ig. 267). Th e solen oid’s plu n ger
(2) Usin g Tool C-3981-B, r em ove oil pu m p sea l con sist s of a n in t egr a t ed h ook, wh ich oper a t es t h e
(F ig. 265). sh ift lever pa wl (pa r t of sh ift lever a ssem bly), a n d a
plu n ger r et u r n spr in g (F ig. 268). Th e solen oid a lso
h a s a n in t egr a t ed br a cket , wh ich fa cilit a t es fa st en in g
t o t h e st eer in g colu m n .
Fig. 265 Remove Oil Pump Seal

1 - TOOL C-3981–B
2 - OIL PUMP SEAL
INSTALLATION
(1) Usin g Tool C-4193, in st a ll oil pu m p sea l (F ig.
266). Fig. 267 Brake/Transmission Shift Interlock (BTSI)
Solenoid Location
1 - BTSI SOLENOID
Fig. 266 Install Oil Pump Seal

1 - TOOL C-4193
2 - HANDLE TOOL C-4171
Fig. 268 Solenoid Plunger and Return Spring
(2) In st a ll t r a n sa xle t o veh icle (Refer t o 21 - 1 - PLUNGER
2 - RETURN SPRING
TRANSMISSION/TRANSAXLE /AUTOMATIC - 41TE 3 - BTSI SOLENOID
- INSTALLATION).
SH I FT I N T ERLOCK SOLEN OI D (Cont inue d)
OPERATION
Th e Br a ke/Tr a n sm ission Sh ift In t er lock (BTSI)
Solen oid pr even t s t h e t r a n sm ission sh ift lever fr om
bein g m oved ou t of PARK (P ) u n less t h e br a ke peda l
is a pplied. Th e BTSI solen oid is h a r dwir ed t o a n d
con t r olled by t h e In t elligen t P ower Modu le (IP M).
Ba t t er y volt a ge is a pplied t o on e side of t h e solen oid
wit h t h e ign it ion key is in eit h er t h e OF F, ON/RUN,
or START posit ion s (F ig. 269). Th e gr ou n d side of t h e
solen oid is con t r olled by a dr iver wit h in t h e IP M. It
r elies on volt a ge su pplied fr om t h e st op la m p swit ch
t o t h e st op la m p sen se cir cu it wit h in t h e IP M t o t ell
wh en t h e br a ke peda l is depr essed. Wh en t h e br a ke
peda l is depr essed, t h e gr ou n d cir cu it open s, de-en er-
gizin g t h e solen oid. Wh en t h e br a ke peda l is
r elea sed, t h e gr ou n d cir cu it is closed, en er gizin g t h e
solen oid.
Fig. 270 Pawl Engaged to Shift Lever

1 - GEAR SHIFT LEVER
2 - GEAR SHIFT LEVER PAWL
Fig. 269 Ignition Key/Switch Positions

1 - ACC
2 - LOCK
3 - OFF
4 - ON/RUN
5 - START
Wh en t h e ign it ion key is in eit h er t h e OF F,

ON/RUN, or START posit ion s, t h e BTSI solen oid is
en er gized, a n d t h e solen oid plu n ger h ook pu lls t h e
sh ift lever pa wl in t o posit ion , pr oh ibit in g t h e sh ift
lever fr om m ovin g ou t of PARK (P ) (F ig. 270). Wh en
Fig. 271 Pawl Disengaged From Shift Lever
t h e br a ke peda l is depr essed, t h e gr ou n d cir cu it
open s, de-en er gizin g t h e solen oid. Th is m oves t h e 2 - GEAR SHIFT LEVER PAWL
gea r sh ift lever pa wl ou t of t h e wa y (F ig. 271), a llow-
in g t h e sh ift lever t o be m oved in t o a n y gea r posit ion .
A con ven t ion a l m ech a n ica l in t er lock syst em is a lso ACTION EXPECTED RESPONSE
u sed. Th is syst em m a n u a lly pr oh ibit s sh ift er m ove-
m en t wh en t h e ign it ion swit ch is in t h e LOCK or 6. With the key removed, 6. Shifter cannot be
ACC posit ion s. Solen oid oper a t ion is n ot r equ ir ed in try to shift out of %PARK%. shifted out of %PARK%.
t h ese key posit ion s. NOTE: Any failure to meet these expected
F or in t en ded BTSI syst em oper a t ion , r efer t o t h e responses requires system repair. Refer to the
followin g ch a r t : appropriate Diagnostic Information.
ACTION EXPECTED RESPONSE REMOVAL

1. Turn key to the %OFF% 1. Shifter CAN be shifted
(2) Rem ove in st r u m en t pa n el lower sh r ou d (F ig.
position. out of park with brake
272).
pedal applied.
2. Turn key to the 2. Shifter CANNOT be
%ON/RUN% position. shifted out of park.
3. Turn key to the 3. Shifter CAN be shifted
%ON/RUN% position and out of park.
depress the brake pedal.
4. Leave shifter in any 4. Key cannot be
gear and try to return key returned to the %LOCK% or
to the %LOCK% or %ACC% %ACC% position.
position.
5. Return shifter to 5. Key can be removed
%PARK% and try to remove (after returning to %LOCK%
the key. position).
6. With the key removed, 6. Shifter cannot be
try to shift out of %PARK%. shifted out of %PARK%.
NOTE: Any failure to meet these expected Fig. 272 Instrument Panel Lower Silencer
responses requires system adjustment or repair. 1 - INSTRUMENT PANEL LOWER SILENCER
DIAGNOSIS AND TESTING - BRAKE/ (3) Rem ove kn ee bolst er (F ig. 273).
TRANSMISSION SHIFT INTERLOCK SOLENOID
F or in t en ded BTSI syst em oper a t ion , r efer t o t h e
followin g ch a r t :
ACTION EXPECTED RESPONSE

pedal applied.
to the %LOCK% or %ACC% %ACC% position. Fig. 273 Knee Bolster
position. 1 - KNEE BOLSTER

the key. position).
(4) Rem ove st eer in g colu m n lower sh r ou d. INSTALLATION
(5) Discon n ect br a ke/t r a n sm ission sh ift in t er lock (1) P la ce in t er lock solen oid in t o posit ion en su r in g
(BTSI) solen oid con n ect or (F ig. 274). h ook on en d of solen oid plu n ger en ga ges gea r sh ift
lever pa wl pin . In st a ll a n d t igh t en scr ews (F ig. 276).
Fig. 276 Solenoid Retaining Screw

Fig. 274 BTSI Solenoid Connector 1 - SOLENOID RETAINING SCREW (2)
1 - BTSI SOLENOID
2 - SOLENOID CONNECTOR (2) Ver ify gea r sh ift lever is in PARK (P ) a n d con -
n ect solen oid con n ect or (F ig. 277).
(6) Rem ove t wo (2) solen oid-t o-colu m n scr ews (F ig.
275).
Fig. 275 Solenoid Retaining Screw Fig. 277 BTSI Solenoid Connector
1 - SOLENOID RETAINING SCREW (2) 1 - BTSI SOLENOID
2 - SOLENOID CONNECTOR
(7) Rem ove solen oid.
(3) In st a ll st eer in g colu m n lower sh r ou d. SOLEN OI D/PRESSU RE
(4) In st a ll kn ee bolst er (F ig. 278).
SWI T CH ASSY
DESCRIPTION
Th e Solen oid/P r essu r e Swit ch Assem bly (F ig. 280)
is ext er n a l t o t h e t r a n sa xle a n d m ou n t ed t o t h e
t r a n sa xle ca se. Th e a ssem bly con sist s of fou r sole-
n oids t h a t con t r ol h ydr a u lic pr essu r e t o t h e LR/CC,
2/4, OD, a n d UD fr ict ion elem en t s. Th e r ever se
clu t ch is con t r olled by lin e pr essu r e fr om t h e m a n u a l
va lve in t h e va lve body. Th e solen oids a r e con t a in ed
wit h in t h e Solen oid/P r essu r e Swit ch Assem bly, a n d
ca n on ly be ser viced by r epla cin g t h e a ssem bly.
Th e solen oid a ssem bly a lso con t a in s pr essu r e
swit ch es t h a t m on it or a n d sen d h ydr a u lic cir cu it
in for m a t ion t o t h e P CM/TCM. Likewise, t h e pr essu r e
swit ch es ca n on ly be ser vice by r epla cin g t h e a ssem -
bly.
1 - KNEE BOLSTER
(5) In st a ll in st r u m en t pa n el lower silen cer (F ig.

279).

1 - INSTRUMENT PANEL LOWER SILENCER Fig. 280 Solenoid/Pressure Switch Assembly
1 - SOLENOID AND PRESSURE SWITCH ASSEMBLY
(7) Ver ify pr oper sh ift in t er lock syst em oper a t ion .
MATIC - 31TH /SH IF T INTE RLOCK SOLE NOID -
OP E RATION)
SOLEN OI D/PRESSU RE SWI T CH ASSY (Cont inue d)
OPERATION Th e P CM/TCM a lso t est s t h e 2/4 a n d OD pr essu r e

swit ch es wh en t h ey a r e n or m a lly off (OD a n d 2/4 a r e
SOLENOIDS t est ed in 1st gea r, OD in 2n d gea r, a n d 2/4 in 3r d
Th e solen oids r eceive elect r ica l power fr om t h e gea r ). Th e t est sim ply ver ifies t h a t t h ey a r e oper a -
Tr a n sm ission Con t r ol Rela y t h r ou gh a sin gle wir e. t ion a l, by lookin g for a closed st a t e wh en t h e cor r e-
Th e P CM/TCM en er gizes or oper a t es t h e solen oids spon din g elem en t is a pplied. Im m edia t ely a ft er a
in dividu a lly by gr ou n din g t h e r et u r n wir e of t h e sole- sh ift in t o 1st , 2n d, or 3r d gea r wit h t h e en gin e speed
n oid n eeded. Wh en a solen oid is en er gized, t h e sole- a bove 1000 r pm , t h e P CM/TCM m om en t a r ily t u r n s
n oid va lve sh ift s, a n d a flu id pa ssa ge is open ed or on elem en t pr essu r e t o t h e 2/4 a n d/or OD clu t ch cir-
closed (ven t ed or a pplied), depen din g on it s defa u lt cu it s t o iden t ify t h a t t h e a ppr opr ia t e swit ch h a s
oper a t in g st a t e. Th e r esu lt is a n a pply or r elea se of a closed. If it doesn ’t close, it is t est ed a ga in . If t h e
fr ict ion a l elem en t . swit ch fa ils t o close t h e secon d t im e, t h e a ppr opr ia t e
Th e 2/4 a n d UD solen oids a r e n or m a lly a pplied, Dia gn ost ic Tr ou ble Code (DTC) will set .
wh ich by design a llow flu id t o pa ss t h r ou gh in t h eir
r ela xed or “off” st a t e. Th is a llows t r a n sa xle lim p-in REMOVAL
(P,R,N,2) in t h e even t of a n elect r ica l fa ilu r e.
Th e con t in u it y of t h e solen oids a n d cir cu it s a r e NOTE: If solenoid/pressure switch assembly is
per iodica lly t est ed. E a ch solen oid is t u r n ed on or off being replaced, the “Quick-Learn” procedure must
depen din g on it s cu r r en t st a t e. An in du ct ive spike be performed. (Refer to 8 - ELECTRICAL/ELEC-
sh ou ld be det ect ed by t h e P CM/TCM du r in g t h is t est . TRONIC CONTROL MODULES/TRANSMISSION
It n o spike is det ect ed, t h e cir cu it is t est ed a ga in t o CONTROL MODULE - STANDARD PROCEDURE)
ver ify t h e fa ilu r e. In a ddit ion t o t h e per iodic t est in g,
t h e solen oid cir cu it s a r e t est ed if a speed r a t io or
(2) Rem ove a ir clea n er a ssem bly.
pr essu r e swit ch er r or occu r s.
PRESSURE SWITCHES
(4) Discon n ect in pu t speed sen sor con n ect or (F ig.
Th e P CM/TCM r elies on t h r ee pr essu r e swit ch es t o
281).
m on it or flu id pr essu r e in t h e L/R, 2/4, a n d OD
h ydr a u lic cir cu it s. Th e pr im a r y pu r pose of t h ese
swit ch es is t o h elp t h e P CM/TCM det ect wh en clu t ch
cir cu it h ydr a u lic fa ilu r es occu r. Th e r a n ge for t h e
pr essu r e swit ch closin g a n d open in g poin t s is 11-23
psi. Typica lly t h e swit ch open in g poin t will be
a ppr oxim a t ely on e psi lower t h a n t h e closin g poin t .
F or exa m ple, a swit ch m a y close a t 18 psi a n d open
a t 17 psi. Th e swit ch es a r e con t in u ou sly m on it or ed
by t h e P CM/TCM for t h e cor r ect st a t es (open or
closed) in ea ch gea r a s sh own in t h e followin g ch a r t :
PRESSU RE SWI T CH STAT ES
GEAR L/R 2/4 OD
R OP OP OP
P/N CL OP OP
1st CL OP OP
2nd OP CL OP
D OP OP CL
OD OP CL CL
OP = OPEN Fig. 281 Transmission Connectors
CL = CLOSED 1 - SOLENOID PACK CONNECTOR
A Dia gn ost ic Tr ou ble Code (DTC) will set if t h e 3 - OUTPUT SPEED SENSOR CONNECTOR
P CM/TCM sen ses a n y swit ch open or closed a t t h e
wr on g t im e in a given gea r.
(5) Rem ove in pu t speed sen sor (F ig. 282).
Fig. 282 Input Speed Sensor

1 - INPUT SPEED SENSOR
Gasket
a ssem bly-t o-t r a n sa xle ca se bolt s (F ig. 283). 1 - SOLENOID/PRESSURE SWITCH ASSEMBLY
2 - GASKET
INSTALLATION
NOTE: If solenoid/pressure switch assembly is
being replaced, it is necessary to perform the
“Quick-Learn” procedure. (Refer to 8 - ELECTRI-
CAL/ELECTRONIC CONTROL MODULES/TRANS-
PROCEDURE)

n ew ga sket t o t r a n sa xle (F ig. 284).
(2) In st a ll a n d t or qu e t h r ee (3) bolt s (F ig. 283) t o
13 N·m (110 in . lbs.).
(3) In st a ll in pu t speed sen sor (F ig. 282) a n d t or qu e
t o 27 N·m (20 ft . lbs.).
(4) Con n ect in pu t speed sen sor con n ect or (F ig.
281).
(5) In st a ll solen oid/pr essu r e swit ch 8-wa y con n ec-
Fig. 283 Solenoid/Pressure Switch Assembly-to- t or a n d t or qu e t o 4 N·m (35 in . lbs.) (F ig. 281).
Case Bolts (6) In st a ll a ir clea n er a ssem bly.
1 - BOLTS (7) Con n ect ba t t er y n ega t ive ca ble.
2 - SOLENOID AND PRESSURE SWITCH ASSEMBLY (8) If solen oid/pr essu r e swit ch a ssem bly wa s
r epla ced, per for m t h e “Qu ick-Lea r n ” pr ocedu r e.
(7) Rem ove solen oid/pr essu r e swit ch a ssem bly a n d (Refer t o 8 - E LE CTRICAL/E LE CTRONIC CON-
ga sket (F ig. 284). Use ca r e t o pr even t ga sket m a t e- TROL MODULE S/TRANSMISSION CONTROL
r ia l a n d for eign object s fr om becom e lodged in t h e MODULE - STANDARD P ROCE DURE )
t r a n sa xle ca se por t s.
SPEED SEN SOR - I N PU T OPERATION

Th e In pu t Speed Sen sor pr ovides in for m a t ion on
DESCRIPTION h ow fa st t h e in pu t sh a ft is r ot a t in g. As t h e t eet h of
Th e In pu t Speed Sen sor is a t wo-wir e m a gn et ic t h e in pu t clu t ch h u b pa ss by t h e sen sor coil (F ig.
picku p device t h a t gen er a t es AC sign a ls a s r ot a t ion 287), a n AC volt a ge is gen er a t ed a n d sen t t o t h e
occu r s. It is t h r ea ded in t o t h e t r a n sa xle ca se (F ig. P CM/TCM. Th e P CM/TCM in t er pr et s t h is in for m a -
285), sea led wit h a n o-r in g (F ig. 286), a n d is con sid- t ion a s in pu t sh a ft r pm .
er ed a pr im a r y in pu t t o t h e P ower t r a in /Tr a n sm ission
Con t r ol Modu le.
Fig. 287 Sensor Relation to Input Clutch Hub

2 - TRANSAXLE CASE
Fig. 285 Input Speed Sensor Location 3 - INPUT CLUTCH HUB

Th e P CM/TCM com pa r es t h e in pu t speed sign a l
wit h ou t pu t speed sign a l t o det er m in e t h e followin g:
• Tr a n sm ission gea r r a t io
• Speed r a t io er r or det ect ion
• CVI ca lcu la t ion
Th e P CM/TCM a lso com pa r es t h e in pu t speed sig-
n a l a n d t h e en gin e speed sign a l t o det er m in e t h e fol-
lowin g:
• Tor qu e con ver t er clu t ch slippa ge
• Tor qu e con ver t er elem en t speed r a t io
Fig. 286 O-Ring Location

2 - O-RING
SPEED SEN SOR - I N PU T (Cont inue d)
REMOVAL
288).
Fig. 289 Input (Turbine) Speed Sensor

Fig. 288 Transmission Connectors

1 - SOLENOID PACK CONNECTOR
3 - OUTPUT SPEED SENSOR CONNECTOR
(3) Un scr ew a n d r em ove in pu t speed sen sor (F ig.

289).
(4) In spect speed sen sor o-r in g (F ig. 290) a n d
r epla ce if n ecessa r y.
INSTALLATION
(1) Ver ify o-r in g is in st a lled in t o posit ion (F ig.
290).
(2) In st a ll a n d t igh t en in pu t speed sen sor t o 27
N·m (20 ft . lbs.) (F ig. 289). Fig. 290 O-ring Location
(3) Con n ect speed sen sor con n ect or (F ig. 288). 1 - INPUT SPEED SENSOR
(4) Con n ect ba t t er y n ega t ive ca ble. 2 - O-RING
SPEED SEN SOR - OU T PU T OPERATION

Th e Ou t pu t Speed Sen sor pr ovides in for m a t ion on
DESCRIPTION h ow fa st t h e ou t pu t sh a ft is r ot a t in g. As t h e r ea r
Th e Ou t pu t Speed Sen sor is a t wo-wir e m a gn et ic pla n et a r y ca r r ier pa r k pa wl lu gs pa ss by t h e sen sor
picku p device t h a t gen er a t es a n AC sign a l a s r ot a t ion coil (F ig. 293), a n AC volt a ge is gen er a t ed a n d sen t t o
occu r s. It is t h r ea ded in t o t h e t r a n sa xle ca se (F ig. t h e P CM/TCM. Th e P CM/TCM in t er pr et s t h is in for-
291), sea led wit h a n o-r in g (F ig. 292), a n d is con sid- m a t ion a s ou t pu t sh a ft r pm .
er ed a pr im a r y in pu t t o t h e P owet r a in /Tr a n sm ission
Con t r ol Modu le.
Fig. 293 Sensor Relation to Planet Carrier Park Pawl

1 - OUTPUT SPEED SENSOR
2 - REAR PLANET CARRIER/OUTPUT SHAFT ASSEMBLY
Fig. 291 Output Speed Sensor 3 - TRANSAXLE CASE
Th e P CM/TCM com pa r es t h e in pu t a n d ou t pu t
speed sign a ls t o det er m in e t h e followin g:

2 - O-RING
SPEED SEN SOR - OU T PU T (Cont inue d)
VEHICLE SPEED SIGNAL
Th e veh icle speed sign a l is t a ken fr om t h e Ou t pu t
Speed Sen sor. Th e P CM con ver t s t h is sign a l in t o a
pu lse per m ile sign a l a n d sen ds t h e veh icle speed
m essa ge a cr oss t h e com m u n ica t ion bu s t o t h e BCM.
Th e BCM sen ds t h is sign a l t o t h e In st r u m en t Clu st er
t o displa y veh icle speed t o t h e dr iver. Th e veh icle
speed sign a l pu lse is r ou gh ly 8000 pu lses per m ile.
REMOVAL
(3) Discon n ect ou t pu t speed sen sor con n ect or (F ig.
294).
Fig. 295 Output Speed Sensor


Fig. 296 O-ring Location
(4) Un scr ew a n d r em ove ou t pu t speed sen sor (F ig. 1 - OUTPUT SPEED SENSOR
295). 2 - O-RING
INSTALLATION
296).
N·m (20 ft . lbs.).
(3) Con n ect speed sen sor con n ect or (F ig. 294).
T ORQU E CON V ERT ER

DESCRIPTION
Th e t or qu e con ver t er (F ig. 297) is a h ydr a u lic
device t h a t cou ples t h e en gin e cr a n ksh a ft t o t h e
t r a n sm ission . Th e t or qu e con ver t er con sist s of a n
ou t er sh ell wit h a n in t er n a l t u r bin e, a st a t or, a n
over r u n n in g clu t ch , a n im peller a n d a n elect r on ica lly
a pplied con ver t er clu t ch . Th e con ver t er clu t ch pr o-
vides r edu ced en gin e speed a n d gr ea t er fu el econ om y
wh en en ga ged. Clu t ch en ga gem en t a lso pr ovides
r edu ced t r a n sm ission flu id t em per a t u r es. Th e con -
ver t er clu t ch en ga ges in t h ir d gea r. Th e t or qu e con -
ver t er h u b dr ives t h e t r a n sm ission oil (flu id) pu m p.
Th e t or qu e con ver t er is a sea led, welded u n it t h a t
is n ot r epa ir a ble a n d is ser viced a s a n a ssem bly.
Fig. 297 Torque Converter Assembly

1 - TURBINE
2 - IMPELLER
3 - HUB
4 - STATOR
5 - CONVERTER CLUTCH DISC
6 - DRIVE PLATE
T ORQU E CON V ERT ER (Cont inue d)
IMPELLER
Th e im peller (F ig. 298) is a n in t egr a l pa r t of t h e
con ver t er h ou sin g. Th e im peller con sist s of cu r ved
bla des pla ced r a dia lly a lon g t h e in side of t h e h ou sin g
on t h e t r a n sm ission side of t h e con ver t er. As t h e con -
ver t er h ou sin g is r ot a t ed by t h e en gin e, so is t h e
im peller, beca u se t h ey a r e on e a n d t h e sa m e a n d a r e
t h e dr ivin g m em ber of t h e syst em .
Fig. 298 Impeller

1 - ENGINE FLEXPLATE 4 - ENGINE ROTATION
2 - OIL FLOW FROM IMPELLER SECTION INTO TURBINE 5 - ENGINE ROTATION
SECTION
3 - IMPELLER VANES AND COVER ARE INTEGRAL
TURBINE
Th e t u r bin e (F ig. 299) is t h e ou t pu t , or dr iven ,
m em ber of t h e con ver t er. Th e t u r bin e is m ou n t ed
wit h in t h e h ou sin g opposit e t h e im peller, bu t is n ot
a t t a ch ed t o t h e h ou sin g. Th e in pu t sh a ft is in ser t ed
t h r ou gh t h e cen t er of t h e im peller a n d splin ed in t o
t h e t u r bin e. Th e design of t h e t u r bin e is sim ila r t o
t h e im peller, except t h e bla des of t h e t u r bin e a r e
cu r ved in t h e opposit e dir ect ion .
Fig. 299 Turbine

1 - TURBINE VANE 4 - PORTION OF TORQUE CONVERTER COVER
2 - ENGINE ROTATION 5 - ENGINE ROTATION
3 - INPUT SHAFT 6 - OIL FLOW WITHIN TURBINE SECTION
STATOR
Th e st a t or a ssem bly (F ig. 300) is m ou n t ed on a st a -
t ion a r y sh a ft wh ich is a n in t egr a l pa r t of t h e oil
pu m p. Th e st a t or is loca t ed bet ween t h e im peller a n d
t u r bin e wit h in t h e t or qu e con ver t er ca se (F ig. 301).
Th e st a t or con t a in s a n over-r u n n in g clu t ch , wh ich
a llows t h e st a t or t o r ot a t e on ly in a clockwise dir ec-
t ion . Wh en t h e st a t or is locked a ga in st t h e over-r u n -
n in g clu t ch , t h e t or qu e m u lt iplica t ion fea t u r e of t h e
t or qu e con ver t er is oper a t ion a l.
Fig. 301 Stator Location

1 - STATOR
2 - IMPELLER
3 - FLUID FLOW
4 - TURBINE
Fig. 300 Stator Components

1 - CAM (OUTER RACE)
2 - ROLLER
3 - SPRING
4 - INNER RACE
TORQUE CONVERTER CLUTCH (TCC)

Th e TCC (F ig. 302) wa s in st a lled t o im pr ove t h e
efficien cy of t h e t or qu e con ver t er t h a t is lost t o t h e
slippa ge of t h e flu id cou plin g. Alt h ou gh t h e flu id cou -
plin g pr ovides sm oot h , sh ock–fr ee power t r a n sfer, it
is n a t u r a l for a ll flu id cou plin gs t o slip. If t h e im pel-
ler a n d t u r bin e wer e m ech a n ica lly locked t oget h er, a
zer o slippa ge con dit ion cou ld be obt a in ed. A h ydr a u lic
pist on wa s a dded t o t h e t u r bin e, a n d a fr ict ion m a t e-
r ia l wa s a dded t o t h e in side of t h e fr on t cover t o pr o-
vide t h is m ech a n ica l lock-u p.
Fig. 302 Torque Converter Clutch (TCC)

1 - IMPELLER FRONT COVER
2 - THRUST WASHER ASSEMBLY
3 - IMPELLER
4 - STATOR
5 - TURBINE
6 - PISTON
7 - FRICTION DISC
OPERATION Th is cir cu la t ion of oil fr om im peller t o t u r bin e, t u r bin e t o

Th e con ver t er im peller (F ig. 303) (dr ivin g m em ber ), st a t or, a n d st a t or t o im peller, ca n pr odu ce a m a xim u m
wh ich is in t egr a l t o t h e con ver t er h ou sin g a n d bolt ed t or qu e m u lt iplica t ion of a bou t 2.4:1. As t h e t u r bin e
t o t h e en gin e dr ive pla t e, r ot a t es a t en gin e speed. begin s t o m a t ch t h e speed of t h e im peller, t h e flu id t h a t
Th e con ver t er t u r bin e (dr iven m em ber ), wh ich r ea ct s wa s h it t in g t h e st a t or in su ch a s wa y a s t o ca u se it t o
fr om flu id pr essu r e gen er a t ed by t h e im peller, r ot a t es lock–u p is n o lon ger doin g so. In t h is con dit ion of oper a -
a n d t u r n s t h e t r a n sm ission in pu t sh a ft . t ion , t h e st a t or begin s t o fr ee wh eel a n d t h e con ver t er
a ct s a s a flu id cou plin g.
TURBINE
As t h e flu id t h a t wa s pu t in t o m ot ion by t h e im peller
bla des st r ikes t h e bla des of t h e t u r bin e, som e of t h e
en er gy a n d r ot a t ion a l for ce is t r a n sfer r ed in t o t h e t u r-
bin e a n d t h e in pu t sh a ft . Th is ca u ses bot h of t h em (t u r-
bin e a n d in pu t sh a ft ) t o r ot a t e in a clockwise dir ect ion
followin g t h e im peller. As t h e flu id is lea vin g t h e t r a il-
in g edges of t h e t u r bin e’s bla des it con t in u es in a “h in -
der in g” dir ect ion ba ck t owa r d t h e im peller. If t h e flu id
is n ot r edir ect ed befor e it st r ikes t h e im peller, it will
st r ike t h e im peller in su ch a dir ect ion t h a t it wou ld
t en d t o slow it down .
STATOR
Tor qu e m u lt iplica t ion is a ch ieved by lockin g t h e st a -
t or ’s over-r u n n in g clu t ch t o it s sh a ft (F ig. 304). Un der Fig. 304 Stator Operation
st a ll con dit ion s (t h e t u r bin e is st a t ion a r y), t h e oil lea vin g 1 - DIRECTION STATOR WILL FREE WHEEL DUE TO OIL
t h e t u r bin e bla des st r ikes t h e fa ce of t h e st a t or bla des PUSHING ON BACKSIDE OF VANES
a n d t r ies t o r ot a t e t h em in a cou n t er clockwise dir ect ion . 2 - FRONT OF ENGINE
3 - INCREASED ANGLE AS OIL STRIKES VANES
Wh en t h is h a ppen s t h e over –r u n n in g clu t ch of t h e st a t or 4 - DIRECTION STATOR IS LOCKED UP DUE TO OIL PUSHING
locks a n d h olds t h e st a t or fr om r ot a t in g. Wit h t h e st a t or AGAINST STATOR VANES
locked, t h e oil st r ikes t h e st a t or bla des a n d is r edir ect ed
in t o a “h elpin g” dir ect ion befor e it en t er s t h e im peller.
Fig. 303 Torque Converter Fluid Operation

1 - APPLY PRESSURE 3 - RELEASE PRESSURE
2 - THE PISTON MOVES SLIGHTLY FORWARD 4 - THE PISTON MOVES SLIGHTLY REARWARD
TORQUE CONVERTER CLUTCH (TCC) (2) P la ce t or qu e con ver t er in posit ion on t r a n sm is-
In a st a n da r d t or qu e con ver t er, t h e im peller a n d sion .
t u r bin e a r e r ot a t in g a t a bou t t h e sa m e speed a n d t h e
st a t or is fr eewh eelin g, pr ovidin g n o t or qu e m u lt ipli- CAUTION: Do not damage oil pump seal or bushing
ca t ion . By a pplyin g t h e t u r bin e’s pist on t o t h e fr on t while inserting torque converter into the front of the
cover ’s fr ict ion m a t er ia l, a t ot a l con ver t er en ga ge- transmission.
m en t ca n be obt a in ed. Th e r esu lt of t h is en ga gem en t
(3) Align t or qu e con ver t er t o oil pu m p sea l open -
is a dir ect 1:1 m ech a n ica l lin k bet ween t h e en gin e
in g.
a n d t h e t r a n sm ission .
(4) In ser t t or qu e con ver t er h u b in t o oil pu m p.
Th e en ga gem en t a n d disen ga gem en t of t h e TCC
(5) Wh ile pu sh in g t or qu e con ver t er in wa r d, r ot a t e
a r e a u t om a t ic a n d con t r olled by t h e P ower t r a in Con -
con ver t er u n t il con ver t er is fu lly sea t ed in t h e oil
t r ol Modu le (P CM). Th e en ga gem en t ca n n ot be a ct i-
pu m p gea r s.
va t ed in t h e lower gea r s beca u se it elim in a t es t h e
(6) Ch eck con ver t er sea t in g wit h a sca le a n d
t or qu e m u lt iplica t ion effect of t h e t or qu e con ver t er
st r a igh t edge (F ig. 305). Su r fa ce of con ver t er lu gs
n ecessa r y for a cceler a t ion . In pu t s t h a t det er m in e
sh ou ld be 1/2 in . t o r ea r of st r a igh t edge wh en con -
clu t ch en ga gem en t a r e: coola n t t em per a t u r e, veh icle
ver t er is fu lly sea t ed.
speed a n d t h r ot t le posit ion . Th e t or qu e con ver t er
(7) If n ecessa r y, t em por a r ily secu r e con ver t er wit h
clu t ch is en ga ged by t h e clu t ch solen oid on t h e va lve
C-cla m p a t t a ch ed t o t h e con ver t er h ou sin g.
body. Th e clu t ch will en ga ge a t a ppr oxim a t ely 56
(8) In st a ll t h e t r a n sm ission in t h e veh icle. (Refer
km /h (35 m ph ) wit h ligh t t h r ot t le, a ft er t h e sh ift t o
t h ir d gea r.
- 41TE - INSTALLATION)
(9) F ill t h e t r a n sm ission wit h t h e r ecom m en ded
REMOVAL flu id. (Refer t o 21 - TRANSMISSION/TRANSAXLE /
(1) Rem ove t r a n sm ission a n d t or qu e con ver t er AUTOMATIC - 41TE /F LUID - STANDARD P ROCE -
fr om veh icle. (Refer t o 21 - TRANSMISSION/TRANS- DURE )
AXLE /AUTOMATIC - 41TE - RE MOVAL)
(2) P la ce a su it a ble dr a in pa n u n der t h e con ver t er
h ou sin g en d of t h e t r a n sm ission .
CAUTION: Verify that transmission is secure on the

lifting device or work surface, the center of gravity
of the transmission will shift when the torque con-
verter is removed creating an unstable condition.
The torque converter is a heavy unit. Use caution
when separating the torque converter from the
transmission.
(3) P u ll t h e t or qu e con ver t er for wa r d u n t il t h e cen -

t er h u b clea r s t h e oil pu m p sea l.
(4) Sepa r a t e t h e t or qu e con ver t er fr om t h e t r a n s-
m ission .
INSTALLATION
Ch eck con ver t er h u b a n d dr ive n ot ch es for sh a r p
edges, bu r r s, scr a t ch es, or n icks. P olish t h e h u b a n d
n ot ch es wit h 320/400 gr it pa per or cr ocu s clot h if n ec- Fig. 305 Checking Torque Converter Seating
essa r y. Th e h u b m u st be sm oot h t o a void da m a gin g
1 - SCALE
t h e pu m p sea l a t in st a lla t ion . 2 - STRAIGHTEDGE
(1) Lu br ica t e con ver t er h u b a n d oil pu m p sea l lip
wit h t r a n sm ission flu id.
T RAN SM I SSI ON CON T ROL ca n on ly be ser viced by r em ovin g t h e va lve body. Th e

elect r ica l con n ect or ext en ds t h r ou gh t h e t r a n sa xle
RELAY ca se (F ig. 307).
DESCRIPTION
Th e t r a n sm ission con t r ol r ela y (F ig. 306) is loca t ed
in t h e In t elligen t P ower Modu le (IP M), wh ich is
loca t ed on t h e left side of t h e en gin e com pa r t m en t
bet ween t h e ba t t er y a n d left fen der.
Fig. 307 Transmission Range Sensor (TRS)

Location
1 - TRANSMISSION RANGE SENSOR
Th e Tr a n sm ission Ra n ge Sen sor (TRS) h a s fou r

Fig. 306 Transmission Control Relay Location swit ch con t a ct s t h a t m on it or sh ift lever posit ion a n d
1 - TRANSMISSION CONTROL RELAY sen d t h e in for m a t ion t o t h e P CM/TCM.
2 - LEFT FENDER Th e TRS a lso h a s a n in t egr a t ed t em per a t u r e sen -
3 - INTELLIGENT POWER MODULE (IPM) sor (t h er m ist or ) t h a t com m u n ica t es t r a n sa xle t em -
4 - BATTERY
per a t u r e t o t h e TCM a n d P CM (F ig. 308).
OPERATION
Th e r ela y is su pplied fu sed B+ volt a ge, en er gized by
t h e P CM/TCM, a n d is u sed t o su pply power t o t h e sole-
n oid pa ck wh en t h e t r a n sm ission is in n or m a l oper a t in g
m ode. Wh en t h e r ela y is “off”, n o power is su pplied t o
t h e solen oid pa ck a n d t h e t r a n sm ission is in “lim p-in ”
m ode. Aft er a con t r oller r eset (ign it ion key t u r n ed t o t h e
“r u n ” posit ion or a ft er cr a n kin g en gin e), t h e P CM/TCM
en er gizes t h e r ela y. P r ior t o t h is, t h e P CM/TCM ver ifies
t h a t t h e con t a ct s a r e open by ch eckin g for n o volt a ge a t
t h e swit ch ed ba t t er y t er m in a ls. Aft er t h is is ver ified,
t h e volt a ge a t t h e solen oid pa ck pr essu r e swit ch es is
ch ecked. Aft er t h e r ela y is en er gized, t h e P CM/TCM
m on it or s t h e t er m in a ls t o ver ify t h a t t h e volt a ge is
gr ea t er t h a n 3 volt s.
T RAN SM I SSI ON RAN GE

SEN SOR Fig. 308 Transmission Temperature Sensor
2 - TEMPERATURE SENSOR
DESCRIPTION
Th e Tr a n sm ission Ra n ge Sen sor (TRS) is m ou n t ed
t o t h e t op of t h e va lve body in side t h e t r a n sa xle a n d
T RAN SM I SSI ON RAN GE SEN SOR (Cont inue d)
OPERATION dict ed flu id t em per a t u r e wh ich is ca lcu la t ed fr om a

Th e Tr a n sm ission Ra n ge Sen sor (TRS) (F ig. 307) com bin a t ion of in pu t s:
com m u n ica t es sh ift lever posit ion (SLP ) t o t h e P CM/ • Ba t t er y (a m bien t ) t em per a t u r e
TCM a s a com bin a t ion of open a n d closed swit ch es. • E n gin e coola n t t em per a t u r e
E a ch sh ift lever posit ion h a s a n a ssign ed com bin a - • In -gea r r u n t im e sin ce st a r t -u p
t ion of swit ch st a t es (open /closed) t h a t t h e P CM/TCM
r eceives fr om fou r sen se cir cu it s. Th e P CM/TCM REMOVAL
in t er pr et s t h is in for m a t ion a n d det er m in es t h e (1) Rem ove va lve body a ssem bly fr om t r a n sa xle.
a ppr opr ia t e t r a n sa xle gea r posit ion a n d sh ift sch ed- (Refer t o 21 - TRANSMISSION/TRANSAXLE /AUTO-
u le. MATIC - 41TE /VALVE BODY - RE MOVAL)
Sin ce t h er e a r e fou r swit ch es, t h er e a r e 16 possible (2) Rem ove t r a n sm ission r a n ge sen sor r et a in in g
com bin a t ion s of open a n d closed swit ch es (codes). scr ew a n d r em ove sen sor fr om va lve body (F ig. 309).
Seven of t h ese codes a r e r ela t ed t o gea r posit ion a n d
t h r ee a r e r ecogn ized a s “bet ween gea r ” codes. Th is
r esu lt s in six codes wh ich sh ou ld n ever occu r. Th ese
a r e ca lled “in va lid” codes. An in va lid code will r esu lt
in a DTC, a n d t h e P CM/TCM will t h en det er m in e t h e
sh ift lever posit ion ba sed on pr essu r e swit ch da t a .
Th is a llows r ea son a bly n or m a l t r a n sm ission oper a -
t ion wit h a TRS fa ilu r e.
T RS SWI T CH STAT ES
SLP T42 T41 T3 T1

P CL CL CL OP
R CL OP OP OP
N CL CL OP CL
OD OP OP OP CL
3 OP OP CL OP
L CL OP CL CL
Fig. 309 Remove Transmission Range Sensor
TRANSMISSION TEMPERATURE SENSOR 2 - MANUAL VALVE CONTROL PIN
Th e TRS h a s a n in t egr a t ed t h er m ist or (F ig. 308) 3 - RETAINING SCREW
t h a t t h e P CM/TCM u ses t o m on it or t h e t r a n sm is-
sion ’s su m p t em per a t u r e. Sin ce flu id t em per a t u r e (3) Rem ove TRS fr om m a n u a l sh a ft .
ca n a ffect t r a n sm ission sh ift qu a lit y a n d con ver t or
lock u p, t h e P CM/TCM r equ ir es t h is in for m a t ion t o INSTALLATION
det er m in e wh ich sh ift sch edu le t o oper a t e in . Th e (1) In st a ll t r a n sm ission r a n ge sen sor (TRS) t o t h e
P CM a lso m on it or s t h is t em per a t u r e da t a so it ca n va lve body a n d t or qu e r et a in in g scr ew (F ig. 309) t o 5
en er gize t h e veh icle coolin g fa n (s) wh en a t r a n sm is- N·m (45 in . lbs.).
sion “over h ea t ” con dit ion exist s. If t h e t h er m ist or cir- (2) In st a ll va lve body t o t r a n sa xle. (Refer t o 21 -
cu it fa ils, t h e P CM/TCM will r ever t t o ca lcu la t ed oil TRANSMISSION/TRANSAXLE /AUTOMATIC -
t em per a t u r e u sa ge. 41TE /VALVE BODY - INSTALLATION)
CALCULATED TEMPERATURE
A fa ilu r e in t h e t em per a t u r e sen sor or cir cu it will
r esu lt in ca lcu la t ed t em per a t u r e bein g su bst it u t ed for
a ct u a l t em per a t u r e. Ca lcu la t ed t em per a t u r e is a pr e-
VALV E BODY OPERATION
DESCRIPTION NOTE: Refer to the Hydraulic Schematics for a

visual aid in determining valve location, operation
Th e va lve body a ssem bly con sist s of a ca st a lu m i-
and design.
n u m va lve body, a sepa r a t or pla t e, a n d t r a n sfer
pla t e. Th e va lve body con t a in s va lves a n d ch eck ba lls
t h a t con t r ol flu id deliver y t o t h e t or qu e con ver t er REGULATOR VALVE
clu t ch , solen oid/pr essu r e swit ch a ssem bly, a n d fr ic- Th e r egu la t or va lve con t r ols h ydr a u lic pr essu r e in
t ion a l clu t ch es. Th e va lve body con t a in s t h e followin g t h e t r a n sa xle. It r eceives u n r egu la t ed pr essu r e fr om
com pon en t s (F ig. 310): t h e pu m p, wh ich wor ks a ga in st spr in g t en sion t o
• Regu la t or va lve m a in t a in oil a t specific pr essu r es. A syst em of sleeves
• Solen oid swit ch va lve a n d por t s a llows t h e r egu la t or va lve t o wor k a t on e of
• Ma n u a l va lve t h r ee pr edet er m in ed pr essu r e levels. Regu la t ed oil
• Con ver t er clu t ch swit ch va lve pr essu r e is a lso r efer r ed t o a s “lin e pr essu r e.”
• Con ver t er clu t ch con t r ol va lve
• Tor qu e con ver t er r egu la t or va lve SOLENOID SWITCH VALVE
• Low/Rever se swit ch va lve Th e solen oid swit ch va lve con t r ols lin e pr essu r e
In a ddit ion , t h e va lve body a lso con t a in s t h e t h er- fr om t h e LR/CC solen oid. In on e posit ion , it a llows
m a l va lve, #2,3&4 ch eck ba lls, t h e #5 (over dr ive) t h e low/r ever se clu t ch t o be pr essu r ized. In t h e ot h er,
ch eck va lve a n d t h e 2/4 a ccu m u la t or a ssem bly. (Refer it dir ect s lin e pr essu r e t o t h e con ver t er con t r ol a n d
t o 21 - TRANSMISSION/TRANSAXLE /AUTOMATIC con ver t er clu t ch va lves.
- 41TE /VALVE BODY - DISASSE MBLY)
Fig. 310 Valve Body Assembly

1 - VALVE BODY 5 - MANUAL VALVE
2 - T/C REGULATOR VALVE 6 - CONVERTER CLUTCH SWITCH VALVE
3 - L/R SWITCH VALVE 7 - SOLENOID SWITCH VALVE
4 - CONVERTER CLUTCH CONTROL VALVE 8 - REGULATOR VALVE
VALV E BODY (Cont inue d)
MANUAL VALVE REMOVAL
Th e m a n u a l va lve is oper a t ed by t h e m ech a n ica l
sh ift lin ka ge. It s pr im a r y r espon sibilit y is t o sen d NOTE: If valve body is replaced or reconditioned,
lin e pr essu r e t o t h e a ppr opr ia t e h ydr a u lic cir cu it s the “Quick-Learn” Procedure must be performed.
a n d solen oids. Th e va lve h a s t h r ee oper a t in g r a n ges (Refer to 8 - ELECTRICAL/ELECTRONIC CONTROL
or posit ion s. MODULES/TRANSMISSION CONTROL MODULE -
STANDARD PROCEDURE)
CONVERTER CLUTCH SWITCH VALVE
Th e m a in r espon sibilit y of t h e con ver t er clu t ch (1) Discon n ect ba t t er y n ega t ive ca ble.
swit ch va lve is t o con t r ol h ydr a u lic pr essu r e a pplied (2) Discon n ect gea r sh ift ca ble fr om m a n u a l va lve
t o t h e fr on t (off) side of t h e con ver t er clu t ch pist on . lever.
Lin e pr essu r e fr om t h e r egu la t or va lve is fed t o t h e (3) Rem ove m a n u a l va lve lever fr om m a n u a l sh a ft .
t or qu e con ver t er r egu la t or va lve, wh er e it pa sses (4) Ra ise veh icle on h oist .
t h r ou gh t h e va lve, a n d is sligh t ly r egu la t ed. Th e (5) Rem ove oil pa n bolt s (F ig. 311).
pr essu r e is t h en dir ect ed t o t h e con ver t er clu t ch
swit ch va lve a n d t o t h e fr on t side of t h e con ver t er
clu t ch pist on . Th is pr essu r e pu sh es t h e pist on ba ck
a n d disen ga ges t h e con ver t er clu t ch .
CONVERTER CLUTCH CONTROL VALVE

Th e con ver t er clu t ch con t r ol va lve con t r ols t h e
ba ck (on ) side of t h e t or qu e con ver t er clu t ch . Wh en
t h e P CM/TCM en er gizes or m odu la t es t h e LR/CC
solen oid t o a pply t h e con ver t er clu t ch pist on , bot h
t h e con ver t er clu t ch con t r ol va lve a n d t h e con ver t er
con t r ol va lve m ove, a llowin g pr essu r e t o be a pplied t o
t h e ba ck side of t h e clu t ch .
T/C REGULATOR VALVE

Th e t or qu e con ver t er r egu la t or va lve sligh t ly r egu -
la t es t h e flow of flu id t o t h e t or qu e con ver t er. Fig. 311 Oil Pan Bolts
LOW/REVERSE SWITCH VALVE
Th e low/r ever se clu t ch is a pplied fr om differ en t (6) Rem ove oil pa n (F ig. 312).
sou r ces, depen din g on wh et h er low (1st ) gea r or
r ever se is select ed. Th e low/r ever se swit ch va lve
a lt er n a t es posit ion s depen din g on fr om wh ich dir ec-
t ion flu id pr essu r e is a pplied. By design , wh en t h e
va lve is sh ift ed by flu id pr essu r e fr om on e ch a n n el,
t h e opposin g ch a n n el is blocked. Th e swit ch va lve
a lien a t es t h e possibilit y of a st ickin g ba ll ch eck, t h u s
pr ovidin g con sist en t a pplica t ion of t h e low/r ever se
clu t ch u n der a ll oper a t in g con dit ion s.
Fig. 312 Oil Pan

1 - OIL PAN
2 - 1/8 INCH BEAD OF RTV SEALANT
3 - OIL FILTER
(7) Rem ove oil filt er (F ig. 313). (9) Rem ove pa r k r od r oller s fr om gu ide br a cket
a n d r em ove va lve body fr om t r a n sa xle (F ig. 315) (F ig.
316).
Fig. 313 Oil Filter Fig. 315 Push Park Rod Rollers from Guide Bracket
1 - OIL FILTER
2 - SCREWDRIVER
2 - O-RING
(8) Rem ove t h e va lve body-t o-t r a n sa xle ca se bolt s

(F ig. 314).

1 - VALVE BODY
CAUTION: The valve body manual shaft pilot may

distort and bind the manual valve if the valve body
Fig. 314 Valve Body Attaching Bolts is mishandled or dropped.
2 - VALVE BODY
NOTE: To ease removal of the valve body, turn the

manual valve lever fully clockwise to low or first
gear.
DISASSEMBLY (3) Rem ove Ma n u a l Sh a ft /Roost er Com b and

Tr a n sm ission Ra n ge Sen sor (F ig. 319).
NOTE: If valve body assembly is being recondi-
tioned, the PCM/TCM Quick Learn Procedure must
be performed. (Refer to 8 - ELECTRICAL/ELEC-
TRONIC CONTROL MODULES/TRANSMISSION
CONTROL MODULE - STANDARD PROCEDURE)
(1) Rem ove m a n u a l sh a ft sea l (F ig. 317).
Fig. 319 Manual Shaft/Rooster Comb and

Transmission Range Sensor
2 - MANUAL SHAFT
3 - ROOSTER COMB
(4) Rem ove 2/4 Accu m u la t or Ret a in in g P la t e (F ig.

Fig. 317 Manual Shaft Seal 320).
1 - SEAL
2 - MANUAL SHAFT
(2) Rem ove Tr a n sm ission Ra n ge Sen sor r et a in in g

scr ew (F ig. 318).
Fig. 320 2/4 Accumulator Retaining Plate

1 - 2–4 ACCUMULATOR RETAINING PLATE
2 - DETENT SPRING

2 - MANUAL VALVE CONTROL PIN
3 - RETAINING SCREW
(5) Rem ove 2/4 Accu m u la t or com pon en t s a s sh own (7) In ver t a ssem bly a n d r em ove Tr a n sfer P la t e
in (F ig. 321). (F ig. 323). Bewa r e of loose ch eck ba lls.
Fig. 321 2/4 Accumulator Assembly

1 - VALVE BODY
2 - RETAINER PLATE
3 - DETENT SPRING Fig. 323 Remove Transfer Plate
4 - RETURN SPRINGS
5 - PISTON 1 - TRANSFER PLATE
(6) Rem ove Va lve Body t o Tr a n sfer P la t e scr ews (8) Rem ove oil scr een (F ig. 324).
(F ig. 322).
Fig. 324 Remove Oil Screen

Fig. 322 Remove Valve Body to Transfer Plate 1 - OIL SCREEN
Screws
1 - SCREW (24)
2 - TRANSFER PLATE
3 - VALVE BODY
(9) Rem ove t h e over dr ive clu t ch (#5) ch eck va lve (11) Rem ove t h er m a l va lve (F ig. 327).
(F ig. 325)
Fig. 327 Remove Thermal Valve

Fig. 325 Remove Overdrive Clutch (#5) Check Valve 1 - THERMAL VALVE
1 - OVERDRIVE CLUTCH (#5) CHECK VALVE
(12) Rem ove ch eck ba lls (F ig. 328).
(10) Rem ove sepa r a t or pla t e (F ig. 326).
NOTE: Tag all valve/spring assemblies for reassem-
bly identification.
(13) Rem ove du a l r et a in er pla t e u sin g Tool 6301

(F ig. 329).
(14) Rem ove r egu la t or va lve spr in g r et a in er (F ig.
330).
Fig. 326 Remove Separator Plate

1 - SEPARATOR PLATE
2 - VALVE BODY
Fig. 328 Ball Check Location

1 - (#4) BALL CHECK LOCATION 4 - (#3) BALL CHECK LOCATION
2 - (#2) BALL CHECK LOCATION 5 - LOW/REVERSE SWITCH VALVE
3 - RETAINER 6 - T/C LIMIT VALVE
Fig. 329 Remove Dual Retainer Plate using Tool Fig. 330 Remove Regulator Valve Spring Retainer
6301 using Tool 6302
1 - TOOL 6301 1 - TOOL 6302
2 - RETAINER 2 - RETAINER
(15) Rem ove r em a in in g r et a in er s a s sh own in (F ig.
331).
(16) Rem ove va lves a n d spr in gs a s sh own in (F ig.
332).
NOTE: Refer to Valve Body Cleaning and Inspection

for cleaning procedures.
ASSEMBLY
NOTE: If valve body assembly is reconditioned, the
PCM/TCM Quick Learn Procedure must be per-
formed. (Refer to 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/TRANSMISSION CONTROL
MODULE - STANDARD PROCEDURE)
(1) In st a ll va lves a n d spr in gs a s sh own in (F ig.

332).
Fig. 331 Valve Retainer Location
1 - RETAINER
2 - RETAINER
Fig. 332 Springs and Valves Location

(2) In st a ll r egu la t or va lve spr in g r et a in er (F ig. (4) Ver ify t h a t a ll r et a in er s a r e in st a lled a s sh own
333). in (F ig. 335). Ret a in er s sh ou ld be flu sh or below
va lve body su r fa ce.
Fig. 333 Install Regulator Valve Spring Retainer

using Tool 6302 Fig. 335 Valve Retainer Location
1 - TOOL 6302 1 - RETAINER
(3) In st a ll du a l r et a in er pla t e u sin g Tool 6301 (F ig. (5) In st a ll ch eck ba lls in t o posit ion a s sh own in
334). (F ig. 336). If n ecessa r y, secu r e t h em wit h pet r ola t u m
or t r a n sm ission a ssem bly gel for a ssem bly ea se.
(6) In st a ll t h er m a l va lve in t o t r a n sfer pla t e (F ig.
337).
(7) In st a ll sepa r a t or pla t e t o va lve body (F ig. 338).
Fig. 334 Install Dual Retainer Plate using Tool 6301

1 - TOOL 6301
2 - RETAINER

Fig. 338 Install Separator Plate

Fig. 337 Install Thermal Valve
1 - SEPARATOR PLATE
1 - THERMAL VALVE 2 - VALVE BODY
(8) In st a ll t h e over dr ive clu t ch (#5) ch eck va lve t o (10) In st a ll t r a n sfer pla t e t o va lve body a n d sepa -
sepa r a t or pla t e (F ig. 339) r a t or pla t e. Ma ke su r e oil scr een a n d #5 ch eck va lve
do n ot bin d (F ig. 341).
Fig. 339 Install Overdrive Clutch (#5) Check Valve

1 - OVERDRIVE CLUTCH (#5) CHECK VALVE Fig. 341 Install Transfer Plate
1 - TRANSFER PLATE
(9) In st a ll oil scr een t o sepa r a t or pla t e (F ig. 340).
(11) In st a ll t wen t y-fou r t r a n sfer pla t e t o va lve
body scr ews (F ig. 342) a n d t or qu e t o 5 N·m (45 in .
lbs.).
Fig. 340 Install Oil Screen

1 - OIL SCREEN
Fig. 342 Install Valve Body to Transfer Plate Screws

1 - SCREW (24)
2 - TRANSFER PLATE
3 - VALVE BODY
(12) In st a ll 2/4 Accu m u la t or com pon en t s a s sh own
in (F ig. 343).

Fig. 345 Install Manual Shaft/Rooster Comb and
1 - VALVE BODY
2 - RETAINER PLATE Transmission Range Sensor
3 - DETENT SPRING 1 - TRANSMISSION RANGE SENSOR
4 - RETURN SPRINGS 2 - MANUAL SHAFT
5 - PISTON 3 - ROOSTER COMB
(13) Tor qu e 2/4 Accu m u la t or r et a in er t o 5 N·m (45

in . lbs.) (F ig. 344).

1 - 2–4 ACCUMULATOR RETAINING PLATE Fig. 346 Install Transmission Range Sensor
2 - DETENT SPRING Retaining Screw
(14) In st a ll Ma n u a l Sh a ft /Roost er Com b a n d 2 - MANUAL VALVE CONTROL PIN
Tr a n sm ission Ra n ge Sen sor (F ig. 345). 3 - RETAINING SCREW
(15) Ma ke su r e Ma n u a l Va lve con t r ol pin is con -
t a in ed wit h in t h e r oost er com b slot (F ig. 346). In st a ll
Tr a n sm ission Ra n ge Sen sor r et a in in g scr ew (F ig.
346) a n d t or qu e t o 5 N·m (45 in . lbs.).
(16) In st a ll m a n u a l sh a ft sea l (F ig. 347).
Fig. 349 Valve Body Attaching Bolts

Fig. 347 Manual Shaft Seal 1 - VALVE BODY ATTACHING BOLTS (18)
1 - SEAL 2 - VALVE BODY
2 - MANUAL SHAFT
(2) In st a ll t r a n sa xle oil filt er (F ig. 350). In spect
INSTALLATION t h e o-r in g a n d r epla ce if n ecessa r y.
NOTE: If valve body assembly is being replaced or

reconditioned, the “Quick-Learn” procedure must
(1) In st a ll va lve body a ssem bly t o t r a n sa xle (F ig.

348). In st a ll a n d t or qu e va lve body-t o-t r a n sa xle ca se
bolt s (F ig. 349) t o 12 N·m (105 in . lbs.).
Fig. 350 Oil Filter

1 - OIL FILTER
2 - O-RING

1 - VALVE BODY
(3) E n su r e t h e t r a n sa xle oil pa n a n d t r a n sa xle
ca se sea lin g su r fa ces a r e clea n a n d dr y. In st a ll a n
1/8” bea d of Mopa r ! Silicon e Ru bber Adh esive Sea l-
a n t t o t h e oil pa n a n d in st a ll (F ig. 351). Tor qu e oil
pa n -t o-t r a n sa xle ca se bolt s (F ig. 352) t o 19 N·m (165
in . lbs.).
Fig. 352 Oil Pan Bolts

(5) Con n ect t r a n sm ission r a n ge sen sor con n ect or.

(6) In st a ll m a n u a l va lve lever t o m a n u a l sh a ft .
(7) In st a ll gea r sh ift ca ble t o m a n u a l va lve lever.
Fig. 351 Oil Pan (8) Con n ect ba t t er y n ega t ive ca ble.
(9) F ill t r a n sa xle wit h Mopa r ! ATF +4 Tr a n sm is-
1 - OIL PAN
2 - 1/8 INCH BEAD OF RTV SEALANT sion flu id. (Refer t o 21 - TRANSMISSION/TRANS-
3 - OIL FILTER AXLE /AUTOMATIC - 41TE /F LUID - STANDARD
P ROCE DURE )
(4) Lower veh icle.
4 1 T E AU T OM AT I C T RAN SAX LE
TABLE OF CONTENTS
page page
41TE AUTOMATIC TRANSAXLE INPUT CLUTCH ASSEMBLY

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 147 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 237
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 149 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
DIAGNOSIS AND TESTING OIL PUMP
DIAGNOSIS AND TESTING - 4XTE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 261
TRANSAXLE GENERAL DIAGNOSIS . . . . . . 149 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 261
DIAGNOSIS AND TESTING - ROAD TEST . . 150 DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 261
DIAGNOSIS AND TESTING - HYDRAULIC ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 263
PRESSURE TESTS . . . . . . . . . . . . . . . . . . . 150 PLANETARY GEARTRAIN
DIAGNOSIS AND TESTING - CLUTCH AIR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 263
PRESSURE TESTS . . . . . . . . . . . . . . . . . . . 153 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 263
DIAGNOSIS AND TESTING - TORQUE SEAL - OIL PUMP
CONVERTER HOUSING FLUID LEAKAGE . . 154 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 264
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 157 SHIFT INTERLOCK SOLENOID
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 174 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 264
SCHEMATICS AND DIAGRAMS DIAGNOSIS AND TESTING - BRAKE/
4XTE TRANSAXLE HYDRAULIC TRANSMISSION SHIFT INTERLOCK
SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . 199 SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . 266
SPECIFICATIONS - 41TE TRANSAXLE . . . . . . 211 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
SPECIAL TOOLS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 267
41TE AUTOMATIC TRANSAXLE . . . . . . . . . 213 SOLENOID/PRESSURE SWITCH ASSY
ACCUMULATOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 268
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 218 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 268
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 218 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
DRIVING CLUTCHES INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 270
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 219 SPEED SENSOR - INPUT
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 219 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 271
FINAL DRIVE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 271
DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 220 SPEED SENSOR - OUTPUT
ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 224 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 273
ADJUSTMENTS OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 273
ADJUSTMENT - DIFFERENTIAL BEARING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
PRELOAD . . . . . . . . . . . . . . . . . . . . . . . . . . 228 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 274
FLUID TORQUE CONVERTER
STANDARD PROCEDURE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 275
FLUID LEVEL AND CONDITION CHECK . . . 230 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 278
STANDARD PROCEDURE - FLUID AND REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . 231 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 280
GEAR SHIFT CABLE TRANSMISSION CONTROL RELAY
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 281
ADJUSTMENTS TRANSMISSION RANGE SENSOR
GEARSHIFT CABLE ADJUSTMENT . . . . . . . 235 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 281
HOLDING CLUTCHES OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 282
VALVE BODY DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 286

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 283 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
4 1 T E AU T OM AT I C • Solen oid/P r essu r e swit ch a ssem bly

• In t egr a l differ en t ia l a ssem bly
T RAN SAX LE Con t r ol of t h e t r a n sa xle is a ccom plish ed by fu lly
a da pt ive elect r on ics. Opt im u m sh ift sch edu lin g is
DESCRIPTION a ccom plish ed t h r ou gh con t in u ou s r ea l-t im e sen sor
Th e 41TE (F ig. 1) is a fou r-speed t r a n sa xle t h a t is feedba ck in for m a t ion pr ovided t o t h e P ower t r a in
a con ven t ion a l h ydr a u lic/m ech a n ica l a ssem bly wit h Con t r ol Modu le (P CM) or Tr a n sm ission Con t r ol Mod-
a n in t egr a l differ en t ia l, a n d is con t r olled wit h a da p- u le (TCM).
t ive elect r on ic con t r ols a n d m on it or s. Th e h ydr a u lic Th e P CM/TCM is t h e h ea r t of t h e elect r on ic con t r ol
syst em of t h e t r a n sa xle con sist s of t h e t r a n sa xle syst em a n d r elies on in for m a t ion fr om va r iou s dir ect
flu id, flu id pa ssa ges, h ydr a u lic va lves, a n d va r iou s a n d in dir ect in pu t s (sen sor s, swit ch es, et c.) t o det er-
lin e pr essu r e con t r ol com pon en t s. An in pu t clu t ch m in e dr iver dem a n d a n d veh icle oper a t in g con di-
a ssem bly wh ich h ou ses t h e u n der dr ive, over dr ive, t ion s. Wit h t h is in for m a t ion , t h e P CM/TCM ca n
a n d r ever se clu t ch es is u sed. It a lso u t ilizes sepa r a t e ca lcu la t e a n d per for m t im ely a n d qu a lit y sh ift s
h oldin g clu t ch es: 2n d/4t h gea r a n d Low/Rever se. Th e t h r ou gh va r iou s ou t pu t or con t r ol devices (solen oid
pr im a r y m ech a n ica l com pon en t s of t h e t r a n sa xle con - pa ck, t r a n sm ission con t r ol r ela y, et c.).
sist of t h e followin g: Th e P CM/TCM a lso per for m s cer t a in self-dia gn os-
• Th r ee m u lt iple disc in pu t clu t ch es t ic fu n ct ion s a n d pr ovides com pr eh en sive in for m a t ion
• Two m u lt iple disc h oldin g clu t ch es (sen sor da t a , DTC’s, et c.) wh ich is h elpfu l in pr oper
• F ou r h ydr a u lic a ccu m u la t or s dia gn osis a n d r epa ir. Th is in for m a t ion ca n be viewed
• Two pla n et a r y gea r set s wit h t h e DRB sca n t ool.
• H ydr a u lic oil pu m p
• Va lve body
Fig. 1 41TE Automatic Transaxle

1 - TRANSAXLE CASE 7 - REVERSE CLUTCH 13 - OUTPUT SHAFT GEAR
2 - TORQUE CONVERTER 8 - FRONT PLANET CARRIER 14 - TRANSFER SHAFT GEAR
3 - OIL PUMP 9 - 2/4 CLUTCH 15 - TRANSFER SHAFT
4 - INPUT SPEED SENSOR 10 - L/R CLUTCH 16 - DIFFERENTIAL
5 - UNDERDRIVE CLUTCH 11 - OUTPUT SPEED SENSOR 17 - CONVERTER DRIVE PLATE
6 - OVERDRIVE CLUTCH 12 - REAR PLANET CARRIER/OUTPUT 18 - INPUT SHAFT
SHAFT
TRANSAXLE IDENTIFICATION
Th e 41TE t r a n sa xle is iden t ified by a ba r code la bel
t h a t is fixed t o t h e t r a n sa xle ca se a s sh own in (F ig.
2).
Fig. 3 Identification Label Breakdown

1 - T=TRACEABILITY
2 - SUPPLIER CODE (PK=KOKOMO)
Fig. 2 Transaxle Identification Label 3 - COMPONENT CODE (TK=KOKOMO TRANSMISSION)
1 - IDENTIFICATION LABEL 4 - BUILD DAY (344=DEC. 9)
5 - BUILD YEAR (9=1999)
6 - LINE/SHIFT CODE (3=3RD SHIFT)
Th e la bel con t a in s a ser ies of digit s t h a t ca n be 7 - BUILD SEQUENCE NUMBER
t r a n sla t ed in t o u sefu l in for m a t ion su ch a s t r a n sa xle 8 - LAST THREE OF P/N
9 - ALPHA
pa r t n u m ber, da t e of m a n u fa ct u r e, m a n u fa ct u r in g 10 - TRANSAXLE PART NUMBER
or igin , pla n t sh ift n u m ber, bu ild sequ en ce n u m ber, 11 - P=PART NUMBER
et c. Refer t o (F ig. 3) for iden t ifica t ion la bel br ea k-
down . DI AGN OSI S AN D T EST I N G
If t h e t a g is n ot legible or m issin g, t h e “P K” n u m -
ber, wh ich is st a m ped in t o t h e t r a n sa xle ca se beh in d DIAGNOSIS AND TESTING - 4XTE TRANSAXLE
t h e t r a n sfer gea r cover, ca n be r efer r ed t o for iden t i-
fica t ion . Th is n u m ber differ s sligh t ly in t h a t it con -
GENERAL DIAGNOSIS
t a in s t h e en t ir e t r a n sa xle pa r t n u m ber, r a t h er t h a n NOTE: Before attempting any repair on a 4XTE four-
t h e la st t h r ee digit s. speed automatic transaxle, check for diagnostic trou-
ble codes (DTC’s) using the DRB scan tool. Refer to
OPERATION the Transmission Diagnostic Procedures Manual.
Tr a n sm ission ou t pu t is dir ect ed t o a n in t egr a l dif-
fer en t ia l by a t r a n sfer gea r syst em in t h e followin g Tr a n sa xle m a lfu n ct ion s m a y be ca u sed by t h ese
in pu t -t o-ou t pu t r a t ios: gen er a l con dit ion s:
• P oor en gin e per for m a n ce
F ir st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.84 : 1 • Im pr oper a dju st m en t s
Secon d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.57 : 1 • H ydr a u lic m a lfu n ct ion s
Th ir d . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.00 : 1 • Mech a n ica l m a lfu n ct ion s
Over dr ive . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.69 : 1 • E lect r on ic m a lfu n ct ion s
Rever se . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21 : 1 Dia gn osis of t h ese pr oblem s sh ou ld a lwa ys begin
by ch eckin g t h e ea sily a ccessible va r ia bles: flu id level
a n d con dit ion , gea r sh ift ca ble a dju st m en t . Th en per-
for m a r oa d t est t o det er m in e if t h e pr oblem h a s been
cor r ect ed or t h a t m or e dia gn osis is n ecessa r y. If t h e
pr oblem per sist s a ft er t h e pr elim in a r y t est s a n d cor-
r ect ion s a r e com plet ed, h ydr a u lic pr essu r e ch ecks
sh ou ld be per for m ed.
DIAGNOSIS AND TESTING - ROAD TEST h a ve seized. Bot h of t h ese st a t or defect s r equ ir e
P r ior t o per for m in g a r oa d t est , ver ify t h a t t h e r epla cem en t of t h e t or qu e con ver t er a n d t h or ou gh
flu id level, flu id con dit ion , a n d lin ka ge a dju st m en t t r a n sa xle clea n in g.
h a ve been a ppr oved. Slippin g clu t ch es ca n be isola t ed by com pa r in g t h e
Du r in g t h e r oa d t est , t h e t r a n sa xle sh ou ld be oper- “E lem en t s in Use” ch a r t wit h clu t ch oper a t ion
a t ed in ea ch posit ion t o ch eck for slippin g a n d a n y en cou n t er ed on a r oa d t est . Th is ch a r t iden t ifies
va r ia t ion in sh ift in g. wh ich clu t ch es a r e a pplied a t ea ch posit ion of t h e
If t h e veh icle oper a t es pr oper ly a t h igh wa y speeds, select or lever.
bu t h a s poor a cceler a t ion , t h e con ver t er st a t or over- A slippin g clu t ch m a y a lso set a DTC a n d ca n be
r u n n in g clu t ch m a y be slippin g. If a cceler a t ion is n or- det er m in ed by oper a t in g t h e t r a n sa xle in a ll select or
m a l, bu t h igh t h r ot t le open in g is n eeded t o m a in t a in posit ion s.
h igh wa y speeds, t h e con ver t er st a t or clu t ch m a y
ELEM EN T S I N U SE AT EACH POSI T I ON OF SELECT OR LEV ER
Shift Lever INPUT CLUTCHES HOLDING CLUTCHES

Position Underdrive Overdrive Reverse 2/4 Low/Reverse
P - PARK X
R - REVERSE X X
N - NEUTRAL X
OD -
OVERDRIVE
First X X
Second X X
Direct X X
Overdrive X X
D - DRIVE*
First X X
Second X X
Direct X X
L - LOW*
First X X
Second X X
Direct X X
* Vehicle upshift and downshift speeds are increased when in these selector positions.
Th e pr ocess of elim in a t ion ca n be u sed t o det ect Befor e per for m in g pr essu r e t est s, be cer t a in t h a t
a n y u n it wh ich slips a n d t o con fir m pr oper oper a t ion flu id level a n d con dit ion , a n d sh ift ca ble a dju st m en t s
of good u n it s. Roa d t est a n a lysis ca n dia gn ose slip- h a ve been ch ecked a n d a ppr oved. F lu id m u st be a t
pin g u n it s, bu t t h e ca u se of t h e m a lfu n ct ion ca n n ot oper a t in g t em per a t u r e (150 t o 200 degr ees F.).
be det er m in ed. P r a ct ica lly a n y con dit ion ca n be In st a ll a n en gin e t a ch om et er, r a ise veh icle on h oist
ca u sed by lea kin g h ydr a u lic cir cu it s or st ickin g wh ich a llows fr on t wh eels t o t u r n , a n d posit ion
va lves. t a ch om et er so it ca n be r ea d.
DIAGNOSIS AND TESTING - HYDRAULIC

PRESSURE TESTS
P r essu r e t est in g is a ver y im por t a n t st ep in t h e
dia gn ost ic pr ocedu r e. Th ese t est s u su a lly r evea l t h e
ca u se of m ost h ydr a u lic t r a n sa xle pr oblem s.
At t a ch 300 psi ga u ge (C-3293SP ) t o por t (s) (1) At t a ch ga u ge t o t h e u n der dr ive clu t ch t a p.
r equ ir ed for t est (s) bein g con du ct ed. Use a da pt er set (2) Move select or lever t o t h e (OD) posit ion .
L-4559 t o a da pt ga u ge(s) t o t r a n sa xle. (3) Allow wh eels t o r ot a t e fr eely a n d in cr ea se
Test por t loca t ion s a r e sh own in (F ig. 4). t h r ot t le open in g t o a ch ieve a n in dica t ed speed of 40
m ph .
(4) Un der dr ive clu t ch pr essu r e sh ou ld r ea d below
5 psi. If n ot , t h en eit h er t h e solen oid a ssem bly or
P CM/TCM is a t fa u lt .
TEST THREE-OVERDRIVE CLUTCH CHECK (3rd and

2nd Gear)
(1) At t a ch ga u ge t o t h e over dr ive clu t ch t a p.
(3) Allow veh icle wh eels t o t u r n a n d in cr ea se
of 20 m ph . Veh icle sh ou ld be in 3r d gea r.
(4) Over dr ive clu t ch pr essu r e sh ou ld r ea d 74 t o 95
psi.
(5) Move select or lever t o t h e (3) posit ion a n d
in cr ea se in dica t ed veh icle speed t o 30 m ph .
Fig. 4 Pressure Taps
(6) Th e veh icle sh ou ld be in secon d gea r a n d over-
1 - OVERDRIVE CLUTCH dr ive clu t ch pr essu r e sh ou ld be less t h a n 5 psi.
2 - TORQUE CONVERTER OFF
3 - LOW/REVERSE CLUTCH (7) Th is t est ch ecks t h e over dr ive clu t ch h ydr a u lic
4 - 2/4 CLUTCH cir cu it a s well a s t h e sh ift sch edu le.
5 - REVERSE CLUTCH
TEST FOUR-SELECTOR IN OVERDRIVE (4th Gear)
TEST ONE-SELECTOR IN LOW (1st GEAR) (1) At t a ch ga u ge t o t h e 2/4 clu t ch t a p.
(1) At t a ch pr essu r e ga u ge t o t h e low/r ever se clu t ch (2) Move select or lever t o t h e (OD) posit ion .
t a p. (3) Allow veh icle fr on t wh eels t o t u r n a n d in cr ea se
(2) Move select or lever t o t h e (L) posit ion . t h r ot t le open in g t o a ch ieve a n in dica t ed veh icle speed
(3) Allow veh icle wh eels t o t u r n a n d in cr ea se of 30 m ph . Veh icle sh ou ld be in 4t h gea r.
t h r ot t le open in g t o a ch ieve a n in dica t ed veh icle speed (4) Th e 2/4 clu t ch pr essu r e sh ou ld r ea d 75 t o 95
t o 20 m ph . psi.
(4) Low/r ever se clu t ch pr essu r e sh ou ld r ea d 115 t o (5) Th is t est ch ecks t h e 2/4 clu t ch h ydr a u lic cir-
145 psi. cu it .
(5) Th is t est ch ecks pu m p ou t pu t , pr essu r e r egu la -
t ion a n d con dit ion of t h e low/r ever se clu t ch h ydr a u lic
TEST FIVE-SELECTOR IN OVERDRIVE (4th Gear-CC
cir cu it a n d sh ift sch edu le. on)
(1) At t a ch ga u ge t o t h e t or qu e con ver t er clu t ch off
TEST TWO-SELECTOR IN DRIVE (2nd GEAR) pr essu r e t a p.
NOTE: This test checks the underdrive clutch (3) Allow veh icle wh eels t o t u r n a n d in cr ea se
hydraulic circuit as well as the shift schedule. t h r ot t le open in g t o a ch ieve a n in dica t ed veh icle speed
of 50 m ph . Veh icle sh ou ld be in 4t h gea r, CC on .
(1) At t a ch ga u ge t o t h e u n der dr ive clu t ch t a p.
(2) Move select or lever t o t h e 3 posit ion . CAUTION: Both wheels must turn at the same
(3) Allow veh icle wh eels t o t u r n a n d in cr ea se speed.
of 30 m ph . (4) Tor qu e con ver t er clu t ch off pr essu r e sh ou ld be
(4) In secon d gea r t h e u n der dr ive clu t ch pr essu r e less t h a n 5 psi.
sh ou ld r ea d 110 t o 145 psi. (5) Th is t est ch ecks t h e t or qu e con ver t er clu t ch
h ydr a u lic cir cu it .
TEST TWO A–SELECTOR IN OD (4th Gear)
TEST SIX-SELECTOR IN REVERSE
NOTE: This test checks the underdrive clutch (1) At t a ch ga u ges t o t h e r ever se a n d LR clu t ch
hydraulic circuit as well as the shift schedule. t a p.
(2) Move select or lever t o t h e (R) posit ion . (2) Low pr essu r e in a ll posit ion s in dica t es a defec-
(3) Rea d r ever se clu t ch pr essu r e wit h ou t pu t st a - t ive pu m p, a clogged filt er, or a st u ck pr essu r e r egu -
t ion a r y (foot on br a ke) a n d t h r ot t le open ed t o a ch ieve la t or va lve.
1500 r pm . (3) Clu t ch cir cu it lea ks a r e in dica t ed if pr essu r es
(4) Rever se a n d LR clu t ch pr essu r e sh ou ld r ea d do n ot fa ll wit h in t h e specified pr essu r e r a n ge.
165 t o 235 psi. (4) If t h e over dr ive clu t ch pr essu r e is gr ea t er t h a n
(5) Th is t est ch ecks t h e r ever se clu t ch h ydr a u lic 5 psi in St ep 4 of Test Th r ee, a wor n r ea ct ion sh a ft
cir cu it . sea l r in g or a defect ive solen oid a ssem bly is in di-
ca t ed.
TEST RESULT INDICATIONS (5) If t h e u n der dr ive clu t ch pr essu r e is gr ea t er
(1) If pr oper lin e pr essu r e is fou n d in a n y on e t est , t h a n 5 psi in St ep 4 of Test Two A, a defect ive sole-
t h e pu m p a n d pr essu r e r egu la t or a r e wor kin g pr op- n oid a ssem bly or P CM/TCM is t h e ca u se.
er ly.
PRESSU RE CH ECK SPECI FI CAT I ON S
Pressure Taps
Torque
Low/
Gear Selector Underdrive Overdrive Reverse Converter 2/4
Actual Gear Reverse
Position Clutch Clutch Clutch Clutch Clutch
Clutch
Off
Park *
PARK 0-2 0-5 0-2 60-110 0-2 115-145
0 mph
REVERSE *
REVERSE 0-2 0-7 165-235 50-100 0-2 165-235
0 mph
NEUTRAL *
NEUTRAL 0-2 0-5 0-2 60-110 0-2 115-145
0 mph
L #
FIRST 110-145 0-5 0-2 60-110 0-2 115-145
20 mph
3 #
SECOND 110-145 0-5 0-2 60-110 115-145 0-2
30 mph
3 #
DIRECT 75-95 75-95 0-2 60-90 0-2 0-2
45 mph
OD #
OVERDRIVE 0-2 75-95 0-2 60-90 75-95 0-2
30 mph
OD # OVERDRIVE
0-2 75-95 0-2 0-5 75-95 0-2
50 mph WITH TCC
* Engine speed at 1500 rpm
# CAUTION: Both front wheels must be turning at the same speed.
DIAGNOSIS AND TESTING - CLUTCH AIR

PRESSURE TESTS
In oper a t ive clu t ch es ca n be loca t ed u sin g a ser ies
of t est s by su bst it u t in g a ir pr essu r e for flu id pr essu r e
(F ig. 5) (F ig. 6). Th e clu t ch es m a y be t est ed by a pply-
in g a ir pr essu r e t o t h eir r espect ive pa ssa ges. Th e
va lve body m u st be r em oved a n d Tool 6056 in st a lled.
To m a ke a ir pr essu r e t est s, pr oceed a s follows:
NOTE: The compressed air supply must be free of

all dirt and moisture. Use a pressure of 30 psi.
Rem ove oil pa n a n d va lve body. See Va lve body

r em ova l.
Fig. 6 Testing Reverse Clutch

1 - TOOL 6056
2 - AIR NOZZLE
2/4 CLUTCH
Apply a ir pr essu r e t o t h e feed h ole loca t ed on t h e
2/4 clu t ch r et a in er. Look in t h e a r ea wh er e t h e 2/4
pist on con t a ct s t h e fir st sepa r a t or pla t e a n d wa t ch
ca r efu lly for t h e 2/4 pist on t o m ove r ea r wa r d. Th e
pist on sh ou ld r et u r n t o it s or igin a l posit ion a ft er t h e
a ir pr essu r e is r em oved.
LOW/REVERSE CLUTCH
Apply a ir pr essu r e t o t h e low/r ever se clu t ch feed
h ole (r ea r of ca se, bet ween 2 bolt h oles). Th en , look
Fig. 5 Air Pressure Test Plate in t h e a r ea wh er e t h e low/r ever se pist on con t a ct s t h e
1 - TOOL 6056 fir st sepa r a t or pla t e. Wa t ch ca r efu lly for t h e pist on t o
2 - ACCUMULATORS m ove for wa r d. Th e pist on sh ou ld r et u r n t o it s or igi-
n a l posit ion a ft er t h e a ir pr essu r e is r em oved.
OVERDRIVE CLUTCH
Apply a ir pr essu r e t o t h e over dr ive clu t ch a pply UNDERDRIVE CLUTCH
pa ssa ge a n d wa t ch for t h e pu sh /pu ll pist on t o m ove Beca u se t h is clu t ch pist on ca n n ot be seen , it s oper-
for wa r d. Th e pist on sh ou ld r et u r n t o it s st a r t in g a t ion is ch ecked by fu n ct ion . Air pr essu r e is a pplied
posit ion wh en t h e a ir pr essu r e is r em oved. t o t h e low/r ever se a n d t h e 2/4 clu t ch es. Th is locks t h e
ou t pu t sh a ft . Use a piece of r u bber h ose wr a pped
REVERSE CLUTCH a r ou n d t h e in pu t sh a ft a n d a pa ir of cla m p-on plier s
Apply a ir pr essu r e t o t h e r ever se clu t ch a pply pa s- t o t u r n t h e in pu t sh a ft . Next a pply a ir pr essu r e t o
sa ge a n d wa t ch for t h e pu sh /pu ll pist on t o m ove r ea r- t h e u n der dr ive clu t ch . Th e in pu t sh a ft sh ou ld n ot
wa r d. Th e pist on sh ou ld r et u r n t o it s st a r t in g r ot a t e wit h h a n d t or qu e. Relea se t h e a ir pr essu r e
posit ion wh en t h e a ir pr essu r e is r em oved. a n d con fir m t h a t t h e in pu t sh a ft will r ot a t e.
DIAGNOSIS AND TESTING - TORQUE

CONVERTER HOUSING FLUID LEAKAGE
Wh en dia gn osin g con ver t er h ou sin g flu id lea ks,
t h r ee a ct ion s m u st be t a ken befor e r epa ir :
(1) Ver ify pr oper t r a n sm ission flu id level.
(2) Ver ify t h a t t h e lea k or igin a t es fr om t h e con -
ver t er h ou sin g a r ea a n d is t r a n sm ission flu id.
(3) Det er m in e t h e t r u e sou r ce of t h e lea k.
F lu id lea ka ge a t or a r ou n d t h e t or qu e con ver t er a r ea
m a y or igin a t e fr om a n en gin e oil lea k (F ig. 7). Th e a r ea
sh ou ld be exa m in ed closely. F a ct or y fill flu id is r ed a n d,
t h er efor e, ca n be dist in gu ish ed fr om en gin e oil.
Fig. 8 Converter Leak Points - Typical
1 - OUTSIDE DIAMETER WELD
2 - TORQUE CONVERTER HUB WELD
3 - STARTER RING GEAR
4 - LUG
REMOVAL
NOTE: If transaxle assembly is being replaced or
overhauled (clutch and/or seal replacement), it is
necessary to perform the “Quick-Learn” Procedure.
MODULES/TRANSMISSION CONTROL MODULE -
STANDARD PROCEDURE)

(2) Rem ove ba t t er y sh ield (F ig. 9).
Fig. 7 Converter Housing Leak Paths
1 - PUMP SEAL
2 - PUMP VENT
3 - PUMP BOLT
4 - PUMP GASKET
5 - CONVERTER HOUSING
6 - CONVERTER
7 - REAR MAIN SEAL LEAK
Som e su spect ed con ver t er h ou sin g flu id lea ks m a y n ot

be lea ks a t a ll. Th ey m a y on ly be t h e r esu lt of r esidu a l
flu id in t h e con ver t er h ou sin g, or excess flu id spilled
du r in g fa ct or y fill, or fill a ft er r epa ir. Con ver t er h ou sin g
lea ks h a ve sever a l pot en t ia l sou r ces. Th r ou gh ca r efu l
obser va t ion , a lea k sou r ce ca n be iden t ified befor e
r em ovin g t h e t r a n sm ission for r epa ir.
P u m p sea l lea ks t en d t o m ove a lon g t h e dr ive h u b
a n d on t o t h e r ea r of t h e con ver t er (F ig. 7). P u m p o-r in g
or pu m p body lea ks follow t h e sa m e pa t h a s a sea l lea k.
P u m p a t t a ch in g bolt lea ks a r e gen er a lly deposit ed on
t h e in side of t h e con ver t er h ou sin g a n d n ot on t h e con -
ver t er it self. P u m p sea l or ga sket lea ks u su a lly t r a vel
down t h e in side of t h e con ver t er h ou sin g (F ig. 7).
TORQUE CONVERTER LEAKAGE Fig. 9 Battery Thermal Guard

P ossible sou r ces of t or qu e con ver t er lea ka ge a r e: 1 - BATTERY THERMOWRAP (IF EQUIPPED)
• Tor qu e con ver t er weld lea ks a t t h e ou t side dia m - 2 - INTEGRATED POWER MODULE
et er weld (F ig. 8).
• Tor qu e con ver t er h u b weld (F ig. 8).
(3) Rem ove coola n t r ecover y bot t le (F ig. 10).
Fig. 11 Component Connector Location—Typical

1 - SOLENOID/PRESSURE SWITCH ASSY. CONNECTOR
Fig. 10 Coolant Recovery Bottle 3 - OUTPUT SPEED SENSOR CONNECTOR
2 - HOSE
3 - BOLT
4 - SUB FRAME RAIL
(4) Rem ove flu id level in dica t or /t u be a ssem bly.

P lu g open in g t o pr even t debr is fr om en t er in g t r a n s-
a xle.
(5) Discon n ect t r a n sa xle oil cooler lin es u sin g Tool
8875A. (Refer t o 7 - COOLING/TRANSMISSION -
STANDARD P ROCE DURE ). In st a ll plu gs t o pr even t
debr is in t r u sion .
(6) Discon n ect in pu t a n d ou t pu t sh a ft speed sen sor
con n ect or s (F ig. 11).
(7) Discon n ect t r a n sm ission r a n ge sen sor (TRS)
(9) Discon n ect gea r sh ift ca ble fr om m a n u a l va lve
lever a n d u pper m ou n t br a cket (F ig. 12).
(10) Discon n ect cr a n ksh a ft posit ion sen sor (if
equ ipped). Rem ove sen sor fr om bellh ou sin g.

(11) Reposit ion lea k det ect ion pu m p h a r n ess a n d
h oses.
bolt s (F ig. 13).
(13) Rem ove t r a n sa xle u pper bellh ou sin g-t o-block
bolt s.
(15) Rem ove t r a n sa xle oil pa n a n d dr a in flu id in t o
su it a ble con t a in er.
(16) Rem ove fr on t wh eel/t ir e a ssem blies.
(17) Rem ove left a n d r igh t h a lfsh a ft a ssem blies.
SH AF T - RE MOVAL)
(18) AWD m odels: Rem ove power t r a n sfer u n it .
(Refer t o 21 - TRANSMISSION/TRANSAXLE /
P OWE R TRANSF E R UNIT - RE MOVAL)
lower (h or izon t a l) bolt (F ig. 13).
(20) Rem ove fr on t m ou n t /br a cket a ssem bly.
(21) Rem ove st a r t er m ot or. Fig. 14 Left Mount-to-Bracket
(22) Rem ove la t er a l ben din g br a ce. 1 - BOLT - BRACKET TO FRAME RAIL
(23) Rem ove in spect ion cover. 2 - BOLT - MOUNT TO RAIL THROUGH
(24) Rem ove t or qu e con ver t er-t o-dr ive pla t e bolt s. 3 - BOLT - LEFT MOUNT TO TRANSAXLE
4 - TRANSAXLE
(25) Su ppor t en gin e/t r a n sa xle a ssem bly a t en gin e 5 - MOUNT - LEFT
oil pa n wit h scr ew ja ck a n d wood block. 6 - BRACKET - LEFT MOUNT
(26) P a r t ia lly r em ove left wh eelh ou se spla sh sh ield
t o ga in a ccess t o a n d r em ove u pper m ou n t t h r u -bolt (27) Lower en gin e/t r a n sa xle a ssem bly wit h scr ew
(F ig. 14). ja ck.

1 - BOLT - VERTICAL 3 - BOLT - HORIZONTAL
(28) Obt a in h elper a n d/or t r a n sm ission ja ck. (4) Rem ove oil pa n -t o-ca se bolt s (F ig. 16).
Secu r e t r a n sm ission ja ck t o t r a n sa xle a ssem bly.
(29) Rem ove u pper m ou n t br a cket fr om t r a n sa xle
(F ig. 14).
(30) Rem ove r em a in in g t r a n sa xle bellh ou sin g-t o-
en gin e bolt s.
(31) Rem ove t r a n sa xle a ssem bly fr om veh icle.
DISASSEMBLY
NOTE: If transaxle is being overhauled (clutch
and/or seal replacement) or replaced, it is neces-
sary to perform the PCM/TCM Quick Learn Proce-
dure. (Refer to 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/POWERTRAIN/TRANSMIS-
SION CONTROL MODULE - STANDARD PROCE-
DURE)
Fig. 16 Remove Oil Pan Bolts
NOTE: This procedure does not include final drive 1 - OIL PAN BOLTS (USE RTV UNDER BOLT HEADS)
(differential) disassembly.
(5) Rem ove oil pa n (F ig. 17).
(1) Rem ove in pu t a n d ou t pu t speed sen sor s.
a ssem bly-t o-ca se bolt s.
(3) Rem ove solen oid/pr essu r e swit ch a ssem bly a n d
ga sket (F ig. 15).
Fig. 17 Remove Oil Pan

1 - OIL PAN
2 - 1/8 INCH BEAD OF MOPAR" ATF RTV (MS-GF41)
3 - OIL FILTER

Gasket
2 - GASKET
(6) Rem ove oil filt er (F ig. 18). (9) Usin g a scr ewdr iver, pu sh pa r k r od r oller s
a wa y fr om gu ide br a cket (F ig. 20) a n d r em ove va lve
body a ssem bly (F ig. 21).
Fig. 18 Remove Oil Filter Fig. 20 Push Park Rod Rollers from Guide Bracket
1 - OIL FILTER
2 - SCREWDRIVER
2 - O-RING
(7) Tu r n m a n u a l va lve fu lly clock-wise t o get pa r k

r od in t o posit ion for r em ova l.
(8) Rem ove va lve body-t o-ca se bolt s (F ig. 19).
Fig. 21 Remove Valve Body

1 - VALVE BODY
NOTE: Depending on engine application, some

accumulators will have two springs and others will
have one spring. The springs are color-coded
Fig. 19 Remove Valve Body Attaching Bolts according to application and year. When disassem-
1 - VALVE BODY ATTACHING BOLTS (18) bling, mark accumulator spring location to ease
2 - VALVE BODY assembly.
CAUTION: Do not handle the valve body assembly

from the manual valve. Damage can result.
(10) Rem ove u n der dr ive a n d over dr ive a ccu m u la - (12) Rem ove low/r ever se a ccu m u la t or plu g (F ig.
t or s (F ig. 22). 24).
Fig. 24 Remove Low/Reverse Accumulator Plug

(Cover)
Fig. 22 Underdrive and Overdrive Accumulators 2 - PLUG
2 - UNDERDRIVE PISTON AND SPRING (13) Rem ove low/r ever se a ccu m u la t or pist on u sin g
su it a ble plier s (F ig. 25) (F ig. 26).
(11) Rem ove low/r ever se a ccu m u la t or sn a p r in g
(F ig. 23).
Fig. 23 Remove Low/Reverse Accumulator Snap

Ring Fig. 25 Low/Reverse Accumulator Piston
1 - SNAP RING 1 - ACCUMULATOR PISTON
2 - PLUG
(15) Rem ove oil pu m p-t o-ca se bolt s (F ig. 28).

Fig. 28 Remove Pump Attaching Bolts
1 - PISTON
2 - RETURN SPRINGS 1 - PUMP ATTACHING BOLTS
2 - PUMP HOUSING
(14) Mea su r e in pu t sh a ft en d pla y. P la ce t r a n sa xle
CAUTION: Be sure input speed sensor is removed
so in pu t sh a ft is ver t ica l. Set u p en d pla y set a n d
before removing oil pump.
dia l in dica t or a s sh own in (F ig. 27). In p u t s h a ft e n d
p la y s h o u ld be w ith in 0.13-0.64 m m (0.005-0.025 (16) In st a ll pu ller s Tool C-3752 a s sh own in (F ig.
in .) If ou t side of t h is r a n ge, a #4 t h r u st pla t e ch a n ge 29).
is r equ ir ed. Recor d in dica t or r ea din g for r efer en ce
u pon r ea ssem bly.
Fig. 29 Install Tool C-3752

1 - PULLERS TOOL C-3752
2 - PUMP
Fig. 27 Measure Input Shaft End Play Using End

Play Set 8266
1 - TOOL 8266–8
2 - TOOL 8266–2
3 - TOOL C-3339
(17) Rem ove oil pu m p a ssem bly (F ig. 30) (F ig. 31). (18) Rem ove oil pu m p ga sket (F ig. 32).
Fig. 30 Remove Oil Pump Fig. 32 Remove Oil Pump Gasket

1 - “PUSH IN” ON INPUT SHAFT WHILE REMOVING PUMP 1 - PUMP GASKET
CAUTION: If transaxle failure has occurred, the

cooler bypass valve must be replaced. Do not
re-use or attempt to clean valve.
(19) Rem ove cooler bypa ss va lve (F ig. 33).
Fig. 31 Oil Pump Removed

1 - OIL PUMP
2 - GASKET
Fig. 33 Remove Bypass Valve

(20) Rem ove #1 n eedle bea r in g (F ig. 34). (22) Rem ove #4 t h r u st pla t e (F ig. 36).
Fig. 34 Remove Caged Needle Bearing Fig. 36 No. 4 Thrust Plate

1 - #1 CAGED NEEDLE BEARING 1 - OVERDRIVE SHAFT ASSEMBLY
2 - NOTE: TANGED SIDE OUT 2 - #4 THRUST PLATE (SELECT)
(21) Rem ove in pu t clu t ch a ssem bly (F ig. 35).
(23) Rem ove fr on t su n gea r a ssem bly a n d #4
t h r u st wa sh er (F ig. 37).
Fig. 35 Remove Input Clutch Assembly

2 - #4 THRUST WASHER Fig. 37 Remove Front Sun Gear Assembly
(24) Rem ove fr on t ca r r ier /r ea r a n n u lu s a ssem bly
a n d #6 n eedle bea r in g (F ig. 38).

Fig. 38 Remove Front Carrier and Rear Annulus 2 - REAR SUN GEAR
Assembly
(26) Set u p t ool 5058 a s sh own in (F ig. 41). Com -
2 - FRONT CARRIER AND REAR ANNULUS ASSEMBLY (TWIST pr ess 2/4 clu t ch r et u r n spr in g (ju st en ou gh t o r em ove
AND PULL OR PUSH TO REMOVE OR INSTALL). sn a p r in g) a n d r em ove sn a p r in g.
(25) Rem ove r ea r su n gea r a n d #7 n eedle bea r in g NOTE: Verify that Tool 5058 is centered properly
(F ig. 39). over the 2/4 clutch retainer before compressing. If
necessary, fasten the 5058 bar to the bellhousing
NOTE: The number 7 needle bearing has three anti- flange with any combination of locking pliers and
reversal tabs and is common with the number five bolts to center the tool properly.
and number two position. The orientation should
allow the bearing to seat flat against the rear sun
gear (Fig. 40). A small amount of petrolatum can be
used to hold the bearing to the rear sun gear.
Fig. 41 Remove 2/4 Clutch Retainer Snap Ring

1 - TOOL 5058
2 - SCREWDRIVER
3 - SNAP RING
Fig. 39 Remove Rear Sun Gear
2 - REAR SUN GEAR
NOTE: The 2/4 Clutch Piston has bonded seals (29) Rem ove 2/4 clu t ch pa ck (F ig. 44). Ta g 2/4
which are not individually serviceable. Seal replace- c lu tc h p a c k fo r re a s s e m bly id e n tific a tio n .
(27) Rem ove 2/4 clu t ch r et a in er (F ig. 42).
Fig. 44 Remove 2/4 Clutch Pack

1 - CLUTCH PLATE (4)
2 - CLUTCH DISC (4)
1 - 2/4 CLUTCH RETAINER (30) Rem ove t a per ed sn a p r in g (F ig. 45).
(28) Rem ove 2/4 clu t ch r et u r n spr in g (F ig. 43).
Fig. 45 Remove Tapered Snap Ring

1 - LOW/REVERSE CLUTCH REACTION PLATE
2 - SCREWDRIVER
Fig. 43 Remove 2/4 Clutch Return Spring 3 - LOW/REVERSE TAPERED SNAP RING (TAPERED SIDE UP)
1 - 2/4 CLUTCH RETURN SPRING 4 - OIL PAN FACE
5 - LONG TAB
(31) Rem ove low/r ever se r ea ct ion pla t e (F ig. 46). (33) Rem ove low/r ever se r ea ct ion pla t e sn a p r in g
(F ig. 48).
Fig. 46 Remove Low/Reverse Reaction Plate

1 - LOW/REVERSE REACTION PLATE (FLAT SIDE UP) Fig. 48 Remove Low/Reverse Reaction Plate Snap
Ring
(32) Rem ove on e low/r ever se clu t ch disc (F ig. 47). 1 - SCREWDRIVER
(34) Rem ove low/r ever se clu t ch pa ck (F ig. 49).
Fig. 47 Remove One Disc

Fig. 49 Remove Low/Reverse Clutch Pack

1 - CLUTCH PLATES (5)
2 - CLUTCH DISCS (5)
(35) Rem ove t r a n sfer gea r cover-t o-ca se bolt s (F ig. (37) Usin g Tool 6259, r em ove t r a n sfer sh a ft gea r-
50). t o-sh a ft n u t a n d con ed wa sh er (F ig. 52) (F ig. 53).
Fig. 50 Remove Rear Cover Bolts Fig. 52 Remove Transfer Shaft Gear Nut
1 - REAR COVER BOLTS 1 - TRANSFER SHAFT GEAR
2 - REAR COVER 2 - OUTPUT GEAR
3 - USE SEALANT ON BOLTS 3 - SPECIAL TOOL 6259
(36) Rem ove t r a n sfer gea r cover (F ig. 51).
Fig. 53 Transfer Shaft Gear Nut and Coned Washer

1 - TRANSFER SHAFT
Fig. 51 Remove Rear Cover 2 - LOCK WASHER
3 - NUT
1 - REAR COVER
(38) Usin g t ool L-4407A, r em ove t r a n sfer sh a ft (40) Rem ove bea r in g cu p r et a in er (F ig. 56).
gea r (F ig. 54).
Fig. 56 Remove Bearing Cup Retainer

Fig. 54 Remove Transfer Shaft Gear 1 - ALIGN INDEXING TAB TO SLOT
1 - SPECIAL TOOL L4407-6 2 - BEARING CUP RETAINER
3 - SPECIAL TOOL L4407A (41) Rem ove t r a n sfer gea r bea r in g con e u sin g
set u p sh own in (F ig. 57).
(39) Rem ove t r a n sfer gea r sh im (select ) (F ig. 55).
Fig. 57 Remove Transfer Gear Bearing Cone

Fig. 55 Remove Transfer Shaft Gear and (Select)
1 - WRENCHES
Shim 2 - TOOL 5048 WITH JAWS TOOL 5048–4 AND BUTTON TOOL
1 - TRANSFER SHAFT GEAR L-4539–2
2 - BEARING CUP RETAINER 3 - TRANSFER SHAFT GEAR
3 - SHIM (SELECT)
(42) Rem ove t r a n sfer sh a ft bea r in g cu p fr om (44) Usin g t ool 5049A, r em ove t r a n sfer sh a ft fr om
r et a in er u sin g Tool 6062 (F ig. 58). t r a n sa xle (F ig. 60).
Fig. 58 Remove Transfer Shaft Bearing Cup Fig. 60 Remove Transfer Shaft
1 - WRENCHES 1 - SPECIAL TOOL 5049–A
2 - TOOL 6062 2 - TRANSFER SHAFT
3 - TRANSFER SHAFT BEARING CUP RETAINER 3 - OUTPUT GEAR
(43) Usin g Tool 6051, r em ove t r a n sfer sh a ft bea r- (45) Slip bea r in g cu p r et a in er a n d oil ba ffle off of
in g sn a p r in g (F ig. 59). sh a ft (F ig. 61).
Fig. 59 Remove Transfer Shaft Bearing Snap Ring

Fig. 61 Bearing Cup Removed
2 - TRANSFER SHAFT BEARING SNAP RING 1 - BEARING CUP
3 - TRANSFER SHAFT 2 - BEARING CONE
3 - TRANSFER SHAFT
4 - OIL BAFFLE
5 - O-RING
(46) Usin g t ool P -334, pr ess t r a n sfer sh a ft bea r in g (49) Rem ove st ir r u p a n d st r a p (F ig. 64).
con e off of sh a ft (F ig. 62).
Fig. 64 Remove Stirrup Strap

Fig. 62 Remove Transfer Shaft Bearing Cone 1 - OUTPUT GEARBOLT
2 - RETAINING STRAP
1 - ARBOR PRESS RAM 3 - STIRRUP
2 - TRANSFER SHAFT
3 - TOOL P-334
4 - BEARING CONE (50) Usin g Tool 6259 (F ig. 65), r em ove ou t pu t sh a ft
gea r-t o-sh a ft bolt a n d wa sh er (F ig. 66).
(47) Ben d ou t pu t gea r r et a in in g st r a p ea r s fla t t o
a llow bolt r em ova l.
(48) Rem ove ou t pu t sh a ft st ir r u p st r a p bolt s (F ig.
63).
Fig. 65 Remove Output Gear Bolt

1 - OUTPUT GEAR
2 - TOOL 6259
Fig. 63 Remove Strap Bolts

1 - RETAINING STRAP
2 - STIRRUP
(52) Rem ove ou t pu t gea r bea r in g sh im (select )
(F ig. 68).

1 - OUTPUT GEAR
2 - BOLT
3 - CONED LOCK WASHER Fig. 68 Output Gear and (Select) Shim
(51) Usin g Tool L4407A, a n d bu t t on 6055, r em ove 2 - SHIM (SELECT)
3 - OUTPUT GEAR
ou t pu t gea r fr om sh a ft (F ig. 67).
(53) Usin g set u p a s sh own in (F ig. 69), r em ove
ou t pu t gea r bea r in g con e.
Fig. 67 Remove Output Gear

1 - OUTPUT GEAR
2 - BUTTON TOOL 6055 Fig. 69 Remove Bearing Cone
3 - WRENCHES
1 - TOOL 5048 WITH JAWS 5048–5 AND BUTTON L-4539–2
4 - TOOL L4407A
2 - WRENCHES
5 - BOLTS TOOL L4407–6
3 - OUTPUT GEAR
(54) Rem ove r ea r ca r r ier a ssem bly fr om t r a n sa xle (56) In st a ll low/r ever se spr in g com pr essor t ool a s
(F ig. 70). sh own in (F ig. 72) (F ig. 73).
Fig. 70 Remove Rear Carrier Assembly Fig. 72 Low/Reverse Spring Compressor Tool
1 - REAR CARRIER ASSEMBLY 1 - TOOL 6057
2 - TOOL 5059
(55) Rem ove r ea r ca r r ier a ssem bly bea r in g con e 3 - TOOL 5058–3
u sin g set u p sh own in (F ig. 71).

Fig. 71 Remove Rear Carrier Bearing Cone 1 - LOW/REVERSE CLUTCH RETURN SPRING
1 - TOOL 5048 WITH JAWS 5048–3 AND BUTTON 6055 2 - SNAP RING (INSTALL AS SHOWN)
2 - WRENCHES 3 - TOOL 6057
3 - REAR CARRIER ASSEMBLY 4 - TOOL 5059
5 - TOOL 5058–3
(57) Com pr ess low/r ever se pist on r et u r n spr in g (59) Usin g a su it a ble pu n ch , dr ive ou t pa r k gu ide
a n d r em ove sn a p r in g (F ig. 74). br a cket pivot sh a ft plu g (F ig. 76).
Fig. 74 Remove Snap Ring Fig. 76 Remove Anchor Shaft and Plug
1 - SNAP RING OPENING MUST BE BETWEEN SPRING LEVERS 1 - GUIDE BRACKET ANCHOR SHAFT
(AS SHOWN) 2 - PIVOT SHAFT
2 - SNAP RING PLIERS 3 - ANCHOR SHAFT PLUG
3 - TOOL 6057
(60) Usin g or din a r y plier s, r em ove pivot sh a ft a n d
(58) Rem ove low/r ever se spr in g com pr essor t ool
gu ide br a cket a ssem bly (F ig. 77).
a n d low r ever se pist on r et u r n spr in g (F ig. 75).
Fig. 75 Low/Reverse Piston Return Spring Fig. 77 Pivot Shaft and Guide Bracket
1 - LOW/REVERSE PISTON RETURN SPRING 1 - ANTIRACHET SPRING
2 - PISTON 2 - GUIDE BRACKET
3 - PIVOT SHAFT
4 - PAWL
(61) In spect gu ide br a cket com pon en t s for exces- (63) Rem ove low/r ever se pist on r et a in er-t o-ca se
sive wea r a n d r epla ce if n ecessa r y (F ig. 78). scr ews (F ig. 80).
Fig. 80 Remove Piston Retainer Attaching Screws

2 - SCREWDRIVER
3 - TORX-LOC SCREWS
1 - ANTIRATCHET SPRING (64) Rem ove low/r ever se pist on r et a in er (F ig. 81).
2 - GUIDE BRACKET
3 - SPLIT SLEEVE
4 - SPACER
5 - PAWL
6 - STEPPED SPACER
NOTE: The Low/Reverse Clutch Piston has bonded

assembly.
(62) Rem ove low/r ever se clu t ch pist on (F ig. 79).
Fig. 81 Remove Piston Retainer

2 - GASKET
Fig. 79 Remove Low/Reverse Clutch Piston

2 - BONDED SEAL
3 - BONDED SEAL
ga sket (F ig. 82).
Fig. 84 Remove Output Bearing Outer Cup

1 - TOOL 6062
Fig. 82 Remove Piston Retainer Gasket
1 - GASKET HOLES MUST LINE UP NOTE: If transaxle is being overhauled (clutch
and/or seal replacement), the TCM/PCM Quick Learn
(66) Usin g a h a m m er a n d su it a ble dr ift , dr ive ou t procedure must be performed. (Refer to 8 - ELEC-
in n er ou t pu t bea r in g cu p (F ig. 83). TRICAL/ELECTRONIC CONTROL MODULES/TRANS-
PROCEDURE)
(1) In st a ll bot h ou t pu t bea r in g cu ps u sin g Tool

5050 (F ig. 85).
Fig. 83 Remove Output Bearing Inner Cup

1 - OUTPUT BEARING CUPS (REPLACE IN PAIRS)
2 - HAMMER
3 - BRASS DRIFT
(67) Usin g t ool 6062, r em ove ou t er ou t pu t bea r in g Fig. 85 Install Both Output Bearing Cups
cu p (F ig. 84). 1 - OUTPUT BEARING CUPS
2 - WRENCHES
3 - TOOL 5050
ASSEMBLY
(2) In st a ll low/r ever se pist on r et a in er ga sket (F ig. (4) In st a ll low/r ever se pist on r et a in er-t o-ca se bolt s
86). Ma ke su r e ga sket h oles lin e u p wit h ca se. (F ig. 88) a n d t or qu e t o 5 N·m (45 in . lbs.).
Fig. 86 Install Piston Retainer Gasket Fig. 88 Install Piston Retainer Attaching Screws
1 - GASKET HOLES MUST LINE UP 1 - LOW/REVERSE CLUTCH PISTON RETAINER
2 - LOW/REVERSE CLUTCH PISTON RETAINER GASKET 2 - SCREWDRIVER
3 - TORX-LOC SCREWS
(3) In st a ll low/r ever se pist on r et a in er (F ig. 87).
NOTE: The Low/Reverse Clutch Piston has bonded
assembly.
(5) In st a ll low/r ever se clu t ch pist on (F ig. 89).
Fig. 87 Install Piston Retainer

2 - GASKET
Fig. 89 Install Low/Reverse Clutch Piston

2 - BONDED SEAL
3 - BONDED SEAL
(6) Assem ble pa r k gu ide br a cket a ssem bly (F ig. (7) In st a ll gu ide br a cket in t o posit ion a n d in ser t
91) (F ig. 90). pivot sh a ft (F ig. 92).
Fig. 92 Pivot Shaft and Guide Bracket

2 - GUIDE BRACKET
Fig. 90 Guide Bracket Disassembled 3 - PIVOT SHAFT
4 - PAWL
1 - ANTIRATCHET SPRING
2 - GUIDE BRACKET
3 - SPLIT SLEEVE
(8) In st a ll a n ch or sh a ft a n d plu g (F ig. 93). Ma ke
4 - SPACER su r e gu ide br a cket a n d split sleeve a r e in con t a ct
5 - PAWL wit h t h e r ea r of t h e t r a n sa xle ca se.
6 - STEPPED SPACER
Fig. 93 Install Anchor Shaft and Plug

Fig. 91 Guide Bracket
1 - GUIDE BRACKET 2 - PIVOT SHAFT
2 - ANTIRATCHET SPRING (MUST BE ASSEMBLED AS SHOWN) 3 - ANCHOR SHAFT PLUG
3 - PAWL
(9) In st a ll low/r ever se pist on r et u r n spr in g (F ig.
94).

1 - SNAP RING OPENING MUST BE BETWEEN SPRING LEVERS
Fig. 94 Low/Reverse Piston Return Spring (AS SHOWN)
1 - LOW/REVERSE PISTON RETURN SPRING 3 - TOOL 6057
2 - PISTON
(11) In st a ll r ea r ca r r ier bea r in g con e u sin g Tool
(10) In st a ll low/r ever se spr in g com pr essor in t o 6053 (F ig. 97).
posit ion (F ig. 95). Com pr ess low/r ever se pist on a n d
in st a ll sn a p r in g a s sh own in (F ig. 96).
Fig. 97 Install Rear Carrier Bearing Cone

Fig. 95 Compressor Tool in Use 1 - ARBOR PRESS RAM
2 - TOOL 6053
1 - LOW/REVERSE CLUTCH RETURN SPRING 3 - NEW BEARING CONE
2 - SNAP RING (INSTALL AS SHOWN) 4 - REAR CARRIER ASSEMBLY
3 - TOOL 6057
4 - TOOL 5059
5 - TOOL 5058–3
(12) In st a ll r ea r ca r r ier a ssem bly t o t r a n sa xle ca se (d) P u sh a n d pu ll t h e gea r wh ile r ot a t in g ba ck
(F ig. 98). a n d for t h t o en su r e sea t in g of bea r in g r oller s.
(e) Usin g a dia l in dica t or m ou n t ed t o t h e t r a n s-
a xle ca se, m ea su r e ou t pu t gea r en d pla y a s sh own
in (F ig. 100).
(f) Refer t o t h e ou t pu t gea r bea r in g sh im ch a r t
for t h e r equ ir ed sh im t o obt a in pr oper bea r in g set -
t in g.
(g) Use Tool 6259 t o r em ove t h e ou t pu t gea r
r et a in in g bolt a n d wa sh er. To r em ove t h e ou t pu t
gea r, u se Tool L4407A.
(h ) Rem ove t h e ga u gin g sh im a n d in st a ll t h e
pr oper sh im det er m in ed by t h e ch a r t . Use gr ea se
t o h old t h e sh im in pla ce.
Fig. 98 Install Rear Carrier Assembly

(13) In st a ll ou t pu t gea r bea r in g con e u sin g Tool

5052 (F ig. 99).
Fig. 100 Checking Output Gear Bearings End Play

1 - TOOL L-4432
2 - DIAL INDICATOR
3 - SPECIAL SCREWS TOOL 6260
4 - OUTPUT GEAR
Fig. 99 Install Output Gear Bearing Cone

1 - ARBOR PRESS RAM
2 - HANDLE C-4171
3 - TOOL 5052
4 - OUTPUT GEAR
(14) OU TP U T GEAR B EARIN G AD J U S T-

MEN T:
(a ) Wit h ou t pu t gea r r em oved, in st a ll a 4.50 m m
(0.177 in .) ga u gin g sh im (F ig. 101) on t h e r ea r ca r-
r ier a ssem bly h u b, u sin g gr ea se t o h old t h e sh im in
pla ce.
(b) Usin g Tool 6259, in st a ll ou t pu t gea r a n d
bea r in g a ssem bly. Tor qu e t o 271 N·m (200 ft . lbs.). Fig. 101 Output Gear and (Select) Shim
(c) Mea su r e bea r in g en d pla y. At t a ch Tool L-4432 1 - REAR CARRIER ASSEMBLY
t o t h e gea r (F ig. 100). 2 - SHIM (SELECT)
3 - OUTPUT GEAR
OU T PU T GEAR BEARI N G SH I M CH ART
0.05mm 4.42mm 0.53mm 3.94mm
4412830AB 4412818AB
(0.002 in.) (0.174 in.) (0.021 in.) (0.155 in.)
0.08mm 4.38mm 0.56mm 3.90mm
4412829AB 4412817AB
(0.003 in.) (0.172 in.) (0.022 in.) (0.154 in.)
0.10mm 4.38mm 0.58mm 3.90mm
4412829AB 4412817AB
(0.004 in.) (0.172 in.) (0.023 in.) (0.154 in.)
0.13mm 4.34mm 0.61mm 3.86mm
4412828AB 4412816AB
(0.005 in.) (0.171 in.) (0.024 in.) (0.152 in.)
0.15mm 4.30mm 0.64mm 3.82mm
4412827AB 4412815AB
(0.006 in.) (0.169 in.) (0.025 in.) (0.150 in.)
0.18mm 4.30mm 0.66mm 3.82mm
4412827AB 4412815AB
(0.007 in.) (0.169 in.) (0.026 in.) (0.150 in.)
0.20mm 4.26mm 0.69mm 3.78mm
4412826AB 4412814AB
(0.008 in.) (0.168 in.) (0.027 in.) (0.149 in.)
0.23mm 4.22mm 0.71mm 3.74mm
4412825AB 4412813AB
(0.009 in.) (0.166 in.) (0.028 in.) (0.147 in.)
0.25mm 4.22mm 0.74mm 3.74mm
4412825AB 4412813AB
(0.010 in.) (0.166 in.) (0.029 in.) (0.147 in.)
0.28mm 4.18mm 0.76mm 3.70mm
4412824AB 4412812AB
(0.011 in.) (0.165 in.) (0.030 in.) (0.146 in.)
0.30mm 4.14mm 0.79mm 3.66mm
4412823AB 4412811AB
(0.012 in.) (0.163 in.) (0.031 in.) (0.144 in.)
0.33mm 4.14mm 0.81mm 3.66mm
4412823AB 4412811AB
(0.013 in.) (0.163 in.) (0.032 in.) (0.144 in.)
0.36mm 4.10mm 0.84mm 3.62mm
4412822AB 4412810AB
(0.014 in.) (0.161 in.) (0.033 in.) (0.143 in.)
0.38mm 4.10mm 0.86mm 3.62mm
4412822AB 4412810AB
(0.015 in.) (0.161 in.) (0.034 in.) (0.143 in.)
0.41mm 4.06mm 0.89mm 3.58mm
4412821AB 4412809AB
(0.016 in.) (0.160 in.) (0.035 in.) (0.141)
0.43mm 4.02mm 0.91mm 3.54mm
4412820AB 4412808AB
(0.017 in.) (0.158 in.) (0.036in.) (0.139 in.)
0.46mm 4.02mm 0.94mm 3.54mm
4412820AB 4412808AB
(0.018 in.) (0.158 in.) (0.037 in.) (0.139 in.)
0.48mm 3.98mm 0.97mm 3.50mm
4412819AB 4412807AB
(0.019 in.) (0.157 in.) (0.038 in.) (0.138 in.)
0.51mm 3.94mm
4412818AB
(0.020 in.) (0.155 in.)
(15) In st a ll t h e ou t pu t gea r a n d bea r in g a ssem bly
u sin g Tool 6261 (F ig. 102).
Fig. 104 Tighten Output Gear to 271 N•m (200 ft.

lbs.)
Fig. 102 Install Output Gear 1 - OUTPUT GEAR
2 - TORQUE WRENCH
1 - WRENCHES 3 - 200 FT. LBS.
2 - TOOL 6261 WITH STUD 4 - TOOL 6259
3 - OUTPUT GEAR
(17) Usin g a n in ch pou n d t or qu e wr en ch (F ig.
(16) In st a ll NE W ou t pu t gea r r et a in in g bolt a n d 105), ch eck ou t pu t sh a ft t u r n in g t or qu e. Ou tp u t
wa sh er (F ig. 103). Usin g Tool 6259, t or qu e ou t pu t s h a ft tu rn in g to rqu e s h o u ld be w ith in 3-8 in .
gea r r et a in in g bolt t o 271 N·m (200 ft . lbs.) (F ig. lbs . If t h e t u r n in g t or qu e is t oo h igh , in st a ll a 0.04
104). m m (0.0016 in .) t h icker sh im . If t h e t u r n in g t or qu e is
Repea t u n t il t h e pr oper t u r n in g t or qu e of 3-8 in . lbs.
is obt a in ed.

1 - OUTPUT GEAR
2 - BOLT
Fig. 105 Check Output Gear Bearings Turning
Torque
1 - INCH-POUND TORQUE WRENCH
2 - OUTPUT GEAR
(18) In st a ll ou t pu t gea r st ir r u p wit h ser r a t ed side (21) Rot a t e st ir r u p clockwise a ga in st fla t s of
ou t (F ig. 106). r et a in in g bolt (F ig. 108).
Fig. 106 Install Stirrup Fig. 108 Turn Stirrup Clockwise Against Bolt Flats
1 - STIRRUP 1 - RETAINING STRAP
2 - OUTPUT GEAR RETAINING BOLT 2 - STIRRUP
(19) In st a ll r et a in in g st r a p. (22) Tor qu e st ir r u p st r a p bolt s t o 23 N·m (200 in .

(20) In st a ll st r a p bolt s bu t do n ot t igh t en a t t h is lbs.) (F ig. 109).
t im e (F ig. 107).
Fig. 109 Tighten Stirrup Strap Bolts To 23 N·m (200

in.) lbs.)
Fig. 107 Install Strap Bolts
1 - RETAINING STRAP
1 - RETAINING STRAP 2 - STIRRUP
2 - STIRRUP
(23) Ben d t a bs on st r a p u p a ga in st fla t s of bolt s (25) In st a ll bea r in g cu p a n d oil ba ffle t o t r a n sfer
(F ig. 110). sh a ft (F ig. 112).
Fig. 110 Bend Tabs On Strap Up Against Flats Of Fig. 112 Install Bearing Cup to Shaft
Bolts 1 - BEARING CUP
1 - RETAINING STRAP TABS 2 - BEARING CONE
2 - RETAINING STRAP 3 - TRANSFER SHAFT
3 - STIRRUP 4 - OIL BAFFLE
5 - O-RING
(24) In st a ll t r a n sfer sh a ft bea r in g con e u sin g Tool
6052 (F ig. 111). (26) Usin g Tool 5049A, in st a ll t r a n sfer sh a ft (F ig.
113).
Fig. 111 Install Transfer Shaft Bearing Cone

1 - TOOL 6052 Fig. 113 Install Transfer Shaft
2 - NEW BEARING CONE
3 - TRANSFER SHAFT 1 - SPECIAL TOOL 5049–A
4 - ARBOR PRESS RAM 2 - TRANSFER SHAFT
3 - OUTPUT GEAR
(27) Usin g Tool 6051, in st a ll t r a n sfer sh a ft bea r in g (29) In st a ll bea r in g cu p r et a in er t o t r a n sa xle (F ig.
sn a p r in g (F ig. 114). 116).
Fig. 114 Install Transfer Shaft Bearing Snap Ring Fig. 116 Remove Bearing Cup Retainer
1 - ALIGN INDEXING TAB TO SLOT
2 - TRANSFER SHAFT BEARING SNAP RING
2 - BEARING CUP RETAINER
3 - TRANSFER SHAFT
(28) In st a ll t r a n sfer sh a ft bea r in g cu p in t o r et a in er (30) In st a ll t r a n sfer gea r bea r in g con e t o t r a n sfer

u sin g Tool 6061 (F ig. 115). gea r u sin g Tool 5052 (F ig. 117).
Fig. 115 Install Transfer Shaft Bearing Cup Into Fig. 117 Install Transfer Gear Bearing Cone
Retainer 1 - ARBOR PRESS RAM
2 - HANDLE C-4171
1 - ARBOR PRESS RAM 3 - NEW BEARING CONE
2 - HANDLE C-4171 4 - TRANSFER SHAFT GEAR
3 - TOOL 6061 5 - TOOL 5052
4 - TRANSFER SHAFT BEARING CUP RETAINER
5 - USE REMOVED BEARING CUP TO SUPPORT RETAINER
(31) TRAN S F ER GEAR B EARIN G AD J U S T-
MEN T:
(a ) In st a ll a 4.66 m m (0.184 in .) ga u gin g sh im
on t h e t r a n sfer sh a ft (F ig. 118).
(b) In st a ll t r a n sfer sh a ft gea r u sin g Tool 6261.
Usin g Tool 6259, in st a ll t r a n sfer sh a ft gea r r et a in -
in g n u t t o 271 N·m (200 ft . lbs.).
(c) Mea su r e en d pla y. At t a ch Tool L4432 t o t h e
t r a n sfer gea r.
(d) Mou n t a st eel ba ll wit h gr ea se in t o t h e en d
of t h e t r a n sfer sh a ft .
(e) P u sh a n d pu ll t h e gea r wh ile r ot a t in g ba ck
a n d for t h t o en su r e sea t in g of t h e bea r in g r oller s.
(f) Usin g a dia l in dica t or, m ea su r e t r a n sfer sh a ft
en d pla y.
(g) Refer t o t h e t r a n sfer sh a ft bea r in g sh im
ch a r t for t h e r equ ir ed sh im com bin a t ion t o obt a in Fig. 118 Install Transfer Shaft Gear and
t h e pr oper bea r in g set t in g. (Select) Shim
(h ) Use Tool 6259 t o r em ove t h e r et a in in g n u t 1 - TRANSFER SHAFT GEAR
a n d wa sh er. Rem ove t h e t r a n sfer sh a ft gea r u sin g 2 - BEARING CUP RETAINER
Tool L4407A. 3 - SHIM
(SELECT)
(i) Rem ove t h e ga u gin g sh im (F ig. 118) a n d
in st a ll t h e pr oper sh im in dica t ed by t h e ch a r t .
T RAN SFER SH AFT BEARI N G SH I M CH ART
0.05mm 4.66mm 0.76mm 3.94mm
4505588AB 4412818AB
(0.002 in.) (0.183 in.) (0.030 in.) (0.155 in.)
0.08mm 4.62mm 0.79mm 3.90mm
4412835AB 4412817AB
(0.003 in.) (0.182 in.) (0.031 in.) (0.154 in.)
0.10mm 4.58mm 0.81mm 3.90mm
4412834AB 4412817AB
(0.004 in.) (0.180 in.) (0.032 in.) (0.154 in.)
0.13mm 4.58mm 0.84mm 3.86mm
4412834AB 4412816AB
(0.005 in.) (0.180 in.) (0.033 in.) (0.152 in.)
0.15mm 4.54mm 0.86mm 3.82mm
4412833AB 4412815AB
(0.006 in.) (0.178 in.) (0.034 in.) (0.150 in.)
0.18mm 4.50mm 0.89mm 3.82mm
4412832AB 4412815AB
(0.007 in.) (0.177 in.) (0.035 in.) (0.150 in.)
0.20mm 4.50mm 0.91mm 3.78mm
4412832AB 4412814AB
(0.008 in.) (0.177 in.) (0.036 in.) (0.149 in.)
0.23mm 4.46mm 0.94mm 3.74mm
4412831AB 4412813AB
(0.009 in.) (0.175 in.) (0.037 in.) (0.147 in.)
0.25mm 4.46mm 0.97mm 3.74mm
4412831AB 4412813AB
(0.010 in.) (0.175 in.) (0.038 in.) (0.147 in.)
0.28mm 4.42mm 0.99mm 3.70mm
4412830AB 4412812AB
(0.011 in.) (0.174 in.) (0.039 in.) (0.146 in.)
0.30mm 4.38mm 1.02mm 3.66mm
4412829AB 4412811AB
(0.012 in.) (0.172 in.) (0.040 in.) (0.144 in.)
0.33mm 4.38mm 1.04mm 3.66mm
4412829AB 4412811AB
(0.013 in.) (0.172 in.) (0.041 in.) (0.144 in.)
0.36mm 4.34mm 1.07mm 3.62mm
4412828AB 4412810AB
(0.014 in.) (0.171 in.) (0.042 in.) (0.143 in.)
0.38mm 4.30mm 1.08mm 3.62mm
4412827AB 4412810AB
(0.015 in.) (0.169 in.) (0.043 in.) (0.143 in.)
0.41mm 4.30mm 1.12mm 3.58mm
4412827AB 4412809AB
(0.016 in.) (0.169 in.) (0.044 in.) (0.141)
0.43mm 4.26mm 1.14mm 3.54mm
4412826AB 4412808AB
(0.017 in.) (0.168 in.) (0.045 in.) (0.139 in.)
0.46mm 4.22mm 1.17mm 3.54mm
4412825AB 4412808AB
(0.018 in.) (0.166 in.) (0.046 in.) (0.139 in.)
0.48mm 4.22mm 1.19mm 3.50mm
4412825AB 4412807AB
(0.019 in.) (0.166 in.) (0.047 in.) (0.138 in.)
0.50mm 4.18mm 1.22mm 3.46mm
4412824AB 4412806AB
(0.020 in.) (0.165 in.) (0.048 in.) (0.136 in.)
0.53mm 4.18mm 1.24mm 3.46mm
4412824AB 4412806AB
(0.021 in.) (0.165 in.) (0.049 in.) (0.136 in.)
0.56mm 4.14mm 1.27mm 3.42mm
4412823AB 4412805AB
(0.022 in.) (0.163 in.) (0.050 in.) (0.135 in.)
0.58mm 4.10mm 1.30mm 3.38mm
4412822AB 4412804AB
(0.023 in.) (0.161 in.) (0.051 in.) (0.133 in.)
0.61mm 4.10mm 1.32mm 3.38mm
4412822AB 4412804AB
(0.024 in.) (0.161 in.) (0.052 in.) (0.133 in.)
0.64mm 4.06mm 1.35mm 3.34mm
4412821AB 4412803AB
(0.025 in.) (0.160 in.) (0.053 in.) (0.132 in.)
0.66mm 4.02mm 1.37mm 3.34mm
4412820AB 4412803AB
(0.026 in.) (0.158 in.) (0.054 in.) (0.132 in.)
0.69mm 4.02mm 1.40mm 3.30mm
4412820AB 4412802AB
(0.027 in.) (0.158 in.) (0.055 in.) (0.130 in.)
0.71mm 3.98mm 1.45mm 3.26mm
4412819AB 4412801AB
(0.028 in.) (0.157 in.) (0.057 in (0.128 in.)
0.74mm 3.94mm 1.47mm (0.058 2.22mm (0.127
4412818AB 4505570AB
(0.029 in.) (0.155 in.) in.) in.)
(32) In st a ll t h e t r a n sfer sh a ft gea r u sin g Tool 6261 (35) Mea su r e t r a n sfer sh a ft en d pla y. Tra n s fe r
(F ig. 119). s h a ft e n d p la y s h o u ld be w ith in 0.05-0.10 m m
(0.002-0.004 in .). If t h e en d pla y is t oo h igh , in st a ll a
0.04 m m (0.0016 in .) t h icker sh im . If t h e en d pla y is
Repea t u n t il 0.05-0.10 m m (0.002-0.004 in .) en d pla y
is obt a in ed.
(36) In st a ll a bea d of Mopa r ! ATF RTV (MS-GF 41)
t o t r a n sfer gea r cover (F ig. 121).
Fig. 119 Install Transfer Shaft Gear

1 - WRENCHES
3 - OUTPUT GEAR
CAUTION: Install a NEW retaining nut, as the origi-

nal nut MUST NOT be reused.
Fig. 121 Install Rear Cover
(33) In st a ll t h e n ew r et a in in g n u t a n d wa sh er. 1 - REAR COVER
(34) Usin g Tool 6259, t or qu e t r a n sfer gea r r et a in -
in g n u t t o 271 N·m (200 ft . lbs.) (F ig. 120). (37) In st a ll t r a n sfer gea r cover-t o-ca se bolt s a n d
t or qu e t o 20 N·m (175 in . lbs.) t or qu e (F ig. 122).
Fig. 120 Tighten Transfer Gear Nut to 271 N•m (200

ft. lbs.)
Fig. 122 Install Rear Cover Bolts
2 - 200 FT. LBS. 1 - REAR COVER BOLTS
3 - TORQUE WRENCH 2 - REAR COVER
4 - SPECIAL TOOL 6259 3 - USE SEALANT ON BOLTS
(38) In st a ll low/r ever se clu t ch pa ck (F ig. 123). (40) In st a ll r em a in in g low/r ever se clu t ch disc (F ig.
Lea ve u pper m ost disc ou t u n t il sn a p r in g is in st a lled. 125).
Fig. 123 Install Low/Reverse Clutch Pack Fig. 125 Install One Disc
1 - CLUTCH PLATES (5) 1 - ONE DISC FROM LOW/REVERSE CLUTCH
2 - CLUTCH DISCS (5)
(41) In st a ll low/r ever se r ea ct ion pla t e wit h fla t
(39) In st a ll low/r ever se r ea ct ion pla t e fla t sn a p side u p (F ig. 126).
r in g (F ig. 124).
Fig. 126 Install Low/Reverse Reaction Plate

Fig. 124 Install Low/Reverse Reaction Plate Snap 1 - LOW/REVERSE REACTION PLATE (FLAT SIDE UP)
Ring
1 - SCREWDRIVER
(42) In st a ll t a per ed sn a p r in g (wit h t a per ed side
u p) a s sh own in (F ig. 127) (F ig. 128).
Fig. 129 Check Low/Reverse Clutch Clearance

1 - DIAL INDICATOR
3 - HOOK TOOL
LOW/REV ERSE REACT I ON PLAT E CH ART

4799846AA 5.88 mm (0.232 in.)
4799847AA 6.14 mm (0.242 in.)
4799848AA 6.40 mm (0.252 in.)
Fig. 127 Tapered Snap Ring Instructions
4799849AA 6.66 mm (0.262 in.)
4799855AA 6.92 mm (0.273 in.)
(44) In st a ll 2/4 clu t ch pa ck (F ig. 130).
Fig. 128 Snap Ring Installed

1 - SCREWDRIVER
2 - TAPERED SNAP RING (INSTALL AS SHOWN)
(43) Set u p dia l in dica t or a s sh own in (F ig. 129) t o Fig. 130 Install 2/4 Clutch Pack
m ea su r e low/r ever se clu t ch clea r a n ce. P r ess down on 1 - CLUTCH PLATE (4)
clu t ch pa ck wit h fin ger a n d zer o dia l in dica t or. Lo w / 2 - CLUTCH DISC (4)
Re v e rs e c lu tc h p a c k c le a ra n c e is 0.89-1.47 m m
su r em en t in fou r (4) pla ces. Ta ke a ver a ge of r ea din gs
a n d select t h e pr oper low/r ever se r ea ct ion pla t e t o
a ch ieve specifica t ion s.
NOTE: The 2/4 Clutch Piston has bonded seals (46) Usin g t ool 5058, com pr ess 2/4 clu t ch r et u r n
which are not individually serviceable. Seal replace- spr in g ju st en ou gh t o in st a ll sn a p r in g (F ig. 133).
(45) Or ien t 2/4 clu t ch r et u r n spr in g t o r et a in er a s

sh own in (F ig. 131), a n d in st a ll t o t r a n sa xle (F ig.
132).
Fig. 133 Install 2/4 Clutch Retainer Snap Ring

1 - TOOL 5058
2 - SCREWDRIVER
3 - SNAP RING
Fig. 131 Proper Orientation of 2/4 Clutch Retainer

(47) In st a ll sn a p r in g.
and Spring
(48) Set u p dia l in dica t or a s sh own in (F ig. 134)
1 - NOTE POSITION a n d m ea su r e 2/4 clu t ch clea r a n ce. P r ess down on
2 - RETURN SPRING
3 - 2/4 CLUTCH RETAINER clu t ch pa ck wit h fin ger a n d zer o dia l in dica t or. 2/4
c lu tc h pack c le a ra n c e is 0.76-2.64 mm
su r em en t in fou r (4) pla ces. Ta ke a ver a ge of r ea d-
in gs. If clea r a n ce is ou t side t h is r a n ge, t h e clu t ch is
a ssem bled im pr oper ly. Th e re is n o a d ju s tm e n t fo r
2/4 c lu tc h c le a ra n c e .

Fig. 134 Check 2/4 Clutch Clearance

1 - DIAL INDICATOR
2 - HOOK TOOL
(49) In st a ll r ea r su n gea r a n d #7 n eedle bea r in g (50) In st a ll fr on t ca r r ier /r ea r a n n u lu s a ssem bly
(F ig. 136). a n d #6 n eedle bea r in g (F ig. 137).
NOTE: The number seven needle bearing has three

anti-reversal tabs and is common with the number
five and number two position. The orientation
should allow the bearing to seat flat against the
rear sun gear (Fig. 135). A small amount of petrola-
tum can be used to hold the bearing to the rear sun
gear.
Fig. 137 Install Front Carrier and Rear Annulus

Assembly
2 - FRONT CARRIER AND REAR ANNULUS ASSEMBLY (TWIST
AND PULL OR PUSH TO REMOVE OR INSTALL).
(51) In st a ll fr on t su n gea r a ssem bly a n d #4 t h r u st

wa sh er (F ig. 138).

2 - REAR SUN GEAR
Fig. 138 Install Front Sun Gear Assembly

Fig. 136 Install Rear Sun Gear and #7 Needle

Bearing
2 - REAR SUN GEAR
(52) D ETERMIN IN G #4 THRU S T P LATE (f) Mea su r e t h e in pu t sh a ft en d pla y wit h t h e
THICKN ES S / IN P U T S HAF T EN D P LAY: t r a n sa xle in t h e ver t ica l posit ion . In p u t s h a ft e n d
(a ) Select t h e t h in n est #4 t h r u st pla t e t h ickn ess p la y m u s t be w ith in 0.005 to 0.025 in c h . F or
a n d in st a ll t o in pu t clu t ch a ssem bly (F ig. 139). Use exa m ple, if en d pla y r ea din g is 0.055 in ch , select
pet r ola t u m t o r et a in . No. 4 Th r u st P la t e wh ich is 0.071 t o 0.074 t h ick.
(b) In st a ll in pu t clu t ch a ssem bly in t o posit ion a n d Th is sh ou ld pr ovide a n in pu t sh a ft en d pla y r ea d-
ver ify t h a t it is com plet ely sea t ed by viewin g t h r ou gh in g of 0.020 in ch wh ich is wit h in specifica t ion s.
in pu t speed sen sor h ole. If view t h r ou gh in pu t speed (g) Refer t o t h e No. 4 t h r u st pla t e ch a r t t o select
sen sor h ole is n ot a s sh own in (F ig. 140), t h e in pu t t h e pr oper No. 4 t h r u st pla t e:
clu t ch a ssem bly is n ot sea t ed pr oper ly.
(c) Rem ove oil pu m p o-r in g (F ig. 141). B e s u re
to re in s ta ll o il p u m p o -rin g a fte r s e le c tin g th e
p ro p e r #4 th ru s t p la te .
(d) In st a ll pu m p a n d ga sket t o t r a n sm ission .
In st a ll a n d t or qu e bolt s.
(e) Set u p in pu t sh a ft for m ea su r em en t wit h
In dica t or Set C3339 a n d E n d P la y Set 8266 a s
Fig. 141 Remove Oil Pump O-Ring

1 - OIL PUMP ASSEMBLY
2 - O-RING
Fig. 139 Select Thinnest No. 4 Thrust Plate

1 - OVERDRIVE SHAFT ASSEMBLY
Fig. 142 Measure Input Shaft End Play Using End

Play Set 8266
1 - TOOL 8266–8
2 - TOOL 8266–2
Fig. 140 View Through Input Speed Sensor Hole 3 - TOOL C-3339
1 - INPUT CLUTCH RETAINER
2 - INPUT SPEED SENSOR HOLE
3 - OIL COOLER FITTINGS
N O. 4 T H RU ST PLAT E CH ART (54) In st a ll #1 ca ged n eedle bea r in g (F ig. 144).

4431665AB 1.60mm (0.063 in.)
3836237AB 1.73mm (0.068 in.)
4431666AB 1.80mm (0.071 in.)
3836238AB 1.96mm (0.077 in.)
4431667AB 2.03mm (0.080 in.)
3836239AB 2.16mm (0.085 in.)
4431668AB 2.24mm (0.088 in.)
3836240AB 2.39mm (0.094 in.)
4431669AB 2.46mm (0.097 in.)
3836241AB 2.62mm (0.103 in.)
4446670AB 2.67mm (0.105 in.)
4446671AB 2.90mm (0.114 in.) Fig. 144 Install Caged Needle Bearing
1 - #1 CAGED NEEDLE BEARING
2 - NOTE: TANGED SIDE OUT
(53) In st a ll in pu t clu t ch a ssem bly (F ig. 143).
(55) In st a ll cooler bypa ss va lve wit h o-r in g en d

t owa r ds r ea r of ca se (F ig. 145).
Fig. 143 Install Input Clutch Assembly

Fig. 145 Install Cooler Bypass Valve

(56) In st a ll oil pu m p ga sket (F ig. 146). (58) In st a ll oil pu m p-t o-ca se bolt s a n d t or qu e t o 27
N·m (20 ft . lbs.) (F ig. 148).
Fig. 146 Install Oil Pump Gasket Fig. 148 Install Pump-to-Case Bolts
1 - PUMP GASKET 1 - PUMP ATTACHING BOLTS
2 - PUMP HOUSING
(57) In st a ll oil pu m p a ssem bly (F ig. 147).
(59) In st a ll low/r ever se a ccu m u la t or (F ig. 149).
Fig. 147 Install Oil Pump

1 - OIL PUMP
2 - GASKET 1 - PISTON
2 - RETURN SPRINGS
(60) In st a ll low/r ever se a ccu m u la t or plu g (F ig. (62) In st a ll u n der dr ive a n d over dr ive a ccu m u la t or s
150). (F ig. 152).
Fig. 150 Install Low/Reverse Accumulator Plug

(Cover)
2 - PLUG Fig. 152 Underdrive and Overdrive Accumulators
(61) In st a ll low/r ever se a ccu m u la t or sn a p r in g 2 - UNDERDRIVE PISTON AND SPRING
(F ig. 151).
(63) In st a ll va lve body t o t r a n sa xle (F ig. 153).
Rot a t e m a n u a l va lve sh a ft fu lly clockwise t o ea se
in st a lla t ion . Ma ke su r e pa r k r od r oller s a r e posi-
t ion ed wit h in pa r k gu ide br a cket .
Fig. 151 Install Low/Reverse Accumulator Snap

Ring
1 - SNAP RING
2 - PLUG
Fig. 153 Install Valve Body
NOTE: Depending on engine application, some 1 - VALVE BODY
accumulators will have two springs, and others will
have one spring. The springs are color-coded for
application and year.
(64) In st a ll a n d t or qu e va lve body-t o-ca se bolt s t o (66) Apply a n 1/8” bea d of Mopa r ! ATF RTV (MS-
12 N·m (105 in . lbs.) (F ig. 154). GF 41) t o oil pa n a n d im m edia t ely in st a ll t o ca se (F ig.
156).
Fig. 156 Install Oil Pan

1 - OIL PAN
Fig. 154 Install Valve Body-to-Case Bolts 2 - 1/8 INCH BEAD OF MOPAR" ATF RTV (MS-GF41)
3 - OIL FILTER
2 - VALVE BODY
(67) In st a ll oil pa n -t o-ca se bolt s a n d t or qu e t o 19
(65) In st a ll oil filt er a n d n ew o-r in g (F ig. 155). N·m (165 in . lbs.).
ga sket t o ca se (F ig. 157).
Fig. 155 Install Oil Filter

1 - OIL FILTER
2 - O-RING

Gasket
2 - GASKET
(69) In st a ll a n d t igh t en solen oid/pr essu r e swit ch
a ssem bly-t o-t r a n sa xle ca se bolt s t o 12 N·m (110 in .
lbs.) (F ig. 158).
Fig. 159 Left Mount to Bracket and Transaxle

Fig. 158 Solenoid Pack-to-Transaxle Bolts 4 - TRANSAXLE
1 - BOLTS 5 - MOUNT - LEFT
2 - SOLENOID AND PRESSURE SWITCH ASSEMBLY 6 - BRACKET - LEFT MOUNT
(70) In st a ll a n d t or qu e in pu t a n d ou t pu t speed (12) AWD m odels: In st a ll power t r a n sfer u n it .

sen sor s t o ca se t o 27 N·m (20 ft . lbs.). (Refer t o 21 - TRANSMISSION/TRANSAXLE /
P OWE R TRANSF E R UNIT - INSTALLATION)
INSTALLATION (13) In st a ll left a n d r igh t h a lfsh a ft a ssem blies.
NOTE: If transaxle assembly has been replaced or SH AF T - INSTALLATION)
overhauled (clutch and/or seal replacement), it is (14) In st a ll fr on t wh eel/t ir e a ssem blies.
necessary to perfrom the “Quick-Learn” procedure. (15) Lower veh icle.
(Refer to 8 - ELECTRICAL/ELECTRONIC CONTROL (16) Tor qu e r em a in in g r ea r m ou n t br a cket -t o-t r a n -
MODULES/TRANSMISSION CONTROL MODULE - sa xle ver t ica l bolt s (F ig. 160) t o 102 N·m (75 ft . lbs.).
STANDARD PROCEDURE) (17) In st a ll t r a n sa xle u pper bellh ou sin g-t o-block
bolt s a n d t or qu e t o 95 N·m (70 ft . lbs.).
(1) Usin g a t r a n sm ission ja ck a n d a h elper, posi- (18) In st a ll a n d con n ect cr a n k posit ion sen sor (if
t ion t r a n sa xle a ssem bly t o en gin e. In st a ll a n d t or qu e equ ipped).
bellh ou sin g bolt s t o 95 N·m (70 ft . lbs.). (19) Con n ect gea r sh ift ca ble t o u pper m ou n t
(2) In st a ll u pper m ou n t a ssem bly t o t r a n sa xle a n d br a cket a n d t r a n sa xle m a n u a l va lve lever (F ig. 161).
t or qu e bolt s t o 54 N·m (40 ft . lbs.) (F ig. 159). (20) Con n ect solen oid/pr essu r e swit ch a ssem bly
(3) Ra ise en gin e/t r a n sa xle a ssem bly in t o posit ion . (F ig. 162).
In st a ll a n d t or qu e u pper m ou n t -t o-br a cket t h r u -bolt (21) Con n ect t r a n sm ission r a n ge sen sor con n ect or
t o 75 N·m (55 ft . lbs.) (F ig. 159). (F ig. 162).
(4) Rem ove t r a n sm ission ja ck a n d scr ew ja ck. (22) Con n ect in pu t a n d ou t pu t speed sen sor con -
(5) Secu r e left wh eelh ou se spla sh sh ield. n ect or s (F ig. 162).
(6) In st a ll t or qu e con ver t er-t o-dr ive pla t e bolt s a n d (23) Rem ove plu gs a n d con n ect t r a n sa xle oil cooler
t or qu e t o 88 N·m (65 ft . lbs.) lin es. (Refer t o 7 - COOLING/TRANSMISSION -
(7) In st a ll in spect ion cover. STANDARD P ROCE DURE )
(8) In st a ll la t er a l ben din g br a ce. (24) Rem ove plu g a n d In st a ll flu id level in dica t or /
(9) In st a ll st a r t er m ot or. t u be a ssem bly.
(10) In st a ll fr on t m ou n t /br a cket a ssem bly.
(11) Align a n d in st a ll r ea r m ou n t br a cket -t o-ca se
bolt s by h a n d (F ig. 160). Tor qu e h or izon t a l bolt t o
102 N·m (75 ft . lbs.).

Fig. 162 Component Connector Location - Typical

Fig. 161 Gearshift Cable at Transaxle - Typical 1 - SOLENOID/PRESSURE SWITCH ASSY. CONNECTOR
1 - MANUAL VALVE LEVER 3 - OUTPUT SPEED SENSOR CONNECTOR
2 - GEAR SHIFT CABLE 4 - TRANSMISSION RANGE SENSOR CONNECTOR
(25) In st a ll coola n t r ecover y bot t le (F ig. 163). (26) In st a ll ba t t er y sh ield.
(28) F ill t r a n sa xle wit h su it a ble a m ou n t of ATF +4
(Au t om a t ic Tr a n sm ission F lu id—Type 9602). (Refer
- 41TE /F LUID - STANDARD P ROCE DURE )
Fig. 163 Coolant Recovery Bottle

2 - HOSE
3 - BOLT
4 - SUB FRAME RAIL
SCH EM AT I CS AN D DI AGRAM S
4XTE TRANSAXLE HYDRAULIC SCHEMATICS
Park/Neutral (Speed Under 8 MPH)

Neutral (Speed Over 8 MPH)

Reverse
Reverse Block (Shift to Reverse W/Speed Over 8 mph)

First Gear
Second Gear
Second Gear (EMCC)

Direct Gear
Direct Gear (CC On)

Overdrive
Overdrive (EMCC)
Overdrive (CC On)

SPECIFICATIONS - 41TE TRANSAXLE

Fully adaptive, electronically controlled, four speed
Transaxle Type
automatic with torque converter and integral differential
Cooling Method Air-to-oil heat exchanger
Lubrication Pump (internal-external gear-type
GEAR RAT I OS
First Gear 2.84
Second Gear 1.57
Direct Gear 1.00
Overdrive Gear 0.69
Reverse Gear 2.21
BEARI N G SET T I N GS (EN D PLAY & T U RN I N G T ORQU E)

Differential Assembly 0.6-2 N·m 5-18 in. lbs.
Output Hub 0.3-2 N·m 3-8 in. lbs.
Transfer Shaft (End Play) 0.051-0.102 mm 0.002-0.004 in.
Overall Drag At Output Hub 0.3-1.9 N·m 3-16 in. lbs.
CLU T CH CLEARAN CES

Low/Rev Clutch (Select Reaction
0.89-1.47 mm 0.035-0.058 in.
Plate)
Two/Four Clutch (No Selection) 0.76-2.64 mm 0.030-0.104 in.
Reverse Clutch (Select Snap Ring) 0.89-1.37 mm 0.035-0.054 in.
Overdrive Clutch (No Selection) 1.07-3.25 mm 0.042-0.128 in.
Underdrive Clutch (Select Pressure
0.94-1.50 mm 0.037-0.059 in.
Plate)
OI L PU M P CLEARAN CES

Outer Gear-to-Crescent 0.060-0.298 mm 0.0023-0.0117 in.
Inner Gear-to-Crescent 0.093-0.385 mm 0.0036-0.0151 in.
Outer Gear-to-Pocket 0.089-0.202 mm 0.0035-0.0079 in.
Outer Gear Side Clearance 0.020-0.046 mm 0.0008-0.0018 in.
Inner Gear Side Clearance 0.020-0.046 mm 0.0008-0.0018 in.
I N PU T SH AFT
DESCRIPTION METRIC SPECIFICATION

End Play 0.127-0.635mm 0.005-0.025 in.

Bolt, Differential
19 — 165
Cover-to-Case
Bolt, Differential Ring
95 70 —
Gear-to-Case
Bolt, Differential Bearing
28 21 —
Retainer-to-Case
Bolt, Driveplate-to-
95 70 —
Crankshaft
Bolt, Extension Housing/
28 21 —
Plate-to-Case
Bolt, Oil Pan-to-Case 19 — 165
Bolt, Output Gear 271 200 —
Bolt, Output Gear
23 17 —
Stirrup/Strap
Bolt, Oil Pump-to-Case 27 20 —
Bolt, Reaction Support-to-
27 20 —
Case
Bolt, Solenoid/Pressure
12 — 110
Switch Assy.-to-Case
Bolt, Torque Converter-to-
75 55 —
Driveplate
Bolt, Transfer Gear Cover 20 — 175
Bolt, Valve Body-to-Case 12 — 105
Fitting, Oil Cooler Line 12 — 105
Nut, Tranfer Gear 271 200 —
Tap, Transaxle Pressure 5 — 45
Screw, L/R Clutch
5 — 45
Retainer
Screw, Solenoid/Pressure
4 — 35
Switch Assy. Connector
Screw, Valve Body-to-
5 — 45
Transfer Plate
Sensor, Input Speed 27 20 —
Sensor, Output Speed 27 20 —
Sensor, Transmission
5 — 45
Range Sensor
SPECI AL T OOLS
41TE AUTOMATIC TRANSAXLE
Puller C-637 Universal Handle C-4171
Pressure Gauge (High) C-3293SP Seal Installer C-4193A
Dial Indicator C-3339
Adapter C-4996
Oil Pump Puller C-3752
Remover Kit L-4406
Seal Puller C-3981B

Gear Puller L-4407A Special Jaw Set L-4518
Bearing Installer L-4410 Installer L-4520
Gear Checking Plate L-4432

Thrust Button L-4539-2
Bearing Puller L-4435
Adapter L-4559
Differential Tool L-4436A
Adapter L-4559-2
Bearing Splitter P-334 Compressor 5058A
Puller Set 5048 Compressor 5059-A
Remover/Installer 5049-A Installer 5067
Installer 5050A
Pliers 6051
Installer 5052
Installer 6052
Installer 6053 Installer 6061
Button 6055 Remover 6062-A
Plate 6056 Holder 6259
Disk 6057 Bolt 6260

Installer 6261 Installer 6536-A
Puller 7794-A
Tip 6268
End Play Socket Set 8266

Input Clutch Pressure Fixture 8391

ACCU M U LAT OR Th e 2/4 a ccu m u la t or is loca t ed in t h e va lve body. It

is r et a in ed by a cover a n d r et a in in g scr ews (F ig.
166).
DESCRIPTION
Th e 4XTE u n der dr ive, over dr ive, low/r ever se, a n d
2/4 clu t ch h ydr a u lic cir cu it s ea ch con t a in a n a ccu m u -
la t or. An a ccu m u la t or t ypica lly con sist s of a pist on ,
sea ls, r et u r n spr in g(s), a n d a cover or plu g. Th e over-
dr ive a n d u n der dr ive a ccu m u la t or s a r e loca t ed
wit h in t h e t r a n sa xle ca se, a n d a r e r et a in ed by t h e
va lve body (F ig. 164).

1 - VALVE BODY
2 - RETAINER PLATE
3 - DETENT SPRING
4 - SPRINGS
5 - SEALS
6 - PISTON

OPERATION
1 - RETURN SPRING
2 - UNDERDRIVE CLUTCH ACCUMULATOR
Th e fu n ct ion of a n a ccu m u la t or is t o cu sh ion t h e
3 - SEAL RING (2) a pplica t ion of a fr ict ion a l clu t ch elem en t . Wh en pr es-
4 - OVERDRIVE CLUTCH ACCUMULATOR su r ized flu id is a pplied t o a clu t ch cir cu it , t h e a ppli-
ca t ion for ce is da m pen ed by flu id collect in g in t h e
Th e low r ever se a ccu m u la t or (F ig. 165) is a lso r espect ive a ccu m u la t or ch a m ber a ga in st t h e pist on
loca t ed wit h in t h e t r a n sa xle ca se, bu t t h e a ssem bly is a n d spr in g(s). Th e in t en ded r esu lt is a sm oot h , fir m
r et a in ed by a cover a n d a sn a p-r in g. clu t ch a pplica t ion .
Fig. 165 Low/Reverse Accumulator Assembly

1 - ACCUMULATOR PISTON
2 - SEAL RINGS
3 - RETURN SPRINGS
4 - (NOTE NOTCH)
DRI V I N G CLU T CH ES UNDERDRIVE CLUTCH

Th e u n der dr ive clu t ch is h ydr a u lica lly a pplied in
DESCRIPTION fir st , secon d, a n d t h ir d (dir ect ) gea r s by pr essu r ized
Th r ee h ydr a u lica lly a pplied in pu t clu t ch es a r e u sed flu id a ga in st t h e u n der dr ive pist on . Wh en t h e u n der-
t o dr ive pla n et a r y com pon en t s. Th e u n der dr ive, over- dr ive clu t ch is a pplied, t h e u n der dr ive h u b dr ives t h e
dr ive, a n d r ever se clu t ch es a r e con sider ed in pu t r ea r su n gea r.
clu t ch es a n d a r e con t a in ed wit h in t h e in pu t clu t ch
a ssem bly (F ig. 167). Th e in pu t clu t ch a ssem bly a lso OVERDRIVE CLUTCH
con t a in s: Th e over dr ive clu t ch is h ydr a u lica lly a pplied in
• In pu t sh a ft t h ir d (dir ect ) a n d over dr ive gea r s by pr essu r ized flu id
• In pu t h u b a ga in st t h e over dr ive/r ever se pist on . Wh en t h e over-
• Clu t ch r et a in er dr ive clu t ch is a pplied, t h e over dr ive h u b dr ives t h e
• Un der dr ive pist on fr on t pla n et ca r r ier.
• Over dr ive/r ever se pist on
• Over dr ive h u b REVERSE CLUTCH
• Un der dr ive h u b Th e r ever se clu t ch is h ydr a u lica lly a pplied in
r ever se gea r on ly by pr essu r ized flu id a ga in st t h e
over dr ive/r ever se pist on . Wh en t h e r ever se clu t ch is
a pplied, t h e fr on t su n gea r a ssem bly is dr iven .
FI N AL DRI V E
DESCRIPTION
Th e 41TE differ en t ia l is a con ven t ion a l open
design . It con sist s of a r in g gea r a n d a differ en t ia l
ca se. Th e differ en t ia l ca se con sist s of pin ion a n d side
gea r s, a n d a pin ion sh a ft . Th e differ en t ia l ca se is
su ppor t ed in t h e t r a n sa xle by t a per ed r oller bea r in gs
(F ig. 168).
Fig. 167 Input Clutch Assembly

1 - INPUT SHAFT
3 - OVERDRIVE CLUTCH
4 - REVERSE CLUTCH
5 - OVERDRIVE SHAFT
6 - UNDERDRIVE SHAFT
OPERATION Fig. 168 Differential Assembly

Th e t h r ee in pu t clu t ch es a r e r espon sible for dr ivin g 1 - DIFFERENTIAL CASE
differ en t com pon en t s of t h e pla n et a r y gea r t r a in . 2 - RING GEAR
3 - TRANSFER SHAFT
4 - PINION GEAR
NOTE: Refer to the “Elements In Use” chart in Diag- 5 - PINION SHAFT
nosis and Testing for a collective view of which 6 - SIDE GEAR
selector lever.
OPERATION
Th e differ en t ia l a ssem bly is dr iven by t h e t r a n sfer
sh a ft by wa y of t h e differ en t ia l r in g gea r. Th e r in g
gea r dr ives t h e differ en t ia l ca se, a n d t h e ca se dr ives
t h e dr ivesh a ft s t h r ou gh t h e differ en t ia l gea r s. Th e
differ en t ia l pin ion a n d side gea r s a r e su ppor t ed in
t h e ca se by t h r u st wa sh er s a n d a pin ion sh a ft . Dif-
fer en t ia l pin ion a n d side gea r s m a ke it possible for
fr on t t ir es t o r ot a t e a t differ en t speeds wh ile cor n er-
in g.
DISASSEMBLY
Differential service is limited to bearing cups and
Fig. 170 Remove Differential Cover
cones. Any other differential component failure
must be remedied by differential assembly and 2 - DIFFERENTIAL COVER
transfer shaft replacement.
Th e t r a n sfer sh a ft sh ou ld be r em oved for differ en -

t ia l r epa ir a n d bea r in g t u r n in g t or qu e ch eckin g.
(1) Rem ove t h e differ en t ia l cover a n d bolt s (F ig.
169) (F ig. 170).


(2) Rem ove t h e differ en t ia l bea r in g r et a in er a n d

bolt s (F ig. 171) (F ig. 172).
(3) Usin g a pla st ic h a m m er, r em ove ext en sion
h ou sin g/a da pt er pla t e on t h e r igh t side of t h e t r a n s-
a xle.
WARNING: HOLD ONTO DIFFERENTIAL ASSEMBLY

TO PREVENT IT FROM ROLLING OUT OF HOUSING.

a n d L-4539-2 Bu t t on t o r em ove t h e differ en t ia l bea r- Fig. 172 Remove Bearing Retainer
in g con e on t h e ext en sion h ou sin g side. 1 - DIFFERENTIAL BEARING RETAINER
2 - TOOL L-4435
in g con e on t h e bea r in g r et a in er side (F ig. 173) (F ig.
174) (F ig. 175).
Fig. 175 Remove Differential Bearing

Cone (Ring Gear Side)
2 - RING GEAR
Fig. 173 Position Button and Collets Onto

Differential and Bearing (Ring Gear Side)
1 - SPECIAL TOOL L-4539-2
Fig. 176 Position Bearing Cup

Remover Tool in Retainer
Fig. 174 Position Tool 5048 Over Button and Collets

at Differential Bearing (Ring Gear Side)
1 - SPECIAL TO0L 5048
2 - DIFFERENTIAL
(6) Usin g Miller Specia l Tool L-4518, r em ove t h e

differ en t ia l bea r in g r a ce fr om t h e ext en sion h ou sin g.
(7) Usin g Miller Specia l Tool 6062A, r em ove t h e
differ en t ia l bea r in g r a ce fr om t h e bea r in g r et a in er
(F ig. 176) (F ig. 177).
Fig. 177 Remove Bearing Cup

(8) Rem ove r in g gea r-t o-differ en t ia l ca se bolt s a n d (10) Sepa r a t e differ en t ia l cover fr om ca se u sin g
floa t in g pin ion sh a ft r et a in er s (F ig. 178). su it a ble scr ewdr iver s a t posit ion sh own in (F ig. 180)
Fig. 178 Ring Gear-to-Case Bolts Fig. 180 Separating Differential Support with
1 - DIFFERENTIAL CASE Screwdrivers
2 - PINION SHAFT RETAINER 1 - DIFFERENTIAL SUPPORT
3 - RING GEAR 2 - DIFFERENTIAL CASE
4 - RING GEAR-TO-CASE BOLT 3 - SCREWDRIVER
4 - RELIEF (2 @ 180° APART)
(9) Sepa r a t e r in g gea r fr om differ en t ia l ca se (F ig.
179). (11) Lift su ppor t fr om ca se (F ig. 181).
Fig. 181 Differential Support Removal

1 - DIFFERENTIAL SUPPORT
2 - DIFFERENTIAL CASE
Fig. 179 Ring Gear Removal
1 - DIFFERENTIAL CASE
2 - RING GEAR
(12) Rem ove side gea r t h r u st wa sh er (F ig. 182). (14) Rem ove pin ion sh a ft (F ig. 184).
Fig. 182 Side Gear Thrust Washer Removal Fig. 184 Pinion Shaft Removal
1 - SIDE GEAR THRUST WASHER 1 - PINION SHAFT
(13) Rem ove side gea r (F ig. 183). (15) Rem ove pin ion gea r s a n d t a bbed wa sh er s
(F ig. 185).
Fig. 183 Side Gear Removal

1 - DIFFERENTIAL SIDE GEAR Fig. 185 Pinion Gear and Washer Removal
1 - PINION GEAR
2 - TABBED WASHER
3 - LOCATING TAB
4 - NOTCH
(16) Rem ove differ en t ia l side gea r (F ig. 186). (1) In st a ll side gea r t h r u st wa sh er t o differ en t ia l
ca se (F ig. 188).
Fig. 186 Side Gear Removal

1 - DIFFERENTIAL SIDE GEAR Fig. 188 Thrust Washer Installation
1 - THRUST WASHER
(17) Rem ove side gea r t h r u st wa sh er (F ig. 187).
(2) In st a ll side gea r t o differ en t ia l ca se (F ig. 189).
Fig. 187 Side Gear Thrust Washer Removal

1 - THRUST WASHER Fig. 189 Side Gear Installation
1 - DIFFERENTIAL SIDE GEAR
(18) In spect a ll com pon en t s for excessive wea r.
ASSEMBLY
Differential service is limited to bearing cups and
cones. Any other differential component failure
must be remedied by differential assembly and
transfer shaft replacement.
(3) In st a ll bot h pin ion gea r s a n d wa sh er s t o ca se, (5) In st a ll side gea r t o ca se (F ig. 192).
wh ile or ien t a t in g wa sh er t a bs t o n ot ch in ca se (F ig.
190).
Fig. 192 Side Gear Installation

1 - DIFFERENTIAL SIDE GEAR
Fig. 190 Pinion Gear and Washer Installation
1 - PINION GEAR (6) In st a ll side gea r t h r u st wa sh er t o ca se (F ig.
2 - TABBED WASHER 193).
3 - LOCATING TAB
4 - NOTCH
(4) In st a ll pin ion sh a ft (F ig. 191).
Fig. 193 Side Gear Thrust Washer

1 - SIDE GEAR THRUST WASHER
Fig. 191 Pinion Shaft Installation

1 - PINION SHAFT
(7) In st a ll differ en t ia l su ppor t in t o posit ion , wh ile (9) In st a ll r in g gea r-t o-ca se bolt s, wit h pin ion sh a ft
a lign in g t h r ou gh -h oles (F ig. 194). r et a in er s (F ig. 196), a n d t or qu e bolt s t o 95 N·m (70
ft . lbs.).
Fig. 194 Diff Support Installation

1 - DIFFERENTIAL SUPPORT Fig. 196 Ring Gear-to-Case Bolts
2 - DIFFERENTIAL CASE 1 - DIFFERENTIAL CASE
2 - PINION SHAFT RETAINER
(8) In st a ll differ en t ia l r in g gea r t o ca se (F ig. 195). 3 - RING GEAR
4 - RING GEAR-TO-CASE BOLT
(10) Usin g Miller Specia l Tool L-4410, a n d C-4171,

in st a ll differ en t ia l bea r in g t o differ en t ia l (ext en sion
h ou sin g side) (F ig. 197).
Fig. 197 Position Bearing Cone Onto Differential—

Typical
Fig. 195 Ring Gear Installation 1 - DIFFERENTIAL ASSEMBLY
1 - DIFFERENTIAL CASE 2 - DIFFERENTIAL BEARING
2 - RING GEAR
in st a ll differ en t ia l bea r in g t o differ en t ia l (bea r in g
r et a in er side).
in st a ll differ en t ia l bea r in g r a ce t o bea r in g r et a in er
(F ig. 198).

(15) Apply a bea d of Mopa r ! Silicon e Ru bber

Adh esive Sea la n t t o ext en sion h ou sin g/a da pt er pla t e
a n d in st a ll in t o posit ion . In st a ll a n d t or qu e bolt s t o
Fig. 198 Differential Bearing Retainer 28 N·m (21 ft . lbs.).
1 - DIFFERENTIAL BEARING CUP (16) Mea su r e a n d a dju st differ en t ia l bea r in g pr e-
2 - DIFFERENTIAL BEARING RETAINER loa d. (Refer t o 21 - TRANSMISSION/TRANSAXLE /
AUTOMATIC - 41TE /F INAL DRIVE -
(13) Usin g Miller Specia l Tool L–4520 a n d C-4171, ADJ USTME NTS)
in st a ll differ en t ia l bea r in g t o ext en sion h ou sin g. (17) Apply a bea d of Mopa r ! Silicon e Ru bber
Adh esive Sea la n t t o differ en t ia l cover a n d in st a ll t o
NOTE: Use Mopar" Silicone Rubber Adhesive Seal-
ca se (F ig. 201).
ant, or equivalent, on retainer and extension hous-
ing/adapter plate to seal to case.
(14) In st a ll differ en t ia l a ssem bly in t o t r a n sa xle

ca se. In st a ll differ en t ia l bea r in g r et a in er (F ig.
199)a n d t or qu e r et a in er-t o-ca se bolt s (F ig. 200)t o 28
N·m (21 ft . lbs.).
Fig. 201 Install Differential Cover

Fig. 199 Differential Bearing Retainer

1 - DIFFERENTIAL BEARING CUP
(18) In st a ll a n d t or qu e cover-t o-ca se bolt s t o 19
N·m (165 in . lbs.) (F ig. 202).
Fig. 203 Tool L-4436 and Torque Wrench

Fig. 202 Differential Cover Bolts 2 - TORQUE WRENCH
ADJ U ST M EN T S
ADJUSTMENT - DIFFERENTIAL BEARING
PRELOAD
NOTE: Perform all differential bearing preload mea-
surements with the transfer shaft and gear
removed.
DIFFERENTIAL BEARING PRELOAD ADJUSTMENT

USING EXISTING SHIM
(1) P osit ion t h e t r a n sa xle a ssem bly ver t ica lly on
t h e su ppor t st a n d, differ en t ia l bea r in g r et a in er side
u p. Fig. 204 Checking Differential Bearings Turning
(2) In st a ll Tool L-4436A in t o t h e differ en t ia l a n d Torque
on t o t h e pin ion m a t e sh a ft (F ig. 203). 1 - SPECIAL TOOL L-4436–A
(3) Rot a t e t h e differ en t ia l a t lea st on e fu ll r evolu - 2 - TORQUE WRENCH
t ion t o en su r e t h e t a per ed r oller bea r in gs a r e fu lly
sea t ed. (d) Mea su r e t h e exist in g sh im .
(4) Usin g Tool L-4436A a n d a n in ch -pou n d t or qu e (e) If t h e t u r n in g t or qu e wa s t oo h igh wh en m ea -
wr en ch , ch eck t h e t u r n in g t or qu e of t h e differ en t ia l su r ed, in st a ll a 0.05 m m (0.002 in ch ) t h in n er sh im .
(F ig. 204). Th e tu rn in g to rqu e s h o u ld be If t h e t u r n in g t or qu e is wa s t oo low, in st a ll a 0.05
be tw e e n 5 a n d 18 in c h -p o u n d s . m m (0.002 in ch ) t h icker sh im . Repea t u n t il 5-18
(5) If t h e t u r n in g t or qu e is wit h in specifica t ion s, in ch -pou n ds t u r n in g t or qu e is obt a in ed. Oil Ba ffle
r em ove t ools. Set u p is com plet e. is n ot r equ ir ed t o be in st a lled wh en m a kin g sh im
(6) If t u r n in g t or qu e is n ot wit h in specifica t ion s select ion .
pr oceed wit h t h e followin g st eps. (f) In st a ll t h e pr oper sh im u n der t h e bea r in g
(a ) Rem ove differ en t ia l bea r in g r et a in er fr om cu p. Ma ke su r e t h e oil ba ffle is in st a lled pr oper ly
t h e t r a n sa xle ca se. in t h e bea r in g r et a in er, below t h e bea r in g sh im
(b) Rem ove t h e bea r in g cu p fr om t h e differ en t ia l a n d cu p.
bea r in g r et a in er u sin g Tool 6062A. (g) In st a ll t h e differ en t ia l bea r in g r et a in er u sin g
(c) Rem ove t h e exist in g sh im fr om u n der t h e Tool 5052 a n d C-4171. Sea l t h e r et a in er t o t h e
cu p.
h ou sin g wit h MOPAR! Silicon e Ru bber Adh esive • Tr a n sa xle ca se
Sea la n t a n d t or qu e bolt s t o 28 N·m (250 in . lbs.). • Differ en t ia l ca r r ier
(7) Usin g Tool L-4436A a n d a n in ch -pou n d t or qu e • Differ en t ia l bea r in g r et a in er
wr en ch , r ech eck t h e t u r n in g t or qu e of t h e differ en t ia l • E xt en sion h ou sin g
(F ig. 204). Th e tu rn in g to rqu e s h o u ld be w ith in • Differ en t ia l bea r in g cu ps a n d con es
5-18 in c h -p o u n d s .
Sh im t h ickn ess n eed be det er m in ed on ly if a n y of
t h e followin g pa r t s a r e r epla ced:
DI FFEREN T I AL BEARI N G SH I M CH ART
PART NUMBER SHIM THICKNESS

MM INCH
4659257 .980 0.0386
4659258 1.02 0.0402
4659259 1.06 0.0418
4659260 1.10 0.0434
4659261 1.14 0.0449
4659262 1.18 0.0465
4659263 1.22 0.0481
4659264 1.26 0.0497
4659265 1.30 0.0512
4659266 1.34 0.0528
4659267 1.38 0.0544
4659268 1.42 0.0560
4659269 1.46 0.0575
4659270 1.50 0.0591
4659271 1.54 0.0607
4659272 1.58 0.0623
4659273 1.62 0.0638
4659274 1.66 0.0654
4659275 1.70 0.0670
4659283 2.02 0.0796
4659284 2.06 0.0812
(5) P osit ion t h e t r a n sa xle a ssem bly ver t ica lly on

PRELOAD ADJUSTMENT W/O SHIM
t h e su ppor t st a n d a n d in st a ll Miller Specia l Tool
(1) Rem ove t h e bea r in g cu p fr om t h e differ en t ia l
L-4436-A in t o t h e bea r in g r et a in er.
bea r in g r et a in er u sin g Miller specia l Tool 6062A.
(6) Rot a t e t h e differ en t ia l a t lea st on e fu ll r evolu -
(2) Rem ove exist in g sh im fr om u n der bea r in g cu p.
t ion t o en su r e t h e t a per ed r oller bea r in gs a r e fu lly
(3) Rein st a ll t h e bea r in g cu p in t o t h e r et a in er
sea t ed.
u sin g Miller Specia l Tool 6061, a n d C-4171.
(7) At t a ch a dia l in dica t or t o t h e ca se a n d zer o t h e
NOTE: Oil baffle is not required when making the dia l. P la ce t h e t ip on t h e en d of Specia l Tool
shim calculation. L-4436-A.
(8) P la ce a la r ge scr ewdr iver t o ea ch side of t h e
(4) In st a ll t h e bea r in g r et a in er in t o t h e ca se. r in g gea r a n d lift . Ch eck t h e dia l in dica t or for t h e
Tor qu e bolt s t o 28 N·m (250 in . lbs.). a m ou n t of en d pla y.
CAUTION: Do not damage the transaxle case and/or
differential retainer sealing surface.
(9) Usin g t h e en d pla y m ea su r em en t t h a t wa s

det er m in ed, a dd 0.18m m (0.007 in ch ). Th is sh ou ld
give you bet ween 5-18 in ch pou n ds of bea r in g pr e-
loa d. Refer t o t h e Differ en t ia l Bea r in g Sh im Ch a r t t o
det er m in e wh ich sh im t o u se.
(10) Rem ove t h e differ en t ia l bea r in g r et a in er.
Rem ove t h e bea r in g cu p.
(11) In st a ll t h e oil ba ffle. In st a ll t h e pr oper sh im
com bin a t ion u n der t h e bea r in g cu p.
(12) In st a ll t h e differ en t ia l bea r in g r et a in er. Sea l
t h e r et a in er t o t h e h ou sin g wit h Mopa r ! Silicon e
Ru bber Adh esive Sea la n t . Tor qu e bolt s t o 28 N·m
(250 in . lbs.).
(13) Usin g Miller Specia l Tool L-4436-A a n d a n Fig. 205 Fluid Level Indicator
in ch -pou n d t or qu e wr en ch , ch eck t h e t u r n in g t or qu e 1 - FLUID LEVEL INDICATOR
of t h e differ en t ia l (F ig. 204). Th e t u r n in g t or qu e
sh ou ld be bet ween 5-18 in ch -pou n ds. FLUID LEVEL CHECK USING DRB
NOTE: If turning torque is too high install a 0.05mm NOTE: Engine and Transaxle should be at normal
(0.002 inch) thicker shim. If the turning torque is too operating temperature before performing this proce-
low, install a 0.05mm (0.002 inch) thinner shim. dure.
Repeat until 5-18 inch-pounds of turning torque is
obtained. (1) St a r t en gin e a n d a pply pa r kin g br a ke.
(2) H ook u p DRB sca n t ool a n d select t r a n sm is-
sion .
(3) Select sen sor s.
FLU I D (4) Rea d t h e t r a n sm ission t em per a t u r e va lu e.
(5) Com pa r e t h e flu id t em per a t u r e va lu e wit h t h e
STAN DARD PROCEDU RE flu id t em per a t u r e ch a r t (F ig. 206).
(6) Adju st t r a n sm ission flu id level sh own on t h e
FLUID LEVEL AND CONDITION CHECK in dica t or a ccor din g t o t h e ch a r t .
(7) Ch eck t r a n sm ission for lea ks.
NOTE: Only transmission fluid of the type labeled Low flu id level ca n ca u se a va r iet y of con dit ion s
Mopar ATF+4 (Automatic Transmission Fluid) beca u se it a llows t h e pu m p t o t a ke in a ir a lon g wit h
should be used in this transaxle. t h e flu id. As in a n y h ydr a u lic syst em , a ir bu bbles
m a ke t h e flu id spon gy, t h er efor e, pr essu r es will be
low a n d bu ild u p slowly.
FLUID LEVEL CHECK Im pr oper fillin g ca n a lso r a ise t h e flu id level t oo
Th e t r a n sm ission su m p h a s a flu id level in dica t or h igh . Wh en t h e t r a n sa xle h a s t oo m u ch flu id, t h e
(dipst ick) t o ch eck oil sim ila r t o m ost a u t om a t ic gea r s ch u r n u p foa m a n d ca u se t h e sa m e con dit ion s
t r a n sm ission s. It is loca t ed on t h e left side of t h e wh ich occu r wit h a low flu id level.
en gin e. Be su r e t o wipe a ll dir t fr om dipst ick h a n dle In eit h er ca se, a ir bu bbles ca n ca u se over h ea t in g
befor e r em ovin g. a n d/or flu id oxida t ion , a n d va r n ish in g. Th is ca n
Th e t or qu e con ver t er fills in bot h t h e P P a r k a n d N in t er fer e wit h n or m a l va lve, clu t ch , a n d a ccu m u la t or
Neu t r a l posit ion s. P la ce t h e select or lever in P P a r k oper a t ion . F oa m in g ca n a lso r esu lt in flu id esca pin g
t o be su r e t h a t t h e flu id level ch eck is a ccu r a t e. Th e fr om t h e t r a n sa xle ven t wh er e it m a y be m ist a ken
e n g in e s h o u ld be ru n n in g a t id le s p e e d fo r a t for a lea k.
le a s t o n e m in u te , w ith th e v e h ic le o n le v e l
g ro u n d . At n or m a l oper a t in g t em per a t u r e 82° C FLUID CONDITION
(180° F ), t h e flu id level is cor r ect if it is in t h e H OT Alon g wit h flu id level, it is im por t a n t t o ch eck t h e
r egion on t h e oil level in dica t or (F ig. 205). Th e flu id con dit ion of t h e flu id. Wh en t h e flu id sm ells bu r n ed,
level sh ou ld be wit h in t h e COLD r egion of t h e dip- a n d is con t a m in a t ed wit h m et a l or fr ict ion m a t er ia l
st ick a t 27° C (80° F ) flu id t em per a t u r e. pa r t icles, a com plet e t r a n sa xle r econ dit ion is pr oba -
bly r equ ir ed. Be su r e t o exa m in e t h e flu id on t h e dip-
Fig. 206 Transmission Fluid Temperature Chart

1 - MAX. LEVEL 2 - MIN. LEVEL
st ick closely. If t h er e is a n y dou bt a bou t it s con dit ion , STANDARD PROCEDURE - FLUID AND FILTER
dr a in ou t a sa m ple for a dou ble ch eck.
SERVICE
Mopa r ! ATF +4 (Au t om a t ic Tr a n sm ission F lu id)
wh en n ew is r ed in color. Th e ATF is dyed r ed so it NOTE: Refer to the maintenance schedules in
ca n be iden t ified fr om ot h er flu ids u sed in t h e veh icle LUBRICATION and MAINTENANCE, or the vehicle
su ch a s en gin e oil or a n t ifr eeze. Th e r ed color is n ot owner’s manual, for the recommended maintenance
per m a n en t a n d is n ot a n in dica t or of flu id con dit ion . (fluid/filter change) intervals for this transaxle.
As t h e veh icle is dr iven , t h e ATF will begin t o look
da r ker in color a n d m a y even t u a lly becom e br own .
Th is is n o rm a l. ATF +4 a lso h a s a u n iqu e odor t h a t NOTE: Only fluids of the type labeled Mopar" ATF+4
m a y ch a n ge wit h a ge. Con sequ en t ly, o d o r a n d c o lo r (Automatic Transmission Fluid) should be used. A
c a n n o t be u s e d to in d ic a te th e flu id c o n d itio n filter change should be made at the time of the
o r th e n e e d fo r a flu id c h a n g e . transmission oil change. The magnet (on the inside
Aft er t h e flu id h a s been ch ecked, sea t t h e dipst ick of the oil pan) should also be cleaned with a clean,
fu lly t o sea l ou t wa t er a n d dir t . dry cloth.
NOTE: If the transaxle is disassembled for any rea-

son, the fluid and filter should be changed.
FLUID/FILTER SERVICE (RECOMMENDED)
(1) Ra ise veh icle on a h oist . Refer t o LUBRICA-
TION a n d MAINTE NANCE for pr oper pr ocedu r es.
P la ce a dr a in con t a in er wit h a la r ge open in g, u n der
t r a n sa xle oil pa n .
(2) Loosen pa n bolt s a n d t a p t h e pa n a t on e cor n er
t o br ea k it loose a llowin g flu id t o dr a in , t h en r em ove
t h e oil pa n .
(3) In st a ll a n ew filt er a n d o-r in g on bot t om of t h e
va lve body (F ig. 207).
Fig. 208 Fluid Level Indicator

DIPSTICK TUBE FLUID SUCTION METHOD

(ALTERNATIVE)
(1) Wh en per for m in g t h e flu id su ct ion m et h od,
m a ke su r e t h e t r a n sa xle is a t fu ll oper a t in g t em per-
a t u r e.
(2) To per for m t h e dipst ick t u be flu id su ct ion
m et h od, u se a su it a ble flu id su ct ion device (Va cu la ™
or equ iva len t ).
(3) In ser t t h e flu id su ct ion lin e in t o t h e dipst ick
t u be.
Fig. 207 Filter and O-Ring
1 - OIL FILTER NOTE: Verify that the suction line is inserted to the
2 - O-RING lowest point of the transaxle oil pan. This will
ensure complete evacuation of the fluid in the pan.
(4) Clea n t h e oil pa n a n d m a gn et . Rein st a ll pa n
u sin g n ew Mopa r Silicon e Adh esive sea la n t . Tigh t en (4) F ollow t h e m a n u fa ct u r er s r ecom m en ded pr oce-
oil pa n bolt s t o 19 N·m (165 in . lbs.). du r e a n d eva cu a t e t h e flu id fr om t h e t r a n sa xle.
(5) P ou r fou r qu a r t s of Mopa r ! ATF +4 (Au t om a t ic (5) Rem ove t h e su ct ion lin e fr om t h e dipst ick t u be.
Tr a n sm ission F lu id) t h r ou gh t h e dipst ick open in g. (6) P ou r fou r qu a r t s of Mopa r ! ATF +4 (Au t om a t ic
(6) St a r t en gin e a n d a llow t o idle for a t lea st on e Tr a n sm ission F lu id) t h r ou gh t h e dipst ick open in g.
m in u t e. Th en , wit h pa r kin g a n d ser vice br a kes (7) St a r t en gin e a n d a llow t o idle for a t lea st on e
a pplied, m ove select or lever m om en t a r ily t o ea ch m in u t e. Th en , wit h pa r kin g a n d ser vice br a kes
posit ion , en din g in t h e pa r k or n eu t r a l posit ion . a pplied, m ove select or lever m om en t a r ily t o ea ch
(7) Ch eck t h e t r a n sa xle flu id level a n d a dd a n posit ion , en din g in t h e pa r k or n eu t r a l posit ion .
a ppr opr ia t e a m ou n t t o br in g t h e t r a n sa xle flu id level (8) Ch eck t h e t r a n sa xle flu id level a n d a dd a n
t o 3m m (1/8 in .) below t h e lowest m a r k on t h e dip- a ppr opr ia t e a m ou n t t o br in g t h e t r a n sa xle flu id level
st ick (F ig. 208). t o 3m m (1/8 in .) below t h e lowest m a r k on t h e dip-
(8) Rech eck t h e flu id level a ft er t h e t r a n sa xle h a s st ick (F ig. 208).
r ea ch ed n or m a l oper a t in g t em per a t u r e (180°F.). Refer (9) Rech eck t h e flu id level a ft er t h e t r a n sa xle h a s
t o F lu id Level a n d Con dit ion Ch eck for t h e pr oper r ea ch ed n or m a l oper a t in g t em per a t u r e (180°F.).
flu id fill pr ocedu r e. (Refer t o 21 - TRANSMISSION/TRANSAXLE /AUTO-
(9) To pr even t dir t fr om en t er in g t r a n sa xle, m a ke MATIC - 41TE /F LUID - STANDARD P ROCE DURE )
cer t a in t h a t dipst ick is fu lly sea t ed in t o t h e dipst ick (10) To pr even t dir t fr om en t er in g t r a n sa xle, m a ke
open in g. cer t a in t h a t dipst ick is fu lly sea t ed in t o t h e dipst ick
open in g.
GEAR SH I FT CABLE (7) Rem ove in st r u m en t pa n el lower silen cer (F ig.

210).
REMOVAL
(3) Rem ove ba t t er y.
(4) Rem ove speed con t r ol ser vo a n d posit ion ou t of
wa y.
(5) Discon n ect gea r sh ift ca ble a t m a n u a l va lve
lever (F ig. 209).
(6) Discon n ect gea r sh ift ca ble fr om u pper m ou n t

1 - INSTRUMENT PANEL LOWER SILENCER
(8) Rem ove kn ee bolst er (F ig. 211).

1 - KNEE BOLSTER
(9) Discon n ect gea r sh ift ca ble fr om gea r sh ift INSTALLATION
lever (F ig. 212). (1) F ish gea r sh ift ca ble da sh pa n el open in g in t o
en gin e com pa r t m en t a n d secu r e gr om m et (F ig. 214).
Fig. 212 Gearshift Cable at Column

1 - GEAR SHIFT CABLE Fig. 214 Gearshift Cable/Grommet at Dash Panel
1 - CABLE GROMMET
(10) Rem ove gea r sh ift ca ble fr om colu m n br a cket 2 - DASH PANEL
(F ig. 212).
(11) Disen ga ge gr om m et fr om da sh pa n el (F ig. (2) In st a ll gea r sh ift ca ble t h r ou gh colu m n br a cket
213) a n d r em ove gea r sh ift ca ble fr om in side veh icle. (F ig. 215) u n t il a u dible “click” is h ea r d.
(3) Con n ect gea r sh ift ca ble t o gea r sh ift lever (F ig.
215).
Fig. 213 Gearshift Cable/Grommet at Dash Panel

1 - CABLE GROMMET
2 - DASH PANEL Fig. 215 Gearshift Cable at Column
(4) In st a ll kn ee bolst er (F ig. 216).

1 - KNEE BOLSTER

217).
Fig. 218 Gearshift Cable at Transaxle
ADJ U ST M EN T S
GEARSHIFT CABLE ADJUSTMENT
VERIFICATION
(1) P la ce gea r sh ift lever in ga t ed pa r k (P ).
(2) At t em pt t o m ove veh icle by r ockin g ba ck a n d
for t h on level gr ou n d. If veh icle does n ot m ove,
a t t em pt t o st a r t en gin e. If en gin e st a r t s, t h e pa r k
posit ion is cor r ect .
(3) Set pa r kin g br a ke.
(4) Tu r n key t o on /r u n a n d depr ess br a ke peda l.
Fig. 217 Instrument Panel Lower Silencer P la ce gea r sh ift lever in n eu t r a l (N).
1 - INSTRUMENT PANEL LOWER SILENCER (5) At t em pt t o st a r t en gin e. If en gin e st a r t s in
bot h n eu t r a l (N) or pa r k (P ), gea r sh ift ca ble is
(6) In st a ll gea r sh ift ca ble t o t r a n sa xle u pper a dju st ed pr oper ly. No a dju st m en t is r equ ir ed.
m ou n t br a cket (F ig. 218). An a u dible “click” sh ou ld (6) If en gin e does n ot st a r t in eit h er pa r k (P ) or
be h ea r d. n eu t r a l (N), per for m a dju st m en t pr ocedu r e.
(7) Con n ect gea r sh ift ca ble en d t o t r a n sa xle m a n -
u a l va lve lever (F ig. 218). ADJUSTMENT
(8) Adju st gea r sh ift ca ble. (Refer t o 21 - TRANS- (1) P a r k t h e veh icle on level gr ou n d a n d set t h e
MISSION/TRANSAXLE /AUTOMATIC - 41TE /GE AR pa r kin g br a ke.
SH IF T CABLE - ADJ USTME NTS) (2) P la ce t h e gea r sh ift lever in ga t ed pa r k (P ) a n d
(9) In st a ll speed con t r ol ser vo in t o posit ion . r em ove ign it ion key.
(10) In st a ll ba t t er y. (3) Loosen t h e ca ble a dju st m en t scr ew a t t h e
(11) In st a ll ba t t er y sh ield. t r a n sa xle m a n u a l va lve lever (F ig. 219).
(12) Con n ect ba t t er y ca bles. (4) P u ll t h e gea r sh ift lever fu lly for wa r d t o t h e
pa r k det en t posit ion .
(5) Relea se t h e pa r k br a ke, t h en r ock t h e veh icle
t o a ssu r e it is in pa r k. Reset t h e pa r k br a ke.
(6) Tigh t en t h e ca ble a dju st m en t scr ew t o 8 N·m
(70 in . lbs.). Gea r sh ift ca ble sh ou ld n ow be pr oper ly
a dju st ed.
(7) Ver ify a dju st m en t by u sin g t h e ver ifica t ion pr o-
cedu r e.
Fig. 219 Gearshift Cable Adjustment

1 - GEARSHIFT CABLE ADJUSTMENT SCREW
2 - GEARSHIFT CABLE
H OLDI N G CLU T CH ES Fig. 220 2/4 and Low/Reverse Clutches

1 - FRONT PLANET CARRIER/REAR ANNULUS
2 - 2/4 CLUTCH
DESCRIPTION 3 - L/R CLUTCH
Two h ydr a u lica lly a pplied m u lt i-disc clu t ch es a r e 4 - REAR PLANET CARRIER/FRONT ANNULUS
u sed t o h old pla n et a r y gea r t r a in com pon en t s st a t ion - 5 - REAR SUN GEAR
a r y wh ile t h e in pu t clu t ch es dr ive ot h er s. Th e 2/4
a n d Low/Rever se clu t ch es a r e con sider ed h oldin g
2/4 CLUTCH
clu t ch es a n d a r e con t a in ed a t t h e r ea r of t h e t r a n s-
Th e 2/4 clu t ch is h ydr a u lica lly a pplied in secon d
a xle ca se. (F ig. 220).
a n d fou r t h gea r s by pr essu r ized flu id a ga in st t h e 2/4
clu t ch pist on . Wh en t h e 2/4 clu t ch is a pplied, t h e
OPERATION fr on t su n gea r a ssem bly is h eld or gr ou n ded t o t h e
t r a n sa xle ca se.
NOTE: Refer to the “Elements In Use” chart in Diag-
nosis and Testing for a collective view of which
LOW/REVERSE CLUTCH
Th e Low/Rever se clu t ch is h ydr a u lica lly a pplied in
selector lever.
pa r k, r ever se, n eu t r a l, a n d fir st gea r s by pr essu r ized
flu id a ga in st t h e Low/Rever se clu t ch pist on . Wh en
t h e Low/Rever se clu t ch is a pplied, t h e fr on t pla n et
ca r r ier /r ea r a n n u lu s a ssem bly is h eld or gr ou n ded t o
I N PU T CLU T CH ASSEM BLY (4) P r y u p a n d r em ove r ever se clu t ch r ea ct ion

pla t e (F ig. 223).
DISASSEMBLY
(1) Mou n t in pu t clu t ch a ssem bly t o In pu t Clu t ch
P r essu r e F ixt u r e (Tool 8391).
(2) Ta p down r ever se clu t ch r ea ct ion pla t e t o
r elea se pr essu r e fr om sn a p r in g (F ig. 221).
Fig. 223 Pry Reverse Clutch Reaction Plate

2 - SCREWDRIVER
3 - SCREWDRIVER
Fig. 221 Tapping Reaction Plate

2 - TAP DOWN REVERSE CLUTCH REACTION PLATE TO
REMOVE OR INSTALL SNAP RING
(3) Rem ove r ever se clu t ch sn a p r in g (F ig. 222).
Fig. 222 Reverse Clutch Snap Ring

1 - REACTION PLATE
2 - SCREWDRIVER
3 - REVERSE CLUTCH SNAP RING (SELECT)
(5) Rem ove r ever se clu t ch pa ck (F ig. 224). Ta g
c o m p o n e n ts fo r a s s e m bly id e n tific a tio n .

3 - CLUTCH DISC (2)
(6) Rem ove t h e OD/Rever se pr essu r e pla t e sn a p
r in g (F ig. 225).
(7) Rem ove OD/Rever se pr essu r e pla t e (F ig. 225).
(8) Rem ove OD/Rever se pr essu r e pla t e wa ve sn a p
r in g (F ig. 225).
(9) Rem ove OD clu t ch pa ck (F ig. 225). Ta g c o m -
p o n e n ts fo r a s s e m bly id e n tific a tio n .

(10) Rem ove a n d in spect OD a n d UD Sh a ft s, a s
well a s #3 t h r u st wa sh er a n d pla t e, a n d #2 n eedle

(11) Rem ove t h e OD/UD r ea ct ion pla t e t a per ed
sn a p r in g, r ea ct ion pla t e, a n d fir st fr ict ion disc (F ig.
227).
(12) Rem ove t h e UD clu t ch fla t sn a p r in g a n d r est
of UD clu t ch pa ck (F ig. 227). Ta g c lu tc h p a c k fo r
a s s e m bly id e n tific a tio n .

2 - OD/UD REACTION PLATE 5 - CLUTCH PLATE
3 - CLUTCH DISC 6 - INPUT CLUTCH ASSEMBLY
remove or install snap ring.
(13) Usin g Tool 5059A a n d a n a r bor pr ess, com -

pr ess UD clu t ch pist on /spr in g en ou gh t o r em ove sn a p
r in g (F ig. 228) (F ig. 229).
Fig. 228 UD Spring Retainer Snap Ring

2 - ARBOR PRESS RAM
3 - SNAP RING

(14) Rem ove spr in g r et a in er, spr in g, a n d pist on (17) Sepa r a t e clu t ch r et a in er fr om OD/Rever se pis-
(F ig. 229). t on (F ig. 232).
(15) Rem ove in pu t h u b t a per ed sn a p r in g (F ig.
230) (F ig. 236).
Fig. 232 Pull Retainer from Piston

1 - OVERDRIVE/REVERSE PISTON
Fig. 230 Input Hub Tapered Snap Ring 2 - INPUT CLUTCHES RETAINER
1 - INPUT SHAFT
2 - INPUT HUB SNAP RING (TAPERED SIDE UP WITH TABS IN (18) Usin g Tool 6057 a n d a n a r bor pr ess, com pr ess
CAVITY) r et u r n OD/Rever se pist on r et u r n spr in g ju st en ou gh
t o r em ove sn a p r in g (F ig. 233).
(16) Ta p on in pu t h u b wit h soft fa ced h a m m er a n d
sepa r a t e in pu t h u b fr om OD/Rever se pist on a n d
clu t ch r et a in er (F ig. 231).
Fig. 233 Remove Snap Ring

2 - SCREWDRIVER
3 - SNAP RING
Fig. 231 Tap on Input Hub 4 - SPECIAL TOOL 6057
1 - INPUT SHAFT AND HUB ASSEMBLY 5 - OD/REVERSE PISTON
2 - PLASTIC HAMMER 6 - RETURN SPRING
(19) Rem ove in pu t sh a ft t o in pu t clu t ch h u b sn a p (20) Usin g a su it a bly sized socket a n d a n a r bor
r in g (F ig. 234) (F ig. 236). pr ess, r em ove in pu t sh a ft fr om in pu t sh a ft h u b (F ig.
235).
Fig. 234 Remove Input Shaft Snap Ring

Fig. 235 Remove Input Shaft
1 - INPUT SHAFT
2 - SHARP-POINTED TOOL 1 - ARBOR PRESS RAM
3 - SNAP RING 2 - SOCKET
4 - O-RINGS 3 - SEAL
5 - SEALS 4 - O-RINGS
5 - INPUT SHAFT
6 - SEAL

ASSEMBLY (3) Usin g a n a r bor pr ess a n d Tool 6057, In st a ll

Use pet r ola t u m on a ll sea ls t o ea se a ssem bly of OD/Rever se pist on r et u r n spr in g a n d sn a p r in g (F ig.
com pon en t s. 239) (F ig. 240).
(1) Usin g a n a r bor pr ess, in st a ll in pu t sh a ft t o
in pu t sh a ft h u b (F ig. 237).
Fig. 239 Return Spring and Snap Ring

2 - RETURN SPRING
Fig. 237 Install Input Shaft 3 - SNAP RING
1 - INPUT SHAFT 4 - O-RING
2 - ARBOR PRESS RAM
(2) In st a ll in pu t sh a ft sn a p r in g (F ig. 238).

2 - SCREWDRIVER
Fig. 238 Install Input Shaft Snap Ring 3 - SNAP RING
1 - INPUT SHAFT 4 - SPECIAL TOOL 6057
2 - SCREWDRIVER (DO NOT SCRATCH BEARING SURFACE) 5 - OD/REVERSE PISTON
3 - SNAP RING 6 - RETURN SPRING
4 - O-RINGS
5 - SEALS
(4) In st a ll t h e OD/Rever se pist on a ssem bly t o t h e (6) In st a ll in pu t h u b t a per ed sn a p r in g (F ig. 243)
in pu t clu t ch r et a in er a s sh own in (F ig. 241). (F ig. 244).
Fig. 241 Install OD/Reverse Piston Fig. 243 Install Input Hub Tapered Snap Ring
1 - PUSH DOWN TO INSTALL OVERDRIVE/REVERSE PISTON 1 - INPUT SHAFT
2 - INPUT CLUTCHES RETAINER 2 - INPUT HUB SNAP RING (TAPERED SIDE UP WITH TABS IN
CAVITY)
(5) In st a ll t h e in pu t h u b/sh a ft a ssy. t o t h e OD/Re- 3 - SNAP RING PLIERS
ver se pist on /clu t ch r et a in er a ssy. (F ig. 242).
Fig. 242 Install Input Shaft Hub Assembly

1 - PUSH DOWN TO INSTALL INPUT SHAFT HUB ASSEMBLY
(ROTATE TO ALIGN SPLINES)
2 - OD/REV. PISTON

(7) In st a ll UD clu t ch pist on (F ig. 245). (9) Usin g Tool 5059A a n d a n a r bor pr ess, In st a ll
t h e UD spr in g r et a in er a n d sn a p r in g (F ig. 247) (F ig.
248) (F ig. 249) Com pr ess ju st en ou gh t o in st a ll sn a p
r in g.

install snap ring.
Fig. 245 Underdrive Clutch Piston

1 - PISTON
(8) In st a ll UD pist on r et u r n spr in g a n d Tool 5067

a s sh own in (F ig. 246).
Fig. 247 UD Return Spring and Retainer

1 - UNDERDRIVE SPRING RETAINER
2 - SNAP RING
3 - SEAL
Fig. 246 Seal Compressor Special Tool 5067

Fig. 248 Install UD Spring Retainer and Snap Ring

1 - ARBOR PRESS RAM
3 - SNAP RING
5 - TOOL 5067
6 - TOOL 5059A

(10) In st a ll t h e UD clu t ch pa ck. Lea ve ou t u pper
disc, u n t il sn a p r in g is in st a lled (F ig. 250).
Fig. 252 Install Last UD Clutch Disc

1 - ONE UNDERDRIVE CLUTCH DISC
Fig. 250 Underdrive Clutch Pack

1 - CLUTCH PLATE
2 - ONE UD CLUTCH DISC
3 - CLUTCH DISC
(11) In st a ll t h e UD clu t ch fla t sn a p r in g (F ig. 251).
Fig. 253 OD/UD Reaction Plate

1 - OD/UD CLUTCH REACTION PLATE (TAPERED STEP SIDE UP)
Fig. 251 UD Clutch Flat Snap Ring

1 - UNDERDRIVE CLUTCH REACTION PLATE FLAT SNAP RING
2 - SCREWDRIVER
(12) In st a ll t h e la st UD clu t ch disc (F ig. 252).

(13) In st a ll t h e OD/UD clu t ch r ea ct ion pla t e a n d
sn a p r in g (F ig. 253) (F ig. 254). Th e OD/UD clu t ch es
r ea ct ion pla t e h a s a st ep on bot h sides. In st a ll t h e
OD/UD clu t ch es r ea ct ion pla t e t a per ed st ep side u p.
NOTE: Snap ring ends must be located within one

finger of the input clutch hub. Be sure that snap
ring is fully seated, by pushing with screwdriver,
Fig. 254 Tapered Snap Ring
into snap ring groove all the way around. 1 - OVERDRIVE/UNDERDRIVE CLUTCHES REACTION PLATE
TAPERED SNAP RING
2 - SCREWDRIVER (DO NOT SCRATCH REACTION PLATE)
(14) Sea t t a per ed sn a p r in g t o en su r e pr oper
in st a lla t ion (F ig. 255) (F ig. 256).
Fig. 255 Seating Tapered Snap Ring

TAPERED SNAP RING
2 - SCREWDRIVER

2 - OD/UD REACTION PLATE 5 - CLUTCH PLATE
3 - CLUTCH DISC 6 - INPUT CLUTCH ASSEMBLY
(15) In st a ll in pu t clu t ch a ssem bly t o t h e In pu t
Clu t ch P r essu r e F ixt u r e–Tool 8391 (F ig. 257).
Fig. 258 Set Up Dial Indicator to Measure UD Clutch

Clearance
1 - DIAL INDICATOR
Fig. 257 Input Clutch Assembly on Pressure Fixture
Tool 8391
2 - INPUT CLUTCH PRESSURE FIXTURE 8391
(16) Set u p dia l in dica t or on t h e UD clu t ch pa ck a s

(17) Usin g m oder a t e pr essu r e, pr ess down a n d
h old (n ea r in dica t or ) t h e UD clu t ch pa ck wit h scr ew-
259). Wh en r elea sin g pr essu r e on clu t ch pa ck, in dica -
t or r ea din g sh ou ld a dva n ce 0.005–0.010.
CAUTION: Do not apply more than 30 psi (206 kPa)

to the underdrive clutch pack.
(18) Apply 30 psi (206 kP a ) t o t h e u n der dr ive h ose

on Tool 8391 a n d m ea su r e UD clu t ch clea r a n ce. Mea -
su r e a n d r ecor d UD clu t ch pa ck m ea su r em en t in fou r
(4) pla ces, 90° a pa r t .
pa r e wit h UD clu t ch pa ck clea r a n ce specifica t ion .
U n d e rd riv e c lu tc h p a c k c le a ra n c e m u s t be 0.94-
1.50 m m (0.037-0.059 in .).
(20) If n ecessa r y, select t h e pr oper r ea ct ion pla t e Fig. 259 Press Down on UD Clutch Pack and Zero
t o a ch ieve specifica t ion s: Dial Indicator
1 - DIAL INDICATOR
UNDERDRIVE REACTION PLATE THICKNESS 2 - UNDERDRIVE CLUTCH
4659939AB 5.837-5.937 mm (0.230-0.234 in.)

4659940AB 6.147-6.248 mm (0.242-0.246 in.)
4659941AB 6.457-6.557 mm (0.254-0.258 in.)
(21) In st a ll t h e OD clu t ch pa ck (fou r fr ict ion s/t h r ee (23) In st a ll t h e OD/Rever se pr essu r e pla t e wit h
st eels) (F ig. 260). la r ge st ep down (t owa r ds OD clu t ch pa ck) (F ig. 262).
Fig. 262 OD/Reverse Pressure Plate

Fig. 260 Install OD Clutch Pack
1 - OVERDRIVE/REVERSE PRESSURE PLATE
1 - OVERDRIVE CLUTCH PACK 2 - (STEP SIDE DOWN)
(22) In st a ll OD pr essu r e pla t e wa ved sn a p r in g (24) In st a ll OD pr essu r e pla t e fla t sn a p r in g (F ig.

(F ig. 261). 263) (F ig. 264).
Fig. 261 Install Waved Snap Ring Fig. 263 Install Flat Snap Ring
1 - OVERDRIVE PRESSURE PLATE WAVED SNAP RING 1 - ARBOR PRESS RAM
2 - SCREWDRIVER 2 - TOOL 5059A
3 - FLAT SNAP RING

(25) Mea su r e OD clu t ch pa ck clea r a n ce. Set u p
dia l in dica t or on t op of t h e OD/Rever se pr essu r e
pla t e a s sh own in (F ig. 265).
Fig. 266 Install Reverse Clutch Pack

1 - REVERSE CLUTCH PLATE
2 - REVERSE CLUTCH DISCS
Fig. 265 Measure OD Clutch Pack Clearance

1 - DIAL INDICATOR
2 - OD/REVERSE REACTION PLATE
(26) Zer o dia l in dica t or a n d a pply 30 psi (206 kP a )

a ir pr essu r e t o t h e over dr ive clu t ch h ose on Tool
8391. Mea su r e a n d r ecor d OD clu t ch pa ck m ea su r e-
m en t in fou r (4) pla ces, 90° a pa r t .
pa r e wit h OD clu t ch pa ck clea r a n ce specifica t ion .
Fig. 267 Install Reaction Plate
Th e o v e rd riv e (OD ) c lu tc h p a c k c le a ra n c e is
1.07-3.25 m m (0.042-0.128 in .). 1 - REVERSE CLUTCH REACTION PLATE (FLAT SIDE DOWN)
If n ot wit h in specifica t ion s, t h e clu t ch is n ot
a ssem bled pr oper ly. Th er e is n o a dju st m en t for t h e
OD clu t ch clea r a n ce.
(28) In st a ll r ever se clu t ch pa ck (t wo fr ict ion s/on e
st eel) (F ig. 266).
(29) In st a ll r ever se clu t ch r ea ct ion pla t e wit h t h e
fla t side down t owa r ds r ever se clu t ch (F ig. 267).
(30) Ta p r ea ct ion pla t e down t o a llow in st a lla t ion
of t h e r ever se clu t ch sn a p r in g. In st a ll r ever se clu t ch
sn a p r in g (F ig. 268) (F ig. 269).
Fig. 268 Install Reverse Clutch Snap Ring

1 - REVERSE CLUTCH SNAP RING (SELECT) Fig. 270 Pry Up Reaction Plate to Seat Against Snap
2 - SCREWDRIVER
Ring
1 - SCREWDRIVER
(31) P r y u p r ever se r ea ct ion pla t e t o sea t a ga in st 2 - SNAP RING
3 - SCREWDRIVER
sn a p r in g (F ig. 270). 4 - MUST RAISE REVERSE REACTION PLATE TO RAISE SNAP
RING

3 - CLUTCH DISC (2)
(32) Set u p a dia l in dica t or on t h e r ever se clu t ch
pa ck a s sh own in (F ig. 271).
Fig. 272 Press Down on Reverse Clutch and Zero

Indicator
Fig. 271 Measure Reverse Clutch Pack Clearance 1 - DIAL INDICATOR
2 - REVERSE CLUTCH
1 - DIAL INDICATOR
2 - REVERSE CLUTCH
(36) To com plet e t h e a ssem bly, r ever se clu t ch a n d
(33) Usin g m oder a t e pr essu r e, pr ess down a n d over dr ive clu t ch m u st be r em oved.
h old (n ea r in dica t or ) r ever se clu t ch disc wit h scr ew- (37) In st a ll t h e #2 n eedle bea r in g (F ig. 273).
272). Wh en r elea sin g pr essu r e, in dica t or sh ou ld
a dva n ce 0.005-0.010. a s clu t ch pa ck r ela xes.
(34) Apply 30 psi (206 kP a ) a ir pr essu r e t o t h e
r ever se clu t ch h ose on Tool 8391. Mea su r e a n d r ecor d
r ever se clu t ch pa ck m ea su r em en t in fou r (4) pla ces,
90° a pa r t .
pa r e wit h r ever se clu t ch pa ck clea r a n ce specifica t ion .
Th e re v e rs e c lu tc h p a c k c le a ra n c e is 0.89-1.37
m m (0.035-0.054 in .). Select t h e pr oper r ever se
clu t ch sn a p r in g t o a ch ieve specifica t ion s:
REVERSE CLUTCH SNAP RING THICKNESS

4377195 1.53-1.58 mm (0.060-0.062 in.)
4412871 1.77-1.83 mm (0.070-0.072 in.) Fig. 273 Install No. 2 Needle Bearing
4412872 2.02-2.07 mm (0.080-0.082 in.) 1 - #2 NEEDLE BEARING (NOTE 3 SMALL TABS)
4412873 2.27-2.32 mm (0.090-0.091 in.) 2 - TABS UP
(38) In st a ll t h e u n der dr ive sh a ft a ssem bly (F ig. (40) In st a ll t h e #3 t h r u st pla t e t o t h e bot t om of t h e
274). over dr ive sh a ft a ssem bly. Ret a in wit h pet r ola t u m or
t r a n sm ission a ssem bly gel (F ig. 276).
Fig. 274 Install Underdrive Shaft Assembly

Fig. 276 Install No. 3 Thrust Plate
1 - UNDERDRIVE SHAFT ASSEMBLY
2 - #2 NEEDLE BEARING 1 - OVERDRIVE SHAFT ASSEMBLY
2 - DABS OF PETROLATUM (FOR RETENTION)
3 - #3 THRUST PLATE (NOTE 3 TABS)
(39) In st a ll t h e #3 t h r u st wa sh er t o t h e u n der dr ive
sh a ft a ssem bly. Be su r e five t a bs a r e sea t ed pr oper ly (41) In st a ll t h e over dr ive sh a ft a ssem bly (F ig. 277)
(F ig. 275). (F ig. 278).
Fig. 275 Install No. 3 Thrust Washer Fig. 277 Install Overdrive Shaft Assembly
1 - #3 THRUST WASHER (NOTE 5 TABS) 1 - OVERDRIVE SHAFT ASSEMBLY
2 - UNDERDRIVE SHAFT ASSEMBLY 2 - #3 THRUST PLATE
(42) Rein st a ll over dr ive a n d r ever se clu t ch a s

sh own . Re c h e c k in g th e s e c lu tc h c le a ra n c e s is
n o t n e c e s s a ry.

OI L PU M P DISASSEMBLY
Wh en disa ssem blin g t h e t r a n sa xle it is n ecessa r y
DESCRIPTION t o in spect t h e oil pu m p for wea r a n d da m a ge.
Th e oil pu m p is loca t ed in t h e pu m p h ou sin g in side (1) Rem ove t h e r ea ct ion sh a ft su ppor t -t o-pu m p
t h e bell h ou sin g of t h e t r a n sa xle ca se (F ig. 279). Th e body bolt s (F ig. 280).
oil pu m p con sist s of a n in n er a n d ou t er gea r, a h ou s-
in g, a n d a cover t h a t a lso ser ves a s t h e r ea ct ion sh a ft
su ppor t .

1 - BOLT (6)
2 - PUMP BODY
1 - PUMP BODY (2) Rem ove r ea ct ion sh a ft su ppor t fr om pu m p
2 - OUTER GEAR h ou sin g (F ig. 281).
3 - INNER GEAR
5 - SEAL RINGS (4)
6 - REACTION SHAFT
7 - CRESCENT
OPERATION
As t h e t or qu e con ver t er r ot a t es, t h e con ver t er h u b
r ot a t es t h e in n er a n d ou t er gea r s. As t h e gea r s
r ot a t e, t h e clea r a n ce bet ween t h e gea r t eet h
in cr ea ses in t h e cr escen t a r ea , a n d cr ea t es a su ct ion
a t t h e in let side of t h e pu m p. Th is su ct ion dr a ws
flu id t h r ou gh t h e pu m p in let fr om t h e oil pa n . As t h e
clea r a n ce bet ween t h e gea r t eet h in t h e cr escen t a r ea
decr ea ses, it for ces pr essu r ized flu id in t o t h e pu m p
ou t let a n d t o t h e va lve body.
Fig. 281 Reaction Shaft Support

1 - PUMP BODY
2 - PUMP GEARS
(3) Rem ove t h e pu m p gea r s (F ig. 282) a n d ch eck (6) Mea su r e clea r a n ce bet ween ou t er gea r a n d
for wea r a n d da m a ge on pu m p h ou sin g a n d gea r s. cr escen t (F ig. 284). Clea r a n ce sh ou ld be 0.060-0.298
m m (0.0023-0.0117 in .).

1 - PUMP BODY Fig. 284 Measuring Outer Gear-to-Crescent
2 - OUTER GEAR 1 - FEELER GAUGE
3 - INNER GEAR 2 - OUTER GEAR
4 - REACTION SHAFT SUPPORT 3 - CRESCENT
5 - SEAL RINGS (4) 4 - INNER GEAR
6 - REACTION SHAFT
7 - CRESCENT
(7) Mea su r e clea r a n ce bet ween in n er gea r a n d
(4) Re-in st a ll t h e gea r s a n d ch eck clea r a n ces. cr escen t (F ig. 285). Clea r a n ce sh ou ld be 0.093-0.385
(5) Mea su r e t h e clea r a n ce bet ween t h e ou t er gea r m m (0.0036-0.0151 in .).
a n d t h e pu m p pocket (F ig. 283). Clea r a n ce sh ou ld be
0.089–0.202 m m (0.0035-0.0079 in .).
Fig. 285 Measuring Inner Gear-to-Crescent

1 - FEELER GAUGE
Fig. 283 Measuring Outer Gear-to-Pocket 2 - OUTER GEAR
3 - CRESCENT
1 - FEELER GAUGE 4 - INNER GEAR
2 - OUTER GEAR
3 - PUMP BODY
(8) P osit ion a n a ppr opr ia t e piece of P la st iga ge
a cr oss bot h pu m p gea r s.
(9) Align t h e P la st iga ge t o a fla t a r ea on t h e r ea c-
t ion sh a ft su ppor t h ou sin g.
(10) In st a ll t h e r ea ct ion sh a ft t o t h e pu m p h ou sin g
(F ig. 280). Tigh t en t h e bolt s t o 27 N·m (20 ft . lbs.).
(11) Rem ove bolt s a n d ca r efu lly sepa r a t e t h e h ou s-
in gs. Mea su r e t h e P la st iga ge followin g t h e in st r u c-
t ion s su pplied.
(12) Clea r a n ce bet ween bot h gea r en d fa ces a n d
t h e r ea ct ion sh a ft su ppor t sh ou ld be 0.020-0.046 m m
(0.0008-0.0018 in .).
ASSEMBLY
(1) Assem ble oil pu m p a s sh own in (F ig. 286).

1 - BOLT (6)
2 - PUMP BODY

1 - PUMP BODY
2 - OUTER GEAR
3 - INNER GEAR
5 - SEAL RINGS (4)
6 - REACTION SHAFT Fig. 288 Planetary Geartrain
7 - CRESCENT
2 - #6 THRUST BEARING
(2) In st a ll a n d t or qu e r ea ct ion sh a ft su ppor t -t o-oil 3 - #7 THRUST BEARING
pu m p h ou sin g bolt s t o 28 N·m (20 ft . lbs.) t or qu e 4 - REAR CARRIER/FRONT ANNULUS ASSEMBLY
(F ig. 287). 5 - REAR SUN GEAR
6 - FRONT CARRIER/REAR ANNULUS ASSEMBLY
PLAN ETARY GEART RAI N OPERATION

Th e pla n et a r y gea r t r a in u t ilizes t wo pla n et a r y gea r
DESCRIPTION set s t h a t con n ect t h e t r a n sm ission in pu t sh a ft t o t h e
ou t pu t sh a ft . In pu t a n d h oldin g clu t ch es dr ive or lock
Th e pla n et a r y gea r t r a in is loca t ed bet ween t h e
differ en t pla n et a r y m em ber s t o ch a n ge ou t pu t r a t io
in pu t clu t ch a ssem bly a n d t h e r ea r of t h e t r a n sa xle
or dir ect ion .
ca se. Th e pla n et a r y gea r t r a in con sist s of t wo su n
gea r s, t wo pla n et a r y ca r r ier s, t wo a n n u lu s (r in g)
gea r s, a n d on e ou t pu t sh a ft (F ig. 288).
SEAL - OI L PU M P SH I FT I N T ERLOCK SOLEN OI D

REMOVAL DESCRIPTION
(1) Rem ove t r a n sa xle fr om veh icle (Refer t o 21 - Th e Br a ke/Tr a n sm ission Sh ift In t er lock syst em
TRANSMISSION/TRANSAXLE /AUTOMATIC - 41TE con sist s of a n elect r o-m a gn et ic solen oid m ou n t ed t o
- RE MOVAL). t h e st eer in g colu m n (F ig. 291). Th e solen oid’s plu n ger
(2) Usin g Tool C-3981-B, r em ove oil pu m p sea l con sist s of a n in t egr a t ed h ook, wh ich oper a t es t h e
(F ig. 289). sh ift lever pa wl (pa r t of sh ift lever a ssem bly), a n d a
plu n ger r et u r n spr in g (F ig. 292). Th e solen oid a lso
h a s a n in t egr a t ed br a cket , wh ich fa cilit a t es fa st en in g
t o t h e st eer in g colu m n .
Fig. 289 Remove Oil Pump Seal

1 - TOOL C-3981–B
2 - OIL PUMP SEAL
INSTALLATION
(1) Usin g Tool C-4193, in st a ll oil pu m p sea l (F ig.
290). Fig. 291 Brake/Transmission Shift Interlock (BTSI)
Solenoid Location
1 - BTSI SOLENOID
Fig. 290 Install Oil Pump Seal

1 - TOOL C-4193
2 - HANDLE TOOL C-4171
Fig. 292 Solenoid Plunger and Return Spring
(2) In st a ll t r a n sa xle t o veh icle (Refer t o 21 - 1 - PLUNGER
2 - RETURN SPRING
TRANSMISSION/TRANSAXLE /AUTOMATIC - 41TE 3 - BTSI SOLENOID
- INSTALLATION).
OPERATION
Th e Br a ke/Tr a n sm ission Sh ift In t er lock (BTSI)
Solen oid pr even t s t h e t r a n sm ission sh ift lever fr om
bein g m oved ou t of PARK (P ) u n less t h e br a ke peda l
is a pplied. Th e BTSI solen oid is h a r dwir ed t o a n d
con t r olled by t h e In t elligen t P ower Modu le (IP M).
Ba t t er y volt a ge is a pplied t o on e side of t h e solen oid
wit h t h e ign it ion key is in eit h er t h e OF F, ON/RUN,
or START posit ion s (F ig. 293). Th e gr ou n d side of t h e
solen oid is con t r olled by a dr iver wit h in t h e IP M. It
r elies on volt a ge su pplied fr om t h e st op la m p swit ch
t o t h e st op la m p sen se cir cu it wit h in t h e IP M t o t ell
wh en t h e br a ke peda l is depr essed. Wh en t h e br a ke
peda l is depr essed, t h e gr ou n d cir cu it open s, de-en er-
gizin g t h e solen oid. Wh en t h e br a ke peda l is
r elea sed, t h e gr ou n d cir cu it is closed, en er gizin g t h e
solen oid.
Fig. 294 Pawl Engaged to Shift Lever

2 - GEAR SHIFT LEVER PAWL
Fig. 293 Ignition Key/Switch Positions

1 - ACC
2 - LOCK
3 - OFF
4 - ON/RUN
5 - START
Wh en t h e ign it ion key is in eit h er t h e OF F,

ON/RUN, or START posit ion s, t h e BTSI solen oid is
en er gized, a n d t h e solen oid plu n ger h ook pu lls t h e
sh ift lever pa wl in t o posit ion , pr oh ibit in g t h e sh ift
lever fr om m ovin g ou t of PARK (P ) (F ig. 294). Wh en
Fig. 295 Pawl Disengaged From Shift Lever
t h e br a ke peda l is depr essed, t h e gr ou n d cir cu it
open s, de-en er gizin g t h e solen oid. Th is m oves t h e 2 - GEAR SHIFT LEVER PAWL
gea r sh ift lever pa wl ou t of t h e wa y (F ig. 295), a llow-
in g t h e sh ift lever t o be m oved in t o a n y gea r posit ion .
A con ven t ion a l m ech a n ica l in t er lock syst em is a lso ACTION EXPECTED RESPONSE
u sed. Th is syst em m a n u a lly pr oh ibit s sh ift er m ove-
m en t wh en t h e ign it ion swit ch is in t h e LOCK or 6. With the key removed, 6. Shifter cannot be
ACC posit ion s. Solen oid oper a t ion is n ot r equ ir ed in try to shift out of %PARK%. shifted out of %PARK%.
t h ese key posit ion s. NOTE: Any failure to meet these expected
F or in t en ded BTSI syst em oper a t ion , r efer t o t h e responses requires system repair. Refer to the
followin g ch a r t : appropriate Diagnostic Information.
ACTION EXPECTED RESPONSE REMOVAL

(2) Rem ove in st r u m en t pa n el lower sh r ou d (F ig.
296).
pedal applied.
to the %LOCK% or %ACC% %ACC% position.
position.
the key. position).
6. With the key removed, 6. Shifter cannot be
try to shift out of %PARK%. shifted out of %PARK%.
NOTE: Any failure to meet these expected Fig. 296 Instrument Panel Lower Silencer
responses requires system adjustment or repair. 1 - INSTRUMENT PANEL LOWER SILENCER
DIAGNOSIS AND TESTING - BRAKE/ (3) Rem ove kn ee bolst er (F ig. 297).
TRANSMISSION SHIFT INTERLOCK SOLENOID
F or in t en ded BTSI syst em oper a t ion , r efer t o t h e
followin g ch a r t :
ACTION EXPECTED RESPONSE

pedal applied.
to the %LOCK% or %ACC% %ACC% position. Fig. 297 Knee Bolster
position. 1 - KNEE BOLSTER

the key. position).
(4) Rem ove st eer in g colu m n lower sh r ou d. INSTALLATION
(5) Discon n ect br a ke/t r a n sm ission sh ift in t er lock (1) P la ce in t er lock solen oid in t o posit ion en su r in g
(BTSI) solen oid con n ect or (F ig. 298). h ook on en d of solen oid plu n ger en ga ges gea r sh ift
lever pa wl pin . In st a ll a n d t igh t en scr ews (F ig. 300).

Fig. 298 BTSI Solenoid Connector 1 - SOLENOID RETAINING SCREW (2)
1 - BTSI SOLENOID
2 - SOLENOID CONNECTOR (2) Ver ify gea r sh ift lever is in PARK (P ) a n d con -
n ect solen oid con n ect or (F ig. 301).
(6) Rem ove t wo (2) solen oid-t o-colu m n scr ews (F ig.
299).

Fig. 301 BTSI Solenoid Connector
1 - SOLENOID RETAINING SCREW (2)
1 - BTSI SOLENOID
2 - SOLENOID CONNECTOR
(7) Rem ove solen oid.
(3) In st a ll st eer in g colu m n lower sh r ou d. t r a n sa xle ca se. Th e a ssem bly con sist s of fou r sole-
(4) In st a ll kn ee bolst er (F ig. 302). n oids t h a t con t r ol h ydr a u lic pr essu r e t o t h e LR/CC,
2/4, OD, a n d UD fr ict ion elem en t s. Th e r ever se
clu t ch is con t r olled by lin e pr essu r e fr om t h e m a n u a l
va lve in t h e va lve body. Th e solen oids a r e con t a in ed
wit h in t h e Solen oid/P r essu r e Swit ch Assem bly, a n d
ca n on ly be ser viced by r epla cin g t h e a ssem bly.
Th e solen oid a ssem bly a lso con t a in s pr essu r e
swit ch es t h a t m on it or a n d sen d h ydr a u lic cir cu it
in for m a t ion t o t h e P CM/TCM. Likewise, t h e pr essu r e
swit ch es ca n on ly be ser vice by r epla cin g t h e a ssem -
bly.

1 - KNEE BOLSTER

303).
Fig. 304 Solenoid/Pressure Switch Assembly

1 - SOLENOID AND PRESSURE SWITCH ASSEMBLY
OPERATION
SOLENOIDS
Th e solen oids r eceive elect r ica l power fr om t h e
1 - INSTRUMENT PANEL LOWER SILENCER Tr a n sm ission Con t r ol Rela y t h r ou gh a sin gle wir e.
Th e P CM/TCM en er gizes or oper a t es t h e solen oids
in dividu a lly by gr ou n din g t h e r et u r n wir e of t h e sole-
(7) Ver ify pr oper sh ift in t er lock syst em oper a t ion .
n oid n eeded. Wh en a solen oid is en er gized, t h e sole-
n oid va lve sh ift s, a n d a flu id pa ssa ge is open ed or
MATIC - 31TH /SH IF T INTE RLOCK SOLE NOID -
closed (ven t ed or a pplied), depen din g on it s defa u lt
OP E RATION)
oper a t in g st a t e. Th e r esu lt is a n a pply or r elea se of a
fr ict ion a l elem en t .
SOLEN OI D/PRESSU RE Th e 2/4 a n d UD solen oids a r e n or m a lly a pplied,
wh ich by design a llow flu id t o pa ss t h r ou gh in t h eir
SWI T CH ASSY r ela xed or “off” st a t e. Th is a llows t r a n sa xle lim p-in
(P,R,N,2) in t h e even t of a n elect r ica l fa ilu r e.
DESCRIPTION Th e con t in u it y of t h e solen oids a n d cir cu it s a r e
Th e Solen oid/P r essu r e Swit ch Assem bly (F ig. 304) per iodica lly t est ed. E a ch solen oid is t u r n ed on or off
is ext er n a l t o t h e t r a n sa xle a n d m ou n t ed t o t h e depen din g on it s cu r r en t st a t e. An in du ct ive spike
sh ou ld be det ect ed by t h e P CM/TCM du r in g t h is t est . REMOVAL
It n o spike is det ect ed, t h e cir cu it is t est ed a ga in t o
ver ify t h e fa ilu r e. In a ddit ion t o t h e per iodic t est in g, NOTE: If solenoid/pressure switch assembly is
t h e solen oid cir cu it s a r e t est ed if a speed r a t io or being replaced, the “Quick-Learn” procedure must
pr essu r e swit ch er r or occu r s. be performed. (Refer to 8 - ELECTRICAL/ELEC-
PRESSURE SWITCHES CONTROL MODULE - STANDARD PROCEDURE)
Th e P CM/TCM r elies on t h r ee pr essu r e swit ch es t o
m on it or flu id pr essu r e in t h e L/R, 2/4, a n d OD (1) Discon n ect ba t t er y n ega t ive ca ble.
h ydr a u lic cir cu it s. Th e pr im a r y pu r pose of t h ese (2) Rem ove a ir clea n er a ssem bly.
swit ch es is t o h elp t h e P CM/TCM det ect wh en clu t ch (3) Discon n ect solen oid/pr essu r e swit ch a ssem bly
cir cu it h ydr a u lic fa ilu r es occu r. Th e r a n ge for t h e con n ect or (F ig. 305).
pr essu r e swit ch closin g a n d open in g poin t s is 11-23 (4) Discon n ect in pu t speed sen sor con n ect or (F ig.
psi. Typica lly t h e swit ch open in g poin t will be 305).
a ppr oxim a t ely on e psi lower t h a n t h e closin g poin t .
F or exa m ple, a swit ch m a y close a t 18 psi a n d open
a t 17 psi. Th e swit ch es a r e con t in u ou sly m on it or ed
by t h e P CM/TCM for t h e cor r ect st a t es (open or
closed) in ea ch gea r a s sh own in t h e followin g ch a r t :
PRESSU RE SWI T CH STAT ES
GEAR L/R 2/4 OD
R OP OP OP
P/N CL OP OP
1st CL OP OP
2nd OP CL OP
D OP OP CL
OD OP CL CL
OP = OPEN
CL = CLOSED
A Dia gn ost ic Tr ou ble Code (DTC) will set if t h e
P CM/TCM sen ses a n y swit ch open or closed a t t h e
wr on g t im e in a given gea r. Fig. 305 Transmission Connectors
Th e P CM/TCM a lso t est s t h e 2/4 a n d OD pr essu r e
swit ch es wh en t h ey a r e n or m a lly off (OD a n d 2/4 a r e 2 - INPUT SPEED SENSOR CONNECTOR
t est ed in 1st gea r, OD in 2n d gea r, a n d 2/4 in 3r d 3 - OUTPUT SPEED SENSOR CONNECTOR
gea r ). Th e t est sim ply ver ifies t h a t t h ey a r e oper a - 4 - TRANSMISSION RANGE SENSOR CONNECTOR
t ion a l, by lookin g for a closed st a t e wh en t h e cor r e-
spon din g elem en t is a pplied. Im m edia t ely a ft er a
sh ift in t o 1st , 2n d, or 3r d gea r wit h t h e en gin e speed
a bove 1000 r pm , t h e P CM/TCM m om en t a r ily t u r n s
on elem en t pr essu r e t o t h e 2/4 a n d/or OD clu t ch cir-
cu it s t o iden t ify t h a t t h e a ppr opr ia t e swit ch h a s
closed. If it doesn ’t close, it is t est ed a ga in . If t h e
swit ch fa ils t o close t h e secon d t im e, t h e a ppr opr ia t e
Dia gn ost ic Tr ou ble Code (DTC) will set .
(5) Rem ove in pu t speed sen sor (F ig. 306).
Fig. 306 Input Speed Sensor

Gasket
a ssem bly-t o-t r a n sa xle ca se bolt s (F ig. 307). 1 - SOLENOID/PRESSURE SWITCH ASSEMBLY
2 - GASKET
INSTALLATION
NOTE: If solenoid/pressure switch assembly is
being replaced, it is necessary to perform the
“Quick-Learn” procedure. (Refer to 8 - ELECTRI-
CAL/ELECTRONIC CONTROL MODULES/TRANS-
PROCEDURE)

n ew ga sket t o t r a n sa xle (F ig. 308).
(2) In st a ll a n d t or qu e t h r ee (3) bolt s (F ig. 307) t o
13 N·m (110 in . lbs.).
(3) In st a ll in pu t speed sen sor (F ig. 306) a n d t or qu e
t o 27 N·m (20 ft . lbs.).
(4) Con n ect in pu t speed sen sor con n ect or (F ig.
305).
(5) In st a ll solen oid/pr essu r e swit ch 8-wa y con n ec-
Fig. 307 Solenoid/Pressure Switch Assembly-to- t or a n d t or qu e t o 4 N·m (35 in . lbs.) (F ig. 305).
Case Bolts (6) In st a ll a ir clea n er a ssem bly.
1 - BOLTS (7) Con n ect ba t t er y n ega t ive ca ble.
2 - SOLENOID AND PRESSURE SWITCH ASSEMBLY (8) If solen oid/pr essu r e swit ch a ssem bly wa s
r epla ced, per for m t h e “Qu ick-Lea r n ” pr ocedu r e.
(7) Rem ove solen oid/pr essu r e swit ch a ssem bly a n d (Refer t o 8 - E LE CTRICAL/E LE CTRONIC CON-
ga sket (F ig. 308). Use ca r e t o pr even t ga sket m a t e- TROL MODULE S/TRANSMISSION CONTROL
r ia l a n d for eign object s fr om becom e lodged in t h e MODULE - STANDARD P ROCE DURE )
t r a n sa xle ca se por t s.
SPEED SEN SOR - I N PU T OPERATION

Th e In pu t Speed Sen sor pr ovides in for m a t ion on
DESCRIPTION h ow fa st t h e in pu t sh a ft is r ot a t in g. As t h e t eet h of
Th e In pu t Speed Sen sor is a t wo-wir e m a gn et ic t h e in pu t clu t ch h u b pa ss by t h e sen sor coil (F ig.
picku p device t h a t gen er a t es AC sign a ls a s r ot a t ion 311), a n AC volt a ge is gen er a t ed a n d sen t t o t h e
occu r s. It is t h r ea ded in t o t h e t r a n sa xle ca se (F ig. P CM/TCM. Th e P CM/TCM in t er pr et s t h is in for m a -
309), sea led wit h a n o-r in g (F ig. 310), a n d is con sid- t ion a s in pu t sh a ft r pm .
er ed a pr im a r y in pu t t o t h e P ower t r a in /Tr a n sm ission
Con t r ol Modu le.
Fig. 311 Sensor Relation to Input Clutch Hub

2 - TRANSAXLE CASE
Fig. 309 Input Speed Sensor Location 3 - INPUT CLUTCH HUB

Th e P CM/TCM com pa r es t h e in pu t speed sign a l
wit h ou t pu t speed sign a l t o det er m in e t h e followin g:
Th e P CM/TCM a lso com pa r es t h e in pu t speed sig-
n a l a n d t h e en gin e speed sign a l t o det er m in e t h e fol-
lowin g:
• Tor qu e con ver t er clu t ch slippa ge
• Tor qu e con ver t er elem en t speed r a t io

2 - O-RING
SPEED SEN SOR - I N PU T (Cont inue d)
REMOVAL
312).
Fig. 313 Input (Turbine) Speed Sensor


(3) Un scr ew a n d r em ove in pu t speed sen sor (F ig.

313).
INSTALLATION
314).
N·m (20 ft . lbs.) (F ig. 313). Fig. 314 O-ring Location
(3) Con n ect speed sen sor con n ect or (F ig. 312). 1 - INPUT SPEED SENSOR
(4) Con n ect ba t t er y n ega t ive ca ble. 2 - O-RING
SPEED SEN SOR - OU T PU T OPERATION

Th e Ou t pu t Speed Sen sor pr ovides in for m a t ion on
DESCRIPTION h ow fa st t h e ou t pu t sh a ft is r ot a t in g. As t h e r ea r
Th e Ou t pu t Speed Sen sor is a t wo-wir e m a gn et ic pla n et a r y ca r r ier pa r k pa wl lu gs pa ss by t h e sen sor
picku p device t h a t gen er a t es a n AC sign a l a s r ot a t ion coil (F ig. 317), a n AC volt a ge is gen er a t ed a n d sen t t o
occu r s. It is t h r ea ded in t o t h e t r a n sa xle ca se (F ig. t h e P CM/TCM. Th e P CM/TCM in t er pr et s t h is in for-
315), sea led wit h a n o-r in g (F ig. 316), a n d is con sid- m a t ion a s ou t pu t sh a ft r pm .
er ed a pr im a r y in pu t t o t h e P owet r a in /Tr a n sm ission
Con t r ol Modu le.
Fig. 317 Sensor Relation to Planet Carrier Park Pawl

2 - REAR PLANET CARRIER/OUTPUT SHAFT ASSEMBLY
Fig. 315 Output Speed Sensor 3 - TRANSAXLE CASE
Th e P CM/TCM com pa r es t h e in pu t a n d ou t pu t
speed sign a ls t o det er m in e t h e followin g:
VEHICLE SPEED SIGNAL

Th e veh icle speed sign a l is t a ken fr om t h e Ou t pu t
Speed Sen sor. Th e P CM con ver t s t h is sign a l in t o a
pu lse per m ile sign a l a n d sen ds t h e veh icle speed
m essa ge a cr oss t h e com m u n ica t ion bu s t o t h e BCM.
Th e BCM sen ds t h is sign a l t o t h e In st r u m en t Clu st er
t o displa y veh icle speed t o t h e dr iver. Th e veh icle
speed sign a l pu lse is r ou gh ly 8000 pu lses per m ile.

2 - O-RING
SPEED SEN SOR - OU T PU T (Cont inue d)
REMOVAL
(3) Discon n ect ou t pu t speed sen sor con n ect or (F ig.
318).
Fig. 319 Output Speed Sensor


(4) Un scr ew a n d r em ove ou t pu t speed sen sor (F ig.

319).
INSTALLATION
320).
(2) In st a ll a n d t igh t en in pu t speed sen sor t o 27 Fig. 320 O-ring Location
N·m (20 ft . lbs.). 1 - OUTPUT SPEED SENSOR
(3) Con n ect speed sen sor con n ect or (F ig. 318). 2 - O-RING
T ORQU E CON V ERT ER

DESCRIPTION
Th e t or qu e con ver t er (F ig. 321) is a h ydr a u lic
device t h a t cou ples t h e en gin e cr a n ksh a ft t o t h e
t r a n sm ission . Th e t or qu e con ver t er con sist s of a n
ou t er sh ell wit h a n in t er n a l t u r bin e, a st a t or, a n
over r u n n in g clu t ch , a n im peller a n d a n elect r on ica lly
a pplied con ver t er clu t ch . Th e con ver t er clu t ch pr o-
vides r edu ced en gin e speed a n d gr ea t er fu el econ om y
wh en en ga ged. Clu t ch en ga gem en t a lso pr ovides
r edu ced t r a n sm ission flu id t em per a t u r es. Th e con -
ver t er clu t ch en ga ges in t h ir d gea r. Th e t or qu e con -
ver t er h u b dr ives t h e t r a n sm ission oil (flu id) pu m p.
Th e t or qu e con ver t er is a sea led, welded u n it t h a t
is n ot r epa ir a ble a n d is ser viced a s a n a ssem bly.
Fig. 321 Torque Converter Assembly

1 - TURBINE
2 - IMPELLER
3 - HUB
4 - STATOR
5 - CONVERTER CLUTCH DISC
6 - DRIVE PLATE
IMPELLER
Th e im peller (F ig. 322) is a n in t egr a l pa r t of t h e
con ver t er h ou sin g. Th e im peller con sist s of cu r ved
bla des pla ced r a dia lly a lon g t h e in side of t h e h ou sin g
on t h e t r a n sm ission side of t h e con ver t er. As t h e con -
ver t er h ou sin g is r ot a t ed by t h e en gin e, so is t h e
im peller, beca u se t h ey a r e on e a n d t h e sa m e a n d a r e
t h e dr ivin g m em ber of t h e syst em .
Fig. 322 Impeller

1 - ENGINE FLEXPLATE 4 - ENGINE ROTATION
2 - OIL FLOW FROM IMPELLER SECTION INTO TURBINE 5 - ENGINE ROTATION
SECTION
3 - IMPELLER VANES AND COVER ARE INTEGRAL
TURBINE
Th e t u r bin e (F ig. 323) is t h e ou t pu t , or dr iven ,
m em ber of t h e con ver t er. Th e t u r bin e is m ou n t ed
wit h in t h e h ou sin g opposit e t h e im peller, bu t is n ot
a t t a ch ed t o t h e h ou sin g. Th e in pu t sh a ft is in ser t ed
t h r ou gh t h e cen t er of t h e im peller a n d splin ed in t o
t h e t u r bin e. Th e design of t h e t u r bin e is sim ila r t o
t h e im peller, except t h e bla des of t h e t u r bin e a r e
cu r ved in t h e opposit e dir ect ion .
Fig. 323 Turbine

1 - TURBINE VANE 4 - PORTION OF TORQUE CONVERTER COVER
2 - ENGINE ROTATION 5 - ENGINE ROTATION
3 - INPUT SHAFT 6 - OIL FLOW WITHIN TURBINE SECTION
STATOR
Th e st a t or a ssem bly (F ig. 324) is m ou n t ed on a st a -
t ion a r y sh a ft wh ich is a n in t egr a l pa r t of t h e oil
pu m p. Th e st a t or is loca t ed bet ween t h e im peller a n d
t u r bin e wit h in t h e t or qu e con ver t er ca se (F ig. 325).
Th e st a t or con t a in s a n over-r u n n in g clu t ch , wh ich
a llows t h e st a t or t o r ot a t e on ly in a clockwise dir ec-
t ion . Wh en t h e st a t or is locked a ga in st t h e over-r u n -
n in g clu t ch , t h e t or qu e m u lt iplica t ion fea t u r e of t h e
t or qu e con ver t er is oper a t ion a l.
Fig. 325 Stator Location

1 - STATOR
2 - IMPELLER
3 - FLUID FLOW
4 - TURBINE
Fig. 324 Stator Components

1 - CAM (OUTER RACE)
2 - ROLLER
3 - SPRING
4 - INNER RACE
TORQUE CONVERTER CLUTCH (TCC)

Th e TCC (F ig. 326) wa s in st a lled t o im pr ove t h e
efficien cy of t h e t or qu e con ver t er t h a t is lost t o t h e
slippa ge of t h e flu id cou plin g. Alt h ou gh t h e flu id cou -
plin g pr ovides sm oot h , sh ock–fr ee power t r a n sfer, it
is n a t u r a l for a ll flu id cou plin gs t o slip. If t h e im pel-
ler a n d t u r bin e wer e m ech a n ica lly locked t oget h er, a
zer o slippa ge con dit ion cou ld be obt a in ed. A h ydr a u lic
pist on wa s a dded t o t h e t u r bin e, a n d a fr ict ion m a t e-
r ia l wa s a dded t o t h e in side of t h e fr on t cover t o pr o-
vide t h is m ech a n ica l lock-u p.
OPERATION
Th e con ver t er im peller (F ig. 327) (dr ivin g m em ber ),
Fig. 326 Torque Converter Clutch (TCC)
wh ich is in t egr a l t o t h e con ver t er h ou sin g a n d bolt ed
1 - IMPELLER FRONT COVER
t o t h e en gin e dr ive pla t e, r ot a t es a t en gin e speed. 2 - THRUST WASHER ASSEMBLY
Th e con ver t er t u r bin e (dr iven m em ber ), wh ich r ea ct s 3 - IMPELLER
fr om flu id pr essu r e gen er a t ed by t h e im peller, r ot a t es 4 - STATOR
5 - TURBINE
a n d t u r n s t h e t r a n sm ission in pu t sh a ft . 6 - PISTON
7 - FRICTION DISC
TURBINE
As t h e flu id t h a t wa s pu t in t o m ot ion by t h e im pel- t u r bin e a n d t h e in pu t sh a ft . Th is ca u ses bot h of t h em
ler bla des st r ikes t h e bla des of t h e t u r bin e, som e of (t u r bin e a n d in pu t sh a ft ) t o r ot a t e in a clockwise
t h e en er gy a n d r ot a t ion a l for ce is t r a n sfer r ed in t o t h e dir ect ion followin g t h e im peller. As t h e flu id is lea v-
Fig. 327 Torque Converter Fluid Operation

1 - APPLY PRESSURE 3 - RELEASE PRESSURE
2 - THE PISTON MOVES SLIGHTLY FORWARD 4 - THE PISTON MOVES SLIGHTLY REARWARD
in g t h e t r a ilin g edges of t h e t u r bin e’s bla des it con -

t in u es in a “h in der in g” dir ect ion ba ck t owa r d t h e
im peller. If t h e flu id is n ot r edir ect ed befor e it st r ikes
t h e im peller, it will st r ike t h e im peller in su ch a
dir ect ion t h a t it wou ld t en d t o slow it down .
STATOR
Tor qu e m u lt iplica t ion is a ch ieved by lockin g t h e
st a t or ’s over-r u n n in g clu t ch t o it s sh a ft (F ig. 328).
Un der st a ll con dit ion s (t h e t u r bin e is st a t ion a r y), t h e
oil lea vin g t h e t u r bin e bla des st r ikes t h e fa ce of t h e
st a t or bla des a n d t r ies t o r ot a t e t h em in a cou n t er-
clockwise dir ect ion . Wh en t h is h a ppen s t h e over –r u n -
n in g clu t ch of t h e st a t or locks a n d h olds t h e st a t or
fr om r ot a t in g. Wit h t h e st a t or locked, t h e oil st r ikes
t h e st a t or bla des a n d is r edir ect ed in t o a “h elpin g”
Fig. 328 Stator Operation
dir ect ion befor e it en t er s t h e im peller. Th is cir cu la -
t ion of oil fr om im peller t o t u r bin e, t u r bin e t o st a t or, 1 - DIRECTION STATOR WILL FREE WHEEL DUE TO OIL
PUSHING ON BACKSIDE OF VANES
a n d st a t or t o im peller, ca n pr odu ce a m a xim u m 2 - FRONT OF ENGINE
t or qu e m u lt iplica t ion of a bou t 2.4:1. As t h e t u r bin e 3 - INCREASED ANGLE AS OIL STRIKES VANES
4 - DIRECTION STATOR IS LOCKED UP DUE TO OIL PUSHING
begin s t o m a t ch t h e speed of t h e im peller, t h e flu id AGAINST STATOR VANES
t h a t wa s h it t in g t h e st a t or in su ch a s wa y a s t o
ca u se it t o lock–u p is n o lon ger doin g so. In t h is con - TORQUE CONVERTER CLUTCH (TCC)
dit ion of oper a t ion , t h e st a t or begin s t o fr ee wh eel In a st a n da r d t or qu e con ver t er, t h e im peller a n d
a n d t h e con ver t er a ct s a s a flu id cou plin g. t u r bin e a r e r ot a t in g a t a bou t t h e sa m e speed a n d t h e
st a t or is fr eewh eelin g, pr ovidin g n o t or qu e m u lt ipli-
ca t ion . By a pplyin g t h e t u r bin e’s pist on t o t h e fr on t
cover ’s fr ict ion m a t er ia l, a t ot a l con ver t er en ga ge-
m en t ca n be obt a in ed. Th e r esu lt of t h is en ga gem en t (3) Align t or qu e con ver t er t o oil pu m p sea l open -
is a dir ect 1:1 m ech a n ica l lin k bet ween t h e en gin e in g.
a n d t h e t r a n sm ission . (4) In ser t t or qu e con ver t er h u b in t o oil pu m p.
Th e en ga gem en t a n d disen ga gem en t of t h e TCC (5) Wh ile pu sh in g t or qu e con ver t er in wa r d, r ot a t e
a r e a u t om a t ic a n d con t r olled by t h e P ower t r a in Con - con ver t er u n t il con ver t er is fu lly sea t ed in t h e oil
t r ol Modu le (P CM). Th e en ga gem en t ca n n ot be a ct i- pu m p gea r s.
va t ed in t h e lower gea r s beca u se it elim in a t es t h e (6) Ch eck con ver t er sea t in g wit h a sca le a n d
t or qu e m u lt iplica t ion effect of t h e t or qu e con ver t er st r a igh t edge (F ig. 329). Su r fa ce of con ver t er lu gs
n ecessa r y for a cceler a t ion . In pu t s t h a t det er m in e sh ou ld be 1/2 in . t o r ea r of st r a igh t edge wh en con -
clu t ch en ga gem en t a r e: coola n t t em per a t u r e, veh icle ver t er is fu lly sea t ed.
speed a n d t h r ot t le posit ion . Th e t or qu e con ver t er (7) If n ecessa r y, t em por a r ily secu r e con ver t er wit h
clu t ch is en ga ged by t h e clu t ch solen oid on t h e va lve C-cla m p a t t a ch ed t o t h e con ver t er h ou sin g.
body. Th e clu t ch will en ga ge a t a ppr oxim a t ely 56 (8) In st a ll t h e t r a n sm ission in t h e veh icle. (Refer
km /h (35 m ph ) wit h ligh t t h r ot t le, a ft er t h e sh ift t o t o 21 - TRANSMISSION/TRANSAXLE /AUTOMATIC
t h ir d gea r. - 41TE - INSTALLATION)
(9) F ill t h e t r a n sm ission wit h t h e r ecom m en ded
REMOVAL flu id. (Refer t o 21 - TRANSMISSION/TRANSAXLE /
(1) Rem ove t r a n sm ission a n d t or qu e con ver t er AUTOMATIC - 41TE /F LUID - STANDARD P ROCE -
fr om veh icle. (Refer t o 21 - TRANSMISSION/TRANS- DURE )
AXLE /AUTOMATIC - 41TE - RE MOVAL)
(2) P la ce a su it a ble dr a in pa n u n der t h e con ver t er
h ou sin g en d of t h e t r a n sm ission .
CAUTION: Verify that transmission is secure on the

lifting device or work surface, the center of gravity
of the transmission will shift when the torque con-
verter is removed creating an unstable condition.
The torque converter is a heavy unit. Use caution
when separating the torque converter from the
transmission.
(3) P u ll t h e t or qu e con ver t er for wa r d u n t il t h e cen -

t er h u b clea r s t h e oil pu m p sea l.
(4) Sepa r a t e t h e t or qu e con ver t er fr om t h e t r a n s-
m ission .
INSTALLATION
Ch eck con ver t er h u b a n d dr ive n ot ch es for sh a r p
edges, bu r r s, scr a t ch es, or n icks. P olish t h e h u b a n d
n ot ch es wit h 320/400 gr it pa per or cr ocu s clot h if n ec- Fig. 329 Checking Torque Converter Seating
essa r y. Th e h u b m u st be sm oot h t o a void da m a gin g 1 - SCALE
t h e pu m p sea l a t in st a lla t ion . 2 - STRAIGHTEDGE
(1) Lu br ica t e con ver t er h u b a n d oil pu m p sea l lip
wit h t r a n sm ission flu id.
(2) P la ce t or qu e con ver t er in posit ion on t r a n sm is-
sion .
CAUTION: Do not damage oil pump seal or bushing

while inserting torque converter into the front of the
transmission.
T RAN SM I SSI ON CON T ROL ca n on ly be ser viced by r em ovin g t h e va lve body. Th e

elect r ica l con n ect or ext en ds t h r ou gh t h e t r a n sa xle
RELAY ca se (F ig. 331).
DESCRIPTION
Th e t r a n sm ission con t r ol r ela y (F ig. 330) is loca t ed
in t h e In t elligen t P ower Modu le (IP M), wh ich is
loca t ed on t h e left side of t h e en gin e com pa r t m en t
bet ween t h e ba t t er y a n d left fen der.
Fig. 331 Transmission Range Sensor (TRS)

Location
Th e Tr a n sm ission Ra n ge Sen sor (TRS) h a s fou r

Fig. 330 Transmission Control Relay Location swit ch con t a ct s t h a t m on it or sh ift lever posit ion a n d
1 - TRANSMISSION CONTROL RELAY sen d t h e in for m a t ion t o t h e P CM/TCM.
2 - LEFT FENDER Th e TRS a lso h a s a n in t egr a t ed t em per a t u r e sen -
3 - INTELLIGENT POWER MODULE (IPM) sor (t h er m ist or ) t h a t com m u n ica t es t r a n sa xle t em -
4 - BATTERY
per a t u r e t o t h e TCM a n d P CM (F ig. 332).
OPERATION
Th e r ela y is su pplied fu sed B+ volt a ge, en er gized by
t h e P CM/TCM, a n d is u sed t o su pply power t o t h e sole-
n oid pa ck wh en t h e t r a n sm ission is in n or m a l oper a t in g
m ode. Wh en t h e r ela y is “off”, n o power is su pplied t o
t h e solen oid pa ck a n d t h e t r a n sm ission is in “lim p-in ”
m ode. Aft er a con t r oller r eset (ign it ion key t u r n ed t o t h e
“r u n ” posit ion or a ft er cr a n kin g en gin e), t h e P CM/TCM
en er gizes t h e r ela y. P r ior t o t h is, t h e P CM/TCM ver ifies
t h a t t h e con t a ct s a r e open by ch eckin g for n o volt a ge a t
t h e swit ch ed ba t t er y t er m in a ls. Aft er t h is is ver ified,
t h e volt a ge a t t h e solen oid pa ck pr essu r e swit ch es is
ch ecked. Aft er t h e r ela y is en er gized, t h e P CM/TCM
m on it or s t h e t er m in a ls t o ver ify t h a t t h e volt a ge is
gr ea t er t h a n 3 volt s.
T RAN SM I SSI ON RAN GE

SEN SOR Fig. 332 Transmission Temperature Sensor
2 - TEMPERATURE SENSOR
DESCRIPTION
Th e Tr a n sm ission Ra n ge Sen sor (TRS) is m ou n t ed
t o t h e t op of t h e va lve body in side t h e t r a n sa xle a n d
T RAN SM I SSI ON RAN GE SEN SOR (Cont inue d)
OPERATION dict ed flu id t em per a t u r e wh ich is ca lcu la t ed fr om a

Th e Tr a n sm ission Ra n ge Sen sor (TRS) (F ig. 331) com bin a t ion of in pu t s:
com m u n ica t es sh ift lever posit ion (SLP ) t o t h e P CM/ • Ba t t er y (a m bien t ) t em per a t u r e
TCM a s a com bin a t ion of open a n d closed swit ch es. • E n gin e coola n t t em per a t u r e
E a ch sh ift lever posit ion h a s a n a ssign ed com bin a - • In -gea r r u n t im e sin ce st a r t -u p
t ion of swit ch st a t es (open /closed) t h a t t h e P CM/TCM
r eceives fr om fou r sen se cir cu it s. Th e P CM/TCM REMOVAL
in t er pr et s t h is in for m a t ion a n d det er m in es t h e (1) Rem ove va lve body a ssem bly fr om t r a n sa xle.
a ppr opr ia t e t r a n sa xle gea r posit ion a n d sh ift sch ed- (Refer t o 21 - TRANSMISSION/TRANSAXLE /AUTO-
u le. MATIC - 41TE /VALVE BODY - RE MOVAL)
Sin ce t h er e a r e fou r swit ch es, t h er e a r e 16 possible (2) Rem ove t r a n sm ission r a n ge sen sor r et a in in g
com bin a t ion s of open a n d closed swit ch es (codes). scr ew a n d r em ove sen sor fr om va lve body (F ig. 333).
Seven of t h ese codes a r e r ela t ed t o gea r posit ion a n d
t h r ee a r e r ecogn ized a s “bet ween gea r ” codes. Th is
r esu lt s in six codes wh ich sh ou ld n ever occu r. Th ese
a r e ca lled “in va lid” codes. An in va lid code will r esu lt
in a DTC, a n d t h e P CM/TCM will t h en det er m in e t h e
sh ift lever posit ion ba sed on pr essu r e swit ch da t a .
Th is a llows r ea son a bly n or m a l t r a n sm ission oper a -
t ion wit h a TRS fa ilu r e.
T RS SWI T CH STAT ES
SLP T42 T41 T3 T1

P CL CL CL OP
R CL OP OP OP
N CL CL OP CL
OD OP OP OP CL
3 OP OP CL OP
L CL OP CL CL
TRANSMISSION TEMPERATURE SENSOR 2 - MANUAL VALVE CONTROL PIN
Th e TRS h a s a n in t egr a t ed t h er m ist or (F ig. 332) 3 - RETAINING SCREW
t h a t t h e P CM/TCM u ses t o m on it or t h e t r a n sm is-
sion ’s su m p t em per a t u r e. Sin ce flu id t em per a t u r e (3) Rem ove TRS fr om m a n u a l sh a ft .
ca n a ffect t r a n sm ission sh ift qu a lit y a n d con ver t or
lock u p, t h e P CM/TCM r equ ir es t h is in for m a t ion t o INSTALLATION
det er m in e wh ich sh ift sch edu le t o oper a t e in . Th e (1) In st a ll t r a n sm ission r a n ge sen sor (TRS) t o t h e
P CM a lso m on it or s t h is t em per a t u r e da t a so it ca n va lve body a n d t or qu e r et a in in g scr ew (F ig. 333) t o 5
en er gize t h e veh icle coolin g fa n (s) wh en a t r a n sm is- N·m (45 in . lbs.).
sion “over h ea t ” con dit ion exist s. If t h e t h er m ist or cir- (2) In st a ll va lve body t o t r a n sa xle. (Refer t o 21 -
cu it fa ils, t h e P CM/TCM will r ever t t o ca lcu la t ed oil TRANSMISSION/TRANSAXLE /AUTOMATIC -
t em per a t u r e u sa ge. 41TE /VALVE BODY - INSTALLATION)
CALCULATED TEMPERATURE
A fa ilu r e in t h e t em per a t u r e sen sor or cir cu it will
r esu lt in ca lcu la t ed t em per a t u r e bein g su bst it u t ed for
a ct u a l t em per a t u r e. Ca lcu la t ed t em per a t u r e is a pr e-
VALV E BODY OPERATION
DESCRIPTION NOTE: Refer to the Hydraulic Schematics for a

visual aid in determining valve location, operation
Th e va lve body a ssem bly con sist s of a ca st a lu m i-
and design.
n u m va lve body, a sepa r a t or pla t e, a n d t r a n sfer
pla t e. Th e va lve body con t a in s va lves a n d ch eck ba lls
t h a t con t r ol flu id deliver y t o t h e t or qu e con ver t er REGULATOR VALVE
clu t ch , solen oid/pr essu r e swit ch a ssem bly, a n d fr ic- Th e r egu la t or va lve con t r ols h ydr a u lic pr essu r e in
t ion a l clu t ch es. Th e va lve body con t a in s t h e followin g t h e t r a n sa xle. It r eceives u n r egu la t ed pr essu r e fr om
com pon en t s (F ig. 334): t h e pu m p, wh ich wor ks a ga in st spr in g t en sion t o
• Regu la t or va lve m a in t a in oil a t specific pr essu r es. A syst em of sleeves
• Solen oid swit ch va lve a n d por t s a llows t h e r egu la t or va lve t o wor k a t on e of
• Ma n u a l va lve t h r ee pr edet er m in ed pr essu r e levels. Regu la t ed oil
• Con ver t er clu t ch swit ch va lve pr essu r e is a lso r efer r ed t o a s “lin e pr essu r e.”
• Con ver t er clu t ch con t r ol va lve
• Tor qu e con ver t er r egu la t or va lve SOLENOID SWITCH VALVE
• Low/Rever se swit ch va lve Th e solen oid swit ch va lve con t r ols lin e pr essu r e
In a ddit ion , t h e va lve body a lso con t a in s t h e t h er- fr om t h e LR/CC solen oid. In on e posit ion , it a llows
m a l va lve, #2,3&4 ch eck ba lls, t h e #5 (over dr ive) t h e low/r ever se clu t ch t o be pr essu r ized. In t h e ot h er,
ch eck va lve a n d t h e 2/4 a ccu m u la t or a ssem bly. (Refer it dir ect s lin e pr essu r e t o t h e con ver t er con t r ol a n d
t o 21 - TRANSMISSION/TRANSAXLE /AUTOMATIC con ver t er clu t ch va lves.
- 41TE /VALVE BODY - DISASSE MBLY)
Fig. 334 Valve Body Assembly

MANUAL VALVE MODULES/TRANSMISSION CONTROL MODULE -
Th e m a n u a l va lve is oper a t ed by t h e m ech a n ica l STANDARD PROCEDURE)
sh ift lin ka ge. It s pr im a r y r espon sibilit y is t o sen d (1) Discon n ect ba t t er y n ega t ive ca ble.
lin e pr essu r e t o t h e a ppr opr ia t e h ydr a u lic cir cu it s (2) Discon n ect gea r sh ift ca ble fr om m a n u a l va lve
a n d solen oids. Th e va lve h a s t h r ee oper a t in g r a n ges lever.
or posit ion s. (3) Rem ove m a n u a l va lve lever fr om m a n u a l sh a ft .
CONVERTER CLUTCH SWITCH VALVE (5) Rem ove oil pa n bolt s (F ig. 335).
Th e m a in r espon sibilit y of t h e con ver t er clu t ch
swit ch va lve is t o con t r ol h ydr a u lic pr essu r e a pplied
t o t h e fr on t (off) side of t h e con ver t er clu t ch pist on .
Lin e pr essu r e fr om t h e r egu la t or va lve is fed t o t h e
t or qu e con ver t er r egu la t or va lve, wh er e it pa sses
t h r ou gh t h e va lve, a n d is sligh t ly r egu la t ed. Th e
pr essu r e is t h en dir ect ed t o t h e con ver t er clu t ch
swit ch va lve a n d t o t h e fr on t side of t h e con ver t er
clu t ch pist on . Th is pr essu r e pu sh es t h e pist on ba ck
a n d disen ga ges t h e con ver t er clu t ch .
CONVERTER CLUTCH CONTROL VALVE

Th e con ver t er clu t ch con t r ol va lve con t r ols t h e
ba ck (on ) side of t h e t or qu e con ver t er clu t ch . Wh en
t h e P CM/TCM en er gizes or m odu la t es t h e LR/CC
solen oid t o a pply t h e con ver t er clu t ch pist on , bot h
t h e con ver t er clu t ch con t r ol va lve a n d t h e con ver t er Fig. 335 Oil Pan Bolts
con t r ol va lve m ove, a llowin g pr essu r e t o be a pplied t o 1 - OIL PAN BOLTS (USE RTV UNDER BOLT HEADS)
t h e ba ck side of t h e clu t ch .
(6) Rem ove oil pa n (F ig. 336).
T/C REGULATOR VALVE
Th e t or qu e con ver t er r egu la t or va lve sligh t ly r egu -
la t es t h e flow of flu id t o t h e t or qu e con ver t er.
LOW/REVERSE SWITCH VALVE

Th e low/r ever se clu t ch is a pplied fr om differ en t
sou r ces, depen din g on wh et h er low (1st ) gea r or
r ever se is select ed. Th e low/r ever se swit ch va lve
a lt er n a t es posit ion s depen din g on fr om wh ich dir ec-
t ion flu id pr essu r e is a pplied. By design , wh en t h e
va lve is sh ift ed by flu id pr essu r e fr om on e ch a n n el,
t h e opposin g ch a n n el is blocked. Th e swit ch va lve
a lien a t es t h e possibilit y of a st ickin g ba ll ch eck, t h u s
pr ovidin g con sist en t a pplica t ion of t h e low/r ever se
clu t ch u n der a ll oper a t in g con dit ion s.
REMOVAL Fig. 336 Oil Pan

NOTE: If valve body is replaced or reconditioned, 1 - OIL PAN
the “Quick-Learn” Procedure must be performed. 3 - OIL FILTER
(7) Rem ove oil filt er (F ig. 337). (9) Rem ove pa r k r od r oller s fr om gu ide br a cket
a n d r em ove va lve body fr om t r a n sa xle (F ig. 339) (F ig.
340).
Fig. 337 Oil Filter Fig. 339 Push Park Rod Rollers from Guide Bracket
1 - OIL FILTER
2 - SCREWDRIVER
2 - O-RING
(8) Rem ove t h e va lve body-t o-t r a n sa xle ca se bolt s

(F ig. 338).

1 - VALVE BODY
CAUTION: The valve body manual shaft pilot may

distort and bind the manual valve if the valve body
Fig. 338 Valve Body Attaching Bolts is mishandled or dropped.
2 - VALVE BODY
NOTE: To ease removal of the valve body, turn the

manual valve lever fully clockwise to low or first
gear.
DISASSEMBLY (3) Rem ove Ma n u a l Sh a ft /Roost er Com b and

Tr a n sm ission Ra n ge Sen sor (F ig. 343).
NOTE: If valve body assembly is being recondi-
tioned, the PCM/TCM Quick Learn Procedure must
(1) Rem ove m a n u a l sh a ft sea l (F ig. 341).
Fig. 343 Manual Shaft/Rooster Comb and

2 - MANUAL SHAFT
3 - ROOSTER COMB
(4) Rem ove 2/4 Accu m u la t or Ret a in in g P la t e (F ig.

Fig. 341 Manual Shaft Seal 344).
1 - SEAL
2 - MANUAL SHAFT
(2) Rem ove Tr a n sm ission Ra n ge Sen sor r et a in in g

scr ew (F ig. 342).

2 - DETENT SPRING

3 - RETAINING SCREW
(5) Rem ove 2/4 Accu m u la t or com pon en t s a s sh own (7) In ver t a ssem bly a n d r em ove Tr a n sfer P la t e
in (F ig. 345). (F ig. 347). Bewa r e of loose ch eck ba lls.

1 - VALVE BODY
2 - RETAINER PLATE
3 - DETENT SPRING Fig. 347 Remove Transfer Plate
4 - RETURN SPRINGS
5 - PISTON 1 - TRANSFER PLATE
(6) Rem ove Va lve Body t o Tr a n sfer P la t e scr ews (8) Rem ove oil scr een (F ig. 348).
(F ig. 346).
Fig. 348 Remove Oil Screen

Fig. 346 Remove Valve Body to Transfer Plate 1 - OIL SCREEN
Screws
1 - SCREW (24)
2 - TRANSFER PLATE
3 - VALVE BODY
(9) Rem ove t h e over dr ive clu t ch (#5) ch eck va lve (11) Rem ove t h er m a l va lve (F ig. 351).
(F ig. 349)
Fig. 351 Remove Thermal Valve

Fig. 349 Remove Overdrive Clutch (#5) Check Valve 1 - THERMAL VALVE
(12) Rem ove ch eck ba lls (F ig. 352).
(10) Rem ove sepa r a t or pla t e (F ig. 350).
NOTE: Tag all valve/spring assemblies for reassem-
bly identification.
(13) Rem ove du a l r et a in er pla t e u sin g Tool 6301

(F ig. 353).
(14) Rem ove r egu la t or va lve spr in g r et a in er (F ig.
354).
Fig. 350 Remove Separator Plate

1 - SEPARATOR PLATE
2 - VALVE BODY

Fig. 353 Remove Dual Retainer Plate using Tool Fig. 354 Remove Regulator Valve Spring Retainer
6301 using Tool 6302
1 - TOOL 6301 1 - TOOL 6302
(15) Rem ove r em a in in g r et a in er s a s sh own in (F ig.
355).
(16) Rem ove va lves a n d spr in gs a s sh own in (F ig.
356).
NOTE: Refer to Valve Body Cleaning and Inspection

for cleaning procedures.

1 - RETAINER
2 - RETAINER
Fig. 356 Springs and Valves Location

ASSEMBLY
NOTE: If valve body assembly is reconditioned, the
PCM/TCM Quick Learn Procedure must be per-
formed. (Refer to 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/TRANSMISSION CONTROL
MODULE - STANDARD PROCEDURE)
(1) In st a ll va lves a n d spr in gs a s sh own in (F ig.

356).
(2) In st a ll r egu la t or va lve spr in g r et a in er (F ig.
357).
Fig. 358 Install Dual Retainer Plate using Tool 6301

1 - TOOL 6301
2 - RETAINER
Fig. 357 Install Regulator Valve Spring Retainer

using Tool 6302
1 - TOOL 6302
2 - RETAINER
(3) In st a ll du a l r et a in er pla t e u sin g Tool 6301 (F ig.

358).
(4) Ver ify t h a t a ll r et a in er s a r e in st a lled a s sh own
in (F ig. 359). Ret a in er s sh ou ld be flu sh or below
va lve body su r fa ce.

1 - RETAINER
2 - RETAINER
(5) In st a ll ch eck ba lls in t o posit ion a s sh own in
(F ig. 360). If n ecessa r y, secu r e t h em wit h pet r ola t u m
or t r a n sm ission a ssem bly gel for a ssem bly ea se.
(6) In st a ll t h er m a l va lve in t o t r a n sfer pla t e (F ig.
361).
Fig. 361 Install Thermal Valve

1 - THERMAL VALVE

(7) In st a ll sepa r a t or pla t e t o va lve body (F ig. 362). (9) In st a ll oil scr een t o sepa r a t or pla t e (F ig. 364).
Fig. 362 Install Separator Plate Fig. 364 Install Oil Screen
1 - SEPARATOR PLATE 1 - OIL SCREEN
2 - VALVE BODY
(10) In st a ll t r a n sfer pla t e t o va lve body a n d sepa -

(8) In st a ll t h e over dr ive clu t ch (#5) ch eck va lve t o
r a t or pla t e. Ma ke su r e oil scr een a n d #5 ch eck va lve
sepa r a t or pla t e (F ig. 363)
do n ot bin d (F ig. 365).
Fig. 363 Install Overdrive Clutch (#5) Check Valve

Fig. 365 Install Transfer Plate
1 - TRANSFER PLATE
(11) In st a ll t wen t y-fou r t r a n sfer pla t e t o va lve (13) Tor qu e 2/4 Accu m u la t or r et a in er t o 5 N·m (45
body scr ews (F ig. 366) a n d t or qu e t o 5 N·m (45 in . in . lbs.) (F ig. 368).
lbs.).

2 - DETENT SPRING
(14) In st a ll Ma n u a l Sh a ft /Roost er Com b and

Fig. 366 Install Valve Body to Transfer Plate Screws Tr a n sm ission Ra n ge Sen sor (F ig. 369).
1 - SCREW (24)
2 - TRANSFER PLATE
3 - VALVE BODY
(12) In st a ll 2/4 Accu m u la t or com pon en t s a s sh own

in (F ig. 367).
Fig. 369 Install Manual Shaft/Rooster Comb and

Fig. 367 2/4 Accumulator Assembly 1 - TRANSMISSION RANGE SENSOR
2 - MANUAL SHAFT
1 - VALVE BODY
3 - ROOSTER COMB
2 - RETAINER PLATE
3 - DETENT SPRING
4 - RETURN SPRINGS
5 - PISTON
(15) Ma ke su r e Ma n u a l Va lve con t r ol pin is con - INSTALLATION
t a in ed wit h in t h e r oost er com b slot (F ig. 370). In st a ll
Tr a n sm ission Ra n ge Sen sor r et a in in g scr ew (F ig. NOTE: If valve body assembly is being replaced or
370) a n d t or qu e t o 5 N·m (45 in . lbs.). reconditioned, the “Quick-Learn” procedure must
(1) In st a ll va lve body a ssem bly t o t r a n sa xle (F ig.

372). In st a ll a n d t or qu e va lve body-t o-t r a n sa xle ca se
bolt s (F ig. 373) t o 12 N·m (105 in . lbs.).
Fig. 370 Install Transmission Range Sensor

Retaining Screw
3 - RETAINING SCREW
(16) In st a ll m a n u a l sh a ft sea l (F ig. 371). 1 - VALVE BODY
Fig. 371 Manual Shaft Seal

Fig. 373 Valve Body Attaching Bolts
1 - SEAL
2 - MANUAL SHAFT 1 - VALVE BODY ATTACHING BOLTS (18)
2 - VALVE BODY
(2) In st a ll t r a n sa xle oil filt er (F ig. 374). In spect
t h e o-r in g a n d r epla ce if n ecessa r y.
Fig. 375 Oil Pan

1 - OIL PAN
3 - OIL FILTER
Fig. 374 Oil Filter

1 - OIL FILTER
2 - O-RING
(3) E n su r e t h e t r a n sa xle oil pa n a n d t r a n sa xle

ca se sea lin g su r fa ces a r e clea n a n d dr y. In st a ll a n
1/8” bea d of Mopa r ! Silicon e Ru bber Adh esive Sea l-
a n t t o t h e oil pa n a n d in st a ll (F ig. 375). Tor qu e oil
pa n -t o-t r a n sa xle ca se bolt s (F ig. 376) t o 19 N·m (165
in . lbs.).
(4) Lower veh icle.
(5) Con n ect t r a n sm ission r a n ge sen sor con n ect or.
(6) In st a ll m a n u a l va lve lever t o m a n u a l sh a ft .
(7) In st a ll gea r sh ift ca ble t o m a n u a l va lve lever.
(9) F ill t r a n sa xle wit h Mopa r ! ATF +4 Tr a n sm is-
Fig. 376 Oil Pan Bolts
sion flu id. (Refer t o 21 - TRANSMISSION/TRANS-
AXLE /AUTOMATIC - 41TE /F LUID - STANDARD
P ROCE DURE )
RS TIRES/WHEELS 22 - 1
TIRES/WHEELS
page page
TIRES/WHEELS DIAGNOSIS AND TESTING

DIAGNOSIS AND TESTING - TIRE AND DIAGNOSIS AND TESTING - TIRE NOISE . . . 14
WHEEL VIBRATION . . . . . . . . . . . . . . . . . . . . . 1 DIAGNOSIS AND TESTING - TIRE/VEHICLE
STANDARD PROCEDURE LEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
STANDARD PROCEDURE - TIRE AND DIAGNOSIS AND TESTING - TIRE WEAR
WHEEL BALANCE . . . . . . . . . . . . . . . . . . . . . . 5 PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . 16
STANDARD PROCEDURE - TIRE AND DIAGNOSIS AND TESTING - TREAD WEAR
WHEEL MATCH MOUNTING . . . . . . . . . . . . . . 7 INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . . 16
STANDARD PROCEDURE - TIRE AND STANDARD PROCEDURE
WHEEL ROTATION . . . . . . . . . . . . . . . . . . . . . 7 STANDARD PROCEDURE - TIRE INFLATION
REMOVAL PRESSURES . . . . . . . . . . . . . . . . . . . . . . . . . 16
REMOVAL - TIRE AND WHEEL ASSEMBLY STANDARD PROCEDURE - TIRE
(ALUMINUM WHEEL) . . . . . . . . . . . . . . . . . . . . 8 PRESSURE FOR HIGH SPEED
REMOVAL - TIRE AND WHEEL ASSEMBLY OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 17
(STEEL WHEEL) . . . . . . . . . . . . . . . . . . . . . . . 8 STANDARD PROCEDURE - TIRE LEAK
INSTALLATION REPAIRING . . . . . . . . . . . . . . . . . . . . . . . . . . 17
INSTALLATION - TIRE AND WHEEL CLEANING - TIRES .................... . 18
ASSEMBLY (ALUMINUM WHEEL) . . . . . . . . . . 8 WHEELS
INSTALLATION - TIRE AND WHEEL DESCRIPTION - WHEEL . . . . . . . . . . . . . . . . . . 18
ASSEMBLY (STEEL WHEEL) . . . . . . . . . . . . . . 8 DIAGNOSIS AND TESTING - WHEEL
TIRE PRESSURE MONITORING INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . 19
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . 9 CLEANING
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 WHEEL AND WHEEL TRIM CARE . . . . . . . . . 19
SENSOR - TPM SPECIFICATIONS
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 10 WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 WHEEL COVER
CAUTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 19
DIAGNOSIS AND TESTING - TIRE PRESSURE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 20
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 WHEEL MOUNTING STUDS - FRONT
TIRES INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21
DESCRIPTION WHEEL MOUNTING STUDS - REAR
DESCRIPTION - TIRE . . . . . . . . . . . . . . . . . . 13 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
DESCRIPTION - RADIAL-PLY TIRES . . . . . . . 13 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 22
DESCRIPTION - REPLACEMENT TIRES . . . . 14
DESCRIPTION - SPARE TIRE
(TEMPORARY) . . . . . . . . . . . . . . . . . . . . . . . 14
T I RES/WH EELS VISUAL INSPECTION

Visu a l in spect ion of t h e veh icle is r ecom m en ded
DIAGNOSIS AND TESTING - TIRE AND WHEEL pr ior t o r oa d t est in g or per for m in g a n y ot h er pr oce-
du r e. Ra ise veh icle on a su it a ble h oist . (Refer t o
VIBRATION LUBRICATION & MAINTE NANCE /H OISTING -
Tir e a n d wh eel im ba la n ce, r u n ou t a n d for ce va r ia -
t ion ca n ca u se veh icles t o exh ibit st eer in g wh eel
In spect for t h e followin g:
vibr a t ion .
• Ver ify cor r ect (OE M) wh eel a n d t ir e, a s well a s
cor r ect wh eel weigh t s. Alu m in u m wh eels r equ ir e
22 - 2 TIRES/WHEELS RS
T I RES/WH EELS (Cont inue d)
u n iqu e wh eel weigh t s. Th ey a r e design ed t o fit t h e TIRE AND WHEEL BALANCE
con t ou r of t h e wh eel (F ig. 1). (1) Ba la n ce t h e t ir e a n d wh eel a ssem blies a s n ec-
• In spect t ir es a n d wh eels for da m a ge, m u d pa ck- essa r y followin g t h e wh eel ba la n cer m a n u fa ct u r er ’s
in g a n d u n u su a l wea r ; cor r ect a s n ecessa r y. in st r u ct ion s a n d u sin g t h e in for m a t ion list ed in St a n -
• Ch eck a n d a dju st t ir e a ir pr essu r e t o t h e pr es- da r d P r ocedu r e - Tir e An d Wh eel Ba la n ce. (Refer t o
su r e list ed on t h e la bel a t t a ch ed t o t h e r ea r fa ce of 22 - TIRE S/WH E E LS - STANDARD P ROCE DURE )
t h e dr iver ’s door. (2) Roa d t est t h e veh icle for a t lea st 5 m iles, fol-
lowin g t h e for m a t descr ibed in Roa d Test .
(3) If t h e vibr a t ion per sist s, con t in u e wit h t h is
dia gn osis a n d t est in g pr ocedu r e.
TIRE AND WHEEL RUNOUT/MATCH MOUNTING

(1) S y s te m Ra d ia l Ru n o u t. Th is on -t h e-veh icle
syst em ch eck will m ea su r e t h e r a dia l r u n ou t in clu d-
in g t h e h u b, wh eel a n d t ir e.
(a ) Ra ise veh icle so t ir es clea r floor. (Refer t o
(b) Apply m a skin g t a pe a r ou n d t h e cir cu m fer-
en ce of t h e t ir e in t h e loca t ion s t o be m ea su r ed
(F ig. 2). Do n ot over la p t h e t a pe.
(c) Ch eck syst em r u n ou t u sin g Dia l In dica t or
Set , Specia l Tool C-3339A wit h 25-W wh eel, or
Fig. 1 Aluminum Wheel Weight equ iva len t . P la ce t h e en d of t h e in dica t or a ga in st
1 - TIRE ea ch t a ped a r ea (on e a t a t im e) (F ig. 2) a n d r ot a t e
2 - WHEEL
3 - WHEEL WEIGHT t h e t ir e a n d wh eel. Syst em r a dia l r u n ou t sh ou ld
n ot exceed 0.76 m m (0.030 in ch ) wit h n o t r ea d
ROAD TEST “dips” or “st eps.” Tr ea d “dips” a n d “st eps” ca n be
Roa d t est veh icle on a sm oot h r oa d for a lea st five iden t ified by spikes of t h e dia l in dica t or ga u ge.
m iles t o wa r m t ir es (r em ove a n y fla t spot s). Ligh t ly • Tr ea d %dips%; Ra pid decr ea se t h en in cr ea se in
pla ce h a n ds on st eer in g wh eel a t t h e 10:00 a n d 2:00 dia l in dica t or r ea din g over 101.6 m m (4.0 in ch ) of
posit ion s wh ile slowly sweepin g u p a n d down fr om 90 t r ea d cir cu m fer en ce.
t o 110 km /h (55 t o 70 m ph ) wh er e lega l speed lim it s • Tr ea d %st eps%; Ra pid decr ea se or in cr ea se in dia l
a llow. in dica t or r ea din g over 101.6 m m (4.0 in ch ) of t r ea d
Obser ve t h e st eer in g wh eel for : cir cu m fer en ce.
• Visu a l Nibble (oscilla t ion : clockwise/cou n t er- (d) If syst em r u n ou t is excessive, r e-in dex t h e
clockwise, u su a lly du e t o t ir e im ba la n ce) t ir e a n d wh eel a ssem bly on t h e h u b. Rem ove
• Visu a l Bu zzin ess (h igh fr equ en cy, r a pid vibr a - a ssem bly fr om veh icle a n d in st a ll it ba ck on t h e
t ion u p a n d down ) h u b t wo st u ds over fr om or igin a l m ou n t in g posi-
To r u le ou t vibr a t ion s du e t o br a kes or power t r a in : t ion . If r e-in dexin g t h e t ir e a n d wh eel a ssem bly
• Ligh t ly a pply br a kes a t speed; if vibr a t ion occu r s cor r ect s or r edu ces syst em r u n ou t , ch eck h u b
or is en h a n ced, vibr a t ion is likely du e t o ca u ses ot h er r u n ou t a n d r epa ir a s n ecessa r y (Refer t o 5 -
t h a n t ir e a n d wh eel a ssem blies. BRAKE S - BASE /H YDRAULIC/ME CH ANICAL/
• Sh ift t r a n sm ission in t o n eu t r a l wh ile vibr a t ion ROTORS - DIAGNOSIS AND TE STING).
is occu r r in g; if vibr a t ion is elim in a t ed, vibr a t ion is (e) If syst em r u n ou t is st ill excessive, con t in u e
likely du e t o ca u ses ot h er t h a n t ir e a n d wh eel a ssem - wit h t h is dia gn osis a n d t est in g pr ocedu r e.
blies. (2) Tire a n d Wh e e l As s e m bly Ra d ia l Ru n o u t.
F or br a ke vibr a t ion s, (Refer t o 5 - BRAKE S - Th is r a dia l r u n ou t ch eck is per for m ed wit h t h e t ir e
BASE /H YDRAULIC/ME CH ANICAL/ROTORS - a n d wh eel a ssem bly off t h e veh icle.
DIAGNOSIS AND TE STING). (a ) Rem ove t ir e a n d wh eel a ssem bly fr om veh icle
F or power t r a in vibr a t ion s, (Refer t o 3 - DIF F E R- a n d in st a ll it on a su it a ble wh eel ba la n cer.
E NTIAL & DRIVE LINE - DIAGNOSIS AND TE ST-
ING).
F or t ir e a n d wh eel a ssem bly vibr a t ion s, con t in u e
wit h t h is dia gn osis a n d t est in g pr ocedu r e.
Fig. 2 Radial Runout Measurement

1 - MASKING TAPE
2 - DIAL INDICATOR
Fig. 3 Marking Tire
(b) Ch eck syst em r u n ou t u sin g Dia l In dica t or 1 - REFERENCE MARK
Set , Specia l Tool C-3339A wit h 25-W wh eel, or 2 - EXAMPLE HIGH SPOT ON TIRE
equ iva len t . P la ce t h e en d of t h e in dica t or a ga in st 3 - WHEEL
4 - VALVE STEM
ea ch t a ped a r ea (on e a t a t im e) (F ig. 2) a n d r ot a t e
t h e t ir e a n d wh eel. Ra dia l r u n ou t sh ou ld n ot
exceed 0.76 m m (0.030 in ch ) wit h n o t r ea d “dips”
or “st eps.” Tr ea d “dips” a n d “st eps” ca n be iden t i-
fied by spikes of t h e dia l in dica t or ga u ge.
(c) If r u n ou t exceeds lim it s, m a r k t h e or igin a l
loca t ion of t h e t ir e on t h e wh eel a t t h e va lve st em
(F ig. 3). Also, m a r k t h e t ir e a n d wh eel t o in dica t e
t h e or igin a l h igh spot of t h e a ssem bly a n d r ecor d
t h e r u n ou t m ea su r em en t .
(d) If r u n ou t exceeds lim it s, t h e t ir e will n eed t o
be dism ou n t ed fr om t h e wh eel t o ver ify wh eel vs.
t ir e con t r ibu t ion . Refer t o Wh eel Ru n ou t below.
(3) La te ra l Ru n o u t. La t er a l r u n ou t for t h e veh i-
cle syst em a s well a s t h e t ir e a n d wh eel a ssem bly
sh ou ld be less t h a n 0.76 m m (0.030 in ch ). Th e sa m e
pr ocedu r e a n d t h eor y descr ibed for r a dia l r u n ou t ca n
a lso be a pplied t o iden t ify a n d r edu ce la t er a l r u n ou t .
(4) Wh e e l Ru n o u t. Th is r u n ou t ch eck is per- Fig. 4 Checking Radial Runout Of Wheel
for m ed a s follows:
1 - MOUNTING CONE
(a ) Dism ou n t t h e t ir e fr om t h e wh eel. 2 - SPINDLE SHAFT
(b) Mou n t t h e wh eel ba ck on t h e wh eel ba la n cer. 3 - WING NUT
(c) Mea su r e r a dia l r u n ou t of t h e wh eel a t t h e 4 - PLASTIC CUP
5 - DIAL INDICATOR
t ir e bea d sea t (F ig. 4). Ru n ou t sh ou ld n ot exceed 6 - WHEEL
0.254 m m (0.010 in ch ) for a lu m in u m wh eels a n d 7 - DIAL INDICATOR
0.508 m m (.020 in ch ) for st eel wh eels. Repla ce t h e
wh eel if it exceeds t h e lim it .
(d) Mea su r e la t er a l r u n ou t of t h e wh eel a t t h e
t ir e bea d sea t (F ig. 5). Ru n ou t sh ou ld n ot exceed
0.762 m m (0.030 in ch ) for a ll wh eels. Repla ce t h e
wh eel if it exceeds t h e lim it .
Fig. 5 Checking Lateral Runout Of Wheel

1 - MOUNTING CONE
2 - SPINDLE SHAFT
3 - WING NUT
4 - PLASTIC CUP
5 - DIAL INDICATOR Fig. 6 Remount Tire 180 Degrees
6 - WHEEL
7 - DIAL INDICATOR 1 - VALVE STEM
2 - REFERENCE MARK
(5) Ma tc h Mo u n tin g . If t h e wh eel r u n ou t is

wit h in specifica t ion s, t ir e a n d wh eel a ssem bly r u n ou t
ca n be im pr oved by r e-in dexin g (m a t ch m ou n t in g)
t h e t ir e t o t h e wh eel a s descr ibed below.
(a ) Rem ou n t t h e t ir e on t h e r im 180 degr ees
fr om it s or igin a l loca t ion (F ig. 6). E n su r e t h e t ir e
bea d is pr oper ly sea t ed.
(b) Re-m ea su r e t h e t ot a l r u n ou t . Ma r k t h e t ir e
a t t h e h igh spot a n d r ecor d t h e m ea su r em en t .
If r u n ou t is st ill excessive, per for m t h e followin g:
• If t h e n ew h igh spot is wit h in 102 m m (4.0 in ch )
of t h e fir st h igh spot on t h e t ir e, r epla ce t h e t ir e.
• If t h e n ew h igh spot is wit h in 102 m m (4.0 in ch )
of t h e fir st h igh spot on t h e wh eel, t h e wh eel m a y be
ou t of specifica t ion . Refer t o Wh eel Ru n ou t a bove.
• If t h e n ew h igh spot is NOT wit h in 102 m m (4.0
in ch ) of eit h er h igh spot , dr a w a n a r r ow on t h e t r ea d
fr om n ew h igh spot t owa r d t h e or igin a l (F ig. 7).
Br ea k down t h e t ir e a n d r em ou n t it 90 degr ees on
r im in t h a t dir ect ion , t h en r e-m ea su r e r u n ou t . Th is
will n or m a lly r edu ce t h e r u n ou t t o a n a ccept a ble
a m ou n t . Fig. 7 Remount Tire 90 Degrees In Direction of
(6) On ce ba ck t oget h er, r oa d t est t h e veh icle for a t Arrow
lea st 5 m iles, followin g t h e for m a t descr ibed in Roa d 1 - 2ND HIGH SPOT ON TIRE
Test . If vibr a t ion per sist s, a n d a ll com pon en t s t est ed 2 - 1ST HIGH SPOT ON TIRE
a r e wit h in specifica t ion , t h e t ir es m a y h a ve a n exces-
sive r a dia l for ce con dit ion . Ra dia l for ce va r ia t ion ca n
on ly be ch ecked a s in dica t ed below. If t h is equ ipm en t
is n ot a va ila ble, con su lt wit h t h e t ir e m a n u fa ct u r er.
RADIAL FORCE VARIATION STAN DARD PROCEDU RE
Ra dia l F or ce Va r ia t ion ca n be ch ecked u sin g t h e
H u n t er GSP 9700 Vibr a t ion Con t r ol Syst em (Wh eel STANDARD PROCEDURE - TIRE AND WHEEL
Ba la n cer ) or equ iva len t , if a va ila ble. Th is t ype of BALANCE
equ ipm en t h elps t o cor r ect r ide dist u r ba n ces by
r edu cin g t h e r a dia l for ce va r ia t ion of a n a ssem bly NOTE: Balance equipment must be calibrated and
t h r ou gh r e-in dexin g of t h e t ir e t o wh eel. maintained per equipment manufacturer’s specifica-
Th e equ ipm en t m a n u fa ct u r er or Da im ler Ch r ysler tions.
Cor por a t ion m a y su pply r efer en ce va lu es a s gu ide-
lin es. Ra dia l for ce m ea su r em en t s a bove t h e r efer en ce Wh eel ba la n cin g ca n be a ccom plish ed wit h eit h er
va lu e m a y n ot a lwa ys r esu lt in a r ide dist u r ba n ce, on -veh icle or off-veh icle equ ipm en t .
n or do t h ey a u t om a t ica lly m ea n t h e a ssem bly com po-
n en t s a r e ou t of specifica t ion . Do n ot r epla ce com po- NOTE: If using on-vehicle balancing equipment, on
n en t s ba sed on r a dia l for ce va lu es a lon e. Ba la n cin g, the driving axle, remove the opposite wheel and tire
r u n ou t dia gn osis, r e-in dexin g, a n d su bject ive r oa d assembly.
t est in g m u st be per for m ed a s ou t lin ed in pr eviou s
sect ion s of t h is dia gn osis a n d t est in g pr ocedu r e. It is r ecom m en ded t h a t a t wo-pla n e dyn a m ic ba l-
Use t h e Ra dia l F or ce equ ipm en t t o iden t ify su spect a n cer be u sed wh en a wh eel a n d t ir e a ssem bly
a ssem blies a n d m in im ize t h e r a dia l for ces. Aft er a ll r equ ir es ba la n cin g. A st a t ic ba la n cer sh ou ld on ly be
su spect a ssem blies a r e opt im ized, r ein st a ll t h e u sed wh en a t wo-pla n e ba la n cer is n ot a va ila ble.
a ssem blies a n d r oa d t est t h e veh icle. If a dist u r ba n ce Ba la n ce wh eel a n d t ir e a ssem blies dyn a m ica lly a n d
st ill exist s a n d a ll ot h er vibr a t ion dia gn ost ic pr oce- st a t ica lly t o less t h a n 0.25 (1 ⁄4 ) ou n ce.
du r es h a ve been com plet ed, r epla ce on e t ir e or on e F or st a t ic ba la n cin g, fin d loca t ion of h ea vy spot
wh eel a t a t im e, st a r t in g wit h t h e a ssem bly h a vin g ca u sin g im ba la n ce. Cou n t er ba la n ce wh eel dir ect ly
t h e h igh est for ce va r ia t ion . Be su r e t o m in im ize ea ch opposit e t h e h ea vy spot . Det er m in e weigh t r equ ir ed
n ew a ssem bly. Roa d t est t h e veh icle followin g ea ch t o cou n t er ba la n ce t h e a r ea of im ba la n ce. P la ce h a lf of
r epla cem en t . Con t in u e t h is pr ocess u n t il t h e dist u r- t h is weigh t on t h e in n e r r im fla n ge a n d t h e ot h er
ba n ce is r esolved. h a lf on t h e o u te r r im fla n ge (F ig. 8).
F or dyn a m ic ba la n cin g, t h e ba la n ce equ ipm en t is
NOTE: When using Radial Force equipment, it is design ed t o in dica t e t h e loca t ion a n d a m ou n t of
critically important to set proper tire inflation pres- weigh t t o be a pplied t o bot h t h e in n er a n d ou t er r im
sure and ensure centering of the wheel on the fla n ges (F ig. 9).
equipment spindle. Th e a lu m in u m wh eels on t h is veh icle u se a u n iqu e
wh eel weigh t (F ig. 10). Th is wh eel weigh t is design ed
RADI AL FORCE VARI AT I ON REFEREN CE t o fit t h e con t ou r ed su r fa ce of t h e wh eel (F ig. 10).
VALU ES Wh en ba la n cin g a n a lu m in u m wh eel, t h is wh eel
weigh t m u st be u sed. Do n ot u se a n y ot h er t ype of
DESCRIPTION SPECIFICATION wh eel weigh t . It will n ot pr oper ly fit t h e con t ou r of
t h e wh eel.
Total Radial Force Less Than 22 Lbs. ± 2
Alwa ys ver ify t h e Ba la n ce. Wh en u sin g off-veh icle
Variation (RFV) Lbs.
equ ipm en t , r ot a t e a ssem bly 180 degr ees on ba la n ce
Radial First Harmonic Less Than 16 Lbs. ± 2 equ ipm en t t o ver ify ba la n ce. Va r ia t ion sh ou ld n ot be
(R1H) Lbs. m or e t h a n 0.125 (1 ⁄8 ) ou n ce. If va r ia t ion is m or e t h a n
Radial Second Harmonic Less Than 12 Lbs. ± 2 0.125 ou n ce, ba la n cin g equ ipm en t cou ld be m a lfu n c-
(R2H) Lbs. t ion in g.
Fig. 8 Static Unbalance & Balance

1 - HEAVY SPOT 4 - CORRECTIVE WEIGHT LOCATION
2 - CENTER LINE OF SPINDLE 5 - TIRE OR WHEEL TRAMP, OR WHEEL HOP
3 - ADD BALANCE WEIGHTS HERE
Fig. 9 Dynamic Unbalance & Balance

1 - CENTER LINE OF SPINDLE 3 - CORRECTIVE WEIGHT LOCATION
2 - ADD BALANCE WEIGHTS HERE 4 - HEAVY SPOT WHEEL SHIMMY AND VIBRATION
r edu ced by t im ely r ot a t ion of t ir es. Th e ben efit s of
r ot a t ion a r e especia lly wor t h wh ile. Rot a t ion will
in cr ea se t r ea d life, h elp t o m a in t a in m u d, sn ow, a n d
wet t r a ct ion levels, a n d con t r ibu t e t o a sm oot h , qu iet
r ide.
Th e su ggest ed r ot a t ion m et h od is t h e for wa r d-cr oss
t ir e r ot a t ion m et h od (F ig. 11). Th is m et h od t a kes
a dva n t a ge of cu r r en t t ir e in du st r y pr a ct ice wh ich
a llows r ot a t ion of r a dia l-ply t ir es. Ot h er r ot a t ion
m et h ods m a y be u sed, bu t m a y n ot h a ve a ll t h e ben -
efit s of t h e r ecom m en ded m et h od.
NOTE: Only the 4 tire rotation method may be used

if the vehicle is equipped with a low mileage or tem-
porary spare tire.
Fig. 10 Aluminum Wheel Weight
1 - TIRE
2 - WHEEL
3 - WHEEL WEIGHT
If difficu lt t o ba la n ce, br ea k down t h e wh eel a n d

t ir e a ssem bly a n d ch eck for loose debr is in side t ir e.
P r ior t o disa ssem bly, m a r k (in dex) t h e t ir e a t t h e
va lve st em . Use t h is m a r k in or der t o r em ou n t t h e
t ir e in it s or igin a l or ien t a t ion wit h r espect t o t h e
wh eel.
STANDARD PROCEDURE - TIRE AND WHEEL

MATCH MOUNTING
Wh eels a n d t ir es a r e m a t ch m ou n t ed a t t h e fa ct or y.
Th is m ea n s t h a t t h e h igh spot of t h e t ir e is m a t ch ed
t o t h e low spot on t h e wh eel r im . Th is t ech n iqu e is
u sed t o r edu ce r u n ou t in t h e wh eel a n d t ir e a ssem -
bly. Th e h igh spot on t h e t ir e is m a r ked wit h a pa in t
m a r k or a br igh t color ed a dh esive la bel on t h e ou t -
boa r d sidewa ll. Th e low spot on t h e wh eel is iden t i-
fied wit h a la bel on t h e ou t side of t h e r im a n d a dot
or lin e in t h e dr op well a r ea of t h e r im (in side wh er e Fig. 11 Forward-Cross Tire Rotation Method
t h e t ir e m ou n t s). If t h e ou t side la bel h a s been DIRECTIONAL TREAD PATTERN TIRES
r em oved, t h e t ir e will h a ve t o be r em oved t o loca t e Som e veh icles a r e fit t ed wit h specia l h igh -per for-
t h e dot or lin e on t h e in side of t h e r im . Th e t ir e ca n m a n ce t ir es h a vin g a dir ect ion a l t r ea d pa t t er n . Th ese
t h en be m a t ch m ou n t ed t o t h e t ir e. t ir es a r e design ed t o im pr ove t r a ct ion on wet pa ve-
In for m a t ion on m a t ch m ou n t in g t h e t ir e t o t h e m en t . To obt a in t h e fu ll ben efit s of t h is design , t h e
wh eel ca n be fou n d in Tir e a n d Wh eel Ru n ou t /Ma t ch t ir es m u st be in st a lled so t h a t t h ey r ot a t e in t h e cor-
Mou n t in g, it em s (2) t h r ou gh (5), wit h in Dia gn osis r ect dir ect ion . Th is is in dica t ed by a r r ows on t h e t ir e
An d Test in g - Tir e An d Wh eel Vibr a t ion . (Refer t o 22 sidewa lls.
- TIRE S/WH E E LS - DIAGNOSIS AND TE STING) Wh en wh eels a n d t ir es a r e bein g in st a lled, ext r a
ca r e is n eeded t o en su r e t h a t t h is dir ect ion of r ot a -
STANDARD PROCEDURE - TIRE AND WHEEL t ion is m a in t a in ed.
ROTATION Refer t o Own er ’s Ma n u a l for r ot a t ion sch edu le.
NON-DIRECTIONAL TREAD PATTERN TIRES

Tir es on t h e fr on t a n d r ea r a xles oper a t e a t differ-
en t loa ds a n d per for m differ en t fu n ct ion s. F or t h ese
r ea son s, t h ey wea r a t u n equ a l r a t es, a n d t en d t o
develop ir r egu la r wea r pa t t er n s. Th ese effect s ca n be
REM OVAL I N STALLAT I ON

REMOVAL - TIRE AND WHEEL ASSEMBLY INSTALLATION - TIRE AND WHEEL ASSEMBLY
(ALUMINUM WHEEL) (ALUMINUM WHEEL)
(1) Ra ise t h e veh icle so t h e t ir e a n d wh eel a ssem -
bly clea r s gr ou n d level. NOTE: Never use oil or grease on studs or wheel
(2) Rem ove t h e 5 wh eel m ou n t in g n u t s fr om t h e mounting nuts.
st u ds.
(3) Rem ove t h e t ir e a n d wh eel fr om t h e h u b. (1) P osit ion t h e t ir e a n d wh eel a ssem bly on t h e
wh eel m ou n t in g st u ds u sin g t h e h u b pilot a s a gu ide.
REMOVAL - TIRE AND WHEEL ASSEMBLY P la ce a n d h old t h e wh eel flu sh u p a ga in st t h e m ou n t -
in g su r fa ce.
(STEEL WHEEL) (2) Loosely in st a ll a ll 5 wh eel m ou n t in g n u t s.
(1) Ra ise t h e veh icle so t h e t ir e a n d wh eel a ssem - Ligh t ly sn u g t h e wh eel n u t s, t h en pr ogr essively
bly clea r s gr ou n d level. t igh t en t h em in t h e pr oper sequ en ce (F ig. 13).
(2) Not in g t h e loca t ion of t h e va lve st em in r ela - Tigh t en wh eel m ou n t in g n u t s t o 135 N·m (100 ft .
t ion sh ip t o t h e wh eel m ou n t in g n u t s, r em ove t h e lbs.).
t h r ee wh eel m ou n t in g n u t s secu r in g t h e wh eel cover
t o t h e wh eel a n d h u b (F ig. 12).
Fig. 13 Tightening Sequence

Fig. 12 NUTS SECURING WHEEL COVER
1 - VALVE STEM
2 - BOLT-ON WHEEL COVER
INSTALLATION - TIRE AND WHEEL ASSEMBLY
3 - NUTS SECURING WHEEL COVER (STEEL WHEEL)
CAUTION: When removing the wheel cover, do not NOTE: Never use oil or grease on studs or wheel
pry the wheel cover from the wheel. This can result mounting nuts.
in damage to the wheel cover. The wheel cover is
removed by pulling it off the wheel by hand. (1) P osit ion t h e t ir e a n d wh eel a ssem bly on t h e
wh eel m ou n t in g st u ds u sin g t h e h u b pilot a s a gu ide.
(3) Gr a sp t h e wh eel cover a t t h e edges in lin e wit h P la ce a n d h old t h e wh eel flu sh u p a ga in st t h e m ou n t -
t h e r em a in in g in st a lled wh eel m ou n t in g n u t s a n d in g su r fa ce.
pu ll st r a igh t ou t wa r d fr om t h e wh eel. Th is will pop
t h e wh eel cover r et a in in g t a bs over t h e t wo r em a in - NOTE: Wheel mounting nuts must be installed on
in g wh eel n u t s, r em ovin g t h e wh eel cover fr om t h e the studs as shown (Fig. 14) to allow proper instal-
veh icle. lation of the wheel cover.
(4) Rem ove t h e t wo r em a in in g wh eel m ou n t in g
n u t s fr om t h e h u b’s st u ds. (2) Usin g t h e va lve st em a s a n in dex pla ced a t t h e
(5) Rem ove t h e wh eel a n d t ir e fr om t h e h u b. 12 O’clock posit ion , in st a ll a n d lig h tly tig h te n t wo
wh eel m ou n t in g n u t s on t h e st u ds loca t ed a t t h e 4
O’clock a n d 8 O’clock posit ion s a s sh own (F ig. 14).
(4) In st a ll a n d lig h tly tig h te n t h e t h r ee r em a in -
in g wh eel m ou n t in g n u t s, secu r in g t h e wh eel cover in
pla ce (F ig. 12).
(5) P r ogr essively t igh t en a ll five wh eel m ou n t in g
n u t s in t h e pr oper sequ en ce (F ig. 16). Tigh t en wh eel
n u t s t o a t or qu e of 135 N·m (100 ft . lbs.).
Fig. 14 TWO WHEEL MOUNTING NUTS INSTALLED

1 - WHEEL
2 - VALVE STEM
3 - HUB PILOT
4 - NUTS
(3) P la ce t h e wh eel cover on t h e wh eel in t h e fol-

lowin g fa sh ion : Fig. 16 NUT TIGHTENING SEQUENCE
(a ) Align t h e va lve n ot ch in t h e wh eel cover wit h
t h e va lve st em on t h e wh eel.
(b) At t h e sa m e t im e, a lign t h e t wo h oles in t h e
wh eel cover h a vin g t h e r et a in in g t a bs wit h t h e t wo T I RE PRESSU RE M ON I T ORI N G
in st a lled wh eel n u t s (F ig. 15).
(c) P r ess in on cen t er of wh eel cover u n t il wh eel
DESCRIPTION
cover r et a in in g t a bs pu sh pa st a n d en ga ge r ea r of
Som e ver sion s of t h is veh icle a r e equ ipped wit h
pr eviou sly in st a lled wh eel m ou n t in g n u t s (F ig. 15).
Tir e P r essu r e Mon it or in g (TP M). TP M m on it or s a ir
Th is will h old t h e wh eel cover in pla ce.
pr essu r e in t h e fou r r oa d t ir es. Th e syst em a ler t s t h e
dr iver wh en t ir e pr essu r e in a n y of t h e fou r r oa d
wh eels fa lls below a pr edet er m in ed t h r esh old (pr es-
su r e t oo low).
Depen din g on opt ion a l equ ipm en t , a veh icle m a y
h a ve fou r or five sen sor s (fift h sen sor loca t ed in spa r e
wh eel). Alt h ou gh a pr essu r e sen sor m a y be pr esen t in
t h e spa r e t ir e wh eel of t h e five sen sor syst em , pr es-
su r e in t h e spa r e t ir e is n ot m on it or ed.
Th er e a r e t wo syst em s a va ila ble, Ba se a n d P r e-
m iu m . Th e Ba se syst em offer s a n in dica t or la m p,
wa r n in g t h e dr iver of a pr essu r e issu e. An a u dible
ch im e a lso sou n ds on ce wh en a pr essu r e issu e occu r s.
In a ddit ion t o t h ese fea t u r es, t h e P r em iu m syst em
offer s a n E lect r on ic Veh icle In for m a t ion Cen t er
(E VIC) displa y of in for m a t ion .
F or fu r t h er in for m a t ion , r efer t o t h e Own er s Ma n -
Fig. 15 WHEEL COVER INSTALLATION OVER TWO u a l or t h e a ppr opr ia t e dia gn ost ic in for m a t ion .
NUTS
1 - RETAINING TABS
2 - VALVE STEM
T I RE PRESSU RE M ON I T ORI N G (Cont inue d)
OPERATION E a ch sen sor h a s a n in t er n a l ba t t er y t h a t la st s u p

Th e Tir e P r essu r e Mon it or in g (TP M) syst em u ses t o 10 yea r s. Th e ba t t er y is n ot ser vicea ble. At t h e
r a dio a n d sen sor t ech n ology t o m on it or t ir e a ir pr es- t im e of ba t t er y fa ilu r e, t h e sen sor m u st be r epla ced.
su r e levels. Sen sor s, m ou n t ed t o ea ch r oa d wh eel a s Th e ser vicea ble com pon en t s of t h e t ir e pr essu r e sen -
pa r t of t h e va lve st em , t r a n sm it a low fr equ en cy in di- sor a r e:
ca t in g t h eir in dividu a l pr essu r e t o a r eceiver loca t ed • Sen sor-To-Wh eel Gr om m et
in t h e Wir eless Con t r ol Modu le (WCM) por t ion of t h e • Va lve St em Ca p
Sen t r y Key Rem ot e E lect r on ic E n t r y Modu le • Va lve St em Cor e
(SKRE E M). Th ese t r a n sm ission s occu r a ppr oxim a t ely Va lve st em ca ps a n d cor es a r e specifica lly design ed
on ce ever y m in u t e a t speeds over 20 m ph (32 km /h ). for t h e t ir e pr essu r e m on it or in g sen sor s. Alt h ou gh
Th e Tir e P r essu r e Mon it or in g syst em r em a in s a ct ive sim ila r t o st a n da r d va lve st em ca ps a n d cor es, t h ey
even if n o t ir e pr essu r e r ela t ed m essa ge is displa yed. a r e differ en t .
Th e sen sor s la y dor m a n t (P a r k Mode), t h en wa ke
CAUTION: Do not use a standard valve stem cap or
a n d st a r t t r a n sm it t in g (Dr ive Mode) wh en t h e veh icle
core in a tire pressure sensor. Always use the orig-
fir st r ea ch es speeds over 20 m ph (32 km /h ). On ce t h e
inal equipment style sensor cap and core.
wh eels st op r ot a t in g for a per iod of a ppr oxim a t ely 30
m in u t es, t h e sen sor s sh u t down u n t il a ga in a wa ken .
Alt h ou gh n ot t r a n sm it t in g a s wh en in Dr ive Mode, CAUTION: Do not reuse the Sensor-To-Wheel Grom-
wh ile in P a r k Mode, t h e sen sor s st ill t r a n sm it met. Always use a new grommet when installing a
a ppr oxim a t ely on ce ever y 13 h ou r s t o let t h e r eceiver pressure sensor and properly torque the sensor
kn ow a ir pr essu r e st a t u s a t t h a t t im e. nut.
Th e r eceiver on ly r eceives in for m a t ion fr om t h e
fou r r ot a t in g t ir es. A fift h sen sor m a y be loca t ed in
t h e spa r e t ir e wh eel, depen din g on veh icle opt ion s. CAUTION: Do not attempt to install a tire pressure
Alt h ou gh t h is fift h sen sor m a y be pr esen t , it does n ot sensor in an aftermarket wheel. Use only in original
br oa dca st a n y in for m a t ion beca u se it does n ot r ot a t e. style factory wheels.
Wh en t h e syst em det ect s t h a t a t ir e is goin g low,
below t h e Low P r essu r e (la m p) ON Th r esh old (See
followin g t a ble), t h e dr iver is a ler t ed t o t h e sit u a t ion . OPERATION
Th e Ba se syst em illu m in a t es a n in dica t or la m p, Th e ba t t er y oper a t ed t ir e pr essu r e sen sor s la y dor-
wa r n in g t h e dr iver of a pr essu r e issu e a n d sou n ds a n m a n t (P a r k Mode), t h en wa ke a n d st a r t t r a n sm it t in g
a u dible ch im e. In equ ipped wit h t h e P r em iu m sys- (Dr ive Mode) wh en t h e veh icle fir st r ea ch es speeds
t em , t h e in for m a t ion is a lso displa yed on t h e E lec- over 20 m ph (32 km /h ). On ce t h e wh eels st op r ot a t -
t r on ic Veh icle In for m a t ion Cen t er (E VIC). in g for a per iod of a ppr oxim a t ely 30 m in u t es, t h e
On ce pr essu r e in t h e su spect t ir e r a ises a bove t h e sen sor s sh u t down u n t il a ga in a wa ken . Alt h ou gh n ot
Low P r essu r e (la m p) OF F Th r esh old, t h e la m p will t r a n sm it t in g a s wh en in Dr ive Mode, wh ile in P a r k
go ou t a n d t h e syst em r et u r n s t o n or m a l. Mode, t h e sen sor s st ill t r a n sm it a ppr oxim a t ely on ce
ever y 13 h ou r s t o let t h e r eceiver kn ow a ir pr essu r e
T PM T H RESH OLD PRESSU RES st a t u s a t t h a t t im e.
E a ch sen sor t r a n sm it s t ir e pr essu r e da t a a ppr oxi-
m a t ely on ce ever y m in u t e. E a ch sen sor ’s (t r a n sm it -
Placard Pressure (Cold) 36 PSI (248 kPa) t er ) br oa dca st is u n iqu ely coded so t h a t t h e wir eless
Low Pressure OFF Threshold 33 PSI (228 kPa) con t r ol m odu le (WCM) ca n m on it or t h e st a t e of ea ch
Low Pressure ON Threshold 28 PSI (193 kPa) of t h e sen sor s on t h e fou r r ot a t in g r oa d wh eels. Th e
WCM (loca t ed in t h e SKRE E M) a u t om a t ica lly lea r n s
a n d st or es t h e sen sor ’s ID wh ile dr ivin g a ft er a sen -
SEN SOR - T PM sor h a s been r epla ced. Th er e is n o r et r a in in g n eces-
sa r y.
Th e r eceiver on ly r eceives in for m a t ion fr om t h e
DESCRIPTION
fou r r ot a t in g t ir es. A fift h sen sor m a y be loca t ed in
On veh icles equ ipped wit h Tir e P r essu r e Mon it or-
t h e spa r e t ir e wh eel, depen din g on veh icle opt ion s.
in g, on e t ir e pr essu r e sen sor is m ou n t ed t o ea ch r oa d
Alt h ou gh t h is fift h sen sor m a y be pr esen t , it does n ot
wh eel (F ig. 18), a n d depen din g on fa ct or y wh eel
br oa dca st a n y in for m a t ion beca u se it does n ot r ot a t e.
opt ion s, a sen sor m a y be loca t ed in t h e spa r e t ir e
F or a ddit ion a l in for m a t ion , r efer t o Appr opr ia t e
wh eel. Bot h a lu m in u m a n d st eel wh eels a r e u sed in
Dia gn ost ic In for m a t ion .
t h is syst em , a lt h ou gh sen sor s for on e t ype wh eel ca n -
n ot be u sed in t h e ot h er t ype wh eel.
SEN SOR - T PM (Cont inue d)
CAUTION (2) Dism ou n t t ir e fr om wh eel followin g t ir e

ch a n ger m a n u fa ct u r er s in st r u ct ion s wh ile pa yin g
CAUTION: The use of tire sealants is strictly prohib- specia l a t t en t ion t o t h e followin g t o a void da m a gin g
ited for vehicles equipped with the Tire Pressure t h e pr essu r e sen sor :
Monitoring system. Tire sealants can clog tire pres- (a ) Wh en br ea kin g t h e t ir e bea d loose fr om t h e
sure sensors. wh eel r im , a void u sin g t h e Bea d Br ea ker in t h e
a r ea of t h e sen sor. Th a t in clu des bot h fr on t a n d
CAUTION: Tire pressure sensor valve stem caps r ea r bea ds of t h e t ir e.
and cores are specially designed for the sensors. (b) Wh en pr epa r in g t o dism ou n t t h e t ir e fr om
Due to risk of corrosion, do not use a standard t h e wh eel, ca r efu lly in ser t t h e m ou n t in g/dim ou n t -
valve stem cap or core in a tire pressure sensor in in g t ool a t t h e va lve st em ± 10° (F ig. 17), t h en pr o-
place of the original equipment style sensor cap ceed t o dism ou n t t h e t ir e fr om t h e wh eel. Use t h is
and core. pr ocess on bot h t h e u pper a n d lower t ir e bea ds.
CAUTION: Do not attempt to install a tire pressure

sensor in a steel wheel or aftermarket wheel. Use
tire pressure sensors in original style factory
wheels only.
NOTE: TPM thresholds have been established for

the original tire size equipped on the vehicle. Use
original size tires only to maintain system accuracy.
DIAGNOSIS AND TESTING - TIRE PRESSURE

SENSOR
NOTE: Tire pressure may increase from 2 to 6 psi
(14 to 41 kPa) during normal driving conditions. Do
NOT reduce this normal pressure build up.
If a fa u lt in t h e syst em is det ect ed, a lwa ys ch eck

a ir pr essu r e in t h e t ir es fir st wit h a kn own a ccu r a t e
a ir ga u ge a n d cor r ect t h e in fla t ion pr essu r e. If a n y
t ir e is low, in spect a ll t h e t ir es.
If t h e ga u ge-r ea d pr essu r e in t h e t ir es does n ot
Fig. 17 Start Mount/Dismount Tool Within 10
in dica t e a t ir e pr essu r e issu e, r efer t o t h e a ppr opr i-
Degrees Of Valve Stem
a t e dia gn ost ic in for m a t ion .
(3) Usin g a t h in wa ll socket , r em ove specia l n u t
REMOVAL r et a in in g sen sor t o wh eel (F ig. 18).
(1) Rem ove t ir e a n d wh eel a ssem bly fr om veh icle. (4) Rem ove sen sor fr om wh eel (F ig. 18).
(Refer t o 22 - TIRE S/WH E E LS - RE MOVAL)
INSTALLATION
CAUTION: The cap used on this valve stem con-
tains an O-ring seal to prevent contamination and NOTE: Before reinstalling a tire pressure sensor,
moisture from entering the valve stem. Retain this replace sealing grommet at base of valve stem.
valve stem cap for reuse. Do not substitute a regu-
lar valve stem cap in its place. (1) Wipe a r ea clea n wh er e sen sor sea lin g gr om m et
con t a ct s wh eel. Ma ke su r e su r fa ce of wh eel is n ot
da m a ged.
CAUTION: The valve stem used on this vehicle is (2) In st a ll sen sor in wh eel a s sh own (F ig. 18). Do
made of aluminum and the core is nickel plated n ot a t t em pt t o m ou n t sen sor ot h er wise, da m a ge m a y
brass. The original valve stem core must be rein- occu r.
stalled and not substituted with a valve stem core (3) Usin g a t h in wa ll socket , in st a ll specia l sen sor
made of a different material. This is required to pre- n u t (F ig. 18). Tigh t en n u t t o 4 N·m (35 in . lbs.)
vent corrosion in the valve stem caused by the dif- t or qu e.
ferent metals.
SEN SOR - T PM (Cont inue d)
Fig. 18 Sensor Mounting To Wheel

1 - TIRE PRESSURE SENSOR
2 - WHEEL
3 - NUT
CAUTION: Over-torquing the sensor nut by as little

as 12 N·m (106 in. lbs.) may result in sensor sepa-
Fig. 19 Mounting Tire Using Rotating Wheel
ration from the valve stem. Under this condition,
Machine
the sensor may still function, however, the condi-
tion should be corrected immediately. 1 - HEAD OF CHANGER LOCATED HERE
2 - VALVE STEM
(4) Mou n t t ir e on wh eel followin g t ir e ch a n ger

m a n u fa ct u r er s in st r u ct ion s, pa yin g specia l a t t en t ion
t o t h e followin g t o a void da m a gin g t ir e pr essu r e sen -
sor :
(a ) Rot a t in g Wh eel Tir e Ch a n ger s - On ce t h e
wh eel is m ou n t ed t o t h e ch a n ger, posit ion t h e sen -
sor va lve st em a ppr oxim a t ely 210° fr om t h e h ea d
of t h e ch a n ger in a clockwise dir ect ion befor e r ot a t -
in g t h e wh eel (a lso in a clockwise dir ect ion ) t o
m ou n t t h e t ir e (F ig. 19). Use t h is pr ocedu r e on
bot h t h e u pper a n d lower t ir e bea ds.
(b) Rot a t in g Tool Tir e Ch a n ger s - P osit ion t h e
wh eel on t h e ch a n ger so t h a t t h e sen sor va lve st em
is a ppr oxim a t ely 210° fr om t h e h ea d of t h e ch a n ger
in a clockwise dir ect ion fr om t h e m ou n t in g en d of
t h e t ool (F ig. 20) Ma ke su r e t h e sen sor is clea r of
t h e lower bea d br ea ker a r ea t o a void da m a gin g t h e
sen sor wh en t h e br ea ker r ises (F ig. 20). Rot a t e t h e
t ool in a cou n t er clockwise dir ect ion t o m ou n t t h e
t ir e. Use t h is pr ocedu r e on bot h t h e u pper a n d
lower t ir e bea ds.
(5) In st a ll wh eel a n d t ir e a ssem bly on veh icle.
(Refer t o 22 - TIRE S/WH E E LS - INSTALLATION)
Fig. 20 Mounting Tire Using Rotating Tool Machine
1 - VALVE STEM
2 - MOUNTING END OF TOOL
3 - BEAD BREAKER (KEEP CLEAR OF SENSOR)
T I RES T I RE I DEN T I FI CAT I ON
TIRE TYPE (Not P - Passenger

DESCRI PT I ON P
present on all tires)
T - Temporary
DESCRIPTION - TIRE
Tir es a r e design ed a n d en gin eer ed for ea ch specific C - Commercial
veh icle. Th ey pr ovide t h e best over a ll per for m a n ce LT - Light Truck
for n or m a l oper a t ion . Th e r ide a n d h a n dlin g ch a r a c-
SHOWN IN
t er ist ics m a t ch t h e veh icle’s r equ ir em en t s. Wit h 225 SECTIONAL WIDTH
MILLIMETERS
pr oper ca r e t h ey will give excellen t r elia bilit y, t r a c-
t ion , skid r esist a n ce, a n d t r ea d life. SECTIONAL HEIGHT
Dr ivin g h a bit s h a ve m or e effect on t ir e life t h a n ÷ SECTIONAL WIDTH
60 ASPECT RATIO
a n y ot h er fa ct or. Ca r efu l dr iver s will obt a in , in m ost (Refer to Aspect Ratio
ca ses, m u ch gr ea t er m ilea ge t h a n sever e u se or ca r e- Figure 21 )
less dr iver s. A few of t h e dr ivin g h a bit s wh ich will CONSTRUCTION R - RADIAL
R
sh or t en t h e life of a n y t ir e a r e: TYPE
• Ra pid a cceler a t ion
B - BIAS BELTED
• Sever e a pplica t ion of br a kes
• H igh -speed dr ivin g D - DIAGONAL (BIAS)
• Ta kin g t u r n s a t excessive speeds 16 WHEEL DIAMETER SHOWN IN INCHES
• St r ikin g cu r bs a n d ot h er obst a cles 97 LOAD INDEX *
• Oper a t in g veh icle wit h over or u n der in fla t ed
t ir e pr essu r es T SPEED RATING *
Ra dia l ply t ir es a r e m or e pr on e t o ir r egu la r t r ea d
wea r. It is im por t a n t t o follow t h e t ir e r ot a t ion in t er- * NOTE: Consult the tire manufacturer regarding
va l sh own in t h e sect ion on Tir e Rot a t ion . Th is will any questions on tire specifications or capabilities.
h elp t o a ch ieve a gr ea t er t r ea d-life pot en t ia l.
TIRE IDENTIFICATION
Tir e t ype, size, loa d in dex a n d speed r a t in g a r e
en coded in t h e let t er s a n d n u m ber s im pr in t ed on t h e
side wa ll of t h e t ir e. Refer t o t h e Tir e Iden t ifica t ion
ch a r t t o deciph er t h e code. F or exa m ple pu r poses, t h e
t ir e size P 225/60 R 16 97 T is u sed in t h e ch a r t . An
All Sea son t ype t ir e will a lso h a ve eit h er M + S, M &
S or M - S (in dica t in g m u d a n d sn ow t r a ct ion )
im pr in t ed on t h e side wa ll. An E xt r a or Ligh t Loa d
m a r kin g “XL” or “LL” m a y a lso be list ed on t h e side-
wa ll. Th e a bsen ce of a n “XL” or “LL” m a r kin g in fer s
a st a n da r d loa d t ir e.
Fig. 21 Tire Aspect Ratio

1 - SECTIONAL WIDTH
2 - SECTIONAL HEIGHT
TIRE CHAINS
Refer t o t h e own er s m a n u a l su pplied wit h t h e veh i-
cle t o det er m in e wh et h er t h e u se of t ir e ch a in s is per-
m it t ed on t h is veh icle.
DESCRIPTION - RADIAL-PLY TIRES

Ra dia l-ply t ir es im pr ove h a n dlin g, t r ea d life, r ide
qu a lit y a n d decr ea se r ollin g r esist a n ce.
T I RES (Cont inue d)
Ra dia l-ply t ir es m u st a lwa ys be u sed in set s of fou r • Tr a ct ion
a n d u n der n o cir cu m st a n ces sh ou ld t h ey be u sed on • Rollin g r esist a n ce
t h e fr on t on ly. It is r ecom m en ded t h a t t ir es fr om dif- • Speed ca pa bilit y
fer en t m a n u fa ct u r er s NOT be m ixed. Th ey m a y be Th e u se of t ir es sm a ller t h a n t h e m in im u m t ir e
m ixed wit h a t em por a r y spa r e t ir e wh en n ecessa r y. A size a ppr oved for t h e veh icle ca n r esu lt in t ir e over-
m a xim u m speed of 80 km /h (50 m ph ) is r ecom - loa din g a n d fa ilu r e.
m en ded wh ile a t em por a r y spa r e is in u se. Use t ir es t h a t h a ve t h e a ppr oved loa d r a t in g for
Ra dia l-ply t ir es h a ve t h e sa m e loa d-ca r r yin g ca pa c- t h e veh icle a n d n ever over loa d t h em . F a ilu r e t o equ ip
it y a s ot h er t ypes of t ir es of t h e sa m e size. Th ey a lso t h e veh icle wit h t ir es h a vin g a dequ a t e speed ca pa bil-
u se t h e sa m e r ecom m en ded in fla t ion pr essu r es. it y ca n r esu lt in su dden t ir e fa ilu r e a n d loss of veh i-
cle con t r ol.
DESCRIPTION - REPLACEMENT TIRES Th e u se of over size t ir es m a y ca u se in t er fer en ce
wit h veh icle com pon en t s. Un der ext r em es of su spen -
WARNING: FAILURE TO EQUIP THE VEHICLE WITH sion a n d st eer in g t r a vel, in t er fer en ce wit h veh icle
TIRES HAVING ADEQUATE SPEED CAPABILITY com pon en t s m a y ca u se t ir e da m a ge.
CAN RESULT IN SUDDEN TIRE FAILURE.
DESCRIPTION - SPARE TIRE (TEMPORARY)
Th e t em por a r y (con ven ien ce) spa r e t ir e is design ed
WARNING: IN ORDER TO MAINTAIN THE SPEED
for em er gen cy u se on ly. Th e or igin a l t ir e sh ou ld be
CAPABILITY OF THE VEHICLE, REPLACEMENT
r epa ir ed a n d r ein st a lled, or r epla ced wit h a n ew, a t
TIRES MUST HAVE SPEED RATINGS EQUAL TO OR
t h e fir st oppor t u n it y.
HIGHER THAN THOSE FITTED TO THE VEHICLE AS
Th e t em por a r y (con ven ien ce) spa r e t ir e sh ou ld be
ORIGINAL EQUIPMENT. IF TIRES WITH LOWER
in fla t ed t o t h e pr essu r e list ed on it s sidewa ll. Do n ot
SPEED RATINGS ARE FITTED, THE VEHICLE’S
exceed speeds of 80 km /h (50 m ph ) wh en t h e t em po-
HANDLING MAY BE AFFECTED AND THE SPEED
r a r y spa r e t ir e is in u se on t h e veh icle. Refer t o t h e
CAPABILITY OF THE VEHICLE MAY BE LOWERED
Own er ’s Ma n u a l for m or e det a ils.
TO THE MAXIMUM SPEED CAPABILITY OF THE
REPLACEMENT TIRES. TO AVOID AN ACCIDENT
RESULTING IN SEVERE OR FATAL INJURY, CON- DI AGN OSI S AN D T EST I N G
SULT THE TIRE MANUFACTURER IN REGARDS TO
MAXIMUM SPEED RATINGS. DIAGNOSIS AND TESTING - TIRE NOISE
Un u su a l t ir e n oise ca n be a ssocia t ed wit h t ir e a n d
It is r ecom m en ded t h a t t ir es equ iva len t t o t h e or ig-
wh eel vibr a t ion or ir r egu la r t ir e wea r. F or vibr a t ion ,
in a l equ ipm en t t ir es be u sed wh en r epla cem en t is
(Refer t o 22 - TIRE S/WH E E LS - DIAGNOSIS AND
n eeded.
TE STING). F or ir r egu la r t ir e wea r, (Refer t o 22 -
F a ilu r e t o u se equ iva len t r epla cem en t t ir es m a y
TIRE S/WH E E LS/TIRE S - DIAGNOSIS AND TE ST-
a dver sely a ffect t h e sa fet y a n d h a n dlin g of t h e veh i-
ING).
cle.
Th e or igin a l equ ipm en t t ir es pr ovide a pr oper com -
bin a t ion of m a n y ch a r a ct er ist ics su ch a s:
DIAGNOSIS AND TESTING - TIRE/VEHICLE
• Ride LEAD
• Noise Use t h e followin g Veh icle Lea d Dia gn osis An d Cor-
• H a n dlin g r ect ion Ch a r t t o dia gn ose a n d cor r ect a veh icle lea d
• Du r a bilit y or dr ift pr oblem .
• Tr ea d life
V EH I CLE LEAD DI AGN OSI S AN D CORRECT I ON CH ART
Fig. 22 Tire Wear Patterns

DIAGNOSIS AND TESTING - TIRE WEAR
PATTERNS
Un der in fla t ion will ca u se wea r on t h e sh ou lder s of
t ir e. Over in fla t ion will ca u se wea r a t t h e cen t er of
t ir e.
E xcessive ca m ber ca u ses t h e t ir e t o r u n a t a n
a n gle t o t h e r oa d. On e side of t r ea d is t h en wor n
m or e t h a n t h e ot h er (F ig. 22).
E xcessive t oe-in or t oe-ou t ca u ses wea r on t h e
t r ea d edges a n d a fea t h er ed effect a cr oss t h e t r ea d
(F ig. 22).
DIAGNOSIS AND TESTING - TREAD WEAR

INDICATORS
Tr ea d wea r in dica t or s a r e m olded in t o t h e bot t om
of t h e t r ea d gr ooves. Wh en t r ea d dept h is 1.6 m m
(1/16 in .), t h e t r ea d wea r in dica t or s will a ppea r a s a
13 m m (1/2 in .) ba n d (F ig. 23).
Tir e r epla cem en t is n ecessa r y wh en in dica t or s
a ppea r in t wo or m or e gr ooves or if loca lized ba ldin g Fig. 23 Tread Wear Indicators
occu r s.
1 - TREAD ACCEPTABLE
2 - TREAD UNACCEPTABLE
3 - WEAR INDICATOR
A qu a lit y a ir pr essu r e ga u ge is r ecom m en ded t o
STANDARD PROCEDURE - TIRE INFLATION ch eck t ir e a ir pr essu r e. Tir e pr essu r e sh ou ld be
PRESSURES ch ecked cold on ce per m on t h . Ch eck t ir e pr essu r e
Th e specified t ir e pr essu r es h a ve been ch osen t o m or e fr equ en t ly wh en t h e wea t h er t em per a t u r e va r-
pr ovide sa fe oper a t ion , veh icle st a bilit y, a n d a sm oot h ies widely. Tir e pr essu r e will decr ea se wh en t h e ou t -
r ide. Th e pr oper t ir e pr essu r e specifica t ion ca n be door t em per a t u r e dr ops. Aft er ch eckin g t h e a ir
fou n d on t h e Tir e In fla t ion P r essu r e La bel pr ovided pr essu r e, r epla ce va lve ca p fin ger t igh t .
wit h t h e veh icle (u su a lly on t h e dr iver ’s side B-pil-
la r ).
In fla t ion pr essu r es specified on t h e Tir e In fla t ion
P r essu r e La bel a r e a lwa ys t h e cold in fla t ion pr essu r e
of t h e t ir e. Cold in fla t ion pr essu r e is obt a in ed a ft er
t h e veh icle h a s n ot been oper a t ed for a t lea st 3
h ou r s, or t h e veh icle is dr iven less t h a n on e m ile
a ft er bein g in oper a t ive for 3 h ou r s. Tir e in fla t ion
pr essu r es m a y in cr ea se fr om 2 t o 6 pou n ds per
squ a r e in ch (psi) (14 t o 41 kP a ) du r in g oper a t ion . Do
n ot r edu ce t h is n or m a l pr essu r e bu ildu p.
Im pr oper in fla t ion ca n ca u se:
• Un even wea r pa t t er n s
• Redu ced t r ea d life
• Redu ced fu el econ om y
• Un sa t isfa ct or y r ide
• Th e veh icle t o dr ift .
WARNING: OVER OR UNDER INFLATED TIRES CAN Fig. 25 Over Inflation Wear
AFFECT VEHICLE HANDLING. THE TIRE CAN FAIL 1 - THIN TIRE TREAD AREA
SUDDENLY, RESULTING IN LOSS OF VEHICLE
CONTROL. STANDARD PROCEDURE - TIRE PRESSURE
FOR HIGH SPEED OPERATION
Un der in fla t ion ca u ses r a pid sh ou lder wea r, t ir e
Da im ler Ch r ysler Cor por a t ion a dvoca t es dr ivin g a t
flexin g, a n d ca n r esu lt in t ir e fa ilu r e (F ig. 24).
sa fe speeds wit h in post ed speed lim it s. Wh er e speed
lim it s a llow t h e veh icle t o be dr iven a t h igh speeds,
cor r ect t ir e in fla t ion pr essu r e is ver y im por t a n t .
Veh icles loa ded t o m a xim u m ca pa cit y sh ou ld n ot be
dr iven a t con t in u ou s speeds over 120 km /h (75 m ph ).
Never exceed t h e m a xim u m speed ca pa cit y of t h e
t ir e. F or in for m a t ion on t ir e iden t ifica t ion a n d speed
r a t in gs, (Refer t o 22 - TIRE S/WH E E LS/TIRE S -
DE SCRIP TION).
STANDARD PROCEDURE - TIRE LEAK

REPAIRING
F or pr oper r epa ir in g, a r a dia l t ir e m u st be r em oved
fr om t h e wh eel. Repa ir s sh ou ld on ly be m a de if t h e
defect , or pu n ct u r e, is in t h e t r ea d a r ea (F ig. 26). Th e
t ir e sh ou ld be r epla ced if t h e pu n ct u r e is loca t ed in
Fig. 24 Under Inflation Wear t h e sidewa ll.
Defla t e t ir e com plet ely befor e a t t em pt in g t o dis-
1 - THIN TIRE TREAD AREAS
m ou n t t h e t ir e fr om t h e wh eel. U s e a lu bric a n t
Over in fla t ion ca u ses r a pid cen t er wea r a n d loss of s u c h a s a m ild s o a p s o lu tio n w h e n d is m o u n tin g
t h e t ir e’s a bilit y t o cu sh ion sh ocks (F ig. 25). o r m o u n tin g tire . Use t ools fr ee of bu r r s or sh a r p
edges wh ich cou ld da m a ge t h e t ir e or wh eel r im .
Befor e m ou n t in g t ir e on wh eel, m a ke su r e a ll r u st
is r em oved fr om t h e r im bea d a n d r epa in t if n eces-
sa r y.
In st a ll wh eel on veh icle, a n d pr ogr essively t igh t en
t h e 5 wh eel n u t s t o a t or qu e of 135 N·m (100 ft . lbs.).
Fig. 27 Safety Rim

1 - TIRE
2 - WELL
Fig. 26 Tire Repair Area 3 - SAFETY HUMPS
4 - FLANGE
1 - REPAIRABLE AREA
CLEANING - TIRES
Befor e deliver y of a veh icle, r em ove t h e pr ot ect ive
coa t in g on t h e t ir es wit h wh it e sidewa lls or r a ised
wh it e let t er s. To r em ove t h e pr ot ect ive coa t in g, a pply
wa r m wa t er a n d let it soa k for a few m in u t es. Aft er-
wa r ds, scr u b t h e coa t in g a wa y wit h a soft br ist le
br u sh . St ea m clea n in g m a y a lso be u sed t o r em ove
t h e coa t in g.
CAUTION: DO NOT use gasoline, mineral oil, oil-

based solvent or a wire brush for cleaning.
WH EELS
Fig. 28 Styled Aluminum Wheel Weight
DESCRIPTION - WHEEL 1 - TIRE
Or igin a l equ ipm en t wh eels a r e design ed for pr oper 2 - WHEEL
3 - STYLED WHEEL WEIGHT
oper a t ion a t a ll loa ds u p t o t h e specified m a xim u m
veh icle ca pa cit y. Wh en wh eel a lign m en t is n ecessa r y on a veh icle
All m odels u se eit h er st eel or a lu m in u m dr op-cen - wit h ca st a lu m in u m wh eels, specia l wh eel cla m ps a r e
t er wh eels. E ver y wh eel h a s r a ised sect ion s bet ween r equ ir ed t o a void da m a ge t o t h e wh eel’s fin ish .
t h e r im fla n ges a n d r im dr op well ca lled sa fet y Th e wh eel st u ds a n d n u t s a r e design ed for specific
h u m ps (F ig. 27). In it ia l in fla t ion of t h e t ir es for ces wh eel a pplica t ion s a n d m u st be r epla ced wit h equ iv-
t h e bea d over t h ese r a ised sect ion s. In ca se of a ir a len t pa r t s.
loss, t h e sa fet y h u m ps h old t h e t ir e in posit ion on t h e All a lu m in u m wh eels h a ve wh eel m ou n t in g (lu g)
wh eel u n t il t h e veh icle ca n be br ou gh t t o a sa fe st op. n u t s wit h a n en la r ged n ose. Th is en la r ged n ose is
Ca st a lu m in u m wh eels r equ ir e specia l ba la n ce n ecessa r y t o en su r e pr oper r et en t ion of t h e wh eels.
weigh t s t o fit on t h e fla n ge of t h e r im (F ig. 28).
WH EELS (Cont inue d)
DIAGNOSIS AND TESTING - WHEEL DO NOT USE :

• An y a br a sive clea n er
INSPECTION
• An y a br a sive clea n in g pa d (su ch a s st eel wool)
In spect wh eels for :
or a br a sive br u sh
• E xcessive r u n ou t
• An y clea n er t h a t con t a in s a n a cid wh ich ca n
• Den t s, cr a cks or ir r egu la r ben ds
r ea ct wit h a n d discolor t h e ch r om e su r fa ce. Ma n y
• Da m a ged wh eel st u d (lu g) h oles
w h e e l c le a n e rs c o n ta in a c id s th a t c a n h a rm th e
• Air Lea ks
w h e e l s u rfa c e .
NOTE: Do not attempt to repair a wheel by hammer- • Oven clea n er
ing, heating or welding. • A ca r wa sh t h a t u ses ca r bide-t ipped wh eel clea n -
in g br u sh es or a cidic solu t ion s.
If a wh eel is da m a ged, a n or igin a l equ ipm en t
r epla cem en t wh eel sh ou ld be u sed. Wh en obt a in in g
r epla cem en t wh eels, t h ey m u st be equ iva len t in loa d
SPECI FI CAT I ON S
ca r r yin g ca pa cit y. Th e dia m et er, widt h , offset , pilot
h ole a n d bolt cir cle of t h e wh eel sh ou ld be t h e sa m e WHEEL
a s t h e or igin a l wh eel. SPECI FI CAT I ON S
WARNING: FAILURE TO USE EQUIVALENT DESCRIPTION SPECIFICATION

REPLACEMENT WHEELS MAY ADVERSELY
Wheel Mounting (Lug)
AFFECT THE SAFETY AND HANDLING OF THE 19 mm
Nut Hex Size
VEHICLE.
Wheel Mounting Stud
M12 x 1.5 mm
Size
WARNING: REPLACEMENT WITH USED WHEELS IS
NOT RECOMMENDED. THE SERVICE HISTORY OF
THE WHEEL MAY HAVE INCLUDED SEVERE TREAT-
MENT OR VERY HIGH MILEAGE. THE RIM COULD
FAIL WITHOUT WARNING. Ft. In.
DESCRIPTION N·m
Lbs. Lbs.
TPM Sensor Mounting Nut 4 — 35
CLEAN I N G Wheel Mounting (Lug ) Nut 135 100 —
WHEEL AND WHEEL TRIM CARE

All wh eels a n d wh eel t r im , especia lly a lu m in u m WH EEL COV ER
a n d ch r om e pla t ed, sh ou ld be clea n ed r egu la r ly u sin g
m ild soa p a n d wa t er t o m a in t a in t h eir lu st er a n d t o DESCRIPTION
pr even t cor r osion . Wa sh t h em wit h t h e sa m e soa p Th is veh icle u ses a bolt -on t ype wh eel cover (F ig.
solu t ion r ecom m en ded for t h e body of t h e veh icle. 29).
Wh en clea n in g ext r em ely dir t y wh eels, ca r e m u st Th is bolt -on wh eel cover ca n n ot be r em oved fr om
be t a ken in t h e select ion of t ir e a n d wh eel clea n in g t h e wh eel u n t il t h r ee of t h e five wh eel m ou n t in g n u t s
ch em ica ls a n d equ ipm en t t o pr even t da m a ge t o t h e sh own a r e r em oved (F ig. 29). Th e bolt -on wh eel cover
wh eels. Mopa r ! Wh eel Tr ea t m en t or Mopa r ! Ch r om e ca n t h en be r em oved wit h t h e r em a in in g t wo wh eel
Clea n er is r ecom m en ded. An y of t h e “DO NOT USE ” n u t s t igh t en ed in pla ce.
it em s list ed below ca n da m a ge wh eels a n d wh eel
t r im . REMOVAL
(1) Not in g t h e loca t ion of t h e va lve st em in r ela -
t ion sh ip t o t h e wh eel m ou n t in g n u t s, r em ove t h e
t h r ee wh eel m ou n t in g n u t s secu r in g t h e wh eel cover
t o t h e wh eel a n d h u b (F ig. 29).
CAUTION: When removing the wheel cover, do not

pry the wheel cover from the wheel. This can result
in damage to the wheel cover. The wheel cover is
removed by pulling it off the wheel by hand.
WH EEL COV ER (Cont inue d)
(a ) Align t h e va lve n ot ch in t h e wh eel cover wit h
t h e va lve st em on t h e wh eel.
(b) At t h e sa m e t im e, a lign t h e t wo h oles in t h e
wh eel cover h a vin g t h e r et a in in g t a bs wit h t h e t wo
in st a lled wh eel n u t s (F ig. 31).
(c) P r ess in on cen t er of wh eel cover u n t il wh eel
cover r et a in in g t a bs pu sh pa st a n d en ga ge r ea r of
pr eviou sly in st a lled wh eel m ou n t in g n u t s (F ig. 31).
Th is will h old t h e wh eel cover in pla ce.
Fig. 29 Nuts Securing Wheel Cover

1 - VALVE STEM
3 - NUTS SECURING WHEEL COVER
(2) Gr a sp t h e wh eel cover a t t h e edges in lin e wit h

t h e r em a in in g in st a lled wh eel n u t s a n d pu ll st r a igh t
ou t wa r d fr om t h e wh eel. Th is will pop t h e wh eel
cover r et a in in g t a bs over t h e t wo r em a in in g wh eel
n u t s, r em ovin g t h e wh eel cover fr om t h e wh eel.
Fig. 31 Wheel Cover Installation Over Two Nuts
INSTALLATION 1 - RETAINING TABS
2 - VALVE STEM
NOTE: Wheel mounting nuts must be installed on
the studs as shown to allow installation of the
(2) In st a ll a n d lig h tly tig h te n t h e t h r ee r em a in -
wheel cover (Fig. 30).
in g wh eel m ou n t in g n u t s, secu r in g t h e wh eel cover in
pla ce (F ig. 29).
(3) Tigh t en a ll five wh eel m ou n t in g n u t s in t h e
pr oper sequ en ce (F ig. 32). Tigh t en wh eel n u t s t o a
Fig. 30 Two Wheel Mounting Nuts Installed

1 - WHEEL
2 - VALVE STEM
3 - HUB PILOT
4 - NUTS
Fig. 32 Nut Tightening Sequence
(1) P la ce t h e wh eel cover on t h e wh eel in t h e fol-
lowin g fa sh ion :
WH EEL M OU N T I N G ST U DS - (6) On wh eel m ou n t in g st u d t o be r em oved, in st a ll

a wh eel m ou n t in g (lu g) n u t fa r en ou gh so t h e t h r ea ds
FRON T on t h e st u d a r e even wit h en d of n u t . In st a ll
Rem over, Specia l Tool C-4150A, on h u b a n d bea r in g
REMOVAL fla n ge a n d wh eel st u d (F ig. 34).
NOTE: Before proceeding, (Refer to 5 - BRAKES -

WARNING)(Refer to 5 - BRAKES - CAUTION).
CAUTION: Wheel mounting studs MUST NOT be

hammered out of hub flange of hub and bearing
assembly. If a stud is removed by hammering it out,
damage to hub and bearing assembly will occur
leading to premature bearing failure.

DURE )
(2) Rem ove fr on t wh eel a n d t ir e a ssem bly. (Refer
t o 22 - TIRE S/WH E E LS - RE MOVAL)
(3) Rem ove t wo a da pt er m ou n t in g bolt s secu r in g
disc br a ke ca liper a da pt er t o st eer in g kn u ckle (F ig. Fig. 34 Wheel Stud Removal (Typical)
33). 1 - WHEEL MOUNTING (LUG) NUT
2 - HUB AND BEARING ASSEMBLY
5 - WHEEL STUD
(7) Tigh t en down on Rem over, pu sh in g wh eel st u d

ou t of h u b fla n ge. On ce sh ou lder of wh eel st u d is
pa st fla n ge, r em ove specia l t ool. Rem ove n u t fr om
st u d a n d r em ove st u d fr om h u b fla n ge.
INSTALLATION
(1) In st a ll r epla cem en t wh eel st u d in t o fla n ge of
h u b a n d bea r in g fr om r ea r. In st a ll wa sh er s on wh eel
st u d, t h en in st a ll a st a n da r d t ype wh eel m ou n t in g
(lu g) n u t on st u d wit h fla t side of lu g n u t a ga in st
wa sh er s a s sh own (F ig. 35).
(2) Tigh t en n u t , pu llin g wh eel st u d in t o h u b
fla n ge. On ce h ea d of st u d is fu lly sea t ed a ga in st r ea r
Fig. 33 Front Brake Mounting of h u b fla n ge, r em ove n u t a n d wa sh er s fr om st u d.
1 - BRAKE ROTOR (3) In st a ll br a ke r ot or ba ck on h u b a n d bea r in g
2 - HUB AND BEARING
3 - STEERING KNUCKLE (F ig. 33).
4 - ADAPTER MOUNTING BOLTS (4) In st a ll br a ke ca liper a n d a da pt er ba ck over
5 - BRAKE CALIPER br a ke r ot or a lign in g a da pt er wit h m ou n t in g h oles on
6 - ADAPTER
7 - CLIP st eer in g kn u ckle (F ig. 33).
(5) In st a ll t wo a da pt er m ou n t in g bolt s secu r in g
(4) Rem ove disc br a ke ca liper a n d a da pt er a s a da pt er t o st eer in g kn u ckle. Tigh t en m ou n t in g bolt s
a ssem bly fr om st eer in g kn u ckle (F ig. 33). H a n g t o 169 N·m (125 ft . lbs.) t or qu e.
a ssem bly ou t of wa y u sin g wir e or a bu n gee cor d. (6) In st a ll wh eel a n d t ir e a ssem bly. Tigh t en wh eel
Use ca r e n ot t o over ext en d br a ke h ose wh en doin g m ou n t in g (lu g) n u t s in pr oper sequ en ce t o 135 N·m
t h is. (100 ft . lbs.) t or qu e.
(5) Rem ove br a ke r ot or fr om h u b by pu llin g it (7) Lower veh icle.
st r a igh t off wh eel m ou n t in g st u ds (F ig. 33).
WH EEL M OU N T I N G ST U DS - FRON T (Cont inue d)
Fig. 35 Installing Wheel Stud (Typical) Fig. 36 Wheel Stud Removal From Hub And Bearing
1 - WASHERS 1 - HUB AND BEARING ASSEMBLY
2 - HUB AND BEARING ASSEMBLY 2 - WHEEL MOUNTING (LUG) NUT
3 - WHEEL MOUNTING (LUG) NUT 3 - WHEEL STUD
4 - STEERING KNUCKLE 4 - SPECIAL TOOL C-4150A
(8) Roa d t est veh icle t o en su r e pr oper oper a t ion of st u d, t h en in st a ll a wh eel lu g n u t on st u d wit h fla t
t h e br a kes. side of lu g n u t a ga in st wa sh er s (F ig. 37).
WH EEL M OU N T I N G ST U DS -
REAR
REMOVAL
CAUTION: If a wheel attaching stud needs to be
replaced in the hub and bearing assembly the studs
MUST NOT be hammered out of the hub flange. If a
stud is removed by hammering it out of the bearing
flange, damage to the hub and bearing assembly
will occur leading to premature hub and bearing
failure.
(1) Ra ise veh icle on ja ckst a n ds or cen t er ed on a Fig. 37 Wheel Stud Installation
fr a m e con t a ct t ype h oist . See H oist in g in Lu br ica t ion 1 - WHEEL MOUNTING (LUG) NUT
a n d Ma in t en a n ce. 2 - HUB AND BEARING ASSEMBLY
(2) Rem ove t h e r ea r wh eel a n d t ir e a ssem bly. 3 - WASHERS
4 - WHEEL STUD
(3) Rem ove t h e br a ke dr u m or disc br a ke ca liper
a n d r ot or. Refer t o Br a kes. (2) Tigh t en t h e wh eel lu g n u t , pu llin g t h e wh eel
(4) In st a ll a lu g n u t on t h e wh eel st u d t o be st u d in t o t h e fla n ge of t h e h u b a n d bea r in g a ssem bly.
r em oved fr om t h e h u b a n d bea r in g a ssem bly (F ig. 36) Wh en t h e h ea d of t h e st u d is fu lly sea t ed a ga in st t h e
so t h e t h r ea ds on st u d a r e even wit h en d of lu g n u t . bea r in g fla n ge, r em ove lu g n u t a n d wa sh er s fr om
In st a ll Rem over, Specia l Tool C-4150A on h u b a n d wh eel st u d.
bea r in g a ssem bly fla n ge a n d wh eel st u d (F ig. 36). (3) In st a ll t h e br a ke dr u m or disc br a ke r ot or a n d
(5) Tigh t en in g down on specia l t ool will pu sh wh eel ca liper on t h e h u b a n d bea r in g a ssem bly.
st u d ou t of t h e h u b a n d bea r in g a ssem bly fla n ge. (4) In st a ll wh eel a n d t ir e a ssem bly on veh icle.
(6) Rem ove lu g n u t fr om st u d a n d r em ove wh eel Tigh t en t h e wh eel m ou n t in g st u d n u t s in pr oper
st u d fr om fla n ge. sequ en ce u n t il a ll n u t s a r e t or qu ed t o h a lf specifica -
t ion . Th en r epea t t h e t igh t en in g sequ en ce t o t h e fu ll
INSTALLATION specified t or qu e of 135 N·m (100 ft . lbs.).
(1) In st a ll r epla cem en t wh eel st u d in t o fla n ge of (5) Lower veh icle t o t h e gr ou n d.
h u b a n d bea r in g a ssem bly. In st a ll wa sh er s on wh eel
RS BODY 23 - 1
BODY
page page
BODY DOOR - FRONT . . . . . . . . . . . . . . . . . . . . . . . . . 14

DESCRIPTION - VEHICLE IDENTIFICATION . . . . 1 DOORS - SLIDING . . . . . . . . . . . . . . . . . . . . . . . 24
WARNING DECKLID/HATCH/LIFTGATE/TAILGATE . . . . . . . 40
SAFETY PRECAUTIONS AND WARNINGS . . . 1 EXTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
DIAGNOSIS AND TESTING HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
WATER LEAKS . . . . . . . . . . . . . . . . . . . . . . . . 1 INSTRUMENT PANEL . . . . . . . . . . . . . . . . . . . . . 65
WIND NOISE . . . . . . . . . . . . . . . . . . . . . . . . . . 2 INTERIOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
STANDARD PROCEDURE PAINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
STANDARD PROCEDURE - PLASTIC BODY SEATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
PANEL REPAIR . . . . . . . . . . . . . . . . . . . . . . . . 3 STATIONARY GLASS . . . . . . . . . . . . . . . . . . . . 161
STANDARD PROCEDURE - HEAT STAKING . . 9 WEATHERSTRIP/SEALS . . . . . . . . . . . . . . . . . . 166
SPECIFICATIONS SUNROOF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 BODY STRUCTURE . . . . . . . . . . . . . . . . . . . . . 177
BODY LUBRICATION . . . . . . . . . . . . . . . . . . . 12
SPECIAL TOOLS
BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
BODY nents. Damage to vehicle can result.

Do not weld exterior panels unless combustible
material on the interior of vehicle is removed from
DESCRIPTION - VEHICLE IDENTIFICATION
the repair area. Fire or hazardous conditions, can
Th r ou gh ou t t h is gr ou p, r efer en ces t o t h e
result.
Da im ler Ch r ysler Cor por a t ion veh icle fa m ily iden t ifi-
Always have a fire extinguisher ready for use when
ca t ion code a r e u sed wh en descr ibin g a pr ocedu r e
welding.
t h a t is u n iqu e t o t h a t veh icle. Refer t o In t r odu ct ion
Disconnect the negative (-) cable clamp from the
Gr ou p of t h is m a n u a l for det a iled in for m a t ion on
battery when servicing electrical components that
veh icle iden t ifica t ion . If a pr ocedu r e is com m on t o a ll
are live when the ignition is OFF. Damage to electri-
veh icles cover ed in t h is m a n u a l, n o r efer en ce will be
cal system can result.
m a de t o a veh icle fa m ily code.
Do not use abrasive chemicals or compounds on
painted surfaces. Damage to finish can result.
WARN I N G Do not use harsh alkaline based cleaning solvents
on painted or upholstered surfaces. Damage to fin-
SAFETY PRECAUTIONS AND WARNINGS ish or color can result.
Do not hammer or pound on plastic trim panel
WARNING: USE A OSHA APPROVED BREATHING when servicing interior trim. Plastic panels can
FILTER WHEN SPRAYING PAINT OR SOLVENTS IN break.
A CONFINED AREA. PERSONAL INJURY CAN
RESULT.
AVOID PROLONGED SKIN CONTACT WITH PETRO-
LEUM OR ALCOHOL – BASED CLEANING SOL-
VENTS. PERSONAL INJURY CAN RESULT. WATER LEAKS
DO NOT STAND UNDER A HOISTED VEHICLE THAT Wa t er lea ks ca n be ca u sed by poor sea lin g,
IS NOT PROPERLY SUPPORTED ON SAFETY im pr oper body com pon en t a lign m en t , body sea m
STANDS. PERSONAL INJURY CAN RESULT. por osit y, m issin g plu gs, or blocked dr a in h oles. Cen -
t r ifu ga l a n d gr a vit a t ion a l for ce ca n ca u se wa t er t o
dr ip fr om a loca t ion a wa y fr om t h e a ct u a l lea k poin t ,
CAUTION: When holes must be drilled or punched m a kin g lea k det ect ion difficu lt . All body sea lin g
in an inner body panel, verify depth of space to the poin t s sh ou ld be wa t er t igh t in n or m a l wet -dr ivin g
outer body panel, electrical wiring, or other compo- con dit ion s. Wa t er flowin g down wa r d fr om t h e fr on t of
23 - 2 BODY RS
BODY (Cont inue d)
t h e veh icle sh ou ld n ot en t er t h e pa ssen ger or lu gga ge Som e wa t er lea ks m u st be t est ed for a con sider a ble
com pa r t m en t . Movin g sea lin g su r fa ces will n ot len gt h of t im e t o becom e a ppa r en t . Wh en a lea k
a lwa ys sea l wa t er t igh t u n der a ll con dit ion s. At a ppea r s, fin d t h e h igh est poin t of t h e wa t er t r a ck or
t im es, side gla ss or door sea ls will a llow wa t er t o dr op. Th e h igh est poin t u su a lly will sh ow t h e poin t of
en t er t h e pa ssen ger com pa r t m en t du r in g h igh pr esen t r y. Aft er lea k poin t h a s been fou n d, r epa ir t h e
su r e wa sh in g or h a r d dr ivin g r a in (sever e) con di- lea k a n d wa t er t est t o ver ify t h a t t h e lea k h a s
t ion s. Over com pen sa t in g on door or gla ss st opped.
a dju st m en t s t o st op a wa t er lea k t h a t occu r s u n der Loca t in g t h e en t r y poin t of wa t er t h a t is lea kin g
sever e con dit ion s ca n ca u se pr em a t u r e sea l wea r a n d in t o a ca vit y bet ween pa n els ca n be difficu lt . Th e
excessive closin g or la t ch in g effor t . Aft er com plet in g t r a pped wa t er m a y spla sh or r u n fr om t h e ca vit y,
a r epa ir, wa t er t est veh icle t o ver ify lea k h a s st opped oft en a t a dist a n ce fr om t h e en t r y poin t . Most wa t er
befor e r et u r n in g veh icle t o u se. lea ks of t h is t ype becom e a ppa r en t a ft er a cceler a t in g,
st oppin g, t u r n in g, or wh en on a n in clin e.
VISUAL INSPECTION BEFORE WATER LEAK TESTS
Ver ify t h a t floor a n d body plu gs a r e in pla ce, body MIRROR INSPECTION METHOD
dr a in s a r e clea r, a n d body com pon en t s a r e pr oper ly Wh en a lea k poin t a r ea is visu a lly obst r u ct ed, u se
a lign ed a n d sea led. If com pon en t a lign m en t or sea l- a su it a ble m ir r or t o ga in visu a l a ccess. A m ir r or ca n
in g is n ecessa r y, r efer t o t h e a ppr opr ia t e sect ion of a lso be u sed t o deflect ligh t t o a lim it ed-a ccess a r ea
t h is gr ou p for pr oper pr ocedu r es. t o a ssist in loca t in g a lea k poin t .
WATER LEAK TESTS BRIGHT LIGHT LEAK TEST METHOD

Som e wa t er lea ks in t h e lu gga ge com pa r t m en t ca n
WARNING: DO NOT USE ELECTRIC SHOP LIGHTS be det ect ed wit h ou t wa t er t est in g. P osit ion t h e veh i-
OR TOOLS IN WATER TEST AREA. PERSONAL cle in a br igh t ly lit a r ea . F r om in side t h e da r ken ed
INJURY CAN RESULT. lu gga ge com pa r t m en t in spect a r ou n d sea ls a n d body
sea m s. If n ecessa r y, h a ve a h elper dir ect a dr op ligh t
Wh en t h e con dit ion s ca u sin g a wa t er lea k h a ve over t h e su spect ed lea k a r ea s a r ou n d t h e lu gga ge
been det er m in ed, sim u la t e t h e con dit ion s a s closely com pa r t m en t . If ligh t is visible t h r ou gh a n or m a lly
a s possible. sea led loca t ion , wa t er cou ld en t er t h r ou gh t h e open -
• If a lea k occu r s wit h t h e veh icle pa r ked in a in g.
st ea dy ligh t r a in , flood t h e lea k a r ea wit h a n open -
en ded ga r den h ose. PRESSURIZED LEAK TEST METHOD
• If a lea k occu r s wh ile dr ivin g a t h igh wa y speeds Wh en a wa t er lea k in t o t h e pa ssen ger com pa r t -
in a st ea dy r a in , t est t h e lea k a r ea wit h a r ea son a ble m en t ca n n ot be det ect ed by wa t er t est in g, pr essu r ize
velocit y st r ea m or fa n spr a y of wa t er. Dir ect t h e t h e pa ssen ger com pa r t m en t a n d soa p t est ext er ior of
spr a y in a dir ect ion com pa r a ble t o a ct u a l con dit ion s. t h e veh icle. To pr essu r ize t h e pa ssen ger com pa r t -
• If a lea k occu r s wh en t h e veh icle is pa r ked on a n m en t , close a ll door s a n d win dows, st a r t en gin e, a n d
in clin e, h oist t h e en d or side of t h e veh icle t o sim u - set h ea t er con t r ol t o h igh blower in H E AT posit ion . If
la t e t h is con dit ion . Th is m et h od ca n be u sed wh en en gin e ca n n ot be st a r t ed, con n ect a ch a r ger t o t h e
t h e lea k occu r s wh en t h e veh icle a cceler a t es, st ops or ba t t er y t o en su r e a dequ a t e volt a ge t o t h e blower.
t u r n s. If t h e lea k occu r s on a cceler a t ion , h oist t h e Wit h in t er ior pr essu r ized, a pply dish det er gen t solu -
fr on t of t h e veh icle. If t h e lea k occu r s wh en br a kin g, t ion t o su spect ed lea k a r ea on t h e ext er ior of t h e
h oist t h e ba ck of t h e veh icle. If t h e lea k occu r s on left veh icle. Apply det er gen t solu t ion wit h spr a y device or
t u r n s, h oist t h e left side of t h e veh icle. If t h e lea k soft br ist le br u sh . If soa p bu bbles occu r a t a body
occu r s on r igh t t u r n s, h oist t h e r igh t side of t h e veh i- sea m , join t , sea l or ga sket , t h e lea k en t r y poin t cou ld
cle. F or h oist in g r ecom m en da t ion s (Refer t o LUBRI- be a t t h a t loca t ion .
CATION & MAINTE NANCE /H OISTING -
STANDARD P ROCE DURE ). WIND NOISE
Win d n oise is t h e r esu lt of m ost a ir lea ks. Air lea ks
WATER LEAK DETECTION ca n be ca u sed by poor sea lin g, im pr oper body com po-
To det ect a wa t er lea k poin t -of-en t r y, do a wa t er n en t a lign m en t , body sea m por osit y, or m issin g plu gs
t est a n d wa t ch for wa t er t r a cks or dr oplet s for m in g in t h e en gin e com pa r t m en t or door h in ge pilla r a r ea s.
on t h e in side of t h e veh icle. If n ecessa r y, r em ove in t e- All body sea lin g poin t s sh ou ld be a ir t igh t in n or m a l
r ior t r im cover s or pa n els t o ga in visu a l a ccess t o t h e dr ivin g con dit ion s. Movin g sea lin g su r fa ces will n ot
lea k a r ea . If t h e h ose ca n n ot be posit ion ed wit h ou t a lwa ys sea l a ir t igh t u n der a ll con dit ion s. At t im es,
bein g h eld, h a ve som eon e h elp do t h e wa t er t est . side gla ss or door sea ls will a llow win d n oise t o be
RS BODY 23 - 3
BODY (Cont inue d)
n ot iced in t h e pa ssen ger com pa r t m en t du r in g h igh Flexible Plastics:
cr oss win ds. Over com pen sa t in g on door or gla ss E xa m ples of flexible pla st ic u se: F a scia s, Body
a dju st m en t s t o st op win d n oise t h a t occu r s u n der Moldin gs, a n d u pper a n d lower F a scia Cover s.
sever e con dit ion s ca n ca u se pr em a t u r e sea l wea r a n d
excessive closin g or la t ch in g effor t . Aft er a r epa ir pr o- Repair Procedure:
cedu r e h a s been per for m ed, t est veh icle t o ver ify Th e r epa ir pr ocedu r e for a ll t h r ee ca t egor ies of
n oise h a s st opped befor e r et u r n in g veh icle t o u se. pla st ics is ba sica lly t h e sa m e. Th e on e differ en ce is
t h e m a t er ia l u sed for t h e r epa ir. Th e m a t er ia ls m u st
VISUAL INSPECTION BEFORE TESTS be specific for ea ch su bst r a t e, r igid r epa ir m a t er ia l
Ver ify t h a t floor a n d body plu gs a r e in pla ce a n d for r igid pla st ic r epa ir, sem i-r igid r epa ir m a t er ia l for
body com pon en t s a r e a lign ed a n d sea led. If com po- sem i-r igid pla st ic r epa ir a n d flexible r epa ir m a t er ia l
n en t a lign m en t or sea lin g is n ecessa r y, r efer t o t h e for flexible pla st ic r epa ir.
a ppr opr ia t e sect ion of t h is gr ou p for pr oper pr oce-
du r es. Adhesion Promoter/Surface Modifier:
Adh esion P r om ot er s/Su r fa ce Modifier s a r e r equ ir ed
ROAD TESTING WIND NOISE for cer t a in pla st ics. All t h r ee ca t egor ies m a y h a ve
(1) Dr ive t h e veh icle t o ver ify t h e gen er a l loca t ion pla st ics t h a t r equ ir e t h e u se of a dh esion pr om ot er /
of t h e win d n oise. su r fa ce m odifier s. Alwa ys follow r epa ir m a t er ia l m a n -
(2) Apply 50 m m (2 in .) m a skin g t a pe in 150 m m u fa ct u r er ’s pla st ic iden t ifica t ion and r epa ir
(6 in .) len gt h s a lon g wea t h er st r ips, weld sea m s or pr ocedu r es.
m oldin gs. Aft er ea ch len gt h is a pplied, dr ive t h e veh i-
cle. If n oise goes a wa y a ft er a piece of t a pe is a pplied, SAFETY PRECAUTION AND WARNINGS
r em ove t a pe, loca t e, a n d r epa ir defect .
WARNING:
POSSIBLE CAUSE OF WIND NOISE • EYE PROTECTION SHOULD BE USED WHEN
• Moldin gs st a n din g a wa y fr om body su r fa ce ca n SERVICING COMPONENTS. PERSONAL INJURY
ca t ch win d a n d wh ist le. CAN RESULT.
• Ga ps in sea led a r ea s beh in d over h a n gin g body • USE AN OSHA APPROVED BREATHING MASK
fla n ges ca n ca u se win d-r u sh in g sou n ds. WHEN MIXING EPOXY, GRINDING, AND SPRAYING
• Misa lign ed m ova ble com pon en t s. PAINT OR SOLVENTS IN A CONFINED AREA. PER-
• Missin g or im pr oper ly in st a lled plu gs in pilla r s. SONAL INJURY CAN RESULT.
• Weld bu r n t h r ou gh h oles. • AVOID PROLONGED SKIN CONTACT WITH
RESIN, PETROLEUM, OR ALCOHOL BASED SOL-
VENTS. PERSONAL INJURY CAN RESULT.
STAN DARD PROCEDU RE • DO NOT VENTURE UNDER A HOISTED VEHI-
CLE THAT IS NOT PROPERLY SUPPORTED ON
STANDARD PROCEDURE - PLASTIC BODY SAFETY STANDS. PERSONAL INJURY CAN
PANEL REPAIR RESULT.
Th er e a r e m a n y differ en t t ypes of pla st ics u sed in
t oda y’s a u t om ot ive en vir on m en t . We gr ou p pla st ics in
t h r ee differ en t ca t egor ies: Rigid, Sem i-Rigid, a n d NOTE:
F lexible. An y of t h ese pla st ics m a y r equ ir e t h e u se of • When holes must be drilled or cut in body pan-
a n a dh esion pr om ot er for r epa ir. Th ese t ypes of pla s- els, verify locations of internal body components
t ic a r e u sed ext en sively on Da im ler Ch r ysler Mot or s and electrical wiring. Damage to vehicle can result.
veh icles. Alwa ys follow r epa ir m a t er ia l m a n u fa ct u r- • Do not use abrasive chemicals or compounds
er ’s pla st ic iden t ifica t ion a n d r epa ir pr ocedu r es. on undamaged painted surfaces around repair
areas. Damage to finish can result.
Rigid Plastics:
E xa m ples of r igid pla st ic u se: F a scia s, H oods,
Door s, a n d ot h er Body P a n els, wh ich in clu de SMC,
ABS, a n d P olyca r bon a t es.
Semi-Rigid Plastics:
E xa m ples of sem i-r igid pla st ic u se: In t er ior P a n els,
Un der H ood P a n els, a n d ot h er Body Tr im P a n els.
23 - 4 BODY RS
BODY (Cont inue d)
RIGID, SEMI-RIGID, AND FLEXIBLE PLASTIC PARTS TYPES
CODE FAMILY NAME COMMON TRADE NAME TYPICAL APPLICATION

ASA ACRYLONITRILE STYRENE LURAN S CONSOLES, GRILLES
ACRYLITE
ABS ACRYLONITRILE TERLURAN %A% PILLARS, CONSOLES,
BUTADIENE STYRENE GRILLES
ABS/PC ABS/PC ALLOY PULSE, PROLOY, BAYBLEND DOORS, INSTRUMENT
PANELS
ABS/PVC ABS/PV ALLOY PROLOY, PULSE, LUSTRAN, DOOR PANELS, GRILLES,
CYCLOVIN TRIM
BMC BULK MOLDING BMC FENDER EXTENSIONS
COMPOUND
EMA EHTYLENE METHYL SURLYN, EMA, IONOMER BUMPER GUARDS, PADS
ACRYLATE/IONOMER
METTON METTON METTON GRILLES, KICK PANELS,
RUNNING BOARDS
MPPO MODIFIED MPPO SPOILER ASSEMBLY
POLYPHENYLENE OXIDE
PA POLYAMID ZYTEL, VYDYNE, PA, FENDERS, QUARTER
MINLON PANELS
PET THERMOPLASTIC RYNITE TRIM
POLYESTER
PBT/PPO PBT/PPO ALLOY GERMAX CLADDINGS
PBTP POLYBUTYLENE PBT, PBTP, POCAN, VALOX WHEEL COVERS, FENDERS,
THEREPTHALATE GRILLES
PBTP/EEBC POLYBUTYLENE BEXLOY, %M%, PBTP/EEBC FASCIAS, ROCKER PANEL,
THEREPTHALATE/EEBC MOLDINGS
ALLOY
PC POLYCARBONATE LEXAN, MERLON, CALIBRE, TAIL LIGHT LENSES, IP TRIM,
MAKROLON PC VALANCE PANELS
PC/ABS PC/ABS ALLOY GERMAX, BAY BLENDS, DOORS, INSTRUMENT
PULSE PANELS
PPO POLYPHENYLENE OXIDE AZDEL, HOSTALEN, INTERIOR TRIM, DOOR
MARLEX, PRFAX, NORYL, PANELS, SPLASH SHIELDS,
GTX, PPO STEERING COLUMN
SHROUD
PPO/PA POLYPHENYLENE/ PPO/PA, GTX 910 FENDERS, QUARTER
POLYAMID PANELS
PR/FV FIBERGLASS REINFORCED FIBERGLASS, FV, PR/FV BODY PANELS
PLASTIC
PS POLYSTYRENE LUSTREX, STYRON, PS DOOR PANELS, DASH
PANELS
RTM RESIN TRANSFER RTM BODY PANELS
MOLDING COMPOUND
SMC SHEET MOLDED SMC BODY PANELS
COMPOUND
TMC TRANSFER MOLDING TMC GRILLES
COMPOUND
RS BODY 23 - 5
BODY (Cont inue d)
CODE FAMILY NAME COMMON TRADE NAME TYPICAL APPLICATION

UP UNSATURATED SMC, BMC, TMC, ZMC, IMC, GRILLE OPENING PANEL,
POLYESTER XSMC, UP LIFTGATES, FLARESIDE
(THERMOSETTING) FENDERS, FENDER
EXTENSIONS
EEBC ETHER/ESTER BLOCKED EEBC BUMPERS
CO-POLYMER
EEBC/PBTP EEBC/POLYBUTYLENE EEBC, PBTP, BEXLOY BUMPER, ROCKER PANELS
TEREPTHALATE
EMPP ETHYLENE MODIFIED EMPP BUMPER COVERS
POLYPROPYLENE
EPDM ETHYLENE/ EPDM, NORDEL, VISTALON BUMPERS
PROPROPYLENE DIENE
MONOMER
EPM ETHYLENE/ EPM FENDERS
PROPROPYLENE CO-
POLYMER
MPU FOAM POLYURETHANE MPU SPOILERS
PE POLYETHYLENE ALATHON, DYLAN, -
LUPOLEN, MARLEX
PP POLYPROPYLENE NORYL, AZDEL, MARLOX, INNER FENDER, SPOILERS,
(BLENDS) DYLON, PRAVEX KICK PANELS,A-PILLARS,
DOOR PANELS, B-PILLARS,
QUARTER PANELS, SPORT
BAR TRIM, LIFTGATE TRIM,
DECKLID TRIM SCUFF
PLATES, KICK PANELS,
CONSOLES
PP/EPDM PP/EPDM ALLOY PP/EPDM SPOILERS, GRILLES
PUR POLYURETHANE COLONELS, PUR, PU FASCIAS, BUMPERS
PUR/PC PUR/PC ALLOY TEXIN BUMPERS
PVC POLYVINYL CHLORIDE APEX, GEON, VINYLITE BODY MOLDINGS, WIRE
INSULATION, STEERING
WHEELS
RIM REACTION INJECTED RIM, BAYFLEX FRONT FASCIAS, MODULAR
MOLDED POLYURETHANE WINDOWS
RRIM REINFORCED REACTION PUR, RRIM FASCIAS, BODY PANELS,
INJECTED MOLDED BODY TRIMS
TPE THERMO POLYETHYLENE TPE, HYTREL, BEXLOY-V FASCIAS, BUMPERS,
CLADDINGS
TPO THERMOPOLYOLEFIN POLYTROPE, RENFLEX, BUMPERS, END CAPS,
SANTOPRENE, VISAFLEX, TELCAR, RUBBER, STRIPS,
ETA, APEX, TPO, SHIELDS, SIGHT, INTERIOR B POST
CLADDINGS
TPP THERMO-POLYPROPYLENE TPP BUMPERS
TPU THERMOPOLYURETHANE, TPU, HYTREL, TEXIN, BUMPERS, BODY SIDE,
POLYESTER ESTANE MOLDINGS, FENDERS,
FASCIAS
23 - 6 BODY RS
BODY (Cont inue d)
PANEL SECTIONING PANEL REINFORCEMENT

If it is r equ ir ed t o sect ion a la r ge pa n el for a pla s- St r u ct u r a l r epa ir pr ocedu r es for r igid pa n els wit h
t ic r epa ir, it will be n ecessa r y t o r ein for ce t h e pa n el la r ge cr a cks a n d h oles will r equ ir e a r ein for cem en t
(F ig. 1). To bon d t wo pla st ic pa n els t oget h er, a r ein - ba ckin g. Rein for cem en t s ca n be m a de wit h sever a l
for cem en t m u st over la p bot h pa n els. Th e pa n els a pplica t ion s of gla ss clot h sa t u r a t ed wit h st r u ct u r a l
m u st be “V’d” a t a 20 degr ee a n gle. Th e a r ea t o be a dh esive. Sem i-r igid or flexible r epa ir m a t er ia ls
r ein for ced sh ou ld be wa sh ed, t h en sa n ded. Be su r e t o sh ou ld be u sed for sem i-r igid or flexible ba ckin g r ein -
wipe off a n y excess soa p a n d wa t er wh en fin ish ed. for cem en t (F ig. 2) a n d (F ig. 3). Open m esh ed fiber-
Ligh t ly sa n d or a br a de t h e pla st ic wit h a n a br a sive gla ss dr y wa ll t a pe ca n be u sed t o for m a
pa d or sa n dpa per. Blow off a n y du st wit h com pr essed r ein for cem en t . Th e dr y wa ll t a pe a llows t h e r esin t o
a ir or wipe wit h a clea n dr y r a g. pen et r a t e t h r ou gh a n d m a ke a good bon d bet ween
t h e pa n el a n d t h e a dh esive. St r u ct u r a lly, t h e m or e
dr y wa ll t a pe u sed, t h e st r on ger t h e r epa ir.
An ot h er kin d of r epa ir t h a t ca n be don e t o r epa ir
la r ge cr a cks a n d h oles is t o u se a scr a p piece of sim -
ila r pla st ic a n d bon d wit h st r u ct u r a l a dh esive. Th e
r ein for cem en t sh ou ld cover t h e en t ir e br ea k a n d
sh ou ld h a ve a gen er ou s a m ou n t of over la p on eit h er
side of t h e cr a cked or br oken a r ea .
Wh en r epa ir in g pla st ic, t h e da m a ged a r ea is fir st
“V’d” ou t , or beveled. La r ge bon din g a r ea s a r e desir-
a ble wh en r epa ir in g pla st ic beca u se sm a ll r epa ir s a r e
less likely t o h old per m a n en t ly. Bevelin g t h e a r ea
a r ou n d a cr a ck a t a 20 degr ee a n gle will in cr ea se t h e
bon din g su r fa ce for a r epa ir (F ig. 4). It is r ecom -
m en ded t h a t sh a r p edges be a voided beca u se t h e
join t m a y sh ow t h r ou gh a ft er t h e pa n el is r efin ish ed.
Fig. 1 PANEL SECTIONING
1 - EXISTING PANEL
2 - NEW PANEL
3 - PANEL ADHESIVE
4 - BONDING STRIP
Wh en bon din g pla st ic pa n els, F ollow r epa ir m a t e-

r ia l m a n u fa ct u r er s r ecom m en da t ion s. Be su r e t h a t
en ou gh a dh esive h a s been a pplied t o a llow squ eeze
ou t a n d t o fill t h e fu ll bon d lin e. On ce t h e pieces
h a ve been br ou gh t t oget h er, do n ot m ove t h em u n t il
t h e a dh esive is cu r ed. Th e a ssem bly ca n be h eld
t oget h er wit h cla m ps, r ivet s, et c. A fa st er cu r e ca n be Fig. 2 SOFTENED EDGES
obt a in ed by h ea t in g wit h a h ea t la m p or h ea t gu n . 1 - SOFTENED EDGES
Aft er t h e pa r t s h a ve been bon ded a n d h a ve h a d t im e 2 - PANEL ADHESIVE
3 - BONDING STRIP
t o cu r e, r ou gh sa n d t h e sea m a n d a pply t h e fin a l
a dh esive filler t o t h e a r ea bein g r epa ir ed. Sm oot h t h e
filler wit h a spr ea der, wooden t on gu e depr essor, or
squ eegee. F or fin e t ext u r in g, a sm a ll a m ou n t of
wa t er ca n be a pplied t o t h e filler su r fa ce wh ile
sm oot h in g. Th e cu r ed filler ca n be sa n ded a s n eces-
sa r y a n d, a s a fin a l st ep, clea n u p ca n be don e wit h
soa py wa t er. Wipe t h e su r fa ce clea n wit h a dr y clot h
a llowin g t im e for t h e pa n el t o dr y befor e m ovin g on
wit h t h e r epa ir.
Fig. 3 PANEL REINFORCEMENT

1 - PANEL ADHESIVE
2 - REINFORCEMENT
RS BODY 23 - 7
BODY (Cont inue d)
Fig. 4 BEVELING ANGLE - 20 DEGREE

• P a n el r epa ir for bot h flexible a n d r igid pa n els
a r e ba sica lly t h e sa m e. Th e pr im a r y differ en ce
bet ween flexible pa n el r epa ir a n d r igid pa n el r epa ir Fig. 6 DAMAGE COMPONENT
is in t h e a dh esive m a t er ia ls u sed (F ig. 5). 1 - PUNCTURE
• Th e t ech n icia n sh ou ld fir st decide wh a t n eeds t o
be don e wh en wor kin g on a n y t ype of body pa n el. PANEL SURFACE PREPARATION
On e sh ou ld det er m in e if it is possible t o r et u r n t h e If a body pa n el h a s been pu n ct u r ed, cr a cked, or
da m a ge pa r t t o it s or igin a l st r en gt h a n d a ppea r a n ce cr u sh ed, t h e da m a ged a r ea m u st be r em oved fr om
wit h ou t exceedin g t h e va lu e of t h e r epla cem en t pa r t . t h e pa n el t o a ch ieve a su ccessfu l r epa ir. All spider
• Wh en pla st ic r epa ir s a r e r equ ir ed, it is r ecom - web cr a cks lea din g a wa y fr om a da m a ged a r ea m u st
m en ded t h a t t h e pa r t be left on t h e veh icle wh en be st opped or r em oved. To st op a r u n n in g cr a ck in a
ever y possible. Th a t will sa ve t im e, a n d t h e pa n el pa n el, dr ill a 6 m m (0.250 in .) h ole a t t h e en d of t h e
will r em a in st a t ion a r y du r in g t h e r epa ir. Misa lign - cr a ck fa r t h est a wa y fr om t h e da m a ge. If spider web
m en t ca n ca u se st r ess in t h e r epa ir a r ea s a n d ca n cr a cks ca n n ot be st opped, t h e pa n el wou ld r equ ir e
r esu lt in fu t u r e fa ilu r e. r epla cem en t . Th e su r fa ces a r ou n d t h e da m a ged a r ea
sh ou ld be st r ipped of pa in t a n d fr eed fr om wa x a n d
oil. Scu ff su r fa ces a r ou n d r epa ir a r ea wit h 360 gr it
wet /dr y sa n dpa per, or equ iva len t , t o a ssu r e a dh esion
of r epa ir m a t er ia ls.
PATCHING PANELS
An pa n el t h a t h a s ext en sive pu n ct u r e t ype da m a ge
ca n be r epa ir ed by cu t t in g ou t t h e da m a ged m a t er ia l
(F ig. 7). Use a su it a ble r ecipr oca t in g sa w or cu t off
wh eel t o r em ove t h e sect ion of t h e pa n el t h a t is da m -
a ged. Th e piece cu t ou t ca n be u sed a s a t em pla t e t o
Fig. 5 FIBERGLASS TAPE sh a pe t h e n ew pa t ch . It is n ot n ecessa r y t o h a ve
VISUAL INSPECTION a ccess t o t h e ba ck of t h e pa n el t o in st a ll a pa t ch .
Com posit e m a t er ia ls ca n m a sk t h e sever it y of a n Bevel edges of cu t ou t a t 20 degr ees t o expose a la r ger
a cciden t . Adh esive bon d lin es, in t er ior st r u ct u r e of bon din g a r ea on t h e ou t er side. Th is will a llow for a n
t h e door s, a n d st eel st r u ct u r es n eed t o be in spect ed in cr ea sed r ein for cem en t a r ea s.
ca r efu lly t o get a t r u e da m a ge a ssessm en t . Close
in spect ion m a y r equ ir e pa r t ia l r em ova l of in t er ior PANEL PATCH FABRICATIONS
t r im or in n er pa n els. A pa t ch ca n be fa br ica t ed fr om a n y r igid fiber gla ss
Iden t ify t h e t ype of r epa ir : P u n ct u r e or Cr a ck - pa n el t h a t h a s com pa r a ble con t ou r wit h t h e r epa ir
Da m a ge t h a t h a s pen et r a t ed com plet ely t h r ou gh t h e a r ea . Lift ga t es a n d fen der s ca n be u sed t o su pply
pa n el. Da m a ge is con fin ed t o on e gen er a l a r ea ; a pa t ch m a t er ia l. If exist in g m a t er ia l is n ot a va ila ble
pa n el sect ion is n ot r equ ir ed. H owever, a ba cker or com pa t ible, a pa t ch ca n be con st r u ct ed wit h a dh e-
pa n el, open fiber gla ss t a pe, or m a t t ed m a t er ia l m u st sive a n d r ein for cem en t m esh (dr y wa ll t a pe). P er for m
be bon ded fr om beh in d (F ig. 7) (F ig. 6). t h e followin g oper a t ion if r equ ir ed:
23 - 8 BODY RS
BODY (Cont inue d)
PANEL PATCH INSTALLATION
(1) Ma ke a pa per or ca r dboa r d pa t t er n t h e size
a n d sh a pe of t h e cu t ou t h ole in t h e pa n el.
(2) Tr im 3 m m (0.125 in .) fr om edges of pa t t er n so
pa t ch will h a ve a ga p bet ween con n ect in g su r fa ces.
(3) Usin g t h e pa t t er n a s a gu ide, cu t t h e pa t ch t o
size.
(4) Cu t scr a p pieces of pa t ch m a t er ia l in t o 50 m m
(2 in .) squ a r es t o u se a s pa t ch su ppor t s t o su st a in
t h e pa t ch in t h e cu t ou t .
(5) Dr ill 4 m m (0.160 in .) h oles 13 m m (0.5 in .) in
fr om edge of cu t ou t h ole (F ig. 7).
(6) Dr ill 4 m m (0.160 in .) h oles 13 m m (0.5 in .)
a wa y fr om edge of pa t ch a cr oss fr om h oles dr illed
a r ou n d cu t ou t .
Fig. 7 DAMAGED PANEL CUTOUT AND PATCH (7) Dr ill 3 m m (0.125 in .) h oles in t h e su ppor t
1 - CUTOUT squ a r es 13 m m (0.5 in .) fr om t h e edge in t h e cen t er
2 - DAMAGED BODY PANEL
3 - 4 MM (0.160 IN.) HOLES
of on e side.
4 - PATCH CUT TO SIZE (8) Scu ff t h e ba ckside of t h e body pa n el a r ou n d t h e
cu t ou t h ole wit h a scu ff pa d or sa n dpa per.
(1) Cover wa xed pa per or pla st ic wit h a dh esive (9) Mix en ou gh a dh esive t o cover on e side of a ll
ba cked n ylon m esh (dr y wa ll t a pe) la r ger t h a n t h e su ppor t squ a r es.
pa t ch r equ ir ed (F ig. 8). (10) Apply a dh esive t o cover on e side of a ll su ppor t
(2) Ta pe wa xed pa per or pla st ic sh eet wit h m esh t o squ a r es.
a su r fa ce t h a t h a s a com pa t ible con t ou r t o t h e r epa ir (11) Usin g n u m ber 8 sh eet m et a l scr ews, secu r e
a r ea . su ppor t squ a r es t o ba ck side of body pa n el wit h
(3) Apply a liber a l coa t of a dh esive over t h e r ein - a dh esive sa n dwich ed bet ween t h e pa n el a n d squ a r es
for cem en t m esh (F ig. 8). If n ecessa r y a pply a secon d (F ig. 9).
or t h ir d coa t of a dh esive a n d m esh a ft er fir st coa t
h a s cu r ed. Th e t h ickn ess of t h e pa t ch sh ou ld be t h e
sa m e a s t h e r epa ir a r ea .
(4) Aft er pa t ch h a s cu r ed, peel wa xed pa per or
pla st ic fr om t h e ba ck of t h e pa t ch .
(5) If desir ed, a t h in film coa t of a dh esive ca n be
a pplied t o t h e ba ck of t h e pa t ch t o cover m esh for
a dded st r en gt h .
Fig. 9 SECURE SUPPORT SQUARES TO BODY

PANEL
1 - SUPPORT SQUARES
2 - SCREWS
3 - DAMAGED BODY PANEL
(12) P osit ion pa t ch in cu t ou t a ga in st su ppor t

Fig. 8 FABRICATED PANEL squ a r es a n d a dju st pa t ch u n t il t h e ga p is equ a l a lon g
1 - STRUCTURAL ADHESIVE a ll sides (F ig. 10).
2 - FIBERGLASS CLOTH OR FIBERGLASS MESH TAPE (13) Dr ill 3 m m (0.125 in .) h oles in t h e su ppor t
3 - WIDTH OF V-GROOVE squ a r es t h r ou gh t h e pr e-dr illed h oles in t h e pa t ch .
4 - WAXED PAPER
(14) Apply a coa t of a dh esive t o t h e exposed en ds
of t h e su ppor t squ a r es (F ig. 11).
RS BODY 23 - 9
BODY (Cont inue d)
(15) In st a ll scr ews t o h old t h e pa t ch t o su ppor t
squ a r es (F ig. 12). Tigh t en scr ews u n t il pa t ch su r fa ce
is flu sh wit h pa n el su r fa ce.
(16) Allow a dh esive t o cu r e, a n d r em ove a ll scr ews.
(17) Usin g a 125 m m (5 in .) 24 gr it disc gr in der,
gr in d a 50 m m (2 in .) t o 75 m m (3 in .) wide a n d 2
m m (0.080 in .) deep pa t h a cr oss t h e ga ps a r ou n d t h e
pa t ch (F ig. 13). Wit h com pr essed a ir, blow du st fr om
a r ou n d pa t ch .
(18) Apply a dh esive ba cked n ylon m esh (dr y wa ll
t a pe) over ga ps a r ou n d pa t ch (F ig. 14).
(19) Mix en ou gh a dh esive t o cover t h e en t ir e pa t ch
a r ea .
(20) Apply a dh esive over t h e m esh a r ou n d pa t ch ,
a n d sm oot h epoxy wit h a wide spr ea der t o r edu ce fin -
ish gr in din g. Use t wo t o t h r ee la yer s of m esh a n d
a dh esive t o cr ea t e a st r on ger r epa ir (F ig. 15). Fig. 12 INSTALL SCREWS
1 - PATCH
2 - GAP
Fig. 10 POSITION PATCH IN CUTOUT AND ALIGN

1 - CUTOUT
2 - SUPPORT SQUARES Fig. 13 GRIND SURFACE
1 - PATCH
2 - GAP
3 - DISC GRINDER
PATCHED PANEL SURFACING

Aft er pa t ch pa n el is in st a lled, t h e pa t ch a r ea ca n
be fin ish ed u sin g t h e sa m e m et h ods a s fin ish in g
ot h er t ypes of body pa n els. If m esh m a t er ia l is
exposed in t h e pa t ch ed a r ea , gr in d su r fa ce down , a n d
a pply a coa t of h igh qu a lit y r igid pla st ic body filler.
P r im e, block sa n d, a n d pa in t a s r equ ir ed.
STANDARD PROCEDURE - HEAT STAKING

(1) Rem ove t r im pa n el.
(2) Ben d or m ove t h e t r im pa n el com pon en t s a t
t h e h ea t st a ked join t s. Obser ve t h e h ea t st a ked loca -
t ion s a n d/or com pon en t sea m s for loosen ess.
Fig. 11 APPLY ADHESIVE TO SUPPORT SQUARES
(3) H ea t st a ke t h e com pon en t s.
1 - APPLICATOR
2 - SUPPORT SQUARES
3 - ADHESIVE
23 - 10 BODY RS
BODY (Cont inue d)
Fig. 14 COVER GAPS WITH MESH Fig. 15 COVER MESH WITH ADHESIVE
1 - GROUND DOWN AREA 1 - ADHESIVE
2 - PATCH 2 - MESH
3 - MESH 3 - PATCH
4 - SPREADER
(a ) If t h e h ea t st a ked or com pon en t sea m loca -
t ion is loose, h old t h e t wo com pon en t s t igh t ly in g t h e glu e. On ce t h e n ew m a t er ia l is in pla ce, it
t oget h er a n d u sin g a solder in g gu n wit h a fla t t ip, m a y be n ecessa r y t o u se a solder in g gu n t o m elt
m elt t h e m a t er ia l secu r in g t h e com pon en t s t h e n ewly a pplied m a t er ia l. Do n ot over h ea t t h e
t oget h er. Do n ot over h ea t t h e a ffect ed a r ea , da m - a ffect ed a r ea , da m a ge t o t h e ext er ior of t h e t r im
a ge t o t h e ext er ior of t h e t r im pa n el m a y occu r. pa n el m a y occu r.
(b) If t h e h ea t st a ked m a t er ia l is br oken or m iss- (4) Allow t h e r epa ir ed a r ea t o cool a n d ver ify t h e
in g, u se a h ot glu e gu n t o a pply n ew m a t er ia l t o r epa ir.
t h e a r ea t o be r epa ir ed. Th e pa n els t h a t a r e bein g (5) In st a ll t r im pa n el.
h ea t st a ked m u st be h eld t oget h er wh ile t h e a pply-
SPECI FI CAT I ON S
TORQUE

All seat belt anchor bolts 39 29 —
Armrest shoulder bolt 29 21 —
Bench seat riser bolts 48 35 —
Bench seat track nuts 48 35 —
Quad bucket seat track to cushion frame bolts 40 30 —
Bucket seat back pivot bolts 33 24 —
Center seat to seat track bolts 24 17 —
Child seat module screws (bench seats) 7 — 62
Child seat module screws (quad seats) 13.5 10 —
Crossmember to radiator closure panel bolts 28 21 —
Door check strap to door end frame 12 — 105
Door latch to door end frame bolts 10 — 89
Floor latch to seat cushion frame bolts 27 19 —
RS BODY 23 - 11
BODY (Cont inue d)

Front cover to seat track screws 4 — 32
Front door hinge to hinge pillar bolts 34 25 —
Front door hinge to door nuts and bolts 34 25 —
Front door latch striker bolts 28 21 —
Front/quad seat cushion bolts 28.5 21 —
Front seat belt retractor bolts 38 28 —
Front seat riser to floor nuts 60 44 —
Front seat track cover screws 4 — 35
Front seat riser to seat track nuts 81 60 —
Front seatback pivot bolts 54 40 —
Front seatback recliner nut 12 — 105
Front seatback assist strap screws 2.5 — 22
Grocery bag holder screws 2 — 17
Hinge to liftgate bolts 33 24 —
Hood latch to bolts 13.5 10 —
Hood latch striker bolts 13.5 10 —
Hood hinge to hood bolts 13.5 10 —
Liftgate exterior handle outer screws 20 15 —
Liftgate exterior handle inner bolts 40 30 —
Lifgate hinge to roof header bolts 33 24 —
Liftgate latch bolts 16 12 —
Liftgate latch striker bolts 28 21 —
Liftgate lift motor link to liftgate 28 21 —
Liftgate spoiler bolts 9 — 80
Lifgate stabilizer wedge striker to D-pillar bolts 3 — 30
Luggage rack crossbar fasteners 4 — 35
Lumbar support handle screw 1 — 9
Pivot bolt to the body half of hood hinge 28 21 —
Prop assembly to lifgate bolts 28 21 —
Rear door glass to regulator bolt 11 8 —
Rear door hinge to B-pillar bolt 28 20 —
Rear door hinge to door bolt 28 20 —
Rear door latch striker 28 20 —
Rear latch to sliding door end frame 28 20 —
Rear seat back to seat cushion bolt 27 19 —
Recliner to seat back frame 12 9 —
Seatback frame upper rail 8 — 71
Seatback hinge bolt 48 35 —
Seatback hinge cover screws 2.3 — 20
Shoulder belt turning loop onto height adjuster 39 29 —
Side view mirror bolts 10 — 85
Sliding door center hinge adjusting bolt 15 — 130
23 - 12 BODY RS
BODY (Cont inue d)

Sliding door glass nuts 3.4 — 30
Sliding door latch striker 28 21 —
Sliding door to roller arm bracket 12 9 —
Storage bin track guide to seat riser 3.5 — 31
Sunroof opening panel to lifter arm screws 5 44
Sunroof opening panel motor screws 4 35
Sunroof trough bracket to roof bolts 6 53
Sunroof trough to trough bracket bolts 6 53
Sunroof trough bracket bolts 6 53
Support cylinders to liftgate 28 21 —
BODY LUBRICATION ALL OTHER BODY MECHANISMS

(1) Clea n com pon en t a s descr ibed a bove.
LUBRICATION REQUIREMENTS (2) Apply specified lu br ica n t t o a ll pivot in g a n d
Body m ech a n ism s a n d lin ka ges sh ou ld be slidin g con t a ct a r ea s of com pon en t .
in spect ed, clea n ed, a n d lu br ica t ed, a s r equ ir ed, t o
m a in t a in ea se of oper a t ion a n d t o pr ovide pr ot ect ion LUBRICANT USAGE
a ga in st r u st a n d wea r. Wh en per for m in g ot h er u n der
h ood ser vices, t h e h ood la t ch r elea se m ech a n ism a n d ENGINE OIL
sa fet y ca t ch sh ou ld be in spect ed, clea n ed, a n d lu br i- • Door H in ges – H in ge P in a n d P ivot Con t a ct
ca t ed. Du r in g t h e win t er sea son , ext er n a l door lock Ar ea s
cylin der s sh ou ld be lu br ica t ed t o a ssu r e pr oper oper- • H ood H in ges – P ivot P oin t s
a t ion wh en exposed t o wa t er a n d ice. • Lift ga t e H in ges
P r ior t o t h e a pplica t ion of a n y lu br ica n t , t h e pa r t s
con cer n ed sh ou ld be wiped clea n t o r em ove du st a n d MOPAR" SPRAY WHITE LUBE OR EQUIVALENT
gr it . If n ecessa r y, a su it a ble solven t ca n be u sed t o • Door Ch eck St r a ps
clea n t h e it em t o be lu br ica t ed. Aft er lu br ica t in g a • Lift ga t e La t ch es
com pon en t , a n y excess oil or gr ea se sh ou ld be • Lift ga t e P r op P ivot s
r em oved. • Ash Receiver
• F u el F iller Door Rem ot e Con t r ol La t ch Mech a -
LUBRICANT APPLICATION n ism
• P a r kin g Br a ke Mech a n ism
DOOR LOCK CYLINDERS • Slidin g Sea t Tr a cks
(1) Apply a sm a ll a m ou n t of lu br ica n t dir ect ly in t o • Lift ga t e La t ch
t h e lock cylin der.
(2) Apply a sm a ll a m ou n t of lu br ica n t t o t h e key. MOPAR" Multipurpose GREASE OR EQUIVALENT
(3) In ser t key in t o lock cylin der a n d cycle t h e • All Ot h er H ood Mech a n ism s
m ech a n ism fr om t h e locked t o t h e u n locked posit ion .
MOPAR" LOCK CYLINDER LUBRICANT OR
NOTE: Do not add more lubricant. EQUIVALENT
• Door Lock Cylin der s
(4) Cycle t h e lock cylin der m ech a n ism sever a l • Lift ga t e Lock Cylin der
t im es t o a llow t h e lu br ica n t t o flow t h r ou gh ou t t h e
cylin der.
(5) Wipe a ll lu br ica n t fr om ext er ior of lock cylin der
a n d key.
RS BODY 23 - 13
BODY (Cont inue d)
SPECI AL T OOLS
BODY
Trim Stick C-4755
REMOVER, MOLDINGS C-4829-A
TORX BIT SET C-4794-B
Fig. 16 Outer Belt Molding Remover - 9093

23 - 14 DOOR - FRONT RS
DOOR - FRON T
TABLE OF CONTENTS
page page
APPLIQUE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 LOCK CYLINDER
CHECK STRAP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 19
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 TRIM PANEL
DOOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 20
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 WATERSHIELD
DOOR GLASS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 WINDOW CRANK
FRAME CLOSEOUT MOLDING INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 21
REMOVAL – A-PILLAR-HEADER, OR B-PILLAR . 17 EXTERIOR HANDLE
INSTALLATION – A-PILLAR-HEADER, OR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
B-PILLAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 22
HINGE WINDOW REGULATOR - POWER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
LATCH WINDOW REGULATOR - MANUAL
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
LATCH STRIKER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
APPLI QU E INSTALLATION
(1) P osit ion a ppliqu e on veh icle.
REMOVAL (2) H ook r ea r edge of a ppliqu e over r ea r edge of
(1) Roll door gla ss down . door fr a m e a n d sea t a ppliqu e bot t om edge on sh eet
(2) Rem ove ou t er door belt m oldin g. m et a l.
(3) Disen ga ge clips h oldin g fr on t edge of a ppliqu e (3) E n ga ge clips t o h old fr on t edge of a ppliqu e t o
t o door fr a m e. door fr a m e.
(4) Rem ove a ppliqu e fr om veh icle (F ig. 1). (4) In st a ll ou t er door belt m oldin g.
RS DOOR - FRONT 23 - 15
APPLI QU E (Cont inue d)
Fig. 2 FRONT DOOR CHECK STRAP

1 - FRONT DOOR
2 - DOOR CHECK STRAP
Fig. 1 FRONT DOOR APPLIQUE
1 - GLASS RUN WEATHERSTRIP DOOR
2 - CLIPS
3 - APPLIQUE
4 - FRONT DOOR REMOVAL
(1) Rem ove fr on t wh eelh ou se spla sh sh ield. (Refer
CH ECK ST RAP t o 23 - BODY/E XTE RIOR/LF WH E E LH OUSE
SP LASH SH IE LD - RE MOVAL)
REMOVAL (2) Disen ga ge clips a t t a ch in g door h a r n ess wir e
con n ect or t o in n er fen der br a ce.
(1) Rem ove fr on t door t r im pa n el.
(3) Discon n ect posit ive lock slide on t h e side of t h e
(2) Rem ove fr on t door wa t er sh ield (Refer t o 23 -
wir e con n ect or s (F ig. 3).
BODY/DOOR - F RONT/WATE RSH IE LD -
(4) Depr ess lock t a b a t t a ch in g wir e con n ect or
RE MOVAL).
h a lves t oget h er.
(3) Rem ove fr on t door spea ker, if equ ipped.
(5) Discon n ect door h a r n ess fr om body wir in g h a r-
(4) Rem ove bolt s a t t a ch in g door ch eck st r a p t o
n ess.
A-pilla r.
(6) Rem ove bolt s a t t a ch in g door ch eck st r a p t o
(5) Rem ove n u t s a t t a ch in g ch eck st r a p t o door en d
A-pilla r (F ig. 4).
fr a m e (F ig. 2).
(7) Su ppor t door on su it a ble lift in g device.
(6) Rem ove ch eck st r a p fr om door t h r ou gh spea ker
(8) Rem ove bolt s a t t a ch in g lower h in ge t o door en d
h ole.
fr a m e (F ig. 5).
(9) St ea dy door on lift in g device a n d r em ove bolt s
INSTALLATION a t t a ch in g u pper h in ge t o door en d fr a m e.
(1) P osit ion ch eck st r a p on door t h r ou gh spea ker
(10) Rem ove door fr om veh icle.
h ole.
(2) In st a ll n u t s t o a t t a ch ch eck st r a p t o door en d
fr a m e. Tigh t en n u t s t o 11 N·m (90 in . lbs.) t or qu e.
INSTALLATION
(3) In st a ll bolt s t o a t t a ch ch eck st r a p t o A-pilla r. NOTE: If new hinge pins are to be used, verify that
Tigh t en bolt s t o 12 N·m (105 in . lbs.) t or qu e. the knurling on the hinge pin is aligned with the
(4) In st a ll door spea ker, if equ ipped. knurling on in the door hinge prior to driving in the
(5) In st a ll fr on t door t r im pa n el. pin. Also, verify that the hinge pin is fully seated to
the door hinge and a new retaining clip is installed.
(1) Su ppor t door on su it a ble lift in g device.

DOOR (Cont inue d)
Fig. 5 FRONT DOOR - HINGE BOLT REMOVAL

1 - FRONT DOOR
2 - UPPER HINGE
3 - CHECK STRAP
Fig. 3 FRONT DOOR WIRE CONNECTORS 4 - LOWER HINGE
1 - LOCK TAB
2 - POSITIVE LOCK (2) P osit ion door t o veh icle. Ver ify n et pier ce n u b-
3 - BODY HARNESS CONNECTOR
4 - FRONT FENDER bin is en ga ged if r eu sin g or igin a l h in ges. Applies t o
5 - DOOR HARNESS CONNECTOR body h a lf of h in ge on ly.
6 - BODY HARNESS (3) St ea dy door on lift in g device a n d in st a ll bolt s
a t t a ch in g u pper h in ge t o door en d fr a m e. Tigh t en
bolt s t o 34 N·m (25 ft . lbs.) t or qu e.
(4) In st a ll bolt s a t t a ch in g lower h in ge t o door en d
fr a m e. Tigh t en bolt s t o 34 N·m (25 ft . lbs.) t or qu e.
Align door t o a ch ieve equ a l spa cin g t o su r r ou n din g
body pa n els. P a n els sh ou ld be flu sh a cr oss a ll ga ps.
(5) In st a ll bolt s a t t a ch in g door ch eck st r a p t o
A-pilla r. Tigh t en bolt s t o 12 N·m (105 in . lbs.) t or qu e.
(6) Con n ect door h a r n ess in t o body wir in g h a r n ess.
(7) Con n ect posit ive lock slide on t h e side of t h e
wir e con n ect or s.
(8) Con n ect clips a t t a ch in g door h a r n ess wir e con -
n ect or t o in n er fen der br a ce.
(9) In st a ll fr on t wh eelh ou se spla sh sh ield.
(10) Ver ify door oper a t ion a n d a lign m en t . Adju st
a s n ecessa r y.
DOOR GLASS
Fig. 4 FRONT DOOR - HINGE PIN REMOVAL REMOVAL
1 - FRONT DOOR (1) Rem ove wa t er sh ield. (Refer t o 23 - BODY/
2 - CLIP
3 - A-PILLAR DOOR - F RONT/WATE RSH IE LD - RE MOVAL)
4 - HINGE PIN (2) Rem ove in n er belt m oldin g.(Refer t o 23 -
5 - CLIP BODY/WE ATH E RSTRIP /SE ALS/F DR INNE R BE LT
6 - DOOR CHECK STRAP
WE ATH E RSTRIP - RE MOVAL)
DOOR GLASS (Cont inue d)
(3) P osit ion gla ss t o ga in a ccess t o fr on t a n d r ea r
r egu la t or lift pla t es t h r ou gh fr on t a n d r ea r a ccess
h oles in door pa n el.
(4) Loosen t wo scr ews on r egu la t or cla m pin g gla ss
(F ig. 6).
(5) Rem ove gla ss fr om r egu la t or lift pla t es.
(6) Disen ga ge gla ss fr om gla ss r u n wea t h er st r ip.
(7) In ser t fr on t of gla ss bet ween gla ss r u n ch a n n el
a n d ou t er door pa n el.
(8) Lift gla ss u pwa r d a n d ou t of ext er ior side of
t h e open in g a t t op of door (F ig. 7).
(9) Rem ove gla ss fr om veh icle.
Fig. 7 FRONT DOOR GLASS

1 - DOOR GLASS
2 - FRONT DOOR
3 - GLASS RUN CHANNEL
FRAM E CLOSEOU T M OLDI N G

REMOVAL – A-PILLAR-HEADER, OR B-PILLAR
(1) Roll door gla ss down .
(2) Usin g a h ook t ool, pu ll fr on t door fr a m e close-
ou t m oldin g fr om win dow fr a m e ch a n n el.
(3) Rem ove closeou t m oldin g fr om veh icle.
Fig. 6 FRONT DOOR GLASS CLIPS
1 - DOOR GLASS
INSTALLATION – A-PILLAR-HEADER, OR
2 - REGULATOR GLASS CLAMP ASSEMBLY B-PILLAR
3 - GLASS LIFT PLATE (1) P osit ion closeou t m oldin g in win dow fr a m e.
(2) In ser t closeou t m oldin g in t o win dow fr a m e
INSTALLATION ch a n n el st a r t in g a t t h e cor n er s a n d wor kin g in wa r d.
(1) E n su r e cla m p open in g is set t o 6 m m (0.2 in .) (3) Ver ify door gla ss oper a t ion .
fr on t a n d r ea r (F ig. 6).
(2) P la ce gla ss in win dow open in g wit h fr on t
in ser t ed bet ween r u n ch a n n el a n d ou t er door pa n el H I N GE
(F ig. 7).
(3) Lower gla ss down wa r d in t o door. REMOVAL
(4) In ser t en ds of gla ss in t o gla ss r u n wea t h er st r ip (1) Relea se fr on t door la t ch a n d open door.
ch a n n els a t fr on t a n d r ea r of door. (2) Ma r k h in ge foot pr in t on bot h door a n d pilla r
(5) P la ce gla ss in posit ion on r egu la t or lift pla t es. t o a id wh en in st a llin g door.
(6) Roll gla ss u p t o level t o t ie down t wo gla ss (3) Su ppor t door on su it a ble lift in g device.
cla m ps a n d fa st en . (4) Rem ove bolt s a t t a ch in g fr on t door t o door
(7) In st a ll in n er belt m oldin g.(Refer t o 23 - BODY/ h in ge.
WE ATH E RSTRIP /SE ALS/F RONT DOOR INNE R (5) Rem ove bolt s a t t a ch in g h in ge t o pilla r.
BE LT MOLDING - INSTALLATION) (6) Rem ove door h in ge fr om veh icle.
(8) Ver ify door gla ss oper a t ion a n d fit .
(9) In st a ll wa t er sh ield. (Refer t o 23 - BODY/DOOR
- F RONT/WATE RSH IE LD - INSTALLATION)
H I N GE (Cont inue d)
INSTALLATION
CAUTION: When installing a new hinge, make sure
that the head of each hinge pin is fully seated into
the door hinge. Also, remove the plastic shipping
clip and replace it with the correct metal retaining
clip once the hinge pin is seated.
(1) P a in t h in ge pr ior t o in st a lla t ion , if n ecessa r y.

(2) P osit ion door t o veh icle. Ver ify n et pier ce n u b-
bin is en ga ged if r eu sin g or igin a l h in ges. Applies t o
body h a lf of h in ge on ly.
(3) In st a ll bolt s a t t a ch in g h in ge t o pilla r. Tigh t en
bolt s t o 34 N·m (25 ft . lbs.).
(4) In st a ll bolt s a t t a ch in g fr on t door t o door h in ge.
Tigh t en bolt s t o 34 N·m (25 ft . lbs.).
(5) Align door t o a ch ieve equ a l spa cin g t o su r-
r ou n din g body pa n els. P a n els sh ou ld be flu sh a cr oss
a ll ga ps.
(6) Ver ify door a lign m en t a n d oper a t ion . Adju st a s
n ecessa r y.
Fig. 8 LATCH ASSEMBLY

LAT CH 1 - OUTSIDE HANDLE TO LATCH LINK
2 - KEY CYLINDER TO LATCH LINK
REMOVAL 3 - LATCH ASSEMBLY
(1) Roll door gla ss u p. 4 - INSIDE HANDLE LINK AND SLEEVE
5 - LOCK KNOB LINK
(2) Rem ove fr on t door t r im pa n el. (Refer t o 23 -
BODY/DOOR - F RONT/TRIM PANE L - RE MOVAL)
(3) Rem ove wa t er sh ield a s n ecessa r y t o ga in a ccess
t o t h e ou t side door h a n dle.
(4) Th r ou gh a ccess h ole a t r ea r of in n er door
pa n el, discon n ect wir e con n ect or fr om power door
lock m ot or, if equ ipped.
(5) Disen ga ge clips h oldin g lin ka ge t o door la t ch
(F ig. 8).
(6) Rem ove lin ka ges fr om door la t ch .
(7) Rem ove scr ews a t t a ch in g door la t ch t o door en d
fr a m e (F ig. 9).
(8) Rem ove door la t ch fr om door.
INSTALLATION
NOTE: The screws attaching the door latch to the
door end frame have nylon patches on the threads.
Fig. 9 FRONT DOOR LATCH
All screws must be replaced when the latch has
1 - FRONT DOOR
been removed. 2 - LATCH ASSEMBLY
3 - INSIDE HANDLE LINK
(1) In ser t in side h a n dle la t ch lin k t o door la t ch
a n d en ga ge clip (F ig. 8). (5) Con n ect wir e con n ect or in t o power door lock
(2) P la ce door la t ch in posit ion on door en d fr a m e. m ot or, if equ ipped.
(3) In st a ll scr ews a t t a ch in g door la t ch t o door en d (6) In ser t a h ex wr en ch t h r ou gh t h e elon ga t ed h ole
fr a m e. Tigh t en scr ews t o 10 N·m (90 in . lbs.) t or qu e loca t ed in t h e door sh u t fa ce a bove t h e la t ch .
(F ig. 9). (7) Loosen a llen h ea d scr ew.
(4) In ser t ot h er lin ka ges t o door la t ch a n d en ga ge (8) P u ll ou t wa r d on t h e ou t side door h a n dle a n d
clips. r elea se.
(9) Tigh t en a llen h ea d scr ew.
(10) Ver ify door la t ch a n d power door lock oper a - LOCK CY LI N DER
t ion .
(11) In st a ll wa t er sh ield a n d fr on t door t r im pa n el.
REMOVAL
(1) Roll door gla ss u p.
LAT CH ST RI K ER (2) Rem ove fr on t door wa t er sh ield a s n ecessa r y t o
ga in a ccess t o t h e ou t side door h a n dle. (Refer t o 23 -
BODY/DOOR - F RONT/WATE RSH IE LD -
REMOVAL
RE MOVAL)
(1) Ma r k ou t lin e of door st r iker on B-pilla r t o a id
(3) Th r ou gh a ccess h ole a t r ea r of in n er door
in in st a lla t ion .
pa n el, discon n ect Veh icle Th eft Secu r it y Syst em
(2) Rem ove scr ews a t t a ch in g door la t ch st r iker t o
(VTSS) swit ch con n ect or fr om door h a r n ess, if
B-pilla r (F ig. 10).
equ ipped.
(3) Rem ove door la t ch st r iker fr om veh icle.
(4) Disen ga ge pu sh in fa st en er s a t t a ch in g VTSS
(4) Ret r ieve a n y sh im s fou n d bet ween la t ch st r iker
swit ch h a r n ess t o in n er door r ein for cem en t ba r, if
a n d B-pilla r.
equ ipped.
(5) Disen ga ge clip h oldin g door la t ch lin ka ge t o
door la t ch (F ig. 11).
(6) Rem ove la t ch lin ka ge fr om la t ch .
(7) Disen ga ge clip h oldin g door lock lin ka ge t o
door la t ch .
(8) Rem ove lock lin ka ge fr om la t ch .
(9) Rem ove n u t s a t t a ch in g ou t side door h a n dle t o
door ou t er pa n el.
(10) Rem ove ou t side door h a n dle fr om veh icle.
(11) Disen ga ge clip h oldin g lock cylin der in t o ou t -
side h a n dle.
(12) P u ll lock cylin der fr om door h a n dle.
INSTALLATION
(1) E n ga ge clip in t o ou t side h a n dle t o h old lock
cylin der (F ig. 11).
(2) Wit h lin k a r m t owa r d r ea r of veh icle, pu sh lock
cylin der in t o door h a n dle u n t il clip sn a ps in t o pla ce.
(3) In ser t lock lin ka ge in t o door la t ch .
Fig. 10 DOOR LATCH STRIKER (4) E n ga ge clip t o h old door lock lin ka ge t o la t ch .
1 - B-PILLAR (5) In ser t la t ch lin ka ge in t o door la t ch .
2 - SHIM (6) E n ga ge clip t o h old door la t ch lin ka ge t o la t ch .
3 - DOOR LATCH STRIKER
(7) In st a ll pu sh in fa st en er s a t t a ch in g VTSS
INSTALLATION equ ipped.
(1) P osit ion la t ch st r iker a n d a n y sh im s r et r ieved
(8) Con n ect VTSS swit ch con n ect or in t o door h a r-
on veh icle.
n ess, if equ ipped.
(2) Loosely in st a ll scr ews a t t a ch in g la t ch st r iker t o
(9) Ver ify door la t ch oper a t ion .
B-pilla r.
(10) In st a ll wa t er sh ield a n d door t r im pa n el.
(3) Align la t ch st r iker t o ou t lin e on B-pilla r m a de
pr eviou sly.
(4) Tigh t en fa st en er s t o 28 N·m (21 ft . lbs.) t or qu e.
(5) Ver ify door fit a n d oper a t ion . Adju st la t ch
st r iker a s n ecessa r y.
LOCK CY LI N DER (Cont inue d)
Fig. 11 OUTSIDE DOOR HANDLE

1 - CLIP 5 - LOCK KNOB LINK
2 - LOCK CYLINDER 6 - FRONT DOOR
3 - KEY CYLINDER TO LATCH LINK 7 - KEY POSITION SWITCH
4 - OUTSIDE HANDLE TO LATCH LINK 8 - OUTSIDE HANDLE
T RI M PAN EL
REMOVAL
(1) Rem ove t h e plu g a n d r em ove scr ew a t t a ch in g
door pu ll cu p t o in n er door pa n el.
(2) Rem ove swit ch bezel a n d discon n ect power win -
dow/m em or y swit ch .
(3) Rem ove scr ews a t t a ch in g t r im pa n el t o door
fr om below m a p pocket .
(4) If equ ipped, r em ove win dow cr a n k. (Refer t o 23
- BODY/DOOR - F RONT/WINDOW CRANK -
RE MOVAL)
(5) Rem ove scr ew h oldin g door t r im t o door pa n el
fr om beh in d in side la t ch r elea se h a n dle.
(6) Disen ga ge clips a t t a ch in g door t r im t o door
fr a m e a r ou n d per im et er of pa n el. Fig. 12 INSIDE DOOR HANDLE LINKAGE
(7) Lift t r im pa n el u pwa r d t o disen ga ge fla n ge
1 - DOOR LATCH HANDLE
fr om in n er belt m oldin g a t t op of door. 2 - DOOR TRIM
(8) Tilt t op of t r im pa n el a wa y fr om door t o ga in 3 - LATCH LINKAGE
a ccess t o la t ch lin ka ge. 4 - CLIP
5 - MEMORY SEAT SWITCH
(9) Disen ga ge clip a t t a ch in g lin ka ge r od t o in side
la t ch r elea se h a n dle (F ig. 12).
(10) Sepa r a t e lin ka ge r od fr om la t ch h a n dle.
INSTALLATION
(1) H old t op of t r im pa n el a wa y fr om door t o ga in
(11) Discon n ect t h e power door swit ch , cou r t esy
a ccess t o la t ch lin ka ge.
la m p elect r ica l con n ect or s.
(2) P la ce lin ka ge r od in posit ion on la t ch h a n dle.
(12) Rem ove fr on t door t r im pa n el fr om veh icle.
(3) E n ga ge clip t o h old lin ka ge r od t o in side la t ch
r elea se h a n dle.
T RI M PAN EL (Cont inue d)
(4) P la ce fr on t door t r im pa n el in posit ion on door. WI N DOW CRAN K
(5) In st a ll t r im pa n el in t o in n er belt m oldin g a t
t op of door.
REMOVAL
(6) In st a ll clips t o a t t a ch door t r im t o door fr a m e
(1) Usin g a win dow cr a n k r em ova l t ool, disen ga ge
a r ou n d per im et er of pa n el.
clip a t t a ch in g win dow cr a n k t o r egu la t or sh a ft (F ig.
(7) If equ ipped, in st a ll scr ew t o a t t a ch door t r im t o
13).
door pa n el beh in d in side la t ch r elea se h a n dle.
(8) If equ ipped, con n ect power swit ch in t o wir e NOTE: Wrap a shop towel around the window crank
con n ect or. to catch the clip when it springs out.
(9) P la ce power a ccessa r y swit ch in posit ion on
door t r im . (2) P u ll win dow cr a n k fr om r egu la t or sh a ft .
(10) Con n ect wir e con n ect or in t o m em or y sea t /m ir-
r or swit ch a n d in st a ll swit ch in t o t r im pa n el.
(11) In st a ll scr ews t o a t t a ch a ccessa r y swit ch
pa n el t o door t r im .
(12) In st a ll scr ew cover in t o swit ch pa n el.
(13) If equ ipped, in st a ll win dow cr a n k.
(14) If equ ipped, in st a ll scr ews t o a t t a ch t r im
pa n el t o door in side m a p pocket .
(15) If equ ipped, in st a ll scr ew t o a t t a ch door pu ll
cu p t o in n er door pa n el.
(16) If equ ipped, in st a ll scr ews t o a t t a ch door
a ssist h a n dle t o in n er door pa n el.
(17) Con n ect wir e con n ect or in t o cou r t esy la m p.
(18) In st a ll la m p in door t r im .
(19) In st a ll swit ch bezel.
Fig. 13 WINDOW CRANK - TYPICAL
1 - WINDOW CRANK REMOVAL TOOL
WAT ERSH I ELD 2 - WINDOW CRANK
(1) Rem ove door t r im pa n el. (Refer t o 23 - BODY/ (1) P la ce t h e clip on t o t h e win dow cr a n k h a n dle.
DOOR - F RONT/TRIM PANE L - RE MOVAL) (2) P osit ion win dow cr a n k t o r egu la t or sh a ft .
(2) Rem ove t h e fr on t door spea ker. (Refer t o 8 - (3) P u sh win dow cr a n k on t o r egu la t or sh a ft t o
E LE CTRICAL/AUDIO/SP E AKE R - RE MOVAL) en ga ge r et a in in g clip.
(3) P eel wa t er sh ield a wa y fr om a dh esive a r ou n d
per im et er of in n er door pa n el.
EX T ERI OR H AN DLE
INSTALLATION
(1) In su r e t h a t en ou gh a dh esive r em a in s t o REMOVAL
secu r ely r et a in t h e wa t er da m . Repla ce a s n ecessa r y. (1) Roll door gla ss u p.
(2) P la ce t h e sh ield in t o posit ion a n d pr ess (2) Rem ove t h e wa t er sh ield a s n ecessa r y t o ga in
secu r ely t o a dh esive m a kin g su r e t o pr oper ly r ou t e a ccess t o t h e ou t side door h a n dle. (Refer t o 23 -
wir in g a n d lin ka ges. BODY/DOOR - F RONT/WATE RSH IE LD -
(3) In st a ll t h e fr on t door spea ker. (Refer t o 8 - RE MOVAL)
E LE CTRICAL/AUDIO/SP E AKE R - INSTALLATION) (3) Th r ou gh a ccess h ole a t r ea r of in n er door
(4) In st a ll door t r im pa n el. (Refer t o 23 - BODY/ pa n el, discon n ect Veh icle Th eft Secu r it y Syst em
DOOR - F RONT/TRIM PANE L - INSTALLATION) (VTSS) swit ch con n ect or fr om door h a r n ess, if
equ ipped.
(4) Disen ga ge pu sh in fa st en er s a t t a ch in g VTSS
equ ipped.
(5) Disen ga ge clip h oldin g door la t ch lin ka ge t o
door la t ch (F ig. 11).
(6) Rem ove la t ch lin ka ge fr om la t ch .
EX T ERI OR H AN DLE (Cont inue d)
(7) Disen ga ge clip h oldin g door lock lin ka ge t o
door la t ch .
(8) Rem ove lock lin ka ge fr om la t ch .
(9) Rem ove n u t s h oldin g ou t side door h a n dle t o
door ou t er pa n el.
(10) Rem ove ou t side door h a n dle fr om veh icle.
INSTALLATION
If ou t side door h a n dle r epla cem en t is n ecessa r y,
t r a n sfer lock cylin der fr om t h e or igin a l h a n dle t o t h e
n ew on e.
(1) P la ce ou t side door h a n dle in posit ion on veh i-
cle.
(2) In st a ll n u t s a t t a ch in g ou t side door h a n dle t o
door ou t er pa n el (F ig. 11). Tigh t en n u t s t o 6 N·m (50
in . lbs.).
(3) In ser t lock lin ka ge in t o door la t ch . Fig. 14 FRONT DOOR POWER WINDOW
(4) E n ga ge clip t o h old door lock lin ka ge t o la t ch . 1 - POWER WINDOW MOTOR
(5) In ser t la t ch lin ka ge in t o door la t ch . 2 - FRONT DOOR
3 - GUIDE RAILS
(6) E n ga ge clip t o h old door la t ch lin ka ge t o la t ch .
(7) In st a ll pu sh -in fa st en er s t o h old VTSS swit ch
(2) In ser t r ea r gu ide r a il t h r ou gh r ea r a ccess h ole.
h a r n ess t o in n er door r ein for cem en t ba r, if equ ipped.
(3) P la ce win dow r egu la t or in posit ion on in n er
(8) Con n ect VTSS swit ch con n ect or in t o door h a r-
door pa n el.
n ess, if equ ipped.
(4) P la ce scr ew h ea ds on gu ide r a ils in posit ion
(9) Ver ify door la t ch oper a t ion .
t h r ou gh key h ole slot s in in n er door pa n el.
(10) In st a ll sou n d sh ield a n d door t r im pa n el.
(5) Tigh t en scr ews t o a t t a ch fr on t a n d r ea r gu ide
r a ils t o in n er door pa n el t o 8.5–10.7 N·m (75–95 in
WI N DOW REGU LAT OR - lbs). Tigh t en t op scr ew fir st a n d bot t om scr ew sec-
on d.
POWER (6) Tigh t en scr ews t o a t t a ch m ot or /h ou sin g t o
in n er door pa n el t o 2.8 N·m (25 in lbs).
REMOVAL (7) Con n ect wir e con n ect or in t o power win dow
(1) Rem ove wa t er sh ield. (Refer t o 23 - BODY/ m ot or.
DOOR - F RONT/WATE RSH IE LD - RE MOVAL) (8) In st a ll door gla ss. (Refer t o 23 - BODY/DOOR -
(2) Rem ove in n er belt m oldin g.(Refer t o 23 - F RONT/DOOR GLASS - INSTALLATION)
BODY/WE ATH E RSTRIP /SE ALS/F DR INNE R BE LT (9) Ver ify door gla ss a lign m en t a n d oper a t ion .
WE ATH E RSTRIP - RE MOVAL) (10) In st a ll in n er belt m oldin g (Refer t o 23 -
(3) Rem ove door gla ss. (Refer t o 23 - BODY/DOOR BODY/WE ATH E RSTRIP /SE ALS/F DR INNE R BE LT
- F RONT/DOOR GLASS - RE MOVAL). WE ATH E RSTRIP - INSTALLATION)
(4) Discon n ect wir e con n ect or fr om power win dow (11) In st a ll wa t er sh ield. (Refer t o 23 - BODY/
m ot or. DOOR - F RONT/WATE RSH IE LD - INSTALLATION)
(5) Loosen scr ews a t t a ch in g fr on t a n d r ea r win dow
gu ide r a ils t o in n er door pa n el.
(6) Rem ove scr ew h ea ds on gu ide r a ils fr om key WI N DOW REGU LAT OR -
h ole slot s in in n er door pa n el. M AN U AL
(7) Loosen scr ews a t t a ch in g m ot or /h ou sin g t o in n er
door pa n el. REMOVAL
(8) Rem ove r egu la t or fr om in n er door pa n el.
(1) Rem ove wa t er sh ield. (Refer t o 23 - BODY/
(9) E xt r a ct r ea r gu ide r a il t h r ou gh in n er door
DOOR - F RONT/WATE RSH IE LD - RE MOVAL)
pa n el r ea r a ccess h ole (F ig. 14).
(2) Rem ove in n er belt m oldin g.(Refer t o 23 -
(10) E xt r a ct fr on t gu ide r a il t h r ou gh fr on t a ccess
BODY/WE ATH E RSTRIP /SE ALS/F DR INNE R BE LT
h ole.
WE ATH E RSTRIP - RE MOVAL)
(3) Rem ove door gla ss. (Refer t o 23 - BODY/DOOR
INSTALLATION - F RONT/DOOR GLASS - RE MOVAL).
(1) In ser t fr on t gu ide r a il t h r ou gh fr on t a ccess
h ole.
WI N DOW REGU LAT OR - M AN U AL (Cont inue d)
(4) Loosen scr ews a t t a ch in g fr on t a n d r ea r win dow
gu ide r a ils t o in n er door pa n el. (F ig. 15).
(5) Rem ove scr ew h ea ds on gu ide r a ils fr om key
h ole slot s in in n er door pa n el.
(6) Loosen scr ews a t t a ch in g r egu la t or t o in n er door
pa n el.
(7) Rem ove r egu la t or fr om in n er door pa n el.
(8) E xt r a ct r ea r gu ide r a il t h r ou gh in n er door
pa n el r ea r a ccess h ole.
(9) E xt r a ct fr on t gu ide r a il t h r ou gh fr on t a ccess
h ole.
INSTALLATION
(1) In ser t fr on t gu ide r a il t h r ou gh fr on t a ccess
h ole.
(2) In ser t r ea r gu ide r a il t h r ou gh r ea r a ccess h ole.
(3) P la ce win dow r egu la t or in posit ion on in n er Fig. 15 FRONT DOOR MANUAL WINDOW
door pa n el. REGULATOR
(4) P la ce scr ew h ea ds on gu ide r a ils in posit ion 1 - FRONT DOOR
t h r ou gh key h ole slot s in in n er door pa n el. 2 - MANUAL WINDOW REGULATOR
3 - GUIDE RAILS
(5) Tigh t en scr ews t o a t t a ch fr on t a n d r ea r gu ide
r a ils t o in n er door pa n el t o 8.5–10.7 N·m (75–95 in
(8) Ver ify door gla ss a lign m en t a n d oper a t ion .
lbs). Tigh t en t op scr ew fir st a n d bot t om scr ew secon d
(9) In st a ll in n er belt m oldin g (Refer t o 23 - BODY/
on ea ch r a il.
WE ATH E RSTRIP /SE ALS/F DR INNE R BE LT
(6) Tigh t en scr ews t o a t t a ch r egu la t or t o in n er
WE ATH E RSTRIP - INSTALLATION)
door pa n el t o 2.8 N·m (25 in lbs).
(10) In st a ll wa t er sh ield. (Refer t o 23 - BODY/
(7) In st a ll door gla ss. (Refer t o 23 - BODY/DOOR -
DOOR - F RONT/WATE RSH IE LD - INSTALLATION)
F RONT/DOOR GLASS - INSTALLATION)
23 - 24 DOORS - SLIDING RS
DOORS - SLI DI N G
TABLE OF CONTENTS
page page
CENTER HINGE ADJUSTMENTS

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 SLIDING DOOR ADJUSTMENTS . . . . . . . . . . 30
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 24 STABILIZER
SLIDING DOOR STOP BUMPER BEZEL REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25 STABILIZER SOCKET
STOP BUMPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25 TRIM PANEL
HOLD OPEN LATCH REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 25 INSIDE LATCH HANDLE
HOLD OPEN LATCH STRIKER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 26 BELLCRANK
LATCH / LOCK ASSEMBLY REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 27 OUTSIDE HANDLE
INSIDE HANDLE ACTUATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 27 UPPER HINGE
CENTER STRIKER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 28 OUTSIDE HANDLE CABLE
LOWER HINGE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 28 INSIDE HANDLE CABLE
REAR LATCH STRIKER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 29 HOLD OPEN LATCH CABLE
SLIDING DOOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 29
CEN T ER H I N GE (4) Rem ove bolt s a t t a ch in g cen t er h in ge t o slidin g

door.
(5) Rem ove cen t er h in ge fr om slidin g door.
REMOVAL
(6) Roll cen t er h in ge t o r ea r of r oller ch a n n el.
NOTE: For power sliding door procedures refer to (7) Rem ove cen t er h in ge fr om veh icle.
POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section. INSTALLATION
(1) Open slidin g door t o t h e m id poin t of it s t r a vel. NOTE: For power sliding door procedures refer to
(2) Su ppor t slidin g door on a su it a ble lift in g POWER SLIDING DOOR SYSTEM in the ELECTRI-
device. CAL section.
(3) Ma r k ou t lin e of cen t er h in ge of in n er door
pa n el t o a id in st a lla t ion .
RS DOORS - SLIDING 23 - 25
CEN T ER H I N GE (Cont inue d)
NOTE: Center hinge has an adjustable bolt for INSTALLATION
up/down alignment. (Refer to 23 - BODY/DOORS - (1) P la ce st op bu m per in posit ion on veh icle.
SLIDING/SLIDING DOOR - ADJUSTMENTS) (2) In st a ll scr ew a t t a ch in g fr on t of st op bu m per t o
door in n er pa n el (F ig. 1).
(1) P la ce cen t er h in ge in posit ion on veh icle.
(3) Tigh t en scr ews a t t a ch in g r ea r of st op bu m per
(2) Roll cen t er h in ge for wa r d in r oller ch a n n el. t o door in n er pa n el.
(3) P la ce cen t er h in ge in posit ion on slidin g door
(4) In st a ll door st op bu m per bezel.
a n d a lign m a r ks.
(4) In st a ll bolt s a t t a ch in g cen t er h in ge t o slidin g
door. H OLD OPEN LAT CH
(5) Ver ify slidin g door a lign m en t a n d oper a t ion .
REMOVAL
SLI DI N G DOOR ST OP BU M PER (1) Open slidin g door.
(2) Rem ove slidin g door sill pla t e. (Refer t o 23 -
BEZ EL BODY/INTE RIOR/SLIDING DOOR SILL P LATE -
RE MOVAL)
REMOVAL (3) Rem ove n u t s a t t a ch in g h old open la t ch t o lower
(1) Usin g a t r im st ick (C-4755), disen ga ge clips r oller a r m (F ig. 2).
a t t a ch in g door st op bu m per bezel t o t h e door t r im (4) Rem ove h old open la t ch fr om lower a r m .
pa n el. (5) Discon n ect ca ble fr om h old open la t ch .
(2) Rem ove bezel fr om veh icle (F ig. 1). (6) Rem ove h old open la t ch fr om veh icle.
Fig. 1 SLIDING DOOR STOP BUMPER

1 - DOOR STOP BUMPER
2 - DOOR STOP BUMPER BEZEL
3 - SLIDING DOOR Fig. 2 SLIDING DOOR HOLD OPEN LATCH
1 - SLIDING DOOR HOLD OPEN LATCH - MANUAL DOOR
2 - LOWER ROLLER ARM
INSTALLATION
(1) P la ce door st op bu m per bezel in t o posit ion (F ig.
1).
INSTALLATION
(2) E n ga ge clips a t t a ch in g door st op bu m per bezel (1) P la ce h old open la t ch in posit ion on veh icle.
t o t h e door t r im pa n el. (2) Con n ect ca ble t o h old open la t ch .
(3) P la ce h old open la t ch in posit ion on lower a r m .
(4) In st a ll n u t s a t t a ch in g t h e h old open la t ch t o
ST OP BU M PER lower r oller a r m . Tigh t en n u t s t o 5 N·m (45 in . lbs.)
t or qu e.
REMOVAL (5) In st a ll slidin g door sill pla t e. (Refer t o 23 -
(1) Rem ove door st op bu m per bezel. BODY/INTE RIOR/SLIDING DOOR SILL P LATE -
(2) Loosen scr ews a t t a ch in g r ea r of st op bu m per t o INSTALLATION)
door in n er pa n el (F ig. 1). (6) Ver ify slidin g door oper a t ion .
(3) Rem ove scr ew a t t a ch in g fr on t of door st op
bu m per t o door in n er pa n el.
(4) Rem ove door st op bu m per fr om veh icle.
H OLD OPEN LAT CH ST RI K ER LAT CH / LOCK ASSEM BLY

REMOVAL REMOVAL
NOTE: For power sliding door procedures refer to NOTE: For power sliding door procedures refer to
POWER SLIDING DOOR SYSTEM in the ELECTRI- POWER SLIDING DOOR SYSTEM in the ELECTRI-
CAL section. CAL section.
(1) Open slidin g door, do n ot la t ch open . (1) Rem ove slidin g door t r im pa n el. (Refer t o 23 -
(2) Rem ove slidin g door sill pla t e. (Refer t o 23 - BODY/DOORS - SLIDING/TRIM PANE L -
BODY/INTE RIOR/SLIDING DOOR SILL P LATE - RE MOVAL)
RE MOVAL) (2) Rem ove slidin g door st op bu m per. (Refer t o 23 -
(3) Rem ove t wo bolt s a t t a ch in g slidin g door h old BODY/DOORS - SLIDING/STOP BUMP E R -
open la t ch st r iker t o door sill (F ig. 3). RE MOVAL)
(4) Rem ove h old open la t ch st r iker fr om veh icle. (3) P eel wa t er sh ield a wa y fr om a dh esive a r ou n d
(4) Disen ga ge ext er n a l ca ble fr om la t ch /lock
(5) Rem ove foa m block.
(6) Rem ove in side door h a n dle a ssem bly (Refer t o
23 - BODY/DOORS - SLIDING/INSIDE LATCH
H ANDLE - RE MOVAL).
(7) Disen ga ge in side ca ble fr om la t ch /lock a ssem -
bly.
(8) Disen ga ge lin k fr om bellcr a n k.
(9) Disen ga ge h old open la t ch ca ble fr om lower
h in ge.
(10) Rem ove bolt s a t t a ch in g la t ch /lock con t r ol t o
slidin g door (F ig. 5).
(11) If equ ipped, lower la t ch a n d discon n ect wir e
con n ect or fr om power door lock m ot or.
(12) Rem ove la t ch /lock fr om door.
Fig. 3 SLIDING DOOR HOLD OPEN LATCH STRIKER
1 - POWER DOOR LOWER TRACK
2 - POWER DOOR HOLDING STRIKER
3 - MANUAL DOOR HOLDING STRIKER
4 - MANUAL DOOR LOWER TRACK
INSTALLATION
NOTE: For power sliding door procedures refer to
CAL section.
(1) P la ce h old open la t ch st r iker in posit ion on

veh icle.
(2) In st a ll t wo bolt s a t t a ch in g slidin g door h old
open la t ch st r iker t o door sill.
(3) In st a ll slidin g door sill pla t e. (Refer t o 23 -
BODY/INTE RIOR/SLIDING DOOR SILL P LATE -
INSTALLATION) Fig. 4 SLIDING DOOR LATCH/LOCK ASSEMBLY
(4) Ver ify slidin g door oper a t ion . 1 - SLIDING DOOR
2 - LATCH LOCK ASSEMBLY
LAT CH / LOCK ASSEM BLY (Cont inue d)
(14) In st a ll la t ch /lock cover.
(15) In su r e t h a t en ou gh a dh esive r em a in s t o
secu r ely r et a in t h e wa t er sh ield. Repla ce a s n ecessa r y.
(16) P la ce t h e wa t er sh ield in t o posit ion a n d pr ess
secu r ely t o a dh esive m a kin g su r e t o pr oper ly r ou t e
wir in g a n d lin ka ges.
(17) In st a ll slidin g door st op bu m per.(Refer t o 23 -
BODY/DOORS - SLIDING/STOP BUMP E R -
INSTALLATION)
(18) In st a ll slidin g door t r im pa n el.(Refer t o 23 -
BODY/DOORS - SLIDING/TRIM PANE L - INSTAL-
LATION)
I N SI DE H AN DLE ACT U AT OR
REMOVAL
(1) Rem ove la t ch /lock a ssem bly. (Refer t o 23 -
BODY/DOORS - SLIDING/LATCH /LOCK CONTROL
Fig. 5 REMOVING SLIDING DOOR LATCH/LOCK - RE MOVAL).
ASSEMBLY (2) Rem ove lock a ct u a t or t h r ee a t t a ch in g scr ews
1 - WIRE HARNESS
(F ig. 6).
2 - LATCH/LOCK ASSEMBLY
3 - BELLCRANK LINK ROD
4 - LINK AND SLEEVE ASSEMBLY
INSTALLATION
CAL section.
(1) P osit ion la t ch /lock lockin g lever in u n locked

posit ion .
(2) If equ ipped, en ga ge wir e con n ect or in t o power
door lock m ot or (F ig. 4).
(3) P la ce la t ch /lock in posit ion on door (F ig. 5).
CAUTION: REPLACE BOLTS IF INSTALLING NEW

LATCH.
(4) In ser t bolt in t o slot s in slidin g door in n er

pa n el. Fig. 6 LOCK ACTUATOR
(5) Tigh t en bolt s a t t a ch in g la t ch /lock a ssem bly t o
1 - INSIDE HANDLE ACTUATOR
slidin g door. 2 - LATCH/LOCK ASSEMBLY
(6) E n ga ge in side ca ble in t o la t ch /lock a ssem bly. 3 - THREE ATTACHING SCREWS
(7) In st a ll in side door h a n dle a ssem bly (Refer t o
23 - BODY/DOORS - SLIDING/INSIDE LATCH (3) Rem ove lock a ct u a t or.
H ANDLE - INSTALLATION).
(8) In st a ll foa m block. INSTALLATION
(9) E n ga ge ext er n a l ca ble t o la t ch /lock a ssem bly. (1) P la ce lock a ct u a t or in t o posit ion on la t ch /lock
(10) E n ga ge lin k r od t o bellcr a n k. a ssem bly.
(11) E n ga ge h old open la t ch ca ble fr om lower (2) In sa ll a t t a ch in g scr ews (F ig. 6).
h in ge. (3) In st a ll la t ch /lock a ssem bly. (Refer t o 23 -
(12) E n ga ge clip t o h old bellcr a n k lin k t o la t ch /lock BODY/DOORS - SLIDING/LATCH / LOCK CON-
con t r ol. TROL - INSTALLATION).
(13) Ver ify slidin g door oper a t ion .
CEN T ER ST RI K ER (3) Rem ove slidin g door sill pla t e. (Refer t o 23 -

RE MOVAL)
REMOVAL
(4) Rem ove scr ews a t t a ch in g open la t ch t o lower
(1) Rem ove slidin g door t r im pa n el. (Refer t o 23 -
r oller a r m .
BODY/DOORS - SLIDING/TRIM PANE L -
(5) Rem ove open la t ch fr om lower a r m .
RE MOVAL)
(6) Su ppor t slidin g door on a su it a ble lift in g device
(2) Rem ove bolt s a t t a ch in g st op bu m per. Rem ove
wit h a pa dded u pper su r fa ce. Th e door m u st be
st op bu m per fr om door.
m ovea ble wit h lift in g device in pla ce.
(3) Rem ove scr ews a t t a ch in g cen t er st r iker a ssem -
(7) Rem ove h old open la t ch st r iker.
bly t o door en d fr a m e (F ig. 7).
(8) Rem ove bolt s a t t a ch in g lower r oller a r m t o
(4) Rem ove cen t er st r iker a ssem bly fr om door
slidin g door.
t h r ou gh a ccess h ole.
(9) Rem ove r oller a r m fr om slidin g door.
(10) Disen ga ge r oller a r m fr om lower ch a n n el.
(11) Rem ove r oller a r m fr om veh icle.
Fig. 7 SLIDING DOOR CENTER STRIKER

ASSEMBLY
1 - STRIKER BOLT ASSEMBLY
2 - SLIDING DOOR Fig. 8 SLIDING DOOR LOWER ROLLER ARM
1 - POWER LOWER ROLLER ARM
INSTALLATION 2 - MANUAL LOWER ROLLER ARM
(1) P la ce cen t er st r iker in posit ion on door t h r ou gh

a ccess h ole (F ig. 7). INSTALLATION
(2) In st a ll scr ews t o a t t a ch cen t er st r iker t o door
en d fr a m e.
(3) In st a ll bolt s a t t a ch in g st op bu m per.
CAL section.
(4) In st a ll slidin g door t r im pa n el (Refer t o 23 -
BODY/DOORS - SLIDING/TRIM PANE L - INSTAL- (1) P la ce r oller a r m in t o posit ion (F ig. 8).
LATION). (2) E n ga ge r oller a r m t o lower ch a n n el.
(3) In st a ll r oller a r m t o slidin g door.
(4) In st a ll bolt s a t t a ch in g lower r oller a r m t o slid-
LOWER H I N GE in g door.
(5) In st a ll h old open la t ch st r iker.
REMOVAL (6) In st a ll scr ews a t t a ch in g open la t ch t o lower
r oller a r m .
(7) In st a ll slidin g door sill pla t e. (Refer t o 23 -
CAL section.
INSTALLATION)
(1) Open slidin g door. (8) Ch eck slidin g door for pr oper oper a t ion .
(2) Ma r k ou t lin e of r oller a r m on slidin g door t o
a id in st a lla t ion (F ig. 8).
REAR LAT CH ST RI K ER (6) Rem ove cen t er st op fr om slidin g door. (Refer t o

23 - BODY/DOORS - SLIDING/STOP BUMP E R -
RE MOVAL)
REMOVAL
(7) Rem ove slidin g door sill pla t e. (Refer t o 23 -
(1) Open slidin g door.
(2) Ma r k ou t lin e of st r iker on C-pilla r door ja m b
RE MOVAL)
fa ce t o a id in st a lla t ion .
(8) Rem ove h old open la t ch st r iker (Refer t o 23 -
(3) Rem ove scr ews a t t a ch in g st r iker t o C-pilla r
(F ig. 9).
STRIKE R - RE MOVAL).
(4) Rem ove st r iker fr om veh icle.
(9) Open qu a r t er gla ss.
(10) Rem ove cen t er r oller ch a n n el en d cover (F ig.
11).
(11) Su ppor t slidin g door on a su it a ble lift in g
device wit h a pa dded u pper su r fa ce. Th e door m u st
be m ovea ble wit h lift in g device in pla ce.
CAUTION: Do not allow the center hinge roller to

contact the quarter glass. Glass can break.
(12) Slide door r ea r wa r d u n t il t h e u pper slidin g

door h in ge r oller disen ga ges fr om t h e u pper ch a n n el
(F ig. 12).
(13) Con t in u e m ovin g t h e door r ea r wa r d u n t il t h e
lower r oller s exit t h e lower t r a ck.
(14) Con t in u e m ovin g door r ea r wa r d t ill cen t er
h in ge r oller exit s t h e ch a n n el (F ig. 13)
Fig. 9 SLIDING DOOR LATCH STRIKER (15) Rem ove slidin g door fr om veh icle.
1 - LATCH STRIKER
2 - SLIDING DOOR
INSTALLATION
(1) P la ce st r iker in posit ion on veh icle.
(2) Align st r iker t o ou t lin e m a r ks on C-pilla r.
(3) In st a ll scr ews a t t a ch in g st r iker t o C-pilla r.
Tigh t en scr ews t o 28 N·m (21 ft . lbs.) t or qu e.
(4) Ver ify slidin g door a lign m en t a n d oper a t ion .
SLI DI N G DOOR
REMOVAL
CAL section. Fig. 10 SLIDING DOOR UPPER STOP
1 - UPPER STOP PLATE
(1) Apply m a skin g t a pe t o ou t side su r fa ce of qu a r- 2 - SLIDING DOOR
3 - UPPER SLIDING DOOR HINGE
t er pa n el below t h e cen t er r oller ch a n n el, r ea r wa r d of
t h e door open in g.
INSTALLATION
(2) Relea se slidin g door la t ch a n d open door.
(3) Apply m a skin g t a pe t o door ja m b a r ea , r ea r- NOTE: For power sliding door procedures refer to
wa r d of t h e u pper r oller ch a n n el. POWER SLIDING DOOR SYSTEM in the ELECTRI-
(4) Rem ove scr ew a t t a ch in g u pper st op bu m per t o CAL section.
u pper r oller a r m (F ig. 10).
(5) Rem ove u pper st op fr om u pper r oller a r m . (1) P la ce slidin g door in posit ion on lift in g device.
(2) E n ga ge cen t er h in ge r oller in t o ch a n n el a n d
m ove door for wa r d (F ig. 13).
SLI DI N G DOOR (Cont inue d)
Fig. 13 SLIDING DOOR CENTER ROLLER

Fig. 11 CENTER CHANNEL END COVER
1 - SLIDING DOOR
1 - CENTER CHANNEL 2 - QUARTER GLASS
2 - CENTER CHANNEL END COVER 3 - CENTER HINGE ROLLERS
3 - PLASTIC NUT 4 - CENTER HINGE
(8) In st a ll slidin g door sill pla t e.

(9) In st a ll cen t er r oller ch a n n el en d cover (F ig. 11).
(10) In st a ll cen t er st op on slidin g door. (Refer t o 23
- BODY/DOORS - SLIDING/STOP BUMP E R -
INSTALLATION)
(11) P la ce u pper r oller st op bu m per in posit ion on
u pper r oller a r m .
(12) In st a ll scr ew a t t a ch in g u pper r oller a r m st op
bu m per t o u pper r oller a r m (F ig. 10).
(13) Rem ove m a skin g t a pe fr om body su r fa ces.
(14) Ver ify door oper a t ion a n d fit . Adju st a s n eces-
sa r y. (Refer t o 23 - BODY/DOORS - SLIDING/SLID-
ING DOOR - ADJ USTME NTS)
ADJ U ST M EN T S
Fig. 12 SLIDING DOOR UPPER ROLLER
1 - SLIDING DOOR SLIDING DOOR ADJUSTMENTS
2 - UPPER HINGE
3 - UPPER CHANNEL NOTE: For power sliding door procedures refer to
(3) P osit ion door r ea r wa r d of t h e slidin g door open - CAL section.
in g.
CAUTION: Do not allow the center hinge roller to PRELIMINARY CHECKS

contact the quarter glass. Glass can break. (1) Close t h e slidin g door, visu a lly ch eckin g C-pil-
la r st r iker a lign m en t en t r y in t o la t ch . St r iker a t t h is
(4) E n ga ge t h e cen t er h in ge r oller in t o t h e ch a n n el
poin t m u st n ot a ffect a lign m en t . St r iker sh ou ld go
(F ig. 13).
st r a igh t in t o t h e la t ch in g m ech a n ism .
(5) Roll door for wa r d u n t il lower r oller en ga ge in t o
(2) F or t h e left slidin g door, ch eck t h e fu el door
r ea r of t h e t r a ck.
blocker st r iker en t r y in t o la t ch . St r iker a t t h is poin t
(6) E n ga ge t h e u pper slidin g door h in ge in t o t h e
m u st n ot a ffect a lign m en t .
u pper ch a n n els (F ig. 12).
(3) Ch eck C-pilla r a n d B-pilla r for door t o a per t u r e
(7) In st a ll h old open la t ch st r iker (Refer t o 23 -
ga ps a n d door t o door ga ps. All ga ps sh ou ld be 5 m m
± 1 mm.
STRIKE R - INSTALLATION).
(4) Ch eck door for h eigh t u sin g ch a r a ct er lin es a s (f) Tigh t en lower r oller a r m br a cket bolt s t o 13
a r efer en ce. Also ch eck r oof con t ou r a s a con t r ollin g N·m (115 in . lbs.) t or qu e.
fa ct or. (g) Ver ify a lign m en t , a dju st a s n ecessa r y.
Usin g t h e pr ocedu r es n ot ed below, a dju st t h e side (5) If t h e slidin g door is low a t t h e C-pilla r ;
door in t h e or der t h e in dividu a l st eps a r e ca lled ou t . (a ) Open t h e door t o m id-poin t of t r a vel.
(b) Ma r k ou t lin e of cen t er h in ge on slidin g door
DOOR FLUSHNESS ADJUSTMENT t o a ssist in m a kin g a dju st m en t s.
(1) Ch eck slidin g door flu sh n ess a t t h e C-pilla r (c) Adju st t h e a dju st m en t bolt u p or down t o
st r iker. m ove t h e door posit ion . (F ig. 14).
(2) If t h e slidin g door is u n der or over flu sh , (d) Move h in ge down wa r d t o r a ise t h e door.
r em ove st r iker a ssem bly a n d m ove t h r ea d pla t e over (e) Tigh t en cen t er h in ge bolt s t o 13 N·m (115 in .
keepin g on e bolt in pla t e so it will n ot fa ll bet ween lbs.) t or qu e.
in n er a n d ou t er pa n els. (f) Ver ify a lign m en t a dju st a s n ecessa r y.
(3) Adju st t h e C-pilla r st r iker in or ou t u n t il t h e (6) If t h e slidin g door is h igh a t t h e B-pilla r ;
door is flu sh . Th en , t h e on size h ole ca n be elon ga t ed (a ) Rem ove a ccess plu g in t h e slidin g door t r im
in t h e dir ect ion r equ ir ed. Th is ca n be don e by gr in d- pa n el.
in g or filin g t h e sh eet m et a l a n d t h en pa in t in g r a w (b) Open t h e door t o m id-poin t of t r a vel.
edge t o pr even t r u st in g. (c) Ma r k ou t lin e of lower r oller a r m br a cket on
(4) Ch eck u pper B-pilla r flu sh n ess t o A-pilla r slidin g door t o a ssist in m a kin g a dju st m en t s.
cover. (d) Loosen lower r oller a r m br a cket bolt s (F ig.
(5) Th e slidin g door u pper h in ge ca n on ly be 15).
m oved ou t boa r d by a ddin g a 1 m m sh im beh in d t h e (e) Move h in ge u pwa r d t o r a ise t h e door.
h in ge m ou n t in g a r ea on ce t h e t wo a t t a ch m en t bolt s (f) Tigh t en lower r oller a r m br a cket bolt s t o 13
a r e r em oved a n d r ein st a lled. N·m (115 in . lbs.) t or qu e.
(6) Ch eck flu sh n ess a t u pper C-pilla r. (g) Ver ify a lign m en t , a dju st a s n ecessa r y.
(7) If u pper C-pilla r flu sh n ess is ou t of specifica - (7) F u lly open t h e slidin g door.
t ion u se a h ea vy r u bber m a llet on t h e door a ssem bly (8) Ver ify t h a t a ll cen t er h in ge bolt s a r e t igh t .
u n t il door is in specifica t ion s. (9) Adju st t h e r ea r of t h e slidin g door u p by t u r n -
in g t h e cen t er h in ge bolt clockwise (F ig. 14).
DOOR GAP ADJUSTMENT - UP/DOWN
(1) Ch eck h eigh t of slidin g door a t t h e B-pilla r a n d
C-pilla r t o det er m in e wh ich a r ea is con t r ibu t in g t h e
gr ea t est t o t h e in cor r ect ga ps.
(2) Visu a lly in spect t h e slidin g door for fit t in g low
a t t h e t op of t h e door by ch eckin g t h e a lign m en t of
t h e t op con t ou r of t h e door t o t h e qu a r t er pa n el.
(3) If t h e slidin g door is h igh a t t h e C-pilla r.
(a ) Open t h e door t o m id-poin t of t r a vel.
(b) Ma r k ou t lin e of cen t er h in ge on slidin g door
t o a ssist in m a kin g a dju st m en t s.
(c) Loosen cen t er h in ge bolt s (F ig. 14).
(d) Move h in ge for e or a ft t o posit ion t h e slidin g
door in t o t h e cor r ect loca t ion .
(e) Tigh t en cen t er h in ge bolt s t o 13 N·m (115 in .
lbs.) t or qu e.
(f) Ver ify a lign m en t , a dju st a s n ecessa r y.
(4) If t h e slidin g door is low a t t h e B-pilla r ;
(a ) Rem ove a ccess plu g in t h e slidin g door t r im
pa n el. Fig. 14 SLIDING DOOR CENTER HINGE
(b) Open t h e door t o m id-poin t of t r a vel.
1 - ADJUSTING BOLT
(c) Ma r k ou t lin e of lower r oller a r m br a cket on 2 - WELD NUT
slidin g door t o a ssist in m a kin g a dju st m en t s.
(d) Loosen lower r oller a r m br a cket bolt s (F ig. (10) Close t h e door a n d ch eck t h e slidin g door
15). a lign m en t .
(e) Move h in ge u pwa r d t o r a ise t h e door. (11) Adju st t h e fr on t of t h e slidin g door u p by
a dju st in g lower h in ge bolt s.
DOOR SEAL COMPRESSION
(1) F ir st ch eck Ga p & F lu sh (Refer t o 23 - BODY/
BODY STRUCTURE /GAP AND F LUSH - SP E CIF I-
CATIONS). Ch eck sea l com pr ession n ea r t h e m iddle
of t h e door even wit h t h e la t ch a ssem bly. Usin g a
piece of pa per, pla ce it a cr oss door sea l a n d close
door. P u ll pa per ou t of door open in g. If pa per t ea r s
set t in g is t o t igh t , if pa per slides t h ou gh t t o ea sily
t h e com pr ession is in su fficien t a n d n eeds t o be
a dju st ed.
(2) Adju st sea l com pr ession a t t h e t op of t h e B-pil-
la r sea l;
(a ) Open door t o m id-poin t of t r a vel.
(b) Ma r k ou t lin e of u pper r oller a r m on door t o
a ssist in m a kin g a dju st m en t s.
(c) Loosen bolt s a t t a ch in g u pper r oller a r m t o
Fig. 15 SLIDING DOOR LOWER ROLLER ARM door (F ig. 16).
1 - LOWER ROLLER ARM BRACKET (d) Decr ea se t h e len gt h of t h e u pper r oller a r m
2 - BOLTS t o in cr ea se sea l com pr ession .
3 - SLIDING DOOR
(e) In cr ea se t h e len gt h of t h e u pper r oller a r m t o
decr ea se sea l com pr ession .
(12) Open door h a lf wa y a n d r em ove lower h in ge
(f) Tigh t en a ll u pper r oller a r m bolt s t o 13 N·m
bolt a ccess plu g.
(13) Loosen bolt s a s n ecessa r y t o m ove t h e fr on t of
(g) Ver ify door a lign m en t , a dju st a s n ecessa r y.
door u p or down .
(14) Ch eck t h e u pper h in ge for possible bin d,
a dju st a s n ecessa r y.
(15) Close t h e door a n d ch eck t h e slidin g door
a lign m en t .
(16) F u lly open door a n d a pply t h r ea d lock n u t
on t o t h e cen t er h in ge bolt . Tigh t en n u t u n t il t ill it
bu t t s u p a ga in st t h e welded n u t on t h e cen t er h in ge.
Tigh t en n u t t o 13 N·m (115 in . lbs.) t or qu e. It m a y be
n ecessa r y t o h old t h e cen t er h in ge bolt t o pr even t it
fr om t u r n in g wh ile t igh t en in g n u t .
(17) Ver ify a lign m en t , a dju st a s n ecessa r y.
DOOR GAP ADJUSTMENT - FORE/AFT

(1) Ch eck C-pilla r a n d B-pilla r for door t o a per t u r e
ga ps (5 m m + 1 m m ), a n d door t o door ga p (5 m m +
1 m m ).
(2) If a dju st ga ps r equ ir e a dju st m en t , loosen cen - Fig. 16 Sliding Door Upper Roller Arm
t er h in ge scr ews a s n ecessa r y t o m ove cen t er h in ge 1 - UPPER STOP PLATE
for wa r d or r ea r wa r d. 2 - SLIDING DOOR
(3) Movin g cen t er h in ge r ea r wa r d in cr ea ses t h e 3 - UPPER SLIDING DOOR HINGE
ga p a t C-pilla r a n d decr ea ses ga p a t B-pilla r. Movin g
(3) Adju st sea l com pr ession a t t h e bot t om of B-pil-
cen t er h in ge for wa r d decr ea ses ga p a t t h e C-pilla r
la r sea l.
a n d in cr ea ses ga p a t t h e B-pilla r
(a ) Open door t o m id-poin t of t r a vel.
(4) Move cen t er h in ge a s n ecessa r y, a n d t igh t en
(b) Ma r k ou t lin e of lower r oller a r m on lower
scr ews.
r oller a r m br a cket t o a ssist in m a kin g a dju st m en t s
(5) Close t h e door a n d ch eck t h e slidin g door a lign -
(F ig. 17).
m en t .
(c) Loosen bolt s h oldin g lower r oller a r m t o
(6) Ver ify door a lign m en t , a dju st a s n ecessa r y.
lower r oller a r m br a cket .
(7) Tigh t en cen t er h in ge scr ews t o 13 N·m (115 in .
(d) P ivot lower r oller a r m t owa r d cen t er of veh i-
lbs.) t or qu e.
cle t o decr ea se sea l com pr ession .
(e) P ivot lower r oller a r m ou t wa r d t o in cr ea se
sea l com pr ession .
(f) Tigh t en lower r oller a r m bolt s t o 13 N·m (115
in . lbs.) t or qu e.
(g) Ver ify a lign m en t , a dju st a s n ecessa r y.
NOTE: Adjusting seal compression at the B-pillar

can affect door flushness the C-pillar.
Fig. 18 SLIDING DOOR STABILIZER

1 - SLIDING DOOR
2 - STABILIZER
STABI LI Z ER SOCK ET
REMOVAL
Fig. 17 Sliding Door Lower Roller Arm (2) Rem ove scr ews h oldin g st a bilizer socket t o
1 - POWER LOWER ROLLER ARM
B-pilla r (F ig. 19).
2 - MANUAL LOWER ROLLER ARM (3) Rem ove st a bilizer socket fr om veh icle.
STABILIZER ADJUSTMENT - UPPER/LOWER

(2) Loosen t h e bolt s h oldin g t h e m a le st a bilizer s t o
t h e slidin g door en ou gh t h a t t h e st a bilizer s ca n m ove
wit h som e effor t .
(3) Close a n d t h en r eopen slidin g door.
(4) Tigh t en a ll st a bilizer s bolt s.
STABI LI Z ER
REMOVAL
(2) Rem ove scr ews a t t a ch in g st a bilizer t o door en d
fr a m e (F ig. 18).
(3) Rem ove st a bilizer fr om veh icle.
INSTALLATION
(1) P la ce st a bilizer in posit ion on veh icle. Fig. 19 SLIDING DOOR STABILIZER SOCKET
1 - B-PILLAR
NOTE: Loose install screws first. Fit should be 2 - STABILIZER SOCKET
snug but free to move when closing door to align to
body half stabilizer. INSTALLATION
(2) In st a ll scr ews a t t a ch in g st a bilizer t o door en d (1) P la ce st a bilizer socket in posit ion on veh icle.
fr a m e.
NOTE: Ensure that sealing feature damaged, if reus-
(3) Open door a n d fin a l t igh t en scr ews.
ing stabilizer socket.
(4) Ver ify slidin g door oper a t ion .
STABI LI Z ER SOCK ET (Cont inue d)
(2) In st a ll scr ews t o h old st a bilizer socket t o B-pil- (6) In st a ll slidin g door u pper fr a m e m oldin g.
la r. Tigh t en n u t s t o 5 N·m (45 in . lbs.) t or qu e.
(3) Close slidin g door a n d ver ify oper a t ion .
I N SI DE LAT CH H AN DLE
T RI M PAN EL REMOVAL
(1) Rem ove slidin g door t r im pa n el. (Refer t o 23 -
REMOVAL BODY/DOORS - SLIDING/TRIM PANE L -
(1) Rem ove slidin g door u pper fr a m e m oldin g. RE MOVAL)
(2) If r em ovin g t h e left slidin g door t r im pa n el, (2) Rem ove scr ews a t t a ch in g bot t om of in side la t ch
r em ove scr ew fr om in side a sh r eceiver bezel. h a n dle t o slidin g door (F ig. 21).
(3) Rem ove scr ew fr om pu ll cu p. (3) Rem ove t wo scr ew a t t a ch in g t op of in side la t ch
(4) Disen ga ge pu sh -in fa st en er s h oldin g t r im t o h a n dle t o slidin g door.
door pa n el a r ou n d per im et er a n d u pper edge of door (4) Rem ove la t ch h a n dle fr om slidin g door.
(F ig. 20). (5) Disen ga ge ca ble en d fr om clip on r elea se h a n -
(5) Rem ove slidin g door t r im pa n el fr om veh icle. dle m ech a n ism .
(6) Disen ga ge ca ble en d fr om r elea se h a n dle m ech -
a n ism .
(7) Rem ove pu sh pin fa st en er a t t a ch in g ca ble en d
t o r elea se h a n dle.
(8) Disen ga ge ca ble ca sin g en d fr om r elea se h a n dle
(F ig. 22).
(9) Disen ga ge ca ble en d fr om la t ch h a n dle.
(10) Rem ove h a n dle fr om veh icle.
Fig. 20 SLIDING DOOR TRIM PANEL

1 - PUSH-IN FASTENERS
2 - SLIDING DOOR UPPER FRAME MOLDING
3 - SLIDING DOOR TRIM PANEL
6 - SLIDING DOOR
Fig. 21 SLIDING DOOR INSIDE HANDLE
1 - INSIDE ASSIST HANDLE
INSTALLATION 2 - INSIDE RELEASE HANDLE CABLE
(1) P la ce slidin g door t r im pa n el in posit ion on 3 - ATTACHING SCREWS
veh icle.
(2) Align loca t in g pin s on ba ckside of t r im pa n el t o INSTALLATION
m a t in g h oles in t h e in n er door pa n el. (1) P la ce in side la t ch h a n dle in posit ion on veh icle.
(3) E n ga ge pu sh -in fa st en er s t o h old t r im t o door (2) E n ga ge ca ble en d in t o la t ch h a n dle.
pa n el a r ou n d per im et er a n d u pper edge of door (F ig. (3) E n ga ge ca ble ca sin g en d in t o r elea se h a n dle.
20). (4) In st a ll pu sh pin fa st en er t o h old ca ble in t o
(4) In st a ll pu ll cu p scr ew. r elea se h a n dle.
(5) If n ecessa r y, in st a ll scr ew fr om in side a sh (5) E n ga ge ca ble en d in t o r elea se h a n dle m ech a -
r eceiver bezel on left slidin g door t r im pa n el. n ism .
I N SI DE LAT CH H AN DLE (Cont inue d)
Fig. 22 RELEASE HANDLE CABLE Fig. 23 BELLCRANK

1 - ASSIST HANDLE MECHANISM 1 - OUTSIDE HANDLE
2 - SLIDING DOOR INSIDE ASSIST HANDLE 2 - OUTSIDE HANDLE BRACKET ATTACHING NUT
3 - RELEASE HANDLE CABLE 3 - LOCK KNOB
4 - LATCH LINK
5 - LOCKING LINK
(6) E n ga ge clip t o h old ca ble en d in t o r elea se h a n - 6 - DOOR LOCKING LEVER (BELLCRANK)
dle m ech a n ism .
(7) P la ce la t ch h a n dle in posit ion on slidin g door. (3) P la ce lock lin k in t o posit ion a n d en ga ge clip
(8) In st a ll scr ew t o h old t op of in side r elea se h a n - (F ig. 23).
dle t o slidin g door. (4) P la ce lin k a n d sleeve in t o posit ion a n d en ga ge
(9) In st a ll scr ews t o h old bot t om of in side la t ch clip.
h a n dle t o slidin g door. (5) P la ce t h e wa t er sh ield in t o posit ion a n d pr ess
(10) Ver ify slidin g door oper a t ion . Adju st a s n eces- secu r ely t o a dh esive m a kin g su r e t o pr oper ly r ou t e
sa r y. (Refer t o 23 - BODY/DOORS - SLIDING/SLID- wir in g a n d lin ka ges.
ING DOOR - ADJ USTME NTS) (6) In st a ll slidin g door t r im pa n el (Refer t o 23 -
(11) In st a ll slidin g door t r im pa n el.(Refer t o 23 - BODY/DOORS - SLIDING/TRIM PANE L - INSTAL-
BODY/DOORS - SLIDING/TRIM PANE L - INSTAL- LATION).
LATION) (7) In st a ll st op bu m per (Refer t o 23 - BODY/
DOORS - SLIDING/STOP BUMP E R - INSTALLA-
TION).
BELLCRAN K
REMOVAL OU T SI DE H AN DLE
(1) Rem ove st op bu m per (Refer t o 23 - BODY/
DOORS - SLIDING/STOP BUMP E R - RE MOVAL). REMOVAL
(2) Rem ove slidin g door t r im pa n el. (Refer t o 23 - (1) Rem ove slidin g door t r im pa n el. (Refer t o 23 -
BODY/DOORS - SLIDING/TRIM PANE L - BODY/DOORS - SLIDING/TRIM PANE L -
RE MOVAL) RE MOVAL)
(3) P eel wa t er sh ield a wa y fr om a dh esive a r ou n d (2) Rem ove slidin g door st op bu m per. (Refer t o 23 -
per im et er of in n er door pa n el a s n ecessa r y t o ga in BODY/DOORS - SLIDING/STOP BUMP E R -
a ccess t o la t ch bellcr a n k. RE MOVAL)
(4) Disen ga ge lock lin k (F ig. 23). (3) P eel wa t er sh ield a wa y fr om a dh esive a r ou n d
(5) Disen ga ge lin k a n d sleeve per im et er of in n er door pa n el a s n ecessa r y t o a ccess
(6) Rem ove bellcr a n k by r ot a t in g bellcr a n k t o ou t side r elea se h a n dle fa st en er s.
r elea se it fr om door. (4) Disen ga ge clip a t t a ch in g ou t side door h a n dle
(7) Rem ove bellcr a n k fr om veh icle. lin ka ge t o door ca ble.
(5) Rem ove lin ka ge fr om ou t side door h a n dle.
INSTALLATION (6) Rem ove t h r ee n u t s a t t a ch in g ou t side door h a n -
(1) P osit ion bellcr a n k on veh icle. dle t o ou t er door pa n el (F ig. 24).
(2) Rot a t e bellcr a n k in t o posit ion . (7) Rem ove ou t side door h a n dle fr om veh icle.
OU T SI DE H AN DLE (Cont inue d)
(5) Ma r k ou t lin e of u pper h in ge br a cket on slidin g
door.
(6) Rem ove bolt s a t t a ch in g u pper r oller t o slidin g
door (F ig. 26).
(7) Rem ove u pper h in ge fr om door.
(8) Slide r oller ou t of r ea r en d of r oof u pper ch a n -
n el.
(9) Rem ove u pper h in ge fr om veh icle.
Fig. 24 SLIDING DOOR OUTSIDE LATCH RELEASE

HANDLE
1 - OUTSIDE HANDLE
2 - OUTSIDE HANDLE BRACKET ATTACHING NUT
3 - LOCK KNOB
4 - LATCH LINK
5 - LOCKING LINK
6 - DOOR LOCKING LEVER (BELLCRANK)
INSTALLATION
Fig. 25 SLIDING DOOR UPPER STOP
(1) P osit ion ou t side door h a n dle on veh icle.
(2) In st a ll n u t s a t t a ch in g ou t side door h a n dle t o 1 - UPPER STOP PLATE
2 - SLIDING DOOR
ou t er door pa n el. 3 - UPPER SLIDING DOOR HINGE
(3) E n ga ge clip a t t a ch in g lin ka ge t o ou t side door
h a n dle.
(4) E n ga ge r iggin g ca m t o la t ch /lock con t r ol m ech -
a n ism .
(5) Move clip on la t ch /lock con t r ol t o bot t om of slot
a n d en ga ge lin ka ge t o la t ch /lock con t r ol.
(6) Ver ify slidin g door oper a t ion . Adju st a s n eces-
sa r y.
(7) P la ce t h e wa t er sh ield in t o posit ion a n d pr ess
secu r ely t o a dh esive m a kin g su r e t o pr oper ly r ou t e
wir in g a n d lin ka ges.
(8) In st a ll slidin g door st op bu m per. (Refer t o 23 -
BODY/DOORS - SLIDING/STOP BUMP E R -
INSTALLATION)
(9) In st a ll slidin g door t r im pa n el. (Refer t o 23 -
BODY/DOORS - SLIDING/TRIM PANE L - INSTAL-
LATION)
Fig. 26 SLIDING DOOR UPPER HINGE
U PPER H I N GE 1 - SLIDING DOOR UPPER HINGE
2 - SLIDING DOOR
(1) Open slidin g door, do n ot la t ch open . (1) P la ce u pper h in ge in posit ion on veh icle (F ig.
(2) Rem ove scr ew a t t a ch in g u pper st op br a cket t o 26).
u pper r oller br a cket (F ig. 25). (2) Slide r oller in t o r ea r en d of r oof u pper ch a n n el.
(3) Rem ove st op br a cket fr om veh icle. (3) P la ce u pper h in ge in posit ion on door.
(4) P la ce a pa dded block bet ween t h e open slidin g (4) Align ou t lin e m a r ks on slidin g door t o u pper
door a n d t h e r oof r a il. r oller br a cket
U PPER H I N GE (Cont inue d)
(5) In st a ll bolt s a t t a ch in g u pper h in ge t o slidin g (2) P osit ion t h e ou t side h a n dle ca ble on t h e side
door. door.
(6) Rem ove pa dded block fr om bet ween slidin g (3) Con n ect t h e ou t side h a n dle ca ble on t h e h a n dle
door a n d r oof r a il. a ssem bly. H ook t h e swedged ca ble en d on t h e h a n dle
(7) P la ce st op br a cket in posit ion on veh icle. lin k a n d gen t ly pu sh t h e ca ble sleeve r et a in er in t h e
(8) In st a ll scr ew a t t a ch in g u pper st op br a cket t o h a n dle br a cket .
u pper r oller br a cket (F ig. 25).
(9) Ver ify slidin g door a lign m en t a n d oper a t ion . NOTE: The outside handle cable is marked with red
Adju st a s n ecessa r y. (Refer t o 23 - BODY/DOORS - tape. It must be attached to the latch at the lowest
SLIDING/SLIDING DOOR - ADJ USTME NTS) point. This is marked with a “R” on the latch.
(4) Con n ect t h e ou t side h a n dle ca ble on t h e la t ch

OU T SI DE H AN DLE CABLE a ssem bly. H ook t h e swedged ca ble en d on t h e la t ch
lin k a n d gen t ly pu sh t h e ca ble sleeve r et a in er in t h e
REMOVAL la t ch br a cket .
(5) Tr a ce t h e ou t side h a n dle ca ble a lon g it s r ou t in g
NOTE: For power sliding door procedures refer to pa t h a n d in st a ll on it s r et a in in g clips a n d posit ion
POWER SLIDING DOOR SYSTEM in the ELECTRI- foa m in su la t or s. Use pr eviou sly m a de sch em a t ic a s a
CAL section. gu ide or r em ove t h e opposit e side door t r im pa n el
a n d u se t h a t door a s a gu ide.
ca ble. CAUTION: Be certain replacement cable is routed
(2) Rem ove st op bu m per (Refer t o 23 - BODY/ and retained correctly and foam insulators are
DOORS - SLIDING/STOP BUMP E R - RE MOVAL). properly positioned.
(3) Rem ove t h e a ppr opr ia t e side door t r im pa n el.
(Refer t o 23 - BODY/DOORS - SLIDING/TRIM (6) P la ce t h e wa t er sh ield in t o posit ion a n d pr ess
PANE L - RE MOVAL) secu r ely t o a dh esive m a kin g su r e t o pr oper ly r ou t e
(4) P eel wa t er sh ield a wa y fr om a dh esive a r ou n d wir in g a n d lin ka ges.
per im et er of in n er door pa n el. (7) In st a ll t h e a ppr opr ia t e side door t r im pa n el on
t h e veh icle. (Refer t o 23 - BODY/DOORS - SLIDING/
CAUTION: Make note of cable routing and foam TRIM PANE L - INSTALLATION)
insulator placement. This will prove helpful when (8) In st a ll st op bu m per (Refer t o 23 - BODY/
reinstalling replacement cable. Be certain replace- DOORS - SLIDING/STOP BUMP E R - INSTALLA-
ment cable is routed and retained correctly. TION).
(5) Tr a ce t h e ou t side h a n dle ca ble a lon g it s r ou t in g
pa t h a n d discon n ect fr om it s r et a in in g clips.
(6) Discon n ect t h e ou t side h a n dle ca ble fr om t h e I N SI DE H AN DLE CABLE
la t ch a ssem bly. Gen t ly pr y ca ble sleeve r et a in er ou t
of t h e la t ch m ou n t in g br a cket a n d t h en u n h ook REMOVAL
swedged ca ble en d fr om t h e la t ch lin k.
(7) Discon n ect t h e ou t side h a n dle ca ble fr om t h e NOTE: For power sliding door procedures refer to
h a n dle a ssem bly. Gen t ly pr y ca ble sleeve r et a in er ou t POWER SLIDING DOOR SYSTEM in the ELECTRI-
of t h e h a n dle br a cket a n d t h en u n h ook swedged CAL section.
ca ble en d fr om t h e h a n dle lin k.
(8) Rem ove t h e ou t side h a n dle ca ble fr om t h e side (1) Discon n ect a n d isola t e t h e n ega t ive ba t t er y
door. ca ble.
(2) Rem ove t h e a ppr opr ia t e side door t r im pa n el
INSTALLATION fr om t h e veh icle. (Refer t o 23 - BODY/DOORS -
SLIDING/TRIM PANE L - RE MOVAL)
NOTE: For power sliding door procedures refer to (3) P eel wa t er sh ield a wa y fr om a dh esive a r ou n d
POWER SLIDING DOOR SYSTEM in the ELECTRI- per im et er of in n er door pa n el.
CAL section. (4) Rem ove t h e in side h a n dle a ssem bly fr om t h e
side door. (Refer t o 23 - BODY/DOORS - SLIDING/
(1) Ma t ch t h e r epla cem en t ca ble u p a ga in st t h e old INSIDE LATCH H ANDLE - RE MOVAL)
ca ble t o ver ify t h e cor r ect pa r t . (5) Discon n ect t h e in side h a n dle ca ble fr om t h e
h a n dle a ssem bly. Gen t ly pr y ca ble sleeve r et a in er ou t
I N SI DE H AN DLE CABLE (Cont inue d)
of t h e h a n dle br a cket a n d t h en u n h ook swedged (7) In st a ll t h e la t ch a ssem bly. Refer t o t h e P ower
ca ble en d fr om t h e h a n dle lin k. Side Door s sect ion for t h e pr ocedu r e.
(6) Open t h e side door a n d r em ove t h e la t ch (8) P la ce t h e wa t er sh ield in t o posit ion a n d pr ess
a ssem bly. Refer t o t h e P ower Side Door s sect ion for secu r ely t o a dh esive m a kin g su r e t o pr oper ly r ou t e
t h e pr ocedu r e. wir in g a n d lin ka ges.
(9) In st a ll t h e a ppr opr ia t e side door t r im pa n el on
CAUTION: Make note of cable routing and foam t h e veh icle. (Refer t o 23 - BODY/DOORS - SLIDING/
insulator placement. This will prove helpful when TRIM PANE L - INSTALLATION)
reinstalling replacement cable. Be certain replace- (10) Con n ect t h e n ega t ive ba t t er y ca ble.
ment cable is routed and retained correctly.
(7) Tr a ce t h e in side h a n dle ca ble a lon g it s r ou t in g H OLD OPEN LAT CH CABLE

pa t h a n d discon n ect fr om it s r et a in in g clips.
(8) Discon n ect t h e in side h a n dle ca ble fr om t h e REMOVAL
la t ch a ssem bly. Gen t ly pr y ca ble sleeve r et a in er ou t
of t h e la t ch m ou n t in g br a cket a n d t h en u n h ook NOTE: For power sliding door procedures refer to
swedged ca ble en d fr om t h e la t ch lin k. POWER SLIDING DOOR SYSTEM in the ELECTRI-
(9) Rem ove t h e in side h a n dle ca ble fr om t h e side CAL section.
door.
INSTALLATION ca ble.
(2) Rem ove t h e a ppr opr ia t e side door t r im pa n el
NOTE: For power sliding door procedures refer to fr om t h e veh icle. (Refer t o 23 - BODY/DOORS -
POWER SLIDING DOOR SYSTEM in the ELECTRI- SLIDING/TRIM PANE L - RE MOVAL)
CAL section. (3) P eel wa t er sh ield a wa y fr om a dh esive a r ou n d
(1) Ma t ch t h e r epla cem en t ca ble u p a ga in st t h e old (4) Open t h e side door a n d r em ove t h e la t ch
ca ble t o ver ify t h e cor r ect pa r t . a ssem bly. (Refer t o 8 - E LE CTRICAL/P OWE R
(2) P osit ion t h e in side h a n dle ca ble on t h e side DOORS/LATCH - RE MOVAL)
door.
(3) Con n ect t h e in side h a n dle ca ble on t h e h a n dle CAUTION: Make note of cable routing and foam
a ssem bly. H ook t h e swedged ca ble en d on t h e h a n dle insulator placement. This will prove helpful when
lin k a n d gen t ly pu sh t h e ca ble sleeve r et a in er in t h e reinstalling replacement cable. Be certain replace-
h a n dle br a cket . ment cable is routed and retained correctly.
(4) In st a ll t h e in side h a n dle a ssem bly on t h e side
door. (Refer t o 23 - BODY/DOORS - SLIDING/IN- (5) Tr a ce t h e h old open la t ch ca ble a lon g it s r ou t -
SIDE LATCH H ANDLE - INSTALLATION) in g pa t h a n d discon n ect fr om it s r et a in in g clips.
(6) Discon n ect t h e h old open la t ch ca ble fr om t h e
NOTE: The inside handle cable is marked with blue la t ch a ssem bly. Gen t ly pr y ca ble sleeve r et a in er ou t
tape and must be attached to the latch at the center of t h e la t ch m ou n t in g br a cket a n d t h en u n h ook
(just above the lower cable). This position is swedged ca ble en d fr om t h e la t ch lin k.
marked with a “B” on the latch. (7) Rem ove t h e h old open la t ch fr om t h e side door.
(Refer t o 23 - BODY/DOORS - SLIDING/H OLD
(5) Con n ect t h e in side h a n dle ca ble on t h e la t ch OP E N LATCH - RE MOVAL)
a ssem bly. H ook t h e swedged ca ble en d on t h e la t ch (8) Discon n ect t h e h old open la t ch ca ble fr om t h e
lin k a n d gen t ly pu sh t h e ca ble sleeve r et a in er in t h e h old open la t ch . Gen t ly pr y ca ble sleeve r et a in er ou t
la t ch br a cket . of t h e h a n dle br a cket a n d t h en u n h ook swedged
(6) Tr a ce t h e in side h a n dle ca ble a lon g it s r ou t in g ca ble en d fr om t h e la t ch lin k.
pa t h a n d in st a ll on it s r et a in in g clips a n d posit ion (9) Rem ove t h e h old open la t ch ca ble fr om t h e side
foa m in su la t or s. Use pr eviou sly m a de sch em a t ic a s a door.
gu ide or r em ove t h e opposit e side door t r im pa n el
a n d u se t h a t door a s a gu ide. INSTALLATION
CAUTION: Be certain replacement cable is routed NOTE: For power sliding door procedures refer to
and retained correctly and foam insulators are POWER SLIDING DOOR SYSTEM in the ELECTRI-
properly positioned. CAL section.
H OLD OPEN LAT CH CABLE (Cont inue d)
(1) Ma t ch t h e r epla cem en t ca ble u p a ga in st t h e old (6) Tr a ce t h e ou t side h a n dle ca ble a lon g it s r ou t in g
ca ble t o ver ify t h e cor r ect pa r t . pa t h a n d in st a ll on it s r et a in in g clips a n d posit ion
(2) P osit ion t h e h old open la t ch ca ble on t h e side foa m in su la t or s. Use pr eviou sly m a de sch em a t ic a s a
door. gu ide or r em ove t h e opposit e side door t r im pa n el
a n d u se t h a t door a s a gu ide.
NOTE: The hold open latch cable is marked with
white tape. It must be attached to the upper most CAUTION: Be certain replacement cable is routed
cable attachment at the latch. This position is and retained correctly and foam insulators are
marked with a “W” on the latch. properly positioned.
(3) Con n ect t h e h old open la t ch ca ble on t h e h old (7) In st a ll t h e la t ch a ssem bly. (Refer t o 8 - E LE C-
open la t ch a ssem bly. H ook t h e swedged ca ble en d on TRICAL/P OWE R DOORS/LATCH - INSTALLATION)
t h e la t ch lin k a n d gen t ly pu sh t h e ca ble sleeve (8) P la ce t h e wa t er sh ield in t o posit ion a n d pr ess
r et a in er in t h e la t ch br a cket . secu r ely t o a dh esive m a kin g su r e t o pr oper ly r ou t e
(4) In st a ll t h e h old open la t ch on t h e side door.(Re- wir in g a n d lin ka ges.
fer t o 23 - BODY/DOORS - SLIDING/H OLD OP E N (9) In st a ll t h e a ppr opr ia t e side door t r im pa n el on
LATCH - INSTALLATION) t h e veh icle. (Refer t o 23 - BODY/DOORS - SLIDING/
(5) Con n ect t h e h old open la t ch ca ble on t h e la t ch TRIM PANE L - INSTALLATION)
a ssem bly. H ook t h e swedged ca ble en d on t h e la t ch (10) Con n ect t h e n ega t ive ba t t er y ca ble.
lin k a n d gen t ly pu sh t h e ca ble sleeve r et a in er in t h e
la t ch br a cket .
23 - 40 DECKLID/HATCH/LIFTGATE/TAILGATE RS
DECK LI D/H AT CH /LI FT GAT E/TAI LGAT E
TABLE OF CONTENTS
page page
EXTERIOR HANDLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 42

REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 SUPPORT CYLINDER
HINGE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 43
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 TRIM PANEL
LATCH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 43
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 SLAM BUMPER
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 41 REMOVAL
LATCH STRIKER REMOVAL - BODY SIDE . . . . . . . . . . . . . . . . 44
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 REMOVAL - LIFTGATE SIDE . . . . . . . . . . . . . 44
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 42 INSTALLATION
LIFTGATE INSTALLATION - BODY SIDE .. . . . . . . . . . . 44
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 INSTALLATION - LIFTGATE SIDE . . . . . . . . . 44
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 42
LOCK CYLINDER
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
EX T ERI OR H AN DLE H I N GE
REMOVAL REMOVAL
(1) Rem ove lift ga t e t r im pa n el. (Refer t o 23 - (1) Relea se lift ga t e la t ch a n d open lift ga t e.
BODY/DE CKLID/H ATCH /LIF TGATE /TAILGATE / (2) Su ppor t lift ga t e on a su it a ble lift in g device in
TRIM PANE L - RE MOVAL) t h e fu ll open posit ion .
(2) Discon n ect t h e ext er ior h a n dle elect r ica l con - (3) Apply sever a l la yer s of du ct t a pe on t h e ou t side
n ect or s. of t o r oof a cr oss t h e ga p t o t h e lift ga t e t o h old t h e
(3) Rem ove t h e t wo ou t er scr ews a n d t h e t wo in n er lift ga t e in posit ion .
scr ews. (4) Rem ove bolt s a t t a ch in g lift ga t e h in ge t o r oof
(4) Rem ove t h e ext er ior h a n dle/licen se pla t e ligh t h ea der.
a ssem bly. (5) Discon n ect VTSS swit ch fr om t h e body h a r-
n ess.
INSTALLATION (6) Rem ove bolt s a t t a ch in g h in ge t o lift ga t e (F ig.
(1) Rou t e t h e ext er ior h a n dle elect r ica l con n ect or 1).
t h r ou gh t h e door a n d posit ion h a n dle. (7) Rem ove h in ge fr om veh icle.
(2) In st a ll t h e t wo ou t scr ews a n d t igh t en t o 3 N·m
(22 in . lbs.). INSTALLATION
(3) In st a ll t h e t wo in n er bolt s a n d t igh t en t o 5 (1) If n ecessa r y, pa in t r epla cem en t h in ge befor e
N·m (40 in . lbs.). in st a lla t ion .
(4) Con n ect t h e elect r ica l con n ect or. (2) P la ce h in ge in posit ion on veh icle.
(5) In st a ll t h e t r im pa n el. (Refer t o 23 - BODY/ (3) Align h in ge t o m a r ks on lift ga t e.
DE CKLID/H ATCH /LIF TGATE /TAILGATE /TRIM (4) In st a ll bolt s a t t a ch in g h in ge t o lift ga t e (F ig. 1).
PANE L - INSTALLATION) Tigh t en bolt s t o 33 N·m (24 ft . lbs.) t or qu e.
(5) Align h in ge t o m a r ks on r oof h ea der.
RS DECKLID/HATCH/LIFTGATE/TAILGATE 23 - 41
H I N GE (Cont inue d)
Fig. 1 LIFTGATE HINGE

1 - LIFTGATE
2 - HINGE
3 - REAR ROOF HEADER
(6) In st a ll bolt s a t t a ch in g lift ga t e h in ge t o r oof

h ea der. Tigh t en ou t er t wo bolt s t o 33 N·m (24 ft . lbs.) Fig. 2 LIFTGATE LATCH
t or qu e. Th e sh eet m eda l scr ew a t cen t er 12 N·m (105
in . lbs.) 2 - LIFTGATE LATCH
(7) Rem ove du ct t a pe fr om r oof a n d lift ga t e. 3 - SCREW
(8) Ver ify lift ga t e a lign m en t . Refer t o Lift ga t e 4 - LIFTGATE
Rem ove a n d In st a lla t ion for pr oper ga p m ea su r e-
m en t s.
LAT CH ST RI K ER
LAT CH REMOVAL
REMOVAL (2) Ma r k ou t lin e of st r iker on sill t o a id in st a lla -
(1) Rem ove lift ga t e t r im pa n el. t ion .
(2) Disen ga ge ou t side key cylin der lin k fr om clip (3) Rem ove scr ews a t t a ch in g st r iker t o sill (F ig. 3).
on la t ch . (4) Rem ove st r iker fr om veh icle.
(3) Discon n ect wir e con n ect or fr om lift ga t e la t ch
(F ig. 2).
(4) Rem ove scr ews a t t a ch in g la t ch t o lift ga t e.
(5) Rem ove la t ch fr om veh icle.
INSTALLATION
(1) E n ga ge key cylin der lin k a n d pla ce la t ch in
posit ion on veh icle.
(2) In st a ll scr ews a t t a ch in g la t ch t o lift ga t e.
Tigh t en t o 11 N·m (95 in . lbs.) t or qu e.
(3) Con n ect wir e con n ect or t o lift ga t e la t ch .
(4) Ver ify lift ga t e fit a n d oper a t ion . Adju st a s n ec-
essa r y.
(5) In st a ll lift ga t e t r im pa n el.
Fig. 3 LIFTGATE LATCH STRIKER

1 - LIFTGATE SILL
2 - LIFTGATE STRIKER
LAT CH ST RI K ER (Cont inue d)
INSTALLATION (4) Recon n ect power lift ga t e lin k, if equ ipped.

(1) P la ce st r iker in posit ion on veh icle. (5) Rem ove lift in g device fr om u n der lift ga t e.
(2) Align st r iker t o ou t lin e m a r k on sill. (6) Con n ect lift ga t e wir e h a r n ess in t o body wir e
(3) In st a ll scr ews a t t a ch in g st r iker t o sill. Tigh t en h a r n ess.
scr ews t o 28 N·m (21 ft . lbs.) t or qu e. (7) In st a ll scr ews a t t a ch in g wir e con n ect or t o r ea r
(4) Ver ify lift ga t e a lign m en t a n d oper a t ion . h ea der.
(8) Con n ect r ea r win dow wa sh er h ose on t o spr a y
n ozzle.
LI FT GAT E (9) In st a ll lift ga t e u pper fr a m e m oldin g.
(10) In st a ll ba t t er y n ega t ive ca ble.
REMOVAL (11) Ver ify lift ga t e a lign m en t . Th e lift ga t e sh ou ld
(1) Discon n ect a n d isola t e t h e ba t t er y n ega t ive h a ve a ga p t o a dja cen t pa n els a n d fit flu sh a cr oss t h e
ca ble. ga ps. Th e ga p is; (Refer t o 23 - BODY/BODY STRUC-
(2) Relea se lift ga t e la t ch a n d open lift ga t e. TURE /GAP AND F LUSH - SP E CIF ICATIONS).
(3) Rem ove lift ga t e u pper fr a m e m oldin g. • 8.0 m m ± 2.5 t o t h e r ea r fa scia ,
(4) Rem ove scr ews a t t a ch in g lift ga t e wir e con n ec- • 8.0 m m ± 2.0 t o t h e r oof,
t or t o r ea r h ea der. • 2.0 m m ± 0.5 m m t o t h e a per t u r e.
(5) Discon n ect lift ga t e wir e h a r n ess fr om body
wir e h a r n ess.
(6) Discon n ect r ea r win dow wa sh er h ose fr om
LOCK CY LI N DER
spr a y n ozzle.
(7) Su ppor t lift ga t e on a su it a ble lift in g device. REMOVAL
(8) Discon n ect power lift ga t e lin k, if equ ipped. (1) Rem ove t h e lift ga t e t r im pa n el. (Refer t o 23 -
(9) Rem ove scr ews a t t a ch in g su ppor t cylin der s t o BODY/DE CKLID/H ATCH /LIF TGATE /TAILGATE /
lift ga t e. TRIM PANE L - RE MOVAL)
(10) Rem ove bolt s a t t a ch in g lift ga t e h in ge t o r oof (2) Discon n ect t h e elect r ica l con n ect or.
h ea der (F ig. 4). (3) Discon n ect t h e la t ch r od.
(11) Wit h a ssist a n ce, r em ove lift ga t e fr om veh icle. (4) Rot a t e pla st ic lock cylin der n u t on e qu a r t er
t u r n a n d r em ove n u t a n d spr in g wa sh er.
(5) Rem ove t h e lock cylin der fr om t h e lift ga t e.
INSTALLATION
(1) In st a ll lock cylin der in t o lift ga t e.
(2) In st a ll t h e pla st ic lock cylin der lock n u t , spr in g
wa sh er a n d r ot a t e on e qu a r t er t u r n .
(4) Con n ect t h e la t ch r od.
(5) In st a ll t h e t r im pa n el. (Refer t o 23 - BODY/
DE CKLID/H ATCH /LIF TGATE /TAILGATE /TRIM
PANE L - INSTALLATION)
(6) Ver ify lock cylin der oper a t ion .
SU PPORT CY LI N DER
Fig. 4 LIFTGATE
1 - HINGE
REMOVAL
2 - ROOF (1) Relea se lift ga t e la t ch a n d open lift ga t e.
3 - NET HOLE OR SLOT (2) Su ppor t lift ga t e on a su it a ble lift in g device in
t h e fu ll open posit ion .
INSTALLATION (3) P u ll lift ga t e open in g wea t h er st r ip fr om D-pilla r
(1) Wit h a ssist a n ce, pla ce lift ga t e in posit ion on fla n ge n ext t o pr op a ssem bly en d pivot .
veh icle. (4) Rem ove bolt a t t a ch in g en d pivot t o D-pilla r
(2) In st a ll bolt s a t t a ch in g lift ga t e h in ge t o r oof (F ig. 5).
h ea der. Tigh t en bolt s t o 33 N·m (24 ft . lbs.) t or qu e. (5) Rem ove bolt a t t a ch in g pr op a ssem bly t o lift -
(3) In st a ll scr ews a t t a ch in g su ppor t cylin der s t o ga t e.
lift ga t e. Tigh t en bolt s t o 28 N·m (21 ft . lbs.) t or qu e. (6) Rem ove pr op a ssem bly fr om veh icle.
RS DECKLID/HATCH/LIFTGATE/TAILGATE 23 - 43
SU PPORT CY LI N DER (Cont inue d)
Fig. 6 LIFTGATE MOTOR

1 - LIFTGATE MOTOR LINK BOLT
2 - LIFTGATE MOTOR
Fig. 5 LIFTGATE PROP ASSEMBLY 3 - LIFTGATE
1 - LIFTGATE
2 - PROP ASSEMBLY
INSTALLATION
E n su r e t h a t t h e cylin der en d is a t t a ch ed t o t h e
D-pilla r a n d t h e sh a ft en d is a t t a ch ed t o t h e lift ga t e.
(1) P la ce pr op a ssem bly in posit ion .
(2) In st a ll bolt a t t a ch in g pr op a ssem bly t o lift ga t e.
(3) In st a ll bolt a t t a ch in g en d pivot t o D-pilla r.
Tigh t en bolt s t o 28 N·m (21 ft . lbs.) t or qu e.
(4) In st a ll lift ga t e open in g wea t h er st r ip t o D-pilla r
fla n ge n ext t o pr op a ssem bly en d pivot .
(5) Close lift ga t e. Ch eck lift ga t e oper a t ion .
T RI M PAN EL
REMOVAL Fig. 7 LIFTGATE TRIM
(1) Rem ove t h e bolt a t t a ch in g t h e lift m ot or lin k, if 1 - LIFTGATE
equ ipped (F ig. 6). 2 - LOWER TRIM PANEL
3 - ASSIST HANDLE SCREWS
(2) Rem ove lift ga t e u pper fr a m e m oldin g (F ig. 7). 4 - UPPER TRIM
(3) Rem ove a ssist h a n dle scr ews. 5 - UPPER TRIM CLIPS
(4) Disen ga ge h idden clips h oldin g t r im pa n el t o
lift ga t e fr om a r ou n d per im et er or lift ga t e (F ig. 7). (3) Con n ect wir e con n ect or in t o la m p.
(5) Discon n ect wir e con n ect or fr om la m ps. (4) In st a ll cou r t esy la m ps in t o lift ga t e t r im .
(6) Rem ove lift ga t e t r im pa n el fr om veh icle. (5) In st a ll scr ews t o h old a ssist h a n dle t o lift ga t e.
(6) In st a ll u pper fr a m e side m oldin gs.
INSTALLATION (7) In st a ll lift ga t e u pper fr a m e m oldin g.
(1) P la ce lift ga t e t r im pa n el in posit ion on veh icle. (8) In st a ll t h e bolt a t t a ch in g t h e lifga t e m ot or lin k
(2) E n ga ge h idden clips t o h old t r im pa n el t o lift - a n d t igh t en t o 28 N·m (21 ft . lbs.)
ga t e a n d fa st en er s a r ou n d per im et er of lift ga t e (F ig.
7).
SLAM BU M PER REMOVAL - LIFTGATE SIDE

(2) Rem ove lift ga t e st op bu m per lift ga t e side
REM OVAL a t t a ch in g r ivet s by dr illin g ou t old r ivet s.
(3) Rem ove lift ga t e st op bu m per.
REMOVAL - BODY SIDE
(2) Rem ove lift ga t e st op bu m per body side a t t a ch - I N STALLAT I ON
in g bolt s (F ig. 8).
(3) Rem ove lift ga t e st op bu m per. INSTALLATION - BODY SIDE
(1) P la ce lift ga t e st op bu m per in t o posit ion .
(2) In st a ll bolt s a t t a ch in g lift ga t e st op bu m per t o
body side (F ig. 8).
(3) Close lift ga t e.
INSTALLATION - LIFTGATE SIDE

(1) P la ce lift ga t e st op bu m per in t o posit ion .
(2) In st a ll r ivet s a t t a ch in g lift ga t e st op bu m per t o
lift ga t e.
NOTE: Verify that ships or parts of drilled out rivet

does not rattle in the liftgate. If there is rattling
sound, detrim liftgate and retrieve debris.
(3) Close lift ga t e.
Fig. 8 LIFTGATE STOP BUMPER - BODY SIDE

1 - LIFTGATE STOP BUMPER
2 - LIFTGATE OPENING
RS EXTERIOR 23 - 45
EX T ERI OR
TABLE OF CONTENTS
page page
BODY SIDE MOLDINGS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 46 UPPER RADIATOR CROSSMEMBER
COWL GRILLE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 50 FRONT WHEELHOUSE SPLASH SHIELD
EXTERIOR NAME PLATES - TAPE ATTACHED REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 51 LUGGAGE RACK RISER
EXTERIOR NAME PLATES - ADHESIVE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
ATTACHED INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 58
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 LUGGAGE RACK CROSSBAR
FRONT FENDER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 59
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 REAR QUARTER PANEL/FENDER AIR
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . 52 EXHAUSTER
FUEL FILL DOOR DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 59
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
FUEL FILL DOOR BLOCKER LATCH ROOF JOINT MOLDING
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
FUEL FILL DOOR BLOCKER LATCH STRIKER SIDE VIEW MIRROR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
FUEL FILL DOOR BLOCKER LOCKOUT LINK GLASS-OUTSIDE REARVIEW MIRROR
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
GRILLE
DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . 55
BODY SI DE M OLDI N GS (2) If equ ipped, r em ove pop r ivet s h oldin g m oldin g
edge t o wh eelh ou se lip.
(3) P u ll st ick on m oldin g fr om pa in t ed su r fa ce.
REMOVAL
(4) Rem ove a dh esive t a pe r esidu e fr om pa in t ed
Refer t o (F ig. 1), (F ig. 2), (F ig. 3), (F ig. 4) or (F ig.
su r fa ce of veh icle. Use a 3M Scot ch -Br it e™ Moldin g
5)for pr oper loca t ion of fa st en er s h oldin g t h e m oldin g
Adh esive a n d St r ipe Rem ova l Disc, or equ iva len t , t o
t o t h e wh eelh ou se lip a n d r ocker pa n els.
clea n a dh esive r esidu e fr om pa in t ed su r fa ces. Th ese
(1) Wa r m t h e a ffect ed st ick on m oldin g a n d body
pr odu ct s a r e a va ila ble fr om a u t om ot ive pa in t su ppli-
m et a l t o a ppr oxim a t ely 38° C (100° F ) u sin g a su it -
er s. Refer t o in st r u ct ion s su pplied wit h t h e specific
a ble h ea t la m p or h ea t gu n .
pr odu ct for pr oper u sa ge.
23 - 46 EXTERIOR RS
BODY SI DE M OLDI N GS (Cont inue d)
Fig. 1 BODY SIDE MOLDINGS - BASE TYPICAL

1 - GUIDE PINS 3 - SLIDING DOOR MOLDING
2 - FRONT DOOR MOLDING 4 - QUARTER PANEL MOLDING
INSTALLATION (2) Clea n body su r fa ce wit h Mopa r ! Su per Kleen ,

Refer t o (F ig. 1), (F ig. 2), (F ig. 3), (F ig. 4) or (F ig. or equ iva len t . Wipe su r fa ce dr y wit h lin t fr ee clot h .
5)for pr oper loca t ion of fa st en er s t o h old t h e m oldin g (3) Rem ove pr ot ect ive cover fr om t a pe on ba ck of
t o t h e wh eelh ou se lip a n d r ocker pa n els. m oldin g.
(1) If m oldin g is t o be r eu sed; (4) Apply m oldin g t o body fr om fr on t t o r ea r,
(a ) Rem ove t a pe r esidu e fr om m oldin g. in ser t in g loca t or pin s in t o h ole in body pa n el.
(b) Clea n ba ck of m oldin g wit h Mopa r ! Su per (5) Usin g a r oller t ool, r oll m oldin g on t o body
Kleen , or equ iva len t . pa n el wit h en ou gh for ce t o a ssu r e a dh esion . Do n ot
(c) Wipe m oldin g dr y wit h lin t fr ee clot h . a pply excessive for ce, or da m a ge t o body pa n els m a y
(d) Apply a sin gle coa t of Mopa r ! TP O Moldin g r esu lt .
P r ep t o t a pe side of m oldin g a n d a llow t o dr y t h or- (6) In st a ll pop r ivet s t o h old m oldin g edge t o
ou gh ly. wh eelh ou se lip, if n ecessa r y.
(e) Apply n ew body side m oldin g (t wo sided
a dh esive) t a pe t o ba ck of m oldin g.
RS EXTERIOR 23 - 47
Fig. 2 BODY SIDE MOLDINGS - HIGHLINE TYPICAL

1 - QUARTER PANEL 6 - SLIDING DOOR MOLDING
2 - FRONT FENDER 7 - GUIDE PINS
3 - POP-RIVET 8 - QUARTER PANEL MOLDING
4 - FENDER MOLDING 9 - LIFTGATE MOLDING
5 - FRONT DOOR MOLDING 10 - POP-RIVET
23 - 48 EXTERIOR RS
Fig. 3 BODY SIDE MOLDINGS - PREMIUM TYPICAL

1 - QUARTER PANEL 7 - FRONT DOOR MOLDING
2 - FRONT FENDER 8 - SLIDING DOOR MOLDING
4 - FENDER MOLDING 10 - FASCIA MOLDING
5 - POP-RIVET 11 - POP-RIVET
6 - FASCIA
RS EXTERIOR 23 - 49
Fig. 4 BODY SIDE MOLDINGS - PREMIUM TYPICAL

1 - QUARTER PANEL 7 - FRONT DOOR MOLDING
2 - FRONT FENDER 8 - SLIDING DOOR MOLDING
4 - FENDER MOLDING 10 - FASCIA MOLDING
5 - POP-RIVET 11 - POP-RIVET
6 - FASCIA
23 - 50 EXTERIOR RS
Fig. 5 BODY SIDE MOLDINGS WITH APPLIQUE - TYPICAL

1 - FRONT ROCKER PANEL APPLIQUE 4 - REAR ROCKER PANEL APPLIQUE
2 - FRONT DOOR MOLDING 5 - LIFTGATE MOLDING
3 - SLIDING DOOR MOLDING 6 - POP-RIVET
COWL GRI LLE ou t boa r d en d t o clea r sim u lt a n eou sly t op of wiper

pivot sh a ft a n d bot t om cor n er of h ood.
(6) Close h ood. Do n ot la t ch . Rem ove ou t boa r d
REMOVAL
scr ews. (F ig. 7).
(1) Rem ove wiper a r m s. (Refer t o 8 - E LE CTRI-
(7) Discon n ect wa sh er h ose in lin e con n ect or.
CAL/WIP E RS/WASH E RS/WIP E R ARMS -
(8) Discon n ect wa sh er h ose a n d gr om m et fr om
RE MOVAL)
h ole in wiper m odu le a n d pu ll ou t .
(2) Rem ove fou r (4) scr ews secu r in g cowl cover t o
(9) Rem ove cowl gr ille by r a isin g over opposit e
wiper m odu le (F ig. 6).
wiper pivot sh a ft a n d r em ovin g a wa y fr om veh icle.
(3) Disen ga ge qu a r t er t u r n fa st en er s a t ou t boa r d
(10) Rem ove cowl cover fr om veh icle.
en ds of cowl gr ill fr om body.
INSTALLATION
CAUTION: To prevent hood scratching of cowl grille (1) Rever se r em ova l pr ocedu r e.
before removal, cover outboard exterior ends of (2) Wh en in st a llin g cowl cover over wiper m odu le,
cowl grille with masking tape or equivalent method. m a ke su r e for e a ft loca t or on t h e u n der side of cowl
gr ill sea t in t o t h e loca t or gr ooves on t op of wiper
m odu le.
NOTE: Do not over bend cowl grille during removal. (3) St a r t a ll cowl gr ille m ou n t in g scr ews by h a n d
Bend cowl grille just enough to clear top of wiper befor e t or qu in g t o specifica t ion s.
pivot shaft and bottom rear corner of hood. (4) Assu r e wa sh er h ose is pr oper ly r ou t ed a n d n ot
pin ch ed.
(5) Rem ove cowl gr ill by r a isin g a bove dr iver side (5) Cen t er cowl gr ille t o body a n d win dsh ield.
wiper pivot sh a ft a n d swin gin g a wa y t owa r ds en gin e (6) Assu r e “a r r ow” in dica t or h ea d of qu a r t er t u r n
com pa r t m en t . Th e cowl gr ille will n eed t o be ben t on fa st en er s is poin t in g t owa r d win dsh ield.
RS EXTERIOR 23 - 51
COWL GRI LLE (Cont inue d)
EX T ERI OR N AM E PLAT ES -
TAPE AT TACH ED
REMOVAL
(1) Ma r k r efer en ce poin t s befor e r em ovin g.
(2) Usin g a h ea t gu n gen t ly a pply h ea t in a cir cu -
la r m ot ion t o loosen t h e a dh esive bon d.
(3) Usin g a n on m et a llic pr yin g device, su ch a s a
pla st ic or wood t r im st ick gen t ly pr y u p a t cor n er s
a n d r em ove.
(4) Clea n off a ll t r a ces of a dh esive or dou ble sided
t a pe fr om t h e pa n el wit h a gen er a l pu r pose a dh esive
r em over.

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GROU P TAB LOCAT OR

0 Lubrication & Maintenance

3 Differential & Driveline

8E Electronic Control Modules

8Q Vehicle Theft Security

13 Frame & Bumpers

24 Heating & Air Conditioning

Component and System Index

Service Manual Comment Forms (Rear of Manual)

BODY CODE PLATE TORQUE REFERENCES

BODY CODE PLAT E

BODY CODE PLATE – LINE 3

DIGITS 22 AND 23 DIGIT 4

DIGITS 5 THROUGH 7 DIGITS 7 THROUGH 23

FAST EN ER U SAGE THREADED HOLE REPAIR

INTERNATIONAL CONTROL AND DISPLAY SYMBOLS

M ET RI C SY ST EM Th e followin g ch a r t will a ssist in con ver t in g m et r ic

CON V ERSI ON FORM U LAS AN D EQU I VALEN T VALU ES

MULTIPLY BY TO GET MULTIPLY BY TO GET

COM M ON M ET RI C EQU I VALEN T S

1 inch = 25 Millimeters 1 Cubic Inch = 16 Cubic Centimeters

Refer t o t h e Met r ic Con ver sion Ch a r t t o con ver t

METRIC CONVERSION CHART

T ORQU E REFEREN CES

V EH I CLE I DEN T I FI CAT I ON

V I N CODE BREAK DOWN CH ART

POSITION INTERPRETATION CODE = DESCRIPTION

Country of Origin 1 = Manufactured By DaimlerChrysler Corporation

Vehicle Type 4 = Multipurpose Pass. Vehicle Less Side Air Bags

1 = Chrysler Caravan - FWD

POSITION INTERPRETATION CODE = DESCRIPTION

6 Series 4 = High Line

6 - Export Series B = 4-Speed Automatic Transaxle

N = 5-Speed Manual Transaxle

1 = Van - Caravan C/V

7 Body Style 3 = Extended Van - Grand Caravan C/V

1 = EURO Wagon - Long Wheelbase (RG - 53 - S Series)

2 = EURO Wagon - Short Wheelbase (RG - 52 - H Series)

B = 2.4L I4 Cyl. 16-Valve Gasoline DOHC (MPI)

E = 3.3L V6 Cyl. OHV Flex Fuel

8 Engine L = 3.8L V6 Cyl. Gasoline (SMPI)

9 Check Digit See explanation in this section.

10 Model Year 5 = 2005

11 Assembly Plant B = St. Louis Assembly South

12 through 17 Sequence Number A six digit number assigned by assembly plant.

V EH I CLE CERT I FI CAT I ON

Fig. 5 MANUFACTURER PLATE

LUBRICATION & MAINTENANCE

INTERNATIONAL SYMBOLS FLUID CAPACITIES

I N T ERN AT I ON AL SY M BOLS FLU I D T Y PES

ENGINE OIL ADDITIVES/SUPPLEMENTS

• Th e u se of lea ded ga s is pr oh ibit ed by F eder a l

DESCRIPTION - FUEL REQUIREMENTS - Th e r ecom m en ded lu br ica n t for t h e Over r u n n in g

FLU I D FI LL/CH ECK At Each Stop for Fuel

CAUTION: Failure to perform the required mainte-

* Th is m a in t en a n ce is r ecom m en ded by t h e m a n u - # Th is m a in t en a n ce is r equ ir ed on ly for police,

Miles 102, 000 108, 000 114, 000 120, 000

* Th is m a in t en a n ce is r ecom m en ded by t h e m a n u - WARNING: You can be badly injured working on or

DESCRIPTION - EXPORT At Each Stop for Fuel

SCHEDULE A - EXPORT ONLY

Kilometers 12 000 24 000 36 000 48 000 60 000 72 000

* Th is m a in t en a n ce is r ecom m en ded by t h e m a n u - In spect ion a n d ser vice sh ou ld a lso be per for m ed

Kilometers 5 000 10 000 14 000 19 000 24 000 29 000

Kilometers 34 000 38 000 43 000 48 000 53 000 58 000